SERVICE MANUAL

Machine: PLP

Manual No 119002

Edition 2008B

1 General information and technical data

Scope of Service Manual ............................................................................................... 1.3

General ................................................................................................................ 1.3
Scope of the P series .......................................................................................... 1.3

How to use the manual .................................................................................................. 1.4

Structure .............................................................................................................. 1.4
Symbol key .......................................................................................................... 1.4

Safety instructions ......................................................................................................... 1.5

General ................................................................................................................ 1.5
Gas springs in platform and steering arm ............................................................ 1.6
Inspection/Preparation ................................................................................................... 1.6
Lifting the truck .................................................................................................... 1.6
Inspection/Preparation ................................................................................................... 1.6
Permitted lifting points .................................................................................................... 1.7
Welding on the truck ............................................................................................ 1.8
Atlet AB takes care of the environment ............................................................... 1.8
Environmental impact .......................................................................................... 1.8
Waste .................................................................................................................. 1.8

Preparations ................................................................................................................... 1.9

Service ................................................................................................................. 1.9
Trouble shooting .................................................................................................. 1.9

Data PLP ........................................................................................................................ 1.10

Designations ...................................................................................................... 1.10
Truck designation ......................................................................................................... 1.10
Type designation .......................................................................................................... 1.11
Dimensions and weights .................................................................................... 1.14
Machine specification ................................................................................................... 1.15
Component specification ................................................................................... 1.16

Recommended consumable materials ....................................................................... 1.17

SERVICE MANUAL
1.2

Oil and grease ....................................................................................................1.17

Standards and abbreviations .......................................................................................1.18

Screws ...............................................................................................................1.18
Tightening torque, screws and nuts .............................................................................. 1.18
Screw types and tensile grades .................................................................................... 1.18
Tightening torque, hydraulic couplings ...............................................................1.20
Conversion tables ..............................................................................................1.20
Standard abbreviations ......................................................................................1.21
Colour of the truck ..............................................................................................1.21
Colour codes, cabling ........................................................................................1.22
Designations ......................................................................................................1.22

SERVICE MANUAL
 General information and technical data / Scope of Service Manual / General 1.3

Edition 2008B

1 General information and technical data

Scope of Service Manual

General
This manual describes the service procedures for ATLET low lifter PLP. Use the manual
for quick and correct service of respective truck models.
You may find contradictions in the manual compared to the models supplied due to op-
tional designs and upgrades, 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 authorised representative should be contacted.

Unauthorised modification of the truck is not permitted. The user may only implement
changes or modifications to the truck if the truck manufacturer no longer exists as a com-
pany and no other company has taken over the operations of the truck manuafacturer, on
the assumption that the user:
• Arranges so that the modifications or changes are designed, tested and imple-
mented by one or more experts on industrial trucks and their safety.
• Prepares and archives documentation for the design, testing and implementation of
the modifications or changes.
• Approves and makes suitable changes to type plates, decals, and markings, and in
the instruction manuals.
• Attaches a permanent and clearly visible sign, or the equivalent, that reports in
which way the truck has been modified or changed, together with the date of the
modification or change and the name and address of the organisation that has con-
ducted the assignment.
The content of this service manual is protected by copyright law and may not be copied,
fully or in part, without written permission. The material has undergone careful exami-
nation with regard to correctness. Subject to alteration. In the event of inconsistent infor-
mation 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.

Scope of the P series

The manual covers the low lifters PLP 200 and PLP 250.

SM_PLP_01_119002_2008B.fm
SERVICE MANUAL
1.4 General information and technical data / How to use the manual / Structure

How to use the manual

Structure
The manual is built up according to the same principles as ATLET spare parts catalogues,
with the truck divided into one subsystem per section.
Sections 1 - 3 in this manual contain more comprehensive information regarding techni-
cal data, general service instructions and tools.
Sections 4-12 in this manual contain information limited to a specific area in the truck
concerning the description of the mechanical handling of different components, e.g.
Masts (section 6) and Hydraulic system (section 8).
The software is described in section 10.
The main principle for extra accessories is to place them under the respective sections.
Otherwise they are placed under section 12 “Miscellaneous”. For this reason section 12
is not always included in the Service Manual.
For specific problems or information about procedures, look in the main index for the
correct section in the manual.

Symbol key
Warning!
Used for risk of personal injury.

Important!
Used for risk of damage to machine.

Note!
Used for general observation.

SERVICE MANUAL
 General information and technical data / Safety instructions / General 1.5

Safety instructions

General
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.
• Local fire directives should always be followed.
• The drive wheel should always be lifted up free from the floor during service work
to prevent the vehicle from moving.
• The battery plug should be pulled out before working on the electrical system. The
battery plug may only be connected while trouble shooting, and when the greatest
of care is exercised, (with the truck raised).
• To prevent injuries caused by crushing the battery plug should always be removed
when working on and around the mast and hydraulic unit. The mast or hydraulic
unit can be actuated due to an electrical fault or a mistake while working.

Warning!
Having the power connected to the truck while working on and around the mast can
lead to fatal injury!

• When working on and around lifting devices and the hydraulic unit, they must be
locked by using the mast lock, wooden blocks or some other appropriate means.
• No other persons should be in the vicinity of the truck when it is test run in con-
junction with repair work, in view of the risk of accidents or near-accidents from
the truck making an unexpected manoeuvre.
• The system should not be pressurised, e.g. the pump motor switched off and the
forks in their lowest position, when dismantling parts of the hydraulic system.
• All metal objects such as watches, chains, spectacles and rings should be removed
when working on the electrical system, or in its immediate vicinity. A short-circuit
from such objects can result in serious burn injuries.

SERVICE MANUAL
1.6 General information and technical data / Safety instructions / Gas springs in platform and steering

Gas springs in platform and steering arm

Inspection/Preparation
The functioning of the platform and steering arm should be checked. The gas springs in
both of these functions are a very critical factor for their correct functioning.
Since the gas springs are exposed to dirt and a large number of operations, they should be
checked very carefully during preventive maintenance.
During service and preventive maintenance it is important if the truck is a model with a
foldable platform to check that the platform is raised up automatically when the driver
gets off it. If this does not happen it should be reported to the truck supervisor, with the
recommendation that the truck be taken out of service until the requisite measures have
been implemented.
During service and preventive maintenance it is important to check that the steering arm
is raised up automatically when the driver releases it. If this does not happen it should be
reported to the truck supervisor, with the recommendation that the truck be taken out of
service until the requisite measures have been implemented.

Warning!
Great caution must be observed when dismantling the gas springs.
• Make sure that no other persons are in the vicinity or in the lengthwise direction of
the gas springs.
• Stand to the side of the gas spring when removing.
• Never point the gas spring toward any person or part of the body.

Lifting the truck

Inspection/Preparation
• When the truck is lifted using a jack, make sure you secure it with 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 lifting
the truck.
• Ensure that the drive wheel runs free of the floor before trouble shooting.

SERVICE MANUAL
 General information and technical data / Safety instructions / Lifting the truck 1.7

Permitted lifting points

Figure 1.1 Permitted lifting points

Figure1.1 shows where the permitted lifting points are placed on the truck.

Warning!
The machine must never be lifted in any other points than the ones shown.

Figure 1.2 shows where the jack should be placed.

Figure 1.2 Lifting point, jack

SERVICE MANUAL
1.8 General information and technical data / Safety instructions / Welding on the truck

Welding on the truck

• During welding work the battery plug should always be disconnected and all con-
nections to the control units and controllers (applies to all electronic units) discon-
nected. On completion of welding work the contactors should first be connected to
the electronic units, after which the battery plug is then connected to the battery.
• The return cable clamp should always be connected as close to the welding area as
possible to eliminate damage to surrounding components.

Atlet AB takes care of the environment

The majority of our products consist of metal that can be completely recycled.

Environmental impact
All products have an impact on the environment throughout their entire life cycle.
The consumption of energy during their use is one of the most important factors that in-
fluences the environment.
Through correct care, maintenance and use the consumption of energy can be reduced,
thereby reducing the environmental impact.

Waste
Waste material in conjunction with repairs, maintenance, cleaning, or scrapping, should
be collected and disposed of in an environment-friendly way and in accordance with the
directives of respective countries. Such work should only be carried out in areas intended
for this purpose.
Recyclable material should be taken care of by specialised authorities.
Environmentally hazardous waste, such as oil filters, batteries and electronics, can have
a negative effect on the environment, or health, if handled incorrectly.

SERVICE MANUAL
 General information and technical data / Preparations / Service 1.9

Preparations

Service
• Go through all the safety instructions.
• Make sure that you have all the essential tools close at hand before starting work.
• Before cabling or other electrical components are disconnected, check the colour
codes and check for damage to cables or connections.
• When complex components are repaired and dismantled, make sure that you have
good control of the different component parts to avoid the risk of confusion.
• When repairing or maintaining sensitive components, make sure that 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.

Trouble shooting
When you suspect that a component is defective, do not replace it immediately. First
check the surrounding equipment and carry out complete trouble shooting according to
the trouble shooting chart. Make sure you know the reason for the fault before replacing
a component.

SERVICE MANUAL
1.10 General information and technical data / Data PLP / Designations

Data PLP

Designations

Truck designation
Table 1.1 Truck designations

Truck type PLP 200 Low lifter

PLP 250 Low lifter

Load capacity PLP 200 2,000 kg

PLP 250 2,500 kg

SERVICE MANUAL
 General information and technical data / Data PLP / Designations 1.11

Type designation

1
Modell
Model
Modell
Modèle

2
Serie nr. Vikt utan batterie
Serial no. Weight without battery Kg
Serien-Nr Gewicht ohne Batterie
Nº de serie Poids propre sans batteri

3
Tillverkningsår Batteri vikt min.
Year of construction Battery weight min. Kg
Baujahr Batteriegewicht min.
Année de construction Poids de batterie mini.

4
Tillåten last Batteri vikt max.
Load capacity Battery weight max. Kg
Tragfähigkeit Batteriegewicht max.
Charge limite Poids de batterie maxi.
Tyngdpunktsavstånd Batterispänning
Distance of load center Kg Batteryvoltage V- DC
Lastschwerpunktabstand Batteriespannung
Distance de centre Tension de la batterie
Tillverkare
Manufacturer
Hersteller
Fabriccat
Atlet AB Mölnlycke Sweden

Figure 1.3 Example of type plate (–2006w36)

1. Model designation.
2. Type Series no./Version (S=Special ver.).
3. Year of manufacture, week, and warranty period in months (only Sweden).
(On the assumption that the service instructions in the warranty regulations are fol-
lowed).
4. Where appropriate, load limitations depending on the position of the load on the
forks (D) and/or lifting height (Q).

SERVICE MANUAL
1.12 General information and technical data / Data PLP / Designations

1 Model
Modell

2 Serial no.
Serie nr.

3 Year of manufacturing
Tillverkningsår

4 Load capacity
Tillåten last

Load centre distance

Tyngdpunktsavstånd

Weight without battery

Vikt utan batteri

Battery weight min.

Batterivikt min.

Battery weight max.

Batterivikt max.

Battery voltage
Batterispänning

Refernce number
Referensnummer

ATLET AB MÖLNLYCKE SWEDEN

Figure 1.4 Example of type plate (2006w37–)

1. Model designation.
2. Type Series no./Version (S=Special ver.).
3. Year of manufacture, week, and warranty period in months (only Sweden).
(On the assumption that the service instructions in the warranty regulations are fol-
lowed).
4. Where appropriate, load limitations depending on the position of the load on the
forks (D) and/or lifting height (Q).

SERVICE MANUAL
 General information and technical data / Data PLP / Designations 1.13

Note!
In cases where the machine plate has been lost or become illegible, it must be re-
newed immediately. In order to identify the machine's serial number, there is a plate
located on each main component such as drive motor, gearbox, hydraulic unit,
TMC etc. For some machines there is even a plate attached inside the battery com-
partment, or serial number punched on the side of the mast.

SER XXXXXX

WEEK XXXX

SER XXXXXX

WEEK XXXX

Figure 1.5 Example of plate with serial number.

Explanation of Model designation

Example: PLP 200 160 30

Truck type

Load capacity/10

Battery Ah/5

Charger Ampere

SERVICE MANUAL
1.14 General information and technical data / Data PLP / Dimensions and weights

Dimensions and weights

Dimensions PLP

1595

877
919

634

55

H4
180

H1
149

453 L4 L2
52

L1

L3

B1
B2
560
578

B
R2

Figure 1.6 Positions for dimensions PLP

SERVICE MANUAL
 General information and technical data / Data PLP / Dimensions and weights 1.15

Machine specification
No. PLP 200 PLP 250

1 Lifting capacity, rated Q kg 2000 2500

1a Distance to centre of gravity D mm 600 600

2 Lifting height H4 mm 200 200

2a Mast height H3 mm
H5 mm
2b Transport free lift H2 mm
2c Full free lift
2d Straddle lift

4 Lifting speed without load – with rated load m/s

4a Lifting time without load – with rated load s 2.0-2.5 2.0-2.7

5 Lowering speed without load – with rated load m/s

Lifting time without load – with rated load s 2.5 2.5

6 Driving speed without load – with rated load km/h 10.0-8.5 12.0-9
Driving speed without load – with rated load m/s 2.77-2.36 3.3-2.77

8 Reversing capacity without load – with rated load Max % 10-10 10-10

10 Turning radius R2 mm 770 + L2 835 + L2

11 Minimum aisle width Ast incl. 200 mm R2-L2 + load

length + 200
Load length 800 mm Ast mm
Load length 1,000 mm Ast mm
Load length 1,200 mm Ast mm

13 Height over protective roof H6 mm

14 Truck length L mm 750 + L1 825 + L1

15 Truck width B mm 770 770

16 Fork length, std L1 mm 1000 / 2375 1000 / 2375

17 Width over forks, std max-min W mm 680 / 460 680 / 480

17a Width between fork gaffel shanks mm W - 350 W - 350

19 Truck length to fork support area L4 mm 750 825

20 Fork arm, width – thickness B1 mm 175 - 55 175 - 55

20a For height, min H1 mm 85 85

21 Straddle lift height H7 mm

22 Width between fork straddle lift B2 mm

23 Dim. for front axle – fork support area L2 mm 785 - 1765 785 - 1465

24 Wheelbase L3 mm 551 + L2 626 + L2

25 Wheel track – front, back centre of wheel mm W - 175/526 W - 175/526

26 Ground clearance, half wheelbase load mm 30 - 145 30 - 145

27 Service weight with/without battery kg 860 - 530 925 - 545

28 Max axle pressure, load wheel with/without rated load kg 212 / 1828 212 / 2238

29 Max axle pressure, drive wheel with/without rated load kg 705 - 1110 715 - 1215

39 Battery capacity kWh 4.8-9.6 7.5-14.4

Ah 200-400 300-600
39a Battery voltage V 24 24

41 Traction motor kW 2.2 / 2.4 AC 2.2 / 2.4 AC

42 Speed controlling Transistor Transistor

43 Lift motor kW - %/ 2.2 - 12/10 2.2 - 12/10

43a Hydraulic tank min 9 11
MPa

44 Wheel type Vulkollan Vulkollan

44a Number of drive/castor/load wheels 3-4 3-4

SERVICE MANUAL
1.16 General information and technical data / Data PLP / Component specification

45 Wheel dimensions
45a Load wheel D* width mm (4x) 85x75 (4x) 85x75
45b Drive wheel D* width mm (1x) 230x90 (1x) 230x90
45c Castor wheel mm (2x) 150x60 (2x) 150x60

46 Control system Tiller arm Tiller arm

47 Main brake, type – actuated part El. drive mech. El. drive mech.

48 Parking brake, type – actuated part El. drive mech. El. drive mech.

Component specification
Table 1.2 Component specification

Component Specification

Traction motor Drive voltage 24V

Output standard 2.2 / 2.4 kW

60 min

Gearbox Gear ratio (standard) 15:1

Oil volume 0.85 litre

Hydraulic system Max pressure 21 MPa

Oil volume max 1.6 litre

Hydraulic unit (motor and pump) Output 2.2 kW

Control system for traction Type FZ2007 AC1 CAN

motor

Voltage 24 V

Max current 250A (RMS)

for 2 min

Fuses Control fuse 1 5A

Pump motor fuse 1 250 A

Traction motor fuse 1 250 A

SERVICE MANUAL
 General information and technical data / Recommended consumable materials / Oil and grease

Recommended consumable materials

Oil and grease

Table 1.3 Table of recommended types of oil and grease

Brand Gearbox oil Hydraulic oil Bearing

As per API value As per ISO VG 32, VG 15 grease
GL-5 NLGI 2
Lithium
Normal Cold store Normal Cold store base
(32) (15)

BP BP Energear BP Energear BP Bartran BP Bartran Energrease

HYPO SHX-S HV-32 SHF-S LC 2
80W/140 EP 75W/140 EP

Castrol - - Hyspin Hydraulic oil LMx

SHS 32 OM 15
Alt: Hyspin
AWH 15

Mobil - - DTE 13 M Flowrex 1 Mobilplex 48

SHS 32

Shell - - Tellus oil Tellus oil T Retinax EP2

TX 32 15

Statoil / - - SHS 32 J 26 Uniway LIX

Exxon 625

Texaco - - Rando oil Rando oil Hytex EP2

HDZ 32 HDZ 15

Important!
Do not mix different lubricants, and absolutely not synthetic oil with mineral oil,
since this can affect the properties of the oil!

SERVICE MANUAL
1.18 General information and technical data / Standards and abbreviations / Screws

Standards and abbreviations

Screws

Tightening torque, screws and nuts

Table 1.4 Tightening torque, screws and nuts

DIM Tensile grade

4.6 8.8 10.9 12.9

Nm Nm Nm Nm

M4 1.1 2.9 4.0 4.9

M5 2.2 5.7 8.1 9.7

M6 3.7 9.8 14 17

M8 8.9 24 33 40

M10 17 47 65 79

M12 30 81 114 136

M14 48 128 181 217

M16 74 197 277 333

M18 103 275 386 463

M20 144 385 541 649

The tightening torque in the table above are standard values. In some cases a specific
tightening torque is specified in respective sections. If no tightening torque is specified
in the service instructions, the values shown in the table above apply.

Screw types and tensile grades

Table 1.5

Figure Screw type Designation Tensile grade

M6S Hexagon screw 8.8

10.9

MC6S Hexagon hole screw 8.8

10.9
12.9

SERVICE MANUAL
 General information and technical data / Standards and abbreviations / Screws 1.19

Table 1.5

Figure Screw type Designation Tensile grade

MF6S Hexagon hole screw, 10.9

countersunk

MCS Slotted screw 4.6

MVBF Oval head counter- 4.6

sunk screw

Marking with the manufacturer’s trademark, including the tensile grade, is compulsory
for screws with a thread diameter from 5 mm and in tensile grades according to the table
above. Marking only takes place when the shape of the product permits this.

8.8

8.8

12.9

12.9

Figure 1.7 Example of marking

SERVICE MANUAL
1.20 General information and technical data / Standards and abbreviations / Tightening torque, hydrau-

Tightening torque, hydraulic couplings

Table 1.6 Tightening torque, hydraulic couplings

Tightening torque: Pipe thread / metric thread:

Metric fine Whitworth pipe MA (Nm) with MA (Nm) with elastic

thread thread pipe olive (O-ring coupling)

M10 x 1 G 1/8" 25 10

M12 x 1.5 30 20

M14 x 1.5 G 1/4" 50 30

M16 x 1.5 G 3/8" 80 35

M18 x 1.5 90 40

M20 x 1.5 G 1/2" 130 50

M22 x 1.5 150 60

M26 x 1.5 250 70

M27 x 1.5 G 3/4" 250 80

M27 x 2 250 90

G 1" 350 140

M33 x 2 400 140

M42 x 2 G 11/4" 600 240

M48 x 2 G 11/2" 800 300

Conversion tables

Table 1.7 Conversion table, torque units

Newton metre Kilopond metre Poundforce inch Poundforce foot

(Nm) (kpm) (lbg x in) (lbf x ft)

1 0.10 8.85 0.74

9.81 1 86.80 7.23

0.11 0.01 1 0.08

1.36 0.14 12.00 1

SERVICE MANUAL
General information and technical data / Standards and abbreviations / Standard abbreviations

Table 1.8 Conversion table, pressure units

Pa Bar at dry atm

(N/m2) (1mb=1hPa) (kp/cm2) (mm Hg, 0 C)

1 10 -5 1.020*10 -5 7.501*10 -3 9.869*10 -6

9.807*10 4 0.9807 1 735.6 0.9678

133.3 1.333*10 -3 1.360*10 -3 1 1.316*10 -3

1.013*10 5 1.013 1.033 760 1

Table 1.9 Conversion table, speed

m/s km/h

1 3.6

0.278 1

Standard abbreviations

Table 1.10 Standard abbreviations

Magnitude Unit Designation

Current Ampere A

Voltage Volt V

Resistance Ohm Ω
Output Watt W

Torque Newton metre Nm

Pressure Pascal Pa

Colour of the truck

0

The truck is painted in colours with the following NCS colour codes:

Table 1.11 NCS colour codes

Machine colour Designation

Yellow NCS 0070-Y20R

Medium grey NCS 7000

Dark grey NCS 8000

SERVICE MANUAL
1.22 General information and technical data / Standards and abbreviations / Colour codes, cabling

Colour codes, cabling

The colour markings of all cables included in the truck can be seen in the Atlet wiring
diagrams. The abbreviations have the following significance:

Table 1.12 Colour codes Atlet wiring diagrams

Code Cable colour

Y Yellow

BL Blue

SB Black

W White

GN Green

GR Grey

R Red

BN Brown

VO Violet

P Pink

OR Orange

Note!
Two-colour cables are shown with both colour codes separated by a slash.
E.g. blue/yellow cable is shown with colour code BL/Y.

Designations
Electrical components normally have a designation of two letters:
Table 1.13 First letter

Code Designation

A Component or function without its

own letter below

C Capacitor

D/V Diode

E Electrical component

F Fuse

I Indicator

K Contactor/relay

L Coil/inductive element

SERVICE MANUAL
General information and technical data / Standards and abbreviations / Designations 1.23

Table 1.13 First letter

Code Designation

M Motor

P/X Connection

R Resistor

S Switch/Change-over switch

T Terminal

Y Valve/brake

H Audible warning unit/lamps/lights

G Battery

Table 1.14 Second letter

Code Designation

B Brake

C Control system

E Emergency function

F Forward

H Hour

K Key

L Lower

M Manoeuvre

P Pump

R Reverse

S Speed

SERVICE MANUAL
1.24 General information and technical data / Standards and abbreviations / Designations

SERVICE MANUAL
 SERVICE MANUAL
Machine: PLP

Manual No: 119002

Edition 2007B

2 Special tools

Special tools PLP ........................................................................................................... 2.3

Introduction .......................................................................................................... 2.3
List of tools .......................................................................................................... 2.3

SERVICE MANUAL
2.2

SERVICE MANUAL
 Special tools / Special tools PLP / Introduction 2.3

Edition 2007B

2 Special tools
Special tools PLP

Introduction
All special tools can be ordered from Atlet AB.

List of tools
Table 2.1 List of tools

Designation Figure Part number Applications

Cleaning fluid P/N 112268 Cleaning of electric motors from gearbox

oil and other dirt

Chain spray P/N 001196 Lubrication of chains

Crimping tool Molex P/N 006454 Cable connections

Pin extractor P/N 006456 Cable connector

Lifting eye P/N 104737 Lifting eye for drive unit.

Lifting device 2.1 P/N 118515 Lifting tool

For detailed information on the above products, please contact Atlet.

SM_PLP_02_0001A.eps

Bild 2.1 Lifting device

SM_PLP_02_119002_2007B.fm
SERVICE MANUAL
2.4 Special tools / Special tools PLP / List of tools

SERVICE MANUAL
 SERVICE MANUAL
Macine: PLP

Manual No: 119002

Edition 2007B

3 Service

Regular maintenance 3
Introduction .......................................................................................................... 3.3
Safety .................................................................................................................. 3.3
Recommendation ................................................................................................ 3.3
Daily inspection ................................................................................................... 3.4
This is the responsibility of the truck driver (before each shift). ..................................... 3.4
This is the responsibility of the truck driver (after each shift). ........................................ 3.4
Weekly inspection (30 hours of operation) .......................................................... 3.5
Responsibility: Truck driver ............................................................................................ 3.5
First service ......................................................................................................... 3.5
Main service ........................................................................................................ 3.5
Extra service inspections ..................................................................................... 3.6
Check list, service inspection .............................................................................. 3.7
Code explanation ................................................................................................3.11
Lubrication chart ................................................................................................ 3.15
PLP ............................................................................................................................... 3.15
Symbol key, lubrication chart ....................................................................................... 3.16

Specific instructions 17
Traction motor ................................................................................................... 3.17
Preventive maintenance ............................................................................................... 3.17
Gearbox ............................................................................................................. 3.17
First service .................................................................................................................. 3.17
Preventive maintenance ............................................................................................... 3.17
Lift chains and forks ........................................................................................... 3.18
Check ........................................................................................................................... 3.18
Hydraulic oil ....................................................................................................... 3.19
First service .................................................................................................................. 3.19
Intervals ........................................................................................................................ 3.19
Emergency stop ................................................................................................. 3.19
Recommended replacement ............................................................................. 3.20
Storage of machines and motors ....................................................................... 3.20

SERVICE MANUAL
3.2

SERVICE MANUAL
 Service / Regular maintenance / Introduction 3.3

Edition 2007B

3 Service
Regular maintenance

Introduction
Preventive maintenance should be carried out regularly when the truck is used in normal
conditions. The planned service includes operations such as test driving, function tests,
and the changing of filters and oils etc. Service is planned at different intervals depending
on the running time of the truck. If the truck is working in extreme conditions or in de-
manding environments, servicing must be planned at tighter intervals.

Safety
Important!
Check under each separate section which safety instructions are applicable for
work on the truck.

Inspection of the external functions in the power steering system should be carried out
after every service and after work carried out in the electrical system. All function tests
of the safety system should be made with the speed controller in neutral position, see sec-
tion 10.

Recommendation
Information on what the truck owner should take into consideration.

Regular inspection should be carried out by specially appointed and trained personnel with a good
working knowledge of the function and maintenance of the truck.
To obtain the best results from your investment in your truck we advise you to contact your local Atlet
representative and to sign up for a service contract for regular inspection.

SM_PLP_03_119002_2007B.fm
SERVICE MANUAL
3.4 Service / Regular maintenance / Daily inspection

Daily inspection
(This section is an extract from the driver instructions.)
This section provides information on what the truck owner should take into considera-
tion.

Important!
Naked flames or smoking are prohibited when checking the specific acid weight and
level.

When changing or checking the battery use ergonomic work procedures to avoid in-
jury.

This is the responsibility of the truck driver (before each shift).

1. The battery should be checked every day. See separate maintenance instruction.
Note that the acid level rises somewhat during charging.
2. Check that the battery cables, connections and plugs are connected correctly and
not damaged.
3. Check that the battery is properly secured in its compartment.
4. Check if the truck has leaked oil.
5. Check the transport and safety signals.
6. Check the braking effect on the main brake and parking brake.
7. Check for external damage on the wheels.
8. On trucks equipped with a truck computer, check that there are no error messages
on the display.

Important!
Faults detected during daily inspection are reported to the management. See driver
instructions.

This is the responsibility of the truck driver (after each shift).

Battery charging
Battery service should only be carried out by specially trained personnel. This training is
given on truck driver courses. Batteries may, however, be charged by other personnel on
the assumption that the battery plug is used to connect the battery to the charging unit.
The battery is charged in accordance with the recommendation from the battery manu-
facturer. Only fully automatic charging units should be used. If an unregulated charger is
used the battery charging should be checked by measuring the specific acid weight in the
cells.

SERVICE MANUAL
 Service / Regular maintenance / Weekly inspection (30 hours of operation) 3.5

Important!
The specific acid weight should also be checked even when an automatic charger is
used. For other information concerning batteries and fully automatic chargers, see
the separate maintenance instructions on the battery and charger.

Weekly inspection (30 hours of operation)

(This section is an extract from the driver instructions.)

Responsibility: Truck driver

1. The battery is cleaned externally with hot water and rags.
2. Check the oil level in the hydraulic system by pushing all the hydraulic cylinders
to their end positions. Now check that the fork carriage goes all the way up to max-
imum lifting height without the pump sucking air.
3. Check that the wheels have not separated – tread/hub and tread/cord.
4. Check the specific acid weight. See separate battery maintenance instructions.
5. The outside of the truck should be cleaned. Vacuum clean, and wipe with moist
cloth in the driver cab. Use care when using a water hose. Electric panels and cir-
cuit boards should always be protected from splashed water when washing.

First service
The first service should be carried out after 200 hours. This service has the purpose of
ensuring the function of the truck and its component parts.
• Change the oil in the gearbox.
• Change the hydraulic oil filter.
• Test the function of the entire machine in accordance with the following list.

Main service
EN-1726 and ISO 3691 specify that regular preventive maintenance should be carried out
on the truck. To guarantee high quality, operation reliability and personal safety, this
maintenance should be carried out by Atlet Service or by personnel specially trained by
Atlet. To comply with this requirement Atlet has prepared the following main service
points (A service), which should be checked every 500 hours of operation.
• Check for external damage on chassis.
• Check of weld joints at vital points.
• Check of lifting devices.
• Check of component attachments.
• Function test, control lever.

SERVICE MANUAL
3.6 Service / Regular maintenance / Extra service inspections

• Check of the horn.

• Test drive backwards and forwards, and turning.
• Check of the drive unit.
• Check of all the wheels.
• Test of the brake function.
• Oil and filter change according to instructions.
• Check for oil leakage.
• Check of the hydraulic unit, pipes and hoses.
• Check of the cylinders.
• Function test, lifting and lowering.
• Lubrication in accordance with lubrication chart.
• Measurement and check of the battery and charging function.

Extra service inspections

What has been mentioned above is applicable on the assumption that the machine is
working in normal conditions on single shifts. In dirty or dusty environments, poor floor
conditions, or where there are large variations in temperatures, the service intervals must
be arranged more frequently.
None of the above mentioned inspection can be debited to Atlet Products.

SERVICE MANUAL
 Service / Regular maintenance / Check list, service inspection 3.7

Check list, service inspection

For further information about procedures for inspections, repairs and replacements refer
to respective sections. Planned service inspections are implemented in accordance with
the following points:

Chassis

Inspection points Symptom Inspection Service code

Signs/Decals None, illegible Visual 1024, 1101

Panels Attachment, damage Visual, tools 1102, 1032

Load wheel, Cas- Damage, wear Visual 1108, 1109

tor wheel
Noise Listen, tool

Attachment Visual, tools

Rubber mats, Rub- Damage Visual 1105, 1058

ber protectors
Attachment Visual, tools

Chassis, general Appearance Visual 1001, 1033,

1112
Damage Visual

Loose screws Tools

Mast

Inspection points Symptom Inspection Service code

Pull rods Locking. Tools 2105

Damage Visual

Forks Cracks, damage Visual 2026

Wear Visual

Angle, deformation Visual, tools

Fork carriage Cracks, damage Visual 2007, 2004

Play, damage, wear Visual, operating

on rollers test

Angle, deformation Visual

Attachment rollers Visual, tools

Mast sections Cracks, damage Visual 2101

Wear, cracks Visual

Drive unit

Inspection points Symptom Inspection Service code

Gearbox Oil level Visual, filling 3006, 3101,

3107
Oil leakage Visual, tools

SERVICE MANUAL
3.8 Service / Regular maintenance / Check list, service inspection

Drive unit

Inspection points Symptom Inspection Service code

Traction motor Function, noise Listen, tool 7028, 7113,

7039, 7027,
Cable connections Visual, tools 7112

Drive wheel Noise Listen, tool 3002, 3005

Damage, wear Visual

Attachment, play Visual, tools

Sliding bearing Noise Listen, lubricate 3103

Drive shaft Noise Listen, tool 3104

Gear Noise Listen, tool 3102, 3106

Steering

Inspection points Symptom Inspection Service code

Guide bearing Noise Listen, lubricate 4101

Tiller arm attach- Play Visual 4103

ment
Attachment Tools

Guide belt Play Visual 4005

Brake

Inspection points Symptom Inspection Service code

Braking force Malfunction Function test, tools 5012

Parking brake Malfunction Function test, tools 5014

Brake cable Abrasion Visual 5002

Brake disc Wear Visual, tools 5104

Hydraulic system

Inspection points Symptom Inspection Service code

Hydraulic tank Oil level Visual, filling 6012, 6102

Damage, leakage Visual, cleaning

contamination

Filter blocked Visual, replace

SERVICE MANUAL
 Service / Regular maintenance / Check list, service inspection 3.9

Hydraulic system

Inspection points Symptom Inspection Service code

Cylinders Function Function test, stop- 6001, 6017

watch

Damage Visual, replace

Leakage Visual, tools,

replace

Weld damage Visual, tools,

replace

Damage, Visual, tools

chain attachments

Hoses Leakage, damage Visual, tools 6007, 6008

Attachment Visual, tools

Nipples Leakage Visual, tools 6019

Pump motor Function, noise Listen, tool 7030, 7029

Cable Visual, tools

connections

Hydraulic pump Leakage Visual, tools 6109

Damage Visual, tools

Noise Listen

Relief valve Malfunction Test 6105

Leakage Visual, tools

Solenoid valve Malfunction Test 6018

Leakage Visual, tools

Prop. valve Malfunction Test 6018

Leakage Visual, tools

For more information regarding the hydraulic system, also see section 8 and lift cylinders
section 9.

Electrical system

Inspection points Symptom Inspection Service code

Contactors Malfunction Visual, tools, 7107

replace

Cable break Visual, tools

Contactor tip Visual, tools

SERVICE MANUAL
3.10 Service / Regular maintenance / Check list, service inspection

Electrical system

Inspection points Symptom Inspection Service code

Battery Charging Tools 7032

Low acid level Tools

Low acid weight Tools

Damage Visual

Transistor Cable break Visual, tools 7025

system AC

Cabling Damage, break Visual, tools 7007, 7009

7010, 7039
7104, 7112

Horn Malfunction Function test 7014

Speed controller Attachment Visual, tools 7011, 7106

Malfunction Function test

Calibration

Fuses Blown Visual, replace 7103

Battery plug Malfunction Function test, 7008

tools

Hour meter Malfunction 7012

Battery indicator Malfunction 7013

Safety switch Emergency stop Malfunction 7020

Microswitch Function Function test 7017

ATC T4 Function Visual 7004

Cable connections

SERVICE MANUAL
 Service / Regular maintenance / Code explanation 3.11

Code explanation
Chassis

Code Designation Check Reference to

section

1001 Machine housing Cracks in weld joints, collision damage, tight- 1

ening of screws/attachments.

1024 Machine plate Attachment: text should correspond with 1

machine type, and symbols and warning decals
should be fitted.

1032 Panels Attached with screws and clips, as well as 4

bonded parts.

1033 Colour Peeling of paint and 1

attachment/lack of decals.

1042 Load guard Cracks in weld joints, collision damage, tight- 1

ening of screws/attachments.

1058 Rubber strips Attached with glue or -

screws/weld bolts

1101 Decals Damage -

1102 Chassis, covers Damage, battery cover 4

1108 Load wheel bearing The operation is frictionless, remove any string, 4
1109 Castor wheel bearing plastic bands etc. that have stuck. 6
Vulkollan wheel wear. Dirt.

1112 Accessories User Manual, areometer and battery water bot- -

tle.

Mast

Code Designation Check Reference to

section

2004 Frame section Attachment of the mast in machine housing. 1

2007 Rollers in fork car- Washers. Lubrication of roller surfaces. 1

riage 6

2026 Forks Cracks, damage, parallelism, height over 6

floor.

2101 Mast play Check max play, Cams. Lubricate slide sur- 6
faces.

2102 Lift chains Check wear. 4

2105 Push rods / Pull rods Locking, damage 6

SERVICE MANUAL
3.12 Service / Regular maintenance / Code explanation

Drive unit

Code Designation Check Reference to

section

3002 Drive wheel Wear, damage, clean 5

3005 Drive wheel bolt Attachment. 5

3006 Oil leakage Leakage from axles, joints, plugs or 5

material.

3101 Oil level Oil level. Oil change. 1

5

3102 Noise Gears. 5

3103 Sliding bearing Noise, lubrication 5

3104 Drive shaft Tightening, play 5

3106 Gears Gear ratio 5

3107 Gear housing Check wear. 5

Steering

Code Designation Check Reference to

section

4103 Tiller arm attachment Play, bushings, attachment 7

4104 Guide bearing Play, lubrication 1

7

Brake unit

Code Designation Check Reference to

section

5002 Brake cable Attachment, damage 11

5012 Braking force Braking distance 11

5014 Parking brake Function, cable connections 11

5104 Brake discs Friction surface> min level all round 11

SERVICE MANUAL
 Service / Regular maintenance / Code explanation 3.13

Hydraulic system

Code Designation Check Reference to

section

6001 Lift cylinders Leakage at attachments, weld joints, 9

scraper, piston rod

6007 Couplings Leakage. -

6008 Hoses Cracks, wear, damage. 1

6012 Oil level in tank Oil level between min and max. 1
8

6017 Lowering Check lowering speed. 8

6018 Solenoid valve Leakage in slide, connections, tightening. -

6019 Nipples Leakage. Tightening. -

6102 Filter Replace if necessary. 8

6105 Relief valve Function, adjustment as per max 8

lifting capacity. Locking.

6109 Hydraulic pump Leakage between pump and motor. -

SERVICE MANUAL
3.14 Service / Regular maintenance / Code explanation

Electrical system

Code Designation Check Reference to

section

7004 Truck computer Error log. 10

7007 Battery cables Attachment, damage. -

7008 Battery connections That cable connections are not overheating. -

Remove oxide.

7009 Main power cable Attachment, damage. -

7010 Control cable Attachment, damage. -

7011 Speed controller Function. -

7014 Horn Function. Oxide deposits. -

7017 Microswitch Function. Attachment. -

7020 Emergency switch Function. -

7025 Transistor system Dirt, moisture. Cable connections, oxide. -

7029 Pump motor carbon Wear. 8

brushes

7030 Pump motor Attachment. Cleaning. 5

7032 Battery Acid level, charging. Note: read-off from -

hydrometer, clean if necessary.

7035 Speed switch Switches in gates and platform that control 10

creep speed. Attachment.

7103 Fuses That they are not brittle, oxidised. 1

7104 Cabling Cable connections, attachment, run free from -

sharp edges. Insulation.

7106 Speed controller Attachment and function. 11

7107 Contactors Contact surfaces, cable connections, -

dust guard.

7112 Traction motor cables Attachment, damage, insulation, oxidation. -

7039

7113 Housing, traction Noise, grease, play. 5

motor

SERVICE MANUAL
 Service / Regular maintenance / Lubrication chart 3.15

Lubrication chart

PLP

D
C
E

2
G

Figure 3.1 Lubrication chart PLP. For explanation of symbols, see table 3.2

1. 500 h service
2. Annual service
All the panels must be removed when lubricating the truck, see section 4. The electric
panel should also be released and folded back to improve access. The electric panel is fit-
ted with two socket head cap screws to the battery wall. When lubricating the mast sec-
tions, push out the battery slightly and brush grease on the roller and slide surfaces.
Service on an Atlet truck can be divided into service that should be carried out regardless
of how severely the truck is loaded and used (see "Check list, service inspection" on page
3.7) and an annual recurrent service:

SERVICE MANUAL
3.16 Service / Regular maintenance / Lubrication chart

Table 3.1 Components to lubricate, PLP

Position- Explanation
ing

A Mast section – roller surfaces and slide surfaces

B Gates – bearing surfaces lubricated

C Spring-mounted drive unit – link bearings, 12 grease nipples

D Hydraulic oil

E Castor wheel - sliding bearings, 2 grease nipples

F Gearbox oil

G Platform, 2 grease nipples

Symbol key, lubrication chart

Table 3.2 Symbol key for lubrication chart

Symbol Explanation Symbol Explanation

Hydraulic oil Hydraulic oil, change

Gearbox oil Gearbox oil, change

Grease Chain spray

Chain spray / oil Only cold store version

Applicable in general for the symbols:

• Unfilled symbol – Check / lubrication.
• Filled symbol – Change.

SERVICE MANUAL
 Service / Specific instructions / Traction motor 3.17

Specific instructions

Traction motor

Preventive maintenance
Preventive maintenance is implemented in accordance with the recommended intervals
in the service chart.
In some cases, however, exceptions must be made and the intervals shortened in relation
to the conditions at the customer, e.g. a severe environment with dust, high humidity lev-
els, or salt, etc.
• Listen for abnormal noise from the bearings when the motor is run. Check that it
does not vibrate abnormally.
• The motor is blown clean with dry compressed air, or cleaned with a vacuum
cleaner. A cleaning fluid should be used to drive out oil and dirt, if oil has leaked
from the gearbox into the motor.
• Check the insulation resistance for the motor, see specification in section 1 for cor-
rect value.

Gearbox

First service
First oil
change after • The first oil change should be made after approx. 200 hours.
200 hours
• Use a recommended type of oil, see section 1.

Preventive maintenance
Oil level • The oil level is checked during each service.
checked dur-
ing each
service • The guide bearing must be greased at least once a year. New greasing is essential if
steam cleaning or high-pressure washing has been carried out.

Note!
Remember to fill up the gearbox after changing the oil or changing the gearbox. See
section 5 for procedure.

Note!
Spent oil should be taken care of and recycled according to the applicable legislation
in respective countries.

SERVICE MANUAL
3.18 Service / Specific instructions / Lift chains and forks

Lift chains and forks

Check
For safety reasons the forks should be checked during each service, see "Check list, serv-
The forks ice inspection" on page 3.7
should be
checked dur-
ing each serv-
ice

SERVICE MANUAL
 Service / Specific instructions / Hydraulic oil 3.19

Hydraulic oil

First service
Hydraulic oil
filer change
after 500 • Oil filters should be changed after 500 hours.
hours

Intervals
After 500 hours of operation: The hydraulic oil filter and air filter to the hydraulic oil
tank should be changed after no more than 500 hours of operation. This refers to those
types of trucks that have replaceable filters. Clean the suction filter.
After every 1000 hours of operation: Change the hydraulic oil, oil filter and air filter
after 1000 hours of operation, or once every year (which ever comes is first).
If the hydraulic oil has been heated over 60 degrees Celsius the oil and the filter should
be immediately replaced since its lubricating properties can have been changed.
If the hydraulic oil has been contaminated with water (e.g. from cold store) this can be
detected in that the oil becomes milky, or smells bad.
It can also be checked with the following simple test:
1. Use protective glasses, gloves and clothes, and observe the fire instructions for the
premises.

Warning!
Risk for burn injuries on the skin.

2. Take a little hydraulic oil in a teaspoon and heat the spoon with a cigarette lighter –
if there is a crackling sound this proves that it contains water and should be
changed.
The hydraulic oil should be filtered when filling, by pouring the oil through the filter.

Emergency stop
Special emphasis should be placed on the inspection of the emergency stop. Of the con-
tactor tip seems to be worn during a visual inspection, it should be replaced on a preven-
tive basis. Applies to emergency stop SE.

Warning!
The unit should be replaced if the emergency stop has been used in a dangerous sit-
uation.

SERVICE MANUAL
3.20 Service / Specific instructions / Recommended replacement

Recommended replacement
Hydraulic hoses should be replaced after 5 years, since the rubber in the hose is perisha-
ble.

Storage of machines and motors

Machines in storage that will not to be used within one month, must be given special at-
tention so that problems do not occur when they are to be used again. Dust, dirt, conden-
sation and moisture caused by large changes in temperature and problems with rust and
oxidisation must be prevented. Motors should therefore be protected with waxed paper
or the like, and a moisture absorbing material.

SERVICE MANUAL
 SERVICE MANUAL
Machine: PLP

Manual No: 119002

Edition 2005B

4 Chassis

Design and function ....................................................................................................... 4.3

Scope .................................................................................................................. 4.3
Machine housing ................................................................................................. 4.3
Covers and panels ............................................................................................... 4.3
Castor wheel ........................................................................................................ 4.4

Repair instructions ......................................................................................................... 4.5

Covers and panels ............................................................................................... 4.5
Dismantling of panels ..................................................................................................... 4.5
Castor wheel ........................................................................................................ 4.6
Replacing the castor wheel/bearing ............................................................................... 4.6
Battery ................................................................................................................. 4.8
Changing the battery ...................................................................................................... 4.8
Replacing the battery rollers ........................................................................................... 4.8

SERVICE MANUAL
4.2

SERVICE MANUAL
 Chassis / Design and function / Scope 4.3

Edition 2005B

4 Chassis
Design and function

Scope
A chassis normally includes the supporting parts of a construction and in the case of a
truck the chassis consists of the machine housing, panels and castor wheel.
The straddle lift and load wheel could be considered to be part of the chassis, but since
they are part of the mast the instructions for these are to be found in chapter 6, Mast, in-
stead.

Machine housing
The chassis on the PLP truck consists of a machine housing. This is where all the truck
components, such as the mast, drive unit, and hydraulic system are mounted.

Figure 4.1 Machine housing PLP

Covers and panels

The function of the panels is to protect the driver from moving parts, electrical compo-
nents, oils and fluids, and to protect the components inside from external damage and
dirtying.

SM_PLP_04_119002_2005B.fm
SERVICE MANUAL
4.4 Chassis / Design and function / Castor wheel

Castor wheel
The caster wheel is a fully turning, non-driven wheel placed under the machine housing.
PLP has two castor wheels.

SERVICE MANUAL
 Chassis / Repair instructions / Covers and panels 4.5

Repair instructions

Covers and panels

The recyclable panels are manufactured of sheet metal and durable plastic.

Dismantling of panels
1. Loosen the two screws to the side panels (pos 1), from the outside. Remove the
panels.
2. Loosen the plate bolts (pos 2).
3. To remove the panels pos 3, you must first unscrew the knob on the emergency
stop button. Press in the emergency stop. Pick off the small plastic plug that is
located in the plastic cover on the battery. Insert a round bar or similar with a
diameter of around 3 mm. Turn the emergency stop button until the hole in the axle
is identified. Then remove the emergency stop button by turning anti-clockwise.
Remove the two retaining screws and lift out the panels by unfolding the gates to
3/4 and work the panels over the gates.
4. The battery cover, pos 4 and 5, has four screws that can be accessed by opening the
cover. Loosen these and lift off the cover and plastic panel.

3
1

Figure 4.2

Clean the panels with soapy water. White impact marks may appear in the case of minor
damage to the plastic panels. These marks can be removed by carefully heating with a hot
air gun.

SERVICE MANUAL
4.6 Chassis / Repair instructions / Castor wheel

Castor wheel

12

15

17

1 14 13

4 16

7
11

10

8 9

Figure 4.3

Replacing the castor wheel/bearing

Dismantling
• Remove the plastic cover from the machine housing.
• Lift up the machine housing approx. 30 cm, and secure with blocks underneath.
• Loosen the bolts, pos. 12, see figure4.3.
• Take out the castor wheel unit and support the fork in a vice.
• Tap out the retaining pin, pos. 11, drive out the wheel axle, pos. 7, and remove the
wheel from the fork.

Note!
Take care of the spacers, pos. 8.

• Support the wheel in the vice instead of the fork.

SERVICE MANUAL
 Chassis / Repair instructions / Castor wheel 4.7

• Pull out the bearings with a bearing extractor.

Assembly
• Lubricate the wheel bearing seats with grease, and press in the bearings with a suit-
able drift.
• Place the wheel fork with the side facing down.
• Hold the wheel and spacers together, and insert the wheel in the fork.
• Fit the wheel axle, pos. 7.
• Tap in the retaining pin, pos. 11.
• Bring up the complete castor wheel under the machine housing, and fit the screws,
pos. 12.

Note!
Check the positioning to make sure the grease cup comes in the right direction.

• Tighten to the correct torque.

• Fit the plastic cover and lift down the machine to the floor.

SERVICE MANUAL
4.8 Chassis / Repair instructions / Battery

Battery

Changing the battery

Work in an area where the old battery can be removed without risk to the environment
from battery acid. Wear acidproof gloves and clothes, plus acidproof glasses, to provide
protection from burn injuries.
A battery trolley must be used when changing the battery.
1. Separate the battery plug.

Figure 4.4 Illustration of changing the battery

2. Release the battery lock.

3. Roll out the battery onto the battery trolley.

Warning!
Observe care to avoid “splashing” waste acid or oxide from the battery.

Replacing the battery rollers

0

1. Remove the battery.

Warning!
Observe care to avoid “splashing” waste acid or oxide from the battery.

2. The battery rollers are loose in their seats. Lift up the rollers in the back edge, and
pull backwards and upwards.

SERVICE MANUAL
 SERVICE MANUAL
Machine: PLP

Manual No: 119002

Edition 2007B

5 Drive unit

Design and function ....................................................................................................... 5.3

Introduction .......................................................................................................... 5.3
Traction motor ..................................................................................................... 5.3
Gearbox ............................................................................................................... 5.3

Repair instructions ......................................................................................................... 5.4

Preparations ........................................................................................................ 5.4
Dismantling the drive unit housing ....................................................................... 5.4
Traction motor ..................................................................................................... 5.5
Storage of traction motor ................................................................................................ 5.5
Gearbox ............................................................................................................... 5.5
Motor mounting .............................................................................................................. 5.6
Changing the wheel studs .............................................................................................. 5.6
Service and fitting of the lower shaft seal on the gearbox .............................................. 5.6
Guide bearing ................................................................................................................. 5.6
Gear collar and drive pinion ........................................................................................... 5.6
Checking the oil level and filling up with oil .................................................................... 5.6
Oil change ...................................................................................................................... 5.6
Drive wheel .......................................................................................................... 5.7
Replacing the drive wheel .............................................................................................. 5.7

Diagnostics and trouble shooting ................................................................................ 5.8

Trouble shooting chart ......................................................................................... 5.8

SERVICE MANUAL
5.2

SERVICE MANUAL
 Drive unit / Design and function / Introduction 5.3

Edition 2007B

5 Drive unit
Design and function

Introduction
The drive unit is mounted in a vertically moving assembly containing the brakes, traction
motor, gearbox and drive wheel.
PLP is equipped with a technical solution for five-wheel pedestrian trucks, designated
Friction Force, which efficiently ensures that an optimum drive wheel pressure is always
available.
Friction Force utilises the principle of increasing the force on the load wheel with an in-
creasing effective force on the forks. The load wheel force is transferred via a link system
to the vertically moving suspended drive wheel, so that the wheel forces are concentrated
there. The suspension also includes compression springs, which make the wheel insensi-
tive to irregularities in the floor and ensure an optimum drive wheel pressure even when
the truck is not loaded.
Friction Force also ensures improved ergonomics in that a cushioning effect is also
achieved at the load wheel and also by reducing rattling noise in the lifting system.
For technical data regarding component parts, see section 1.

Traction motor
The traction motor on PLP is a three-phase induction motor. A pulse transducer is en-
closed in the bearing on the non-driving end of the motor and this provides speed return
to the traction controller, see section 10.
The motor is mounted directly on the gearbox and the transmission of power takes place
via individually adjusted gear wheels.

Gearbox
The gearbox is designed to produce the best gear ratio over the speed range of the traction
motor.

SM_PLP_05_119002_2007B.fm
SERVICE MANUAL
5.4 Drive unit / Repair instructions / Preparations

Repair instructions

Preparations
1. Separate the battery plug.
2. Remove the panels on the machine housing, see section 4.

Dismantling the drive unit housing

2
1

Figure 5.1

1. Dismantle the gates. Start with the gas spring.

2. Release all the electrical connections to the traction motor and brake.
3. Release the electric panel and fold back.
4. Release the gas spring to the platform.
5. Unscrew the eight socket head cap screws holding the traction motor, and lift it
out. Protect the motor shaft and the hole in the gearbox, e.g. with rags.
6. Unscrew the three socket head cap screws holding the motor bed to the gearbox.
Lift out the motor bed.

SERVICE MANUAL
 Drive unit / Repair instructions / Traction motor 5.5

7. Release the two springs pressing down the drive wheel when it is unloaded by
completely screwing off the four nuts. Use a long socket.
8. The two long bolts to the springs must be taken out from underneath. Lift up the
truck to a suitable height and secure with blocks. Remove the two bolts.
9. Release and remove the cable duct on the top of the machine housing.
10. Release the electrical connections to the tiller arm, and release and lift out the com-
plete assembly with steering axle, tiller arm head and guide belt.
11. Release and drive out the two shafts (pos. 1 in fig. 5.1) in the lower link arms as far
as is possible. The shafts must not be completely removed.
12. Release and drive out the four shafts (pos. 2 and 3. in fig. 5.1) in the upper link
arms.
13. The drive unit housing can now be lifted out from the truck. Mark the position of
the gearbox in the drive unit housing before removing the gearbox from the hous-
ing.
14. Assemble in the reverse order. Note that the springs should be compressed to 180
mm on PLP 200 and to 156 mm on PLP 250. The length of the springs when
unloaded is 203 mm. When the guide belt is to be refitted it is important that the
drive wheel is standing straight up when seen from behind, has the wheel nuts to
the left, and that the stops on the steering axle point straight down. The zero posi-
tion of the steering will be incorrect if this is not the case.

Traction motor
The traction motor is mounted on the top of the inner ring in the guide bearing, with a
total of six screws. When assembling and dismantling the traction motor the contact sur-
faces between the motor and gearbox must be thoroughly cleaned. It is also important that
the pinion teeth are in line with the drive teeth so that the tooth flanks are not damaged.

Storage of traction motor

Machines in storage that will not to be used within one month must be given special at-
tention so that problems do not occur when they are to be used again. Dust, dirt, conden-
sation and moisture caused by large changes in temperature and problems with rust and
oxidisation must be prevented. Motors should therefore be protected with waxed paper
or the like, and a moisture absorbing material.

Gearbox
Service work on the gearbox is limited to changing the wheel studs on the wheel and
changing the lower shaft seal.

SERVICE MANUAL
5.6 Drive unit / Repair instructions / Gearbox

Motor mounting
The motor mounting is screwed in the gearbox with three socket head cap screws. These
should be treated with Loctite 243 or the equivalent when fitted.

Changing the wheel studs

After removing the wheel stud that is to be changed the threads on the new wheel stud
and the threads in the hole should be cleaned from oil and grease. The threads should be
treated with Loctite 243 or the equivalent before the new wheel stud is screwed in.

Service and fitting of the lower shaft seal on the gearbox

The shaft seal can be removed after removing the protective disc.
The seal seat in the casing and the surface to which the seal is to seal should be cleaned
before fitting a new seal. The seal should also be greased before it is fitted. The protective
disc is replaced after fitting the shaft seal.

Guide bearing
The guide bearing is protected by rubber rings and is maintenance-free as long as not spe-
cial cleaning has been carried out with a high-pressure jet.

Gear collar and drive pinion

The guide gear collar and drive pinion on the gearbox should be greased with standard
grease.

Checking the oil level and filling up with oil

Oil is poured in through the upper filler screw hole. The correct level is at the lower edge
of the hole.
The oil level should be regularly checked to avoid damaging the gearbox.

Oil change
The oil is drained out through the lower oil plug hole. The oil can be drained more easily
if it is warm.
Spent oil should be taken care of and recycled according to the applicable legislation in
respective countries.
Before screwing in the oil plug again it should be cleaned.

SERVICE MANUAL
 Drive unit / Repair instructions / Drive wheel 5.7

Drive wheel

Replacing the drive wheel

0

1. Loosen the wheel nuts.

2. Lift up the truck so that the drive wheel can rotate freely.
3. Separate the battery plug.
4. Turn the drive wheel 45°.

Figure 5.2 Loosen the nuts on the drive wheel.

5. Remove the wheel nuts.

6. Replace the drive wheel.
7. Tighten the wheel nuts to 84 Nm.
8. Start the truck and test drive in both directions. The wheel must not catch or jam.

SERVICE MANUAL
5.8 Drive unit / Diagnostics and trouble shooting / Trouble shooting chart

Diagnostics and trouble shooting

Trouble shooting chart

Symptom Cause Action

The wheel has a flapping The tyre has separated 1. Change the wheel.
sound when driving. due to impact.
2. Examine the floor for any
irregularities.

The wheel squeaks continu- Bearing is damaged. 1. Replace bearing.

ously when driving.
2. Inform the driver that
string and plastic etc.
should be removed daily,
and the floor kept clean.

The wheel is flat after long The wheel mass has become Try a different type of wheel.
breaks, but becomes round warm while driving and
after driving for a while. deforms when parked.

The wheel has a deformity A “blow out” has taken place Change the wheel.
that does not disappear when due to overheating and
driving. changed the molecular struc-
ture of the wheel mass.

The truck seems to jerk when Hard foreign object has fas- 1. Remove the object or
driving. tened in the drive wheel. change the wheel.
2. See also items above.

The truck jumps at regular The wheel is oval. 1. Change the wheel.
intervals, proportional to the
2. Check/adjust the brake.
speed, when driving.
3. See also items above.

The wheel has transverse The wheel has been heated. 1. Lower the acceleration and
cracks, and small bits have Small cracks appear with reversing rate.
fallen out of the tyre. hard acceleration and revers-
2. Change the wheel if neces-
ing.
sary.

The wheel has one or more Locking of the brakes so that 1. Remove objects on the
small deformations. the wheel slides, or loose floor.
objects on the floor that pre-
2. Tell the driver to brake
vent the wheel from rotating.
more smoothly.

Oil on the floor. Leaking seal around the • Replace seal

drive axle. or:
• If there are cracks in the
casting the gearbox must
be replaced.

SERVICE MANUAL
 Drive unit / Diagnostics and trouble shooting / Trouble shooting chart 5.9

Symptom Cause Action

Grating noise when acceler- 1. Defective gear wheel in Check the teeth by removing
ating or using the reversing the drive unit. the cover.
brake.
2. Too little oil in the gear- If there are cracks in the cast-
box. ing the gearbox must be
replaced.

Grating noise when the truck Faulty bearing in the traction Dismantle and renovate the
is lifted up and the drive motor. traction motor.
wheel can rotate freely and
the motor rotates.

The truck rolls "sluggishly". 1. The brakes are applied. • Replace brake disc.
If this does not help:

• replace the complete brake

unit.

2. The drive unit has seized. If there are cracks in the cast-
ing the gearbox must be
replaced.

Clicking sound when driv- Faulty wheel bearing. Change the wheel.
ing.

Clicking sound when driv- Loose wheel. • Tighten the wheel.

ing.
If this does not help:

• Change the wheel.

The drive unit pulls at an 1. Too much slack in control 1. Tighten the control belt,
angle which is felt in the belt. see Chapter 7.
tiller arm. This makes it diffi-
2. The drive unit leans. 2. The bushings in the links
cult maintaining the right
for the drive unit housing
course when accelerating and 3. The machine housing
should be replaced.
braking. (Applies to ma- leans.
chines without servo) 3. The caster wheels are un-
4. Drive wheel camber
evenly worn. Replace both
missing. Or track is worn.
caster wheels, or use
shims.
4. Replace drive wheel. See
also Parts and Service News
2093.

SERVICE MANUAL
5.10 Drive unit / Diagnostics and trouble shooting / Trouble shooting chart

SERVICE MANUAL
 SERVICE MANUAL
Machine: PLP

Manual No: 119002

Edition 2003

6 Mast system

Design and function ....................................................................................................... 6.3

Lift system ........................................................................................................... 6.3

Repair instructions ......................................................................................................... 6.4

Fork carriage, general ......................................................................................... 6.4
Dismantling the fork carriage .......................................................................................... 6.4
Adjusting the fork carriage ................................................................................... 6.4

Diagnostics and trouble shooting ................................................................................ 6.6

Trouble shooting chart ......................................................................................... 6.6

SERVICE MANUAL
6.2

SERVICE MANUAL
 Mast system / Design and function / Lift system 6.3

Edition 2003

6 Mast system
Design and function

Lift system
The truck variants PLP 200 and PLP 250 have low-lifting fork carriages.

SM_PLP_06_119002_2003.fm
SERVICE MANUAL
6.4 Mast system / Repair instructions / Fork carriage, general

Repair instructions

Fork carriage, general

Dismantling the fork carriage

1. Separate the battery plug.
2. Remove the covers over the machine housing.
3. Release and drive out the four shafts, pos. 1 and 2.

Figure 6.1

4. Lift the fork carriage straight up.

Important!
Observe great caution!

Adjusting the fork carriage

The truck must stand on a level surface. Lower the forks and check the height from the
floor to the top of the forks. The height should be 85-93 mm, with a difference of only 5 mm
between the four measuring points, see figure 6.2. If the forks are too high, or too low,
this is adjusted with the adjusting screw over the lift cylinder.

SERVICE MANUAL
 Mast system / Repair instructions / Adjusting the fork carriage 6.5

85 +8
-0

Figure 6.2 85 +8
-0

SERVICE MANUAL
6.6 Mast system / Diagnostics and trouble shooting / Trouble shooting chart

Diagnostics and trouble shooting

Trouble shooting chart

0

Table 6.1 Symptom/Action table

Symptom Possible reason Action

Play to mast. Mast rollers not shimmed enough. Adjust the side sup-
ports.

The fork carriage low- Side supports adjusted too hard. Adjust the side sup-
ers unevenly, jumps. ports.

No grease on the mast roller surfaces. Grease roller sur-

faces.

The fork carriage No grease on the mast roller surfaces. Grease roller sur-
squeaks. faces.

SERVICE MANUAL
 SERVICE MANUAL
Machine: PLP

Manual No: 119002

Edition 2007B

7 Steering

Design and function ....................................................................................................... 7.3

General ................................................................................................................ 7.3
Steering ............................................................................................................... 7.3
Servo unit (–2005w19) ........................................................................................ 7.3
Servo unit, diagnosis (–2005w19) .................................................................................. 7.4
Servo unit (2005w20–) ........................................................................................ 7.5
Servo unit, diagnostics (2005w20–) ............................................................................... 7.6

Repair instructions ......................................................................................................... 7.7

Cleaning .............................................................................................................. 7.7
Tiller arm head (–2007w27) ................................................................................. 7.7
Replacing ....................................................................................................................... 7.7
Tiller arm head (2007w28–) ................................................................................. 7.8
Dismantling the tiller arm head ....................................................................................... 7.8
Dismantling buttons lift/lower .......................................................................................... 7.9
Dismantling the speed controller .................................................................................... 7.9
Assembly of main cables and brake switch .................................................................... 7.9
Tiller arm (2007w28–) ........................................................................................ 7.12
Dismantling the gas spring ........................................................................................... 7.12
Replacing the steering belt ................................................................................ 7.13
Adjusting the steering belt ................................................................................. 7.13
Adjustment, limit switch ..................................................................................... 7.13
Adjustment, electrical steering ........................................................................... 7.14
Servo steering (2006w15–) ............................................................................... 7.17
Adjusting the steering force .......................................................................................... 7.17
Troubleshooting steering force ..................................................................................... 7.19

SERVICE MANUAL
7.2

SERVICE MANUAL
 Steering / Design and function / General 7.3

Edition 2007B

7 Steering
Design and function

General
The steering movement is transferred mechanically from the tiller arm to the drive unit
with a drive belt.

Steering
The truck is steered by turning the complete tiller arm, which via a drive belt affects the
angle of the drive wheel. There is a switch in the arm, which by means of switching off
the current and actuating the brake causes the truck to stop when the arm is in its upper
and lower end positions. It is therefore only possible to drive the truck when the arm is
between these end positions. There is also a belly switch, which stops the truck when
pushed in. The purpose of the belly switch it to prevent the operator being crushed be-
tween the truck and other objects.
This electronic steering system is designed as a help system for the mechanical steering,
which means that the servo assists when the mechanical steering is actuated. The servo
unit uses 2 voltage-controlled signals for control and the servo will shut down if one of
the signals fails. A red fault indication lamp lights on the servo unit in the event of a
simple fault and the servo function will fail to operate. The truck will now operate as a
normal PLP without servo.
All sensor inputs are short circuit proof against short circuits to the ± battery. However,
the motor connection is not short circuit proof. A contactor is needed in series with the
servomotor so that the servomotor can generate voltage itself. Failure to connect the
battery and performing a quick manoeuvre and if the generated voltage of the servomotor
exceeds 35 Volts will damage the truck's electrical system.

Servo unit (–2005w19)

The position indicators emit identical output signals to the servo, which are 6.0 volts in
neutral position. The servo will shut down if there is a difference of more than 0.5 volts
between the position indicators (red light diodes on PSA Servo box).
The servo has a dead zone of ±0.5 volts around 6.0 volts. Full drive is provided at ±1.7
volts. The dead zone's mid-position can be adjusted ± 0.3V by means of a small hole on
the right underside of the PSA servo box (max 300 degree turn).
The servo function can be blocked by an external signal of 24 volts, which is ± 95-degree
control; there is a mechanical blocking function at ± 105 degrees. When the servo is
blocked the same red light diode lights that indicates incorrectly adjusted position indi-
cator. The limit switch also breaks the contactor to the servo motor.

SM_PLP_07_119002_2007B.fm
SERVICE MANUAL
7.4 Steering / Design and function / Servo unit (–2005w19)

Servo unit, diagnosis (–2005w19)

Electric power from battery
Table 7.1 2-terminals pin AMP gray

Position Cable colour Description

#1 Red Battery + 16-32V

#2 Blue Battery - 0V

Electric power motor

Table 7.2 2-terminals pin AMP black

Position Cable colour Description

#1 Motor +

#2 Black 250 mm Motor -

Sensor 1
Table 7.3 4-terminal minifit pin

Position Cable colour Description

#1 Grey Positive feed sensor
12VDC +-5%

#2 White Signal sensor

#3 Not connected

#4 Black 0V

Sensor 2
Table 7.4 4-terminal minifit pin

Position Cable colour Description

#1 Grey Positive feed sensor
12VDC +-5%

#2 White Signal sensor

#3 Not connected

#4 Black 0V

Blocking signal from braking

Table 7.5 2-terminal minifit pin
Position Cable colour Description
#1 Yellow Blocking 16-32V

#2 Not connected

SERVICE MANUAL
 Steering / Design and function / Servo unit (2005w20–) 7.5

Servo unit (2005w20–)

The position sensors must produce identical output signals to the servo, 6.0 Volts in
neutral. Where there is more than 1 Volt difference between the position sensors, the
servo shuts down (red LED on the PSA servo box).
The servo has a dead zone of ±0.5 Volts around 6.0 Volts. Full drive is reached at 1.9
Volts.
The servo function can be blocked by an external signal of 24 Volts. This signal is
controlled by a breaker in the arm that is activated when the arm is in active mode. For
older models, an end position breaker can also block the servo function. The same red
LED lights when the servo is blocked as the one that indicates an incorrectly adjusted
position sensor.

SERVICE MANUAL
7.6 Steering / Design and function / Servo unit (2005w20–)

Servo unit, diagnostics (2005w20–)

Power connection from battery
Table 7.6 Contact piece X22, 5-pin sleeve AMP

Position Cable colour Description

# 1, X22.1 Red/Blue Battery +24V

# 2, X22.2 Blue Battery - 0V

# 3, X22.3 Pink/White Blocking signal +24V

Power connection, motor

Table 7.7 Contact piece X22, 5-pin sleeve AMP

Position Cable colour Description

# 4, X22.4 Red Motor +

# 5, X22.5 Black Motor -

Sensor 1 and Sensor 2

Table 7.8 Contact piece X24, 8 pin minifit

Position Cable colour Description

# 1, X24.1 Orange Positive feed sensor 1,
12VDC +-5%

# 2, X24.2 Green Signal sensor

# 3, X24.3 Black 0V

# 4, X24.4 Black 0V

# 5, X24.5 -

# 6, X24.6 Orange Positive feed sensor 2,

12VDC +-5%

# 7, X24.7 Green Signal sensor

# 8, X24.8 Black 0V

SERVICE MANUAL
 Steering / Repair instructions / Cleaning 7.7

Repair instructions

Cleaning
The tiller arm and tiller arm head are cleaned with compressed air, or by vacuum clean-
ing. The covers can be cleaned with lukewarm water and a mild soap solution.

Note!
High-pressure washing must not be used.

Tiller arm head (–2007w27)

Replacing

3
3

Figure 7.1 Tiller arm head

1. Loosen the three screws, pos. 3 see Figure 7.1, that secure the upper cover.
2. Press in the belly switch, pos. 1 see Figure 7.1, and release the cover by carefully
pushing it upwards and outwards.
3. Loosen the two screws, pos. 2 see Figure 7.1.
4. Loosen the requisite connectors to replace the head.
5. Assemble in the reverse order.

SERVICE MANUAL
7.8 Steering / Repair instructions / Tiller arm head (2007w28–)

Tiller arm head (2007w28–)

Dismantling the tiller arm head

1. Adjust the arm to its shortest position and unscrew the control lever (only applies
to PLP with adjustable arm).
2. Undo the screws that hold the upper and lower cover together.
3. Release the snap on clip (A) at the front of the tiller arm head.
4. Carefully lift up the front section of the upper cover, shown by arrow B. Now
move the upper cover backwards, see arrow C.

Figure 7.2 Dismantling the tiller arm head

5. Turn the upper cover to the right. The cover can now hang by the main cable.

Important!
Make sure the programming cable load is not too great.

6. Assemble in the reverse order.

Important!
Ensure that no cables get jammed when fitting the head.

SERVICE MANUAL
 Steering / Repair instructions / Tiller arm head (2007w28–) 7.9

Dismantling buttons lift/lower

1. Open the tiller arm head as shown in the description “Dismantling the tiller arm
head” on page 8.
2. Dismantle the buttons by releasing the snap on clips from the inside, see Figure 7.3.

Figure 7.3 Dismantling buttons lift/lower

3. Dismantle the inner section by sliding it in the direction of the axle. Now lift the
section out from the top.

Important!
Following dismantling, a new button must be fitted as the snap fasteners may be
damaged.

Dismantling the speed controller

Important!
Apply the removable thread locking solution, e.g. Loctite 243, to the screws of the
speed controller.

Assembly of main cables and brake switch

Attaching the tiller arm main cable (PLP with fixed arm):
Attach the cable to the control lever head using the cable clip. Pull the cable down to the
tiller foot, to the right of the steering shaft. Attach the cable to the machine with cable ties
to the cable bar.
Pull the cable from the break switch to the left of the steering shaft and attach to the cable
bar using cable ties.

Important!
Ensure that the cables do not chafe against any sharp edges.

Important!
The cables are to have enough slack to ensure that you can lower the arm to its
lowest position and turn as far as possible to the left and right without stretching the

SERVICE MANUAL
7.10 Steering / Repair instructions / Tiller arm head (2007w28–)

cable. It must be possible to open the top section of the control lever head without
the cable being a restriction.

Important!
The main cable must not be of such a length that the programming cable has to take
the load when the top part is hanging from the cable.

Attaching the tiller arm main cable (PLP with adjustable arm):
Attach the cable using the cable clip in the tiller arm head. Run the cable down through
the tiller foot, in front of the steering axle to the forks. Attach the cable in the machine
using cable ties on the cable bar.

Important!
The cable should almost be at full stretch when the arm (adjusted in its furthest
position) is in its bottom position and is turned as far as possible to the right or the
left. If this is done correctly, the length of the cable is adjusted to ensure that it is
possible to open the top section of the tiller arm head in such a way that does not put
a strain on the programming cable.

Cable routing standard design

Figure 7.4 Cable routing, standard design

SERVICE MANUAL
 Steering / Repair instructions / Tiller arm head (2007w28–) 7.11

Cable routing optional

Figure 7.5 Cable routing, optional

Table 7.9 Cable routing, optional

Position Description

1 Smartcard

2 Heat resistance

SERVICE MANUAL
7.12 Steering / Repair instructions / Tiller arm (2007w28–)

Tiller arm (2007w28–)

Dismantling the gas spring

14

8
13

12

30

9 7
6
5

29

2
31

4 32

SM_PLP_07015A.eps 33
3

Figure 7.6 Tiller arm

1. Loosen the screw (14).

2. Loosen the cam (12) by angling the arm at about 45º and then moving the cam
forwards.
3. Loosen the stop screw (6).
4. Lift up the rubber damper (31) along the piston at the same time as you angle the
tiller arm upwards.
5. Loosen the gas spring by opening the strap on the ball retainer (32) using a
screwdriver. Now pull off the gas spring from the ball screw.
6. Assemble in the reverse order.

Important!
Apply grease to the ball retainer (32) and to the fork (30).

SERVICE MANUAL
 Steering / Repair instructions / Replacing the steering belt 7.13

Replacing the steering belt

1. Separate the battery plug.
2. Remove the panels on the machine housing, see section 4.
3. Release all the electrical connections to the traction motor and brake.
4. Unscrew the eight socket head cap screws holding the traction motor, and lift it
out. Protect the motor shaft and the hole in the gearbox, e.g. with rags.
5. Unscrew the three socket head cap screws holding the motor bed to the gearbox.
Lift out the motor bed.
6. Completely unscrew the two bolts holding the belt tensioner in the bottom of the
steering axle, and the two bolts holding the steering axle upper bearing.
7. Replace the belt.
8. Assemble in the reverse order.

Adjusting the steering belt

1. Switch off the power.
2. Roll out the battery.
3. Slightly release the two bolts holding the belt tensioner.
4. Adjust the belt with the adjusting screw.
5. Tighten the two bolts holding the belt tensioner.

Adjustment, limit switch

Ensure the following when adjusting the limit switch:
• That the contact breaker is not in a mechanically closed position.
• That the end position is not actuated before it should be (>95 degrees). This is
checked by moving the tiller arm to the right and left in its outer position. The limit
switch should only be actuated by >95 degrees of turning.

SERVICE MANUAL
7.14 Steering / Repair instructions / Adjustment, electrical steering

Adjustment, electrical steering

An inspection and if necessary adjustments are always to be made following any
adjustment to the belt tension. When adjusting the belt tension check and if necessary
adjust the voltage level in neutral position on the potentiometers, see point 2.
Measuring the looseness of the tiller arm checks the belt tension. The looseness should
be about 30 mm on a machine with servo.
There are several reasons why the steering could have a sluggish feeling.
• Too much belt tension
• The steering axle bearing is seized up
• The axles adjusting the potentiometer voltage, hits the body of the potentiometer.

There are only two ways of adjusting the PSA servo.

Alternative 1
1. Adjust the dead zone (max 300-degree turn)

Figure 7.7 Adjusting the dead zone

The dead zone can be adjusted by means of a small hole on the right underside of the PSA
servo box, using a small slot screwdriver. Undo the lower fixing screw and pull out the
servo box so that you can see the screw hole.

Note!
Do not apply too much pressure to the screwdriver when you adjust the dead zone
on the PSA servo box.

Adjusting the dead zone clockwise means that the arm moves easier to the left and more
sluggishly to the right. Adjust until the actuator arm moves equally freely in both
directions.

SERVICE MANUAL
 Steering / Repair instructions / Adjustment, electrical steering 7.15

Alternative 2
1. Ensure that the axles to the potentiometer arms have the same distance on both
sides. .

0-2 mm

Figure 7.8 Adjusting the potentiometer arms

2. Adjust by undoing 2 screws on the consoles of the potentiometers on the rear of the
drive unit housing.

Figure 7.9 Undoing the screws on the consoles

3. Carefully move the tiller arm a little to the right and left without activating the
actuator arm breaker. Stop the tiller arm in the middle of the play that exists prior
to moving the driving wheel. Measure the signal from the position indicators,
X23.2 and X24.2 to B-.
4. Adjust one potentiometer at a time to 6.20V ±0.10V.

SERVICE MANUAL
7.16 Steering / Repair instructions / Adjustment, electrical steering

Note!
It is important to adjust both of the position indicators equally e.g. (6.13 and 6.10V)
or (5.85 and 5.9V). NOT 5.8 and 6.2V.

If it is not possible to achieve 6.0V on both sides because one of the potentiometers is in
its limit position, remove or alternatively add a shim (118016).

Figure 7.10 Adding a shim

Figure 7.11 Adjusting the position indicators

• Left breaker: For higher voltage, turn the potentiometer clockwise.

• Right breaker: For lower voltage, turn the potentiometer clockwise.

SERVICE MANUAL
 Steering / Repair instructions / Servo steering (2006w15–) 7.17

Servo steering (2006w15–)

Adjusting the steering force
Function:
You can adjust the servo steering force by loosening or tightening the guide belt. In
general you could say that a looser guide belt gives a greater range of movement for the
potentiometer and increases the power to the steering servo motor making the machine
easier to control. If more sluggish steering is required, you can tighten he guide belt to
the potentiometer to produce a narrower range with less power to the steering servo motor
as a result. the guide belt to the potentiometer to produce a narrower range with less
power to the steering servo motor as a result.

10

15

20

19

30

35

33
SM_PLP_07_0011A.eps

32

Figure 7.12 Servo steering

SERVICE MANUAL
7.18 Steering / Repair instructions / Servo steering (2006w15–)

Adjusting the guide belt:

1. Disconnect the battery connector and move the battery sufficiently enough to
access the adjuster screw and locking screws from the battery compartment.
Secure the battery so that it cannot roll.
2. Loosen the two locking screws a little (pos 35, see Figure 7.12) to the belt
tensioner and adjust using the adjuster screw (33) to the desired value. As a starting
point, the belt tensioner can be adjusted to ensure that it is square with the drive
unit housing, figure A, see Figure 7.13

B
A

Figure 7.13 Adjusting the guide belt.

3. Figure B ( see Figure 7.13) shows the adjustment for a looser belt that gives more
steering force power and figure C shows a tight belt that gives less steering force.
4. The quality of the floor and type of wheel affect the steering force which then
needs to be adjusted to new values.
Adjusting the potentiometer:
5. Connect the battery and measure with a voltmeter between B- and X24.4. The
value must be 6V in neutral. In other words the drive wheel is facing forwards and
the guide belt does not affect the mechanism to the potentiometer.
6. To achieve the value of 6V, turn the bracket the potentiometer is mounted in until
the value is reached, see Figure 7.14. If the steering is stiffer clockwise, adjust the
bracket clockwise. Likewise, adjust the bracket anticlockwise if the steering is
stiffer anticlockwise.

SERVICE MANUAL
 Steering / Repair instructions / Servo steering (2006w15–) 7.19

Figure 7.14 Adjusting the potentiometer.

7. Check by turning the tiller to the right and left while reading the voltage. A good
symmetry is when steering to the right gives around 8V, steering to the left gives
around 4V and neutral 6V.
8. The quality of the floor and type of wheel affect the steering force which then
needs to be adjusted to new values.

Troubleshooting steering force

Steering too stiff or too loose.

Is the steering also either stiff or too loose?

Yes

First adjust the steering force using the belt

tensioner.

If the steering is uneven in any direction or No
Ready.

jerky?

Yes

Adjust the balance of the steering force

using the potentiometer.

SERVICE MANUAL
7.20 Steering / Repair instructions / Servo steering (2006w15–)

Uneven or jerky steering.

If the steering is uneven in any direction or

jerky?

Yes

Is the steering also either stiff or too loose? No
Adjust the balance of the steering force
using the potentiometer.

Yes

First adjust the steering force using the belt

tensioner.

Now adjust the balance of the steering

force using the potentiometer.

SERVICE MANUAL
 SERVICE MANUAL
Machine: PLP

Manual No: 119002

Edition 2006B

8 Hydraulic system

Design and function ....................................................................................................... 8.3

General ................................................................................................................ 8.3
Lift ................................................................................................................................... 8.3
Lowering ......................................................................................................................... 8.3
Electric solenoid valve ......................................................................................... 8.3
General ........................................................................................................................... 8.3
Lifting function ................................................................................................................ 8.3
Lowering function ........................................................................................................... 8.4
Hydraulic diagram ................................................................................................ 8.4
Hydraulic diagram PLP ................................................................................................... 8.6

Repair instructions ......................................................................................................... 8.8

Hydraulic system ................................................................................................. 8.8
General rules .................................................................................................................. 8.8
Installation ...................................................................................................................... 8.8
Connections ................................................................................................................... 8.9
Start up ........................................................................................................................... 8.9
Hydraulic oil, changing/draining ......................................................................... 8.10
Requisite equipment: .................................................................................................... 8.10
Procedure: .................................................................................................................... 8.10
Air filter ......................................................................................................................... 8.10
Properties of the hydraulic oil ....................................................................................... 8.11
Motor, hydraulic unit .......................................................................................... 8.12
When should the brushes be replaced? ....................................................................... 8.12
Replacing the brushes .................................................................................................. 8.12
Tips for prolonging the service-life of the motor ........................................................... 8.13
Solenoid valve ................................................................................................... 8.14
General instructions when working with solenoid valve ............................................... 8.14
Solenoid valve, dismantling and assembling ................................................................ 8.16
Installation instruction for pipe couplings ........................................................... 8.16

Diagnostics and trouble shooting .............................................................................. 8.19

Symptom and Action ......................................................................................... 8.19

SERVICE MANUAL
8.2

SERVICE MANUAL
 Hydraulic system / Design and function / General 8.3

Edition 2006B

8 Hydraulic system
Design and function

General

Lift
The driver activates a switch, which starts the lift motor by means of a contactor. The
electric motor drives the hydraulic pump, which pumps hydraulic oil to the lift cylinders.
The hydraulic system includes a relief valve, which limits the maximum hydraulic oil
pressure. The pressure of the hydraulic oil is built up when the cylinder goes towards its
end position. The relief valve opens if the maximum system pressure is reached and leads
the oil from the pump back to the tank. The opening pressure of the relief valve is set at
the factory, so that the machine will be able to handle the load it is designed for.

Warning!
The relief valve must only be adjusted by authorised and trained personnel, since it
is a safety part. All work with the hydraulic system must be carried out in a pres-
sureless state, and in a clean environment. If the relief valve is adjusted it must be
resealed.

Lowering
There is a fixed restrictor valve in the hydraulic unit, which regulates the lowering speed
by restricting the return flow of hydraulic oil.

Electric solenoid valve

General
The electric solenoid valve controls the lifting and lowering movements on the truck. The
solenoid valve is actuated electrically by the driver by means of a switch.

Lifting function
The pump produces a pressure and flow to the lift cylinder. If the lift cylinder is obstruct-
ed, or has an excessive load, the oil goes back to the tank through the relief valve.

SM_PLP_08_119002_2006B.fm
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8.4 Hydraulic system / Design and function / Hydraulic diagram

Lowering function
The solenoid valve opens to release the oil from the lift cylinder. When the fork carriage
presses down the lift cylinder the oil flow goes through the lowering valve, which regu-
lates the lowering speed.

Hydraulic diagram
Table 8.1 List of hydraulic diagrams for PLP

Description Reference Page

Hydraulic diagram PLP 108011 8.6

SERVICE MANUAL
Hydraulic system / Design and function / Hydraulic diagram 8.5

SERVICE MANUAL
8.6 Hydraulic system / Design and function / Hydraulic diagram

Hydraulic diagram PLP

SERVICE MANUAL
Hydraulic system / Design and function / Hydraulic diagram 8.7

SERVICE MANUAL
8.8 Hydraulic system / Repair instructions / Hydraulic system

Repair instructions

Hydraulic system

General rules

Important!
Cleanliness during all work with hydraulic components is of the greatest impor-
tance for the operating safety and service-life of the system. The following should be
taken into consideration:

• Dirt particles must not get into components.

• Do not use cloths that release fibres or particles.
• Only use clean tools.
• Carefully clean tanks, pipes and hoses before installation.
• Welded or hot-bent pipes must be pickled (cleaned with acid bath) and washed
before they are built-in.
• The oil tank must be closed and provided with an efficient air filter to prevent dirt
contaminating the hydraulic oil.
• Sealing compounds such as flax, cement or thread tape are not permitted.
• Take into consideration the specified operating data.
• Do not exceed permitted pressures and volume flows.
• Do not exceed or go below the specified temperature range.
• Pay attention to specified electrical voltages and power consumption.

Note!
All work with the hydraulic system should be carried in a pressureless state and in
a clean environment.

Installation
To prevent dirt and corrosion in the hydraulic system all hydraulic components should be
provided with plastic plugs in the connections before they are delivered. Only remove
these plugs just before the component is to be installed in the machine. Retaining screws
and connections must correspond with those on the drawing. Retaining screws should not
be tightened with a higher torque than what is specified on the drawing. If such informa-
tion is missing, the torque should not exceed what is specified in section 1.

SERVICE MANUAL
 Hydraulic system / Repair instructions / Hydraulic system 8.9

Connections
Couplings should be fitted according to the torque specified in the table in section 1. We
recommend couplings with elastic seals.
Connect pipes and hoses in accordance with the hydraulic diagram. Pay attention to the
connection designations. Do not use force, and avoid building-in tensions in pipes, etc,

Start up
Check that everything is connected in accordance with the hydraulic diagram. Set the re-
lief valves down to a very low pressure if they are not sealed. Start-up with low pressure
and volume flows.
Test the function and tightness of the system. Check the oil level. Set the pressure and
volume flows slowly to the values they should have. Check the connected measuring
equipment regularly, where appropriate. Pay attention to the noise level since abnormal
noise implies defects. Test during variable loads that components are correctly fitted, and
that the system is tight.
In the event of returning equipment to the manufacturer, protect polished surfaces from
damage and dirt by covering them with foil and protective paper. Fit plastic plugs in all
connections. Send the complete components, not loose parts.

SERVICE MANUAL
8.10 Hydraulic system / Repair instructions / Hydraulic oil, changing/draining

Hydraulic oil, changing/draining

Requisite equipment:
• New oil, or purifying equipment for the old.
• A tray to collect the oil in.

Procedure:
1. Lower down the forks and disconnect the battery.
2. Remove the panels enclosing the area where the hydraulic unit is placed.
3. Check how much oil needs to be filled by marking the existing level. e.g. with a
strip of tape. Before marking the level the lift cylinder should be run several times
to check that the pump does not suck air (screaming noise at the end). If this should
be the case the marking should be moved correspondingly so that this does not
happen when new oil has been filled.
4. Remove the cap on the hydraulic oil tank.
5. Suck up the oil with a pump, and pump over the old oil to a suitable container.

Important!
Avoid spilling oil outside the container. The oil should be handled in accordance
with the applicable environmental legislation and local directives.

6. Fill up with oil to the previously marked level. If possible, filter the new oil when
filling. Follow the recommendations in section 1 for the correct type of oil.
7. The lift cylinder should be run several times to check that the oil level is correct
and so that any air will disappear, and also to check for excess oil. Excess oil runs
the risk of the oil overflowing.
Wipe up any oil spillage and refit the panels.

Air filter
There is an air filter in the refilling plug on the hydraulic tank, which during service/oil
change should be cleaned. The filter is cleaned with a suitable grease solvent that will not
damage the rubber, e.g. turpentine.
Pull out the filler plug from the tank and remove the red cap fixed with three barbs. Wash
the foam rubber filter and blow clean, or squeezze dry with paper. Refit in the reverse or-
der. The filter should be replaced if the foam rubber is damaged.

SERVICE MANUAL
 Hydraulic system / Repair instructions / Hydraulic oil, changing/draining 8.11

Properties of the hydraulic oil

The hydraulic oils recommended in this manual, section 1, have properties that promote
a long service-life and good functionality, and these are the oils that should be used in the
truck. The hydraulic oil used in Atlet trucks must comply with Atlet quality requirements:

Important!
Never mix oils of different types or brands! Environmentally adapted oils must not
be used without the approval of Atlet if the warranty it to be valid.

• Smooth action.
• Long service-life.
• High viscosity index with wide range of temperature applications.
• Good low-temperature properties.
• High filterability.
• Good air and water separating capacity.
• Good wear protection.
• Good oxidation stability.
• Minimum foaming.
• Provide protection from rust and corrosion.
• Good adhesive capacity.

SERVICE MANUAL
8.12 Hydraulic system / Repair instructions / Motor, hydraulic unit

Motor, hydraulic unit

If the performance of the electric motor changes it should be inspected internally. One of
the most common sources of faults is wear on the carbon brushes in the motor.
The brushes can wear out, or stick in the brush holders. In both cases inadequate contact
between the brushes and the commutator can lead to serious damage on the commutator
surface.

When should the brushes be replaced?

• If a carbon brush cannot move freely in the brush holder. To check this the brush
holder must be released from the brush rigging. The force from the brush spring
should then press out the brush from the brush holder as far as is permitted by the
cable.
• If a carbon brush is approaching the end of its usable length. The length of the
brushes must never be less than 10 mm (a new brush has a length of 17 mm). Since
this is difficult to measure there is an alternative method. Measure the difference
between the cable and the groove in the brush holder. The difference should be at
least 1 mm. Even if the difference should be slighter more it is recommended to
change the brushes anyway, since their remaining service-life may be shorter than
the interval to the next inspection.

Replacing the brushes

The repair kit consists of brush, brush holder and spring. They should be installed as fol-
lows.

1
3

2
4

Figure 8.1

1. Release the cables from the terminals on the motor (pos. 1 figure 8.1).
2. Release the through bolts from the rear end on the motor (pos. 2 figure 8.1).
3. Lift out the electric motor from the truck.
4. Place the electric motor on the drive end.

SERVICE MANUAL
 Hydraulic system / Repair instructions / Motor, hydraulic unit 8.13

5. Loosen the nuts on the terminals, (pos. 3 figure8.1). If the motor has a return earth
the earth connection on the rear end of the motor should also be released (pos. 4
figure 8.1).
6. Loosen the rear end (pos 5. figure8.1). Make sure that the terminals remain in their
positions.

B
1

Figure 8.2

7. Disconnect all four carbon brushes by releasing the screws, pos. 1, figure 8.2 - A,
figure 8.2. Now press each brush set to the commutator. - B, figure 8.2. Remove
the brush set from the brush rigging – C. The old brush set is replaced with a new
set by the reverse procedure. It is recommended to replace each brush separately to
avoid confusion. Make sure that each brush set is replaced with the correct part, i.e.
one that has the cable on the correct side. (The service kits consist of two matching
pairs of brush sets!)
8. Tightent the screw, pos. 1 figure 8.2, to approx. 1.3-1.8 Nm.
9. Replace the terminals in the grooves in the rear end, and replace it back on the
motor. Check that there is a washer between the rotor and the end (pos. 2 figure
8.2) and that the attachment is located with a tooth and a slot on the casing and end.
10. Insert the through bolts and replace the electric motor in the truck. Tighten the
bolts to approx. 4.8-6.8 Nm.
11. Tighten the terminal bolts to 10-14 Nm (pos. 3 figure 8.1).
12. Replace the cables to the motor terminals.

Tips for prolonging the service-life of the motor

• The rapid wearing of carbon brushes and the commutator is often caused by oil.
Oil or grease is burned by the sparks produced at the brushes, and leaves a residue
of abrasive ash. If oil or grease is detected in the motor the reason for this must be
eliminated immediately.

SERVICE MANUAL
8.14 Hydraulic system / Repair instructions / Solenoid valve

• Never overload the motor. Brushes that have been severely overheated expand per-
manently and can fasten in the brush holders.
• The service-life of the brushes does not only depend on the loading, but also on
how worn the commutator is. The commutator should have smooth, level and grey-
ish black surface. A worn commutator must be machine milled (never use abrasive
paper, grindstone or file) to a surface fineness of Ra = 0.8-1.8 µm and a maximum
runout of 0.03 mm (with the rotor resting in the bearing seats). The service-life of
the commutator is prolonged if it is machined a little and often, rather than seldom
and a lot. The minimum diameter of the commutator is 40.8 mm.
• The motor must not be exposed to full load immediately after changing the
brushes.
• Look for signs of overheating on the windings, dark patches, brittle or burned insu-
lation, and damage to the soldering on the commutator. The electric motor should
be replaced if such damage is found.
• If possible, remove dust and dirt from inside the motor with compressed air.
• A dirty commutator should always be cleaned with a cloth moistend with petrol
(do not used cotton rags since these shred fibres), and carefully blown dry with
compressed air.
• If the bearing cup look as if it has run out of oil (i.e. if there is a lot of oil on the
rotor washer or brush holder) lubricate it with a little bearing grease.

Solenoid valve

General instructions when working with solenoid valve

1. Cleanliness

• Dirt particles must not get into components.

• Cloths must not shed fibres and particles.
• Tools must be clean.
• Tanks, pipes and hoses must be carefully cleaned before installation.
• Welded or hot-bent pipes must be pickled and cleaned before they
are built-in
• The oil tank must be closed and provided with an efficient breather
filter that prevents the penetration of dirt.

2. Sealing compound

• Hemp, cement or sealing tape is not permitted.

SERVICE MANUAL
 Hydraulic system / Repair instructions / Solenoid valve 8.15

3. Operating data

• Do not exceed permitted pressures and volume flows.

• Do not go beyond the specified temperature range.
• Pay attention to specified electrical voltages and maximum power
consumption.

SERVICE MANUAL
8.16 Hydraulic system / Repair instructions / Installation instruction for pipe couplings

Solenoid valve, dismantling and assembling

1. Lower down the forks and relieve the pressure in the hydraulic system.
2. Place protective paper under the valve and release the electric cables to the valve.
3. Loosen all the oil pipes connected to the valve and plug them.
4. Loosen the valve from the truck, and lift it out.
5. When fitting, tighten the valve and then the oil pipes.
6. Adjust the relief valve to the rated weight in accordance with the machine plate.
7. Seal the setting.

Installation instruction for pipe couplings

To achieve a safe and tight connection when installing pipe couplings in the hydraulic
system, the following points should be taken into consideration:
1. The pipe should be cut at right angles by means of a pipe cutter (see figure 8.3 and
8.4), after which it is deburred internally and externally, and carefully cleaned.

Important!
When using a pipe cutter the end of the pipe becomes skew, with the formation of
substantial burrs internally and externally. It is therefore important to straighten
the end of the pipe and remove the burrs, both internally and externally.

Figure 8.3 Cut at right-angles!

Figure 8.4 Pipe cutter

2. Oil the thread and pipe olive (not grease) if this type of coupling is used. Put the
nut and pipe olive over the pipe end as shown in the figure. If the pipe olive cannot

SERVICE MANUAL
 Hydraulic system / Repair instructions / Installation instruction for pipe couplings 8.17

be worked over the pipe end it must absolutely not be enlarged. File down the pipe
end instead.
3. Small pipe dimensions can be fitted directly in the coupling connected to the
machine part. Screw the nut by hand until it lies flush with pipe olive, press the
pipe towards the shoulder in the coupling cone, and tighten the nut a ¾ turn.

Important!
The pipe must not follow round.

4. The pipe olive will now have gripped the pipe, and no longer needs to be pressed
against the shoulder. Complete the fitting with an additional ¾ turn of the nut. A
mark on the nut simplifies following the specified torque, see figure 8.5.

Figure 8.5 A mark on the nut simplifies the specified torque

5. Larger pipe dimensions and couplings in free pipes are preferably fitted by placing
the coupling body in a vice. The U-ring spanner should be 15 times the nut width
(can be extended with a piece of pipe). Otherwise fit according to point 3.
If several couplings of the same type are to be fitted, make sure that each pipe end
goes in the same coupling cone it was previously fitted in.
Fitting is simplified if the nut is loosened and oil is applied between the friction
surfaces.

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8.18 Hydraulic system / Repair instructions / Installation instruction for pipe couplings

6. After fitting, release the cap nut and check that the pipe olive has pressed up a vis-
ible swelling in the area in front of it, see figure 8.6. If not, give it another short
turn. It is of no importance whether the pipe olive can still be turned.

Figure 8.6 A visible swelling should have formed after tightening

After a visible swelling has formed the nut should be fitted without extension of
the U-ring spanner, and without excessive force.

Important!
Refitting: After a visible swelling has formed the nut should be fitted without exten-
sion of the U-ring spanner, and without excessive force.

7. If the pipe is to be bent after a coupling, the straight pipe end should have a length
of at least 2 nut heads, H.
Long and heavily loaded pipes should be provided with pipe clips.

H
2H

Figure 8.7 Straight pipe length between bend and coupling

8. The final assembly should be done with at least 1 turn of the nut from the point
where it cannot be turned by hand.

SERVICE MANUAL
 Hydraulic system / Diagnostics and trouble shooting / Symptom and Action 8.19

Diagnostics and trouble shooting

Symptom and Action

A number of fault symptoms have been listed in the table below, with a number of pos-
sible faults and repair procedures. It is therefore possible for other faults to have occurred
in addition to the ones listed.
Table 8.2

Symptom Possible fault Action

The lift motor runs, but The lowering valve has 1. Close the valve.
the fork carriage does jammed and is open.
2. Adjust, or remove any dirt from
not lift.
the valve.

The lift motor runs, but The machine is overloaded. Lighten the load.
the fork carriage lifts
very slowly. The relief valve is defective. Adjust the valve to the rated weight.

A foreign object has partially Take apart and clean.

blocked a hose, hydraulic
pipe or valve.

Hydraulic hose has been Rearrange the hose and clamp secure.
clenched.

The lift motor emits a The oil level is too low in the 1. Fill with hydraulic oil.
screeching noise just hydraulic tank. When the tank is almost full, try
before the fork carriage with 0.1 litre at a time to avoid
reaches the top. overfilling.
2. Find out the reason for the low
level, and rectify the fault.

The fork carriage will Valve does not open on Dismantle valve and clean.
not lower. return because of foreign
object in the system.

The fork carriage low- The lowering valve is dirty Dismantle the valve and clean, or
ers too slowly. or defective. alternatively replace defective parts.

The oil filter is blocked and Change filter.

dirty.

Dirt in the fixed restrictor in Dismantle and clean the dirt from the
the hydraulic unit. restrictor.

Hydraulic oil flows out Oil level too high. Reduce the oil level to correct level.
via the air filter.
The oil foams. Change the oil with oil that has the
correct properties.

Condensation water in oil Empty the tank of oil and fill with
tank. new hydraulic oil to correct level.

The fork carriage rocks Air in the hydraulic system. Bleed the system via the air cylin-
when lifting. ders.

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8.20 Hydraulic system / Diagnostics and trouble shooting / Symptom and Action

Table 8.2

Symptom Possible fault Action

The hydraulic oil has a The oil separators in the 1. Change the oil and filter.
bad smell, sulphur. hydraulic oil are ruined.
2. Flush the complete system with
Motor oil has been used and new hydraulic oil.
caused the hydraulic oil to
emulsify with water and then
rot.

The hydraulic oil has become 1. Change the oil and oil filter.
too hot.
2. Check the breaking function of
the lift stop.

SERVICE MANUAL
 SERVICE MANUAL
Machine: PLP

Manual No: 119002

Edition 2003

9 Lift cylinders

Design and function ....................................................................................................... 9.3

Introduction .......................................................................................................... 9.3
Lift cylinder .......................................................................................................... 9.3
Dismantling and assembling .......................................................................................... 9.3

SERVICE MANUAL
9.2

SERVICE MANUAL
 Lift cylinders / Design and function / Introduction 9.3

Edition 2003

9 Lift cylinders
Design and function

Introduction
The lift cylinder consists of a single-acting hydraulic cylinder, where hydraulic oil is
pumped into the cylinder and presses out the piston rod.
When the driver activates the lowering function the cylinders are pressed together
through a control valve releasing oil out from the cylinder. This is then pushed together
by the weight of the forks and the load, at the same time as the oil returns to the hydraulic
tank.

Lift cylinder

Dismantling and assembling

1. Move the battery out of the way.
2. Remove the hydraulic hose and hydraulic coupling on the cylinder.
3. Plug the hydraulic hose to avoid dirt getting into the hydraulic system.

Figure 9.1

4. Remove the plate in the fork carriage (pos. 1 in Figure 9.1). Keep the spacers in a
safe place.
5. Lift out the cylinder.
6. Assemble in the reverse order.

SM_PLP_09_119002_2003.fm
SERVICE MANUAL
9.4 Lift cylinders / Design and function / Lift cylinder

SERVICE MANUAL
 SERVICE MANUAL
Machine: PLP

Manual No: 119002

Edition 2008A

10 Electrical System

Design and Function .................................................................................................... 10.5

General .............................................................................................................. 10.5
Description of Components .......................................................................................... 10.5
Description of Components and Interface .................................................................... 10.6

Repair Instructions ....................................................................................................... 10.7

General .............................................................................................................. 10.7
Safety Procedures ........................................................................................................ 10.7
Abbreviations ............................................................................................................... 10.8
Battery ............................................................................................................... 10.8
Battery Capacity ........................................................................................................... 10.8
General Handling ............................................................................................. 10.10
Function Keyboard ..................................................................................................... 10.10
Menu Tree – Start-up and Top Level ......................................................................... 10.11
Connectors in Cold Storage Rooms ................................................................ 10.12
Greasing ..................................................................................................................... 10.12
Drive and Valve Controller ............................................................................... 10.13
Connector Traction Motor Controller, Specification .................................................... 10.13
Wiring Diagram ................................................................................................ 10.14
Insulation Resistance ...................................................................................... 10.15
Routine Test ............................................................................................................... 10.15

SERVICE MANUAL
10.2

Main Controller Unit ATC, Handling .................................................................10.15

Menus ......................................................................................................................... 10.15
Settings ....................................................................................................................... 10.17
Total Reset ................................................................................................................. 10.17
Set Truck Type ........................................................................................................... 10.18
Monitor menu .............................................................................................................. 10.18
Traction ....................................................................................................................... 10.18
In/Out .......................................................................................................................... 10.19
Set Options ................................................................................................................. 10.19
Calibrate accelerator .................................................................................................. 10.19
Calibration of lifting and lowering controls (ATC T4 mk2, 2007w28–) ........................ 10.20
Add New Driver .......................................................................................................... 10.21
Change Format of Driver ID and Access Code .......................................................... 10.22
Change Access Code for Local or Atlet Service Menu ............................................... 10.22
Log Functions and Hour Counter ............................................................................... 10.23
Read Hour Counter .................................................................................................... 10.23
Temperature Log ........................................................................................................ 10.24
Error Log ..................................................................................................................... 10.25
Read Error Log ........................................................................................................... 10.25
Clear Error Log ........................................................................................................... 10.26
Performance Parameters ........................................................................................... 10.26
Driver Categories ........................................................................................................ 10.26
Set Driver Parameters ................................................................................................ 10.27
Pin Code ..................................................................................................................... 10.27
Safety Checks ............................................................................................................ 10.27
Speed Limits ............................................................................................................... 10.28
General Functional Description .................................................................................. 10.29
Truck Mode ................................................................................................................. 10.29
Temperatures ............................................................................................................. 10.31
Options ....................................................................................................................... 10.32
.................................................................................................................................... 10.33
ATC Logic ........................................................................................................10.33
Direction Selection ..................................................................................................... 10.35
Brake System ............................................................................................................ 10.36
Lift System ................................................................................................................. 10.36
Download .........................................................................................................10.37
Download of Service Data and Logs to a PC ............................................................. 10.37
Download of "Truck Manager" Statistical Logs to a PC .............................................. 10.37
ATC Connector ................................................................................................10.39
Digital I/Os .......................................................................................................10.39
Digital Inputs ATC ....................................................................................................... 10.39
Digital Inputs TMC ...................................................................................................... 10.40
Digital 24V Outputs TMC ............................................................................................ 10.40
Cold Resistance Values ..................................................................................10.41
Fuses .............................................................................................................10.41

Diagnostics and Trouble Shooting ...........................................................................10.42

Truck Remote ACcess, TRAC .........................................................................10.42
Prerequisites ............................................................................................................... 10.42
Utilization .................................................................................................................... 10.42
Connecting Procedure ................................................................................................ 10.42
Illustrated instructions are attached to the TRAC cable. ..................................10.42

SERVICE MANUAL
 10.3

Error Codes ..................................................................................................... 10.43

Error Code Indicating ATC: ........................................................................................ 10.43
Error Code Indicating TMC: ........................................................................................ 10.47
Other Trouble Shooting .............................................................................................. 10.50

Appendix 1, Summary menu tree ............................................................................. 10.59

SERVICE MANUAL
10.4

SERVICE MANUAL
 Electrical System / Design and Function / General 10.5

Edition 2008A

10 Electrical System
Design and Function

General

Description of Components

6
4

1
3

Figure 10.1 Components

1. Drive motor, TM.

2. Pump motor, PM.
3. Traction motor controller, TMC.
4. Emergency stop push button.
5. ATLET truck controller, ATC.
6. Battery plug.

SM_PLP_10_119002_2008A.fm
SERVICE MANUAL
10.6 Electrical System / Design and Function / General

Description of Components and Interface

The ATC system consists of a keyboard (pos. 1), display (pos. 2) and an ATC card (pos.
3).

Figure 10.2

SERVICE MANUAL
 Electrical System / Repair Instructions / General 10.7

Repair Instructions

General

Safety Procedures
Extreme importance must be placed on precautionary measures to avoid accidents during
all work on the vehicle.
• The drive wheel should always be lifted up free from the floor during service work
to prevent the vehicle from moving.
• The battery plug should be pulled out before working on the electrical system. The
battery plug may only be connected while trouble shooting, and when the greatest
of care is exercised, (with the truck raised).
• No other persons should be in the vicinity of the truck when it is test run in con-
junction with repair work, in view of the risk of accidents or near-accidents from
the truck making an unexpected manoeuvre.
• All metal objects such as watches, chains, spectacles and rings should be removed
when working on the electrical system, or in its immediate vicinity. A short-circuit
from such objects can result in serious burn injuries.
• Working with electrical vehicles can result in personal injury. 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 rotate freely during work.

Warning!
Working with electrical vehicles can result in personal injury.

Electronic Controllers
• All the electronic controllers in the truck have multiple safety systems.
• When replacing or repairing the electronic controllers, or removing cables, the bat-
tery should always be disconnected.

Important!
Incorrectly connected battery cables can destroy the electronic controllers.

Warning!
During all work on the truck the drive wheel must be lifted up from the floor to pre-
vent accidents occurring.

After the power has been disconnected to the controller and work or trouble shooting is
to be conducted, there can be residual voltage in the capacitors for a few minutes. For this
reason observe care when working with current-carrying tools during this period.

SERVICE MANUAL
10.8 Electrical System / Repair Instructions / Battery

Abbreviations

AC Alternating Current

ATC ATLET Truck Controller

B+ Battery positive

B- Battery negative

BDI Battery discharge indicator

CAN Controller Area Network

DC Direct Current

ELCB Electronically load compensated brake

EPS Electric Power Steering

PSA Powered steering assistance

TMC Traction Motor Controller

WG Wire Guidance

Battery
0

Battery Capacity

100% 50%

90% 40%
80% 30%

70% 20%

60%

Figure 10.3 Battery capacity

The battery capacity is shown to the left on the bottom row on the display. Measurements
are fully controlled by software, and no further electronics are required. The capacity is
measured by measuring the battery voltage.
When the battery capacity gets too low the battery capacity value starts flashing and a
buzzer is actuated.

SERVICE MANUAL
 Electrical System / Repair Instructions / Battery 10.9

When battery capacity reaches 20%, a lift lock out occurs within 3 minutes of active time
and error code E50 will be logged.

Battery capacity % Unloaded pole voltage Acid density g/cm3

0 22.92 1,070

10 23.20 1,093

20 23.47 1,116

30 23.75 1,139

40 24.03 1,162

50 24.30 1,185

60 24.58 1,208

70 24.85 1,231

80 25.13 1,254

90 25.41 1,277

100 25.68 1,300

In order to carry out a complete battery discharge indicator (BDI) adjustment, the follow-
ing procedure has to be performed:
1. Connect a voltmeter directly to the B+ and B- poles of the battery.
2. Power up the truck and enter “ATLET menu => Settings => Battery => Calibrate”.
Key in the value from the voltmeter by using the keyboard. For example if the volt-
age 25.2 V is read from the voltmeter, key in 252.
3. Enter (ATLET menu => Settings => Battery =>) “Stepdown hi”. This parameter
(0-9) decides how quickly the BDI reduces the indicated level when the battery has
been recently charged.

• If the indicator does not indicate 100% after a full recharge cycle, or
drops too quickly in the range 100%-60%, this parameter should be
decreased.
• If the indicator drops too slowly in the range 100%-60%, this parameter
should be increased.

4. Enter (ATLET menu => Settings => Battery =>) “Stepdown lo”. This parameter
(0-9) decides how quickly the BDI reduces the indicated level when the battery is
close to becoming discharged

• If the indicator drops too slowly in the range 60%-20%, this parameter
should be increased.
• If the indicator drops too slowly in the range 60%-20%, shows too high
a battery status, or the truck stops due to under voltage alarms, this
parameter should be increased.

SERVICE MANUAL
10.10 Electrical System / Repair Instructions / General Handling

General Handling

Function Keyboard
The keyboard is used for driver identification, settings, and for diagnostics. The keyboard
consists of 12 keys, which have different functions depending on which position the sys-
tem is in.

Function in
Key:
Input mode: Operational mode: Service mode:

Enter a zero. - -

Enter a one. - -

Enter a two. Switch between creep Step one step down in the
speed and full speed. menu tree.

Enter a three. - -

Enter a four. - Step one step to the left in

the menu tree.

Enter a five. - -

Enter a six. - Step one step to the right

in the menu tree.

Enter a seven. - -

Enter an eight. Set the truck to full speed. Step one step up in the
menu tree.

Enter a nine. - -

- Used for input to the level Steps to the upper menu

selector and to change the level loop if pressed dur-
system status. ing input in the upper
level.

SERVICE MANUAL
 Electrical System / Repair Instructions / General Handling 10.11

Function in
Key:
Input mode: Operational mode: Service mode:

Used to accept the shown Used to confirm a selected Used to select the shown
value. level in the level selector. menu alternative.

Function key combinations

A “monitor menu” can be obtained if the keys are pressed down

at the same time in the Operational mode.

Menu Tree – Start-up and Top Level

1sec Time-out
OR 27-nov-97 10:16
System off timer standing by...
(no power supply) elapsed

Time-out
timer
Power on
elapsed
shutting down...
ATC T4 OR
model v1.00
1sec

Operator ID: Valid ID + Belly button Operational

? Mode

Horn Button Local Code: Valid code Local Menu

ENT
???? Tree
2sec

Invalid code Invalid Code:

2sec

Horn Button ATLET Code: Valid code ATLET Menu

???? ENT
Tree

Horn Button Settings Settings Menu

ENT
Tree

Figure 10.4 Menu tree

SERVICE MANUAL
10.12 Electrical System / Repair Instructions / Connectors in Cold Storage Rooms

In Operational Mode
If the [i] key is pressed for one second the truck will go to the “stand-by” mode. The
changeover is confirmed by a peep.
In Stand-by Mode
If the [i] key is pressed for less than two seconds the truck will go to the “operational
mode” without asking for a PIN code. If the [i] key is pressed for one second the truck
will return to the upper level and ask for an operator ID.
There is no reason for the operator to release the [i] key to log out directly from the op-
erational mode.

Connectors in Cold Storage Rooms

0

Greasing
Kryotox grease, ATLET part number 110781, should be applied in all electrical connec-
tors. The hand pump, part number 110782, should be used in order to do this. The grease
should be applied to the contact surfaces when the connectors are drawn apart. The con-
nectors are then reconnected and the grease is pressed from behind into the connector
housing so that it is filled. All blocks that have more than one cable are considered to be
connector blocks. Flat pins protected by some form of sheath should not be greased.

SERVICE MANUAL
 Electrical System / Repair Instructions / Drive and Valve Controller 10.13

Drive and Valve Controller

0

Connector Traction Motor Controller, Specification

The traction motor controller has two connectors with I/Os for 11 1
valves, sensors, change-over switches and programming tools, etc.
Each connector pin is specified below with, where appropriate, the
X6
voltage level in connected condition.

Connector X6 (figure shows connector from the cabling side).

20 10

Table 10.1 Connector X6 traction motor conntroller AC1

Pin Description Comment

X6.1 Controlling of Main contactor. Controlled to B-.

X6.2 Supply to Main contactor. +24V

X6.3 Controlling of electric brake. Controlled to B-.

X6.4 Controlling of pump contactor. Controlled to B-.

X6.5 Supply to pump contactor/horn. +24V

X6.6 Controlling of horn. Controlled to B-.

X6.7 CAN communication. CAN Low.

X6.8 - -

X6.9 Pos. supply to drive motor encoder. +12V

X6.10 Neg. supply to drive motor encoder. B-

X6.11 Controlling of lowering valve. +24V

X6.12 Neg. supply to lowering valve. B-

X6.13 Signal input temp. sensor.

X6.14 - -

X6.15 - -

X6.16 +12V supply to HVC. +12V (Not used as std.)

X6.17 CAN communication. CAN High.

X6.18 - -

X6.19 Input A from drive motor encoder. Synchronises the motor movement with
pulses from the encoder.

X6.20 Input B from drive motor encoder. Synchronises the motor movement with
pulses from the encoder.

SERVICE MANUAL
10.14 Electrical System / Repair Instructions / Wiring Diagram

Connector X5 (figure shows connector from the cabling side).

7 1

X5

12 6

Table 10.2 Connector X5 traction motor controller AC0

Pin Description Comment

X5.1 Supply from F3 fuse. +24V

X5.2 Joint supply to all digital +24V

inputs.

X5.3 Input from brake switch. Closes in upper and lower arm position.

X5.4 - -

X5.5 Input from gate switches. Closes with the gates in upper position.

X5.6 Input from platform. Closes with the platform down.

X5.7 Input from lift stop switch. The lift stop switch breaks at lift stop.

X5.8 Input from platform. Closes when the platform is up.

X5.9 Input from fixed platform Closes when standing on the platform.
switch.

X5.10 - -

X5.11 - -

X5.12 - -

Wiring Diagram
All the wiring diagrams can be found in a separate “Wiring diagram manual”, contact At-
let for further information.
The relevant wiring diagrams are specified in the table below.
Table 10.3

Description Machine Reference Document code

Wiring diagram PLP 108007 (–2005w17)

118270 (2005w18–)
118222 (2007w28–)

Circuit diagram PLP 108186 (–2005w17)

118275 (2005w18–)

SERVICE MANUAL
 Electrical System / Repair Instructions / Insulation Resistance 10.15

Insulation Resistance
0

Routine Test
You must first disconnect the connectors (plugs) before the truck is insulation tested in
order to protect the controllers and other electrical components on the truck. This is be-
cause 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 measuring terminals. Do not
touch the terminals during testing.

Routines for insulation testing of all truck models.

1. Take out the insulation measurement instrument.
2. Set the test voltage to 100 volt.
3. Pull out the battery plug. Electrical components and electronic systems can be
damaged by the test voltage. For this reason disconnect connections and contactors
to these before doing the test.
4. Connect the instrument’s earth lead to the truck chassis at a point with good electri-
cal contact. The other lead is connected to the plus pole on the electrical panel
plug.
5. Press the start button and wait until the display has stabilised, then release the but-
ton and read-off the value on the display. The approved value on 24 volt machines
should be at least 24000 Ω , (24 k Ω ).
6. Let the earth lead remain attached to the chassis and connect the other lead to the
minus pole on the electrical panel plug. After this repeat point 5.

Main Controller Unit ATC, Handling

0

Menus
When starting the ATC system there are four different basic menus the user can select.
The user navigates between these different menus by means of the [i] key as shown in fig.
Certain of the menus are protected by a password.

Operator ID:
?

i
O

SERVICE MANUAL
10.16 Electrical System / Repair Instructions / Main Controller Unit ATC, Handling

Local code:
????

i
O

ATLET code:
????

i
O

Settings

Navigation in the menus takes place by means of the keys on the keyboard. The keys four
and six are used to step up and down, and keys two and eight to step from side to side.
The arrows on the display show the possible directions.
The enter key is used to go into the submenus. To leave a selected menu, use the Exit se-
lection together with the enter key. One refinement is that the horn key can be used as an
escape key. It can also be used to step back in the menus to the Exit position. This function
can also be used to cancel an initiated parameter change.
The menus are divided into three levels, as follows:
Operational
This menu is used to log into the Operational mode. Logon takes place by selecting driver
ID, entering a password, and finally using the safety switch as an enter key. In the Oper-
ational mode it is possible to use the truck and all its functions.
Local Service
In the Local Service menu it is possible to change passwords for local service, add and
remove drivers, and set the time/date, LCD contrast, and key sound. Certain statistical
functions are also available here. A password is needed to access the Local Service menu.
Atlet Service
Atlet Service includes all the functions used by Atlet authorised service personnel. A
password is needed to access the Atlet Service menu. The Atlet Service menu is built up
as shown in fig.


ATLET menu:
< Exit >


ATLET menu:
< Options >


ATLET menu:
< Settings >


ATLET menu:
< Tests >


ATLET menu:
< Calibrate >


ATLET menu:
< Logs/Counter >


ATLET menu:
< Set access >

SERVICE MANUAL
 Electrical System / Repair Instructions / Main Controller Unit ATC, Handling 10.17

ATLET menu:
< Total reset >


• Exit – selected to exit the Atlet menu.
• Options – possibility to set the options available for the truck.
• Settings – possibility to set driver parameters, hydraulic parameters and battery
parameters.
• Tests – tests I/Os.
• Calibrate – possibility to calibrate inputs.
• Log/Counters – possibility to read and clear temperature log, error log, and hour
counter.
• Set access – possibility to add drivers, and set passwords for Atlet and local ser-
vice.
• Total reset - Possibility to restore all settings, options, users, calibrations and logs
to default values.

Settings
Under the settings menu it is possible to select the language shown in the display. Swed-
ish, English, French, and a “custom” language can be selected. It is possible by using a
PC and a special program to add on a “custom” language.

Total Reset
In the Total reset menu it is possible to restore all settings, options, users, calibrations and
logs to default values.
• Exit: Exits the Total reset menu and performs a restart of the system. Note that the
command means leaving the Atlet menu and performing an actual restart of the
system.
• All Users: Clears all users. The default user will be set instead. Also the Atlet code
and the Local code will be set to the default codes.
• Options: Restores all options to default values.
• Settings: Restores all settings to default values.
• Calibration: Clears all calibrated values. A new calibration must be performed to
make the truck work again.
• Logs: Clears all logs. Hour meters will not be cleared.

SERVICE MANUAL
10.18 Electrical System / Repair Instructions / Main Controller Unit ATC, Handling

Set Truck Type

After clearing all settings or installing a new ATC, the truck type has to be set. When
powering up the truck again the ATC will automatically open a menu asking which truck
the ATC will be used in.
PLP 200 <-
PLP 250

Scroll to the desired truck type and press enter. If the wrong type is selected, reset all set-
tings in the Reset menu and try again.

Monitor menu
By pressing the enter and 7 key at the same time it is possible to access the Monitor menu
from the Operational mode. The Monitor menu shows the speed, power consumption,
motor temperature and TMC temperature.

Monitor menu
Traction

Monitor menu
Pump

Monitor menu
Steering

Monitor menu
Wire guide

Monitor menu
In/Out

Traction
Under the Traction menu it is possible to control the motor speed in real time and the cur-
rent consumption or motor and TMC temperature.
C: 025 degC
M: 027 degC

1800 RPM
56 A

Pump: Not relevant for PLP.

Steering: Not relevant for PLP.
Wire guide: Not relevant for PLP.

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 Electrical System / Repair Instructions / Main Controller Unit ATC, Handling 10.19

In/Out
Under In/Out it is possible to check all inputs to ATC, TMC and HVC in real time. It is
also possible to check the ATC internal interlock functions. The function to check the in-
puts is built up as shown in fig:

ATC inputs:

TMC inputs:

HVC inputs:

EPS inputs:

ATC in/out:

Note that the truck is in Operational mode when the Monitor menu is shown. In other
words the truck can be driven, and therefore it is appropriate to block it up in accordance
with the safety instructions.

Set Options
There are several different options under option. They are used to explain to ATC which
accessories the truck is equipped with. Further information on which options are avail-
able and their function can be found under "Options" on page 10.32.
The option name and which status the option has (off or on) is specified in the first bar in
the display. Setting an option is done as follows:
1. Step forward to the option to be set, and press enter.
Transp indic: no
0:no 1:yes

2. Press the 0 key to switch off the option, or 1 to set it.

Transp indic: yes
New value saved!

Calibrate accelerator
Under Calibrate it is possible to calibrate the accelerator. This is done as follows:
• Select accelerator, and press enter.
CALIBRATE:
Accelerator v^

• Leave the accelerator in neutral, and press enter.

Release throttle
and press ENT

SERVICE MANUAL
10.20 Electrical System / Repair Instructions / Main Controller Unit ATC, Handling

• Apply maximum acceleration in both directions without pressing hard to the end
position, and then press enter.
Go to end points
and press ENT

• The display shows if the calibration was successful or not. (only Software 2.23–)
Ok!
Press ENT

Not successful!
Press ENT

• The calibration is now finished. A window is shown where it is possible to test the
response of the accelerator. Press enter to end.
Signal check:
2.3V Out: 064%

Important!
The accelerator must be calibrated at each service.

Calibration of lifting and lowering controls (ATC T4 mk2,

2007w28–)

Important!
The lifting and lowering controls must be calibrated both at ON/OFF and
proportional adjustment.

1. Open the Atlet menu => Calibrate => Lift/Lower. The following display appears:
Release lift
press ENT

2. Check that there are no controllers activated. Now press ENT. The following
display appears.
Order full raise
press ENT

3. Press lift fully down on the right lift and lower control. Now press ENT.
4. The following display now appears.
Order full lower
press ENT

Press lower fully down on the right lift and lower control. Now press ENT.
5. The display shows if the calibration was successful or not. (only Software 2.23–)
Ok!
Press ENT

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 Electrical System / Repair Instructions / Main Controller Unit ATC, Handling 10.21

Not successful!
Press ENT

6. The following display appears:

Signal control:
x.xV Out: xxx%

You can now use this menu to check that the calibration is correct. Signal check should
give the following values:
• When lift is activated: 4.7V (± 0.1V)
• Neutral (control not activated): 2.7V (± 0.1V)
• When lower is activated: 0.6V (± 0.1V)
Press ENT.
7. Repeat the same calibration procedure for the left lift and lower control by
selecting Channel 2, and follow steps 1-5. Exit by pressing ENT.
8. Leave the Atlet menu by going to Exit and pressing ENT.
9. Loosen the battery and then restart the truck.
10. Perform a function test of the lift and lower function.

Add New Driver

New drivers can be added in the menu Set Access. Select Operator to add new driver.
• Select new/change and press enter.
OPERATOR:
New/change v^

• Write in the driver ID to be changed/added.

Operator ID:
?

• Select the driver category the driver is to belong to.

Operator categ:3
?

• Select the code applicable for the driver. If the code or category is to be changed
for an existing driver, the code associated with this driver ID must be specified
first.
New code:
????

• To verify the code it must be entered one more time.

Verify new code:
***?

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10.22 Electrical System / Repair Instructions / Main Controller Unit ATC, Handling

• Press enter to end.

OK!
Press ENT

Change Format of Driver ID and Access Code

In the submenu Set Access there is a function to set the number of digits in the driver ID
and access code. Both these can be set from between one to seven digits. Note that drivers
with longer codes will not be able to logon if the number of digits is reduced! On the other
hand if the number of digits is increased the requisite number of zeros will be added to
existing, shorter codes.
• The format of code/ID is changed in Set Access => Operator => Format.
OPERATOR:
Format v^

• A warning in two parts is shown. Press 2 to see the second part of the warning.
Continue by pressing 1.
CAUTION! Reduced
length may lead


to lost entries
0:escape 1:go on

• Change the length of ID or Code.

ID length: 5
v


Code length: 4
^

• Step out by pressing a four, or the horn key.

Change Access Code for Local or Atlet Service Menu

The codes for both Atlet and Local service can be changed in Set Access. This is done in
the same way for both, as follows:
• Select Set Access => Local, and press enter.
SET ACCESS:
Local v^

• Specify the valid code.

Old code:
****???

• Write in the new code.

New code:
???????

• Verify the new code.

Verify new code:
****???

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 Electrical System / Repair Instructions / Main Controller Unit ATC, Handling 10.23

• Press enter to end.

OK!
Press ENT

Log Functions and Hour Counter

There are two different log functions in ATC, error log and temperature log. Both can be
read and cleared in Atlet Service.
There are also a number of hour counters and these can divided up into two categories,
total time and trip time. Both can be read in Atlet Service, but only the trip category can
be cleared. The times measured are:
• Active time – the time the truck is used actively, or in other words the total of
travel time and pump time.
• Log time – the time the system has been logged on.
• Travel time – the time the drive motor has been used.
• Pump time – the time the pump motor has been used.
The hour counters can also be read in external units, e.g. a TMC or HVC.
The total hour meters can be set in Atlet menu => logs/counters => set hour mtrs. Note
that the total hour meters only can be set to a higher value than the existing. There will
not be an error message if a lower value is set, but the new value will not be saved.

Read Hour Counter

• Select Hour counters under Logs/Counters.
LOGS/COUNTERS:
Hour meters v^

• Select Trip, Total or External.

HOUR COUNTER:
Total v^

HOUR COUNTER:
Trip v^

HOUR COUNTER:
Read external v^

• Navigate between the four different hour counters.

TOTAL pump:
00001.246h

• Step back with the 4 key or with the horn key.

SERVICE MANUAL
10.24 Electrical System / Repair Instructions / Main Controller Unit ATC, Handling

Temperature Log
The temperator log registers temperature measurements from the TMC in five different
temperature intervals. The log saves the number of hours the different temperatures have
been measured. See fig:
Table 10.4 TMC

Temp. ranges: Hours (the numbers are examples)

-40°C 436.53 h

41-50°C 271.28 h

51-60°C 42.74 h

61-70°C 3.61 h

>71°C 0.00 h

SERVICE MANUAL
 Electrical System / Repair Instructions / Main Controller Unit ATC, Handling 10.25

Error Log
ATC has an error log system that logs external and internal errors. External errors are er-
rors that external units detect and report to ATC. Internal errors are errors that ATC de-
tects itself. The error code, description of the error, date and time, are saved in the error
log.
The error log function is based on four error classes:
• A – Shown in the display and saved in the log. Only cleared after it has been read.
• B – Shown in the display and saved in the log. Cleared when the error has ceased.
• C – Saved in the log. Not shown in the display.
• Warning – Gives a text warning. Certain warnings are logged.
In addition to being shown in the display, also indicates an error through an audible sig-
nal. The signal is repeated every other minute as long as the error/warning is shown in
the display. The warning is shown in the full top bar on the display, while the error is
shown in the second bar position 5-8.
The error log is divided into primary and secondary faults. A secondary error is an error
that occurs 2 seconds after the first error occurred. If the last primary error is repeated
without any other error occurring, this error will not be logged separately in the log. It
will be added to a counter in the log of the last error instead.
Example of how the error log works:

Primary Log Secondary Log

01:030122 +01:030122
07:49+ 07:49
Traction Traction
system system
Low voltage No
#3 030215 communication
18:09
+01:030122
07:49
Valve system
No
communication

The fault “Traction system, Low voltage” has occurred three times. The first time at
07:49 220103 and the third time at 18:09 150203. There are two secondary faults associ-
ated with the first fault, which are shown by the plus character after the time 07:49.

Read Error Log

• The error log is opened with Log/Counters => Error log.
ATLET MENU:
< Logs/Counters >

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10.26 Electrical System / Repair Instructions / Main Controller Unit ATC, Handling

• The primary faults in the error log are navigated with the 8 and 2 keys. Information
is read from the error log as follows:

Number in errorlog Error code

13: E105
030221 12:04:26
Date when error occurred Time when error occurred

Error description

Traction system
no communication

Number of times the error has been repeated

#015 occurred:
030402 12:27:15
Date when latest error occurred Time when latest error occurred

Figure 10.5

• The [i] key is used to access the secondary log. The secondary errors can then be
navigated with the 2 and 8 keys.

Clear Error Log

• To clear the error logs, select Logs/Counters => Reset.
LOGS/COUNTERS:
Reset v^

• Select Error log.

RESET:
Error log v^

• Select Yes.
Reset error log?
0:no 1:yes

Performance Parameters
The performance parameters in ATC are divided into two levels, machine parameters and
driver parameters. The machine parameters represent the basic setting of the machine.
They are preset at the factory and can only be changed by using a special PC program.
The driver parameters are percentages of the machine parameters.

Driver Categories
The software in ATC supports four different driver categories. These are used to give dif-
ferent drivers difference performances. One example is the possibility to have a category

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 Electrical System / Repair Instructions / Main Controller Unit ATC, Handling 10.27

for experienced drivers and one for beginners. All driver IDs must be associated with a
driver category.

Parameter Description Limits

Fwd Speed Maximum speed forward 20-100%

Rev Speed Maximum speed in reverse 20-100%

Tract Accel Acceleration 20-100%

Cutback 1 Creep speed 0-90%

Cutback 2 Not used -

Tract Curr Current limit 20-100%

Rdc brake Braking torque for reducer brake 0-100%

Neut brake Braking torque for neutral position brake 0-100%

Rev brake Braking torque for reversing brake 50-100%

Brake pedal Braking torque for the ELCB brake 50-100%

Set Driver Parameters

• Select Settings => Performance. Select the category the driver parameters are to be
changed for.
PERFORMANCE:
Op category 1 v^

• Navigate amoung the different driver paraemeters with the 2 and 8 keys. Press
enter to select parameter.
Cutback 2 20%
v^

• Write in a new value and press enter.

Cutback 2 25%
New value saved!

Pin Code
ATC uses a pin code instead of a key switch. Each driver is defined with a unique ID num-
ber. A pin code is linked to each driver ID, which can be 1-7 digits in length. Up to 100
driver IDs can be saved. The driver ID and code are used together to access the truck,
thereby replacing the key switch.

Safety Checks
When logging into the truck there is a safety check of the brake switch, lift system, belly
button switch and speed controller. The lifting and speed controller should be inactivated
when logging on and the brake switch should previously have been in neutral position. If
any of these safety tests fail a warning is shown in the display, with a request to reset the

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10.28 Electrical System / Repair Instructions / Main Controller Unit ATC, Handling

activated control to neutral position. Depending on which control is activated an interlock

function will be actuated to prevent the use of certain of the truck functions.

Warning text in Cause Interlock func-

display tion actuated

Release Throttle The speed controller is actuated during logon. This warn- Speed interlock
ing can also be shown if the steering arm is moved to oper-
ational mode with an excessive throttle.

Release Tiller The brake switch was not in neutral position during start- Safety interlock
up.

Release controls One of the keys for lifting/lowering was actuated during Lift interlock
logon. Also shown if more than one lifting/lowering con-
trol is actuated simultaneously.

Release controls The belly button switch has returned to neutral position Safety interlock
after logon.

Interlock function System in the truck obstructed

Speed interlock Drive system

Safety interlock Drive system

Lift interlock Lift system

Speed Limits
In ATC there is a way of achieving a reduction in speed during the operation of the truck
called creep speed. Creep speed is selected by switching with the 2 key between creep
speed and full speed (key 8 to go straight to full speed). The actual position is shown in
the display with a symbol representing a tortoise or a hare.

Figure 10.6

For safety reasons the maximum speed is decided by the positions of the gates and the
platform. See below for a description of the gates and platform states.

Gates Platform Driver on Allowed speed see fig.

out up platform

0 0 0 No travel allowed A

0 0 1 6 B

0 1 0 6 C

0 1 1 Fault state

1 0 0 No travel allowed D

1 0 1 Full speed E

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 Electrical System / Repair Instructions / Main Controller Unit ATC, Handling 10.29

1 1 0 No travel allowed F

1 1 1 Fault state

A B

C D

E F

Figure 10.7

General Functional Description

For the truck to be in neutral position the following is necessary:
• The tiller arm must be raised.
• The drive wheel must point straight forwards.
• Forks in bottom position.
• Battery plug disconnected.
• Truck in room temperature (20°C).
• Safety gates are in upper position.
• Platform is in upper position.
• Emergency push button is in its upper position.

Truck Mode
The truck can be in four different modes:
• OFF: Voltage disconnected.

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10.30 Electrical System / Repair Instructions / Main Controller Unit ATC, Handling

• Logged on/Operational: To be compared with the battery plug connected and the
key in the lock, key in on position.
• Logged off: To be compared with the battery plug connected but the key removed.
• Standby: To be compared with the battery plug connected and the key in the lock,
but in off position.

Off

Remove battery plug Connect battery plug

Logged off Held down for 1s

Pin plus Bellybutton

Logged on Standby

Held down for 1s

Figure 10.8

In Operational mode all the truck functions such as lifting/lowering and travel can be
used. Logon with ID and pin code is required to access the Operational mode. In the Op-
erational mode the driver can utilise a lot of information via the display, such as date,
time, battery status, error codes and warning messages, etc.

Date Time

27-nov-97 10:16
^ 2652h
Battery indicator Hourmeter
Field for error codes Full speed/creep speed symbol

Lift stop indicator

Figure 10.9

• Date - shows ATC date.

• Time - shows ATC time.
• Field for error codes – an error code is shown when an error occurs. When a warn-
ing is shown it is shown in the full upper bar instead.

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 Electrical System / Repair Instructions / Main Controller Unit ATC, Handling 10.31

• Symbol for creep speed/full speed - shows if the truck is in full speed or creep
speed mode.
• Hour counter – shows active or logged on time, depending on which selection was
made in the options menu.
• Battery indicator – shows battery status. When 20% battery status is reached the
lift system ceases to be available.

Temperatures
The TMC measure temperature and sends, if necessary, a warning to the ATC. The tem-
peratures measured are the internal controller temperature and the traction motor temper-
ature. The traction motor temperature is only measured in two steps; over and below
125°C. If a value greater than 125°C is measured the TMC reduces the current and the
warning “Motor temp high“ is presented on the display.
The internal controller temperature is measured and handled in two steps. If the temper-
ature is over 75°C the TMC reduces the maximum current. If the temperature is over
100°C the current is reduced to zero and the truck stops. With a controller temperature
over 75°C the warning “Ctrl temp high“ is presented on the display.

SERVICE MANUAL
10.32 Electrical System / Repair Instructions / Main Controller Unit ATC, Handling

Options

Option Description

Lift limit Lift stop for the fork lift. Stops the pump when the lift stop switch is actuated.
The lift stop is connected to a digital input on TMC.

Restart Restart of the fork lift, activated by pressing 2 on the keypad.

Safety syst Safety system S3 (only PP* servo). When the safety system is enabled the speed
is reduced during cornering. The safety system is a part of Fleet Management.

Effici log Efficiency log. Included in Fleet Management.

Impact sens Collision sensor. Included in Fleet Management. The collision sensor is purely
software based. The speed is monitored, and sudden and rapid reductions in
speed are interpreted - as different degrees of colliding.
*Log level -Setting for logging collisions.
*Warning level -Setting for collisions that give a warning on the display.
*Horn level -Setting for collisions that activate the horn.
*Stop level -Setting for collisions that stop the truck.
*Supervis level -Setting for collisions that require the truck to be unlocked
using a code.

Damage rep Damage log. 10 seconds after logging the truck reverts to crawl speed and the
driver receives a number of questions about any damage. If the driver answers
no, the truck switches to Operational, i.e. the truck runs as normal. Otherwise a
question is asked about damage to different parts of the truck. Included in Fleet
Management.

Time logoff Time for automatic logging off.

*Del time a -Time to go to Standby.
*Del time b -Time to log off.
*Dis tiller res (Disable tiller reset) -If the parameter is set to “Yes”, you log on
from Standby to Operational by pressing the “I”-button twice. If the parame-
ter is set to “No”, you log on by activating the tiller arm's brake switch.

Smartcard Smartcard is a unit mounted on the machine housing (servo) or the tiller arm.
Smartcard permits a log on using a card instead of a PIN-code.
*Damage rep -Damage log for the Smartcard. Works as the damage log Dam-
age rep.

Disp log on If the option is enabled the log on time is shown on the display. Otherwise the
active time is shown.

Summer time Automatically sets the clock to summer time.

Keyswitch If the option is enabled the keyswitch is used instead of the PIN-code when log-
ging on.

Speed red Speed reduction is connected to a digital input on TMC.

Service-Alarm Automatic service reminder.

*Interval -Time for service interval.

Fixed platf Activated when a fixed platform is used (only PLP).

TillerUpD Holding in the button on the tiller arm allows the truck to be driven at crawl
speed, without actuating the tiller arm brake switch (only PLL/PSD/PS).

Footswitch Activates the foot switch on the operator lift (only PP).

Reverse ind Reversing warning unit which is connected on HVC (only PP).

SERVICE MANUAL
 Electrical System / Repair Instructions / ATC Logic 10.33

Raise steer Accompanying control (only PP).

Dual lift Double proportional buttons (only PS/PSH)

Straddle Adjustable support arm (only PSH). Can not be combined with Dual lift.

Belly start If the parameter is set to “Yes”, the belly switch must be activated in order to
log on (used as an “Enter” button). If the parameter is set to “No”, you are
immediately logged on once the code has been entered.

*Only shown if the option is activated.

Warning!
When options are stated as being truck specific, under no circumstance may these
be activated on any other type of truck than the ones stated. This is on account of
the software using the same digital inputs for different functions on different truck
models.

ATC Logic
The truck control logic is nowadays mainly generated in the ATC software, and not as
previously with cabling and the series and parallel connection of switches. For this reason
it is no longer possible to measure all the logical conditions by means of a multimeter.
This can now be done with the help of the Monitor menu function for input control. There
is no circuit diagram for the software. Instead, a graphic description of the software con-
ditions required for ATC to request procedures has been generated.

The condition does not rule

if it is true. Can be compared
with a NC contact.

The condition rules if it is

true. Can be compared with
a NO contact.

Two conditions after each other generate an “and” condition, i.e both conditions must
rule for the objective to be achieved. Two parallel conditions generate an “or” condition,

SERVICE MANUAL
10.34 Electrical System / Repair Instructions / ATC Logic

which means that it is sufficient for one of the conditions to rule for the objective to be
achieved.

OR AND

Figure 10.10

Below is an example of how the horn works:

Hornbutton 1

ATC sends order to start horn

Hornbutton 2

Figure 10.11

It is therefore sufficient for one of the horn keys to be actuated for it to start.

SERVICE MANUAL
 Electrical System / Repair Instructions / ATC Logic 10.35

Direction Selection

Throttle command
>Deadzone Safety interlock Tillerswitch

Speed interlock

Platform down Platform up Gates

Forward
direction
request

Platform down Platform up

Throttle command
Safety interlock Tillerswitch
<Deadzone

Speed interlock

Platform down Platform up Grindar

Backward
direction
request

Platform down Platform up

Figure 10.12

An explanation of the different interlock conditions is available under "Safety Checks"

on page 10.27.

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10.36 Electrical System / Repair Instructions / ATC Logic

Brake System

Tiller switch

Speed interlock

Engage brake

Actual vehicle Timer elapsed

speed=0 500 ms

Throttle command
in deadzone

Figure 10.13

An explanation of the different interlock conditions is available under "Safety Checks"

on page 10.27. Note that the brake will be automatically engaged after 500 ms on a sta-
tionary truck with the speed controller in neutral position.

Lift System

Pushbutton
raise 1

Pushbutton Pushbutton
Liftstop Lift interlock
lower 1 lower 2
Pushbutton Start pumpmotor
raise 2

Pushbutton
lower 1

Pushbutton Pushbutton
raise 2 Lift interlock
raise 1
Pushbutton Opens lowering valve
lower 2

Figure 10.14

An explanation of the different interlock conditions is available under "Safety Checks"

on page 10.27.

SERVICE MANUAL
 Electrical System / Repair Instructions / Download 10.37

Download

Download of Service Data and Logs to a PC

1. Log off the truck and disconnect the battery connector.
2. Turn on the PC.
3. Connect the PC serial COM port to the data connector X3 in the tiller head. Use PC
downloding cable ATLET part no 108005.
4. Reconnect the battery connector.
PC
5. Start Windows HyperTerminal.
6. Create a new HyperTerminal connection.
7. Connect directly to your serial COM port.
8. Adjust the com parameters as follows:

• Baud Rate: 9600

• Data Bits: 8

• Parity: None

• Stop Bits: 1

• Flow Control: None

9. Activate "Capture Text" mode under "Transfer" menu.

Truck
10. Log into "ATLET menu".
11. Select "LOGS/COUNTERS" and "Download".
12. The service information is now transferred to the PC.
Disconnect
13. Turn off the HyperTerminal and the PC, log off the truck and disconnect battery
plug.
14. Disconnect the PC downloding cable.

Download of "Truck Manager" Statistical Logs to a PC

1. Log off the truck and disconnect the battery connector.
2. Turn on the PC.

SERVICE MANUAL
10.38 Electrical System / Repair Instructions / Download

3. Connect the PC serial COM port to the data connector X30 under the armrest. Use
PC downloding cable ATLET part no 108005.
4. Reconnect the battery connector.
PC
5. Start Windows HyperTerminal.
6. Create a new HyperTerminal connection.
7. Connect directly to your serial COM port.
8. Adjust the com parameters as follows:

• Baud Rate: 9600

• Data Bits: 8

• Parity: None

• Stop Bits: 1

• Flow Control: None

9. Activate "Capture Text" mode under "Transfer" menu.

Truck
10. Log into "LOCAL MENU".
11. Select "FLEET MANAGER" and "Download".
12. The statistical data is now transferred to the PC.
Disconnect
13. Turn off the HyperTerminal and the PC, log off the truck and disconnect battery
plug.
14. Disconnect the PC downloding cable.

SERVICE MANUAL
 Electrical System / Repair Instructions / ATC Connector 10.39

ATC Connector
ATC, connector and pin numbering.

XJ5 XJ1 XJ2 XJ3 XJ4

XJ9 XJ10
XJ13
XJ6
XJ14 XJ8

XJ7

XJ12

XJ11

Connector top view:

2 XJ8, XJ14
1

43 XJ1, XJ2, XJ3, XJ4, XJ5, XJ9, XJ11, XJ12

21

6 54 XJ7
3 21

87 65 XJ10
43 21

XJ6
14 1

Figure 10.15 Cortex card

Digital I/Os

Digital Inputs ATC

There are twelve digital inputs on the ATC card, of which seven are used for the pushbut-
tons on the tiller arm. The pushbuttons control functions as lift/lower and the horn.
The other five digital inputs are not used in these truck models.
The fact that the inputs are read by ATC can easily be confirmed by selecting Test =>In-
puts in the ATLET service menu, and then activating the different functions.
The signal supply of approx. 5V is on pin no 1 in the following connectors:

Connec- Function Comment

tor

XJ1.3 Lift

XJ2.3 Lower

XJ3.3 Lift

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10.40 Electrical System / Repair Instructions / Digital I/Os

Connec- Function Comment

tor

XJ4.3 Lower

XJ8.1 Horn 1 Supply 5V pin no 2.

XJ14.1 Horn 2

Digital Inputs TMC

There are ten digital inputs in to the TMC, of which seven can be used for these truck
models.
Signal supply 24V is taken from pin no X5.2.

Connec- Function Comment

tor

X5.3 Brake switch Closes in the upper and lower arm position.

X5.5 Safety gates Closes in upper position.

X5.6 Platform down switch Closes when platform is down.

X5.7 Lift stop switch Breaks at end position.

X5.8 Platform up switch Closes when platform is up.

X5.9 Fixed platform switch Closes when standing on the fixed platform (option).

X6.14 Speed reduction switch Breaks at slow speed and must be set from option menu.

Digital 24V Outputs TMC

There are five digital outputs in TMC. Four of these are of the “low side” type, which
means that they close to B-. The fifth output is of the “high side” type, which means that
it closes to B+. It is this fifth output that closes the lowering valve Y2.

Connec- Function Comment

tor

X6.1 Energises main contactor K1 24V supply from X6.2.

X6.3 Energises the electric brake Y1 24V supply via brake switch.

X6.4 Energises the lift contactor K2 24V supply via X6.5.

X6.6 Energises the horn H1 24V supply via X6.5.

X6.11 Energises the lowering valve 0V supply via X6.12. NOTE! This output is not short-
Y2 circuit-proof.

SERVICE MANUAL
 Electrical System / Repair Instructions / Cold Resistance Values 10.41

Cold Resistance Values

Component Resistance

Contactor K1 approx. 47 Ohm

Contactor K2 approx. 19 Ohm

Valve coil Y2 approx. 26 Ohm

Brake Y1 approx. 20 Ohm

Fuses

Fuses

F1 250A Drive motor

F2 250A Pump motor

F3 7.5A Manoeuvring

F4 5A For extra equipment. Max 120W

F5 25A Power steering

SERVICE MANUAL
10.42 Electrical System / Diagnostics and Trouble Shooting / Truck Remote ACcess, TRAC

Diagnostics and Trouble Shooting

Truck Remote ACcess, TRAC

00

The purpose of TRAC is to create a remote access to the display and keyboard of the
truck, so that an expert can make a remote analysis of the truck and guide local service
personnel to trouble shooting.

Prerequisites
• GSM-phone with built in modem and serial cable (local TRAC experts can provide
more information on suitable phones).
• GSM telephone subscription featuring “data call“ and a “data phone“ telephone
number.

Utilization
After agreement with a TRAC expert to use the TRAC system:
• Prepare and connect according to the connecting procedure below.
• The TRAC expert may send text messages to you through the display of the truck.
• When the TRAC session is closed, await a phone call from the expert or call the
expert yourself.
• Disconnect in reverse order (see connecting procedure).

Connecting Procedure
1. Step to TRAC using the arrow button, and enter the menu with the Enter button.
2. Choose “init phone“ and return to the TRAC menu with arrow .
3. When the phone rings, choose “answer phone“. Return with arrow .

Illustrated instructions are attached to the TRAC cable.

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 Electrical System / Diagnostics and Trouble Shooting / Error Codes 10.43

Error Codes

Error Code Indicating ATC:

The error codes 1-33 are all memory errors that can occur in conjunction with program
errors during unsuccessful reprogramming or during electrostatic discharge.

Table 10.1

Error code indicating Class Explanation Control/Procedure

E1 ATC B Attempt to write to invalid E2PROM Settings lost. No action.

invalid NVM access. address.

E2 Not used.

E3 Not used.

E4 Not used.

E5 ATC NVM C Efficiency log is full (all 100 entries Settings lost. No action.
Efficiency log is full. are used) ->first entry will be over-
written.

E6 ATC NVM C Efficiency log was corrupt and Settings lost. No action.
Efficiency Log Reset repaired/cleared during Startup
during startup. Check.

E7 ATC NVM C Chronological Impact Log was cor- Settings lost. No action.
Chronological Impact rupt and repaired/cleared during
Log Reset during startup. Startup Check.

E8 ATC NVM C Chronological Damage Log was cor- Settings lost. No action.
Chronological Damage rupt and repaired/cleared during
Log Reset during startup. Startup Check.

E9 ATC NVM C Temperature Session Log was cor- Settings lost. No action.
Temp Log Reset during rupt and repaired/cleared during
startup. Startup Check.

E10 ATC NVM C Operator Session Log was corrupt Settings lost. No action.
Operator Session Log and repaired/cleared during Startup
was corrupt and repaired/ Check.
cleared during Startup
Check.

E11 ATC NVM C One or more parameters New settings may be nec-
parameters partially reset (parameters/accessories/settings) essary.
during start-up outside the area. This can also hap-
pen when the system starts up for the
first time.

E12 ATC NVM C Local access code outside area New settings may be nec-
local code reset during (0-9999999). This can also happen essary.
start-up when the system starts up for the
first time.

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10.44 Electrical System / Diagnostics and Trouble Shooting / Error Codes

Table 10.1

Error code indicating Class Explanation Control/Procedure

E13 ATC NVM C ATLET access code outside area New settings may be nec-
ATLET code reset during (0-9999999). This can also happen essary.
start-up when the system starts up for the
first time.

E14 ATC NVM C User ID/code or profile outside area. New settings may be nec-
user entry cleared during essary.
start-up

E15 ATC NVM C Error log corrupt. No action.

error log cleared
during start-up

E16 ATC NVM C Timer outside area. No action.

timer (timers) cleared
during start-up

E17 Not used.

E18 Not used.

E19 Not used.

E20 ATC NVM C ATLET/LOCAL code forced to reset

ATLET/LOCAL code in RESET menu.
forced to reset.

E21 ATC NVM C All users forced to reset in the reset New settings may be nec-
all users forced to reset. menu. essary.

E22 ATC NVM C Option Parameters forced to reset in

Option Parameters forced RESET menu.
to reset.

E23 ATC NVM C Setting parameters forced to reset in New settings may be nec-
setting of parameters the reset menu. essary.
forced to reset

E24 ATC NVM C Calibration parameters forced to New settings may be nec-
calibration parameters reset in the reset menu. essary.
forced to reset

E25 ATC NVM C All logs forced to reset in the reset No action.
all logs forced to reset menu.

E26 Not used.

E27 ATC NVM C Error logs forced to resest in the No action.

error log forced to reset ATLET menu.

E28 ATC NVM C Temperature logs forced to resest in No action.

temperature log forced to the ATLET menu.
reset

E29 ATC NVM C Trip meter time/utilisation forced to No action.

trip meter time/utilisation resest in the ATLET menu.
forced to reset

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 Electrical System / Diagnostics and Trouble Shooting / Error Codes 10.45

Table 10.1

Error code indicating Class Explanation Control/Procedure

E30 ATC NVM C driver log forced to resest in the No action.

diver log forced to resest LOCAL menu.
in the LOCAL menu

E31 ATC NVM C Effective time forced to resest in the No action.

effective time forced to LOCAL menu.
resest in the LOCAL
menu

E32 ATC NVM C Damage log forced to resest in the No action.

damage log forced to LOCAL menu.
resest in the LOCAL
menu

E33 ATC NVM C Collision log forced to resest in the No action.

collision log forced to LOCAL menu.
resest in the LOCAL
menu

E34 Not used. No action.

E35 ATC 1721 B “ADC PotLowOutput” > ADC

Analog Common Pot COMMON POT LOW SUPERVI-
Low Input Range Fault SION LEVEL.

E36 ATC 1721 B “ADC PotHighOutput” > ADC

Analog Common Pot COMMON POT HIGH SUPERVI-
High Input Range Fault SION LEVEL.

E37 ATC 1721 B “ADC BrakeOutput” > ADC MAX

Analog Brake Input BRAKE SUPERVISION LEVEL or
Range Fault “ADC BrakeOutput” > ADC MIN
BRAKE SUPERVISION LEVEL.

E38 ATC 1721 B “ADC Raise Output” > ADC MAX

Analog Raise Input RAISE SUPERVISION LEVEL or
Range Fault “ADC Raise Output” > ADC MIN
RAISE SUPERVISION LEVEL.

E39 ATC 1721 B “ADC Lower Output” > ADC MAX

Analog Lower Input LOWER SUPERVISION LEVEL or
Range Fault “ADC Lower Output” > ADC MIN
LOWER SUPERVISION LEVEL.

E40 ATC 1721 B “ADC Aln1 Output” > ADC MAX

Analog A-IN1 Input AIN1 SUPERVISION LEVEL or
Range Fault “ADC Aln1 Output” > ADC MIN
AIN1 SUPERVISION LEVEL.

E41 ATC 1721 B “ADC Aln2 Output” > ADC MAX

Analog A-IN2 Input AIN2 SUPERVISION LEVEL or
Range Fault “ADC Aln2 Output” > ADC MIN
AIN2 SUPERVISION LEVEL.

E42 ATC 1721 B Belly button redundancy check

Belly button supervision failed.
fault

SERVICE MANUAL
10.46 Electrical System / Diagnostics and Trouble Shooting / Error Codes

Table 10.1

Error code indicating Class Explanation Control/Procedure

E43 ATC 1721 B Speed signal / Speed neutral switch

Throttle supervision fault check failed.

E44 Not used.

E45 Not used.

E46

E47

E48

E49

E50 ATC/TMC C Liftlock occurs due to low battery Charge the battery.
low battery voltage.

E51 Com pot low fault B Common low supply range fault 1. Replace the lift/lower
switch.
2. If the error still occurs
replace the ATC.

E52 Not used

E53 Hyd pot high fault B High supply to hydraulic controls 1. Replace the lift/lower
supply range fault switch.
2. If the error still occurs
replace the ATC.

E54 Not used

E55 Not used

E56 Lift range fault B Lift/lowering signal out of allowed • Tiller with on/off
range buttons: Reset
calibration of lift
lower and aux 1.
• Tiller with rocker
switch: Check the
inductive sensors and
the connections.

E57 Not used.

E58 Not used.

E59 Not used.

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 Electrical System / Diagnostics and Trouble Shooting / Error Codes 10.47

Error Code Indicating TMC:

Table 10.2

Error code indicating Class Explanation Control/Procedure

E100 CAN error B CAN communication error 1. Check that TMC receives
TMC on start-up voltage supply.
2. Check the CAN commu-
nication link between ATC
and TMC to make sure
there is no fault or short-cir-
cuit in the cables.
See wiring diagram.
3. The may be a short-cir-
cuit on the ATC or the
TMC. Change TMC first
and ATC as the other unit.

E101 TMC B TMC monitoring has triggered. Try restarting the truck. If
Watchdog this does not help, change
TMC.

E102 TMC B Positive supply voltage to the logic 1. Try restarting

logic error 1 is outside the range. 2. Charge the battery if it is
getting flat.
3. Check that the thick
cables between the motor
and TMC are properly
tightened and that they have
a low ohm factor. Check
also the supply cables to
TMC, and the cable and
voltage supply to contact
X5.1.
4. Change TMC.
5. Change drive motor.

E103 TMC B Error in the part of the logic that 1. Try restarting.
logic error 2 handles the return supply of the 2. Charge the battery if it is
phase voltage. getting flat.
3. Check that the thick
cables between the motor
and TMC are properly
tightened and that they have
a low ohm factor. Check
also the supply cables to
TMC, and the cable and
voltage supply to contact
X5.1.
4. Change TMC.
5. Change drive motor.

E104 TMC B Error in the part of the logic that 1. Try restarting.
logic error 3 handles the overlead protection. If the error recurs, change
TMC.
2. Change the motor.

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10.48 Electrical System / Diagnostics and Trouble Shooting / Error Codes

Table 10.2

Error code indicating Class Explanation Control/Procedure

E105 TMC emergency B Communication response from 1. Restart

monitoring has tripped TMC has not been received in 2. Check the CAN bus
time. cable carefully if the error
occurs repeatedly, to make
sure there is no play on the
connector ring and that the
terminal resistance main-
tains
120 Ohm +/- 5%.
3. Check that the CAN bus
is separated from the thick
cables. Interferance can
give rise to the error.

E106 TMC supply low B This test is done on start-up and 1. Motor cable fault, con-
E107 TMC supply high when stationary (No drive nection fault, insulation
manoeuvre is given). fault in the motor or to
chassis.
2. Change TMC.

E108 TMC A The main contactor contact tips are Check main contactor K1 to
contactor closed closed before voltage has reached make sure the contact tips
the coil. are not welded, or that it is
not short-circuited over the
terminals via the cables.

E109 TMC A The logic has low voltage to main 1. Break in cables to the
contactor open contactor K1 but the contactor tips coil.
do not close. 2. Break in coil.
3. The contactor tips do not
close, or fail to connect
with TMC.

E110 TMC B Check that the current is zero when Change TMC.
current measuring in truck is stationary.
standby mode is not
equal to zero

E111 TMC B The capacitor in TMC does not 1. Check that there is bat-
capacitor charging charge up as it should during start- tery voltage to TMC,
up. between B- and contact
X5.1.
If not, check battery volt-
age, supply cables and their
connections.
2. Change TMC.

E112 TMC A The output to the main contactor 1. Check that there is no
output short-circuited coil is short-circuited. short-circuit in main con-
tactor K1, the coil, or that
the freewheel diode is not
reversed or short-circuited.
Cut the diode and check
that there is no short-circuit
in the cables to the coil.
2. Change TMC.

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 Electrical System / Diagnostics and Trouble Shooting / Error Codes 10.49

Table 10.2

Error code indicating Class Explanation Control/Procedure

E113 TMC B The output for the main contactor 1. Change TMC.
contactor output does not function.

E114 TMC A One of the outputs X6.1, X6.3, 1. There is a short-circuit in

coil short-circuited X6.4 or X6.6 is short circuited. either the main contactor
coil K1, the brake coil Y1,
lift contactor coil K2, or in
the horn.
2. There is a short-circuit in
the cabling that connects to
the components or in the
freewheel diodes, or in the
capacitor that suppresses
the horn.
3. Internal short-circuit in
one of these outputs,
change TMC.

E115 TMC B TMC self-test does not work. 1. Try restarting a few
generic error times.
If this does not rectify the
problem, change TMC.
NOTE! The error is prob-
ably logged together with
E123, but should nor-
mally never occur.
If E115 or E123 are still
be logged, this should be
reported to the service
function at ATLET AB.

E116 TMC A Communication command from 1. If other CAN errors are

CAN bus ATC not received in time. logged, rectify these first.
2. There may be an error on
ATC, interference on the
CAN bus, or play in the
CAN bus connector ring.

E117 TMC B Incorrect battery voltage. TMC may be incorrectly

wrong battery configured.
Change TMC.

E118 TMC B Error on the signal from the trans- Check and measure the
pulse transducer error ducer bearing in the drive motor. transducer in accordance
with the trouble shooting
chart for "Drive motor" on
page 10.53.

E119 Not used.

E120 TMC C EEPROM set to default. Error in The battery settings have
EEPROM error the range that includes adjustable probably been lost. See
values. "Battery Capacity" on page
10.8.

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10.50 Electrical System / Diagnostics and Trouble Shooting / Error Codes

Table 10.2

Error code indicating Class Explanation Control/Procedure

E121 TMC Warn- The internal temperature monitor- 1. See trouble shooting for
controller temperature ing C ing has exceeded the 75°C warning "The drive motor looses
level. power and the speed slowly
The current is limited in relation to drops." on page 10.55.
the temperature. 2. Change TMC.
TMC stops completely at 100°C.

E122 TMC Warn- The drive motor temperature has 1. See trouble shooting for
motor temperature ing C exceeded the warning level. "High temperature in drive
motor E122" on page
10.55.

E123 TMC Warn- Generic warning. Try restarting a few times.

generic ing C If the error does not disap-
pear, change TMC.
NOTE! The error is prob-
ably logged together with
E115, but should nor-
mally never occur.
If E115 or E123 are still
be logged, this should be
reported to the service
function at ATLET AB.

E124 TMC B The output to lowering valve Y2 First confirm that the valve
PEV output connection X6.11 is defective. coil is not short-circuited,
that the freewheel diode
short-circuits or is reversed,
or that there is a short-cir-
cuit in the cabling.
NOTE! This output con-
nects to B+ and is not
short-circuit-proof. For
this reason make sure to
check that no external
short-circuit exists before
changing TMC.

E125 TMC Warn- The internal temperature sensor is Change TMC.

temperature sensor ing C defective.

E126 Not used.

E127 TMC C Current calibration in progress. Try restarting a few times.

Current sensor error If this does not help, change
TMC.

Other Trouble Shooting

Main contactor does not close

SERVICE MANUAL
 Electrical System / Diagnostics and Trouble Shooting / Error Codes 10.51

There may be other reasons why the main contactor does not close. For this reason, start
trouble shooting by rectifying the last logged primary error code.

Have any related error codes been logged? Yes
See trouble shooting for respective error
codes.

No 
Is there 24V from TMC connection X6.2? No
Change TMC.

Yes 
Is there 24V to the main contactor plus con- No
Check connection X6.2 - K1.1.
nection K1.1?

Yes 
Measure directly over the main contactor No
Check if cable connection K1.2 - X6.2 is
coil. Is there 24V? OK and has low resistance by measuring
the resistance to the front edge of X6,
when the connector is pulled from TMC, to
the front edge of the flat pin. If there is no
connection, change or repair the cabling.
Otherwise, change TMC.

Yes 
Replace contactor.

*The normal cold contactor resistance is approx. 47 ohm.

The truck and ATC have total function loss – the display does not go on

Is there 24V between F1 (between the large No
Check the battery, battery plug, electrical
fuses) and the B- insulation point? panel plug and their connections.

Yes 
Is there 24V between insulation bolt X16 No
Check 7.5A fuse F3, and that there is 24V
and the B- insulation point? to one side of the fuse holder. Only mea-
sured with the fuse pulled out of the holder.

Yes 
Is there 24V between X1.1 (the contact that No
Check that there is 24V on all the red/white
connects to the steering arm) and theB- cable connections in connector X21. Either
insulation point? there is a break or poor contact between
X16 and X21.1, in toggle X21.1 - X21.2,
or in the connection X21.2 - X1.1.

Yes 
Is there 24V between X1.1 and X1.5? No
Indicates break or poor connection in the
blue minus cable between B- inslation bolt
and X1.5.

Yes 

SERVICE MANUAL
10.52 Electrical System / Diagnostics and Trouble Shooting / Error Codes

Open the steering arm head. Is there 24V No
Change the steering arm cabling, or repair.
between XJ10.1 and X1J10.5?

Yes 
Change ATC.

All minus cables = blue

All plus cables in machine housing = red/

white

All plus cables in steering arm = red

NOTE! There may be a fault on the display or display cable

Fuse
The fuse for the drive motor (F1) is defective.

Change the fuse (with correct fuse value) The most likely reason is that the mean
and restart. current exceeds the rated current of the
fuse. In conjunction with the change, care-
fully check the motor cables and the plus
and minus cables to TMC to make sure
they are correctly connected.


Does the fuse blow just after the main con- Yes
Change TMC. If TMC is defective the
tactor has closed? most likely error is an exciter error with
error codes E106 and E107.

No 
Start the truck again.


Does the fuse blow again after the truck has Yes
Check that the mechanical torque in the
been running for some time? gearbox is not excessive.

Increased friction, increased load, high If the truck has been run with a heavy load
speed and rapid starting/stopping increase and at a high speed and with many stops
the average current for the controller. The and starts, or in some other way has
truck may have been driven over its maxi- exceeded its limitations, try to reduce the
mum performance. speed, load, acceleration and retardation.

SERVICE MANUAL
 Electrical System / Diagnostics and Trouble Shooting / Error Codes 10.53

Drive motor
The drive motor only runs at low speed and with a ticking sound, or alternatively the mo-
tor does not start or runs irregularly with a low torque. TMC encoder error E118 is prob-
ably logged.

Pull out contact X9 that connects to the No
Pull out the contact X6 and check the con-
drive motor. Is there 12V between pin X6.9 nections X6.9 - X9.1 and X6.10-X9.4. If
and X6.10 in TMC? the cables are OK, change TMC.

Yes 
Is there 12V between pin 1 and 4 in contact No
Repair or change the cabling.
X9?

Yes 
Replace the contacts and measure the volt- No
Carefully check that the cabling connec-
age between X6.10 and X6.19 at the same tion between X6.19 and X9.3 is OK and
time as the motor is running. An average has a low resistance. If not, repair or
value of 4-6 volt should be read off when change the cabling, otherwise change the
measuring the DC. Ok? drive motor.

Yes 
Measure the voltage between X6.10 and No
Carefully check that the cabling connec-
X6.20 at the same time as the motor is run. tion between X6.20 and X9.2 is OK and
An average value of 4-6 volt should be read has a low resistance. If not, repair or
off when measuring the DC. Ok? change the cabling, otherwise change the
drive motor.

Yes 
An oscilloscope is required for further trou-
ble shooting to determine whether the
pulses from the motor sensor bearing are
OK and 90 degrees out of phase. The error
can either be in the motor or in TMC. Try
the motor if it has low insulation resistance
to the chassis. Otherwise start with replac-
ing the TMC.

SERVICE MANUAL
10.54 Electrical System / Diagnostics and Trouble Shooting / Error Codes

Drive function
The drive function does not work in one or two directions.

NOTE! If the brakes are applied and cor- No
Check that the safety switch has not tem-
rectly adjusted they will hold the truck in porarily jammed. If the error remains it
spite of full modulation. For this reason, Reset will not be possible to restart the truck, and
always check if the controller is working. It the truck the question about the safety switch will
can be heard as a slight humming sound. still be in the display. Check also that the
modulation from ATC works from approx.
2.5V in neutral position to close to 5V
when driving in the direction of the forks,
and close to 0V when driving in the oppo-
site direction to the forks. Recalibrate if
necessary.
There may be an error on the brake switch.
Check that the brake switch has not
jammed by checking the input for this via
the test menu. The switch is normally open
when the arm is between its upper and
lower position. If there is 24V on TMC
contact X5.3 the controller will not modu-
late and the brake will not be power actu-
ated.

Yes 
Reset the truck

Is there 24V to brake contact X7 when the No
Check that there is 24V on the brake
truck is manoeuvred? switch contact X4.3 when the arm is in
drive position. Check also that there is a
connection between X4.3 and X7.1. If not,
repair or change the cabling, or alterna-
tively change brake switch S9 if this does
not work.

Yes 
There is either a mechanical or an electrical
fault in the brake. The resistance should be
approx. 20 Ohm. Test if the brake functions
if it is released from the motor. If not,
change the brake.

NOTE! The brake switch input is tested during every new start to ensure that it closes to X5.3. If it
not, a message is given to release up the arm before driving is permitted.

Also see table and figure 10.7 during which circumstances the truck is in a fault condition and the
truck is not allowed to drive.

SERVICE MANUAL
 Electrical System / Diagnostics and Trouble Shooting / Error Codes 10.55

High temperature in drive motor E122

If other error codes are logged, rectify these first. The drive motor may have become
overheated because it has been run over its performance level for a long period. Check
motor and gearbox.

Is the warning also given when the motor is No
The truck may have been driven over its
cold? maximum performance. There may be a
fault on the motor or gearbox. Reduce the
drive performance temporarily.

Yes 
Between X8.1 and X8.2 there is an internal
thermo switch connected. If the internal
motor temperature is below 125°C this
switch is closed, and above 125°C it
breaks. Check this switch when the motor
is cold and observe that the cable connec-
tion X8 must be disconnected from the
motor when measuring. If the termo switch
seems ok then check that there is no cable
break or bad connection in the cabling.
This can be checked with the power on and
by measuring that there is 24V to both X8.1
and X8.2 with B- as reference and the
motor in a cold condition


Did this solve the problem? If not, change
TMC.

For information on temperature log, see "Temperature Log" on page 10.24.

The drive motor looses power and the speed slowly drops.
High temperature in drive controller, error code E121 may be logged. A warning text is
normally shown in the display.
TMC starts to module down the motor current linearly at 75°C to stop completely at
100°C. If the error occurs with a cold controller there is probably an error on the TMC
internal temperature monitoring. If other error codes are logged, start the trouble shooting
by rectifying these first. Otherwise, change the controller.

Check that the fan that cools TMC is work- No
Check the fan cabling and that there is 24V
ing as it should and that the cooling on the to the fan. Otherwise, change the fan and
TMC are not blocked by dust and dirt. OK? clean up dust and dirt.

Yes 
Run the truck for an extended period in No
The truck may have been driven over its
raised position and without load. Does the maximum performance. Try to reduce the
temperature in the controller still go over speed, load, acceleration and retardation.
75°C?

SERVICE MANUAL
10.56 Electrical System / Diagnostics and Trouble Shooting / Error Codes

Yes 
Try to confirm if there is something that is No
Rectify the gearbox or change the motor.
increasing the torque, such as a worn or
jamming gearbox, and if the motor is work-
ing normally. OK?

Yes 
Change TMC

For information on temperature log, see "Temperature Log" on page 10.24.

Lowering of the forks does not work

Does ATC read the input(s) in the menu No
Check that the pushbutton closes at
“test inputs”? See, "Monitor menu" on approx. 5V to ATC. Check also that 5V is
page 10.18 available, otherwise change ATC.

Yes 
Is there 24V over the valve coil during low- No
Test the cable connection between X6.11
ering? and Y2.1 and between X6.12 and Y2.2. If
OK, change TMC.

Yes 
Check that there is no break in the valve
coil. A normal resistance value is approx.
19 ohm. If not, change coil.

NOTE! If other pushbuttons for the hydraulic function are actuated at the same time as the lowering
button, the lowering is stopped. “Release controls” comes up in the display.

SERVICE MANUAL
 Electrical System / Diagnostics and Trouble Shooting / Error Codes 10.57

Lifting of the forks does not work

NOTE! All trucks are equipped with end position stop. Before trouble shooting, tempo-
rarily set this option to “no”. If this solves the problem the top position switch should be
checked in accordance with the trouble shooting chart for this.

Does the lift contactor actuate without the No
Check that the inputs for lift are read by
pump running? ATC in the “inputs” menu in the test menu.
If not, check that the pushbuttons work and
close when actuated. Check that the push-
buttons receive approx. 5V from ATC. If
not, change ATC. Check that there is not a
break to pump contactor K2 by checking
the cabling, and that there is not a break in
the connector coil.
If there is +24 V to the contactor with B- as
reference and the contactor still does not
pull, change TMC.

Yes 
Is the fuse F2 intact? No
Change the fuse.

Yes 
Check that 24V goes to the motor terminal. No
The contact tips do not seem to conduct.
OK?

Yes 
Check the brushes to the hydraulic unit, No
Change the brushes, or adjust.
and that they are rest against the commuta-
tor. OK?

Yes 
Change unit

If the pump runs and the forks still do not

lift there may be a fault in the hydraulics, a
pump fault, or incorrectly connected
hydraulic hoses.

NOTE!
• Remember to reset the option for end position switch lift.
• If the battery is below 20% the lift stop will be actuated. Charge the battery.
• If other pushbuttons for the hydraulic function are actuated at the same time as the lifting button,
the lifting is stopped. “Release controls” comes up in the display.
• Normal pump motor current values are approximately 38A without load, 105A with 2500kg and
125A at end stop. The end stop value can be checked if the option “lift limit“ is temporarily set to
no. See options menu under Menu Tree Atlet Menu.

SERVICE MANUAL
10.58 Electrical System / Diagnostics and Trouble Shooting / Error Codes

The top position switch for lifting does not function

The top position switch for lifting must normally be closed to enable lifting. The switch
function can be checked in "Monitor menu" on page 10.18

Pull apart contact X15 and measure the No
Check that the switch is not in mechani-
resistance of the switch between pin 1 and cally actuated position. If OK, change
2 when the forks are completely lowered. switch.
OK?

Yes 
Check that there is 24V to the switch and No
Check the cabling and that TMC supplies
that TMC receives 24V on contact X5.7. 24 V from contact X5.2. If not, change
OK? TMC.

Yes 
Remove the option for top position switch
in the options menu, or alternatively
change TMC.

SERVICE MANUAL
 Electrical System / Appendix 1, Summary menu tree / Error Codes 10.59

Appendix 1, Summary menu tree

In the following section, Appendix 1, menu trees ( Software 2.23) can be found for the
menus listed below:

• Menu tree, Local menu

• Menu tree, Atlet menu
• Menu tree, Monitor menu
• Menu tree, Reset menu
• Menu tree, Language
• Menu tree, TRAC

SERVICE MANUAL
10.60 Electrical System / Appendix 1, Summary menu tree / Error Codes

SERVICE MANUAL
 1

Local Menu Tree

Level 1 Level 2 Level 3 Level 4 Level 5 Remarks:

LOCAL MENU:
< Exit >

LOCAL MENU: SET ACCESS: OPERATOR: Operator ID: The level 3 displays are always followed in sequence.
< Set access ENT / v -> Operator ^ ENT -> New/Change ENT -> ? The no of question marks corresponds to the chosen id length (ATLET menu).
Operator categ:x
?
Old code: this screens will only be displayed if the user ID exists and user code length > 0
???? The no of question marks corresponds to the chosen code length (ATLET menu).
New code: this screens will only be displayed if the user code length > 0
???? The no of question marks corresponds to the chosen code length (ATLET menu).
Verify new code: this screens will only be displayed if the user code length > 0
???? The no of question marks corresponds to the chosen code length (ATLET menu).
Ok!
Press ENT
Not successful!
invalid old code / verifyed code wrong / category out of range (1..4) / all 100 user ID's used / no
Press ENT access to E2PROM

OPERATOR: CAUTION! Reduced

Format ENT -> length may lead.

0 v ^

.to lost entries

0:escape 1:go on

Id length: x Id length: x
v ENT -> New value: ?
Id length: x
New value saved!
Input rejected!
Press ENT

Code length: x Code length: x

^ ENT -> New value: ?
Code length: x
New value saved!
Input rejected!
Press ENT

SET ACCESS: Operator ID: The level 3 displays are always followed in sequence.
Delete oper ^ ENT -> ?
Delete op x?
0:No 1:Yes (No)
Ok!
Press ENT
Not successful! invalid ID / 0:(No) pressed or input aborted/ no access to E2PROM
Press ENT
 2

Local Menu Tree

Level 1 Level 2 Level 3 Level 4 Level 5 Remarks:

SET ACCESS: Old code: The level 3 displays are always followed in sequence.
Local ^ ENT -> ???????
New code:
???????
Verify new code:
???????
Ok!
Press ENT
Not successful! invalid old code / verifyed code wrong / no access to E2PROM
Press ENT

This menu entry resets the Impact Sensor actions. To be used by warehouse manegement to
LOCAL MENU: FLEET MANAGER: acknowledge impact.
<Fleet manager ENT / v -> Unlock ^v

FLEET MANAGER: READ LOGS: <o>: [date] List of the 30 most recent operator sessions.
Read logs ^ ENT -> Operator log ^ ENT -> [time] - [time]

READ LOGS: EFFICIENCY: <o>: xx(mn)% List sorted from worst to best operator (Act). xx = active time / logged on time * 100;
Efficiency ^ ENT -> Worst ^v ENT -> Curr:iii(mn)A iii = mean main active current draw; mn = corresponding mean value for all operators;

EFFICIENCY: <o>: xx(mn)% List sorted from best to worst operator (Act). xx = active time / logged on time * 100;
Best ^v ENT -> Curr:iii(mn)A iii = mean main active current draw; mn = corresponding mean value for all operators;

Operator id: <o>: xx(mn)% Any operator's efficiency. <o> = operator id (1 - 100)
? ENT -> T:xx(mn)P:xx(mn) T = traction; P = pump; mn = corresponding mean value for all operators;

READ LOGS: DAMAGE LOG: <o>: xxx(mn) <o> = operator who used the truck immediately before damage was reported.
xxx = number of reported damages. List sorted from greatest to smallest no of reported
Damage log ^ ENT -> Worst ^v ENT -> <o>: xxx(mn) damages.

DAMAGE LOG: <o>: xxx(mn) <o> = operator who used the truck immediately before damage was reported.
xxx = number of reported damages. List sorted from smallest to greatest no of reported
Best ^v ENT -> <o>: xxx(mn) damages.

DAMAGE LOG: 30:[date] [time] List sorted in chronological order.

Chronological ^ v ENT -> <o>: <dc> <o> = operator who used the truck immediately before damage was reported.
v <dc> = damage code (max two characters long).
v
v
01:[date] [time]
<o>: <dc>
 3

Local Menu Tree

Level 1 Level 2 Level 3 Level 4 Level 5 Remarks:

not implemented yet !

READ LOGS: IMPACT LOG: <o>: ^xx(mn) Top = peak impact value; mn = mean impact value for all operators;
Impact log ^ ENT -> Worst ^v ENT -> IOM:xxx Mn:xxx% IOM = number of impacts over mean (mn); Mn = operator's mean value.

IMPACT LOG: <o>: ^xx(mn) Top = peak impact value; mn = mean impact value for all operators;
Best ^v ENT -> IOM:xxx Mn:xxx% IOM = number of impacts over mean (mn); Mn = operator's mean value.

IMPACT LOG: 30:[date] [time] List sorted in chronological order.

Chronological ^ v ENT -> <o>: <il> <o> = operator who used the truck immediately before damage was reported.
v <il> = impact level (max two characters long).
v
v
01:[date] [time]
<o>: <il>

FLEET MANAGER:
Download ^ ENT -> Send fleet manager data to serial port.

FLEET MANAGER: RESET LOG: Reset optr log?

Reset ^ ENT -> Operator log ^ ENT -> 0:No 1:Yes (No)

RESET LOG: Resetthis log?

Effic/Dmg/Imp ENT -> 0:No 1:Yes (No)

LOCAL MENU: SETTINGS: TIME & DATE: 11:39

< Settings > ENT / v -> Time & Date ^ ENT / v -> Set time ^ ENT -> New time: hh:mm
hh:mm
Ok! Press ENT
Input rejected!
Press ENT

TIME & DATE: dd.mm.yyyy

Set date ^ ENT -> New: yy-mm-dd
2001-09-18
Ok! Press ENT
Input rejected!
Press ENT

TIME & DATE: Select format:

Date format ^ ENT -> 2001-09-18 ^v
18-Sep-01 ^v
18.09.2001 ^v
09.18.2001 ^v

SETTINGS: LCD contrast: x LCD contrast: x x = 0..9

LCD contrast ^ ENT / v -> ENT -> New value: ?
LCD contrast: y
New value saved!
Input rejected!
Press ENT
 4

Local Menu Tree

Level 1 Level 2 Level 3 Level 4 Level 5 Remarks:

SETTINGS: Key sound: xxx Key sound: xxx

Key sound ^ ENT / v -> ENT -> 0:no 1:yes
Key sound: yyy
New value saved!
Input rejected!
Press ENT

LOCAL MENU: CARD READER: Smartcard:xxx smartcard:xxx

< Card reader ENT / v -> Enable/disable ENT / v -> ^v ENT -> 0:no 1:yes
smartcard:yyy
New value saved!
Input rejected!
Press ENT
 1

TRAC

TRAC MENU:
< Exit >

TRAC MENU: Initphone

< Initphone > ENT / v ->

TRAC MENU: Answer call

< Answer call > ENT / v ->
 1

ATLET Menu tree

Level 1 Level 2 Level 3 Level 4 Level 5 Level 6 Remarks:

ATLET MENU:
< Exit >

ATLET MENU: Lift limit: xxx Lift limit: xxx xxx = currently used value.
< Options > ENT / v -> ^v ENT -> 0:no 1:yes
Lift limit: yyy New value 'yyy' replaces the old 'xxx'.
New value saved! Screen stays on for 1 s.
Input rejected! Displayed if value is out of range.
Press ENT

Restart: xxx Restart: xxx

^v ENT -> 0:no 1:yes
Restart: yyy
New value saved!
Input rejected!
Press ENT

Safety syst:xxx Safety syst:xxx

^v ENT -> 0:no 1:yes
Safety syst:yyy
New value saved!
Input rejected!
Press ENT

Effici log:xxx Effici log:xxx

^v ENT -> 0:no 1:yes
Effici log:yyy
New value saved!
Input rejected!
Press ENT
 2

ATLET Menu tree

Level 1 Level 2 Level 3 Level 4 Level 5 Level 6 Remarks:

Impact sens:xxx Impact sens:xxx
^v ENT -> 0:no 1:yes
Imp sensor:yyy
New value saved!
Input rejected! Appears only if
Press ENT Imp sensor is
'yes' above!
Log level: xxx Log level: xxx
^v ENT -> New value: ?
Log level: yyy
New value saved!
Input rejected!
Press ENT

Horn level :xxx Horn level :xxx

^v ENT -> New value: ?
Horn level :yyy
New value saved!
Input rejected!
Press ENT

Warning lev :xxx Warning lev :xxx

^v ENT -> New value: ?
Warning lev :yyy
New value saved!
Input rejected!
Press ENT

Stop level:xxx Stop level:xxx

^v ENT -> New value: ?
Stop level:yyy
New value saved!
Input rejected!
Press ENT

Supervis lev :xxx Supervis lev :xxx

^v ENT -> New value: ?
Supervis lev :yyy
New value saved!
Input rejected!
Press ENT

Damage rep:xxx Damage rep:xxx

^v ENT -> 0:no 1:yes
Damage rep:yyy
New value saved!
Input rejected!
Press ENT
 3

ATLET Menu tree

Level 1 Level 2 Level 3 Level 4 Level 5 Level 6 Remarks:

Time logoff:xxx Time logoff:xxx
^v ENT -> 0:no 1:yes
Time logoff:yyy
New value saved! Appears only if
Input rejected! Time logoff is
Press ENT 'yes' above!

Del time a: xxx Del time a:xxs

^v ENT -> New value: ?
Delay time a:yys
New value saved!
Input rejected!
Press ENT

Del time b: xxx Del time b:xxmin

^v ENT -> New value: ?
Delay time b:yymin
New value saved!
Input rejected!
Press ENT

Dis tiller res:xxx Dis tiller res:xxx

^v ENT -> 0:no 1:yes
Dis tiller res:yyy
New value saved!
Input rejected!
Press ENT

Smartcard:xxx smartcard:xxx
^v ENT -> 0:no 1:yes
smartcard:yyy
New value saved! Appears only if
Input rejected! Time logoff is
Press ENT 'yes' above!

Damage rep:xxx Damage rep:xxx

^v ENT -> 0:no 1:yes
Damage rep:yyy
New value saved!
Input rejected!
Press ENT

Disp log on:xxx Disp log on:xxx

^v ENT -> 0:no 1:yes
Disp log on:yyy
New value saved!
Input rejected!
Press ENT

Summer time:xxx Summer time:xxx

^v ENT -> 0:no 1:yes
Summer time:yyy
New value saved!
Input rejected!
Press ENT

Keyswitch :xxx Keysw pwr of:xxx

^v ENT -> 0:no 1:yes
Keysw pwr of:yyy
New value saved!
Input rejected!
Press ENT
 4

ATLET Menu tree

Level 1 Level 2 Level 3 Level 4 Level 5 Level 6 Remarks:

Speed red:xxx Speed red:xxx

^v ENT -> 0:no 1:yes
Speed red:yyy
New value saved! Appears only if
Input rejected! Speed red is
Press ENT 'yes' above!

Cutback3: xxxx% Cutback3: xxxx%

^v ENT -> New value: ?
Cutback3: yyyy%
New value saved!
Input rejected!
Press ENT

Service alrm:xxx Service alrm:xxx

^v ENT -> 0:no 1:yes
Service alrm:yyy
New value saved!
Input rejected!
Press ENT Appears only if
Service alrm is
Interval: xxxxh Interval: xxxxh 'yes' above!
^v ENT -> New value: ?
Interval: yyyyh
New value saved!
Input rejected!
Press ENT

Fixed platf. :xxx Fixed platf.:xxx

^v ENT -> 0:no 1:yes
Fixed Platf:yyy
New value saved!
Input rejected!
Press ENT

TillerUpD :xxx TillerUpD :xxx

^v ENT -> 0:no 1:yes
TillerUpD :yyy
New value saved!
Input rejected!
Press ENT

Footswitch :xxx Footswitch :xxx

^v ENT -> 0:no 1:yes
Footswitch :yyy
New value saved!
Input rejected!
Press ENT

Reverse ind :xxx Reverse ind :xxx

^v ENT -> 0:no 1:yes
Reverse ind :yyy
New value saved!
Input rejected!
Press ENT
 5

ATLET Menu tree

Level 1 Level 2 Level 3 Level 4 Level 5 Level 6 Remarks:

Raise steer :xxx Raise steer :xxx

^v ENT -> 0:no 1:yes
Raise steer :yyy
New value saved!
Input rejected!
Press ENT

Dual lift :xxx Dual lift :xxx

^v ENT -> 0:no 1:yes
Dual lift :yyy
New value saved!
Input rejected!
Press ENT

Straddle :xxx Straddle :xxx

^v ENT -> 0:no 1:yes
Straddle :yyy
New value saved!
Input rejected!
Press ENT

Belly start :xxx Belly start :xxx

^v ENT -> 0:no 1:yes
Belly start :yyy
New value saved!
Input rejected!
Press ENT

ATLET MENU: SETTINGS: PERFORMANCE: Fwd speed: xxx% Fwd speed: xxx% xxx = currently used value.
< Settings > ENT / v -> Performance ^v ENT -> Op category 1 ^ v ENT -> ^v ENT -> New value: ?
Fwd speed: yyy% New value 'yyy' replaces the old 'xxx'.
New value saved! Screen stays on for 1 s.
Input rejected! Displayed if value is out of range.
Press ENT

Rev speed :xxx% Rev speed :xxx%

^v ENT -> New value: ?
Rev speed: yyy%
New value saved!
Input rejected!
Press ENT

Tract accel:xxx%
^v ENT -> acc to above!
Tract cutb1:xxx%
^v ENT -> acc to above!
Tract cutb2:xxx%
^v ENT -> acc to above!
Tract curr :xxx%
^v ENT -> acc to above!
Rdc brake :xxx%
^v ENT -> acc to above!
Neut brake :xxx%
^v ENT -> acc to above!
Rev brake :xxx%
^v ENT -> acc to above!
Brake pedal:xxx%
^v ENT -> acc to above!
Steer hi spd::xxx%
^v ENT -> acc to above!
 6

ATLET Menu tree

Level 1 Level 2 Level 3 Level 4 Level 5 Level 6 Remarks:

PERFORMANCE:
Op category 2 ^ v ENT -> Acc to above

PERFORMANCE:
Op category 3 ^ v ENT -> Acc to above

PERFORMANCE:
Op category 4 ^ v ENT -> Acc to above

SETTINGS: TRACTION: Breakp lo: xxx% Breakp lo: xxx% Defines the ouput signal level at 30% of the input signal
Traction ^v ENT -> Throttle map ^v ENT -> ^v ENT -> New value: ? 'xxx' = 'on' or 'off' (currently used)
Breakp lo: yyy% New value 'yyy' replaces the old 'xxx'.
New value saved! Screen stays on for 1 s.
Input rejected! Displayed if value is out of range.
Press ENT

Breakp hi: xxx% Breakp hi: xxx% Defines the ouput signal level at 70% of the input signal
^v ENT -> New value: ? 'xxx' = 'on' or 'off' (currently used)
Breakp hi: yyy% New value 'yyy' replaces the old 'xxx'.
New value saved! Screen stays on for 1 s.
Input rejected! Displayed if value is out of range.
Press ENT

Deadzone: xxx% Deadzone: xxx% 'xxx' = 'on' or 'off' (currently used)

^v ENT -> New value: ?
Deadzone: xxx% New value 'yyy' replaces the old 'xxx'.
New value saved! Screen stays on for 1 s.
Input rejected! Displayed if value is out of range.
Press ENT

TRACTION: Breakp lo: xxx% Breakp lo: xxx% Defines the ouput signal level at 30% of the input signal
Brake map ^v ENT -> ^v ENT -> New value: ? 'xxx' = 'on' or 'off' (currently used)
Breakp lo: xxx% New value 'yyy' replaces the old 'xxx'.
New value saved! Screen stays on for 1 s.
Input rejected! Displayed if value is out of range.
Press ENT

Breakp hi: xxx% Breakp hi: xxx% Defines the ouput signal level at 70% of the input signal
^v ENT -> New value: ? 'xxx' = 'on' or 'off' (currently used)
Breakp hi: xxx% New value 'yyy' replaces the old 'xxx'.
New value saved! Screen stays on for 1 s.
Input rejected! Displayed if value is out of range.
Press ENT

Deadzone: xxx% Deadzone: xxx% 'xxx' = 'on' or 'off' (currently used)

^v ENT -> New value: ?
Deadzone: xxx% New value 'yyy' replaces the old 'xxx'.
New value saved! Screen stays on for 1 s.
Input rejected! Displayed if value is out of range.
Press ENT

TRACTION: Motor: NN Motor: NN

Motor type ^v ENT -> ENT -> 0:Kordel 1:Sauer
Motor: NN
New value saved!
Input rejected!
Press ENT
 7

ATLET Menu tree

Level 1 Level 2 Level 3 Level 4 Level 5 Level 6 Remarks:

SETTINGS:
Brake ^v ENT ->

SETTINGS: Cont Delay: xr Cont Delay: xr

Pump ^v ENT -> ENT -> New value: ?
Cont Delay: xr
New value saved!
Input rejected!
Press ENT

SETTINGS: HYDRAULICS: HVC 1: xxx HVC 1: xxx 'xxx' = 'on' or 'off' (currently used)
Hydraulics ^v ENT -> HVC Setup ^v ENT -> ^v ENT -> 0:off 1:on
HVC 1: yyy New value 'yyy' replaces the old 'xxx'.
New value saved! Screen stays on for 1 s.
Input rejected! Displayed if value is out of range.
Press ENT

HVC 1 PWM:xxxxHz HVC 1 PWM:xxxHz 'xxx' = currently used value

^v ENT -> New value: ?
HVC 1 PWM:yyyHz New value 'yyy' replaces the old 'xxx'.
New value saved! Screen stays on for 1 s.
Input rejected! Displayed if value is out of range.
Press ENT

HVC 2: xxx
^v ENT -> acc to above!
HVC 2 PWM:xxxxHz
^v ENT -> acc to above!
HVC 3: xxx
^v ENT -> acc to above!
HVC 3 PWM:xxxxHz
^v ENT -> acc to above!
HVC 4: xxx
^v ENT -> acc to above!
HVC 4 PWM:xxxxHz
^v ENT -> acc to above!
 8

ATLET Menu tree

Level 1 Level 2 Level 3 Level 4 Level 5 Level 6 Remarks:

HYDRAULICS: Raise ctrl:xxxxx Raise ctrl:xxxxx 'xxxxx' = currently used value
Lift ^v ENT -> ^v ENT -> 0:OnOff 1:Speed
Raise ctrl:yyyyy New value 'yyyyy' replaces the old 'xxxxx'.
New value saved! Screen stays on for 1 s.
Input rejected! Displayed if value is out of range.
Press ENT
Appears only if
speed control is
Speed ctrl:xxxxx Speed ctrl:xxxxx
selected above!
^v ENT -> 0:Valve 1:Motor
Speed ctrl:yyyyy
New value saved!
Input rejected!
Press ENT

Raise min: xxx% Raise min: xxx Refers to [ valve PWM ] or [ pump motor speed ] depending on
^v ENT -> New value: ? choice above. Note that the min/max parameters only are used
Raise min: yyy if speed control are selected.
New value saved!
Input rejected!
Press ENT

Raise max: xxx%

^v ENT -> acc to above!
Lower min: xxx%
^v ENT -> acc to above!
Lower max: xxx%
^v ENT -> acc to above!
Breakp: xxx% Defines the ouput signal level at 50% of the input signal
^v ENT -> acc to above!
Deadzone: xxx%
^v ENT -> acc to above!

HYDRAULICS: Ch2 ctrl: xxxxx ENT -> Ch2 ctrl: xxxxx 'xxxxx' = currently used value
Channel 2 ^v ENT -> ^v <- OnOff 0:OnOff 1:Speed
Ch2 ctrl: yyyyy New value 'yyyyy' replaces the old 'xxxxx'.
New value saved! Screen stays on for 1 s.
Input rejected! Displayed if value is out of range.
Press ENT
Appears only if
speed control is
Speed ctrl:xxxxx Speed ctrl:xxxxx
selected above!
^v 0:Valve 1:Motor
Speed ctrl:yyyyy
New value saved!
Input rejected!
Press ENT

Ch2 pos min:xxx% Pos min: xxx Refers to [ valve PWM ] or [ pump motor speed ] depending
^v ENT -> New value: ? on choice above.
Pos min: yyy
New value saved!
Input rejected!
Press ENT

Ch2 pos max:xxx%

^v ENT -> acc to above!
Ch2 neg min:xxx%
^v ENT -> acc to above!
Ch2 neg max:xxx%
^v ENT -> acc to above!
Breakp: xxx% Defines the ouput signal level at 50% of the input signal
^v ENT -> acc to above!
Deadzone: xxx%
^v ENT -> acc to above!
 9

ATLET Menu tree

Level 1 Level 2 Level 3 Level 4 Level 5 Level 6 Remarks:

HYDRAULICS:
Channel 3 ^v ENT -> Acc to above

HYDRAULICS: ENT -> Acc to above

Channel 4 ^v

HYDRAULICS: ENT -> Open ramp: xr Open ramp: xr

ramps ^v ^v ENT -> New value: ?
Open ramp: xr
New value saved!
Input rejected!
Press ENT

Closing ramp: xr Closing ramp: xr

^v ENT -> New value: ?
Closing ramp: xr
New value saved!
Input rejected!
Press ENT

SETTINGS: EPS: xxx EPS: xxx

Steering ^v ENT -> ^v ENT -> 0:off 1:on
EPS: yyy
New value saved!
Input rejected!
Press ENT

Steer ctrl:xxxxx Steer ctrl:xxxxx

^v ENT -> 1:Speed 2:Posit
Speed ctrl:yyyyy
New value saved!
Input rejected!
Press ENT

Limit rough: Limit rough: xx

^v ENT -> New value: ?
Limit rough: xx
New value saved!
Input rejected!
Press ENT

Limit fine CW: Limit fine CW: xx

^v ENT -> New value: ?
Limit fine CW: xx
New value saved!
Input rejected!
Press ENT

Limit fine CCW: Limit fine CCW: xx

^v ENT -> New value: ?
Limit fine CCW: xx
New value saved!
Input rejected!
Press ENT
 10

ATLET Menu tree

Level 1 Level 2 Level 3 Level 4 Level 5 Level 6 Remarks:

SETTINGS: BATTERY: Measured: xxx

Battery ^v ENT -> Calibrate ^v ENT -> New value: ?
Measured: yyy
New value saved!
Input rejected!
Press ENT

BATTERY: Stepdown hi: x

Stepdown hi ^v ENT -> New value: ?
Stepdown hi: y
New value saved!
Input rejected!
Press ENT

BATTERY: Stepdown lo: x

Stepdown lo ^v ENT -> New value: ?
Stepdown lo: y
New value saved!
Input rejected!
Press ENT

SETTINGS: TRUCKTYOE XX = trucktype

Trucktype ^v ENT -> XX

Strings of the same digit are bar graphs for analog/steering enc
ATLET MENU: TESTS: TEST INPUTS: 111222333444555A inputs. The digit identifies the input, and the number of digits
< Tests > ENT / v -> Inputs ^v ENT -> Overview ^v ENT -> 66677BCDEFGHIJK represents the input signal level.
E.g "1" means: 10%<spd cmd<50%, "11" means:
TEST INPUTS: Signal check: 50%<spd cmd<90%, "111" means: spd cmd>90%.
Accelerator ^v ENT -> x.x V Out:syyy% s' = sign Single letters means digital input activated.

TEST INPUTS: Signal check:

Brake ^v ENT -> x.x V Out:syyy% s' = sign

TEST INPUTS: Signal check:

Lift ^v ENT -> x.x V Out:syyy% s' = sign

TEST INPUTS: Signal check:

Aux AI 1 ^v ENT -> x.x V Out:syyy% s' = sign

TEST INPUTS: Signal check:

Aux AI 2 ^v ENT -> x.x V Out:syyy% s' = sign

TEST INPUTS: Signal check:

Aux AI 3 ^v ENT -> x.x V Out:syyy% s' = sign

TEST INPUTS: Steering rpm:

Steering ^v ENT -> syyy
 11

ATLET Menu tree

Level 1 Level 2 Level 3 Level 4 Level 5 Level 6 Remarks:

TESTS: TEST OUTPUT: If "ENT" is pressed, the currently displayed output will be
Outputs ^v ENT -> LED 1 ^v ENT -> engaged as long as the key is kept pressed.

TEST OUTPUT:
LED 2 ^v ENT ->

TEST OUTPUT:
OUT 4 ^v ENT ->

TEST OUTPUT:
HEATER ^v ENT ->

TEST OUTPUT:
ANALOG OUT ENT ->

TESTS: READ VERSION: HW:

Versions ^v ENT -> Traction ^v ENT -> SW:

READ VERSION: HW:

HVC ^v ENT -> SW:

READ VERSION: HW:

Power steering^ v ENT -> SW:

READ VERSION: HW: MM.mm

ATC ^v ENT -> VCL SW: MM.mm ^v

OS date: yy-mm-dd
OS ver: MM.mm ^v

TESTS: 0:no 1:yes:

TM encoder ^v ENT ->
enc disabled
Press ENT

ATLET MENU: CALIBRATE:

< Calibrate > ENT / v -> All ^v ENT ->

CALIBRATE: Release throttle Covers both butterfly and pedal type throttle
Accelerator ^v ENT -> and press ENT The level 3 displays are always followed in sequence.
Go to end points
and press ENT
OK!:
Press ENT s = sign (+ raise, - lower)
Not successful!
Press ENT
<- ENT Signal check:
x.x V Out:syyy%

CALIBRATE: Release brake The level 3 displays are always followed in sequence.
Brake ^v ENT -> and press ENT
Order full brake
and press ENT
OK!:
Press ENT
Not successful!
Press ENT
<- ENT Signal check:
x.x V Out:syyy%
 12

ATLET Menu tree

Level 1 Level 2 Level 3 Level 4 Level 5 Level 6 Remarks:

CALIBRATE: Release lift Covers both combined and separate raise/lower controls.
Lift ^v ENT -> and press ENT The level 3 displays are always followed in sequence.
Order full raise
and press ENT
Order full lower
and press ENT
OK!:
Press ENT s = sign (+ raise, - lower)
Not successful!
Press ENT
<- ENT Signal check:
x.x V Out:syyy%

CALIBRATE: Release ch2

Channel 2 ^v ENT -> and press ENT
Order full +dir
and press ENT
Order full -dir
and press ENT
OK!:
Press ENT
Not successful!
Press ENT
<- ENT Signal check:
x.x V Out:syyy%

CALIBRATE:
Channel 3 ^v ENT -> According to "Channel 2"

CALIBRATE:
Channel 4 ^v ENT -> According to "Channel 2"

CALIBRATE: Center steering

Steering ^v ENT -> and press ENT
Calibration done
press ENT
Calicrate failed
Press ENT

CALIBRATE:
Update angle ^v ENT -> Update angle
 13

ATLET Menu tree

Level 1 Level 2 Level 3 Level 4 Level 5 Level 6 Remarks:

LOGS/COUNTERS: 30: Exxx < +01: Exxx Latest error is shown first.
ENT / v -> Error log ^v ENT -> [date] [time] ENT -> Offset: zzz ms The [i] key can be used to jump directly to the next error
ATLET MENU: v^ v^ (primary and secondary error log) xxx is the error code
<Logs/counters > [error text line 1] [error text line 1] yyy is the number of errors occured
Appears only if the [error text line 2] [error text line 2] "+" idicates that there is a secondary error
error is a VCL or v^ v^
OS ERROR #yyy occurred: +02: Exxx
instead of the 2 [date] [time] Offset: zzz ms
screens above! No v^ v^
secondary log is next primary error… [error text line 1]
possible. [error text line 2]
v^
+03: Exxx
VCL (or OS) ERROR Offset: zzz ms
Module id: mmm v^
v^ [error text line 1]
Error id: eee [error text line 2]
Line: LLL v^
+04: Exxx
Offset: zzz ms
v^
[error text line 1]
[error text line 2]
v^
Temperatures for traction motor, traction controller, pump motor, pump
LOGS/COUNTERS: Tract motor temp controller, hydr oil,
Temp log ^v ENT -> - 60C:xxxx.xh power steering motor, power steering controller, all in five
v intervals. Intervals differs depending on the objects working
v temperature range.
v
Tract motor temp
121 - :xxxx.xh
-
-
-

LOGS/COUNTERS: HOUR METER: TOTAL Active: xxxxx -> hours

Hour meters ^ v ENT -> Total ^v ENT -> xxxxx.yyyh yyy -> 1/1000 hours
TOTAL Logged on:
xxxxx.yyyh
TOTAL Traction:
xxxxx.yyyh
TOTAL Pump:
xxxxx.yyyh

HOUR METER: TRIP Active: xxxxx -> hours

Trip ^v ENT -> xxxxx.yyyh yyy -> 1/1000 hours
TRIP Logged on:
xxxxx.yyyh
TRIP Traction:
xxxxx.yyyh
TRIP Pump:
xxxxx.yyyh

HOUR METER: READ Traction:

Read external ^ v ENT -> xxxxx h
READ Pump:
xxxxx h
READ Pwr Steer:
xxxxx h
 14

ATLET Menu tree

Level 1 Level 2 Level 3 Level 4 Level 5 Level 6 Remarks:

LOGS/COUNTERS: Tract: iii A xx% "iii" is the calculated "mean main active current", "xx" is
Utilisation ^v ENT -> Pump: iii A xx% calculated as: [active time] / [calendar time since last reset].

LOGS/COUNTERS: RESET: Reset error log?

Reset ^v ENT -> Error log ^v ENT -> 0:no 1:yes
Successful reset
Press ENT
Reset aborted!
Press ENT

RESET: Reset temp log?

Temp log ^v ENT -> 0:no 1:yes
Successful reset
Press ENT
Reset aborted!
Press ENT

RESET: Reset trip/util?

Trip meters/Util^ v ENT -> 0:no 1:yes
Successful reset
Press ENT
Reset aborted!
Press ENT

RESET: Reset service?

Service alarm ^ v ENT -> 0:no 1:yes
Successful reset
Press ENT
Reset aborted!
Press ENT

LOGS/COUNTERS: SET HOURS: Logged on xxxh Logged on: xxx

Set hour mtrs ^v ENT -> Logged on ^ v ENT -> ENT -> New value: ? Hour meters can only be set to a higher value than before.
Logged on: yyy
New value saved!
Input rejected!
Press ENT

SET HOURS: Active: xxxhActive: xxx

Active ^ v ENT -> ENT -> New value: ?
Active: yyy
New value saved!
Input rejected!
Press ENT

SET HOURS: Traction: xxTraction: xxx

Traction ^ v ENT -> ENT -> New value: ?
Traction: yyy
New value saved!
Input rejected!
Press ENT

SET HOURS: Pump: xxxh Pump: xxx

Pump ^ v ENT -> ENT -> New value: ?
Pump: yyy
New value saved!
Input rejected!
Press ENT
 15

ATLET Menu tree

Level 1 Level 2 Level 3 Level 4 Level 5 Level 6 Remarks:

LOGS/COUNTERS:
Download ^v ENT -> Send all above logs to serial port truck serial no, versions and settings (not fleet manager statistics)

SET ACCESS: OPERATOR: Operator ID: The level 3 displays are always followed in sequence.
ENT / v -> Operator ^v ENT -> New/Change ^v ENT -> ? The no of question marks corresponds to the chosen id length
ATLET MENU: Operator categ:x (ATLET menu).
< Set access > ?
Old code: this screens will only be displayed if the user ID exists and user code
???? length > 0 The no of question marks corresponds to the chosen code
New code: length (ATLET menu). this screens will only be displayed if the user code
???? length > 0 The no of question marks corresponds to the chosen code
Verify new code: length (ATLET menu). this screens will only be displayed if the user code
???? length > 0 The no of question marks corresponds to the chosen code
Ok! length (ATLET menu).
Press ENT
Not successful!
Press ENT invalid old code / verifyed code wrong / category out of range (1..4) / all
100 user ID's used / no access to E2PROM
OPERATOR: CAUTION! Reduced
Format ^v ENT -> length may lead.

0 v ^

.to lost entries

0:escape 1:go on

Id length: x Id length: x
v ENT -> New value: ?
Id length: x
New value saved!
Input rejected!
Press ENT

Code length: x Code length: x

^ ENT -> New value: ?
Code length: x
New value saved!
Input rejected!
Press ENT

SET ACCESS: Old code:

Local ^v ENT -> ???????
New code:
???????
Verify new code:
???????
Ok!
Press ENT
Not successful! invalid old code / verifyed code wrong / no access to E2PROM
Press ENT

SET ACCESS: Old code:

Atlet ^v ENT -> ???????
New code:
???????
Verify new code:
???????
Ok!
Press ENT
Not successful! invalid old code / verifyed code wrong / no access to E2PROM
Press ENT

ENT -> Go to Reset menu

ATLET MENU:
< Total reset >
 16

ATLET Menu tree

Level 1 Level 2 Level 3 Level 4 Level 5 Level 6 Remarks:

Selection is done 'semiautomatically' during CALIBRATION between: Every unique VCL sw variant
1. Combined raise/lower control (e g joystick) includes rules for:
2. Individual raise and lower controls (e g pushbuttons in tiller head)
1. which inputs are allowed to be
used to each channel. Final decision
of which of these allowed inputs will
be used is made by 'auto-sense'
feature during calibration.

Selection is done 'semiautomatically' during CALIBRATION between: 2. which outputs will be used:
1. Combined pos/neg direction control (e g joystick) a) if onoff control is selected
INPUTS pos
2. Individual Atlet
andmenu/Calibrate
neg direction controls (e g pushbuttons in tiller head) b)
VCLif valve
appl PWM
code is selected
Hydraulic Control Channels c) if motor speed control is selected.

3. which interlocks should exist Selection

OUTPUT isAtlet
decided in SETTINGS between:
menu/Settings/Hydraulics
between the different channels. 1. OnOff control.
2. Speed control.
Lift channel 2.1 Valve PWM control.
Selection is done 'semiautomatically' during CALIBRATION between: 2.2 Pump motor speed control.
1. Combined pos/neg direction control (e g joystick)
2. Individual pos and neg direction controls (e g pushbuttons in tiller head)

Selection is decided in SETTINGS between:

1. OnOff control.
2. Speed control.
Channel 2
2.1 Valve PWM control.
Selection is done 'semiautomatically' during CALIBRATION between:
2.2 Pump motor speed control.
1. Combined pos/neg direction control (e g joystick)
2. Individual pos and neg direction controls (e g pushbuttons in tiller head)

Selection is decided in SETTINGS between:

1. OnOff control.
Channel 3 2. Speed control.
2.1 Valve PWM control.
2.2 Pump motor speed control.

Selection is decided in SETTINGS between:

1. OnOff control.
Channel 4 2. Speed control.
2.1 Valve PWM control.
2.2 Pump motor speed control.
 17

ATLET Menu tree

Level 1 Level 2 Level 3 Level 4 Level 5 Level 6 Remarks:

Example 1 - tiller application

Lift channel is analog, with valve PWM output. Inputs are decided in Atlet menu/Calibrate/Lift menu. When the display requests "full raise" the proportional pushbutton
connected to J9 (lift) is activated by the engineer followed by ENT. Cortex then recognises this input as the raise input. The display requests "full lower" and the operator pushes the button connected to J8 (lower).
Cortex has now detected which inputs are used for raise and lower, and has also stored at which input levels full output should be given.
Output type is selected in Atlet menu/Settings/Hydraulics/Lift. First of all, speed control is selected. Now, further settings are needed. In this case, a porportional valve will be controlled by HVC 1.
The engineer selects valve speed control. Fixed outputs for contactor prop valve and dir valve are hardcoded. Output relations to dead zone passing and to calibrated maximum input are entered.

Channel 2 is 'digital', with onoff valve control. No input calibrations need to be done, since output is defined as 'onoff'. Hardcoded definitions for input and output associations take effect.

Example 2 - rider stacker

Lift channel is analog, with joystick and pump motor speed control. Input calibration is carried out as in example 1. Cortex recognizes the a 'combined' raise/lower control from the voltage levels read during calibration.
Output setting s are set to 'speed control' and 'motor'. Raise command is sent to hardcoded adress in PMC, lower command is sent to HVC 1.
 1

Language Tree

Level 1 Level 2 Level 3 Level 4 Level 5 Remarks:

SELECT LANGUAGE:
English ^v
Svenska
Deutsch
Francais
Custom
 1

Monitor menu

Level 1 Level 2 Level 3 Remarks:

MONITOR MENU:
< Exit >

MONITOR MENU: TRACTION: xxxxrpm "xxxx" = motor speed in rpm;

< Traction > ENT / v -> Drive Monitor ^ v ENT -> +/-iii A "iii" = motor current

TRACTION: C: +/-ttt degC "ttt" = controller temperature; "TTT" = motor temperature

Temp Monitor ^ v ENT -> M: +/-TTT degC

MONITOR MENU: xxxxrpm

< Pump > ENT / v -> +/-iii A
v^
C:ttt M:TTT degC

MONITOR MENU: Angle: xx

< Steering > ENT / v ->

Record angle

MONITOR MENU: not implemented yet

< Wire guide > ENT / v ->

MONITOR MENU: IN/OUT: Accelerator xxx

< In/Out > ATC inputs: ^v ENT / v -> Raise1 xxx
Raise2 xxx
Lower1 xxx
Lower2 xxx
Belly x
BellyInv x
TillerUpD x
Horn x
Dig_in1 x
Dig_in2 x
Dig_in3 x
Dig_in4 x
Dig_in5 x
 2

Monitor menu

Level 1 Level 2 Level 3 Remarks:

IN/OUT: Dig_in1 x
TMC inputs: ^v ENT / v -> Dig_in2 x
Dig_in3 x
Dig_in4 x
Dig_in5 x
Dig_in6 x
Dig_in7 x

IN/OUT:
HVC inputs: ^v ENT / v -> Dig_in1 x
Dig_in2 x
Dig_in3 x
A_in 1 xxx

IN/OUT:
EPS inputs: ^v ENT / v ->

IN/OUT: Lift int x

ATC int/out: ^v ENT / v -> Speed int x
Safety int x
Max spd xxx
Forward x
Reverse x
Brake x
Liftstop x
Reset menu

Level 1 Level 2 Level 3 Level 4 Level 5 Remarks:

RESET: Reset all users?
All users ^v ENT -> 0:no 1:yes
Successful reset
Press ENT
Reset aborted!
Press ENT

RESET: Reset options?

Options ^v ENT -> 0:no 1:yes
Successful reset
Press ENT
Reset aborted!
Press ENT

RESET: Reset settings?

Settings ^v ENT -> 0:no 1:yes
Successful reset
Press ENT
Reset aborted!
Press ENT

RESET: Reset calib?

Calibration ^v ENT -> 0:no 1:yes
Successful reset
Press ENT
Reset aborted!
Press ENT

RESET: Reset logs?

Logs ^v ENT -> 0:no 1:yes
Successful reset
Press ENT
Reset aborted!
Press ENT
 SERVICE MANUAL
Machine: PLP

Manual No: 119002

Edition 2007A

11 Brake and drive system

Design and function ..................................................................................................... 11.3

Electric brake ......................................................................................................11.3

Repair instructions ....................................................................................................... 11.4

Electric brake ......................................................................................................11.4
Service ......................................................................................................................... 11.4
Replacing the brake disc (–2006w46) .......................................................................... 11.4
Replacing the brake disc (2006w47–) .......................................................................... 11.5
Emergency release ...................................................................................................... 11.6

SERVICE MANUAL
11.2

SERVICE MANUAL
 Brake and drive system / Design and function / Electric brake 11.3

Edition 2007A

11 Brake and drive system

Design and function

Electric brake
PLL is equipped with an electric brake. The electric brake is a safety brake with two fric-
tion surfaces. The braking torque is produced by spring pressure. The brake is activated
when the voltage over the coil is lost, i.e. the truck is braked when it is without voltage.
When the brake is activated the springs press on the plate, which is pressed axially to the
rotor. When the brake is to be released the coil is supplied with battery voltage. The mag-
netic field created between the plate and the magnetic part allows the rotor to rotate freely.
The brake is activated by the TMC and EPS via the ATC (see also wiring diagram).

SM_PLP_11_119002_2007A.fm
SERVICE MANUAL
11.4 Brake and drive system / Repair instructions / Electric brake

Repair instructions

Electric brake

Service
The brake does not need adjusting.
When serviced the gap between the magnetic parts should be measured to ensure that the
brake disc is not worn.

Figure 11.1

The gap A can be measured with the brake fitted (figure 11.1).

Warning!
The brake disc is worn out and should be replaced if the measured gap is greater
than 0.6 mm!

Replacing the brake disc (–2006w46)

1. Disconnect the electrical connection to the magnetic part.
2. Release the three retaining screws holding the magnetic part, and carefully lift off.
Clean the magnetic part.
3. Lift off the brake disc and clean all the surfaces.
4. Fit the new brake disc and refit the magnetic part. Tighten the three retaining
screws to 9.5 Nm.
5. Reconnect the electrical connection to the magnetic part.

Warning!
Check that you have a safe braking capacity.

SERVICE MANUAL
 Brake and drive system / Repair instructions / Electric brake 11.5

Replacing the brake disc (2006w47–)

C
B
Figure 11.2 Electric brake (2006w47–)

1. Disconnect the electrical connections to the magnetic part.

2. Undo the three retaining screws, pos B in figure11.2.
3. Dismantle the brake by unscrewing 3 screws, pos C.
4. Lift out the brake disc and clean the magnetic part and brake plate.
5. Mount the new brake disc and refit the magnetic part. Tighten the three retaining
screws at 9.5 Nm.
6. Reconnect the electrical connections to the magnetic part.

Warning!
Check that you have a safe braking capacity.

SERVICE MANUAL
11.6 Brake and drive system / Repair instructions / Electric brake

Emergency release
The brake can be released manually if necessary.

Note!
If the brake is released manually there will be no functioning parking or emergency
brake. Never leave a machine with a manually released brake!

Figure 11.3

To manually release the brake, screw in two screws (M6x55) in the two marked holes
(figure 11.3).

SERVICE MANUAL