ATLET A-Ergo Service Manual Download Page 63

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SERVICE MANUAL

Mac

Machi

hine:

ne: A-E

A-Ergo

rgo

Man

Manual

ual No:

No: 00

00597

5975

ATLET SERVICE MANUAL A-ERGO

Edition 2004A

5 Drive

Drive unit

unit

Design

Design and

and function

function ....................

............................................

........................................

.......................................

................... 5.3

5.3

Introduction

Introduction ....................

........................................

............................................

.............................................

....................... 5.3

5.3

Drive

Drive motor

motor ...................

........................................

.........................................

............................................

......................

.. 5.3

5.3

Gearbox

Gearbox .......................

............................................

.........................................

........................................

............................................

...........................

... 5.3

5.3

Repair

Repair instructions

instructions ....................

........................................

............................................

........................................

...................... 5.4

5.4

Preparations

Preparations ....................

............................................

.........................................

........................................

................... 5.4

5.4

Drive

Drive motor

motor ...................

........................................

.........................................

............................................

......................

.. 5.4

5.4

Dismantling

Dismantling the

the drive

drive motor

motor ........................................................................

............................................................................................

.................... 5.4

5.4

Assembling

Assembling the

the drive

drive motor ....................................................................................

motor ............................................................................................

........ 5.5

5.5

Dismantling

Dismantling drive

drive motor

motor ...................................................................................

..................................................................................................

............... 5.5

5.5

Assembly

Assembly drive

drive motor

motor ..........................................................................

.....................................................................................................

........................... 5.5

5.5

Storage of

Storage of the dri

the drive

ve motor ...................................................................

motor ..............................................................................................

........................... 5.5

5.5

Gearbox

Gearbox .......................

............................................

.........................................

........................................

............................................

...........................

... 5.6

5.6

Oil

Oil change,

change, gearbox .......................................................................................................

gearbox ....................................................................................................... 5.6

5.6

Dismantling

Dismantling and

and assembling t

assembling the

he gearbox

gearbox ......................................................................

...................................................................... 5.6

5.6

Reconditioning

Reconditioning of

of the

the gearbox

gearbox ....................

........................................

............................................

.....................................

............. 5.8

5.8

Replacing

Replacing the

the drive

drive shaft

shaft seal

seal ....................................................................

........................................................................................

.................... 5.8

5.8

Assembly

Assembly of

of gearbox

gearbox ..................................................................................

......................................................................................................

.................... 5.8

5.8

Drive

Drive wheel,

wheel, replacement

replacement ........................

............................................

........................................

......................................

.................. 5.13

5.13

Diagnosis

Diagnosis and

and trouble

trouble shooting ........

shooting ...........................

..........................................

...........................................

...............................

........... 5.14

5.14

Troub

Trouble

le shooting

shooting chart

chart ...............

......................................

...........................................

........................................

.............................

......... 5.14

5.14

https://www.besttruckmanuals.com/

Summary of Contents for A-Ergo

Page 1: ...cks Preparations reparations 1 6 1 6 Permitted Permitted lifting lifting points points 1 6 1 6 Welding Welding on on the the truck truck 1 7 1 7 T Taking aking the the environment environment into int...

Page 2: ...gs hydraulic couplings 1 18 1 18 Conversion Conversion table table 1 18 1 18 Screw types Screw types and and tensile grades tensile grades 1 19 1 19 Colour of the truck 1 20 Colour of the truck 1 20 C...

Page 3: ...fected ATLET AB or its authorised representative should be contacted The electrical system must never be rewired in any form after delivery without written The electrical system must never be rewired...

Page 4: ...n 8 section 8 With regard to software this is With regard to software this is described under section 10 described under section 10 The main principle for extra The main principle for extra accessorie...

Page 5: ...e mast and hydraulic unit The mast or hydraulic unit when working on or around the mast and hydraulic unit The mast or hydraulic unit can be actuated due to an electrical fault or can be actuated due...

Page 6: ...pacity b ity befo efore lif re lifting ting the truck the truck Ens Ensure t ure that hat the d the driv rive wh e whee eel run l runs fr s free o ee of the f the floo floor be r befor fore tr e troub...

Page 7: ...s possible to eliminate possible to eliminate damage to surrounding components damage to surrounding components Taking the environment into consideration Taking the environment into consideration Atle...

Page 8: ...control of the different component parts to avoid the risk of confusion good control of the different component parts to avoid the risk of confusion When r When rep epairi airing or m ng or main ainta...

Page 9: ...gnation designation Table 1 2 Table 1 2 Truck designations Truck designations T Tr ru uc ck k t ty yp pe e A A E Er rg go o S St ta an nd d o on n s st ta ac ck ke er r S St ta an nd da ar rd d A A E...

Page 10: ...R OF R OF MA MANUF NUF B BA AUJ UJA AHR HR A AN DE F N DE FA ABR BR TILL TEN L TILL TEN LAS AST T A ACTU CTUA AL C L CA AP PA ACITY CITY WIRKLICHETR WIRKLICHETRA AGF HIGKEIT GF HIGKEIT C CA AP PA ACIT...

Page 11: ...a renewed 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 plate located on each main component...

Page 12: ...a A A Er Ergo go D Des esi ign gnat atio ions ns ATLET SERVICE MANUAL A ERGO ATLET SERVICE MANUAL A ERGO Figure 1 4 Figure 1 4 Example of plate with serial number Example of plate with serial number S...

Page 13: ...ity 10 N Na ar rr ro ow w g ga au ug ge e S S B Br ro oa ad d g ga au ug ge e B B T Te el le es sc co op pi ic c m ma as st t T T T Te el le es sc co op pi ic c m ma as st t F Fr re ee e l li if ft t...

Page 14: ...e 1 5 Figure 1 5 Positions for dimensions A Ergo Positions for dimensions A Ergo Figure 1 6 Figure 1 6 Positions for dimensions A Ergo TF Positions for dimensions A Ergo TF B1 B1 V V B B B2 B2 R R 2 2...

Page 15: ...7 5 5 M MP Pa a 175 kp cm 175 kp cm O Oi il l v vo ol lu um me e m ma ax x 1 19 9 l li it tr re es s H Hy yd dr ra au ul li ic c u un ni it t m mo ot to or r a an nd d p pu um mp p T Ty yp pe e 1 1 O...

Page 16: ...Energear Energear Hypo Hypo 80W 140 80W 140 EP EP BP BP Energear Energear SHX S SHX S 75W 140 75W 140 BP Bartran BP Bartran HV 32 HV 32 BP Bartran BP Bartran SHF S SHF S BP Energrease BP Energrease LC...

Page 17: ...ecified in respective sections If no tightening torque is specified in the service instructions the in the service instructions the values shown in the table values shown in the table above apply abov...

Page 18: ...5 3 30 0 2 20 0 M M1 14 4 x x 1 1 5 5 G G 1 1 4 4 5 50 0 3 30 0 M M1 16 6 x x 1 1 5 5 G G 3 3 8 8 8 80 0 3 35 5 M M1 18 8 x x 1 1 5 5 9 90 0 4 40 0 M M2 20 0 x x 1 1 5 5 G G 1 1 2 2 1 13 30 0 5 50 0 M...

Page 19: ...the table above Marking only takes place when the shape of the product permits this to the table above Marking only takes place when the shape of the product permits this Table 1 8 Table 1 8 F Fi ig g...

Page 20: ...e Two colour cables are shown with both colour codes separated by a slash 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 E...

Page 21: ...ti io on n w wi it th ho ou ut t i it ts s own letter below own letter below D D D Di io od de e E E E El le ec ct tr ri ic ca al l c co om mp po on ne en nt t F F F Fu us se e I I I In nd di ic ca a...

Page 22: ...abbreviations Standard abbreviations Table 1 13 Table 1 13 Standard abbreviations Standard abbreviations M Ma ag gn ni it tu ud de e U Un ni it t D De es si ig gn na at ti io on n C Cu ur rr re en nt...

Page 23: ...al Special tools tools Special Special tools tools A Ergo A Ergo 2 3 2 3 Introduction Introduction 2 3 2 3 List List of of tools tools 2 3 2 3 Hand Hand terminal terminal 2 3 2 3 Cleaning Cleaning flu...

Page 24: ...2 2 2 2 ATLET SERVICE MANUAL A ERGO ATLET SERVICE MANUAL A ERGO https www besttruckmanuals com...

Page 25: ...4 4 40 00 0 P Pr ro og gr ra am mm mi in ng g t to oo ol l f fo or r t th he e c co on nt tr ro ol l u un ni it ts s f fo or r t th he e d dr ri iv ve e motor and steering motor and steering Figure 2...

Page 26: ...smantling tool buttons and lamps D De es si ig gn na at ti io on n P Pa ar rt t n nu um mb be er r A Ap pp pl li ic ca at ti io on ns s C Ch he ec ck k n nu ut t ex ext tr rac act to or r P P N N 1 10...

Page 27: ...Responsibility Foreman Foreman 3 6 3 6 First First service service 3 6 3 6 Check Check list list service service inspektion inspektion 3 7 3 7 Code Code explanation explanation 3 12 3 12 Lubrication...

Page 28: ...MANUAL A ERGO 3 2 3 2 Hydraulic oil 3 23 Hydraulic oil 3 23 First First service service 3 23 3 23 Replacement Replacement intervals intervals 3 23 3 23 Recommended replacement 3 23 Recommended replac...

Page 29: ...separate section which safety instructions are applicable for y instructions are applicable for work on the truck work on the truck The external functions in the steering The external functions in th...

Page 30: ...k the bra e brakin king cap g capac acity o ity of the ma f the main b in brak rake and p e and park arking b ing brak rake e 7 7 Che Check t ck that hat the the whe wheels els hav have no e no ex ext...

Page 31: ...tions After this check that the fork carriage goes all the the fork carriage goes all the way up to way up to maximum lifting height without maximum lifting height without the pump sucking air the pum...

Page 32: ...f e forw orwar ards ds b bac ackw kwar ards ds an and d tu turn rnin ing g C Ch he ec ck o k of t f th he e d dr ri iv ve e u un ni it t C Ch he ec ck k o of f t th he e w wh he ee el ls s T Tes est...

Page 33: ...al l t to oo ol ls s 1 10 03 35 5 Deformation cracks Deformation cracks other damage other damage Visual tools Visual tools L Lo oa ad d w wh he ee el l D Da am ma ag ge e w we ea ar r V Vi is su ua a...

Page 34: ...t ta ac ch hm me en nt r t ro ol ll le er rs s V Vi is su ua al l t to oo ol ls s F Fo or rk k c ca ar rr ri ia ag ge e C Cr ra ac ck ks s W We el ld d d da am ma ag ge e V Vi is su ua al l t to oo ol...

Page 35: ...i io on n L Li is st te en n l lu ub br ri ic ca at te e 3 31 10 03 3 Steering Steering I In ns sp pe ec ct ti io on n p po oi in nt ts s S Sy ym mp pt to om m I In ns sp pe ec ct ti io on n S Se er r...

Page 36: ...wa at tc ch h 6 60 01 17 7 6 60 00 01 1 D Da am ma ag ge e V Vi is su ua al l r re ep pl la ac ce e L Le ea ak ka ag ge e V Vi is su ua al l t to oo ol ls s r re ep pl la ac ce e Cra Crack cks W s Wel...

Page 37: ...t tools Function test tools A AC C r re eg gu ul la at to or r C Ca ab bl le e b br re ea ak k V Vi is su ua al l t to oo ol ls s 7 70 02 25 5 C Ca ab bl li in ng g D Da am ma ag ge e b br re ea ak k...

Page 38: ...t S Se et tt ti in ng g t ti il lt t f fu un nc ct ti io on n l lo oa ad d a an nd d a an ng gl le e adjustment attachment in chassis adjustment attachment in chassis 4 4 1 11 10 08 8 L Lo oad ad w w...

Page 39: ...1 1 3 31 10 04 4 D Dr ri iv ve e s sh ha af ft t T Ti ig gh ht te en ni in ng g o of f n nu ut ts s 1 1 a an nd d 5 5 3 31 10 06 6 G Ge ea ar rs s G Ge ea ar r r ra at ti io o 1 1 Steering Steering C...

Page 40: ...s se ec ct ti io on ns s c co on nn ne ec ct ti io on ns s 8 8 6 60 01 12 2 O Oi il l l le ev ve el l i in n t ta an nk k O Oi il l l le ev ve el l b be et tw we ee en n m mi in n a an nd d m ma ax x...

Page 41: ...it ti io on n a an nd f d fu un nc ct ti io on n o of f t th he e switch switch 7 70 03 35 5 S Sp pe ee ed d s sw wi it tc ch h S Sw wi it tc ch he es s i in n m ma as st t f fo or rk k c ca ar rr ri...

Page 42: ...rings in the machine should be lubricated during each service ervice Figure 3 1 Figure 3 1 Lubrication chart A Ergo For explanation of symbols see table Lubrication chart A Ergo For explanation of sym...

Page 43: ...anation of symbols see 3 3 3 3 Table 3 2 Table 3 2 Supplementary components to lubricate TF Supplementary components to lubricate TF L Lo oc ca at ti io on n E Ex xp pl la an na at ti io on n L Lo oc...

Page 44: ...l le ed d s sy ym mb bo ol l C Ch ha an ng ge e Table 3 3 Table 3 3 Explanation of symbols for lubrication chart Explanation of symbols for lubrication chart S Sy ym mb bo ol l E Ex xp pl la an na at...

Page 45: ...emented in accordance with the intervals set out in d in accordance with the intervals set out in the the service chart service chart However However in in some cases exceptions must be made and some...

Page 46: ...leas t least onc t once a yea e a year r If ste If steam cl am clean eaning o ing or hig r high h pressure washing has been carried out pressure washing has been carried out then new greasing is essen...

Page 47: ...n s the chain so that all working su o that all working surfaces are continuously rfaces are continuously lubricated lubricated The chain should be kept in motion when lubricating to ensure that the l...

Page 48: ...t ring the firs he first t service 200 hours service 200 hours 2 2 The ti The tighten ghtening to ing torque rque betw between th een the fram e frame and e and mach machine ho ine housin using sho g...

Page 49: ...eir be immediately replaced since their properties will have been changed properties will have been changed If the hydraulic oil has become contaminated with water e g during work in cold If the hydra...

Page 50: ...rvi vice ce S Sp pe eci cif fi ic i c ins nst tru ruct ctio ion ns R s Re eco com mme men nde ded r d re epl pla ace ceme men nt t ATLET SERVICE MANUAL A ERGO ATLET SERVICE MANUAL A ERGO https www bes...

Page 51: ...4 6 4 6 Mounting the Mounting the arm arm rest rest 4 7 4 7 Steering Steering wheel wheel panel panel 4 8 4 8 Dismantling the steering wheel panel 4 8 Dismantling the steering wheel panel 4 8 Mounting...

Page 52: ...ATLET SERVICE MANUAL A ERGO ATLET SERVICE MANUAL A ERGO 4 2 4 2 https www besttruckmanuals com...

Page 53: ...hine housing which is available in different versions depending on the size of the battery different versions depending on the size of the battery All the truck All the truck components such as the ma...

Page 54: ...functions as a support wheel for the drive wheel since the drive wheel drive wheel is asymmetrically mounted on one side of the truck is asymmetrically mounted on one side of the truck The castor whee...

Page 55: ...ach machine h ine housi ousing an ng and roo d roof grill f grille pil e pillars lars 4 4 Li Lift ft o of ff t f th he g e gr ril ille le Mounting the overhead guard Mounting the overhead guard 1 1 Sc...

Page 56: ...scre k screw at th w at the rig e right atta ht attachme chment can nt can be rel be release eased d 4 4 Lift up Lift up the a the arm re rm rest an st and d d discon isconnec nect all t all the c the...

Page 57: ...he co conn nnec ecto tors rs 4 4 Fit t Fit the l he left g eft guid uide rai e rail and l and gas s gas sprin pring in g in the their g ir groo rooves ves 5 5 Press Press down down the p the panel an...

Page 58: ...de rai rail l 6 6 Relea Release th se the wing e wing nut fo nut for adju r adjusting sting the he the height ight and lif and lift of t off the s f the steeri teering whe ng wheel pan el panel el Mo...

Page 59: ...m e mac achi hine ne co cove ver r 5 5 Secur Secure the e the cap s cap screw crew in the in the hing hinge with e with an Alle an Allen key n key and r and releas elease the l e the lock n ock nut u...

Page 60: ...truck page 4 11 page 4 11 Dismantling castor wheel Dismantling castor wheel 1 1 Re Remo move t ve the c he cas asto tor whe r wheel f el fro rom th m the tru e truck ck se see e Disman Dismantling th...

Page 61: ...k on a n a le leve vel s l surf urfac ace e 2 2 Ch Chec eck if k if th the t e tru ruck ck sta stand nds a s at an t an an angl gle e 3 3 If ali If alignm gnment is ent is nec neces essar sary y rem r...

Page 62: ...ery by y by mean means of s of the b the battery attery stop stop and and repla replace t ce the ba he battery ttery plug plug Replacing the battery rollers Replacing the battery rollers 0 0 1 1 Re Re...

Page 63: ...ve drive motor motor 5 5 5 5 Dismantling Dismantling drive drive motor motor 5 5 5 5 Assembly Assembly drive drive motor motor 5 5 5 5 Storage of Storage of the dri the drive ve motor motor 5 5 5 5 Ge...

Page 64: ...ATLET SERVICE MANUAL A ERGO ATLET SERVICE MANUAL A ERGO 5 2 5 2 https www besttruckmanuals com...

Page 65: ...e motor which provides speed the motor which provides speed feedback to the drive r feedback to the drive regulator egulator see section 10 see section 10 The motor is mounted directly on the gearbox...

Page 66: ...n the 8 e 8 so socke cket h t head ead ca cap sc p scre rews h ws hold olding ing th the e motor together with the gearbox see pos 2 motor together with the gearbox see pos 2 5 5 Care Carefu fully lly...

Page 67: ...ditioning the motor to replaced when reconditioning the motor to ensure continued reliable operation ensure continued reliable operation 4 4 The ho The housin using is sp g is spraye rayed with d with...

Page 68: ...2 Dismantling and assembling the gearbox Dismantling and assembling the gearbox 00 00 1 1 Bloc Block up the tr k up the truck uck The dr The drive wh ive wheel sh eel should ru ould run free a n free...

Page 69: ...ing the s the specif pecified ti ied tighten ghtening ing torqu torque mus e must be t be applied applied 47 Nm 47 Nm 10 10 Fill up with Fill up with new oil s new oil see tab ee table of reco le of r...

Page 70: ...bly removed before reassembly 7 7 Care Careful fully cl ly clean t ean the se he seat fo at for sea r seal bo l box in th x in the gea e gear hou r housin sing g 8 8 When When asse assemblin mbling t...

Page 71: ...housing 1 1 Pre Press b ss bear earing ing p pos os 6 6 o on t n the p he pini inion on sha shaft ft 2 2 Se Set ou t out re t requ quire ired nu d numb mber of s er of shi hims ms po pos 7 s 7 3 3 Pl...

Page 72: ...th t the s e sea eal l po pos s 12 12 2 2 Se Set ou t out re t requ quire ired nu d numb mber o er of sh f shim ims p s pos os 13 13 3 3 Place Place the s the spacer pacer ring ring pos pos 14 14 in i...

Page 73: ...e mar arki king ngs on s on th the ge e gear t ar tee eeth th 4 4 Th The fi e figur gure be e below low sho shows t ws the he cor correc rect en t enga gagem gemen ent t 5 5 If th If the eng e engage...

Page 74: ...n an n and ti d tighten ghten with with the s the screws crews pos 18 pos 18 3 3 Pla Place th ce the gui e guide w de whee heel be l beari aring in ng in its p its pos ositio ition an n and tig d tigh...

Page 75: ...e 3 3 Rem Remove ove th the wh e wheel eel nut nuts an s and l d lift t ift the w he whee heel fo l forwa rward rd 4 4 Fit Fit th the n e new w ew whee heel l tig tighte hten t n the he nut nuts b s b...

Page 76: ...he truck seems to jerk whe The truck seems to jerk when n driving driving Hard foreign object has Hard foreign object has fastened in the drive wheel fastened in the drive wheel 1 1 Rem Remove ove th...

Page 77: ...Faulty bearing in the drive Faulty bearing in the drive motor motor Dismantle and recondition the Dismantle and recondition the drive motor drive motor Th The t e tr ru uc ck r k ro oll lls s s sl lu...

Page 78: ...O ATLET SERVICE MANUAL A ERGO 5 5 16 16 Dr Driv ive u e un nit it D Di iag agno nosi sis a s and nd tr trou oub ble le sh sho oot oti ing ng T Tro roub uble le sh shoo ooti ting ng ch char art t https...

Page 79: ...e mast straddle legs mast straddle legs on on the the chassis chassis 6 11 6 11 Dismantling Dismantling the the mast mast 6 14 6 14 General General 6 14 6 14 Adjusting the la Adjusting the lateral inc...

Page 80: ...or and fork drive motor and gearbox TF gearbox TF 6 33 6 33 Replacing the Replacing the cabling fork cabling fork drive motor drive motor TF TF 6 34 6 34 Straddle lift 6 35 Straddle lift 6 35 Adjustin...

Page 81: ...ifting movement is the same as for a intermediate mast The lifting movement is the same as for a telescopic mast and all the telescopic mast and all the masts begin to move masts begin to move up or d...

Page 82: ...pic forks fixed forks to complex units with telescopic forks Fixed forks Fixed forks Forks with a fixed width and length Forks with a fixed width and length Laterally adjustable forks Laterally adjust...

Page 83: ...4 6 4 For adjusting instructions For adjusting instructions see Adjusting the overload see Adjusting the overload clutch TF on page 6 32 clutch TF on page 6 32 Fork drive motor telescopic forks TF Fo...

Page 84: ...loor W the floor With masts with straddle lift i ith masts with straddle lift it is possible to transport a pallet on the t is possible to transport a pallet on the fork fork carriage and if the fork...

Page 85: ...tch on the mast limit switch i e a height position switch on the mast limits the lifting height when the s the lifting height when the stabilisers are withdrawn When the stabilisers stabilisers are wi...

Page 86: ...raddle legs Dismantle the mast straddle legs from the chassis Dismantle the mast straddle legs from the chassis 1 1 Re Remo move ve th the b e ba att tte ery ry 2 2 Bl Blo oc ck k u up t p the he c ch...

Page 87: ...he sc f the screw h rew hole oles on the s s on the spa pacer b cer betw etween th een the e guide and chassis in order to guide and chassis in order to hold up the spacer when dismantling hold up the...

Page 88: ...st on the c n the chas hassis sis 7 7 Re Rele leas ase th e the hy e hydr drau auli lic co c conn nnect ectio ions ns Important Important Contain surplus hydraulic oil in a suitable way Contain surplu...

Page 89: ...ast i ast is sui s suitably tably sup supported ported so t so that it hat it canno cannot mo t move ve If the mast has straddle lift If the mast has straddle lift Figure 6 14 Figure 6 14 Example of s...

Page 90: ...o screw t ew tight ight the s the space pacer bet r between ween the m the mast ast and and chas chassis sis in in the guide in one of the screw holes that are not used the guide in one of the screw h...

Page 91: ...the stra trap and s p and scre crew hol w holdi ding th ng the spa e space cer to the g r to the guid uides es Figure 6 18 Figure 6 18 Remove screw spacer guides Remove screw spacer guides 10 10 Chec...

Page 92: ...en lifting and lowering when lifting and lowering Adjusting the lateral inclination in top position Adjusting the lateral inclination in top position 0 0 1 1 Lo Lowe wer th r the ma e mast a st and nd...

Page 93: ...ameter er with a larger diameter Thrust rollers are available in Thrust rollers are available in three different diameters the diameter is specified on each three different diameters the diameter is s...

Page 94: ...ile rofiles so t s so that it hat it comes under the intermediate cylinder Lower the inner and intermediate mast s comes under the intermediate cylinder Lower the inner and intermediate mast so o that...

Page 95: ...smantle the mast the mast see Dismantle the mast straddle legs from the chassis on page 6 8 see Dismantle the mast straddle legs from the chassis on page 6 8 and and set it down set it down 11 11 Remo...

Page 96: ...Remembe member to re r to remove move the ca the cable ti ble ties es 6 6 Rem Remove ove the u the uppe pper ret r retain aining ing scr screws ews for th for the sid e side cy e cylin linder ders s...

Page 97: ...e cylin linder ders s 6 6 Lift the Lift the inner inner mast mast straig straight up u ht up until th ntil the low e lower th er thrust rust roller roller on the on the inne inner mas r mast and t t a...

Page 98: ...ts olts on t on the lif he lift cylin t cylinder f der from th rom the in e inner ner mast mast 8 8 Re Remo move ve th the lo e lowe wer re r reta tain inin ing s g scr crew ew 9 9 Caref Carefully l u...

Page 99: ...ctly and to ensure there is important to align them correctly and to ensure there is no no deterioration of the clearance deterioration of the clearance Check Check Che Check t ck tha hat th t the ch...

Page 100: ...t the c he cha hain ru in runs e ns easi asily o ly over ver the the pul pulley ley whe wheel an el and do d does n es not j ot jam am Lu Lubr brica icate te th the c e cha hain a in aft fter c er cle...

Page 101: ...e included in the fork test If the f Seven inspection points are included in the fork test If the forks fail to meet any of the orks fail to meet any of the points the machine must be taken out of ser...

Page 102: ...e tips of the forks Difference in height between the tips of the forks The difference in height dH The difference in height dH between the tips must not exceed 3 of the between the tips must not excee...

Page 103: ...n P Po os si it ti io on n E Ex xp pl la an na at ti io on n 1 1 T Th hi ic ck kn ne es ss s 5 5 S Sh ha an nk k A A C Ca ar rr ri ie er r surface surface 2 2 T Ti ip p 6 6 H Ho oo ok k h h H He ei ig...

Page 104: ...d rollers and by replacing the rollers rollers and by replacing the rollers For permitted play For permitted play see Adjusting the play in see Adjusting the play in the mast on page 6 15 the mast on...

Page 105: ...tion on the back of the fork carriage see fi on the back of the fork carriage see figure gure6 29 6 29 2 2 Lower Lower the for the fork ca k carriage rriage to a to a suitab suitable h le heigh eight...

Page 106: ...at the chain slackens and the chain lock pos pos 3 and 4 3 and 4 can be can be removed see removed see figure figure6 30 6 30 6 6 Loo Loose sen the bo n the bolts c lts comp omplet letely a ely and li...

Page 107: ...a 2 and re nd remove move the c the chains hains p pos 3 os 3 figure figure6 32 6 32 10 10 Remov Remove the sp e the sproc rockets in th kets in the tips o e tips of the inn f the inner fo er forks r...

Page 108: ...in the in the tips of t tips of the inn he inner for er forks Li ks Lightly g ghtly grease rease the be the bearing aring inside inside and and outside before fitting outside before fitting 2 2 Fit th...

Page 109: ...nd so that it gives 2 4 mm in t between the sprockets and so that it gives 2 4 mm in the middle Lock the motor he middle Lock the motor attachment and the sprocket Lightly grease attachment and the sp...

Page 110: ...rewed in and locked with stop screws The bearing pos 2 stop screws The bearing pos 2 and sprocket pos 3 should and sprocket pos 3 should be lightly lubricated with cold resistant grease 35 C see figur...

Page 111: ...ox TF Replacing the coupling between fork drive motor and gearbox TF 1 1 Di Dism sman antl tle e th the m e mot otor or s see ee see Replacing the fork drive motor TF on page 6 33 see Replacing the fo...

Page 112: ...nel over t l over the com he compon ponent bo ent box in x includi cluding all th ng all the clips h e clips holdi olding the c ng the cabl able e 5 5 Che Check t ck the ma he markin rkings a gs and p...

Page 113: ...d the play with the straddle lift it play with the straddle lift it its lower position should be max 1 5 mm and the its lower position should be max 1 5 mm and the reverse reverse 5 5 Check Check the...

Page 114: ...nd pull ou ll out the l t the load wh oad wheel p eel pull ull rods and pressure link rods and pressure link arm complete arm complete 4 4 T Tap o ap out t ut the s he shaf hafts f ts from rom the the...

Page 115: ...6 and check the residual suspension See table 6 6 Adjusting the length of side stabilisers Adjusting the length of side stabilisers Mec Mechan hanica ical ad l adjust justmen ment is m t is made ade...

Page 116: ...t ti io on n P Pl la ay y i in n m ma as st t T To oo o f fe ew w s sh hi im ms s o on n m ma as st t r ro ol ll le er rs s R Re e s sh hi im m The mast lowers The mast lowers unevenly jumps unevenly...

Page 117: ...tor Regulator steering steering servo servo motor motor 7 4 7 4 Repair Repair instructions instructions 7 5 7 5 Steer Steering ing wheel wheel step step motor motor sensor sensor 7 5 7 5 Replacement R...

Page 118: ...ATLET SERVICE MANUAL A ERGO ATLET SERVICE MANUAL A ERGO 7 2 7 2 https www besttruckmanuals com...

Page 119: ...sensor in the form of a steering takes place by means of a sensor in the form of a step motor under the steering step motor under the steering wheel The sensor gives a wheel The sensor gives a signal...

Page 120: ...g De Desi sig gn a n and nd fu fun nct cti io on n R Re eg gu ula lat tor or s ste tee er ri ing ng se ser rvo vo m mo oto tor r Regulator Regulator steering servo steering servo motor motor For infor...

Page 121: ...el sens ensor or 3 3 Uns Unscr crew t ew the s he ste teer erin ing wh g whee eel se l sens nsor or 4 4 Lift o Lift over ver the f the fixed ixed comp componen onents to ts to the n the new s ew stee...

Page 122: ...d 4 4 Unscre Unscrew the w the steer steering se ing servo m rvo motor g otor gearbo earbox and x and caref carefully re ully release lease it the it the comp componen onent t gears are loose gears ar...

Page 123: ...hoo oot tin ing g Re Repl plac acin ing t g the he st stee eeri ring ng se serv rvo s o sen enso sor r 7 7 7 7 Diagnosis and trouble shooting Diagnosis and trouble shooting See section 10 for See sect...

Page 124: ...ICE MANUAL A ERGO 7 7 8 8 St Ste eer eri ing ng D Di iag agno nosi sis a s and nd tr trou oubl ble s e sho hoot otin ing g Re Repl plac acin ing t g the he st stee eeri ring ng se serv rvo s o sen ens...

Page 125: ...4 valve 104014 2008w45 2008w45 8 4 8 4 Hydraulic Hydraulic diagram Manual diagram Manual valve 10 valve 104014 4014 2008w46 2008w46 8 6 8 6 Hydraulic diagram Hydraulic diagram Proportional Proportiona...

Page 126: ...in the electric hydraulic the electric hydraulic valve valve 8 28 8 28 Adjusting Adjusting the the working working pressure pressure 8 29 8 29 Emergency Emergency lowering lowering valve valve 8 29 8...

Page 127: ...ry so that the machine machine will be able to do will be able to do the work it is designed for the work it is designed for Warning Warning The pressure limiting valve must only be adjusted by author...

Page 128: ...d they are integrated as a valves and they are integrated as a function in the control valve function in the control valve instead see instead see Electric Electric control valve on page 8 2 control v...

Page 129: ...mp from the pump Lowering brake function Lowering brake function The pressure chamber is the heart of the electrical control valve The pressure chamber is the heart of the electrical control valve Imp...

Page 130: ...ra au ul li ic s c sy ys st tem em D De es si ig gn a n an nd f d fu un nc ct ti io on n H Hy yd dr ra au ul li ic d c di ia agr gram am Hydraulic diagram Manual valve 104014 2008w45 Hydraulic diagra...

Page 131: ...A ERGO SERVICE MANUAL A ERGO H Hyd ydr ra au ul li ic s c sys yst te em m D De esi sig gn a n an nd f d fu unc nct ti io on n H Hy yd dr ra au ul li ic d c di ia ag gr ra am m 8 8 5 5 https www besttr...

Page 132: ...ra au ul li ic s c sy ys st tem em D De es si ig gn a n an nd f d fu un nc ct ti io on n H Hy yd dr ra au ul li ic d c di ia agr gram am Hydraulic diagram Manual valve 104014 2008w46 Hydraulic diagra...

Page 133: ...A ERGO SERVICE MANUAL A ERGO H Hyd ydr ra au ul li ic s c sys yst te em m D De esi sig gn a n an nd f d fu unc nct ti io on n H Hy yd dr ra au ul li ic d c di ia ag gr ra am m 8 8 7 7 https www besttr...

Page 134: ...ul li ic s c sy ys st tem em D De es si ig gn a n an nd f d fu un nc ct ti io on n H Hy yd dr ra au ul li ic d c di ia agr gram am Hydraulic diagram Proportional valve 104005 2008w45 Hydraulic diagra...

Page 135: ...A ERGO SERVICE MANUAL A ERGO 8 8 9 9 H Hyd ydr ra au ul li ic s c sy ys st tem em D De es si ig gn a n an nd f d fu un nc ct ti io on n H Hy yd dr ra au ul li ic d c di ia agr gram am https www besttr...

Page 136: ...ra au uli lic s c sys yst tem em D De esi sig gn a n an nd f d fu un nct ctio ion n Hy Hyd dr ra au ul li ic d c di ia agr gram am Hydraulic diagram Proportional valve 104005 2008w46 Hydraulic diagram...

Page 137: ...L A ERGO SERVICE MANUAL A ERGO H Hyd ydra rau ul li ic s c sys yste tem D m De esi sig gn a n an nd f d fu unc ncti tio on H n Hyd ydra raul uli ic d c di ia ag gr ra am m 8 8 1 11 1 https www besttru...

Page 138: ...O 8 8 1 12 2 Hy Hyd dr ra au uli lic s c sys yst tem em D De esi sig gn a n an nd f d fu un nct ctio ion n Hy Hyd dr ra au ul li ic d c di ia agr gram am Hydraulic diagram ALL 104913 Hydraulic diagram...

Page 139: ...L A ERGO SERVICE MANUAL A ERGO H Hyd ydra rau ul li ic s c sys yste tem D m De esi sig gn a n an nd f d fu unc ncti tio on H n Hyd ydra raul uli ic d c di ia ag gr ra am m 8 8 1 13 3 https www besttru...

Page 140: ...ot p not perm ermitte itted d T Tak ake in e into co to cons nsid ider erat atio ion th n the sp e spec ecif ifie ied op d oper erat atin ing da g data ta Do n Do not e ot exc xcee eed p d per ermi mi...

Page 141: ...ot sealed Start up with low pressure and volume flows low pressure and volume flows T Test the function and ti est the function and tightness of the system Clean ghtness of the system Clean the system...

Page 142: ...out a t abr bras asio ion n L Lo on ng g s se er rv vi ic ce e l li if fe e Hig High v h visc iscosi osity ty ind index ex wi with w th wide ide ra range nge of of tem temper peratu ature re app appl...

Page 143: ...Important Make sure that the oil does not overflow in the tray The oil should be taken care of Make sure that the oil does not overflow in the tray The oil should be taken care of in accordance with e...

Page 144: ...Un Unsc scre rew t w the he ca cap on p on th the fi e filte lter ho r hou usin sing g 2 2 T Tak ake e ou out t t the he fi filt lter er 3 3 Wi Wipe cl pe clean th ean the filt e filter ho er housi us...

Page 145: ...in lter insert sert wait u wait until the ntil the oil ha oil has mana s managed to ged to run of run off the f f the filter ilter and t and then hen lift it out lift it out 5 5 Pu Pull ll th the f e...

Page 146: ...se 3 3 If the If the hydr hydraulic aulic pump pump sucks sucks air lo air lower d wer down a own all th ll the hyd e hydrauli raulic fun c function ctions to s to their their lower positions open the...

Page 147: ...ing using pos 1 and plug it pos 1 and plug it 4 4 Unscre Unscrew the w the lowe lowering sp ring speed v eed valve alve pos pos 2 an 2 and plug d plug the va the valve lve housi housing p ng pos os 1...

Page 148: ...02 2 7 7 5 5 9 9 6 6 1 10 0 A A 1 16 60 0 T T S SB B2 25 5C C 3 33 34 42 2 1 13 3 5 5 1 1 8 8 3 37 7 A A 1 16 60 0 T TV V S SB B2 25 5C C 3 33 34 42 2 1 13 3 5 5 1 1 8 8 3 37 7 A A 1 16 60 0 T TF FV V...

Page 149: ...d inder er 5 5 Uns Unscre crew t w the h he hos ose ru e ruptu pture v re valv alve p e pos os 1 fi 1 figur gure e 8 6 8 6 that is that is screwed into the cylinder screwed into the cylinder 6 6 If a...

Page 150: ...o op po or rt ti io on na al l v va al lv ve e L LB B3 3C C 3 37 79 91 1 2 2 4 4 8 80 0 A A 1 16 60 0 T TV V L LB B3 3C C 9 91 17 75 5 1 1 2 2 5 50 0 A A 1 16 60 0 2 20 00 0 T TF F T TF FV V F Fr re e...

Page 151: ...clea leane ned be d befor fore e installation installation W Weld elded o ed or ho r hot be t bent p nt pipes ipes sho should uld be p be pick ickled led an and wa d wash shed b ed befo efore t re the...

Page 152: ...ch s microswitch s 4 4 Loo Loose sen all th n all the oil p e oil pipe ipes con s connec nected t ted to the v o the valv alve an e and plu d plug the g them m 5 5 Loo Loose sen th n the va e valve lv...

Page 153: ...Loosen a sen all the o ll the oil pi il pipes c pes conn onnect ected to t ed to the va he valv lve and e and plu plug the g them m 6 6 Loo Loosen sen the the val valve ve from from the the tru truck...

Page 154: ...be checked first in the solenoid valves should be checked first in accordance with accordance with Adjusting Adjusting the regulator electric valve on page the regulator electric valve on page 8 28 8...

Page 155: ...tuated ted screw screw in the in the adjusting screw until the fork carriage begins to lift fr adjusting screw until the fork carriage begins to lift from the floor and then screw om the floor and the...

Page 156: ...o lic motor tor 4 4 Loos Loosen th en the re e retainin taining bol g bolts t ts that h hat hold old the p the pump ump at the at the hydra hydraulic ulic moto motor r 5 5 Loos Loosen an en and rem d...

Page 157: ...T fe The le he lengt ngth of t h of the b he brus rushes hes mus must t never be less than 10 mm a new brush has a never be less than 10 mm a new brush has a length of 17 mm Since this is diffi lengt...

Page 158: ...ush set separately to avoid set separately to avoid confusion Make sure that each brush set is replaced with the correct part i confusion Make sure that each brush set is replaced with the correct par...

Page 159: ...mm with the rotor resting in the bearing seats For the service life of the resting in the bearing seats For the service life of the commutator it is better to machine it a little and more often than...

Page 160: ...the the prete pretension nsion in th in the sp e spring ring unit unit 4 4 Pu Pull ll ou out t t the he ba batt tter ery p y plu lug g 5 5 Re Rele leas ase t e the he ho hose ses a s and nd pl plug u...

Page 161: ...xternally It is therefore important to straighten e important to straighten the end of the pipe and remove the burrs bot the end of the pipe and remove the burrs both internally and externally h inter...

Page 162: ...the nut can be extended with a piece of pipe Otherwise fit according to point 3 to point 3 If several couplings of the same type are to be fitted If several couplings of the same type are to be fitted...

Page 163: ...of the U ring spanner and without excessive force extension of the U ring spanner and without excessive force 7 7 If the p If the pipe ipe is to is to be b be bent aft ent after a er a coupl coupling...

Page 164: ...amp it secure secure The lift motor emits a The lift motor emits a screeching noise just screeching noise just before the fork carriage before the fork carriage reaches the top reaches the top The oil...

Page 165: ...ec ct t properties properties Con Condens densati ation in the o on in the oil tank il tank Drai Drain the oi n the oil out of th l out of the tank an e tank and fill d fill with new hydraulic oil to...

Page 166: ...SERVICE MANUAL A ERGO 8 8 40 40 Hy Hydr drau auli lic s c sys yst tem em Di Diag agno nosi sis a s and nd tr trou oubl ble s e sho hoot oti ing ng S Sym ympt ptom om an and A d Act cti ion on https ww...

Page 167: ...eeding of of cylinders wi cylinders without a thout air ir screw screw 9 4 9 4 Free lift Free lift cylinder cylinder TFV TFV DTFV DTFV 9 5 9 5 Dismantling Dismantling and and assembling assembling 9 5...

Page 168: ...ATLET SERVICE MANUAL A ERGO ATLET SERVICE MANUAL A ERGO 9 2 9 2 https www besttruckmanuals com...

Page 169: ...ders are pressed together by When the driver activates the lowering function the cylinders are pressed together by means of a control valve releasing oil out from the cylinders They are then pushed me...

Page 170: ...t there is s re is suffi ufficien cient oil in t oil in the hy the hydraul draulic tan ic tank and k and that th that the pu e pump do mp does no es not t suck air suck air 3 3 Caref Carefully ully ru...

Page 171: ...6 Lo Loos osen en an and d d dis isco conn nnec ect th t the oi e oil pi l pipe pe 7 7 Rem Remove ove th the c e clam lamp p and and lif lift ou t out th t the cy e cylin linder der 8 8 P Pl lu ug g...

Page 172: ...FV D DTF TFV V 9 9 Asse Assemble in mble in the rev the reverse o erse order rder Lub Lubricate ricate all pa all parts wi rts with hyd th hydraul raulic oil ic oil before before fitting fitting Figur...

Page 173: ...and lower it down onto the blocks blocks 2 2 Loo Loosen sen the the upp upper er reta retaini ining ng scr screws ews p pos os 1 1 see Figure 9 3 see Figure 9 3 3 3 Low Lower d er down own the the cy...

Page 174: ...cylin linder der in in a vi a vice ce Important Important Risk of deformation use moderate force Risk of deformation use moderate force 4 4 Pla Place a co ce a conta ntaine iner for o r for oil sp il...

Page 175: ...ift ft cy cyl li in nd der er T TV V T TFV FV DT DTF FV V 9 9 9 9 Note Note Always use original spare parts for maximum safety and service life Always use original spare parts for maximum safety and...

Page 176: ...everse the truck away 4 4 Place Place a wood a wooden b en block u lock under nder the in the inner m ner mast 1 ast 10 15 c 0 15 cm thi m thick a ck and ca nd careful refully lowe ly lower r the inne...

Page 177: ...place it ca e it carefully refully on th on the ben e bench to ch to avoi avoid d damaging it damaging it 4 4 Re Remo move t ve the p he par arts ts po pos 3 s 3 4 4 5 6 5 6 7 a 7 and 8 nd 8 5 5 Cle C...

Page 178: ...MANUAL A ERGO ATLET SERVICE MANUAL A ERGO 9 9 1 12 2 L Lif ift c t cyl yli ind nde er rs s R Rep epa ai ir i r in nst str ru uct cti io on ns s L Li ift ft cy cyl li in nde der T r T https www besttru...

Page 179: ...13 10 13 Function Function 10 13 10 13 Drive Drive motor motor regulator regulator AC1 AC1 10 15 10 15 Function Function drive drive motor motor regulator regulator AC1 AC1 10 15 10 15 Connector speci...

Page 180: ...52 Circuit Circuit diagram diagram 10 52 10 52 Wiring Wiring diagram diagram 10 52 10 52 Error Error codes codes 10 52 10 52 Multimeter Multimeter 10 52 10 52 Input Input and and output output specifi...

Page 181: ...rk able to rotate freely during work Electronic regulators Electronic regulators All e All elec lectron tronic r ic reg egula ulators tors in in the the tru truck h ck have ave mul multip tiple s le s...

Page 182: ...see Error codes steering servo regulator EPS on page 10 61 Error codes steering servo regulator EPS on page 10 61 The steering motor monitor system is checked by disconnecting a cable connection to th...

Page 183: ...it is motor circuit is not possible since it i not possible since it is a three phase motor and neither is s a three phase motor and neither is it necessary it necessary There are different systems th...

Page 184: ...regulator and the steering servo regulator can be checked or regulator and the steering servo regulator can be checked and adjusted by means of and adjusted by means of the six buttons on the the six...

Page 185: ...se e T To o s sc cr ro ol ll l d do ow wn n i in n t th he e m me en nu us s R RO OL LL L 1 1 T To o s sc cr ro ol ll l u up p i in n t th he e m me en nu us s R RO OL LL L 2 2 T To o g go o i in nt...

Page 186: ...resented through the Hand terminal see also presented through the Hand terminal see Error codes on Error codes on page 10 56 page 10 56 T To o s se el le ec ct t C CO ON NF FI IG G M ME EN NU U R RO O...

Page 187: ...lat ato or r 2 2 C Ca an nB Bu us s l li in nk k 3 3 S Ste teer erin ing s g ser ervo vo re regu gula lato tor r 4 4 Mu Mult lti F i Fun unkt ktio ion D n Dis ispl play ay M MDI DI 5 5 S Sp pe eed ed...

Page 188: ...on Display MDI 4 Display MDI 4 The controller units have a self diagnosis part The controller units have a self diagnosis part that can generate error codes These error that can generate error codes T...

Page 189: ...actor 8 which starts the lift lift motor 9 The drive motor regulator also forwards via the motor 9 The drive motor regulator also forwards via the CAN link 2 the magnitude CAN link 2 the magnitude of...

Page 190: ...l on the steering wheel 12 to the regulator for the steering 12 to the regulator for the steering servo motor 3 which in turn forwards a servo motor 3 which in turn forwards a proportional drive volta...

Page 191: ...ols The truck operating time error codes and the MDI The truck operating time error codes and the MDI software version are indicated on the software version are indicated on the alphanumeric display p...

Page 192: ...shown b wn brie riefly o fly on sta n start up rt up EP EPXXX w XXX wher here XXX e XXX rep repres resent ents s the version the version Other symbols Other symbols A to A tort rtoi oise se sh show o...

Page 193: ...the drive regulator regulator A A sensor increment sensor incremental encoder placed in t al encoder placed in the he motor with two phases displaced 90 is used for this If motor with two phases displ...

Page 194: ...AN N c co om mm mu un ni ic ca at ti io on n C CA AN N L Lo ow w E E1 1 8 8 N Ne eg g s su up pp pl ly y t to o L Li if ft t L Lo ow we er r c co on nt tr ro ol l B B E E1 1 9 9 P Po os s s su up pp...

Page 195: ...el E E2 2 6 6 N No ot t u us se ed d i in n t th he e A A mo mod del el E E2 2 7 7 P Pr ro op p v va al lv ve e Stabilisers up Stabilisers up Man valve Man valve Stabilisers up and down Stabilisers up...

Page 196: ...igure shows connector on the regulator Connector C figure shows connector on the regulator Figure 10 11 Figure 10 11 Connections battery and motor Connections battery and motor Table 10 4 Table 10 4 S...

Page 197: ...al menus Drive motor regulator D Di is sp pl la ay y w wi in nd do ow w D Di is sp pl la ay y w wi in nd do ow w AC1 ZAPI Vx x AC1 ZAPI Vx x 24V 250A 00000 24V 250A 00000 MAIN MENU MAIN MENU PARAMETER...

Page 198: ...s throttle demand is decreased decreased B BR RA AK KE E C CU UT TB BA AC CK K 5 5 5 5 5 5 5 5 5 5 B Br ra ak ke e t to or rq qu ue e w wh he en n s sp pe ee ed d reduction switch is reduction switch...

Page 199: ...4 1 10 00 0 1 10 00 0 1 10 00 0 1 10 00 0 1 10 00 0 M Ma ax xi im mu um m v vo ol lt ta ag ge e t to o other valves other valves V VA AL LV VE ES S V VO OL LT TA AG GE E 2 24 4 2 24 4 2 24 4 2 24 4 2...

Page 200: ...W H Hz z 6 67 7 7 72 2 7 78 8 8 89 9 9 94 4 9 99 9 1 10 09 9 1 11 14 4 1 11 19 9 1 12 24 4 M MA AX X S SP PE EE ED D B BW W H Hz z 6 67 7 7 72 2 7 78 8 8 89 9 9 94 4 9 99 9 1 10 09 9 1 11 14 4 1 11 1...

Page 201: ...4 0 0 6 6 0 0 8 8 1 1 0 0 1 1 2 2 1 1 4 4 1 1 6 6 1 1 8 8 2 2 0 0 V2 CLOSING V2 CLOSING RAMP RAMP S Se ec c 0 0 2 2 0 0 4 4 0 0 6 6 0 0 8 8 1 1 0 0 1 1 2 2 1 1 4 4 1 1 6 6 1 1 8 8 2 2 0 0 V3 CLOSING V...

Page 202: ...T TE ER RY Y C CH HA AR RG GE E C Ch ha ar rg gi in ng g s st ta at tu us s o of f t th he e b ba at tt te er ry y i in n T TE EM MP PE ER RA AT TU UR RE E C C T Th he e r re eg gu ul la at to or r t...

Page 203: ...ETERS Drive motor regulator RESTORE RESTORE PARAMETERS PARAMETERS All parameters stored in the Hand terminal All parameters stored in the Hand terminal memory can be downloaded in the regulator memory...

Page 204: ...l ly y s sw wi it tc ch h BRAKE BRAKE Pin E2 7 is used as input for brake Pin E2 7 is used as input for brake EXCLUSIVE EXCLUSIVE HYDRO HYDRO Pin E2 7 is used as Pin E2 7 is used as EXCLUSIVE HYDRO EX...

Page 205: ...relation to how much the brake pedal is pressed down The force in relation to how much the brake pedal is pressed down The minimum braking force is determined by the parameter Release minimum braking...

Page 206: ...m m t th he e l lo ow we er ri in ng g potentiometer when the lowering switch is potentiometer when the lowering switch is activated activated SET BATTERY SET BATTERY TYPE TYPE 24V 24V 36V 36V 48V 48V...

Page 207: ...down the ramp until the time set in the parameter slowly down the ramp until the time set in the parameter Auxiliary time has expired and then the electric brake is Auxiliary time has expired and the...

Page 208: ...ula lato tor r EP EPS S AC AC Steering servoregulator EPS AC Steering servoregulator EPS AC Figure 10 12 Figure 10 12 Steering servo regulator Steering servo regulator E3 E3 E4 E4 1 1 6 6 10 10 1 1 12...

Page 209: ...e regulator will s indicated the regulator will disconnect the drive to the drive motor disconnect the drive to the drive motor and allow the drive motor brake to pull and allow the drive motor brake...

Page 210: ...tion indicating releasing without the end position indicating releasing A third sensor S8 senses whether the wheel is A third sensor S8 senses whether the wheel is turned more than 45 degrees from tur...

Page 211: ...h E3 E3 4 4 No Not t us used ed i in t n th he A e A mo mod del el E E3 3 5 5 S Sp pe ee ed d r red edu uct cti io on n E3 E3 6 6 No Not t us used ed i in t n th he A e A mo mod del el E E3 3 7 7 F Fr...

Page 212: ...F Fr ro om m s st te ee er ri in ng g w wh he ee el l s se en ns so or r S St te ep p m mo ot to or r E E4 4 4 4 F Fr ro om m s st te ee er ri in ng g w wh he ee el l s se en ns so or r S St te ep p...

Page 213: ...otor regulator regulator Figure 10 16 Figure 10 16 Connector C the figure shows the connector from the cabling side Connector C the figure shows the connector from the cabling side Table 10 19 Table 1...

Page 214: ...ge 10 6 Table 10 20 Table 10 20 Main flow in the Hand terminal menus Main flow in the Hand terminal menus D Di is sp pl la ay y w wi in nd do ow w D Di is sp pl la ay y w wi in nd do ow w AC1 ZAPI V0...

Page 215: ...N No ot t u us se ed d C CO OM MPE PEN NS SA AT TI IO ON N 2 2 S Se et ts s t th he e c co omp mpe en ns sa at ti io on n f fo or r v vo ol lt tag age e d dr ro op p i in n c ca ab bl les es a an nd...

Page 216: ...ed in the reverse direction reverse direction The Hand terminal is used to The Hand terminal is used to calibrate the start position and max position see calibrate the start position and max position...

Page 217: ...rox 0 2 pprox 0 2 V from neutral can be appropriate V from neutral can be appropriate 9 9 P Pr re es ss s O OU UT T 10 10 Pre Press E ss ENTE NTER to s R to save t ave the v he valu alue e Press OUT i...

Page 218: ...MI EV MIN an N and re d repeat peat the procedure steps 8 to 12 in the the procedure steps 8 to 12 in the direction of the forks direction of the forks Step to SET ACC REV MAX and repeat Step to SET...

Page 219: ...control should provide 2 5 V control should provide 2 5 V When the lever When the lever is moved to is moved to lifting lifting position the voltage increases to 4 5V and decreases to 1 0 V when lower...

Page 220: ...Press OUT if the value is NOT to Press OUT if the value is NOT to be be saved saved 1 11 1 The The di displ splay ay no now s w show hows s CONFIG MENU CONFIG MENU ADJUSTMENT ADJUSTMENT 12 12 Pre Pre...

Page 221: ...he lifting lowering control is now calibrated The lifting lowering control is now calibrated 19 19 The The dis displa play n y now ow sho shows ws CONFIG MENU CONFIG MENU ADJUSTMENT ADJUSTMENT 20 20 R...

Page 222: ...NS NS 3 3 Ba Batte ttery ry le leve vel B l BA ATT TTER ERY L Y LEV EVEL EL I In ns st tr ru uc ct ti io on ns s D Di is sp pl la ay y a an nd d k ke ey yb bo oa ar rd d 1 1 Co Conn nnec ect th t the...

Page 223: ...ws wha hat is t is sa save ved wh d whil ile it e it is carried out is carried out READING READING ACCELER DELAY ECC ACCELER DELAY ECC 9 9 Wh When en ev ever eryt ythi hing i ng is re s read ady th y...

Page 224: ...be All the values in the regulator memory will be overwritten with the parameters in overwritten with the parameters in the Hand terminal the Hand terminal I In ns st tr ru uc ct ti io on ns s D Di is...

Page 225: ...on the display the display ARE YOU SURE ARE YOU SURE YES YES ENTER ENTER NO NO OUT OUT 9 9 Th The di e disp spla lay s y sho hows w ws wha hat is t is sa save ved wh d whil ile it e it is carried out...

Page 226: ...00000 24V 250A 00000 2 2 Af Afte ter st r star art up t up pr pres ess bu s butt tton on 3 E 3 ENT NTER t ER to o enter the MAIN MENU enter the MAIN MENU MAIN MENU MAIN MENU PARAMETER CHANGE PARAMETER...

Page 227: ...m em R Rep epai air i r ins nstr truc ucti tion ons s Ch Chec ecki king ng er erro ror r co code des s 10 10 4 49 9 10 10 Press Press OUT to OUT to exit exit the A the ALARM LARM windo window w AC1 ZA...

Page 228: ...lean the contact surface between the Scrape clean the contact surface between the regulator regulator and attachment plate and attachment plate 8 8 Steering servo regulator Steering servo regulator Ap...

Page 229: ...ng servo sensor 1 1 Scre Screw in the w in the sen sensor a sor and fol nd follow th low the ca e cable s ble so that o that it doe it does no s not twist t twist until until it meet it meets s th the...

Page 230: ...upplied with each truck or can be found in can be found in a separate Wiring a separate Wiring Diagram Handbook Diagram Handbook Error codes Error codes Error codes are read off on the MDI see Error c...

Page 231: ...ng 10 10 5 53 3 Input and output specification Input and output specification Pin numbering in contactors see Pin numbering in contactors see Connector E1 drive motor regulator AC1 Connector E1 drive...

Page 232: ...itch switch Submenu TEST Submenu TESTER Drive ER Drive motor regulator on page 10 24 motor regulator on page 10 24 and the output and the output signal from signal from the speed the speed controller...

Page 233: ...a essages ges see see Error codes on page 10 56 Error codes on page 10 56 2 2 Che Check ck th the e sy syste stem m se setti tting ngs s wi with th Delivery Settings in Drive Controller A with Zapi De...

Page 234: ...ring servo regulator on Error codes steering servo regulator on page 10 61 page 10 61 1 16 6 M Mu ul lt ti i F Fu un nc ct ti io on n D Di is sp pl la ay y S Se ee e t ta ab bl le e 10 25 10 25 below...

Page 235: ...s has di disa sapp ppear eared ed note that all adjustable parameters note that all adjustable parameters have gone back to the default have gone back to the default values and that a new setting must...

Page 236: ...motor speed feedback sensor Encoder Encoder 1 1 Chec Check the k the enco encoder si der signal w gnal with ith the the Hand terminal Hand terminal 2 2 Chec Check cab k cablin ling bet g between ween...

Page 237: ...his error code indicates that there This error code indicates that there is a fault in the cables to the speed is a fault in the cables to the speed controller potentiometer controller potentiometer C...

Page 238: ...the steering servo contact E3 11 From there is goes via the E3 11 From there is goes via the CAN system to the drive regulator CAN system to the drive regulator and is compared with the primary and is...

Page 239: ...tor If the error persists replace regulator 0 06 6A A1 17 7 L LO OG GI IC C FAILURE 3 FAILURE 3 Internal error steering servo Internal error steering servo regulator regulator High rest potential betw...

Page 240: ...bov ove er e error rors a s are re found replace regulator found replace regulator 0 06 6A A4 40 0 K KS O S OP PE EN N O Occ ccu ur rs w s wh he en n sa saf fe et ty y c co on nt tac act t o op pe en...

Page 241: ...N Occurs when the operator changes Occurs when the operator changes ADJUSTMENT 1 to level 1 ADJUSTMENT 1 to level 1 Switching the key off and on resets Switching the key off and on resets the alarm t...

Page 242: ...A ERGO ATLET SERVICE MANUAL A ERGO 10 10 6 64 4 El Elec ectr tric ical al sy syst stem em Di Diag agno nosi sis a s and nd tr trou oubl ble e sh shoo ooti ting ng Er Erro ror c r cod odes es https www...

Page 243: ...tric electric brake brake 2006w46 2006w46 11 4 11 4 Adjusting Adjusting the the electric electric brake brake 2006w47 2006w47 11 4 11 4 Replacing the Replacing the magnetic part magnetic part electric...

Page 244: ...ATLET SERVICE MANUAL A ERGO ATLET SERVICE MANUAL A ERGO 11 2 11 2 https www besttruckmanuals com...

Page 245: ...springs press on the plate which is pressed axially to the the rotor rotor When the brake is to be released the coil is su When the brake is to be released the coil is supplied with battery voltage pp...

Page 246: ...m 2006 w47 is adjusted at the factory Electric brake in new design from 2006 w47 is adjusted at the factory and cannot be and cannot be 1 1 Fit Fit the the ele electri ctric b c brak rake a e and nd t...

Page 247: ...e see figure 11 1 11 1 Warning Warning Remember to lock any adjustments Remember to lock any adjustments arn ng arn ng Check that you have a Check that you have a safe braking capacity safe braking ca...

Page 248: ...and r c and refit th efit the mag e magnetic p netic part art Tig Tighten t hten the th he three re ree retainin taining g screws at 9 5 Nm screws at 9 5 Nm 11 11 6 6 Br Brak ake e an and d sp spee e...

Page 249: ...ere necessary Note Note If the If the brake is released manually there is brake is released manually there is no working parking or emergency brake no working parking or emergency brake Never leave a...

Page 250: ...y measuring it or by measuring it connected in the system and supplied with voltage connected in the system and supplied with voltage W We recommend measuring the switch e recommend measuring the swit...

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