Atlet SERVICE

SERVICE MANUAL
Machine: PLP
Manual No 119002
Edition 2010A
1 General information and technical data
Scope of Service Manual ............................................................................................... 1.3

General ................................................................................................................ 1.3
Scope of the 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 ............................................................................................... 1.5
Gas springs in platform and steering arm ............................................................ 1.7
Inspection/Preparation ................................................................................................... 1.7
Lifting the truck .................................................................................................... 1.7
Inspection/Preparation ................................................................................................... 1.7
Permitted lifting points .................................................................................................... 1.8
Welding on the truck ............................................................................................ 1.9
Atlet AB takes care of the environment ............................................................... 1.9
Environmental impact .......................................................................................... 1.9
Waste .................................................................................................................. 1.9
Preparations ................................................................................................................. 1.10

Service ............................................................................................................... 1.10
Trouble shooting ................................................................................................ 1.10
Data PLP ........................................................................................................................ 1.11

Designations .......................................................................................................1.11
Truck designation ......................................................................................................... 1.11
Type designation .......................................................................................................... 1.12
Dimensions and weights .................................................................................... 1.15
Machine specification ................................................................................................... 1.16
SERVICE MANUAL
1.2
Component specification ....................................................................................1.17
Recommended consumable materials .......................................................................1.18

Oil and grease ....................................................................................................1.18
Standards and abbreviations .......................................................................................1.19

Screws ...............................................................................................................1.19
Tightening torque, screws and nuts .............................................................................. 1.19
Screw types and tensile grades .................................................................................... 1.19
Tightening torque, hydraulic couplings ...............................................................1.21
Conversion tables ..............................................................................................1.21
Standard abbreviations ......................................................................................1.22
Colour of the truck ..............................................................................................1.22
Colour codes, cabling ........................................................................................1.23
Designations ......................................................................................................1.23
SERVICE MANUAL
General information and technical data / Scope of Service Manual / General 1.3
Edition 2010A
1 General information and technical data

Scope of Service Manual
General
This manual describes the service procedures for ATLET low lifter PLP. Use the manual
for quick and correct service of respective truck models.
You may find contradictions in the manual compared to the models supplied due to op-
tional designs and 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 exami-
nation with regard to correctness. Subject to alteration. In the event of inconsistent infor-
mation 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 the P series

The manual covers the low lifters PLP 200 and PLP 250.
01_SM_PLP_En_119002_2010A.fm
SERVICE MANUAL
1.4 General information and technical data / How to use the manual / Structure
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 techni-
cal 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.
SERVICE MANUAL
General information and technical data / Safety instructions / General 1.5
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 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 due to 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 con-
junction with repair work, in view of the risk of accidents or near-accidents from
the truck making an unexpected manoeuvre.
• The system should not be pressurised, e.g. the pump motor switched off and the
forks in their lowest position, when dismantling parts of the hydraulic system.
• 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.
Truck modification
Note!
Unauthorized truck modification is not permitted.
SERVICE MANUAL
1.6 General information and technical data / Safety instructions / Truck modification
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
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.
SERVICE MANUAL
General information and technical data / Safety instructions / Gas springs in platform and steering
Gas springs in platform and steering arm
Inspection/Preparation
The functioning of the platform and steering arm should be checked. The gas springs in
both of these functions are a very critical factor for their correct functioning.
Since the gas springs are exposed to dirt and a large number of operations, they should be
checked very carefully during preventive maintenance.
During service and preventive maintenance it is important if the truck is a model with a
foldable platform to check that the platform is raised up automatically when the driver
gets off 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.
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.
Warning!
Great caution must be observed when dismantling the gas springs.
• Make sure that no other persons are in the vicinity or in the lengthwise direction of
the gas springs.
• Stand to the side of the gas spring when removing.
• Never point the gas spring toward any person or part of the body.
Lifting the truck
Inspection/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.
SERVICE MANUAL
1.8 General information and technical data / Safety instructions / Lifting the truck
Permitted lifting points
Figure 1.1 Permitted lifting points
Figure1.1 shows where the permitted lifting points are placed on the truck.
Warning!
The machine must never be lifted in any other points than the ones shown.
Figure 1.2 shows where the jack should be placed.
Figure 1.2 Lifting point, jack
SERVICE MANUAL
General information and technical data / Safety instructions / Welding on the truck 1.9
Welding on the truck

• During welding work the battery plug should always be disconnected and all con-
nections to the control units and controllers (applies to all electronic units) discon-
nected. 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 return cable clamp should always be connected as close to the welding area as
possible to eliminate damage to surrounding components.
Atlet AB takes care of the environment

The majority of our products consist of metal that 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 that in-
fluences 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, should
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.
SERVICE MANUAL
1.10 General information and technical data / Preparations / Service
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
good control 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 that a component is defective, do not replace it immediately. First
check the surrounding equipment and carry out complete trouble shooting according to
the trouble shooting chart. Make sure you know the reason for the fault before replacing
a component.
SERVICE MANUAL
General information and technical data / Data PLP / Designations 1.11
Data PLP
Designations
Truck designation
Table 1.1 Truck designations
Truck type PLP 200 Low lifter
PLP 250 Low lifter
Load capacity PLP 200 2,000 kg
PLP 250 2,500 kg
SERVICE MANUAL
1.12 General information and technical data / Data PLP / Designations
Type designation
1
Modell
Model
Modell
Modèle
2
Serie nr. Vikt utan batterie
Serial no. Weight without battery Kg
Serien-Nr Gewicht ohne Batterie
Nº de serie Poids propre sans batteri
3
Tillverkningsår Batteri vikt min.
Year of construction Battery weight min. Kg
Baujahr Batteriegewicht min.
Année de construction Poids de batterie mini.
4
Tillåten last Batteri vikt max.
Load capacity Battery weight max. Kg
Tragfähigkeit Batteriegewicht max.
Charge limite Poids de batterie maxi.
Tyngdpunktsavstånd Batterispänning
Distance of load center Kg Batteryvoltage V- DC
Lastschwerpunktabstand Batteriespannung
Distance de centre Tension de la batterie
Tillverkare
Manufacturer
Hersteller
Fabriccat
Atlet AB Mölnlycke Sweden
Figure 1.3 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 (only Sweden).
(On the assumption that the service instructions in the warranty regulations are fol-
lowed).
4. Where appropriate, load limitations depending on the position of the load on the
forks (D) and/or lifting height (Q).
SERVICE MANUAL
General information and technical data / Data PLP / Designations 1.13
1 Model
Modell
2 Serial no.
Serie nr.
3 Year of manufacturing
Tillverkningsår
4 Load capacity
Tillåten last
Load centre distance

Tyngdpunktsavstånd
Weight without battery

Vikt utan batteri
Battery weight min.

Batterivikt min.
Battery weight max.

Batterivikt max.
Battery voltage
Batterispänning
Refernce number
Referensnummer
ATLET AB MÖLNLYCKE SWEDEN
Figure 1.4 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 (only Sweden).
(On the assumption that the service instructions in the warranty regulations are fol-
lowed).
4. Where appropriate, load limitations depending on the position of the load on the
forks (D) and/or lifting height (Q).
SERVICE MANUAL
1.14 General information and technical data / Data PLP / Designations
Note!
In cases where the machine plate has been lost or become illegible, it must be re-
newed immediately. In order to identify the machine's serial number, there is a plate
located on each main component such as drive motor, gearbox, hydraulic unit,
TMC etc. For some machines there is even a plate attached inside the battery com-
partment, or serial number punched on the side of the mast.
SER XXXXXX
WEEK XXXX
SER XXXXXX
WEEK XXXX
Figure 1.5 Example of plate with serial number.
Explanation of Model designation
Example: PLP 200 160 30
Truck type
Load capacity/10
Battery Ah/5
Charger Ampere
SERVICE MANUAL
General information and technical data / Data PLP / Dimensions and weights 1.15
Dimensions and weights

Dimensions PLP
1595
877
919
634
55
H4
180
H1
149
453 L4 L2
52
L1
L3
B1
B2
560
578
B
R2
Figure 1.6 Positions for dimensions PLP
SERVICE MANUAL
1.16 General information and technical data / Data PLP / Dimensions and weights
Machine specification
No. PLP 200 PLP 250
1 Lifting capacity, rated Q kg 2000 2500

1a Distance to centre of gravity D mm 600 600
2 Lifting height H4 mm 200 200

2a Mast height H3 mm
H5 mm
2b Transport free lift H2 mm
2c Full free lift
2d Straddle lift
4 Lifting speed without load – with rated load m/s

4a Lifting time without load – with rated load s 2.0-2.5 2.0-2.7
5 Lowering speed without load – with rated load m/s

Lifting time without load – with rated load s 2.5 2.5
6 Driving speed without load – with rated load km/h 10.0-8.5 12.0-9
Driving speed without load – with rated load m/s 2.77-2.36 3.3-2.77
8 Reversing capacity without load – with rated load Max % 10-10 10-10
10 Turning radius R2 mm 770 + L2 835 + L2
11 Minimum aisle width Ast incl. 200 mm R2-L2 + load

length + 200
Load length 800 mm Ast mm
Load length 1,000 mm Ast mm
Load length 1,200 mm Ast mm
13 Height over protective roof H6 mm
14 Truck length L mm 750 + L1 825 + L1
15 Truck width B mm 770 770
16 Fork length, std L1 mm 1000 / 2375 1000 / 2375
17 Width over forks, std max-min W mm 680 / 460 680 / 480

17a Width between fork gaffel shanks mm W - 350 W - 350
19 Truck length to fork support area L4 mm 750 825
20 Fork arm, width – thickness B1 mm 175 - 55 175 - 55

20a For height, min H1 mm 85 85
21 Straddle lift height H7 mm
22 Width between fork straddle lift B2 mm
23 Dim. for front axle – fork support area L2 mm 785 - 1765 785 - 1465
24 Wheelbase L3 mm 551 + L2 626 + L2
25 Wheel track – front, back centre of wheel mm W - 175/526 W - 175/526
26 Ground clearance, half wheelbase load mm 30 - 145 30 - 145
27 Service weight with/without battery kg 860 - 530 925 - 545
28 Max axle pressure, load wheel with/without rated load kg 212 / 1828 212 / 2238
29 Max axle pressure, drive wheel with/without rated load kg 705 - 1110 715 - 1215
39 Battery capacity kWh 4.8-9.6 7.5-14.4

Ah 200-400 300-600
39a Battery voltage V 24 24
41 Traction motor kW 2.2 / 2.4 AC 2.2 / 2.4 AC
42 Speed controlling Transistor Transistor
43 Lift motor kW - %/ 2.2 - 12/10 2.2 - 12/10

43a Hydraulic tank min 9 11
MPa
44 Wheel type Vulkollan Vulkollan

44a Number of drive/castor/load wheels 3-4 3-4
SERVICE MANUAL
General information and technical data / Data PLP / Component specification 1.17
45 Wheel dimensions
45a Load wheel D* width mm (4x) 85x75 (4x) 85x75
45b Drive wheel D* width mm (1x) 230x90 (1x) 230x90
45c Castor wheel mm (2x) 150x60 (2x) 150x60
46 Control system Tiller arm Tiller arm
47 Main brake, type – actuated part El. drive mech. El. drive mech.
48 Parking brake, type – actuated part El. drive mech. El. drive mech.
Component specification
Table 1.2 Component specification
Component Specification
Traction motor Drive voltage 24V
Output standard 2.2 / 2.4 kW

60 min
Gearbox Gear ratio (standard) 15:1
Oil volume 0.85 litre
Hydraulic system Max pressure 21 MPa
Oil volume max 1.6 litre
Hydraulic unit (motor and pump) Output 2.2 kW
Control system for traction Type FZ2007 AC1 CAN

motor
Voltage 24 V
Max current 250A (RMS)

for 2 min
Fuses Control fuse 1 5A
Pump motor fuse 1 250 A
Traction motor fuse 1 250 A
SERVICE MANUAL
1.18 General information and technical data / Recommended consumable materials / Oil and grease
Recommended consumable materials
Oil and grease
Table 1.3 Table of recommended types of oil and grease
Brand Gearbox oil Hydraulic oil Bearing

As per API value As per ISO VG 32, VG 15 grease
GL-5 NLGI 2
Lithium
Normal Cold store Normal Cold store base
(32) (15)
BP BP Energear BP Energear BP Bartran BP Bartran Energrease

HYPO SHX-S HV-32 SHF-S LC 2
80W/140 EP 75W/140 EP
Castrol - - Hyspin Hydraulic oil LMx

SHS 32 OM 15
Alt: Hyspin
AWH 15
Mobil - - DTE 13 M Flowrex 1 Mobilplex 48

SHS 32
Shell - - Tellus oil Tellus oil T Retinax EP2

TX 32 15
Statoil / - - SHS 32 J 26 Uniway LIX

Exxon 625
Texaco - - Rando oil Rando oil Hytex EP2

HDZ 32 HDZ 15
Important!
Do not mix different lubricants, and absolutely not synthetic oil with mineral oil,
since this can affect the properties of the oil!
SERVICE MANUAL
General information and technical data / Standards and abbreviations / Screws 1.19
Standards and abbreviations
Screws
Tightening torque, screws and nuts

Table 1.4 Tightening torque, screws and nuts
DIM Tensile grade
4.6 8.8 10.9 12.9
Nm Nm Nm Nm
M4 1.1 2.9 4.0 4.9
M5 2.2 5.7 8.1 9.7
M6 3.7 9.8 14 17
M8 8.9 24 33 40
M10 17 47 65 79
M12 30 81 114 136
M14 48 128 181 217
M16 74 197 277 333
M18 103 275 386 463
M20 144 385 541 649
The tightening torque in the table above are standard values. In some cases a specific
tightening torque is specified in respective sections. If no tightening torque is specified
in the service instructions, the values shown in the table above apply.
Screw types and tensile grades
Table 1.5
Figure Screw type Designation Tensile grade
M6S Hexagon screw 8.8

10.9
MC6S Hexagon hole screw 8.8

10.9
12.9
SERVICE MANUAL
1.20 General information and technical data / Standards and abbreviations / Screws
Table 1.5
Figure Screw type Designation Tensile grade
MF6S Hexagon hole screw, 10.9

countersunk
MCS Slotted screw 4.6
MVBF Oval head counter- 4.6

sunk screw
Marking with the manufacturer’s trademark, including the tensile grade, is compulsory
for screws with a thread diameter from 5 mm and in tensile grades according to the table
above. Marking only takes place when the shape of the product permits this.
8.8
8.8
12.9
12.9
Figure 1.7 Example of marking
SERVICE MANUAL
General information and technical data / Standards and abbreviations / Tightening torque, hydrau-
Tightening torque, hydraulic couplings

Table 1.6 Tightening torque, hydraulic couplings
Tightening torque: Pipe thread / metric thread:
Metric fine Whitworth pipe MA (Nm) with MA (Nm) with elastic

thread thread pipe olive (O-ring coupling)
M10 x 1 G 1/8" 25 10
M12 x 1.5 30 20
M14 x 1.5 G 1/4" 50 30
M16 x 1.5 G 3/8" 80 35
M18 x 1.5 90 40
M20 x 1.5 G 1/2" 130 50
M22 x 1.5 150 60
M26 x 1.5 250 70
M27 x 1.5 G 3/4" 250 80
M27 x 2 250 90
G 1" 350 140
M33 x 2 400 140
M42 x 2 G 11/4" 600 240
M48 x 2 G 11/2" 800 300
Conversion tables
Table 1.7 Conversion table, torque units
Newton metre Kilopond metre Poundforce inch Poundforce foot

(Nm) (kpm) (lbg x in) (lbf x ft)
1 0.10 8.85 0.74
9.81 1 86.80 7.23
0.11 0.01 1 0.08
1.36 0.14 12.00 1
SERVICE MANUAL
1.22 General information and technical data / Standards and abbreviations / Standard abbreviations
Table 1.8 Conversion table, pressure units
Pa Bar at dry atm

(N/m2) (1mb=1hPa) (kp/cm2) (mm Hg, 0 C)
1 10 -5 1.020*10 -5 7.501*10 -3 9.869*10 -6
9.807*10 4 0.9807 1 735.6 0.9678
133.3 1.333*10 -3 1.360*10 -3 1 1.316*10 -3
1.013*10 5 1.013 1.033 760 1
Table 1.9 Conversion table, speed
m/s km/h
1 3.6
0.278 1
Standard abbreviations
Table 1.10 Standard abbreviations
Magnitude Unit Designation
Current Ampere A
Voltage Volt V
Resistance Ohm Ω
Output Watt W
Torque Newton metre Nm
Pressure Pascal Pa
Colour of the truck

0
The truck is painted in colours with the following NCS colour codes:
Table 1.11 NCS colour codes
Machine colour Designation
Yellow NCS 0070-Y20R
Medium grey NCS 7000
Dark grey NCS 8000
SERVICE MANUAL
General information and technical data / Standards and abbreviations / Colour codes, cabling
Colour codes, cabling

The colour markings of all cables included in the truck can be seen in the Atlet wiring
diagrams. The abbreviations have the following significance:
Table 1.12 Colour codes Atlet wiring diagrams
Code Cable colour
Y Yellow
BL Blue
SB Black
W White
GN Green
GR Grey
R Red
BN Brown
VO Violet
P Pink
OR Orange
Note!
Two-colour cables are shown with both colour codes separated by a slash.
E.g. blue/yellow cable is shown with colour code BL/Y.
Designations
Electrical components normally have a designation of two letters:
Table 1.13 First letter
Code Designation
A Component or function without its

own letter below
C Capacitor
D/V Diode
E Electrical component
F Fuse
I Indicator
K Contactor/relay
L Coil/inductive element
SERVICE MANUAL
1.24 General information and technical data / Standards and abbreviations / Designations
Table 1.13 First letter
Code Designation
M Motor
P/X Connection
R Resistor
S Switch/Change-over switch
T Terminal
Y Valve/brake
H Audible warning unit/lamps/lights
G Battery
Table 1.14 Second letter
Code Designation
B Brake
C Control system
E Emergency function
F Forward
H Hour
K Key
L Lower
M Manoeuvre
P Pump
R Reverse
S Speed
SERVICE MANUAL
SERVICE MANUAL
Machine: PLP
Manual No: 119002
Edition 2007B
2 Special tools
Special tools PLP ........................................................................................................... 2.3

Introduction .......................................................................................................... 2.3
List of tools .......................................................................................................... 2.3
SERVICE MANUAL
2.2
SERVICE MANUAL
Special tools / Special tools PLP / Introduction 2.3
Edition 2007B
2 Special tools
Special tools PLP
Introduction
All special tools can be ordered from Atlet AB.
List of tools
Table 2.1 List of tools
Designation Figure Part number Applications
Cleaning fluid P/N 112268 Cleaning of electric motors from gearbox

oil and other dirt
Chain spray P/N 001196 Lubrication of chains
Crimping tool Molex P/N 006454 Cable connections
Pin extractor P/N 006456 Cable connector
Lifting eye P/N 104737 Lifting eye for drive unit.
Lifting device 2.1 P/N 118515 Lifting tool
For detailed information on the above products, please contact Atlet.
SM_PLP_02_0001A.eps
Bild 2.1 Lifting device
SM_PLP_02_119002_2007B.fm
SERVICE MANUAL
2.4 Special tools / Special tools PLP / List of tools
SERVICE MANUAL
SERVICE MANUAL
Macine: PLP
Manual No: 119002
Edition 2011A
3 Service
Regular maintenance 3
Introduction .......................................................................................................... 3.3
Safety .................................................................................................................. 3.3
Recommendation ................................................................................................ 3.3
Daily service ........................................................................................................ 3.3
Weekly service (30 operating hours) ................................................................... 3.3
First service ......................................................................................................... 3.4
Main service ........................................................................................................ 3.4
Extra service inspections ..................................................................................... 3.4
Check list, service inspection .............................................................................. 3.6
Code explanation ............................................................................................... 3.10
Lubrication chart ................................................................................................ 3.14
PLP ............................................................................................................................... 3.14
Symbol key, lubrication chart ....................................................................................... 3.15
Specific instructions 16
Traction motor ................................................................................................... 3.16

Preventive maintenance ............................................................................................... 3.16
Gearbox ............................................................................................................. 3.16
First service .................................................................................................................. 3.16
Preventive maintenance ............................................................................................... 3.16
Lift chains and forks ........................................................................................... 3.17
Check ........................................................................................................................... 3.17
Hydraulic oil ....................................................................................................... 3.18
First service .................................................................................................................. 3.18
Intervals ........................................................................................................................ 3.18
Emergency stop ................................................................................................. 3.18
Recommended replacement ............................................................................. 3.19
Storage of machines and motors ....................................................................... 3.19
SERVICE MANUAL
3.2
SERVICE MANUAL
Service / Regular maintenance / Introduction 3.3
Edition 2011A
3 Service
Regular maintenance
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 de-
manding environments, servicing must be planned at tighter intervals.
Safety
Important!
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 function tests
of the safety system should be made with the speed controller in neutral position, see sec-
tion 10.
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.
Daily service
For instructions, refer to the Operators Manual.
Weekly service (30 operating hours)
For instructions, refer to the Operators Manual.
03_SM_PLP_En_119002_2011A.fm
SERVICE MANUAL
3.4 Service / Regular maintenance / First service
First service
The first service should 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.
• Change the hydraulic oil filter.
• Test the function of the entire machine in accordance with the following list.
Main service
EN-1726 and ISO 3691 specify that regular preventive maintenance should be carried out
on the truck. To guarantee high quality, operation 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 should be checked every 500 hours of operation.
• Check for external damage on chassis.
• Check of weld joints at vital points.
• Check of lifting devices.
Tightening • Check of component attachments.
torque:
195Nm • Function test, lever (lever bolts195 Nm).
• Check of the horn.
• Test drive backwards and forwards, and turning.
• Check of the drive unit.
• Check of all the wheels.
• Test of the brake function.
• Oil and filter change according to instructions.
• Check for oil leakage.
• Check of the hydraulic unit, pipes and hoses.
• Check of the cylinders.
• Function test, lifting and lowering.
• Lubrication in accordance with lubrication chart.
• Measurement and check of the battery and charging function.
Extra service inspections
What has been mentioned above is applicable on the assumption that the machine is
working in normal conditions on single shifts. In dirty or dusty environments, poor floor
conditions, or where there are large variations in temperatures, the service intervals must
be arranged more frequently.
SERVICE MANUAL
Service / Regular maintenance / Extra service inspections 3.5
None of the above mentioned inspection can be debited to Atlet Products.
SERVICE MANUAL
3.6 Service / Regular maintenance / Check list, service inspection
Check list, service inspection
For further information about procedures for inspections, repairs and replacements refer
to respective sections. Planned service inspections are implemented in accordance with
the following points:
Chassis
Inspection points Symptom Inspection Service code
Signs/Decals None, illegible Visual 1024, 1101
Panels Attachment, damage Visual, tools 1102, 1032
Load wheel, Cas- Damage, wear Visual 1108, 1109
tor wheel
Noise Listen, tool
Attachment Visual, tools
Rubber mats, Rub- Damage Visual 1105, 1058
ber protectors
Chassis, general Appearance 1001, 1033,
Visual 1112
Damage Visual
Tightening
torque: Loose screws, bolts Tools
195Nm (lever bolts 195 Nm)
Driving seat, seat Settings, tilt, load and Visual 1107
angle adjustments,
attachment to the
chassis, damage,
lubrication, seat
switch (10w46 - )
Mast
Pull rods Locking. Tools 2105
Damage Visual
Forks Cracks, damage Visual 2026
Wear Visual
Angle, deformation Visual, tools
Fork carriage Cracks, damage Visual 2007, 2004
Play, damage, wear Visual, operating
on rollers test
Angle, deformation Visual
Attachment rollers Visual, tools
SERVICE MANUAL
Service / Regular maintenance / Check list, service inspection 3.7
Mast
Mast sections Cracks, damage Visual 2101
Wear, cracks Visual
Drive unit
Gearbox Oil level Visual, filling 3006, 3101,
3107
Oil leakage Visual, tools
Traction motor Function, noise Listen, tool 7028, 7113,
7039, 7027,
Cable connections Visual, tools 7112
Drive wheel Noise Listen, tool 3002, 3005
Damage, wear Visual
Attachment, play Visual, tools
Sliding bearing Noise Listen, lubricate 3103
Drive shaft Noise Listen, tool 3104
Gear Noise Listen, tool 3102, 3106
Steering
Guide bearing Noise Listen, lubricate 4101
Tiller arm attach- Play Visual 4103
ment
Attachment Tools
Guide belt Play Visual 4005
Brake
Braking force Malfunction Function test, tools 5012
Parking brake Malfunction Function test, tools 5014
Brake cable Abrasion Visual 5002
Brake disc Wear Visual, tools 5104
SERVICE MANUAL
3.8 Service / Regular maintenance / Check list, service inspection
Hydraulic system
Hydraulic tank Oil level Visual, filling 6012, 6102
Damage, leakage Visual, cleaning
contamination
Filter blocked Visual, replace
Cylinders Function Function test, stop- 6001, 6017
watch
Damage Visual, replace
Leakage Visual, tools,
replace
Weld damage Visual, tools,
replace
Damage, Visual, tools
chain attachments
Hoses Leakage, damage Visual, tools 6007, 6008
Nipples Leakage Visual, tools 6019
Pump motor Function, noise Listen, tool 7030, 7029
Cable Visual, tools
connections
Hydraulic pump Leakage Visual, tools 6109
Damage Visual, tools
Noise Listen
Relief valve Malfunction Test 6105
Leakage Visual, tools
Solenoid valve Malfunction Test 6018
Prop. valve Malfunction Test 6018
For more information regarding the hydraulic system, also see section 8 and lift cylinders
section 9.
SERVICE MANUAL
Service / Regular maintenance / Check list, service inspection 3.9
Electrical system
Contactors Malfunction Visual, tools, 7107
replace
Cable break Visual, tools
Contactor tip Visual, tools
Battery Charging Tools 7032
Low acid level Tools
Low acid weight Tools
Damage Visual
Transistor Cable break Visual, tools 7025
system AC
Cabling Damage, break Visual, tools 7007, 7009
7010, 7039
7104, 7112
Horn Malfunction Function test 7014
Speed controller Attachment Visual, tools 7011, 7106
Malfunction Function test
Calibration
Fuses Blown Visual, replace 7103
Battery plug Malfunction Function test, 7008
tools
Hour meter Malfunction 7012
Battery indicator Malfunction 7013
Safety switch Emergency stop Malfunction 7020
Microswitch Function Function test 7017
ATC T4 Function Visual 7004
Cable connections
SERVICE MANUAL
3.10 Service / Regular maintenance / Code explanation
Code explanation
Chassis
Code Designation Check Reference to
section
1001 Machine housing Cracks in weld joints, collision damage, tight- 1
ening of screws/attachments.
1024 Machine plate Attachment: text should correspond with 1
machine type, and symbols and warning decals
should be fitted.
1032 Panels Attached with screws and clips, as well as 4
bonded parts.
1033 Colour Peeling of paint and 1
attachment/lack of decals.
1042 Load guard Cracks in weld joints, collision damage, tight- 1
ening of screws/attachments.
1058 Rubber strips Attached with glue or -
screws/weld bolts
1101 Decals Damage -
1102 Chassis, covers Damage, battery cover 4
1108 Load wheel bearing The operation is frictionless, remove any string, 4
1109 Castor wheel bearing plastic bands etc. that have stuck. 6
Vulkollan wheel wear. Dirt.
1112 Accessories User Manual, areometer and battery water bot- -
tle.
Mast
section
2004 Frame section Attachment of the mast in machine housing. 1
2007 Rollers in fork car- Washers. Lubrication of roller surfaces. 1
riage 6
2026 Forks Cracks, damage, parallelism, height over 6
floor.
2101 Mast play Check max play, Cams. Lubricate slide sur- 6
faces.
2102 Lift chains Check wear. 4
2105 Push rods / Pull rods Locking, damage 6
SERVICE MANUAL
Service / Regular maintenance / Code explanation 3.11
Drive unit
section
3002 Drive wheel Wear, damage, clean 5
3005 Drive wheel bolt Attachment. 5
3006 Oil leakage Leakage from axles, joints, plugs or 5
material.
3101 Oil level Oil level. Oil change. 1
5
3102 Noise Gears. 5
3103 Sliding bearing Noise, lubrication 5
3104 Drive shaft Tightening, play 5
3106 Gears Gear ratio 5
3107 Gear housing Check wear. 5
Steering
section
4103 Tiller arm attachment Play, bushings, attachment 7
4104 Guide bearing Play, lubrication 1
7
Brake unit
section
5002 Brake cable Attachment, damage 11
5012 Braking force Braking distance 11
5014 Parking brake Function, cable connections 11
5104 Brake discs Friction surface> min level all round 11
SERVICE MANUAL
3.12 Service / Regular maintenance / Code explanation
Hydraulic system
section
6001 Lift cylinders Leakage at attachments, weld joints, 9
scraper, piston rod
6007 Couplings Leakage. -
6008 Hoses Cracks, wear, damage. 1
6012 Oil level in tank Oil level between min and max. 1
8
6017 Lowering Check lowering speed. 8
6018 Solenoid valve Leakage in slide, connections, tightening. -
6019 Nipples Leakage. Tightening. -
6102 Filter Replace if necessary. 8
6105 Relief valve Function, adjustment as per max 8
lifting capacity. Locking.
6109 Hydraulic pump Leakage between pump and motor. -
SERVICE MANUAL
Service / Regular maintenance / Code explanation 3.13
Electrical system
section
7004 Truck computer Error log. 10
7007 Battery cables Attachment, damage. -
7008 Battery connections That cable connections are not overheating. -
Remove oxide.
7009 Main power cable Attachment, damage. -
7010 Control cable Attachment, damage. -
7011 Speed controller Function. -
7014 Horn Function. Oxide deposits. -
7017 Microswitch Function. Attachment. -
7020 Emergency switch Function. -
7025 Transistor system Dirt, moisture. Cable connections, oxide. -
7029 Pump motor carbon Wear. 8
brushes
7030 Pump motor Attachment. Cleaning. 5
7032 Battery Acid level, charging. Note: read-off from -
hydrometer, clean if necessary.
7035 Speed switch Switches in gates and platform that control 10
creep speed. Attachment.
7103 Fuses That they are not brittle, oxidised. 1
7104 Cabling Cable connections, attachment, run free from -
sharp edges. Insulation.
7106 Speed controller Attachment and function. 11
7107 Contactors Contact surfaces, cable connections, -
dust guard.
7112 Traction motor cables Attachment, damage, insulation, oxidation. -
7039
7113 Housing, traction Noise, grease, play. 5
motor
SERVICE MANUAL
3.14 Service / Regular maintenance / Lubrication chart
Lubrication chart
Note!
For recommended oil and grease types, see section 1.
PLP
D
C
E
2
G
Figure 3.1 Lubrication chart PLP. For explanation of symbols, see table 3.2
1. 500 h service
2. Annual service
All the panels must be removed when lubricating the truck, see section 4. The electric
panel should also be released and folded back to improve access. The electric panel is fit-
ted with two socket head cap screws to the battery wall. When lubricating the mast sec-
tions, push out the battery slightly and brush grease on the roller and slide surfaces.
Service on an Atlet truck can be divided into service that should be carried out regardless
of how severely the truck is loaded and used (see "Check list, service inspection" on page
3.6) and an annual recurrent service:
SERVICE MANUAL
Service / Regular maintenance / Lubrication chart 3.15
Table 3.1 Components to lubricate, PLP

Position- Explanation
ing
A Mast section – roller surfaces and slide surfaces
B Gates – bearing surfaces lubricated
C Spring-mounted drive unit – link bearings, 12 grease nipples
D Hydraulic oil
E Castor wheel - sliding bearings, 2 grease nipples
F Gearbox oil
G Platform, 2 grease nipples
Symbol key, lubrication chart
Table 3.2 Symbol key for lubrication chart

Symbol Explanation Symbol Explanation
Hydraulic oil Hydraulic oil, change
Gearbox oil Gearbox oil, change
Grease Chain spray
Chain spray / oil Only cold store version
Applicable in general for the symbols:

• Unfilled symbol – Check / lubrication.
• Filled symbol – Change.
SERVICE MANUAL
3.16 Service / Specific instructions / Traction motor
Specific instructions
Note!
Traction motor
Preventive maintenance
Preventive maintenance is implemented in accordance with the recommended intervals
in the service chart.
In some cases, however, exceptions must be made and the intervals shortened in relation
to the conditions at the customer, e.g. a severe environment with dust, high humidity lev-
els, or salt, etc.
• Listen for abnormal noise from the bearings when the motor is run. Check that it
does not vibrate abnormally.
• The motor is blown clean with dry compressed air, or cleaned with a vacuum
cleaner. A cleaning fluid should be used to drive out oil and dirt, if oil has leaked
from the gearbox into the motor.
• Check the insulation resistance for the motor, see specification in section 1 for cor-
rect value.
Gearbox
First service
• The first oil change should be made after approx. 200 hours.
First oil
change after
• Use a recommended type of oil, see section 1.

200 hours
Preventive maintenance
Oil level
• The oil level is checked during each service.
checked dur-
ing each
service
• The guide bearing must be greased at least once a year. New greasing is essential if
steam cleaning or high-pressure washing has been carried out.
Note!
Remember to fill up the gearbox after changing the oil or changing the gearbox. See
section 5 for procedure.
SERVICE MANUAL
Service / Specific instructions / Lift chains and forks 3.17
Note!
Spent oil should be taken care of and recycled according to the applicable legislation
in respective countries.
Lift chains and forks
Check
For safety reasons the forks should be checked during each service, see "Check list, serv-
The forks
ice inspection" on page 3.6
should be
checked dur-
ing each serv-
ice
SERVICE MANUAL
3.18 Service / Specific instructions / Hydraulic oil
Hydraulic oil
Note!
First service
Hydraulic oil
filer change
after 500 • Oil filters should be changed after 500 hours.

hours
Intervals
After 500 hours of operation: The hydraulic oil filter and air filter to the hydraulic oil
tank should be changed after no more than 500 hours of operation. This refers to those
types of trucks that have replaceable filters. Clean the suction filter.
After every 1000 hours of operation: Change the hydraulic oil, oil filter and air filter
after 1000 hours of operation, or once every year (which ever comes is first).
If the hydraulic oil has been heated over 60 degrees Celsius the oil and the filter should
be immediately replaced since its lubricating properties can have been changed.
If the hydraulic oil has been contaminated with water (e.g. from cold store) this can be
detected in that the oil becomes milky, or smells bad.
It can also be checked with the following simple test:
1. Use protective glasses, gloves and clothes, and observe the fire instructions for the
premises.
Warning!
Risk for burn injuries on the skin.
2. Take a little hydraulic oil in a teaspoon and heat the spoon with a cigarette lighter –
if there is a crackling sound this proves that it contains water and should be
changed.
The hydraulic oil should be filtered when filling, by pouring the oil through the filter.
Emergency stop
Special emphasis should be placed on the inspection of the emergency stop. Of the con-
tactor tip seems to be worn during a visual inspection, it should be replaced on a preven-
tive basis. Applies to emergency stop SE.
Warning!
The unit should be replaced if the emergency stop has been used in a dangerous sit-
uation.
SERVICE MANUAL
Service / Specific instructions / Recommended replacement 3.19
Recommended replacement
Hydraulic hoses should be replaced after 5 years, since the rubber in the hose is perisha-
ble.
Storage of machines and motors

Machines in storage that will not to be used within one month, must be given special at-
tention so that problems do not occur when they are to be used again. Dust, dirt, conden-
sation and moisture caused by large changes in temperature and problems with rust and
oxidisation must be prevented. Motors should therefore be protected with waxed paper
or the like, and a moisture absorbing material.
SERVICE MANUAL
3.20 Service / Specific instructions / Storage of machines and motors
SERVICE MANUAL
SERVICE MANUAL
Machine : PLP
Manual no: 119002
Edition 2010B
4 Chassis
4.1 Design and function .....................................................................................................4.3

4.1.1 Scope ..............................................................................................................4.3
4.1.2 Machine housing .............................................................................................4.3
4.1.3 “Friction force” system .....................................................................................4.4
4.1.4 Covers and panels ..........................................................................................4.4
4.1.5 Castor wheel ...................................................................................................4.4
4.2 Repair and maintenance instructions .........................................................................4.5

4.2.1 Covers and panels ..........................................................................................4.5
4.2.2 Castor wheel ...................................................................................................4.6
4.2.3 Mechanical “friction force” (–2010w21) ...........................................................4.7
4.2.4 Hydraulical “friction force” (2010w22–) ...........................................................4.8
4.2.5 Battery .............................................................................................................4.9
SERVICE MANUAL PLP

4.2
SERVICE MANUAL PLP

Chassis / Design and function 4.3
Edition 2010B
4 Chassis
4.1 Design and function
4.1.1 Scope
A chassis normally includes the supporting parts of a construction and in the case
of a truck the chassis consists of the machine housing, panels and castor wheel.
The straddle lift and load wheel could be considered to be part of the chassis, but
since they are part of the mast the instructions for these are to be found in chapter
6, Mast, instead.
4.1.2 Machine housing

The chassis on the PLP truck consists of a machine housing. This is where all the
truck components, such as the mast, drive unit, and hydraulic system are mounted.
Figure 4.1 Machine housing PLP, mechanical “friction force” (-2010w21)
SERVICE MANUAL PLP

4.4 Chassis / Design and function
Figure 4.2 Machine housing PLP, hydraulical “friction force” (2010w22-)
4.1.3 “Friction force” system

A “friction force” system will increase the pressure on the drive wheel as more load
is placed on the forks, providing greater traction and minimizing the risk of sliding
when turning corners with a load. The latest system is hydraulically controlled as
opposed to the previously mechanically controlled system.
4.1.4 Covers and panels

The function of the panels is to protect the driver from moving parts, electrical
components, oils and fluids, and to protect the components inside from external
damage and dirtying.
4.1.5 Castor wheel

The caster wheel is a fully turning, non-driven wheel placed under the machine
housing. PLP has two castor wheels.
SERVICE MANUAL PLP

Chassis / Repair and maintenance instructions 4.5
4.2 Repair and maintenance instructions
4.2.1 Covers and panels

The recyclable panels are manufactured of sheet metal and durable plastic.
4.2.1.1 Dismantling of panels

1. Loosen the two screws to the side panels (pos 1), from the
outside. Remove the panels.
2. Loosen the plate bolts (pos 2).
3. To remove the panels pos 3, you must first unscrew the knob on the
emergency stop button. Press in the emergency stop. Pick off the small
plastic plug that is located in the plastic cover on the battery. Insert a round
bar or similar with a diameter of around 3 mm. Turn the emergency stop
button until the hole in the axle is identified. Then remove the emergency
stop button by turning anti-clockwise. Remove the two retaining screws and
lift out the panels by unfolding the gates to 3/4 and work the panels over the
gates.
4. The battery cover, pos 4 and 5, has four screws that can be accessed by
opening the cover. Loosen these and lift off the cover and plastic panel.
3
1
Figure 4.3
Clean the panels with soapy water. White impact marks may appear in the case of
minor damage to the plastic panels. These marks can be removed by carefully
heating with a hot air gun.
SERVICE MANUAL PLP

4.6 Chassis / Repair and maintenance instructions
4.2.2 Castor wheel
12
15
17
1 14 13
4 16
7
11
10
8 9
Figure 4.4
4.2.2.1 Dismantling the castor wheel/bearing

• Remove the plastic cover from the machine housing.
• Lift up the machine housing approx. 30 cm, and secure with blocks underneath.
• Loosen the bolts, pos. 12, see Figure 4.4.
• Take out the castor wheel unit and support the fork in a vice.
• Tap out the retaining pin, pos. 11, drive out the wheel axle, pos. 7, and remove
the wheel from the fork.
Note!
Take care of the spacers, pos. 8.
• Support the wheel in the vice instead of the fork.
• Pull out the bearings with a bearing extractor.
SERVICE MANUAL PLP

4.2.2.2 Assembling the castor wheel/bearing

• Lubricate the wheel bearing seats with grease, and press in the bearings with a
suitable drift.
• Place the wheel fork with the side facing down.
• Hold the wheel and spacers together, and insert the wheel in the fork.
• Fit the wheel axle, pos. 7.
• Tap in the retaining pin, pos. 11.
• Bring up the complete castor wheel under the machine housing, and fit the
screws, pos. 12.
Note!
Check the positioning to make sure the grease cup comes in the right direction.
• Tighten to the correct torque.
• Fit the plastic cover and lift down the machine to the floor.
4.2.3 Mechanical “friction force” (–2010w21)

The mechanical “friction force” system has two mechanical springs.
4.2.3.1 Adjusting the “friction force” tension

• Adjust the tension of the mechanically adjusted springs by loosening the top nut
(A) and adjust the spring height to 169 mm (PLP 200) /157 mm (PLP 250) with the
inner nut (B). Secure with the top nut.
A
B
Figure 4.5 Mechanical “friction force”
SERVICE MANUAL PLP

4.2.4 Hydraulical “friction force” (2010w22–)

The hydraulical “friction force” system has two springs, one mechanically adjusted
spring and one which is hydraulically adjusted.
The left hand spring (red) is attached to the drive unit housing and is mechanically
adjusted at the top of the spring.
The right hand spring (yellow) is mounted to a pull cylinder which is connected to
the hydraulic lift system. The screw positioned on top of the cylinder is equipped
with a air breather and locks the spring to the guide bracket.
When mounting the hydraulical spring make sure the hydraulic hose has free
Tightening
torque:
movement from the drive unit housing to make sure it is free from contact. Tighten
36 Nm the top screw with 36 Nm.
D
A
B
Figure 4.6 Hydraulical “friction force”
4.2.4.1 Adjusting the “friction force” tension
Note!
When adjusting the tension the truck must stand on the floor.
• Adjust the tension of the mechanically adjusted spring by loosening the top nut (A)
and adjust the spring height to 169 mm (PLP 200) /157 mm (PLP 250) with the inner
nut (B). Secure with the top nut.
Note!
The hydraulical spring is mounted with no tension.
SERVICE MANUAL PLP

4.2.4.2 Adjusting the position of the drive unit housing

To achieve a more stable traction the sideway movement of the drive unit housing
can be adjusted.
• Loosen the two locking screws (C) located on either side of the drive unit
housing.
• Fully tighten the two adjusting screws (D), then turn the adjusting screws ¼
turn counterclockwise.
• Secure with the locking screws.
4.2.5 Battery
4.2.5.1 Changing the battery

Work in an area where the old battery can be removed without risk to the
environment from battery acid. Wear acidproof gloves and clothes, plus acidproof
glasses, to provide protection from burn injuries.
A battery trolley must be used when changing the battery.
1. Separate the battery plug.
Figure 4.7 Illustration of changing the battery
2. Release the battery lock.

3. Roll out the battery onto the battery trolley.
Warning!
Observe care to avoid “splashing” waste acid or oxide from the battery.
4.2.5.2 Replacing the battery rollers

0
1. Remove the battery.
SERVICE MANUAL PLP

Warning!
Observe care to avoid “splashing” waste acid or oxide from the battery.
2. The battery rollers are loose in their seats. Lift up the rollers in the back edge,
and pull backwards and upwards.
SERVICE MANUAL PLP

SERVICE MANUAL
Machine : PLP
Manual no: 119002
Edition 2010B
5 Drive unit

5.1.1 Introduction .....................................................................................................5.3
5.1.2 Traction motor .................................................................................................5.3
5.1.3 Gearbox ..........................................................................................................5.3

5.2.1 Preparations ....................................................................................................5.4
5.2.2 Dismantling the drive unit housing (–2010w21) ..............................................5.4
5.2.3 Assembling the drive unit housing (–2010w21) ..............................................5.5
5.2.4 Dismantling the drive unit housing (2010w22–) ..............................................5.6
5.2.5 Assembling the drive unit housing (2010w22–) ..............................................5.7
5.2.6 Traction motor .................................................................................................5.7
5.2.7 Gearbox ..........................................................................................................5.7
5.2.8 Drive wheel .....................................................................................................5.9
5.3 Diagnostics and trouble shooting .............................................................................5.10

5.3.1 Trouble shooting chart ...................................................................................5.10
SERVICE MANUAL PLP

5.2
SERVICE MANUAL PLP

Drive unit / Design and function 5.3
Edition 2010B
5 Drive unit
5.1.1 Introduction
The drive unit is mounted in a vertically moving assembly containing the brakes,
traction motor, gearbox and drive wheel.
PLP is equipped with a technical solution for five-wheel pedestrian trucks,
designated Friction Force, which efficiently ensures that an optimum drive wheel
pressure is always available.
Friction Force utilises the principle of increasing the force on the load wheel with
an increasing effective force on the forks. The load wheel force is transferred via a
link system to the vertically moving suspended drive wheel, so that the wheel forces
are concentrated there. The suspension also includes compression springs, which
make the wheel insensitive to irregularities in the floor and ensure an optimum drive
wheel pressure even when the truck is not loaded.
Friction Force also ensures improved ergonomics in that a cushioning effect is also
achieved at the load wheel and also by reducing rattling noise in the lifting system.
For technical data regarding component parts, see section 1.
5.1.2 Traction motor

The traction motor on PLP is a three-phase induction motor. A pulse transducer is
enclosed in the bearing on the non-driving end of the motor and this provides speed
return to the traction controller, see section 10.
The motor is mounted directly on the gearbox and the transmission of power takes
place via individually adjusted gear wheels.
5.1.3 Gearbox
The gearbox is designed to produce the best gear ratio over the speed range of the
traction motor.
SERVICE MANUAL PLP

5.4 Drive unit / Repair and maintenance instructions
5.2.1 Preparations
2. Remove the panels on the machine housing, see section 4.
5.2.2 Dismantling the drive unit housing (–2010w21)
2
1
Figure 5.1
1. Dismantle the gates. Start with the gas spring.

2. Release all the electrical connections to the traction motor and brake.
3. Release the electric panel and fold back.
4. Release the gas spring to the platform.
5. Unscrew the eight socket head cap screws holding the traction motor, and lift
it out.
Important!
Protect the motor shaft and the hole in the gearbox, e.g. with rags.
6. Unscrew the three socket head cap screws holding the motor bed to the
gearbox. Lift out the motor bed.
7. Release the two springs pressing down the drive wheel when it is unloaded
by completely screwing off the four nuts. Use a long socket.
8. The two long bolts to the springs must be taken out from underneath. Lift up
the truck to a suitable height and secure with blocks. Remove the two bolts.
SERVICE MANUAL PLP

Drive unit / Repair and maintenance instructions 5.5
9. Release and remove the cable duct on the top of the machine housing.
10. Release the electrical connections to the tiller arm, and release and lift out the
complete assembly with steering axle, tiller arm head and guide belt.
11. Release and drive out the two shafts (pos. 1 in fig. Figure 5.1) in the lower
link arms as far as is possible. The shafts must not be completely removed.
12. Release and drive out the four shafts (pos. 2 and 3. in fig. Figure 5.1) in the
upper link arms.
13. The drive unit housing can now be lifted out from the truck. Mark the
position of the gearbox in the drive unit housing before removing the
gearbox from the housing.
5.2.3 Assembling the drive unit housing (–2010w21)

1. Assemble in reverse order. Adjust the spring tension, as
described in Section 4, “Adjusting the spring tension friction
force”.
Important!
Note that the spring tension is to be set when the truck is lowered so that the
drive wheel and caster wheel are on the same level.
Important!
When you refit the guide belt, it is important that the drive wheel is straight
and has wheel nuts on the left side as seen from behind, and the stop lug on the
steering axle is pointing straight backwards. If this is incorrect the steering's
zero position will be wrong.
SERVICE MANUAL PLP

5.2.4 Dismantling the drive unit housing (2010w22–)
Bild 5.2
1. Disconnect the gates. Start with the gas spring.

2. Disconnect all electrical connections to the drive motor and brake.
3. Remove the electrical panel and fold it aside.
4. Remove the gas spring to the platform.
5. Loosen the eight Allen screws that secure the drive motor and lift it out.
Important!
Protect the motor shaft and the hole in the gearbox with rags etc.
6. Loosen the three Allen screws that attach the motor bed to the gearbox. Lift
out the motor bed.
7. Disconnect the hydraulic hose connected to the traction cylinder (pos 1 Bild
5.2). Make sure the hydraulic system is depressurised by checking the blades
are lowered.
8. Lift the truck high enough to secure with blocks.
9. Remove the nuts that attach the traction cylinder and the right-hand spring
(yellow) on the underside of the drive unit housing (pos 2 Bild 5.2).
10. Remove the two Allen screws that attach the holder with the traction cylinder
to the drive unit housing (pos 3 Bild 5.2).
11. Remove the spring (yellow), traction cylinder and holder.
Important!
Avoid turning the top screw on the traction cylinder as the plate in the holder
may end up in the wrong position in relation to the hydraulic coupling.
SERVICE MANUAL PLP

12. Remove the left spring (red) by unscrewing the nuts (pos 4 Bild 5.2) with a
long sleeve. Take out the long bolt downwards.
13. Disconnect and remove the cable duct on the top of the machine housing.
14. Remove the electrical connections to the steering arm, loosen and lift out the
whole assembly with the steering axle, steering arm head and guide belt.
15. Loosen and drive out the four axles in the link arms (pos 5 Bild 5.2).
16. You can now remove the drive unit housing from the truck. Mark the position of
the gearbox in the drive unit housing before removing the gearbox from the
housing.
5.2.5 Assembling the drive unit housing (2010w22–)

1. Assemble in reverse order. Adjust the spring tension on the left
spring (red), as described in Section 4, “Adjusting the spring
tension friction force”.
Important!
Note that the spring tension is to be set when the truck is lowered so that the
drive wheel and caster wheel are on the same level.
Important!
Fit the hydraulic spring (yellow) without preloading.
Important!
When you refit the guide belt, it is important that the drive wheel is straight
and has wheel nuts on the left side as seen from behind, and the stop lug on the
steering axle is pointing straight backwards. If this is incorrect the steering's
zero position will be wrong.
5.2.6 Traction motor

The traction motor is mounted on the top of the inner ring in the guide bearing, with
a total of six screws. When assembling and dismantling the traction motor the
contact surfaces between the motor and gearbox must be thoroughly cleaned. It is
also important that the pinion teeth are in line with the drive teeth so that the tooth
flanks are not damaged.
5.2.6.1 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
with waxed paper or the like, and a moisture absorbing material.
5.2.7 Gearbox
Service work on the gearbox is limited to changing the wheel studs on the wheel and
changing the lower shaft seal.
SERVICE MANUAL PLP

5.2.7.1 Motor mounting

The motor mounting is screwed in the gearbox with three socket head cap screws.
These should be treated with Loctite 243 or the equivalent when fitted.
5.2.7.2 Changing the wheel studs

After removing the wheel stud that is to be changed the threads on the new wheel
stud and the threads in the hole should be cleaned from oil and grease. The threads
should be treated with Loctite 243 or the equivalent before the new wheel stud is
screwed in.
5.2.7.3 Lower shaft seal on the gearbox

The shaft seal can be removed after removing the protective disc.
The seal seat in the casing and the surface to which the seal is to seal should be
cleaned before fitting a new seal. The seal should also be greased before it is fitted.
The protective disc is replaced after fitting the shaft seal.
5.2.7.4 Guide bearing

The guide bearing is protected by rubber rings and is maintenance-free as long as
not special cleaning has been carried out with a high-pressure jet.
5.2.7.5 Gear collar and drive pinion

The guide gear collar and drive pinion on the gearbox should be greased with
standard grease.
5.2.7.6 Checking the oil level and filling up with oil

Oil is poured in through the upper filler screw hole. The correct level is at the lower
edge of the hole.
The oil level should be regularly checked to avoid damaging the gearbox.
5.2.7.7 Oil change

The oil is drained out through the lower oil plug hole. The oil can be drained more
easily if it is warm.
Spent oil should be taken care of and recycled according to the applicable
legislation in respective countries.
Before screwing in the oil plug again it should be cleaned.
SERVICE MANUAL PLP

5.2.8 Drive wheel
5.2.8.1 Replacing the drive wheel

0
1. Loosen the wheel nuts.

2. Lift up the truck so that the drive wheel can rotate freely.
4. Turn the drive wheel 45°.
Figure 5.3 Loosen the nuts on the drive wheel.
5. Remove the wheel nuts.

6. Replace the drive wheel.
7. Tighten the wheel nuts to 84 Nm.
8. Start the truck and test drive in both directions. The wheel must not catch or
jam.
SERVICE MANUAL PLP

5.10 Drive unit / Diagnostics and trouble shooting
5.3 Diagnostics and trouble shooting
5.3.1 Trouble shooting chart
Table 5.2
Symptom Cause Action
The wheel has a flapping The tyre has separated 1. Change the wheel.
sound when driving. due to impact.
2. Examine the floor for any
irregularities.
The wheel squeaks Bearing is damaged. 1. Replace bearing.

continuously when driving.
2. Inform the driver that
string and plastic etc.
should be removed daily,
and the floor kept clean.
The wheel is flat after long The wheel mass has become Try a different type of wheel.
breaks, but becomes round warm while driving and
after driving for a while. deforms when parked.
The wheel has a deformity A “blow out” has taken Change the wheel.
that does not disappear place due to overheating
when driving. and changed the molecular
structure of the wheel mass.
The truck seems to jerk Hard foreign object has 1. Remove the object or
when driving. fastened in the drive wheel. change the wheel.
2. See also items above.
The truck jumps at regular The wheel is oval. 1. Change the wheel.
intervals, proportional to the
2. Check/adjust the brake.
speed, when driving.
3. See also items above.
The wheel has transverse The wheel has been heated. 1. Lower the acceleration
cracks, and small bits have Small cracks appear with and reversing rate.
fallen out of the tyre. hard acceleration and
2. Change the wheel if nec-
reversing.
essary.
The wheel has one or more Locking of the brakes so 1. Remove objects on the
small deformations. that the wheel slides, or floor.
loose objects on the floor
2. Tell the driver to brake
that prevent the wheel from
more smoothly.
rotating.
Oil on the floor. Leaking seal around the • Replace seal

drive axle.
or:
• If there are cracks in the
casting the gearbox must
be replaced.
SERVICE MANUAL PLP

Drive unit / Diagnostics and trouble shooting 5.11
Table 5.2
Symptom Cause Action
Grating noise when 1. Defective gear wheel in Check the teeth by removing
accelerating or using the the drive unit. the cover.
reversing brake.
2. Too little oil in the gear- If there are cracks in the
box. casting the gearbox must be
replaced.
Grating noise when the Faulty bearing in the Dismantle and renovate the
truck is lifted up and the traction motor. traction motor.
drive wheel can rotate freely
and the motor rotates.
The truck rolls "sluggishly". 1. The brakes are applied. • Replace brake disc.
If this does not help:
• replace the complete

brake unit.
2. The drive unit has If there are cracks in the

seized. casting the gearbox must be
replaced.
Clicking sound when Faulty wheel bearing. Change the wheel.

driving.
Clicking sound when Loose wheel. • Tighten the wheel.

driving.
If this does not help:
• Change the wheel.
The drive unit pulls at an 1. Too much slack in con- 1. Tighten the control belt,
angle which is felt in the trol belt. see Chapter 7.
tiller arm. This makes it
2. The drive unit leans. 2. The bushings in the links
difficult maintaining the
for the drive unit housing
right course when 3. The machine housing
should be replaced.
accelerating and braking. leans.
(Applies to ma-chines 3. The caster wheels are un-
4. Drive wheel camber
without servo) evenly worn. Replace
missing. Or track is
both caster wheels, or use
worn.
shims.
4. Replace drive wheel. See
also Parts and Service
News 2093.
SERVICE MANUAL PLP

5.12 Drive unit / Diagnostics and trouble shooting
SERVICE MANUAL PLP

SERVICE MANUAL
Machine : PLP
Manual no: 119002
Edition 2010B
6 Mast system

6.1.1 Lift system .......................................................................................................6.3

6.2.1 Replacing the fork carriage .............................................................................6.4
6.2.2 Replacing pressure plates (2010w22–) ...........................................................6.5
6.2.3 Adjusting the fork carriage ..............................................................................6.6
6.3 Diagnostics and trouble shooting ...............................................................................6.7

6.3.1 Trouble shooting chart .....................................................................................6.7
SERVICE MANUAL PLP

6.2
SERVICE MANUAL PLP

Mast system / Design and function 6.3
Edition 2010B
6 Mast system
6.1.1 Lift system

The truck variants PLP 200 and PLP 250 have low-lifting fork carriages.
Figure 6.1
SERVICE MANUAL PLP

6.4 Mast system / Repair and maintenance instructions
6.2.1 Replacing the fork carriage
6.2.1.1 Dismantling the fork carriage

2. Remove the covers over the machine housing.
3. Release and drive out the four shafts, pos. 1 and 2.
Figure 6.2
4. Mechanical steering: Lift the fork carriage straight up.

Hydraulical steering: Lift the machine housing straight up to detach the fork
carriage.
Important!
Observe great caution!
6.2.1.2 Mounting the fork carriage

Mount the fork carriage in reverse order.
SERVICE MANUAL PLP

Mast system / Repair and maintenance instructions 6.5
6.2.2 Replacing pressure plates (2010w22–)

For the hydraulically controlled friction force system there are pressure plates
mounted between the chassis and the pull bars.
6.2.2.1 Dismantling the pressure plate

• Unscrew the nuts holding the pressure plate.
• Remove the pressure plate.
6.2.2.2 Mounting the pressure plate

• Push the pressure plate through the chassis holes and lock in place with washer
Tightening
torque:
and nut.
9,8 Nm • Tighten with 9,8 Nm.
9,8 Nm
Figure 6.3
SERVICE MANUAL PLP

6.6 Mast system / Repair and maintenance instructions
6.2.3 Adjusting the fork carriage

The truck must stand on a level surface. Lower the forks and check the height from
the floor to the top of the forks. The height should be 85-90 mm with a difference of
only 5 mm between the four measuring points, see Figure 6.4. If the forks are too
high, or too low, this is adjusted with the adjusting screw over the lift cylinder.
85 +8
-0
85 +8
-0
Figure 6.4
SERVICE MANUAL PLP

Mast system / Diagnostics and trouble shooting 6.7
6.3.1 Trouble shooting chart

0
Figure 6.5 Symptom/Action table
Symptom Possible reason Action
Play to mast. Mast rollers not shimmed enough. Adjust the side
supports.
The fork carriage Side supports adjusted too hard. Adjust the side
lowers unevenly, supports.
jumps.
No grease on the mast roller surfaces. Grease roller
surfaces.
The fork carriage No grease on the mast roller surfaces. Grease roller
squeaks. surfaces.
SERVICE MANUAL PLP

6.8 Mast system / Diagnostics and trouble shooting
SERVICE MANUAL PLP

SERVICE MANUAL
Machine : PLP
Manual no: 119002
Edition 2010B
7 Steering

7.1.1 General ...........................................................................................................7.3
7.1.2 Steering ...........................................................................................................7.3
7.1.3 Servo unit (–2005w19) ....................................................................................7.3
7.1.4 Servo unit (2005w20–) ....................................................................................7.5

7.2.1 Cleaning ..........................................................................................................7.7
7.2.2 Tiller arm head (–2007w27) ............................................................................7.7
7.2.3 Tiller arm head (2007w28–) ............................................................................7.8
7.2.4 Tiller arm (2007w28–) ...................................................................................7.12
7.2.5 Replacing the steering belt ............................................................................7.13
7.2.6 Adjusting the steering belt .............................................................................7.13
7.2.7 Adjustment, limit switch .................................................................................7.13
7.2.8 Adjustment, electrical steering ......................................................................7.14
7.2.9 Servo steering (2006w15–) ...........................................................................7.17
SERVICE MANUAL PLP

7.2
SERVICE MANUAL PLP

Steering / Design and function 7.3
Edition 2010B
7 Steering
7.1.1 General
The steering movement is transferred mechanically from the tiller arm to the drive
unit with a drive belt.
7.1.2 Steering
The truck is steered by turning the complete tiller arm, which via a drive belt affects
the angle of the drive wheel. There is a switch in the arm, which by means of
switching off the current and actuating the brake causes the truck to stop when the
arm is in its upper and lower end positions. It is therefore only possible to drive the
truck when the arm is between these end positions. There is also a belly switch,
which stops the truck when pushed in. The purpose of the belly switch it to prevent
the operator being crushed between the truck and other objects.
This electronic steering system is designed as a help system for the mechanical
steering, which means that the servo assists when the mechanical steering is
actuated. The servo unit uses 2 voltage-controlled signals for control and the servo
will shut down if one of the signals fails. A red fault indication lamp lights on the
servo unit in the event of a simple fault and the servo function will fail to operate.
The truck will now operate as a normal PLP without servo.
All sensor inputs are short circuit proof against short circuits to the ± battery.
However, the motor connection is not short circuit proof. A contactor is needed in
series with the servomotor so that the servomotor can generate voltage itself. Failure
to connect the battery and performing a quick manoeuvre and if the generated
voltage of the servomotor exceeds 35 Volts will damage the truck's electrical
system.
7.1.3 Servo unit (–2005w19)

The position indicators emit identical output signals to the servo, which are 6.0 volts
in neutral position. The servo will shut down if there is a difference of more than 0.5
volts between the position indicators (red light diodes on PSA Servo box).
The servo has a dead zone of ±0.5 volts around 6.0 volts. Full drive is provided at
±1.7 volts. The dead zone's mid-position can be adjusted ± 0.3V by means of a small
hole on the right underside of the PSA servo box (max 300 degree turn).
The servo function can be blocked by an external signal of 24 volts, which is ± 95-
degree control; there is a mechanical blocking function at ± 105 degrees. When the
servo is blocked the same red light diode lights that indicates incorrectly adjusted
position indicator. The limit switch also breaks the contactor to the servo motor.
SERVICE MANUAL PLP

7.4 Steering / Design and function
7.1.3.1 Servo unit, diagnosis (–2005w19)

Electric power from battery
Table 7.1 2-terminals pin AMP gray
Position Cable colour Description

#1 Red Battery + 16-32V
#2 Blue Battery - 0V
Electric power motor

Table 7.2 2-terminals pin AMP black

#1 Motor +
#2 Black 250 mm Motor -
Sensor 1
Table 7.3 4-terminal minifit pin

#1 Grey Positive feed sensor
12VDC +-5%
#2 White Signal sensor
#3 Not connected
#4 Black 0V
Sensor 2

#1 Grey Positive feed sensor
12VDC +-5%
#2 White Signal sensor
#3 Not connected
#4 Black 0V
Blocking signal from braking


#1 Yellow Blocking 16-32V
#2 Not connected
SERVICE MANUAL PLP

Steering / Design and function 7.5
7.1.4 Servo unit (2005w20–)

The position sensors must produce identical output signals to the servo, 6.0 Volts in
neutral. Where there is more than 1 Volt difference between the position sensors,
the servo shuts down (red LED on the PSA servo box).
The servo has a dead zone of ±0.5 Volts around 6.0 Volts. Full drive is reached at
1.9 Volts.
The servo function can be blocked by an external signal of 24 Volts. This signal is
controlled by a breaker in the arm that is activated when the arm is in active mode.
For older models, an end position breaker can also block the servo function. The
same red LED lights when the servo is blocked as the one that indicates an
incorrectly adjusted position sensor.
SERVICE MANUAL PLP

7.6 Steering / Design and function
7.1.4.1 Servo unit, diagnostics (2005w20–)

Power connection from battery
Table 7.2 Contact piece X22, 5-pin sleeve AMP

# 1, X22.1 Red/Blue Battery +24V
# 2, X22.2 Blue Battery - 0V
# 3, X22.3 Pink/White Blocking signal +24V
Power connection, motor

Table 7.3 Contact piece X22, 5-pin sleeve AMP

# 4, X22.4 Red Motor +
# 5, X22.5 Black Motor -
Sensor 1 and Sensor 2

Table 7.4 Contact piece X24, 8 pin minifit

# 1, X24.1 Orange Positive feed sensor 1,
12VDC +-5%
# 2, X24.2 Green Signal sensor
# 3, X24.3 Black 0V
# 4, X24.4 Black 0V
# 5, X24.5 -
# 6, X24.6 Orange Positive feed sensor 2,

12VDC +-5%
# 7, X24.7 Green Signal sensor
# 8, X24.8 Black 0V
SERVICE MANUAL PLP

Steering / Repair and maintenance instructions 7.7
7.2.1 Cleaning
The tiller arm and tiller arm head are cleaned with compressed air, or by vacuum
cleaning. The covers can be cleaned with lukewarm water and a mild soap solution.
Note!
High-pressure washing must not be used.
7.2.2 Tiller arm head (–2007w27)
7.2.2.1 Replacing
3
3
Figure 7.1 Tiller arm head
1. Loosen the three screws, pos. 3 se Figure 7.1, that secure the
upper cover.
2. Press in the belly switch, pos. 1 se Figure 7.1, and release the cover by
carefully pushing it upwards and outwards.
3. Loosen the two screws, pos. 2 se Figure 7.1.
4. Loosen the requisite connectors to replace the head.
5. Assemble in the reverse order.
SERVICE MANUAL PLP

7.8 Steering / Repair and maintenance instructions
7.2.3 Tiller arm head (2007w28–)
7.2.3.1 Dismantling the tiller arm head

1. Adjust the arm to its shortest position and unscrew the control
lever (only applies to PLP with adjustable arm).
2. Undo the screws that hold the upper and lower cover together.
3. Release the snap on clip (A) at the front of the tiller arm head.
4. Carefully lift up the front section of the upper cover, shown by arrow B. Now
move the upper cover backwards, see arrow C.
Figure 7.2 Dismantling the tiller arm head
5. Turn the upper cover to the right. The cover can now hang by the main cable.
Important!
Make sure the programming cable load is not too great.
Important!
Ensure that no cables get jammed when fitting the head.
SERVICE MANUAL PLP

7.2.3.2 Dismantling buttons lift/lower

1. Open the tiller arm head as shown in the description
“Dismantling the tiller arm head” on page 8.
2. Dismantle the buttons by releasing the snap on clips from the inside, se Figure
7.3.
Figure 7.3 Dismantling buttons lift/lower
3. Dismantle the inner section by sliding it in the direction of the axle. Now lift
the section out from the top.
Important!
Following dismantling, a new button must be fitted as the snap fasteners may
be damaged.
7.2.3.3 Dismantling the speed controller
Important!
Apply the removable thread locking solution, e.g. Loctite 243, to the screws of
the speed controller.
7.2.3.4 Assembly of main cables and brake switch

Attaching the tiller arm main cable (PLP with fixed arm):
Attach the cable to the control lever head using the cable clip. Pull the cable down
to the tiller foot, to the right of the steering shaft. Attach the cable to the machine
with cable ties to the cable bar.
Pull the cable from the break switch to the left of the steering shaft and attach to the
cable bar using cable ties.
Important!
Ensure that the cables do not chafe against any sharp edges.
Important!
The cables are to have enough slack to ensure that you can lower the arm to its
lowest position and turn as far as possible to the left and right without
SERVICE MANUAL PLP

stretching the cable. It must be possible to open the top section of the control
lever head without the cable being a restriction.
Important!
The main cable must not be of such a length that the programming cable has
to take the load when the top part is hanging from the cable.
Attaching the tiller arm main cable (PLP with adjustable arm):
Attach the cable using the cable clip in the tiller arm head. Run the cable down
through the tiller foot, in front of the steering axle to the forks. Attach the cable in
the machine using cable ties on the cable bar.
Important!
The cable should almost be at full stretch when the arm (adjusted in its furthest
position) is in its bottom position and is turned as far as possible to the right or
the left. If this is done correctly, the length of the cable is adjusted to ensure
that it is possible to open the top section of the tiller arm head in such a way
that does not put a strain on the programming cable.
Cable routing standard design
Figure 7.4 Cable routing, standard design
SERVICE MANUAL PLP

Cable routing optional
Figure 7.5 Cable routing, optional
Table 7.2 Cable routing, optional
Position Description
1 Smartcard
2 Heat resistance
SERVICE MANUAL PLP

7.2.4 Tiller arm (2007w28–)
7.2.4.1 Dismantling the gas spring
14
8
13
12
30
9 7
6
5
29
2
31
4 32
SM_PLP_07015A.eps 33
3
Figure 7.6 Tiller arm
1. Loosen the screw (14).

2. Loosen the cam (12) by angling the arm at about 45º and then moving the
cam forwards.
3. Loosen the stop screw (6).
4. Lift up the rubber damper (31) along the piston at the same time as you angle
the tiller arm upwards.
5. Loosen the gas spring by opening the strap on the ball retainer (32) using a
screwdriver. Now pull off the gas spring from the ball screw.
Important!
Apply grease to the ball retainer (32) and to the fork (30).
SERVICE MANUAL PLP

7.2.5 Replacing the steering belt

2. Remove the panels on the machine housing, see section 4.
3. Release all the electrical connections to the traction motor and brake.
4. Unscrew the eight socket head cap screws holding the traction motor, and lift
it out. Protect the motor shaft and the hole in the gearbox, e.g. with rags.
5. Unscrew the three socket head cap screws holding the motor bed to the
gearbox. Lift out the motor bed.
6. Completely unscrew the two bolts holding the belt tensioner in the bottom of
the steering axle, and the two bolts holding the steering axle upper bearing.
7. Replace the belt.
7.2.6 Adjusting the steering belt

1. Switch off the power.
2. Roll out the battery.
3. Slightly release the two bolts holding the belt tensioner.
4. Adjust the belt with the adjusting screw.
5. Tighten the two bolts holding the belt tensioner.
7.2.7 Adjustment, limit switch

Ensure the following when adjusting the limit switch:
• That the contact breaker is not in a mechanically closed position.
• That the end position is not actuated before it should be (>95 degrees). This is
checked by moving the tiller arm to the right and left in its outer position. The
limit switch should only be actuated by >95 degrees of turning.
SERVICE MANUAL PLP

7.2.8 Adjustment, electrical steering

An inspection and if necessary adjustments are always to be made following any
adjustment to the belt tension. When adjusting the belt tension check and if
necessary adjust the voltage level in neutral position on the potentiometers, see
point 2.
Measuring the looseness of the tiller arm checks the belt tension. The looseness
should be about 30 mm on a machine with servo.
There are several reasons why the steering could have a sluggish feeling.
• Too much belt tension
• The steering axle bearing is seized up
• The axles adjusting the potentiometer voltage, hits the body of the
potentiometer.
There are only two ways of adjusting the PSA servo.

Alternative 1
1. Adjust the dead zone (max 300-degree turn)
Figure 7.7 Adjusting the dead zone
The dead zone can be adjusted by means of a small hole on the right underside of
the PSA servo box, using a small slot screwdriver. Undo the lower fixing screw and
pull out the servo box so that you can see the screw hole.
Do not apply too much pressure to the screwdriver when you adjust the dead
zone on the PSA servo box.
Adjusting the dead zone clockwise means that the arm moves easier to the left and
more sluggishly to the right. Adjust until the actuator arm moves equally freely in
both directions.
SERVICE MANUAL PLP

Alternative 2
1. Ensure that the axles to the potentiometer arms have the same
distance on both sides. .
0-2 mm
Figure 7.8 Adjusting the potentiometer arms
2. Adjust by undoing 2 screws on the consoles of the potentiometers on the rear

of the drive unit housing.
Figure 7.9 Undoing the screws on the consoles
3. Carefully move the tiller arm a little to the right and left without activating
the actuator arm breaker. Stop the tiller arm in the middle of the play that
exists prior to moving the driving wheel. Measure the signal from the
position indicators, X23.2 and X24.2 to B-.
4. Adjust one potentiometer at a time to 6.20V ±0.10V.
It is important to adjust both of the position indicators equally e.g. (6.13 and
6.10V) or (5.85 and 5.9V). NOT 5.8 and 6.2V.
SERVICE MANUAL PLP

If it is not possible to achieve 6.0V on both sides because one of the potentiometers
is in its limit position, remove or alternatively add a shim (118016).
Figure 7.10 Adding a shim
Figure 7.11 Adjusting the position indicators
• Left breaker: For higher voltage, turn the potentiometer clockwise.

• Right breaker: For lower voltage, turn the potentiometer clockwise.
SERVICE MANUAL PLP

7.2.9 Servo steering (2006w15–)

7.2.9.1 Adjusting the steering force
Function:
You can adjust the servo steering force by loosening or tightening the guide belt. In
general you could say that a looser guide belt gives a greater range of movement for
the potentiometer and increases the power to the steering servo motor making the
machine easier to control. If more sluggish steering is required, you can tighten he
guide belt to the potentiometer to produce a narrower range with less power to the
steering servo motor as a result. the guide belt to the potentiometer to produce a
narrower range with less power to the steering servo motor as a result.
10
15
20
19
30
35
33
SM_PLP_07_0011A.eps
32
Figure 7.12 Servo steering
SERVICE MANUAL PLP

Adjusting the guide belt:

1. Disconnect the battery connector and move the battery
sufficiently enough to access the adjuster screw and locking
screws from the battery compartment. Secure the battery so that
it cannot roll.
2. Loosen the two locking screws a little (pos 35, se Figure 7.12) to the belt
tensioner and adjust using the adjuster screw (33) to the desired value. As a
starting point, the belt tensioner can be adjusted to ensure that it is square
with the drive unit housing, figure A, se Figure 7.13
B
A
Figure 7.13 Adjusting the guide belt.
3. Figure B ( se Figure 7.13) shows the adjustment for a looser belt that gives
more steering force power and figure C shows a tight belt that gives less
steering force.
4. The quality of the floor and type of wheel affect the steering force which
then needs to be adjusted to new values.
Adjusting the potentiometer:
5. Connect the battery and measure with a voltmeter between B- and X24.4.
The value must be 6V in neutral. In other words the drive wheel is facing
forwards and the guide belt does not affect the mechanism to the
potentiometer.
6. To achieve the value of 6V, turn the bracket the potentiometer is mounted in
until the value is reached, se Figure 7.14. If the steering is stiffer clockwise,
adjust the bracket clockwise. Likewise, adjust the bracket anticlockwise if
the steering is stiffer anticlockwise.
SERVICE MANUAL PLP

Figure 7.14 Adjusting the potentiometer.
7. Check by turning the tiller to the right and left while reading the voltage. A
good symmetry is when steering to the right gives around 8V, steering to the
left gives around 4V and neutral 6V.
8. The quality of the floor and type of wheel affect the steering force which
then needs to be adjusted to new values.
7.2.9.2 Troubleshooting steering force

Steering too stiff or too loose.
Is the steering also either stiff or too loose?
Yes
First adjust the steering force using the belt

tensioner.
If the steering is uneven in any direction or No Ready.

jerky?
Yes
Adjust the balance of the steering force

using the potentiometer.
SERVICE MANUAL PLP

Uneven or jerky steering.
If the steering is uneven in any direction or

jerky?
Yes
Is the steering also either stiff or too loose? No Adjust the balance of the steering force
using the potentiometer. Check that the
bearing between the steering shaft and belt
sensor runs easily without jerking.
Yes
First adjust the steering force using the belt

tensioner.
Now adjust the balance of the steering

force using the potentiometer.
SERVICE MANUAL PLP

SERVICE MANUAL
Machine : PLP
Manual no: 119002
Edition 2010B
8 Hydraulic system

8.1.1 General ...........................................................................................................8.3
8.1.2 Electric solenoid valve .....................................................................................8.3
8.1.3 Lift limit pressure switch ..................................................................................8.4
8.1.4 Hydraulic diagram ...........................................................................................8.4
8.2 Repair and maintenance instructions .......................................................................8.10

8.2.1 Hydraulic system ...........................................................................................8.10
8.2.2 Hydraulic oil, changing/draining ....................................................................8.12
8.2.3 Motor, hydraulic unit ......................................................................................8.14
8.2.4 Adjusting the lift limit pressure switch (–2010w21) ........................................8.17
8.2.5 Solenoid valve ...............................................................................................8.18
8.2.6 Installation instruction for pipe couplings .......................................................8.18
8.3 Diagnostics and trouble shooting .............................................................................8.22

8.3.1 Symptom and Action .....................................................................................8.22
SERVICE MANUAL PLP

8.2
SERVICE MANUAL PLP

Hydraulic system / Design and function 8.3
Edition 2010B
8 Hydraulic system
8.1.1 General
8.1.1.1 Lifting
The driver activates a switch, which starts the lift motor by means of a contactor.
The electric motor drives the hydraulic pump, which pumps hydraulic oil to the lift
cylinders.
The hydraulic system includes a relief valve, which limits the maximum hydraulic
oil pressure. The pressure of the hydraulic oil is built up when the cylinder goes
towards its end position. The relief valve opens if the maximum system pressure is
reached and leads the oil from the pump back to the tank. The opening pressure of
the relief valve is set at the factory, so that the machine will be able to handle the
load it is designed for.
Warning!
The relief valve must only be adjusted by authorised and trained personnel,
since it is a safety part. All work with the hydraulic system must be carried out
in a pressureless state, and in a clean environment. If the relief valve is adjusted
it must be resealed.
8.1.1.2 Lowering
There is a fixed restrictor valve in the hydraulic unit, which regulates the lowering
speed by restricting the return flow of hydraulic oil.
8.1.2 Electric solenoid valve
8.1.2.1 General
The electric solenoid valve controls the lifting and lowering movements on the
truck. The solenoid valve is actuated electrically by the driver by means of a switch.
8.1.2.2 Lifting function

The pump produces a pressure and flow to the lift cylinder. If the lift cylinder is
obstructed, or has an excessive load, the oil goes back to the tank through the relief
valve.
SERVICE MANUAL PLP

8.4 Hydraulic system / Design and function
8.1.2.3 Lowering function

The solenoid valve opens to release the oil from the lift cylinder. When the fork
carriage presses down the lift cylinder the oil flow goes through the lowering valve,
which regulates the lowering speed.
8.1.3 Lift limit pressure switch

The function of the electrical lift limit pressure switch is to turn off the hydraulic
motor when the fork carriage reaches the top position. This will protect the
hydraulic motor from overheating. For adjustments, see “Adjusting the lift limit
pressure switch (–2010w21)” on page 17.
The pressure lift limit pressure switch have been replaced by an inductive sensor
(2010w22-) which is set to activate before the top of the end stroke to avoid self-
locking of the forks in the top position.
8.1.4 Hydraulic diagram

Table 8.1 List of hydraulic diagrams for PLP
Description Reference Page
Hydraulic diagram PLP (-2010w21) 108011 page 8.6
Hydraulic diagram PLP (2010w22-) 108423 page 8.8
SERVICE MANUAL PLP

Hydraulic system / Design and function 8.5
SERVICE MANUAL PLP

8.6 Hydraulic system / Design and function /
Hydraulic diagram PLP (-2010w21)
SERVICE MANUAL PLP

Hydraulic system / Design and function / 8.7
Hydraulic diagram PLP (-2010w21)
SERVICE MANUAL PLP

8.8 Hydraulic system / Design and function /
Hydraulic diagram PLP (2010w22-)
SERVICE MANUAL PLP

Hydraulic system / Design and function / 8.9
Hydraulic diagram PLP (2010w22-)
SERVICE MANUAL PLP

8.10 Hydraulic system / Repair and maintenance instructions
8.2.1 Hydraulic system
8.2.1.1 General rules
Important!
Cleanliness during all work with hydraulic components is of the greatest
importance for the operating safety and service-life of the system. The
following should be taken into consideration:
• Dirt particles must not get into components.
• Do not use cloths that release fibres or particles.
• Only use clean tools.
• Carefully clean tanks, pipes and hoses before installation.
• Welded or hot-bent pipes must be pickled (cleaned with acid bath) and washed
before they are built-in.
• The oil tank must be closed and provided with an efficient air filter to prevent
dirt contaminating the hydraulic oil.
• Sealing compounds such as flax, cement or thread tape are not permitted.
• Take into consideration the specified operating data.
• Do not exceed permitted pressures and volume flows.
• Do not exceed or go below the specified temperature range.
• Pay attention to specified electrical voltages and power consumption.
Note!
All work with the hydraulic system should be carried in a pressureless state
and in a clean environment.
8.2.1.2 Installation
To prevent dirt and corrosion in the hydraulic system all hydraulic components
should be provided with plastic plugs in the connections before they are delivered.
Only remove these plugs just before the component is to be installed in the machine.
Retaining screws and connections must correspond with those on the drawing.
Retaining screws should not be tightened with a higher torque than what is specified
on the drawing. If such information is missing, the torque should not exceed what
is specified in section 1.
8.2.1.3 Connections
Couplings should be fitted according to the torque specified in the table in section
1. We recommend couplings with elastic seals.
Connect pipes and hoses in accordance with the hydraulic diagram. Pay attention to
the connection designations. Do not use force, and avoid building-in tensions in
pipes, etc,
SERVICE MANUAL PLP

Hydraulic system / Repair and maintenance instructions 8.11
8.2.1.4 Start up
Check that everything is connected in accordance with the hydraulic diagram. Set
the relief valves down to a very low pressure if they are not sealed. Start-up with
low pressure and volume flows.
Test the function and tightness of the system. Check the oil level. Set the pressure
and volume flows slowly to the values they should have. Check the connected
measuring equipment regularly, where appropriate. Pay attention to the noise level
since abnormal noise implies defects. Test during variable loads that components
are correctly fitted, and that the system is tight.
In the event of returning equipment to the manufacturer, protect polished surfaces
from damage and dirt by covering them with foil and protective paper. Fit plastic
plugs in all connections. Send the complete components, not loose parts.
SERVICE MANUAL PLP

8.2.2 Hydraulic oil, changing/draining
8.2.2.1 Requisite equipment

• New oil, or purifying equipment for the old.
• A tray to collect the oil in.
8.2.2.2 Procedure
1. Lower down the forks and disconnect the battery.
2. Remove the panels enclosing the area where the hydraulic unit is placed.
3. Check how much oil needs to be filled by marking the existing level. e.g.
with a strip of tape. Before marking the level the lift cylinder should be run
several times to check that the pump does not suck air (screaming noise at
the end). If this should be the case the marking should be moved
correspondingly so that this does not happen when new oil has been filled.
4. Remove the cap on the hydraulic oil tank.
5. Suck up the oil with a pump, and pump over the old oil to a suitable
container.
Important!
Avoid spilling oil outside the container. The oil should be handled in
accordance with the applicable environmental legislation and local directives.
6. Fill up with oil to the previously marked level. If possible, filter the new oil
when filling. Follow the recommendations in section 1 for the correct type of
oil.
7. The lift cylinder should be run several times to check that the oil level is
correct and so that any air will disappear, and also to check for excess oil.
Excess oil runs the risk of the oil overflowing.
Wipe up any oil spillage and refit the panels.
8.2.2.3 Air filter

There is an air filter in the refilling plug on the hydraulic tank, which during service/
oil change should be cleaned. The filter is cleaned with a suitable grease solvent that
will not damage the rubber, e.g. turpentine.
Pull out the filler plug from the tank and remove the red cap fixed with three barbs.
Wash the foam rubber filter and blow clean, or squeezze dry with paper. Refit in the
reverse order. The filter should be replaced if the foam rubber is damaged.
8.2.2.4 Properties of the hydraulic oil

The hydraulic oils recommended in this manual, section 1, have properties that
promote a long service-life and good functionality, and these are the oils that should
be used in the truck. The hydraulic oil used in Atlet trucks must comply with Atlet
quality requirements:
SERVICE MANUAL PLP

Important!
Never mix oils of different types or brands! Environmentally adapted oils must
not be used without the approval of Atlet if the warranty it to be valid.
• Smooth action.
• Long service-life.
• High viscosity index with wide range of temperature applications.
• Good low-temperature properties.
• High filterability.
• Good air and water separating capacity.
• Good wear protection.
• Good oxidation stability.
• Minimum foaming.
• Provide protection from rust and corrosion.
• Good adhesive capacity.
SERVICE MANUAL PLP

8.2.3 Motor, hydraulic unit

If the performance of the electric motor changes it should be inspected internally.
One of the most common sources of faults is wear on the carbon brushes in the
motor.
The brushes can wear out, or stick in the brush holders. In both cases inadequate
contact between the brushes and the commutator can lead to serious damage on the
commutator surface.
8.2.3.1 When should the brushes be replaced?

• If a carbon brush cannot move freely in the brush holder. To check this the
brush holder must be released from the brush rigging. The force from the brush
spring should then press out the brush from the brush holder as far as is
permitted by the cable.
• If a carbon brush is approaching the end of its usable length. The length of the
brushes must never be less than 10 mm (a new brush has a length of 17 mm).
Since this is difficult to measure there is an alternative method. Measure the
difference between the cable and the groove in the brush holder. The difference
should be at least 1 mm. Even if the difference should be slighter more it is
recommended to change the brushes anyway, since their remaining service-life
may be shorter than the interval to the next inspection.
8.2.3.2 Replacing the brushes

The repair kit consists of brush, brush holder and spring. They should be installed
as follows.
1
3
2
4
Figure 8.1
1. Release the cables from the terminals on the motor (pos. 1 figure
8.1).
2. Release the through bolts from the rear end on the motor (pos. 2 figure 8.1).
3. Lift out the electric motor from the truck.
4. Place the electric motor on the drive end.
SERVICE MANUAL PLP

5. Loosen the nuts on the terminals, (pos. 3 figure8.1). If the motor has a return
earth the earth connection on the rear end of the motor should also be
released (pos. 4 figure 8.1).
6. Loosen the rear end (pos 5. figure8.1). Make sure that the terminals remain in
their positions.
B
1
Figure 8.2
7. Disconnect all four carbon brushes by releasing the screws, pos. 1, figure 8.2
- A, figure 8.2. Now press each brush set to the commutator. - B, figure 8.2.
Remove the brush set from the brush rigging – C. The old brush set is
replaced with a new set by the reverse procedure. It is recommended to
replace each brush separately to avoid confusion. Make sure that each brush
set is replaced with the correct part, i.e. one that has the cable on the correct
side. (The service kits consist of two matching pairs of brush sets!)
8. Tightent the screw, pos. 1 figure 8.2, to approx. 1.3-1.8 Nm.
9. Replace the terminals in the grooves in the rear end, and replace it back on
the motor. Check that there is a washer between the rotor and the end (pos. 2
figure 8.2) and that the attachment is located with a tooth and a slot on the
casing and end.
10. Insert the through bolts and replace the electric motor in the truck. Tighten
the bolts to approx. 4.8-6.8 Nm.
11. Tighten the terminal bolts to 10-14 Nm (pos. 3 figure 8.1).
12. Replace the cables to the motor terminals.
8.2.3.3 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.
SERVICE MANUAL PLP

• 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 file) to a surface fineness of Ra = 0.8-1.8 µm 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 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 look 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.
SERVICE MANUAL PLP

8.2.4 Adjusting the lift limit pressure switch (–2010w21)
Figure 8.3 Adjusting pressure
1. Unscrew the connector securing screw (indicated by the arrow).

2. The pressure can be adjusted with the connector still connected using an
Allen key (size 2) through the hole were the screw in point 1 is fitted.
3. Put the max rated load on the forks and tune the pressure switch setting to
allow continuous movement during lifting and to stop the movement directly
when the top position is reached.
SERVICE MANUAL PLP

8.2.5 Solenoid valve
8.2.5.1 General instructions when working with solenoid valve

1. Cleanliness
• Dirt particles must not get into components.

• Cloths must not shed fibres and particles.
• Tools must be clean.
• Tanks, pipes and hoses must be carefully cleaned before installation.
• Welded or hot-bent pipes must be pickled and cleaned before they are
built-in
• The oil tank must be closed and provided with an efficient breather
filter that prevents the penetration of dirt.
2. Sealing compound
• Hemp, cement or sealing tape is not permitted.
3. Operating data
• Do not exceed permitted pressures and volume flows.

• Do not go beyond the specified temperature range.
• Pay attention to specified electrical voltages and maximum power
consumption.
8.2.5.2 Solenoid valve, dismantling and assembling

1. Lower down the forks and relieve the pressure in the hydraulic
system.
2. Place protective paper under the valve and release the electric cables to the
valve.
3. Loosen all the oil pipes connected to the valve and plug them.
4. Loosen the valve from the truck, and lift it out.
5. When fitting, tighten the valve and then the oil pipes.
6. Adjust the relief valve to the rated weight in accordance with the machine
plate.
7. Seal the setting.
8.2.6 Installation instruction for pipe couplings

To achieve a safe and tight connection when installing pipe couplings in the
hydraulic system, the following points should be taken into consideration:
1. The pipe should be cut at right angles by means of a pipe cutter (
see Figure 8.4 and see Figure 8.5), after which it is deburred
internally and externally, and carefully cleaned.
SERVICE MANUAL PLP

Important!
When using a pipe cutter the end of the pipe becomes skew, with the formation
of substantial burrs internally and externally. It is therefore important to
straighten the end of the pipe and remove the burrs, both internally and
externally.
Figure 8.4 Cut at right-angles!
Figure 8.5 Pipe cutter
2. Oil the thread and pipe olive (not grease) if this type of coupling is used. Put
the nut and pipe olive over the pipe end as shown in the figure. If the pipe
olive cannot be worked over the pipe end it must absolutely not be enlarged.
File down the pipe end instead.
3. Small pipe dimensions can be fitted directly in the coupling connected to the
machine part. Screw the nut by hand until it lies flush with pipe olive, press
the pipe towards the shoulder in the coupling cone, and tighten the nut a ¾
turn.
Important!
The pipe must not follow round.
4. The pipe olive will now have gripped the pipe, and no longer needs to be
pressed against the shoulder. Complete the fitting with an additional ¾ turn
SERVICE MANUAL PLP

of the nut. A mark on the nut simplifies following the specified torque, see
Figure 8.6.
Figure 8.6 A mark on the nut simplifies the specified torque
5. Larger pipe dimensions and couplings in free pipes are preferably fitted by
placing the coupling body in a vice. The U-ring spanner should be 15 times
the nut width (can be extended with a piece of pipe). Otherwise fit according
to point 3.
If several couplings of the same type are to be fitted, make sure that each
pipe end goes in the same coupling cone it was previously fitted in.
Fitting is simplified if the nut is loosened and oil is applied between the
friction surfaces.
SERVICE MANUAL PLP

6. After fitting, release the cap nut and check that the pipe olive has pressed up
a visible swelling in the area in front of it, see figure see Figure 8.7. If not,
give it another short turn. It is of no importance whether the pipe olive can
still be turned.
Figure 8.7 A visible swelling should have formed after tightening
After a visible swelling has formed the nut should be fitted without extension
of the U-ring spanner, and without excessive force.
Important!
Refitting: After a visible swelling has formed the nut should be fitted without
extension of the U-ring spanner, and without excessive force.
7. If the pipe is to be bent after a coupling, the straight pipe end should have a
length of at least 2 nut heads, H.
Long and heavily loaded pipes should be provided with pipe clips.
H
2H
Figure 8.8 Straight pipe length between bend and coupling
8. The final assembly should be done with at least 1 turn of the nut from the
point where it cannot be turned by hand.
SERVICE MANUAL PLP

8.22 Hydraulic system / Diagnostics and trouble shooting
8.3.1 Symptom and Action

A number of fault symptoms have been listed in the table below, with a number of
possible faults and repair procedures. It is therefore possible for other faults to have
occurred in addition to the ones listed.
Table 8.2
Symptom Possible fault Action
The lift motor keeps The switch is not properly Adjust the switch so that it trips 20
running even though adjusted. mm before the truck reaches its top
the forks are at the top position.
of their mechanical
stop.
Note: Only applies to
machines with
switches as lift stops.
The lift motor runs, The lowering valve has 1. Close the valve.
but the fork carriage jammed and is open.
2. Adjust, or remove any dirt from
does not lift.
the valve.
The lift motor runs, The machine is overloaded. Lighten the load.
but the fork carriage
lifts very slowly. The relief valve is defective. Adjust the valve to the rated weight.
A foreign object has Take apart and clean.

partially blocked a hose,
hydraulic pipe or valve.
Hydraulic hose has been Rearrange the hose and clamp

clenched. secure.
The lift motor emits a The oil level is too low in 1. Fill with hydraulic oil.
screeching noise just the hydraulic tank. When the tank is almost full, try
before the fork with 0.1 litre at a time to avoid
carriage reaches the overfilling.
top.
2. Find out the reason for the low
level, and rectify the fault.
The lift motor keeps The pressure guard is not Lower the pressure in the pressure
running even though properly adjusted. guard, see “Adjusting the lift limit
the forks are at the top pressure switch (–2010w21)” on
of their mechanical page 17.
stop.
Cannot adjust the pressure Replace the pressure guard.
guard.
The lift motor stops The pressure guard is not Increase the pressure in the pressure
when lifting maximum properly adjusted. guard, see “Adjusting the lift limit
load or less. pressure switch (–2010w21)” on
page 17.
Cannot adjust the pressure Replace the pressure guard.

guard so the pump stays in
top position.
SERVICE MANUAL PLP

Hydraulic system / Diagnostics and trouble shooting 8.23
Table 8.2
Symptom Possible fault Action
The lift motor runs The limit values between Check and adjust the overflow valve
intermittently with the overflow valve and where necessary to the maximum
load. pressure guard are too close load and then adjust the pressure
to each other. guard according to instructions.
If it still does not work replace the
pressure guard.
The fork carriage will Valve does not open on Dismantle valve and clean.
not lower. return because of foreign
object in the system.
The fork carriage The lowering valve is dirty Dismantle the valve and clean, or
lowers too slowly. or defective. alternatively replace defective parts.
The oil filter is blocked and Change filter.

dirty.
Dirt in the fixed restrictor in Dismantle and clean the dirt from
the hydraulic unit. the restrictor.
Hydraulic oil flows Oil level too high. Reduce the oil level to correct level.
out via the air filter.
The oil foams. Change the oil with oil that has the
correct properties.
Condensation water in oil Empty the tank of oil and fill with
tank. new hydraulic oil to correct level.
The fork carriage Air in the hydraulic system. Bleed the system via the air
rocks when lifting. cylinders.
The hydraulic oil has a The oil separators in the 1. Change the oil and filter.
bad smell, sulphur. hydraulic oil are ruined.
2. Flush the complete system with
Motor oil has been used and new hydraulic oil.
caused the hydraulic oil to
emulsify with water and
then rot.
The hydraulic oil has 1. Change the oil and oil filter.
become too hot.
2. Check the breaking function of
the lift stop.
SERVICE MANUAL PLP

8.24 Hydraulic system / Diagnostics and trouble shooting
SERVICE MANUAL PLP

SERVICE MANUAL
Machine: PLP
Manual No: 119002
Edition 2003
9 Lift cylinders
Design and function ....................................................................................................... 9.3

Introduction .......................................................................................................... 9.3
Lift cylinder .......................................................................................................... 9.3
Dismantling and assembling .......................................................................................... 9.3
SERVICE MANUAL
9.2
SERVICE MANUAL
Lift cylinders / Design and function / Introduction 9.3
Edition 2003
9 Lift cylinders
Design and function
Introduction
The lift cylinder consists of a single-acting hydraulic cylinder, where hydraulic oil is
pumped into the cylinder and presses out the piston rod.
When the driver activates the lowering function the cylinders are pressed together
through a control valve releasing oil out from the cylinder. This is then pushed together
by the weight of the forks and the load, at the same time as the oil returns to the hydraulic
tank.
Lift cylinder
Dismantling and assembling

1. Move the battery out of the way.
2. Remove the hydraulic hose and hydraulic coupling on the cylinder.
3. Plug the hydraulic hose to avoid dirt getting into the hydraulic system.
Figure 9.1
4. Remove the plate in the fork carriage (pos. 1 in Figure 9.1). Keep the spacers in a
safe place.
5. Lift out the cylinder.
SM_PLP_09_119002_2003.fm
SERVICE MANUAL
9.4 Lift cylinders / Design and function / Lift cylinder
SERVICE MANUAL
SERVICE MANUAL
Machine : PLP
Manual no: 119002
Edition 2010B
10 Electrical System
10.1 Design and Function ................................................................................................10.3

10.1.1 General .......................................................................................................10.3
10.2 Repair and maintenance instructions .....................................................................10.5

10.2.1 General .......................................................................................................10.5
10.2.2 Battery .........................................................................................................10.6
10.2.3 General Handling ........................................................................................10.8
10.2.4 Connectors in Cold Storage Rooms .......................................................... 10.11
10.2.5 Drive and Valve Controller ......................................................................... 10.12
10.2.6 Wiring Diagram .........................................................................................10.13
10.2.7 Insulation Resistance ................................................................................ 10.14
10.2.8 Main Controller Unit ATC, Handling ..........................................................10.14
10.2.9 ATC Logic ..................................................................................................10.32
10.2.10 Download ................................................................................................10.36
10.2.11 ATC Connector ........................................................................................10.38
10.2.12 Digital I/Os ...............................................................................................10.38
10.2.13 Cold Resistance Values ......................................................................... 10.40
10.2.14 Fuses .................................................................................................... 10.40
10.3 Diagnostics and Trouble Shooting ........................................................................ 10.41

10.3.1 Truck Remote ACcess, TRAC ...................................................................10.41
10.3.2 Error Codes ...............................................................................................10.42
10.4 Appendix 1, Summary menu tree .......................................................................... 10.59
SERVICE MANUAL PLP

10.2
SERVICE MANUAL PLP

Electrical System / Design and Function 10.3
Edition 2010B
10 Electrical System
10.1 Design and Function
10.1.1 General
10.1.1.1 Description of Components
6
4
1
3
Figure 10.1 Components
1. Drive motor, TM.

2. Pump motor, PM.
3. Traction motor controller, TMC.
4. Emergency stop push button.
5. ATLET truck controller, ATC.
6. Battery plug.
SERVICE MANUAL PLP

10.4 Electrical System / Design and Function
10.1.1.2 Description of Components and Interface

The ATC system consists of a keyboard (pos. 1), display (pos. 2) and an ATC card
(pos. 3).
Figure 10.2
SERVICE MANUAL PLP

Electrical System / Repair and maintenance instructions 10.5
10.2.1 General
10.2.1.1 Safety Procedures

Extreme importance must be placed on precautionary measures to avoid accidents
during all work on the vehicle.
• 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).
• 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.
• 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.
• Working with electrical vehicles can result in personal injury. All testing,
trouble shooting and adjusting must be carried out by authorised personnel. The
drive wheel should run free of the floor and be able to rotate freely during
work.
Warning!
Working with electrical vehicles can result in personal injury.
Electronic Controllers
• All the electronic controllers in the truck have multiple safety systems.
• When replacing or repairing the electronic controllers, or removing cables, the
battery should always be disconnected.
Important!
Incorrectly connected battery cables can destroy the electronic controllers.
Warning!
During all work on the truck the drive wheel must be lifted up from the floor
to prevent accidents occurring.
After the power has been disconnected to the controller and work or trouble
shooting is to be conducted, there can be residual voltage in the capacitors for a few
minutes. For this reason observe care when working with current-carrying tools
during this period.
SERVICE MANUAL PLP

10.6 Electrical System / Repair and maintenance instructions
10.2.1.2 Abbreviations
AC Alternating Current
ATC ATLET Truck Controller
B+ Battery positive
B- Battery negative
BDI Battery discharge indicator
CAN Controller Area Network
DC Direct Current
ELCB Electronically load compensated brake
EPS Electric Power Steering
PSA Powered steering assistance
TMC Traction Motor Controller
WG Wire Guidance
10.2.2 Battery
10.2.2.1 Battery Capacity
100% 50%
90% 40%
80% 30%
70% 20%
60%
Figure 10.3 Battery capacity
The battery capacity is shown to the left on the bottom row on the display.
Measurements are fully controlled by software, and no further electronics are
required. The capacity is measured by measuring the battery voltage.
When the battery capacity gets too low the battery capacity value starts flashing and
a buzzer is actuated.
SERVICE MANUAL PLP

When battery capacity reaches 20%, a lift lock out occurs within 3 minutes of active
time and error code E50 will be logged.
Table 10.1
Battery capacity % Unloaded pole voltage Acid density g/cm3
0 22.92 1,070
10 23.20 1,093
20 23.47 1,116
30 23.75 1,139
40 24.03 1,162
50 24.30 1,185
60 24.58 1,208
70 24.85 1,231
80 25.13 1,254
90 25.41 1,277
100 25.68 1,300
In order to carry out a complete battery discharge indicator (BDI) adjustment, the
following procedure has to be performed:
1. Connect a voltmeter directly to the B+ and B- poles of the
battery.
2. Power up the truck and enter “ATLET menu => Settings => Battery =>
Calibrate”. Key in the value from the voltmeter by using the keyboard. For
example if the voltage 25.2 V is read from the voltmeter, key in 252.
3. Enter (ATLET menu => Settings => Battery =>) “Stepdown hi”. This
parameter (0-9) decides how quickly the BDI reduces the indicated level
when the battery has been recently charged.
• If the indicator does not indicate 100% after a full recharge cycle, or
drops too quickly in the range 100%-60%, this parameter should be
decreased.
• If the indicator drops too slowly in the range 100%-60%, this parameter
should be increased.
4. Enter (ATLET menu => Settings => Battery =>) “Stepdown lo”. This
parameter (0-9) decides how quickly the BDI reduces the indicated level
when the battery is close to becoming discharged
• If the indicator drops too slowly in the range 60%-20%, this parameter
should be increased.
• If the indicator drops too slowly in the range 60%-20%, shows too high
a battery status, or the truck stops due to under voltage alarms, this
parameter should be increased.
SERVICE MANUAL PLP

10.2.3 General Handling
10.2.3.1 Function Keyboard

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 10.2
Function in
Key:
Input mode: Operational mode: Service mode:
Enter a zero. - -
Enter a one. - -
Enter a two. Switch between creep Step one step down in

speed and full speed. the 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 Step one step up in the
speed. menu tree.
Enter a nine. - -
SERVICE MANUAL PLP

Table 10.2
Function in
Key:
Input mode: Operational mode: Service mode:
- Used for input to the Steps to the upper menu

level selector and to level loop if pressed
change the system status. during input in the upper
level.
Used to accept the shown Used to confirm a Used to select the shown
value. selected level in the level menu alternative.
selector.
Function key combinations
A “monitor menu” can be obtained if the keys are pressed down

at the same time in the Operational mode.
SERVICE MANUAL PLP

10.2.3.2 Menu Tree – Start-up and Top Level
1sec Time-out
OR 27-nov-97 10:16
System off timer standing by...
(no power supply) elapsed
Time-out
timer
Power on
elapsed
shutting down...
ATC T4 OR
model v1.00
1sec
Operator ID: Valid ID + Belly button Operational

? Mode
Horn Button Local Code: Valid code Local Menu

ENT
???? Tree
2sec
Invalid code Invalid Code:
2sec
Horn Button ATLET Code: Valid code ATLET Menu

???? ENT
Tree
Horn Button Settings Settings Menu

ENT
Tree
Figure 10.4 Menu tree
In Operational Mode
If the [i] key is pressed for one second the truck will go to the “stand-by” mode. The
changeover is confirmed by a peep.
In Stand-by Mode
If the [i] key is pressed for less than two seconds the truck will go to the “operational
mode” without asking for a PIN code. If the [i] key is pressed for one second the
truck will return to the upper level and ask for an operator ID.
There is no reason for the operator to release the [i] key to log out directly from the
operational mode.
SERVICE MANUAL PLP

10.2.4 Connectors in Cold Storage Rooms
10.2.4.1 Greasing
Kryotox grease, ATLET part number 110781, should be applied in all electrical
connectors. The hand pump, part number 110782, should be used in order to do this.
The grease should be applied to the contact surfaces when the connectors are drawn
apart. The connectors are then reconnected and the grease is pressed from behind
into the connector housing so that it is filled. All blocks that have more than one
cable are considered to be connector blocks. Flat pins protected by some form of
sheath should not be greased.
SERVICE MANUAL PLP

10.2.5 Drive and Valve Controller
10.2.5.1 Connector Traction Motor Controller, Specification
The traction motor controller has two connectors with I/Os for 11 1
valves, sensors, change-over switches and programming tools, etc.
Each connector pin is specified below with, where appropriate, the
X6
voltage level in connected condition.
Connector X6 (figure shows connector from the cabling side).

20 10
Table 10.3 Connector X6 traction motor conntroller AC1
Pin Description Comment
X6.1 Controlling of Main contactor. Controlled to B-.
X6.2 Supply to Main contactor. +24V
X6.3 Controlling of electric brake. Controlled to B-.
X6.4 Controlling of pump contactor. Controlled to B-.
X6.5 Supply to pump contactor/horn. +24V
X6.6 Controlling of horn. Controlled to B-.
X6.7 CAN communication. CAN Low.
X6.8 - -
X6.9 Pos. supply to drive motor encoder. +12V
X6.10 Neg. supply to drive motor encoder. B-
X6.11 Controlling of lowering valve. +24V
X6.12 Neg. supply to lowering valve. B-
X6.13 Signal input temp. sensor.
X6.14 - -
X6.15 - -
X6.16 +12V supply to HVC. +12V (Not used as std.)
X6.17 CAN communication. CAN High.
X6.18 - -
X6.19 Input A from drive motor encoder. Synchronises the motor movement with
pulses from the encoder.
X6.20 Input B from drive motor encoder. Synchronises the motor movement with
pulses from the encoder.
SERVICE MANUAL PLP

Connector X5 (figure shows connector from the cabling side).

7 1
X5
12 6
Table 10.4 Connector X5 traction motor controller AC0
Pin Description Comment
X5.1 Supply from F3 fuse. +24V
X5.2 Joint supply to all digital +24V

inputs.
X5.3 Input from brake switch. Closes in upper and lower arm position.
X5.4 - -
X5.5 Input from gate switches. Closes with the gates in upper position.
X5.6 Input from platform. Closes with the platform down.
X5.7 Input from lift stop switch. The lift stop switch breaks at lift stop.
X5.8 Input from platform. Closes when the platform is up.
X5.9 Input from fixed platform Closes when standing on the platform.
switch.
X5.10 - -
X5.11 - -
X5.12 - -
10.2.6 Wiring Diagram

All the wiring diagrams can be found in a separate “Wiring diagram manual”,
contact Atlet for further information.
The relevant wiring diagrams are specified in the table below.
Table 10.5
Description Machine Reference Document code
Wiring diagram PLP 108007 (–2005w17)

118270 (2005w18–)
118222 (2007w28–)
Circuit diagram PLP 108186 (–2005w17)

118275 (2005w18–)
SERVICE MANUAL PLP

10.2.7 Insulation Resistance
10.2.7.1 Routine Test

You must first disconnect the connectors (plugs) before the truck is insulation tested
in order to protect the controllers and other electrical components on the truck. This
is because damage can occur, which will shorten the life of component parts. In the
event of large insulation errors it is appropriate to use a universal instrument until
the error has been found and then make a final insulation test.
This applies to all electronic units on the truck.
The instrument has a dangerous voltage across the measuring terminals. Do

not touch the terminals during testing.
Routines for insulation testing of all truck models.

1. Take out the insulation measurement instrument.
2. Set the test voltage to 100 volt.
3. Pull out the battery plug. Electrical components and electronic systems can
be damaged by the test voltage. For this reason disconnect connections and
contactors to these before doing the test.
4. Connect the instrument’s earth lead to the truck chassis at a point with good
electrical contact. The other lead is connected to the plus pole on the
electrical panel plug.
5. Press the start button and wait until the display has stabilised, then release
the button and read-off the value on the display. The approved value on 24
volt machines should be at least 24000 Ω , (24 k Ω ).
6. Let the earth lead remain attached to the chassis and connect the other lead to
the minus pole on the electrical panel plug. After this repeat point 5.
10.2.8 Main Controller Unit ATC, Handling
10.2.8.1 Menus
When starting the ATC system there are four different basic menus the user can
select. The user navigates between these different menus by means of the [i] key as
shown in fig. Certain of the menus are protected by a password.
Operator ID:
?
i
O
Local code:
????
i
O
ATLET code:
????
SERVICE MANUAL PLP

i
O
Settings
Navigation in the menus takes place by means of the keys on the keyboard. The keys
four and six are used to step up and down, and keys two and eight to step from side
to side. The arrows on the display show the possible directions.
The enter key is used to go into the submenus. To leave a selected menu, use the
Exit selection together with the enter key. One refinement is that the horn key can
be used as an escape key. It can also be used to step back in the menus to the Exit
position. This function can also be used to cancel an initiated parameter change.
The menus are divided into three levels, as follows:
Operational
This menu is used to log into the Operational mode. Logon takes place by selecting
driver ID, entering a password, and finally using the safety switch as an enter key.
In the Operational mode it is possible to use the truck and all its functions.
Local Service
In the Local Service menu it is possible to change passwords for local service, add
and remove drivers, and set the time/date, LCD contrast, and key sound. Certain
statistical functions are also available here. A password is needed to access the
Local Service menu.
Atlet Service
Atlet Service includes all the functions used by Atlet authorised service personnel.
A password is needed to access the Atlet Service menu. The Atlet Service menu is
built up as shown in fig.

ATLET menu:
< Exit >

ATLET menu:
< Options >

ATLET menu:
< Settings >

ATLET menu:
< Tests >

ATLET menu:
< Calibrate >

ATLET menu:
< Logs/Counter >

ATLET menu:
< Set access >

ATLET menu:
< Total reset >

• Exit – selected to exit the Atlet menu.

• Options – possibility to set the options available for the truck.
SERVICE MANUAL PLP

• Settings – possibility to set driver parameters, hydraulic parameters and battery

parameters.
• Tests – tests I/Os.
• Calibrate – possibility to calibrate inputs.
• Log/Counters – possibility to read and clear temperature log, error log, and
hour counter.
• Set access – possibility to add drivers, and set passwords for Atlet and local
service.
• Total reset - Possibility to restore all settings, options, users, calibrations and
logs to default values.
10.2.8.2 Settings
Under the settings menu it is possible to select the language shown in the display.
Swedish, English, French, and a “custom” language can be selected. It is possible
by using a PC and a special program to add on a “custom” language.
10.2.8.3 Total Reset

In the Total reset menu it is possible to restore all settings, options, users,
calibrations and logs to default values.
• Exit: Exits the Total reset menu and performs a restart of the system. Note that
the command means leaving the Atlet menu and performing an actual restart of
the system.
• All Users: Clears all users. The default user will be set instead. Also the Atlet
code and the Local code will be set to the default codes.
• Options: Restores all options to default values.
• Settings: Restores all settings to default values.
• Calibration: Clears all calibrated values. A new calibration must be performed
to make the truck work again.
• Logs: Clears all logs. Hour meters will not be cleared.
SERVICE MANUAL PLP

10.2.8.4 Set Truck Type

After clearing all settings or installing a new ATC, the truck type has to be set.
When powering up the truck again the ATC will automatically open a menu asking
which truck the ATC will be used in.
PLP 200 <-
PLP 250
Scroll to the desired truck type and press enter. If the wrong type is selected, reset
all settings in the Reset menu and try again.
10.2.8.5 Monitor menu

By pressing the enter and 7 key at the same time it is possible to access the Monitor
menu from the Operational mode. The Monitor menu shows the speed, power
consumption, motor temperature and TMC temperature.
Monitor menu
Traction
Monitor menu
Pump
Monitor menu
Steering
Monitor menu
Wire guide
Monitor menu
In/Out
10.2.8.6 Traction
Under the Traction menu it is possible to control the motor speed in real time and
the current consumption or motor and TMC temperature.
C: 025 degC
M: 027 degC
1800 RPM
56 A
Pump: Not relevant for PLP.

Steering: Not relevant for PLP.
Wire guide: Not relevant for PLP.
SERVICE MANUAL PLP

10.2.8.7 In/Out
Under In/Out it is possible to check all inputs to ATC, TMC and HVC in real time.
It is also possible to check the ATC internal interlock functions. The function to
check the inputs is built up as shown in fig:
ATC inputs:
TMC inputs:
HVC inputs:
EPS inputs:
ATC in/out:
Note that the truck is in Operational mode when the Monitor menu is shown. In
other words the truck can be driven, and therefore it is appropriate to block it up in
accordance with the safety instructions.
10.2.8.8 Set Options

There are several different options under option. They are used to explain to ATC
which accessories the truck is equipped with. Further information on which options
are available and their function can be found under “Options” on page 31.
The option name and which status the option has (off or on) is specified in the first
bar in the display. Setting an option is done as follows:
1. Step forward to the option to be set, and press enter.
Transp indic: no
0:no 1:yes
2. Press the 0 key to switch off the option, or 1 to set it.

Transp indic: yes
New value saved!
10.2.8.9 Calibrate accelerator

Under Calibrate it is possible to calibrate the accelerator. This is done as follows:
• Select accelerator, and press enter.
CALIBRATE:
Accelerator v^
• Leave the accelerator in neutral, and press enter.

Release throttle
and press ENT
SERVICE MANUAL PLP

• Apply maximum acceleration in both directions without pressing hard to the

end position, and then press enter.
Go to end points
and press ENT
• The display shows if the calibration was successful or not. (only Software
2.23–)
Ok!
Press ENT
Not successful!
Press ENT
• The calibration is now finished. A window is shown where it is possible to test

the response of the accelerator. Press enter to end.
Signal check:
2.3V Out: 064%
Important!
The accelerator must be calibrated at each service.
10.2.8.10 Calibration of lifting and lowering controls (ATC T4 mk2,

2007w28–)
Important!
The lifting and lowering controls must be calibrated both at ON/OFF and
proportional adjustment.
1. Open the Atlet menu => Calibrate => Lift/Lower. The following
display appears:
Release lift
press ENT
2. Check that there are no controllers activated. Now press ENT. The following
display appears.
Order full raise
press ENT
3. Press lift fully down on the right lift and lower control. Now press ENT.
4. The following display now appears.
Order full lower
press ENT
Press lower fully down on the right lift and lower control. Now press ENT.
5. The display shows if the calibration was successful or not. (only Software
2.23–)
Ok!
Press ENT
SERVICE MANUAL PLP

Not successful!
Press ENT
6. The following display appears:

Signal control:
x.xV Out: xxx%
You can now use this menu to check that the calibration is correct. Signal check
should give the following values:
• When lift is activated: 4.7V (± 0.1V)
• Neutral (control not activated): 2.7V (± 0.1V)
• When lower is activated: 0.6V (± 0.1V)
Press ENT.
7. Repeat the same calibration procedure for the left lift and lower control by
selecting Channel 2, and follow steps 1-5. Exit by pressing ENT.
8. Leave the Atlet menu by going to Exit and pressing ENT.
9. Loosen the battery and then restart the truck.
10. Perform a function test of the lift and lower function.
10.2.8.11 Add New Driver

New drivers can be added in the menu Set Access. Select Operator to add new
driver.
• Select new/change and press enter.
OPERATOR:
New/change v^
• Write in the driver ID to be changed/added.

Operator ID:
?
• Select the driver category the driver is to belong to.

Operator categ:3
?
• Select the code applicable for the driver. If the code or category is to be
changed for an existing driver, the code associated with this driver ID must be
specified first.
New code:
????
• To verify the code it must be entered one more time.

Verify new code:
***?
• Press enter to end.

OK!
Press ENT
SERVICE MANUAL PLP

10.2.8.12 Change Format of Driver ID and Access Code

In the submenu Set Access there is a function to set the number of digits in the driver
ID and access code. Both these can be set from between one to seven digits. Note
that drivers with longer codes will not be able to logon if the number of digits is
reduced! On the other hand if the number of digits is increased the requisite number
of zeros will be added to existing, shorter codes.
• The format of code/ID is changed in Set Access => Operator => Format.
OPERATOR:
Format v^
• A warning in two parts is shown. Press 2 to see the second part of the warning.
Continue by pressing 1.
CAUTION! Reduced
length may lead

to lost entries
0:escape 1:go on
• Change the length of ID or Code.

ID length: 5
v

Code length: 4
^
• Step out by pressing a four, or the horn key.
10.2.8.13 Change Access Code for Local or Atlet Service Menu

The codes for both Atlet and Local service can be changed in Set Access. This is
done in the same way for both, as follows:
• Select Set Access => Local, and press enter.
SET ACCESS:
Local v^
• Specify the valid code.

Old code:
****???
• Write in the new code.

New code:
???????
• Verify the new code.

Verify new code:
****???
• Press enter to end.

OK!
Press ENT
SERVICE MANUAL PLP

10.2.8.14 Log Functions and Hour Counter

There are two different log functions in ATC, error log and temperature log. Both
can be read and cleared in Atlet Service.
There are also a number of hour counters and these can divided up into two
categories, total time and trip time. Both can be read in Atlet Service, but only the
trip category can be cleared. The times measured are:
• Active time – the time the truck is used actively, or in other words the total of
travel time and pump time.
• Log time – the time the system has been logged on.
• Travel time – the time the drive motor has been used.
• Pump time – the time the pump motor has been used.
The hour counters can also be read in external units, e.g. a TMC or HVC.
The total hour meters can be set in Atlet menu => logs/counters => set hour mtrs.
Note that the total hour meters only can be set to a higher value than the existing.
There will not be an error message if a lower value is set, but the new value will not
be saved.
10.2.8.15 Read Hour Counter

• Select Hour counters under Logs/Counters.
LOGS/COUNTERS:
Hour meters v^
• Select Trip, Total or External.

HOUR COUNTER:
Total v^
HOUR COUNTER:
Trip v^
HOUR COUNTER:
Read external v^
• Navigate between the four different hour counters.

TOTAL pump:
00001.246h
• Step back with the 4 key or with the horn key.
10.2.8.16 Temperature Log

The temperator log registers temperature measurements from the TMC in five
different temperature intervals. The log saves the number of hours the different
temperatures have been measured. See fig:
Table 10.6 TMC
Temp. ranges: Hours (the numbers are examples)
-40°C 436.53 h
SERVICE MANUAL PLP

Table 10.6 TMC
Temp. ranges: Hours (the numbers are examples)
41-50°C 271.28 h
51-60°C 42.74 h
61-70°C 3.61 h
>71°C 0.00 h
SERVICE MANUAL PLP

10.2.8.17 Error Log

ATC has an error log system that logs external and internal errors. External errors
are errors that external units detect and report to ATC. Internal errors are errors that
ATC detects itself. The error code, description of the error, date and time, are saved
in the error log.
The error log function is based on four error classes:
• A – Shown in the display and saved in the log. Only cleared after it has been
read.
• B – Shown in the display and saved in the log. Cleared when the error has
ceased.
• C – Saved in the log. Not shown in the display.
• Warning – Gives a text warning. Certain warnings are logged.
In addition to being shown in the display, also indicates an error through an audible
signal. The signal is repeated every other minute as long as the error/warning is
shown in the display. The warning is shown in the full top bar on the display, while
the error is shown in the second bar position 5-8.
The error log is divided into primary and secondary faults. A secondary error is an
error that occurs 2 seconds after the first error occurred. If the last primary error is
repeated without any other error occurring, this error will not be logged separately
in the log. It will be added to a counter in the log of the last error instead.
Example of how the error log works:
Primary Log Secondary Log
01:030122 +01:030122
07:49+ 07:49
Traction Traction
system system
Low voltage No
#3 030215 communication
18:09
+01:030122
07:49
Valve system
No
communication
The fault “Traction system, Low voltage” has occurred three times. The first time
at 07:49 220103 and the third time at 18:09 150203. There are two secondary faults
associated with the first fault, which are shown by the plus character after the time
07:49.
SERVICE MANUAL PLP

10.2.8.18 Read Error Log

• The error log is opened with Log/Counters => Error log.
ATLET MENU:
< Logs/Counters >
• The primary faults in the error log are navigated with the 8 and 2 keys.
Information is read from the error log as follows:
Number in errorlog Error code
13: E105
030221 12:04:26
Date when error occurred Time when error occurred
Error description
Traction system
no communication
Number of times the error has been repeated
#015 occurred:
030402 12:27:15
Date when latest error occurred Time when latest error occurred
Figure 10.5
• The [i] key is used to access the secondary log. The secondary errors can then
be navigated with the 2 and 8 keys.
10.2.8.19 Clear Error Log

• To clear the error logs, select Logs/Counters => Reset.
LOGS/COUNTERS:
Reset v^
• Select Error log.

RESET:
Error log v^
• Select Yes.
Reset error log?
0:no 1:yes
10.2.8.20 Performance Parameters

The performance parameters in ATC are divided into two levels, machine
parameters and driver parameters. The machine parameters represent the basic
SERVICE MANUAL PLP

setting of the machine. They are preset at the factory and can only be changed by
using a special PC program. The driver parameters are percentages of the machine
parameters.
10.2.8.21 Driver Categories

The software in ATC supports four different driver categories. These are used to
give different drivers difference performances. One example is the possibility to
have a category for experienced drivers and one for beginners. All driver IDs must
be associated with a driver category.
Table 10.7
Parameter Description Limits
Fwd Speed Maximum speed forward 20-100%
Rev Speed Maximum speed in reverse 20-100%
Tract Accel Acceleration 20-100%
Cutback 1 Creep speed 0-90%
Cutback 2 Not used -
Tract Curr Current limit 20-100%
Rdc brake Braking torque for reducer brake 0-100%
Neut brake Braking torque for neutral position brake 0-100%
Rev brake Braking torque for reversing brake 50-100%
Brake Braking torque for the ELCB brake 50-100%

pedal
10.2.8.22 Set Driver Parameters

• Select Settings => Performance. Select the category the driver parameters are
to be changed for.
PERFORMANCE:
Op category 1 v^
• Navigate amoung the different driver paraemeters with the 2 and 8 keys. Press
enter to select parameter.
Cutback 2 20%
v^
• Write in a new value and press enter.

Cutback 2 25%
New value saved!
SERVICE MANUAL PLP

10.2.8.23 Pin Code

ATC uses a pin code instead of a key switch. Each driver is defined with a unique
ID number. A pin code is linked to each driver ID, which can be 1-7 digits in length.
Up to 100 driver IDs can be saved. The driver ID and code are used together to
access the truck, thereby replacing the key switch.
10.2.8.24 Safety Checks

When logging into the truck there is a safety check of the brake switch, lift system,
belly button switch and speed controller. The lifting and speed controller should be
inactivated when logging on and the brake switch should previously have been in
neutral position. If any of these safety tests fail a warning is shown in the display,
with a request to reset the activated control to neutral position. Depending on which
control is activated an interlock function will be actuated to prevent the use of
certain of the truck functions.
Table 10.8
Warning text in Cause Interlock

display function
actuated
Release Throttle The speed controller is actuated during logon. This Speed interlock
warning can also be shown if the steering arm is moved to
operational mode with an excessive throttle.
Release Tiller The brake switch was not in neutral position during start- Safety interlock
up.
Release controls One of the keys for lifting/lowering was actuated during Lift interlock
logon. Also shown if more than one lifting/lowering
control is actuated simultaneously.
Release controls The belly button switch has returned to neutral position Safety interlock
after logon.
Table 10.9
Interlock function System in the truck obstructed
Speed interlock Drive system
Safety interlock Drive system
Lift interlock Lift system
10.2.8.25 Speed Limits

In ATC there is a way of achieving a reduction in speed during the operation of the
truck called creep speed. Creep speed is selected by switching with the 2 key
SERVICE MANUAL PLP

between creep speed and full speed (key 8 to go straight to full speed). The actual
position is shown in the display with a symbol representing a tortoise or a hare.
Figure 10.6
For safety reasons the maximum speed is decided by the positions of the gates and
the platform. See below for a description of the gates and platform states.
Gates Platform Driver on Allowed speed see fig.

out up platform
0 0 0 No travel allowed A
0 0 1 6 B
0 1 0 6 C
0 1 1 Fault state
1 0 0 No travel allowed D
1 0 1 Full speed E
1 1 0 No travel allowed F
1 1 1 Fault state
A B
C D
E F
Figure 10.7
SERVICE MANUAL PLP

10.2.8.26 General Functional Description

For the truck to be in neutral position the following is necessary:
• The tiller arm must be raised.
• The drive wheel must point straight forwards.
• Forks in bottom position.
• Battery plug disconnected.
• Truck in room temperature (20°C).
• Safety gates are in upper position.
• Platform is in upper position.
• Emergency push button is in its upper position.
10.2.8.27 Truck Mode

The truck can be in four different modes:
• OFF: Voltage disconnected.
• Logged on/Operational: To be compared with the battery plug connected and
the key in the lock, key in on position.
• Logged off: To be compared with the battery plug connected but the key
removed.
• Standby: To be compared with the battery plug connected and the key in the
lock, but in off position.
Off
Remove battery plug Connect battery plug
Logged off Held down for 1s
Pin plus Bellybutton
Logged on Standby
Held down for 1s
Figure 10.8
In Operational mode all the truck functions such as lifting/lowering and travel can
be used. Logon with ID and pin code is required to access the Operational mode. In
SERVICE MANUAL PLP

the Operational mode the driver can utilise a lot of information via the display, such
as date, time, battery status, error codes and warning messages, etc.
Date Time
27-nov-97 10:16
^ 2652h
Battery indicator Hourmeter
Field for error codes Full speed/creep speed symbol
Lift stop indicator
Figure 10.9
• Date - shows ATC date.

• Time - shows ATC time.
• Field for error codes – an error code is shown when an error occurs. When a
warning is shown it is shown in the full upper bar instead.
• Symbol for creep speed/full speed - shows if the truck is in full speed or creep
speed mode.
• Hour counter – shows active or logged on time, depending on which selection
was made in the options menu.
• Battery indicator – shows battery status. When 20% battery status is reached
the lift system ceases to be available.
10.2.8.28 Temperatures
The TMC measure temperature and sends, if necessary, a warning to the ATC. The
temperatures measured are the internal controller temperature and the traction
motor temperature. The traction motor temperature is only measured in two steps;
over and below 125°C. If a value greater than 125°C is measured the TMC reduces
the current and the warning “Motor temp high“ is presented on the display.
The internal controller temperature is measured and handled in two steps. If the
temperature is over 75°C the TMC reduces the maximum current. If the temperature
is over 100°C the current is reduced to zero and the truck stops. With a controller
temperature over 75°C the warning “Ctrl temp high“ is presented on the display.
SERVICE MANUAL PLP

10.2.8.29 Options
Table 10.10
Option Description
Lift limit Lift stop for the fork lift. Stops the pump when the lift stop switch is actuated.
The lift stop is connected to a digital input on TMC.
Restart Restart of the fork lift, activated by pressing 2 on the keypad.
Safety syst Safety system S3 (only PP* servo). When the safety system is enabled the speed
is reduced during cornering. The safety system is a part of Fleet Management.
Effici log Efficiency log. Included in Fleet Management.
Impact sens Collision sensor. Included in Fleet Management. The collision sensor is purely
software based. The speed is monitored, and sudden and rapid reductions in
speed are interpreted - as different degrees of colliding.
*Log level -Setting for logging collisions.
*Warning level -Setting for collisions that give a warning on the display.
*Horn level -Setting for collisions that activate the horn.
*Stop level -Setting for collisions that stop the truck.
*Supervis level -Setting for collisions that require the truck to be unlocked
using a code.
Damage rep Damage log. 10 seconds after logging the truck reverts to crawl speed and the
driver receives a number of questions about any damage. If the driver answers
no, the truck switches to Operational, i.e. the truck runs as normal. Otherwise a
question is asked about damage to different parts of the truck. Included in Fleet
Management.
Time logoff Time for automatic logging off.

*Del time a -Time to go to Standby.
*Del time b -Time to log off.
*Dis tiller res (Disable tiller reset) -If the parameter is set to “Yes”, you log on
from Standby to Operational by pressing the “I”-button twice. If the
parameter is set to “No”, you log on by activating the tiller arm's brake switch.
Smartcard Smartcard is a unit mounted on the machine housing (servo) or the tiller arm.
Smartcard permits a log on using a card instead of a PIN-code.
*Damage rep -Damage log for the Smartcard. Works as the damage log
Damage rep.
Disp log on If the option is enabled the log on time is shown on the display. Otherwise the
active time is shown.
Summer time Automatically sets the clock to summer time.
Keyswitch If the option is enabled the keyswitch is used instead of the PIN-code when
logging on.
Speed red Speed reduction is connected to a digital input on TMC.
Service-Alarm Automatic service reminder.

*Interval -Time for service interval.
Fixed platf Activated when a fixed platform is used (only PLP).
TillerUpD Holding in the button on the tiller arm allows the truck to be driven at crawl
speed, without actuating the tiller arm brake switch (only PLL/PSD/PS).
SERVICE MANUAL PLP

Table 10.10
Footswitch Activates the foot switch surveillance (only PP). On trucks with operator lift the
access to the Foot switch is limited. In case of a break down of the Foot limit
switch the operator lift can still be raised during service if the option is set to
NO. Note! Option must be set back to YES after service.
Reverse ind Reversing warning unit which is connected on HVC (only PP).
Raise steer Accompanying control (only PP).
Dual lift Double proportional buttons (only PS/PSH)
Straddle Adjustable straddle lift (only PSH). Can not be combined with Dual lift.
Belly start If the parameter is set to “Yes”, the belly switch must be activated in order to
log on (used as an “Enter” button). If the parameter is set to “No”, you are
immediately logged on once the code has been entered.
*Only shown if the option is activated.
When options are stated as being truck specific, under no circumstance may
these be activated on any other type of truck than the ones stated. This is on
account of the software using the same digital inputs for different functions on
different truck models.
10.2.9 ATC Logic

The truck control logic is nowadays mainly generated in the ATC software, and not
as previously with cabling and the series and parallel connection of switches. For
this reason it is no longer possible to measure all the logical conditions by means of
a multimeter. This can now be done with the help of the Monitor menu function for
input control. There is no circuit diagram for the software. Instead, a graphic
description of the software conditions required for ATC to request procedures has
been generated.
The condition does not rule

if it is true. Can be compared
with a NC contact.
The condition rules if it is

true. Can be compared with
a NO contact.
Two conditions after each other generate an “and” condition, i.e both conditions
must rule for the objective to be achieved. Two parallel conditions generate an “or”
SERVICE MANUAL PLP

condition, which means that it is sufficient for one of the conditions to rule for the
objective to be achieved.
OR AND
Figure 10.10
Below is an example of how the horn works:
Hornbutton 1
ATC sends order to start horn
Hornbutton 2
Figure 10.11
It is therefore sufficient for one of the horn keys to be actuated for it to start.
SERVICE MANUAL PLP

10.2.9.30 Direction Selection
Throttle command
>Deadzone Safety interlock Tillerswitch
Speed interlock
Platform down Platform up Gates
Forward
direction
request
Platform down Platform up
Throttle command
Safety interlock Tillerswitch
<Deadzone
Speed interlock
Platform down Platform up Grindar
Backward
direction
request
Platform down Platform up
Figure 10.12
An explanation of the different interlock conditions is available under “Safety

Checks” on page 27.
SERVICE MANUAL PLP

10.2.9.31 Brake System
Tiller switch
Speed interlock
Engage brake
Actual vehicle Timer elapsed

speed=0 500 ms
Throttle command
in deadzone
Figure 10.13

Checks” on page 27. Note that the brake will be automatically engaged after 500 ms
on a stationary truck with the speed controller in neutral position.
10.2.9.32 Lift System
Pushbutton
raise 1
Pushbutton Pushbutton
Liftstop Lift interlock
lower 1 lower 2
Pushbutton Start pumpmotor
raise 2
Pushbutton
lower 1
Pushbutton Pushbutton
raise 2 Lift interlock
raise 1
Pushbutton Opens lowering valve
lower 2
Figure 10.14

Checks” on page 27.
SERVICE MANUAL PLP

10.2.10 Download
10.2.10.1 Download of Service Data and Logs to a PC

1. Log off the truck and disconnect the battery connector.
2. Turn on the PC.
3. Connect the PC serial COM port to the data connector X3 in the tiller head.
Use PC downloding cable ATLET part no 108005.
4. Reconnect the battery connector.
PC
5. Start Windows HyperTerminal.
6. Create a new HyperTerminal connection.
7. Connect directly to your serial COM port.
8. Adjust the com parameters as follows:
• Baud Rate: 9600

• Data Bits: 8
• Parity: None
• Stop Bits: 1
• Flow Control: None
9. Activate "Capture Text" mode under "Transfer" menu.

Truck
10. Log into "ATLET menu".
11. Select "LOGS/COUNTERS" and "Download".
12. The service information is now transferred to the PC.
Disconnect
13. Turn off the HyperTerminal and the PC, log off the truck and disconnect
battery plug.
14. Disconnect the PC downloding cable.
10.2.10.2 Download of "Truck Manager" Statistical Logs to a PC

1. Log off the truck and disconnect the battery connector.
2. Turn on the PC.
3. Connect the PC serial COM port to the data connector X30 under the
armrest. Use PC downloding cable ATLET part no 108005.
4. Reconnect the battery connector.
PC
5. Start Windows HyperTerminal.
6. Create a new HyperTerminal connection.
SERVICE MANUAL PLP

7. Connect directly to your serial COM port.

8. Adjust the com parameters as follows:
• Baud Rate: 9600

• Data Bits: 8
• Parity: None
• Stop Bits: 1
• Flow Control: None
9. Activate "Capture Text" mode under "Transfer" menu.

Truck
10. Log into "LOCAL MENU".
11. Select "FLEET MANAGER" and "Download".
12. The statistical data is now transferred to the PC.
Disconnect
13. Turn off the HyperTerminal and the PC, log off the truck and disconnect
battery plug.
14. Disconnect the PC downloding cable.
SERVICE MANUAL PLP

10.2.11 ATC Connector

ATC, connector and pin numbering.
XJ5 XJ1 XJ2 XJ3 XJ4

XJ9 XJ10
XJ13
XJ6
XJ14 XJ8
XJ7
XJ12
XJ11
Connector top view:
2 XJ8, XJ14
1
43 XJ1, XJ2, XJ3, XJ4, XJ5, XJ9, XJ11, XJ12

21
6 54 XJ7
3 21
87 65 XJ10
43 21
XJ6
14 1
Figure 10.15 Cortex card
10.2.12 Digital I/Os
10.2.12.1 Digital Inputs ATC

There are twelve digital inputs on the ATC card, of which seven are used for the
pushbuttons on the tiller arm. The pushbuttons control functions as lift/lower and
the horn.
The other five digital inputs are not used in these truck models.
The fact that the inputs are read by ATC can easily be confirmed by selecting Test
=>Inputs in the ATLET service menu, and then activating the different functions.
The signal supply of approx. 5V is on pin no 1 in the following connectors:
Table 10.11
Connect Function Comment

or
XJ1.3 Lift
SERVICE MANUAL PLP

Table 10.11

or
XJ2.3 Lower
XJ3.3 Lift
XJ4.3 Lower
XJ8.1 Horn 1 Supply 5V pin no 2.
XJ14.1 Horn 2
10.2.12.2 Digital Inputs TMC

There are ten digital inputs in to the TMC, of which seven can be used for these
truck models.
Signal supply 24V is taken from pin no X5.2.
Table 10.12

or
X5.3 Brake switch Closes in the upper and lower arm position.
X5.5 Safety gates Closes in upper position.
X5.6 Platform down switch Closes when platform is down.
X5.7 Lift stop switch Breaks at end position.
X5.8 Platform up switch Closes when platform is up.
X5.9 Fixed platform switch Closes when standing on the fixed platform (option).
X6.14 Speed reduction switch Breaks at slow speed and must be set from option
menu.
10.2.12.3 Digital 24V Outputs TMC

There are five digital outputs in TMC. Four of these are of the “low side” type,
which means that they close to B-. The fifth output is of the “high side” type, which
means that it closes to B+. It is this fifth output that closes the lowering valve Y2.
Table 10.13

or
X6.1 Energises main contactor K1 24V supply from X6.2.
X6.3 Energises the electric brake 24V supply via brake switch.
Y1
X6.4 Energises the lift contactor K2 24V supply via X6.5.
SERVICE MANUAL PLP

Table 10.13

or
X6.6 Energises the horn H1 24V supply via X6.5.
X6.11 Energises the lowering valve 0V supply via X6.12. NOTE! This output is not short-
Y2 circuit-proof.
10.2.13 Cold Resistance Values

Table 10.14
Component Resistance
Contactor K1 approx. 47 Ohm
Contactor K2 approx. 19 Ohm
Valve coil Y2 approx. 26 Ohm
Brake Y1 approx. 20 Ohm
10.2.14 Fuses
Table 10.15
Fuses
F1 250A Drive motor
F2 250A Pump motor
F3 7.5A Manoeuvring
F4 5A For extra equipment. Max 120W
F5 25A Power steering
SERVICE MANUAL PLP

Electrical System / Diagnostics and Trouble Shooting 10.41
10.3 Diagnostics and Trouble Shooting
10.3.1 Truck Remote ACcess, TRAC

The purpose of TRAC is to create a remote access to the display and keyboard of
the truck, so that an expert can make a remote analysis of the truck and guide local
service personnel to trouble shooting.
10.3.1.1 Prerequisites
• GSM-phone with built in modem and serial cable (local TRAC experts can
provide more information on suitable phones).
• GSM telephone subscription featuring “data call“ and a “data phone“ telephone
number.
10.3.1.2 Utilization
After agreement with a TRAC expert to use the TRAC system:
• Prepare and connect according to the connecting procedure below.
• The TRAC expert may send text messages to you through the display of the
truck.
• When the TRAC session is closed, await a phone call from the expert or call
the expert yourself.
• Disconnect in reverse order (see connecting procedure).
10.3.1.3 Connecting Procedure

1. Step to TRAC using the arrow button, and enter the menu with
the Enter button.
2. Choose “init phone“ and return to the TRAC menu with arrow .
3. When the phone rings, choose “answer phone“. Return with arrow .
Illustrated instructions are attached to the TRAC cable.
SERVICE MANUAL PLP

10.42 Electrical System / Diagnostics and Trouble Shooting
10.3.2 Error Codes
10.3.2.1 Error Code Indicating ATC:

The error codes 1-33 are all memory errors that can occur in conjunction with
program errors during unsuccessful reprogramming or during electrostatic
discharge.
Table 10.16
Error code indicating Class Explanation Control/Procedure
E1 ATC B Attempt to write to invalid E2PROM Settings lost. No action.

invalid NVM access. address.
E2 Not used.
E3 Not used.
E4 Not used.
E5 ATC NVM C Efficiency log is full (all 100 entries Settings lost. No action.
Efficiency log is full. are used) ->first entry will be
overwritten.
E6 ATC NVM C Efficiency log was corrupt and Settings lost. No action.
Efficiency Log Reset repaired/cleared during Startup
during startup. Check.
E7 ATC NVM C Chronological Impact Log was Settings lost. No action.

Chronological Impact corrupt and repaired/cleared during
Log Reset during startup. Startup Check.
E8 ATC NVM C Chronological Damage Log was Settings lost. No action.

Chronological Damage corrupt and repaired/cleared during
Log Reset during startup. Startup Check.
E9 ATC NVM C Temperature Session Log was Settings lost. No action.

Temp Log Reset during corrupt and repaired/cleared during
startup. Startup Check.
E10 ATC NVM C Operator Session Log was corrupt Settings lost. No action.
Operator Session Log and repaired/cleared during Startup
was corrupt and repaired/ Check.
cleared during Startup
Check.
E11 ATC NVM C One or more parameters New settings may be

parameters partially reset (parameters/accessories/settings) necessary.
during start-up outside the area. This can also
happen when the system starts up for
the first time.
SERVICE MANUAL PLP

Table 10.16
E12 ATC NVM C Local access code outside area New settings may be
local code reset during (0-9999999). This can also happen necessary.
start-up when the system starts up for the
first time.
E13 ATC NVM C ATLET access code outside area New settings may be
ATLET code reset during (0-9999999). This can also happen necessary.
start-up when the system starts up for the
first time.
E14 ATC NVM C User ID/code or profile outside area. New settings may be
user entry cleared during necessary.
start-up
E15 ATC NVM C Error log corrupt. No action.

error log cleared
during start-up
E16 ATC NVM C Timer outside area. No action.

timer (timers) cleared
during start-up
E17 Not used.
E18 Not used.
E19 Not used.
E20 ATC NVM C ATLET/LOCAL code forced to reset

ATLET/LOCAL code in RESET menu.
forced to reset.
E21 ATC NVM C All users forced to reset in the reset New settings may be
all users forced to reset. menu. necessary.
E22 ATC NVM C Option Parameters forced to reset in

Option Parameters forced RESET menu.
to reset.
E23 ATC NVM C Setting parameters forced to reset in New settings may be
setting of parameters the reset menu. necessary.
forced to reset
E24 ATC NVM C Calibration parameters forced to New settings may be

calibration parameters reset in the reset menu. necessary.
forced to reset
E25 ATC NVM C All logs forced to reset in the reset No action.
all logs forced to reset menu.
E26 Not used.
E27 ATC NVM C Error logs forced to resest in the No action.

error log forced to reset ATLET menu.
E28 ATC NVM C Temperature logs forced to resest in No action.

temperature log forced to the ATLET menu.
reset
SERVICE MANUAL PLP

Table 10.16
E29 ATC NVM C Trip meter time/utilisation forced to No action.

trip meter time/utilisation resest in the ATLET menu.
forced to reset
E30 ATC NVM C driver log forced to resest in the No action.

diver log forced to resest LOCAL menu.
in the LOCAL menu
E31 ATC NVM C Effective time forced to resest in the No action.

effective time forced to LOCAL menu.
resest in the LOCAL
menu
E32 ATC NVM C Damage log forced to resest in the No action.

damage log forced to LOCAL menu.
resest in the LOCAL
menu
E33 ATC NVM C Collision log forced to resest in the No action.

collision log forced to LOCAL menu.
resest in the LOCAL
menu
E34 Not used. No action.
E35 ATC 1721 B “ADC PotLowOutput” > ADC

Analog Common Pot COMMON POT LOW
Low Input Range Fault SUPERVISION LEVEL.
E36 ATC 1721 B “ADC PotHighOutput” > ADC

Analog Common Pot COMMON POT HIGH
High Input Range Fault SUPERVISION LEVEL.
E37 ATC 1721 B “ADC BrakeOutput” > ADC MAX

Analog Brake Input BRAKE SUPERVISION LEVEL or
Range Fault “ADC BrakeOutput” > ADC MIN
BRAKE SUPERVISION LEVEL.
E38 ATC 1721 B “ADC Raise Output” > ADC MAX

Analog Raise Input RAISE SUPERVISION LEVEL or
Range Fault “ADC Raise Output” > ADC MIN
RAISE SUPERVISION LEVEL.
E39 ATC 1721 B “ADC Lower Output” > ADC MAX

Analog Lower Input LOWER SUPERVISION LEVEL or
Range Fault “ADC Lower Output” > ADC MIN
LOWER SUPERVISION LEVEL.
E40 ATC 1721 B “ADC Aln1 Output” > ADC MAX

Analog A-IN1 Input AIN1 SUPERVISION LEVEL or
Range Fault “ADC Aln1 Output” > ADC MIN
AIN1 SUPERVISION LEVEL.
E41 ATC 1721 B “ADC Aln2 Output” > ADC MAX

Analog A-IN2 Input AIN2 SUPERVISION LEVEL or
Range Fault “ADC Aln2 Output” > ADC MIN
AIN2 SUPERVISION LEVEL.
SERVICE MANUAL PLP

Table 10.16
E42 ATC 1721 B Belly button redundancy check

Belly button supervision failed.
fault
E43 ATC 1721 B Speed signal / Speed neutral switch

Throttle supervision fault check failed.
E44 Not used.
E45 Not used.
E46
E47
E48
E49
E50 ATC/TMC C Liftlock occurs due to low battery Charge the battery.
low battery voltage.
E51 Com pot low fault B Common low supply range fault 1. Replace the lift/lower
switch.
2. If the error still occurs
replace the ATC.
E52 Not used
E53 Hyd pot high fault B High supply to hydraulic controls 1. Replace the lift/lower
supply range fault switch.
2. If the error still occurs
replace the ATC.
E54 Not used
E55 Not used
E56 Lift range fault B Lift/lowering signal out of allowed • Tiller with on/off
range buttons: Reset
calibration of lift
lower and aux 1.
• Tiller with rocker
switch: Check the
inductive sensors and
the connections.
E57 Not used.
E58 Not used.
E59 Not used.
SERVICE MANUAL PLP

10.3.2.2 Error Code Indicating TMC:
Table 10.17
E100 CAN error B CAN communication error 1. Check that TMC receives
TMC on start-up voltage supply.
2. Check the CAN
communication link
between ATC and TMC to
make sure there is no fault
or short-circuit in the
cables.
See wiring diagram.
3. The may be a short-
circuit on the ATC or the
TMC. Change TMC first
and ATC as the other unit.
E101 TMC B TMC monitoring has triggered. Try restarting the truck. If
Watchdog this does not help, change
TMC.
E102 TMC B Positive supply voltage to the logic 1. Try restarting

logic error 1 is outside the range. 2. Charge the battery if it is
getting flat.
3. Check that the thick
cables between the motor
and TMC are properly
tightened and that they have
a low ohm factor. Check
also the supply cables to
TMC, and the cable and
voltage supply to contact
X5.1.
4. Change TMC.
5. Change drive motor.
E103 TMC B Error in the part of the logic that 1. Try restarting.
logic error 2 handles the return supply of the 2. Charge the battery if it is
phase voltage. getting flat.
3. Check that the thick
cables between the motor
and TMC are properly
tightened and that they have
a low ohm factor. Check
also the supply cables to
TMC, and the cable and
voltage supply to contact
X5.1.
4. Change TMC.
5. Change drive motor.
E104 TMC B Error in the part of the logic that 1. Try restarting.
logic error 3 handles the overlead protection. If the error recurs, change
TMC.
2. Change the motor.
SERVICE MANUAL PLP

Table 10.17
E105 TMC emergency B Communication response from 1. Restart

monitoring has tripped TMC has not been received in 2. Check the CAN bus
time. cable carefully if the error
occurs repeatedly, to make
sure there is no play on the
connector ring and that the
terminal resistance
maintains
120 Ohm +/- 5%.
3. Check that the CAN bus
is separated from the thick
cables. Interferance can
give rise to the error.
E106 TMC supply low B This test is done on start-up and 1. Motor cable fault,
E107 TMC supply high when stationary (No drive connection fault, insulation
manoeuvre is given). fault in the motor or to
chassis.
2. Change TMC.
E108 TMC A The main contactor contact tips are Check main contactor K1 to
contactor closed closed before voltage has reached make sure the contact tips
the coil. are not welded, or that it is
not short-circuited over the
terminals via the cables.
E109 TMC A The logic has low voltage to main 1. Break in cables to the
contactor open contactor K1 but the contactor tips coil.
do not close. 2. Break in coil.
3. The contactor tips do not
close, or fail to connect
with TMC.
E110 TMC B Check that the current is zero when Change TMC.
current measuring in truck is stationary.
standby mode is not
equal to zero
E111 TMC B The capacitor in TMC does not 1. Check that there is
capacitor charging charge up as it should during start- battery voltage to TMC,
up. between B- and contact
X5.1.
If not, check battery
voltage, supply cables and
their connections.
2. Change TMC.
SERVICE MANUAL PLP

Table 10.17
E112 TMC A The output to the main contactor 1. Check that there is no
output short-circuited coil is short-circuited. short-circuit in main
contactor K1, the coil, or
that the freewheel diode is
not reversed or short-
circuited. Cut the diode and
check that there is no short-
circuit in the cables to the
coil.
2. Change TMC.
E113 TMC B The output for the main contactor 1. Change TMC.
contactor output does not function.
E114 TMC A One of the outputs X6.1, X6.3, 1. There is a short-circuit in

coil short-circuited X6.4 or X6.6 is short circuited. either the main contactor
coil K1, the brake coil Y1,
lift contactor coil K2, or in
the horn.
2. There is a short-circuit in
the cabling that connects to
the components or in the
freewheel diodes, or in the
capacitor that suppresses
the horn.
3. Internal short-circuit in
one of these outputs,
change TMC.
E115 TMC B TMC self-test does not work. 1. Try restarting a few
generic error times.
If this does not rectify the
problem, change TMC.
NOTE! The error is
probably logged together
with E123, but should
normally never occur.
If E115 or E123 are still
be logged, this should be
reported to the service
function at ATLET AB.
E116 TMC A Communication command from 1. If other CAN errors are

CAN bus ATC not received in time. logged, rectify these first.
2. There may be an error on
ATC, interference on the
CAN bus, or play in the
CAN bus connector ring.
E117 TMC B Incorrect battery voltage. TMC may be incorrectly

wrong battery configured.
Change TMC.
SERVICE MANUAL PLP

Table 10.17
E118 TMC B Error on the signal from the Check and measure the
pulse transducer error transducer bearing in the drive transducer in accordance
motor. with the trouble shooting
chart for “Drive motor” on
page 53.
E119 Not used.
E120 TMC C EEPROM set to default. Error in The battery settings have
EEPROM error the range that includes adjustable probably been lost. See
values. “Battery Capacity” on
page 6.
E121 TMC Warning The internal temperature 1. See trouble shooting for
controller temperature C monitoring has exceeded the 75°C “The drive motor looses
warning level. power and the speed slowly
The current is limited in relation to drops.” on page 55.
the temperature. 2. Change TMC.
TMC stops completely at 100°C.
E122 TMC Warning The drive motor temperature has 1. See trouble shooting for
motor temperature C exceeded the warning level. “High temperature in drive
motor E122” on page 55.
E123 TMC Warning Generic warning. Try restarting a few times.

generic C If the error does not
disappear, change TMC.
NOTE! The error is
probably logged together
with E115, but should
normally never occur.
If E115 or E123 are still
be logged, this should be
reported to the service
function at ATLET AB.
E124 TMC B The output to lowering valve Y2 First confirm that the valve
PEV output connection X6.11 is defective. coil is not short-circuited,
that the freewheel diode
short-circuits or is reversed,
or that there is a short-
circuit in the cabling.
NOTE! This output
connects to B+ and is not
short-circuit-proof. For
this reason make sure to
check that no external
short-circuit exists before
changing TMC.
E125 TMC Warning The internal temperature sensor is Change TMC.

temperature sensor C defective.
E126 Not used.
SERVICE MANUAL PLP

Table 10.17
E127 TMC C Current calibration in progress. Try restarting a few times.

Current sensor error If this does not help, change
TMC.
10.3.2.3 Other Trouble Shooting

Main contactor does not close
There may be other reasons why the main contactor does not close. For this reason,
start trouble shooting by rectifying the last logged primary error code.
Have any related error codes been logged? Yes See trouble shooting for respective error
codes.
No
Is there 24V from TMC connection X6.2? No Change TMC.
Yes
Is there 24V to the main contactor plus No Check connection X6.2 - K1.1.
connection K1.1?
Yes
Measure directly over the main contactor No Check if cable connection K1.2 - X6.2 is
coil. Is there 24V? OK and has low resistance by measuring
the resistance to the front edge of X6,
when the connector is pulled from TMC, to
the front edge of the flat pin. If there is no
connection, change or repair the cabling.
Otherwise, change TMC.
Yes
Replace contactor.
*The normal cold contactor resistance is approx. 47 ohm.
The truck and ATC have total function loss – the display does not go on
Is there 24V between F1 (between the large No Check the battery, battery plug, electrical
fuses) and the B- insulation point? panel plug and their connections.
Yes
Is there 24V between insulation bolt X16 No Check 7.5A fuse F3, and that there is 24V
and the B- insulation point? to one side of the fuse holder. Only
measured with the fuse pulled out of the
holder.
SERVICE MANUAL PLP

Yes
Is there 24V between X1.1 (the contact that No Check that there is 24V on all the red/white
connects to the steering arm) and theB- cable connections in connector X21. Either
insulation point? there is a break or poor contact between
X16 and X21.1, in toggle X21.1 - X21.2,
or in the connection X21.2 - X1.1.
Yes
Is there 24V between X1.1 and X1.5? No Indicates break or poor connection in the
blue minus cable between B- inslation bolt
and X1.5.
Yes
Open the steering arm head. Is there 24V No Change the steering arm cabling, or repair.
between XJ10.1 and X1J10.5?
Yes
Change ATC.
All minus cables = blue
All plus cables in machine housing = red/

white
All plus cables in steering arm = red
NOTE! There may be a fault on the display or display cable
Fuse
The fuse for the drive motor (F1) is defective.
Change the fuse (with correct fuse value) The most likely reason is that the mean
and restart. current exceeds the rated current of the
fuse. In conjunction with the change,
carefully check the motor cables and the
plus and minus cables to TMC to make
sure they are correctly connected.

Does the fuse blow just after the main Yes Change TMC. If TMC is defective the
contactor has closed? most likely error is an exciter error with
error codes E106 and E107.
No
Start the truck again.

Does the fuse blow again after the truck has Yes Check that the mechanical torque in the
been running for some time? gearbox is not excessive.
SERVICE MANUAL PLP

Increased friction, increased load, high If the truck has been run with a heavy load
speed and rapid starting/stopping increase and at a high speed and with many stops
the average current for the controller. The and starts, or in some other way has
truck may have been driven over its exceeded its limitations, try to reduce the
maximum performance. speed, load, acceleration and retardation.
SERVICE MANUAL PLP

Drive motor
The drive motor only runs at low speed and with a ticking sound, or alternatively
the motor does not start or runs irregularly with a low torque. TMC encoder error
E118 is probably logged.
Pull out contact X9 that connects to the No Pull out the contact X6 and check the
drive motor. Is there 12V between pin X6.9 connections X6.9 - X9.1 and X6.10-X9.4.
and X6.10 in TMC? If the cables are OK, change TMC.
Yes
Is there 12V between pin 1 and 4 in contact No Repair or change the cabling.
X9?
Yes
Replace the contacts and measure the No Carefully check that the cabling
voltage between X6.10 and X6.19 at the connection between X6.19 and X9.3 is OK
same time as the motor is running. An and has a low resistance. If not, repair or
average value of 4-6 volt should be read off change the cabling, otherwise change the
when measuring the DC. Ok? drive motor.
Yes
Measure the voltage between X6.10 and No Carefully check that the cabling
X6.20 at the same time as the motor is run. connection between X6.20 and X9.2 is OK
An average value of 4-6 volt should be read and has a low resistance. If not, repair or
off when measuring the DC. Ok? change the cabling, otherwise change the
drive motor.
Yes
An oscilloscope is required for further
trouble shooting to determine whether the
pulses from the motor sensor bearing are
OK and 90 degrees out of phase. The error
can either be in the motor or in TMC. Try
the motor if it has low insulation resistance
to the chassis. Otherwise start with
replacing the TMC.
SERVICE MANUAL PLP

Drive function
The drive function does not work in one or two directions.
NOTE! If the brakes are applied and No Check that the safety switch has not
correctly adjusted they will hold the truck temporarily jammed. If the error remains it
in spite of full modulation. For this reason, Reset will not be possible to restart the truck, and
always check if the controller is working. It the truck the question about the safety switch will
can be heard as a slight humming sound. still be in the display. Check also that the
modulation from ATC works from approx.
2.5V in neutral position to close to 5V
when driving in the direction of the forks,
and close to 0V when driving in the
opposite direction to the forks. Recalibrate
if necessary.
There may be an error on the brake switch.
Check that the brake switch has not
jammed by checking the input for this via
the test menu. The switch is normally open
when the arm is between its upper and
lower position. If there is 24V on TMC
contact X5.3 the controller will not
modulate and the brake will not be power
actuated.
Yes
Reset the truck
Is there 24V to brake contact X7 when the No Check that there is 24V on the brake
truck is manoeuvred? switch contact X4.3 when the arm is in
drive position. Check also that there is a
connection between X4.3 and X7.1. If not,
repair or change the cabling, or
alternatively change brake switch S9 if this
does not work.
Yes
There is either a mechanical or an electrical
fault in the brake. The resistance should be
approx. 20 Ohm. Test if the brake functions
if it is released from the motor. If not,
change the brake.
NOTE! The brake switch input is tested during every new start to ensure that it closes to X5.3. If it
not, a message is given to release up the arm before driving is permitted.
Also see table and figure se Figure 10.7 during which circumstances the truck is in a fault condition
and the truck is not allowed to drive.
SERVICE MANUAL PLP

High temperature in drive motor E122

If other error codes are logged, rectify these first. The drive motor may have become
overheated because it has been run over its performance level for a long period.
Check motor and gearbox.
Is the warning also given when the motor is No The truck may have been driven over its
cold? maximum performance. There may be a
fault on the motor or gearbox. Reduce the
drive performance temporarily.
Yes
Between X8.1 and X8.2 there is an internal
thermo switch connected. If the internal
motor temperature is below 125°C this
switch is closed, and above 125°C it
breaks. Check this switch when the motor
is cold and observe that the cable
connection X8 must be disconnected from
the motor when measuring. If the termo
switch seems ok then check that there is no
cable break or bad connection in the
cabling. This can be checked with the
power on and by measuring that there is
24V to both X8.1 and X8.2 with B- as
reference and the motor in a cold condition

Did this solve the problem? If not, change
TMC.
For information on temperature log, see “Temperature Log” on page 22.
The drive motor looses power and the speed slowly drops.
High temperature in drive controller, error code E121 may be logged. A warning
text is normally shown in the display.
TMC starts to module down the motor current linearly at 75°C to stop completely
at 100°C. If the error occurs with a cold controller there is probably an error on the
TMC internal temperature monitoring. If other error codes are logged, start the
trouble shooting by rectifying these first. Otherwise, change the controller.
Check that the fan that cools TMC is No Check the fan cabling and that there is 24V
working as it should and that the cooling on to the fan. Otherwise, change the fan and
the TMC are not blocked by dust and dirt. clean up dust and dirt.
OK?
Yes
SERVICE MANUAL PLP

Run the truck for an extended period in No The truck may have been driven over its
raised position and without load. Does the maximum performance. Try to reduce the
temperature in the controller still go over speed, load, acceleration and retardation.
75°C?
Yes
Try to confirm if there is something that is No Rectify the gearbox or change the motor.
increasing the torque, such as a worn or
jamming gearbox, and if the motor is
working normally. OK?
Yes
Change TMC
For information on temperature log, see “Temperature Log” on page 22.
Lowering of the forks does not work
Does ATC read the input(s) in the menu No Check that the pushbutton closes at
“test inputs”? See, “Monitor menu” on approx. 5V to ATC. Check also that 5V is
page 17 available, otherwise change ATC.
Yes
Is there 24V over the valve coil during No Test the cable connection between X6.11
lowering? and Y2.1 and between X6.12 and Y2.2. If
OK, change TMC.
Yes
Check that there is no break in the valve
coil. A normal resistance value is approx.
19 ohm. If not, change coil.
NOTE! If other pushbuttons for the hydraulic function are actuated at the same time as the lowering
button, the lowering is stopped. “Release controls” comes up in the display.
SERVICE MANUAL PLP

Lifting of the forks does not work

NOTE! All trucks are equipped with end position stop. Before trouble shooting,
temporarily set this option to “no”. If this solves the problem the top position switch
should be checked in accordance with the trouble shooting chart for this.
Does the lift contactor actuate without the No Check that the inputs for lift are read by
pump running? ATC in the “inputs” menu in the test menu.
If not, check that the pushbuttons work and
close when actuated. Check that the
pushbuttons receive approx. 5V from ATC.
If not, change ATC. Check that there is not
a break to pump contactor K2 by checking
the cabling, and that there is not a break in
the connector coil.
If there is +24 V to the contactor with B- as
reference and the contactor still does not
pull, change TMC.
Yes
Is the fuse F2 intact? No Change the fuse.
Yes
Check that 24V goes to the motor terminal. No The contact tips do not seem to conduct.
OK?
Yes
Check the brushes to the hydraulic unit, No Change the brushes, or adjust.
and that they are rest against the
commutator. OK?
Yes
Change unit
If the pump runs and the forks still do not

lift there may be a fault in the hydraulics, a
pump fault, or incorrectly connected
hydraulic hoses.
NOTE!
• Remember to reset the option for end position switch lift.
• If the battery is below 20% the lift stop will be actuated. Charge the battery.
• If other pushbuttons for the hydraulic function are actuated at the same time as the lifting button,
the lifting is stopped. “Release controls” comes up in the display.
• Normal pump motor current values are approximately 38A without load, 105A with 2500kg and
125A at end stop. The end stop value can be checked if the option “lift limit“ is temporarily set to
no. See options menu under Menu Tree Atlet Menu.
SERVICE MANUAL PLP

The top position switch for lifting does not function

The top position switch for lifting must normally be closed to enable lifting. The
switch function can be checked in “Monitor menu” on page 17
Pull apart contact X15 and measure the No Check that the switch is not in
resistance of the switch between pin 1 and mechanically actuated position. If OK,
2 when the forks are completely lowered. change switch.
OK?
Yes
Check that there is 24V to the switch and No Check the cabling and that TMC supplies
that TMC receives 24V on contact X5.7. 24 V from contact X5.2. If not, change
OK? TMC.
Yes
Remove the option for top position switch
in the options menu, or alternatively
change TMC.
SERVICE MANUAL PLP

Electrical System / Appendix 1, Summary menu tree 10.59
10.4 Appendix 1, Summary menu tree

In the following section, Appendix 1, menu trees (Software 2.28) can be found for
the menus listed below:
• Menu tree, Local menu

• Menu tree, Atlet menu
• Menu tree, Monitor menu
• Menu tree, Reset menu
• Menu tree, Language
• Menu tree, TRAC
SERVICE MANUAL PLP

10.60 Electrical System / Appendix 1, Summary menu tree
SERVICE MANUAL PLP

Local Menu Tree 1 of 3
Level 1 Level 2 Level 3 Level 4 Level 5 Remarks:
LOCAL MENU:
< Exit >
LOCAL MENU: SET ACCESS: OPERATOR: Operator ID:

< Set access > ENT / v -> Operator ^v ENT -> New/Change ^v ENT -> ?
Operator categ:x
?
Old code:
????
New code:
????
Verify new code:
????
Ok!
Press ENT
Not successful!
Press ENT
OPERATOR: CAUTION! Reduced

Format ^v ENT -> length may lead.
0 v ^
.to lost entries

0:escape 1:go on
Id length: x Id length: x
v ENT -> New value: ?
Id length: x
New value saved!
Input rejected!
Press ENT
Code length: x Code length: x

^ ENT -> New value: ?
Code length: x
New value saved!
Input rejected!
Press ENT
SET ACCESS: Operator ID: The level 3 displays are always followed in sequence.
Delete oper ^v ENT -> ?
Delete op x?
0:No 1:Yes (No)
Ok!
Press ENT
Not successful! invalid ID / 0:(No) pressed or input aborted/ no access to E2PROM
Press ENT
SET ACCESS: Old code: The level 3 displays are always followed in sequence.
Local ^v ENT -> ???????
New code:
???????
Verify new code:
???????
Ok!
Press ENT
Not successful! invalid old code / verifyed code wrong / no access to E2PROM
Press ENT
LOCAL MENU: FLEET MANAGER: This menu entry resets the Impact Sensor actions. To be used by warehouse manegement to acknowledge impact.
<Fleet manager > ENT / v -> Unlock ^v
FLEET MANAGER: READ LOGS: <o>: [date] List of the 30 most recent operator sessions.
Read logs ^v ENT -> Operator log ^v ENT -> [time] - [time]
READ LOGS: EFFICIENCY: <o>: xx(mn)% List sorted from worst to best operator (Act). xx = active time / logged on time * 100; iii = mean main active current draw;
Efficiency ^v ENT -> Worst ^v ENT -> Curr:iii(mn)A mn = corresponding mean value for all operators;
EFFICIENCY: <o>: xx(mn)% List sorted from best to worst operator (Act). xx = active time / logged on time * 100; iii = mean main active current draw;
Best ^v ENT -> Curr:iii(mn)A mn = corresponding mean value for all operators;
Operator id: <o>: xx(mn)% Any operator's efficiency. <o> = operator id (1 - 100)
? ENT -> T:xx(mn)P:xx(mn) T = traction; P = pump; mn = corresponding mean value for all operators;
READ LOGS: DAMAGE LOG: <o>: xxx(mn) <o> = operator who used the truck immediately before damage was reported.
Damage log ^v ENT -> Worst ^v ENT -> <o>: xxx(mn) xxx = number of reported damages. List sorted from greatest to smallest no of reported damages.
DAMAGE LOG: <o>: xxx(mn) <o> = operator who used the truck immediately before damage was reported.
Best ^v ENT -> <o>: xxx(mn) xxx = number of reported damages. List sorted from smallest to greatest no of reported damages.
DAMAGE LOG: 30:[date] [time] List sorted in chronological order.

Chronological ^ v ENT -> <o>: <dc> <o> = operator who used the truck immediately before damage was reported.
v <dc> = damage code (max two characters long).
v
v
01:[date] [time]
<o>: <dc>
not implemented yet !

READ LOGS: IMPACT LOG: <o>: ^xx(mn) Top = peak impact value; mn = mean impact value for all operators; IOM = number of impacts over mean (mn);
Impact log ^v ENT -> Worst ^v ENT -> IOM:xxx Mn:xxx% Mn = operator's mean value.
IMPACT LOG: <o>: ^xx(mn) Top = peak impact value; mn = mean impact value for all operators; IOM = number of impacts over mean (mn);
Best ^v ENT -> IOM:xxx Mn:xxx% Mn = operator's mean value.
IMPACT LOG: 30:[date] [time] List sorted in chronological order.

Chronological ^ v ENT -> <o>: <il> <o> = operator who used the truck immediately before damage was reported.
v <il> = impact level (max two characters long).
v
v
01:[date] [time]
<o>: <il>
FLEET MANAGER:
Download ^v ENT -> Send fleet manager data to serial port.
FLEET MANAGER: RESET LOG: Reset optr log?

Reset ^v ENT -> Operator log ^v ENT -> 0:No 1:Yes (No)
RESET LOG: Resetthis log?

Effic/Dmg/Imp ^ ENT -> 0:No 1:Yes (No)
RESET LOG: Time stamp number of days since last reset

Time stamp ^v ENT -> xxx days
LOCAL MENU: SETTINGS: TIME & DATE: 11:39

< Settings > ENT / v -> Time & Date ^v ENT / v -> Set time ^v ENT -> New time: hh:mm
hh:mm
Ok! Press ENT
Input rejected!
Press ENT
TIME & DATE: dd.mm.yyyy

Set date ^v ENT -> New: yy-mm-dd
2001-09-18
Ok! Press ENT
Input rejected!
Press ENT
TIME & DATE: Select format:

Date format ^v ENT -> 2001-09-18 ^v
18-Sep-01 ^v
18.09.2001 ^v
09.18.2001 ^v
SETTINGS: LCD contrast: x LCD contrast: x x = 0..9

LCD contrast ^v ENT / v -> ENT -> New value: ?
LCD contrast: y
New value saved!
Input rejected!
Press ENT
SETTINGS: Key sound: xxx Key sound: xxx

Key sound ^v ENT / v -> ENT -> 0:no 1:yes
Key sound: yyy
New value saved!
Input rejected!
Press ENT
LOCAL MENU: CARD READER: Smartcard:xxx smartcard:xxx

< Card reader ENT / v -> Enable/disable ENT / v -> ^v ENT -> 0:no 1:yes
smartcard:yyy
New value saved!
Input rejected!
Press ENT
ATLET Menu Tree 1 of 17
Level 1 Level 2 Level 3 Level 4 Level 5 Level 6 Remarks:
SERVICE MENU:
< Exit >
SERVICE MENU: Lift limit: xxx Lift limit: xxx xxx = currently used value.
< Options > ENT / v -> ^v ENT -> 0:no 1:yes
Lift limit: yyy New value 'yyy' replaces the old 'xxx'.
New value saved! Screen stays on for 1 s.
Input rejected! Displayed if value is out of range.
Press ENT
Restart: xxx Restart: xxx

^v ENT -> 0:no 1:yes
Restart: yyy
New value saved!
Input rejected!
Press ENT
Safety syst:xxx Safety syst:xxx

Safety syst:yyy
New value saved!
Input rejected!
Press ENT
Effici log:xxx Effici log:xxx

Effici log:yyy
New value saved!
Input rejected!
Press ENT
Impact sens:xxx Impact sens:xxx

Imp sensor:yyy
New value saved! Appears only if
Input rejected! Imp sensor is
Press ENT 'yes' above!
Log level: xxx Log level: xxx

^v ENT -> New value: ?
Log level: yyy
New value saved!
Input rejected!
Press ENT
Horn level :xxx Horn level :xxx

Horn level :yyy
New value saved!
Input rejected!
Press ENT
Warning lev :xxx Warning lev :xxx

Warning lev :yyy
New value saved!
Input rejected!
Press ENT
Stop level:xxx Stop level:xxx

Stop level:yyy
New value saved!
Input rejected!
Press ENT
Supervis lev :xxx Supervis lev :xxx

Supervis lev :yyy
New value saved!
Input rejected!
Press ENT
Damage rep:xxx Damage rep:xxx

Damage rep:yyy
New value saved!
Input rejected!
Press ENT
Time logoff:xxx Time logoff:xxx

Time logoff:yyy
Input rejected! Time logoff is
Del time a: xxx Del time a:xxs

Delay time a:yys
New value saved!
Input rejected!
Press ENT
Del time b: xxx Del time b:xxmin

Delay time b:yymin
New value saved!
Input rejected!
Press ENT
Dis tiller res:xxx Dis tiller res:xxx

Dis tiller res:yyy
New value saved!
Input rejected!
Press ENT
Smartcard:xxx smartcard:xxx
smartcard:yyy
Input rejected! Time logoff is
Damage rep:xxx Damage rep:xxx

Damage rep:yyy
New value saved!
Input rejected!
Press ENT
Disp log on:xxx Disp log on:xxx

Disp log on:yyy
New value saved!
Input rejected!
Press ENT
Summer time:xxx Summer time:xxx

Summer time:yyy
New value saved!
Input rejected!
Press ENT
Keyswitch :xxx Keysw pwr of:xxx

Keysw pwr of:yyy
New value saved!
Input rejected!
Press ENT
Speed red:xxx Speed red:xxx

Speed red:yyy
Input rejected! Speed red is
Cutback3: xxxx% Cutback3: xxxx%

Cutback3: yyyy%
New value saved!
Input rejected!
Press ENT
Service alrm:xxx Service alrm:xxx

Service alrm:yyy
New value saved!
Input rejected!
Press ENT Appears only if
Service alrm is
Interval: xxxxh Interval: xxxxh 'yes' above!
Interval: yyyyh
New value saved!
Input rejected!
Press ENT
Fixed platf. :xxx Fixed platf.:xxx

Fixed Platf:yyy
New value saved!
Input rejected!
Press ENT
TillerUpD :xxx TillerUpD :xxx

TillerUpD :yyy
New value saved!
Input rejected!
Press ENT
Reverse ind :xxx Reverse ind :xxx

Reverse ind :yyy
New value saved!
Input rejected!
Press ENT
Raise steer :xxx Raise steer :xxx

Raise steer :yyy
New value saved!
Input rejected!
Press ENT
Stop on ramp :xxx Stop on Ramp :xxx

Stop on ramp :yyy
New value saved!
Input rejected!
Press ENT
Straddle :xxx Straddle :xxx

Straddle :yyy
New value saved!
Input rejected!
Press ENT
Belly start :xxx Belly start :xxx

Belly start :yyy
New value saved!
Input rejected!
Press ENT
Battery creep :xxx Battery creep :xxx

Battery creep :yyy
New value saved!
Input rejected!
Press ENT
SERVICE MENU: SETTINGS: PERFORMANCE: Fwd speed: xxx% Fwd speed: xxx% xxx = currently used value.
< Settings > ENT / v -> Performance ^v ENT -> Op category 1 ^ v ENT -> ^v ENT -> New value: ?
Fwd speed: yyy% New value 'yyy' replaces the old 'xxx'.
Press ENT
Rev speed :xxx% Rev speed :xxx%

Rev speed: yyy%
New value saved!
Input rejected!
Press ENT
Tract accel:xxx%
^v ENT -> acc to above!
Tract cutb1:xxx%
Tract cutb2:xxx%
Tract curr :xxx%
Rdc brake :xxx%
Neut brake :xxx%
Rev brake :xxx%
Brake pedal:xxx%
PERFORMANCE:
Op category 2 ^ v ENT -> Acc to above
PERFORMANCE:
PERFORMANCE:
SETTINGS: TRACTION: Breakp lo: xxx% Breakp lo: xxx% Defines the ouput signal level at 30% of the input signal
Traction ^v ENT -> Throttle map ^v ENT -> ^v ENT -> New value: ? 'xxx' = 'on' or 'off' (currently used)
Breakp lo: yyy% New value 'yyy' replaces the old 'xxx'.
Press ENT
Breakp hi: xxx% Breakp hi: xxx% Defines the ouput signal level at 70% of the input signal
^v ENT -> New value: ? 'xxx' = 'on' or 'off' (currently used)
Breakp hi: yyy% New value 'yyy' replaces the old 'xxx'.
Press ENT
Deadzone: xxx% Deadzone: xxx% 'xxx' = 'on' or 'off' (currently used)

Deadzone: xxx% New value 'yyy' replaces the old 'xxx'.
Press ENT
TRACTION: Breakp lo: xxx% Breakp lo: xxx% Defines the ouput signal level at 30% of the input signal
Brake map ^v ENT -> ^v ENT -> New value: ? 'xxx' = 'on' or 'off' (currently used)
Breakp lo: xxx% New value 'yyy' replaces the old 'xxx'.
Press ENT
Breakp hi: xxx% Breakp hi: xxx% Defines the ouput signal level at 70% of the input signal
^v ENT -> New value: ? 'xxx' = 'on' or 'off' (currently used)
Breakp hi: xxx% New value 'yyy' replaces the old 'xxx'.
Press ENT
Deadzone: xxx% Deadzone: xxx% 'xxx' = 'on' or 'off' (currently used)

Deadzone: xxx% New value 'yyy' replaces the old 'xxx'.
Press ENT
TRACTION: Motor: NN Motor: NN

Motor type ^v ENT -> ENT -> 0:Kordel 1:Sauer
Motor: NN
New value saved!
Input rejected!
Press ENT
SETTINGS:
Brake ^v ENT ->
SETTINGS: Cont Delay: xr Cont Delay: xr

Pump ^v ENT -> ENT -> New value: ?
Cont Delay: xr
New value saved!
Input rejected!
Press ENT
Delay1: Delay1: xxx

ENT -> New value: ?
Delay 1: x
New value saved!
Input rejected!
Press ENT
Delay2: Delay2: xxx

ENT -> New value: ?
Delay 2: x
New value saved!
Input rejected!
Press ENT
Lower acc: Lower acc: xxx

ENT -> New value: ?
Lower acc: xxx
New value saved!
Input rejected!
Press ENT
Lower ret: Lower ret: xxx

ENT -> New value: ?
Lower ret: xxx
New value saved!
Input rejected!
Press ENT
SETTINGS: HYDRAULICS: HVC 1: xxx HVC 1: xxx 'xxx' = 'on' or 'off' (currently used)
Hydraulics ^v ENT -> HVC Setup ^v ENT -> ^v ENT -> 0:off 1:on
HVC 1: yyy New value 'yyy' replaces the old 'xxx'.
Press ENT
HVC 1 PWM:xxxxHz HVC 1 PWM:xxxHz 'xxx' = currently used value

HVC 1 PWM:yyyHz New value 'yyy' replaces the old 'xxx'.
Press ENT
HVC 2: xxx
HVC 2 PWM:xxxxHz
HVC 3: xxx
HVC 3 PWM:xxxxHz
HVC 4: xxx
HVC 4 PWM:xxxxHz
HYDRAULICS: Raise ctrl:xxxxx Raise ctrl:xxxxx 'xxxxx' = currently used value

Lift ^v ENT -> ^v ENT -> 0:OnOff 1:Speed
Raise ctrl:yyyyy New value 'yyyyy' replaces the old 'xxxxx'.
Press ENT
Appears only if speed
control is selected above!
Speed ctrl:xxxxx Speed ctrl:xxxxx
^v ENT -> 0:Valve 1:Motor
Speed ctrl:yyyyy
New value saved!
Input rejected!
Press ENT
Raise min: xxx% Raise min: xxx Refers to [ valve PWM ] or [ pump motor speed ] depending on choice above.
^v ENT -> New value: ? Note that the min/max parameters only are used if speed control are selected.
Raise min: yyy
New value saved!
Input rejected!
Press ENT
Raise max: xxx%

Lower min: xxx%
Lower max: xxx%
Breakp: xxx% Defines the ouput signal level at 50% of the input signal
Deadzone: xxx%
HYDRAULICS: Ch2 ctrl: xxxxx ENT -> Ch2 ctrl: xxxxx 'xxxxx' = currently used value
Channel 2 ^v ENT -> ^v <- OnOff 0:OnOff 1:Speed
Ch2 ctrl: yyyyy New value 'yyyyy' replaces the old 'xxxxx'.
Press ENT
Appears only if speed
control is selected above!
Speed ctrl:xxxxx Speed ctrl:xxxxx
^v 0:Valve 1:Motor
Speed ctrl:yyyyy
New value saved!
Input rejected!
Press ENT
Ch2 pos min:xxx% Pos min: xxx Refers to [ valve PWM ] or [ pump motor speed ] depending on choice above.
Pos min: yyy
New value saved!
Input rejected!
Press ENT
Ch2 pos max:xxx%

Ch2 neg min:xxx%
Ch2 neg max:xxx%
Breakp: xxx% Defines the ouput signal level at 50% of the input signal
Deadzone: xxx%
HYDRAULICS:
Channel 3 ^v ENT -> Acc to above
HYDRAULICS: ENT -> Acc to above

Channel 4 ^v
HYDRAULICS: ENT -> Hydra lock: xx

Hydraul lock ^v 0:off 1:on
Hydra lock: xx
New value saved!
Input rejected!
Press ENT
SETTINGS: FB adjust Adj FB mode Key 4 '<' Plese wait, Restart system This menu appears when FB adjust mode is 'On'
Steering ^v ENT -> ^v ENT -> 0:off 1:on storing data. and adjust FB
Adj FB mode xx
Press '<' key FB adj. Complete This menu appears when FB adjust mode is 'Off'
Input rejected! Restart system
Press ENT
EPS: xxx EPS: xxx

^v ENT -> 0:off 1:on
EPS: yyy
New value saved!
Input rejected!
Press ENT
Numbness Numbness x
Numbness x
New value saved!
Input rejected!
Press ENT
Steer ctrl:xxxxx Steer ctrl:xxxxx

^v ENT -> 1:Speed 2:Posit
Speed ctrl:yyyyy
New value saved!
Input rejected!
Press ENT
Limit rough: Limit rough: x

Limit rough: x
New value saved!
Input rejected!
Press ENT
Limit fine CW: xx Limit fine CW: x

Limit fine CW: x
New value saved!
Input rejected!
Press ENT
Limit fine CCW: xx Limit fine CCW: x

Limit fine CCW: x
New value saved!
Input rejected!
Press ENT
Steer hi spd: Steer hi spd: xx

Steer hi spd: xx
New value saved!
Input rejected!
Press ENT
SETTINGS: BATTERY: Battery type: x

Battery ^v ENT -> Battery type: ENT -> Wet:0 Gel:1 x
Battery type: x
New value saved!
Input rejected!
Press ENT
BATTERY: Measured: xxx

Calibrate ^ ENT -> New value: ?
Measured: yyy
New value saved!
Input rejected!
Press ENT
BATTERY: ENT -> Wet battery: ENT -> Stepdown hi: x

Wet battery ^v Stepdown hi ^v New value: ?
Stepdown hi: y
New value saved!
Input rejected!
Press ENT
Wet battery: ENT -> Stepdown lo: x

Stepdown lo ^v New value: ?
Stepdown lo: y
New value saved!
Input rejected!
Press ENT
BATTERY: ENT -> Gel battery: ENT -> Stepdown hi: x

Gel battery ^v Stepdown hi ^v New value: ?
Stepdown hi: y
New value saved!
Input rejected!
Press ENT
Gel battery: ENT -> Stepdown lo: x

Stepdown lo ^v New value: ?
Stepdown lo: y
New value saved!
Input rejected!
Press ENT
SETTINGS: TRUCKTYOE XX = trucktype

Trucktype ^ ENT -> XX
SERVICE MENU: TESTS: TEST INPUTS: 111222333444555A Strings of the same digit are bar graphs for analog/steering enc inputs. The digit identifies the input, a
< Tests > ENT / v -> Inputs ^v ENT -> Overview ^v ENT -> 66677BCDEFGHIJK the number of digits represents the input signal level.
E.g "1" means: 10%<spd cmd<50%, "11" means: 50%<spd cmd<90%, "111" means: spd cmd>90%.
TEST INPUTS: Signal check: Single letters means digital input activated.
Accelerator ^v ENT -> x.x V Out:syyy% s' = sign
TEST INPUTS: Signal check:

Brake ^v ENT -> x.x V Out:syyy% s' = sign

Lift ^v ENT -> x.x V Out:syyy% s' = sign

Aux AI 1 ^v ENT -> x.x V Out:syyy% s' = sign


TEST INPUTS: Steering rpm:

Steering ^v ENT -> syyy
TEST INPUTS: SP pot: x.xxV

EPS sensors ^ ENT -> FB pot: x.xxV
TESTS: TEST OUTPUT: If "ENT" is pressed, the currently displayed output will be engaged as long as the key is kept pressed
Outputs ^v ENT -> LED 1 ^v ENT ->
TEST OUTPUT:
LED 2 ^v ENT ->
TEST OUTPUT:
OUT 4 ^v ENT ->
TEST OUTPUT:
HEATER ^v ENT ->
TEST OUTPUT:
ANALOG OUT ENT ->
TESTS: READ VERSION: HW:

Versions ^v ENT -> Traction ^v ENT -> SW:
READ VERSION: HW:

HVC ^v ENT -> SW:
READ VERSION: HW:

Power steering^ v ENT -> SW:
READ VERSION: HW: MM.mm

ATC ^v ENT -> VCL SW: MM.mm ^v
OS date: yy-mm-dd
OS ver: MM.mm ^v
TESTS: Disable?
TM encoder ^v ENT -> 0:no 1:yes:
enc disabled
Press ENT
TESTS: Disable?
PP footswitch ^ ENT -> 0:no 1:yes:
Footsw. disabled
Press ENT
SERVICE MENU: CALIBRATE:

< Calibrate > ENT / v -> All ^v ENT ->
CALIBRATE: Release throttle Covers both butterfly and pedal type throttle
Accelerator ^v ENT -> and press ENT The level 3 displays are always followed in sequence.
Go to end points
and press ENT
OK!:
Press ENT s = sign (+ raise, - lower)
Not successful!
Press ENT
<- ENT Signal check:
x.x V Out:syyy%
CALIBRATE: Release brake The level 3 displays are always followed in sequence.
Brake ^v ENT -> and press ENT
Order full brake
and press ENT
OK!:
Press ENT
Not successful!
Press ENT
x.x V Out:syyy%
CALIBRATE: Release lift Covers both combined and separate raise/lower controls.
Lift ^v ENT -> and press ENT The level 3 displays are always followed in sequence.
Order full raise
and press ENT
Order full lower
and press ENT
OK!:
Press ENT s = sign (+ raise, - lower)
Not successful!
Press ENT
x.x V Out:syyy%
CALIBRATE: Release ch2

Channel 2 ^v ENT -> and press ENT
Order full +dir
and press ENT
Order full -dir
and press ENT
OK!:
Press ENT
Not successful!
Press ENT
x.x V Out:syyy%
CALIBRATE:
Channel 3 ^v ENT -> According to "Channel 2"
CALIBRATE:
Channel 4 ^v ENT -> According to "Channel 2"
CALIBRATE: Center steering

Steering ^v ENT -> and press ENT
Calibration done
press ENT
Calicrate failed
Press ENT
CALIBRATE: Update angle

Update angle ^v ENT ->
SERVICE MENU: LOGS/COUNTERS: 30: Exxx < +01: Exxx Latest error is shown first.
<Logs/counters > ENT / v -> Error log ^v ENT -> [date] [time] ENT -> Offset: zzz ms The [i] key can be used to jump directly to the next error (primary and secondary error log)
v^ v^ xxx is the error code
[error text line 1] [error text line 1] yyy is the number of errors occured
Appears only if the [error text line 2] [error text line 2] "+" idicates that there is a secondary error
error is a VCL or v^ v^
OS ERROR #yyy occurred: +02: Exxx
instead of the 2 [date] [time] Offset: zzz ms
screens above! No v^ v^
secondary log is next primary error… [error text line 1]
possible. [error text line 2]
v^
+03: Exxx
VCL (or OS) ERROR Offset: zzz ms
Module id: mmm v^
v^ [error text line 1]
Error id: eee [error text line 2]
Line: LLL v^
+04: Exxx
Offset: zzz ms
v^
[error text line 1]
[error text line 2]
v^
LOGS/COUNTERS: Tract motor temp Temperatures for traction motor, traction controller, pump motor, pump controller, hydr oil,
Temp log ^v ENT -> - 60C:xxxx.xh power steering motor, power steering controller, all in five intervals. Intervals differs depending on
v the objects working temperature range.
v
v
Tract motor temp
121 - :xxxx.xh
-
-
-
LOGS/COUNTERS: HOUR METER: TOTAL Active: xxxxx -> hours

Hour meters ^ v ENT -> Total ^v ENT -> xxxxx.yyyh yyy -> 1/1000 hours
TOTAL Logged on:
xxxxx.yyyh
TOTAL Traction:
xxxxx.yyyh
TOTAL Pump:
xxxxx.yyyh
HOUR METER: TRIP Active: xxxxx -> hours

Trip ^v ENT -> xxxxx.yyyh yyy -> 1/1000 hours
TRIP Logged on:
xxxxx.yyyh
TRIP Traction:
xxxxx.yyyh
TRIP Pump:
xxxxx.yyyh
HOUR METER: READ Traction:

Read external ^ v ENT -> xxxxx h
READ Pump:
xxxxx h
READ Pwr Steer:
xxxxx h
LOGS/COUNTERS: Tract: iii A xx% "iii" is the calculated "mean main active current", "xx" is calculated as: [active time] / [calendar time
Utilisation ^v ENT -> Pump: iii A xx% since last reset].
LOGS/COUNTERS: RESET: Reset error log?

Reset ^v ENT -> Error log ^ ENT -> 0:no 1:yes
Successful reset
Press ENT
Reset aborted!
Press ENT
RESET: Reset temp log?

Temp log ^ ENT -> 0:no 1:yes
Successful reset
Press ENT
Reset aborted!
Press ENT
RESET: Reset trip/util?

Trip meters/Util^ ENT -> 0:no 1:yes
Successful reset
Press ENT
Reset aborted!
Press ENT
RESET: Reset service?

Service alarm ^ v ENT -> 0:no 1:yes
Successful reset
Press ENT
Reset aborted!
Press ENT
LOGS/COUNTERS: SET HOURS: Logged on xxxh Logged on: xxx

Set hour mtrs ^v ENT -> Logged on ^ v ENT -> ENT -> New value: ? Hour meters can only be set to a higher value than before.
Logged on: yyy
New value saved!
Input rejected!
Press ENT
SET HOURS: Active: xxxh Active: xxx

Active ^ v ENT -> ENT -> New value: ?
Active: yyy
New value saved!
Input rejected!
Press ENT
SET HOURS: Traction: xxx Traction: xxx

Traction ^ v ENT -> ENT -> New value: ?
Traction: yyy
New value saved!
Input rejected!
Press ENT
SET HOURS: Pump: xxxh Pump: xxx

Pump ^ v ENT -> ENT -> New value: ?
Pump: yyy
New value saved!
Input rejected!
Press ENT
LOGS/COUNTERS:
Download ^v ENT -> Send all above logs to serial port truck serial no, versions and settings (not fleet manager statistics)
SERVICE MENU: SET ACCESS: OPERATOR: Operator ID: The level 3 displays are always followed in sequence.
< Set access > ENT / v -> Operator ^v ENT -> New/Change ^v ENT -> ? The no of question marks corresponds to the chosen id length (ATLET menu).
Operator categ:x
?
Old code: this screens will only be displayed if the user ID exists and user code length > 0
???? The no of question marks corresponds to the chosen code length (ATLET menu).
New code: this screens will only be displayed if the user code length > 0
Verify new code: this screens will only be displayed if the user code length > 0
Ok!
Press ENT
Not successful!
Press ENT invalid old code / verifyed code wrong / category out of range (1..4) / all 100 user ID's used / no acces
OPERATOR: CAUTION! Reduced

Format ^v ENT -> length may lead.
0 v ^
.to lost entries

0:escape 1:go on
Id length: x Id length: x
v ENT -> New value: ?
Id length: x
New value saved!
Input rejected!
Press ENT
Code length: x Code length: x

^ ENT -> New value: ?
Code length: x
New value saved!
Input rejected!
Press ENT
SET ACCESS: Old code:

Local ^v ENT -> ???????
New code:
???????
Verify new code:
???????
Ok!
Press ENT
Press ENT
SET ACCESS: Old code:

Service ^v ENT -> ???????
New code:
???????
Verify new code:
???????
Ok!
Press ENT
Press ENT
SERVICE MENU:
< Total reset > ENT -> Go to Reset menu
INPUTS Atlet menu/Calibrate VCL appl code

Hydraulic Control Channels
Selection
OUTPUT isAtlet
decided in SETTINGS between:
menu/Settings/Hydraulics
Selection is done 'semiautomatically' during CALIBRATION between: Every unique VCL sw variant includes 1. OnOff control.
1. Combined raise/lower control (e g joystick) rules for: 2. Speed control.
Lift channel 2. Individual raise and lower controls (e g pushbuttons in tiller head) 2.1 Valve PWM control.
1. which inputs are allowed to be used 2.2 Pump motor speed control.
to each channel. Final decision of
which of these allowed inputs will be
used is made by 'auto-sense' feature
during calibration.
Selection is decided in SETTINGS between:
Selection is done 'semiautomatically' during CALIBRATION between: 2. which outputs will be used:
1. OnOff control.
1. Combined pos/neg direction control (e g joystick) a) if onoff control is selected
2. Speed control.
Channel 2 2. Individual pos and neg direction controls (e g pushbuttons in tiller head) b) if valve PWM is selected
2.1 Valve PWM control.
c) if motor speed control is selected.
2.2 Pump motor speed control.
3. which interlocks should exist
between the different channels.

Selection is done 'semiautomatically' during CALIBRATION between: 1. OnOff control.
1. Combined pos/neg direction control (e g joystick) 2. Speed control.
Channel 3 2. Individual pos and neg direction controls (e g pushbuttons in tiller head) 2.1 Valve PWM control.

Selection is done 'semiautomatically' during CALIBRATION between: 1. OnOff control.
1. Combined pos/neg direction control (e g joystick) 2. Speed control.
Channel 4 2. Individual pos and neg direction controls (e g pushbuttons in tiller head) 2.1 Valve PWM control.
Example 1 - tiller application

Lift channel is analog, with valve PWM output. Inputs are decided in Atlet menu/Calibrate/Lift menu. When the display requests "full raise" the proportional pushbutton
connected to J9 (lift) is activated by the engineer followed by ENT. Cortex then recognises this input as the raise input. The display requests "full lower" and the operator pushes the button connected to J8 (lower).
Cortex has now detected which inputs are used for raise and lower, and has also stored at which input levels full output should be given.
Output type is selected in Atlet menu/Settings/Hydraulics/Lift. First of all, speed control is selected. Now, further settings are needed. In this case, a porportional valve will be controlled by HVC 1.
The engineer selects valve speed control. Fixed outputs for contactor prop valve and dir valve are hardcoded. Output relations to dead zone passing and to calibrated maximum input are entered.
Channel 2 is 'digital', with onoff valve control. No input calibrations need to be done, since output is defined as 'onoff'. Hardcoded definitions for input and output associations take effect.
Example 2 - rider stacker

Lift channel is analog, with joystick and pump motor speed control. Input calibration is carried out as in example 1. Cortex recognizes the a 'combined' raise/lower control from the voltage levels read during calibration.
Output setting s are set to 'speed control' and 'motor'. Raise command is sent to hardcoded adress in PMC, lower command is sent to HVC 1.
Monitor menu 1 of 3
Level 1 Level 2 Level 3 Remarks:
MONITOR MENU:
< Exit >
MONITOR MENU: TRACTION: xxxxrpm "xxxx" = motor speed in rpm;

< Traction > ENT / v -> Drive Monitor ^ v ENT -> +/-iii A "iii" = motor current
TRACTION: C: +/-ttt degC "ttt" = controller temperature; "TTT" = motor temperature

Temp Monitor ^ v ENT -> M: +/-TTT degC
MONITOR MENU: xxxxrpm

< Pump > ENT / v -> +/-iii A
v^
C:ttt M:TTT degC
MONITOR MENU: Adjust FB Steer 90deg left

< Steering > ENT / v -> v^ ENT / v -> and press ENT
Steer 90deg rght

and press ENT
Adjustment done Jumps to 'Exit' when pressing ENT

Press ENT
Read sensors SP pot: n.nnV "n.nn"= Read value in Volts

v^ ENT / v -> FB pot: n.nnV
FB pot: n.nnV
FB enc: n.nnV
Angle: xx
Set steer 0-pos "nnnn"= 0-position in mV, ENT escape button instead of key 4.
<4 nnnnmV 6>
Record angle
Monitor menu 2 of 3
MONITOR MENU: not implemented yet

< Wire guide > ENT / v ->
MONITOR MENU: IN/OUT: Accelerator xxx

< In/Out > ATC inputs: ^v ENT / v -> Raise1 xxx
Raise2 xxx
Lower1 xxx
Lower2 xxx
Belly x
BellyInv x
TillerUpD x
Horn x
Dig_in1 x
Dig_in2 x
Dig_in3 x
Dig_in4 x
Dig_in5 x
IN/OUT: Dig_in1 x
TMC inputs: ^v ENT / v -> Dig_in2 x
Dig_in3 x
Dig_in4 x
Dig_in5 x
Dig_in6 x
Dig_in7 x
IN/OUT:
HVC inputs: ^v ENT / v -> Dig_in1 x
Dig_in2 x
Dig_in3 x
A_in 1 xxx
Monitor menu 3 of 3
IN/OUT:
EPS inputs: ^v ENT / v ->
IN/OUT: Lift int x

ATC int/out: ^v ENT / v -> Speed int x
Safety int x
Max spd xxx
Forward x
Reverse x
Brake x
Liftstop x
Reset menu 1 of 1
RESET: Reset all users?

All users ^v ENT -> 0:no 1:yes
Successful reset
Press ENT
Reset aborted!
Press ENT
RESET: Reset options?

Options ^v ENT -> 0:no 1:yes
Successful reset
Press ENT
Reset aborted!
Press ENT
RESET: Reset settings?

Settings ^v ENT -> 0:no 1:yes
Successful reset
Press ENT
Reset aborted!
Press ENT
RESET: Reset calib?

Calibration ^v ENT -> 0:no 1:yes
Successful reset
Press ENT
Reset aborted!
Press ENT
RESET: Reset logs?

Logs ^v ENT -> 0:no 1:yes
Successful reset
Press ENT
Reset aborted!
Press ENT
Language Tree 1 of 1
SELECT LANGUAGE:
English ^v
Svenska
Deutsch
Francais
Custom
TRAC 1 of 1
TRAC MENU:
< Exit >
TRAC MENU: Initphone

< Initphone > ENT / v ->
TRAC MENU: Answer call

< Answer call > ENT / v ->
SERVICE MANUAL
Machine: PLP
Manual No: 119002
Edition 2009B
11 Speed control and Brake system
Design and function ..................................................................................................... 11.3

Electric brake ......................................................................................................11.3
Repair and maintenance instructions ........................................................................ 11.4

Electric brake ......................................................................................................11.4
Service ......................................................................................................................... 11.4
Replacing the brake disc (–2006w46) .......................................................................... 11.4
Replacing the brake disc (2006w47–) .......................................................................... 11.5
Emergency release ...................................................................................................... 11.6
SERVICE MANUAL
11.2
SERVICE MANUAL
Speed control and Brake system / Design and function / Electric brake 11.3
Edition 2009B
11 Speed control and Brake system

Design and function
Electric brake
PLL is equipped with an electric brake. The electric brake is a safety brake with two fric-
tion surfaces. The braking torque is produced by spring pressure. The brake is activated
when the voltage over the coil is lost, i.e. the truck is braked when it is without voltage.
When the brake is activated the springs press on the plate, which is pressed axially to the
rotor. When the brake is to be released the coil is supplied with battery voltage. The mag-
netic field created between the plate and the magnetic part allows the rotor to rotate freely.
The brake is activated by the TMC and EPS via the ATC (see also wiring diagram).
11_SM_PLP_En_119002_2009B.fm
SERVICE MANUAL
11.4 Speed control and Brake system / Repair and maintenance instructions / Electric brake
Repair and maintenance instructions
Electric brake
Service
The brake does not need adjusting.
When serviced the gap between the magnetic parts should be measured to ensure that the
brake disc is not worn.
Figure 11.1
The gap A can be measured with the brake fitted (figure 11.1).
Warning!
The brake disc is worn out and should be replaced if the measured gap is greater
than 0.6 mm!
Replacing the brake disc (–2006w46)

1. Disconnect the electrical connection to the magnetic part.
2. Release the three retaining screws holding the magnetic part, and carefully lift off.
Clean the magnetic part.
3. Lift off the brake disc and clean all the surfaces.
4. Fit the new brake disc and refit the magnetic part. Tighten the three retaining
screws to 9.5 Nm.
5. Reconnect the electrical connection to the magnetic part.
Warning!
Check that you have a safe braking capacity.
SERVICE MANUAL
Speed control and Brake system / Repair and maintenance instructions / Electric brake 11.5
Replacing the brake disc (2006w47–)
C
B
Figure 11.2 Electric brake (2006w47–)
1. Disconnect the electrical connections to the magnetic part.

2. Undo the three retaining screws, pos B in figure11.2.
3. Dismantle the brake by unscrewing 3 screws, pos C.
4. Lift out the brake disc and clean the magnetic part and brake plate.
5. Mount the new brake disc and refit the magnetic part. Tighten the three retaining
screws at 9.5 Nm.
6. Reconnect the electrical connections to the magnetic part.
Warning!
Check that you have a safe braking capacity.
SERVICE MANUAL
11.6 Speed control and Brake system / Repair and maintenance instructions / Electric brake
Emergency release
The brake can be released manually if necessary.
Note!
If the brake is released manually there will be no functioning parking or emergency
brake. Never leave a machine with a manually released brake!
Figure 11.3
To manually release the brake, screw in two screws (M6x55) in the two marked holes
(figure 11.3).
SERVICE MANUAL

Atlet SERVICE

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Atlet SERVICE

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SERVICE MANUAL

1 General information and technical data

Scope of Service Manual ............................................................................................... 1.3

How to use the manual .................................................................................................. 1.4

Safety instructions ......................................................................................................... 1.5

Preparations ................................................................................................................. 1.10

Data PLP ........................................................................................................................ 1.11

Component specification ....................................................................................1.17

Recommended consumable materials .......................................................................1.18

Standards and abbreviations .......................................................................................1.19

1 General information and technical data

Scope of the P series

How to use the manual

No modifications or alterations to a powered industrial truck, which may affect, for

Gas springs in platform and steering arm

Lifting the truck

Permitted lifting points

Figure 1.1 Permitted lifting points

Figure 1.2 shows where the jack should be placed.

Figure 1.2 Lifting point, jack

Welding on the truck

Atlet AB takes care of the environment

Truck type PLP 200 Low lifter

PLP 250 Low lifter

Load capacity PLP 200 2,000 kg

PLP 250 2,500 kg

Figure 1.3 Example of type plate (–2006w36)

Load centre distance

Weight without battery

Battery weight min.

Battery weight max.

ATLET AB MÖLNLYCKE SWEDEN

Figure 1.4 Example of type plate (2006w37–)

Figure 1.5 Example of plate with serial number.

Explanation of Model designation

Example: PLP 200 160 30

Dimensions and weights

Figure 1.6 Positions for dimensions PLP

1 Lifting capacity, rated Q kg 2000 2500

2 Lifting height H4 mm 200 200

4 Lifting speed without load – with rated load m/s

5 Lowering speed without load – with rated load m/s

10 Turning radius R2 mm 770 + L2 835 + L2

11 Minimum aisle width Ast incl. 200 mm R2-L2 + load

13 Height over protective roof H6 mm

14 Truck length L mm 750 + L1 825 + L1

15 Truck width B mm 770 770

16 Fork length, std L1 mm 1000 / 2375 1000 / 2375

17 Width over forks, std max-min W mm 680 / 460 680 / 480

19 Truck length to fork support area L4 mm 750 825

20 Fork arm, width – thickness B1 mm 175 - 55 175 - 55

21 Straddle lift height H7 mm

22 Width between fork straddle lift B2 mm

24 Wheelbase L3 mm 551 + L2 626 + L2

25 Wheel track – front, back centre of wheel mm W - 175/526 W - 175/526

26 Ground clearance, half wheelbase load mm 30 - 145 30 - 145

27 Service weight with/without battery kg 860 - 530 925 - 545

39 Battery capacity kWh 4.8-9.6 7.5-14.4

41 Traction motor kW 2.2 / 2.4 AC 2.2 / 2.4 AC

42 Speed controlling Transistor Transistor

43 Lift motor kW - %/ 2.2 - 12/10 2.2 - 12/10

44 Wheel type Vulkollan Vulkollan

46 Control system Tiller arm Tiller arm

Traction motor Drive voltage 24V

1 10 -5 1.02010 -5 7.50110 -3 9.869*10 -6

133.3 1.33310 -3 1.36010 -3 1 1.316*10 -3