Atlet Pallet Stackers PS 125, PSH 160, PSH 200 Workshop Service Manual

01 General information and technical data PS/PSH 1 01 GENERAL INFORMATION AND TECHNICAL DATA 1.1 Introduction 3 1.1.1 General .............................................................................................................................. 3 1.1.2 The trucks .......................................................................................................................... 3 1.1.3 Structure of the Manual ..................................................................................................... 3 1.1.4 Symbol key ........................................................................................................................ 3 1.2 Safety 3 1.2.1 General .............................................................................................................................. 3 1.2.2 Truck modification.............................................................................................................. 5 1.2.3 Lifting the truck .................................................................................................................. 6 1.2.4 Welding on the truck .......................................................................................................... 6 1.2.5 Gas spring ......................................................................................................................... 6 1.3 Environmental considerations 7 1.3.1 We respect the environment .............................................................................................. 7 1.4 Preparations 7 1.4.1 Service............................................................................................................................... 7 1.4.2 Trouble shooting ................................................................................................................ 7 1.5 Data 8 1.5.1 Designations ...................................................................................................................... 8 1.5.2 Dimensions and weights................................................................................................... 11 1.6 Component specification 12 1.7 Recommended consumable materials 12 1.7.1 Oil and grease types........................................................................................................ 12 1.8 Standards and abbreviations 13 1.8.1 Screws ............................................................................................................................. 13 1.8.2 Standard abbreviations and units .................................................................................... 14 1.8.3 Screw types and tensile grades....................................................................................... 14 1.8.4 Colour coding according to NCS ..................................................................................... 15 1.8.5 Colour codes for wiring diagrams .................................................................................... 15 1.8.6 Designations for electrical components ........................................................................... 16

01 General information and technical data 2 PS/PSH

01 General information and technical data PS/PSH 3 01 GENERAL INFORMATION AND TECHNICAL DATA 1.1 Introduction 1.1.1 General This manual describes the service procedures for Atlet stackers. Use the manual for quick and correct service of respective truck models. You may find contradictions in this Manual compared to the models supplied due to special design features, upgrades, and other detail differences. The content of this 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 Service Manual Change. 1.1.2 The trucks The manual covers the PS and PSH stackers which are included in the P series of stackers and low lifters . 1.1.3 Structure of the Manual The manual is arranged in accordance with the same principles as the Atlet spare part catalogues, i.e. a system consisting of 12 Chapters, where Chapters 4 - 12 contain information limited to specific parts of the truck. For example the Mast (Chapter 6) and Hydraulic System (Chapter 8). Chapters 1 - 3 in this Manual contain more general information regarding technical data, general service instructions and tools. The software is described in Chapter 10. The main principle for extra accessories is to place them in their respective Chapters. Otherwise they are placed in Chapter 12 "Miscellaneous". For this reason Chapter 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. 1.1.4 Symbol key WARNING! Used for risk of personal injury. CAUTION! Used with the risk of damage to the machine. NOTE! Used for general observation. 1.2 Safety 1.2.1 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:

01 General information and technical data 4 PS/PSH • Local fire directives should always be followed. • 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. • The drive wheel must 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 must be pulled out The battery plug may only be connected while trouble shooting, while taking great care (with the truck raised). • It is essential that all cables (especially the battery cables) are connected correctly as the electronics used in the truck are sensitive to incorrectly polarised supply voltage. • When working on or close by the electrical system, all metal objects such as watches and rings should be taken off. A short-circuit from such objects can result in serious burn injuries. • To ensure correct operation, all dust and magnetic particles should be regularly cleaned off solenoid switches and magnets. • To prevent injuries caused by crushing the battery plug should always be removed when working on and around the mast and hydraulic unit. The mast or hydraulic unit can be actuated and move due to an electrical fault or a mistake while working. The battery plug may only be connected while trouble shooting, while taking great care (with the truck raised). WARNING! Having the power connected to the truck while working on and around the mast can lead to fatal injury! • When working on and around lifting devices 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. • Ensure that straps, wires or chains have a sufficient lifting capacity before lifting the truck. • 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.

01 General information and technical data PS/PSH 5 • The system should not be pressurised, e.g. the pump motor shut off and the forks down, when dismantling parts of the hydraulic system. Figure 1. Emergency release valve in the hydraulic unit. • If the forks need to be released in an emergency, due to a short-circuit or similar occurrence. Press the emergency release valve in the hydraulic unit. • Always use Atlet genuine spare parts. This ensures correct and safe operation of the truck and is a condition for any guarantee claim to succeed. Anyone using non-approved spare parts must accept, without exception, full responsibility for any resulting damage. Hydraulic hoses should be kept so that they do not age too quickly. • Only service personnnel who have been authorised by Atlet, shouldcarry out servicing and maintenance. Atlet cannot accept responsibility for servicing or maintenance that is carried out by personnel who have not been authorised. 1.2.2 Truck modification NOTE! Unauthorized truck modification is not permitted. No modifications or alterations to a powered industrial fork lift truck, which may affect, for example, the 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 obtaining approval from the truck manufacturer, its authorized representative, or a successor thereof, the capacity plate, decals, labels and operation and maintenance handbooks shall also be changed appropriately. 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: • Arrange for the modification or alteration to be designed, tested and implemented by an engineer(s) expert in industrial trucks and their safety; • Maintain a permanent record of the design, test(s) and implementation of the modification or alteration;

01 General information and technical data 6 PS/PSH • Approve measures and in an equivalent manner make appropriate changes to the capacity plate(s), decals, labels and Instruction Handbooks. • 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. 1.2.3 Lifting the truck Inspection and preparation • 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 trouble shooting. Lifting points Figure 2. Permitted lifting points • Permitted fork lift truck lifting points. The lifting points are marked with a decal representing a lifting hook. WARNING! The machine must never be lifted in any other points than the ones shown. 1.2.4 Welding on the truck • During welding work the battery plug must always be disconnected and all connections to the control units and controllers (applies to all electronic units) disconnected. On completion of welding work the connectors must first be connected to the electronic units, after which the battery plug is then connected to the battery. • The welding ground connection must always be connected as close to the welding area as possible to eliminate damage to surrounding components. 1.2.5 Gas spring WARNING! During service and preventive maintenance it is important to check that the steering arm is raised up automatically when the driver releases it. If this does not happen it should be reported to the truck supervisor, with the recommendation that the truck be taken out of service until the requisite measures have been implemented.

01 General information and technical data PS/PSH 7 WARNING! Care must be taken when dismantling the gas springs. 1. Make sure that no other persons are in the vicinity, or in the lengthwise direction of the gas springs. 2. Stand to the side of the gas spring when removing. 3. Never point the gas spring toward any person or part of the body. 1.3 Environmental considerations 1.3.1 We respect the environment The majority of our products consist of steel, and can be completely recycled. Environmental impact All products have an impact on the environment throughout their entire life cycle. The consumption of energy when in 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 reducing 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 respective countries. Such work should only be carried out in areas intended for this purpose. Recyclable material should be taken care of by specialised authorities. Environmentally hazardous waste, such as oil filters, hydraulic oil, batteries and electronic equipment, can, if handled incorrectly, have a negative effect on the environment and human health. 1.4 Preparations 1.4.1 Service • Go through all the safety instructions. • Make sure that you have all the essential tools close at hand before starting work. • Before wiring or other electrical components are disconnected, check the colour codes and check for any damage to the wiring or connections. • When complex components are repaired and dismantled, make sure that you keep track 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. Refer to the respective Chapters for detailed information. 1.4.2 Trouble shooting When you suspect that a component is defective, 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.

01 General information and technical data 8 PS/PSH 1.5 Data 1.5.1 Designations 1.5.1.1 Truck designation Truck Type Load capacity PS 125 Pedestrian stacker 1250 kg PSH 160 Pedestrian stacker 1600 kg PSH 200 Pedestrian stacker 2000 kg Explanation of Model designation Example: PS 125 TV 299 Truck Type PS Load capacity *10 [kg] 125 Mast type TV Mast lifting height [cm] 299 = lifting height [cm] Table 1. Truck designations

01 General information and technical data PS/PSH 9 1.5.1.2 Type designation Figure 3. Example of type plate (–2006w36) 1. Model designation. 2. Type Series no./Version (S=Special ver.). 3. Year of manufacture, week, and warranty period in months (on the assumption that the service instructions in the warranty regulations are followed). 4. Where appropriate, load limitations depending on the position of the load on the forks (D) and/or lifting height (Q).

01 General information and technical data 10 PS/PSH Figure 4. Example of type plate (2006w37-) 1. Model designation. 2. Type Series no./Version (S=Special ver.). 3. Year of manufacture, week, and warranty period in months (on the assumption that the service instructions in the warranty regulations are followed). 4. Where appropriate, load limitations depending on the position of the load on the forks (D) and/or lifting height (Q). NOTE! If the machine plate is lost or becomes illegible, it must be replaced as soon as possible. In order to identify the serial number of the machine there is a label placed on each principal component, such as the traction motor, gearbox, hydraulic unit, TMC, etc. On some machines there is also a label glued inside the battery space or the serial number is punched on the side of the mast.

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Atlet Pallet Stackers PS 125, PSH 160, PSH 200 Workshop Service Manual

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