Atlet Reach Truck Type X-Ergo, XLL-Ergo, XML-Ergo, XTF-Ergo Workshop Service Manual

SERVICE MANUAL Machine: X-Ergo Manual No: 005997 SERVICE MANUAL Edition 2010A 1 General information and technical data Scope of Service Manual ............................................................................................... 1.3 General ................................................................................................................ 1.3 Scope of X-Ergo .................................................................................................. 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 Inspection/Preparation ................................................................................................... 1.6 Permitted lifting points .................................................................................................... 1.7 Welding on the truck ............................................................................................ 1.8 Atlet AB takes care of the environment ............................................................... 1.8 Environmental impact .......................................................................................... 1.8 Waste .................................................................................................................. 1.8 Preparations ................................................................................................................... 1.9 Service ................................................................................................................. 1.9 Trouble shooting .................................................................................................. 1.9 Data X-Ergo ................................................................................................................... 1.10 Designations ...................................................................................................... 1.10 Truck designation ......................................................................................................... 1.10 Type designation .......................................................................................................... 1.11 Dimensions and weights .................................................................................... 1.15 Dimensions X-Ergo ..................................................................................................... 1.15 Machine specification ................................................................................................... 1.17 Component specification ................................................................................... 1.22 Recommended consumable materials ....................................................................... 1.23

SERVICE MANUAL 1.2 Oil and grease .................................................................................................... 1.23 Standards and abbreviations ....................................................................................... 1.24 Tightening torque, screws and nuts ................................................................... 1.24 Tightening torque, hydraulic couplings ............................................................... 1.24 Conversion tables .............................................................................................. 1.25 Standard abbreviations ...................................................................................... 1.26 Screw types and tensile grades ......................................................................... 1.26 Colour of the truck .............................................................................................. 1.27 Colour codes, cabling ........................................................................................ 1.28 Designations for electrical components ............................................................. 1.29

General information and technical data / Scope of Service Manual / General 1.3 SERVICE MANUAL 01_SM_X-Ergo_En_005997_2010A.fm Edition 2010A 1 General information and technical data Scope of Service Manual General This manual describes the service procedures for ATLET Sit-on stackers in the X-Ergo series. Use the manual for quick and correct service of respective truck models. The manual describes models manufactured when X-Ergo was introduced at the end of 2003. You may find contradictions in the manual compared to the models supplied due to op- tional designs and upgrades, and the like. The contents of this Service Manual are protected by copyright law and may not be cop- ied, fully or in part, without written permission. The material has undergone careful ex- amination with regard to its 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. Printing errors and manifest errors found in the manual should be reported on the Correc- tion Report Form available on Gateway. The form can also be obtained from After Sales Support in Mölnlycke, Sweden. Scope of X-Ergo The Sit-on stacker trucks in the X-Ergo series are available in a number of different var- iants with mast system, adjustable straddle lift, extendable stabilisers and telescopic forks.

1.4 General information and technical data / How to use the manual / Structure SERVICE MANUAL How to use the manual Structure The manual is built up according to the same principles as ATLET spare parts catalogues, with the truck divided into one subsystem per section. Sections 1 - 3 in this manual contain more comprehensive information regarding technical data, general service instructions and tools. Sections 4-12 in this manual contain information limited to a specific area in the truck concerning the description of the mechanical handling of different components, e.g. Masts (section 6) and Hydraulic System (section 8). The software is described in 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. Symbol key Warning! Used for risk of personal injury. Important! Used for risk of damage to machine. Note! Used for general observation. As

General information and technical data / Safety instructions / General 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 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 directives should always be followed. • The drive wheel should always be lifted up free from the floor during service work to prevent the vehicle from moving. • The battery plug should be pulled out before working on the electrical system. The battery plug may only be connected while trouble shooting, and when the greatest of care is exercised, (with the truck raised). • To prevent crush injuries the battery plug should always be removed when working on and around the mast and hydraulic unit. The mast or hydraulic unit can be actu- ated by an electrical fault or a mistake while working. 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. • When dismantling parts in the hydraulic system the system must be relieved of pressure. For example, the pump motor should be switched off and the forks should be in their lowest position. • All metal objects such as watches, chains, spectacles 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. As

1.6 General information and technical data / Safety instructions / Truck modification SERVICE MANUAL 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 In- struction 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/Preparation • When the truck is lifted up with 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.

General information and technical data / Safety instructions / Lifting the truck 1.7 SERVICE MANUAL Permitted lifting points Figure1.1 shows where the permitted lifting points are placed on the truck. The lifting points are marked with a decal representing a lifting hook, and the lifting holes in the out- er mast must be used. Warning! The machine must never be lifted from the overhead guard. Figure 1.1 Permitted lifting points X-Ergo

1.8 General information and technical data / Safety instructions / Welding on the truck SERVICE MANUAL Welding on the truck • During welding work the battery plug should always be disconnected and all connections to the control units and controllers (applies to all electronic units) disconnected. On completion of welding work the contactors should first be connected to the electronic units, after which the battery plug is then connected to the battery. • The welding earth should always be connected as close to the welding area as pos- sible to eliminate damage to surrounding components. Atlet AB takes care of 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 during their use is one of the most important factors regarding impact on 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, batteries and electronics, can have a negative effect on the environment, or health, if handled incorrectly.

General information and technical data / Preparations / Service 1.9 SERVICE MANUAL 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 a good overview 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 X-Ergo / Designations SERVICE MANUAL Data X-Ergo Designations Truck designation Table 1.1 Truck designations Truck type X-Ergo Sit-on stacker, standard XTF-Ergo Sit-on stacker with telescopic forks XLL-Ergo Sit-on stacker, low-lifting XML-Ergo Sit-on stacker, medium-lifting Load capacity X-Ergo 1,600 alternatively 2,000 kg XTF-Ergo 1,000 kg XLL-Ergo 2,000 kg XML-Ergo 1,600 kg

Atlet Reach Truck Type X-Ergo, XLL-Ergo, XML-Ergo, XTF-Ergo Workshop Service Manual

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