Atlet Low Picking Truck PPC 120, PPD 200, PPD 250, PPF 120, PPL 200, PPL 250, PPS 200 Workshop Service Manual

SERVICE MANUAL Machine: PP* Manual No: 119036 SERVICEMANUAL Edition 2010A 1 General information and technical data Service manual scope ................................................................................................... 1.3 General ................................................................................................................ 1.3 Scope of P series ................................................................................................ 1.3 How to use the manual .................................................................................................. 1.4 Structure .............................................................................................................. 1.4 Symbol key .......................................................................................................... 1.4 Safety instructions ......................................................................................................... 1.5 General ................................................................................................................ 1.5 Truck modification ............................................................................................... 1.6 Lifting the truck .................................................................................................... 1.6 Welding of truck ................................................................................................... 1.8 Atlet cares about the environment ....................................................................... 1.8 Environmental impact .......................................................................................... 1.8 Waste .................................................................................................................. 1.8 Preparations ................................................................................................................... 1.9 Service ................................................................................................................. 1.9 Troubleshooting ................................................................................................... 1.9 Data PP* ........................................................................................................................ 1.10 Designations ...................................................................................................... 1.10 Dimensions and weights .................................................................................... 1.14 Component specifications .............................................................................. 1.16 Recommended incidental material ............................................................................. 1.18 Oil and grease ................................................................................................... 1.18 Standards and abbreviations ...................................................................................... 1.19 Screws ............................................................................................................... 1.19

1.2 / / SERVICEMANUAL Tightening torque for hydraulic connections ...................................................... 1.21 Conversion tables .............................................................................................. 1.21 Standard abbreviations ...................................................................................... 1.22 Colour of truck .................................................................................................... 1.22 Colour codes cabling ......................................................................................... 1.23 Designations ...................................................................................................... 1.23

General information and technical data / Service manual scope 1.3 SERVICE MANUAL 01_SM_PPX_En_119036_2010A.fm Edition 2010A 1 General information and technical data Service manual scope General This manual describes the service procedure for ATLET Low Picking Truck PP*. Use the manual for quick and correct service of respective truck models. You may find inconsistencies in the manual compared to the models supplied due to optional designs, upgrades and the like. 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. We reserve the right to make alterations. In the event of contradictory 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 P series This manual covers the Low Picking Trucks PPC, PPD, PPL, PPF and PPS. For a description, see Table 1.1 “Truck designations” on page 10.

1.4 General information and technical data / How to use the manual SERVICE MANUAL How to use the manual Structure The manual is arranged according to the same principles as ATLET's spare part catalogues, with the truck divided into one subsystem per Tab. Tabs 1-3 in this manual contain comprehensive information regarding technical data, service instructions and tools. Tabs 4-12 in the manual contain information limited to a specific part of the truck dealing with the mechanical operation of the various components, for example, Masts (Tab 6) and Hydraulic System (Tab 8). The software is described under Tab 10. The main principle for extra accessories is to place them under the relevant Tab. Otherwise they are placed under Tab 12 “Miscellaneous”. For this reason Tab 12 is not always included in the Service Manual. For specific problems and information about procedures, look in the main index for the correct section in the manual. Symbol key Warning! Indicates risk of personal injury. Important! Indicates risk of damage to truck. Note! Indicates general observations.

General information and technical data / Safety instructions 1.5 SERVICE MANUAL Safety instructions General Extreme importance must be placed on precautionary measures to avoid accidents during all work on the vehicle. A general rule is always to 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 should be observed. • Always lift the drive wheel free from the floor during service work to prevent the vehicle from moving. • Remove the battery plug before working on the electrical system. The battery plug may only be connected while troubleshooting, and when the greatest of care is exercised, (with the truck raised). • In order to avoid crushing injuries, always remove the battery plug when working on or around masts and hydraulic units. The mast or hydraulic unit may be actuated due to an electrical fault or a mistake while working. Warning! Having live current connected to the truck when working on and around the mast can be fatal! • When working on and around the lifting device and 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-incidents from the truck making an unexpected manoeuvre. • The system should not be pressurised, e.g. the pump motor shut off and the forks in lowest position, when dismantling parts of the hydraulic system. • Remove all metal objects such as watches, chains, glasses and rings when working on the electrical system, or in its immediate vicinity. A short-circuit from such objects may result in serious burn injuries. Warning! Great caution must be observed when dismantling the gas springs. 1. Make sure that no other persons are in the vicinity or in the lengthwise direction of the gas spring.

1.6 General information and technical data / Safety instructions SERVICE MANUAL 2. Stand to the side of the gas spring when removing. Never point the gas spring at any person or part of the body. 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 ATLET, its authorized representative, or a successor thereof. Contact an authorized ATLET 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 of ATLET, 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 ATLET 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. Lifting the truck Inspection/Preparations • When the truck is lifted using a jack, make sure you secure it with blocks. The truck must not rest on the jack while work is carried out. • Ensure that straps, wires or chains have a sufficient lifting capacity before lifting the truck. • Ensure that the drive wheel runs free of the floor before troubleshooting the electrics.

General information and technical data / Safety instructions 1.7 SERVICE MANUAL Permitted lifting points Figure 1.1 shows where the permitted lifting points are located on the truck. Warning! Never lift the truck using points other than those specified. . Figure 1.2 shows where the jack is to be placed. Figure 1.1 Permitted lifting points Figure 1.2 Lifting point, jack SM_PPX_01_0001A.eps

1.8 General information and technical data / Safety instructions SERVICE MANUAL Welding of truck • For welding work, always disconnect the battery plug along with all connections to controllers and regulators (applies to all electronic units). Following completion of the welding work, connect all connectors to the electronic units first, followed by the battery plug to the battery. • Always connect the return current clamp as close to the welding area as possible to eliminate damage to surrounding components. Atlet cares about the environment The majority of our products consist of metal, and can be fully recycled. Environmental impact All products have an impact on the environment throughout their entire life cycle. The consumption of energy during their use is one of the most important factors that influences the environment. Through correct care, maintenance and use, the consumption of energy can be reduced, thereby alleviating the environmental impact. Waste Waste material in conjunction with repairs, maintenance, cleaning, or scrapping, must be collected and disposed of in an environment-friendly way and in accordance with the directives of the relevant country. Only carry out this type of work in areas intended for this purpose. Recyclable material should be taken care of by specialists. Environmentally hazardous waste, such as oil filters, batteries and electronics, can have a negative effect on the environment, or health, if handled incorrectly.

General information and technical data / Preparations 1.9 SERVICE MANUAL Preparations Service • Go through all safety instructions • Make sure that you have all the essential tools close at hand before starting work. • Before disconnecting cabling or other electrical components, check the colour codes and check for damage to cables or connections. • When complex components are repaired and dismantled, work methodically to avoid the risk of mixing component parts. • 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 relevant Tab for detailed information. Troubleshooting When you suspect a faulty component, do not replace it immediately. Start by checking the surrounding equipment and then run a complete troubleshooting procedure as specified in the troubleshooting chart. Make sure you know the reason for the fault before replacing a component.

1.10 General information and technical data / Data PP* SERVICE MANUAL Data PP* Designations Truck designation *See Key to model designation on page 13. Table 1.1 Truck designations Truck type PPL Low picking truck, low-lifters PPD Low picking truck, low-lifters+driver-lift PPF Low picking truck, fork-lift PPC Low picking truck, fork-lift+driver-lift PPS Low picking truck, scissor lift PPS D* Low picking truck, scissor lift + operator lift Load capacity PPL 2000 kg PPD 2000 kg PPF 1200 kg PPC 1200 kg PPS 2000 kg

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Atlet Low Picking Truck PPC 120, PPD 200, PPD 250, PPF 120, PPL 200, PPL 250, PPS 200 Workshop Service Manual

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