Escolar Documentos
Profissional Documentos
Cultura Documentos
U - AC Power Plus
Manual Nr: 005954
Edition:
A
Approved 2000-11-10
by:
Johan Rydenskog
Product Responsible
Bo Bidhagen
Technical Documentation
Atlet AB is certified
according to ISO 9001
1:A
2:A
Special tools
3:A
Service
4:A
Chassis
5:A
Drive unit
6:A
Mast
7:A
Steering
8:A
Hydraulic system
9:A
Lift cylinder
10:A
Electrical system
11:A
12:A
Options
Service Manual
U - AC Power Plus
Manual No: 005953
Section:1 Issue: A
1.1
1.2
The manual describes the service procedures on ATLET reach trucks in the U** AC Power Plus range.
Use the manual for quick and correct service of respective truck models.
The manual describes models manufactured from January 2000.
You may find contradictions in the manual compared with the models supplied due to optional designs and
the like.
Warning! If the truck is rebuilt after delivery or supplemented in such a manner that safety
may be affected, ATLET AB or its representative should be contacted.
The content of this manual is protected by copyright law and may not be copied, fully or in part, without
written permission. The material has undergone careful examination with regard to correctness. Subject to
alteration. We reserve the right to make changes.
In the event of inconsistent information in the Swedish and translated editions, it is the Swedish edition
that applies.
Modifications and updates will be distributed via ATLET AB Service Manual Change.
1.1
General information
The new generation of reach trucks in the U** AC Power Plus range have a new exterior design and new
content. The trucks have been developed with the focus set on the drivers working environment and a
completely new driver environment with improved ergonomics.
New time saving solutions reduce the time required for servicing. The drive motor, hydraulic motor and all
service points are easily accessible. The trucks are also equipped with truck computer, which facilitate
trouble shooting.
1.2
The manual is arranged according to the same principles as the Atlet's spare part catalogues, i.e. a system
consists of 12 tabs, where tabs 4 - 12 contains information limited to a specific part of the truck. For
example, Masts (section 6) and Hydraulic system (section 8). Tabs 1 - 3 in this manual contain more
comprehensive information regarding technical data, general service instructions and tools.
For specific problems or information about procedures, look in the list of contents for the correct section.
1.2.1
Symbol key
Warning! Used with risk of personal injury.
)
"
1.3
1.3
Safety
1.3.1
Lifting points
SM 172.1
Figure 1.1
The picture above shows where the permitted lifting points are located on the truck. The lifting points are
marked with a decal representing a lifting hook. When lifting just the mast, the lifting hole in the outer
mast must be used (point A). When lifting the entire truck use the lifting points on the chassis support
frame (point B)
1.4
Warning! The machine must never be lifted from the drivers overhead guard.
1.3.2
Safety instructions
When the truck is lifted using a jack, make sure you secure it using blocks. The truck must not rest on
the jack, while work is carried out.
Ensure that straps, wires or chains have a sufficient lifting capacity before use.
Pull out the plug and wait 2 minutes before starting work on the electrical system. See the warning
sign.
Ensure the drive wheel runs free of the floor before trouble shooting.
When dismantling hydraulic components, the system should not be pressurised, e.g. the pump motor
shutoff and the forks down, .
The battery plug must always be disconnected and all connections to the truck computer unit, servo
unit, and regulators (applies to all electronic units) must be disconnected during all welding work.
Once the welding work has been completed the connector must first be connected to the truck
computer unit, then connect the battery plug.
Persons must not be in the area between the mast and the machine housing if the battery plug is
connected.
Warning! Operation of the electrical emergency switch does not make the truck completely
dead.
1.3.3
Environment
Waste material that arises due to repair, maintenance or cleaning should be collected and disposed of in
accordance with the directives of each country. Such work may only be carried out in areas intended for
this purpose. Take care of the environment!
1.3.4
Handling
Ensure all essential tools are close at hand before starting work.
Check colour codes and for damage to cables and connectors before the cable harness or other
electrical components are disconnected.
When complex assemblies are repaired and need to be dismantled ensure that you have good control of
the different component parts so that confusion is avoided.
When repairing or maintaining sensitive components ensure you use clean tools and work on a clean
work surface.
Dismantle, inspect and adjust components according to the prescribed routines. See respective sections
for detailed information.
Ensure gaskets, O-rings, etc. are replaced with new parts each time they are dismantled.
Always use Atlets original spare parts. Those persons using non approved spare parts accept, without
exception, full responsibility for any damage. Hydraulic hoses should be kept so that they do not age
too quickly.
1.5
Use the screws and bolts stated in the spare parts catalogue. Tighten according to instructions. In those
cases where the tightening torque is not stated refer to the table of standard tightening torques, see
section 1.6 Tightening torque
1.3.5
Trouble shooting
When you suspect a faulty component, do not replace it immediately. First check the surrounding
equipment and carry out complete trouble shooting routines. Be sure of the reason for the fault before
replacing components.
1.4
Type designations
Truck type
UNS, UHS
Designations:
U = Reach truck
N = Normal
RF = Rotating forks
S = Standard
H = High lift
TF = Telescope forks
F = Four way
E = Ergonomics
C = Compact
Battery types:
UNS
UHS
UNS / UHS:
R, X, M
R = Reach
M = Motor powered battery rollers
X = Battery on rollers
Battery size:
UNS:
C, E, F, G
UHS:
E, F, G
Battery
C:
capacity:
E:
F:
G:
1.6
Combina-
tions:
Loading capacity / 10
Mast type
DTF
Figure 1.2
RC
X
X
X
RE
X
X
X
X
X
X
RF
X
X
X
X
X
RG
X
X
XC
X
X
X
XE
X
X
X
X
X
X
XF
XG
XFM
X
X
X
X
X
1.7
1.5
Component specification
1.5.1
Drive motor
Elmo
Output
1.5.2
Electric brakes
Braking torque
125 Nm
1.5.3
Gearbox
Kordel
Gear ratio
18,37:1
Oil volume
3.5 l
Oil type
1.5.4
Hydraulic unit
Elmo / Eckerle
Output
Max pressure
175 bar
Working pressure
150-165 bar
Flow
13.3 cm3/r
Tank volume
Max 34 l
1.8
1.5.5
Make
Inmotion
Type
83R09027A
Voltage
48 V
1.5.6
Battery
Voltage
48 V
300 - 900 Ah
900 Ah
300 - 750 Ah
1.5.7
Servo motor
Make
Kordel
Voltage
48 V
1.5.8
Make
Inmotion
Voltage
48 V
Current capacity
21 A
Fly by Wire
1.9
1.6
Tightening torque
DIM
4.6
Nm
Tensile grade
8.8
10.9
Nm
Nm
12.9
Nm
M4
M5
M6
M8
1.1
2.2
3.7
8.9
2.9
5.7
9.8
24
4.0
8.1
14
33
4.9
9.7
17
40
M10
M12
M14
M16
M18
M20
17
30
48
74
103
144
47
81
128
197
275
385
65
114
181
277
386
541
79
136
217
333
463
649
The tightening torque values in the table above are standard values. In some cases specific tightening
torque values are stated in respective tabs. If no tightening torque value is stated in the service instructions
the values shown in the table above apply.
1.6.1
1.10
Kilo pond
metre (kpm)
Pound force
inch (lbg x in)
1
9.81
0.11
1.36
0.10
1
0.01
0,14
8.85
86.8
1
12
0.74
7.23
0.08
1
1.6.2
Designation
Tensile grade
M6S
Hexagon bolt
8.8
10.9
8.8
8.8
10.9
12.9
MC6S
MF6S
10.9
MCS
Slotted screw
4.6
MVBF
4.6
8.8
10.0
SM 166.1
8.8
8.8
12.9
12.9
SM 031.1
Figure 1.3
1.11
1.7
Lubrication
1.7.1
H
A
C
K
L
F
M
N
O
Service
rlig Service
SM 174.1
Figure 1.4
1.12
1.7.2
Key
Symbol
Key
Hydraulic oil
Gearbox oil
Grease
Chain spray
Teflon paste
Applicable in general for the symbols:
Unfilled symbol - Check lubrication
Filled symbol - Replace
A.
Mast damping
J.
Chain pulley
B.
L.
Hydraulic tank
C.
M.
Hinge
D.
N.
E.
O.
Gearbox
F.
G.
H.
I.
IMPORTANT! All torsion springs in the machine should be lubricated during each service.
1.13
1.8
Gearbox oil
According to APIclass GL-5
Hydraulic oil
According to VG class
32, 15
Normal
Cold
storage
Normal
(32)
Cold store
(15)
Normal
BP
BP
Energear
FE 80 W140
BP
Energear
75W-140
EP-S
Bartran
SHF-S 32
Bartran
HV32
BP
Energol
SHF-Lt 15
Energrease
LS EP2
Mobil
Mobilube
SHC
80W-140
Mobilub e DTE 13 M
SHC
75W-140
DTE 11M
Mobilplex
48
Shell
Tellus oil
T32
or: TX32
Tellus oil
T 15
Alvania
G2
or:
Retinax
LX2
Exxon /
Statoil
Gearway
G5
85W-140
Syntol
75W-140
Hydraway
HV 32
Texaco
Geartex
EPC
80W-140
Rando oil
HDZ 32
Rando oil
HDZ 15
Multifak
EP2
Castrol
Hypoy C
80W-140
Hyspin
AWH 32
Hydraulic
OM 15
or: Hyspin
AWH15
Speerol
SW2
or: AP2
Gleitmo
Grease, bearings,
mast, seat, etc.
Tergoseat
bushing
Side-shift
Teflon
paste
Molybd.
Alloy
882EP
HVY
Cold
storage
Univis J 26 Uniway Li
42
or: Li62
Gleitmo
805
Others
The side-shifts slide surfaces should be lubricated using open gear grease.
IMPORTANT! Do not mix different lubricants - definitely not synthetic oil with mineral oil!
1.14
1.9
Recommended replacement
1.10
1.11
"
Notation
Yellow
Medium grey
Dark grey
NCS 0070-Y20R
NCS 7000
NCS 8000
Cable colour
BE
BL
BN
GN
GR
O
P
R
SB
VO
W
Y
Beige
Blue
Brown
Green
Grey
Orange
Pink
Red
Black
Violet
White
Yellow
Note! Twin coloured cables are shown with both colour codes separated by a slash. For
example, Blue and yellow cables are defined with the colour code BL/Y.
1.15
1.12
First letter
Code Designation
A
Component or function.
without its own letter below
Contactor
Diode
Electronic component
Fuse
Battery
Indicator
Relay
Motor
P/X Plug
R
Resistor
Switch
Terminal
Brakes
Second letter
Code Designation
B
Brakes
Control system
Emergency function
Forward
Hour
Key
Lower
Manoeuvre
Pump
Reverse
Speed
1.13
Units
Abbreviation
Key
A
V
V/A
W
Nm
k
M
Ampere
Volt
Ohm
Watt
Newton metre
kilo (=1000)
Mega (=1 000 000)
1.17
1.18
Service Manual
U - AC Power Plus
Manual No: 005953
Section:2 Issue: A
2 Special tools....................................................................................2.3
2.1 List of tools....................................................................................................................................2.3
2.1
2.2
Special tools
2.1
List of tools
Tool
110360
001210
015101
015100
110782
111111
112268
110668
2.3
2.4
Service Manual
U - AC Power Plus
Manual No: 005953
Section:3 Issue: A
3 Service ............................................................................................3.3
3.1 Service inspection list....................................................................................................................3.3
3.2 Code explanation ...........................................................................................................................3.9
3.1
3.2
Service
Service should be carried out regularly two times a year with normal truck usage, i.e. 1000 operating hours
per year. The planned service (500 h) includes stages such as driving tests, operating tests, filter
replacement, oil changing and replacement of carbon brushes, etc. Servicing takes place at different time
intervals depending on the trucks number of operating hours. The service interval should be more frequent
if the truck works in extreme conditions or in rugged environments.
3.1
A complete operations test must be performed before the inspection. Faulty functions must be rectified
before the inspection.
IMPORTANT! The truck must be cleaned, springs and all moving parts (axles) must be
lubricated with every service inspection. All mountings on the drivers guard, battery partition,
side plates and drive unit must be tightened with every service inspection.
Special attention should be made to the inspection of the electrical emergency stop device. If contactor tips
on the contactors appear to be worn with a visual inspection these should be replaced as a preventive
measure. Applies to contactors K10, K11 and K12.
IMPORTANT! The contactor tips should always be replaced and the entire device operations
tested if the emergency stop has been used in an emergency situation.
For further information about procedures for inspections, repairs and replacement refer to respective
sections. See the list of contents. Planned service inspections take place according to the following points:
3.3
Chassis
Inspection
points
Symptom
Signs/Decals
Doors, panels
None, unreadable
Mounting
damage
Driver seat
Mounting, damage,
lubrication *
Overhead guard
Mounting
Deformation,
cracks, other
damage
Load wheel
Damage, wear
Noise
Mounting
Battery stop,
Damage,
Battery rollers,
mounting,
Battery lock
lubrication *
Rubber mats,
compartment,
Chassis, general
Damage
Mounting
Appearance
Damage
Loose bolts
Inspection
Service code
Visual
Visual, tools,
1024, 1101
1005, 1102
1032 *
1107, 1034
*
1035
Visual, tools,
Visual, tools,
Visual, tools,
Visual
Listen, tool
Visual, tools,
1051, 1108
Visual, tools,
1014,
1013
*
1105, 1058
Visual
Visual, tools,
Visual
Visual
Tool
3.4
1033, 1112
*
Frame
Inspection
points
Symptom
Lift chains #
Chain adjustment
Lubrication *
Damage, chain
Damage, chain bolt
and chain bolt
mounting
Forks #
Weld damage
Wear
Angle
Mast
Cracks/Weld
damage
Mast dampening
Lubrication *
Play damage,
wear to rollers
Angle, parallel
deformation
Mounting rollers
Reach carriage Crack formation/
welded joints
Lubrication
Play damage,
wear to rollers
Deformation
Fork carriage
Cracks/Weld
damage
Wear,
damage
Inspection
Service code
By hand
Visual, tools,
Visual
Visual
2008
Visual
Visual
Visual
Visual, tools,
2026, 2107
Operating test
Visual, tools,
Visual, tools,
operating test
Visual
Visual, tools,
Visual/tools,
2101,
2103
Visual, tools,
Visual, tools,
operating test
Visual
Visual, tools,
2007, 2004
2033
Visual
3.5
Drive unit
Inspection
points
Gearbox *
Drive axle
Gear
Drive motor
Symptom
Inspection
Service code
Oil level
Noise
Noise
Oil leakage
Function, noise
Visual, filling
Listen, tool
Listen, tool
Visual, tools,
Listen, tool
3101, 3006
3104
3106
Cable connections
Drive wheel
Noise
Damage, wear
Mounting, play
Turning bearing Noise, lubrication *
Visual, tools,
Listen, tool
Visual
Visual, tools,
Listen, lubricate
7027, 7112,
7104
3005, 3102,
3002
3103
Steering
Symptom
Inspection
Inspection
points
Gear
Servo motor
Mini/Midi
steering wheel
Tachometer
3.6
Noise
Mounting
Carbon brush wear
Mounting
Damage, wear
Listen, lubricate
Visual, tools,
Visual, tools,
Visual, tools,
Visual,
function test
tools
Service code
4009
4014
4013
Brakes
Inspection
points
Symptom
Inspection
Service code
Braking force #
Operating fault
5012
Braking effect
Parking
brake
Brake disc
Braking distance
Operating fault
Function test
tools
Measure, tool
Function test
tools
Visual, tools,
Wear
5014
5104
Inspection
points
Hydraulic system
Symptom
Inspection
Hydraulic tank
Oil level
Visual, filling
Damage, leakage,
Visual, cleaning
contamination
Air, oil filter
Visual, replacement
blocked #
Cylinders
Function
Function test, stop watch
Damage
Visual, replacement
Leakage
Visual, tools, replace
Cracks/
Visual, tools,
Weld damage
replacement
Damage, chain
Visual, tools,
bracket
Hoses
Leakage, damage
Visual, tools,
Mounting
Visual, tools,
Nipples
Leakage
Visual, tools,
Pump motor
Function, noise
Listen, tool
Cable connections
Visual, tools,
Hydraulic pump
Leakage
Visual, tools,
Damage
Visual, tools,
Noise
Listen
Proportional
Operating fault
Test of lever function
valve, on/off
Operating fault
Calibration of levers
valve
Leakage
Visual, tools,
Service code
6012, 6102
6017, 6001
6106
6019
6109
6009
# Filter replacement at the latest every 1000 operating hours or if necessary (when it is dirty).
For more information regarding the hydraulic system, also see section 8 and lift cylinders section 9.
3.7
Electrical system
Symptom
Inspection
Inspection
points
Cables, switch
Connectors
Battery
AC
regulator
Cable harness
Horn
Speed controller
and brake pedal
Level selector
Speed
switch
Fuses
Damage operating
faults, not clean
Operating fault
Cable breakage
Contactor strip
Charging error
Low acid level
Low acid weight
Damage
Visual, tools,
replace
Visual, tools,
replace
Visual, tools,
Visual, tools,
Tool
Tools,
Tools,
Visual
Tools,
DC voltmeter
Operating test,
tools
Visual, tools,
Damage, breakage
Operating fault
Mounting
Operating fault
Operating fault
Operating fault
Operating fault
Visual, tools,
Function test
Visual, tools,
Function test
Calibration
Function test
Function test
7104
7014
7106
Blown
Visual, measure,
replace
Visual,
contact surfaces
Visual, tools,
Visual
Function test
tools
Visual, tools,
Function test
Function test
service functions
Visual
Visual, tools,
7103
Battery plug
Operating fault
Video camera
Mounting
Damage
Operating fault
Truck computer:
Display,
Keyboard,
Control unit
Damage, wear
Operating fault
Mounting
Read error log#
Incorrect display of
measurement
values
3.8
Service code
7107
7032
7025
7034
7035
7008
7037
7203, 7012
7202, 7004
Electrical system
Symptom
Inspection
Inspection
points
Cooling fans
Function #
Service code
Function test
3.2
Code explanation
Chassis
Code
Designation
Check
1112
Optional equipment
1005
1024
Doors
Machine plate
1032
Panels
1033
Paint
1058
1035
Rubber strips
Overhead guard
1107
Seat
1051
1108
Rail wheel
Rail wheel bearing
1013
Battery locking
Reference.
1.9
1.4
4.3
1.11
1.9, 4.1
4.5
4.2.2
4.2.2
4.2
Mast
Code
Designation
Check
Refer to
2008
Lift chains
6.6.2
2026
Forks
2101
Mast play
2007
2033
6.4.3
6.2
6.4
3.9
Mast
Code
Designation
Check
Refer to
2103
Mast rollers
Drive unit
Code
Designation
Check
Refer to
3006
Oil leakage
5.6
3101
3005
3106
3103
3104
3002
3102
Oil level
Drive wheel bolts
Gears
Sliding bearing
Drive axle
Drive wheel
Noise
1.7.3, 5.4.1
1.9
1.7.3
1.10
1.9, 5.6
5.7
1.9
Steering
Code
Designation
Check
Refer to
4004
4009
4014
4013
Gear drive
Intermediate wheel
Servo motor
Mini-wheel
Play, lubrication.
Axle locking, lubrication
Mounting, carbon brush wear
Mounting, rotary motion
1.10
1.10
7.2
7.2
Brake unit
Code
Designation
Check
Refer to
5012
Braking force
Braking distance.
5014
5104
Parking brake
Brake disc
11.2.1
11.3.4
11.5
11.4.2
Hydraulic system
Code
Designation
Check
Refer to
6012
6017
6106
6001
1.14
1.5, 1.6
1.15
9
6019
6109
Nipples
Hydraulic pump
3.10
Hydraulic system
Code
Designation
Check
Refer to
6009
6111
6102
Hydraulic valve
Optional equipment
Filter
8.5
8.1
8.1
3.11
Electrical system
Code
Designation
Check
7101
Connectors
7032
Battery
7025
7104
Transistor system
Cable harness
7014
7106
7012
7034
Horn
Speed controller
Hour meter
Level selector
7035
Speed switch
7017
7103
7008
7037
Microswitch
Fuses
Battery connections
Video equipment
7203
7202
Display
Keyboard
7027
7112
7030
Noise
Fastening, damage. Need of cleaning.
Mounting. Need of cleaning.
Refer to
3.12
Service Manual
U - AC Power Plus
Manual No: 005953
Section:4 Issue: A
4 Chassis ............................................................................................4.3
4.1 Chassis, plates ...............................................................................................................................4.3
4.1.1 Dismantling, assembling the overhead guard ....................................................................4.3
4.1.2 Dismantling, assembling the overhead guard stanchion ....................................................4.4
4.2 Chassis, machine housing components ........................................................................................4.4
4.2.1 Dismantling, assembling the rail wheel .............................................................................4.4
4.2.2 Adjusting the door .............................................................................................................4.5
4.2.3 Battery lock, battery type R ................................................................................................4.6
4.3 Panels.............................................................................................................................................4.7
4.3.1 Dismantling, assembling of the panels ..............................................................................4.7
4.4 Adjustable arm rest U*S................................................................................................................4.8
4.4.1 Dismantling, assembling the arm rest. ...............................................................................4.8
4.5 Driver seat U*S .............................................................................................................................4.9
4.5.1 Adjusting the dampening ...................................................................................................4.9
4.5.2 Adjusting the lumbar support ............................................................................................4.9
4.5.3 Adjusting the arm rest ........................................................................................................4.9
4.5.4 Adjusting the seat forwards/backwards .............................................................................4.9
4.5.5 Vertically adjusting the front edge of the seat cushion ......................................................4.9
4.1
4.2
Chassis
The chassis on trucks in the U-range are built-up of modules. The different chassis parts are mounted on
the chassis base.
4.1
Chassis, plates
19
15
"
14
12
3
4
20
21
1413
22
8
9
23
6
10
11
12
24
29
13
28
27
26
30
31
32
37
33
36
A 281.1
35
34
Figure 4.1
4.1.1
Bolt pos 2, Figure 4.1, which screws into the overhead guard support should be assembled from above.
Nuts are fitted from below.
The tightening torque for the nut is 81 Nm.
4.3
4.1.2
Bolts securing the overhead guard stanchion to the side plate are assembled from above.
Nuts are fitted from below.
The tightening torque for the nut is 81 Nm.
"
Note! Other bolts and screws are tightened to the torque stated in the table in section 1.
4.2
4.2.1
23
24
23
26
26
27
25
PA 286.1
22
Figure 4.2
4.4
4.2.2
The door hinge is adjustable so that the door can be opened and closed with a
good fit against the chassis.
Adjust the height of the door using the screws at the end of the hinge, pos
1. The top edge of the door, towards the hinge side, should protrude a
little above the edge of the chassis.
1
2
3
Counter hold using an open ended spanner on the eccentric cam, pos 16.
16
Turn the eccentric cam to adjust the fit of the door, lock the eccentric
cam using screw, pos 15. Check and readjust, if necessary.
17
15
18
3
2
1
Figure 4.3
4.5
4.2.3
1
2
SM 177.1
Figure 4.4
4.6
4.3
Panels
The recyclable panels are manufactured of durable, vacuum formed ABS plastic.
4.3.1
7
2
A 280.1
Figure 4.5
4.7
4.4
4.4.1
15
57
21
18
19
28
PA 283.1
Figure 4.6
4.8
20
22
4.5
The driver seat is fitted with adjustable gas cartridge dampening dependent on the body weight. The
lumbar support can be adjusted in three positions. The arm rests can be rotated to give a comfortable
working position and lifted to assist entering and alighting from the driver compartment.
4.5.1
4.5.2
d
b
4.5.3
e
c
SM 191.1
Figure 4.7
4.5.4
4.5.5
4.9
4.10
Service Manual
U - AC Power Plus
Manual No: 005953
Section:5 Issue: A
5.1
5.2
Drive unit
The drive unit is mounted in an assembly containing the brakes, drive motor, gearbox and drive wheel. The
steering servo motor is mounted on the same motor bed.
For technical data regarding component parts, see section 1.
5.1
1
3
2
6
SM 175.2
Figure 5.1
"
5.3
5.2
For further technical information regarding the drive motor, see section 1 Technical data.
Warning! The battery plug must be removed and the machine lifted so that the drive wheel
runs free of the ground when working on the motor.
5.2.1
Machines in storage that will not be used within a month, must be given special attention so that problems
do not occur when they are to be used. Dust, dirt, condensation and moisture that occurs during large
changes in temperature, as well as problems with rust and oxidisation must be prevented. Consequently
motors should be protected using waxed paper or the like, as well as using a moisture absorbing material,
e.g. silica gel.
5.2.2
First service
5.2.3
Preventive maintenance
Preventive maintenance is implemented in accordance with the intervals set out in the service chart. See
section 3, Service.
However, in some cases exceptions must be made and the intervals can be shortened, depending on the
conditions in customer's premises, e.g. a rugged environment with dust, high humidity levels, salt, etc.
Listen for noise from the bearings when the motor is run. Check that it does not vibrate abnormally.
Blow down the motor using dry compressed air or clean using a vacuum cleaner. A special cleaning
fluid P/N 122268 should be used to drive out oil and dirt, if oil has leaked from the gearbox into the
motor. Finally blow dry using compressed air.
Check that the insulation resistance for the motor does not fall below 48 K ohm.
5.4
5.2.4
"
3
4
5
6
SM 176.1
Figure 5.2
5.3
A total overhaul of the motor is recommended after 3000 to 5000 operating hours. The motor should be
removed from the drive unit (see 5.1, 5.2). Now dismantle the motor so that the end shields, armature are
released. Great care should be exercised because the tacho sensor is integrated in one of the bearings so
that the sensor is not damaged.
5.3.1
Motor bearings
The motor bearings should always be replaced when reconditioning the motors to ensure continued
reliable operation.
5.5
5.3.2
5.3.3
Stator housing
The housing is cleaned using a special fluid P/N 112268 and then blown dry; after the housing has dried,
make an insulation test:
Check that the insulation is satisfactory. Measure the resistance between the coil and stator housing see
section 5.2.3 Preventive maintenance If the resistance is lower the motor must be blown clean and
tested again.
5.3.4
Assembly
5.4
Gearbox
For further technical information regarding the gearbox, see section 1 Technical data.
5.4.1
First service
The first oil change should take place after approximately 150 200 hours.
Drain the oil from the gear housing. (pos 40 fig 5.4)
5.4.2
Preventive maintenance
Oil change takes place after approximately 1000 operating hours or at least once a year.
The steering bearing must be greased at least once a year. If steam cleaning or high pressure washing
has been carried out then grease bearing immediately.
5.6
5.4.3
"
"
5
6
pB 280.1
Figure 5.3
5.7
5.5
1
27
33
31
30
34
32
37 38
15
16
17
39 40
18
19
20
21
pB 202.3
Figure 5.4
29
28
35
36
5.6
Lift up and remove the blocks, lower the machine onto the floor.
Tighten the wheel nuts to the prescribed tightening torque 150 Nm.
5.9
5.7
Cause
Action
5.10
Service Manual
U - AC Power Plus
Manual No: 005953
Section:6 Issue: A
6 Mast ................................................................................................6.3
6.1 Mast 140, 160 ................................................................................................................................6.3
6.1.1 Dismantling the mast .........................................................................................................6.3
6.1.2 Adjusting the mast .............................................................................................................6.4
6.2 Mast 141, 200 ................................................................................................................................6.6
6.2.1 Dismantling the mast .........................................................................................................6.6
6.2.2 Adjusting the brass lugs .....................................................................................................6.7
6.2.3 Adjusting the mast, top ......................................................................................................6.7
6.3 Reach carriage ...............................................................................................................................6.8
6.3.1 Dismantling the reach carriage ..........................................................................................6.8
6.3.2 Adjusting the reach carriage. 141, 200 DTFV ...................................................................6.9
6.3.3 Adjusting the reach carriage 140, 160 DTFV ..................................................................6.10
6.4 Fork carriage................................................................................................................................6.11
6.4.1 Adjusting the fork carriage 140, 160 DTFV ....................................................................6.11
6.4.2 Adjusting the fork carriage, 141, 200 DTFV ...................................................................6.12
6.4.3 Dismantling, assembling the fork carriage ......................................................................6.12
6.4.4 Fork test ...........................................................................................................................6.13
6.5 Lift cylinders ...............................................................................................................................6.14
6.5.1 Adjusting, the cylinder mounting on the mast .................................................................6.14
6.6 Lift chains....................................................................................................................................6.15
6.6.1 Adjusting the lift chains ...................................................................................................6.15
6.6.2 Inspecting the lift chains ..................................................................................................6.15
6.7 Trouble shooting chart.................................................................................................................6.16
6.8 Fork side shift unit.......................................................................................................................6.16
6.8.1 Trouble shooting ..............................................................................................................6.17
6.1
6.2
Mast
6.1
3
1
Double telescopic.
9
10
8
2
13
11 12
6
1 5
3
1
14
15
16
17
18
12 11
17
24
21
19
25
22
23
20
27 26
27
26
30
6.1.1
1
2
29
41
40
24
28
26
42
26
43
25
33
34
35
44
36
37
36
11
C 281.1
38
39
12
Figure 6.1
Check that the thrust rollers lie against the roller surfaces on the mast. Also check that they roll easily.
An operating test must be made after each measure/action on the mast system. The mast must not jam
or run slowly (the mast sections may move in the wrong order) when lifting and lowering.
6.3
6.1.2
sm 183.1
Figure 6.2
sm 184.1
Figure 6.3
sm 185.1
Figure 6.4
6.4
sm 186.1
Figure 6.5
IMPORTANT! If necessary,
dismantle the sensor, level
measurement chain and other
optional parts before the mast
sections and lowered.
sm 187.1
Figure 6.6
6.5
6.2
Double telescopic.
Have free lift function, i.e. the fork carriage runs to the top of the inner mast before the mast section
moves upwards.
6.2.1
1
2
3
4
5
6
7
8
9
1 2
7
4
12 13
12 10
10
6
5
4
14
15
2
8
20
21
22
15
24
28
25
30
27 26
27
26
35
36
30
51
37
27
26
31
32
60
34
32
29
33
26
38
42
27
28
39
40
41
43
31
14
16
29
17
18
19
23
10
16
9
11
40
44
42
45
46
43
44
16
15
14
50
45
55
56
57
58
52
50
46
49
47
53
54
48
16
15
14
47
48
49
C 200.5
Figure 6.7
Check that the thrust rollers lie against the roller surfaces on the mast and that they roll easily.
Check that the thrust rollers run square to the roller surfaces. If not this will result in damage, e.g. deep
grooves or chips on the masts roller surfaces.
An operating test must be made after each measure/action on the mast system. The mast must not jam
or run slowly (the mast sections may move in the wrong order) when lifting and lowering.
6.6
6.2.2
42
43
44
45
46
pC 200.3
Figure 6.8
6.2.3
1 2
5
6
30
31
32
p2C 200.3
Figure 6.9
6.7
6.3
Reach carriage
6.3.1
6.8
6.3.2
35
7
5
9
10
11
12
13
3
30
31
29
37
38 12
13
19
36
28
27
34
33
32
42
22
21
20
26
5
23
24
25
20
22
21
5
14
15
16
17
18
39
40
41
C 210.4
Figure 6.10
6.9
6.3.3
6
35
7
1
6
5
9
10
11
12
13
30
29
37
38
36
19
4
15
16
5
21
22
20
C 280.1
5
14
6
Figure 6.11
6.10
12
13
6.4
Fork carriage
Different fork arrangements are mounted on the back of the fork carriage from basic forks to complex units
with side shift, fork spread and telescopic forks.
6.4.1
7
6
6
1
11
12
3
13
16
17
19
33
20
C 282.1
Figure 6.12
6.11
6.4.2
7
6
6
1
11
12
8
9
10
13
15
14
16
17
18
19
20
27
26
24
21
22
C 206.2
28
23
Figure 6.13
6.4.3
Lift up the inner mast using a crane until the fork carriage is released.
6.12
25
6.4.4
Fork test
Marking
Difference in height
between fork arm tips
SM 020.1e
Figure 6.14
Shank
Tip
Thickness
Hook
Blade
Heel
Length
SM 021.1e
Figure 6.15
Fork angle: The angle between the blade and the shank may be max 93 degrees.
The height difference between the tips of the forks: Must not exceed 3% of the blade length.
Locking device: Check that the locking device works.
Labelling: The fork's marking should be clear and comprise the lifting capacity in I kg for one fork and the
centre of gravity distance in mm.
6.13
6.5
Lift cylinders
6.5.1
6.14
SM 094.2
Figure 6.16
Lift chains
6.6.1
5 2
6.6
SM 075.1
Figure 6.17
6.6.2
If the lift chains do not pass the inspection at any point the whole chain
should be replaced. It is not permitted to join or re-rivet lift chains.
SM 169.1
Figure 6.18
Make sure the chains are clean. Make the inspection without a load.
Lift up the forks about 20 cm above the floor. Measure over the 25 links
that run over the guide rollers, as the elongation is normally at its
greatest here. Compare with the measurements below. If the chain has
stretched by more than 2% it should be replaced.
3/4"
1"
1 1/4"
The trucks lift chains should be inspected regularly, after about 1000
operating hours.
Pmeasurem
ent
Measurement 25
links
new chain
Max measurement 25
links
2% elongation
19.05 mm
25.40 mm
31.75 mm
476.25 mm
635.00 mm
793.75 mm
485.00 mm
658.00 mm
809.00 mm
Check that there are no visible cracks on any of the side plates.
Check that the chains run easily over the guide cogs and do not jam.
6.15
6.7
Cause
Action
Play on mast.
6.8
2
9
10
6
5
I 10.1
4
3
Figure 6.19
6.16
6.8.1
Trouble shooting
Symptom
No side shift
Side shift
runs too slow
Cause
Side shift unit deformed by
collision or overloading.
No play under the lower mounting
blocks.
Worn hydraulic hoses.
Defective hydraulic pipes.
Insufficient hydraulic pressure.
Irregular
side shift
"
Action
Straighten!
Adjust the blocks so that 1 mm of play
is obtained!
Replace the hoses!
Correct!
Increase the pressure!
Check the computers values under the
menu VALVE PARAMETERS
Replace/repair the hydraulic pump!
Replace the cylinder!
Replace the cylinder!
Change the bush, clean and oil!
Check the trucks oil level in the tank and
pump!
Check that the hoses are tight!
Replace/repair the hydraulic pump!
Increase the pressure!
Check the computers values under the
menu VALVE PARAMETERS
Bleed the system and check the oil level.
Fill with oil if necessary!
Replace the bush, clean and lubricate!
Bleed the system!
Replace the cylinder!
Check the valve function!
Note! The cylinder is sealed and cannot be opened. There any no spare parts available.
6.17
6.18
Service Manual
U - AC Power Plus
Manual No: 005953
Section:7 Issue: A
7 Steering...........................................................................................7.3
7.1 Servo motor ...................................................................................................................................7.3
7.1.1 Dismantling the servo motor ..............................................................................................7.3
7.2 Electronic steering (ACC) .............................................................................................................7.4
7.2.1 Servo steering unit, functions ............................................................................................7.4
7.2.2 Settings ...............................................................................................................................7.5
7.2.3 Function control of the electric servo ................................................................................7.7
7.3 Diagnostics ....................................................................................................................................7.8
7.3.1 Outputs from the steering unit ...........................................................................................7.8
7.3.2 Control connection 13 pins ................................................................................................7.8
7.4 Trouble shooting table...................................................................................................................7.9
7.5 Settings U** ..................................................................................................................................7.9
7.1
7.2
Steering
The trucks in the U AC Power Plus range are equipped with an electric steering as standard and are
manoeuvred using a mini wheel mounted on the left-hand armrest. The steering is divided into 3 units on
the electrical side and gear transfer of power between the steering servo motor and the drive unit. The first
unit, the mini wheel is a progressive steering unit. The quicker the wheel is turned the faster the movement.
The second unit is a servo steering unit, which converts the steering signals to the third unit, the steering
motor. There is no mechanical connection between the mini wheel and the steering wheel. The electrical
section is monitored by a safety system that stops the truck if an error should occur. An error code is then
shown on the display and these are then saved in the ATCII log.
7.1
Servo motor
The only adjustment of the steering system takes place electrically, the number of turns of the steering, the
steering force and compensation can be set.
7.1.1
SM 190.1
Figure 7.1
7.3
7.2
7.2.1
RE1
RELAY
5 6 7 OFF
M1
M2
SW1
OPEN
1 2 3
K2
8 9 10
11 12 13
ON
LIN
1
2
3 3
4
5
6 4
7
8
K1
LIN
ERROR
ERROR
SM 033.1
Figure 7.2
Switch function
(dipswitch)
No.
1
2
3
4
5
6
7
8
"
Function
Not used
Current limit
IR-compensation
Sensitivity
7.4
LED No
Indicator lamp
Indicates the following when on
1
2
3
4
5
Everything OK
End position
End position
Fault
Fault
7.2.2
Settings
The current limit to the motor can be adjusted and thereby also the motors torque. The limit value can be
set to 4 different levels through the dipswitches 2 and 3. If the torque is too low, the steering movement
will be weak and slow and lag behind with rapid turning of the mini wheel.
The current limit should be set so that:
The top current does not exceed the motors rated data.
The produced torque is not greater than the strength of the mechanical components.
Dipswitch 2
Dipswitch 3
10
14
18
21
Open
Open
Closed
Closed
Open
Closed
Open
Closed
Min. current A
Max. current A
IR compensation affects the motors ability to follow the mini wheel. Compensation can be set in 4
different levels by using dipswitches 4 and 5.
If it is set too low the motor will not follow slow wheel movement.
No compensation
1/3 compensation
2/3 compensation
Full compensation
Dipswitch 4
Open
Open
Closed
Closed
Dipswitch 5
Open
Closed
Open
Closed
7.5
The sensitivity of the tachometer affects the relation between the speed of the mini wheel and the
steering motor, which in turn affects how quickly the steering reacts.
The sensitivity can be set in 8 different levels using dipswitches 5, 6, 7 and 8.
If the sensitivity is too high the steering movement can be too powerful at high speeds.
To obtain a good sensitivity level at high and low speeds the unit is fitted with progressive steering. This
means the sensitivity automatically increases with rapid steering wheel movement.
Max. sensitivity
Min. sensitivity
Tachometer
voltage
Dipswitch 6
Dipswitch 7
Dipswitch 8
+/- 1.5 V
+/-3.0 V
+/-4.0 V
+/-5.5 V
+/-6.5 V
+/-7.5 V
+/-8.5 V
+/-9.5 V
Closed
Open
Closed
Open
Closed
Open
Closed
Open
Closed
Closed
Open
Open
Closed
Closed
Open
Open
Closed
Closed
Closed
Closed
Open
Open
Open
Open
7.6
7.2.3
Start the truck and check that the operation of the end stops in both directions is correct.
Turn the mini wheel maximum clockwise. Connect the red/black cable with the pink/black cable
coming from X18s connection closest to the servo box. Turn the steering to the centre position. After
approx. 10 mm of movement on the gearbox the servo contactor should break. Check that the brakes
are really applied and that it is not possible to drive the machine. If the brakes are not on and the
machine can be driven then the circuit must be checked. The drive regulator E1 is fed from the servo
connector E4 pin 8. Check that pin 8 is not voltage fed, if it is replace the servo box. Reset using the
off-on buttons on the keyboard.
Brown/white cable. Perform the same procedure with the opposite switch by connecting together the
red/black cable with the brown/white cable.
Pull apart the connector P14 (tied to the return hose on UNS). The servo contactor should break and it
should be impossible to release the brake; it should also be impossible to drive the truck. Connect P14
again.
Pull out the motor fuse for the servo motor (F4). The servo motor should stop and it should be
impossible to release the brake; it should also be impossible to drive the truck. Fit the fuse again.
If it is possible to release the brake after points 2, 3, 4 or 5 have been implemented, or it is possible to
drive the truck, the truck must be checked carefully and not used until the fault has been rectified.
Finally check that drive unit does not hit the mechanical stop in the end positions.
IMPORTANT! Remove error codes E05 and E06 by resetting in the ATCIIs service menu
log book.
7.7
7.3
Diagnostics
7.3.1
Unit active
7.3.2
1.
48 V
In
Not connected
4.
In
0V
Tachometer
5.
In
48 V
Negative direction
6.
In
7.
Out -12V
8.
Out 48 V
Safety relay
9.
In
0V
10.
In
-12/+12V
UFS: full motor modulation with automatic turning of the drive wheel
11.
In
48 V
12.
Out
13
Out
+12V
Positive direction
UFS: with automatic driving of the drive wheel
In
48V
Battery voltage +
In
0V
Battery voltage -
M1 Out
Motor connection +
M2 Out
Motor connection -
7.8
7.4
LED 1
Green
OFF
ON
ON
ON
OFF
OFF
ON
ON
ON
ON
ON
ON
ON
7.5
OFF
ON
ON
Indicates
Action
No control current
OK
Negative direction
active
Positive direction
active
Fault in tachometer
circuit. Cable
breakage, short-circuit
or wrong type of
tachometer
Fault in the steering
unit or in the motor
circuit. Cable
breakage or short
circuit
Fault in steering unit
Check supply.
None
None
None
Check the cables and connectors.
If OK replace the tachometer. If
still faulty, check that the right
tachometer is used.
Check the cables, connectors and
motor brushes. If OK, replace the
motor or steering unit.
Settings U**
Switch
1. Not connected
2. Current limit
3. Current limit
4. Load compensation
5. Load compensation
6. Sensitivity
7. Sensitivity
8. Sensitivity
Miniwheel
X
Midiwheel
O
X
X
X
X
O
O
O
O
O
X
X
O
X
7.9
7.10
Service Manual
U - AC Power Plus
Manual No: 005953
Section:8 Issue: A
8.1
8.2
Hydraulic system
Figure 8.1
8.3
8.3
"
)
8.4
50
"
49
Figure 8.4
8.5
8.3
"
)
8.4
50
"
49
Figure 8.4
8.5
8.5
Cylinders
8.5.1
Figure 8.5
8.5.2
Tilt the mast to it foremost position and lower the forks to their lowest position.
8.6
8.6
8.7
8.10
8.5.4
E 206.2
Figure 8.7
8.8
8.6
8.7
8.10
9.2
110703:E 1/1
Service Manual
U - AC Power Plus
Manual No: 005953
Section:9 Issue: A
9.1
9.2
Lift cylinders
9.1
Dismantling,
assembling the centre
cylinder
10
11
4
6
9.2
11 2
12
Dismantling,
assembling the outer
cylinders
SM 182.1
Figure 9.1
9.3
9.3
Loosen the bleeding screws, pos 25 figure 9.2 and pos 13 figure 9.3 a little to bleed the cylinders.
Tighten the screws when oil starts to run out.
Lift the forks to the top position. Perform this lift 3 times.
Bleed the cylinders again, until all the air has been evacuated from the system.
9.4
19
19
20
21
21
1
3
22
4
35
24
5
25
6
7
33
11
31
10
32
30
17
23
27
12
13
14
15
16
18
28
F 207.3
Figure 9.2
9.4
9.5
3
2
10
"
12
13
14
12
17
15
16
4
F 206.1
Figure 9.3
9.5
9.6
10
a 48 Volt battery
an ATC
a drive regulator
a pump regulator
electric brakes
electric steering
electric fans
Trucks equipped for use in cold storage facilities have covered cabs with electric heating and lighting as
extra equipment.
Some trucks are equipped with radio equipment.
Other electrical installations may be encountered due to specific customer requirements. These are not
taken up in this Service Manual.
10.3
10.1
Safety procedures
Electric powered vehicles can be dangerous. All testing, trouble shooting and adjusting must be
carried out by authorised personnel. The drive wheel should run free of the floor and be able to run
freely during work.
Take off watches and rings before starting repair and trouble shooting work.
The electrical system has a multi-stage safety system to provide the highest possible level of safety.
Abnormal conditions are detected and depending on the type of fault different measures are
implemented. The least critical condition only generates a warning via the display. Faults that may
result in dangerous situations result in a stop and trouble shooting assistance via the error log.
The battery must always be disconnected with all replacement and repair work on the electrical
system.
It is essential that all cables (especially the battery cables) are connected correctly as the electronics
used in the truck are sensitive to incorrectly polarised supply voltage.
All dust and magnetic particles should be regularly cleaned from solenoid switches and magnets to
guarantee operations.
Extreme importance must be placed on precautionary measures to avoid accidents during all work on
the vehicle. A general rule is to always implement preventive measures that are adapted to the type of
vehicle to be worked on. The general rules below must always be observed:
Smoking or naked flames are strictly forbidden as there is a risk of explosion in the vicinity of batteries
and while working on gas equipped vehicles. The battery should always be protected during grinding
work. The fire regulations for the building shall also be observed.
The truck shall always be lifted so that the drive wheel is free of the ground to prevent the vehicle from
running away. The vehicle must not rest solely on the jack, but must be secured by some form of
blocking.
The battery plug must always be removed on electric reach trucks to prevent the risk of injuries caused
by crushing. The mast, carriage and power pack can be actuated due to an electrical fault or mistake
while working. The battery plug may only be connected while trouble shooting and when the greatest
of care is exercised, (with the truck raised).
During work on and around the mast and power pack, these must be locked using the mast lock,
wooden blocks or other appropriate material. No other persons may be in the vicinity of the truck
when this is test run in combination with repair work as there is a risk of incidents and accidents
occurring due to the truck making an unexpected manoeuvre.
Warning! To stand on the carriage between the mast and battery partition with the current
connected to the truck can represent Mortal danger!
The system should not be pressurised, for example, the pump motor shutoff and the forks down, when
dismantling parts of the hydraulic system.
10.2
Grease Kryotox ATLET article number 110781 should be applied to all electrical connectors in the
machine housing and mast/mast base on cold store designed models. The hand applicator, part number
110782, should be used in order to do this. The grease should be applied to contactor surfaces when the
connectors are drawn apart. The contactors are then reconnected and the grease is pressed from behind into
10.4
IMPORTANT! Connectors filled with Kryotox should not be treated with 3M. In general the
electrical system is treated as before.
10.3
Check that the cables are labelled, if not label the cables before removing.
Loosen the bolts holding the regulators. Most bolts are accessible without the need of dismantling the
bracket.
IMPORTANT! When fitting a new regulator, check that the air tunnel where the regulator is
mounted is free of dust, etc.
10.4
You must first disconnect the connections (plugs) before the truck is insulation tested in order to protect
the regulators and other electrical components on the truck. This is because damage can occur, which will
shorten the life of component parts. In the event of large insulation errors it is appropriate to use a
universal instrument until the error has been found and then make a final insulation test.
This applies to all electronic units on the truck.
Warning! The instrument has a dangerous voltage across the measurement poles, Do not
touch the poles during testing.
Routines for insulation testing of all truck models.
1
Pull out the battery plug. Disconnect connections/terminals to electrical components and electronic
systems before the test is performed as these can be damaged by the test voltage.
Connect the instruments earth lead to the truck chassis at a point with good electrical contact. The
other lead is connected to the electrical panel plugs positive pole.
Press the start button and wait until the display has stabilised, now release the button and read off the
value on the display. An approved value on 48 volt trucks shall be at least 48,000 ohm, (48 kohm).
Let the earth lead remain attached to the chassis and connect the other lead to the electrical panel
plugs negative pole. Now repeat point 5.
ATLET SERVICE MANUAL U - AC Power Plus
10.5
10.5
sm 199.1
Figure 10.1
Display:
The top row is used for information.
The lower row is the status row.
1 9 - AU - 9 4
75
0 7 : 48
1 0H
sm 200.1
Figure 10.2
1 9 - AU - 9 4
75
0 7 : 48
1 0H
sm 202.1
Figure 10.3
1 9 - AU - 9 4
75
0 7 : 48
1 0H
sm203.1
Figure 10.4
10.6
1 9 - AU - 9 4
7 5 E1 5
0 7 : 48
1 0H
sm 201.1
Figure 10.5
10.5.1
General
The service functions are activated via the S (service) key on the keyboard. These functions are divided
into levels, Driver, Local Service, Atlet Service and Customer Service.
The Driver level allows the language to be changed as well as tuning of the trucks travel and hydraulic
characteristics.
On the Local level its possible to change the ID and password for the driver and local service, set the
speed and lift controls, check inputs and outputs, read statistics and make a hardcopy. A password must be
entered to select any of the Local Service functions.
On the ATLET level its possible to change all IDs and passwords, set parameters for the height
preselection, set options, read the error log, make hardcopies and download settings from another ATC or
PC. A password must be entered to select any of the ATLET Service functions.
The Customer Service level allows reading and printing of statistical information, communication with
PSION palm-sized computers, unlocking of a collision-locked truck and resetting of customer logs and
counters.
The menu that appears once the correct password has been entered will be abbreviated. This is because
only the menu title and one menu option (0: Exit) are shown. You can browse through the menus using the
number and arrow keys, while the Enter key selects the menu.
When you enter a form, i.e. where it is possible to change parameter values, you should use the arrow keys
when you do NOT wish to change the values. If you wish to make changes enter the new numerical values
and confirm using Enter. If you make a mistake you must continue to the closest end point and start
again. In some functions it is possible to go back using the arrow key.
10.7
10.5.2
Service functions
The service functions are primarily used to facilitate the ATLET Service. In addition, the service functions
make it possible to read off all the measurements made using the Measurement/Statistics functions.
Functions included are:
Changing the ID and password for Driver, Local and ATLET service levels.
Hardcopies.
10.5.3
Change passwords.
It is possible to change the service password as well as the drivers ID and password.
10.5.4
Hydraulic levers are calibrated by measuring the maximum stroke and neutral position for this function.
10.8
10.5.5
Total usage.
Forwards.
Backwards.
The running time of each unit presented in hours. The maximum number of hours is 99999. When printing
the running hours are also calculated and shown as a percentage of the total usage.
The running hours can either be reset for all units or individually.
10.5.6
Printing of statistics
A function is available under CUSTOMER Service to print all statistic functions either individually or all
at once. Any serial printer or a PC can be used for this purpose.
10.5.7
Collision sensor
When one of the 5 levels is exceeded a warning text is shown on the display at the same time as the impact
force of the collision is stored with the time, date and driver ID in the customer log.
10.9
100k
2k2
100nF
sm 194.1
Figure 10.8
4k7
100k
100nF
sm 195.1
Figure 10.9
10.11
Lowering outputs.
a)
b)
c)
16 Volt
Sence
Sence
R
Sence
R
Watchdog
sm 196.1
Figure 10.10
Supply outputs.
Watchdog
sm 197.1
Figure 10.11
10.12
24 Volt
Function
Type
Remarks
XC3:10
XC3:11
1.0A A High
1.0A A High
+ / Supply
+ / Supply
XC3:21
XC3:22
XC1:22
XC1:23
XC1:24
XC4:23
XC1:21
XC8:22
Buzzer
Main connector
Brakes
Flashing lights
Horn
Key relay
Reserved
Constant current valve level selector
1.0 A Low
1.0 A Low
3.0A A Low
1.0 A Low
3.0A A Low
0.1A A Low
1.0 A Low
1.0 A Low
- / Supply
- / Supply
- / Supply
- / Supply
- / Supply
- / Supply
- / Supply
- / Supply
XC8:23
XC6:23
XC6:24
XC2:22
XC3:01
XC3:08
Reserved
Lamp rail wheel 0 degrees
Lamp rail wheel 90 degrees
Position light
Reserved
Reserved
1.0 A Low
1.0 A Low
1.0 A Low
0.1 A Lamp
0.1 A High
0.1 A High
- / Supply
- / Supply
- / Supply
- / Supply
+ / Supply
+ / Supply
Type
Remarks
0.1 A Lamp
0.1 A Lamp
0.1 A Lamp
0.1 A Lamp
0.1 A Lamp
0.1 A Lamp
0.1 A Lamp
- / Supply
- / Supply
- / Supply
- / Supply
- / Supply
- / Supply
- / Supply
Function
Not connected
Not connected
Automatic drive wheel rotation anticlockwise UFS
Automatic drive wheel rotation clockwise UFS
Truck-on lamp
Straight steering lamp
Brake lamp
10.13
10.6
Function
B+ lift valve plate
B+ PWM lower valve plate
B+ Reach IN
B+ Reach OUT
B+ tilt IN
B+ tilt OUT
B+ side shift pedal side
B+ side shift seat side
B+ fork spread OUT
B+ fork spread IN
5V PWM supply steering wheel indicator
B+ PWP regulator fan
Type
1.0 A Low
1.0 A Low
1.0 A Low
1.0 A Low
1.0 A Low
1.0 A Low
1.0 A Low
1.0 A Low
1.0 A Low
1.0 A Low
1.0 A Low
1.0 A Low
Remarks
- / Supply
- / Supply
- / Supply
- / Supply
- / Supply
- / Supply
- / Supply
- / Supply
- / Supply
- / Supply
- / Supply
- / Supply
Valve parameters
A description of the valve section, lift/lowering is given below, however, the same applies to reach, tilt,
side shift, rotate/side shift. Nevertheless, it may be problematic to determine which movements correspond
to POSITIVE. Lift, reach-in, tilt up, rotate clockwise, forks together and side shift towards the driver are
all POSITIVE movements.
10.14
10.6.1
POS MAX DUTY and NEG MAX DUTY define the speed of the movement at max. joystick actuation,
these are not normally changed, but if you want calmer/slower movement, for example, while tilting these
parameters can be reduced.
POS MIN DUTY for lifting should be set so that when the joystick starts the pump, for a lift with empty
forks and for forks under free lift, the forks do NOT move.
NEG MIN DUTY for lowering should be set so that its possible to gradually run the pump or lowering
movement with a minimum of joystick actuation (lower values give lower speeds).
FETCH B./SCALEF. for reach is used for battery retrieval and for lift is used as a limiter for the overall
pump output with simultaneous movement. The value is set to 1 with the battery on the rollers to
shutdown the function.
10.7
The battery capacity is shown as a percentage of a fully charged battery to the left of the lower row on the
display. Measurements are fully controlled by software, and no further electronics are required. The
battery capacity is measured by measuring the battery voltage when the truck has been at rest for 3
minutes. If the period between measurements becomes too long, the ATC uses the running time counter to
calculate the capacity.
When the battery capacity becomes too low a warning message is given on the displays top row and the
battery capacity value starts to flash. The truck speed is limited to creep speed.
Lift stop with a weak battery is linked to the battery capacity measurement.
Both the warning level and the stop level are set in the service function.
Battery capacity%
Voltage 48 V sys.
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
45.84
45.95
46.06
46.17
46.28
46.39
46.50
46.61
46.72
46.83
46.94
47.05
47.16
47.28
47.39
1.070
1.075
1.079
1.084
1.088
1.093
1.098
1.102
1.107
1.111
1.116
1.121
1.125
1.130
1.134
10.15
10.16
Battery capacity%
Voltage 48 V sys.
30
32
34
36
38
40
42
44
47.50
47.61
47.72
47.83
47.94
48.05
48.16
48.27
1.139
1.144
1.148
1.153
1.157
1.162
1.167
1.171
46
48
50
52
54
56
58
60
62
64
66
68
70
72
74
76
78
80
82
84
86
88
90
92
94
96
98
100
48.38
48.49
48.60
48.71
48.82
48.93
48.04
49.15
49.26
49.37
49.48
49.59
49.70
49.81
49.92
50.04
50.15
50.26
50.37
50.48
50.59
50.70
50.81
50.92
51.03
51.14
51.25
51.36
1.176
1.180
1.185
1.190
1.194
1.199
1.203
1.208
1.213
1.217
1 222
1.226
1.231
1.236
1.240
1.245
1.249
1.254
1.259
1.263
1.268
1.272
1.277
1.282
1.286
1.291
1.295
1.300
10.7.1
Nominal battery voltage, state 1 for 48 Volt, 0 for 24 Volt. 48 Volt is Default.
Actual battery voltage to ATC. You can make corrections for voltage losses in
cables and connectors up to the ATC by changing these values. To make the
Measured B+
correction, measure the battery voltage at the poles using a voltmeter that can
(mV)
show 4 digits at 50 Volts, then state the voltage in mV. (If the voltmeter shows
48.12 Volt, press 48120 Ent).
Battery size (Ah) Stated in Ah. This is normally stated on the battery. Default is 550.
Pump size (kW) State in whole kW. Default is 14.
Usage, stated from 50 to 200 per cent, and used to correct for light/hard driving.
Utilisation (%) The standard is 100. Higher values are used with harder driving, lower values for
lighter driving.
Calculation constant to receive a warning of whether the chassis has an
Chassis const. 1 unpermitted HIGH voltage depending on too low resistance between the chassis
and the batterys positive pole. See table. Default is 917.
Chassis const. 2
Low batt. level
Lift stop level
10.8
This should be checked using a calibrated DMM in order to determine whether the ATC makes good
contact with the rest of the chassis. Set the digital multimeter to resistance measurement, measurement
range 200 Ohm. Touch the measurement probes together and read off the display, it should be 0.0 to
approx. 0.6 Ohm.
Connect one of the measurement probes to one of the bright screw heads on the ATC box and the other
probe to the screw for the chassis connection, (located on the battery wall under the ATC connection
green/yellow cable). The value read off should not be more than max. 0.5 Ohm higher than the read off
value under point 1.
If the value is higher make a check on some of the other screws on the ATC box. If this does not help
the screw for the chassis connection must be checked. First check by measuring this across another
clean metal surface, if the value is also too high the thread for the chassis connection should be cleaned
using a plug tap and a new check should be performed.
10.9
The potential measurement is performed with a voltage divider connected between B+ and B-, with the
ATLET SERVICE MANUAL U - AC Power Plus
10.17
centre outlet connected to the chassis. The voltage divider has sufficiently large resistance to comply with
EUs insulation requirements at the same time as potential changes can be measured via an analogue input
on the ATC.
If voltage is discovered on the chassis an error code is displayed. The error code is stored together with the
time and date in the error log.
10.10
Error codes
Check the error log and write down or print out the contents of the log before starting any trouble shooting.
Error codes and sub-information that reoccurs within a twenty-four hour time frame (00:00 - 23:59) is not
logged, which is why the log must be emptied in order for the fault to be logged again.
Please note:
That there is more information available for codes marked by an asterisk by pressing the I button when
reading the error log. The extra information is always included in the printout. Codes within brackets are
not used in version 3.30 or later.
Error text
High temperature
Chassis + voltage
Chassis - voltage
Cable fault
Servo tacho fault
Servo motor fault
Servo regulator fault
Fk7 fault
Several chassis faults
Joystick fault
NVR small fault
NVR total reset
NVR forced reset
Battery par. reset
Serv. par. reset
Valve par. reset
Travel. par. reset
Options reset
err 19
err 20
Motor carbon brush worn
P1 carbon brush worn
P2 carbon brush worn
Error code
Error text
(E24)
(E25)
E26
E27
E28
E29
E30
(E31)
(E32)
(E33)
(E34)
E35
E36
E37
E38
E39
E40
(E41)
(E42)
(E43)
(E44)
(E45)
(E46)
(E47)
E48
(E49)
E50
E51
E52
E53
E54
E55
E56
E57
E58
(E59)
E60
E61
E62
E63
P1 overheated
P2 overheated
Servo overheated
Hyd oil overheated
Temp1 overheated.
Temp2 overheated.
ATC overheated.
err 39
NV3 forced reset
Chassis to In.
Output to In.
Unknown chassis fault
Chassis to Out.
Chassis to BChassis to B+
No. of inputs
Brake sensor low
err 49
err 50
F6 Fuse blown
F8 Fuse blown
F7 Fuse blown
err 54
err 55
err 56
err 57
err 58
Test command error
Wheel angle sensor
Rotation sensor
err 62
err 63
10.19
Error code
10.20
Error text
E64*
E65*
E66*
E67
E68
E69
E70
E71
High short-circuit
Low short-circuit
Lmp short-circuit
High out intermittent
Low out intermittent
Lamp out intermittent
High output unknown
Low output unknown
E72
E73
E74
E75
E76
E77
E78
E79
E80*
E81*
E82*
E83*
E84*
E85*
E86*
E87
E88
E89*
E90*
E91*
E92*
E93
E94
E95*
E96*
E97*
E98*
E99*
E100*
E 101*
10.11
Temperature measurement
Temperature measurements are made using NTC resistance (Negative Temperature Coefficient). The
temperature can be shown from 0 to approx. 150 C. ATC has 6 channels to measure the temperature.
When the temperature is too high the driver receives an error message on the display. This takes place in
two stages. The temperature limiters can be set from the service function. The first stage involves an error
message and the second stage involves a new error message and e.g. the pump/drive motor being
shutdown.
The following statistics are saved for the temperature:
The number of times the temperature has been reached in intervals:
Only the oil temperature is measured with NTC resistance in Power Plus.
In the drive and pump motor systems the temperature is measured in the regulators and motors using PTC
resistance. The temperature is reported to the ATC via the CAN network.
Oil
Temp. above 75 C
above 120 C
Temp. 71 - 75 C
Temp. 66 - 70 C
Temp. 61 - 65 C
Temp. 56 - 60 C
111 - 120 C
101 -110 C
91 -100 C
81 -90 C
Function
Symbol
Tilt out
Tilt in
Side shift display side
Side shift seat side
Fork spread in
Fork spread out
to TO
ti TI
S<SLL
S>SR
>< SO
< > SC
Connector
P82,1 P82,2
P81,1 P81,2
P53,1 P53,2
P50,1 P50,2
P54,1 P54,2
P51,1 P51,2
10.21
10.12
Battery replacement
Continue to activate the lever at the same time as the arrow up key on the
keyboard is pressed. The reach carriage will then slide in a little further.
Loosen the battery stop by pressing down the pedal with your right foot
on U*S. Keep holding down and move out the reach carriage. The
battery will now follow out.
Replace the battery and then run in the reach carriage until it stops,
Continue to activate the lever at the same time as the arrow up key on the
keyboard is pressed. The reach carriage will then slide in a little further.
The battery is locked automatically when it reaches its innermost
position.
Now run out the reach carriage and check that the battery lock has
locked correctly.
10.22
SM 179.1
SM 179.1
Figure 10.12
10.13
30
29
32 31
33
35
34
SM 180.1
Figure 10.13
10.23
10.14
The ATC language should be set to English in order to follow the instructions below.
If necessary also refer to the section menu tree.
Setting of driver categories: Up to four sets of parameters representing performance categories may be
defined. The system should be used to define, for example, the two categories experienced drivers and
learners. All parameters are preset at the factory and are only intended to be modified by qualified
personnel. Consequently, the setting options are protected under the ATLET service
3: ATLET service
4: Settings
1: Performance
1
AC Driver 1 (Preset to normal experienced drivers represents performance according to the data
sheet.
AC Driver 4 (Preset throughout to max. performance. Intended to show the trucks maximum capacity
at demonstrations and must not be set for a driver to perform daily operations.)
Travel speed
Crawl speed
Acceleration travel
Current limit Drive
Reduction brake,
travel
10.24
Top speed
Speed limitation activated by [arrow down] key or
by the ATC logic (Tortoise on the display).
Time based ramp
Max. permitted current limit
Braking torque when the accelerator is released.
20 - 100%
10 - 90%
20 - 100%
20 - 100%
0 - 100%
Travel speed
Reversing brake,
travel
Brake pedal
Max. speed, reversing
Max. pump speed
Max. lowering speed
Acceleration pump
Soft hydraulics
Steering sensitivity
Steering progressive
Top speed
Braking torque when the driving direction is
reversed.
Braking torque when the brake pedal is used.
Top speed in the direction of the forks as a
percentage of the Drive speed above.
20 - 100%
50 - 100%
50 - 100%
70 - 100%
20 - 100%
0 = off
1 = on
50 - 100%
20 - 100%
Not introduced
Not introduced
Individual driver settings Each driver ID code can have its own performance profile, but this must be
linked to one of the four driver categories. When a new driver is defined a new question is asked Driver
category? - at the end of the sequence. On delivery factory code 1/2222 is linked to AC Driver 1
category.
IMPORTANT! When delivered category 4 is set for the demonstration of the trucks maximum
capacity and should be readjusted if its to be used for practical operations.
100
40
100
80
90
75
80
40
90
70
75
70
50
40
80
60
70
70
100
50
100
100
100
100
100
100
100
100
100
0
100
100
100
80
100
100
100
0
90
90
90
80
90
100
90
1
80
80
100
100
100
100
100
0
100
100
The parameters that the driver can tune make up a percentage of the corresponding category parameters in
the category he/she has been placed in. For example, the top speed is set by:
Top speed = Machine parameter (see 2.1) Driver category% (see 2.2) Driver%
Example: Top speed = 12 km/h 90% 100% = 10.8 km/h
10.25
IMPORTANT! If the parameter Max. speed reverse is set lower than 100% it will also be
added to the above calculation example when reversing.
Driver parameters: Each driver can set his/her own performance profile; under the condition that
individual driver IDs are used. The performance profile is activated each time the driver starts the truck.
Follow the instructions to store your own performance profile.
1
Press the [S] key with the battery plug connected, but in the logged off mode.
Select 6 Driver parameters by pressing the [6] key, or scroll using the arrow keys. Press [ENT].
Default 100%
Default 100%
Default 70%
Default 70%
Move to the parameter you wish to change. Use the number keys to define a new value. Save the value
by pressing [ENT
10.15
Fuses
Standard fuses
10.26
F1
F4
F5
F2 heavy
F3 heavy
F4
10A
5A
5A
250A
250A
20A
F6
10A
F7
5A
Standard fuses
F8
F9
F10
F12
F14
5A
10A
5A
5A
5A
Fan door
ATC
B+ ref (see trouble shooting, warning low battery)
Charging circuit regulator
Emergency stop circuits
Fuses extra accessories
F11 heavy
F13
F15
F17
F21
F22
10.16
80A
A fuse box
with 8 fuses,
see wiring
diagram
074530
5A
5A
63A
5A
Radio
Headlamp
Motor circuit, motorised battery rollers
Manoeuvre, motorised battery rollers
Horn
When connecting the horn the terminals on the terminal block should be turned towards you. Connected
according to the standard wiring diagram.
Setting the sound: A number of dipswitches labelled 1-5 can be found at the rear of the horn. The switches
are set so that 1-3 are closed and 4-5 are open. The tones obtained will then be 970 Hz for the horn and 2850
Hz for the buzzer. There is also a potentiometer screw that can be turned clockwise to the stop to give the
maximum sound level.
10.17
Warnings
The ATC display shows a warning message to the side of the described error conditions. Typical warning
conditions are when the temperature of a regulator or motor approaches a critical level. This results in
reduced power to the overheated unit. However, the truck remains operational. System temperatures under
-20C result in a power reduction and a warning condition. The warning message on the display disappears
once conditions return to normal.
Function
Warning
temperature
Stop temperature
Drive motor
Lift motor
Drive regulator
Lift regulator
Hydraulic oil temperature
145
145
85
85
60
165
165
125
125
65
10.27
10.18
Service menu
1: Set language
Select language
1.0: Exit and return to "Service menu"
1.1 :English
1.2: Svenska
1.3: Deutsch
1.4: Francais
1.5: Custom lang.1
1.6: Custom lang.2
1.7: Text test OK
2: Local Service ( Password required )(2)
Local Service
2.0: Exit and return to "Service menu"
2.1: Set drivercode
(2.1)
2.2: Run tests
Select test:
2.2.0: Exit and return to "Local service"
2.2.1: Drive test
Drive menu:
2.2.1.0: Exit and return to "Select test"
2.2.1.1: Drive inputs(2.2.1.1)
2.2.1.2: Set acceler. (2.2.1.2)
2.2.1.3: Drive outputs(2.2.1.3)
2.2.1.4: Set brake(2.2.1.4)
2.2.1.5: Regulator inp(2.2.1.5)
2.2.1.6: Brake test(2.2.1.6)
2.2.1.7: Calib. wheel(2.2.1.7)
2.2.1.8: Analog wheel(2.2.1.8)
2.2.2: Hydraul. test
Hydraul menu:
2.2.2.0: Exit and return to "Select test"
2.2.2.1: Hydr. inputs (2.2.2.1)
2.2.2.2: Read joyst. (2.2.2.2)
2.2.2.3: Pump tests (2.2.2.3)
2.2.2.4: Regulator inp (2.2.2.4)
2.2.2.5: Std. valves(2.2.2.5)
2.2.2.6: Opt. valves (2.2.2.6)
2.2.2.7: Hydr. lamps (2.2.2.7)
2.2.2.8: Calib. joyst.(2.2.2.8)
10.28
#4
10.29
#6
(3.4.3)
(3.4.4)
3.5: Spare
3.6: Spare
10.30
10.31
3.7.5: Acquisition
Acquision menu
3.7.5.0: Exit and return to "Select test"
3.7.5.1: Read data(3.7.5.1)
3.7.5.2: Print data(3.7.5.2)
3.7.5.3: Setup acq. 1(3.7.5.X)
3.7.5.4: Setup acq. 2(3.7.5.X)
3.7.5.5: Setup acq. 3(3.7.5.X)
3.7.5.6: Setup acq. 4(3.7.5.X)
3.7.5.7: Setup acq. 5(3.7.5.X)
3.7.5.8: Clear all acq.
3.7.5.9: Reset all acq.
3.7.6: Spare
3.7.7: Test any output (3.7.7)
3.7.8: Show inputs
(3.7.8)
3.7.9: System setup
#5
10.32
4: Custom serv.
Custom service
4.0: Exit and return to "Service menu"
4.1: Unlock
(4.1)
4.2: Communication
(4.2)
4.3: Printout
Print Custom
4.3.0: Exit and return to "Custom service"
4.3.1: Print counters (4.3.X)
4.3.2: Print cus.log
(4.3.X)
4.3.3: Print tmp.log
(4.3.X)
4.3.4: Print srv.log
(4.3.X)
4.3.5: Print err. log
(4.3.X)
4.3.6: Print settings
(4.3.X)
4.3.7: Spare
4.3.8: Print all log
(4.3.X)
4.4:Readout
Read custom
4.4.0: Exit and return to "Custom service"
4.4.1: Cust. counter
(4.4.1)
4.4.2: Cust. log
4.5: Reset custom ( password required )(4.5)
Reset custom
4.5.0: Exit and return to "Custom service"
4.5.1: Cust. counter
4.5.2: Cust. log
#5
(3.7.8)
5: Startup
6: Driver param.
(6)
10.33
Comments:
#1
Removed in issue C
#2
Removed in issue B
#3
#4
#5 Line 1 shows "Ana.inp XCnn.pp" or "Dig.inp XCnn.pp" where nn is the connector number and pp is
pin number.
#6
Either select function by pressing key 1' to 5' or touch the joystick for the function.
#7 Asks for password and then goes thru options list ( 3.3), calibration of speed pedal ( 2.2.1.2) and
hydraulic levers ( 2.2.2.8).
10.34
10.18.2 Subinfo
Error codes with underlying subinfo menu. Read the fault log in the log and bring up subinfo by pressing
the I on the keyboard!
ATC seems as if it does not work as it should, check the internal fuses F1, F4 and F5 in the ATC.
Check the nine measurement points in the form of insulation support under the instrument panel.
B 5V should be 5V.
B+5 should be B+ 48V when the truck is logged on and the servo is active.
If B+ or B- deviate, check the battery plug, electrical panel plug and associated cable connections.
If B+2 deviates, check the fuse F14 and the emergency stops SE1 and SE2. Also check that the
connectors K11 and K12 through the visual inspection of the contact strips and that the coils are not
short circuited and that the freewheel diodes across the coils are intact. Check the connectors cable
connections too.
If AGND deviates, check the connections between AGND measurement point and ATC XC1.10. If
AGND is broken it gives a calibration error. If AGND is not put out by ATC, change the ATC.
If B12V deviates, check the connections between B12V and ATC XC3.17. If B12V is broken the
indicating lamps will not light. Ensure that nothing loads 12V by pulling out all ATC connectors
except XC9, also disconnect the CAN bus, now check whether the ATC puts 12V out on pin XC3.17,
if not change the ATC.
If B+3 deviates, check the fuse F6 and connections from the key relay K3.30 to K3.87, if the relay
ATLET SERVICE MANUAL U - AC Power Plus
10.35
does not make check the coil resistance (should be approx. 300 ohm), the freewheel diode across both
relay coils and cable connections to the ATC XC1.17 and XC1.27. If the relay circuit is OK, check that
B+ 48V puts out on ATC XC1.17 and that the output XC4.23 draws to 0V when logging on, if not,
replace the ATC.
If B+4 deviates, make a check as set out above but on F7 and K6.30, K6.87
If B+5V deviates, check that the cable connections between B5V and ATC XC1.11 are intact. Ensure
that nothing loads 5V by pulling out all ATC connectors except XC9, also disconnect the CAN bus,
now measure whether there is 5V on the measurement points or XC1.11, if not change the ATC.
10.19
Trouble shooting
10.19.1 Low temp drive or Low temp hydraulics - Warning on the display
10.36
No
Yes
Yes
No
No
Yes
No
Yes
No
Yes
No
10.37
No
Yes
No
Yes
No
Yes
10.38
No
Yes
No
Yes
Yes
No
No
Yes
10.39
IMPORTANT! Error codes E05 tacho fault, E06 servo motor fault and E07 servo regulator
fault are generally overwritten by error code E97.
IMPORTANT! If both the LEDs ERROR 4 and ERROR 5 are on, the servo box should be
replaced (E07).
10.40
No
Yes
Yes
No
Yes
No
No
Yes
10.41
10.19.6 Symptom: The pump regulators status lamp flashes on and off
1. The truck shall be logged on.
Yes
Go to point 5 below.
No
Yes
Yes
No
Go to point 8 below.
No
Yes
No
Yes
10.42
No
Yes
10.43
10.19.7 Symptom: Main connectors do not close once the truck is logged
on.
ATC is voltage fed.
Have any related error codes been
logged?
Yes
No
No
Yes
No
Yes
No
Yes
10.44
10.19.8 Symptom: The fuse for the power supply has failed.
The probable cause for a blown fuse is a
short circuit in the regulators power
stage or that the average current exceeds
the fuses rated current.
Yes
No
Yes
10.45
10.19.9 Symptom: The drive regulators status lamp flashes on and off
1. The truck shall be logged on.
Yes
Go to point 5 below.
No
Yes
Yes
No
Yes
No
10.46
10.19.10 Symptom: The drive motor only runs at a low speed with a ticking
noise.
Or the motor attempts to start, but cannot run or runs unevenly with a low torque.
1. Are the motor cables correctly
connected and make good contact
between the drive motor and the drive
regulator?
No
Yes
IMPORTANT!
If you cannot switch the regulators go to
point 4.
No
Go to point 8 below.
No
Yes
Yes
No
No
10.47
Yes
Yes
No
10.48
No
Go to point 4 below.
Yes
No
Yes
No
Yes
IMPORTANT! If the truck is allowed to continue working despite the temperature warnings it
can result in an automatic stop of the drive motor system, the error codes will be E98 with
Hydraulics stopped subinfo will be motor temp too high e2 or controllers temp too high
e4 registered in the log. If the temperature is allowed to drop to the normal level again, the
truck will rum at full capacity again.
10.49
No
Yes
Yes
No
Yes
No
No
Yes
10.50
No
Go to point 4 below.
Yes
No
Yes
No
Yes
IMPORTANT! If the truck is allowed to continue working despite the temperature warnings it
can result in an automatic stop of the drive motor system, the error codes will be E97 with
Drive stopped subinfo will be motor temp too high e2 or controllers temp too high e4
registered in the log. If the temperature is allowed to drop to the normal level again, the truck
will rum at full capacity again.
10.51
10.19.14 The pump motor only runs at a low speed with a ticking noise.
1. Are the motor cables correctly
connected and make good contact
between the pump motor and the pump
regulator?
No
Yes
IMPORTANT!
If you can not switch the regulators go to
point 4.
No
Yes
Go to point 8 below.
No
Yes
Yes
No
No
Yes
10.52
Yes
No
10.53
10.54
Subinfo: Overcurrent e8
Finished!
No
Yes
Subinfo: Overcurrent e8
Finished!
No
Yes
10.55
10.19.17 Drive system stopped/ Hydraulics stopped Subinfo: DC bus too low
e64
Yes
No
Yes
No
10.56
Yes
No
Finished!
10.57
Yes
No
10.58
Finished!
No
Yes
Finished!
No
Yes
10.59
No
Finished!
Yes
10.60
10.61
Yes
No
Yes
No
10.62
10.20
Go to point 7.
Yes
No
No
Yes
Yes
No
Rectify or replace!
Yes
No
10.63
No
Yes
Go to point 10.
Yes
No
Yes
No
Yes
No
10.64
IMPORTANT!
When measuring voltage across the valve
coil the connector shall be connected to
the valve plate. In the event of breakage/
short circuit the connector should not be
connected.
Go to point 5.
Yes
No
No
Yes
No
Yes
No
Yes
10.65
Go to point 8.
Yes
No
Yes
No
Yes
No
10.66
Go to point 4.
Yes
No
No
Yes
No
Yes
Go to point 7.
Yes
No
10.67
Yes
No
Yes
No
10.68
IMPORTANT!
When measuring voltage across the valve
coil the connector shall be connected to
the lever. In the event of breakage/short
circuit measuring on the lever the
connector should not be connected.
10.20.4 The drive function does not work, one or two directions
IMPORTANT!
If the brakes are applied these will hold
the truck despite full power. Check that
the regulator works, a weak humming
noise should be audible.
No
Yes
Yes
No
Yes
Go to point 5
No
Yes
10.69
No
Go to point 9.
No
Yes
Yes
No
Rectify!
10.70
No
Yes
Go to point 5.
Yes
No
Yes
No
Yes
No
10.71
10.21
Cause
Action
10.72
10.22
DL1
DL2
DL1
------
10.73
2:
Local service
2.1
Set drivercode
Code
:
???????
Local service
1:Set drivercode
Note 1
User id:
?
Note 3
Driver category
1
Note 2
Old code:
????
Note 2
New code:
????
Note 2
Verify:
????
Password OK
2.2.1.1
Drive inputs
Drive menu:
1: Drive inputs
Note 8
10.74
2.2.1.2
Set acceler.
Drive menu:
2: Set acceler.
Release acceler.
and hit digitkey
Push acceler max
and hit digitkey
Calibration fail
Press Enter
2.2.1.3
Drive outputs
Drive menu:
3: Drive outputs
0 1 2 3 4 5 6 7
ExTrFoBaS1B1B2B3
Truck on lamp
0:Exit
0 1 2 3 4 5 6 7
Func. not
0 1 2 3 4 5 6 7
Func. not avail.
Speed limit 1
0:Exit 1:Toggle
Brake step 1
0:Exit
Brake step 2
0:Exit 1:Toggle
10.75
2.2.1.4
Set brake
Drive menu:
4: Set brake
Release brakeped
and hit digitkey
Push brake max
and hit digitkey
Calibration fail
Press Enter
2.2.1.5
Regulator ing.
Drive menu:
5:Regulator inp
Accel. Volt -.-Drive out
--%
2.2.1.6
Brake test
Drive menu:
6: Brake test
Brake Volt -.-Brake out
--%
10.76
2.2.1.7
Calib. wheel
Drive menu:
7: Calib. wheel
Pulses per rev.
-Indicate forward
Press Enter
Arrows for FWD
Indicate side
Press Enter
Arrows for side
2.2.1.8
Analog wheel
Drive menu:
8: Analog wheel
Wheel angle
xx
8: Analog wheel
2.2.2.1
Hydr. inputs
Hydraul. menu:
1:Hydr. inputs
Note 9
10.77
2.2.2.4
Regulator inp
Hydraul. menu:
4:Regulator inp
Lift
Volt x.yy
Pump Out
zz%
2.2.2.5
Std. valves
Hydraul. menu:
5: Std. valves
Only on
elektric
valve block
0 1 2 3 4 5 6 7
ExLiDoRiRoTiTo
10.78
Lift
0:Exit
1:Toggle
Lower
0:Exit
1:Toggle
Reach in
0:Exit 1:Toggle
Reach out
0:Exit 1:Toggle
Tilt in
0:Exit 1:Toggle
Tilt out
0:Exit 1:Toggle
2.2.2.6
Opt. valves
Only on
elektric
valve block
Hydraul. menu:
6: Opt. valves
0 1 2 3 4 5 6 7
ExSrSlRrRl
2.2.2.7
Hydr. lamps
Sideshift right
0:Exit
Sideshift left
0:Exit
Rotate
0:Exit
right
1:Toggle
Rotate
0:Exit
left
1:Toggle
Hydraul. menu:
7: Hydr. lamps
0 1 2 3 4 5 6 7
ExTiSiRo
Tilt lamp
0:Exit
Sideshift lamp
0:Exit
Rotate lamp
0:Exit 1:Toggle
10.79
2.2.2.8
Calib. joyst.
Hydraul. menu:
8: Calib. joyst.
Select joyst.
8: Calib joyst.
0,6,7,8,9
Channel Lift
Max and min
Channel Lift
and hit digitkey
OK ?
Calibration OK
Press Enter
Calibration fail
Press Enter
Channel 2
Max and min
Channel 2
and hit digitkey
OK ?
Calibration OK
Press Enter
10.80
Calibration fail
Press Enter
Select
channel
with digit
or with
lever
Channel 3
Max and min
Channel 3
and hit digitkey
OK ?
Calibration OK
Press Enter
Calibration fail
Press Enter
Channel 4
Max and min
Channel 4
and hit digitkey
OK ?
Calibration OK
Press Enter
Calibration fail
Press Enter
Channel 5
Max and min
Channel 5
and hit digitkey
OK ?
Calibration OK
Press Enter
Calibration fail
Press Enter
10.81
2.2.3.1
2.2.3.2
Optional inp.
Optional outp
Options menu:
1:Optional inp.
Note 10
Options menu:
2: Optional outp
0 1 2 3 4 5 6 7
ExSiSoFlSt
2.2.3.3
Height encod.
Func. not
avail.
Func. not
avail.
Flash light
0:Exit. 1:Toggle
Stright lamp
0:Exit. 1:Toggle
Options menu:
3: Height encod.
Note 11
2.2.3.4
Temp.inputs
Options menu:
1:Temp. inputs
Oil temp:
Dr: --C,Pu:
10.82
--C
--C
2.2.3.5
Ext. temp.inp
Options menu:
1:Ext. Temp.inp
ATC temp:
--C
T1
--C,T2 --C
2.2.3.6
AC Regul temp
Options menu:
6:AC Regul.temp
Regulator temp
Dr: --C,Pu: --C
2.2.4.1
Battery test
Misc menu:
1: Battery test
Batt. Volt --.-
2.2.4.2
Chassis test
Misc menu:
2: Chassis test
Limits: -.----.Chass. Volt --.-
2.2.4.3
Horn test
Misc menu:
3: Horn test
Horn
10.83
2.2.4.4.1
Custom inputs
Prepared
for special.
2.2.4.4.2
Custom output
Prepared
for special.
2.2.4.4.1
Custom calibr
Prepared
for special.
2.2.4.4.1
Custom spare
10.84
Prepared
for special.
2.3.1
If measuring
channel is
ON, is
shown for 1
second
Drive motor
temp
If measuring
channel is
ON, is
shown for 1
second
Drive motor
temp
Drive motor
temp
Drive motor
temp
Drive motor
temp
Drive motor
temp
10.85
ATLET Computer
56- 60C: -.--h
ATLET Computer
61- 65C: -.--h
ATLET Computer
66- 70C: -.--h
ATLET Computer
71- 75C: -.--h
ATLET Computer
76C: -.--h
10.86
Om
If
measuring
mtkanalen
channel
is
r pisvisas
ON,
under
shown1 for 1
sekund
second
Extra 1 Temp
Extra 1 Temp ON
Extra 1 Temp
56- 60C: -.--h
If measuring
channel is
ON, is
shown for 1
second
Extra 1 Temp
61- 65C: -.--h
Extra 1 Temp
66- 70C: -.--h
Extra 1 Temp
71- 75C: -.--h
Extra 1 Temp
76C: -.--h
Extra 2 Temp
Extra 2 Temp ON
Extra 2 Temp
81- 90C: -.--h
If measuring
channel is
ON, is
shown for 1
second
Extra 2 Temp
91-100C: -.--h
Extra 2 Temp
101-110C: -.--h
Extra 2 Temp
111-120C: -.--h
Extra 2 Temp
121C: -.--h
10.87
Dr regul. temp.
81- 90C: -.--h
DR regul. temp.
91-100C: -.--h
Dr regul. temp.
101-110C: -.--h
Dr regul. temp.
111-120C: -.--h
Dr regul. temp.
121C: -.--h
Pu regul. temp.
81- 90C: -.--h
Pu regul. temp.
91-100C: -.--h
Pu regul. temp.
101-110C: -.--h
Pu regul. temp.
111-120C: -.--h
Pu regul. temp.
121C: -.--h
10.88
2.3.2
Read err.log
30 :991228
10:14
i
01 :991012
08:33
2.3.3
Read total c
---
Logged on
Total :
---
Sum of time
when any
function has
been active
Forward drive
Total :
--Backward drive
Total :
--Pump total
Total :
---
Pump 1
Total :
---
Pump 2
Total :
---
Pump 3
Total :
---
Pump 4
Total :
---
Pump 5
Total :
---
10.89
2.3.4
Read work. c
---
Logged on
Tid:
---
Forward drive
Time :
--Backward drive
Time :
---
10.90
Pump total
Time :
---
Pump 1
Time :
---
Pump 2
Time :
---
Pump 3
Time :
---
Pump 4
Time :
---
Pump 5
Time :
---
Sum of time
when any
function has
been active
2.4.1
Read time
Clock menu:
1: Read time
20:38:15
1: Read time
2.4.2
Read date
Clock menu:
2: Read date
02-03-
Date format
can be
changed.
2000
2.4.3
Set time
Clock menu:
3: Set time
Note 5
Time setting
XX:XX:XX
2.4.4
Set date
Clock menu:
4: Set date
Note 6
Date setting
XX-XX-XXXX
2.4.5
Clock menu:
5: Set date
Date format
Note 7
2.4.6
Set day of w
Clock menu:
6: Set day of w
Wednesday
Set day 1-7,H,E
10.91
3:
3.1.1
Code :
ATLET service
???????
Password menu
6:Set ATLET code
Old code:
???????
New code:
???????
Verify :
???????
Password OK
3.1.2
Password menu
2:Set def. drive
3.1.3
Password menu
3:Del. one passw
User id:
?
Valid
ID ?
Id not found
10.92
Reset password ?
0:No 1:Yes (No )
Number of
digits depends
on setting
3.1.4
Password menu
4:Set local code
Old code :
???????
New code :
???????
Verify :
???????
Password OK
3.1.5
Password menu
5:Set def. local
Reset passwords?
0:No 1:Yes (No )
3.1.6
Password menu
6:Set cust. code
Old code :
???????
New code :
???????
Verify :
???????
Password OK
10.93
3.1.7
Password menu
5:Set def. cust.
Reset passwords?
0:No 1:Yes (No )
3.1.8
Set passw.par.
Password menu
8:Set passw.par.
Can be set
from 1 to 7
Id length:
1
Password length:
4
10.94
Can be set
from 0 to 7
3.2.5
Reset working
Counters menu
5:Reset working
Truck
0:No 1:Yes (No )
Logged on
0:No 1:Yes (No )
Forward drive
0:No 1:Yes (No )
Backward drive
0:No 1:Yes (No )
Pump total
0:No 1:Yes (No )
Pump 1
0:No 1:Yes (No )
Pump 2
0:No 1:Yes (No )
Pump 3
0:No 1:Yes (No )
Pump 4
0:No 1:Yes (No )
Pump 5
0:No 1:Yes (No )
10.95
3.3
Set options
ATLET service
3:Set options
Switch levelsys.
0:No 1:Yes (No )
Pulse levelsys.
0:No 1:Yes (No )
Lift limiting
0:No 1:Yes (No )
Yes / No
Custom system
0:No 1:Yes (No )
Yes / No
Func. not awail.
Press Enter
10.96
10.97
System supervis.
0:No 1:Yes (No )
Display logon-h.
0:No 1:Yes (No )
Transp. indicat.
0:No 1:Yes (No )
Battery shunt op
0:No 1:Yes (No )
Extra 1 Temp.
0:No 1:Yes (No )
Yes / No
Warning Extra T1
60
Stop Extra T1
65
Extra 2 Temp.
0:No 1:Yes (No )
Yes / No
Warning extra T2
100
Stop Extra T2
120
Summer time
0:No 1:Yes (Yes)
10.98
Show hight
0:No 1:Yes (Yes)
Yes / No
Feet inch height
0:No 1:Yes (No )
10.99
3.4.1.X
AC driver X
AC Parameters
AC driver X
Maximum speed
--Creep speed
--Acceleration dri
--Curr Limit Drive
--Reduc.brakes dri
--Reverse braking
--Pedal braking
--Max backw. speed
--Max pump speed
--Max lower speed
--Acc. pump
--Hydralic spare
--Steering spare 1
--Steering spare 2
---
10.100
X can be 1
to 4.
All values are
from 0 to 100
percent of
machine max
performance
Select joystick
3.4.2.X
Channel :
xxxxx:
1.
Lyft
2
2
3
3
4
4
Channel : zzzzz
1.
Lower
2
Extend
3
Tiltout
4
ShiftR
5
Open
Channel xxxxx
Press Enter
yyyyy
max level
---
yyyyy
min level
---
zzzzz
max level
---
zzzzz
min level
---
Channel can
be selected
by digit 1 to 5
or by touching
the lever.
Channel : yyyyy
1.
Raise
2
Retract
3
Tiltin
4
ShiftL
5
Close
Joyst. deadzone:
--yyyyyy acc:
--yyyyyy ret.:
--zzzzzz acc:
--zzzzzz ret.:
--Fetch B./Scalef.
--Pos. Motor close
--Neg. Motor close
---
10.101
3.4.3
Set battery
Select setting:
3:Stta batteri
Select 48V batt.
0:No 1:Yes (Yes)
Measured B+ (mV)
----Battery size(Ah)
--Pump size
(kW)
---
Utilisation (%)
--Chassis const. 1
--Chassis const. 2
--Low batt. level
--Lift stop level
--Spare 1
---
3.4.4
10.102
Set levelsyst
Select setting
4:Set levelsyst
See M403,
M404,
M405 resp.
M406.
3.7.5.1
Read data
Acquisition menu
1:Read data
Forward
0 0
3.7.5.2
Print data
Note 4
Acquisition menu
2: Print data
DP1000 printer ?
0:No 1:Yes (No )
Printing
please wait !
3.7.5.X
Setup acq. N
Acquisition menu
X:Setup acq. N
Pin to acquire ?
-
N is channel
between 1
and 5
See M330
for more info.
Size of bin(.1s)
Invert 0=No 1=Ye
--
3.7.7
Select test
7: Test any outp
Outputno: (0=ex)
0
Exit ?
--------------0:Exit 1:Toggle
On line 1
selected output
is diplayed.
10.103
3.7.8
Show inputs
Select test
8:Show inputs
Se Not 12
Dig.Input XC2:12
XXXXXXXXXXXXXX
3.8.3
Read service
3.8.4
Sign service
3.8.8
NVR upload.
10.104
Terminated
automaticly.
3.9
ATLET service
9:Set all def.
Are you sure ?
0:No 1:Yes (No )
Yes/ No
Terminated
automaticly.
10.105
4.1
Custom service
1: Unlock
Unlock
Code :
???????
Code OK
Code :
Id not found.
4.2
Communication
Custom service
2:Communication
DL2
Press Enter
PSION COMM.
4.3.X
Print yyyyy
Print custom
X:Print yyyyy
DP1000 printer?
0:No 1:Yes (No )
Printing
please wait !
10.106
X
1
2
3
4
5
6
7
8
yyyyyyy
counters
cus.log
tmp.log
serv.log
err.log
settings
spare
all log
4.4.1
Cust. counter
Read custom
1: Cust counter
ID
ON
N
MMDD HH:MM
ID
N
OFF MMDD HH:MM
ID
Drive:
ID
Lift:
ID
N
Logged:
N: user ID
Time for first
logon
Time for last
logoff.
-.--h
Sum of driving
time
-.--h
Sum of liftting
time
-.--h
Sum of logged
on time.
more ID
4.5
Reset custom
Custom service
5: Reset custom
Code :
???????
code OK
4.5.0
Code :
Id not found.
4
10.107
Service menu
6: Driver param
Driver param
Number of
digits depends
on setting
User id:
?
Number of
digits depends
on setting
Valid
ID ?
Code
Id not found
*
:
****
Valid
code ?
Id not found
Maximum speed
--Acceleration dri
--Reduc.brakes dri
--Reverse braking
--Hydralic spare
--Steering spare 1
--Steering spare 2
---
10.108
****
Note Description
1
Time setting: The keys Ent and down displays one more digit
every time they are pressed. Up arrow displays one less digit
every time it is pressed. Digits are entered as values.
Format is:
HH:MM:SS
HH Hours
MM Minutes
SS Seconds
Date setting: The keys Ent and down displays one more digit
every time they are pressed. Up arrow displays one less digit
every time it is pressed. Digits are entered as values.
Formatet r:
DD:MM:YYYY
DD Day
MM Month
YYYY Year
Date format:
1: dd-mon-yy
2: dd-mm-yyyy
3: mm-dd-yyyy
4: yyyy-mm-dd
10.109
Drive input-symbols:
UNS/URF/UTF
SaAFdBdMFP
LoFHiF<@><->S1S2
Sa: Safety switch ( Left foot )
A Aisle
Fd: Forward switch
Bd: Reverse switch
M: Fuse drive regulator
F: Fuse pump regulator
P: Fuse power-steering
LoF: Low fork height ( 1/2 meter )
HiF: High fork height (3 meter )
<@: Forks turned counter clockwise
@<: Forks turned clockwise
<-: Forks shifted left
->: Forks shifted right
S1: PS fault signal 1
S2: PS fault signal 2
UFS
SaAFdBdMFP
LoFHiF <-> S1S2
Sa: Safety switch ( Left foot )
A Aisle
Fd: Forward switch
Bd: Reverse switch
M: Fuse drive regulator
F: Fuse pump regulator
P: Fuse power-steering
LoF: Low fork height ( 1/2 meter )
HiF: High fork height (3 meter )
<@: Forks turned counter clockwise
@<: Forks turned clockwise
S1: PS fault signal 1
S2: PS fault signal 2
10.110
UNS 5-lever
l L reRE tiTI
S>SR <>SORSRO
or
d DriRI toTO
<SSL ><SC
10.111
UNS 3- lever
L L I I xx
TB SB RB
xx
or
d D O O xx
TB SB RB
xx
10.112
UFS
l L
RE tiTO
<>SORSRO
or
d D
RI toTO
><SC
10.113
URF
l L <-<-
@>@>
RSRO
or
d D->->
<@<@
UTF
eller
l L <-<-
d D->->
RSRO
l liftlever in lift position
d liftlever in lower position
L logic in lift position
D logic in lower position
-> sideshift lever in shift right position
<- sideshift lever in shift left position
-> logic in shift right position
<- logic in shift left position
RS Reachstop
RO Reach out
10.114
10
Options input symbols, the same for UNS, UNE, URF / UTF
LLi
Seat:
St Ho
RSRIRO
12
10.115
10.23
Wiring diagram
The wiring diagrams are placed in number order at the end of section 10.
Description
Wiring Diagram
Wiring Diagram
Options
Circuit diagram
Machine
type
Reference
Document code
Issue
U**
U**
111239
111370
D.
C
U*S, U*F
111693
10.116
10.117
110703:E 1/1
111239:D 2/8
111239:D 3/8
111239:D 4/8
111239:D 5/8
111239:D 6/8
111239:D 7/8
111239:D 8/8
110703:E 1/1
111239:D 2/8
111239:D 3/8
111239:D 4/8
111239:D 5/8
111239:D 6/8
111239:D 7/8
111239:D 8/8
111370:C 9/23
111370:C 10/23
111370:C 11/23
111370:C 12/23
111370:C 13/23
111370:C 14/23
111370:C 15/23
111370:C 16/23
111370:C 17/23
111370:C 18/23
111370:C 19/23
111370:C 20/23
111370:C 21/23
111370:C 22/23
111370:C 23/23
110703:E 1/1
111239:D 2/8
111239:D 3/8
111239:D 4/8
111239:D 5/8
111239:D 6/8
111239:D 7/8
111239:D 8/8
111370:C 9/23
111370:C 10/23
111370:C 11/23
111370:C 12/23
111370:C 13/23
111370:C 14/23
111370:C 15/23
111370:C 16/23
111370:C 17/23
111370:C 18/23
Service Manual
U - AC Power Plus
Manual No: 005953
Section:11 Issue: A
11.1
11.2
11
11.1
10
11
7
23
1
67
12
24
25
13
22
15 16
14
17
18
29
23
20
21
24
25
26
19
30
26
28
32
11.1.1
1
69
34
33
70
29
72
40
41
71
42
63
54
62
53
35
31
35
36
24
54
36
24
25
25
60
53
58
25
59
24
25
39
60
59
24
25
58
52
39
H 270.2
61
56
48
56
57
Figure 11.1
11.3
11.1.2
Check that the return springs for the direction selectors (pos 12, fig. 11.1) have sufficient force to lift
the direction selectors to their upper position.
Go to DRIVE Inputs in the ATC. Check that the text: Fwd and Bwd appear and disappear on the
display when the direction selectors are pressed down.
Fwd = Forwards
Bwd = Reverse
This instruction only applies to software 3.22. The ATC language should be set to English in order to
follow the instructions below.
If necessary also refer to the related document, service manual Truck Computer.
11.1.3
Start by checking that the moving aluminium plate (39 fig 11.1) is very close (approx. 0.5 mm) and
completely parallel with the SLOAN sensor when the pedal is fully pressed down. The procedure to
calibrate the pedal is identical with UNS-DC. The only difference is that the SLOAN sensor potentiometer
should be adjusted to give 2.0V with the pedal in the neutral position to give the best possible
characteristics. This voltage level should be checked with the ATC under the service menu ([S] button).
3: ATLET service
7: Run test
1: Drive tests
5: Regulator inputs
Read Accel.Volt. The voltage level can be adjusted if necessary using the trim potentiometer on the
sensor.
When the voltage level is right, calibrate the sensor on the accelerator by entering:
3: ATLET service
7: Run test
1: Drive tests
2: Set accelerator
Follow the instructions on the display.
11.4
accel volt
drive out
11.2
Accelerator
released
4.5 - 5.0
100%
11.5
11.2.1
SM 022.1
Figure 11.2
11.6
Brake
volt
Brake out
Brake pedal
fully released
Special
settings for
UFS
500%
NOTE! when 100% is measured it gives the maximum
electric motor brake, further pedal movement has no
bearing on the electric motor brake.
At approx. 300%, the ATC shall activate the electric
magnetic brake that is mounted on the motors top end.
At approximately 450 - 500% the emergency brake
microswitch, which is activated by the brake pedal,
should be activated so that the electric magnetic brake
under all circumstances is switched on.
4.5 5.0
Volt
approx.
100%
The values above only apply if the last log on has been with a performance category where the parameter
pedal brake is set to 100%
11.7
11.3
5
3
7
11.3.1
Dismantling, assembling
the left-foot switch
5
9
10
11.3.2
H 280.1
Figure 11.3
11.3.3
Preventive maintenance
The shaft is lubricated with each preventive maintenance so that is runs easily and eliminates wear. The
shaft must be replaced if wear is so much that there is a risk that it can jam or that the microswitch roller is
no longer actuated by a good margin. Also lubricate the spring.
11.3.4
The function of the electric brake is to act as a parking brake and emergency brake (not as a travel brake,
when there is a motor brake).
Assemble the electric brake and tighten the bolts. Check that the spacing (A) between the magnetic
section, see Figure 11.4 and the plate is 0.4 mm all round. During normal usage and normal conditions the
brake is virtually maintenance free. The braking force is not possible to adjust.
Adjustment of the spacing A is done as follows:
11.8
SM 189.1
Figure 11.4
Connect the electrical connector to the brake and connect the battery plug.
Test the brakes by driving and test braking. The following braking distances applies:
Unloaded
Loaded
Braking distance
2.0 -2.5 metres
2.5 -3.0 metres
Measurement A
Min
Max
0.4 mm
0.8 mm
Braking distances are measured at max speed. Loaded means with the classified weight and a truck
equipped as standard.
The friction surfaces must be at least 1 mm thick. If not, the brake discs must be replaced.
11.9
11.4
Trouble shooting
Check the LED indications for faulty steering function: LED 4 and 5 on the ACC unit, error code
E05, E06 and E07 on the ATC display.
Check that the limit switch for the brake in the pedal unit functions.
If the brake still does not release, check that there is 48 volt on the brake connections on the drive
motor when the brake is released.
Also check that the left-foot brake SA functions under the menu drive inputs. If the switch does not
work, no pulsing is received from the drive motor!
11.10
Service Manual
U - AC Power Plus
Manual No: 005953
Section:12 Issue: A
12.1
12.2
12
Extra accessories
12.1
Level selector
6
4
9 7
10 9
21
20
17
16
15
19
20
19
21
10
22
11
68
18
16
66
69
70
15
63
38
67
32
31
73
64
65
71
72
33
34
1615
13
12
58
14
25
27
28
61
30
29
62
60
35
37
23
24
59
36
Figure 12.1
12.3
12.1.1
The following variables are set in Set level sys so that the forks, with the customers greatest load,
stop at a suitable height for depositing.
Up pwm: (>500) defines the speed, after passing the output level with lift preset. This value should
be greater than 500, usually about 600.
Up time: (.1s) defines how long the lift shall continue after passing the collection level and is stated
in tenths of a second. Normal value is 6.
Wait time: (.1s) states how long the ATC should wait from when the depositing height has been
reached to when it should start lowering to the collection level and is stated in tenths of a second.
Normal is 4.
A magnetic sensor to count the levels and a magnet for each collection level.
12.1.2
The driver selects collection and deposit levels from the keyboard and orders lift via the lift control. The
pump then starts and runs at a speed corresponding to the control movement. While the forks are raised the
ATC calculates the levels as they are passed. When the selected level is reached, the pump collection is
lowered until the preset collection (UP PWM) and then switches off completely after a set time (UP
TIME). If the collection has been selected, the ATC lowers the forks until the level is reached again. This is
done to improve accuracy when positioning. When the lifting lever is placed in the neutral position, once
the level has been reached, the preselection is completed (LEVEL REACHED).
In addition, immobilizers are fitted to prevent the system from being used, if it has not been correctly reset
or if an invalid level has been selected.
12.1.3
Selection
To select OUT, press O or for IN press I. The display shows:
Select level. Press the numbers for the level. If the forks are above the selected level the error message
Incorrect level! is shown and the selection is not approved.
If Ent is pressed instead of a number, with collection selected, the forks are lowered to the closest level.
This can be used to place the load.
As an option to Ent the lift/lower lever can be used. Use lift if a higher level is selected, and lower if a
lower level is selected.
If the forks have not activated the resetting sensor, after logging on, the display shows Syst. Not reset!
12.4
12.1.4
Usage example.
The driver presses 3 + E. The display shows Level:O03(00) where O03 means that he has
selected collection level number 3, 00 is the last passed level.
The driver actuates the lift control until the forks stop and the display shows Level reached!.
The driver presses I for depositing. The display shows Sys. Not reset.
The driver presses I again for depositing and then 5 and E. The display shows Level: I05(00)
where O05 means that he has selected the depositing level 5, and 00 is the level last passed.
The driver actuates the lift control until the forks stop and the display shows Level reached!.
The driver presses E as the level is correct. The display shows Level: O02(02) where O02
ATLET SERVICE MANUAL U - AC Power Plus
12.5
means that he has selected collection level 2, and 02 is the level on which the forks are at.
3
12.1.5
The driver selects a collection or depositing level from the keyboard and then actuates the lifting lever.
Pump will now run at the speed corresponding to the lifting levers movement. ATC counts the pulses from
the sensor and converts these to millimetres. The height is compared with the selected value and when the
distance to the select level is 400 mm or less, the pump speed is successively reduced until the level is
reached.
If the forks stop more than 10 mm too high, the ATC opens the lowering valve until the level is reached.
When the lifting lever is placed in the neutral position, once the level has been reached, the preselection is
completed.
The system must be reset before it can be used, i.e. the forks should pass the resetting sensor. If an
incorrect level is stated the preselection stops immediately.
Normally the level selection is used when lifting, but it can also be used for lowering, if the distance is less
than 400 mm. No lever movement is then required.
12.1.6
Operation.
Selection
To select collection, press O or for deposit press I. The display then shows:
Select level. Press the numbers for the level number. If the forks are above the selected level the error
message Incorrect level! is shown and the selection is not approved.
If O has been pressed, you can then press Ent instead of numbers, to lower the forks to the closest
collection level. This can be used to place the load.
The forks must have activated the resetting sensor since the last log on to use the system. Otherwise the
display shows Syst. Not reset.! And the system will not start.
If everything is correct the display shows kk:nnn (mmm) until the level is reached or you cancel the
operation. kk is the selected level number, nnn is the selected level in cm and mmm is the current
height of the forks.
Cancel.
To cancel/reset a selection, move the lifting lever for a moment to lowering. The display shows Level
CANCELLED!.
A preselection that results in lowering of the forks can be cancelled by a lift order.
Lift.
Pull the lift lever until the pump stops. Now let the lever return to the neutral position. You can cancel the
lift (stop) and then continue without the selection disappearing.
When the lever is moved to the neutral position and the level is reached the display shows Level
reached!.
12.6
To set levels
1
Select 4: Set levels A number of parameters are shown. If the displayed values are to be kept, press
Ent, otherwise change and press Ent.
IMPORTANT! Incorrect input cannot be corrected, you must first complete all the questions
and then restart!
12.1.7
Checking settings
This section describes how you check that the parameter Forkzero offset is set correctly.
1
Lift with a low pump output to the height where the free lift ends and the final stroke shall starts, that
is before the measurement starts. Now measure the distance from the floor to the top of the forks.
12.1.8
Usage example.
The driver presses 3 + Ent. The display shows, e.g. 03:200 (082) where 03 means the selected
level, 200 is the height the forks shall move to, in cm, and 082 is the current fork height, in cm.
The driver actuates the lift lever until the forks stop and the display shows Level reached!.
The driver presses I again for depositing and 5 and Ent. The display shows 05:380 (008)
where 05 means the selected level, 380 is the height the forks shall move to, in cm, and 008 is
ATLET SERVICE MANUAL U - AC Power Plus
12.7
The driver actuates the lift lever until the forks stop and the display shows Level reached!.
The driver presses Ent as the level is correct. The display shows
The display shows 02:100 (110) where 02 means the selected level, 100 is the height the forks
shall move to, in cm, and 110 is the current fork height, in cm.
12.2
As extra equipment the truck can be fitted with an instrument that shows the height of the forks in mm or
inches. Indication is only possible above the free lift position. All trucks with the height measurement
instrument must be equipped with a low fork indicator switch; this is because this indicator is used for both
low fork indication and resetting of the height measurement instrument. Lof does not need to be
activated in ATC.
12.2.1
Technology
The instrument is preset to work as a pulse counter. The pulses come to the instrument on two channels
with 90 mutual phase displacement. The phase displacement gives the instrument the possibility to
determine the forks direction of movement and in doing so count in the right direction. The pulses are
generated by means of a chain and unit (complete with a sprocket, block and two inductive sensors) placed
on the mast. Accuracy is +- 15 mm at a lifting height of 10 m.
12.2.2
Settings
The instrument has two setting modes, programming mode and operating mode. Programming mode is
accessed by pulling out the instruments mechanism from the casing 5-10 mm. This requires some force
and if you pull out the mechanism to far the feed to this is lost. If this happens slide in the mechanism until
the feed returns.
12.2.3
Programming
If the truck goes to a country that uses the metric system the instrument only needs to be locked once the
offset value has been set. In other cases modification to COEFF and dECPt must be done. dECPt = how
many decimals are used.
12.8
12.2.4
Place the forks exactly at the transition between free lift and final stroke. Measure the height to the top of
the forks, this is the offset height. Set the instrument in the programming mode, press P until the display
shows Prot, now press one of the 5 small buttons until no is displayed. Setting the instrument in
operating mode. Press P and set P1 to the offset height by stepping to the right value using the five small
buttons. Ex: If the offset is 182 cm, P1 should be set to 1.82 (m). Press P again and set P2 in the same way,
display P1 again and press RST until inst. offset is shown on the display.
12.2.5
In order to protect the offset value from modification proceed as follows. Set the instrument in
programming mode and go to the Prot menu, press one of the 5 small buttons until YES,P1,P2 and RST are
shown on the display, if COEFF is not to be changed reset the instrument to the operating mode.
12.2.6
Setting COEFF
In programming mode press P repeatedly until COEFF is shown on the display. COEFF is used to recount
the number of pulses so that the right value is shown. With metric measurement COEFF should be 1.000,
but when the truck is used in USA this should be set to 3.935. Set this using the same buttons as used for
P1 and P2.
12.2.7
Setting dECPt
In programming mode go to the menu dECPt by pressing P repeatedly. Press one of the small round
buttons until a decimal appears after the decimal point. Reset the instrument to operating mode.
12.2.8
Final test
When all this has been done the height measurement can be test run, run the forks up and down over the
final stroke and check that the instrument counts in the right direction. Test a few times at the free lift
transition point to be sure that everything is fitted correctly. Compare the instruments height measurement
with that shown on the ATC display. It can happen that they sometimes differ by one, but this is OK,
however they should not differ more.
12.2.9
Sensor
The sensor is equipped with LEDs that flash with each pulse.
12.9
12.3
Wheel indicator.
The system consists of an incremental sensor mounted in connection to the steering servos output axle and
an inductive sensor for synchronisation. On trucks with a 180 degree drive unit a sensor mounted in front
of the motor is used and on 360 degree drive units the sensor is located between the drive motor and the
pump motor.
The setting of the wheel indicator is done in Atlet Service, Run test, Drive tests and Calibrate wheel.
Pulses per revolution is the number of pulses delivered by the incremental sensor connected to the servo
systems axle with a complete revolution of the drive wheel. The value is calculated according to: The
sensors marking x 4 x mechanical reduction. (2000-05-10: 500 x 4 x teeth on the large cog/teeth on the
servo pinion = 5.5185 Total 11037). After this the display instrument shall be set to point straight laterally
towards the pedal side. This is done by means of the arrow keys. Press Enter. Now manoeuvre the
instrument to point straight sideways towards the seat side. Press Enter. Go to the menu Analogue wheel.
The drive wheel can be turned using the steering wheel. With a 180 degree drive unit calibration takes
place when the wheel is turned clockwise passed the straight position. With a 360 degree drive unit
calibration takes place with the wheel position straight to the side. Turn the steering wheel quickly.
While driving the systems angular value and passage straight ahead or to the side are monitored. If the
angular value does not correspond the error code 60 or 61 is shown.
12.4
The system consists of an incremental sensor mounted in connection to the steering servos output axle and
an inductive sensor for synchronisation. On trucks with a 180 degree drive unit a sensor mounted in front
of the motor is used and on 360 degree drive units the sensor is located between the drive motor and the
pump motor.
The setting of the wheel indicator is done in Atlet Service, Run test, Drive tests and Calibrate wheel.
Pulses per revolution is the number of pulses delivered by the incremental sensor connected to the servo
systems axle with a complete revolution of the drive wheel. The value is calculated according to: The
sensors marking x 4 x mechanical reduction. (2000-05-10: 500 x 4 x teeth on the large cog/teeth on the
servo pinion = 5.5185 Total 11037). After this the display instrument shall be set to point straight laterally
towards the pedal side. This is done by means of the arrow keys. Press Enter. Now manoeuvre the
instrument to point straight sideways towards the seat side. Press Enter. Go to the menu Analogue wheel.
The drive wheel can be turned using the steering wheel. With a 180 degree drive unit calibration takes
place when the wheel is turned clockwise passed the straight position. With a 360 degree drive unit
calibration takes place with the wheel position straight to the side. Turn the steering wheel quickly.
12.10
While driving the systems angular value and passage straight ahead or to the side are monitored. If the
angular value does not correspond the error code 60 or 61 is shown.
12.5
Cab
In those cases where the truck is equipped with a cab, all fans and heaters should be kept clean. A dirty
heater gives inferior heat and can cause the thermal fuse to blow. The ventilation damper must never be
closed completely, as this can result in the thermal fuse blowing.
12.11
12.12