SERVICE MANUAL

Machine: A-Ergo

Manual No: 005975

Edition 2008B

1 General information and technical data

Scope, service manual .................................................................................................. 1.3

General ................................................................................................................ 1.3
Scope of the A-Ergo model ................................................................................. 1.3

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

Structure .............................................................................................................. 1.4
History ................................................................................................................. 1.4
Symbol key .......................................................................................................... 1.4

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

General ................................................................................................................ 1.5
Lifting the truck .................................................................................................... 1.6
Checks/Preparations ...................................................................................................... 1.6
Permitted lifting points .................................................................................................... 1.6
Welding on the truck ............................................................................................ 1.7
Taking the environment into consideration .......................................................... 1.7

Preparations ................................................................................................................... 1.8

Service ................................................................................................................. 1.8
Trouble shooting .................................................................................................. 1.8

Data A-Ergo ..................................................................................................................... 1.9

Designations ........................................................................................................ 1.9
Truck designation ........................................................................................................... 1.9
Type designation .......................................................................................................... 1.10
Dimensions and weights .................................................................................... 1.14
Dimensions A-Ergo ...................................................................................................... 1.14
Component specification ................................................................................... 1.15

Recommended consumable material ......................................................................... 1.16

Oil and grease ................................................................................................... 1.16

Standards and abbreviations ...................................................................................... 1.17

ATLET SERVICE MANUAL A-ERGO

1.2

Screws ...............................................................................................................1.17
Tightening torque, screws and nuts .............................................................................. 1.17
Tightening torque, hydraulic couplings ......................................................................... 1.18
Conversion table ........................................................................................................... 1.18
Screw types and tensile grades .................................................................................... 1.19
Colour of the truck ..............................................................................................1.20
Colour codes, cabling ........................................................................................1.20
Designations, electrical components .................................................................1.21
Standard abbreviations ......................................................................................1.22

ATLET SERVICE MANUAL A-ERGO

 General information and technical data / Scope, service manual / General 1.3

Edition 2008B

1 General information and technical data

Scope, service manual

General
This manual describes the service procedures for ATLET stand-on stackers in the A-Ergo
series. Use the manual for quick and correct service of respective truck models.
The manual describes models manufactured from and including the introduction of A-
Ergo at the end of 2002.
You may find contradictions in the manual compared with the models supplied due to
optional designs, upgrades and the like.

Warning!
If the truck is rebuilt after delivery or supplemented in such a manner that safety
may be affected, ATLET AB or its authorised representative should be contacted.

The electrical system must never be rewired in any form after delivery without written
authorisation from Atlet AB, since this may change the measured and applicable EMC.
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
examination with regard to correctness. Subject to alteration. In the event of inconsistent
information in the Swedish and translated editions, it is the Swedish edition that applies.
Modifications and updates will be distributed via ATLET AB Service Manual Change.

Scope of the A-Ergo model

The stand-on stacker trucks in the A-Ergo series are available in a number of different
variants with mast system, straddle lift, extendable stabilisors and telescopic forks (ATF).

SMA-Ergo_01_2008B.fm
ATLET SERVICE MANUAL A-ERGO
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 principle as ATLET spare parts catalogues,
with the truck divided into one subsystem per section.
Sections 1 - 3 in this manual contain comprehensive information regarding technical data,
service instructions and tools.
Sections 4-12 in the manual contain information limited to a specific area in the truck
concerning a description of the mechanical handling of different components. For
example, Masts (section 6) and Hydraulic System (section 8).
With regard to software this is described under 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.

History
The following modifications affect the service procedure.

Table 1.1 Upgrades of the truck that affect the service procedure

Date Chassis no. Event

Symbol key
Warning!
Used if there is a risk of personal injury.

Important!
Used if there is a risk of damage to machine.

Note!
Used for general observation.

ATLET SERVICE MANUAL A-ERGO

 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 regulations must be followed.
• The drive wheel should always be lifted up free from the floor during service work
to prevent the vehicle from moving.
• Before working on the electrical system the battery plug should be pulled out.
• To prevent injuries caused by crushing the battery plug should always be removed
when working on or around the mast and hydraulic unit. The mast or hydraulic unit
can be actuated due to an electrical fault or a mistake while working. The battery
plug may only be connected while trouble shooting, and when the greatest of care
is exercised, (with the truck raised).

Warning!
Having the power connected to the truck when working on or around the mast can
result in fatal injury!

• When working on or around the mast and the hydraulic unit, they must be locked
by using the mast lock, wooden blocks or some other appropriate means.
• No other persons should be in the vicinity of the truck when it is test run in
conjunction with repair work, in view of the risk of accidents or near-accidents
from the truck making an unexpected manoeuvre.
• The system should not be pressurised, e.g. the pump motor shutoff and the forks
down, when dismantling parts of the hydraulic system.
• All metal objects such as watches 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.

ATLET SERVICE MANUAL A-ERGO

1.6 General information and technical data / Safety instructions / Lifting the truck

Lifting the truck

Checks/Preparations
• When the truck is lifted by 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.

Permitted lifting points

01001_SM_A-Ergo.eps

Figure 1.1 Permitted lifting points, A-Ergo

Figure1.1 shows where the permitted lifting points are placed on the truck. The lifting
points are marked with a decal representing a lifting hook; the lifting holes in the outer
mast should be used.

Warning!
The machine must never be lifted from the overhead guard.

ATLET SERVICE MANUAL A-ERGO

General information and technical data / Safety instructions / Welding on the truck 1.7

Welding on the truck

• During welding work the battery plug should always be disconnected and all
connections to the control units and regulators (concerns all electronic units)
should be disconnected. On completion of welding work the connectors should
first be connected to the electronic units, after which the battery plug is connected
to the battery.
• The welding earth should always be connected as close to the welding area as
possible to eliminate damage to surrounding components.

Taking the environment into consideration

Atlet AB takes care of the environment. 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 must only be carried out in areas intended for this purpose.
Environmentally hazardous waste, such as oil filters, batteries, hydraulic hoses and
electronics, can have a negative effect on the environment, or health, if handled
incorrectly. Recyclable material should be taken care of by specialised authorities.

ATLET SERVICE MANUAL A-ERGO

1.8 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 a faulty component, do not replace it immediately. First check the
surrounding equipment and carry out complete trouble shooting routines. Make sure you
know the reason for the fault before replacing a component.

ATLET SERVICE MANUAL A-ERGO

 General information and technical data / Data A-Ergo / Designations 1.9

Data A-Ergo

Designations

Truck designation

Table 1.2 Truck designations

Truck type A-Ergo Stand-on stacker, Standard

A-Ergo TF Stand-on stacker with telescopic forks

Load capacity A-Ergo 1600 or 2000 kg

A-Ergo TF 1000 kg

ATLET SERVICE MANUAL A-ERGO

1.10 General information and technical data / Data A-Ergo / Designations

Type designation

ATLET AB MÖLNLYCKE SWEDEN

MODELL
MODEL
MODELL
160 SDTFV 800 A 1
MODELE

SERIE NR.
SERIAL NO.
SERIEN NR.
A 10568/01 S 2
NOMERO DESERIE

TILLV. ÅR
YEAR OF MANUF.
BAUJAHR 2003w01-6 3
AN DE FABR

TILLÅTEN LAST
ACTUAL CAPACITY
Q WIRKLICHE TRAGFÄHIGKEIT
CAPACITE EFFECTIVE

D H
TYNGDPUNKTSAVSTÅND LYFTHÖJD
LOAD CENTRE DISTANCE LIFTHEIGHT
LASTSCHWERPUNKT HUBHÖHE
DISTANCE DE CENTRE
HAUTEUR DE LEVEE

H MM D MM Q KG

8000 600 1600

4
3600 500 1000

BATTERISPÄNNING VOLT-DC
BATTERY VOLTAGE
BATTERIESPANNUNG 24
TENSION DE LA BATTERIE

VIKT UTAN BATTERI KG

WEIGHT WITHOUT BATTERY
GEWICHT OHNE BATTERIE 1150
MASSE SANS BATTERIE

MINSTA BATTERIVIKT
KG
MINIMUM BATTERY WEIGHT
MINDESTGEWICHT DER BATTERIE 370
MASSE MINIMAL DE LA BATTERIE

MAXIMAL BATTERIVIKT KG
MAXIMUM BATTERY WEIGHT
HÖCHSTGEWICHT DER BATTERIE 540
MASSE MAXIMAL DE LA BATTERIE

Typskylt.eps

Figure 1.2 Example of type plate (–2006w36)

1. Model designation.
2. Type Series no./Version (S=Special version.).
3. Year of manufacture, week, and warranty period in months (only Sweden).
(On the assumption that the service instructions in the warranty regulations are
followed.)
4. Any load restrictions, depending on the position of the load on the forks (D) and/or
lifting height (Q).

ATLET SERVICE MANUAL A-ERGO

 General information and technical data / Data A-Ergo / Designations 1.11

Model
Modell
1
Serial no.
Serie nr.
2
Year of manufacturing
Tillverkningsår
3
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

XXXXXXXX

H
D

H (mm) D (mm) Q (kg)

4

SM_A-Ergo_1A.eps

Figure 1.3 Example of type plate (2006w37–)

1. Model designation.
2. Type Series no./Version (S=Special version.).
3. Year of manufacture, week, and warranty period in months (only Sweden).
(On the assumption that the service instructions in the warranty regulations are
followed.)
4. Any load restrictions, depending on the position of the load on the forks (D) and/or
lifting height (Q).

Note!
In cases where the machine plate has been lost or become illegible, it must be
renewed 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
compartment, or serial number punched on the side of the mast.

ATLET SERVICE MANUAL A-ERGO

1.12 General information and technical data / Data A-Ergo / Designations

SER XXXXXX

WEEK XXXX

SER XXXXXX

WEEK XXXX

Figure 1.4 Example of plate with serial number.

ATLET SERVICE MANUAL A-ERGO

 General information and technical data / Data A-Ergo / Designations 1.13

Explanation of Model designation

Example: A 160 S DTF V S 360 225 40

Truck type

Load capacity/10

Narrow gauge S
Broad gauge B
Telescopic mast T
Telescopic mast, Free-lift TF
Double telescopic mast DT
Double telescopic mast, Free-lift DTF

Free-view mast V

Stabilisers S
Straddle lift H

Lifting height in cm

Battery Ah/5

Charger Ampere

ATLET SERVICE MANUAL A-ERGO

1.14 General information and technical data / Data A-Ergo / Dimensions and weights

Dimensions and weights

Dimensions A-Ergo

B2
B
R2

H6

H3
H4
H5
H7

L2

H2
H1
L3
L4 L1
B1 L

A-Ergo Mått A.eps

Figure 1.5 Positions for dimensions A-Ergo

B1

B2
B
V

U L1
R2
H6

H3
H4
H5
H2
H7

L2
H1
H7

L3
L4 L1
L

A-Ergo Mått ATF.eps

Figure 1.6 Positions for dimensions A-Ergo TF

ATLET SERVICE MANUAL A-ERGO

 General information and technical data / Data A-Ergo / Component specification 1.15

Component specification
Table 1.3 Component specification

Component Specification

Drive motor Drive voltage 16V

Output standard 2.2 / 2.4 kW

S2 60 min

Insulation resistance >24 kΩ

Gearbox Gear ratio (standard) 16,95:1

Oil volume 1.5 litres

Hydraulic system Max pressure 17.5 MPa

(=175 kp/cm²)

Oil volume max 19 litres

Hydraulic unit (motor and pump) Type 1 Output 3.5 kW

Type 2 Output 4.5 kW

Type 3 Output 7.6 kW

Control system for drive motor Type Zapi AC1 AC Transistor

Voltage 24 V

Max current 250A (RMS)

in 2 min

Control system for steering wheel Type Zapi AC1 AC Transistor

Voltage 24V

Max current 70A

Fuses Control fuses 2 pcs. 7.5A

30.0A

Pump motor fuse 1 pcs. 250A

Drive motor fuse 1 pcs. 160A

ATLET SERVICE MANUAL A-ERGO

1.16 General information and technical data / Recommended consumable material / Oil and grease

Recommended consumable material

Oil and grease

Table 1.4 Table of recommended types of oil and grease

Brand Gearbox oil Hydraulic oil Bearing grease Worm gear oil
As per API value As per ISO VG 32, VG 15 NLGI 2 (Only ATF)
GL-5 Lithium base

Normal Cold store Normal Cold store

(32) (15)

BP BP BP BP Bartran BP Bartran BP Energrease BP Energol

Energear Energear HV-32 SHF-S LC 2 SGXP 150
Hypo SHX-S
80W/140 75W/140
EP

Castrol Hypol C - Hyspin Hydraulic LMx Alpha syn

80 W/90 SHS 32 oil OM 15 T 220
Alt:Hyspin
AWH 15

Mobil Mobilube - DTE 13 M Flowrex 1 Mobilplex 48 GLY

HD 85 W/ SHS 32 goyle 30
90

Shell Spirax HD - Tellus oil Tellus oil Retinax EP2 Tivela WB

85 W/90 TX 32 T 15

Statoil / Gearway - SHS 32 J 26 Uniway Snäckväxel-

Exxon G5 LIX 625 olja 375 S
80 W/90

Texaco Geartex - Rando oil Rando oil Hytex EP2 Synlube

EP- HDZ 32 HDZ 15 CLP 220
C 80 W/90

Important!
Do not mix different lubricants – definitely not synthetic oil with mineral oil!

ATLET SERVICE MANUAL A-ERGO

 General information and technical data / Standards and abbreviations / Screws 1.17

Standards and abbreviations

Screws

Tightening torque, screws and nuts

Table 1.5 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.

ATLET SERVICE MANUAL A-ERGO

1.18 General information and technical data / Standards and abbreviations / Screws

Tightening torque, hydraulic couplings

Table 1.6 Tightening torque, hydraulic couplings

Tightening torque: Pipe thread / metric thread:

Metric fine thread Whitworth pipe thread MA (Nm) with MA (Nm) with elastic
ring

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 table

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

ATLET SERVICE MANUAL A-ERGO

 General information and technical data / Standards and abbreviations / Screws 1.19

Screw types and tensile grades

Table 1.8

Figure Screw type Designation Tensile grade

M6S Hexagon screw 8,8

10,9

MC6S Hexagon hole screw 8,8

10,9
12,9

MF6S Hexagon hole screw, 10,9

countersunk

MCS Slotted screw 4,6

MVBF Oval head 4,6

countersunk screw

Marking with the manufacturer trademark, including the tensile grade, is compulsory for
screws with a thread diameter from and including 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

SM 031.1

Figure 1.7 Example of marking

ATLET SERVICE MANUAL A-ERGO

1.20 General information and technical data / Standards and abbreviations / Colour of the truck

Colour of the truck

0

The truck is painted with the following NCS colour codes:

Table 1.9 NCS colour codes

Machine colour Designation

Yellow NCS 0070-Y20R

Medium grey NCS 7000

Dark grey NCS 8000

Colour codes, cabling

The colour codes of all the cables in the truck can be read off from the Atlet wiring
diagram. The abbreviations have the following implication:

Table 1.10 Colour codes, Atlet wiring diagram

Code Cable colour

BE Beige

BL Blue

BN Brown

GN Green

GR Grey

OR Orange

P Pink

R Red

SB Black

VO Violet

W White

Y Yellow

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.

ATLET SERVICE MANUAL A-ERGO

General information and technical data / Standards and abbreviations / Designations, electrical

Designations, electrical components

Electrical components normally have a designation of two letters:
Table 1.11 First letter

Code Designation

A Component or function without its

own letter below

D Diode

E Electrical component

F Fuse

I Indicator

K Connector

L Lamp

M Motor

P Plug

R Relay

S Switch

T Terminal

V Valve

W Audible warning

Table 1.12 Second letter

Code Designation

B Brake

C Control system

E Emergency function

F Forward

H Hour

K Key

L Lowering

M Manoeuvre

P Pump

R Reverse

S Speed

Example SL = Switch for Lowering function

ATLET SERVICE MANUAL A-ERGO

1.22 General information and technical data / Standards and abbreviations / Standard abbreviations

Standard abbreviations

Table 1.13 Standard abbreviations

Magnitude Unit Designation

Current Ampere A

Voltage Volt V

Resistance Ohm Ω
Output Watt W

Torque Newton metre Nm

Pressure Pascal Pa

ATLET SERVICE MANUAL A-ERGO

 SERVICE MANUAL
Machine: A-Ergo

Manual No: 005975

Edition 2004A

2 Special tools

Special tools A-Ergo ...................................................................................................... 2.3

Introduction .......................................................................................................... 2.3
List of tools .......................................................................................................... 2.3
Hand terminal ................................................................................................................. 2.3
Cleaning fluid .................................................................................................................. 2.4
Dismantling tool, buttons and lamps .............................................................................. 2.4
Crimping tool .................................................................................................................. 2.4
Lifting eye ....................................................................................................................... 2.4

ATLET SERVICE MANUAL A-ERGO

2.2 / /

ATLET SERVICE MANUAL A-ERGO

 Special tools / Special tools A-Ergo / Introduction 2.3

Edition 2004A

2 Special tools
Special tools A-Ergo

Introduction
All special tools can be ordered from Atlet AB.

List of tools

Hand terminal

Table 2.1 Hand terminal, programming tool

Designation Part number Applications

Hand terminal Zapi 104 400 Programming tool for the control units for the drive
steering regulators motor and steering

1 PARAM. IMAX B.RECERSE

BRAKING COMPENS.
2 TESTER ACCEL. R.BRAKE
MAX SP. SPEED I
S.P.I SPEED II
3 SAVE
S.P.II SPEED III
BYPASS FIELD WEAK..
4 RESTORE
I MOT V.POT.
5 ALARMS TEMP V.BATT
V.MOT VMN.MOT.
6 ACCELERATOR M.SW.TEST

7 MOTOR DATA

1 3 5
ROLL ENTER SET
ROLL OUT SET
2 4 6

10_003_SM_A-ERGO.eps

Figure 2.1 Hand terminal Zapi steering regulators, see section 10 for how they are used

SMA-Ergo_02_2004A.fm
ATLET SERVICE MANUAL A-ERGO
2.4 Special tools / Special tools A-Ergo / List of tools

Cleaning fluid

Table 2.2 Cleaning fluid, electronics

Designation Part number Applications

Cleaning fluid P/N 112268 Cleaning of electric motors to counteract gearbox oil
and other dirt

Dismantling tool, buttons and lamps

Table 2.3 Dismantling tool, buttons and lamps

Designation Part number Applications

Check nut extractor P/N 103 885 Tool for releasing check nuts on lamps and buttons

Kontramutterdragare.eps

Figure 2.2 Check nut extractor

Crimping tool
Table 2.4 Crimping tool

Designation Part number Applications

Crimping tool Molex P/N 006454 Cable connections

Pin extractor P/N 006456 Cable connector

Lifting eye
Table 2.5 Lifting eye

Designation Part number Applications

Lifting eye P/N 104737 Lifting eye for drive unit.

For detailed information on the above products, please contact Atlet.

ATLET SERVICE MANUAL A-ERGO

 SERVICE MANUAL
Machine: A-Ergo

Manual No: 005975

Edition 2002B

3 Service

Regular maintenance ..................................................................................................... 3.3

Introduction .......................................................................................................... 3.3
Safety .................................................................................................................. 3.3
Recommendation ................................................................................................ 3.3
Daily service ........................................................................................................ 3.4
The truck driver is obliged to do the following (before each shift) .................................. 3.4
The truck driver is obliged to do the following (after each shift) ..................................... 3.4
Weekly service (30 operating hours) ................................................................... 3.5
Responsibility: Truck driver ............................................................................................ 3.5
Service, 500 hours service interval ...................................................................... 3.6
Responsibility: Foreman ................................................................................................ 3.6
First service ......................................................................................................... 3.6
Check list, service inspektion .............................................................................. 3.7
Code explanation ............................................................................................... 3.12
Lubrication chart ................................................................................................ 3.16
A-Ergo .......................................................................................................................... 3.16
Supplementary lubrication chart, telescopic forks, (TF) ............................................... 3.17
Explanation of symbols, lubrication chart ..................................................................... 3.18

Specific instructions .................................................................................................... 3.19

Storage of machines and motors ....................................................................... 3.19
Drive motor ........................................................................................................ 3.19
Preventive maintenance ............................................................................................... 3.19
Gearbox ............................................................................................................. 3.20
First service .................................................................................................................. 3.20
Preventive maintenance ............................................................................................... 3.20
Lift chains and forks ........................................................................................... 3.21
Check ........................................................................................................................... 3.21
Regular maintenance ................................................................................................... 3.21
Overhead guard ................................................................................................. 3.21
First service .................................................................................................................. 3.21
Mast ................................................................................................................... 3.22
First service .................................................................................................................. 3.22

ATLET SERVICE MANUAL A-ERGO

3.2

Hydraulic oil .......................................................................................................3.23

First service .................................................................................................................. 3.23
Replacement intervals .................................................................................................. 3.23
Recommended replacement ..............................................................................3.23

ATLET SERVICE MANUAL A-ERGO

 Service / Regular maintenance / Introduction 3.3

Edition 2002B

3 Service
Regular maintenance

Introduction
Service should be carried out regularly two times a year with normal truck usage, i.e. 1000
operating hours per year. The planned service includes procedures such as driving tests,
function tests, replacing filters and changing oils etc. Servicing is carried out at different
intervals depending on the running time of the truck. When the truck is working in extreme
conditions or in demanding environments, servicing can be planned at tighter intervals.

Safety
Important!
Check under every separate section which safety instructions are applicable for
work on the truck.

The external functions in the steering servo system should be checked after every service
and after all work carried out in the electrical system. All function tests of the safety
system should be carried out with the truck speed controller in neutral, see section 10.

Recommendation
This section provides information on what the truck owner should take into
consideration.

Regular service should be carried out by specially appointed and trained personnel with a good
knowledge of the function and servicing of the truck.
To achieve the best results from your investment in the truck we advise you to contact Atlet Service
and to subscribe to a service subscription for regular service.

SMA-Ergo_03_2002B.fm
ATLET SERVICE MANUAL A-ERGO
3.4 Service / Regular maintenance / Daily service

Daily service
This section provides information on what the truck owner should take into consideration.

The truck driver is obliged to do the following (before each shift)

Important!
NOTE! Naked flames or smoking are prohibited when checking the specific acid
weight and the acid level.

NOTE! Ergonomic loading procedures should be taken into consideration when

replacing the battery or checking the battery to avoid injuries.

1. The battery acid level should be checked every day. See separate service
instruction. Note that the acid level rises slightly during charging.
2. Check that the battery cables, connections and plugs are correctly connected and
undamaged.
3. Check that the battery is properly locked in its compartment.
4. Check whether the truck has leaked oil.
5. Check the transport and safety signal.
6. Check the braking capacity of the main brake and parking brake.
7. Check that the wheels have no external damage.
8. On trucks equipped with a truck computer, check that the test routine is followed
and that no error messages are shown on the display.
9. Check the battery indicator.

Important!
NOTE! Faults detected during daily maintenance are reported to the foreman. See
driver instructions.

The truck driver is obliged to do the following (after each shift)

Battery charging.
Battery service must only be carried out by specially trained personnel. This training is
provided during the truck driver course. The battery may, however, be charged by other
personnel on the assumption that the battery plug is used to connect the battery to the
charging unit. The battery is charged according to the recommendations of the battery
manufacturer. Only fully automatic charging units should be used. The battery charging
should be checked by measuring the acid weight in the cells if an unregulated charger
is used.

ATLET SERVICE MANUAL A-ERGO

 Service / Regular maintenance / Weekly service (30 operating hours) 3.5

Important!
NOTE! The acid weight should also be checked when an automatic charger is used.
For other details concerning the battery and fully automatic chargers, see the
separate service instructions for the battery and charger.

Weekly service (30 operating hours)

Responsibility: Truck driver

1. The battery is cleaned externally with warm water and rags.
2. Check the oil level in the hydraulic system by pushing out all the hydraulic
cylinders to their end positions. After this check that the fork carriage goes all the
way up to maximum lifting height without the pump sucking air.
3. Check that the wheels have not separated – tread/hub and tread/cord.
4. Check the acid weight. When the acid weight is checked the value for a fully charged
battery should be 1.25–1.28 (25°C). The acid weight must not be less than 1.16
(25°C), i.e. have at least 20% capacity left if the battery is to maintain its service life.
5. The truck should be cleaned externally. Vacuum clean and wipe with a damp cloth
in the driver compartment. Observe caution when using water jets. Electric panels
and circuit cards should always be protected from splashing water when washing.

ATLET SERVICE MANUAL A-ERGO

3.6 Service / Regular maintenance / Service, 500 hours service interval

Service, 500 hours service interval

Responsibility: Foreman
See EN 1726 or ISO 3691
A service is carried out by ATLET service or specially trained personnel. Servicing is
normally carried out after 500 hours or six months, but the working environment and
application should be taken into consideration when deciding the service intervals. The
service includes checking the complete truck, with the emphasis on both personal safety
and operational reliability. A service interval of 250 hours is recommended for cold store
trucks.
• Overall function test, control lever.
• Check of the horn.
• Test drive forwards, backwards and turning.
• Check of the drive unit.
• Check of the wheels.
• Test of the brake function.
• Check of oil levels and oil leakage.
• Check of the hydraulic unit, pipes and hoses.
• Check of the cylinders.
• Function test, lifting and lowering.
• Lubrication according to the lubrication chart.
• Measuring and check of the battery and charging function.
• Changing of oils and filters according to instructions.
• Check of damage on the chassis.
• Check of the attachments.
• Check of damage in welds.
• Check of the lifting forks.
(See “Check list, service inspektion” on page 3.7)

First service
The first service should be carried out after 200 hours of operation. See “Specific
instructions” on page 3.19 for instructions.

ATLET SERVICE MANUAL A-ERGO

 Service / Regular maintenance / Check list, service inspektion 3.7

Check list, service inspektion

For further information about procedures for inspections, repairs and replacement, 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

Doors, panels Attachment, damage Visual, tools 1005, 1102,

1032

Overhead guard Attachment Visual, tools 1035

Deformation, cracks, Visual, tools

other damage

Load wheel Damage, wear Visual 1051, 1108

Noise Listen, tool

Attachment Visual, tools

Battery stop, Damage, Visual, tools 1014,

Battery rollers, mounting, 1013
Battery lock lubrication * *

Rubber mats, Damage Visual 1105, 1058

compartment
Attachment Visual, tools

Chassis, general Appearance Visual 1033, 1112

Damage Visual

Loose screws Tools

* See “Lubrication chart” on page 3.16.

Frame

Inspection points Symptom Inspection Service code

Lift chains.** Chain tensioning By hand 2008

Lubrication * Visual, tools

Damage, chain Visual

Damage, chain bolt and Visual

chain bolt mounting

ATLET SERVICE MANUAL A-ERGO

3.8 Service / Regular maintenance / Check list, service inspektion

Frame

Inspection points Symptom Inspection Service code

Forks.** Cracks Visual 2026, 2107

Wear Visual

Angle Visual

Mast Cracks/Weld damage Visual, tools

2101, 2103
Mast dampening Operating test

Lubrication * Visual, tools

Play, damage, Visual, tools, operating

wear on rollers test

Angle, parallel Visual

deformation

Attachment rollers Visual, tools

Fork carriage Cracks/Weld damage Visual, tools 2007, 2004

2033
Wear, damage Visual

Link system, bar Locking, damage Visual, tools

TF chains Chain tensioning Visual

TF forks Locking, damage visual

Angle gear Oil level Visual, tools

Leakage Visual, tools

Function Visual, tools

Stabilisers Function Visual

Stabiliser cylinders Function Visual

Spring unit, Lubrication Visual

stabiliser cylinders

* See “Lubrication chart” on page 3.16.

** Fork tests and chain tests must be carried out at least every 1000 operating hours, see
section 6.

ATLET SERVICE MANUAL A-ERGO

 Service / Regular maintenance / Check list, service inspektion 3.9

Drive unit

Inspection points Symptom Inspection Service code

Gearbox * Oil level Visual, filling 3101, 3006,

Drive shaft 3104, 3106
Gear Noise Listen, tool

Oil leakage Visual, tools

Drive motor Function, noise Listen, tool 7027, 7112,

7104
Cable connections Visual, tools

Drive wheel Noise Listen 3005, 3102,

3002
Damage, wear Visual

Attachment Visual, tools

Sliding bearing Noise, lubrication * Listen, lubricate 3103

* See “Lubrication chart” on page 3.16.

Steering

Inspection points Symptom Inspection Service code

Gear Noise Listen, lubricate 4009

Servo motor Attachment Visual, tools 4014

Steering servo unit Attachment Visual, tools 4014

Steering wheel/step Attachment Visual, tools 4013

motor sensor
Damage, wear Visual, function test,
tools

Brake

Inspection points Symptom Inspection Service code

Braking force.* Malfunction Function test, tools 5012

Braking capacity Braking distance Measure, tool

Parking brake Malfunction Function test, tools 5014

Brake discs Wear Visual, tools 5104

* See also section 11.

ATLET SERVICE MANUAL A-ERGO

3.10 Service / Regular maintenance / Check list, service inspektion

Hydraulic system

Inspection points Symptom Inspection Service code

Hydraulic tank Oil level Visual, filling 6012, 6102

Damage, leakage, Visual, cleaning

contamination

Air, oil filter blocked * Visual, replace

Cylinders Function Function test, stop watch 6017, 6001

Damage Visual, replace

Leakage Visual, tools, replace

Cracks/Weld damage Visual, tools, replace

Damage, chain Visual, tools

attachments

Hoses Leakage, damage Visual, tools 6106

Attachment Visual, tools

Nipples Leakage Visual, tools 6019

Pump motor Function, noise Listen, tool

Cable connections Visual, tools

Hydraulic pump Leakage Visual, tools 6109

Damage Visual, tools

Noise Listen

Proportional Malfunction Test of lever function 6009

valve, on/off valve
Malfunction Calibration of levers

Leakage Visual, tools

* Replace filter every 1000 operating hours or when necessary (when it is dirty).
For further information concerning the hydraulic system, see also section 8 and lift
cylinders section 9.

ATLET SERVICE MANUAL A-ERGO

 Service / Regular maintenance / Check list, service inspektion 3.11

Electrical system

Inspection points Symptom Inspection Service code

Cabling, switches Damage, malfunction Visual, tools, replace

Contactors Malfunction Visual, tools, replace 7107

Cable break Visual, tools

Contactor plate Visual, tools

Battery Charging fault Tools 7032

Low acid level Tools,

Low acid weight Tools,

Damage Visual

Low capacity after Tools, DC voltmeter

charging

Battery plug, Function test, tools

malfunction

AC regulator Cable break Visual, tools 7025

Cabling Damage, break Visual, tools 7104

Horn Malfunction Function test 7014

Speed controller and Attachment Visual, tools 7106

brake pedal
Malfunction Function test

Malfunction Calibration

Level selector Malfunction Function test 7034

Speed switch Malfunction Function test 7035

Fuses Blown Visual, measure, replace 7103

Battery plug Malfunction Visual, contact surfaces 7008

Video camera Attachment Visual, tools 7037

Damage Visual

Malfunction Function test, tools

ATLET SERVICE MANUAL A-ERGO

3.12 Service / Regular maintenance / Code explanation

Code explanation
Chassis

Code Designation Check Reference to

section

1005 Doors Screws should be tightened. 1

1013 Battery locking Attachment and locking function 4

1024 Machine plate/ Attachment: text should correspond with 1

Warning decals machine type, and symbols and warning decals
should be legible.

1032 Panels Mounted using screws and clips as well as 4

bonded parts.

1033 Paint Scraping of paint and attachment/ 1

lack of decals

1035 Overhead guard Cracks in weld joints, collision damage, 1 and 4

tightening of screws.

1051 Load wheel Wear on wheel, dirt 4

1058 Rubber strips Attached with glue or screws

1107 Seat Setting, tilt function , load and angle 4

adjustment, attachment in chassis

1108 Load wheel bearing Friction free movement, remove 4

string, plastic bands, etc that have fastened.

1112 Accessories Driver Instructions Manual, hydrometer and

battery water bottle.

Mast

Code Designation Check Reference to

section

2004 Mast/chassis Screws between chassis and mast 6

attachment

2007 Rollers in fork Washers, lubrication of roller surfaces 6

carriage

2008 Lift chains Equally tensioned, bolts locked, rust, wear, 6

chain pulleys locked

2026 Forks Locking device, cracks, damage, 6

parallelism

2033 Side Shift Mounting in fork carriage

2101 Mast play Check the max play. Lubricate sliding surfaces. 6

2103 Mast rollers Washers, lubrication of roller surfaces 6

ATLET SERVICE MANUAL A-ERGO

 Service / Regular maintenance / Code explanation 3.13

Drive unit

Code Designation Check Reference to

section

3002 Drive wheel Wear, damage 5

Clean.

3005 Drive wheel bolt Attachment, tightening torque 1

3006 Oil leakage Leakage from shafts, joints, plugs or material 5

3101 Oil level Oil level, oil change 1 and 5

3102 Noise Gears, nut tightening 1

3103 Sliding bearing Noise, requisite lubrication 1

3104 Drive shaft Tightening of nuts. 1 and 5

3106 Gears Gear ratio 1

Steering

Code Designation Check Reference to

section

4004 Gear drive Play, lubrication 1

4009 Gear wheel Shaft locking, lubrication 1

4013 Mini-wheel Attachment, rotation 7

4014 Servo motor Attachment 7

Brake unit

Code Designation Check Reference to

section

5012 Braking force Braking distance 11

5014 Parking brake Function, cable connections 11

5104 Brake discs Friction surface > min level all round 11

ATLET SERVICE MANUAL A-ERGO

3.14 Service / Regular maintenance / Code explanation

Hydraulic system

Code Designation Check Reference to

section

6001 Lift cylinders Leakage at attachments, weld joints, 9

wiper, piston rod

6009 Hydraulic valve Leakage between sections, connections 8

6012 Oil level in tank Oil level between min and max 3

6017 Lowering Check lowering speed 1

6019 Nipples Leakage

6102 Filter Replace if necessary 8

6106 Hoses Cracks, wear, damage 1

6109 Hydraulic pump Leakage between pump and motor

6111 Accessories Leakage from connections 8

ATLET SERVICE MANUAL A-ERGO

 Service / Regular maintenance / Code explanation 3.15

Electrical system

Code Designation Check Reference to

section

7008 Battery connections That cable connections are not overheating

7012 Hour meter Read off the display

7014 Horn Function

7017 Micro switch Function

7025 Transistor system Dirt, moisture. Cable connections

7027 Drive motor, bearings Noise

7030 Pump motor Attachment, cleaning requirement

7032 Battery Acid level, charging. Note reading from

hydrometer. Clean if necessary

7034 Level selector The mounting, position and function of the

switch

7035 Speed switch Switches in mast, fork carriage, and forks 10

regarding creep speed

7037 Video equipment Function, mounting of camera and monitor,

damage and stretching of cable in mast.

7101 Contactors Contact surfaces, cable connections, dust

guard. Replace the contactor tips if they are
burned.

7103 Fuses That they are not brittle

7104 Cabling Cable connections, attachment, run free from

sharp edges

7106 Speed controller Attachment and function.

7112 Drive motor cables Attachment, wear, cleaning requirement

7202 Keyboard Attachment, damage, readability

7203 Display Attachment, damage

ATLET SERVICE MANUAL A-ERGO

3.16 Service / Regular maintenance / Lubrication chart

Lubrication chart

A-Ergo

B
E

C E

C
F

A-Ergo sm rjschema A.eps

Figure 3.1 Lubrication chart A-Ergo. For explanation of symbols, see table 3.3

The service of an Atlet-truck can be divided into service that should be carried out in
relation to how hard the truck has been loaded and used (see “Check list, service
inspektion” on page 3.7) and regular annual service:
1. 500 hours service
2. Annual service
Table 3.1 Component to lubricate A-Ergo

Location Explanation Location Explanation

A Mast profile – roller surfaces and E Thrust rollers – all

slide surfaces

B Lift chains, all F Chain pulley, Shaft

C Fork carriage – thrust rollers G Hydraulic oil, filter

D Bogie – axle (unloaded) H Gearbox oil

Important!
All torsion springs in the machine should be lubricated during each service.

ATLET SERVICE MANUAL A-ERGO

 Service / Regular maintenance / Lubrication chart 3.17

Supplementary lubrication chart, telescopic forks, (TF)

A-Ergo sm rjschema ATF.eps

Figure 3.2 Supplementary lubrication chart TF. For explanation of symbols, see 3.3

Table 3.2 Supplementary components to lubricate TF

Location Explanation Location Explanation

I Fork carriage – thrust rollers K Chains Fork driving

J Forks, rollers, slide surfaces L Angle gear

ATLET SERVICE MANUAL A-ERGO

3.18 Service / Regular maintenance / Lubrication chart

Explanation of symbols, lubrication chart

Table 3.3 Explanation of symbols 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

ATLET SERVICE MANUAL A-ERGO

 Service / Specific instructions / Storage of machines and motors 3.19

Specific instructions

Storage of machines and motors

Machines in storage that will not to be used within a month, must be given special attention
so that problems do not occur when they are to be used again. Dust, dirt, condensation and
moisture that occurs during large variations in temperature, as well as problems with rust
and oxidisation, must be prevented. Motors should therefore be protected with waxed
paper or the equivalent, and also with a moisture absorbing material.

Drive motor

Preventive maintenance
Preventive maintenance is implemented in accordance with the intervals set out in the
service chart.
However, in some cases exceptions must be made and the intervals shortened, depending
on local conditions in customer premises, e.g. a rugged environment with dust, high
humidity levels, and salt, etc.
• Listen for abnormal noise from the bearings when the motor is run. Check that it
does not vibrate abnormally.
• Blow clean the motor with dry compressed air or clean with a vacuum cleaner. A
special cleaning fluid should be used to drive out oil and dirt, if oil has leaked from
the gearbox into the motor, see section 2. Finally, blow dry with compressed air.
• Check the insulation resistance for the motor, see specification in section 1 for
correct value.

ATLET SERVICE MANUAL A-ERGO

3.20 Service / Specific instructions / Gearbox

Gearbox

First service
First oil
change after • The first oil change should be done after 200 hours.
200 hours
• Fill up with a recommended type of oil, see section 1.

Preventive maintenance
The oil level • The oil level is checked during each service.
is checked
during each
service • The steering bearing must be greased at least once a year. If steam cleaning or high
pressure washing has been carried out then new greasing is essential.

Note!
Remember to fill up the gearbox with oil after changing the oil or replacing the
gearbox. See section 5 for procedure.

Note!
Spent oil should be taken care of and recycled according to the applicable legislation
in respective countries.

ATLET SERVICE MANUAL A-ERGO

 Service / Specific instructions / Lift chains and forks 3.21

Lift chains and forks

Check
Forks and lift For safety reasons the forks and all lift chains should checked during each service.
chains should
be checked
during each If a lift chain fails to be approved in any respect, the complete chain must be replaced;
service and it is not permitted to replace parts of a lift chain.

Important!
If the lift chain fails to be approved in any respect the complete chain must be
replaced.

See under section 6 for instructions concerning checking chains and forks.

Regular maintenance
The chain should be kept clean.
Lubricant (see “Check list, service inspektion” on page 3.7) must be regularly applied
on the chain so that all working surfaces are continuously lubricated.
The chain should be kept in motion when lubricating to ensure that the lubricant
penetrates the working surfaces between the link plates and pins. All excess lubricant
should wiped off, but solvent must not be used.
If the chain runs dry it should be lubricated more often; this also applies if the truck is
working in special environments such as cold stores, etc.

Overhead guard

First service
Retightening
after 200 hours
1. The attachment between the overhead guard and chassis should be retightened
during the first service.
Tightening
torque: 2. The tightening torque between the overhead guard and chassis should be 81 Nm.
81 Nm

ATLET SERVICE MANUAL A-ERGO

3.22 Service / Specific instructions / Mast

Mast

First service
Retightening 1. The attachment between the mast and chassis should be retightened during the first
after 200
service, 200 hours.
hours
Tightening
2. The tightening torque between the frame and machine housing should be 277 Nm.
torque:
277 Nm

03_001_A-Ergo_EdragMast.eps

Figure 3.3 Position of screws that hold the mast to the chassis.

ATLET SERVICE MANUAL A-ERGO

 Service / Specific instructions / Hydraulic oil 3.23

Hydraulic oil

First service
Hydraulic oil
change and
replacement • The oil filter should be replaced after 200 hours.
of filter after
200 hours
Replacement intervals
After 500 hours of operation: The hydraulic oil filter and air filter to the hydraulic oil
tank should be replaced after no more than 500 hours of operation. Replacing the
hydraulic oil filter refers to those types of trucks that have replaceable filters. Clean the
suction filter.
After every 1000 hours of operation: Changing of the hydraulic oil and replacing the oil
filter and air filter after 1000 hours of operations, or once every year (whatever is first).
If the hydraulic oil has been heated over 60 degrees Celsius the oil and the filter should
be immediately replaced since their properties will have been changed.
If the hydraulic oil has become contaminated with water (e.g. during work in cold store)
this can be detected in that the oil will look milky, or smell 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. Put 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.

Recommended replacement
Hydraulic hoses should be replaced after 5 years, since the rubber in the hose is
perishable.

ATLET SERVICE MANUAL A-ERGO

3.24 Service / Specific instructions / Recommended replacement

ATLET SERVICE MANUAL A-ERGO

 SERVICE MANUAL
Machine: A-Ergo

Manual No: 005975

Edition 2005A

4 Chassis

Design and function ....................................................................................................... 4.3

Scope .................................................................................................................. 4.3
Machine housing ................................................................................................. 4.3
Overhead guard ................................................................................................... 4.3
Arm rest and steering wheel panel ...................................................................... 4.4
Covers and panels ............................................................................................... 4.4
Foot plate ............................................................................................................ 4.4
Castor wheel ........................................................................................................ 4.4

Repair instructions ......................................................................................................... 4.5

Overhead guard ................................................................................................... 4.5
Dismantling the overhead guard .................................................................................... 4.5
Mounting the overhead guard ........................................................................................ 4.5
Arm rest ............................................................................................................... 4.6
Dismantling the arm rest ................................................................................................ 4.6
Mounting the arm rest .................................................................................................... 4.7
Steering wheel panel ........................................................................................... 4.8
Dismantling the steering wheel panel ............................................................................. 4.8
Mounting the steering wheel panel ................................................................................. 4.8
Covers and panels ............................................................................................... 4.9
Dismantling the machine housing cover ........................................................................ 4.9
Foot plate ............................................................................................................ 4.9
Dismantling the foot plate ............................................................................................... 4.9
Castor wheel ...................................................................................................... 4.10
Dismantling the castor wheel ....................................................................................... 4.10
Mounting the castor wheel ........................................................................................... 4.10
Dismantling castor wheel ............................................................................................. 4.10
Assembling castor wheel .............................................................................................. 4.10
Adjusting the angle of the truck ..........................................................................4.11
Battery ............................................................................................................... 4.12
Changing the battery .................................................................................................... 4.12
Replacing the battery rollers ......................................................................................... 4.12

ATLET SERVICE MANUAL A-ERGO

4.2

ATLET SERVICE MANUAL A-ERGO

 Chassis / Design and function / Scope 4.3

Edition 2005A

4 Chassis
Design and function

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, arm rest, overhead guard and
castor wheel.
With regard to the straddle legs and load wheels on the truck it could be said that they are
a part of the chassis, but since they are also a part of the mast the instructions concerning
straddle legs and load wheels are described in chapter 6, Mast, instead.

Machine housing
The chassis on A-Ergo trucks consists of a machine housing, which is available in
different versions depending on the size of the battery.
All the truck components such as the mast, drive unit, and hydraulic system are mounted
on the machine housing and this is therefore the most basic component on the truck.
The machine housing structure is prepared for different sizes of batteries. Spacers are
fitted between the machine housing and mast in those cases where a larger battery is used,
see figure 4.1.

04_005_SM_A-Ergo_senior.eps

Figure 4.1 Machine housing prepared for large battery

Overhead guard
The overhead guard consists of a grille roof mounted on two pillars. The grille is designed
to ensure good overhead visibility.
The construction has a design basis to withstand loads in accordance with current standards.
SMA-Ergo_04_2005A.fm
ATLET SERVICE MANUAL A-ERGO
4.4 Chassis / Design and function / Arm rest and steering wheel panel

Arm rest and steering wheel panel

The purpose of the arm rests is to create an ergonomically correct working position for
the driver. Together with the steering wheel panel it is possible to vertically adjust the
arm rest to best suit different drivers.

Covers and panels

The purpose of the panels is to protect the driver from moving parts, electrical compo-
nents, oils and fluids, and to protect components from external damage and fouling.

Foot plate
The foot plate consists of soft mat and a brake pedal (see section 11). The foot plate
covers the attachment of the castor wheel.

Castor wheel
The castor wheel functions as a support wheel for the drive wheel, since the drive wheel
is asymmetrically mounted on one side of the truck.
The castor wheel is a completely separate and free-turning wheel placed under the driver.
It consists of a double-wheel mounted in a wheel fork. Between and at the sides of the
wheel there are spacer washers, which have the purpose of guiding the wheel to the
correct position in the wheel fork.
Shims are mounted between the castor wheel attachment plate and the machine housing
to compensate for differences in the diameter of the drive wheel and the castor wheel.

Note!
Shims should be removed between the castor wheel and machine housing as the
drive wheel becomes worn. This is done to counteract the truck inclining to the side,
or to prevent the drive wheel from spinning. Check the number of shims when
replacing the drive wheel.

ATLET SERVICE MANUAL A-ERGO

 Chassis / Repair instructions / Overhead guard 4.5

Repair instructions

Overhead guard

Dismantling the overhead guard

1. Remove the panel in the driver compartment (5 screws).

04_007_SM_A-Ergo_panelskruvar.eps

Figure 4.2 Attachment of panel in driver compartment

2. Attach a lifting strap to the roof grille, and make sure that weight of the grille is
relieved from the truck.
3. Unscrew the screws between the machine housing and roof grille pillars.
4. Lift off the grille.

Mounting the overhead guard

1. Screw the overhead guard together with the pillars. 81 Nm.

Tightening 2. Attach a lifting strap to the roof grille and lift the grille into position.
torque:
81 Nm 3. Screw tight the screws between the machine housing and roof grille pillars. 81 Nm.

ATLET SERVICE MANUAL A-ERGO

4.6 Chassis / Repair instructions / Arm rest

Arm rest

Dismantling the arm rest

1. Unscrew the wing nut for adjusting the height.
2. Remove the height adjusting knob under the writing surface.
3. Pull up the arm rest so that the lock screw at the right attachment can be released..

04_002_SM_A-ERGO_ArmstDem.eps

Figure 4.3 Front retaining screw, arm rest

4. Lift up the arm rest and disconnect all the cabling at the connectors.
5. Continue to lift the arm rest so that the lock screw on the left attachment can be
released..

04_003_SM_A-ERGO_ArmstDem.eps

Figure 4.4 Arm rest raised

ATLET SERVICE MANUAL A-ERGO

 Chassis / Repair instructions / Arm rest 4.7

04_002-2_SM_A-ERGO_ArmstDem.eps

Figure 4.5 Rear retaining screw, arm rest

6. Lift off the panel.

Mounting the arm rest

1. Fit the left guide rail in its groove.
2. Screw tight the lock screw.
3. Connect the connectors.
4. Fit the left guide rail and gas spring in their grooves.
5. Press down the panel so that the right lock screw can but put in position.
6. Press down the panel, and lock the panel in the required position.

ATLET SERVICE MANUAL A-ERGO

4.8 Chassis / Repair instructions / Steering wheel panel

Steering wheel panel

Dismantling the steering wheel panel

1. Unscrew the wing nut for adjusting the height.
2. Lift up the steering wheel panel as far as it goes, and lock with the wing nut.
3. Open the machine cover.
4. Release all the cabling to the components on the steering wheel panel.
5. Release the lock knob on the inner guide rail..

04001_SM_A-ERGO.eps

Figure 4.6 Lock knob, steering wheel panel

6. Release the wing nut for adjusting the height and lift off the steering wheel panel.

Mounting the steering wheel panel

1. Hold the machine cover open during the complete mounting procedure.
2. Fit the guide rails in their grooves.
3. Screw tight the lock screw when the panel is in it upper position.
4. Connect the connectors.
5. Close the machine cover.
6. Press down the panel, and lock the panel in the required position.

ATLET SERVICE MANUAL A-ERGO

 Chassis / Repair instructions / Covers and panels 4.9

Covers and panels

Dismantling the machine housing cover

1. Remove the panel in the driver compartment.
2. Unscrew the wing nut for adjusting the height on the steering wheel panel.
3. Lift up the steering wheel panel as far as it goes, and lock with the wing nut.
4. Open the machine cover.
5. Secure the cap screw in the hinge with an Allen key and release the lock nut.
6. Release the screw in the hinge and lift down the cover.

Foot plate

Dismantling the foot plate

1. Pry out the cover pieces, 4 pcs, in the mat that cover the retaining screws so that
they can be reached..

04_004_SM_AErgo_FotplDem.eps

Figure 4.7

2. Unscrew the screws and lift up the foot plate.

3. Disconnect the connector to the brake pedal.

ATLET SERVICE MANUAL A-ERGO

4.10 Chassis / Repair instructions / Castor wheel

Castor wheel

Dismantling the castor wheel

1. Check that the battery is pushed in and locked.
2. Remove the foot plate, see “Dismantling the foot plate”, page 4.9.
3. Block up the truck (check the balance).
4. Loosen the bolts to the castor wheel, and remove them.

Warning!
Pinch risk!

5. Pull out the castor wheel.

Mounting the castor wheel

1. Insert the castor wheel under the truck (the truck is assumed to be blocked up).
2. Lift up the wheel and place the shims in position.
Tightening
torque: 3. Insert the bolts and tighten. 81 Nm.
81 Nm
4. Lower down the truck.
5. Check the angle of the truck, see “Adjusting the angle of the truck”, page 4.11.

Dismantling castor wheel

1. Remove the castor wheel from the truck, see “Dismantling the castor wheel”, page
4.10.
2. Support the complete castor wheel in a vice by gripping the opposite side of the
wheel fork where the locking pin is fitted.
3. Tap out the locking pin and drive out the axle.
4. Lift out the castor wheel from the wheel fork; and take care of the spacers.
5. Dismantle the bearings from the castor wheel by means of a bearing extractor.

Assembling castor wheel

1. Press the bearings in the wheel with a drift.
2. The axle is lubricated with oil before fitting.
3. Insert the wheel with the shims in the wheel fork.
4. Check that the hole for the locking pin in the axle comes opposite the hole on the
wheel fork.

ATLET SERVICE MANUAL A-ERGO

 Chassis / Repair instructions / Adjusting the angle of the truck 4.11

5. Carefully press in the axle by using a hammer and a suitable drift.

6. Fit the locking pin.
7. Turn the wheel and check that it rotates freely.
8. Fit the castor wheel in the machine, see “Mounting the castor wheel”, page 4.10.

Adjusting the angle of the truck

The angle of the truck can be adjusted by shimming the castor wheel.
1. Place the truck on a level surface.
2. Check if the truck stands at an angle:

• Or: 1: place a spirit level against the sides of the mast and check
whether the mast is at an angle.
• Or: 2: check with a measuring scale on both sides of the truck
between the floor and the machine housing.

3. If alignment is necessary, remove the castor wheel as per “Dismantling the castor
wheel (page 4.10)”.
4. Add or remove shims. Shims are available in several different dimensions.
5. Fit the castor wheel, see “Mounting the castor wheel (page 4.10)”, and check
measure.

ATLET SERVICE MANUAL A-ERGO

4.12 Chassis / Repair instructions / Battery

Battery

Changing the battery

1. Disconnect the battery plug.
2. Lift up the battery lock..

01001_SM_A-Ergo.eps

Figure 4.8 Battery lock

3. Roll out the battery on the charging/storage structure.

4. Roll in the new battery.
5. Secure the battery by means of the battery stop and replace the battery plug.

Replacing the battery rollers

0

1. Remove the battery.

Warning!
Observe care to avoid “splashing” waste acid or oxide from the battery.

2. The battery rollers sit loosely in their attachments. Lift up the rollers in the back
edge and pull backwards/upwards.

ATLET SERVICE MANUAL A-ERGO

 SERVICE MANUAL
Machine: A-Ergo

Manual No: 005975

Edition 2004A

5 Drive unit

Design and function ....................................................................................................... 5.3

Introduction .......................................................................................................... 5.3
Drive motor .......................................................................................................... 5.3
Gearbox ............................................................................................................... 5.3

Repair instructions ......................................................................................................... 5.4

Preparations ........................................................................................................ 5.4
Drive motor .......................................................................................................... 5.4
Dismantling the drive motor ............................................................................................ 5.4
Assembling the drive motor ............................................................................................ 5.5
Dismantling drive motor .................................................................................................. 5.5
Assembly drive motor ..................................................................................................... 5.5
Storage of the drive motor .............................................................................................. 5.5
Gearbox ............................................................................................................... 5.6
Oil change, gearbox ....................................................................................................... 5.6
Dismantling and assembling the gearbox ...................................................................... 5.6
Reconditioning of the gearbox ............................................................................. 5.8
Replacing the drive shaft seal ........................................................................................ 5.8
Assembly of gearbox ...................................................................................................... 5.8
Drive wheel, replacement .................................................................................. 5.13

Diagnosis and trouble shooting ................................................................................. 5.14

Trouble shooting chart ....................................................................................... 5.14

ATLET SERVICE MANUAL A-ERGO

5.2

ATLET SERVICE MANUAL A-ERGO

 Drive unit / Design and function / Introduction 5.3

Edition 2004A

5 Drive unit
Design and function

Introduction
The drive unit is mounted in an assembly containing the brake, drive motor, gearbox and
drive wheel. The steering servo motor is mounted on the same motor bed.
For technical data regarding component parts, see section 1.

Drive motor
The drive motor on A-ERGO is a brushless three-phase induction motor. A pulse sensor
is enclosed in the bearing on the non-driving end of the motor, which provides speed
feedback to the drive regulator, see section 10.
The motor is mounted directly on the gearbox and the power transmission takes place via
a gear wheel individually adapted to each gearbox.

Gearbox
The gearbox is adapted to provide the best gear ratio over the speed range of the drive
motor.
The drive motor and drive wheel are mounted on the gearbox.
The gearbox is mounted on the truck chassis. A gear ring bearing is mounted on the
gearbox. The steering servo motor drives the gear ring bearing and in this way turns the
gearbox and drive wheel in the required direction when the truck is steered.

SMA-Ergo_05_2004A.fm
ATLET SERVICE MANUAL A-ERGO
5.4 Drive unit / Repair instructions / Preparations

Repair instructions

Preparations
1. Switch off all the power.
2. Release the panel for the control units and move it out of the way, see section 10.

Drive motor

Dismantling the drive motor

Warning!
The battery plug must be removed and the machine lifted so that the drive wheel
runs free of the ground when working on the motor.

3. Disconnect the cables to the drive motor and electric

brake.
4. Loosen the 8 socket head cap screws holding the
motor together with the gearbox, see pos. 2. 2

5. Carefully lift out the motor from the gearbox, so that

the gears are not damaged.
1
6. If the motor is to be replaced, the gear wheel must be
released and put on the new motor. The gear wheel is
paired together with the gearbox.

Important!
It is very important that the gear wheel corresponds
with the gearbox it is rated for.
A-Ergo ByteMotor.eps
7. If the motor is to be repaired or reconditioned, see
section “Dismantling drive motor”, page 5.5.
8. Check/replace the sealing ring, pos. 1

ATLET SERVICE MANUAL A-ERGO

 Drive unit / Repair instructions / Drive motor 5.5

Assembling the drive motor

Tightening 1. Tighten the gear wheel on the motor shaft. Tightening torque 50 Nm.
torque:
50 Nm
2. Apply oil on the sealing ring.
3. Carefully lower the motor down in the gearbox, the gear wheel can be damaged!
To simplify assembly 3 screws without heads can be fitted in three of the 8 screw
holes and used as guide pins.
4. Screw tight the motor on the gearbox (remove any guide screws).
5. Connect all the cabling.
6. Refit the control unit panel and tighten it.

Dismantling drive motor

1. Remove the motor from the machine housing, see “Dismantling the drive motor”,
page 5.4.
2. Release the bearing plates and rotor. Since the tachometer is built into the bearing
on the non-driving side of the motor, great care must be exercised to avoid damag-
ing it.
3. Replace the motor bearing. Press on the inner ring. Slowly heat the bearing to max 50°.

Important!
The motor bearings should always be replaced when reconditioning the motor to
ensure continued reliable operation.

4. The housing is sprayed with cleaning fluid, see section 3, and then blown dry; after
the housing has dried carry out an insulation test.
5. Check that the insulation is satisfactory. Measure the resistance between coil and
stator housing, see specification in section 1 for correct value. If the resistance is
lower the motor must be blown clean and tested again.

Assembly drive motor

1. Assemble in the reverse order to dismantling. Note that the “knob” on the bearing
Tightening should be fitted in the bevel on the plate.
torque:
50 Nm
2. The nut for the pinion on the motor shaft are tightened to 50 Nm.

Storage of the drive motor

Machines in storage that will not to be used within a month, must be given special attention
so that problems do not occur when they are to be used again. Dust, dirt, condensation and
moisture that occurs during large variations in temperature, as well as problems with rust
and oxidisation, must be prevented. Motors should therefore be protected with waxed pa-

ATLET SERVICE MANUAL A-ERGO

5.6 Drive unit / Repair instructions / Gearbox

per or the equivalent, and also with a moisture absorbing material, and stored indoors at
room temperature, preferably in a cardboard box.

Gearbox

Oil change, gearbox

1. If oil needs to be drained off this is done through the plug in the bottom of the
gearbox, pos. 1 figure 5.1
2. Oil is filled either through the plug, pos. 2 figure 5.1, or by dismantling the motor.
3. The oil should lie at the same level as the hole by the screw, pos. 2 figure 5.1. Fill
with oil until the oil starts to run out from the hole.
A suction spray is recommend to simplify filling via pos. 2.

05_001_A-Ergo_vxl da.eps

Figure 5.1 Gearbox

Dismantling and assembling the gearbox

00

1. Block up the truck. The drive wheel should run free, approx. 30 cm above the floor.
2. Loosen the cable connections to the drive motor, servo motor, electric brake and
wheel indicators. Label the cables that are not labelled to ensure correct reassembly.
3. Dismantle the motor, see “Drive motor”, page 5.4
4. Loosen the 6 socket head cap screws on the bolted joint between the motor bed and
chassis.
5. Lower down the gearbox from the machine with great care.

Note!
All the bolts and screws are tightened to the tightening torque specified in the table
in section 1.

6. Drain the oil from the gearbox, see “Oil change, gearbox page 5.6”.

ATLET SERVICE MANUAL A-ERGO

 Drive unit / Repair instructions / Gearbox 5.7

7. If appropriate: Take off the guide ring and guide ring bearing from the old gearbox
and mount on the new gearbox.
8. Fit the new gearbox. Check that the mechanical limit positions come in the correct
position.

Important!
Check that the mechanical limit positions come in the correct position.

Tightening
torque: 9. When refitting in the machine housing the specified tightening torque must be
47 Nm applied, 47 Nm
10. Fill up with new oil, see table of recommended oils in section 1.

Note!
Do not forget to fill the gearbox with oil before starting up. The oil can be filled
before the drive motor is assembled on the gearbox. To ensure the oil level is
correct: open the level plug, pos. 2 figure 5.1, and drain off any excess oil.

Note!
Spent oil should be taken care of and recycled according to the applicable legislation
in respective countries.

ATLET SERVICE MANUAL A-ERGO

5.8 Drive unit / Repair instructions / Reconditioning of the gearbox

Reconditioning of the gearbox

Replacing the drive shaft seal

1. Remove the gearbox, see “Dismantling and assembling the gearbox page 5.6”.
2. Remove the drive wheel.
3. Remove the cover.
4. Loosen the screws holding the crown wheel halfway, and drive out the shaft
towards the drive wheel side.
5. The screws can be fully unscrewed when the crown wheel and bearing have come
free from the shaft. The shaft is pulled out from the drive wheel side. Arrange the
parts in the order they were dismantled to avoid confusion.
6. Remove the roller bearing closest to the seal by tapping the shaft end against a
block of hard wood. Sometimes it is easier to remove the bearing if a sharp object
is inserted down between the inner ring of the bearing and the flank of the shaft.
Any burrs on the shaft must be removed before reassembly.
7. Carefully clean the seat for seal box in the gear housing.
8. When assembling, the first bearing is placed on the drive wheel side.
9. Fit the safety ring and seal in position. Make that it sits correctly.
10. Fit the guard and then carefully press in the drive shaft.
11. Now assemble the crown wheel and bearing. Start with the spacer.
12. Apply Loctite 207 on the shaft threads and screw together the complete drive shaft
assembly with the washer and screws. The screws should be tightened to the
tightening torque specified in the table in section 1.
13. Fit the cover. Remember that the drain hole should be the lowest point. Use a new
seal. Screw in the oil drain plug with a new copper washer.
14. Fill with hypoid oil. See the table of recommended oils, section 1.

Assembly of gearbox
1. Preparation of the gearbox housing (see figure 5.2)

1. Carefully clean the gearbox housing.

2. Fit bearings, pos. 1, 2 and 3 in their positions.
3. Fit the safety ring, pos. 4, in its position.

ATLET SERVICE MANUAL A-ERGO

 Drive unit / Repair instructions / Reconditioning of the gearbox 5.9

1 3

4
Figure 5.2 Preparations for gearbox housing

2. Fit the pinion shaft, pos. 5, in its position (see figure 5.3).

1. Press bearing, pos. 6, on the pinion shaft.

2. Set out required number of shims, pos. 7.
3. Place the spacer pipe, pos. 8, in position on the pinion shaft.
4. Place the gear, pos. 9, in its position.
5. Place the pinion shaft in its position and tighten with the nut, pos. 10.
The nut must be locked with “Delo 5249” or “Loctite 243”.

10
9

8
7
6

5
05_003_2_A-Ergo_vxl da.eps

Figure 5.3 Fit the pinion shaft.

Note!
Always use the correct torque when tightening the nut, pos. 10.
The nut must be locked with “Delo 5249” or “Loctite 243”.

ATLET SERVICE MANUAL A-ERGO

5.10 Drive unit / Repair instructions / Reconditioning of the gearbox

3. Fit the wheel hub, pos. 11, and crown wheel, pos. 15 (see figure 5.4).

1. Press tight the seal, pos. 12.

2. Set out required number of shims, pos. 13.
3. Place the spacer ring, pos. 14, in its position and then the gear, pos.
15, in its position in the gearbox.
4. Push in the hub, pos. 11, from the outside.
5. The hub is locked with a washer, pos. 16, and screw, pos. 17.
The screw should be locked with “Delo 5249” or “Loctite 243”.

15
16 17
14
13

12
11

Figure 5.4 Fit the wheel hub and crown wheel.

Note!
Always use the correct torque when tightening the screw, pos. 17.
The screw should be locked with “Delo 5249” or “Loctite 243”.

ATLET SERVICE MANUAL A-ERGO

 Drive unit / Repair instructions / Reconditioning of the gearbox 5.11

4. Adjusting the engagement of the gear wheel, pos. 5 and pos. 15

1. Paint the gear teeth with a suitable colour for the

purpose.
2. Rotate the gear.
3. Check the markings on the gear teeth.
4. The figure below shows the correct engagement.

5. If the engagement is shown as in the figure, the number

of shims, pos. 7, on the pinion shaft, pos. 5, must be
reduced (see figure 5.3).

6. If the engagement is shown as in the figure below, the

number of shims, pos. 7, on the pinion shaft, pos. 5,
must be increased (see figure 5.3).

ATLET SERVICE MANUAL A-ERGO

5.12 Drive unit / Repair instructions / Reconditioning of the gearbox

5. Fit the guide wheel (see figure 5.5)

1. Apply a floating gasket on the top of the gearbox.

2. Place the guide wheel in its position and tighten with the screws,
pos. 18.
3. Place the guide wheel bearing in its position and tighten.

18

05_003_4_A-Ergo_vxl da.eps

Figure 5.5 Fit the guide wheel.

6. Fit the cover, pos. 21 (see figure 5.6).

1. Remember that the drain hole should be the lowest point. Use a new
gasket, pos. 20. Screw in the oil drain plug, with a new copper
washer, pos 22.

22
20 21
05_003_5_A-Ergo_vxl da.eps

Figure 5.6 Fit the cover.

ATLET SERVICE MANUAL A-ERGO

 Drive unit / Repair instructions / Drive wheel, replacement 5.13

Drive wheel, replacement

0

1. Loosen the drive wheel nuts, without removing them.

05_002_A-Ergo_drivHjByte.eps

Figure 5.7 Loosen the nuts, drive wheel.

2. Block up the machine.

3. Remove the wheel nuts and lift the wheel forward.
4. Fit the new wheel, tighten the nuts by hand.

Tightening
5. Lower down the machine to the floor.
torque:
135 Nm 6. Tighten the nuts, tightening torque 135 Nm

ATLET SERVICE MANUAL A-ERGO

5.14 Drive unit / Diagnosis and trouble shooting / Trouble shooting chart

Diagnosis and trouble shooting

Trouble shooting chart

Symptom Cause Action

The wheel has a flapping The tyre has separated as a 1. Change the wheel.
sound when driving. result of
2. Examine the floor for
impact.
irregularities.

The wheel squeaks Bearing is damaged. 1. Replace bearing.

continuously when driving.
2. Inform the driver that
cords and plastic etc.
should be removed daily
and the floor kept clean.

The wheel goes flat after The wheel mass has become Try another type of wheel.
long breaks, but becomes warm while driving and
round again after driving for deforms when parked.
a while.

The wheel has a deformity A "blow out" has occurred Change the wheel.
that does not disappear when due to overheating and
driving. changed the molecular
structure of the wheel mass.

The truck seems to jerk when Hard foreign object has 1. Remove the object or
driving. fastened in the drive wheel. replace the wheel.
2. See also the above items.

The truck jumps at regular The wheel is oval. 1. Change the wheel.
intervals, proportional to the
2. Check/Adjust the brakes.
speed, when driving.
3. See also the above items.

The wheel has transverse The wheel has been heated. 1. Lower the acceleration and
cracks and small pieces have Small cracks appear with reversing rate.
fallen out of the tyre. hard acceleration and
2. Change wheel if necessary.
reversing.

The wheel has one or more Locking of the brakes so that 1. Remove the objects on the
small deformations. the wheel slides, or loose floor.
objects on the floor that
2. Tell the driver to brake
prevent the wheel from
more smoothly.
rotating.

Oil on the floor. Leaking seal around the • Replace seal.

drive shaft. Or:
• if there are parallel cracks
in the casting then the
gearbox must be replaced.

ATLET SERVICE MANUAL A-ERGO

 Drive unit / Diagnosis and trouble shooting / Trouble shooting chart 5.15

Symptom Cause Action

Grating noise when 1. Defective gear wheel in Check the cogs by removing
accelerating or when using the drive unit. the cover.
the reversing brake.
2. Too little oil in the If there are parallel cracks in
gearbox.. the casting then the gearbox
must be replaced.

Grating noise when the truck Faulty bearing in the drive Dismantle and recondition the
is lifted up, the drive wheel motor. drive motor.
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 seized. If there are parallel cracks in

the casting then 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.

ATLET SERVICE MANUAL A-ERGO

5.16 Drive unit / Diagnosis and trouble shooting / Trouble shooting chart

ATLET SERVICE MANUAL A-ERGO

 SERVICE MANUAL
Machine: A-Ergo

Manual No: 005975

Edition 2009A

6 Mast system

Design and function ....................................................................................................... 6.3

Mast system ........................................................................................................ 6.3
Fork carriage ....................................................................................................... 6.4
Fixed forks ...................................................................................................................... 6.4
Laterally adjustable forks ................................................................................................ 6.4
Telescopic forks (TF) ...................................................................................................... 6.5
Overload clutch, telescopic forks (TF) ............................................................................ 6.5
Fork drive motor, telescopic forks (TF) ........................................................................... 6.5
Straddle lift ........................................................................................................... 6.6
Side stabilisers .................................................................................................... 6.7

Repair instructions ......................................................................................................... 6.8

Replacing the mast/straddle legs ........................................................................ 6.8
Dismantle the mast/straddle legs from the chassis ........................................................ 6.8
Mount the mast/straddle legs on the chassis ............................................................... 6.11
Dismantling the mast ......................................................................................... 6.14
General ......................................................................................................................... 6.14
Adjusting the lateral inclination in top position. ............................................................. 6.14
Adjusting the play in the mast ...................................................................................... 6.15
Replacement, DTFV mast ............................................................................................ 6.16
Replacement, TFV mast ............................................................................................... 6.18
Replacement, TV mast ................................................................................................. 6.19
Replacement, T mast ................................................................................................... 6.20
Lift chains .......................................................................................................... 6.21
Replacement ................................................................................................................ 6.21
Re-fitting the chains ...................................................................................................... 6.21
Check ........................................................................................................................... 6.21
Forks .................................................................................................................. 6.23
Adjusting the lowest height on forged forks .................................................................. 6.23
Adjusting the lowest height on welded forks ................................................................ 6.23
Fork test ....................................................................................................................... 6.23
Fork carriage, general ....................................................................................... 6.26
Adjusting the fork carriage ............................................................................................ 6.26
Dismantling the fork carriage ........................................................................................ 6.26

ATLET SERVICE MANUAL A-ERGO

1.2

Fork carriage, telescopic forks, TF .....................................................................6.27

Dismantling the fork carriage TF .................................................................................. 6.27
Assembling the fork carriage TF ................................................................................... 6.30
Inspection after assembling the fork carriage TF ......................................................... 6.31
Adjusting the overload clutch (TF) ................................................................................ 6.32
Replacing the fork drive motor (TF) .............................................................................. 6.33
Replacing the coupling between fork drive motor and gearbox (TF) ............................ 6.33
Replacing the cabling, fork drive motor (TF) ................................................................ 6.34
Straddle lift .........................................................................................................6.35
Adjusting the straddle lift .............................................................................................. 6.35
Dismantling and assembling of straddle lift .................................................................. 6.36
Side stabilisers ...................................................................................................6.37
Checking the side stabiliser .......................................................................................... 6.37
Adjusting the length of side stabilisers ......................................................................... 6.37
Adjusting the end position switch, side stabilisers ........................................................ 6.38

Diagnosis and trouble shooting ..................................................................................6.39

Trouble shooting chart .......................................................................................6.39

ATLET SERVICE MANUAL A-ERGO

 Mast system / Design and function / Mast system 6.3

Edition 2009A

6 Mast system
Design and function

Mast system
There are four mast systems as standard versions, depending on the application or roof
height, etc.
Table 6.1 Mast types

Designation Description

T Telescopic mast

TV Telescopic Free-view mast

TFV Telescopic Free-lift Free-view mast

DTFV Double Telescopic Free-lift Free-view mast

A telescopic mast consists of an outer and inner mast, fork carriage and lift cylinder. The
fork carriage is lifted up and down in the inner mast, which in turn moves up and down
in the outer mast. The lift cylinder first lifts the fork carriage approx. 15 cm, and then the
mast system follows the lifting movement.
A mast of the double telescopic type also has, in addition to an inner and outer mast, an
intermediate mast. The lifting movement is the same as for a telescopic mast, and all the
masts begin to move up (or down) simultaneously.
A mast type with free-lift function works in a similar way, but with the difference that the
fork carriage moves to its top position in the inner mast before the next mast section starts
to lift. Free-lift frames can be used to advantage in rooms with low ceilings or low door
openings.
A mast of the free-view type implies that the distance between the mast profiles is longer,
which gives better visibility.

SMA-Ergo_06_2009A.fm
ATLET SERVICE MANUAL A-ERGO
6.4 Mast system / Design and function / Fork carriage

Fork carriage
Different fork arrangements are mounted on the back of the fork carriage. From simple
fixed forks to complex units with telescopic forks.

Fixed forks
Forks with a fixed width and length.

A-Ergo Gaffelvagn 2.eps

Figure 6.1 Fork carriage with fixed forks

Laterally adjustable forks

The forks can be adjusted to different widths.

A-Ergo Gaffelvagn 1.eps

Figure 6.2 Fork carriage with laterally adjustable forks

ATLET SERVICE MANUAL A-ERGO

 Mast system / Design and function / Fork carriage 6.5

Telescopic forks (TF)

The fork blades can be pushed out.

A-Ergo Gaffelvagn 3.eps

Figure 6.3 Fork carriage with extendable/telescopic forks

Overload clutch, telescopic forks (TF)

The ATF fork carriage has an overload clutch. The overload clutch is a unit that
safeguards against overloading the components that drive the forks in and out.
The torque that the overload clutch can transfer is limited by the force the pressure
springs, pos. 1, transfer to the pressure plate, pos. 2, and the brake linings, pos. 3, to the
sprocket, pos. 4, (see figure 6.4). For adjusting instructions, see "Adjusting the overload
clutch (TF)" on page 6.32.

4
2,6

3 2

06_001_A-Ergo_TFbroms.eps

Figure 6.4 Overload clutch

Fork drive motor, telescopic forks (TF)

The fork drive motor is mounted on the back of the fork carriage and has the purpose of
pushing the forks in and out so as to reach further forward. The transmission of power
between the motor and forks takes place via an angle gear and chain. The motor is
controlled via controls on the control panel.
For data on the motor, see the motor plate mounted on the motor.

ATLET SERVICE MANUAL A-ERGO

6.6 Mast system / Design and function / Straddle lift

Straddle lift
Straddle lift means that the straddle legs can be raised sufficiently high to lift a pallet from
the floor. With masts with straddle lift it is possible to transport a pallet on the fork
carriage, and if the fork carriage is raised high enough a pallet directly on the straddle
legs. This enables two pallets to be transported at the same time.

SM_A-Ergo_06_0001A.eps

Figure 6.5 Straddle lift

ATLET SERVICE MANUAL A-ERGO

 Mast system / Design and function / Side stabilisers 6.7

Side stabilisers
The truck can be fitted with extendable side stabilisers to guarantee lateral stability and
to eliminate the risk of tipping during high lifts. The system consists of extendable side
stabilisers, which are extended by means of the standard hydraulic unit.
A limit switch, i.e. a height position switch, on the mast limits the lifting height when the
stabilisers are withdrawn. When the stabilisers are extended a pressure switch gives a
signal that the forks can be lifted to their maximum position.

Important!
Driving with the side stabilisors extended involves certain risks.

If the truck is equipped with side stabilisers, then this is a safety function that must
be in operation and function correctly.

SM_A-Ergo_06_0002A_2009A.eps

Figure 6.6 Side stabilisers

ATLET SERVICE MANUAL A-ERGO

6.8 Mast system / Repair instructions / Replacing the mast/straddle legs

Repair instructions

Replacing the mast/straddle legs

Dismantle the mast/straddle legs from the chassis

1. Remove the battery.
2. Block up the chassis.

Bild f.eps

Figure 6.7 Blocking up the chassis

3. Support the mast to relieve the attachment.

Bild g.eps

Figure 6.8 Supporting the mast

ATLET SERVICE MANUAL A-ERGO

 Mast system / Repair instructions / Replacing the mast/straddle legs 6.9

If the mast has straddle lift:

Bild b.eps

Figure 6.9 Straddle lift

4. Screw a screw into one of the screw holes on the spacer between the
guide and chassis in order to hold up the spacer when dismantling.

06_014_A-Ergo_ LåsDist.eps

Figure 6.10 Screw, spacer/guides

5. Fix the guides with a strap to the mast.

06_010_A-Ergo_ LåsGejder.eps

Figure 6.11 Fix the guides

ATLET SERVICE MANUAL A-ERGO

6.10 Mast system / Repair instructions / Replacing the mast/straddle legs

6. Unscrew the screws for the attachment of the mast on the chassis.

06_007_A-Ergo_SkruvMastChassi.eps

Figure 6.12 Upper screw attachment, mast

7. Release the hydraulic connections.

Important!
Contain surplus hydraulic oil in a suitable way.

06_009_A-Ergo_ HydrAnsl.eps

Figure 6.13 Hydraulic connection

ATLET SERVICE MANUAL A-ERGO

 Mast system / Repair instructions / Replacing the mast/straddle legs 6.11

Mount the mast/straddle legs on the chassis

1. Make sure that the mast is suitably supported so that it cannot move.

Bild g.eps

Figure 6.14 Example of supported mast

If the mast has straddle lift:

2. Check that the guides are at the same level and fix them to the mast.

06_010_A-Ergo_ LåsGejder.eps

Figure 6.15 Fix the guides

ATLET SERVICE MANUAL A-ERGO

6.12 Mast system / Repair instructions / Replacing the mast/straddle legs

3. Make sure to screw tight the spacer between the mast and chassis in
the guide in one of the screw holes that are not used.

06_014_A-Ergo_ LåsDist.eps

Figure 6.16 Screw, spacer/guides

4. Insert a suitable number of shims, 3 as standard.

06_011_A-Ergo_ShimH jSt.eps

Figure 6.17 Shims

5. Lower the mast so that the link arms slide in under the chassis when
the mast and chassis are brought together.

6. Connect the hydraulic couplings together.

7. Bring the mast and chassis together and screw tight.
Tightening
torque:
277 Nm
8. The tightening torque between the frame and machine housing when refitting
should be 277 Nm.

ATLET SERVICE MANUAL A-ERGO

 Mast system / Repair instructions / Replacing the mast/straddle legs 6.13

If the mast has straddle lift:

9. Remove the strap and screw holding the spacer to the guides.

06_014_A-Ergo_ LåsDist.eps

Figure 6.18 Remove screw, spacer/guides

10. Check that the gap between the floor and forks is sufficient, see see
"Adjusting the straddle lift" on page 6.35.

ATLET SERVICE MANUAL A-ERGO

6.14 Mast system / Repair instructions / Dismantling the mast

Dismantling the mast

General
The following is generally applicable for all types of masts when dismantling:
• Stand in an area with adequate ceiling height and with approved lifting devices.
The following is generally applicable for all types of masts when assembling:
• The mast is assembled in the reverse order to dismantling.
Inspecting or repairing the mast system:
• Check that the thrust rollers lie flush with the roller surfaces on the mast. Check
also that they roll easily.
• An operating test must be made after each measure/action on the mast system. The
mast must not jam or run too slowly (the mast sections move in the wrong order)
when lifting and lowering.

Adjusting the lateral inclination in top position.

1. Lower the mast and slacken the chains.

2
2. Adjust the attachment of the outer cylinders with the
top nut, pos. 1. Adjust both cylinders equally so that
the mast does not pull skew.
3. If there is sufficient movement in the cylinder
attachment, the rollers will be in contact with the 1
running surfaces of the mast at all lifting heights.
4. Test the operation of the lifting movement. Lift up to
top position and check that the mast does not swing to
the side when the end position is reached.
5. Lock the top nut with the lock screw, pos. 2.
6. Tighten the chain and check that the rollers still make
contact with the runners.
7. The cylinder attachment should be flexible.
SM 094.2

8. Adjust the mast,see "Adjusting the play in the mast"

on page 6.15.

ATLET SERVICE MANUAL A-ERGO

 Mast system / Repair instructions / Dismantling the mast 6.15

Adjusting the play in the mast

The lateral play is adjusted with 0.5 or 1 millimetre shims behind the thrust rollers. If
there is excessive play between thrust roller and roller surface on the mast profile, the
thrust roller must be replaced with a new roller with a larger diameter.
Thrust rollers are available in three different diameters (the diameter is specified on each
roller):
160 mast:
• 78.2 mm, 78.6 mm 79.0 and 79.4 mm.
200 mast and TF-mast:
• 107.0 mm, 107.5 mm 108.0 mm, and 108.5 mm.

Table 6.2 Permitted play between roller surfaces on the mast

Mast type Permitted play between thrust rollers and roller surfaces between mast
sections and fork carriage and mast

160 0.5 mm

200 0.6 mm

TF 0.6 mm

ATLET SERVICE MANUAL A-ERGO

6.16 Mast system / Repair instructions / Dismantling the mast

Replacement, DTFV mast

1. Lower the fork carriage onto a European pool pallet, or the like, so that the
intermediate cylinder lift chain slackens.
2. Release the lift chain from the intermediate cylinder by releasing the chain bolt,
and remove the pin between the bolt and chain.
3. Lift the mast until the fork carriage comes free from the inner mast.
4. Place a wooden block on the straddle legs between the outer profiles so that it
comes under the intermediate cylinder. Lower the inner and intermediate mast so
that the inner mast rests on the wooden block and the outer chains slacken.
5. Remove the two outer chains by removing the pins in the upper chain attachment.
6. Release the hoses that run in the mast from the block in the outer mast, and plug them.
7. Remove the pulley wheel for the hoses from the intermediate mast.
8. Remove the pulley wheel for the chains from the intermediate mast.
9. Unscrew the screw for the lifting stop..

06_013_A-Ergo_SpärrDelaMast.eps

Figure 6.19 Screw, lifting stop

ATLET SERVICE MANUAL A-ERGO

 Mast system / Repair instructions / Dismantling the mast 6.17

10. Lift the inner mast straight up until the lower thrust roller on the inner mast and the
upper thrust roller on the intermediate mast meet, and then pull the inner mast
forwards to release it from the intermediate mast. If the ceiling is too low dismantle
the mast, see "Dismantle the mast/straddle legs from the chassis" on page 6.8, and
set it down.

06_012_A-Ergo_ DelaMast.eps

Figure 6.20 Position for dismantling intermediate masts

11. Remove the upper retaining screws for the side cylinders.
12. Lift out the intermediate mast in the same way as the inner mast.
Tightening
torque: 13. The tightening torque between the frame and machine housing when refitting
277 Nm
should be 277 Nm.

ATLET SERVICE MANUAL A-ERGO

6.18 Mast system / Repair instructions / Dismantling the mast

Replacement, TFV mast

1. Lower the fork carriage onto a European pool pallet, or the like, so that the
intermediate cylinder lift chain slackens.
2. Release the lift chain from the intermediate cylinder by releasing the chain bolt,
and remove the pin between the bolt and chain.
3. Lift the mast until the fork carriage comes free from the inner mast.
4. Lower down the mast to its bottom position.
5. Release the hose from the outer mast and plug it. Remember to remove the cable ties.
6. Remove the upper retaining screws for the side cylinders.
7. Lift the inner mast straight up until the lower thrust roller on the inner mast and the
upper thrust roller on the outer mast meet, and then pull the inner mast forwards to
release it from the outer mast. If the ceiling is too low dismantle the mast, see
"Dismantle the mast/straddle legs from the chassis" on page 6.8, and set it down.

06_012_A-Ergo_ DelaMast.eps

Figure 6.21 Position for dismantling intermediate masts

Tightening
torque: 8. The tightening torque between the frame and machine housing when refitting
277 Nm
should be 277 Nm.

ATLET SERVICE MANUAL A-ERGO

 Mast system / Repair instructions / Dismantling the mast 6.19

Replacement, TV mast
1. Lower the fork carriage onto a European pool pallet, or the like, so that the lift
chains slacken.
2. Release the lift chains from the outer mast by removing the upper pins.
3. Lift until the fork carriage comes free from the inner mast.
4. Lower down the mast to its bottom position.
5. Remove the upper retaining screws for the side cylinders.
6. Lift the inner mast straight up until the lower thrust roller on the inner mast and the
upper thrust roller on the outer mast meet, and then pull the inner mast forwards to
release it from the outer mast. If the ceiling is too low dismantle the mast, see
"Dismantle the mast/straddle legs from the chassis" on page 6.8, and set it down.

06_012_A-Ergo_ DelaMast.eps

Figure 6.22 Position for dismantling intermediate masts

Tightening
torque: 7. The tightening torque between the frame and machine housing when refitting
277 Nm should be 277 Nm.

ATLET SERVICE MANUAL A-ERGO

6.20 Mast system / Repair instructions / Dismantling the mast

Replacement, T mast
1. Lower the fork carriage onto a European pool pallet, or the like, so that the
intermediate cylinder lift chain slackens.
2. Release the lift chain from the intermediate cylinder by releasing the chain bolt,
and remove the pin between the bolt and chain.
3. Lift until the fork carriage comes free from the inner mast.
4. Lower down the mast to its bottom position.
5. Secure the lift cylinder so that it cannot move sideways.
6. Remove and plug the oil pipes.
7. Release the upper retaining bolts on the lift cylinder from the inner mast.
8. Remove the lower retaining screw.
9. Carefully lift up the inner mast until it can be lifted out from the cylinder.
10. Lift the inner mast straight up until the lower thrust roller on the inner mast and the
upper thrust roller on the outer mast meet, and then pull the inner mast forwards to
release it from the outer mast. If the ceiling is too low dismantle the mast, see
"Dismantle the mast/straddle legs from the chassis" on page 6.8, and set it down.

06_012_A-Ergo_ DelaMast.eps

Figure 6.23 Position for dismantling intermediate masts

Tightening
torque:
11. The tightening torque between the frame and machine housing when refitting
277 Nm should be 277 Nm.

ATLET SERVICE MANUAL A-ERGO

 Mast system / Repair instructions / Lift chains 6.21

Lift chains

Replacement
1. Remove the stop screw in the inner mast, where appropriate.

06_013_A-Ergo_SpärrDelaMast.eps

Figure 6.24 Screw, lifting stop

2. Lower down the fork carriage onto a European pool pallet, or the like, so that the
chain slackens.
3. Remove the lift chain.

Re-fitting the chains

When chains are re-fitted it is important to align them correctly and to ensure there is no
deterioration of the clearance.

Check
• Check that the chain is clean. Measure when the forks are unloaded.
• Measure the elongation of the chain; measure over the 25 links that go over the
pulley wheel, since elongation is normally greatest here. Compare with the
measurements below. If the elongation of the chain is more than 2 % it should be
replaced.

ATLET SERVICE MANUAL A-ERGO

6.22 Mast system / Repair instructions / Lift chains

P P

G
SM 169.1

Figure 6.25 Measuring positions

Table 6.3 Chain dimension

Chain P (nominal) P (true) Measureed over Max over

dimension Pitch True pitch 25 links New 25 links
(inches) dimension dimension chain 2% elongation
(mm) (mm) (mm) (mm)

1/2”-2*2 12.70 12.59 314.75 321.05

5/8”-4*4 15.88 15.875 396.88 404.81

3/4”-3*4 19.05 19.05 476.25 485.78

3/4”-4*4 19.05 18.91 472.75 482.21

1”-4*4 25.40 25.32 633.00 645.66

1 1/4”-4*4 31.75 31.54 788.50 804.27

1 1/2”-4*4 38.10 38.06 951.50 970.53

• Measure the height of the chain link plates, dimension G in figure 6.25. Max wear
is 5%. Measure the original height where the chain is not worn as a comparison.

Example: A chain has an original plate height of 23.2 mm, and therefore the plate
height should be at least 23.2 - 5% = 23.2 x 0.95 = 22 mm.
• Make sure than none of the pins in the plates have twisted, see 6.26.

A B

SM 169.2

Figure 6.26 Twisted pin

• Make sure that there are no cracks in the plates.

• Look for traces of mechanical damage or rust.
• Check that the chain runs easily over the pulley wheel and does not jam.
• Lubricate the chain after cleaning and inspection.

ATLET SERVICE MANUAL A-ERGO

 Mast system / Repair instructions / Forks 6.23

Forks

Adjusting the lowest height on forged forks

1. The inner and outer masts should be lowered.
2. Adjust the two outer lift chains so that the mast hangs a little from the lift chains.
3. Adjust the middle chain so that the fork head is 5 ± 2 mm from the ground
(see figure 6.27).
5 2

SM 075.1

Figure 6.27 Distance from floor

Adjusting the lowest height on welded forks

1. The inner and outer masts should be lowered.
2. Adjust the two outer lift chains so that the mast hangs a little from the lift chains.
3. Adjust the chains so that the fork height is as shown in table 6.4.
Fork height in lowered position:
Table 6.4 Height of forks over floor in rest position

Mast type Min Max (mm)

A-Ergo 160 controlled by ground clearance 89

A-Ergo 200 controlled by ground clearance 91

A-Ergo Telescopic forks (TF) controlled by ground clearance 73

Fork test
Seven inspection points are included in the fork test. If the forks fail to meet any of the
points, the machine must be taken out of service. If the customer is not prepared to do
this, it should be written in the report that “The forks do not comply with the requirements
in SS-ISO/ 5057”. When the customer subsequently signs the service order, they bear the
responsibility for the defective forks.

Important!
The truck must pass the fork test to comply with SS-ISO/5057.

ATLET SERVICE MANUAL A-ERGO

6.24 Mast system / Repair instructions / Forks

1. Straightness of the blades and shanks:Deviations from the straightness of the

carrier surface and the support surface must not exceed 0.5% of the length of the
blade and shank. See figure6.28.

L = 1150 mm, max deviation 5.75 mm.

L = 950 mm, max deviation 4.75 mm.
L = 800 mm, max deviation 4.00 mm.
h = 492 mm, max deviation 2.46 mm.
h = 464 mm, max deviation 2.32 mm.

2. Crack formation: Check whether the forks are cracked. Check carefully around
the heel and hooks. See figure6.28.
3. Wear: Check the forks for wear, especially around the heel. The blade thickness
must not be thinner than 90% of the original thickness.

The original thickness is found by:

• Reading the marking on old forks.
• Measuring the blade thickness in the centre of the shank.
• Contacting Atlet for information about blade thickness.

4. Fork angle: The angle,α, between the blade and the shank must be max 93
degrees. See figure6.28.
5. Difference in height between the tips of the forks:The difference in height, dH,
between the tips must not exceed 3% of the blade length. See figure6.28.
6. Locking device: Check that the locking device works.
7. Markings: The fork markings should be explicit and include the lifting capacity in kg
for one fork and the distance to the centre of gravity in mm. See pos. 8 in figure 6.28.

ATLET SERVICE MANUAL A-ERGO

 Mast system / Repair instructions / Forks 6.25

5 h

2
6
1 3
8
xx
7
L xx

xx
xx
S

A
dH

A-Ergo Marking Fork.eps

Figure 6.28 Fork designations

Explanation of figure

Position Explanation Position Explanation Position Explanation

1 Thickness 5 Shank A Carrier

surface

2 Tip 6 Hook h Height

3 Blade 7 Heel dH Difference

in height

4 Thickness 8 Marking L Length

S Support
surface

ATLET SERVICE MANUAL A-ERGO

6.26 Mast system / Repair instructions / Fork carriage, general

Fork carriage, general

Adjusting the fork carriage

1. The thrust rollers have a specific clearance to the roller surfaces.
2. The lateral play is adjusted by adjusting the number of shims behind the load
rollers, and by replacing the rollers.
For permitted play, see "Adjusting the play in the mast" on page 6.15.

Dismantling the fork carriage

1. Lower down the fork carriage on a European pallet, or the like.
2. Remove the lift chain.
3. Lift up the inner mast with standard hydraulic system until the fork carriage
is released.

Important!
Observe great caution!

4. Reverse the truck away.

ATLET SERVICE MANUAL A-ERGO

 Mast system / Repair instructions / Fork carriage, telescopic forks, TF 6.27

Fork carriage, telescopic forks, TF

Dismantling the fork carriage TF

The fork carriage only needs to be lifted out of the frame when replacing fork carriage
rollers. To lift out, see the instructions for dismantling the type of frame the truck is
equipped with.
1. Lift the fork carriage to a suitable height to dismantle the over-cogging protection
on the back of the fork carriage, see figure6.29.

06_016-1_A-Ergo_ TFgafflar.eps

Figure 6.29 Over-cogging protection

2. Lower the fork carriage to a suitable height to achieve a comfortable working

position, and make sure that the forks are fully withdrawn.
3. Pull the battery plug out from the electrical panel plug to disconnect the power to
the electrical system.
4. Release the flexible cable to the fork drive motor by loosening the two nuts that
hold the motor end head, and then remove the cables connections to the motor.

ATLET SERVICE MANUAL A-ERGO

6.28 Mast system / Repair instructions / Fork carriage, telescopic forks, TF

5. Release the bolts, pos. 1, just enough to be able to adjust the chain tensioning bolt,
pos. 2. Screw the bolt to the left so that the chain slackens and the chain lock,
pos. 3 and 4, can be removed, see figure6.30.

2 3

97

1
06_016-2_A-Ergo_ TFgafflar.eps

Figure 6.30 Chain tensioning bolt

6. Loosen the bolts completely and lift off the drive assembly.
7. Unscrew the screws on the forks and pull off the forks, see figure 6.31.

06_016-3_A-Ergo_ TFgafflar.eps

Figure 6.31 Fork attachment

ATLET SERVICE MANUAL A-ERGO

 Mast system / Repair instructions / Fork carriage, telescopic forks, TF 6.29

8. Release the chain adjuster, pos. 1 figure6.32.

3
2
1

06_016-4_A-Ergo_ TFgafflar.eps

Figure 6.32 Chain adjuster

9. Remove the chain lock, pos. 2, and remove the chains, pos. 3 figure6.32.
10. Remove the sprockets in the tips of the inner forks.
11. Remove the side thrust rollers, figure 6.33.

06_016-5_A-Ergo_ TFgafflar.eps

Figure 6.33 Side thrust rollers

ATLET SERVICE MANUAL A-ERGO

6.30 Mast system / Repair instructions / Fork carriage, telescopic forks, TF

12. Remove the outer circlips holding the side bearing for the shaft, pos. 16.34.

97

2
1

06_016-6_A-Ergo_ TFgafflar.eps

Figure 6.34 Outer circlips for side bearing and intermediate bearing

13. Loosen the intermediate bearing, pos. 2 figure6.34. Drive the shaft to one side so
that the side bearing can be pressed out of the fork carriage. Remove the bearing
and lift the shaft out from the fork carriage.
14. Note the order in which the gear, circlips and spacers are fitted, and then work
them off.

Assembling the fork carriage TF

1. Fit the sprockets in the tips of the inner forks. Lightly grease the bearing inside and
outside before fitting.
2. Fit the rear shaft with sprocket, stop rings and bearing housing. Check that the
shaft is not tensioned skew by rotating it by hand at least one turn in each direction.
3. Fit and adjust the fork chains so that they run parallel with the sprockets, and so
that they give 2-4 mm in the middle. Lock the sprockets, stop rings and chain
tensioners. Lightly grease the chains along their entire length.
4. Fit the over-cogging guard.

ATLET SERVICE MANUAL A-ERGO

 Mast system / Repair instructions / Fork carriage, telescopic forks, TF 6.31

5. Fit and adjust the roller attachments by using a fork, so that the play is less than 0.3
mm. Make sure that the forks are centred on the inner forks. Remember to lock
with the screws.
6. Lightly grease all the roller surfaces along their entire length, and fit the forks.
7. Fit the complete motor. Fit and adjust the lower motor chain so that it runs parallel
between the sprockets, and so that it gives 2-4 mm in the middle. Lock the motor
attachment and the sprocket. Lightly grease the chain along its entire length.
8. Remove the plug in the gearbox and check the oil level, which should reach to the
centre of the output shaft. Top up if necessary.

Inspection after assembling the fork carriage TF

Test run the fork carriage and check that:
• the forks do not jam.
• the forks go fully in and out.
• the chains run parallel between the sprockets.
• there is no abnormal noise.
• the overload clutch slips in the end positions

ATLET SERVICE MANUAL A-ERGO

6.32 Mast system / Repair instructions / Fork carriage, telescopic forks, TF

Adjusting the overload clutch (TF)

The spring tension is not adjustable since the tensioning nut, pos. 1, should be fully
screwed in and locked with stop screws. The bearing, pos. 2, and sprocket, pos. 3, should
be lightly lubricated with cold-resistant grease (-35°C), see figure6.35.

Warning!
There must not be any grease on the friction linings.
If the overload clutch is damaged, it must be completely replaced.

3 2,6

06_002_A-Ergo_TFbroms.eps

Figure 6.35 Overload clutch

ATLET SERVICE MANUAL A-ERGO

 Mast system / Repair instructions / Fork carriage, telescopic forks, TF 6.33

Replacing the fork drive motor (TF)

1. Release the cable bracket and the cover over the motor, and lift them off.
2. Note the connection of the electric cables, and release them.
3. Loosen the bolts.
4. Lift the motor straight up.

06_015_A-Ergo_ TFmotor.eps

Figure 6.36 Fork drive motor and gearbox

Replacing the coupling between fork drive motor and gearbox (TF)
1. Dismantle the motor, see see "Replacing the fork drive motor (TF)" on page 6.33.
2. Release the coupling by unscrewing the stop screw, and pull off the coupling.
3. Push on a new one and tighten it with the stop screw.
4. Loosen and pull off the coupling half located in the gear, and fit a new one.
5. Fit the motor, connect the cables, and test drive.

ATLET SERVICE MANUAL A-ERGO

6.34 Mast system / Repair instructions / Fork carriage, telescopic forks, TF

Replacing the cabling, fork drive motor (TF)

1. Lift the forks approx. one metre above the floor.
2. Release the bracket holding the electric cable at the motor.
3. Remove the cover over the drive motor end, where the electric cable goes in.
4. Remove the panel over the component box, including all the clips holding the cable.
5. Check the markings and positioning of the electric cables.
6. Release the cable and pull it out.
7. Move the springs over to the new cable, put it in place, and connect it.
8. Fit the cover and bracket over the drive motor.
9. Clamp the cable secure, lift the forks a number of times, and check that it is not
clenched, catches, or rubs against something.
10. Fit the panels.

ATLET SERVICE MANUAL A-ERGO

 Mast system / Repair instructions / Straddle lift 6.35

Straddle lift

Adjusting the straddle lift

1. Place the truck on a level floor and lower the forks and the adjustable straddle lift.
2. Check that the distance between the floor and top of the forks corresponds with
table 6.5 below. Measure at four points:
- at each fork tip
- at the back of the fork on each side
3. Check that the distance is the same between mast and guides. If necessary adjust to
the same distance with the adjusting screws, both at the top and bottom.
4. The lateral play in the mast should be max 0-0.5 mm. Because of the inexactitude
in the linearity of the mast section a play of max 1.5 mm is permitted at the “worst
point”, raised or lowered.
This means that if for example the play is 0.5 mm with the straddle lift raised, the
play with the straddle lift it its lower position should be max 1.5 mm, and the
reverse.
5. Check the play between the roller surfaces on the mast and guides. For permitted
play see "Adjusting the play in the mast" on page 6.15, 160 mast.
6. Check that the forks are horizontal.
7. If the fork tips point upwards the shims over the pressure plate should be removed
(on the assumption that the forks are straight).
8. If the fork tips point downwards shims should be added over the pressure plate (on
the assumption that the forks are straight).

06_011_A-Ergo_ShimH jSt.eps

Figure 6.37 Positioning of shims

9. When the forks are parallel, check the height. The cylinders can be extended if it is
not high enough.
10. Test lift, and check that the straddle lift does not lift skew. If so, adjust the length of
the cylinders until the best lifting movement is obtained.
11. Check measure, and if necessary make further adjustments.

ATLET SERVICE MANUAL A-ERGO

6.36 Mast system / Repair instructions / Straddle lift

Table 6.5 Height measurements for adjustable straddle lift/forks

Truck with straddle lift

Distance to top of fork Max 95 mm

Distance to top of straddle leg Max 90 mm

Min 85 mm

Dismantling and assembling of straddle lift

1. Lift up the straddle lift with the truck. Place a block under the tips of the straddle
lift and lower down the straddle lift, whereby the load wheel lifts from the floor.
2. Tap out the retaining pin through the shaft and drive out the shaft holding the wheel
fork.
3. Tap out the retaining pin at the pressure link arm and pull out the load wheel, pull
rods and pressure link arm complete.
4. Tap out the shafts from the ends of the pull rods.
5. Check for wear and replace damaged parts if necessary.
6. Assemble in the reverse order.
7. Check the lifting movement. If the straddle lift pulls at an angle it must be
adjusted, see section "Adjusting the straddle lift" page 6.35.

ATLET SERVICE MANUAL A-ERGO

 Mast system / Repair instructions / Side stabilisers 6.37

Side stabilisers

Checking the side stabiliser

1. Place the truck on a level surface.
2. Fix a tape measure with the zero at the top edge of one fork. Lift until the stabiliser
switch in the mast breaks, i.e. until the mast stops, and measure the height. Lift
height should be at 3000 mm +/- 25 mm.
3. Extend the stabilisers until the motor stops. Check that the wheels are pressed
against the floor and check the residual suspension. See table 6.6.

Table 6.6 Reference values for side stabilisers

Reference values for side stabilisers

When the stabilisers are extended at full speed the spring should compress
4-9 mm, when the pump motor has stopped. Irregularities in the floor are
absorbed by the spring in the top of the cylinder, see figure 6.38 below.

Residual suspension with fully extended stabilisers and a 5-10 mm

level floor.

06_003_A-Ergo_SidoStab.eps

Figure 6.38 Check points for side stabilisers

Adjusting the length of side stabilisers

• Mechanical adjustment is made by adjusting the lower end of the piston.

ATLET SERVICE MANUAL A-ERGO

6.38 Mast system / Diagnosis and trouble shooting / Trouble shooting chart

Diagnosis and trouble shooting

Trouble shooting chart

0

Table 6.7 Symptom/Action table

Symptom Possible reason Action

Play in mast. Too few shims on mast rollers. Re-shim.

The mast lowers Too many shims on mast rollers. Re-shim.

unevenly, jumps.
No grease on the mast roller surfaces. Grease roller surfaces.

The mast squeaks. No grease on the mast roller surfaces. Grease roller surfaces.

ATLET SERVICE MANUAL A-ERGO

 SERVICEMANUAL
Machine: A-Ergo

Manual No: 005975

Edition 2002B

7 Steering

Design and function ....................................................................................................... 7.3

General ................................................................................................................ 7.3
Steering ............................................................................................................... 7.3
Regulator, steering servo motor .......................................................................... 7.4

Repair instructions ......................................................................................................... 7.5

Steering wheel, step motor sensor ...................................................................... 7.5
Replacement .................................................................................................................. 7.5
Steering servo motor with gearbox ...................................................................... 7.5
Dismantling ..................................................................................................................... 7.5
Replacing the steering servo sensor ................................................................... 7.6

Diagnosis and trouble shooting ................................................................................... 7.7

ATLET SERVICE MANUAL A-ERGO

7.2

ATLET SERVICE MANUAL A-ERGO

 Steering / Design and function / General 7.3

Edition 2002B

7 Steering
Design and function

General
The steering movement is transferred completely electronically, without mechanical
connection between the steering wheel and wheel. The system consists of steering wheel,
regulator, steering servo unit and servo motor. A monitoring system is built into the
steering servo unit, which stops the truck if an electrical fault occurs in the regulator.

Steering
The steering wheel is mounted in a vertically adjustable panel to allow the best possible
adjustment. The steering wheel has no mechancial contact with the wheel. All the
steering takes place by means of a sensor in the form of a step motor under the steering
wheel. The sensor gives a signal to the servo steering regulator, which converts the signal
to a drive voltage for the steering servo motor to turn to the right or left, depending on the
direction of rotation of the steering wheel, see section 10.
The steering servo motor is of the 3-phase induction motor type. The turning movement
is limited by means of two limit switches, S4 and S5. These are placed in the motor bed
and stop the turning movement before the mechanical end stop is reached.
To maintain control of the acceleration during hard turns there is also a 45° sensor, S8,
on some trucks, placed in the motor bed..

S8
S4, S5

07_004_SM_A-Ergo_S4S5S8.eps

Figure 7.1 Limit switch S4 and S5.

SMA-Ergo_07_2002B.fm
ATLET SERVICE MANUAL A-ERGO
7.4 Steering / Design and function / Regulator, steering servo motor

Regulator, steering servo motor

For information concerning regulators, see section 10.

ATLET SERVICE MANUAL A-ERGO

 Steering / Repair instructions / Steering wheel, step motor sensor 7.5

Repair instructions

Steering wheel, step motor sensor

Replacement

07_003_SM_A-ERGO_RattPulsgiv.eps

Figure 7.2 Position of step motor sensor

1. Remove the steering wheel panel and turn it upside down, see section 4
for instructions.
2. Remove the cables to the steering wheel sensor.
3. Unscrew the steering wheel sensor.
4. Lift over the fixed components to the new steering wheel sensor.
5. Connect the steering wheel sensor and refit the panel.

Steering servo motor with gearbox

Dismantling
1. Move away the power panel, see section 10.
2. Remove the cables to the steering servo motor.

ATLET SERVICE MANUAL A-ERGO

7.6 Steering / Repair instructions / Replacing the steering servo sensor

3. Unscrew the steering servo motor from the motor bed..

07_001_SM_A-ERGO.eps

Figure 7.3

4. Unscrew the steering servo motor gearbox and carefully release it; the component
gears are loose.

Important!
Carefully release the gearbox, the component gears are loose.

Replacing the steering servo sensor

See section 10.

ATLET SERVICE MANUAL A-ERGO

 Steering / Diagnosis and trouble shooting / Replacing the steering servo sensor 7.7

Diagnosis and trouble shooting

See section 10 for trouble shooting of the steering servo system.

ATLET SERVICE MANUAL A-ERGO

7.8 Steering / Diagnosis and trouble shooting / Replacing the steering servo sensor

ATLET SERVICE MANUAL A-ERGO

 SERVICE MANUAL
Machine: A-Ergo

Manual No: 005975

Edition 2009A

8 Hydraulic system

Design and function ....................................................................................................... 8.1

General ................................................................................................................ 8.1
Lift ................................................................................................................................... 8.1
Lower .............................................................................................................................. 8.1
Hose rupture valve .............................................................................................. 8.2
Lowering brake valve ........................................................................................... 8.2
Mechanical control valve ..................................................................................... 8.2
General ........................................................................................................................... 8.2
Lifting function ................................................................................................................ 8.2
Lowering function ........................................................................................................... 8.2
Electric control valve ............................................................................................ 8.2
General ........................................................................................................................... 8.2
Lifting function ................................................................................................................ 8.3
Lowering function ........................................................................................................... 8.3
Lowering brake function ................................................................................................. 8.3
Hydraulic diagram ................................................................................................ 8.3
Hydraulic diagram, Manual valve 104014 (–2008w45) .................................................. 8.4
Hydraulic diagram, Manual valve 104014 (2008w46–) .................................................. 8.6
Hydraulic diagram, Proportional valve 104005 (–2008w45) ........................................... 8.8
Hydraulic diagram, Proportional valve 104005 (2008w46–) ......................................... 8.10
Hydraulic diagram, ALL 104913 ................................................................................... 8.12

Repair instructions ....................................................................................................... 8.14

Hydraulic system ............................................................................................... 8.14
General rules ................................................................................................................ 8.14
Installation .................................................................................................................... 8.14
Connections ................................................................................................................. 8.15
Start up ......................................................................................................................... 8.15
Hydraulic oil, changing/draining ......................................................................... 8.16
Properties of the hydraulic oil ....................................................................................... 8.16
Requisite equipment ..................................................................................................... 8.16
Procedure ..................................................................................................................... 8.17
Air filter, replacing .............................................................................................. 8.18
Oil filter insert, replacement ............................................................................... 8.19
Checking the hydraulic oil level ......................................................................... 8.20

ATLET SERVICE MANUAL A-ERGO

8.2

Lowering brake valve .........................................................................................8.21

Dismantling and assembling ......................................................................................... 8.21
Hose rupture valve .............................................................................................8.23
Dismantling and assembling ......................................................................................... 8.23
Control valve ......................................................................................................8.25
General instructions when working with control valve .................................................. 8.25
Manually operated hydraulic valve, dismantling and assembling ................................. 8.26
Electrically operated control valve, dismantling and assembling .................................. 8.27
Checking the lowering speed ....................................................................................... 8.28
Adjusting the regulator, electric valve ........................................................................... 8.28
Adjusting the lowering speed valve in the electric hydraulic valve ............................... 8.28
Adjusting the working pressure .................................................................................... 8.29
Emergency lowering valve ............................................................................................ 8.29
Hydraulic pump motor ........................................................................................8.30
Dismantling the hydraulic pump motor ......................................................................... 8.30
Hydraulic pump motor ALL ................................................................................8.31
When should the brushes be replaced? ....................................................................... 8.31
Replacing the brushes .................................................................................................. 8.31
Tips to prolong the service-life of the motor ................................................................. 8.33
Stabiliser cylinders .............................................................................................8.34
Dismantling and assembling the stabiliser cylinders .................................................... 8.34
Dismantling and assembling, gaskets .......................................................................... 8.34
...................................................................................................................................... 8.34
Installation instruction for pipe couplings ...........................................................8.35

Diagnosis and trouble shooting ..................................................................................8.38

Symptom and Action ..........................................................................................8.38

ATLET SERVICE MANUAL A-ERGO

 Hydraulic system / Design and function / General 8.1

Edition 2009A

8 Hydraulic system
Design and function

General

Lift
The driver operates a lift lever or alternatively a proportional electric lever that actuates
a microswitch, which in turn actuates the lift motor by means of a contactor. The motor
drives the built-in hydraulic pump, which pumps hydraulic oil to the lift cylinders. The
lift lever/electric lever also controls a control value, which controls the oil flow to the
cylinder performing the work.
In the control valve there is a pressure limiting 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. A pressure limiting valve opens when the maximum system
pressure has been reached , which leads the oil from the pump back to the tank. The
opening pressure of the pressure limiting valve is set at the factory so that the machine
will be able to do the work it is designed for.

Warning!
The pressure limiting valve must only be adjusted by authorised and trained
personnel, since it is essential for the safety of the truck. All work with the hydraulic
system should be carried out in a pressureless state, and in a clean environment.

Lower
When the lowering movement is controlled manually by means of a lever there is a
lowering brake valve placed between the control valve and the cylinder, which regulates
the lowering speed by restricting the return of the hydraulic oil.
In those cases where the lifting and lowering movement is regulated by means of an
electric control valve the lowering brake valve is integrated in the control valve. When
the lowering movement is actuated the oil from the cylinder is led through the control
valve back to the tank when the cylinder is retracted by the weight of the fork carriage.
On certain cylinders there is also a hose rupture valve, which provides protection from
accidents during the uncontrolled discharge of oil.

SMA-Ergo_08_2009A.fm
SERVICE MANUAL A-ERGO
8.2 Hydraulic system / Design and function / Hose rupture valve

Hose rupture valve

Hose rupture valves, the purpose of which is to prevent the forks dropping down out of
control if for example a hydraulic hose ruptures, are fitted in most of the lift and stabiliser
cylinders. They are placed in front of the nipple connected for the supply of hydraulic oil.
In the free-lift cylinder a lowering brake valve is normally fitted instead.

Lowering brake valve

The lowering brake valve regulates the lowering speed and is mounted in a valve housing,
placed in the lower section of the mast. It controls the lowering speed of the cylinders
(TV, TFV, DTFV cylinders). For free-lift there is a lowering brake valve in the bottom of
the free-lift cylinder (T cylinder).
The valve is set at the factory, but may subsequently be adjusted. Check the lowering
speed in relation to table 8.2 before repairing or adjusting.
There are no external lowering brake valves on trucks equipped with electric control
valves and they are integrated as a function in the control valve instead, see "Electric
control valve" on page 8.2. On these trucks there should be a hose rupture valve.

Mechanical control valve

General
The control valve controls the lifting and lowering movements of the truck. The lifting
and lowering speed is proportional to the operation of the control lever.

Lifting function
The pump provides pressure to the lift cylinders through the open control valve. If the lift
cylinders are obstructed, have an excessive load, or if there is a fault on the control valve
so that it does not open, the oil will return to the tank through the pressure limiting valve.

Lowering function
The control valve opens to release the oil from the lift cylinders. When the fork carriage
presses down the lift cylinder the oil flow goes through the lowering brake valve, which
regulates the lowering speed, see table "Adjusting the lowering brake valve" on page 8.22.

Electric control valve

General
The control valve controls the lifting and lowering movements of the truck. The lifting
and lowering speed is proportional to the operation of the control lever.

SERVICE MANUAL A-ERGO

 Hydraulic system / Design and function / Hydraulic diagram 8.3

Lifting function
The pump supplies pressure to the control valve, which in turn closes the pressure
chamber completely. This pressure also opens the non-return valve and then continues
through the open proportional valve to the lift cylinders If the lift cylinders are obstructed,
have an excessive load, or if there is a fault on the proportional valve so that it does not
open, the oil will return to the tank through the pressure limiting valve.

Lowering function
The control valve opens to release the oil from the lift cylinders. Since the non-return
valve is closed, the only way out for the oil is through the pressure chamber. The flow
through the pressure chamber is in turn controlled by the pressure difference over the feed
restriction in the proportional valve, since the control valve does not receive pressure
from the pump.

Lowering brake function

The pressure chamber is the heart of the electrical control valve.

Important!
It is set at the factory and should NEVER be altered.

The feed restriction in the proportional valve has a stroke length limit, which can be set
from outside. The stroke length limit governs the maximum lowering speed.
The pressure chamber maintains a constant pressure drop over the feed restriction in the
proportional valve during lowering. This enables the lowering speed to remain constant
regardless of the load, and therefore no external lowering brake valves are required.

Hydraulic diagram
Table 8.1 List of hydraulic diagrams for A-Ergo

Description Page

Hydraulic diagram, Manual valve 104014 (–2008w45) 8.4

Hydraulic diagram, Manual valve 104014 (2008w46–) 8.6

Hydraulic diagram, Proportional valve 104005 (–2008w45) 8.8

Hydraulic diagram, Proportional valve 104005 (2008w46–) 8.10

Hydraulic diagram, ALL 104913 8.12

SERVICE MANUAL A-ERGO

8.4 Hydraulic system / Design and function / Hydraulic diagram

Hydraulic diagram, Manual valve 104014 (–2008w45)

SERVICE MANUAL A-ERGO

Hydraulic system / Design and function / Hydraulic diagram 8.5

SERVICE MANUAL A-ERGO

8.6 Hydraulic system / Design and function / Hydraulic diagram

Hydraulic diagram, Manual valve 104014 (2008w46–)

SERVICE MANUAL A-ERGO

Hydraulic system / Design and function / Hydraulic diagram 8.7

SERVICE MANUAL A-ERGO

8.8 Hydraulic system / Design and function / Hydraulic diagram

Hydraulic diagram, Proportional valve 104005 (–2008w45)

SERVICE MANUAL A-ERGO

8.9 Hydraulic system / Design and function / Hydraulic diagram

SERVICE MANUAL A-ERGO

8.10 Hydraulic system / Design and function / Hydraulic diagram

Hydraulic diagram, Proportional valve 104005 (2008w46–)

SERVICE MANUAL A-ERGO

Hydraulic system / Design and function / Hydraulic diagram 8.11

SERVICE MANUAL A-ERGO

8.12 Hydraulic system / Design and function / Hydraulic diagram

Hydraulic diagram, ALL 104913

SERVICE MANUAL A-ERGO

Hydraulic system / Design and function / Hydraulic diagram 8.13

SERVICE MANUAL A-ERGO

8.14 Hydraulic system / Repair instructions / Hydraulic system

Repair instructions

Hydraulic system

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 the components.

• Do not use cloths that shred fibres or particles.
• Only use clean tools.
• Carefully clean tanks, pipes and hoses before installation.
• Welded or hot-bent pipes must be pickled (cleaning with acid bath) and washed
before they are built in.
• The oil tank must be sealed and provided with an efficient air filter to prevent dirt
contaminating the hydraulic system.
• 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 out in a pressureless state and
in a clean environment.

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 informa-
tion is lacking the torque should not exceed the tightening torque specified in section 1.

SERVICE MANUAL A-ERGO

 Hydraulic system / Repair instructions / Hydraulic system 8.15

Connections
Couplings should be fitted according to the tightening torque specified in section 1. We
recommend couplings with elastic seals. Such couplings are necessary for control valves.
Ring couplings do not seal at the low torque generally applicable for proportional valves.
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,

Start up
Check that everything is connected in accordance with the hydraulic diagram. Set the
pressure limiting 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. Clean the system by allowing the oil to pass
over the filter for a while, without loading the system (replace the filter insert at the
recommended intervals). 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; abnormal noise indicates defects. Test
during variable loads that components are correctly fitted, and that the system is tight.
In the event of the return of 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 component, not loose parts.

SERVICE MANUAL A-ERGO

8.16 Hydraulic system / Repair instructions / Hydraulic oil, changing/draining

Hydraulic oil, changing/draining

Properties of the hydraulic oil

The hydraulic oil recommend in this manual, section 1, has properties that promote a long
service-life and first-rate functionality, and should be the oil used in the truck. The
hydraulic oil used in Atlet trucks should comply with Atlet quality requirements:
• Smooth and uninterrupted flow without abrasion.
• Long service-life.
• High viscosity index with wide range of temperature applications.
• First-rate low temperature properties.
• High filterability.
• First-rate capacity to separate air and water.
• First-rate wear protection.
• First-rate oxidation stability.
• Negligible foaming.
• Protection from rust and corrosion.
• First-rate adhesive capacity.

Requisite equipment
• New oil, or purifying equipment for the old oil.
• A tray to collect the oil in.
• A clamp or plug for the suction pipe.

SERVICE MANUAL A-ERGO

 Hydraulic system / Repair instructions / Hydraulic oil, changing/draining 8.17

Procedure
1. Lower down the forks and disconnect the battery electrically.
2. Lift up the steering wheel panel and pull out the machine housing cover.
3. Check how much oil needs to be filled by checking the oil level (the level differs
between different truck variants).
4. Lower the forks to their lowest position and disconnect the battery electrically.
5. Place the tray on the floor behind the truck.
6. Clamp the suction pipe between the pump and tank, release the suction hose from
the pump and lead it to the tray, and then release the clamp so that the oil runs out.

Important!
Make sure that the oil does not overflow in the tray. The oil should be taken care of
in accordance with environmental legislation.

Filters are always replaced when changing the oil!

7. Replace the suction pipe, and fill up with new oil through the hydraulic oil filter to
the same level as before. If there has been any leakage it will be necessary to fill to
a higher level than before. To obtain the correct oil level all the cylinders should be
run to their end positions, and check that the pump does not suck air.
8. Run in the cylinders and check that the oil tank does not overflow.

Note!
The hydraulic oil should be filtered when filling, by pouring the oil through
the filter.

9. Wipe up any spilled oil, close the machine housing cover, and lower down the
steering wheel panel.

SERVICE MANUAL A-ERGO

8.18 Hydraulic system / Repair instructions / Air filter, replacing

Air filter, replacing

The air filter is placed on the side of hydraulic tank cap.

08_008_A-ERGO_luftFilt.eps

Figure 8.1 Air filter on hydraulic tank

1. Unscrew the cap on the filter housing.

2. Take out the filter.
3. Wipe clean the filter housing with a cloth that does not shred fibres.
4. Insert a new filter and screw on the cap.

SERVICE MANUAL A-ERGO

 Hydraulic system / Repair instructions / Oil filter insert, replacement 8.19

Oil filter insert, replacement

1. Lower down the forks and disconnect the battery electrically.
2. Open the machine housing cover.
3. Remove the cap located on the top of the hydraulic oil tank.

08_008_A-ERGO_OljeFilt.eps

Figure 8.2 Oil filter

4. Lift up the filter insert, wait until the oil has managed to run off the filter, and then
lift it out.
5. Pull the filter loose from the rod.
6. Clean the magnet on the rod, the purpose of which is to attract swarf.
7. Insert a new filter.
8. Replace the filter insert in the hydraulic oil tank, fit a new O-ring, and screw tight
the cap.
9. Close the machine housing cover.

SERVICE MANUAL A-ERGO

8.20 Hydraulic system / Repair instructions / Checking the hydraulic oil level

Checking the hydraulic oil level

1. Carefully lift the fork carriage to its top position.
2. Check that the hydraulic pump does not suck air. This can be recognised by the
function in operation moving jerkily, or by an abnormal screeching noise.
3. If the hydraulic pump sucks air lower down all the hydraulic functions to their
lower positions, open the machine housing cover, and check the oil level in the
hydraulic tank.
4. Fill with hydraulic oil of the grade recommended in section "Properties of the
hydraulic oil" on page 8.16 so that the level rises a few cm, and then perform the
“test lift” and check as above.
5. Repeat this procedure until a normal function is obtained.

SERVICE MANUAL A-ERGO

 Hydraulic system / Repair instructions / Lowering brake valve 8.21

Lowering brake valve

Dismantling and assembling

1. Lift the forks so that the inner mast lifts approx. 30 cm. Place a block under the
inner mast and carefully lower down so that the mast rests on the block. Continue
lowering until the system is pressureless.
2. Disconnect and push the battery out to improve accessibility.
3. Place protective paper under the truck, release the hose from the valve housing,
pos. 1, and plug it.
4. Unscrew the lowering speed valve, pos. 2, and plug the valve housing, pos. 1.
5. If a fault is suspected on the valve, it should be check measured. There are specific
dimensions for the spring length, depending on which cylinder it is to protect. See
adjustment values in table 8.2.
6. Adjust the valve, or replace with a new one, and fit it in the valve housing.
7. Fit the hose and push back the battery..

2
08_001_A-Ergo_sänkbromsvent1.eps

Figure 8.3 Lowering brake valve

8. Test run.

06_009_A-Ergo_ HydrAnsl.eps

Figure 8.4 Position of lowering brake valve

SERVICE MANUAL A-ERGO

8.22 Hydraulic system / Repair instructions / Lowering brake valve

Table 8.2 Adjusting the lowering brake valve

Machine type Marking s v Q

mm s/m L/min

A Straddle lift SB09C/3402 7,5 9,6 10

A 160 T SB25C/3342 13,5 1,8 37

A 160 TV SB25C/3342 13,5 1,8 37

A 160 TFV SB27C3345 16 1,8 45

A 160 DTFV SB25C3342 13,5 1,8 37

A TF/200 TFV SB27C/3345 16 2,0 45

A TF/200 DTFV SB27C/3345 16 2,0 45

SM 170.1 S

Figure 8.5 Cross-section, lowering brake valve

SERVICE MANUAL A-ERGO

 Hydraulic system / Repair instructions / Hose rupture valve 8.23

Hose rupture valve

Dismantling and assembling

1. Lower down the forks and relieve the pressure.
2. Place protective paper under the cylinder to be repaired.
3. Loosen the pipe or hose that goes to the cylinder, and plug it.
4. Remove the nipple placed in the cylinder.
5. Unscrew the hose rupture valve, pos. 1 figure 8.6, that is screwed into the cylinder.

Slangbrottsvent.eps

Figure 8.6 Hose rupture valve

6. If a fault is suspected, check the length of the spring in relation to the table or data
sheet. Adjust, or fit a new valve.
7. Fit the nipple, connect the pipes, and wipe clean.
8. Test run, see adjustment values for hose rupture valve in table 8.3..

SM210-1

Figure 8.7 Hose rupture valve in cross-section

SERVICE MANUAL A-ERGO

8.24 Hydraulic system / Repair instructions / Hose rupture valve

Table 8.3 Adjustment values for hose rupture valve

Machine type Marking s Q

mm L/min

A 160 T (Electric proportional valve) LB3C/3791 2,4 80

A 160 TV LB3C/9175 1,2 50

A 160/200/TF TFV Free-lift LB3C/3791 2,4 80

A 160/200/TF TFV End stroke LB3C/9185 1,2 50

A 160/200/TF DTFV Free-lift LB4C/3694 2,0 125

A 160/200/TF DTFV End stroke LB3C/3691 2,0 67

SERVICE MANUAL A-ERGO

 Hydraulic system / Repair instructions / Control valve 8.25

Control valve

General instructions when working with control valve

1. Cleanliness

• Dirt particles must not get into the components.

• Cloths must not shred fibres and particles.
• Tools should be clean.
• The tank, pipes and hoses should be carefully cleaned before
installation.
• Welded or hot-bent pipes should be pickled and washed before they
are built in.
• The oil tank must be sealed and provided with an efficient breathing
filter that prevents the penetration of dirt.

2. Sealant

• Hemp, cement or sealing tape are not permitted.

3. Operating data

• Do not exceed permitted pressures and volume flows.

• Do not exceed the specified temperature range.
• Pay attention to specified electrical voltages and max power
consumption.

SERVICE MANUAL A-ERGO

8.26 Hydraulic system / Repair instructions / Control valve

Manually operated hydraulic valve, dismantling and assembling

1. Lower down the forks and relieve the pressure in the hydraulic system.
2. Lift up the hand rest so that the valve becomes accessible. See section 4 for
dismantling of arm rest.

08_007_SM_A-ERGO_PlacManVent.eps

Figure 8.8 Position of manual proportional valve

3. Place protective paper under the valve and release the electric cables to the
microswitch(s).
4. Loosen all the oil pipes connected to the valve, and plug them.
5. Loosen the valve from the truck, and lift it out.
6. When fitting, first place the valve in the truck but do not tighten until all the oil
pipes are connected. Tighten the valve and then the oil pipes.
7. Adjust the pressure limiting valve to the rated weight in accordance with the
machine plate.
8. Seal the setting.

PropVentMan.eps

Figure 8.9 Lever regulated valve

SERVICE MANUAL A-ERGO

 Hydraulic system / Repair instructions / Control valve 8.27

Electrically operated control valve, dismantling and assembling

1. Lower down the forks and relieve the pressure in the hydraulic system.
2. Switch off the key switch.
3. Open the machine housing cover and lift up the hand rest so that the valve becomes
accessible.

08_010_A-ERGO_PlacElPropV.eps

Figure 8.10 Position of electric proportional valve

4. Place protective paper under the valve and release the electric cables to the
microswitch(s).
5. Loosen all the oil pipes connected to the valve, and plug them.
6. Loosen the valve from the truck, and lift it out.
Tightening 7. When fitting, first place the valve in the truck but do not tighten until all the oil
torque:
pipes are connected. Tighten the valve and then the oil pipes, max 60 Nm.
60 Nm.
8. Adjust the pressure limiting valve to the rated weight in accordance with the
machine plate.
9. Seal the setting.

ElPropVent.eps

Figure 8.11 Electrically operated proportional valve

SERVICE MANUAL A-ERGO

8.28 Hydraulic system / Repair instructions / Control valve

Checking the lowering speed

The lowering speed of the fork carriage is checked with the load on the forks specified
on the truck machine plate.
Check the actual lowering speed with the table below.

Important!
In accordance with EN 1726 a load must not be lowered faster than 0.6 m/s.

Table 8.4

Mast type Lowering speed m/s

A 160 max 0.6

A 200/TF max 0.5

If the correct lowering speed cannot be achieved then the electrical signal from the
control unit to the solenoid valves should be checked first, in accordance with "Adjusting
the regulator, electric valve" on page 8.28.
The hydraulic valve is then adjusted in accordance with "Adjusting the lowering speed
valve in the electric hydraulic valve" on page 8.28.

Adjusting the regulator, electric valve

See section 10.

Adjusting the lowering speed valve in the electric hydraulic

valve
As a first step all the the control unit settings should always be checked before a hydraulic
adjustment is made.
See section 10.

SERVICE MANUAL A-ERGO

 Hydraulic system / Repair instructions / Control valve 8.29

If the correct lowering speed has not been obtained (see "Checking the lowering speed"
on page 8.28) adjust the lowering speed valve mounted on the hydraulic valve, see pos.
1 figure 8.12, until the correct lowering speed is obtained.

ElPropVent.eps

Figure 8.12 Electrically operated proportional valve

Adjusting the working pressure

1. Place the max truck load on the forks (specified on the truck machine plate).
2. Unscrew the adjusting screw, pos. 2 see figure8.12, two turns to the left.
3. At the same time as the lift function for the fork carriage is actuated, screw in the
adjusting screw until the fork carriage begins to lift from the floor, and then screw
in an additional ¼ of a turn and lock.
4. Finally, perform repeated lifting operations to ensure that the lifting capacity is
sufficient.
5. Seal!

Emergency lowering valve

The emergency lowering valve is used to lower the forks during power failure.

Warning!
Make sure the forks can be lowered safely before the emergency lowering valve is
opened.

1. Open the emergency lowering valve (3) using a 2.5 mm hexagon wrench.
2. Tighten the emergency lowering valve (3) when the forks are lowered.

SERVICE MANUAL A-ERGO

8.30 Hydraulic system / Repair instructions / Hydraulic pump motor

Hydraulic pump motor

Dismantling the hydraulic pump motor

1. Lift the forks to their highest position to lower the hydraulic oil level in the tank,
thus reducing oil leakage at the pump shaft when the motor is removed.

Warning!
Do not work under the forks.

2. Disconnect the battery electrically.

3. Open the machine housing cover and release the cables to the hydraulic motor.
4. Loosen the retaining bolts that hold the pump at the hydraulic motor.
5. Loosen and remove the bolts that hold the clamp round the hydraulic motor.
6. Remove the loosened retaining bolts and release the pump from the hydraulic
motor. Lift off the hydraulic motor.

Important!
Check that the connector is turned in the right direction and that the motor and
pump journals come at 90° in relation to each other.

Dem HydPump.eps

Figure 8.13 Hydraulic pump motor

Assemble in the reverse order.

Important!
Grease in the pump journal before fitting!

SERVICE MANUAL A-ERGO

 Hydraulic system / Repair instructions / Hydraulic pump motor ALL 8.31

Hydraulic pump motor ALL

If there is a change in the performance of the motor it should be inspected inside. The
brushes are one of the most common sources of a fault.
The brushes can become worn out, or stick in their holders. In both cases inadequate con-
tact between the brushes and the commutator can lead to serious damage to the commu-
tator surface.

When should the brushes be replaced?

• If a brush cannot move freely in the brush holder. To check this the brush holder
must first be released from the brush rocker. The force from the brush spring
should then press out the brush from the brush holder as far as permitted by the
cable.
• If a brush is approaching the end of its useable life. The length of the brushes must
never be less than 10 mm (a new brush has a length of 17 mm). Since this is diffi-
cult to measure, there is another alternative. Measure the difference between the
cable and the slot in the brush holder. The difference should be at least 1 mm. Even
if the difference should be slightly larger it is recommended to replace the brushes,
since their residual service-life may be shorter than the time to the next inspection.

Replacing the brushes

The actual brushes cannot be replaced since they are included in a set consisting of brush,
brush holder and spring. These can be installed as follows.

1
3

2
4

Figure 8.14

1. Release the cables from the terminals on the motor (pos. 1 figure 8.14).
2. Release the through bolts from the rear end head on the motor (pos. 2 figure 8.14).
3. Lift the motor out of the truck.
4. Place the motor on its drive end.

SERVICE MANUAL A-ERGO

8.32 Hydraulic system / Repair instructions / Hydraulic pump motor ALL

5. Release the nuts on the terminals (pos. 3 figure 8.14). If the motor has a return
earth cable the earth connection on the rear end head of the motor should also be
released (pos. 4 figure 8.14).
6. Release the rear end head (pos. 5 figure 8.14). Make sure that the terminals remain
in their positions.

B
1

Figure 8.15

7. Disconnect all four brushes by loosening the screws, pos. 1 figure 8.15 - A.
Now press each brush set to the commutator pos. 2 figure 8.15 - B. Remove the
brush set from the brush rocker - C. The old brush set is replaced with a new set in
the reverse order. It is recommended to replace each brush set separately to avoid
confusion. Make sure that each brush set is replaced with the correct part, in other
words one that has the cable on the correct side. (The service kit consists of two
matching pairs of brush sets!)
8. Tighten the screw, pos. 1 figure 8.15, to approx. 1.3-1.8 Nm.
9. Replace the terminals in the slots in the rear end head, and replace it on the motor.
Check that there is a washer between the rotor and end head (pos. 2 figure 8.15)
and that the holder is held in place with a tooth and slot on the casing in the respec-
tive end.
10. Fit the through bolts and put the motor back in the truck. Tighten the bolts to
approx. 4.8-6.8 Nm.
11. Tighten the terminals to 10-14 Nm (pos. 3 figure 8.14).
12. Replace the cables to the motor terminals.

SERVICE MANUAL A-ERGO

 Hydraulic system / Repair instructions / Hydraulic pump motor ALL 8.33

Tips to prolong the service-life of the motor

• Rapid wear of brushes and commutator is often caused by oil. Oil or grease is
burned by the sparks that develop at the brushes, which leaves a residue of abrasive
ash. If oil or grease is found in the motor the cause of this must be eliminated
immediately.
• Never overload the motor. Brushes that have been intensely overheated expand
permanently and can fasten in the brush holders.
• The lifespan of the brushes not only depends on the load, but also on how worn the
commutator is. The commutator should have a smooth, level, greyish-black sur-
face. A worn commutator must be machined (never use abrasive paper, a whet
stone or file!) to a surface fineness of Ra = 0.8-1.8 µm and a maximum offset of
0.03 mm (with the rotor resting in the bearing seats). For the service-life of the
commutator it is better to machine it a little and more often, than seldom and a lot.
The minimum diameter of the commutator is 40.8 mm.
• The motor must not be exposed to full loading immediately after changing the
brushes.
• Look for signs of overheating on the windings, dark patches, brittle or burned insu-
lation, and damage to the soldering on the commutator. If the motor is damaged in
this way it is no longer serviceable.
• If possible, remove dust and dirt from the inside of the motor with compressed air.
• A dirty commutator should always be cleaned with a clean cloth moistened with
petrol (do not use waste cotton since it sheds fibres), and carefully blown clean
with compressed air.
• If the bearing brass looks as if it are out of oil (i.e. very little oil can be seen on the
rotor washer or on the brush holder) lubricate it with a little bearing grease.

SERVICE MANUAL A-ERGO

8.34 Hydraulic system / Repair instructions / Stabiliser cylinders

Stabiliser cylinders
The stabiliser cylinders have in their upper end a flexible attachment, the purpose of
which is to compensate for minor irregularities in the floor

06_004_A-Ergo_SidoStabHst dB.eps

Figure 8.16 Stabiliser cylinder

Dismantling and assembling the stabiliser cylinders

1. Run out the stabiliser cylinders completely.
2. Remove the cotter in the upper attachment. First grip the cylinder with one hand,
and then pull out the HCB bolt. This is because of the pretension in the spring unit.
3. Lift the stabilisers slightly to release the pretension in the spring unit.
4. Pull out the battery plug.
5. Release the hoses and plug them.
6. Remove the lower screw that goes through the piston rod end.

Dismantling and assembling, gaskets

1. Unscrew the piston rod guide and pull the piston rod out of the cylinder pipe.
2. Support the piston rod in a vice in the end that normally sits in the straddle lift. Use
protective jaws on the vice.
3. Unscrew the nut and remove the gasket holder with the piston seals.

Important!
Before fitting, all seals should be lubricated with hydraulic oil.

4. Assemble in the reverse order.

SERVICE MANUAL A-ERGO

 Hydraulic system / Repair instructions / Installation instruction for pipe couplings 8.35

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 figure8.17
and8.18) after which it is deburred internally and externally, and carefully cleaned.

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.

hydraulror 1.eps
!

Figure 8.17 Cut at right angles!

hydraulror 2.eps

Figure 8.18 Pipe cutter

2. Oil the thread and ring (do not use not grease). Put the nut and ring over the pipe
end as shown in the figure. If the ring 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 the ring, press the pipe
towards the shoulder in the coupling cone, and then tighten the nut a ¾ turn.

Important!
The pipe must not follow round.

SERVICE MANUAL A-ERGO

8.36 Hydraulic system / Repair instructions / Installation instruction for pipe couplings

4. The ring will now have gripped the pipe, and no longer needs to be pressed against
the shoulder. Complete the fitting with an additional ¾ turn of the nut. A mark on
the nut simplifies following the specified torque, see figure 8.19.

Figure 8.19 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 length of the U-ring spanner should be 15 times
the width of the nut (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.
6. After fitting, release the cap nut and check that the ring has pressed up a visible
swelling in the area in front of it, see figure 8.20. If not, give it another short turn. It
is of no importance whether the ring can still be turned.

hydraulror 5.eps

Figure 8.20 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.

SERVICE MANUAL A-ERGO

 Hydraulic system / Repair instructions / Installation instruction for pipe couplings 8.37

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.

0
0

hydraulror 6.eps

Figure 8.21 Straight pipe length between bend and coupling

8. 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 A-ERGO

8.38 Hydraulic system / Diagnosis and trouble shooting / Symptom and Action

Diagnosis and trouble shooting

Symptom and Action

A number of fault symtoms have been listing in the table below with a number of possible
faults and repair procedures. It is therefore possible that other faults not listed can occur.
Table 8.5

Symptom Possible fault Action

The lift motor runs but The lowering valve has 1. Close the valve.
the fork carriage does jammed and is open.
2. Adjust, or remove any dirt in the
not lift.
valve.

The lift motor runs but The machine is overloaded. Lighten the load.
the fork carriage lifts
very slowly. The overflow valve is Adjust the valve to the rated weight.
defective.

An object has partially Dismantle and clean.

blocked hoses, hydraulic
pipes or valves.

A hydraulic hose has been Rearrange the hose and clamp it

clenched. secure.

The lift motor emits a The oil level is too low in the 1. Fill up with hydraulic oil.
screeching noise just hydraulic tank. When the tank is almost full, try
before the fork carriage with 0.1 litre at a time to avoid
reaches the top. overfilling.
2. Find out the reason for the low
level, and rectify the fault.

The fork carriage Valve does not open on Dismantle the valve and clean.
cannot be lowered. return because of object in
the system.

The hose rupture valve is Limit the lowering speed.

closed because the lowering
speed is too high.

The hose rupture valve is Replace the hose rupture valve.

closed because the spring in
the valve is defective.

The fork carriage The lowering valve or 1. Run the motor at full power for 1
lowers too slowly. lowering brake valve is dirty minute to see if the dirt is
or defective. released.
2. If not, dismantle the valve and
clean it, or alternatively replace
defective parts.

The oil filter is blocked and Replace filter.

dirty.

SERVICE MANUAL A-ERGO

 Hydraulic system / Diagnosis and trouble shooting / Symptom and Action 8.39

Table 8.5

Symptom Possible fault Action

The fork carriage The lowering brake valve is Replace the lowering brake valve.
lowers too quickly. defective.

The lowering brake valve is Adjust the lowering brake valve.

incorrectly adjusted.

Hydraulic oil flows out Oil level too high. Reduce the oil level to the correct
through the air filter. level.

The oil foams. Replace with oil with the correct

properties.

Condensation in the oil tank. Drain the oil out of the tank and fill
with new hydraulic oil to the correct
level.

The fork carriage Air in the hydraulic system. Bleed the system through the lift
bounces when lifting. cylinders.

The hydraulic oil The oil separators in the 1. Change the oil and filter.
smells of sulphur. hydraulic oil are destroyed.
2. Flush the complete system with
Motor oil has been used and new hydraulic oil.
caused the hydraulic oil to
emulsify with water, which
has then rotted.

SERVICE MANUAL A-ERGO

8.40 Hydraulic system / Diagnosis and trouble shooting / Symptom and Action

SERVICE MANUAL A-ERGO

 SERVICEMANUAL
Machine: A-Ergo

Manual No: 005975

Edition 2002B

9 Lift cylinders

Design and function ....................................................................................................... 9.3

Introduction .......................................................................................................... 9.3

Repair instructions ......................................................................................................... 9.4

General ................................................................................................................ 9.4
Bleeding of cylinders with air screw ............................................................................... 9.4
Bleeding of cylinders without air screw .......................................................................... 9.4
Free-lift cylinder TFV / DTFV ............................................................................... 9.5
Dismantling and assembling .......................................................................................... 9.5
Dismantling and assembling .......................................................................................... 9.5
Lift cylinder TV/TFV/DTFV ................................................................................... 9.7
Dismantling and assembling .......................................................................................... 9.7
Dismantling and assembling .......................................................................................... 9.8
Lift cylinder T ..................................................................................................... 9.10
Dismantling and assembling ........................................................................................ 9.10
Dismantling and assembling ........................................................................................ 9.11

ATLET SERVICE MANUAL A-ERGO

9.2

ATLET SERVICE MANUAL A-ERGO

 Lift cylinders / Design and function / Introduction 9.3

Edition 2002B

9 Lift cylinders
Design and function

Introduction
The lift cylinders consist of single-acting hydraulic cylinders, 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 by
means of a control valve releasing oil out from the cylinders. They are then pushed
together by the weight of the forks, at the same time as the oil returns to the hydraulic tank.
As opposed to the lift cylinders, the side stabiliser cylinders are double-acting. This means
that a hydraulic oil also acts in the opposite direction and pushes the cylinder together.

SMA-Ergo_09_2002B.fm
ATLET SERVICE MANUAL A-ERGO
9.4 Lift cylinders / Repair instructions / General

Repair instructions

General

Bleeding of cylinders with air screw

Warning!
When bleeding, the air screw must be opened no more than approx. a half turn. If the
air screw is opened completely the oil will spurt out and the forks crash uncontrolla-
bly to bottom position. The hose rupture valves do not function in this phase.

1. Open the air screw a maximum of approx.: one half turn.

X
X
X
X
X

Figure 9.1 Example, air screw.

2. Check that there is sufficient oil in the hydraulic tank and that the pump does not
suck air.
3. Carefully run the cylinder repeatedly between its end positions.
4. When oil without air bubbles comes in the tank the cylinders have been bled.
5. Adjust the oil level in the hydraulic tank.
6. Repeatedly lift from bottom to top position.
7. Check that the forks do not bounce, if so repeat the bleeding again.

Bleeding of cylinders without air screw

Cylinders without air screws are bled by running the cylinder repeatedly between its end
positions.

Important!
Check the oil level regularly.

ATLET SERVICE MANUAL A-ERGO

 Lift cylinders / Repair instructions / Free-lift cylinder TFV / DTFV 9.5

Free-lift cylinder TFV / DTFV

Dismantling and assembling

1. Remove the retaining screw that holds the lower end of the cylinder.
2. Lower down the forks, e.g. on a pallet, so that the chain slackens. Remove the
chain pin that goes through the chain bolt on the cylinder, and place the chain over
the back of the fork carriage.
3. Release the fork carriage from the mast by lifting up the inner mast with the
hydraulic pump. Reverse the truck away.
4. Lower down so that all the cylinders are pushed together completely.
5. Loosen the bolts that hold the clamp at the top end of the cylinder, without
removing it.
6. Loosen and disconnect the oil pipe.
7. Remove the clamp, and lift out the cylinder.
8. Plug the oil pipe.
9. Assemble in the reverse order.

Dismantling and assembling

1. Support the lower end of the cylinder in a vice.

Important!
Risk of deformation, use moderate force.

2. Remove the circlip, pos. 1 see Figure 9.2, and remove the yoke, pos. 2.
3. Place a container for oil spillage under the cylinder.
4. Remove the top nut, pos. 3, with a suitable tool and take it off the piston rod.
5. Take out the piston rod.
6. Remove the seal, pos. 4, and guide rings, pos. 5, on the piston. Use a thin tool that
will not scratch.
7. Remove the seal, pos. 6, and scraper, pos. 7, from the top nut and O-ring, pos. 8.
8. Clean all parts and check for damage. Replace if necessary.

Note!
Always use original spare parts for maximum safety and service-life.

ATLET SERVICE MANUAL A-ERGO

9.6 Lift cylinders / Repair instructions / Free-lift cylinder TFV / DTFV

9. Assemble in the reverse order. Lubricate all parts with hydraulic oil before fitting.

1 2 X
X
X
X
X

7
6

4
09 002_A-Ergo_FrilCyl.eps

Figure 9.2 Free-lift cylinder TFV/DTFV

ATLET SERVICE MANUAL A-ERGO

 Lift cylinders / Repair instructions / Lift cylinder TV/TFV/DTFV 9.7

Lift cylinder TV/TFV/DTFV

Dismantling and assembling

1. Lift the forks until the inner mast is raised approx. 20 mm, place wooden blocks
under the inner mast, and lower it down onto the blocks.
2. Loosen the upper retaining screws, pos. 1 see Figure 9.3.
3. Lower down the cylinder to compressed position.
4. Loosen, disconnect, and plug the oil pipe.
5. Remove the retaining screw, pos. 2 see Figure 9.3.
6. Lift out the cylinder.
7. Assemble in the reverse order.

09 003_A-Ergo_DemDTFV.eps

Figure 9.3 Lift cylinder TV/TFV/DTFV

ATLET SERVICE MANUAL A-ERGO

9.8 Lift cylinders / Repair instructions / Lift cylinder TV/TFV/DTFV

Dismantling and assembling

1. Note how far the adjusting screw, pos. 1 see Figure 9.4, is screwed into the piston
rod end (required when fitting).
2. Unscrew the adjusting screw, pos. 1.
3. Support the lower end of the cylinder in a vice.

Important!
Risk of deformation, use moderate force.

4. Place a container for oil spillage under the cylinder.

5. Loosen the top nut, pos. 2, and remove it, and take out the piston rod, pos. 3.
6. Remove the sealing rings and guides, pos. 4 and 9, from the top nut.
7. Remove the guide rings, pos. 5, from the piston rod.
8. Clean all parts and check for damage. Replace if necessary.

Figure 9.4 Lift cylinder TV/TFV/DTFV

ATLET SERVICE MANUAL A-ERGO

 Lift cylinders / Repair instructions / Lift cylinder TV/TFV/DTFV 9.9

Note!
Always use original spare parts for maximum safety and service-life.

9. Assemble in the reverse order. Lubricate all parts with hydraulic oil before fitting.

ATLET SERVICE MANUAL A-ERGO

9.10 Lift cylinders / Repair instructions / Lift cylinder T

Lift cylinder T

Dismantling and assembling

1. Lower down the forks, e.g. on a pallet, so that the chain slackens. Remove the split
pin bolt, pos. 1, see Figure 9.5, that sits in the top end of the cylinder.
2. Remove the chain and place it over the back of the fork carriage.
3. Release the fork carriage from the mast by lifting up the inner mast with the
hydraulic pump. Reverse the truck away.
4. Place a wooden block under the inner mast, 10-15 cm thick, and carefully lower
the inner mast until it rests on the block.
5. Secure the cylinder so that it cannot drop out of the mast! Remove the circlip, pos.
2, and remove the lower retaining screw, pos. 3.
6. Carefully lower so that the piston rod comes out of the yoke, pos. 4. When the
piston rod is completely pushed in, remove the oil pipe and return pipe, and tilt
forward the cylinder and lift it out.
7. Assemble in the reverse order.

1
4

3
09 005_A-Ergo_DemT.eps

Figure 9.5 Lift cylinder T

ATLET SERVICE MANUAL A-ERGO

 Lift cylinders / Repair instructions / Lift cylinder T 9.11

Dismantling and assembling

1. Place the cylinder on a bench with the chain attachment facing down.
2. Loosen and remove the top nut, pos. 1 see Figure 9.6, with a hook spanner.
3. Pull out the piston rod, pos. 2, and place it carefully on the bench to avoid
damaging it.
4. Remove the parts, pos. 3, 4, 5, 6, 7 and 8.
5. Clean all parts and check for damage. Replace if necessary.

Note!
Always use original spare parts for maximum safety and service-life.

6. Assemble in the reverse order. Lubricate all parts with hydraulic oil before fitting.

X
X 7
X
X
X

2 1

09 006_A-Ergo_DemCylT.eps
3

Figure 9.6 Lift cylinder T

ATLET SERVICE MANUAL A-ERGO

9.12 Lift cylinders / Repair instructions / Lift cylinder T

ATLET SERVICE MANUAL A-ERGO

 SERVICE MANUAL
Machine: A-Ergo

Manual No: 005975

Edition 2005B

10 Electrical system

General .......................................................................................................................... 10.3

Safety procedures ............................................................................................. 10.3
General ......................................................................................................................... 10.3
Electronic regulators ..................................................................................................... 10.3
Safety check ...................................................................................................... 10.4
The steering servo system ........................................................................................... 10.4
Drive motor system ...................................................................................................... 10.4
Operation, Hand terminal .................................................................................. 10.6

Design and function ..................................................................................................... 10.9

General functional description, regulators ......................................................... 10.9
Communication between regulators ........................................................................... 10.10
Drive motor regulator .................................................................................................. 10.10
Steering servo regulator ............................................................................................. 10.12
Multi Function Display Indicator (MDI) ............................................................. 10.13
Display description ..................................................................................................... 10.13
Function ...................................................................................................................... 10.13
Drive motor regulator, AC1 .............................................................................. 10.15
Function, drive motor regulator AC1 .......................................................................... 10.15
Connector, specification, drive motor regulator AC1 .................................................. 10.16
Menu tree, drive motor regulator AC1 ........................................................................ 10.19
Steering servoregulator, EPS-AC .................................................................... 10.30
Function, steering servo regulator EPS-AC ............................................................... 10.31
Connector, specification, steering servo regulator EPS-AC ....................................... 10.33
Menu tree, steering servo regulator EPS-AC ............................................................. 10.36
Wiring diagram ................................................................................................ 10.37

Repair instructions ..................................................................................................... 10.38

Calibration, Speed controller ........................................................................... 10.38
Calibration, Lifting/Lowering control ................................................................ 10.41
Save parameters in the Hand terminal memory .............................................. 10.44
Download parameters from the Hand terminal ................................................ 10.46
Checking error codes ...................................................................................... 10.48
Replacing drive regulator/steering servo regulator .......................................... 10.50

ATLET SERVICE MANUAL A-ERGO

10.2

Replacing MDI .................................................................................................10.50

Replacing the steering servo sensor ................................................................10.51
Dismantling the steering servo sensor ....................................................................... 10.51
Assembling the steering servo sensor ........................................................................ 10.51

Diagnosis and trouble shooting ................................................................................10.52

Safety ...............................................................................................................10.52
Tools for trouble shooting .................................................................................10.52
Circuit diagram ........................................................................................................... 10.52
Wiring diagram ........................................................................................................... 10.52
Error codes ................................................................................................................. 10.52
Multimeter ................................................................................................................... 10.52
Input and output specification ..................................................................................... 10.53
Practical trouble shooting .................................................................................10.54
Error in the drive function ........................................................................................... 10.54
Error in the steering servo system .............................................................................. 10.55
Error in the lifting/lowering system .............................................................................. 10.55
Error symptom, drive motor regulator ......................................................................... 10.55
Error codes ......................................................................................................10.56
Error codes MDI ......................................................................................................... 10.56
Error codes, drive motor regulator .............................................................................. 10.57
Error codes, steering servo regulator ......................................................................... 10.61

ATLET SERVICE MANUAL A-ERGO

 Electrical system / General / Safety procedures 10.3

Edition 2005B

10 Electrical system
General

Safety procedures

General

Warning!
Working with electrical vehicles can result in personal injury.

• During all work on the electrical system, or in its immediate vicinity, rings, watches
and other metal objects must be removed since the battery has such a capacity that a
short circuit over such an object can result in very 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.

Electronic regulators
• All electronic regulators in the truck have multiple safety systems.
• When replacing or repairing the electronic regulators, or removing cables, the
battery should always be disconnected.

Important!
Incorrectly connected battery cables can destroy the electronic regulators.

Warning!
During all work on the truck the drive wheel must be lifted up from the floor to
prevent accidents occurring.
Watches and other metal objects should be removed to avoid burn injuries.

After the power has been disconnected to the regulator and work or trouble shooting is
to be carried out there may still be voltage remaining in the condensers for a few minutes,
so for this reason observe care when working with current-carrying tools during these
few minutes.

SMA-Ergo_10_2005B.fm
ATLET SERVICE MANUAL A-ERGO
10.4 Electrical system / General / Safety check

Safety check
Important!
The function of the external components in the steering servo system should be
checked after every service and after all work carried out in the electrical system.
All function tests of the safety system should be carried out with the truck speed
controller in neutral.

The steering servo system

The steering servo system has a number of safety monitors, partly to check the regulator
circuits but also to check external circuits and components such as the steering wheel
sensor, steering motor and end position sensors.
A function test of the steering servo system safety functions should result in it not being
possible to activate the control system and drive system, and also that it should not be
possible to put the brake in unbraked position.
The monitoring system for the steering wheel sensor and its cabling are checked by
separating the connector to the steering wheel sensor, which should result in an error
code, see "Error codes, steering servo regulator, EPS" on page 10.61.
The steering motor monitor system is checked by disconnecting a cable connection to the
motor, either on the motor or on the regulator. An error code should then be shown when
turning the steering wheel, see "Error codes, steering servo regulator, EPS" on page 10.61.
One dangerous moment is if the end position switches for the steering function are
activated when the wheel is not in the actual end position. This is monitored by the
regulator sensing whether the sensor is actuated even if the wheel moves away from the
sensor. Test this by strapping terminal 2 and 3 in the end position sensor contactors, see
S4 and S5 in the wiring diagram, Wiring Diagram Handbook, steer from the respective
sensor and check that an error code is shown, see "Error codes, steering servo regulator,
EPS" on page 10.61.

4 3
2 1

10_013_SM_A-ERGO_S4 S5 S8.eps

Figure 10.1 Connector S4 and S5 seen from cable side

Drive motor system

The monitoring system checks that starting is done in the correct order, i.e. that the speed
controller does not give an output signal when the truck is started with the key switch.
This function is tested by switching off the key switch, holding the speed controller in
actuated position, and switching the key switch on again. The truck should then not move
before the speed controller has been in neutral.

ATLET SERVICE MANUAL A-ERGO

 Electrical system / General / Safety check 10.5

Testing of the motor circuit is not possible since it is a three-phase motor, and neither is
it necessary.
There are different systems that reduce the top speed of the truck and the lifting height
and load of the forks. These systems are tested by lifting the forks over the switching
height and loading them over the set weight. A tortoise should then be indicated on the
MDI display, see "Multi Function Display Indicator (MDI)" on page 10.13.

ATLET SERVICE MANUAL A-ERGO

10.6 Electrical system / General / Operation, Hand terminal

Operation, Hand terminal

The Hand terminal is connected to the regulators via a 9-pole contactor, connector C. In
the normal position this is covered by a rubber plug, which must be replaced after the
Hand terminal has been disconnected.

-BATT W
V
+BATT
U

1 PARAM. IMAX B.RECERSE

BRAKING COMPENS.
2 TESTER ACCEL. R.BRAKE
MAX SP. SPEED I
S.P.I SPEED II
3 SAVE
S.P.II SPEED III
BYPASS FIELD WEAK..
4 RESTORE
I MOT V.POT.
5 ALARMS TEMP V.BATT
V.MOT VMN.MOT.
6 ACCELERATOR M.SW.TEST

7 MOTOR DATA

1 3 5
ROLL ENTER SET
ROLL OUT SET
2 4 6

10_0016_SM_A-ERGO_handtermReg.eps

Figure 10.2 Hand terminal/programming tool for adjusting the settings on the regulators

All the adjustments of settings in the regulators are made with the Hand terminal.
The settings in the drive motor regulator and the steering servo regulator can be checked
and adjusted by means of the six buttons on the Hand terminal.

ATLET SERVICE MANUAL A-ERGO

 Electrical system / General / Operation, Hand terminal 10.7

See table 10.1 below for instructions how the terminal is used in the menus.
Table 10.1 Instructions for using the Hand terminal

Required function Buttons to use

To scroll down in the menus: ROLL (1)

To scroll up in the menus: ROLL (2)

To go into a menu selection: ENTER (3)

To increase the actual set value: SET (5)

To reduce the actual set value: SET (6)

To exit a menu selection and save the OUT (4)

changed value: +
ENTER (3)

To exit a menu selection without OUT (4)

saving: +
OUT (4)

ATLET SERVICE MANUAL A-ERGO

10.8 Electrical system / General / Operation, Hand terminal

Table 10.1 Instructions for using the Hand terminal

Required function Buttons to use

To select CONFIG MENU: ROLL (1)

+
SET (5)

All error messages are also presented through the Hand terminal, see "Error codes" on
page 10.56.

ATLET SERVICE MANUAL A-ERGO

 Electrical system / Design and function / General functional description, regulators 10.9

Design and function

General functional description, regulators

12

4
8
9
13
10

6
5

11 1
3

10_008_SM_A-ERGO_regulatorer.eps

Figure 10.3 Overview of communication channels, electrical system

1. Drive motor regulator 7. Lift control

2. CanBus link 8. Electrical panel
3. Steering servo regulator 9. Hydraulic pump
4. Multi Funktion Display (MDI) 10. Hydraulic valve
5. Speed controller 11. Hydraulic cylinder, lift
6. Drive motor 12. Steering wheel
13. Steering servo motor

ATLET SERVICE MANUAL A-ERGO

10.10 Electrical system / Design and function / General functional description, regulators

Communication between regulators

Figure 10.4 Communication between regulators

The brain in the system is the regulator for the drive motor (1), which via Canlink (2)
communicates with the regulator for the steering servo motor (3) and the Multi Function
Display (MDI) (4).
The controller units have a self-diagnosis part that can generate error codes. These error
codes are presented on the MDI display (4) and in the Hand terminal (see section 2, Special
tools). The MDI also presents the time the truck has been in operation and the battery status.

Drive motor regulator

Figure 10.5 Overview of drive motor regulator, drive motor

When the lever for the speed controller (5) is actuated the drive motor regulator (1) sends
a drive voltage to the drive motor (6). A pulse transducer in the upper bearing of the drive
motor restores the motor speed to the regulator, which adjusts the drive voltage until its
speed corresponds to the speed control.

ATLET SERVICE MANUAL A-ERGO

Electrical system / Design and function / General functional description, regulators 10.11

Figure 10.6 Overview of drive motor regulator, hydraulic pump motor, lift valve and lift
cylinder

When the control lever for electrically controlled lifting (7) is actuated the regulator for
the drive motor (1) sends a voltage to the lift motor contactor (8), which starts the lift
motor (9). The drive motor regulator also forwards via the CAN link (2) the magnitude
of the response on the control to the MDI (4) and the lift speed is then controlled by the
MDI, which provides an equally high control voltage in proportion to the control level to
the control valve (10), which in turn provides a proportionally equally high flow of
hydraulic oil to the lift cylinder (11), which then provides the variable lifting and
lowering speed.
On trucks with manual hydraulic valves the modulation of the valve is controlled directly
by the position of the lift lever.

ATLET SERVICE MANUAL A-ERGO

10.12 Electrical system / Design and function / General functional description, regulators

Steering servo regulator

Figure 10.7 Overview of steering servo regulator, steering wheel, steering servo motor

When the steering wheel is turned a signal is sent via a step motor on the steering wheel
(12) to the regulator for the steering servo motor (3), which in turn forwards a
proportional drive voltage to the steering servo motor (13), which turns the drive wheel
with the required speed and in the required direction.

ATLET SERVICE MANUAL A-ERGO

 Electrical system / Design and function / Multi Function Display Indicator (MDI) 10.13

Multi Function Display Indicator (MDI)

Display description
The battery charging is indicated by means of five LEDs, four green and one red. When
the battery is fully charged all the green LEDs light up. The LEDs go off as the battery is
discharged and when the battery charge has reached a level that requires the battery to be
charged the red LED lights up (steady signal).

1 2 3 4 5

6
7
8
9

10_007_SM_A-ERGO_MDIdisp.eps

Figure 10.8 Multi Function Display (MDI)

1. Steady red signal: 6. A flashing hourglass

<10% battery capacity indicates that the hour
Flashing red signal: Error counter is active (Hourglass)
code indicating
7. Error code displayed/Service
2. 25% battery capacity necessary (Spanner)
3. 50% battery capacity 8. Reduced top speed (Tortoise)
4. 75% battery capacity 9. Alphanumeric display
5. 100% battery capacity

Function
The display consists of a field with alphanumeric symbols and three different figurative
symbols.
The truck operating time, error codes and the MDI software version are indicated on the
alphanumeric display part:
• The operating time counter indicates the hours the truck has been in operation.
• Error codes are indicated by means of a pre-defined code and by the flashing of the
red LED.

ATLET SERVICE MANUAL A-ERGO

10.14 Electrical system / Design and function / Multi Function Display Indicator (MDI)

• The software version is shown briefly on start up, EPXXX where XXX represents
the version.
Other symbols:
• A tortoise shows that the maximum speed is reduced.
• A spanner is shown in conjunction with the indication of an error code, or when
pre-programmed service should be carried out.
• The hourglass flashes when the hour counter is active.

ATLET SERVICE MANUAL A-ERGO

 Electrical system / Design and function / Drive motor regulator, AC1 10.15

Drive motor regulator, AC1

-BATT W

V
-BATT W
+BATT
V
+BATT
U U

7 1

E2
6
12
11 1

E1

20 10
C

10_009_SM_A-ERGO_regulator.eps

Figure 10.9 Regulator, drive motor and hydraulic motor

Function, drive motor regulator AC1

In an alternating current based control system it is important for the rotation of the motor
to be synchronised with the drive regulator. A sensor, incremental encoder, placed in the
motor with two phases displaced 90° is used for this. If these signals are subject to
interference, or lost, then the synchronisation between the motor and drive regulator will
not function. This will result in the motor running very slowly and consuming maximum
power. Avoid running the motor in this state.

ATLET SERVICE MANUAL A-ERGO

10.16 Electrical system / Design and function / Drive motor regulator, AC1

Connector, specification, drive motor regulator AC1

The drive motor regulator has three connectors with inputs and outputs 11 1
for valves, sensors, changer-over switches and programming tools. etc.
Each connector pin is specified below, with where appropriate the E1
voltage level in connected position.

Connector E1 (the figure shows the connector from the cabling side). 20 10

Table 10.2 Connector E1 drive motor regulator AC1

Pin Description Comment

E1.1 Controlling of Drive contactor Controlled to B-

E1.2 Supply to Drive contactor +24V

E1.3 Controlling of electric brake Controlled to B-

E1.4 Controlling of pump contactor Controlled to B-

E1.5 Supply to pump contactor

E1.6 Controlling of valve for straddle lift Controlled to B-

E1.7 CAN communication CAN Low

E1.8 Neg. supply to Lift/Lower control B-

E1.9 Pos. supply to drive motor encoder +4-5V

E1.10 Neg. supply to drive motor encoder B-

E1.11 Pos. supply to instrument +24V

E1.12 Neg. supply to instrument B-

E1.13 Input from speed reduction switch From pressure switch, see note below (*)

E1.14 Input for lifting of straddle lift +24V on activation

E1.15 Input for lowering of straddle lift +24V on activation

E1.16 +12V supply to instrument +12V

E1.17 CAN communication CAN High

E1.18 Signal from lift control Neutral = approx. 2.5V

Max lifting speed = approx. 4.5V
Max lowering speed = approx. 1.0 V

E1.19 Input A from drive motor encoder Synchronises motor drive with phase
distorted pulses from the encoder

E1.20 Input B from drive motor encoder

(*) The input from the pressure switch is filtered so that pressure surges will not trigger the
reduction of speed. A modified input value is required for at least 1 second to be
accepted. No modification of the input value is accepted during lifting and lowering
movements.

ATLET SERVICE MANUAL A-ERGO

 Electrical system / Design and function / Drive motor regulator, AC1 10.17

Connector E2 (the figure shows the connector from the cabling side). 7 1

E2

12 6

Table 10.3 Connector E2 drive motor regulator AC1

Pin Description Comment

E2.1 Supply from key lock +24V

E2.2 Supply to external units +24V

E2.3 Input from brake switch +24V required for driving

E2.4 Not used in the A model

E2.5 Not used in the A model

E2.6 Not used in the A model

E2.7 Prop. valve: Accessories: Input from control switch

Stabilisers up
Man. valve:
Stabilisers up and down

E2.8 Prop. valve: Accessories: Input from control switch

Stabilisers down
Manual valve:
Start of pump motor

E2.9 Acceleration reduction Reduction with wheel modulation.

B- gives reduction.
Functional lamp L1 required for correct function

E2.10 Input signal from speed Neutral = approx. 2.5V

controller Maximum in direction of forks= approx 1.0V
Maximum in opposite direction= approx 4.5V

E2.11 Neg. supply to speed controller B-

E2.12 Pos. supply to speed controller +5V

and lift control

ATLET SERVICE MANUAL A-ERGO

10.18 Electrical system / Design and function / Drive motor regulator, AC1

Connector C is used to connect the programming tool, Hand terminal.

20 10
C

Figure 10.10 Connector C (figure shows connector on the regulator)

The battery and motor connections are separately located on the motor control unit.

-BATT W

V
-BATT W
+BATT
V
+BATT
U U

Figure 10.11 Connections, battery and motor

Table 10.4 Separate cable connections

Pin Description

-BATT Negative supply from the battery.

+BATT Positive supply from the battery.

U; V; W Motor connections, connected to corresponding marking on the drive motor

ATLET SERVICE MANUAL A-ERGO

 Electrical system / Design and function / Drive motor regulator, AC1 10.19

Menu tree, drive motor regulator AC1

The following main headings are found in the drive motor regulator menu tree. Use the
Hand terminal to see the menus, see "Operation, Hand terminal" on page 10.6.
Table 10.5 Main flow in Hand terminal menus, Drive motor regulator
Display window Display window

AC1 ZAPI Vx.x +

24V 250A 00000

MAIN MENU Table 10.6 on CONFIG MENU (Not available)

PARAMETER CHANGE page 10.20 SET MODEL

MAIN MENU Table 10.10 on CONFIG MENU Table 10.14 on

TESTER page 10.24 SET OPTION page 10.26

MAIN MENU Table 10.11 on CONFIG MENU Table 10.15 on

SAVE PARAMETER page 10.25 ADJUSTMENTS page 10.28

MAIN MENU Table 10.12 on

RESTORE PARAMETER page 10.25

MAIN MENU Table 10.13 on

ALARMS page 10.25

MAIN MENU (Not available)

PROGRAM VACC

MAIN MENU (Not available)

MOTOR DATA

To see what is included in each menu selection, see the tables referred to after each
display window.

ATLET SERVICE MANUAL A-ERGO

10.20 Electrical system / Design and function / Drive motor regulator, AC1

Submenu specification PARAMETER CHANGE

Table 10.6 Delivery Settings in Drive Controller A with Zapi AC 1 in truck
(Parameter Change Menu)
FUNCTION A A Std ATF+ Speed Red. Speed red. NOTES
Incr. speed ALL by With stab
10 km/h Press.switch out <2 m
ACCELERATION 3 3 3 3 3 Acceleration ramp.
DELAY Lower value gives faster
acceleration.
EXTRA ACC DELAY 5 5 5 5 5 Increased acceleration
ramp with 45 degr
steering angle.
RELEASE BRAKING 6 6 6 6 6 Brake torque with throttle
to neutral position.
Option
INVERS BRAKING 8 8 8 8 8 Brake torque with throttle
in reversed direction.
PEDAL BRAKING 7 7 7 7 7 Brake torque with foot
switch released. May not
be changed. EU
regulation
SPEED LIMIT 7 7 7 7 7 Brake torque when
BRAKING throttle demand is
decreased
BRAKE CUTBACK 5 5 5 5 5 Brake torque when speed
reduction switch is
activated.
MAX SPEED FORW 94 119 94 94 94 May not be increased
over this value
MAX SPEED BACK 94 94 94 94 94 May not be increased
over this value
CUTBACK SPEED 1 100 100 100 *1 0 Reduced speed. To be
adjusted according to
specification in the KO,
Special Design
CUTBACK SPEED 2 70 70 100 70 70 To be adjusted to 5 km/h
with forks over switching
level.
H&S CUTBACK 10% 10% 10% 10% 10% Not used in the A model.
FREQUENCY 0.30 0.30 0.30 0.30 0.30 Lowest speed when the
CREEP truck is started.
MAXIMUM 9 9 9 9 9 Maximum current to the
CURRENT drive motor.
INCHING SPEED 0 0 0 0 0 Not used in the A model.
INCHING TIME 0 0 0 0 0 Not used in the A model.
AUXILIARY TIME 10 10 10 10 10 May not be set to other
value.
LIFT CUTBACK 75 75 75 75 75 Setting of valve voltage in
lifting mode.
MIN VALVE 1 5 5 5 5 5 Lowest opening value of
the proportional valve.

ATLET SERVICE MANUAL A-ERGO

 Electrical system / Design and function / Drive motor regulator, AC1 10.21

Table 10.6 Delivery Settings in Drive Controller A with Zapi AC 1 in truck

(Parameter Change Menu)
MIN VALVE 2-4 0 0 0 0 0 Lowest opening value of
the lift stop valve.
MAX VALVE 1 70 70 70 70 70 Max voltage to the
proportional valve
MAX VALVE 2 255 255 255 255 255 Max voltage to the lift
stop valve
MAX VALVE 3 och 4 100 100 100 100 100 Maximum voltage to
other valves
VALVES VOLTAGE 24 24 24 24 24 System voltage to the
valves
OPENING RAMP 0.2 0.2 0.2 0.2 0.2 Opening ramp for the
V1-V4 valves
CLOSING RAMP 0 0 0 0 0 Closing ramp for the
V1-V4 valves

Changes from standard are marked with bold text.

*1 = To be set to values specified in KO, Special Design

Adjustment menu
Tabell 10.7 Adjustment menu

Adjusted parameter Set value

THROTTLE X POINT 54
THROTTLE Y POINT 25
ADJUSTMENT #1 5
ADJUSTMENT #2 9

Option menu
Tabell 10.8 Option menu

Adjusted parameter Set value

HYDRAULIC 0 for manual valve

1 for prop. valve and Stabs
or Risible forks
2 for Prop. valve and Stabs
and Risible forks
PEDAL BRAKING Digital

ATLET SERVICE MANUAL A-ERGO

10.22 Electrical system / Design and function / Drive motor regulator, AC1

Each parameter can be set in ten steps, see table 10.9 below for available alternatives.
Table 10.9 Available parameter values, Drive motor regulator

PARAMETER UNIT PARAMETER LEVEL IN STEPS OF 10

0 1 2 3 4 5 6 7 8 9

ACCELERATION Sec. 1,0 1,5 2,0 2,5 3,0 3,5 4,0 4,5 5,0 5,5
DELAY (*)

EXTRA ACCEL. (**) 1,5 1,8 2,1 2,4 2,7 3,0 3,5 4,0 4,5 5,0
DELAY (**)

RELEASE Sec. 5,5 5,0 4,5 4,0 3,5 3,0 2,5 2,0 1,5 1,0
BRAKING (***)

INVERSE Sec. 5,5 5,0 4,5 4,0 3,5 3,0 2,5 2,0 1,5 1,0
BRAKING (***)

PEDAL BRAKING Sec. 5,5 5,0 4,5 4,0 3,5 3,0 2,5 2,0 1,5 1,0
(***)

SPEED LIMIT Sec. 8,9 8,3 7,7 7,1 6,6 6,0 5,5 4,9 4,4 3,8
BRAKING (***)

BRAKE CUTBACK Sec. 5,5 5,0 4,5 4,0 3,5 3,0 2,5 2,0 1,5 1,0
(***)

MAX SPEED FW Hz 67 72 78 89 94 99 109 114 119 124

MAX SPEED BW Hz 67 72 78 89 94 99 109 114 119 124

CUTBACK SPEED % Max 10 20 30 40 50 60 70 80 90 100

1 Sp

CUTBACK SPEED % Max 10 20 30 40 50 60 70 80 90 100

2 Sp

H&S CUTBACK % Max 10 15 20 25 37 50 62 75 87 100

Sp

FREQUENCY Hz 0,3 0,6 0,9 1,2 1,5 1,8 2,1 2,4 2,7 3,0
CREEP

MAXIMUM % IMax 47 53 58 64 70 76 82 88 94 100

CURRENT

INCHING SPEED Hz 0 2 4 6 8 10 12 14 16 18

INCHING TIME Sec. 0,3 1,0 2,0 2,8 3,63 4,5 5,4 6,2 7,1 8,0

AUXILIARY TIME Sec. 0,0 0,4 0,8 1,4 2,0 3,0 4,0 6,0 8,0 10,0

LIFT CUTBACK % 10 15 20 25 37 50 62 75 87 100

MIN VALVE 1 This parameter can be adjusted in steps of 1 between 1 to 255.

MIN VALVE 2 This parameter can be adjusted in steps of 1 between 1 to 255.

MIN VALVE 3 This parameter can be adjusted in steps of 1 between 1 to 255.

MIN VALVE 4 This parameter can be adjusted in steps of 1 between 1 to 255.

MAX VALVE 1 This parameter can be adjusted in steps of 1 between 1 to 255.

ATLET SERVICE MANUAL A-ERGO

 Electrical system / Design and function / Drive motor regulator, AC1 10.23

Table 10.9 Available parameter values, Drive motor regulator

PARAMETER UNIT PARAMETER LEVEL IN STEPS OF 10

0 1 2 3 4 5 6 7 8 9

MAX VALVE 2 This parameter can be adjusted in steps of 1 between 1 to 255.

VALVE 3 VOLTAGE %V 12 20 25 40 50 60 70 80 90 100

VALVE 4 VOLTAGE %V 12 20 25 40 50 60 70 80 90 100

VALVES VOLTAGE V 12 24 36 48 60 72 80 96 120

V1 OPENING Sec. 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8 2,0
RAMP

V2 OPENING Sec. 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8 2,0
RAMP

V3 OPENING Sec. 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8 2,0
RAMP

V4 OPENING Sec. 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8 2,0
RAMP

V1 CLOSING Sec. 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8 2,0
RAMP

V2 CLOSING Sec. 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8 2,0
RAMP

V3 CLOSING Sec. 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8 2,0
RAMP

V4 CLOSING Sec. 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8 2,0
RAMP

(*) The acceleration time is the time from 0 to 100 Hz. This is an average ramp which in reality
can be affected by different settings and loads.

(**) EXTRA ACCEL. DELAY gives a multiple of the level set in ACCELERATION DELAY.
Example:
• ACCELERATION DELAY=LEVEL 2
• EXTRA ACCEL. DELAY= LEVEL 5
• Gives a delay of 2.0s * 3.0 = 6.0s

(***) The braking capacity is based on the deceleration ramp and is the time between which the
regulator pulses from 100 to 0 Hz, and is an average ramp that can be affected by different
settings and loads.

ATLET SERVICE MANUAL A-ERGO

10.24 Electrical system / Design and function / Drive motor regulator, AC1

Submenu specification for TESTER.

Table 10.10 Submenu TESTER, Drive motor regulator

TEST UNIT/ DESCRIPTION

STATUS

BATT VOLTAGE V Voltage to the key lock.

MOTOR VOLTAGE % Voltage to the motor in % of the battery voltage.

VOLTAGE BOOSTER % Voltage to the motor in % of the battery voltage during loading.

FREQUENCY Hz The pulse frequency of voltage and current to the motor.

ENCODER Hz The motor speed, measured as a frequency from the encoder

bearing in the motor.

SLIP VALUE Hz The slipping of the motor, the difference between modulated
frequency and the motor frequency.

COS FI Cos (ϕ) of the motor, the phase displacement between current and
voltage.

CURRENT RMS A The RMS value of the motor current.

BATTERY CURRENT A Calculated current from the battery.

BATTERY CHARGE % Charging status of the battery in %.

TEMPERATURE °C The regulator temperature of the cooling body.

ACCELERATOR V The voltage from the speed controller shown as voltage to the left
and % to the right.

LIFTING CONTROL V The voltage from the lift potentiometer shown as voltage to the
left and % to the right.

LIFTING SWITCH ON/OFF Status of the lift control.

DECENT SWITCH ON/OFF Status of the lower control.

FORW. SWITCH ON/OFF Status of the forward direction of the speed controller.

BACK. SWITCH ON/OFF Status of the backward direction of the speed controller.

SEAT SWITCH ON/OFF Not used.

H&S CUTBACK ON/OFF Not used.

BRAKE SWITCH ON/OFF Status of the foot pedal. (If Input #4" option is set as Brake)

CUTBACK SWITCH ON/OFF Status for input Speed reduction 1.

DIGITAL INPUT #1 ON/OFF Status for the lift switch.

DIGITAL INPUT #2 ON/OFF Status for lowering switch during lowering (if Input #2 is set as
Present #1).

ATLET SERVICE MANUAL A-ERGO

 Electrical system / Design and function / Drive motor regulator, AC1 10.25

Table 10.11 Submenu SAVE PARAMETER, Drive motor regulator

SAVE PARAMETER All set parameters can be saved in the Hand

terminal memory with this menu.

Table 10.12 Submenu RESTORE PARAMETERS, Drive motor regulator

RESTORE All parameters stored in the Hand terminal

PARAMETERS memory can be downloaded in the regulator
memory with this menu.

Table 10.13 Submenu ALARMS, Drive motor regulator

The following is presented in this menu:
ALARMS CODE = Error code
h = time (which operating hour) the error code occurred.
N° = how many times the actual error code occurred.
°C = temperature of the regulator when error code was set.

ATLET SERVICE MANUAL A-ERGO

10.26 Electrical system / Design and function / Drive motor regulator, AC1

Submenu obtained by pressing button 1 and 5 at the same time on the Hand terminal,
specified below:
• See table 10.14
• See table 10.15..
Table 10.14 Submenu SET OPTION, Drive motor regulator

FUNCTION SELECTION DESCRIPTION

HYDRAULIC 0 Manual valve.

1 Proportional valve with or without side stabilisers or straddle lift.

2 Proportional valve with the combination side stabilisers and straddle

lift.

TILLER HANDLE Pin E2.3 is used as input from foot brake switch.
SWITCH
SEAT Pin E2.3 is used as input from seat switch.

SET INPUT #1 PRESENT Pin E1.13 is used as input for speed reduction.

OPTION #1 Pin E1.13 is used as input for hand brake.

SET INPUT #2 PRESENT

OPTION #1

SET INPUT #3 PRESENT

OPTION #1

SET INPUT #4 BELLY Pin E2.7 is used as input from belly switch.

BRAKE Pin E2.7 is used as input for brake.

EXCLUSIVE Pin E2.7 is used as EXCLUSIVE HYDRO, hydraulic brake input.

HYDRO

HOUR RUNNING The hour counter registers the number of hours driven.
COUNTER

KEY ON The hour counter registers the key hours.

BATTERY ON The battery indicator is active, and when the battery discharging
CHECK exceeds 90% an alarm is activated and the power to the drive motor
is maximised to half of max.

OFF The battery indicator is active, but no alarm or reduction during large
discharge.

HYRDO KEY ON/OFF If this function is set to ON the drive regulator will control a
ON hydraulic contactor when the key is switched on, if the function Aux
output #1 is set as Hydrocontactor or Exclusive hydro.

STOP ON ON/OFF The ramp stop function is activated with the time set in the Auxiliary
RAMP time parameter, and after this time the function of the parameter Aux
output #1 will be activated (see also "Set Aux Output in combina-
tion with Ramp On/Off, Drive motor regulator." on page 10.29).

OFF The ramp stop function is not activated (see also "Set Aux Output
in combination with Ramp On/Off, Drive motor regulator." on
page 10.29).

ATLET SERVICE MANUAL A-ERGO

 Electrical system / Design and function / Drive motor regulator, AC1 10.27

Table 10.14 Submenu SET OPTION, Drive motor regulator

FUNCTION SELECTION DESCRIPTION

AUX OUTPUT HYDRO Pin E1.3 controls a hydraulic function when a direction, brake pedal
#1 CONTACTO is active, or the truck is in motion (see also "Set Aux Output in
R combination with Ramp On/Off, Drive motor regulator." on
page 10.29).

BRAKE Pin E1.3 controls the electric brake(see also "Set Aux Output in
combination with Ramp On/Off, Drive motor regulator." on
page 10.29).

EXCLUSIVE Pin E1.3 drives a hydraulic function when the Exclusive hydro input
HYDRO is active (see also "Set Aux Output in combination with Ramp
On/Off, Drive motor regulator." on page 10.29).

AUX PRESENT, The function controls the delay to the stabilizers where a double
FUNCTON #1 with delay. acting hydraulic function is used. Otherwise no delay is required.

ABSENT,
without delay.

PEDAL ANALOG, The mechanical brake has a potentiometer installed so that when the
BRAKING Option, Set speed controller is released the regulator will modulate a braking
input #4" is force in relation to how much the brake pedal is pressed down. The
set on Belly: minimum braking force is determined by the parameter Release
braking (with slight brake pressure). The maximum braking force is
determined by the parameter Pedal braking.

ANALOG, As for option BELLY above, but with the addition that the
Option, Set mechanical brake also has a switch installed as well as a
input #4 is set potentiometer.
on Belly:

DIGITAL No analog foot brake function.

NONE The mechanical brake has neither a potentiometer nor a switch

installed.

QUICK BELLY The function is activated but not timed.

INVERSION
TIMED The function is timed.

NONE The function is switched off.

AUX OUTPUT 100% Drive voltage to emergency contactor and electric brake in percent
#1 of the battery voltage.

PERFORMAN OPTION #1 Sets the power during Low Performance.

CE
OPTION #2 Sets the power during High Performance.

VALVE 1 TYPE OPTION #1 Electric valve 1 is of the On/Off type.

OPTION #2 Electric valve 1 is of the proportional type.

VALVE 2 TYPE OPTION #1 Electric valve 2 is of the On/Off type.

OPTION #2 Electric valve 2 is of the proportional type.

VALVE 3 TYPE OPTION #1 Electric valve 3 is of the On/Off type.

VALVE 4 TYPE OPTION #1 Electric valve 4 is of the On/Off type.

ATLET SERVICE MANUAL A-ERGO

10.28 Electrical system / Design and function / Drive motor regulator, AC1

See table 10.15 below for specification of submenu ADJUSTMENTS. The submenu is
obtained via buttons 1 and 5 on the Hand terminal..
Table 10.15 Submenu ADJUSTMENTS , Drive motor regulator

FUNCTION VALUES EXPLANATION

Option Basic
setting

MIN LIFT ...V - Saves the lowest value from the lift potentiometer
when the lift switch is activated.
See also
MAX LIFT ...V - Saves the highest value from the lift potentiometer "Calibration,
when the lift switch is activated. Lifting/
MIN LOWER ...V - Saves the minimum value from the lowering Lowering
potentiometer when the lowering switch is control" on
activated page 10.41.

MAX LOWER ...V - Saves the largest value from the lowering
potentiometer when the lowering switch is
activated.

SET BATTERY 24V/ 24V Selects battery voltage.

TYPE 36V/
48V

BATTERY ...V 23.8V Final adjustment of measured battery voltage.

ADJUST

THROTTLE 0 ...% 9% Sets the zero point on the speed controller.

ZONE

THROTTLE X ...% 27% Changes the characteristics from the speed

ZONE controller.

THROTTLE Y ...% 47% The parameter changes the characteristics of the

ZONE speed controller.

ADJUSTMENT 1-9 3 Sets the lower level of battery discharging.

#02

ADJUSTMENT 1-9 3 Sets the upper level of battery discharging.

#01

CHECK UP ON/ - Acknowledgement that Service has been carried

DONE OFF out.

CHECK UP TYPE

NONE 0 - Service reminder indicator switched off.

OPTION 0 - Alarm 99 at 300 hours of operation.

#01

OPTION 0 - Alarm 99 + red LED lights up on MDI at 340 hours of operation.

#02

OPTION 0 - Alarm 99 + red LED lights up on MDI at 380 hours of operation

#03 and the truck is stopped.

ATLET SERVICE MANUAL A-ERGO

 Electrical system / Design and function / Drive motor regulator, AC1 10.29

When setting AUX OUTPUT and RAMP ON/OFF in the menu SET OPTION, different
functions are obtained on output pin E1:3. The combinations are specified in table 10.16
below.
Table 10.16 Set Aux Output in combination with Ramp On/Off, Drive motor regulator.

Aux Output Pin E1.3 Stop on Behaviour of the truck when stopping on a sloping ramp
Driver: ramp

Brake The On The truck is held stationary by means of the drive motor until
magnetic the time set in the parameter Auxiliary time has expired and
brake. then the electric brake is activated and the modulation to the
drive motor is cancelled. Only use this combination if a
negative brake is installed.

Off The truck is held by means of the drive motor but moves
slowly down the ramp until the time set in the parameter
Auxiliary time has expired and then the electric brake is
activated and the modulation to the drive motor is cancelled.
Only use this combination if a negative brake is installed.

Hydr. Cont A hydraulic On The truck is held stationary by means of the drive motor until
contactor. the time set in the parameter Auxiliary time has expired and
then the truck moves slowly down the ramp until it reaches
level ground.

Off The truck is not braked electrically, but only rolls slowly
down a ramp until it comes to a level surface.

Excl. Hydro A hydraulic On The truck is held stationary by means of the drive motor until
contactor. the time set in the parameter Auxiliary time has expired, and
only rolls slowly down a ramp until it comes to a level
surface.

Off The truck is not braked electrically, but only rolls slowly
down a ramp until it comes to a level surface.

ATLET SERVICE MANUAL A-ERGO

10.30 Electrical system / Design and function / Steering servoregulator, EPS-AC

Steering servoregulator, EPS-AC

+BATT -BATT

U
+BATT -BATT

V
U EPS - AC
V
W
W

7 1

E4
6
12
11 1

E3

20 10
C

10_009_SM_A-ERGO_regulatorEPS.eps

Figure 10.12 Steering servo regulator

ATLET SERVICE MANUAL A-ERGO

 Electrical system / Design and function / Steering servoregulator, EPS-AC 10.31

Function, steering servo regulator EPS-AC

1 4
2

3
UVW

5
8

UVW
9
6

11

10_011_SM_A-ERGO_ServoFunk.eps 10

Figure 10.13 Functional overview of steering servo system

1. Steering wheel 6. Steering servo motor

2. Step motor sensor 7. Cabling, safety steering drive motor
brake
3. Step motor sensor
cabling, 6 cables 8. Drive motor brake
4. Steering servo 9. Drive motor
regulator
10. Drive wheel
5. Motor cabling
11. End position sensor

A step motor sensor is connected to the steering wheel, which sends a signal to the
steering servo regulator when the steering wheel is activated. The steering servo regulator
provides drive voltage to the steering servo motor, which turns the drive wheel in the
required direction and with the required speed. If a fault is indicated the regulator will
disconnect the drive to the drive motor and allow the drive motor brake to pull, and in so
doing stop the truck.

ATLET SERVICE MANUAL A-ERGO

10.32 Electrical system / Design and function / Steering servoregulator, EPS-AC

S8
S4, S5

07_004_SM_A-Ergo_S4S5S8.eps

Figure 10.14 Limit position switch S4 and S5.

The end positions of the drive unit are indicated by inductive sensors, S4 and S5. When
a sensor is actuated the turning motion is stopped in this direction. To monitor that the
turning motion is not stopped by the sensor before the drive unit is in the end position,
the steering sensor regulator senses whether the drive unit is moving from the sensor
without the end position indicating releasing.
A third sensor, S8, senses whether the wheel is turned more than 45 degrees from the di-
rection straight ahead. If this is the case the drive motor acceleration is reduced to reduce
the tipping moment that occurs during acceleration sideways. The reduced acceleration
is set with the parameter EXTRA ACCEL DELAY in the menu PARAMETER
CHANGE with the help of the Hand terminal (see section 2, Special tools).

S4
S8
S5

10_015_SM_A-ERGO_styrgivare.eps

Figure 10.15 Sensor positioning, truck seen from above.

ATLET SERVICE MANUAL A-ERGO

 Electrical system / Design and function / Steering servoregulator, EPS-AC 10.33

Connector, specification, steering servo regulator EPS-AC

The steering servo regulator has three connectors with inputs and 11 1
outputs for sensors and programming tools. etc.
Each connector pin is specified below, with where appropriate the E3
voltage level in connected position.

Connector E3 (the figure shows the connector from the cabling 20 10

side).

Table 10.17 Connector E3 steering servo regulator

Pin Description Comment

E3.1 Not used in the A model

E3.2 Not used in the A model

E3.3 CAN communication CAN High

E3.4 Not used in the A model

E3.5 Speed reduction

E3.6 Not used in the A model

E3.7 From steering wheel sensor Step motor

E3.8 Not used in the A model

E3.9 Not used in the A model

E3.10 From steering wheel sensor Step motor

E3.11 Control signal from speed controller Neutral = approx. 2.5V

Maximum in direction of forks= approx 4.5V
Maximum in opposite direction= approx 1.0

E3.12 Not used in the A model

E3.13 CAN communication CAN Low

E3.14 Not used in the A model

E3.15 Not used in the A model

E3.16 Not used in the A model

E3.17 Not used in the A model

E3.18 Not used in the A model

E3.19 Not used in the A model

E3.20 From steering wheel sensor Step motor

ATLET SERVICE MANUAL A-ERGO

10.34 Electrical system / Design and function / Steering servoregulator, EPS-AC

Connector E4 (the figure shows the connector from the cabling side). 7 1

E4

12 6

Table 10.18 Connector E4 steering servo regulator

Pin Description Comment

E4.1 Output from safety relay +24V that is disconnected if there is a fault
in the steering servo

E4.2 Not used in the A model

E4.3 From steering wheel sensor Step motor

E4.4 From steering wheel sensor Step motor

E4.5 Not used in the A model

E4.6 End position signal Stops clockwise steering direction

E4.7 Input to safety relay +24V

E4.8 Not used in the A model

E4.9 From steering wheel sensor Step motor

E4.10 Not used in the A model

E4.11 Not used in the A model

E4.12 End position signal Stops anticlockwise steering direction

ATLET SERVICE MANUAL A-ERGO

 Electrical system / Design and function / Steering servoregulator, EPS-AC 10.35

Connector C is used to connect the programming tool, Hand terminal..

Figure 10.16 Connector C (the figure shows the connector from the cabling side)

The battery and motor connections are separately located on the steering servo motor
regulator.
Table 10.19 Separate cable connections

Pin Description

-BATT Negative supply from the battery.

+BATT Positive supply from the battery.

U; V; W Motor connections.

+BATT -BATT

U
+BATT -BATT

V
U EPS - AC
V
W
W

Figure 10.17 Connections, battery and motor

ATLET SERVICE MANUAL A-ERGO

10.36 Electrical system / Design and function / Steering servoregulator, EPS-AC

Menu tree, steering servo regulator EPS-AC

The following main headings are found in the steering servo motor regulator menu tree.
Use the Hand terminal to view the menus, see "Operation, Hand terminal" on page 10.6.
Table 10.20 Main flow in the Hand terminal menus
Display window Display window

AC1 ZAPI V0.0 +

12V 250A 00000

MAIN MENU Table 10.21 on CONFIG MENU

PARAMETER CHANGE page 10.37 SET MODEL

MAIN MENU CONFIG MENU

TESTER SET OPTION

MAIN MENU CONFIG MENU

SAVE PARAMETER ADJUSTMENTS

MAIN MENU
RESTORE PARAMETER

MAIN MENU
ALARMS

MAIN MENU (Not available)

PROGRAM VACC

MAIN MENU (Not available)

MOTOR DATA

ATLET SERVICE MANUAL A-ERGO

 Electrical system / Design and function / Wiring diagram 10.37

Under menu selection PARAMETER CHANGE it is possible to set certain parameters

for the turning motion, see table 10.21 below.
Table 10.21 Submenu PARAMETER CHANGE, steering servo regulator
PARAMETER/BASIC SETTING EXPLANATION
SPEED LIMIT 7 Sets the maximum turning speed for the steering of the drive wheel
AUX FUNCTION 3 2 Sets the compensation of the sensitivity of the steering wheel
modulation at high speed.
SENSIBILITY 3 Sets the sensitivity of the steering wheel modulation.
AUX FUNCTION 2
CREEP SPEED 7 Reinforcement of power for small turns.
PERSUIT RAMP - Not used
COMPENSATION 2 Sets the compensation for voltage drop in cables and transistors.
DESENSIBILIZAT - Not used
POS ACCURACY - Not used
AUXILARY RAMP - Not used
AUXILIARY TIME 1 Sets the time the wheel is held in locked direction after the steering
wheel is no longer activated.
ANTIROLLBACK 40% Sets the force that holds the wheel in locked direction after the
steering wheel is no longer activated.
HOUR COUNTER RUNNING The time is counted when the system is active and when controlling
is possible.
MICRO CHECK PRESENT Connected monitoring system
MUST NEVER BE DISCONNECTED
ENCODER OFF There is no encoder in this system.
CONTROL
FEEDBACK DEVICE OPTION 1 Not used
DIRECTION GAUGE OPTION 1 Not used
AUTO INPUT 1 Not used
ACTIVE
AUX FUNCTION 1 0 Not used

Wiring diagram
All the wiring diagrams are included in a separate Wiring Diagram Handbook, contact
Atlet for further information.
The wiring diagrams relevant to A_Ergo are specified in the table below.
Table 10.22

Description Machine Reference Document code

Connection A-ERGO 104100

diagram

Circuit diagram A-ERGO 104101

ATLET SERVICE MANUAL A-ERGO

10.38 Electrical system / Repair instructions / Calibration, Speed controller

Repair instructions

Calibration, Speed controller

Supply: 5V The drive is regulated with a linear lever, which is supplied with approx.: 5 V.
Neutral
position: In neutral position the control should provide 2.5 V. When the lever is moved opposite
2.5V to the direction of travel forwards the output signal from the sensor increases to 4.5 V,
compared to 1.0 V when the lever is moved in the reverse direction.
The Hand terminal is used to calibrate the start position and max position, see "Operation,
Hand terminal" on page 10.6 for user instructions.

Instructions Display and keyboard

1. Connect the Hand terminal, the display AC1 ZAPI Vx.x
shows: 24V 250A 00000

2. After start up, press the two outer

buttons.

CONFIG MENU
SET MODEL

3. Step to the Adjustment menu.

CONFIG MENU
ADJUSTMENT

4. Press ENTER to enter.

5. Step to ACCELER MIN.

ADJUSTMENT
ACCELER MIN

6. Press ENTER.

7. The display shows the actual value. ACCELER MIN

...V

ATLET SERVICE MANUAL A-ERGO

 Electrical system / Repair instructions / Calibration, Speed controller 10.39

Instructions Display and keyboard

8. Actuate the control to a position that is
suitable to start the travel in the
“direction of the drive wheel”.
If the control position is too far from
neutral this will reduced controllability.
An increase of the voltage by approx. 0.2
V from neutral can be appropriate.
9. Press OUT.

10. Press ENTER to save the value.

Press OUT if the value is NOT to be

saved.

11. The display now shows: CONFIG MENU

ADJUSTMENT

12. Press ENTER to enter.

13. Step to ACCELER MAX.

ADJUSTMENT
ACCELER MAX

14. Press ENTER.

15. The display shows the actual value. ACCELER MAX

...V

16. Actuate the control to position maximum

speed in the “direction of the drive wheel”.
17. Press OUT.

ATLET SERVICE MANUAL A-ERGO

10.40 Electrical system / Repair instructions / Calibration, Speed controller

Instructions Display and keyboard

18. Press ENTER to save.

19. Step to SET ACC REV MIN and repeat

the procedure steps 8 to 12 in the
direction of the forks.
Step to SET ACC REV MAX and repeat
the procedure steps 14 to 12 also in the
direction of the forks.
20. Press ENTER to save the value.

Press OUT if the value is NOT to be

saved.

21. The display now shows: CONFIG MENU

ADJUSTMENT

22. To return to the main menu, press OUT.

The speed controller is now calibrated in both directions. Test the sensitivity, and if any
parameter does not feel right recalibrate that function.

ATLET SERVICE MANUAL A-ERGO

 Electrical system / Repair instructions / Calibration, Lifting/Lowering control 10.41

Calibration, Lifting/Lowering control

This function stores the minimum and maximum values for the lifting and lowering controls.
The minimum value is the position on the lever when the respective movement is to start,
and the maximum value is the value when the movement reaches maximum speed.

Supply: 5V The lifting and lowering movements are regulated with a linear lever supplied with 5 V.
Neutral
position: In neutral position the control should provide 2.5 V. When the lever is moved to lifting
2.5V position the voltage increases to 4.5V, and decreases to 1.0 V when lowering.
The Hand terminal is used to calibrate the start position and max position.

Instructions Display and keyboard

1. Connect the Hand terminal, the display AC1 ZAPI Vx.x
shows: 12V 250A 00000

2. After start up, press the two outer

buttons.

CONFIG MENU
SET MODEL

3. Step to the Adjustment menu.

CONFIG MENU
ADJUSTMENT

4. Press ENTER to enter this function.

5. Step to MIN LIFT.

ADJUSTMENT
MIN LIFT

6. Press ENTER.

7. The display shows the actual value. MIN LIFT

...V

8. Actuate the control to a position that is

suitable to start the lifting movement.

ATLET SERVICE MANUAL A-ERGO

10.42 Electrical system / Repair instructions / Calibration, Lifting/Lowering control

Instructions Display and keyboard

9. Press OUT.

10. Press ENTER to save the value.

Press OUT if the value is NOT to be

saved.

11. The display now shows: CONFIG MENU

ADJUSTMENT

12. Press ENTER to enter this function.

13. Step to MAX LIFT.

ADJUSTMENT
MAX LIFT

14. Press ENTER.

15. The display shows the actual value. MAX LIFT

...V

16. Actuate the control to position for

maximum lift.
17. Press OUT.

18. Press ENTER to save the value.

Press OUT if the value is NOT to be

saved.

ATLET SERVICE MANUAL A-ERGO

 Electrical system / Repair instructions / Calibration, Lifting/Lowering control 10.43

Instructions Display and keyboard

19. The display now shows: CONFIG MENU
ADJUSTMENT

20. Repeat the procedure for MIN

LOWERING and MAX LOWERING.
21. To return to the main menu, press OUT.

The lifting/lowering control is now calibrated.

ATLET SERVICE MANUAL A-ERGO

10.44 Electrical system / Repair instructions / Save parameters in the Hand terminal memory

Save parameters in the Hand terminal memory

This function stores the set parameters in the Hand terminal memory.
These parameters can then be downloaded into another regulator by using the RESTORE
function.
The following data can be saved by using SAVE PARAMETERS:
1. All parameters (PARAMETER CHANGE).
2. Options (SET OPTIONS).
3. Battery level (BATTERY LEVEL).

Instructions Display and keyboard

1. Connect the Hand terminal, the display AC1 ZAPI Vx.x
shows: 24V 250A 00000

2. After start up, press button 3, ENTER to

enter the MAIN MENU.

MAIN MENU
PARAMETER CHANGE

3. Step to SAVE PARAM.

MAIN MENU
SAVE PARAM.

4. Press ENTER to enter.

5. If this function has been used previously, SELECT: Mod. 00

this is indicated with a two digit FREE
reference.
6. Step up, button 2, or down, button 1,
until the window indicates FREE.

SELECT: Mod. 01
FREE

7. Press ENTER to save.

ATLET SERVICE MANUAL A-ERGO

Electrical system / Repair instructions / Save parameters in the Hand terminal memory 10.45

Instructions Display and keyboard

8. The display shows what is saved while it READING...
is carried out. ACCELER DELAY (ECC)

9. When everything is ready the window MAIN MENU

shows: SAVE PARAM.

10. Press OUT to return to the start window.

AC1 ZAPI Vx.x

24V 250A 00000

ATLET SERVICE MANUAL A-ERGO

10.46 Electrical system / Repair instructions / Download parameters from the Hand terminal

Download parameters from the Hand terminal

This function permits stored parameters in the Hand terminal memory to be downloaded
to the regulator.
The following data can be downloaded by using RESTORE PARAMETERS:
1. All parameters (PARAMETER CHANGE).
2. Options (SET OPTIONS).
3. Battery level (BATTERY LEVEL).

Important!
All the values in the regulator memory will be overwritten with the parameters in
the Hand terminal..

Instructions Display and keyboard

1. Connect the Hand terminal, the display AC1 ZAPI Vx.x
shows: 24V 250A 00000

2. After start up, press button 3, ENTER to

enter the MAIN MENU.

MAIN MENU
PARAMETER CHANGE

3. Step to RESTORE PARAM.

MAIN MENU
RESTORE PARAM.

4. Press ENTER to enter.

5. The display will show the models that SELECT: Mod. 00

are saved with a two digit code. AC1 ZAPI V1

6. Step up, button 2, or down, button 1,

until the required model pops up.

SELECT: Mod. 01
AC1 ZAPI V1

ATLET SERVICE MANUAL A-ERGO

Electrical system / Repair instructions / Download parameters from the Hand terminal 10.47

Instructions Display and keyboard

7. Press ENTER to start downloading.

8. The question Are you sure? comes up on ARE YOU SURE?

the display. YES = ENTER NO = OUT

9. The display shows what is saved while it STORING...

is carried out. ACCELER DELAY

10. When everything is ready the window MAIN MENU

shows: RESTORE PARAM.

11. Press OUT to return to the start window.

AC1 ZAPI Vx.x

24V 250A 00000

ATLET SERVICE MANUAL A-ERGO

10.48 Electrical system / Repair instructions / Checking error codes

Checking error codes

The regulator remembers the last five errors that have occurred. An error code is
presented for every error that is saved, the number of times this error has occurred, what
the hour counter showed, and the temperature of the regulator.

Instructions Display and keyboard

1. Connect the Hand terminal, the display AC1 ZAPI Vx.x
shows: 24V 250A 00000

2. After start up, press button 3, ENTER to

enter the MAIN MENU.

MAIN MENU
PARAMETER CHANGE

3. Step to ALARMS.

MAIN MENU
ALARMS

4. Press ENTER to enter.

5. The display will show the error code, the CODE

number of times the error has occurred, 00005 #02 20ºC
and the temperature of the regulator at
the time of the error.
6. Step up, button 2, to see the next error, or
down, button 1, to see previous errors.

CODE
00007 #03 18ºC

7. Press OUT to exit the ALARM window.

8. The question Clear logbook? comes up. CLEAR LOGBOOK?

YES = ENTER NO = OUT

9. Press ENTER for yes and OUT for no.

ATLET SERVICE MANUAL A-ERGO

 Electrical system / Repair instructions / Checking error codes 10.49

Instructions Display and keyboard

10. Press OUT to exit the ALARM window.

AC1 ZAPI Vx.x

24V 250A 00000

ATLET SERVICE MANUAL A-ERGO

10.50 Electrical system / Repair instructions / Replacing drive regulator/steering servo regulator

Replacing drive regulator/steering servo

regulator
1. If possible save current parameter settings, see “Save parameters in the Hand
terminal memory” on page 44, before dismantling.
2. Switch off the power to the truck and pull out the battery plug.
3. Pull out the electrical panel so that the regulator becomes accessible.
4. Disconnect the motor cabling and supply cabling.
5. Pull out the control cabling, connector E1 and E2, and E3 and E4.
6. Unscrew the regulator.
7. Steering servo regulator: Scrape clean the contact surface between the regulator
and attachment plate.
8. Steering servo regulator: Apply heat extraction paste between the regulator and
attachment plate.
9. Refit the regulator.
10. Connect the control cabling, connector E1 and E2, and E3 and E4.
11. Connect the motor cabling and supply cabling.
12. Download the parameter settings the regulator had previously (assumes that point
1 above has been completed), see “Download parameters from the Hand terminal”
on page 46.

Replacing MDI
1. Switch off the power to the truck and pull out the battery plug.
2. Lift up the control panel, see section 7 for access.
3. Loosen connector E5.
4. Loosen the clamp and pull out the MDI.
5. Assemble in the reverse order.

ATLET SERVICE MANUAL A-ERGO

 Electrical system / Repair instructions / Replacing the steering servo sensor 10.51

Replacing the steering servo sensor

S4
S8
S5

10_015_SM_A-ERGO_styrgivare.eps

Figure 10.18 Positioning steering servo sensor, truck seen from above

Dismantling the steering servo sensor

1. Switch off the power and disconnect the battery.
2. Loosen the lock nut on the sensor.
3. Unscrew the sensor (and follow the cable so that it does not twist).

Assembling the steering servo sensor

1. Screw in the sensor (and follow the cable so that it does not twist) until it meets
the cam.
2. Screw up the sensor 1 turn and tighten the sensor with the nut.
3. Lock the nut with liquid thread locking agent.

Important!
The nut should be locked with liquid thread locking agent. Make sure that the
thread locking agent is applied in the threaded hole.

ATLET SERVICE MANUAL A-ERGO

10.52 Electrical system / Diagnosis and trouble shooting / Safety

Diagnosis and trouble shooting

Safety
Important!
See "Safety procedures" on page 10.3 before starting work on the electrical system.

Tools for trouble shooting

Circuit diagram
The circuit diagram forms the basis for trouble shooting work and provides an overview
of the function of the electric system, from where it is possible to localise faults.
Circuit diagrams are supplied with each truck, or can be found in a separate Wiring
Diagram Handbook.

Wiring diagram
The wiring diagram should be used to translate the principle solutions of the circuit
diagram to the practical connections in the truck.
Wiring diagrams are supplied with each truck, or can be found in a separate Wiring
Diagram Handbook.

Error codes
Error codes are read-off on the MDI, see "Multi Function Display Indicator (MDI)" on
page 10.13, and through the Hand terminal, see "Operation, Hand terminal" on page 10.6.
The implications of the error codes are specified in the following sections:
• Drive motor regulator, see:"Error codes, drive motor regulator" on page 10.57.
• Steering servo regulator see:"Error codes, steering servo regulator" on page 10.61.
• Error codes in the display, see:"Error codes MDI" on page 10.56.

Multimeter
When using the multimeter all measurements should be made with B- as reference.
The safest way of trouble shooting is with the negative test cable connected as close to
the battery as possible, with the exception of if voltage levels from the speed controller
are to be measured, in which case it is best to use B- on the respective regulator.

ATLET SERVICE MANUAL A-ERGO

 Electrical system / Diagnosis and trouble shooting / Tools for trouble shooting 10.53

Input and output specification

Pin numbering in contactors, see
• "Connector E1 drive motor regulator AC1" on page 10.16.
• "Connector E2 drive motor regulator AC1" on page 10.17.
• "Connector E3 steering servo regulator" on page 10.33.
• "Connector E4 steering servo regulator" on page 10.34.

ATLET SERVICE MANUAL A-ERGO

10.54 Electrical system / Diagnosis and trouble shooting / Practical trouble shooting

Practical trouble shooting

For all trouble shooting in the electrical system it is recommended to first connect the
Hand terminal to the actual regulator and to check if it gives an error message, and to
translate this in the tables, see "Error codes" on page 10.56.
Errors which in the first instance appear to refer to a regulator may in actual fact be an
error in another unit, and therefore for this reason search for an error message in all units
if it does not occur in the first.

Error in the drive function

1. Connect the Hand terminal to the drive regulator and read-off any error messages,
they will come up automatically when the Hand terminal has logged into the drive
regulator.
2. If there are no error messages actuate the brake switch and speed controller to see
if any message comes up.
If not, go over to the test menu and read-off the function of the brake switch (Brake
switch "Submenu TESTER, Drive motor regulator" on page 10.24) and the output
signal from the speed controller (ACCELERATOR), .

• see "Calibration, Speed controller" on page 10.38.

There are no separate direction switches, and the direction is

determined by the throttle voltage from the speed controller.
However, the direction selection can be studied in the test menu with
FORW SWITCH and BACK SWITCH (indicate if the system
interprets the travel direction),
• see, "Submenu TESTER, Drive motor regulator" on page 10.24.

3. Check also the position of the switches for speed reduction by means of SPEED
SWITCH 1 and 2 in the test menu,.

• see "Submenu TESTER, Drive motor regulator" on page 10.24.

4. Also check the current to the motor CURRENT RMS.

If current goes to the motor without it moving, or if it moves slowly, this may be
because of an error in the encoder signal from the motor, which can be studied by
using ENCODER in the test menu,.

• see "Submenu TESTER, Drive motor regulator" on page 10.24.

• If the encoder should be defective then the encoder bearing in the
drive motor must be replaced, see section 5.

5. Over +75 °C in the drive regulator reduces the maximum motor current gradually
with increasing temperature. At 100 °C it is reduced to zero.

ATLET SERVICE MANUAL A-ERGO

 Electrical system / Diagnosis and trouble shooting / Practical trouble shooting 10.55

This is presented as an error message HIGH TEMPERATURE in the Hand

terminal and 16A61 in the instrument display (MDI).
6. If error message VACC NOT OK is received in the Hand terminal or 16A78 in the
instrument display (MDI), the error may be because the speed controller is
incorrectly calibrated.

• To calibrate the speed controller, see"Calibration, Speed controller"

on page 10.38.

Error in the steering servo system

1. Connect the Hand terminal to the regulator.
2. Read any error messages, and read the reason and solution in "Error codes" on
page 10.56.

Error in the lifting/lowering system

1. Connect the Hand terminal to the drive regulator and read any error messages, see
"Error codes" on page 10.56.
2. Check the system settings with "Delivery Settings in Drive Controller A with Zapi
AC 1 in truck (Parameter Change Menu)" on page 10.20.
3. Use the Test menu, see "Submenu TESTER, Drive motor regulator" on page 10.24,
to study the following:

• Input voltage from the LIFTING CONTROL.

lifting/lowering control with:
• If the system interprets the LIFTING SWITCH.
lifting requirement with:
• If the system interprets the DESCENT SWITCH.
lowering requirement with:

Error symptom, drive motor regulator

Table 10.23 Error symptoms

Symptom Possible reason Action

Low voltage to drive motor Battery voltage lower than set Charge the battery.
limit value.

The system does not start Incorrect start up sequence. The key lock should switch on
before the speed controller can
be actuated.

ATLET SERVICE MANUAL A-ERGO

10.56 Electrical system / Diagnosis and trouble shooting / Error codes

Error codes

Error codes MDI

1. Indication of which regulator set alarm.

2
2. Alarm number
3. A=Alarm

By looking at the first two digits in the error code it is possible to identify the regulator
that set the alarm, see table 10.24 below.
Table 10.24 Indication of which regulator set alarm.

Regulator code Explanation Error codes

02 Drive motor regulator See "Error codes, drive motor regulator" on

page 10.57.

06 Steering servo regulator See "Error codes, steering servo regulator" on

page 10.61.

16 Multi Function Display See table 10.25 below.

Certain error codes are set unique by MDI, see 10.25 below.
Table 10.25 Error codes presented in Multi Function Display, MDI

Error Error code, Explanation Check/Action

code Hand terminal
MDI

16A67 CAN BUS KO Poor contact with CAN-BUS 1. Check the cabling and contactors.
link.
2. If OK, replace regulator.

16A70 HW OVER Valves connected to E5.4 Check power consumption.

CURR and/or E5.6 short circuited. Replace valve when overcurrent exceeds 2A.

16A74 DRIVER MDI PRC has detected short Check power consumption to ON/OFF
SHORTED circuit at ON/OFF valves. valves.
Replace valve when overcurrent exceeds 2A.

16A75 CONTACTOR Internal error MDI. Replace MDI.

DRIVER

16A89 PEPV NOT Positive voltage to valves Check voltage E5.1 = B+.
OK lacking or too low. If OK, replace MDI.

16A90 NEVP1 NOT Problem with one of the

OK proportional valve guides.

ATLET SERVICE MANUAL A-ERGO

 Electrical system / Diagnosis and trouble shooting / Error codes 10.57

Error codes, drive motor regulator

The following error codes are set by the drive motor regulator, table 10.26.
Table 10.26 Error codes, drive motor regulator, AC1

Error code indicating Explanation Check/Action

MDI Hand
terminal

02A00 BATTERY If the function BATTERY CHECK Charge the battery.

LOW is activated and the battery has less
than 10% left the current will be
reduced to half the set level, at the
same time as an error code is shown.

02A08 WATCHDOG This is an internal test carried out Replace regulator.

both during driving and when
stationary, and it is the logic that is
tested.

02A13 EEPROM KO Error in the area that contains Switch on and off from the key once:
adjustable parameters. • If the error code has disappeared,
note that all adjustable parameters
have gone back to the default
values and that a new setting must
be made.
• If the error persists, replace
regulator.

02A16 AUX When the key is switched on, check Replace regulator.
OUTPUT KO the µP Drive contactor driver for the
electric brake. If the answer is not
correct an error code will be given.

02A17 LOGIC Error in the hardware part that Replace regulator.

FAILURE #3 handles the overcurrent protection to
the different phases to the motor.

02A18 LOGIC Error in the hardware part that Replace regulator.

FAILURE #2 handles the voltage supply in the
different phases to the motor.

02A19 LOGIC Indicates that the over/undervoltage a) A real under/overvoltage has

FAILURE#1 protection has been activated. occurred.
b) Replace regulator.

02A30 VMN LOW/ This test is carried out during start a) Problem with the cables to the
/ VMN HIGH up and when stationary. motor, connections, windings in the
02A31 motor, or contact to material.
b) Replace regulator.

02A37 CONTACTOR Drive contactor closed during start a) Check contactor and cables.
CLOSED b) Replace regulator.

02A38 CONTACTOR The logic has sent a voltage to the a) Break in cables to the coil.
OPEN main contactor coil and this is b) Defective contactor.
expected to be closed, but the
contactors are not closed.

ATLET SERVICE MANUAL A-ERGO

10.58 Electrical system / Diagnosis and trouble shooting / Error codes

Table 10.26 Error codes, drive motor regulator, AC1

Error code indicating Explanation Check/Action

MDI Hand
terminal

02A53 STBY i HIGH Check that the current is 0 when a) Defective current sensor.
stationary. b) Replace regulator.
If not the truck will be stopped.

02A55 PROG LIFT This alarm indicates that there is an Error in the program for lifting/
LEVER error in the program for the lifting/ lowering control.
lowering control.

02A60 CAPACITOR Internal regulator error. Replace regulator.

CHARGE

02A61 HIGH Temperature of cooling flange over 1. Check fan at the electrical panel
TEMPERATU 75°C. The current is limited in
2. No action if no other symptoms are
RE relation to the excess temperature.
shown.
The regulator stops completely at
100°C. 3. Improve cooling

02A67 CAN BUS KO Monitoring of CAN bus. a) Check cables.

b) Replace regulator.

02A70 ENCODER Incorrect signal from the drive 1. Check the encoder signal with the
ERROR motor speed feedback sensor Hand terminal.
(Encoder).
2. Check cabling between the drive
motor encoder and drive regulator.

02A71 HAND- The truck does not start because the a) Switch defective.
BRAKE foot brake switch is not actuated. b) The driver has used the wrong
sequence during start up.
c) Defective cables.
d) If the error persists, replace
regulator.

02A73 THERMIC Incorrect values from the sensor that Replace regulator.
SENSOR KO controls the regulator temperature.

02A74 DRIVER Internal error, regulator. Replace regulator.

SHORTED

02A75 CONTACTOR Internal error, regulator. Replace regulator.

DRIVER

02A76 COIL When the key is switched on, check 1. Check for possible short circuiting
SHORTED the µP Drive contactor driver for in the cabling, and if the coil has
FF.SR. If the answer is not correct the correct resistance.
there will be an error code, in the
2. Replace regulator.
event of this error replace regulator.
FF SR carries out a hardware check
of the current to the drive contactor
coil, and if it is too high the drive
contactor opens and an error code is
shown.

ATLET SERVICE MANUAL A-ERGO

 Electrical system / Diagnosis and trouble shooting / Error codes 10.59

Table 10.26 Error codes, drive motor regulator, AC1

Error code indicating Explanation Check/Action

MDI Hand
terminal

02A78 VACC NOT This test is carried out when a) Speed controller not correctly
OK stationary. The reason for the alarm calibrated.
is that the voltage from the speed b) Speed controller defective.
controller is 1 volt higher that the
minimum value programmed in the
PROGRAM VACC function.

02A79 INCORRECT This alarm indicates that an a) Speed controller defective.

START incorrect start has been made. b) The driver has used the wrong
sequence during start up.
c) Defective cables.
d) If the error persists, replace
regulator.

02A80 FORW + This test is carried out all the time, a) The driver has used the wrong
BACK and means that double travel sequence during start up.
directions have been requested at b) Defective cables.
the same time. c) If the error persists, replace
regulator.

02A86 PEDAL WIRE This error code indicates that there Check the cabling to the speed
KO is a fault in the cables to the speed controller.
controller potentiometer.

02A89 PEV NOT OK The voltage on PEV output is not Replace regulator.
correct.

02A93 INPUT This alarm is detected only at power Check with a multimeter if the battery
ERROR #2 up. Meaning: The battery voltage voltage is really over or under the
differs more than 20% compared to mentioned thresholds.
nominal value. If not, using the Zapi console, check
the”BATTERY VOLTAGE” in the
tester menu.
If you find a mismatch between the
real battery voltage and the Zapi
console battery voltage, you should
tune it:
Go into the adjustment menu. Make
sure that “SET BATTERY TYPE” is
24V and then tune the “ADJUST
BATTERY” parameter to the correct
value. Then switch the truck off and
on.

02A94 CURR.SENS Error in current meter system. Replace regulator.

KO

ATLET SERVICE MANUAL A-ERGO

10.60 Electrical system / Diagnosis and trouble shooting / Error codes

Table 10.26 Error codes, drive motor regulator, AC1

Error code indicating Explanation Check/Action

MDI Hand
terminal

02A99 INPUT The speed controller has two output • Check the speed controller and
ERROR #1 signals, a primary one centred cabling.
around 2.5 V, increasing when
• Measure the voltage levels.
driving in the machine housing
direction and decreasing in the forks
direction, and a secondary one also
centred around 2.5 V but going in
the opposite direction when
accelerating.

This is used as a control signal and

goes in on the steering servo contact
E3.11. From there is goes via the
CAN system to the drive regulator
and is compared with the primary
one.

If these do not correspond the

system will go into neutral position
and the brake will be activated.

Poor contact with speed controller. • Check connector E3 to see that the
contact surfaces are OK.
• Check measure E3.11.

ATLET SERVICE MANUAL A-ERGO

 Electrical system / Diagnosis and trouble shooting / Error codes 10.61

Error codes, steering servo regulator

The following error codes are set by the steering servo regulator, table 10.26.
Table 10.27 Error codes, steering servo regulator, EPS

Error code indicating Explanation Check/Action

MDI Hand
terminal

06A08 MICRO Internal error, steering servo If the error persists, replace regulator.
SLAVE regulator.

06A13 EEPROM KO Internal error, steering servo Carry out a CLEAR EEPROM.
regulator. • Use the Hand terminal, press both
the SET buttons (5+6) at the same
time to enter ALARM CONFIG
MENU.
• Step forward to CLEAR
EEPROM.
• Press ENTER twice (3+3.)
If the error persists, replace regulator.

06A16 LOGIC Internal error, steering servo If the error persists, replace regulator.
FAILURE #4 regulator.
High rest potential between the U and
W phase.

06A17 LOGIC Internal error, steering servo If the error persists, replace regulator.
FAILURE #3 regulator.
High rest potential between the V and
U phase.

06A18 LOGIC Occurs when the required voltage If the error persists, replace regulator.
FAILURE #2 between phase U and W differs from
the measured value.

06A19 LOGIC Occurs when the required voltage If the error persists, replace regulator.
FAILURE #1 between phase U and V differs from
the measured value.

06A28 S.P OUT OF Occurs when the potentiometer for • Check the connections and
RANGE the required steering angle has poor cabling of the steering angle
electrical contact. potentiometer.
• If a fault cannot be found, replace
potentiometer.

06A29 F.B OUT OF Occurs when the potentiometer for • Check the connections and
RANGE resetting the steering angle has poor cabling of the steering angle
electrical contact. potentiometer.
• If a fault cannot be found, replace
potentiometer.

06A32 VMN NOT Occurs when the initial rest potential If the error persists, replace regulator.
OK between at least one phase and signal
earth is high.

ATLET SERVICE MANUAL A-ERGO

10.62 Electrical system / Diagnosis and trouble shooting / Error codes

Table 10.27 Error codes, steering servo regulator, EPS

Error code indicating Explanation Check/Action

MDI Hand
terminal

06A37 KM CLOSED Occurs when safety contact drops in • Check the electrical installation,
advance. pin E4.1 and E4.7.
• Where appropriate, check the
function of change-over-switches
and relays in the circuit.
• If none of the above errors are
found, replace regulator.

06A38 KM OPEN Occurs when safety contact opens too • Where appropriate, check the
late. function of change-over-switches
and relays in the circuit.
• If none of the above errors are
found, replace regulator.

06A39 KS CLOSED Occurs when safety contact drops in • Check the electrical installation,
advance. pin E4.1 and E4.7.
• Where appropriate, check the
function of change-over-switches
and relays in the circuit.
• If none of the above errors are
found, replace regulator.

06A40 KS OPEN Occurs when safety contact opens too • Where appropriate, check the
late. function of change-over-switches
and relays in the circuit.
• If none of the above errors are
found, replace regulator.

06A48 MAIN CONT Occurs during initiation of Probably an alarm from the drive
OPEN synchronisation of the CanBus motor regulator AC1.
system with the drive motor regulator
AC1 if the main contactor does not
close.

06A53 STBY is Rest potential too high. Replace regulator.

HIGH

06A61 HIGH Regulator temperature over 76 °C. Switch off the truck and allow the unit
TEMPERATU to cool.
RE

06A67 KEYOFF A warning that the Sicus module The error code disappears if the Sicus
gives a Key-off command via Can module switches off the command.
Bus.

06A68 One steering end limit switch (S4 or • Check function of both end limit
S5) is closed when it should be open. sensors (S4 and S5).
Each time the steering is turned away
• Check sensor (S4 and S5)
from the end position the limit switch
adjustment.
is checked to see that it opens.
If it does not open, the error shows
and the drive is stopped.

ATLET SERVICE MANUAL A-ERGO

 Electrical system / Diagnosis and trouble shooting / Error codes 10.63

Table 10.27 Error codes, steering servo regulator, EPS

Error code indicating Explanation Check/Action

MDI Hand
terminal

06A70 HIGH Occurs if the current amplifier output If the error persists, replace regulator.
CURRENT signal gives a higher value than the
Imax level for more than one second.

06A71 POWER Occurs with phase loss, steering Check measure steering servo motor
FAILURE #3 servo motor U, V, W. and cabling.

06A72 POWER Occurs with phase loss, steering Check measure steering servo motor
FAILURE #2 servo motor U, V, W. and cabling.

06A73 POWER Occurs with phase loss, steering Check measure steering servo motor
FAILURE #1 servo motor U, V, W. and cabling.

06A81 DATA Occurs when the operator changes Switching the key off and on resets
ACQUISITIO ADJUSTMENT #1 to level 1. the alarm.
N

06A94 MICRO Set point value for steering wheel Check connections.
SLAVE KO modulation and actual value from - Step motor sensor
drive wheel do not correspond. - Steering servo motor
- Limit position sensor, steering
If the error persists, replace regulator.

06A95 D LINE Occurs when the signal from the step 1. Check step motor cabling.
SENSOR KO motor sensor, pin E4.3 EPS, is open.
2. Measure the resistance between
pin E4.3 and signal earth (should
be close to 30Ω).
3. If the error persists, replace step
motor sensor.

06A96 Q LINE Occurs when the signal from the step 1. Check step motor cabling.
SENSOR KO motor sensor, pin E4.9 EPS, is open.
2. Measure the resistance between
pin E4.6 and signal earth (should
be close to 30Ω).
3. If the error persists, replace step
motor sensor.

ATLET SERVICE MANUAL A-ERGO

10.64 Electrical system / Diagnosis and trouble shooting / Error codes

ATLET SERVICE MANUAL A-ERGO

 SERVICEMANUAL
Machine: A-Ergo

Manual No: 005975

Edition 2007A

11 Brake and speed system

Design and function ..................................................................................................... 11.3

Electric brake ......................................................................................................11.3

Repair instructions ....................................................................................................... 11.4

Electric brake ......................................................................................................11.4
Adjusting the electric brake (–2006w46) ...................................................................... 11.4
Adjusting the electric brake (2006w47–) ...................................................................... 11.4
Replacing the magnetic part, electric brake (–2006w46) ............................................. 11.4
Replacing the brake disc (2006w47–) .......................................................................... 11.5
Emergency release ...................................................................................................... 11.7
Speed controller .................................................................................................11.8
Replacing the speed controller ..................................................................................... 11.8
Adjusting the speed controller ...................................................................................... 11.8
Checking the foot pedal ................................................................................................ 11.8

ATLET SERVICE MANUAL A-ERGO

11.2

ATLET SERVICE MANUAL A-ERGO

 Brake and speed system / Design and function / Electric brake 11.3

Edition 2007A

11 Brake and speed system

Design and function

Electric brake
A-Ergo is fitted with an electric brake. The electric brake is a safety brake with two fric-
tion surfaces. The brake torque that can be adjusted using an adjuster screw on the older
model (–2006w46), is generated by spring pressure. The brake is activated when the volt-
age across the coil is cut, i.e. the truck brakes when it has no power supply.

When the brake is actuated 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 magnetic field created between the plate and the magnetic part allows the rotor to
rotate freely.
The brake is actuated in four different ways (see also the wiring diagram):
1. Via the drive motor regulator when the regulator indicates a serious fault.
2. Via the steering servo regulatorn, which disconnects the brake coil supply to the
plus terminal of the battery if a serious fault is indicated.
3. Via the foot pedal, which disconnects the brake coil supply to the plus terminal of
the battery when the driver is not longer actuating it.

SMA-Ergo_11_2007A.fm
ATLET SERVICE MANUAL A-ERGO
11.4 Brake and speed system / Repair instructions / Electric brake

Repair instructions

Electric brake

Adjusting the electric brake (–2006w46)

Adjusting is carried out in the following order.
1. Adjusting of A dimension:

1. Fit the electric brake and tighten the bolts.

A dimension:
A = 0.2 mm 2. Check the gap, see figure11.1, between the magnetic part and the
plate (the A dimension should be: A = 0.2 mm
3. If the gap needs adjusting, release the bolts holding the brake and
turn the adjusting sleeves.
4. Tighten the brake and check that the gap is the same all round.

2. Test the brakes by driving and test braking.

SM104.1

Figure 11.1 Electric brake

Adjusting the electric brake (2006w47–)

Electric brake in new design (from 2006 w47) is adjusted at the factory and cannot be
adjusted later.

Replacing the magnetic part, electric brake (–2006w46)

1. The T dimension should be checked before replacing the magnetic part!

ATLET SERVICE MANUAL A-ERGO

 Brake and speed system / Repair instructions / Electric brake 11.5

2. When refitting the magnetic part adjust the T dimension to the same dimension as
before by means of a hook spanner, see figure 11.1.

Warning!
Remember to lock any adjustments!

Warning!
Check that you have a safe braking capacity.

Warning!
The friction lining must be at least 1 mm, otherwise it must be replaced.

Note!
When you install a new brake, remember to remove the transport lock.

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.

ATLET SERVICE MANUAL A-ERGO

11.6 Brake and speed system / Repair instructions / Electric brake

6. Reconnect the electrical connections to the magnetic part.

Warning!
Check that you have a safe braking capacity.

ATLET SERVICE MANUAL A-ERGO

 Brake and speed system / Repair instructions / Electric brake 11.7

Emergency release
The brake can be released manually where necessary.

Note!
If the brake is released manually, there is no working parking or emergency brake.
Never leave a truck 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).

ATLET SERVICE MANUAL A-ERGO

11.8 Brake and speed system / Repair instructions / Speed controller

Speed controller

Replacing the speed controller

1. Lift up the arm rest, see section 4.

04_003_SM_A-ERGO_ArmstDem.eps

Figure 11.4 Lift up arm rest

2. Release the cabling to the speed controller.

3. Unscrew the two screws holding the controller in place, and take out the controller.

Adjusting the speed controller

See section 10.

Checking the foot pedal

The foot pedal can be checked in two different ways, either by measuring the resistance
or by measuring it connected in the system and supplied with voltage.
We recommend measuring the switch connected in the system and supplied with voltage.
1. Lift up the drive wheel and secure the truck with blocks.
2. Connect a voltmeter over the foot switch connectors.
3. Press down the foot switch.
4. Read-off the value, it should be less than 0.1 Ohm.
5. Release up the foot switch and read-off the value, it should be approx. battery plus.
The resistance of the switch should be measured if it is lower.

ATLET SERVICE MANUAL A-ERGO