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ATLET SERVICE MANUAL A-ERGO

SERVICE MANUAL

Mac

Machi

hine:

ne: A-E

A-Ergo

rgo

Man

Manual

ual No:

No: 00

00597

5975

Edition 2009A

8 Hydraulic

Hydraulic system

system

Design

Design and

and function

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

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

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

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

................... 8.1

8.1

General

General ...................

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

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

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

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

......... 8.1

8.1

Lift

Lift ..............................................................................

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

..................................................... 8.1

8.1

Lower

Lower ...........................................................

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

................................................................... 8.1

8.1

Hose

Hose rupture

rupture valve ..................................

valve ......................................................

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

.................... 8.2

8.2

Lowering

Lowering brake

brake valve

valve ................

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

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

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

........... 8.2

8.2

Mechanical

Mechanical control

control valve

valve ...................

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

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

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

...................... 8.2

8.2

General

General ......................................................................

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

..................................................... 8.2

8.2

Lifting

Lifting function

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

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

.................................. 8.2

8.2

Lowering

Lowering function

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

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

..................................................... 8.2

8.2

Electric

Electric control

control valve

valve .................

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

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

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

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

......... 8.2

8.2

General

General ......................................................................

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

..................................................... 8.2

8.2

Lifting

Lifting function

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

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

.................................. 8.3

8.3

Lowering

Lowering function

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

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

..................................................... 8.3

8.3

Lowering

Lowering brake

brake function ......................................................................

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

........................... 8.3

8.3

Hydraulic

Hydraulic diagram

diagram ....................

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

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

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

.......... 8.3

8.3

Hydraulic

Hydraulic diagram, Manual

diagram, Manual valve 104014

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

Proportional valve 104005

valve 104005 (–2008w45) ...........................................

(–2008w45) ........................................... 8.8

8.8

Hydraulic diagram, Proportional

Hydraulic diagram, Proportional valve 104005

valve 104005 (2008w46–) .........................................

(2008w46–) ......................................... 8.10

8.10

Hydraulic

Hydraulic diagram,

diagram, ALL

ALL 104913 .................................................................

104913 ...................................................................................

.................. 8.12

8.12

Repair

Repair instructions

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

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

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

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

................... 8.14

8.14

Hydraulic

Hydraulic system

system .....................

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

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

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

....... 8.14

8.14

General

General rules

rules ....................................................................

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

............................................ 8.14

8.14

Installation

Installation ........................................................................

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

............................................ 8.14

8.14

Connections

Connections ..........................................................................

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

....................................... 8.15

8.15

Start

Start up

up ...............................................................

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

.......................................................... 8.15

8.15

Hydraulic

Hydraulic oil,

oil, changing/draining

changing/draining ....................

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

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

........ 8.16

8.16

Properties of

Properties of the

the hydraulic oil .......................................................................................

hydraulic oil ....................................................................................... 8.16

8.16

Requisite

Requisite equipment

equipment ........................................................................................

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

............. 8.16

8.16

Procedure

Procedure .....................................................................................

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

................................ 8.17

8.17

Air

Air filter,

filter, replacing

replacing .....................

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

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

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

........ 8.18

8.18

Oil

Oil filter

filter insert,

insert, replacement

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

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

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

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

.................. 8.19

8.19

Checking

Checking the

the hydraulic

hydraulic oil

oil level

level ....................

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

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

........ 8.20

8.20

https://www.besttruckmanuals.com/

Содержание A-Ergo

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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ATLET A-Ergo, Руководство по обслуживанию

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