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ATLET A-Ergo Service Manual

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Edition 2008B
Edition 2008B
Scope, service
Scope,
How to to use
How
Safety instructions
Safety
instructions ....................
Preparations
Preparations ...................
Data A-Ergo
Data
A-Ergo ....................
Recommended consumable
Recommended
Standards
Standa
rds and
1 1 General
General information and
service manual ....................
manual ........................................
General ...................
General
...........................................
............................................
Scope of of the
Scope
the A-Ergo
A-Ergo model
model ...............
use the
the manual ...........
manual ...............................
Struc
Structure
ture ...............
...................................
........................................
History ....................
History
............................................
.............................................
Symbol key
Symbol
key ....................
.........................................
........................................
General ...................
General
...........................................
............................................
Lifting
Lifting the
the truck ..................................
truck ......................................................
Checks/Preparations
Checks/P
reparations .............................................................
Permitted lifting
Permitted
lifting points ............................................................................................
Welding on
Welding
on the
the truck .................................
truck .....................................................
T T aking
aking the
the environment
environment into
.......................................
........................................
Service
Service .........................
.............................................
Trouble shooting
Trouble
shooting ....................
........................................
.........................................
..........................................
Designations
Designations .....................
.............................................
Truck
Truck designation
designation ......................................................
Type designation
Type
designation ........................................................................................
Dimensions
Dimensions and
and weights
weights ....................
Dimensions
Dimensions A-Ergo ......................................................................................................
A-Ergo ...................................................................................................... 1.14
Component specification
Component
specification ...................
consumable material
Oil and
Oil
and grease
grease ................
....................................
and abbreviations .................................
abbreviations ........................................................
https://www.besttruckmanuals.com/
SERVICE MANUAL
SERVICE MANUAL
Mac
Machi hine:
ne:
A-Ergo 
A-E
rgo 
Man
Manual
ual No:
No:
00597
00
5975  5 
information and technical da
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points ....................................................................................................
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into consideration .
consideration ....................
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material ...................
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ATLET SERVICE MANUAL A-ERGO
ATLET SERVICE MANUAL A-ERGO
technical data ta
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........................... ... 1.4
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......................................... 1.6
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........................... .. 1.8
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..................................................... 1.9
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.................. 1.3
1.3
......... 1.3
1.3
.... 1.3
1.3
.... 1.4
1.4
............ 1.4
1.4
1.4
.................... 1.4
1.4
...................... .. 1.5
1.5
......... 1.5
1.5
...................... .. 1.6
1.6
1.6
........ 1.6
1.6
................... 1.7
1.7
.................. 1.7
1.7
............ 1.8
1.8
1.8
............. 1.8
1.8
......... 1.9
1.9
............. 1.9
1.9
1.9
.................. 1.10
1.10
................... 1.14
1.14
1.14
.................... 1.15
1.15
........... 1.16
1.16
................... 1.16
1.16
.......... 1.17
1.17

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Summary of Contents for ATLET A-Ergo

  • Page 1 ......... 1.16 1.16 Oil and and grease grease ........................................1.16 1.16 Standa Standards rds and and abbreviations ......... abbreviations ............................1.17 1.17 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO https://www.besttruckmanuals.com/...
  • Page 2 Colour codes, codes, cabling . cabling ....................................1.20 1.20 Designations, Designations, electrical electrical component components s ..........................1.21 1.21 Standard abbreviations ..................1.22 Standard abbreviations ..................1.22 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO https://www.besttruckmanuals.com/...
  • Page 3 The 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.
  • Page 4 Structure Structure 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.
  • Page 5 A short-circuit from such objects n its immediate vicinity. A short-circuit from such objects can result in serious burn injuries. can result in serious burn injuries. ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO https://www.besttruckmanuals.com/...
  • Page 6 Permitted lifting points Permitted lifting points 01001_SM_A-Ergo.eps 01001_SM_A-Ergo.eps Figure 1.1 Figure 1.1 Permitted lifting points, A-Ergo Permitted lifting points, A-Ergo Figure Figure1.1 1.1 shows where the permitted lifting points are placed on the truck. The l  shows where the permitted lifting points are placed on the truck. The lifting ifting points are marked with a decal representing a lifting hook;...
  • Page 7 Taking the environment into consideration Taking the environment into consideration Atlet AB Atlet AB takes care of the takes care of the environment. W environment. Waste material in conjunction with aste material in conjunction with repairs,...
  • Page 8 Make sure you trouble 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. ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO https://www.besttruckmanuals.com/...
  • Page 9 1 1 6 6 0 0 0 0 o o r r 2 2 0 0 0 0 0 0 k k g g A A - - E E r r g g o o T T F F 1 1 0 0 0 0 0 0 k k g g ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO https://www.besttruckmanuals.com/...
  • Page 10 (D) an (D) and/o d/or r lifting height (Q). lifting height (Q). ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO https://www.besttruckmanuals.com/...
  • Page 11 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. compartment, or serial number punched on the side of the mast. ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO https://www.besttruckmanuals.com/...
  • Page 12 SER XXXXXX SER XXXXXX WEEK XXXX WEEK XXXX SER XXXXXX SER XXXXXX WEEK XXXX WEEK XXXX Figure 1.4 Figure 1.4 Example of plate with serial number. Example of plate with serial number. ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO https://www.besttruckmanuals.com/...
  • Page 13 S S t t r r a a d d d d l l e e l l i i f f t t Lifting height in cm Lifting height in cm Battery Ah/5 Battery Ah/5 Charger Ampere Charger Ampere ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO https://www.besttruckmanuals.com/...
  • Page 14        H        H        H        1        1        7        7        H        H        H        H A-Ergo Mått ATF.eps A-Ergo Mått ATF.eps Figure 1.6 Figure 1.6 Positions for dimensions A-Ergo TF Positions for dimensions A-Ergo TF ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO https://www.besttruckmanuals.com/...
  • Page 15 1 p 1 pcs cs. . 250 0 A A Dri i ve ve mo moto tor f r fus use 1 e 1 pc pcs. s. 160 0 A A ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO https://www.besttruckmanuals.com/...
  • Page 16 C 80 W/90 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! ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO https://www.besttruckmanuals.com/...
  • Page 17 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 apply above apply. . ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO https://www.besttruckmanuals.com/...
  • Page 18 0 0 , , 0 0 8 8 1 1 , , 3 3 6 6 0 0 , , 1 1 4 4 1 1 2 2 , , 0 0 0 0 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO https://www.besttruckmanuals.com/...
  • Page 19 Marking only takes place when the shape of the product permits this. 12.9 12.9 12.9 12.9 SM 031.1 SM 031.1 Figure 1.7 Figure 1.7 Example of marking Example of marking ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO https://www.besttruckmanuals.com/...
  • Page 20 Colour 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 wiring read off from the Atlet wiring diagram. The abbreviations have the following implication: diagram.
  • Page 21 R R e e v v e e r r s s e e S S p p e e e e d d Example SL = Switch for Lowering function Example SL = Switch for Lowering function ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO https://www.besttruckmanuals.com/...
  • Page 22 P P r r e e s s s s u u r r e e P P a a s s c c a a l l P P a a ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO https://www.besttruckmanuals.com/...
  • Page 23 ..2.4 Dismantling Dismantling tool, tool, buttons buttons and and lamps lamps ................................2.4 Crimping Crimping tool tool ..............................................2.4 Lifting Lifting eye eye ................................................2.4 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO https://www.besttruckmanuals.com/...
  • Page 24     2 2 . . 2 2 / / / / ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO https://www.besttruckmanuals.com/...
  • Page 25 Special tools tools Special tools A-Ergo Special tools A-Ergo Introduction Introduction All special tools can be ordered from Atlet AB. All special tools can be ordered from Atlet AB. List of tools List of tools Hand terminal Hand terminal Table 2.1 Table 2.1 Hand terminal, programming tool...
  • Page 26 L L i i f f t t i i n n g g e e y y e e f f o o r r d d r r i i v v e e u u n n i i t t . . For detailed information on the above For detailed information on the above produ products, please contact Atlet. cts, please contact Atlet. ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO https://www.besttruckmanuals.com/...
  • Page 27 ....3.21 3.21 First First service service ..............................................3.21 3.21 Mast Mast ..............................................3.22 3.22 First First service service ..............................................3.22 3.22 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO https://www.besttruckmanuals.com/...
  • Page 28     Hydraulic oil .......................3.23 Hydraulic oil .......................3.23 First First service ........................service ........................3.23 3.23 Replacement Replacement intervals intervals ........................................3.23 3.23 Recommended replacement ................3.23 Recommended replacement ................3.23 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO https://www.besttruckmanuals.com/...
  • Page 29 To achieve the best results from your investment in the truck we advise you to contact Atlet Service To achieve the best results from your investment in the truck we advise you to contact Atlet Service and to subscribe to a service subscription for regular service.
  • Page 30 . ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO https://www.besttruckmanuals.com/...
  • Page 31 Observe caution when using water jets. Electric panels and circuit cards should always be and circuit cards should always be protected from splashing water when washing. protected from splashing water when washing. ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO https://www.besttruckmanuals.com/...
  • Page 32 See EN 1726 or ISO 3691 See EN 1726 or ISO 3691 A service is carried out by ATLET service or specially trained personnel. Servicing is A service is carried out by ATLET service or specially trained personnel. Servicing is...
  • Page 33 D D a a m m a a g g e e , , c c h h a a i i n n V V i i s s u u a a l l Damage, chain bolt and Damage, chain bolt and Visual Visual chain bolt mounting chain bolt mounting ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO https://www.besttruckmanuals.com/...
  • Page 34 ** Fork tests and chain tests must be carried out ** Fork tests and chain tests must be carried out at least every 1000 operating hours, see at least every 1000 operating hours, see section 6. section 6. ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO https://www.besttruckmanuals.com/...
  • Page 35 V V i i s s u u a a l l , , t t o o o o l l s s 5 5 1 1 0 0 4 4 * See also section 11. * See also section 11. ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO https://www.besttruckmanuals.com/...
  • Page 36 For further information concerning the hydraulic system, see also section 8 and lift For further information concerning the hydraulic system, see also section 8 and lift cylinders section 9. cylinders section 9. ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO https://www.besttruckmanuals.com/...
  • Page 37 F F u u n n c c t t i i o o n n t t e e s s t t , , t t o o o o l l s s https://www.besttruckmanuals.com/ ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO...
  • Page 38 W W a a s s h h e e r r s s , , l l u u b b r r i i c c a a t t i i o o n n o o f f r r o o l l l l e e r r s s u u r r f f a a c c e e s s https://www.besttruckmanuals.com/ ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO...
  • Page 39 F F r r i i c c t t i i o o n n s s u u r r f f a a c c e e > > m m i i n n l l e e v v e e l l a a l l l l r r o o u u n n d d 1 1 1 1 https://www.besttruckmanuals.com/ ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO...
  • Page 40 L L e e a a k k a a g g e e f f r r o o m m c c o o n n n n e e c c t t i i o o n n s s https://www.besttruckmanuals.com/ ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO...
  • Page 41 A A t t t t a a c c h h m m e e n n t t , , d d a a m m a a g g e e https://www.besttruckmanuals.com/ ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO...
  • Page 42 Lubrication chart A-Ergo. For explanation of symbols, see table 3.3 The service of an Atlet-truck can be divided into service that should be carried out in The service of an Atlet-truck can be divided into service that should be carried out in...
  • Page 43 F F o o r r k k s s , , r r o o l l l l e e r r s s , , s s l l i i d d e e s s u u r r f f a a c c e e s s A A n n g g l l e e g g e e a a r r https://www.besttruckmanuals.com/ ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO...
  • Page 44 F F i i l l l l e e d d s s y y m m b b o o l l – – C C h h a a n n g g e e https://www.besttruckmanuals.com/ ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO...
  • Page 45 1 for n 1 for correct value. correct value. https://www.besttruckmanuals.com/ ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO...
  • Page 46 Spent oil should be taken care of and recycled according to the applicable le Spent oil should be taken care of and recycled according to the applicable legislation gislation in respective countries. in respective countries. https://www.besttruckmanuals.com/ ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO...
  • Page 47 81 Nm. 81 Nm. torque: torque: 81 Nm 81 Nm https://www.besttruckmanuals.com/ ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO...
  • Page 48 277 Nm 277 Nm 03_001_A-Ergo_EdragMast.eps 03_001_A-Ergo_EdragMast.eps Figure 3.3 Figure 3.3 Position of screws that hold the mast to the chassis. Position of screws that hold the mast to the chassis. https://www.besttruckmanuals.com/ ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO...
  • Page 49 Hydraulic hoses should be replaced after 5 Hydraulic hoses should be replaced after 5 years, since the rubber in the years, since the rubber in the hose is hose is perishable. perishable. https://www.besttruckmanuals.com/ ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO...
  • Page 50 / R s / Re e co com m me men n de ded r d re e pl pla a ce ceme men n t t https://www.besttruckmanuals.com/ ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO...
  • Page 51 Battery .............................................. 4.12 4.12 Changing the battery ....................4.12 Changing the battery ....................4.12 Replacing the battery rollers ..................4.12 Replacing the battery rollers ..................4.12 https://www.besttruckmanuals.com/ ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO...
  • Page 52     https://www.besttruckmanuals.com/ ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO...
  • Page 53 Machine housing Machine housing The chassis on A-Ergo trucks consists of The chassis on A-Ergo trucks consists of a machine housing, which is available in a machine housing, which is available in different versions depending on the size of the battery.
  • Page 54 Check the number of shims when or to prevent the drive wheel from spinning. Check the number of shims when replacing the drive wheel. replacing the drive wheel. https://www.besttruckmanuals.com/ ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO...
  • Page 55 81 Nm. 81 Nm. 81 Nm 81 Nm https://www.besttruckmanuals.com/ ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO...
  • Page 56 04_003_SM_A-ERGO_ArmstDem.eps 04_003_SM_A-ERGO_ArmstDem.eps Figure 4.4 Figure 4.4 Arm rest raised Arm rest raised https://www.besttruckmanuals.com/ ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO...
  • Page 57 Press Press down down the p the panel, anel, and and lock lock the p the panel anel in th in the re e require quired p d posit osition. ion. https://www.besttruckmanuals.com/ ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO...
  • Page 58 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO...
  • Page 59 3. 3. Disc Discon onnec nect th t the c e conn onnect ector or to to the the br brake ake ped pedal. https://www.besttruckmanuals.com/ ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO...
  • Page 60 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO...
  • Page 61 “Moun “Mounting the castor ting the castor wheel (page 4.10)” wheel (page 4.10)”, and check , and check measure. measure. https://www.besttruckmanuals.com/ ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO...
  • Page 62 Lift . Lift up the up the roller rollers in th s in the bac e back k edge and pull edge and pull backwards/upwards backwards/upwards. . https://www.besttruckmanuals.com/ ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO...
  • Page 63 Diagnosis Diagnosis and and trouble trouble shooting ..shooting ................................5.14 5.14 Troub Trouble le shooting shooting chart chart ....................................5.14 5.14 https://www.besttruckmanuals.com/ ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO...
  • Page 64     https://www.besttruckmanuals.com/ ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO...
  • Page 65 For technical data regarding component parts, see section 1. Drive motor Drive motor The drive motor on A-ERGO The drive motor on A-ERGO is a brushless three-phase induction motor is a brushless three-phase induction motor. A pulse sensor . A pulse sensor is enclosed in the...
  • Page 66 ATLET SERVICE MANUAL A ERGO ATLET SERVICE MANUAL A ERGO         5 5 . . 4 4 D D r r i i v v e u e un n i i t t / / R R e e p p a a i i r r i i n n s s t t r r u u c c t t i i o o n n s s / / P P r r e e p p a a r r a a t t i i o o n n s s...
  • Page 67 ATLET SERVICE MANUAL A ERGO ATLET SERVICE MANUAL A ERGO     D ri i v v e e u u n n i i t t / / R R e e p p a a i i r r i i n n s s t t r r u u c c t t i i o o n n s s / / D D r r i i v v e e m m o o t t o o r r 5 5 .
  • Page 68 ATLET SERVICE MANUAL A ERGO ATLET SERVICE MANUAL A ERGO     5 5 . . 6 6 D D r r i i v v e e u u n n i i t t / / R R e e p p a a i i r r i i n n s s t t r r u u c c t t i i o o n n s s / / G G e e a a r r b b o o x x...
  • Page 69 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     D D r r i i v v e e u u n n i i t t / R / Re e p p a a i i r i r in n s s t t r r u u c c t t i i o o n n s s / / G G e e a a r r b b o o x x 5 5 .
  • Page 70 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     5 5 .8 .8 D D ri rive ve u u n n it it / R / Re e p p a a ir ir i i n n st stru ruct ctio ion n s /...
  • Page 71 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     D D r r iv ive u e un n it it / R / Re e p p ai air i r ins nstr tru u ct ctio ion n s /...
  • Page 72 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     5. 5.10 Dri i ve ve un unit it / / Re Repa pair ir i i ns nstr tru u ct ctio ions ns / R / Rec econ...
  • Page 73 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     Driv ive u e uni nit / t / Re Repa pai i r i r ins nstr truc uct t io ions ns / R / Rec eco o nd...
  • Page 74 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     5. 5.12 Dri i ve ve un unit it / / Re Repa pair ir i i ns nstr tru u ct ctio ions ns / R / Rec econ...
  • Page 75 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     Driv ive e un unit it / / Re Repa pai i r r i i ns nst t ru ruct cti i on ons s / / Dr Driv ive e wh...
  • Page 76 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     5. 5.14 Driv ive u e un n it it / D / Di i ag agno nosi sis a s and nd tr trou oub b le le sh...
  • Page 77 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     Driv ive u e uni nit / t / Di Dia a gn gnos osi i s a s and nd tr trou oubl ble s e sho hoot oti i ng...
  • Page 78 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     5. 5.16 Driv ive u e un n it it / D / Di i ag agno nosi sis a s and nd tr trou oub b le le sh...
  • Page 79 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     SERVICE MANUAL SERVICE MANUAL Machi hine: A-Ergo  rgo  Manual ual No: 00597 5975  5  Edition 2009A Edition 2009A 6 6 Mast Mast system system Design Design and and function function ....
  • Page 80 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     Fork carriage, telescopic forks, TF ..............6.27 Fork carriage, telescopic forks, TF ..............6.27 Dismantling Dismantling the the fork fork carriage carriage TF TF ..................................6.27 6.27 Assembling the Assembling the fork carriage fork carriage TF ...................
  • Page 81 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO      M  Ma a s s t t s s y y s s t t e e m m / / D D e e s s i i g g n n a a n n d d f f u u n n c c t t i i o o n n / / M M a a s s t t s s y y s s t t e e m m 6 6 .
  • Page 82 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     6 6 . . 4 4 M M a a s s t t s s y y s s t t e e m / m / D D e e s s i i g g n n a a n n d d f f u u n n c c t t i i o o n n / / F F o o r r k k c c a a r r r r i i a a g g e e...
  • Page 83 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     M M a a s s t t s s y y s s t t e e m / m / D D e e s s i i g g n n a a n n d d f f u u n n c c t t i i o o n n / F / Fo o r r k k c c a a r r r r i i a a g g e e 6 6 .
  • Page 84 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     6 6 . . 6 6 M M a a s s t t s s y y s s t t e e m / m / D D e e s s i i g g n n a a n n d d f f u u n n c c t t i i o o n n / / S S t t r r a a d d d d l l e e l l i i f f t t...
  • Page 85 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO         M M a a s s t t s s y y s s t t e m e m / / D D e e si sig g n n a a n d...
  • Page 86 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     6. 6.8 8 Mast st sy syst ste e m / R m / Re e p p a a i i r i r in n s s tr tru u ct cti i on...
  • Page 87 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     M M as ast s t sys yst t e e m / R m / Re e pa pai i r i r in n st str r u u ct cti i o o n n s / R...
  • Page 88 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO         6. 6.10 Mast st sy syst stem em / R / Rep epai air i r ins nstr truc uct t i i on ons / s / Re...
  • Page 89 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     Mas s t s t sys yste tem / m / Re Repa pair ir in inst stru ruct cti i on ons / s / Re Repl plac acin ing t...
  • Page 90 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     6. 6.12 Mast st sy syst stem em / R / Rep epai air i r ins nstr truc uct t i i on ons / s / Re Repl plac...
  • Page 91 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     Mas s t s t sys yste tem / m / Re Repa pair ir in inst stru ruct cti i on ons / s / Re Repl plac acin ing t...
  • Page 92 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     6. 6.1 1 4 4 Mast st sy syst ste e m / m / Re Rep p a a i i r i r in n st stru ruct cti i on...
  • Page 93 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     Mast st sy syst ste e m / m / Re Rep p a a i i r i r in n st str r uc ucti tio o n n s /...
  • Page 94 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     6. 6.1 1 6 6 Mast st sy syst ste e m / m / Re Rep p a a i i r i r in n st stru ruct cti i on...
  • Page 95 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     Mast st sy syst ste e m / m / Re Rep p a a i i r i r in n st str r uc ucti tio o n n s /...
  • Page 96 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     6. 6.1 1 8 8 Mast st sy syst ste e m / m / Re Rep p a a i i r i r in n st stru ruct cti i on...
  • Page 97 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     Mast st sy syst ste e m / m / Re Rep p a a i i r i r in n st str r uc ucti tio o n n s /...
  • Page 98 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     6. 6.2 2 0 0 Mast st sy syst ste e m / m / Re Rep p a a i i r i r in n st stru ruct cti i on...
  • Page 99 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     Mas s t t s s y y s s t t e e m / m / R R e e p p a a i i r r i i n n s s t t r r u u c c t t i i o n o ns s / / L i L if f t t c c h h a a i i n n s s 6 6 .
  • Page 100 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     6 6 . . 2 2 2 2 Mas s t t s s y y s s t t e e m / m / R R e e p p a a i i r i r in n s s t t r r u u c c t t i i o n o ns s / / L L i i f f t t c c h h a a i i n n s s       G...
  • Page 101 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO         M M a a s s t s t sy y s s t t e e m m / / R R e e p p a a i i r r i i n n s s t t r r u u c c t t i i o o n n s / s / F F o o r r k k s s 6 6 .
  • Page 102 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     6 6 . . 2 2 4 4 M M a a s s t t s s y y s s t t e e m / m / R R e e p p a a i i r i r in n s s t t r r u u c c t t i i o o n n s s / / F F o o r r k k s s 1.
  • Page 103 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     M M a a s s t s t sy y s s t t e e m m / / R R e e p p a a i i r r i i n n s s t t r r u u c c t t i i o o n n s / s / F F o o r r k k s s 6 6 .
  • Page 104 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     6. 6.2 2 6 6 Mast st sy syst ste e m / R m / Re e p p a a i i r i r in n st str r u u ct cti i on...
  • Page 105 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     Mast st sy syst stem / em / Re Repa pair ir i i ns nstr truc ucti tion ons / s / Fo Fork rk ca carr rria iage...
  • Page 106 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     6. 6.28 Mast st sy syst stem / em / Re Repa pai i r i r ins nstr truc uct t i i on ons / s / Fo...
  • Page 107 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     Mast st sy syst stem / em / Re Repa pair ir i i ns nstr truc ucti tion ons / s / Fo Fork rk ca carr rria iage...
  • Page 108 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     6. 6.30 Mast st sy syst stem / em / Re Repa pai i r i r ins nstr truc uct t i i on ons / s / Fo...
  • Page 109 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     Mast st sy syst stem / em / Re Repa pair ir i i ns nstr truc ucti tion ons / s / Fo Fork rk ca carr rria iage...
  • Page 110 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO         6. 6.32 Mast st sy syst stem / em / Re Repa pai i r i r ins nstr truc uct t i i on ons / s / Fo...
  • Page 111 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     Mast st sy syst stem / em / Re Repa pair ir i i ns nstr truc ucti tion ons / s / Fo Fork rk ca carr rria iage...
  • Page 112 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     6. 6.34 Mast st sy syst stem / em / Re Repa pai i r i r ins nstr truc uct t i i on ons / s / Fo...
  • Page 113 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     M M a a s s t s t sy y s s t t e e m / m / R R e e p p a a i r i r i i n s...
  • Page 114 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     6. 6.3 3 6 6 Mast st sy syst ste e m m / / R R e e p p a a i i r r i i n n st str r u u ct cti i on...
  • Page 115 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     M M as ast t s s ys yste tem m / / Re Repa pai i r r in inst str r u u ct cti i o o n n s /...
  • Page 116 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     6. 6.38 Mast st sy syst stem / em / Di Diag agno nosi sis a s and nd tr trou oubl ble s e sho hoot oti i ng...
  • Page 117 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     SERVICEMANUAL SERVICEMANUAL Machi hine: A-Ergo  rgo  Manual ual No: 00597 5975  5  Edition 2002B Edition 2002B 7 Steering 7 Steering Design Design and and function function ..............................
  • Page 118 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     https://www.besttruckmanuals.com/...
  • Page 119 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO      S  St t e e e e r r i i n n g g / / D D e e s s i i g g n n a a n n d d f f u u n n c c t t i i o o n n / / G G e e n n e e r r a a l l 7 7 .
  • Page 120 SMA-Ergo_07_2002B.fm SMA-Ergo_07_2002B.fm ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     7 7 .4 .4 Ste e e e ri rin n g / g / De Desi sig g n a n and nd fu fun n ct cti i o o n /...
  • Page 121 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     S S te tee e r r i i ng ng / R / Rep epa a i i r i r in n st str r u u ct cti i o o n n s /...
  • Page 122 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO         7 7 .6 .6 Ste e e e ri rin n g / g / Re Rep p ai air i r in n s s tr tru u ct ctio ion n s / R...
  • Page 123 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     Stee eeri ring ng / D / Di i ag agno nosi sis a s and nd t t ro roub uble le sh shoo oot t in ing /...
  • Page 124 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     7. 7.8 8 Ste e er eri i ng ng / D / Di i ag agno nosi sis a s and nd tr trou oubl ble s e sho...
  • Page 125 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     SERVICE MANUAL SERVICE MANUAL Machi hine: A-Ergo  rgo  Manual ual No: 00597 5975  5  Edition 2009A Edition 2009A 8 8 Hydraulic Hydraulic system system Design Design and and function function ....

  • Page 126: Table Of Contents

    ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     Lowering brake valve ..................8.21 Lowering brake valve ..................8.21 Dismantling Dismantling and and assembling assembling ....................................8.21 8.21 Hose rupture valve .....................8.23 Hose rupture valve .....................8.23 Dismantling Dismantling and and assembling assembling .................
  • Page 127 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO      H  Hy y d d r r a a u u l l i i c c s s y y s s t t e e m / m / D D e e s s i i g g n n a a n n d d f f u u n n c c t t i i o o n n / / G G e e n n e e r r a a l l 8 8 .

  • Page 128: Lowering Brake Valve

    SMA-Ergo_08_2009A.fm SMA-Ergo_08_2009A.fm SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO     8 8 . . 2 2 H H yd ydr r a a u u l l i i c s c sy y s s t t e m...
  • Page 129 Hydraulic diagram Table 8.1 Table 8.1 List of hydraulic diagrams for A-Ergo List of hydraulic diagrams for A-Ergo D D e e s s c c r r i i p p t t i i o o n n P P a a g g e e H H y y d d r r a a u u l l i i c c d d i i a a g g r r a a m m , , M M a a n n u u a a l l v v a a l l v v e e 1 1 0 0 4 4 0 0 1 1 4 4 ( ( –...
  • Page 130 SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO     8 8 . . 4 4 H H yd ydr r a a u u l l i i c s c sy y s s t t e m e m / D...
  • Page 131 SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO     H H yd ydr r a a u u l l i i c s c sys yst t e e m / m / D D e e si sig g n a...
  • Page 132 SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO     8 8 . . 6 6 H H yd ydr r a a u u l l i i c s c sy y s s t t e m e m / D...
  • Page 133 SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO     H H yd ydr r a a u u l l i i c s c sys yst t e e m / m / D D e e si sig g n a...
  • Page 134 SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO     8 8 . . 8 8 H H yd ydr r a a u u l l i i c s c sy y s s t t e m e m / D...
  • Page 135 SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO     8 8 . . 9 9 H H yd ydr r a a u u l l i i c s c sy y s s t t e m e m / D...
  • Page 136 SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO     8 8 .1 .10 0 Hyd d r r a a u u li lic s c sys yst t em em / D / De e si sig g n a...
  • Page 137 SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO     H H yd ydra rau u l l i i c s c sys yste tem / D m / De e si sig g n a n an n d f...
  • Page 138 SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO     8 8 .1 .12 2 Hyd d r r a a u u li lic s c sys yst t em em / D / De e si sig g n a...
  • Page 139 SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO     H H yd ydra rau u l l i i c s c sys yste tem / D m / De e si sig g n a n an n d f...
  • Page 140 SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO     8. 8.1 1 4 4 Hyd d r r a a u u li lic s c sys yst t em em / R / Re e pa pair ir i i ns...
  • Page 141 SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO     Hydr drau aul l i i c s c sys yste tem / R m / Re e pa pai i r i r in n st str r u u ct cti i o o n n s / H...
  • Page 142 The used in the truck. The hydraulic oil used in Atlet trucks should comply with Atlet quality requirements: hydraulic oil used in Atlet trucks should comply with Atlet quality requirements: •...
  • Page 143 SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO     Hydr drau auli lic c sy syst stem em / R / Rep epai air r in inst stru ruct ctio ions ns / / Hy Hydr drau auli lic c oi oil, l, ch...
  • Page 144 SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO     8. 8.18 Hydr drau auli lic c sy syst stem em / / Re Repa pair ir i i ns nstr truc uct t io ions ns / A / Air ir fi filt lter er, , re repl plac...
  • Page 145 SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO     Hydr drau auli lic sy c syst ste e m / R m / Rep epai air i r ins nst t ru ruct ctio ions / ns / Oi Oil f l fil ilt t er er i i ns...
  • Page 146 SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO     8. 8.20 Hydr drau auli lic s c sys yst t em / em / Re Repa pair ir i i ns nstr truc uct t io ions ns / Ch / Chec...
  • Page 147 SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO     Hydr drau auli lic c sy syst stem em / / Re Repa pair ir i i ns nstr truc uct t io ions ns / / Lo Lowe weri ring ng br brak...
  • Page 148 SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO     8. 8.22 Hydr drau auli lic c sy syst stem em / / Re Repa pair ir i i ns nstr truc uct t io ions ns / L / Low ower eri i ng...
  • Page 149 SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO     Hyd d r r a a u u li lic s c sys yst t e e m / R m / Re e p p a a ir ir i i n n st str r uc...
  • Page 150 SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO     8. 8.2 2 4 4 Hyd d ra rau u li lic s c sy y st stem / em / Re Rep p a a ir ir i i ns nstr tru u ct ctio ion n s / H...

  • Page 151: Control Valve

    SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO     Hydr drau aul l i i c s c sys yste tem / m / R R e e pa pai i r r in inst stru ruct cti i o o n n s /...
  • Page 152 SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO     8. 8.2 2 6 6 Hydr dra a u u li lic s c sys yst t em em / R / Re e p p a a ir ir i i ns...
  • Page 153 Figure 8.9 Figure 8.9 Lever regulated valve Lever regulated valve SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO     Hydr drau aul l i i c s c sys yste tem / m / R R e e pa pai i r r in inst stru ruct cti i o o n n s /...

  • Page 154: Valve

    SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO         8. 8.2 2 8 8 Hydr dra a u u li lic s c sys yst t em em / R / Re e p p a a ir ir i i ns...
  • Page 155 SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO         Hydr drau aul l i i c s c sys yste tem / m / R R e e pa pai i r r in inst stru ruct cti i o o n n s /...

  • Page 156: Hydraulic Pump Motor

    SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO         8. 8.30 Hydr drau auli lic c sy syst stem em / / Re Repa pair ir i i ns nstr truc uct t io ions ns / H / Hyd...
  • Page 157 SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO     Hydr drau aul l i i c s c sy y st stem em / R / Rep epai air i r in n st stru ruct cti i on ons /...
  • Page 158 SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO     8. 8.32 Hydr drau auli lic s c sys yst t em em / R / Rep epai air i r ins nstr truc uct t io ions ns / H / Hyd...

  • Page 159: Brushes

    SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO     Hydr drau aul l i i c s c sy y st stem em / R / Rep epai air i r in n st stru ruct cti i on ons /...

  • Page 160: Stabiliser Cylinders

    SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO         8. 8.34 Hydr drau auli lic c sy syst stem em / / Re Repa pair ir i i ns nstr truc uct t io ions ns / S / Sta tabi bili lise...
  • Page 161 SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO         Hydr drau auli lic s c sys yste tem / R m / Rep epai air i r ins nstr truc ucti tion ons / s / In Inst stal alla lati tion...
  • Page 162 SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO     8. 8.36 Hydr drau auli lic s c sys yste tem / m / Re Repa pair ir in inst stru ruct ctio ions ns / I / Ins nsta tall llat atio ion i...
  • Page 163 After a visible swelling has formed the nut should be fitted without extension of fitted without extension of the U-ring spanner, and without excessive force. the U-ring spanner, and without excessive force. SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO        ...

  • Page 164: Diagnosis And Trouble Shooting

    SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO     8. 8.38 Hydr drau auli lic s c sys yst t em / em / Di Diag agno nosi sis a s and nd tr trou oubl ble s e sho hoot oti i ng...
  • Page 165 SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO     Hydr drau aul l ic ic s s ys yste tem / D m / Di i ag agno nosi sis a s and nd t t ro roub uble le sh...
  • Page 166 SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO     8. 8.40 Hydr drau auli lic s c sys yst t em / em / Di Diag agno nosi sis a s and nd tr trou oubl ble s e sho hoot oti i ng...
  • Page 167 SERVICE MANUAL A-ERGO SERVICE MANUAL A-ERGO     SERVICEMANUAL SERVICEMANUAL Machi hine: A-Ergo  rgo  Manual ual No: 00597 5975  5  Edition 2002B Edition 2002B 9 9 Lift Lift cylinders cylinders Design Design and and function function ..............................
  • Page 168 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     https://www.besttruckmanuals.com/...
  • Page 169 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO      L  Li i f f t t c c yl yli i n n d d e e r r s s / / De Des s i i g g n n a a n n d d f f u u n n c c t t i i o o n n / / I I n n t t r r o d o du u c c t t i i o o n n 9 9 .
  • Page 170 SMA-Ergo_09_2002B.fm SMA-Ergo_09_2002B.fm ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO         9 9 . . 4 4 L L i i f f t t c c y y l l i i n n d d e e r r s s / / R R e e p p a a i i r r i i n n s s t t r r u u c c t t i i o o n n s /...
  • Page 171 Important!  Important!  Check the oil level Check the oil level regularly. regularly. ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     L L if ift c t cyl yli i nd nde e r r s / s / Re...
  • Page 172 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     9 9 .6 .6 L L if ift c t cyl yli i nd nde e r r s / s / R R ep epa a i i r i r in n st str r u u ct cti i o o n n s / F...
  • Page 173 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     L L if ift c t cyl yli i nd nde e r r s / s / Re Rep p a a i i r i r in n st str r u u ct cti i o o n n s /...
  • Page 174 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO         9 9 .8 .8 L L if ift c t cyl yli i nd nde e r r s / s / R R ep epa a i i r i r in n st str r u u ct cti i o o n n s /...
  • Page 175 Figure 9.4 Figure 9.4 Lift cylinder TV/TFV/DTFV Lift cylinder TV/TFV/DTFV ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     L L if ift c t cyl yli i nd nde e r r s / s / Re Rep p a a i i r i r in n st str r u u ct cti i o o n n s /...
  • Page 176 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     9 9 .1 .10 0 L L if ift c t cyl yli i nd nde e r r s / s / R R ep epa a i i r i r in n st str r u u ct cti i o o n n s /...
  • Page 177 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO         Li Lif f t c t cyl yli i n n d d e e r r s / s / R R e e p p a a i i r i r in n st str r u u ct cti i o o ns...
  • Page 178 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     9 9 .1 .12 2 L L if ift c t cyl yli i nd nde e r r s / s / R R ep epa a i i r i r in n st str r u u ct cti i o o n n s /...
  • Page 179 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     SERVICE MANUAL SERVICE MANUAL Machi hine: A-Ergo  rgo  Manual ual No: 00597 5975  5  Edition 2005B Edition 2005B 10 Electrical Electrical system system General General .......................................
  • Page 180 Replacing Replacing drive drive regulator/steering regulator/steering servo servo regulator ......regulator ............10.50 10.50 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     10.2 10.2 Replacing MDI ....................10.50 Replacing MDI ....................10.50 Replacing the steering servo sensor ..............10.51 Replacing the steering servo sensor ..............10.51...
  • Page 181 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO      El  Ele e c c t t r r i i c c a l a l s s y y s s t t e m e m / G...
  • Page 182 SMA-Ergo_10_2005B.fm SMA-Ergo_10_2005B.fm ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO         1 1 0 0 . . 4 4 E E l l e e c c t t r r i i c c a a l s...
  • Page 183 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     E E l l e e c c t t r r i i c c a a l s...
  • Page 184 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     1 1 0 0 .6 .6 El Ele e ct ctr r i i ca cal s l sy y st ste e m / m / Ge Gen n e e r r a a l / l / Op...
  • Page 185 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     E E le lect ctri rica cal s l sys yst t e e m / m / Ge Gen n er eral al / O / Op p e e r r a a ti tio o n n , H...
  • Page 186 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     1 1 0 0 .8 .8 El Ele e ct ctr r i i ca cal s l sy y st ste e m / m / Ge Gen n e e r r a a l / l / Op...
  • Page 187 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     El Elec ectr tric ical al sy syst stem / em / De Desi sign gn an and fu d func ncti tion on / Ge / Gene ner r al al fu func...
  • Page 188 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     10.10 El Elect ectri rical cal sys system tem / D / Desi esign gn an and f d fun uncti ction on / / Gen Gener eral al fun...
  • Page 189 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     El Elect ectri rical...
  • Page 190 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     10.12 El Elect ectri rical cal sys system tem / D / Desi esign gn an and f d fun uncti ction on / / Gen Gener eral al fun...
  • Page 191 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     El Elec ectr tric ical s al sys yste tem / De m / Desi sign a gn and f nd fun unct ctio ion / M n / Mul ulti F...
  • Page 192 LED. red LED. ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     10.1 .14 4 El Elec ectr tric ical s al sys...
  • Page 193 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     El Elec ectr tric ical al sy syst stem / em / De Desi sign gn an and f d fun unct ctio ion / n / Dr Driv ive m...
  • Page 194 Avoid running the motor in this state. power. Avoid running the motor in this state. ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     10.1 .16 6...
  • Page 195 No modification of the input value is accepted during lifting and lowering accepted. No modification of the input value is accepted during lifting and lowering movements. movements. ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     El Elec...
  • Page 196 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     10.1 .18 8 El Elec ectr tric ical al sy syst stem em / D / Des esig ign a n and nd fu func ncti tion on / D...
  • Page 197 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     El Elec ectr tric ical al sy syst stem / em / De Desi sign gn an and f d fun unct ctio ion / n / Dr Driv ive m...
  • Page 198 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     10.2 .20 0 El Elec ectr tric ical al sy syst stem em / D / Des esig ign a n and nd fu func ncti tion on / D...
  • Page 199 L L o o w w e e s s t t o o p p e e n n i i n n g g v v a a l l u u e e o o f f the proportional valve. the proportional valve. ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO    ...
  • Page 200 P P E E D D A A L L B B R R A A K K I I N N G G D D i i g g i i t t a a l l ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO  ...
  • Page 201 1 f 1 be betw twee een 1 t n 1 to 2 o 255 55. . ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     El Elec ectr tric ical al sy syst stem / em / De...
  • Page 202 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     10.2 .24 4 El Elec ectr tric ical al sy syst stem em / D / Des esig ign a n and nd fu func ncti tion on / D...
  • Page 203 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     El Elec ectr tric ical al sy syst stem / em / De Desi sign gn an and f d fun unct ctio ion / n / Dr Driv ive m...
  • Page 204 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     10.2 .26 6 El Elec ectr tric ical al sy syst stem em / D / Des esig ign a n and nd fu func ncti tion on / D...
  • Page 205 Ramp On/Off, Drive motor regulator." on in combination with Ramp On/Off, Drive motor regulator." on page 10.29 page 10.29) ) . . ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     El Elec ectr tric ical al sy...
  • Page 206 4 ve 4 is is of of th the On e On/O /Off ff ty type pe. . ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     10.2 .28 8 El Elec ectr tric ical al sy...
  • Page 207 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     El Elec ectr tric ical al sy syst stem / em / De Desi sign gn an and f d fun...
  • Page 208 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     10.3 .30 0 El Elec ectr tric ical al sy syst stem / em / De Desi sign a gn and nd fu func ncti tion / on / St Stee...
  • Page 209 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     El Elec ectr tric ical al sys syste tem / D m / Des esig ign an n and f d fun unct ctio ion / S n / Ste teer erin ing s...
  • Page 210 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     10.3 .32 2 El Elec ectr tric ical al sy syst stem / em / De Desi sign a gn and nd fu func ncti tion / on / St Stee...
  • Page 211 Figure 10.15 Figure 10.15 Sensor positioning, truck seen from above. Sensor positioning, truck seen from above. ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     El Elec ectr tric ical al sys syste tem / D m / Des...
  • Page 212 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     10.3 .34 4 El Elec ectr tric ical al sy syst stem / em / De Desi sign a gn and nd fu func ncti tion / on / St Stee...
  • Page 213 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     El Elec ectr tric ical al sys syste tem / D m / Des esig ign an n and f d fun unct ctio ion / S n / Ste teer erin ing s...
  • Page 214 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     10.3 .36 6 El Elec ectr tric ical al sy syst stem / em / De Desi sign a gn and nd fu func ncti tion / on / St Stee...
  • Page 215 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     El Elec ectr tric ical al sy syst stem em / D / Des esi i gn gn an and f d fun unct ctio ion / n / Wi...
  • Page 216 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     10.3 .38 8 El Elec ectr tric ical al sy syst stem / em / Re Repa pair i ir ins nstr truc ucti tion ons / C s / Cal alib ibra rati tion...
  • Page 217 ACCELER MIN ACCELER MIN ...V ...V ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     El Elec ectr tric ical al sy syst stem / em / Re...
  • Page 218 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     10.4 .40 0 El Elec ectr tric ical al sy syst stem / em / Re Repa pair i ir ins nstr truc ucti tion ons / C s / Cal alib ibra rati tion...
  • Page 219 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     El Elect ectri rical cal sys syste tem / m / Rep Repair air ins instru truct ction ions s / C / Cal alib ibrat ratio ion, n, Li Lift fting...
  • Page 220 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     10.42 El Elect ectri rical...
  • Page 221 Press OUT if the value is NOT to Press OUT if the value is NOT to be be saved. saved. ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     El Elect ectri rical cal sys syste tem / m / Rep...
  • Page 222 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     10.44 El Elect ectri rical cal sys system tem / / Rep Repai air i r inst nstru ructi ction ons / s / Sav Save e par param amete...
  • Page 223 P P re res s s E s EN N T T E E R t R to s o sa a v v e e . . ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     Elec Electri trical sy...
  • Page 224 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     10.46 El Elect ectri rical cal sy syste stem / m / Rep Repai air i r inst nstruc ructi tion ons / s / Do Down wnloa load p...
  • Page 225 SELECT: Mod. 01 SELECT: Mod. 01 AC1 ZAPI V1 AC1 ZAPI V1 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     Electr ctrica ical sy l syste stem / Rep m / Repai air in r inst struc ructio...
  • Page 226 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     10.4 .48 8 El Elec ectr tric ical al sy syst stem em / / Re Repa pair ir in inst stru ruct ctio ions ns / / Ch Chec...
  • Page 227 ER fo for ye r yes a s and nd OUT OUT fo for n r no. o. ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     El Elec ectr tric ical al sy syst stem em / R...

  • Page 228: Regulator

    ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     10.50 El Elect ectri rical cal sys system tem / R / Repa epair i ir inst nstru ructi ction ons / R s / Rep eplac lacing ing dr drive...

  • Page 229: Replacing The Steering Servo Sensor

    ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO         El Elec ectr tric ical s al sys yste tem / Re m / Repa pair ir in inst stru ruct ctio ions / R ns / Rep...

  • Page 230: Diagnosis And Trouble Shooting

    ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     10.5 .52 2 El Elec ectr tric ical al sy syst stem em / D / Dia iagn gnos osis a is and nd t t ro roub ubl l e s...
  • Page 231 B- on the respective regulator to use B- on the respective regulator. . ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO    ...

  • Page 232: Regulator

    ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     10.54 El Elect ectri rical cal sys syste tem / m / Dia Diagn gnosi osis a s and nd tr troub ouble le sho shoot otin ing / g / Pr...
  • Page 233 At 100 °C it is reduced to zero. with increasing temperature. At 100 °C it is reduced to zero. ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     El Elec ectr tric ical s...

  • Page 234: Error Codes

    ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     10.5 .56 6 El Elec ectr tric ical al sy syst stem em / / Di Diag agno nosi sis a s and nd tr trou...
  • Page 235 E VP P 1 1 N N O O T T Problem with one of the Problem with one of the proportional valve guides. proportional valve guides. ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     El Elec ectr tric ical al sy...
  • Page 236 Defective contactor. expected to be closed, but the expected to be closed, but the contactors are not closed. contactors are not closed. ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     10.5 .58 8 El Elec ectr tric ical al sy...
  • Page 237 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     El Elec ectr tric ical al sy syst stem em / / Di Diag...
  • Page 238 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     10.6 .60 0 El Elec ectr tric ical al sy syst stem em / / Di Diag agno nosi sis a s and nd tr trou oubl ble e sh...
  • Page 239 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     El Elec ectr tric ical al sy syst stem em / / Di Diag agno nosi sis a s and nd tr trou oubl ble e sh shoo ooti ting...

  • Page 240: Motor Regulator

    If the error persists, replace regulator. between at least one phase and signal between at least one phase and signal earth is high. earth is high. ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     10.6 .62 2 El Elec...
  • Page 241 If it does not open, the error shows If it does not open, the error shows and the drive is stopped. and the drive is stopped. ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     El Elec ectr tric ical al sy...
  • Page 242 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     10.6 .64 4 El Elec ectr tric ical al sy syst stem em / / Di Diag agno nosi sis a s and nd tr trou oubl ble e sh...
  • Page 243 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     SERVICEMANUAL SERVICEMANUAL Machi hine: A-Ergo  rgo  Manual ual No: 00597 5975  5  Edition 2007A Edition 2007A 11 Brake Brake and and speed speed system system Design Design and and function function ....
  • Page 244 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     11.2 11.2 https://www.besttruckmanuals.com/...
  • Page 245 Electric brake Electric brake A-Ergo is fitted with a A-Ergo is fitted with an electric brake. The electric brake is a n electric brake. The electric brake is a safety brake with two fric- safety brake with two fric- tion surfaces. The brake torque that can be tion surfaces.
  • Page 246 SMA-Ergo_11_2007A.fm SMA-Ergo_11_2007A.fm ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     11.4 .4 Brak ake e an and d sp spee eed d s s ys yste tem m / / Re Repa pair ir in inst stru ruct cti i on...
  • Page 247 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO         Bra a ke ke an and d sp spee eed d sy syst stem...
  • Page 248 Tighten t hten the th he three re ree retainin taining g screws at 9.5 Nm. screws at 9.5 Nm. ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     11.6 .6 Brak ake e an and d sp spee...
  • Page 249 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     Bra a ke ke an and d sp spee eed d sy syst stem em / / Re Rep p ai air r i i ns nstr truc uct t io ions...
  • Page 250 ATLET SERVICE MANUAL A-ERGO ATLET SERVICE MANUAL A-ERGO     11.8 .8 Brak ake a e and nd sp spee eed s d sys yste tem / m / Re Repa pair ir in inst stru ruct cti i on...

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