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ATLET 110781 - User Manual

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SERVICE MANUALSERVICE MANUAL
Machine:Machine: U AC Power PlusU AC Power Plus
Manual No:Manual No: 005954005954
SERVICE MANUAL U AC Power PlusSERVICE MANUAL U AC Power Plus
Edition 2010AEdition 2010A
Electrical systemElectrical system
10.1 10.1 Introduction..........................Introduction.................................................................................................................................................................................................... 10.510.5
10.1.1 10.1.1 Component deComponent description scription ....................................................................................................................................................................................10.5......10.5
10.1.2 10.1.2 Safety Safety ..................................................................................................................................................................................................................................10.5..............10.5
10.2 10.2 BatteBatteryry .............................................................................................................................................................................................................................................. 10.710.7
10.2.1 10.2.1 Replace .............................Replace ...............................................................................................................................................................................................................10.710.7
10.2.2 10.2.2 Capacity measuCapacity measurement rement ..................................................................................................................................................................................10.8..........10.8
10.2.3 10.2.3 Battery paBattery parameters from rameters from version 3version 3.00 .00 ........................................................................................................................................10.1010.10
10.3 10.3 Chassis.....Chassis................................................................................................................................................................................................................................... 10.1110.11
10.3.1 10.3.1 Checking the ATC Checking the ATC - chassis conne- chassis connection ction ..........................................................................................................10.11........................10.11
10.3.2 10.3.2 Potential measuremePotential measurement nt ........................................................................................................................................................................................10.1110.11
10.3.3 10.3.3 Optical aisle Optical aisle sensor, sensor, rail guidancrail guidance e ......................................................................................................................................10.12..............10.12
10.3.4 10.3.4 Caster wheel rotation Caster wheel rotation lock, UFS lock, UFS ..........................................................................................................................................10.13................10.13
10.4 10.4 Connectors Connectors in in cold cold storage storage roomsrooms.............................................................................................................................................. 10.1510.15
10.4.1 10.4.1 Greasing Greasing ....................................................................................................................................................................................................................................10.1510.15
10.5 10.5 Drive Drive and and pump pump regulator regulator (2005w04–).....................(2005w04–)............................................................................................................... 10.1610.16
10.5.1 10.5.1 Dismantling, assembling ............................Dismantling, assembling ..................................................................................................................................10.16....................10.16
10.5.2 10.5.2 Designation Designation ......................................................................................................................................................................................................10.16....................10.16
10.5.3 10.5.3 General on control of the AC motors .............General on control of the AC motors .................................................................................................................10.16..............10.16
10.5.4 Connections ............................................................................................................10.1610.5.4 Connections ............................................................................................................10.16
10.5.5 10.5.5 Cable connections .Cable connections .....................................................................................................................................................................................10.17................10.17
10.5.6 10.5.6 Power cablePower cables s ..................................................................................................................................................................................................10.17....................10.17
10.6 10.6 Insulation Insulation resistance...resistance......................................................................................................................................................................................... 10.1810.18
10.6.1 10.6.1 Routine test Routine test ......................................................................................................................................................................................................10.18....................10.18
10.7 10.7 TempeTemperature rature measumeasuremenrementt ...................................................................................................................................................................... 10.1910.19
10.7.1 10.7.1 Trouble shooting - hTrouble shooting - hydraulic functions chydraulic functions channels 3, 4 and annels 3, 4 and 5 5 ....................................................10.20..................10.20
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Summary

10 Electrical system

10.1 Introduction

10.1.1 Component description

Lists components of the electrical system: battery, ATC, regulators, sensors, motors, etc.

10.1.2 Safety

General safety precautions for electrical work, handling batteries, and working with powered vehicles.

10.2 Battery

10.2.1 Replace

Step-by-step instructions for removing and installing the battery using the reach lever.

10.2.2 Capacity measurement

Explains how battery capacity is measured and shows a table of voltage vs. capacity.

10.2.3 Battery parameters from version 3.00

Details various battery parameters configurable in the system, like voltage, size, and low battery levels.

10.3 Chassis

10.3.1 Checking the ATC - chassis connection

Procedure to check the electrical connection between the ATC and the chassis using a multimeter.

10.3.2 Potential measurement

Describes how to measure chassis potential using a voltage divider and its implications for error codes.

10.3.3 Optical aisle sensor, rail guidance

Information on optical aisle sensors, their versions, and identification differences.

10.3.4 Caster wheel rotation lock, UFS

Explains the functionality, service, and fault finding for the caster wheel rotation lock.

10.4 Connectors in cold storage rooms

10.4.1 Greasing

Instructions on applying Kryotox grease to electrical connectors in cold storage environments.

10.5 Drive and pump regulator (2005 w04-)

10.5.1 Dismantling, assembling

Steps and important notes for removing and installing drive and pump regulators.

10.5.2 Designation

Explains the naming convention (TMC, PMC) and how to identify their function via wiring.

10.5.3 General on control of the AC motors

Discusses the importance of synchronisation for AC motors using an incremental encoder.

10.5.4 Connections

Specifies tightening torques, material for screws/washers, and connection order for power connections.

10.5.5 Cable connections

Details the functions of pins in the 35-pin control connector for regulators.

10.5.6 Power cables

Guidance on making battery and motor connections, emphasizing polarity and avoiding short circuits.

10.6 Insulation resistance

10.6.1 Routine test

Step-by-step procedure for testing insulation resistance using an instrument and specific voltage settings.

10.7 Temperature measurement

10.7.1 Trouble shooting - hydraulic functions channels 3, 4 and 5

Provides troubleshooting steps for specific hydraulic functions based on display symbols and contact definitions.

10.8 Magnetic switch for the reach stop

10.8.1 Reach stop

Explains the adjustment of the magnetic switch for reach movement and setting reach speed.

10.8.2 Reach stop damping (2005 w04+)

Describes the purpose of reach stop damping and the role of magnetic sensors in gentle mast movement.

10.9 Fuses

10.9.1 Standard

Lists standard fuses with their ratings and applications (e.g., ATC, motors, regulators).

10.9.2 Extra accessories

Lists fuses related to extra accessories like cold storage cabs and radios.

10.10 Horn

10.10.1 Connection

Details horn connection, sound setting, and describes newer electronic signal horns.

10.11 Atlets truck computer ATC

10.11.1 Component and interface description

Describes the ATC system's components: keyboard, display, and ATC unit, with visual aids.

10.11.2 Handling

Explains how to navigate service functions, driver levels, and basic operations on the ATC.

10.11.3 Service functions

Lists various service functions available, including changing IDs, checking sensors, calibration, and reports.

10.11.4 Change passwords

Describes how to change service organization passwords and driver IDs.

10.11.5 Calibration and control of the hydraulic levers

Explains the calibration process for hydraulic levers based on stroke and neutral position.

10.11.6 Running time functions

Details how to read running times for various functions like total usage and motor operation.

10.11.7 Printing of statistics

Describes how to print statistical functions via customer service using a printer or PC.

10.11.8 Collision sensor

Explains the function of the collision sensor, its adjustable limits, and activation of warnings.

10.11.9 ATC connector

Refers to ATC connector and pin numbering, and fuse information.

10.11.10 Checking the inputs and outputs

Procedure for checking ATC inputs and outputs through the service menu, including cyclic checks.

10.11.11 Digital inputs

Describes the 44 digital inputs on the ATC, their characteristics, and voltage readings.

10.11.12 Digital outputs “XC1-XC11”

Details the 35 ATC outputs, their specifications (0.1A, 1A, 3A), overload protection, and supply outputs.

10.11.13 Digital outputs B+ supply

Lists digital outputs providing B+ supply, including connector, function, type, and remarks.

10.11.14 Digital outputs 12 V supply

Lists digital outputs providing 12 V supply, including connector, function, type, and remarks.

10.11.15 Digital outputs B+ supply

Lists more digital outputs providing B+ supply, including connector, function, type, and remarks.

10.11.16 Valve parameters

Describes valve parameters for lift/lowering, reach, tilt, side shift, and rotation functions.

10.11.17 Performance parameters

Explains setting machine and driver parameters, including categories and factory settings.

10.12 Error codes

10.12.1 General

Instructions on checking the error log, purging it, and understanding error code logging behaviour.

10.12.2 Error code description

A table detailing error codes, messages, subinfo, descriptions, and inspection/corrective actions.

10.13 Warnings

10.13.1 Description

Explains ATC warning messages related to critical temperatures, power reduction, and system status.

10.14 Menu tree ATC

10.14.1 Error log

Describes the ATC's error log, its capacity, and how faults are traced.

10.14.2 Subinfo

Explains how to access sub-information for error codes using the 'I' key.

10.14.3 General instructions with all types of faults on trucks in combination with power outage

Provides checks for ATC not working normally, including internal fuses, measurement points, and voltage checks.

10.15 Trouble shooting - operational disturbance

10.15.1 Truck and ATC

Troubleshooting flowchart for complete function stop of the truck and ATC, covering fuses, emergency stop, and voltage checks.

10.15.2 Battery

Troubleshooting for low battery warnings, lift issues, and fuse checks related to the battery.

10.15.3 Main contactor

Troubleshooting steps for main connectors when the truck is logged on, covering fuses, voltage, and connections.

10.15.4 Fuse

Troubleshooting procedure for tripped fuses, identifying causes like short circuits or overcurrent.

10.15.5 The drive regulator status indicator

Explains troubleshooting when the drive regulator status indicator is flashing, involving error codes, voltage, and battery checks.

10.15.6 Traction motor

Troubleshooting for traction motor issues like low speed, ticking noise, or uneven running.

10.15.7 Pump motor

Troubleshooting for pump motor speed dropping, high temperature warnings, and fan checks.

10.15.8 Pump regulator status indicator

Troubleshooting for pump regulator status lamp flashing, involving error codes, voltage, and battery checks.

10.15.9 Steering system - EPS 2001

Troubleshooting for the EPS 2001 steering system, focusing on status lamp, voltage, and connections.

10.15.10 The drive function

Troubleshooting steps when the drive function does not work in one or two directions, covering brakes, sensors, and cables.

10.15.11 Forks

Troubleshooting for fork lowering issues or slow speed, including valve blocks, voltage, and joystick calibration.

10.15.12 Automatic driving of the drive unit - UFS

Troubleshooting for the automatic drive unit (UFS) not working, involving servo steering and switches.

10.15.13 Rotating wheel indication - UFS

Troubleshooting for UFS rotating wheel indication and lamps not working correctly.

10.15.14 Low temp drive;Low temp hydraul

Guidance for operating in low temperature conditions for drive and hydraulics.

10.15.15 High;Low voltage - EPS 2001

Troubleshooting high/low voltage issues with the EPS 2001 system.

10.15.16 High temp Steering;Overheated steer - EPS 2001

Troubleshooting for high temperature or overheating in the EPS 2001 steering system.

10.16 Trouble shooting - error messages

10.16.1 E05, E06, E07, Electric servo - fly by wire

Troubleshooting for electric servo errors (tachometer, motor, regulator) and related fault messages.

10.16.2 CAN

Troubleshooting CAN communication errors, watchdog timeouts, and related issues.

10.16.3 E97, E98. Drive system stopped; Hydraulics stopped

Troubleshooting for drive system or hydraulics stopping, focusing on controller response and CAN bus issues.

10.16.4 E100, E101. Drive system abnormal; Hydraulics abnormal

Troubleshooting for drive system or hydraulics abnormalities, including controller calibration errors.

10.16.5 E102, E103, E107 Servo stopped;Servo abnormal -EPS 2001

Troubleshooting for servo errors (stopped, abnormal, internal faults) related to the EPS 2001 system.

10.16.6 E105, Drive system

Troubleshooting for drive system issues like input voltage too low, overcurrent, or rotation sensor faults.

10.16.7 E106, Pump system

Troubleshooting for pump system issues like input voltage too low, overcurrent, or rotation sensor faults.

10.17 Trouble shooting table - battery

10.17.1 Battery stop

A table indicating causes and actions for battery stop issues like worn stops or defective magnetic switches.

10.18 Wiring diagram

10.19 Appendix 1, Menu tree

Service menu

Lists the main categories within the ATC service menu.

Set language

Option to set the language for the ATC interface.

Local service

Access to local service functions and settings.

ATLET service

Access to ATLET specific service functions and parameters.

Custom service

Access to custom service functions, possibly for specific configurations.

Start up

Menu options related to truck startup procedures and settings.

Remote service

Menu options for remote service and communication.

Logged on service

Menu options related to logged-on service status and functions.

ATLET 110781 Specifications

General IconGeneral
BrandATLET
Model110781
CategoryCables and connectors
LanguageEnglish