PDF Service Manual Atlet A Ergo Forklift - 3 MB
This service manual for the Atlet A Ergo forklift series provides in-depth technical information for maintenance and repair.
It includes detailed procedures, wiring diagrams, and hydraulic schematics to assist technicians in troubleshooting and servicing the equipment.
Adhering to the guidelines in this manual will ensure that the forklift is maintained to the highest standards of safety and performance.
This is an essential document for any service professional.
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Service Manual A-Ergo — D003936, C, GBR, Translated
01 General information and technical data
01 GENERAL INFORMATION AND TECHNICAL DATA
2013B
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 4
1.2.1 General.............................................................................................................................. 4
1.2.2 Truck modification.............................................................................................................. 4
1.2.3 Lifting the truck .................................................................................................................. 5
1.2.4 Welding on the truck.......................................................................................................... 5
1.3 Environmental considerations 5
1.3.1 We respect the environment.............................................................................................. 5
1.4 Preparations 6
1.4.1 Service............................................................................................................................... 6
1.4.2 Trouble shooting ................................................................................................................ 6
1.5 Data 6
1.5.1 Designations...................................................................................................................... 6
1.5.2 Dimensions and weights.................................................................................................... 9
1.5.3 Component specification ................................................................................................. 10
1.6 Recommended consumable materials 11
1.6.1 Oil and grease types.........................................................................................................11
1.7 Standards and abbreviations 12
1.7.1 Screws............................................................................................................................. 12
1.7.2 Standard abbreviations and units .................................................................................... 13
1.7.3 Screw types and tensile grades....................................................................................... 14
1.7.4 Colour coding according to NCS ..................................................................................... 14
1.7.5 Colour codes for wiring diagrams .................................................................................... 15
1.7.6 Designations for electrical components........................................................................... 15
A-Ergo 1
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Service Manual A-Ergo — D003936, C, GBR, Translated
01 General information and technical data
1.6 Recommended consumable materials
1.6.1 Oil and grease types
The table below shows the lubricants which are used in production and are recommended
for servicing. They have been carefully selected and are suitable for, among other things:
• extending the life of the products
• reducing electrical consumption
• having the greatest respect for the environment
If the recommended lubricants cannot be obtained, alternative lubricants must comply with
the stated classifications. Bear in mind that it is important to follow the Atlet requirements for
environmentally-friendly oils for the guarantee to be valid.
Biodegradable-classified oils have a poor conductive ability and therefore require that both
the oil and the filter are well grounded to the chassis. If secure grounding is not present, this
can cause problems, such as static discharge through the oil. If this takes place the oil
becomes black (due to the build-up of sediment) and must be changed to prevent jamming
of the hydraulic valves. We currently have grounding of all the truck models that may be
affected by this problem. It is important that different products and brands are not mixed,
particularly synthetic and mineral oils.
Refer to the purchasing documentation for more information about the products.
CAUTION!
Never mix different lubricants, and definitely not synthetic oil with mineral oil!
Product Brand name and type Part no. Class
Hydraulic oil
Standard Mobil DTE 10 Exel 107173 ISO VG 46, viscosity index 150 or
greater.
Cold store Mobil Univis HVI 26 008936 ISO VG 26, viscosity index 300 or
greater, (Liquid temperature, -40°C
or better).
Biodegradable oil Mobil EAL Hydraulic 32 014160 SS 15 54 34.
CAUTION!
The guarantee only
applies if the truck is
delivered with this oil
from the factory, as this
oil cannot be mixed with
other types of oil.
Oil for the food industry Mobil DTE FM 32 014161 NSF H1.
CAUTION!
The guarantee only
applies if the truck is
delivered with this oil
from the factory, as this
oil cannot be mixed with
other types of oil.
Gearbox oil
Drive unit, all models
Standard Mobilube HD-A 85w-90 116444 Class GL5, 85W-90.
For ZF drive units the oil must be
approved in the ZF list of TE-ML
17B lubricants.
A-Ergo 11
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Service Manual A-Ergo — D003936, B, GBR, Translated
03 Service
03 SERVICE
3.1 Routine periodic maintenance 23
3.1.1 Introduction...................................................................................................................... 23
3.1.2 Safety .............................................................................................................................. 23
3.1.3 Recommendation ............................................................................................................ 23
3.1.4 Daily inspection ............................................................................................................... 23
3.1.5 Weekly inspection (30 hours of operation) ...................................................................... 23
3.1.6 Service , 500 hours interval ............................................................................................. 23
3.1.7 First service ..................................................................................................................... 24
3.1.8 Check list, service inspection .......................................................................................... 24
3.1.9 Code explanation............................................................................................................. 27
3.1.10 Lubrication chart ............................................................................................................. 30
3.2 Specific instructions 33
3.2.1 General............................................................................................................................ 33
3.2.2 Storage of machines and motors..................................................................................... 33
3.2.3 Traction motor.................................................................................................................. 33
3.2.4 Gearbox........................................................................................................................... 33
3.2.5 Lift chains and forks......................................................................................................... 33
3.2.6 Overhead guard............................................................................................................... 34
3.2.7 Mast................................................................................................................................. 34
3.2.8 Hydraulic oil ..................................................................................................................... 35
3.2.9 Recommended replacement ........................................................................................... 35
A-Ergo 21
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Service Manual A-Ergo — D003936, B, GBR, Translated
03 Service
Figure 9. Lubrication schedule for A-Ergo.
For symbol key, see Table 17, page 32.
Service on an Atlet truck can be divided into service that must be carried out regardless of
how heavily the truck is loaded and used (see Section 3.1.8, page 24) and an annual
recurrent service:
1. 500 h service
2. Annual service
Location Explanation Locatio Explanation
n
A Mast section - roller surfaces and slide E Thrust rollers - all
surfaces
B Lift chains, all F Chain pulley, shaft
C Fork carriage - support rollers G Hydraulic oil, filter
D Bogie – axle (unloaded) H Gearbox oil
CAUTION!
All torsion springs in the machine should be lubricated during each service.
A-Ergo 31
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Service Manual A-Ergo — D003936, B, GBR, Translated
04 Chassis
Production week Screw quality Screw Tightening torque Important
identification comments
-2009w35 8.8 Bright zinc-coated 81 Nm
2009w36- 12.9 Black, “12.9” 109 Nm 12.9 quality screws
stamped into the must be lubricated
screw head with special
graphite grease.
See Section 2.1,
page 19.
4.2.2 Armrest
4.2.2.1 Removing the armrest
1) Slacken the height adjustment wing nut.
2) Remove the height adjustment knob from beneath the writing surface.
3) Pull up the armrest so that the locking screw for the right hand bracket can be removed.
Figure 14. Armrest front securing screw
4) Lift up the armrest and detach all the wiring at the connectors.
5) Continue lifting the armrest so that the locking screw on the left bracket can be
removed.
Figure 15. Armrest lifted up
A-Ergo 41
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Service Manual A-Ergo — D003936, B, GBR, Translated
05 Drive unit
5.2.2.4 Assembling the traction motor
1) Assemble in the reverse order to dismantling. Ensure that the "knob" on the bearing is
positioned in alignment with the end shield.
2) Torque
The nuts on the pinion on the motor shaft should be tightened to 50
5.2.2.5 Storage of traction motor
Machines in storage that will not to be used within one month must be given special attention
so that problems do not occur when they are to be used again. Dust, dirt, condensation and
moisture caused by large changes in temperature and problems with rust and oxidisation
must be prevented. Motors should therefore be protected by waxed paper or the like,
together with a moisture absorbing material, and stored indoors at room temperature,
preferably in a cardboard box.
5.2.3 Gearbox
5.2.3.1 Changing the gearbox oil
1) If the oil needs to be drained out, this is done through the plug at the bottom of the
gearbox (item 1).
2) Oil is added either through the plug (item 2) or by removing the motor.
3) The oil level must be at the hole in the plug (item 2). Fill with oil until it just begins to run
out of the hole. A suction jet pump is recommended to facilitate filling and topping up via
(item 2).
Figure 20. Gearbox
5.2.3.2 Removal and installation of the gearbox
1) Position the truck on a pallet. The drive wheel must hang free, about 30 mm above the
floor.
2) Loosen the cable connections to the drive motor, servo motor, electric brake and
steering wheel indicator. Label the cables that are not labelled to ensure correct
reassembly.
3) Remove the motor, refer to Section 5.2.2, page 49.
4) Remove the 6 socket head cap screws from the bolted joint between the motor bed and
the chassis.
5) Carefully lower the gearbox out of the truck (see Section 5.2.4, page 52).
A-Ergo 51
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Service Manual A-Ergo — D003936, C, GBR, Translated
06 Mast system
06 MAST SYSTEM
2013B
6.1 Design and function 63
6.1.1 Mast system .................................................................................................................... 63
6.1.2 Fork carriage ................................................................................................................... 63
6.1.3 Vertically adjustable straddle legs ................................................................................... 65
6.1.4 Side stabilisers ................................................................................................................ 66
6.2 Repair and maintenance instructions 67
6.2.1 Replacing the mast/straddle legs .................................................................................... 67
6.2.2 Dismantling the mast ....................................................................................................... 72
6.2.3 Lift chains ........................................................................................................................ 77
6.2.4 Forks................................................................................................................................ 78
6.2.5 Fork carriage ................................................................................................................... 84
6.2.6 Fork carriage with telescopic forks (TF) .......................................................................... 85
6.2.7 Vertically adjustable straddle legs ................................................................................... 90
6.2.8 Side stabilisers ................................................................................................................ 91
6.3 Diagnostics and trouble shooting 92
6.3.1 Troubleshooting chart ...................................................................................................... 92
A-Ergo 61
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Service Manual A-Ergo — D003936, C, GBR, Translated
06 Mast system
Figure 41. Secure the guides together
3) Be sure to screw tight the spacer between the mast and chassis in the guide in one of
the screw holes that are not used.
Figure 42. Spacer/guide screw
4) Insert a suitable number of shims, 3 is the standard number.
Figure 43. Shims
5) Lower the mast so that the link arms slide in under the chassis when the mast and
chassis are brought together.
6) Connect the hydraulic couplings together.
A-Ergo 71
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Service Manual A-Ergo — D003936, C, GBR, Translated
06 Mast system
Worn forks must not be welded or repaired in any other way.
The original thickness is found by:
• Read the markings. The markings must show the lifting capacity in kg for one fork and the
centre of gravity distance in mm. The markings often also show the original thickness.
• measure the blade thickness at the centre of the shank (position B).
6.2.4.3.5 Fork tip
As soon as a fork tip is worn, it must be shortened or the complete fork changed.
6.2.4.3.6 Fork angle
Measure 500 mm along the fork blade and 500 mm along the back of the fork and mark
these positions. Measure the diagonal distance between these two points and use the table.
The distance must be within the acceptable values in accordance with Table 19, page 81,
otherwise the forks must not be used.
Table 19. Fork angle
The results Measurement result
Optimal 707 mm
Acceptable 695-713 mm
6.2.4.3.7 Difference in height between the tips of the forks
A. Difference in height between the forks
The difference in height between the fork tips must not exceed 3% of the fork blade length.
Example: fork length 1150 mm - max. height difference 34 mm.
If the difference in height between the fork blades is greater than 3%, the forks must not be
used.
A-Ergo 81
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Service Manual A-Ergo — D003936, C, GBR, Translated
06 Mast system
Figure 63. Positioning of shims
9) When the forks are parallel, check the height. The cylinders can be extended if it is not
high enough.
10) Test lift, and check that the straddle legs do not lift skew. If so, adjust the length of the
cylinders until the best lifting movement is obtained.
11) Check measure, and if necessary make further adjustments.
Table 21. Measuring the height of the vertically adjustable straddle legs/forks
Truck with vertically adjustable straddle legs
Distance to the fork upper surface Max 95 mm
Distance to top of straddle leg Max 90 mm
Min 85 mm
6.2.7.2 Dismantling and assembling of the vertically adjustable straddle legs
1) Lift up the straddle legs with the truck. Place a block under the fork tips and lower down
the straddle legs, whereby the load wheel is lifted from floor level.
2) Tap out the retaining pin through the shaft and drive out the shaft that holds the fork
wheel.
3) Tap out the retaining pin at the pressure link arm and pull out the load wheel, pull rods
and pressure link arm as a complete assembly.
4) Tap out the shafts from the ends of the pull rods.
5) Check for wear and replace damaged parts if necessary.
6) Refit in the reverse order.
7) Check the lifting movement. If the straddle lift pulls at an angle it must be adjusted, see
Section 6.2.7.1, page 90.
6.2.8 Side stabilisers
6.2.8.1 Checking the side stabiliser
1) Position the truck on a level surface.
2) Fix a tape measure with the zero at the top edge of one fork. Lift until the stabiliser
switch in the mast breaks, i.e. until the mast stops, and measure the height. The lift
height should be at 3000 mm +/- 25 mm.
3) Extend the stabilisers until the motor stops. Check that the wheels are pressed against
the floor and check the residual suspension. See Table 22, page 92.
A-Ergo 91
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Service Manual A-Ergo — D003936, C, GBR, Translated
08 Hydraulic system
08 HYDRAULIC SYSTEM
2013B
8.1 Design and function 101
8.1.1 General.......................................................................................................................... 101
8.1.2 Hose rupture valve ........................................................................................................ 101
8.1.3 Lowering brake valve..................................................................................................... 101
8.1.4 Mechanical control valve ............................................................................................... 102
8.1.5 Electric proportional valve ............................................................................................. 102
8.1.6 Level limit position switch (ALL) .................................................................................... 102
8.1.7 Hydraulic diagram.......................................................................................................... 103
8.2 Repair and maintenance instructions 109
8.2.1 Hydraulic system ........................................................................................................... 109
8.2.2 Hydraulic oil, changing/draining......................................................................................110
8.2.3 Air filter, replacing ........................................................................................................... 111
8.2.4 Oil filter element, replacement........................................................................................ 111
8.2.5 Checking the hydraulic oil level ......................................................................................112
8.2.6 Lowering brake valve......................................................................................................112
8.2.7 Hose rupture valve .........................................................................................................114
8.2.8 Control valve...................................................................................................................115
8.2.9 Adjusting the level limit position switch (ALL).................................................................119
8.2.10 Hydraulic pump motor ....................................................................................................119
8.2.11 Hydraulic pump motor ALL ............................................................................................ 120
8.2.12 Stabiliser cylinders......................................................................................................... 122