ATLET A-Ergo User manual
SERVICE MANUALSERVICE MANUAL
MacMachihine: ne: A-EA-Ergorgo
ManManual ual No: No: 000059759755
ATLET SERVICE MANUAL A-ERGOATLET SERVICE MANUAL A-ERGO
Edition 2008BEdition 2008B
1 1 General General information and information and technical datechnical datata
Scope, Scope, service service manual ....................manual ................................................................................................................................................................................ 1.31.3
General General ................................................................................................................................................................................................................................ 1.31.3
Scope Scope of of the the A-Ergo A-Ergo model model .................................................................................................................................................................. 1.31.3
How How to to use use the the manual ...........manual ......................................................................................................................................................................................... 1.41.4
StrucStructure ture ............................................................................................................................................................................................................................ 1.41.4
History History .................................................................................................................................................................................................................................. 1.41.4
Symbol Symbol key key .................................................................................................................................................................................................................... 1.41.4
Safety Safety instructions instructions .................................................................................................................................................................................................................. 1.51.5
General General ................................................................................................................................................................................................................................ 1.51.5
Lifting Lifting the the truck ..................................truck ...................................................................................................................................................................... 1.61.6
Checks/PChecks/Preparations reparations ............................................................................................................................................................................................................ 1.61.6
Permitted Permitted lifting lifting points ............................................................................................points ............................................................................................................ 1.61.6
Welding Welding on on the the truck .................................truck ....................................................................................................................................................... 1.71.7
TTaking aking the the environment environment into into consideration .consideration ................................................................................................................... 1.71.7
Preparations Preparations ...................................................................................................................................................................................................................................... 1.81.8
Service Service .................................................................................................................................................................................................................................. 1.81.8
Trouble Trouble shooting shooting .................................................................................................................................................................................................... 1.81.8
Data Data A-Ergo A-Ergo .......................................................................................................................................................................................................................................... 1.91.9
Designations Designations ................................................................................................................................................................................................................ 1.91.9
Truck Truck designation designation ...................................................................................................................................................................................................................... 1.91.9
Type Type designation designation .................................................................................................................................................................................................................... 1.101.10
Dimensions Dimensions and and weights weights ........................................................................................................................................................................ 1.141.14
Dimensions Dimensions A-Ergo ......................................................................................................A-Ergo ...................................................................................................... 1.141.14
Component Component specification specification ...................................................................................................................................................................... 1.151.15
Recommended Recommended consumable consumable material material .................................................................................................................................................. 1.161.16
Oil Oil and and grease grease ...................................................................................................................................................................................................... 1.161.16
StandaStandards rds and and abbreviations .................................abbreviations ........................................................................................................................................... 1.171.17
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ATLET SERVICE MANUAL A-ERGOATLET SERVICE MANUAL A-ERGO
1.21.2
Screws ...............................................................................................................1.17Screws ...............................................................................................................1.17
Tightening torque, Tightening torque, screws and nuts screws and nuts ............................................................................................................................................................ 1.171.17
Tightening Tightening torque, torque, hydraulic couplings .........................................................................hydraulic couplings ......................................................................... 1.181.18
Conversion Conversion table table ...................................................................................................................................................................................................................... 1.181.18
Screw types Screw types and and tensile grades tensile grades ........................................................................................................................................................................ 1.191.19
Colour of the truck ..............................................................................................1.20Colour of the truck ..............................................................................................1.20
Colour Colour codes, codes, cabling .cabling ...............................................................................................................................................................................1.201.20
Designations, Designations, electrical electrical componentcomponents s ..................................................................................................................................1.211.21
Standard abbreviations ......................................................................................1.22Standard abbreviations ......................................................................................1.22
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GeGenenerral al ininfforormamatition on aand nd tetechchninicacal l dadata ta / / ScScoopepe, , seservrvicice e mamanunual al / / GeGenenerralal 1.1.33
ATLET SERVICE MANUAL A-ERGOATLET SERVICE MANUAL A-ERGO
SMA-Ergo_01_2008B.fmSMA-Ergo_01_2008B.fm
Edition 2008BEdition 2008B
1 1 General General information and information and technical technical datadata
Scope, service manualScope, service manual
GeneralGeneral
This manual describeThis manual describes the service procedures for As the service procedures for ATLET stand-on stackerTLET stand-on stackers in the A-Ergos in the A-Ergo
series. Use the manual for series. Use the manual for quick and correct service of quick and correct service of respective truck models.respective truck models.
The manual describes models manufactured from and including the The manual describes models manufactured from and including the introduction of A-introduction of A-
Ergo at the end of 2002.Ergo at the end of 2002.
YYou may find contradictions in ou may find contradictions in the manual compared with the the manual compared with the models supplied due tomodels supplied due to
optional designs, upgrades and the like.optional designs, upgrades and the like.
Warning!Warning!
If the truck is rebuilt after delivery or supplemented in such a manner that safetyIf 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.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 writtenThe electrical system must never be rewired in any form after delivery without written
authorisation from Atlet AB, authorisation from Atlet AB, since this may change the measured and applicable EMC.since this may change the measured and applicable EMC.
The content of this service manual is protected by copyright law The content of this service manual is protected by copyright law and may not be copied,and may not be copied,
fully or in fully or in part, without written permission. The material has undergonpart, without written permission. The material has undergone carefule careful
examination with regard to correctness. Subject to examination with regard to correctness. Subject to alteration. In the event of alteration. In the event of inconsistentinconsistent
information in the Swedish and translated editions, it information in the Swedish and translated editions, it is the Swedish edition that applies.is the Swedish edition that applies.
Modifications and updates will Modifications and updates will be distributed via be distributed via AATLET AB TLET AB Service Manual Change.Service Manual Change.
Scope of the A-Ergo Scope of the A-Ergo modelmodel
The stand-on stacker trucks in the The stand-on stacker trucks in the A-Ergo series are available in a A-Ergo series are available in a number of differentnumber of different
variants with mast system, straddle lift, extendable stabilisors and telescopic forks (ATF).variants with mast system, straddle lift, extendable stabilisors and telescopic forks (ATF).
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1.1.44 GeGeneneraral l iinfnforormamattioion n anand td tecechnhnicical al dadatta / a / HoHow tw to o ususe e ththe me maanunual al / / StStruructctururee
ATLET SERVICE MANUAL A-ERGOATLET SERVICE MANUAL A-ERGO
How to use the manualHow to use the manual
StructureStructure
The manual is built up according to the same principle as ATLET spare parts catalogues,The manual is built up according to the same principle as ATLET spare parts catalogues,
with the truck divided into one subsystem per section.with the truck divided into one subsystem per section.
Sections 1 - 3 Sections 1 - 3 in this manual contain comprehensive information regarding technical data,in this manual contain comprehensive information regarding technical data,
service instructions and tools.service instructions and tools.
Sections 4-12 in the manual contain information limited to a specific area in Sections 4-12 in the manual contain information limited to a specific area in the truckthe truck
concerning a description of the mechanical handling of concerning a description of the mechanical handling of different components. Fordifferent components. For
example, Masts (section 6) and Hydraulic System example, Masts (section 6) and Hydraulic System (section 8).(section 8).
With regard to software this is With regard to software this is described under section 10.described under section 10.
The main principle for extra The main principle for extra accessories is to place them accessories is to place them under the respective sections.under the respective sections.
Otherwise they are placed under section 12 Otherwise they are placed under section 12 “Miscellaneous”“Miscellaneous”. For this . For this reason section 12reason section 12
is not always included in the is not always included in the Service Manual.Service Manual.
For specific problems or information about procedures, look in the main index for theFor specific problems or information about procedures, look in the main index for the
correct section in the manual.correct section in the manual.
HistoryHistory
The following modifications affect the service procedure.The following modifications affect the service procedure.
Symbol keySymbol key
Warning!Warning!
Used if there is a risk of personal injury.Used if there is a risk of personal injury.
Important!Important!
Used if there is a risk of damage to machine.Used if there is a risk of damage to machine.
oteote
Used for general observation.Used for general observation.
Table 1.1Table 1.1 Upgrades of the truck that affect the service procedureUpgrades of the truck that affect the service procedure
DDaattee CChhaassssiis s nnoo.. EEvveenntt
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GeGenenerral al ininfforormamatition on anand d tetechchninicacal l dadata ta / / SaSaffetety y ininststruructctiionons / s / GeGennereralal 1.1.55
ATLET SERVICE MANUAL A-ERGOATLET SERVICE MANUAL A-ERGO
Safety instructionsSafety instructions
GeneralGeneral
Extreme importance must be placed on precautionary measures to avoid accidents duringExtreme importance must be placed on precautionary measures to avoid accidents during
all work on the vehicle.all work on the vehicle.
A general rule is to always implement preventive measures that are adapted to the typeA 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:of vehicle to be worked on. The general rules below must always be observed:
•• SmoSmokinking or nag or nakeked flad flames mes are sare stritrictlctly forby forbididden aden as ths there iere is a riss a risk of exk of exploplosiosion in thn in thee
vicinity of batteries vicinity of batteries and while working on gas eand while working on gas equipped vehicles.quipped vehicles.
•• The The batbattertery sy shouhould ald alwalways ys be be proprotecttected ed durduring ing gringrindiding ng worwork.k.
•• LoLocacal fil fire rre regegululatatioions ns mumust bst be fe folollolowewed.d.
•• The dThe drivrive whee wheel shel shoulould ald alwayways be ls be liftifted ued up frep free froe from the fm the flooloor durr during ing serservicvice woe workrk
to prevent the vehicle from moving.to prevent the vehicle from moving.
•• BefoBefore wore workinrking on g on the ethe eleclectrictrical syal systestem thm the bate battertery pluy plug shog shoululd be pud be pullelled oud out.t.
•• TTo prevo prevent ient injunjuries ries caucausesed by crd by crusushinhing the bg the battattery pery plug slug shouhould alld alwayways be rems be removeovedd
when working on or around the mast and hydraulic unit. The mast or hydraulic unitwhen working on or around the mast and hydraulic unit. The mast or hydraulic unit
can be actuated due to an electrical fault or can be actuated due to an electrical fault or a mistake while working. The batterya mistake while working. The battery
plug may only be plug may only be connected while trouble shooting, and when the greatest of connected while trouble shooting, and when the greatest of carecare
is exercised, (with the truck raised).is exercised, (with the truck raised).
Warning!Warning!
Having the power connected to the truck when working on or around the mast Having the power connected to the truck when working on or around the mast cancan
result in fatal injury!result in fatal injury!
•• WheWhen won workinrking on og on or aror around und the mthe masast and tt and the hyhe hydradrauliulic unc unit, tit, they hey musmust be lot be lockeckedd
by using the mast by using the mast lock, wooden blocks or some other appropriate means.lock, wooden blocks or some other appropriate means.
•• No oNo othether per persorsons sns shouhould bld be in e in the vthe viciicinitnity of ty of the trhe truck uck whewhen it in it is tes test rst run inun in
conjunction with repair work, in view of the risk conjunction with repair work, in view of the risk of accidents or near-accidentsof accidents or near-accidents
from the from the truck making an unexpected manoeuvre.truck making an unexpected manoeuvre.
•• The sThe systystem sem shouhould nold not be pt be presressusurisrised, eed, e.g.g. the p. the pump ump motmotor sor shuthutoff off and tand the fhe forkorkss
down, when dismantling parts of down, when dismantling parts of the hydraulic system.the hydraulic system.
•• All meAll metal tal objobjectects sucs such as wh as watcatchehes ans and rind rings shgs shoulould be rd be remoemoved wved whehen worn workinking ong on
the electrical system, or ithe electrical system, or in its immediate vicinity. A short-circuit from such objectsn its immediate vicinity. A short-circuit from such objects
can result in serious burn injuries.can result in serious burn injuries.
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1.1.66 GeGeneneraral il infnforormamattioion an and nd ttecechnhnicical al dadatta / a / SaSafefetty iy insnstrtrucucttioions ns / L/ Lififtiting ng tthe he trtrucuckk
ATLET SERVICE MANUAL A-ERGOATLET SERVICE MANUAL A-ERGO
Lifting the truckLifting the truck
Checks/PreparationsChecks/Preparations
•• WheWhen thn the true truck is ck is liflifted ted by uby usinsing a jag a jack, ck, makmake sue sure yre you sou secuecure ire it wit with blth blococks.ks.
TheThe truck must notruck must not rest on the jack, while t rest on the jack, while work is carried out.work is carried out.
•• EnsEnsure thure that stat strapraps, wis, wires ores or chair chains hans have a suve a sufffficiicient lent liftiifting cang capacpacity bity befoefore lifre liftingting
the truck.the truck.
•• EnsEnsure ture that hat the dthe drivrive whe wheeeel runl runs frs free oee of the f the floofloor ber beforfore tre troubouble sle shoohootinting.g.
Permitted lifting pointsPermitted lifting points
FigureFigure1.11.1shows where the permitted lifting points are placed on the truck. The lshows where the permitted lifting points are placed on the truck. The liftingifting
points are marked with a decal representing a lifting hook; the lifting holes in the points are marked with a decal representing a lifting hook; the lifting holes in the outerouter
mast should be used.mast should be used.
Warning!Warning!
The machine must never be lifted from the overhead guard.The machine must never be lifted from the overhead guard.
Figure 1.1Figure 1.1 Permitted lifting points, A-ErgoPermitted lifting points, A-Ergo
01001_SM_A-Ergo.eps
01001_SM_A-Ergo.eps
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GeGeneneraral il infnforormamattioion an and nd tteechchnnicical al dadatta / Sa / Safafetety iy insnstrtrucucttiionons / Ws / Weleldiding ng on on ththe te truruckck 1.1.77
ATLET SERVICE MANUAL A-ERGOATLET SERVICE MANUAL A-ERGO
Welding on the truckWelding on the truck
•• DurDuring wing weldelding ing worwork thk the bate battery tery pluplug shg shoulould ald alwayways be ds be disciscononnecnected ated and and allll
connections to the control units aconnections to the control units and regulators (concerns all electronic units)nd regulators (concerns all electronic units)
should be disconnected. On completion of welding work should be disconnected. On completion of welding work the connectors shouldthe connectors should
first be connected to the electronic units, after which the battery plug first be connected to the electronic units, after which the battery plug is connectedis connected
to the battery.to the battery.
•• ThThe wee weldldining eag eartrth shh shouould ald alwlwayays be s be coconnnnectected ed asas clclosose to te to the whe weleldiding ang arerea asa as
possible to eliminate possible to eliminate damage to surrounding components.damage to surrounding components.
Taking the environment into considerationTaking the environment into consideration
Atlet AB Atlet AB takes care of the takes care of the environment. Wenvironment. Waste material in conjunction with aste material in conjunction with repairs,repairs,
maintenance, cleaning, or scrapping, should be collected and disposed of in maintenance, cleaning, or scrapping, should be collected and disposed of in anan
environment-friendly way and in environment-friendly way and in accordance with the directives of accordance with the directives of respective countries.respective countries.
Such work must only be carried out in areas intended for this Such work must only be carried out in areas intended for this purpose.purpose.
Environmentally hazardous waste, such as oil filters, Environmentally hazardous waste, such as oil filters, batteries, hydraulic hoses andbatteries, hydraulic hoses and
electronics, can have a negative effect on telectronics, can have a negative effect on the environment, or health, if handledhe environment, or health, if handled
incorrectlyincorrectly. Recyclable materi. Recyclable material should be al should be taken care of taken care of by specialised authorities.by specialised authorities.
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11.8.8 GeGenneerraal il innfoforrmamattioion n anand td teechchnnicical al dadatta / a / PPrereppaarraatitioonns / s / SeServrviicece
ATLET SERVICE MANUAL A-ERGOATLET SERVICE MANUAL A-ERGO
PreparationsPreparations
ServiceService
•• Go Go ththrorougugh ah all ll ththe se safafetety iy insnstrtrucuctitionons.s.
•• MakMake sue sure thre that yoat you hau have ave all thll the esse essenentiatial tool tools cls closlose at he at hand band befoefore sre starttarting ing worwork.k.
•• BefoBefore cabre cablinling or otg or other eher eleclectrictrical coal compmponeonentnts are dis are discscononnecnectedted, che, check thck the cole colourour
codes and check for damage to codes and check for damage to cables or connections.cables or connections.
•• WheWhen con complmplex cex compompononentents are s are reprepairaired aned and did dismasmantntledled, mak, make sue sure thre that yat you haou haveve
good control of the different component parts to avoid the risk of confusion.good control of the different component parts to avoid the risk of confusion.
•• When rWhen repepairiairing or mng or mainaintaitaininning seng sensitsitive cive compomponeonentsnts, mak, make sure sure thae that you ut you use clse cleanean
tools and work on a clean work surface.tools and work on a clean work surface.
•• DisDismanmantletle, ins, inspepect anct and adjd adjusust comt componponentents accs accordordining to thg to the prese prescribcribed roed routiutinesnes..
See respective sections for detailed information.See respective sections for detailed information.
Trouble shootingTrouble shooting
When you suspect a faulty When you suspect a faulty component, do not replace it icomponent, do not replace it immediatelymmediately. First check the. First check the
surrounding equipment and carry out complete surrounding equipment and carry out complete trouble shooting routines. Make sure youtrouble shooting routines. Make sure you
know the reason for the fault before replacing a component.know the reason for the fault before replacing a component.
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GeGenneeraral il innfoforrmamattioion an annd td teechchnnicicaal dl daatta / a / DDaata ta A-A-ErErggo / o / DDeesisigngnaattioionnss 11.9.9
ATLET SERVICE MANUAL A-ERGOATLET SERVICE MANUAL A-ERGO
Data A-ErgoData A-Ergo
DesignationsDesignations
TrTruck uck designationdesignation
Table 1.2Table 1.2 Truck designationsTruck designations
TTrruucck k ttyyppee AA--EErrggoo SSttaanndd--oon n ssttaacckkeerr, , SSttaannddaarrdd
AA--EErrggo o TTFF SSttaanndd--oon n ssttaacckkeer r wwiitth h tteelleessccooppiic c ffoorrkkss
LLooaad d ccaappaacciittyy AA--EErrggoo 1166000 0 oor r 2200000 0 kkgg
AA--EErrggo o TTFF 1100000 0 kkgg
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1.1.1010 GeGeneneraral il infnforormamattioion an and nd ttecechnhnicical al dadatta / a / DaData ta A-A-ErErgo go / D/ Desesiigngnatatioionsns
ATLET SERVICE MANUAL A-ERGOATLET SERVICE MANUAL A-ERGO
TType ype designationdesignation
11.. MoModdeel del desisiggnnaattiioonn..
2.2. TType Sype Serieeries no.s no./V/Verersiosion (S=n (S=SpeSpeciacial verl versiosion.)n.)..
3.3. YYear oear of manf manufactufacture, wure, week, eek, and and warranwarranty pty period eriod in min months onths (only (only SwedSweden).en).
(On the assumption that the service instructions in the warranty regulations are(On the assumption that the service instructions in the warranty regulations are
followed.)followed.)
4.4. Any lAny load road restricestrictiontions, deps, dependinending on g on the pthe positiosition oon of the f the load oload on the n the forks forks (D) an(D) and/od/orr
lifting height (Q).lifting height (Q).
Figure 1.2Figure 1.2 Example of type plate (–2006w36)Example of type plate (–2006w36)
1
1
22
33
44
TyTypspskylt.kylt.epseps
DD
HH
HH
QQ
AATLETTLETAABBMMÖLNLYCKEÖLNLYCKE SSWEDENWEDEN
H H D D QQ
H H QQ
MMODELLODELL
MMODELODEL
MMODELLODELL
MMODELEODELE
SSERIE NR.ERIE NR.
SSERIERIAAL NO.L NO.
SSERIEN NR.ERIEN NR.
NONOMMERO DEERO DESSERIEERIE
TILLV. ÅRTILLV. ÅR
YEYE
AAR OFR OF MAMANUF.NUF.
BBAAUJUJAAHRHR
AAN DE FN DE F
AABRBR
TILLÅTEN LTILLÅTEN LASASTT
AACTUCTUAAL CL CAAPPAACITYCITY
WIRKLICHE TRWIRKLICHE TR
AAGFÄHIGKEITGFÄHIGKEIT
CCAAPPAACITE EFFECTIVECITE EFFECTIVE
LYFTHÖJDLYFTHÖJD
LIFTHEIGHTLIFTHEIGHT
HUBHÖHEHUBHÖHE
HHAAUTEUR DE LEVEEUTEUR DE LEVEE
TYNGDPUNKTTYNGDPUNKTSASAVVSSTÅNDTÅND
BBAATTERITTERISSPÄNNINGPÄNNING
BBAATTERY VOLTTTERY VOLTAAGEGE
BBAATTERIETTERIESSPPAANNUNGNNUNG
TENTENSSION DE LION DE LAABB
AATTERIETTERIE
VIKT UTVIKT UT
AAN BN B
AATTERITTERI
WEIGHT WITHOUT BWEIGHT WITHOUT B
AATTERYTTERY
GEWICHT OHNE BGEWICHT OHNE B
AATTERIETTERIE
MASSMASSEESASANNSSBB
AATTERIETTERIE
MMININSSTTAABBAATTERIVIKTTTERIVIKT
MMINIINIMMUUMMBB
AATTERY WEIGHTTTERY WEIGHT
MMINDEINDESSTGEWICHT DER BTGEWICHT DER BAATTERIETTERIE
MASSMASSEEMMINIINIMAMAL DE LL DE LAABBAATTERIETTERIE
MAMAXIXIMAMAL BL BAATTERIVIKTTTERIVIKT
MAMAXIXIMMUUMMBB
AATTERY WEIGHTTTERY WEIGHT
HÖCHHÖCHSSTGEWICHT DER BTGEWICHT DER BAATTERIETTERIE
MASSMASSEEMAMAXIXIMAMAL DE LL DE LAABBAATTERIETTERIE
LOLOAAD CENTRE DID CENTRE DISSTTAANCENCE
LL
ASASTTSSCHWERPUNKTCHWERPUNKT
DIDISSTTAANCE DE CENTRENCE DE CENTRE
MMMM
MMMM
KGKG
GG
KGKG
VOLT-DCVOLT-DC
KGKG
KGKG
1
1
66
00
SS
DTFV 8DTFV 8
0000
AA
AA1010568/568/0101SS
2200003w3w0101-6-6
88000000
36360000
660000
550000
11660000
10001000
2424
11115500
373700
545400
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GeGennereraal il infnfoormrmatatioion an and nd ttecechhninicacal dl daatta / Da / Datata Aa A--ErErggo / Do / Desesigignanattioionsns 1.1.1111
ATLET SERVICE MANUAL A-ERGOATLET SERVICE MANUAL A-ERGO
11.. MoModdeel del dessigignnaattioionn..
2.2. TType Sype Serieeries no.s no./V/Versersion (ion (S=SS=Spepeciacial verl versiosion.n.).).
3.3. YYear oear of manf manufactufacture, wure, week, eek, and wand warranarranty pety period iriod in monn months (oths (only Snly Swedenweden).).
(On the assumption that the service instructions in the warranty regulations are(On the assumption that the service instructions in the warranty regulations are
followed.)followed.)
4.4. Any loaAny load resd restrictiotrictions, dns, depenepending ding on the on the positposition of tion of the loahe load on the d on the forks forks (D) an(D) and/ord/or
lifting height (Q).lifting height (Q).
Note!Note!
In cases where the machine plate has been lost or become illegible, it must beIn 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 arenewed 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,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 batteryTMC etc. For some machines there is even a plate attached inside the battery
compartment, or serial number punched on the side of the mast.compartment, or serial number punched on the side of the mast.
Figure 1.3Figure 1.3 Example of type plate (2006w37–)Example of type plate (2006w37–)
SM
SM__AA-E-Ergorgo__1A1A..epseps
MoModdeell
MoModdeellll
SerSerial nial noo..
SerSeriieennrr..
YYeeaarroof manufactuf manufacturriningg
TillvTillverer
kninkningsgsåårr
WWeeiigght withht withoout battut battereryy
Vikt utan battVikt utan battererii
BattBatterery wy weeiigght min.ht min.
BattBattererivikt min.ivikt min.
BattBatterery wy weeiigght max.ht max.
BattBattererivikt max.ivikt max.
BattBatterery vy vooltaltagege
BattBattereriispspänninänningg
RReeffererncnceenumbnumberer
RReeffereerennssnummnummerer
AATLETTLETAABBMMÖLNLYCKEÖLNLYCKE SSWEDENWEDEN
HH(mm)(mm)
HH
XXXXXXXXXXXXXXXX
QQ(k(kgg))
DD(mm)(mm)
DD
QQ
44
33
22
11
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1.1.1212 GeGeneneraral il infnforormamattioion an and nd ttecechnhnicical al dadatta / a / DaData ta A-A-ErErgo go / D/ Desesiigngnatatioionsns
ATLET SERVICE MANUAL A-ERGOATLET SERVICE MANUAL A-ERGO
Figure 1.4Figure 1.4 Example of plate with serial number.Example of plate with serial number.
SER XXXXXX
SER XXXXXX
WEEK XXXXWEEK XXXX
SER XXXXXXSER XXXXXX
WEEK XXXXWEEK XXXX
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GeGennereraal il infnfoormrmatatioion an and nd ttecechhninicacal dl daatta / Da / Datata Aa A--ErErggo / Do / Desesigignanattioionsns 1.1.1313
ATLET SERVICE MANUAL A-ERGOATLET SERVICE MANUAL A-ERGO
Explanation of Model designationExplanation of Model designation
Example:Example: A 160 A 160 S DTF S DTF V S V S 360 225 360 225 4040
Truck typeTruck type
Load capacity/10Load capacity/10
NNaarrrroow w ggaauuggee SS
BBrrooaad d ggaauuggee BB
TTeelleessccooppiic c mmaasstt TT
TTeelleessccooppiic c mmaasstt, , FFrreeee--lliifftt TTFF
DDoouubblle e tteelleessccooppiic c mmaasstt DDTT
DoDoububle tle telelesescocoppic mic masast, Ft, Frreeee-l-liiftft DTDTFF
Free-view Free-view mast mast VV
SSttaabbiilliisseerrss SS
SSttrraaddddlle e lliifftt HH
Lifting height in cmLifting height in cm
Battery Ah/5Battery Ah/5
Charger AmpereCharger Ampere
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1.1.1414 GeGeneneraral l ininfoformrmatatioion n anand td tecechnhnicical al dadata ta / / DaData ta A-A-ErErgo go / / DiDimemensnsioions ns anand d weweigighthtss
ATLET SERVICE MANUAL A-ERGOATLET SERVICE MANUAL A-ERGO
Dimensions and weightsDimensions and weights
Dimensions A-ErgoDimensions A-Ergo
Figure 1.5Figure 1.5 Positions for dimensions A-ErgoPositions for dimensions A-Ergo
Figure 1.6Figure 1.6 Positions for dimensions A-Ergo TFPositions for dimensions A-Ergo TF
B1
B1
VV
BB
B2B2
RR
22
HH
66
L2L2
L3L3
L4L4 L1L1
LL
HH
33
HH
44
HH
55
HH
77
HH
22
HH
11
A-Ergo Mått A.epsA-Ergo Mått A.eps
BB
11
VV
BB
22
BB
RR
22
HH
66
L2L2
L3L3
L4L4
U U L1L1
L1L1
LL
HH
33
HH
44
HH
55
HH
77 HH
22
HH
11
HH
77
A-Ergo Mått ATF.epsA-Ergo Mått ATF.eps
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GeGeneneraral il infnforormamatition on anand d tetechchninicacal dl datata / a / DaData ta A-A-ErErgo go / C/ Comompoponenent nt spspececifificicatatioionn 1.1.1515
ATLET SERVICE MANUAL A-ERGOATLET SERVICE MANUAL A-ERGO
Component specificationComponent specification
Table 1.3Table 1.3 Component specificationComponent specification
CCoommppoonneenntt SSppeecciiffiiccaattiioonn
DDrriivve e mmoottoorr DDrriivve e vvoollttaaggee 1166VV
OOuuttppuut t ssttaannddaarrdd 22..2 2 / / 22..4 4 kkWW
S2 60 minS2 60 min
Insulation resistanceInsulation resistance >24>24 kkΩΩ
GGeeaarrbbooxx GGeeaar r rraattiio o ((ssttaannddaarrdd)) 1166,,9955::11
OOiil l vvoolluummee 11..5 5 lliittrreess
HHyyddrraauulliic c ssyysstteemm MMaax x pprreessssuurree 1177..5 5 MMPPaa
(=175 kp/cm²)(=175 kp/cm²)
OOiil l vvoolluummee mmaax x 119 9 lliittrreess
HHyyddrraauulliic c uunniit t ((mmoottoor r aannd d ppuummpp)) TTyyppe e 11 OOuuttppuutt 33..5 5 kkWW
TTyyppe e 22 OOuuttppuutt 44..5 5 kkWW
TTyyppe e 33 OOuuttppuutt 77..6 6 kkWW
CCoonnttrrool l ssyysstteem m ffoor r ddrriivve e mmoottoorr TTyyppe e ZZaappi i AACC11 AAC C TTrraannssiissttoorr
VVoollttaaggee 224 4 VV
MMaax x ccuurrrreenntt 225500A A ((RRMMSS))
in 2 minin 2 min
CCoonnttrrool l ssyysstteem m ffoor r sstteeeerriinng g wwhheeeell TTyyppe e ZZaappi i AACC11 AAC C TTrraannssiissttoorr
VVoollttaaggee 2244VV
MMaax x ccuurrrreenntt 7700AA
FFuusseess CCoonnttrrool l ffuussees s 2 2 ppccss.. 77..55AA
30.0A30.0A
PPumump mp mototor or fufuse se 1 p1 pcscs.. 252500AA
DrDriive ve momototor fr fususe 1 e 1 pcpcs.s. 161600AA
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1.1.1616 GeGeneneraral il infnforormamatition on anand td tecechnhnicical al dadata ta / R/ Rececomommemendnded ced cononsusumamablble mae mateteririal al / Oi/ Oil al and nd grgreaeasese
ATLET SERVICE MANUAL A-ERGOATLET SERVICE MANUAL A-ERGO
Recommended consumable materialRecommended consumable material
Oil and greaseOil and grease
Important!Important!
Do not mix different lubricants – definitely not synthetic oil with mineral oil!Do not mix different lubricants – definitely not synthetic oil with mineral oil!
Table 1.4Table 1.4 Table of recommended types of oil and greaseTable of recommended types of oil and grease
BBrraanndd GGeeaarrbboox x ooiill
As per API valueAs per API value
GL-5GL-5
Hydraulic oilHydraulic oil
As per ISO VG 32, VG 15As per ISO VG 32, VG 15
Bearing greaseBearing grease
NLGI 2NLGI 2
Lithium baseLithium base
WorWorm gear oim gear oill
(Only ATF)(Only ATF)
NNoorrmmaall CCoolld sd sttoorree NNoorrmmaall
(32)(32)
Cold storeCold store
(15)(15)
BBPP BBPP
EnergearEnergear
HypoHypo
80W/14080W/140
EPEP
BPBP
EnergearEnergear
SHX-SSHX-S
75W/14075W/140
BP BartranBP Bartran
HV-32HV-32
BP BartranBP Bartran
SHF-SSHF-S
BP EnergreaseBP Energrease
LC 2LC 2
BP EnergolBP Energol
SGXP 150SGXP 150
CCaassttrrooll HHyyppool l CC
80 W/9080 W/90
-- HHyyssppiinn
SHS 32SHS 32
HydraulicHydraulic
oil OM 15oil OM 15
Alt:HyspinAlt:Hyspin
AWH 15AWH 15
LLMMxx AAllpphha a ssyynn
T 220T 220
MMoobbiill MMoobbiilluubbee
HD 85 W/HD 85 W/
9090
-- DDTTE E 113 3 MM
SHS 32SHS 32
FFlloowwrreex x 11 MMoobbiillpplleex x 4488 GGLLYY
goyle 30goyle 30
SShheellll SSppiirraax x HHDD
85 W/9085 W/90
-- TTeelllluus s ooiill
TX 32TX 32
Tellus oilTellus oil
T 15T 15
RReettiinnaax x EEPP22 TTiivveella a WWBB
Statoil /Statoil /
ExxonExxon
GearwayGearway
G5G5
80 W/9080 W/90
-- SSHHS S 3322 J J 2266 UUnniiwwaayy
LIX 625LIX 625
Snäckväxel-Snäckväxel-
olja 375 Solja 375 S
TTeexxaaccoo GGeeaarrtteexx
EP-EP-
C 80 W/90C 80 W/90
-- RRaannddo o ooiill
HDZ 32HDZ 32
Rando oilRando oil
HDZ 15HDZ 15
HHyytteex x EEPP22 SSyynnlluubbee
CLP 220CLP 220
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GeGeneneraral il infnforormamatition on anand td tecechnhnicical al dadata ta / S/ Statandndarards ds anand ad abbbbrereviviatatioions ns / S/ Scrcrewewss 1.1.1717
ATLET SERVICE MANUAL A-ERGOATLET SERVICE MANUAL A-ERGO
StaStandards and ndards and abbreviationsabbreviations
ScrewsScrews
Tightening torque, screws and Tightening torque, screws and nutsnuts
The tightening torque in the The tightening torque in the table above are standard values. In some cases a table above are standard values. In some cases a specificspecific
tightening torque is specified in respective sections. If no tightening torque is specifiedtightening torque is specified in respective sections. If no tightening torque is specified
in the service instructions, the in the service instructions, the values shown in the table values shown in the table above applyabove apply..
Table 1.5Table 1.5 Tightening torque, screws and nutsTightening torque, screws and nuts
DDIIMM TTeennssiille e ggrraaddee
44,,66 88,,88 1100,,99 1122,,99
NNmm NNmm NNmm NNmm
MM44 11,,11 22,,99 44,,00 44,,99
MM55 22,,22 55,,77 88,,11 99,,77
MM66 33,,77 99,,88 1144 1177
MM88 88,,99 2244 3333 4400
MM1100 1177 4477 6655 7799
MM1122 3300 8811 111144 113366
MM1144 4488 112288 118811 221177
MM1166 7744 119977 227777 333333
MM1188 110033 227755 338866 446633
MM2200 114444 338855 554411 664499
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1.1.1818 GeGeneneraral il infnforormamatition on anand td tecechnhnicical al dadata ta / / StStanandadardrds as and nd ababbrbreveviaiatitionons / s / ScScrerewsws
ATLET SERVICE MANUAL A-ERGOATLET SERVICE MANUAL A-ERGO
Tightening torque, hydraulic couplingsTightening torque, hydraulic couplings
Conversion tableConversion table
Table 1.6Table 1.6 Tightening torque, hydraulic couplingsTightening torque, hydraulic couplings
Tightening torque: Pipe thread / metric thread:Tightening torque: Pipe thread / metric thread:
MeMetrtriic fic fine tne thrhreeadad WhWhititwwororth th pipipe tpe thrhreeadad MA MA (N(Nm) m) wwitithh
ringring
MA (Nm) with elasticMA (Nm) with elastic
MM110 0 x x 11 G G 11//88"" 2255 1100
MM112 2 x x 11..55 3300 2200
MM114 4 x x 11..55 G G 11//44"" 5500 3300
MM116 6 x x 11..55 G G 33//88"" 8800 3355
MM118 8 x x 11..55 9900 4400
MM220 0 x x 11..55 G G 11//22"" 113300 5500
MM222 2 x x 11..55 115500 6600
MM226 6 x x 11..55 225500 7700
MM227 7 x x 11..55 G G 33//44"" 225500 8800
MM227 7 x x 22 225500 9900
G G 11"" 335500 114400
MM333 3 x x 22 440000 114400
MM442 2 x x 22 G G 1111//44"" 660000 224400
MM448 8 x x 22 G G 1111//22"" 880000 330000
Table 1.7Table 1.7 Conversion table, torque unitsConversion table, torque units
Newton metreNewton metre
(Nm)(Nm) Kilopond metreKilopond metre
(kpm)(kpm) Poundforce inchPoundforce inch
(lbg x in)(lbg x in) Poundforce footPoundforce foot
(lbf x ft)(lbf x ft)
11 00,,1100 88,,8855 00,,7744
99,,8811 11 8866,,8800 77,,2233
00,,1111 00,,0011 11 00,,0088
11,,3366 00,,1144 1122,,0000 11
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GeGeneneraral il infnforormamatition on anand td tecechnhnicical al dadata ta / S/ Statandndarards ds anand ad abbbbrereviviatatioions ns / S/ Scrcrewewss 1.1.1919
ATLET SERVICE MANUAL A-ERGOATLET SERVICE MANUAL A-ERGO
Screw types and tensile gradesScrew types and tensile grades
Marking with the manufacturer trademark, including the tensile grade, is compulsory forMarking with the manufacturer trademark, including the tensile grade, is compulsory for
screws with a thread diameter screws with a thread diameter from and including 5 mm and in from and including 5 mm and in tensile grades accordingtensile grades according
to the table above. Marking only takes place when the shape of the product permits this.to the table above. Marking only takes place when the shape of the product permits this.
Table 1.8Table 1.8
FFiigguurree SSccrreew w ttyyppee DDeessiiggnnaattiioonn TTeennssiille e ggrraaddee
MM66SS HHeexxaaggoon n ssccrreeww 88,,88
10,910,9
MMCC66SS HHeexxaaggoon n hhoolle e ssccrreeww 88,,88
10,910,9
12,912,9
MMFF66SS HHeexxaaggoon n hhoolle e ssccrreeww,,
countersunkcountersunk
10,910,9
MMCCSS SSllootttteed d ssccrreeww 44,,66
MMVVBBFF OOvvaal l hheeaadd
countersunk screwcountersunk screw
4,64,6
Figure 1.7Figure 1.7 Example of markingExample of marking
SM 031.1
SM 031.1
8.88.8
12.912.9
12.912.9
8.88.8
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1.1.2020 GeGeneneraral il infnforormamatition on anand td tecechnhnicical al dadata ta / St/ Stanandadardrds ans and abd abbrbreveviaiatitionons / Cs / Cololouour or of thf the tre trucuckk
ATLET SERVICE MANUAL A-ERGOATLET SERVICE MANUAL A-ERGO
Colour of the truckColour of the truck
0
0
The truck is painted with the following NCS colour codes:The truck is painted with the following NCS colour codes:
Colour codes, cablingColour codes, cabling
The colour codes of all the cables in the truck can be The colour codes of all the cables in the truck can be read off from the Atlet wiringread off from the Atlet wiring
diagram. The abbreviations have the following implication:diagram. The abbreviations have the following implication:
Note!Note!
Two-colour cables are shown with both colour codes separated by a slash.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.E.g. blue/yellow cable is shown with colour code BL/Y.
Table 1.9Table 1.9 NCS colour codesNCS colour codes
MMaacchhiinne e ccoolloouurr DDeessiiggnnaattiioonn
YYeellllooww NNCCS S 00007700--YY2200RR
MMeeddiiuum m ggrreeyy NNCCS S 77000000
DDaarrk k ggrreeyy NNCCS S 88000000
Table 1.10Table 1.10 Colour codes, Atlet wiring diagramColour codes, Atlet wiring diagram
CCooddee CCaabblle e ccoolloouurr
BBEE BBeeiiggee
BBLL BBlluuee
BBNN BBrroowwnn
GGNN GGrreeeenn
GGRR GGrreeyy
OORR OOrraannggee
PP PPiinnk k
RR RReedd
SSBB BBllaacck k
VVOO VViioolleett
WW WWhhiittee
YY YYeellllooww
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