Nissan forklift p frame - pll series service repair manual
- 1. SERVICE MANUAL Machine: PLL PSD PSL PLE Manual No: 119000 SERVICEMANUAL 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 Lifting the truck .................................................................................................... 1.6 Inspection/Preparation ................................................................................................... 1.6 Permitted lifting points .................................................................................................... 1.6 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 PLL, PSD .............................................................................................................. 1.10 Designations ...................................................................................................... 1.10 Truck designation ......................................................................................................... 1.10 Type designation .......................................................................................................... 1.11 Dimensions and weights .................................................................................... 1.14 Component specification ................................................................................... 1.16 Recommended consumable materials ....................................................................... 1.17 Oil and grease ................................................................................................... 1.17 Standards and abbreviations ...................................................................................... 1.18
- 2. SERVICEMANUAL 1.2 Screws ...............................................................................................................1.18 Tightening torque, screws and nuts .............................................................................. 1.18 Tightening torque, hydraulic couplings ......................................................................... 1.19 Conversion tables ......................................................................................................... 1.19 Standard abbreviations ......................................................................................1.20 ...................................................................................................................................... 1.21 Screw types and tensile grades .................................................................................... 1.21 Colour of the truck ..............................................................................................1.22 Colour codes, cabling ........................................................................................1.22 Designations ......................................................................................................1.23
- 3. General information and technical data / Scope of Service Manual / General 1.3 SERVICEMANUAL SM_PLL PSD_01_119000_2008B.fm Edition 2008B 1 General information and technical data Scope of Service Manual General This manual describes the service procedures for ATLET low lifters and stackers. 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 truck modification is not permitted. Only in the event that the truck manu- facturer is no longer in business and there is no successor to the business, may the user arrange for a modification or alteration to a powered industrial truck, provided, however, that the user shall: • Arrange for the modification or alteration to be designed, tested and implemented by an expert engineer(s) in industrial trucks and their safety. • Maintain a permanent record of the design, test(s) and implementation of the mod- ification or alteration. • Approve and make appropriate changes to the capacity plate(s), decals, tags and instruction manuals. • Affix a permanent and readily visible label to the truck stating the manner in which the truck has been modified or altered together with the date of the modification or alteration, and the name and address of the organisation that accomplished the tasks. 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 lifter PLL and stacker PSD.
- 4. 1.4 General information and technical data / How to use the manual / Structure SERVICEMANUAL 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. Mas- ter (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.
- 5. General information and technical data / Safety instructions / General 1.5 SERVICEMANUAL 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.
- 6. 1.6 General information and technical data / Safety instructions / Lifting the truck SERVICEMANUAL 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. Permitted lifting points Figure1.1 shows where the permitted lifting points are placed on the truck. The lifting points are marked with a decal representing a lifting hook. Warning! The machine must never be lifted in any other points than the ones shown. Figure 1.1 Permitted lifting points
- 7. General information and technical data / Safety instructions / Lifting the truck 1.7 SERVICEMANUAL Figure 1.2 shows where the jack should be placed. Figure 1.2 Permitted lifting points, jack
- 8. 1.8 General information and technical data / Safety instructions / Welding on the truck SERVICEMANUAL Welding on the truck • During welding work the battery plug should always be disconnected and all con- nections to the control units and regulators (applies to all electronic units) discon- nected. On completion of welding work the connectors 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 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.
- 9. General information and technical data / Preparations / Service 1.9 SERVICEMANUAL 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.
- 10. 1.10 General information and technical data / Data PLL, PSD / Designations SERVICEMANUAL Data PLL, PSD Designations Truck designation Table 1.1 Truck designations Truck type PLL Low lifter PSD Stacker PSL Stacker Load capacity PLL 145 1450 kg PLL 180 1800 kg PLL 200 2000 kg PSD 125/160 1250 kg forks only. 1600 kg in total (800+800 kg) PSL 125 1250 kg
- 11. General information and technical data / Data PLL, PSD / Designations 1.11 SERVICEMANUAL Type designation 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 followed). 4. Where appropriate load limitations depending on the position of the load on the forks (D) and/or lifting height (Q). Figure 1.3 Example of type plate (–2006w36) 1 2 3 4 DD HH QQ ATLET OBERHAUSEN H D QH D Q MODELL MODEL MODELL MODELE SERIE NR. SERIAL NO. SERIEN NR. NOMERO DESERIE TILLV. ÅR YEAR OF MANUF. BAUJAHR AN DE FABR TILLÅTEN LAST ACTUAL CAPACITY WIRKLICHE TRAGFÄHIGKEIT CAPACITE EFFECTIVE LYFTHÖJD LIFTHEIGHT HUBHÖHE HAUTEUR DE LEVEE TYNGDPUNKTSAVSTÅND BATTERISPÄNNING BATTERY VOLTAGE BATTERIESPANNUNG TENSION DE LA BATTERIE VIKT UTAN BATTERI WEIGHT WITHOUT BATTERY GEWICHT OHNE BATTERIE MASSE SANS BATTERIE MINSTA BATTERIVIKT MINIMUM BATTERY WEIGHT MINDESTGEWICHT DER BATTERIE MASSE MINIMAL DE LA BATTERIE MAXIMAL BATTERIVIKT MAXIMUM BATTERY WEIGHT HÖCHSTGEWICHT DER BATTERIE MASSE MAXIMAL DE LA BATTERIE LOAD CENTRE DISTANCE LASTSCHWERPUNKT DISTANCE DE CENTRE MMMM MMMM KGKG KG VOLT-DC KG KG 160 SDTFV 800 A A 10568/01 S 2003w01-6 8000 3600 600 500 1600 1000 24 1150 370 540
- 12. 1.12 General information and technical data / Data PLL, PSD / Designations SERVICEMANUAL Explanation of Model designation Figure 1.4 Example of type plate (2006w37–) Example: PSD 125 T 160 30 Truck type Load capacity/10 Mast type Battery Ah/5 Charger Ampere Model Modell Serial no. Serie nr. Year of manufacturing Tillverkningsår 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
- 13. General information and technical data / Data PLL, PSD / Designations 1.13 SERVICEMANUAL 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. Figure 1.5 Example of plate with serial number. SER XXXXXX WEEK XXXX SER XXXXXX WEEK XXXX
- 14. 1.14 General information and technical data / Data PLL, PSD / Dimensions and weights SERVICEMANUAL Dimensions and weights Dimensions PLL PSD Figure 1.6 Positions for dimensions PLL h1 D Q H4 B B1 V LB 85 L3 L2 L1L4 LL R2 L Ast
- 15. General information and technical data / Data PLL, PSD / Dimensions and weights 1.15 SERVICEMANUAL Figure 1.7 Positions for dimensions PSD L3 R2 LL V B1 LBh4 h4 h4 90 L2 L1 L L4 Ast h1 a/2a/2
- 16. 1.16 General information and technical data / Data PLL, PSD / Component specification SERVICEMANUAL Component specification Table 1.2 Component specification Component Specification Drive motor Drive voltage 24V Output standard 1 kW 45 min Insulation resistance 25 MΩ Gearbox Gear ratio (standard) 31,3:1 Oil volume 0.8 litres Hydraulic system PLL 180/200 Max pressure 150-160 bar Oil volume max 0.75 litres PLL 145 Max pressure 150-160 bar Oil volume max 0.6 litres Hydraulic unit (motor and pump) Output 2.2 kW Control system for drive motor Type FZ2009 AC0 CAN Voltage 24 V Max current 150A (RMS) for 2 min Fuses Control fuse 1 7.5 A Pump motor fuse 1 80 A Drive motor fuse 1 100 A
- 17. General information and technical data / Recommended consumable materials / Oil and grease SERVICEMANUAL Recommended consumable materials Oil and grease Important! Do not mix different lubricants, and absolutely not synthetic oil with mineral oil, since this can affect the properties of the oil! Table 1.3 Table of recommended types of oil and grease Brand Gearbox oil As per API value GL-5 Hydraulic oil As per ISO VG 32, VG 15 Bearing grease NLGI 2 Lithium baseNormal Cold store Normal (32) Cold store (15) BP BP Energear HYPO 80W140 EP BP Energear SHX-S 75W/140 EPS BP Bartran HV-32 BP Bartran SHF-S Energrease LC 2 Castrol - - Hyspin SHS 32 Hydraulic oil OM 15 Alt: Hyspin AWH 15 LMx Mobil - - DTE 13 M SHS 32 Flowrex 1 Mobilplex 48 Shell - - Tellus oil TX 32 Tellus oil T 15 Retinax EP2 Statoil / Exxon - - SHS 32 J 26 Uniway LIX 625 Texaco - - Rando oil HDZ 32 Rando oil HDZ 15 Hytex EP2
- 18. 1.18 General information and technical data / Standards and abbreviations / Screws SERVICEMANUAL Standards and abbreviations Screws Tightening torque, screws and nuts 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. 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
- 19. General information and technical data / Standards and abbreviations / Screws 1.19 SERVICEMANUAL Tightening torque, hydraulic couplings Conversion tables Table 1.5 Tightening torque, hydraulic couplings Tightening torque: Pipe thread / metric thread: Metric fine thread Whitworth pipe thread MA (Nm) with MA (Nm) with elastic (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 Table 1.6 Conversion table, torque units Newton metre (Nm) Kilopond metre (kpm) Poundforce inch (lbg x in) Poundforce foot (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
- 20. 1.20 General information and technical data / Standards and abbreviations / Standard abbreviations SERVICEMANUAL Standard abbreviations Table 1.7 Conversion table, pressure units Pa (N/m2) Bar (1mb=1hPa) at (kp/cm2) dry (mm Hg, 0 C) atm 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 1.8 Conversion table, speed m/s km/h 1 3.6 0.278 1 Table 1.9 Standard abbreviations Magnitude Unit Designation Current Ampere A Voltage Volt V Resistance Ohm Ω Output Watt W Torque Newton metre Nm Pressure Pascal Pa
- 21. General information and technical data / Standards and abbreviations / Standard abbreviations SERVICEMANUAL Screw types and tensile grades 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. Table 1.10 Figure Screw type Designation Tensile grade M6S Hexagon screw 8.8 10.9 MC6S Hexagon hole screw 8.8 10.9 12.9 MF6S Hexagon hole screw, countersunk 10.9 MCS Slotted screw 4.6 MVBF Oval head counter- sunk screw 4.6 Figure 1.8 Example of marking 8.8 12.9 12.9 8.8
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- 23. 1.22 General information and technical data / Standards and abbreviations / Colour of the truck SERVICEMANUAL Colour of the truck 0 The truck is painted in colours with the following NCS colour codes: 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: 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. Table 1.11 NCS colour codes Machine colour Designation Yellow NCS 0070-Y20R Medium grey NCS 7000 Dark grey NCS 8000 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
- 24. General information and technical data / Standards and abbreviations / Designations 1.23 SERVICEMANUAL Designations Electrical components normally have a designation of two letters: Table 1.13 First letter Code Designation (Eng) A Component or function without its own letter below C Capacitor D/V Diode E Electrical component F Fuse I Indicator K Connector L Coil/inductive element M Motor P/X Connection R Resistor S Switch T Terminal Y Valve/brake H Audible warning unit/light G Battery Table 1.14 Second letter Code Designation (Eng) B Brake C Control system E Emergency function F Forward H Hour K Key L Lowering M Manoeuvre P Pump R Reverse S Speed
- 25. 1.24 General information and technical data / Standards and abbreviations / Designations SERVICEMANUAL