PDF Service Manual Atlet Forklift PLL PSD PSL PLE - 8 MB
This service manual provides comprehensive repair and maintenance information for the Atlet PLL, PSD, PSL, and PLE series forklifts.
It is an essential resource for forklift technicians to perform accurate diagnostics and effective repairs.
The manual covers everything from hydraulic systems to electrical troubleshooting, ensuring your material handling equipment remains reliable and safe.
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PLL PSD PSL PLE SERVICE MANUAL — D002476, 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 3
1.2.1 General.............................................................................................................................. 3
1.2.2 Truck modification.............................................................................................................. 4
1.2.3 Lifting the truck .................................................................................................................. 5
1.2.4 Welding on the truck.......................................................................................................... 6
1.2.5 Gas spring ......................................................................................................................... 6
1.3 Environmental considerations 6
1.3.1 We respect the environment.............................................................................................. 6
1.4 Preparations 7
1.4.1 Service............................................................................................................................... 7
1.4.2 Trouble shooting ................................................................................................................ 7
1.5 Data 7
1.5.1 Designations...................................................................................................................... 7
1.5.2 Dimensions and weights...................................................................................................11
1.6 Component specification 17
1.7 Recommended consumable materials 18
1.7.1 Oil and grease types........................................................................................................ 18
1.8 Standards and abbreviations 19
1.8.1 Screws............................................................................................................................. 19
1.8.2 Standard abbreviations and units .................................................................................... 21
1.8.3 Screw types and tensile grades....................................................................................... 21
1.8.4 Colour coding according to NCS ..................................................................................... 22
1.8.5 Colour codes for wiring diagrams .................................................................................... 22
1.8.6 Designations for electrical components........................................................................... 23
PL*/PS* 1
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PLL PSD PSL PLE SERVICE MANUAL — D002476, C, GBR, Translated
01 General information and technical data
Figure 6. Example of a serial number label
1.5.2 Dimensions and weights
1.5.2.1 Dimensions
Figure 7. Positions for dimensions PLL
PL*/PS* 11
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PLL PSD PSL PLE SERVICE MANUAL — D002476, C, GBR, Translated
01 General information and technical data
1.8.1.4 Conversion table, pressure units
Pa (N/m2) Bar (1mb=1hPa) at (kp/cm2) torr (mm Hg, 0 C) atm
1 10-5 1,020*10-5 7,501*10-3 9,869*10-6
9,807*104 0,9807 1 735,6 0,9678
133,3 1,333*10-3 1,360*10-3 1 1,316*10-3
1,013*105 1,013 1,033 760 1
1.8.1.5 Conversion table, speed
m/s km/h
1 3,6
0,278 1
1.8.2 Standard abbreviations and units
Magnitude Unit Designations
Current Ampere A
Voltage Volt V
Resistance Ohm Ω
Output Watt W
Torque Newton metre Nm
Pressure Pascal Pa
- Kilo (=1000) k
- Mega (=1 000 000) M
1.8.3 Screw types and tensile grades
Screw type Description Tensile grade
M6S Hexagon screw 8,8
10,9
MC6S Hexagon hole screw 8,8
10,9
12,9
MF6S Hexagon hole screw, 10,9
countersunk
MCS Slotted screw 4,6
PL*/PS* 21
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PLL PSD PSL PLE SERVICE MANUAL — D002476, B, GBR, Translated
03 Service
03 SERVICE
3.1 Routine periodic maintenance
3.1.1 Introduction
Preventive maintenance should be carried out regularly when the truck is used in normal
conditions. The planned service includes operations such as test driving, function tests, and
the changing of filters and oils etc. Service is planned at different intervals depending on the
running time of the truck. If the truck is working in extreme conditions or in demanding
environments, servicing must be planned at tighter intervals.
NOTE!
For recommended oil and grease types, see Section 1.7, page 18.
3.1.2 Safety
NOTE!
Check under each separate section which safety instructions are applicable for
work on the truck.
Inspection of the external functions in the power steering system should be carried out after
every service and after work carried out in the electrical system. All functional tests of the
safety system must be carried out with the truck speed controller in its neutral position, see
Section 10, page 105.
3.1.3 Recommendation
Information on what the truck owner should take into consideration.
Regular inspection should be carried out by specially appointed and trained personnel with a
good working knowledge of the function and maintenance of the truck. To obtain the best
results from your investment in your truck we advise you to contact your local Atlet
representative and to sign up for a service contract for regular inspection.
3.1.4 Daily inspection
For instructions, refer to the Operator´s Manual
3.1.5 Weekly inspection (30 hours of operation)
For instructions, refer to the Operator´s Manual
3.1.6 First service (200 hours)
The first service must be carried out after 200 hours. This service has the purpose of
ensuring the function of the truck and its component parts.
• Change the oil in the gearbox.
• Test the function of the entire machine in accordance with Section 3.1.7, page 29
3.1.7 Main service
EN-1726 and ISO 3691 specify that regular preventive maintenance should be carried out on
the truck. To guarantee high quality, operational reliability and personal safety, this
maintenance should be carried out by Atlet Service or by personnel specially trained by Atlet.
To comply with this requirement Atlet has prepared the following main service points (A
service), which must be checked every 500 hours of operation, on condition that the truck is
being used in normal conditions.
• Check for external damage on chassis.
• Check of weld joints at vital points.
PL*/PS* 29
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PLL PSD PSL PLE SERVICE MANUAL — D002476, B, GBR, Translated
03 Service
3.1.11.3 Lubrication chart PSL/PSD
Figure 12. Lubrication chart.
1. 500 hour service 2. Annual service
For symbol key, see Table 24, page 40.
Servicing consists partly of servicing that is required due to how heavily the truck is loaded
an how often it is used (see Section 3.1.9, page 30), and partly of annual routine servicing.
3.1.11.4 Components requiring lubrication
Location Explanation Location Explanation
A1 Mast profile roller surfaces and G Castor wheel - sliding bearing,
slide surfaces grease nipple
A2 Thrust rollers H Speed and brake controls - slide
surfaces and springs
PL*/PS* 39
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MASTER MANUAL
Machine: PLL PSD
Manual No: 119000
Edition 2012B
5 Drive unit
5.1 Design and function.................................................................................................. 5.3
5.1.1 Introduction.................................................................................................. 5.3
5.1.2 Traction motor ............................................................................................. 5.3
5.1.3 Gearbox....................................................................................................... 5.4
5.2 Repair and maintenance instructions ..................................................................... 5.5
5.2.1 General........................................................................................................ 5.5
5.2.2 Preparations ................................................................................................ 5.6
5.2.3 Traction motor ............................................................................................. 5.6
5.2.4 Speed and direction for sensor - External ................................................. 5.10
5.2.5 Gearbox..................................................................................................... 5.12
5.2.6 Drive wheel................................................................................................ 5.13
5.3 Diagnostics and trouble shooting ......................................................................... 5.14
5.3.1 Trouble shooting chart ............................................................................... 5.14
SERVICE MANUAL PLL PSD
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Drive unit / Repair and maintenance instructions / Speed and direction for sensor - External 5.11
TractionMotorController - TMC
1. Measure the feed voltage between X 9,1 - 9,4 X. Approx. 12V.
2. Measure the channel A voltage at X9.3 - X9.4. About 4V when the motor is rotating,
0V or 8V when stationary.
3. Measure the channel B voltage at X9.2 - X9.4. About 4V when the motor is rotating,
0V or 8V when stationary.
SERVICE MANUAL PLL PSD
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PLL PSD PSL PLE SERVICE MANUAL — D002476, C, GBR, Translated
06 Mast system
3) Lift up the inner mast with truck’s standard hydraulic system until the fork carriage is
released.
CAUTION!
Observe great caution!
4) Reverse the truck away.
6.2.2.2 Inspection of welded fork carriages
6.2.2.2.1 General
CAUTION!
Inspection of the forks must be carefully performed by trained personnel.
The purpose of the inspection is to detect damage, faults, deformation, etc. A fork carriage
showing this kind of damage may not be used until it has been repaired.
6.2.2.2.2 The fork blade is bent
A. Ruler B. Deformation location
The fork blade must not be bent downwards by more than a certain proportion of the length
of the fork. If the fork blade is bent too much, the fork carriage must be straightened or
replaced.
l= fork blade length in mm.
k= measurement in mm between the fork blade tips and a ruler.
Measurement when a blade must be straightened: greater than k=l/33. Example: k=1150/33=
34 mm.
NOTE!
Repairs must be carried out by a licensed welder.
6.2.2.2.3 Crack formation
1. Front welded joints 2. Rear welded joints
Check whether the forks are cracked. Take extra care when welding joints at the front (item
1) and rear (item 2). If cracks are detected, the fork carriage must be replaced or repaired.
NOTE!
Repairs must be carried out by a licensed welder.
PL*/PS* 65
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PLL PSD PSL PLE SERVICE MANUAL — D002476, C, GBR, Translated
07 Steering
7.2.3.4 Fitting the main cabling
Securing the tiller arm main cabling
The cabling is secured by cable clips to the tiller arm head. The cabling is secured inside the
truck by cable ties to the motor.
CAUTION!
The cabling must have enough slack so that the arm can be lowered to its lowest
position without straining the cable. It must also be possible to open the upper part
of the tiller head with being restricted by the cabling.
CAUTION!
The cabling must not be so long that the programming cable takes the load when
the upper part is hanging on the cabling.
Cable routing, standard version
Figure 23. Cable routing, standard version
PL*/PS* 75
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PLL PSD PSL PLE SERVICE MANUAL — D002476, C, GBR, Translated
08 Hydraulic system
Figure 31. Hydraulic unit, PSD PLE (2008w39-)
Figure 32. Hydraulic schematic diagram, hydraulic unit PLL (-2009w44)
PL*/PS* 85
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PLL PSD PSL PLE SERVICE MANUAL — D002476, C, GBR, Translated
08 Hydraulic system
8.2.3.4 Tips for prolonging the service-life of the motor
• The rapid wearing of carbon brushes and the commutator is often caused by oil. Oil or
grease is burned by the sparks produced at the brushes, and leaves a residue of
abrasive ash. If oil or grease is detected in the motor the reason for this must be
eliminated immediately.
• Never overload the motor. Brushes that have been severely overheated expand
permanently and can fasten in the brush holders.
• The service-life of the brushes does not only depend on the loading, but also on how
worn the commutator is. The commutator should have smooth, level and greyish black
surface. A worn commutator must be machine milled (never use abrasive paper,
grindstone or a file!) to a surface finish of Ra = 0.8-1.8µm and a maximum runout of
0.03 mm (with the rotor resting in the bearing seats). The service-life of the commutator
is prolonged if it is machined a little and often, rather than seldom and a lot. The
minimum permitted diameter of the commutator is 40.8 mm.
• The motor must not be exposed to full load immediately after changing the brushes.
• Look for signs of overheating on the windings, dark patches, brittle or burned insulation,
and damage to the soldering on the commutator. The electric motor should be replaced
if such damage is found.
• If possible, remove dust and dirt from inside the motor with compressed air.
• A dirty commutator should always be cleaned with a cloth moistend with petrol (do not
used cotton rags since these shred fibres), and carefully blown dry with compressed air.
• If the bearing cup looks as if it has run out of oil (i.e. if there is a lot of oil on the rotor
washer or brush holder) lubricate it with a little bearing grease.
8.2.4 Hose rupture valve
8.2.4.1 Dismantling and assembling
1) Lower the forks and relieve the pressure.
2) Place protective paper under the cylinder to be repaired.
3) Loosen the pipe or hose that goes to the cylinder, and plug it.
4) Remove the nipple placed in the cylinder.
5) Unscrew the hose rupture valve (item 1, see Figure 40, page 95) that is screwed into
the cylinder.
Figure 40. Hose rupture valve
6) If a fault is suspected, check the length of the spring in relation to the table or data
sheet. Adjust, or fit a new valve.
7) Fit the nipple, connect the pipes, and wipe clean.
8) Test run.
PL*/PS* 95
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Lift cylinders / Repair and maintenance instructions 9.5
9.2 Repair and maintenance instructions
9.2.1 General
9.2.1.1 Bleeding of cylinders with air screw
Figure 9.3 Example, air screw.
When bleeding, the air screw must be opened no more than approx. a half
turn. If the air screw is opened completely the oil will spurt out and the forks
crash uncontrollably to bottom position. The hose rupture valves do not func-
tion in this phase.
1. Open the air screw a maximum of approx. one half turn.
2. Check that there is sufficient oil in the hydraulic tank and that the pump does
not suck air.
3. Carefully run the cylinder repeatedly between its end positions.
4. When oil without air bubbles comes in the tank the cylinders have been bled.
5. Adjust the oil level in the hydraulic tank.
6. Repeatedly lift from bottom to top position.
7. Check that the forks do not bounce, if so repeat the bleeding again.
9.2.1.2 Bleeding of cylinders without air screw
Cylinders without air screws are bled by running the cylinder repeatedly between
its end positions.
Important!
Check the oil level regularly.
SERVICE MANUAL PLL/PSD/PSL/PLE
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PLL PSD PSL PLE SERVICE MANUAL — D002476, C, GBR, Translated
10 Electrical system
1. Switch on the voltage to the truck.
2. Go into “Lowering high“ (Service menu » Settings » Battery » Lowering high). This
parameter ((0-9) determines how quickly BDI reduces the indicated level when the
battery has just been charged.
• If the indication does not show 100% after a complete charging cycle, or falls too
quickly in the range 100%-60%, this parameter must be reduced.
• If the indication falls too slowly in the range 100%-60%, this parameter must be
increased.
3. Go into “Lowering low“ (Service menu » Settings » Battery » Lowering low). This
parameter ((0-9) determines how quickly BDI reduces the indicated level when the
battery is almost discharged.
• If the indication falls too quickly in the range 60%-20%, this parameter must be
reduced.
• If the indication falls too slowly in the range 60%-20%, shows too high a battery
status, or if the truck stops due to a low voltage level alarm, this parameter must be
increased.
10.2.3 General handling
10.2.3.1 Keyboard operation
The keyboard is used for driver identification, settings, and for diagnostics. The keyboard
consists of 12 keys, which have different functions depending on which position the system
is in.
Table 30. 10.2
Function in
Key: Input mode: Service mode:
Operation mode:
Enter a zero. - -
Enter an eight. - -
Enter a two. Switch between creep Step one step down in the
speed and full speed. menu tree.
Enter a three. - -
Enter a four. - Step one step to the left in
the menu tree.
Enter a five. - -
Enter a six. - Step one step to the right in
the menu tree.
Enter a seven. - -
Enter an eight. Set the truck to full speed. Step one step up in the
menu tree.
Enter a nine. - -
- Set the truck to standby Steps to the upper menu
mode, or else log off. level loop if pressed during
input in the upper level.
See Section 10.2.3.2,
page 114.
Used to accept the shown - Used to select the shown
value. menu alternative.
PL*/PS* 113
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PLL PSD PSL PLE SERVICE MANUAL — D002476, C, GBR, Translated
10 Electrical system
10.2.8.9 Calibration of lifting and lowering controller (ATC T4mk2, 2007w28–)
NOTE!
The lifting and lowering controller must be calibrated for both ON/OFF and
proportional regulation.
1) Navigate to Service menu » Calibrate » Lift/Lower. The following display appears:
Lift control to 0
press ENT
2) Check that no controllers are activated. Then press ENT. The following display appears:
Give full lifting
press ENT
3) Press lift completely down on the right lifting and lowering control. Then press ENT.
4) The following display then appears:
Give full lowering
press ENT
5) Press lower completely down on the right lifting and lowering control. Then press ENT.
6) The display shows whether the calibration was successful or not. (only software 2.23–)
OK!
Press ENT
Not accepted
Press ENT
7) The following display appears:
Signal check:
x.xV Out: xxx%
In this menu it is now possible to check that the calibration is correct. The signal check
must show the following values:
• With lifting activated: 4.7 V (± 0.1 V)
• Neutral (control not activated): 2.7 V (± 0.1 V)
• With lowering activated: 0.6 V (± 0.1 V)
Press ENT.
8) Repeat the same calibration procedure for the left lifting and lowering control by
selecting Channel 2, and performing steps 1-6. Finish after this with ENT.
9) Exit the Atlet menu by going to Exit and pressing Enter.
10) Disconnect the battery and then restart the truck.
11) Perform a functional test of the lifting/lowering functions.
10.2.8.10 Adding a new driver
New drivers can be added via the Set Access menu. Select Operator to add a new driver.
1) Select new/update, and press enter.