service repair manual

1. SERVICE MANUAL
Machine: OP
Manual nr: 005949
ATLET SERVICE MANUAL
Edition 2008B
General information and technical data
1.1 Introduction ...................................................................................................................1.1
1.2 General information, OP series ...................................................................................1.2
1.3 How to use the manual .................................................................................................1.3
1.3.1 History .............................................................................................................1.3
1.3.2 Symbol key ......................................................................................................1.4
1.4 Tips before next step ....................................................................................................1.5
1.4.1 Lifting points ....................................................................................................1.5
1.4.2 Safety instructions ...........................................................................................1.6
1.4.3 General safety risks when working on fork trucks ...........................................1.6
1.4.4 Environmentally hazardous waste – environment ...........................................1.7
1.4.5 Handling ..........................................................................................................1.7
1.4.6 Trouble shooting ..............................................................................................1.8
1.5 Data OP ..........................................................................................................................1.9
1.6 Dimensions and weights ............................................................................................1.13
1.6.1 Dimensions OP .............................................................................................1.13
1.7 Overview of motor compartment ...............................................................................1.14
1.8 Component specification ...........................................................................................1.15
1.9 Tightening torque .......................................................................................................1.17
1.9.1 Conversion table ...........................................................................................1.18
1.9.2 Bolt types and tensile grades ........................................................................1.18

2. ATLET SERVICE MANUAL
1.10 Lubrication chart ...................................................................................................... 1.20
1.10.1 Lubrication chart OP ................................................................................... 1.20
1.10.2 Symbol explanations, lubrication chart ....................................................... 1.21
1.11 Recommended oil and grease types ...................................................................... 1.22
1.12 Colour of the truck in accordance with NCS colour codes .................................. 1.23
1.13 Colour codes for Atlet’s wiring diagrams .............................................................. 1.24
1.14 Designations for electrical components ................................................................ 1.25
1.15 Technical abbreviations ........................................................................................... 1.26
1.16 Recommended replacement ................................................................................... 1.27

3. General information and technical data 1.1
Introduction SERVICE MANUAL
Edition 2008B
1 General information and technical data
00000000
1.1 Introduction
This manual describes the service procedures for ATLET picking trucks in the OP
series. Use the manual for quick and correct service of respective truck models.
You may find contradictions in the manual compared to the models supplied due to
optional designs 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 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.

4. 1.2 General information and technical data
SERVICE MANUAL General information, OP series
1.2 General information, OP series
Picking trucks in the OP series include OPM, OPH, OPC and OPS.

5. General information and technical data 1.3
How to use the manual ATLET SERVICE MANUAL
1.3 How to use the manual
The manual is arranged according to the same principles as ATLET’s spare part
catalogues, i.e. a system consists of 12 sections, where sections 4 -12 contain
information limited to a specific part of the truck. For example, Chassis (section 4)
and Hydraulic System (section 8). Sections 1 - 3 in this manual contain more
comprehensive information regarding technical data, general service, instructions
and tools. 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.
1.3.1 History
Important changes to be taken into consideration during service on the OP models.
Table 1.1
Date Chassis no. Changed
2001-03-20 OP1429 New connectors for steering and speed
controller units.
OP1107 New type of cable in the mast.
2001-03-20 OP1429 New attachment plate for both ends of the
electric cables in the mast.
2001-03-20 OP1429 New cabling in the platform.
2001-02-20 OP1429 The E4 card has been replaced with a module
with fixed resistance.
New version of regulator for main hydraulic
valve, with extra electronic filter for improved
reliability.
2001-06-15 OP1496 The Ergomast is welded.
Fixed forks welded at the platform.
OP1377 New type of chain. 5/8 inch.
Third chain removed.
2000-10-06 Alternative safety line available as accessory.
OP1431 Platform lighting changed to two halogen
lamps.
2001-05-14 New decals in new position.

6. 1.4 General information and technical data
SERVICE MANUAL How to use the manual
1.3.2 Symbol key
Warning!
Used with risk of personal injury.
Important!
Used with the risk of damage to the machine.
Note!
Used for general observation.

7. General information and technical data 1.5
Tips before next step ATLET SERVICE MANUAL
1.4 Tips before next step
0
1.4.1 Lifting points
Figure above shows where the permitted lifting points are placed on the truck.
When lifting complete truck: Lift in the first instance in the upper mast strut, point
A. Make sure not to damage the hydraulic pipe between the cylinders.
Lifting with jack: Lift at point C.
Figure 1.1 Lifting points
SM 150.1
B
C
A

8. 1.6 General information and technical data
SERVICE MANUAL Tips before next step
1.4.2 Safety instructions
When the truck is lifted using a jack, make sure you secure it with blocks. The truck
must not rest on the jack, while work is carried out.
Ensure that straps, wires or chains have a sufficient lifting capacity before lifting the
truck.
Pull out the battery plug before working on the electrical system.
Ensure that the drive wheel runs free of the floor before trouble shooting.
The system should not be pressurised, e.g. the pump motor shut off and the forks
down, when dismantling parts of the hydraulic system.
1.4.3 General safety risks when working on fork trucks
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.
• The fire regulations for the building should also be observed.
The drive wheel should always be lifted up free from the floor during service work
to prevent the vehicle from moving. The vehicle must not rest solely on the jack, but
must be secured by some form of blocking.
To prevent injuries caused by crushing, the battery plug should always be pulled out
when working around the mast, reach carriage and hydraulic unit on electric Reach
Trucks. The mast, reach carriage and 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!
Standing on the reach carriage between the mast and battery partition with the
current connected to the truck can result in fatal injury!
When working on and around the mast and hydraulic unit, they must be locked by
using a 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
caused by the truck making an unexpected manoeuvre.
When working on the gas equipment on gas driven vehicles the gas system should
be emptied first, if possible, by shutting the main tap and running the motor or
equipment until the system is empty and stops.

9. General information and technical data 1.7
Tips before next step ATLET SERVICE MANUAL
Escaping gas is heavier than air and has a tendency to collect in cavities, and can be
ignited by sparks or a naked flame. The machine should therefore be ventilated with
compressed air before service work is begun. Ventilation should also be carried out
after repairs before the motor or another unit is started, since sparks from the starter
or relays can cause explosions.
The system should not be pressurised, e.g. the pump motor shut off 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.
1.4.4 Environmentally hazardous waste – environment
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.
1.4.5 Handling
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, complete 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.
Make sure that gaskets and O-rings, etc. are replaced with new parts each time they
are dismantled.
Always use ATLET’s original spare parts.
Use the screws and bolts specified in the spare parts catalogue. Tighten according
to instructions. In those cases where the tightening torque is not specified, refer to
the table of standard tightening torque in section 1.7.

10. 1.8 General information and technical data
SERVICE MANUAL Tips before next step
1.4.6 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.

11. General information and technical data 1.9
Data OP ATLET SERVICE MANUAL
1.5 Data OP
0
Figure 1.2 Type designations (example)
Load capacity/10
125 STV S 360 225 40 .../ / /
Narrow track S
Wide track B
Telescopic mast T
Telescopic free lift mast
Dual telescopic mast
Dual telescopic free lift mast DTF
DT
TF
Free visibility mast V
Stabilisers S
Adjustable straddle legs H
Lifting height in cm
Battery Ah/5
Battery charger Ampere
Model type OPM, OPC, OPH, OPS
SM 151.1E

12. 1.10 General information and technical data
SERVICE MANUAL Data OP
1. Type designation.
2. Serial number.
3. Year of manufacture and warranty period in months.
Figure 1.3 Machine name-plate (–2006w36)
D H
Q
ATLETAB MÖLNLYCKE SWEDEN
H D QH D Q
MODELL
MODEL
MODELL
MODELE
SERIE NR.
SERIAL NO.
SERIEN NR.
NOMERO DESERIE
TILLV. ÅR
YEAR OF MANUF.
BAUJAHR
AN DE FABR
TILLÅTEN LAST
ACTUAL CAPACITY
WIRKLICHE TRAGFÄHIGKEIT
CAPACITE EFFECTIVE
LYFTHÖJD
LIFTHEIGHT
HUBHÖHE
HAUTEURDE LEVEE
TYNGDPUNKTSAVSTÅND
BATTERISPÄNNING
BATTERY VOLTAGE
BATTERIESPANNUNG
TENSION DE LA BATTERIE
VIKT UTAN BATTERI
WEIGHT WITHOUT BATTERY
GEWICHT OHNE BATTERIE
MASSE SANS BATTERIE
MINSTA BATTERIVIKT
MINIMUM BATTERY WEIGHT
MINDESTGEWICHT DER BATTERIE
MASSE MINIMAL DE LA BATTERIE
MAXIMAL BATTERIVIKT
MAXIMUM BATTERY WEIGHT
HÖCHSTGEWICHT DER BATTERIE
MASSE MAXIMAL DE LA BATTERIE
LOAD CENTRE DISTANCE
LASTSCHWERPUNKT
DISTANCE DE CENTRE
MMMM MMMM KGKG
KG
VOLT-DC
KG
KG
1
2
3

13. General information and technical data 1.11
Data OP ATLET SERVICE MANUAL
1 Type designation.
2. Serial number.
3. Year of manufacture and warranty period in months.
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.
Figure 1.4 Machine name-plate (2006w37–)
Model
Modell
Serial no.
Serie nr.
Year of manufacturing
Tillverknings r
Weight without battery
Vikt utan batteri
Battery weight min.
Batterivikt min.
Battery weight max.
Batterivikt max.
Battery voltage
Batterisp nning
Refernce number
Referensnummer
ATLET AB M LNLYCKE SWEDEN
H (mm)
H
XXXXXXXX
Q (kg)D (mm)
D
Q
3
2
1
SMOP_010101.eps

14. 1.12 General information and technical data
SERVICE MANUAL Data OP
Figure 1.5 Example of plate with serial number.
Figure 1.6 Serial number
SER XXXXXX
WEEK XXXX
SER XXXXXX
WEEK XXXX
SM 153.1E
Serial number

15. General information and technical data 1.13
Dimensions and weights ATLET SERVICE MANUAL
1.6 Dimensions and weights
0
1.6.1 Dimensions OP
Figure 1.7
OK 384
L3=1695
730
795
885
760
L1
L
25
1000
H4
H7=175
L2=125
1702000
R2
785
930
B
B3
V
280
H1=85
H3
H5
H6
L4

16. 1.14 General information and technical data
SERVICE MANUAL Overview of motor compartment
1.7 Overview of motor compartment
0
Figure 1.8 Overview
Table 1.2
Position Designation Section
1 Distribution board 10
2 Drive unit 5
3 Hydraulic unit 8
4 Hydraulic tank 8
5 Hydraulic valve 8
6 Servo motor 7
SMOP_010100
1
2
3
4
56

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18. General information and technical data 1.15
Component specification ATLET SERVICE MANUAL
1.8 Component specification
0
Table 1.3 Drive motor
Drive motor
(See also section 5, Drive motor)
Output standard 2.1 kW
Table 1.4 Gearbox
Gearbox
(See also section 5, Gearbox)
Gear ratio (standard) 14:1
Oil volume 1.8 litres
Table 1.5 Hydraulic system
Hydraulic system
Max pressure 15 MPa (= 150 kp/cm²)
Table 1.6 Hydraulic unit OPM
Hydraulic unit (motor and pump)
(See also section 8, Hydraulic unit)
Output 3.25 kW
Table 1.7 Hydraulic OPC/OPS
Hydraulic unit (motor and pump)
(See also section 8, Hydraulic unit)
Output 6.8 kW
Table 1.8 Hydraulic unit OPH
Hydraulic unit (motor and pump)
(See also section 8, Hydraulic unit)
Output 4.5 kW

19. 1.16 General information and technical data
SERVICE MANUAL Component specification
Table 1.9 Control system
Control system for motor
Type Curtis 1243 SEPEX Transistor
Voltage 24 V
Table 1.10 Fuses
Fuses
Control fuses 2 pcs. 7.5/10 A
Pump motor fuse 1 pcs. 250 A
Drive motor fuse 1 pcs. 160 A
Steering Supply 30 A
Emergency switch circuit 1 pcs. 7.5 A