Atlet Reach Truck Type A-Ergo: A160DTFV, A160T, A160TF, A160TFV, A160TV, A200DTFV, A200TF, A200TFV Workshop Service Manual

SERVICE MANUAL Machine: A-Ergo Manual No: 005975 ATLET SERVICE MANUAL A-ERGO Edition 2010A 1 General information and technical data Scope, service manual .................................................................................................. 1.3 General ................................................................................................................ 1.3 Scope of the A-Ergo model ................................................................................. 1.3 How to use the manual .................................................................................................. 1.4 Structure .............................................................................................................. 1.4 History ................................................................................................................. 1.4 Symbol key .......................................................................................................... 1.4 Safety instructions ......................................................................................................... 1.5 General ................................................................................................................ 1.5 Truck modification ............................................................................................... 1.6 Lifting the truck .................................................................................................... 1.7 Checks/Preparations ...................................................................................................... 1.7 Permitted lifting points .................................................................................................... 1.7 Welding on the truck ............................................................................................ 1.8 Taking the environment into consideration .......................................................... 1.8 Preparations ................................................................................................................... 1.9 Service ................................................................................................................. 1.9 Trouble shooting .................................................................................................. 1.9 Data A-Ergo ................................................................................................................... 1.10 Designations ...................................................................................................... 1.10 Truck designation ......................................................................................................... 1.10 Type designation .......................................................................................................... 1.11 Dimensions and weights .................................................................................... 1.15 Dimensions A-Ergo ...................................................................................................... 1.15 Component specification ................................................................................... 1.16 Recommended consumable material ......................................................................... 1.17

ATLET SERVICE MANUAL A-ERGO 1.2 Oil and grease .................................................................................................... 1.17 Standards and abbreviations ....................................................................................... 1.18 Screws ............................................................................................................... 1.18 Tightening torque, screws and nuts .............................................................................. 1.18 Tightening torque, hydraulic couplings ......................................................................... 1.19 Conversion table ........................................................................................................... 1.19 Screw types and tensile grades .................................................................................... 1.20 Colour of the truck .............................................................................................. 1.21 Colour codes, cabling ........................................................................................ 1.21 Designations, electrical components ................................................................. 1.22 Standard abbreviations ...................................................................................... 1.23

General information and technical data / Scope, service manual / General 1.3 ATLET SERVICE MANUAL A-ERGO SMA-Ergo_01_2010A.fm Edition 2010A 1 General information and technical data Scope, service manual General This manual describes the service procedures for ATLET stand-on stackers in the A-Ergo series. Use the manual for quick and correct service of respective truck models. The manual describes models manufactured from and including the introduction of A- Ergo at the end of 2002. You may find contradictions in the manual compared with the models supplied due to optional designs, upgrades and the like. Warning! If the truck is rebuilt after delivery or supplemented in such a manner that safety may be affected, ATLET AB or its authorised representative should be contacted. The electrical system must never be rewired in any form after delivery without written authorisation from Atlet AB, since this may change the measured and applicable EMC. The content of this service manual is protected by copyright law and may not be copied, fully or in part, without written permission. The material has undergone careful examination with regard to correctness. Subject to alteration. In the event of inconsistent information in the Swedish and translated editions, it is the Swedish edition that applies. Modifications and updates will be distributed via ATLET AB Service Manual Change. Scope of the A-Ergo model The stand-on stacker trucks in the A-Ergo series are available in a number of different variants with mast system, straddle lift, extendable stabilisors and telescopic forks (ATF).

1.4 General information and technical data / How to use the manual / Structure ATLET SERVICE MANUAL A-ERGO How to use the manual Structure The manual is built up according to the same principle as ATLET spare parts catalogues, with the truck divided into one subsystem per section. Sections 1 - 3 in this manual contain comprehensive information regarding technical data, service instructions and tools. Sections 4-12 in the manual contain information limited to a specific area in the truck concerning a description of the mechanical handling of different components. For example, Masts (section 6) and Hydraulic System (section 8). With regard to software this is described under section 10. The main principle for extra accessories is to place them under the respective sections. Otherwise they are placed under section 12 “Miscellaneous”. For this reason section 12 is not always included in the Service Manual. For specific problems or information about procedures, look in the main index for the correct section in the manual. History The following modifications affect the service procedure. Symbol key Warning! Used if there is a risk of personal injury. Important! Used if there is a risk of damage to machine. Note! Used for general observation. Table 1.1 Upgrades of the truck that affect the service procedure Date Chassis no. Event

General information and technical data / Safety instructions / General 1.5 ATLET SERVICE MANUAL A-ERGO Safety instructions General Extreme importance must be placed on precautionary measures to avoid accidents during all work on the vehicle. A general rule is to always implement preventive measures that are adapted to the type of vehicle to be worked on. The general rules below must always be observed: • Smoking or naked flames are strictly forbidden as there is a risk of explosion in the vicinity of batteries and while working on gas equipped vehicles. • The battery should always be protected during grinding work. • Local fire regulations must be followed. • The drive wheel should always be lifted up free from the floor during service work to prevent the vehicle from moving. • Before working on the electrical system the battery plug should be pulled out. • To prevent injuries caused by crushing the battery plug should always be removed when working on or around the mast and hydraulic unit. The mast or hydraulic unit can be actuated due to an electrical fault or a mistake while working. The battery plug may only be connected while trouble shooting, and when the greatest of care is exercised, (with the truck raised). Warning! Having the power connected to the truck when working on or around the mast can result in fatal injury! • When working on or around the mast and the hydraulic unit, they must be locked by using the mast lock, wooden blocks or some other appropriate means. • No other persons should be in the vicinity of the truck when it is test run in conjunction with repair work, in view of the risk of accidents or near-accidents from the truck making an unexpected manoeuvre. • The system should not be pressurised, e.g. the pump motor shutoff and the forks down, when dismantling parts of the hydraulic system. • All metal objects such as watches and rings should be removed when working on the electrical system, or in its immediate vicinity. A short-circuit from such objects can result in serious burn injuries.

1.6 General information and technical data / Safety instructions / Truck modification ATLET SERVICE MANUAL A-ERGO Truck modification Note! Unauthorized truck modification is not permitted. No modifications or alterations to a powered industrial truck, which may affect, for example, capacity, stability or safety requirements of the truck shall be made without the prior written approval of the truck manufacturer, its authorized representative, or a successor thereof. Contact an authorized dealer before making any modification or alteration to your industrial truck that may affect, for example braking, steering, visibility and the addition of removable attachments. After getting approval from the truck manufacturer, its authorized representative, or a successor thereof, capacity plate, decals tags and operation and maintenance handbooks shall also be changed to the appropriate one. Only in the event that the truck manufacturer is no longer in business and there is no successor in the interest to the business, the user may arrange for a modification or alteration to a powered industrial truck, provided, however, that the user shall: A Arrange for the modification or alteration to be designed, tested and implemented by an engineer(s) expert in industrial trucks and their safety; B Maintain a permanent record of the design, test(s) and implementation of the modification or alteration; C Approve and make appropriate changes to the capacity plate(s), decals, tags and Instruction Handbook; D Affix a permanent and readily visible label to the truck stating the manner in which the truck has been modified or altered together with the date of the modification or alteration, and the name and address of the organization that accomplished the tasks.

General information and technical data / Safety instructions / Lifting the truck 1.7 ATLET SERVICE MANUAL A-ERGO Lifting the truck Checks/Preparations • When the truck is lifted by using a jack, make sure you secure it with blocks. The truck must not rest on the jack, while work is carried out. • Ensure that straps, wires or chains have a sufficient lifting capacity before lifting the truck. • Ensure that the drive wheel runs free of the floor before trouble shooting. Permitted lifting points Figure 1.1 shows where the permitted lifting points are placed on the truck. The lifting points are marked with a decal representing a lifting hook; the lifting holes in the outer mast should be used. Warning! The machine must never be lifted from the overhead guard. Figure 1.1 Permitted lifting points, A-Ergo 01001_SM_A-Ergo.eps

1.8 General information and technical data / Safety instructions / Welding on the truck ATLET SERVICE MANUAL A-ERGO Welding on the truck • During welding work the battery plug should always be disconnected and all connections to the control units and regulators (concerns all electronic units) should be disconnected. On completion of welding work the connectors should first be connected to the electronic units, after which the battery plug is connected to the battery. • The welding earth should always be connected as close to the welding area as possible to eliminate damage to surrounding components. Taking the environment into consideration Atlet AB takes care of the environment. Waste material in conjunction with repairs, maintenance, cleaning, or scrapping, should be collected and disposed of in an environment-friendly way and in accordance with the directives of respective countries. Such work must only be carried out in areas intended for this purpose. Environmentally hazardous waste, such as oil filters, batteries, hydraulic hoses and electronics, can have a negative effect on the environment, or health, if handled incorrectly. Recyclable material should be taken care of by specialised authorities.

General information and technical data / Preparations / Service 1.9 ATLET SERVICE MANUAL A-ERGO Preparations Service • Go through all the safety instructions. • Make sure that you have all the essential tools close at hand before starting work. • Before cabling or other electrical components are disconnected, check the colour codes and check for damage to cables or connections. • When complex components are repaired and dismantled, make sure that you have good control of the different component parts to avoid the risk of confusion. • When repairing or maintaining sensitive components, make sure that you use clean tools and work on a clean work surface. • Dismantle, inspect and adjust components according to the prescribed routines. See respective sections for detailed information. Trouble shooting When you suspect a faulty component, do not replace it immediately. First check the surrounding equipment and carry out complete trouble shooting routines. Make sure you know the reason for the fault before replacing a component.

1.10 General information and technical data / Data A-Ergo / Designations ATLET SERVICE MANUAL A-ERGO Data A-Ergo Designations Truck designation Table 1.2 Truck designations Truck type A-Ergo Stand-on stacker, Standard A-Ergo TF Stand-on stacker with telescopic forks Load capacity A-Ergo 1600 or 2000 kg A-Ergo TF 1000 kg

Atlet Reach Truck Type A-Ergo: A160DTFV, A160T, A160TF, A160TFV, A160TV, A200DTFV, A200TF, A200TFV Workshop Service Manual

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