service repair manual

1. SERVICE MANUAL
Machine: U AC Power Plus
Manual nr: 005954
ATLET SERVICE MANUAL U AC Power Plus
Edition 2008B
General information and technical data
1.1 Introduction................................................................................................................... 1.1
1.1.1 Service manual ..............................................................................................................1.1
1.1.2 The trucks .....................................................................................................................1.1
1.2 Manual structure........................................................................................................... 1.2
1.2.1 Symbol key ...................................................................................................................1.2
1.2.2 History ..........................................................................................................................1.3
1.3 Safety............................................................................................................................. 1.4
1.3.1 Lifting points .................................................................................................................1.4
1.3.2 Safety instructions .........................................................................................................1.5
1.3.3 Environmentally hazardous waste - environment .........................................................1.5
1.3.4 Handling ........................................................................................................................1.6
1.3.5 Trouble shooting ...........................................................................................................1.6
1.4 Designations................................................................................................................. 1.7
1.4.1 Truck types ...................................................................................................................1.7
1.5 Dimension ................................................................................................................... 1.13
1.5.1 Dimension description UNS, UHS .............................................................................1.13
1.5.2 Dimension description UFS ........................................................................................1.14
1.5.3 Dimension description USS ........................................................................................1.15
1.5.4 Dimension description URF .......................................................................................1.16

2. ATLET SERVICE MANUAL U AC Power Plus
1.6 Component specification .......................................................................................... 1.17
1.6.1 Drive motor .................................................................................................................1.17
1.6.2 Electric brake ..............................................................................................................1.17
1.6.3 Gearbox ......................................................................................................................1.17
1.6.4 Hydraulic unit .............................................................................................................1.18
1.6.5 Control system for motor ............................................................................................1.18
1.6.6 Battery ........................................................................................................................1.19
1.6.7 Servo motor ................................................................................................................1.19
1.6.8 Steering servo unit “fly by wire” ................................................................................1.19
1.6.9 Steering servo unit EPS 2001 .....................................................................................1.19
1.7 Torque ......................................................................................................................... 1.20
1.7.1 Conversion table torque ..............................................................................................1.20
1.7.2 Bolt types and tensile grades ......................................................................................1.21
1.8 Lubrication.................................................................................................................. 1.23
1.8.1 Lubrication chart UNS, UNN, UHS, USS, UFS ........................................................1.23
1.8.2 Lubrication chart URF ................................................................................................1.24
1.8.3 Symbol key lubrication chart ......................................................................................1.25
1.9 Recommended oil and grease types........................................................................ 1.26
1.9.1 Recommended changing .............................................................................................1.26
1.10 Code explanations ................................................................................................... 1.27
1.10.1 Machine colours according to NCS ..........................................................................1.27
1.10.2 Colour codes for Atlet's wiring diagrams .................................................................1.27
1.10.3 Designations for electrical components ....................................................................1.28
1.10.4 Units ..........................................................................................................................1.29

3. General information and technical data 1.1
Introduction SERVICE MANUAL
Edition 2008B
1 General information and technical data
00000000
1.1 Introduction
0
1.1.1 Service manual
The manual describes the service procedures on ATLET reach trucks in the U** AC
Power Plus range. Use the manual for quick and correct service of respective truck
models.
The manual describes models manufactured from the introduction of Mark 2 at the
end of 1999.
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 representative should be contacted.
The content of this 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.
1.1.2 The trucks
0
The new generation of reach trucks in the U** AC Power Plus range have a new
exterior design and new content. The trucks have been developed with the focus set
on the driver's working environment and a completely new driver environment with
improved ergonomics.
New time saving solutions reduce the time required for servicing. The drive motor,
hydraulic motor and all service points are easily accessible. The trucks are also
equipped with truck computer,which facilitate trouble shooting.

4. 1.2 General information and technical data
SERVICE MANUAL Manual structure
1.2 Manual structure
0
The manual is arranged according to the same principles as the Atlet's spare part
catalogues, i.e. a system consists of 12 tabs, where tabs 4 - 12 contains information
limited to a specific part of the truck. For example, Masts (section 6) and Hydraulic
System (section 8). Tabs 1 - 3 in this manual contain more comprehensive
information regarding technical data, general service instructions and tools.
For specific problems or information about procedures, look in the list of contents
for the correct section.
1.2.1 Symbol key
Warning!
Used with risk of personal injury.
Important!
Used with the risk of damage to the machine.
Note!
Used for general observation.

5. General information and technical data 1.3
Manual structure ATLET SERVICE MANUAL
1.2.2 History
This service manual covers all variants in the U** AC Power Plus truck series
manufactured since the end of 1999. Note that there may be parallel sections
applicable for U** AC Power Plus trucks for different dates of manufacture and
variants. See the table below.
Table 1.1
Chassis no. Event Truck type
>2000 Mark 2:
Improved ergonomical design introduced.
Trucks manufactured before this event are not described
in this service manual.
140, 160: New mast system introduced.
UFS
>2000 UHS
>1000 UNN
>4000 UNS
>2000 URF
>2000 USS
>2500 Steering:
EPS steering introduced.
UFS
>2500 UHS
>1500 UNN
>4500 UNS
>2500 URF
>2500 USS

6. 1.4 General information and technical data
SERVICE MANUAL Safety
1.3 Safety
0
1.3.1 Lifting points
The figure above shows where the permitted lifting points are placed on the truck.
The lifting points are marked with a decal representing a lifting hook. When only
lifting the mast, the lifting holes to the outer mast are to be used (point A). When
lifting the entire truck, use the lifting points in the frame (point B).
Warning!
The machine must never be lifted from the overhead guard.
Figure 1.1
SM 172.1
B
A

7. General information and technical data 1.5
Safety ATLET SERVICE MANUAL
1.3.2 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 plug and wait 2 minutes before starting work on the electrical
system. See the warning sign.
• 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.
• For welding work the battery plug is always to be disconnected along with all
connections to the truck computer box, servo unit and regulators (applies to all
electronic units). Following completion of the welding work, all contactors are
to be connected to the truck computer box first, followed by connection of the
battery plug.
• Persons must not be in the area between the mast and the machine housing if
the battery plug is connected.
Warning!
Operation of the electrical emergency switch does not make the truck
completely dead.
1.3.3 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.

8. 1.6 General information and technical data
SERVICE MANUAL Safety
1.3.4 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 need to be dismantled
ensure that you have good control of the different component parts so that
confusion is avoided.
• 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.
• Ensure gaskets, O-rings, etc are replaced with new parts each time they are
dismantled.
• Always use Atlet's original spare parts. Those persons using non approved
spare parts accept, without exception, full responsibility for any damage.
Hydraulic hoses should be kept so that they do not age too quickly.
• Use the screws and bolts specified in the spare parts catalogue. Tighten
according to instructions. In those cases where the tightening torque is not
stated, refer to the table of standard tightening torque see section 1.7 Torque.
1.3.5 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.

9. General information and technical data 1.7
Designations ATLET SERVICE MANUAL
1.4 Designations
0
1.4.1 Truck types
Truck type: UNS
UNN
UHS
UFS
URF
USS
Designa-
tions:
U = Reach
truck
N = Normal RF = Rotating forks
S = Standard H = High lift
S = Narrow
(second
letter)
F = Four
way
Load
capacity:
UNS: 1400 kg 1600 kg 2000 kg
UHS 1400 kg 2000 kg
UNN 1400 kg
USS 1400 kg
UFS 2000 kg 2500 kg
URF 1250 kg 1500 kg
Frame type: UNS 140 160 161 141 200
UNN 140
UHS 141 200
USS 141
UFS 200 201 250
URF 125 150

10. 1.8 General information and technical data
SERVICE MANUAL Designations
Type designations (example):
Battery
types:
UNS/UHS: R M X
URF X M
R = Reach, M = Motor powered battery rollers, X = Battery on rollers
Battery size: UNS, UFS C E F G
UNN E
UHS, E F G
USS C E F
URF G
Battery
capacity:
C: Circa 450 Ah/48 V
E: Circa 600 Ah/48 V
F: Circa 750 Ah/48 V
G: Circa 900 Ah/48 V
Figure 1.2
Truck type: UNS
UNS / 140 DTFV R E 540
Mast type DTF
Free visibility mast V
Battery type
Battery size
Lift height H4 cm
SM 173.2
Loading capacity / 10

11. General information and technical data 1.9
Designations ATLET SERVICE MANUAL
Type plate
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).
Figure 1.3 Example of type plate (–2006w36)
1
2
3
4
DD HH
QQ
ATLET AB 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
HAUTEUR DE 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
SM_UXS_01_0001A

12. 1.10 General information and technical data
SERVICE MANUAL Designations
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.
Figure 1.4 Example of type plate (2006w37–)
SM_UXS_01_0002A
Model
Modell
Serial no.
Serie nr.
Year of manufacturing
Tillverkningsår
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
H (mm)
H
XXXXXXXX
Q (kg)D (mm)
D
Q
4
3
2
1

13. General information and technical data 1.11
Designations ATLET SERVICE MANUAL
Figure 1.5 Example of plate with serial number.
SER XXXXXX
WEEK XXXX
SER XXXXXX
WEEK XXXX

14. 1.12 General information and technical data
SERVICE MANUAL Designations
Available battery combinations
RC RE RF RG XC XE XF XG XF
M
UNS 140 X X X X
UNS 160 X X X X
UNS 141 X X X X X X
UNS 200 X X X X X X X X X
UHS 141 X X X X
UHS 200 X X X X X X X
UNN 140 X
USS 141 X X X X X X
URF 125 X X
URF 150 X X
UFS 200 X X X X X X X X X
UFS 201,
250
X X X X X X X

15. General information and technical data 1.13
Dimension ATLET SERVICE MANUAL
1.5 Dimension
0
1.5.1 Dimension description UNS, UHS
Figure 1.6
B
V
H5
L
B2
B1
H4
H3
H2
H8
a b
Y1
H7
H6
H1
L1
X1 L2
U
L3
L4
R2
UNS-UHS-ok0387.eps

16. 1.14 General information and technical data
SERVICE MANUAL Dimension
1.5.2 Dimension description UFS
Figure 1.7
Vmax
B
B2
H5
H4
H3
H2
H8
H1
L1
X1 L4
Y1
H7
H6
ba
L3
R2
B1
B2+473
Vmin
UFS-ok0374.eps

17. General information and technical data 1.15
Dimension ATLET SERVICE MANUAL
1.5.3 Dimension description USS
Figure 1.8
B
B2
H5
H4
H3
H2
H8
H1
L1
U
X1 L4
Y1
H7
H6
ba
L3
R2
B1
L
B2+473
V
USS-ok0381.eps

18. 1.16 General information and technical data
SERVICE MANUAL Dimension
1.5.4 Dimension description URF
Figure 1.9
URF-ok0388.eps
L1H5
H8
Y1
H7
H6
H4
H3
H2
L2 L3
700 L
B
B+144
V
L tot
B1
R2

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20. General information and technical data 1.17
Component specification ATLET SERVICE MANUAL
1.6 Component specification
0
1.6.1 Drive motor
(Also see section 5, Drive motor)
The following drive motor is in the truck models UNS, UHS, USS, UFS, URF:
The following drive motor is in the truck model UNN:
1.6.2 Electric brake
UNS, UHS, UFS, URF (See also section 5, Electric brakes)
UNN (See also section 5, Electric brake)
1.6.3 Gearbox
(See also section 5, Gearbox)
Manufacture Elmo
Output 7.5 kW, S3 60% at
2500 rpm
Manufacture Elmo
Output 6 kW, S2 60% at
2500 rpm
Manufacture Lenze (1 step 1 disc)
Braking torque 125 Nm
Manufacture Lenze (1 step 1 disc)
Braking torque 80 Nm
Manufacture Kordel
Gear ratio 18.37:1
Oil volume 3.5 l
Oil type See section 1.8

21. 1.18 General information and technical data
SERVICE MANUAL Component specification
1.6.4 Hydraulic unit
(See also section 8, Hydraulic unit.)
The following hydraulic unit is in the truck models UNS, UHS, USS, UFS, URF:
The following hydraulic unit is in the truck model UNN:
1.6.5 Control system for motor
The following control system is in the truck models UNS, UHS, USS, UFS, URF:
The following control system is in the truck model UNN:
Motor/Pump
Manufacture Elmo / Eckerle
Output 14 kW, S3 15% at 2300
Max pressure Circa 190 bars
Working pressure Circa 170-185 bars
Flow 13.3 cm3
/r
Tank volume Max 34 l
Oil type normal
environment
See section 1.9
Motor/Pump
Manufacture Elmo / Eckerle
Output 10 kW, S3 15% at 2300
Max pressure Circa 190 bars
Working pressure Circa 170-185 bars
Flow 10.9 cm3/r
Tank volume Max 34 l
Oil type normal
environment
See section 1.9
Manufacture Inmotion
Type ACS4811-83R09027A
Voltage 48 V
Manufacture Inmotion
Type ACS4808-350F01
Voltage 48 V

22. General information and technical data 1.19
Component specification ATLET SERVICE MANUAL
1.6.6 Battery
1.6.7 Servo motor
This section refers to trucks with fly by wire steering, see “History” on page 3.
1.6.8 Steering servo unit “fly by wire”
This section refers to trucks with fly by wire steering, see “History” on page 3.
1.6.9 Steering servo unit EPS 2001
This section refers to trucks with EPS 2001 steering, see “History” on page 3.
Voltage 48 V
Capacity range UN / UH / UFS 300 - 900 Ah
Capacity range URF 900 Ah
Capacity range USS 300 - 750 Ah
Manufacture Kordel
Voltage 48 V
Manufacture Inmotion Fly by Wire
Voltage 48 V
Current
capacity
21 A
Manufacture Inmotion EPS 2001
Voltage 48 V
Current
capacity
25 A