Atlet Electric Reach Truck UFS UHS UNS UNN URF USS

Illustrated Factory Service Training (Workshop) Manual for Atlet Electric Reach Truck U-Series. Original factory manuals for Atlet Forklift Trucks, contains high quality images, circuit diagrams and instructions to help you to operate and repair your truck Covered models: UFS 200 UFS 201 UFS 250 UHS 141 UHS 200 UNN 140 UNS 140 UNS 141 UNS 160 UNS 200 URF 125 URF 150 USS 141 Format: PFD, 398 Pages Language: English Contents: 1 General information and technical data Introduction Service manual The trucks Manual structure Symbol key History Safety Lifting points Safety instructions Truck modification Environmentally hazardous waste - environment Handling Trouble shooting Designations Truck types Dimension Dimension description UNS, UHS Dimension description UFS Dimension description USS Dimension description URF Component specification Drive motor Electric brake Gearbox Hydraulic unit Control system for motor Battery Servo motor Steering servo unit fly by wire Steering servo unit EPS 2001 Torque Conversion table torque Bolt types and tensile grades Recommended oil and grease types Code explanations Machine colours according to NCS Colour codes for Atlets wiring diagrams Designations for electrical components Units Edition 2005C 2 Special tools List of tools Edition 2009B 3 Service Introduction Service intervals Service inspection General Check list Code explanation Lubrication Recommended changing Lubrication chart UNS, UNN, UHS, USS, UFS Lubrication chart URF Symbol key lubrication chart 4 Chassis Introduction Chassis, plates Dismantling, assembling the overhead guard Dismantling, assembling the overhead guard stanchion Chassis, machine housing components Dismantling, assembling the load wheel Adjusting stabilizing lugs (UHH) Adjusting the door Battery lock, battery type R Panels Dismantling, assembling the panels Adjustable arm rest U*S Dismantling, assembling the arm rest Driver seat U*S Adjusting 5 Drive unit Introduction Dismantling, assembling the drive unit Drive wheel nut tightening torque Drive motor, general instructions Storage of machines and motors First service Preventive maintenance Dismantling, assembling the motor Replacing the motor bearings Replacing the bearing housing Reconditioning the motor Motor bearings Pinion nut tightening torque Stator housing Assembly Gearbox First service Preventive maintenance Replacing the gearbox Drive shaft and drive wheel Replacing the drive shaft seal Replacing the drive wheel Trouble shooting chart 6 Mast Mast Dismantling of masts 141, 200 Dismantling of masts 140, 160, 161 Adjusting the brass lugs 141, 200 Adjusting the mast, top 141, 200 Adjusting the masts 140, 160, 161 Mast damper (2003w03=) Reach carriage Dismantling the reach carriage 141, 200 Dismantling of reach carriage 140, 160, 161 Adjusting the reach carriages 141, 200 Adjusting the reach carriages 140, 160, 161 Fork carriage Adjusting the fork carriage, 141,200 Adjusting the fork carriages 140, 160, 161 Dismantling, assembling the fork carriage Fork test Fork side shift unit Trouble shooting Lift cylinders Adjusting the cylinder attachment in the mast Lift chains Adjusting the lift chains Checking the lift chains Regular maintenance Re-fitting the chains Trouble shooting Trouble shooting chart 141, 200 Trouble shooting charts 140, 160, 161 Three-way-stack unit type 134 URF Safety instructions General description Installation instructions Torque [Nm] Pipe and hose connection Function test Hydraulic lines and connections Adjusting Fork holder Rotation cylinders Boom Cam adjustment Pinion drive axle Thrust rollers Hydraulic motor Working conditions and dismantling of motors Inspection list 7 Steering Introduction Chapter structure Comprehensive description - fly by wire steering Comprehensive description - EPS 2001 steering Steering servo motor Adjustment of steering servo system - fly by wire Dismantling the steering servo motor Settings, adjustments and tests Controller, functions - fly by wire Setting of controller - fly by wire Controller factory settings - fly by wire Operation test of steering servo system - fly by wire Mechanical adjustment to the steering sensors - EPS 2001 Operation test of the steering steering sensors - EPS 2001 Calibration of the sensor system - EPS 2001 Setting of steering wheel indicator - EPS 2001 Setting of straight steering - URF EPS 2001 Driver setting for steering sensitivity - EPS 2001 Options Limited or continuous steering - EPS 2001 Mini-wheel or midi-wheel - EPS 2001 Diagnostics and trouble shooting Fly by Wire EPS 2001 8 Hydraulic system Introduction Description Hydraulic system general regulations Installation Connections Start up Installation instruction for pipe couplings Hydraulic filter Replace Pump motor Dismantling Replacing the motor bearings Replacing the bearing housing Assembly Suction hose Replace Tank Draining Cylinders Dismantling the reach cylinder Dismantling, assembling the reach cylinder Bleeding the reach cylinder Dismantling the tilt cylinder from the truck Dismantling, assembling the tilt cylinder Valves Operation of control valve Adjusting the working pressure Emergency lowering valve Troubleshooting control valve Setting the hose rupture valve Hydraulic control Calibration Hydraulic diagram Revision list 9 Lift cylinders Free lift cylinder Dismantling Dismantling Draining, bleeding Outer cylinder Dismantling Dismantling Free lift cylinder URF Dismantling Bleeding Free lift cylinder URF, older design Dismantling Free lift cylinder URF, newer design Dismantling 10 Electrical system Introduction Component description Safety Battery Replace Capacity measurement Battery parameters from version 3.00 Chassis Checking the ATC - chassis connection Potential measurement Optical aisle sensor, rail guidance Caster wheel rotation lock, UFS Connectors in cold storage rooms Greasing Drive and pump regulator (2005w04-) Dismantling, assembling Designation General on control of the AC motors Connections Cable connections Power cables Insulation resistance Routine test Temperature measurement Trouble shooting - hydraulic functions channels 3, 4 and 5 Magnetic switch for the reach stop Reach stop Reach stop damping (2005w04ÿ) (trucks with S3) Fuses Standard Extra accessories Horn Connection Atlets truck computer ATC Component and interface description Handling Service functions Change passwords Calibration and control of the hydraulic levers Running time functions Printing of statistics Collision sensor ATC connector Checking the inputs and outputs Digital inputs Digital outputs XC1-XC11 Digital outputs B+ supply Digital outputs 12 V supply Digital outputs B+ supply Valve parameters Performance parameters Error codes General Error code description Warnings Description Menu tree ATC Error log Subinfo General instructions with all types of faults on trucks in combination with powe 10.56 Trouble shooting - operational disturbance Truck and ATC Battery Main contactor Fuse The drive regulator status indicator Traction motor Pump motor Pump regulator status indicator Steering system - EPS 2001 The drive function Forks Automatic driving of the drive unit - UFS Rotating wheel indication - UFS Low temp drive/Low temp hydraul High/Low voltage - EPS 2001 High temp Steering/Overheated steer - EPS 2001 Trouble shooting - error messages E05, E06, E07, Electric servo - fly by wire CAN E97, E98. Drive system stopped/ Hydraulics stopped E100, E101. Drive system abnormal/ Hydraulics abnormal E102, E103, E107 Servo stopped/Servo abnormal -EPS 2001 E105, Drive system E106, Pump system Trouble shooting table - battery Battery stop Wiring diagram Appendix 1, Menu tree 11 Speed control and Brake system Speed control, U*S Dismantling the speed and brake controls, U*S Inspection and adjustment of the speed control Gill sensor Calibration of speed controller (Gill sensor) Calibration of speed controller (SLOAN) Brake pedal Adjusting and inspecting the brake pedal Calibration of UFS brake pedal Left-foot switch, U*S Dismantling, assembling the left-foot switch Adjusting the left-foot switch Preventive maintenance Electric brake Electric brake, 1 disc (-2003w01) Electrical brake, new version (2003w02-) Service Trouble shooting The brakes do not release 12 Extra accessories Level selector Setting the switch level system Height preselection Operating height preselection Pulse height preset Operation Checking settings Example of use Height measurement instrument General Technology Settings Programming Setting the offset value Protecting the preset value Setting COEFF Setting dECPt Final test Sensor Adjusting the sensor Height indication on the display Cabin Heating and ventilation Ergologic Electric calibration Mechanical adjustment of the lifting/lowering potentiometer Semi-automatic tilt centring Semi-automatic side-shift centring Stability Support System, S3 Identification Functionality Drive Speed Hydraulic functions Technical description S3 option 2 (S3-2) Weight indication Functionality Technical description Calibration Truck Remote ACcess, TRAC