U - AC Power Plus, Manual No 005953 - A

Service Manual
U - AC Power Plus
Manual Nr: 005954
Edition:
A
Approved 2000-11-10
by:
Johan Rydenskog
Product Responsible
Bo Bidhagen
Technical Documentation
Atlet AB is certified
according to ISO 9001
1:A
General information and technical data
2:A
Special tools
3:A
Service
4:A
Chassis
5:A
Drive unit
6:A
Mast
7:A
Steering
8:A
Hydraulic system
9:A
Lift cylinder
10:A
Electrical system
11:A
Drive and brake system
12:A
Options
Service Manual
U - AC Power Plus
Manual No: 005953
Section:1 Issue: A
1 General information and technical data .....................................1.3

1.1 General information ......................................................................................................................1.3
1.2 How to use the manual ..................................................................................................................1.3
1.2.1 Symbol key ........................................................................................................................1.3
1.3 Safety.............................................................................................................................................1.4
1.3.1 Lifting points ......................................................................................................................1.4
1.3.2 Safety instructions ..............................................................................................................1.5
1.3.3 Environment .......................................................................................................................1.5
1.3.4 Handling .............................................................................................................................1.5
1.3.5 Trouble shooting ................................................................................................................1.6
1.4 Type designations..........................................................................................................................1.6
1.5 Component specification ...............................................................................................................1.8
1.5.1 Drive motor ........................................................................................................................1.8
1.5.2 Electric brakes ....................................................................................................................1.8
1.5.3 Gearbox ..............................................................................................................................1.8
1.5.4 Hydraulic unit ....................................................................................................................1.8
1.5.5 Control system for motors .................................................................................................1.9
1.5.6 Battery ................................................................................................................................1.9
1.5.7 Servo motor ........................................................................................................................1.9
1.5.8 Steering servo unit ACC ....................................................................................................1.9
1.6 Tightening torque .......................................................................................................................1.10
1.6.1 Conversion table torque ...................................................................................................1.10
1.6.2 Bolt types and tensile grades ...........................................................................................1.11
1.7 Lubrication ..................................................................................................................................1.12
1.7.1 Lubrication chart U*S ......................................................................................................1.12
1.7.2 Symbol key lubrication chart ...........................................................................................1.13
1.8 Recommended oil and grease......................................................................................................1.14
1.9 Recommended replacement ........................................................................................................1.15
1.10 Machine colours according to NCS...........................................................................................1.15
1.11 Colour codes for Atlet's wiring diagrams..................................................................................1.15
1.12 Designations for electrical components ....................................................................................1.16
First letter ...........................................................................................................................1.16
Second letter.......................................................................................................................1.16
1.13 Units ..........................................................................................................................................1.17
ATLET SERVICE MANUAL U - AC Power Plus
1.1
1.2
General information and technical data
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 January 2000.
You may find contradictions in the manual compared with 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. We reserve the right to make changes.
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
General information
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 drivers 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.
1.2
How to use the manual
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.
1.3
1.3
Safety
1.3.1
Lifting points
SM 172.1
Figure 1.1
The picture above shows where the permitted lifting points are located on the truck. The lifting points are
marked with a decal representing a lifting hook. When lifting just the mast, the lifting hole in the outer
mast must be used (point A). When lifting the entire truck use the lifting points on the chassis support
frame (point B)
1.4
Warning! The machine must never be lifted from the drivers overhead guard.
1.3.2
Safety instructions
When the truck is lifted using a jack, make sure you secure it using 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 use.
Pull out the plug and wait 2 minutes before starting work on the electrical system. See the warning
sign.
Ensure the drive wheel runs free of the floor before trouble shooting.
When dismantling hydraulic components, the system should not be pressurised, e.g. the pump motor
shutoff and the forks down, .
The battery plug must always be disconnected and all connections to the truck computer unit, servo
unit, and regulators (applies to all electronic units) must be disconnected during all welding work.
Once the welding work has been completed the connector must first be connected to the truck
computer unit, then connect 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
Environment
Waste material that arises due to repair, maintenance or cleaning should be collected and disposed of in
accordance with the directives of each country. Such work may only be carried out in areas intended for
this purpose. Take care of the environment!
1.3.4
Handling
Ensure all essential tools are close at hand before starting work.
Check colour codes and for damage to cables and connectors before the cable harness or other
electrical components are disconnected.
When complex assemblies 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 ensure 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 Atlets 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.
1.5
Use the screws and bolts stated 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 torques, see
section 1.6 Tightening 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. Be sure of the reason for the fault before
replacing components.
1.4
Type designations
Truck type
UNS, UHS
Designations:
U = Reach truck
N = Normal
RF = Rotating forks
S = Standard
H = High lift
TF = Telescope forks
S = Narrow (second letter)
F = Four way
E = Ergonomics
C = Compact
Load capacity: UNS / UHS: 1400, 1600, 2000 kg

Mast type:
Battery types:
UNS
140, 160, 141, 200 DTFV
UHS
141, 200 DTFV
UNS / UHS:
R, X, M
R = Reach
M = Motor powered battery rollers
X = Battery on rollers
Battery size:
UNS:
C, E, F, G
UHS:
E, F, G
Battery
C:
Approx. 450 Ah.
capacity:
E:
Approx. 600 Ah.
F:
Approx. 750 Ah.
G:
Approx. 900 Ah.
1.6
Combina-
140 UNS, 160 UNS, 141 UNS, 200 UNS.
tions:
141 UHS, 200 UHS.
Type designations (example):
UNS / 140 DTFV R E 540

Truck type: UNS
Loading capacity / 10
Mast type
DTF
Clear view mast

Battery type
Battery size
Lift height H4 cm
SM 173.1
Figure 1.2
Available battery combinations

UNS 140
UNS 160
UNS 141
UNS 200
UHS 141
UHS 200
RC
X
X
X
RE
X
X
X
X
X
X
RF
X
X
X
X
X
RG
X
X
XC
X
X
X
XE
X
X
X
X
X
X
XF
XG
XFM
X
X
X
X
X
1.7
1.5
Component specification
1.5.1
Drive motor
(Also see section 5, Drive motor)

Make
Elmo
Output
7.5 kW, S3 60% at 2500
1.5.2
Electric brakes
UNS / UHS (Also see section 5, Electric brakes)

Make
Lenze (1 stage 1 disc)
Braking torque
125 Nm
1.5.3
Gearbox
(Also see section 5, Gearbox)

Make
Kordel
Gear ratio
18,37:1
Oil volume
3.5 l
Oil type
See section 1.8
1.5.4
Hydraulic unit
(Also see section 8, Hydraulic unit)

Motor/Pump
Make
Elmo / Eckerle
Output
14 kW, S3 15% at 2300
Max pressure
175 bar
Working pressure
150-165 bar
Flow
13.3 cm3/r
Tank volume
Max 34 l
Oil type normal environment
1.8
See section 1.9
1.5.5
Control system for motors
Make
Inmotion
Type
83R09027A
Voltage
48 V
1.5.6
Battery
Voltage
48 V
Capacity area UN / UH / UFS
300 - 900 Ah
Capacity area URF/UTF
900 Ah
Capacity area USS
300 - 750 Ah
1.5.7
Servo motor
Make
Kordel
Voltage
48 V
1.5.8
Steering servo unit ACC
Make
Inmotion
Voltage
48 V
Current capacity
21 A
Fly by Wire
1.9
1.6
Tightening torque
DIM
4.6
Nm
Tensile grade
8.8
10.9
Nm
Nm
12.9
Nm
M4
M5
M6
M8
1.1
2.2
3.7
8.9
2.9
5.7
9.8
24
4.0
8.1
14
33
4.9
9.7
17
40
M10
M12
M14
M16
M18
M20
17
30
48
74
103
144
47
81
128
197
275
385
65
114
181
277
386
541
79
136
217
333
463
649
The tightening torque values in the table above are standard values. In some cases specific tightening
torque values are stated in respective tabs. If no tightening torque value is stated in the service instructions
the values shown in the table above apply.
1.6.1
1.10
Conversion table torque

Newton metres
(Nm)
Kilo pond
metre (kpm)
Pound force
inch (lbg x in)
Pound force foot

(lbf x ft)
1
9.81
0.11
1.36
0.10
1
0.01
0,14
8.85
86.8
1
12
0.74
7.23
0.08
1
1.6.2
Bolt types and tensile grades

Bolt type
Designation
Tensile grade
M6S
Hexagon bolt
8.8
10.9
8.8
8.8
10.9
12.9
MC6S
Hexagon hole bolt
MF6S
Hexagon hole bolt,

countersunk
10.9
MCS
Slotted screw
4.6
MVBF
Square raised head
4.6
8.8
10.0
SM 166.1
Marking and the manufacturer's trademark as

well as tensile grade are compulsory for bolts
with a thread diameter from 5 mm and in
tensile grades according to the table above.
Marking only takes place when the shape of the
product permits this.
8.8
8.8
12.9
12.9
SM 031.1
Figure 1.3
1.11
1.7
Lubrication
1.7.1
Lubrication chart U*S
H
A
C
K
L
F
M
N
O
Service
rlig Service
SM 174.1
Figure 1.4
1.12
1.7.2
Symbol key lubrication chart

Symbol
Key
Symbol
Key
Hydraulic oil
Hydraulic oil and filter,

replace
Gearbox oil
Gearbox oil, replace
Grease
Chain spray
Chain spray / oil
Only cold storage design
Teflon paste
Applicable in general for the symbols:
Unfilled symbol - Check lubrication
Filled symbol - Replace
A.
Mast damping
J.
Chain pulley
B.
Mast profile, roller surfaces and slide

surfaces
L.
Hydraulic tank
C.
Fork carriage, slide surfaces for fork

carriage
M.
Hinge
D.
Fork carriage, thrust rollers
N.
Torsion ring bearing
E.
Steering transmission chain
O.
Gearbox
F.
Battery lock, slide surfaces and springs P.
G.
Mast shift and tilt cylinders
H.
Mast and carriage bearing, thrust rollers
I.
Lift chains, all lift chains in the mast.
Accelerator and brake controls, slide

surfaces and springs
Chains fork carriage TF
IMPORTANT! All torsion springs in the machine should be lubricated during each service.
1.13
1.8
Recommended oil and grease

Brand
Gearbox oil
According to APIclass GL-5
Hydraulic oil
According to VG class
32, 15
Normal
Cold
storage
Normal
(32)
Cold store
(15)
Normal
BP
BP
Energear
FE 80 W140
BP
Energear
75W-140
EP-S
Bartran
SHF-S 32
Bartran
HV32
BP
Energol
SHF-Lt 15
Energrease
LS EP2
Mobil
Mobilube
SHC
80W-140
Mobilub e DTE 13 M
SHC
75W-140
DTE 11M
Mobilplex
48
Shell
Spirax HD Hypoid oil

85W-140 75W-140
Tellus oil
T32
or: TX32
Tellus oil
T 15
Alvania
G2
or:
Retinax
LX2
Exxon /
Statoil
Gearway
G5
85W-140
Syntol
75W-140
Hydraway
HV 32
Texaco
Geartex
EPC
80W-140
Rando oil
HDZ 32
Rando oil
HDZ 15
Multifak
EP2
Castrol
Hypoy C
80W-140
Hyspin
AWH 32
Hydraulic
OM 15
or: Hyspin
AWH15
Speerol
SW2
or: AP2
Gleitmo
Grease, bearings,
mast, seat, etc.
Tergoseat
bushing
Side-shift
Teflon
paste
Molybd.
Alloy
882EP
HVY
Cold
storage
Univis J 26 Uniway Li
42
or: Li62
Gleitmo
805
Others
The side-shifts slide surfaces should be lubricated using open gear grease.
IMPORTANT! Do not mix different lubricants - definitely not synthetic oil with mineral oil!
1.14
1.9
Recommended replacement
Hoses should be replaced after 5 years as these are perishable.

Hydraulic oil should be replaced after 1 year or 1000 operating hours
1.10
1.11
"
Machine colours according to NCS

Machine colour
Notation
Yellow
Medium grey
Dark grey
NCS 0070-Y20R
NCS 7000
NCS 8000
Colour codes for Atlet's wiring diagrams

Code
Cable colour
BE
BL
BN
GN
GR
O
P
R
SB
VO
W
Y
Beige
Blue
Brown
Green
Grey
Orange
Pink
Red
Black
Violet
White
Yellow
Note! Twin coloured cables are shown with both colour codes separated by a slash. For
example, Blue and yellow cables are defined with the colour code BL/Y.
1.15
1.12
Designations for electrical components
First letter
Code Designation
A
Component or function.
without its own letter below
Contactor
Diode
Electronic component
Fuse
Battery
Indicator
Relay
L/H Lamp unit

M
Motor
P/X Plug
R
Resistor
Switch
Terminal
Warning unit with sound
Brakes
Second letter
Code Designation
B
Brakes
Control system
Emergency function
Forward
Hour
Key
Lower
Manoeuvre
Pump
Reverse
Speed
Example SL = Switch for Lowering function

1.16
1.13
Units
Abbreviation
Key
A
V
V/A
W
Nm
k
M
Ampere
Volt
Ohm
Watt
Newton metre
kilo (=1000)
Mega (=1 000 000)
1.17
1.18
Service Manual
U - AC Power Plus
Manual No: 005953
Section:2 Issue: A
2 Special tools....................................................................................2.3
2.1 List of tools....................................................................................................................................2.3
2.1
2.2
Special tools
2.1
List of tools
Tool
Part number P/N
Communications cable, truck computer

(ATC)
Axle puller for load wheel
Lifting eye M8 (Lift motor)
Lifting eye M12 (Drive motor)
Hand spray (for Kryotox-grease)
Insulation test instrument
Lubrication
Printer
110360
001210
015101
015100
110782
111111
112268
110668
2.3
2.4
Service Manual
U - AC Power Plus
Manual No: 005953
Section:3 Issue: A
3 Service ............................................................................................3.3
3.1 Service inspection list....................................................................................................................3.3
3.2 Code explanation ...........................................................................................................................3.9
3.1
3.2
Service
Service should be carried out regularly two times a year with normal truck usage, i.e. 1000 operating hours
per year. The planned service (500 h) includes stages such as driving tests, operating tests, filter
replacement, oil changing and replacement of carbon brushes, etc. Servicing takes place at different time
intervals depending on the trucks number of operating hours. The service interval should be more frequent
if the truck works in extreme conditions or in rugged environments.
3.1
Service inspection list
A complete operations test must be performed before the inspection. Faulty functions must be rectified
before the inspection.
IMPORTANT! The truck must be cleaned, springs and all moving parts (axles) must be
lubricated with every service inspection. All mountings on the drivers guard, battery partition,
side plates and drive unit must be tightened with every service inspection.
Special attention should be made to the inspection of the electrical emergency stop device. If contactor tips
on the contactors appear to be worn with a visual inspection these should be replaced as a preventive
measure. Applies to contactors K10, K11 and K12.
IMPORTANT! The contactor tips should always be replaced and the entire device operations
tested if the emergency stop has been used in an emergency situation.
For further information about procedures for inspections, repairs and replacement refer to respective
sections. See the list of contents. Planned service inspections take place according to the following points:
3.3
Chassis
Inspection
points
Symptom
Signs/Decals
Doors, panels
None, unreadable
Mounting
damage
Driver seat
Mounting, damage,
lubrication *
Overhead guard
Mounting
Deformation,
cracks, other
damage
Load wheel
Damage, wear
Noise
Mounting
Battery stop,
Damage,
Battery rollers,
mounting,
Battery lock
lubrication *
Rubber mats,
compartment,
Chassis, general
Damage
Mounting
Appearance
Damage
Loose bolts
Inspection
Service code
Visual
Visual, tools,
1024, 1101
1005, 1102
1032 *
1107, 1034
*
1035
Visual, tools,
Visual, tools,
Visual, tools,
Visual
Listen, tool
Visual, tools,
1051, 1108
Visual, tools,
1014,
1013
*
1105, 1058
Visual
Visual, tools,
Visual
Visual
Tool
* See lubrication chart in section 1
3.4
1033, 1112
*
Frame
Inspection
points
Symptom
Lift chains #
Chain adjustment
Lubrication *
Damage, chain
Damage, chain bolt
and chain bolt
mounting
Forks #
Weld damage
Wear
Angle
Mast
Cracks/Weld
damage
Mast dampening
Lubrication *
Play damage,
wear to rollers
Angle, parallel
deformation
Mounting rollers
Reach carriage Crack formation/
welded joints
Lubrication
Play damage,
wear to rollers
Deformation
Fork carriage
Cracks/Weld
damage
Wear,
damage
Inspection
Service code
By hand
Visual, tools,
Visual
Visual
2008
Visual
Visual
Visual
Visual, tools,
2026, 2107
Operating test
Visual, tools,
Visual, tools,
operating test
Visual
Visual, tools,
Visual/tools,
2101,
2103
Visual, tools,
Visual, tools,
operating test
Visual
Visual, tools,
2007, 2004
2033
Visual

# Fork tests and chain tests must be carried out at least every 1000 operating hours, see section 6.
3.5
Drive unit
Inspection
points
Gearbox *
Drive axle
Gear
Drive motor
Symptom
Inspection
Service code
Oil level
Noise
Noise
Oil leakage
Function, noise
Visual, filling
Listen, tool
Listen, tool
Visual, tools,
Listen, tool
3101, 3006
3104
3106
Cable connections
Drive wheel
Noise
Damage, wear
Mounting, play
Turning bearing Noise, lubrication *
Visual, tools,
Listen, tool
Visual
Visual, tools,
Listen, lubricate
7027, 7112,
7104
3005, 3102,
3002
3103
Steering
Symptom
Inspection
Inspection
points
Gear
Servo motor
Mini/Midi
steering wheel
Tachometer
3.6
Noise
Mounting
Carbon brush wear
Mounting
Damage, wear
Listen, lubricate
Visual, tools,
Visual, tools,
Visual, tools,
Visual,
function test
tools
Service code
4009
4014
4013
Brakes
Inspection
points
Symptom
Inspection
Service code
Braking force #
Operating fault
5012
Braking effect
Parking
brake
Brake disc
Braking distance
Operating fault
Function test
tools
Measure, tool
Function test
tools
Visual, tools,
Wear
5014
5104
# Also see section 11.
Inspection
points
Hydraulic system
Symptom
Inspection
Hydraulic tank
Oil level
Visual, filling
Damage, leakage,
Visual, cleaning
contamination
Air, oil filter
Visual, replacement
blocked #
Cylinders
Function
Function test, stop watch
Damage
Visual, replacement
Leakage
Visual, tools, replace
Cracks/
Visual, tools,
Weld damage
replacement
Damage, chain
Visual, tools,
bracket
Hoses
Leakage, damage
Visual, tools,
Mounting
Visual, tools,
Nipples
Leakage
Visual, tools,
Pump motor
Function, noise
Listen, tool
Cable connections
Visual, tools,
Hydraulic pump
Leakage
Visual, tools,
Damage
Visual, tools,
Noise
Listen
Proportional
Operating fault
Test of lever function
valve, on/off
Operating fault
Calibration of levers
valve
Leakage
Visual, tools,
Service code
6012, 6102
6017, 6001
6106
6019
6109
6009
# Filter replacement at the latest every 1000 operating hours or if necessary (when it is dirty).
For more information regarding the hydraulic system, also see section 8 and lift cylinders section 9.
3.7
Electrical system
Symptom
Inspection
Inspection
points
Cables, switch
Connectors
Battery
AC
regulator
Cable harness
Horn
Speed controller
and brake pedal
Level selector
Speed
switch
Fuses
Damage operating
faults, not clean
Operating fault
Cable breakage
Contactor strip
Charging error
Low acid level
Low acid weight
Damage
Visual, tools,
replace
Visual, tools,
replace
Visual, tools,
Visual, tools,
Tool
Tools,
Tools,
Visual
Low capacity after

charging
Battery plug,
operating fault
Cable breakage
Tools,
DC voltmeter
Operating test,
tools
Visual, tools,
Damage, breakage
Operating fault
Mounting
Operating fault
Operating fault
Operating fault
Operating fault
Visual, tools,
Function test
Visual, tools,
Function test
Calibration
Function test
Function test
7104
7014
7106
Blown
Visual, measure,
replace
Visual,
contact surfaces
Visual, tools,
Visual
Function test
tools
Visual, tools,
Function test
Function test
service functions
Visual
Visual, tools,
7103
Battery plug
Operating fault
Video camera
Mounting
Damage
Operating fault
Truck computer:
Display,
Keyboard,
Control unit
Damage, wear
Operating fault
Mounting
Read error log#
Incorrect display of
measurement
values
3.8
Service code
7107
7032
7025
7034
7035
7008
7037
7203, 7012
7202, 7004
Electrical system
Symptom
Inspection
Inspection
points
Cooling fans
Function #
Service code
Function test
# Read error log and temperature log.
3.2
Code explanation
Chassis
Code
Designation
Check
1112
Optional equipment
1005
1024
Doors
Machine plate
1032
Panels
1033
Paint
1058
1035
Rubber strips
Overhead guard
1107
Seat
1051
1108
Rail wheel
Rail wheel bearing
1013
Battery locking
User Manual, hydrometer and

battery water bottle.
Bolts should be tightened.
Mounting, text shall correspond with
machine type, symbols and warning decals
should be fitted.
Mounted using bolts and clips as well as
bonded parts.
Scraping of paint and attachment/
scraping of decals.
Secured with glue or screws.
Cracks in welds, collision damage
tightening of bolts.
Setting, tilt function, load and angle
adjustment. Chassis mounting.
Rubber wheel wear. Dirt.
Friction free movement, remove
string, plastic bands, etc. that has collected.
Mounting and lock function.
Reference.
1.9
1.4
4.3
1.11
1.9, 4.1
4.5
4.2.2
4.2.2
4.2
Mast
Code
Designation
Check
Refer to
2008
Lift chains
6.6.2
2026
Forks
2101
Mast play
2007
2033
Rollers in fork carriage

Side Shift
Equally adjusted, bolts locked, rust, wear,

chain pulley locked.
Locking device, cracks, damage,
parallelism.
Check the max. play. Lubricate sliding
surfaces
Washers. Lubrication of roller surfaces.
Mounting in fork carriage.
6.4.3
6.2
6.4
3.9
Mast
Code
Designation
Check
Refer to
2103
Mast rollers
Washers. Lubrication of roller surfaces.
Drive unit
Code
Designation
Check
Refer to
3006
Oil leakage
Leakage from axles, joints, plugs or

material.
5.6
3101
3005
3106
3103
3104
3002
3102
Oil level
Drive wheel bolts
Gears
Sliding bearing
Drive axle
Drive wheel
Noise
Oil level. Oil change.

Mounting
Gear ratio
Noise, need of lubrication
Tightening of nuts.
Wear, damage, clean.
Gears, nut tightening.
1.7.3, 5.4.1
1.9
1.7.3
1.10
1.9, 5.6
5.7
1.9
Steering
Code
Designation
Check
Refer to
4004
4009
4014
4013
Gear drive
Intermediate wheel
Servo motor
Mini-wheel
Play, lubrication.
Axle locking, lubrication
Mounting, carbon brush wear
Mounting, rotary motion
1.10
1.10
7.2
7.2
Brake unit
Code
Designation
Check
Refer to
5012
Braking force
Braking distance.
5014
5104
Parking brake
Brake disc
Operation, cable connections

Friction surface > min level all round
11.2.1
11.3.4
11.5
11.4.2
Hydraulic system
Code
Designation
Check
Refer to
6012
6017
6106
6001
Oil level in tank

Lowering
Hoses
Lift cylinders
1.14
1.5, 1.6
1.15
9
6019
6109
Nipples
Hydraulic pump
Oil level between min and max

Check lowering speed
Cracks, wear, damage
Leakage by mountings, welds,
wiper, piston rod
Leakage
Leakage between pump and motor
3.10
Hydraulic system
Code
Designation
Check
Refer to
6009
6111
6102
Hydraulic valve
Optional equipment
Filter
Leakage between sections, connections.

Leakage from connections
Replacement necessary
8.5
8.1
8.1
3.11
Electrical system
Code
Designation
Check
7101
Connectors
7032
Battery
7025
7104
Transistor system
Cable harness
7014
7106
7012
7034
Horn
Speed controller
Hour meter
Level selector
7035
Speed switch
7017
7103
7008
7037
Microswitch
Fuses
Battery connections
Video equipment
7203
7202
Display
Keyboard
Contact surfaces, cable connections, dust

guard. Remove the contact strips if they are
burnt.
Acid level, charging. Note read off from the
hydrometer, clean if necessary
Dirt, moisture Cable connections.
Cable connections, fastening, run free from
sharp edges.
Function
Mounting and function.
Read off the display
The mounting and placement of the switch.
Function
Switch in mast, fork carriage, forks
regarding creep speed.
Function
That they are not brittle.
That cable connections are not overheating.
Operation, mounting of cameras and
monitors. Damage and stretching of cables
in the mast.
Fastening, damage.
Mounting, damage, readability
7027
7112
7030
Drive motor, bearings

Drive motor cables
Pump motor
Noise
Fastening, damage. Need of cleaning.
Mounting. Need of cleaning.
Refer to
3.12
Service Manual
U - AC Power Plus
Manual No: 005953
Section:4 Issue: A
4 Chassis ............................................................................................4.3
4.1 Chassis, plates ...............................................................................................................................4.3
4.1.1 Dismantling, assembling the overhead guard ....................................................................4.3
4.1.2 Dismantling, assembling the overhead guard stanchion ....................................................4.4
4.2 Chassis, machine housing components ........................................................................................4.4
4.2.1 Dismantling, assembling the rail wheel .............................................................................4.4
4.2.2 Adjusting the door .............................................................................................................4.5
4.2.3 Battery lock, battery type R ................................................................................................4.6
4.3 Panels.............................................................................................................................................4.7
4.3.1 Dismantling, assembling of the panels ..............................................................................4.7
4.4 Adjustable arm rest U*S................................................................................................................4.8
4.4.1 Dismantling, assembling the arm rest. ...............................................................................4.8
4.5 Driver seat U*S .............................................................................................................................4.9
4.5.1 Adjusting the dampening ...................................................................................................4.9
4.5.2 Adjusting the lumbar support ............................................................................................4.9
4.5.3 Adjusting the arm rest ........................................................................................................4.9
4.5.4 Adjusting the seat forwards/backwards .............................................................................4.9
4.5.5 Vertically adjusting the front edge of the seat cushion ......................................................4.9
4.1
4.2
Chassis
The chassis on trucks in the U-range are built-up of modules. The different chassis parts are mounted on
the chassis base.
4.1
Chassis, plates
Battery wall to bottom frame, pos 8 (M10) is

tightened to 65 Nm.
2
The side plates to bottom frame, pos 21 (M12)

are tightened to 114 Nm.
19
The motor bed pos 28 and 29, are tightened to

320 Nm.
15
Pos 14, M10 nuts on welded studs are

tightened to a torque of 20 Nm.
"
14
12
3
4
Note! Other bolts and screws are

tightened to the torque stated in the
table in section 1.
20
21
1413
22
8
9
23
6
10
11
12
IMPORTANT! All bolted joints for

pos. 1, 5, 6, 7, 15, 19, 31 and 37
shall be retightened as a part of the
routine service.
24
29
13
28
27
26
30
31
32
37
33
36
A 281.1
35
34
Figure 4.1
4.1.1
Dismantling, assembling the overhead guard
Bolt pos 2, Figure 4.1, which screws into the overhead guard support should be assembled from above.
Nuts are fitted from below.
The tightening torque for the nut is 81 Nm.
4.3
4.1.2
Dismantling, assembling the overhead guard support
Bolts securing the overhead guard stanchion to the side plate are assembled from above.
Nuts are fitted from below.
The tightening torque for the nut is 81 Nm.
"
Note! Other bolts and screws are tightened to the torque stated in the table in section 1.
4.2
Chassis, machine housing components
4.2.1
Dismantling, assembling the load wheel
Jack up the rail wheel and support the

chassis.
Remove the circlip, pos 22.
Push out the axle, pos 25.
Remove the old wheel, pos 24.
Fit the new wheel with bearing, pos 23,

and the load wheel tube, pos 27, and the
circlip, pos 26, already fitted.
Insert the axle, pos 25. Lock in position

using the circlip, pos 22.
23
24
23
26
26
27
25
PA 286.1
22
Figure 4.2
4.4
4.2.2
Adjusting the door
The door hinge is adjustable so that the door can be opened and closed with a
good fit against the chassis.
Adjust the height of the door using the screws at the end of the hinge, pos
1. The top edge of the door, towards the hinge side, should protrude a
little above the edge of the chassis.
1
2
3
Adjusting the fit of the door against the chassis:
Loosen the screw, pos 18, a few turns.
Counter hold using an open ended spanner on the eccentric cam, pos 16.
Loosen the screw, pos 15.
16
Turn the eccentric cam to adjust the fit of the door, lock the eccentric
cam using screw, pos 15. Check and readjust, if necessary.
17
Lubricate with oil or chain spray.
Tighten the screw, pos 18.
15
18
3
2
1
Figure 4.3
4.5
4.2.3
Battery lock, battery type R
Press down the up arrow on the

keyboard at the same time as the control
reach in is activated.
Press down the shaft, pos 2, which releases

the battery catch.
Release the arrow up key.
Keep the pedal pressed down and activate

the control for reach out.
To refit the battery again: Actuate the

control for reach in until it stops. Press
the key and continue to actuate the
control for reach in until the battery is
locked.
1
2
SM 177.1
Figure 4.4
4.6
4.3
Panels
The recyclable panels are manufactured of durable, vacuum formed ABS plastic.
4.3.1
Dismantling, assembling of the panels
Loosen the two bolts holding the arm rest.

Dismantle the panels using a 3 mm allen key.
Clean the panels using a soapy water solution.
White impact marks may appear with minor
damage. These can be removed by carefully
heating using a hot air gun.
7
2
A 280.1
Figure 4.5
4.7
4.4
Adjustable arm rest U*S
4.4.1
Dismantling, assembling the arm rest.
The arm rest is adjusted by means of lever,

pos 22.
14
17
15
57
21
18
19
28
PA 283.1
Figure 4.6
4.8
20
22
4.5
Driver seat U*S
The driver seat is fitted with adjustable gas cartridge dampening dependent on the body weight. The
lumbar support can be adjusted in three positions. The arm rests can be rotated to give a comfortable
working position and lifted to assist entering and alighting from the driver compartment.
4.5.1
Adjusting the dampening
The dampening is adjusted using the knob on

the seat frame behind the seat back. (pos a)
4.5.2
Adjusting the lumbar

support
d
b
The lumbar support can be adjusted in three

positions by using the lever on the left-hand
side of the seat. (pos b)
4.5.3
Adjusting the arm rest
The arm rest can be rotated to give a

comfortable working position by means of
screw, pos 7. (pos d)
e
c
SM 191.1
Figure 4.7
4.5.4
Adjusting the seat

forwards/backwards
The seat can be moved further forward or back

by using the loop under the front of the seat.
(pos c)
4.5.5
Vertically adjusting the

front edge of the seat
cushion
The front edge of the seat cushion can be

adjusted in three positions. The cushion is
released by grasping the front edge and pulling
it forwards. When the required height is
obtained push the cushion back in its new
position. (pos e)
4.9
4.10
Service Manual
U - AC Power Plus
Manual No: 005953
Section:5 Issue: A
5 Drive unit .......................................................................................5.3

5.1 Dismantling, assembling the dive unit ..........................................................................................5.3
5.2 Drive motor, general instructions .................................................................................................5.4
5.2.1 Storage of machines and motors ........................................................................................5.4
5.2.2 First service ........................................................................................................................5.4
5.2.3 Preventive maintenance .....................................................................................................5.4
5.2.4 Dismantling, assembling the motor ...................................................................................5.5
5.3 Reconditioning the motor ..............................................................................................................5.5
5.3.1 Motor bearings ...................................................................................................................5.5
5.3.2 Tighten of nuts on the pinion on the motor shaft ...............................................................5.6
5.3.3 Stator housing ....................................................................................................................5.6
5.3.4 Assembly ...........................................................................................................................5.6
5.4 Gearbox .........................................................................................................................................5.6
5.4.1 First service ........................................................................................................................5.6
5.4.2 Preventive maintenance .....................................................................................................5.6
5.4.3 Replacing the gearbox .......................................................................................................5.7
5.5 Replacing the drive axle's stuffing box .........................................................................................5.8
5.6 Replacing the drive wheel .............................................................................................................5.9
5.7 Trouble shooting chart.................................................................................................................5.10
5.1
5.2
Drive unit
The drive unit is mounted in an assembly containing the brakes, drive motor, gearbox and drive wheel. The
steering servo motor is mounted on the same motor bed.
For technical data regarding component parts, see section 1.
5.1
Dismantling, assembling the drive unit
Lift up the machine using a jack, see

section 1 Lift points. Place wooden
blocks under, pos 5 figure 5.1, on both
sides.
Lower the machine so it rests on the

wooden blocks. The drive wheel shall run
free, about 30 mm above the floor.
Loosen the rear chassis/member, pos 4.
Loosen the cable connections to the drive

motor, servo motor, electric brake and
steering wheel indicator. Label the cables
that are not labelled to ensure correct
reassembly.
1
3
Fit the lifting eye, pos A, as illustrated.

(pos A can be ordered from Atlet, see
section 2).
Loosen the 8 bolts, pos 6, on the bolted

joint between the motor bed/chassis.
Carefully lift out the drive unit from the

machine, (the bearings in the motor can be
damaged if you lift jerkily).
The prescribed tightening torque values

and the tensile grade of the bolts must be
observed when reassembling the motor bed
unit in the machine housing.
2
6
SM 175.2
Figure 5.1
Tightening torque: 320 Nm (pos 6)

Tensile grade 12.9.
"
Note! Other bolts and screws are

tightened to the torque stated in the
table in section 1.
5.3
5.2
Drive motor, general instructions
For further technical information regarding the drive motor, see section 1 Technical data.
Warning! The battery plug must be removed and the machine lifted so that the drive wheel
runs free of the ground when working on the motor.
5.2.1
Storage of machines and motors
Machines in storage that will not be used within a month, must be given special attention so that problems
do not occur when they are to be used. Dust, dirt, condensation and moisture that occurs during large
changes in temperature, as well as problems with rust and oxidisation must be prevented. Consequently
motors should be protected using waxed paper or the like, as well as using a moisture absorbing material,
e.g. silica gel.
5.2.2
First service
Check that no noise comes from the motor bearings.
Check that no abnormal vibrations are experienced while running.
5.2.3
Preventive maintenance
Preventive maintenance is implemented in accordance with the intervals set out in the service chart. See
section 3, Service.
However, in some cases exceptions must be made and the intervals can be shortened, depending on the
conditions in customer's premises, e.g. a rugged environment with dust, high humidity levels, salt, etc.
Listen for noise from the bearings when the motor is run. Check that it does not vibrate abnormally.
Blow down the motor using dry compressed air or clean using a vacuum cleaner. A special cleaning
fluid P/N 122268 should be used to drive out oil and dirt, if oil has leaked from the gearbox into the
motor. Finally blow dry using compressed air.
Check that the insulation resistance for the motor does not fall below 48 K ohm.
5.4
5.2.4
"
Dismantling, assembling the motor

Note! In this case only the cables
to the drive motor and electric
brake need to be disconnected.
Remove the bolts, pos 3 figure 5.2.
Carefully lift out the motor, pos 2, from the

gearbox so that the gears are not damaged.
If repairs or reconditioning of the motor

are to carried out, see section 5.3
Reconditioning the motor.
Check/replace the sealing ring, pos 7.
Assemble in the reverse order.
3
4
5
6
SM 176.1
Figure 5.2
5.3
Reconditioning the motor
A total overhaul of the motor is recommended after 3000 to 5000 operating hours. The motor should be
removed from the drive unit (see 5.1, 5.2). Now dismantle the motor so that the end shields, armature are
released. Great care should be exercised because the tacho sensor is integrated in one of the bearings so
that the sensor is not damaged.
5.3.1
Motor bearings
The motor bearings should always be replaced when reconditioning the motors to ensure continued
reliable operation.
5.5
5.3.2
Tighten of motor shaft pinion nut
Nuts securing the motor shaftpinion must be tightened to 21-26 Nm.
5.3.3
Stator housing
The housing is cleaned using a special fluid P/N 112268 and then blown dry; after the housing has dried,
make an insulation test:
Check that the insulation is satisfactory. Measure the resistance between the coil and stator housing see
section 5.2.3 Preventive maintenance If the resistance is lower the motor must be blown clean and
tested again.
5.3.4
Assembly
5.4
Gearbox
For further technical information regarding the gearbox, see section 1 Technical data.
5.4.1
First service
The first oil change should take place after approximately 150 200 hours.
Drain the oil from the gear housing. (pos 40 fig 5.4)
Fill with oil. Recommended oil, see section 1.
5.4.2
Oil change takes place after approximately 1000 operating hours or at least once a year.
The steering bearing must be greased at least once a year. If steam cleaning or high pressure washing
has been carried out then grease bearing immediately.
5.6
5.4.3
Replacing the gearbox
Follow the instructions as set out in section

5.1
Drain the oil from the gear housing. (Pos

40 fig 5.4)
Remove the motor and drive wheel.
Remove the bolts joint, pos 5, holding the

gearbox on the motor bed.
Lower the gearbox from the motor bed.
Fit the new gearbox.
"
"
5
6
Note! Do not forget to fill the

gearbox with oil before starting up.
The oil can be filled before the
drive motor is assembled on the
gearbox. To ensure the oil level is
correct: open the level plug pos 34
fig 5.4 and drain off the excess oil.
Note! Spent oil should be taken
care of and recycled according to
applicable legislation in respective
countries.
pB 280.1
Figure 5.3
5.7
5.5
1
Replacing the drive axle's stuffing box
Lift up and secure the machine as set out in

section 5.1.
Dismantle the drive wheel.
Drain the oil from the gearbox, pos 40.
Remove the cover, pos 36.
Loosen the bolts, pos 29, that hold the

crown wheel halfway, and drive out the
axle towards the drive wheel side.
The bolts can be unscrewed fully when the

crown wheel and bearing have come free
from the axle. The axle is extracted from
the drive wheel side. Place the parts in the
order they were dismantled to avoid
confusion.
Remove the roller bearing closest to the
seal by knocking the axle end against a
block of hard wood. Sometimes the
bearing is removed more easily if you have
an edged object that is inserted between the
bearing's inner ring and the axle's flank.
Any burrs on the axle must be removed
before reassembly.
Carefully clean the seal bearing track in the

gear housing.
When assembling, first mount the bearing,

pos 15, in the drive wheel side of the gear
case.
27
33
31
30
34
32
37 38
15
16
17
39 40
18
19
20
21
pB 202.3
Figure 5.4
10 Assemble the circlip, pos 16, and the seal,

pos 17. Ensure that they sit correctly.
11 Assemble the guard, pos 19, and finally,
carefully press in the drive axle, pos 21.
12 Now assemble the crown wheel and
bearing. Start with the spacer.
13 Apply thread lock to the screw threads
(Loctite 207) and bolt together the entire
drive axle assembly with washers, pos 28,
and bolts, pos 29. The bolts are tightened to
the prescribed tightening torque as set out
in the torque tightening table in section 1.
14 Fit the cover, pos 36. Bear-in-mind that the
drainage hole should be the lowest point.
Use a new gasket, pos 35. Screw in the oil
drainage plug and use a new copper
washer.
15 Fill with hypoid oil. See the table of
recommended oil, section 1.
5.8
29
28
35
36
5.6
Replacing the drive wheel
Loosen the drive wheel nuts, without removing them.
Lift up the machine, secure with blocks.
Lower the machine on blocks.
Remove the wheel nuts and lift the wheel forward.
Assemble the new wheel, tighten the wheel nuts by hand.
Lift up and remove the blocks, lower the machine onto the floor.
Tighten the wheel nuts to the prescribed tightening torque 150 Nm.
5.9
5.7
Trouble shooting chart

Symptom
Cause
Action
The wheel has a flapping sound The tyre has separated

when driving.
due to impact.
The wheel squeaks continuously Bearing is damaged.
when driving.
Change the wheel and check the

floor for unevenness!
Replace the bearing and tell the
driver to remove string, plastic, etc.
daily or keep the floor clean!
The wheel is flat after long
The wheel mass has become
Offload the wheel by, e.g. running
breaks, but becomes round after warm while driving and deforms the mast forwards when charging
driving for a while.
when parked.
or change to a thinner tyre that
gives better cooling!
The wheel has a deformity that
A blow out has taken place due Change the wheel!
does not disappear when driving. to overheating and changed the
molecular structure of the
wheel mass.
The wheel has transverse cracks The wheel has been heated. Small Lower the acceleration and
and small bits have fallen out of cracks appear with hard
reversing ramp, and change the
the tyre.
acceleration and reversing.
wheel if necessary.
The wheel has one or more small Locking of the brakes so that the Remove the objects on the floor
deformities.
wheel slides or loose objects on and tell the driver to brake gently!
the floor that prevent the wheel
from rotating.
Oil on the floor.
Leaking seal around the drive
Replace the seal!
axle.
Or: Replace the drive unit!
Grating noise when accelerating Defective gear wheel in the drive Check the cogs by dismantling the
or with the reversing brake.
unit.
cover/Replace the drive unit!
Grating noise when the truck is Faulty bearing in the drive motor. Dismantle and renovate the drive
lifted up and the drive wheel can
motor!
rotate freely and the motor
rotates.
The truck rolls sluggishly.
The brakes are applied.
Repair and adjust the brakes!
The truck rolls sluggishly.
Drive motor has seized up.
Replace the drive unit!
Clicking sound when driving.
Faulty wheel bearing.
Replace the drive unit!
Clicking sound when driving.
Loose wheel.
Tighten the wheel/Replace the
wheel!
The truck feels jerky when
Hard foreign object has fastened Remove the object or replace
driving.
in the drive wheel.
the wheel!
The truck jumps at regular
The wheel is oval.
Change the wheel!
intervals, proportional to the
Check/Adjust the brakes!
speed, when driving.
5.10
Service Manual
U - AC Power Plus
Manual No: 005953
Section:6 Issue: A
6 Mast ................................................................................................6.3
6.1 Mast 140, 160 ................................................................................................................................6.3
6.1.1 Dismantling the mast .........................................................................................................6.3
6.1.2 Adjusting the mast .............................................................................................................6.4
6.2 Mast 141, 200 ................................................................................................................................6.6
6.2.1 Dismantling the mast .........................................................................................................6.6
6.2.2 Adjusting the brass lugs .....................................................................................................6.7
6.2.3 Adjusting the mast, top ......................................................................................................6.7
6.3 Reach carriage ...............................................................................................................................6.8
6.3.1 Dismantling the reach carriage ..........................................................................................6.8
6.3.2 Adjusting the reach carriage. 141, 200 DTFV ...................................................................6.9
6.3.3 Adjusting the reach carriage 140, 160 DTFV ..................................................................6.10
6.4 Fork carriage................................................................................................................................6.11
6.4.1 Adjusting the fork carriage 140, 160 DTFV ....................................................................6.11
6.4.2 Adjusting the fork carriage, 141, 200 DTFV ...................................................................6.12
6.4.3 Dismantling, assembling the fork carriage ......................................................................6.12
6.4.4 Fork test ...........................................................................................................................6.13
6.5 Lift cylinders ...............................................................................................................................6.14
6.5.1 Adjusting, the cylinder mounting on the mast .................................................................6.14
6.6 Lift chains....................................................................................................................................6.15
6.6.1 Adjusting the lift chains ...................................................................................................6.15
6.6.2 Inspecting the lift chains ..................................................................................................6.15
6.7 Trouble shooting chart.................................................................................................................6.16
6.8 Fork side shift unit.......................................................................................................................6.16
6.8.1 Trouble shooting ..............................................................................................................6.17
6.1
6.2
Mast
6.1
Mast 140, 160

8
The standard mast is of the type DTFV. The

masts are:
3
1
Double telescopic.
9
10
8
2
13
11 12
Have free lift function, i.e. the fork

carriage runs to the top of the inner mast
before the mast section moves upwards.
6
1 5
3
1
14
15
16
17
18
12 11
17
24
21
Free sight type
19
25
22
23
20
27 26
27
26
30
6.1.1
1
2
Dismantling the mast
29
41
Lower the forks to the bottom position.

Secure the entire mast assembly with a
lifting device.
Disconnect and plug the oil pipes.
Remove the fork carriage, see section 6.4.3

Dismantling, assembling the fork carriage.
Disconnect the tilt cylinders, see section 8.
Remove the cap on the carriage.
Lift off the mast.
Remove the lift chains and lift cylinders.
40
24
28
26
42
26
43
25
33
34
35
44
36
37
36
11
C 281.1
Pull out the inner mast.
10 Pull out the intermediate mast.
38
39
12
Figure 6.1
Inspecting or repairing the mast system:
Check that the thrust rollers lie against the roller surfaces on the mast. Also check that they roll easily.
An operating test must be made after each measure/action on the mast system. The mast must not jam
or run slowly (the mast sections may move in the wrong order) when lifting and lowering.
6.3
6.1.2
Adjusting the mast
Adjusting the play on mast 140, 160 DTFV.

Adjustment is carried out by utilising the
advantages of negative H4 i.e. that the inner
mast is lowered so that the load rollers are
accessible without the need of dismantling the
mast. There are two sizes of rollers available
and the possibility of shimming using 0.5 or 1
mm shims behind the load rollers to
compensate for play.
(The diameter is punched on each roller).
1
First check the play and its position before

dismantling the mast. Jack up the load
wheels and support securely on blocks.
sm 183.1
Figure 6.2
Lift up the forks and secure the fork

carriage to the cross stay, see figure.
sm 184.1
Figure 6.3
Remove the lowering dampers, see figure.
sm 185.1
Figure 6.4
6.4
Secure a lifting device to the inner mast,

see figure. Loosen the lift cylinders and
secure them so that they cannot fall
outwards and lower them so that they run
free of the upper cylinder mountings.
sm 186.1
Figure 6.5
Lower the inner mast so that the mast

rollers are free, see figure.
Pull off the rollers and adjust the number of

shims when changing to a roller with a larger
dimensions.
IMPORTANT! If necessary,
dismantle the sensor, level
measurement chain and other
optional parts before the mast
sections and lowered.
sm 187.1
Figure 6.6
6.5
6.2
Mast 141, 200
The standard mast is of the type DTFV. The masts are:
Double telescopic.
Have free lift function, i.e. the fork carriage runs to the top of the inner mast before the mast section
moves upwards.
Free sight type
6.2.1
1
2
3
4
5
6
Dismantling the mast
Secure the entire mast assembly with a

lifting device.
7
8
9
1 2
Remove the fork carriage, see section 6.4.3

Dismantling, assembling the fork carriage.
7
4
12 13
12 10
10
6
5
4
14
15
2
8
20
21
22
15
24
28
25
30
27 26
Place on the floor with the outer mast

downwards.
27
26
35
36
30
51
37
Remove the lift chains and lift cylinders.
Loosen the brass blocks and brass screws.
27
Pull out the inner mast.
26
31
32
60
34
32
29
33
26
38
42
27
28
39
40
41
43
10 Pull out the intermediate mast.
31
14
16
29
17
18
19
Lift off the mast.
23
10
Remove the caps on the reach carriage.
16
9
Remove the tilt cylinders, see section 8.
11
40
44
42
45
46
43
44
16
15
14
50
45
55
56
57
58
52
50
46
49
47
53
54
48
16
15
14
47
48
49
C 200.5
Figure 6.7
Inspecting or repairing the mast system:
Check that the thrust rollers lie against the roller surfaces on the mast and that they roll easily.
Check that the thrust rollers run square to the roller surfaces. If not this will result in damage, e.g. deep
grooves or chips on the masts roller surfaces.
An operating test must be made after each measure/action on the mast system. The mast must not jam
or run slowly (the mast sections may move in the wrong order) when lifting and lowering.
6.6
6.2.2
Adjusting the brass blocks
Make sure the maximum play between the

brass blocks and the mast section, pos 42, does
not exceed 0.4 mm. The play between the
thrust roller and the mast is measured using
feeler gauges. The play is adjusted by inserted
the required number of shims, pos 43.
42
43
44
45
46
pC 200.3
Figure 6.8
6.2.3
Adjusting the mast, top
Tilt the mast forward. The four brass bolts pos

32 at the top of the outer mast and intermediate
mast, are tightened until they touch and are
then loosened 90, lock with pos 31. The four
excentries, pos 4, at the top of the outer mast
and intermediate mast should be adjusted so
that the rollers rest against the roller surfaces.
The mast sections must be parallel.
1 2
5
6
30
31
32
p2C 200.3
Figure 6.9
6.7
6.3
Reach carriage
6.3.1
Dismantling the reach

carriage
Secure the mast assembly with a lifting

device.
Remove the reach cylinder chassis anchor

belt pos 15 fig 8.5.
Disconnect the mast hoses and cable

connectors.
Remove the safety stop screws from the

open end of both reach channels.
Pull out the reach carriage.
6.8
6.3.2
Adjusting the reach carriage. 141, 200 DTFV
The reach carriages sliding plates, pos 27, and

the excentric rollers, pos 23, should be adjusted
so that there is a minimum of vertical play.
35
7
Adjust the side thrust sliding plate, pos 17 by

using the adjuster screws pos 32, so that the
reach carriage is symmetrical and parallel with
the carriage guides on the support arms. The
lateral play on the reach carriage may be a
maximum of 2 mm. Keep roller surfaces clean
and free from debris.
5
9
10
11
12
13
3
30
31
29
Apply grease to the reach channel sliding

surfaces.
37
38 12
13
19
36
28
27
34
33
32
42
22
21
20
26
5
23
24
25
20
22
21
5
14
15
16
17
18
39
40
41
C 210.4
Figure 6.10
6.9
6.3.3
Adjusting the reach carriage 140, 160 DTFV
The rollers on the reach carriage are of the type

full roller. The lateral play is adjusted by
screwing in the screws, pos 15. The lateral play
may be a maximum of 2 mm, and the sliding
surfaces on the support arms should be
lubricated.
6
35
7
1
6
5
9
10
11
12
13
30
29
37
38
36
19
4
15
16
5
21
22
20
C 280.1
5
14
6
Figure 6.11
6.10
12
13
6.4
Fork carriage
Different fork arrangements are mounted on the back of the fork carriage from basic forks to complex units
with side shift, fork spread and telescopic forks.
6.4.1
Adjusting the fork carriage 140, 160 DTFV
The lateral play is adjusted by adapting the

number of shims behind the load rollers and by
replacing the rollers, pos 16, 17.
7
6
6
1
11
12
3
13
16
17
19
33
20
C 282.1
Figure 6.12
6.11
6.4.2
Adjusting the fork carriage, 141, 200 DTFV
Side thrust rollers rest against the roller

surfaces.
7
6
Adjust the four excentric rollers, pos 18 so that

they make contact with the roller surfaces.
6
1
Warning! Tightening too much will

affect the lowering speed or the
mast sections will be lifted in the
wrong order.
11
12
8
9
10
13
15
14
16
17
18
19
20
27
26
24
21
22
C 206.2
28
23
Figure 6.13
6.4.3
Dismantling, assembling the fork carriage
Lower the fork carriage on to a European pool pallet or similar.
Remove the lift chains.
Remove the stop screw on the inner mast.
Lift up the inner mast using a crane until the fork carriage is released.
6.12
25
6.4.4
Fork test
Seven inspection points are included in the fork

test. If the forks do not pass any of the points
the machine must be taken out of service. If the
customer is not prepared to do this, it should be
written in the report that The forks do not
comply with the demands set out in SS-ISO/
5057". When the customer later signs the
service order, he then bears responsibility for
the defective forks.
Straightness of the blades and Shanks:
Deviation from the carrier surface and the
support surface's straightness must not exceed
0.5% of the blade respective shank's length.
Marking
Difference in height
between fork arm tips
SM 020.1e
Figure 6.14
L = 1150 mm, max deviation 5.75 mm.

h = 492 mm, max deviation 2.46 mm.
h = 464 mm, max deviation 2.32 mm.
Crack formation: Check whether the forks are

cracked. Check carefully around the heel and
bends.
Thickness
Wear: Check the forks for wear, especially

around the heel. The blade thickness must not
be thinner than 90% of the original thickness.
The original thickness is found by:
1
Reading the marking on old forks.
Measuring the blade thickness in the centre

of the shank.
Shank
Tip
Thickness
Contacting Atlet for information about

blade thickness.
Hook
Blade
Heel
Length
SM 021.1e
Figure 6.15
Fork angle: The angle between the blade and the shank may be max 93 degrees.
The height difference between the tips of the forks: Must not exceed 3% of the blade length.
Locking device: Check that the locking device works.
Labelling: The fork's marking should be clear and comprise the lifting capacity in I kg for one fork and the
centre of gravity distance in mm.
6.13
6.5
Lift cylinders
6.5.1
Adjusting, the cylinder mounting on the mast
Start by lowering the mast and slackening the

chains.
10
Adjust the outer cylinder mounting with the top

nut, pos 10. Adjust both cylinders equally.
If the movement is sufficient in the cylinders
mounting the rollers will have contact with the
masts runner at all lifting heights, even if the
brass screws are not tightened.
If the truck is fitted with a tilt function the mast
should be tilted forwards.
Operationally test the lifting movement.
Tighten the chain and check that the rollers still
make contact with the runners. The cylinder
mountings should be moveable.
6.14
SM 094.2
Figure 6.16
Lift chains
6.6.1
Adjusting the lift chains
Place the mast vertical.
The inner and outer masts should be

locked.
Adjust the two outer lift chains so that the

mast hangs a little from the lift chains.
Adjust the centre chain so that the fork heel

is: 5 (+/-2) mm from the ground.
5 2
6.6
SM 075.1
Figure 6.17
6.6.2
Inspecting the lift chains

P
If the lift chains do not pass the inspection at any point the whole chain
should be replaced. It is not permitted to join or re-rivet lift chains.
SM 169.1
Figure 6.18
Make sure the chains are clean. Make the inspection without a load.
Lift up the forks about 20 cm above the floor. Measure over the 25 links
that run over the guide rollers, as the elongation is normally at its
greatest here. Compare with the measurements below. If the chain has
stretched by more than 2% it should be replaced.
3/4"
1"
1 1/4"
The trucks lift chains should be inspected regularly, after about 1000
operating hours.
Pmeasurem
ent
Measurement 25
links
new chain
Max measurement 25
links
2% elongation
19.05 mm
25.40 mm
31.75 mm
476.25 mm
635.00 mm
793.75 mm
485.00 mm
658.00 mm
809.00 mm
Check that no pins are loose in the outer side plates.
Check that there are no visible cracks on any of the side plates.
Check that there is no signs of mechanical damage or of corrosion.
Check that the chains run easily over the guide cogs and do not jam.
Lubricate the chain with chain spray.
6.15
6.7
Trouble shooting chart

Symptom
Cause
Action
Play on mast.
Worn brass lugs.

Cams out of position.
Brass lugs adjusted too hard.
Cams adjusted too hard.
Adjust the lugs!

Adjust the cams!
Adjust the lugs!
The mast lowers unevenly,

jumps.
The mast squeaks.
6.8
Adjust the cams!

No grease on the mast roller
Apply grease to the roller
surfaces
surfaces!
The rollers have rubbed
Lubricate or replace the rollers!
together.
Fork side shift unit
The side shift unit is supplied with the slide

segments lubricated with special grease, (see
section 1) (upper and lower) to ensure a good
sliding capacity even after the running in
period. The self-lubricating characteristics may
stop in especially aggressive environment
conditions. Check the sliding capacity of the
side shift unit regularly.
1
Check for wear to the slide segments, both

the upper and lower, bearing-in-mind
damage and normal wear. Replace if
necessary.
2
9
10
Check that the cylinders do not leak, which

can be because of:
Scratches on the piston rod. Replace the
entire cylinder!
Worn external seals. Replace the seals by
dismantling the piston rod bracket and
circlip.
6
5
I 10.1
4
3
Figure 6.19
Worn internal seals. Replace the entire

cylinder!
After 1000 hours: Clean carefully under the

glide segment with its sliding surface, then
grease the sliding surface.
6.16
6.8.1
Trouble shooting
Symptom
No side shift
Side shift
runs too slow
Cause
Side shift unit deformed by
collision or overloading.
No play under the lower mounting
blocks.
Worn hydraulic hoses.
Defective hydraulic pipes.
Insufficient hydraulic pressure.
Hydraulic pump worn.

Cylinder fault.
Worn piston rod gasket
Friction bush worn.
Cavitation jumps pump sucks air.
Hydraulic pump worn.

Insufficient hydraulic pressure.
Irregular
side shift
Air in the hydraulic system.

Friction bush on the piston rod worn.
Side shift only Air in the hydraulic system.

in one direction Cylinder fault.
Defective valve.
"
Action
Straighten!
Adjust the blocks so that 1 mm of play
is obtained!
Replace the hoses!
Correct!
Increase the pressure!
Check the computers values under the
menu VALVE PARAMETERS
Replace/repair the hydraulic pump!
Replace the cylinder!
Change the bush, clean and oil!
Check the trucks oil level in the tank and
pump!
Check that the hoses are tight!
Replace/repair the hydraulic pump!
Increase the pressure!
Check the computers values under the
menu VALVE PARAMETERS
Bleed the system and check the oil level.
Fill with oil if necessary!
Replace the bush, clean and lubricate!
Bleed the system!
Check the valve function!
Note! The cylinder is sealed and cannot be opened. There any no spare parts available.
6.17
6.18
Service Manual
U - AC Power Plus
Manual No: 005953
Section:7 Issue: A
7 Steering...........................................................................................7.3
7.1 Servo motor ...................................................................................................................................7.3
7.1.1 Dismantling the servo motor ..............................................................................................7.3
7.2 Electronic steering (ACC) .............................................................................................................7.4
7.2.1 Servo steering unit, functions ............................................................................................7.4
7.2.2 Settings ...............................................................................................................................7.5
7.2.3 Function control of the electric servo ................................................................................7.7
7.3 Diagnostics ....................................................................................................................................7.8
7.3.1 Outputs from the steering unit ...........................................................................................7.8
7.3.2 Control connection 13 pins ................................................................................................7.8
7.4 Trouble shooting table...................................................................................................................7.9
7.5 Settings U** ..................................................................................................................................7.9
7.1
7.2
Steering
The trucks in the U AC Power Plus range are equipped with an electric steering as standard and are
manoeuvred using a mini wheel mounted on the left-hand armrest. The steering is divided into 3 units on
the electrical side and gear transfer of power between the steering servo motor and the drive unit. The first
unit, the mini wheel is a progressive steering unit. The quicker the wheel is turned the faster the movement.
The second unit is a servo steering unit, which converts the steering signals to the third unit, the steering
motor. There is no mechanical connection between the mini wheel and the steering wheel. The electrical
section is monitored by a safety system that stops the truck if an error should occur. An error code is then
shown on the display and these are then saved in the ATCII log.
7.1
Servo motor
The only adjustment of the steering system takes place electrically, the number of turns of the steering, the
steering force and compensation can be set.
7.1.1
Dismantling the steering motor
Remove the cable connections on the

steering servo motor.
Remove the bolts holding the steering

servo motor, pos 1.
Lift the steering servo motor straight up.
SM 190.1
Figure 7.1
7.3
7.2
Electronic steering (ACC)
7.2.1
Servo steering unit, functions
RE1
RELAY
5 6 7 OFF
M1
M2
SW1
OPEN
1 2 3
K2
8 9 10
11 12 13
ON
LIN
1
2
3 3
4
5
6 4
7
8
K1
LIN
ERROR
ERROR
SM 033.1
Figure 7.2
Switch function
(dipswitch)
No.
1
2
3
4
5
6
7
8
"
Function
Not used
Current limit
IR-compensation
Sensitivity
Note! The switch is open when it is in the off position.
7.4
LED No
Indicator lamp
Indicates the following when on
1
2
3
4
5
Everything OK
End position
End position
Fault
Fault
7.2.2
Settings
The current limit to the motor can be adjusted and thereby also the motors torque. The limit value can be
set to 4 different levels through the dipswitches 2 and 3. If the torque is too low, the steering movement
will be weak and slow and lag behind with rapid turning of the mini wheel.
The current limit should be set so that:
The top current does not exceed the motors rated data.
The produced torque is not greater than the strength of the mechanical components.
Servo steering unit
Dipswitch 2
Dipswitch 3
10
14
18
21
Open
Open
Closed
Closed
Open
Closed
Open
Closed
Min. current A
Max. current A
IR compensation affects the motors ability to follow the mini wheel. Compensation can be set in 4
different levels by using dipswitches 4 and 5.
If it is set too low the motor will not follow slow wheel movement.
If it is too high the motor will oscillate and cause overheating.
No compensation
1/3 compensation
2/3 compensation
Full compensation
Dipswitch 4
Open
Open
Closed
Closed
Dipswitch 5
Open
Closed
Open
Closed
7.5
The sensitivity of the tachometer affects the relation between the speed of the mini wheel and the
steering motor, which in turn affects how quickly the steering reacts.
The sensitivity can be set in 8 different levels using dipswitches 5, 6, 7 and 8.
If the sensitivity is too high the steering movement can be too powerful at high speeds.
If the sensitivity is too low the steering will be slow.
To obtain a good sensitivity level at high and low speeds the unit is fitted with progressive steering. This
means the sensitivity automatically increases with rapid steering wheel movement.
Max. sensitivity
Min. sensitivity
Tachometer
voltage
Dipswitch 6
Dipswitch 7
Dipswitch 8
+/- 1.5 V
+/-3.0 V
+/-4.0 V
+/-5.5 V
+/-6.5 V
+/-7.5 V
+/-8.5 V
+/-9.5 V
Closed
Open
Closed
Open
Closed
Open
Closed
Open
Closed
Closed
Open
Open
Closed
Closed
Open
Open
Closed
Closed
Closed
Closed
Open
Open
Open
Open
IMPORTANT! Switch 1 not used.
7.6
7.2.3
Function check of the electric servo
Start the truck and check that the operation of the end stops in both directions is correct.
Turn the mini wheel maximum clockwise. Connect the red/black cable with the pink/black cable
coming from X18s connection closest to the servo box. Turn the steering to the centre position. After
approx. 10 mm of movement on the gearbox the servo contactor should break. Check that the brakes
are really applied and that it is not possible to drive the machine. If the brakes are not on and the
machine can be driven then the circuit must be checked. The drive regulator E1 is fed from the servo
connector E4 pin 8. Check that pin 8 is not voltage fed, if it is replace the servo box. Reset using the
off-on buttons on the keyboard.
Brown/white cable. Perform the same procedure with the opposite switch by connecting together the
red/black cable with the brown/white cable.
Pull apart the connector P14 (tied to the return hose on UNS). The servo contactor should break and it
should be impossible to release the brake; it should also be impossible to drive the truck. Connect P14
again.
Pull out the motor fuse for the servo motor (F4). The servo motor should stop and it should be
impossible to release the brake; it should also be impossible to drive the truck. Fit the fuse again.
If it is possible to release the brake after points 2, 3, 4 or 5 have been implemented, or it is possible to
drive the truck, the truck must be checked carefully and not used until the fault has been rectified.
Finally check that drive unit does not hit the mechanical stop in the end positions.
IMPORTANT! Remove error codes E05 and E06 by resetting in the ATCIIs service menu
log book.
7.7
7.3
Diagnostics
7.3.1
Outputs from the steering unit
Open collector, active = low

Out 3 high and Out 12 high
Unit active
Out 3 low and Out 12 high
Faulty sensor unit
Out 3 high and Out 12 low
Fault in the steering or motor unit
Out 3 low and Out 12 low
Faulty steering unit
7.3.2
Control connection 13 pins
1.
48 V
In
Start/stop and internal supply
Not connected
Out approx. 0.2- 4.5
Error code no:1
4.
In
0V
Tachometer
5.
In
48 V
Negative direction
6.
In
(+/- 1.5 9.5 V
Reference voltage from tachometer
7.
Out -12V
UFS: with automatic driving of the drive wheel
8.
Out 48 V
Safety relay
9.
In
0V
Minus supply for error indication
10.
In
-12/+12V
UFS: full motor modulation with automatic turning of the drive wheel
11.
In
48 V
12.
Out
approx. 0.2- 4.5 Error code:2
13
Out
+12V
Positive direction
UFS: with automatic driving of the drive wheel
Power connection 4 pins

+
In
48V
Battery voltage +
In
0V
Battery voltage -
M1 Out
Motor connection +
M2 Out
Motor connection -
7.8
7.4
Trouble shooting table
The battery should be connected and the truck logged on.
LED 1
Green
OFF
ON
ON
ON
LED 2 LED 3 LED 4 LED 5

Red
Red
Red
Red
OFF
OFF
OFF
ON
ON
ON
ON
ON
ON
ON
7.5
OFF
ON
ON
Indicates
Action
No control current
OK
Negative direction
active
Positive direction
active
Fault in tachometer
circuit. Cable
breakage, short-circuit
or wrong type of
tachometer
Fault in the steering
unit or in the motor
circuit. Cable
breakage or short
circuit
Fault in steering unit
Check supply.
None
None
None
Check the cables and connectors.
If OK replace the tachometer. If
still faulty, check that the right
tachometer is used.
Check the cables, connectors and
motor brushes. If OK, replace the
motor or steering unit.
Replace steering unit
Settings U**
The table shows ATLETs factory settings:

The switches are set by using a pointed tool or pen. Insert the tool in the
the position marked X.
Switch
1. Not connected
2. Current limit
3. Current limit
4. Load compensation
5. Load compensation
6. Sensitivity
7. Sensitivity
8. Sensitivity
Miniwheel
X
Midiwheel
O
X
X
X
X
O
O
O
O
O
X
X
O
X
7.9
7.10
Service Manual
U - AC Power Plus
Manual No: 005953
Section:8 Issue: A
8 Hydraulic system ...........................................................................8.3

8.2 Dismantling the pump motor.........................................................................................................8.4
8.1 Replacement of the hydraulic filter ...............................................................................................8.4
8.3 Replacing the suction hose ............................................................................................................8.5
8.4 Draining the tank ...........................................................................................................................8.5
8.5 Cylinders .......................................................................................................................................8.6
8.5.2 Dismantling the tilt cylinder from the truck ......................................................................8.6
8.5.1 Dismantling the reach cylinder from the truck ..................................................................8.6
8.5.3 Dismantling, assembling the mast shift cylinder ...............................................................8.7
8.5.4 Bleeding the mast shift cylinder ........................................................................................8.8
8.5.5 Dismantling, assembling the tilt cylinder. .........................................................................8.9
8.6 Control valve U*S .......................................................................................................................8.10
8.7 Setting the hose rupture valve ....................................................................................................8.10
8.8 Calibrating the hydraulic controls ...............................................................................................8.11
8.9 Hydraulic diagram .......................................................................................................................8.11
8.1
8.2
Hydraulic system
The hydraulic system is speed controlled. The

pump motor, pump, hydraulic oil tank and
hydraulic oil filter are integrated in a module,
which can be easily lifted out from the truck if
necessary.
The hydraulic system consists of:
an oil tank with integrated return oil filter

(replaceable filter insert) and filter for air
evacuation from the tank.
a pump unit consisting of an electric motor

and pump.
an electrically operated valve assembly

that consists of several different sections
(number and design can vary due to
different equipment).
An electrical signal is sent from the joystick to the

ATCII when the hydraulic functions are
manoeuvred. The ATCII then controls the hydraulic
pumps speed and the electrically operated valves.
The hydraulic oil then goes from the valve

assembly through the hydraulic pipes and
hoses to the cylinders. Of these only the lift
cylinders are single acting, the others are all
double acting. The lift cylinders are retracted
by the weight of the fork carriage. In the
double acting cylinders it is the oil pressure
that retracts the piston rod.
Figure 8.1
A socket is located on the pressure pipe

between the pump and the actuator valve for
pressure metering, see pos 8 figure 8.1.
Setting the lowering speed is done using an
adjuster screw on the valve assembly, see
section 8.6 Control valve U*S.
A hose rupture valve is located on the outlet on
the lift cylinder which closes the oil flow if a
hose ruptures and prevents the forks from
falling down, see section 8.7 Setting the hose
rupture valve for setting.
8.3
8.3
Replacing the suction hose
Empty the oil from the tank. See section

8.4
Dismantle the hydraulic filter complete.
Remove the suction hose from the pump.
Remove the suction hose from the tank

using an open-ended spanner and a hook
spanner.
Lift out the suction hose through the hole

for the filter.
Assemble in the reverse order. (Always fit

new O-rings and connect the hose to the
pump before tightening the tank, so that
the hose routing will be correct.)
Fill with hydraulic oil through the filter.
"
)
8.4
Note! The screws for the filter

should be fitted with care to avoid
damaging the threads in the tank.
IMPORTANT! Do not forget the
earth connection between the
suction line and the chassis.
50
Draining the tank
Lower the forks to their lowest position

and depressurise the system.
Loosen the rubber clamp holding the

pressure hose on the battery wall.
Loosen the pressure hose from the valve.
Fold out the hose and place in a container.
Start the pump motor and carefully

pump out the oil into a container.
(Carried out slowly to prevent cavitation in
the pump when the tank is empty.)
"
49
Note! Always use new oil when

refilling.
Figure 8.4
Warning! Exercise care when

loosening the hose and pumping
out the oil as this is under great
pressure and can cause serious
damage/injury.
8.5
8.3
Replacing the suction hose
Empty the oil from the tank. See section

8.4
Dismantle the hydraulic filter complete.
Remove the suction hose from the pump.
Remove the suction hose from the tank

using an open-ended spanner and a hook
spanner.
Lift out the suction hose through the hole

for the filter.
Assemble in the reverse order. (Always fit

new O-rings and connect the hose to the
pump before tightening the tank, so that
the hose routing will be correct.)
Fill with hydraulic oil through the filter.
"
)
8.4
Note! The screws for the filter

should be fitted with care to avoid
damaging the threads in the tank.
IMPORTANT! Do not forget the
earth connection between the
suction line and the chassis.
50
Draining the tank
Lower the forks to their lowest position

and depressurise the system.
Loosen the rubber clamp holding the

pressure hose on the battery wall.
Loosen the pressure hose from the valve.
Fold out the hose and place in a container.
Start the pump motor and carefully

pump out the oil into a container.
(Carried out slowly to prevent cavitation in
the pump when the tank is empty.)
"
49
Note! Always use new oil when

refilling.
Figure 8.4
Warning! Exercise care when

loosening the hose and pumping
out the oil as this is under great
pressure and can cause serious
damage/injury.
8.5
8.5
Cylinders
Mast reach cylinders and tilt cylinders are

double acting.
8.5.1
Dismantling the reach

cylinder from the truck
Reach out the mast to its outermost

position and lower the forks to their lowest
position.
Remove the nut, pos 12, in the rear

mounting. The axle, pos 15, can be held
using an allen key from below.
Remove the axle, pos 15.
Retract the cylinder with the lever for the

reach function by moving it backwards.
Pull out the battery plug.
Remove and plug the pressure hose to the

mast reach cylinder.
Remove the axle in the cylinders front

mounting.
Lift out the cylinder.
Figure 8.5
Assemble the cylinder in the reverse order.
8.5.2
Dismantling the tilt cylinder from the truck

Warning! When dismantling the tilt cylinders, one or both, the mast must be secured so that it
does not tip backwards. Remember that a tilt cylinder can be faulty, which can cause an
accident.
Tilt the mast to it foremost position and lower the forks to their lowest position.
Loosen the pressure hoses to the cylinder.
Dismantle the axles on the front and rear mountings.
8.6
8.6
Control valve U*S
8.7
Setting the hose rupture valve
8.10
8.5.4
Bleeding the mast shift cylinder
If you suspected air to be in the cylinder (jerky

movement), the following operations can be
done:
1
Run out the reach carriage.
Dismantle the axle, pos 15.
Run out the piston a little. (IMPORTANT!

Check that the piston rod is not damaged.)
Dismantle the swivel head, pos 11 from the

piston rod. Dismantle the hexagonal nut
and the tab washer, pos 9 and 10.
Run the cylinder slowly in and out, to its

innermost and outermost positions, several
times so that any air is pressed out.
Assemble the cylinder and make an

operations test.
E 206.2
Figure 8.7
8.8
8.6
Control valve U*S
8.7
Setting the hose rupture valve
8.10
9.2
110703:E 1/1
Service Manual
U - AC Power Plus
Manual No: 005953
Section:9 Issue: A
9 Lift cylinders ..................................................................................9.3

9.1 Dismantling, assembling the free lift cylinder ..............................................................................9.3
9.2 Dismantling, assembling the final stroke cylinder ........................................................................9.3
9.3 Draining, bleeding the cylinders ...................................................................................................9.4
9.4 Dismantling, assembling the free lift cylinder ..............................................................................9.4
9.5 Dismantling, assembling the final stroke cylinder ........................................................................9.5
9.1
9.2
Lift cylinders
9.1
Dismantling,
assembling the centre
cylinder
Lower the forks to the lowest position.
Remove the hoses, pos 3 on the lower part

of the cylinder.
Dismantle the chain bolt, pos 4, with the

chain by the cylinder by loosening the nut,
pos 12.
Undo the bolt, pos 5, in the cylinders

lower mounting from below.
Dismantle the clamp, pos 6, around the

cylinder.
10
11
4
6
9.2
11 2
12
Dismantling,
assembling the outer
cylinders
Place a 10 cm wooden block under the

intermediate mast.
Lower the mast so it rests on the wooden

block.
Dismantle the bolt, pos 8.
Lower so that the cylinder retracts

completely.
Dismantle the oil pipe to the cylinder and

plug.
Dismantle the bolt, pos 9 and lift out the

cylinder.
SM 182.1
Figure 9.1
9.3
9.3
Draining, bleeding the cylinders
Lift the forks approx. 0.5 metres above the floor.
Loosen the bleeding screws, pos 25 figure 9.2 and pos 13 figure 9.3 a little to bleed the cylinders.
Tighten the screws when oil starts to run out.
Lift the forks to the top position. Perform this lift 3 times.
Let the forks stay in the top position for a while.
Bleed the cylinders again, until all the air has been evacuated from the system.
The cylinders must not close more than 5 mm.
9.4
Dismantling, assembling the centre cylinder
Remove the safety clamp, pos 6.
Lift off the yoke, pos 11.
Unscrew the top nut, pos 14.
Pull out the piston rod, pos 17.
Before assembling, change the seals and

sliding element, lubricate them with
hydraulic oil.
19
19
20
21
21
1
3
22
4
35
24
5
25
6
7
33
11
31
10
32
30
17
23
27
12
13
14
15
16
18
28
F 207.3
Figure 9.2
9.4
9.5
Dismantling, assembling the outer cylinder
Unscrew the top nut, pos 6, use a hook

spanner.
Pull out the piston rod, pos 5.
Before assembling, change the seals and

sliding element, lubricate them with
hydraulic oil.
3
2
10

11
9
"
Note! Before assembling check

that no impact marks or large
scratches have been made on the
cylinder tube or piston rod as these
can cause leakage. Generally the
cylinder tube and piston rod should
be handled carefully to prevent
damage. Also ensure that seals and
O-rings are not damaged during
assembly.
12
13
14
12
17
15
16
4
F 206.1
Figure 9.3
9.5
9.6
10.16 Horn ...................................................................................................................................... 10.27

10.17 Warnings ............................................................................................................................... 10.27
10.18 Menu tree ATC ..................................................................................................................... 10.28
10.18.1 Log of faults .............................................................................................................. 10.35
10.18.2 Subinfo ...................................................................................................................... 10.35
10.18.3 General instructions with all types of faults on trucks .............................................. 10.35
10.19 Trouble shooting ................................................................................................................... 10.36
10.19.1 Low temp drive or Low temp hydraulics - Warning on the display ......................... 10.36
10.19.2 The truck and ATC are dead: ................................................................................. 10.37
10.19.3 Warning low battery in combination with E02 B+ on the chassis: ........................... 10.38
10.19.4 Electric servo: ............................................................................................................ 10.39
10.19.5 Symptom: The pump motors speed gradually drops ............................................... 10.41
10.19.6 Symptom: The pump regulators status lamp flashes on and off .............................. 10.42
10.19.7 Symptom: Main connectors do not make once the truck is logged on. .................... 10.44
10.19.8 Symptom: The fuse for the power supply has blown. ............................................... 10.45
10.19.9 Symptom: The drive regulators status lamp flashes on and off ............................... 10.46
10.19.10 Symptom: The drive motor only runs at a low speed with a ticking noise. ............ 10.47
10.19.11 Symptom: High pump motor temperature ............................................................. 10.49
10.19.12 Symptom: The drive motors speed gradually drops .............................................. 10.50
10.19.13 Symptom: (High drive motor temperature) ............................................................. 10.51
10.19.14 The pump motor only runs at a low speed with a ticking noise. ............................. 10.51
10.19.15 Drive system stopped/ Hydraulics stopped Subinfo: Controller not responding .... 10.54
10.19.16 Drive system stopped/ Hydraulics stopped Subinfo: Overcurrent e8 ..................... 10.55
10.19.17 Drive system stopped/ Hydraulics stopped Subinfo: DC bus too low e64 ............. 10.56
10.19.18 Drive system stopped/Hydraulics stopped subinfo: No charge DC bus e128 ......... 10.56
10.19.19 Drive system abnormal/ Hydraulics abnormal
Subinfo: Controller calib error. w256 .................................................................. 10.57
Subinfo: Controller rev to default w512 ............................................................... 10.57
10.19.21 Drive system stopped/ Hydraulics stopped
Subinfo: DC bus too high. HW e16 ..................................................................... 10.58
10.19.22 Drive system stopped/ Hydraulics stopped
Subinfo: ATC contradictory. e2048 ..................................................................... 10.59
Subinfo: Controller temp sensor W2 or subinfo: sensor w4 ......................... 10.59
Subinfo: Speed signal out of range. w 128 ........................................................... 10.60
Subinfo: Motor temp sens lost. w32: Motor temp sens shorted. w64 .................. 10.61
10.19.26 Subinfo: CAN too many errors. e256 ...................................................................... 10.62
10.19.27 Subinfo: CAN watchdog time-out. e512 ................................................................. 10.62
10.20 Trouble shooting chart movement functions ..................................................................... 10.63
10.20.1 Lift function does not work - other functions OK ..................................................... 10.63
10.20.2 The reach-in function does not work other functions OK ...................................... 10.65
10.20.3 The reach-out function does not work other functions OK .................................... 10.67
10.20.4 The drive function does not work, one or two directions .......................................... 10.69
10.20.5 Lowering of the forks does not work ........................................................................ 10.71
10.21 Trouble shooting chart battery stop ...................................................................................... 10.72
10.22 Menu tree, leaves .................................................................................................................. 10.73
10.23 Wiring diagram ................................................................................................................... 10.116
10.2
10
Electrical system, general
The electrical system consists of:
a 48 Volt battery
an ATC
a drive regulator
a pump regulator
a number of sensors both microswitch models (solenoids) and analogue-digital models.
sensors for steering
connectors for connection of the power circuits
electric motors for driving the transmission and hydraulic pump
electric brakes
electric steering
electric fans
electrically controlled hydraulic valves
Trucks equipped for use in cold storage facilities have covered cabs with electric heating and lighting as
extra equipment.
Some trucks are equipped with radio equipment.
Other electrical installations may be encountered due to specific customer requirements. These are not
taken up in this Service Manual.
10.3
10.1
Safety procedures
Electric powered vehicles can be dangerous. All testing, trouble shooting and adjusting must be
carried out by authorised personnel. The drive wheel should run free of the floor and be able to run
freely during work.
Take off watches and rings before starting repair and trouble shooting work.
The electrical system has a multi-stage safety system to provide the highest possible level of safety.
Abnormal conditions are detected and depending on the type of fault different measures are
implemented. The least critical condition only generates a warning via the display. Faults that may
result in dangerous situations result in a stop and trouble shooting assistance via the error log.
The battery must always be disconnected with all replacement and repair work on the electrical
system.
It is essential that all cables (especially the battery cables) are connected correctly as the electronics
used in the truck are sensitive to incorrectly polarised supply voltage.
All dust and magnetic particles should be regularly cleaned from solenoid switches and magnets to
guarantee operations.
Extreme importance must be placed on precautionary measures to avoid accidents during all work on
the vehicle. A general rule is to always implement preventive measures that are adapted to the type of
vehicle to be worked on. The general rules below must always be observed:
Smoking or naked flames are strictly forbidden as there is a risk of explosion in the vicinity of batteries
and while working on gas equipped vehicles. The battery should always be protected during grinding
work. The fire regulations for the building shall also be observed.
The truck shall always be lifted so that the drive wheel is free of the ground to prevent the vehicle from
running away. The vehicle must not rest solely on the jack, but must be secured by some form of
blocking.
The battery plug must always be removed on electric reach trucks to prevent the risk of injuries caused
by crushing. The mast, carriage and power pack can be actuated due to an electrical fault or mistake
while working. The battery plug may only be connected while trouble shooting and when the greatest
of care is exercised, (with the truck raised).
During work on and around the mast and power pack, these must be locked using the mast lock,
wooden blocks or other appropriate material. No other persons may be in the vicinity of the truck
when this is test run in combination with repair work as there is a risk of incidents and accidents
occurring due to the truck making an unexpected manoeuvre.
Warning! To stand on the carriage between the mast and battery partition with the current
connected to the truck can represent Mortal danger!
The system should not be pressurised, for example, the pump motor shutoff and the forks down, when
dismantling parts of the hydraulic system.
10.2
Connectors in cold storage rooms
Grease Kryotox ATLET article number 110781 should be applied to all electrical connectors in the
machine housing and mast/mast base on cold store designed models. The hand applicator, part number
110782, should be used in order to do this. The grease should be applied to contactor surfaces when the
connectors are drawn apart. The contactors are then reconnected and the grease is pressed from behind into
10.4
the contactor housing so that this is filled.
IMPORTANT! Connectors filled with Kryotox should not be treated with 3M. In general the
electrical system is treated as before.
10.3
Dismantling, assembling the drive and pump regulators
Dismantling the panels, see section 4.
Loosen the cables connected to the regulators.
Check that the cables are labelled, if not label the cables before removing.
Loosen the bolts holding the regulators. Most bolts are accessible without the need of dismantling the
bracket.
IMPORTANT! When fitting a new regulator, check that the air tunnel where the regulator is
mounted is free of dust, etc.
10.4
Routine test of the insulation resistance
You must first disconnect the connections (plugs) before the truck is insulation tested in order to protect
the regulators and other electrical components on the truck. This is because damage can occur, which will
shorten the life of component parts. In the event of large insulation errors it is appropriate to use a
universal instrument until the error has been found and then make a final insulation test.
This applies to all electronic units on the truck.
Warning! The instrument has a dangerous voltage across the measurement poles, Do not
touch the poles during testing.
Routines for insulation testing of all truck models.
1
Take out the insulation measurement instrument.
Set the test voltage to 100 volt.
Pull out the battery plug. Disconnect connections/terminals to electrical components and electronic
systems before the test is performed as these can be damaged by the test voltage.
Connect the instruments earth lead to the truck chassis at a point with good electrical contact. The
other lead is connected to the electrical panel plugs positive pole.
Press the start button and wait until the display has stabilised, now release the button and read off the
value on the display. An approved value on 48 volt trucks shall be at least 48,000 ohm, (48 kohm).
Let the earth lead remain attached to the chassis and connect the other lead to the electrical panel
plugs negative pole. Now repeat point 5.
10.5
10.5
Atlets truck computer ATC
The ATC system consists of a keyboard and

display in three parts and an ATC unit.
sm 199.1
Figure 10.1
Display:
The top row is used for information.
The lower row is the status row.
1 9 - AU - 9 4
75
0 7 : 48
1 0H
sm 200.1
Figure 10.2
The lower row (75%), indicates here the

remaining battery capacity.
(10h), indicates here the total running time.
1 9 - AU - 9 4
75
0 7 : 48
1 0H
sm 202.1
Figure 10.3
Here a hare indicates normal speed while a

tortoise indicates low speed. The down arrow
is used for speed on/off.
1 9 - AU - 9 4
75
0 7 : 48
1 0H
sm203.1
Figure 10.4
10.6
Error messages are shown in the form of a code

(E15).
1 9 - AU - 9 4
7 5 E1 5
0 7 : 48
1 0H
sm 201.1
Figure 10.5
10.5.1
General
The service functions are activated via the S (service) key on the keyboard. These functions are divided
into levels, Driver, Local Service, Atlet Service and Customer Service.
The Driver level allows the language to be changed as well as tuning of the trucks travel and hydraulic
characteristics.
On the Local level its possible to change the ID and password for the driver and local service, set the
speed and lift controls, check inputs and outputs, read statistics and make a hardcopy. A password must be
entered to select any of the Local Service functions.
On the ATLET level its possible to change all IDs and passwords, set parameters for the height
preselection, set options, read the error log, make hardcopies and download settings from another ATC or
PC. A password must be entered to select any of the ATLET Service functions.
The Customer Service level allows reading and printing of statistical information, communication with
PSION palm-sized computers, unlocking of a collision-locked truck and resetting of customer logs and
counters.
The menu that appears once the correct password has been entered will be abbreviated. This is because
only the menu title and one menu option (0: Exit) are shown. You can browse through the menus using the
number and arrow keys, while the Enter key selects the menu.
When you enter a form, i.e. where it is possible to change parameter values, you should use the arrow keys
when you do NOT wish to change the values. If you wish to make changes enter the new numerical values
and confirm using Enter. If you make a mistake you must continue to the closest end point and start
again. In some functions it is possible to go back using the arrow key.
10.7
10.5.2
Service functions
The service functions are primarily used to facilitate the ATLET Service. In addition, the service functions
make it possible to read off all the measurements made using the Measurement/Statistics functions.
Functions included are:
Changing the ID and password for Driver, Local and ATLET service levels.
Checking that microswitches and cables on inputs function.
Checking that digital outputs and cables function.
Calibrate and check the operation of the accelerator pedal.
Calibrate and check the operation of the brake pedal.
Calibrate and check the operation of the hydraulic levers.
Reports of Measurement/Statistic functions.
Read and reset running times.
Read and reset the error log.
Hardcopies.
Download settings from another ATC or PC.
10.5.3
Change passwords.
It is possible to change the service password as well as the drivers ID and password.
10.5.4
Calibration and control of the hydraulic levers.
Hydraulic levers are calibrated by measuring the maximum stroke and neutral position for this function.
10.8
10.5.5
Running time functions
The running times of the following units are read off:
Total usage.
Pump motor on 5 levels.
Forwards.
Backwards.
The running time of each unit presented in hours. The maximum number of hours is 99999. When printing
the running hours are also calculated and shown as a percentage of the total usage.
The running hours can either be reset for all units or individually.
10.5.6
Printing of statistics
A function is available under CUSTOMER Service to print all statistic functions either individually or all
at once. Any serial printer or a PC can be used for this purpose.
10.5.7
Collision sensor
This function requires a special sensor mounted on the chassis.

The program has 5 adjustable limits and when one of these is exceeded one or more of the following
functions are activated:
1
A warning message is shown on the display.
The trucks normal horn is activated and produces an intermittent signal.
The trucks warning lights come on.
The truck logs off.
A special password is required to stop the above.
When one of the 5 levels is exceeded a warning text is shown on the display at the same time as the impact
force of the collision is stored with the time, date and driver ID in the customer log.
10.9
Switches should be connected as illustrated.

(input)
Normal Common 4.5 Volt

SM 204.1
Figure 10.7 . Input
The appearance of the input.
100k
2k2
100nF
sm 194.1
Figure 10.8
The appearance of the servo input.

+5 Volt
4k7
100k
100nF
sm 195.1
Figure 10.9
10.11
10.5.11 Description of the digital outputs.

There are 35 outputs on the ATC distributed across a number of output connectors.
The outputs are specified for 0.1A, 1A and 3A. All outputs feature overload protection.
12 of the outputs use an optional voltage, for example, 12 volt or B+
The choice of voltage is made by connecting the selected voltage to XC5:23.
Lowering outputs.
a)
b)
c)
16 Volt
Sence
Sence
R
Sence
R
Watchdog
sm 196.1
Figure 10.10
Supply outputs.
Watchdog
sm 197.1
Figure 10.11
10.12
24 Volt
10.5.12 Digital outputs: B+ fed

Connector
Function
Type
Remarks
XC3:10
XC3:11
Reverse steering wheel indicator

Forward steering wheel indicator
1.0A A High
1.0A A High
+ / Supply
+ / Supply
XC3:21
XC3:22
XC1:22
XC1:23
XC1:24
XC4:23
XC1:21
XC8:22
Buzzer
Main connector
Brakes
Flashing lights
Horn
Key relay
Reserved
Constant current valve level selector
1.0 A Low
1.0 A Low
3.0A A Low
1.0 A Low
3.0A A Low
0.1A A Low
1.0 A Low
1.0 A Low
- / Supply
- / Supply
- / Supply
- / Supply
- / Supply
- / Supply
- / Supply
- / Supply
XC8:23
XC6:23
XC6:24
XC2:22
XC3:01
XC3:08
Reserved
Lamp rail wheel 0 degrees
Lamp rail wheel 90 degrees
Position light
Reserved
Reserved
1.0 A Low
1.0 A Low
1.0 A Low
0.1 A Lamp
0.1 A High
0.1 A High
- / Supply
- / Supply
- / Supply
- / Supply
+ / Supply
+ / Supply
Type
Remarks
0.1 A Lamp
0.1 A Lamp
0.1 A Lamp
0.1 A Lamp
0.1 A Lamp
0.1 A Lamp
0.1 A Lamp
- / Supply
- / Supply
- / Supply
- / Supply
- / Supply
- / Supply
- / Supply
10.5.13 Digital outputs 12 Volts supply

Connector
XC2:11
XC2:21
XC3:05
XC3:06
XC3:02
XC3:03
XC3:04
Function
Not connected
Not connected
Automatic drive wheel rotation anticlockwise UFS
Automatic drive wheel rotation clockwise UFS
Truck-on lamp
Straight steering lamp
Brake lamp
10.13
10.5.14 Digital outputs B+ supply

Connector
XC5:01
XC5:02
XC5:03
XC5:04
XC5:05
XC5:06
XC5:07
XC5:08
XC5:09
XC5:10
XC5:11
XC5:12
10.6
Function
B+ lift valve plate
B+ PWM lower valve plate
B+ Reach IN
B+ Reach OUT
B+ tilt IN
B+ tilt OUT
B+ side shift pedal side
B+ side shift seat side
B+ fork spread OUT
B+ fork spread IN
5V PWM supply steering wheel indicator
B+ PWP regulator fan
Type
1.0 A Low
1.0 A Low
1.0 A Low
1.0 A Low
1.0 A Low
1.0 A Low
1.0 A Low
1.0 A Low
1.0 A Low
1.0 A Low
1.0 A Low
1.0 A Low
Remarks
- / Supply
- / Supply
- / Supply
- / Supply
- / Supply
- / Supply
- / Supply
- / Supply
- / Supply
- / Supply
- / Supply
- / Supply
Valve parameters
A description of the valve section, lift/lowering is given below, however, the same applies to reach, tilt,
side shift, rotate/side shift. Nevertheless, it may be problematic to determine which movements correspond
to POSITIVE. Lift, reach-in, tilt up, rotate clockwise, forks together and side shift towards the driver are
all POSITIVE movements.
POS MAX DUTY

POS MIN DUTY
NEG MAX DUTY
NEG MIN DUTY
JOYST.DEADZONE
Pump output for maximum positive movement (max. lift).

Pump output for minimum positive movement (min. lift).
Pump output for maximum negative movement (max. lower).
Pump output for minimum negative movement (min. lower).
The number of steps from the neutral position that the joystick must be moved
before any actuation is made on the pump. This applies to both the positive and
negative movements.
POSITIVE ACC
Damping of increasing pump output for positive movement.
POSITIVE RET
Damping of decreasing pump output for positive movement.
NEGATIVE ACC Damping of increasing pump output for negative movement.
NEGATIVE RET Damping of decreasing pump output for negative movement.
FETCH B./SCALEF Must not be changed!
10.14
10.6.1
Checking and adjusting values.
POS MAX DUTY and NEG MAX DUTY define the speed of the movement at max. joystick actuation,
these are not normally changed, but if you want calmer/slower movement, for example, while tilting these
parameters can be reduced.
POS MIN DUTY for lifting should be set so that when the joystick starts the pump, for a lift with empty
forks and for forks under free lift, the forks do NOT move.
NEG MIN DUTY for lowering should be set so that its possible to gradually run the pump or lowering
movement with a minimum of joystick actuation (lower values give lower speeds).
FETCH B./SCALEF. for reach is used for battery retrieval and for lift is used as a limiter for the overall
pump output with simultaneous movement. The value is set to 1 with the battery on the rollers to
shutdown the function.
10.7
Battery capacity measurement.
The battery capacity is shown as a percentage of a fully charged battery to the left of the lower row on the
display. Measurements are fully controlled by software, and no further electronics are required. The
battery capacity is measured by measuring the battery voltage when the truck has been at rest for 3
minutes. If the period between measurements becomes too long, the ATC uses the running time counter to
calculate the capacity.
When the battery capacity becomes too low a warning message is given on the displays top row and the
battery capacity value starts to flash. The truck speed is limited to creep speed.
Lift stop with a weak battery is linked to the battery capacity measurement.
Both the warning level and the stop level are set in the service function.
Battery capacity%
Voltage 48 V sys.
Acid density g/cm3
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
45.84
45.95
46.06
46.17
46.28
46.39
46.50
46.61
46.72
46.83
46.94
47.05
47.16
47.28
47.39
1.070
1.075
1.079
1.084
1.088
1.093
1.098
1.102
1.107
1.111
1.116
1.121
1.125
1.130
1.134
10.15
10.16
Battery capacity%
Voltage 48 V sys.
Acid density g/cm3
30
32
34
36
38
40
42
44
47.50
47.61
47.72
47.83
47.94
48.05
48.16
48.27
1.139
1.144
1.148
1.153
1.157
1.162
1.167
1.171
46
48
50
52
54
56
58
60
62
64
66
68
70
72
74
76
78
80
82
84
86
88
90
92
94
96
98
100
48.38
48.49
48.60
48.71
48.82
48.93
48.04
49.15
49.26
49.37
49.48
49.59
49.70
49.81
49.92
50.04
50.15
50.26
50.37
50.48
50.59
50.70
50.81
50.92
51.03
51.14
51.25
51.36
1.176
1.180
1.185
1.190
1.194
1.199
1.203
1.208
1.213
1.217
1 222
1.226
1.231
1.236
1.240
1.245
1.249
1.254
1.259
1.263
1.268
1.272
1.277
1.282
1.286
1.291
1.295
1.300
10.7.1
Battery parameters version 3.00 -
Select 48V batt.
Nominal battery voltage, state 1 for 48 Volt, 0 for 24 Volt. 48 Volt is Default.
Actual battery voltage to ATC. You can make corrections for voltage losses in
cables and connectors up to the ATC by changing these values. To make the
Measured B+
correction, measure the battery voltage at the poles using a voltmeter that can
(mV)
show 4 digits at 50 Volts, then state the voltage in mV. (If the voltmeter shows
48.12 Volt, press 48120 Ent).
Battery size (Ah) Stated in Ah. This is normally stated on the battery. Default is 550.
Pump size (kW) State in whole kW. Default is 14.
Usage, stated from 50 to 200 per cent, and used to correct for light/hard driving.
Utilisation (%) The standard is 100. Higher values are used with harder driving, lower values for
lighter driving.
Calculation constant to receive a warning of whether the chassis has an
Chassis const. 1 unpermitted HIGH voltage depending on too low resistance between the chassis
and the batterys positive pole. See table. Default is 917.
Chassis const. 2
Low batt. level
Lift stop level
10.8
Calculation constant to receive a warning of whether the chassis has an

unpermitted LOW voltage depending on too low resistance between the chassis
and the batterys negative pole. See table. Default is 110.
Determines at what percentage of the battery capacity that the ATC shall warn that
it is time to charge the battery. Default is 25%.
Determines at what percentage of the battery capacity that the ATC should
shutdown the lift function and limit the driving speed to crawling speed. Default
is 20%.
Checking the chassis connection ATC
(This is performed in combination with replacing the ATC).

1
This should be checked using a calibrated DMM in order to determine whether the ATC makes good
contact with the rest of the chassis. Set the digital multimeter to resistance measurement, measurement
range 200 Ohm. Touch the measurement probes together and read off the display, it should be 0.0 to
approx. 0.6 Ohm.
Connect one of the measurement probes to one of the bright screw heads on the ATC box and the other
probe to the screw for the chassis connection, (located on the battery wall under the ATC connection
green/yellow cable). The value read off should not be more than max. 0.5 Ohm higher than the read off
value under point 1.
If the value is higher make a check on some of the other screws on the ATC box. If this does not help
the screw for the chassis connection must be checked. First check by measuring this across another
clean metal surface, if the value is also too high the thread for the chassis connection should be cleaned
using a plug tap and a new check should be performed.
IMPORTANT! Chassis faults should always be rectified during the servicing.
10.9
Potential measurement on the truck chassis.
The potential measurement is performed with a voltage divider connected between B+ and B-, with the
10.17
centre outlet connected to the chassis. The voltage divider has sufficiently large resistance to comply with
EUs insulation requirements at the same time as potential changes can be measured via an analogue input
on the ATC.
If voltage is discovered on the chassis an error code is displayed. The error code is stored together with the
time and date in the error log.
10.10
Error codes
Check the error log and write down or print out the contents of the log before starting any trouble shooting.
Error codes and sub-information that reoccurs within a twenty-four hour time frame (00:00 - 23:59) is not
logged, which is why the log must be emptied in order for the fault to be logged again.
Please note:
That there is more information available for codes marked by an asterisk by pressing the I button when
reading the error log. The extra information is always included in the printout. Codes within brackets are
not used in version 3.30 or later.
10.10.1 List of error codes

Error code
(E01)
E02
E03
(E04)
E05
E06
E07
(E08)
E09
E10
E11
E12
E13
E14
E15
E16
E17
E18
E19
E20
(E21)
(E22)
(E23)
10.18
Error text
High temperature
Chassis + voltage
Chassis - voltage
Cable fault
Servo tacho fault
Servo motor fault
Servo regulator fault
Fk7 fault
Several chassis faults
Joystick fault
NVR small fault
NVR total reset
NVR forced reset
Battery par. reset
Serv. par. reset
Valve par. reset
Travel. par. reset
Options reset
err 19
err 20
Motor carbon brush worn
P1 carbon brush worn
P2 carbon brush worn
Error code
Error text
(E24)
(E25)
E26
E27
E28
E29
E30
(E31)
Servo carbon brush worn

Brake lining worn
NV2 small fault
NV2 total reset
NV2 forced reset
NVR -> MITTOR
MITTOR -> NVR
Motor overheated
(E32)
(E33)
(E34)
E35
E36
E37
E38
E39
E40
(E41)
(E42)
(E43)
(E44)
(E45)
(E46)
(E47)
E48
(E49)
E50
E51
E52
E53
E54
E55
E56
E57
E58
(E59)
E60
E61
E62
E63
P1 overheated
P2 overheated
Servo overheated
Hyd oil overheated
Temp1 overheated.
Temp2 overheated.
ATC overheated.
err 39
NV3 forced reset
Chassis to In.
Output to In.
Unknown chassis fault
Chassis to Out.
Chassis to BChassis to B+
No. of inputs
Brake sensor low
err 49
err 50
F6 Fuse blown
F8 Fuse blown
F7 Fuse blown
err 54
err 55
err 56
err 57
err 58
Test command error
Wheel angle sensor
Rotation sensor
err 62
err 63
10.19
Error code
10.20
Error text
E64*
E65*
E66*
E67
E68
E69
E70
E71
High short-circuit
Low short-circuit
Lmp short-circuit
High out intermittent
Low out intermittent
Lamp out intermittent
High output unknown
Low output unknown
E72
E73
E74
E75
E76
E77
E78
E79
E80*
E81*
E82*
E83*
E84*
E85*
E86*
E87
E88
E89*
E90*
E91*
E92*
E93
E94
E95*
E96*
E97*
E98*
E99*
E100*
E 101*
Lamp output unknown

Deletion error NV1
Program. error NV1
Deletion error NV2
Program. error NV2
Deletion error NV3
Program. error NV3
err 79
TRAP error bus
TRAP error instr
TRAP error word
TRAP error prot
TRAP error oper
TRAP error stun
TRAP error stof
err 87
err 88
Stack error
Division with zero
Calculation error
INTERNAL error
err 93
err 94
CAN hardware
CAN software
Drive sys stopped
Hydraulic stopped
CAN fatal error
Drive sys abnormal
Hydraulic abnormal
10.11
Temperature measurement
Temperature measurements are made using NTC resistance (Negative Temperature Coefficient). The
temperature can be shown from 0 to approx. 150 C. ATC has 6 channels to measure the temperature.
When the temperature is too high the driver receives an error message on the display. This takes place in
two stages. The temperature limiters can be set from the service function. The first stage involves an error
message and the second stage involves a new error message and e.g. the pump/drive motor being
shutdown.
The following statistics are saved for the temperature:
The number of times the temperature has been reached in intervals:
Only the oil temperature is measured with NTC resistance in Power Plus.
In the drive and pump motor systems the temperature is measured in the regulators and motors using PTC
resistance. The temperature is reported to the ATC via the CAN network.
Oil
Motors and regulators
Temp. above 75 C
above 120 C
Temp. 71 - 75 C
Temp. 66 - 70 C
Temp. 61 - 65 C
Temp. 56 - 60 C
111 - 120 C
101 -110 C
91 -100 C
81 -90 C
10.11.1 One of the hydraulic functions channels 3, 4 and 5

See the trouble shooting chart for reach-out, trouble shooting corresponds with the function channels 3, 4
and 5 with the symbol and connector definitions as set out below.
Function
Symbol
Tilt out
Tilt in
Side shift display side
Side shift seat side
Fork spread in
Fork spread out
to TO
ti TI
S<SLL
S>SR
>< SO
< > SC
Connector
P82,1 P82,2
P81,1 P81,2
P53,1 P53,2
P50,1 P50,2
P54,1 P54,2
P51,1 P51,2
10.21
10.12
Battery replacement
Use the reach lever when replacing or extracting the battery.

1
Move in the reach carriage until it stops.
Continue to activate the lever at the same time as the arrow up key on the
keyboard is pressed. The reach carriage will then slide in a little further.
Loosen the battery stop by pressing down the pedal with your right foot
on U*S. Keep holding down and move out the reach carriage. The
battery will now follow out.
Replace the battery and then run in the reach carriage until it stops,
Continue to activate the lever at the same time as the arrow up key on the
keyboard is pressed. The reach carriage will then slide in a little further.
The battery is locked automatically when it reaches its innermost
position.
Now run out the reach carriage and check that the battery lock has
locked correctly.
10.22
SM 179.1
SM 179.1
Figure 10.12
10.13
Setting of the megnet switch for the mast reach stop.
The magnet is adjusted so that the reach

movement towards the machine housing stops
at A=1-15 mm.
The reach speed is set via the valve parameter
set valves.
30
29
32 31
33
35
34
SM 180.1
Figure 10.13
10.23
10.14
Adjustment, calibration and repair instructions
The ATC language should be set to English in order to follow the instructions below.
If necessary also refer to the section menu tree.
10.14.1 Performance settings

Machine parameters: Each machine model can have its own basic settings. For example, a UNS can have
a different top speed compared with a UHS. The parameters are preset at the factory and can only be
changed using special PC software. Under normal conditions the factory settings should never be changed
after delivery. Further parameter adjustments described below represent percentages of and therefore limit
the basic settings.
The basic settings are written into the software for ATC II.
Setting of driver categories: Up to four sets of parameters representing performance categories may be
defined. The system should be used to define, for example, the two categories experienced drivers and
learners. All parameters are preset at the factory and are only intended to be modified by qualified
personnel. Consequently, the setting options are protected under the ATLET service
3: ATLET service
4: Settings
1: Performance
1
AC Driver 1 (Preset to normal experienced drivers represents performance according to the data
sheet.
AC Driver 2 (Preset to a little lower performance than AC Driver 1)
AC Driver 3 (Preset to learner performance)
AC Driver 4 (Preset throughout to max. performance. Intended to show the trucks maximum capacity
at demonstrations and must not be set for a driver to perform daily operations.)
Description of parameters in each set

(possible setting range in percentage of max.):
Travel speed
Crawl speed
Acceleration travel
Current limit Drive
Reduction brake,
travel
10.24
Top speed
Speed limitation activated by [arrow down] key or
by the ATC logic (Tortoise on the display).
Time based ramp
Max. permitted current limit
Braking torque when the accelerator is released.
20 - 100%
10 - 90%
20 - 100%
20 - 100%
0 - 100%
Travel speed
Reversing brake,
travel
Brake pedal
Max. speed, reversing
Max. pump speed
Max. lowering speed
Acceleration pump
Soft hydraulics
Steering sensitivity
Steering progressive
Top speed
Braking torque when the driving direction is
reversed.
Braking torque when the brake pedal is used.
Top speed in the direction of the forks as a
percentage of the Drive speed above.
20 - 100%
50 - 100%
Top speed of the pump.

Top speed for fork lowering.
Current limit. Limits the torque and acceleration.
Gentler hydraulic control
50 - 100%
70 - 100%
20 - 100%
0 = off
1 = on
50 - 100%
20 - 100%
Not introduced
Not introduced
Individual driver settings Each driver ID code can have its own performance profile, but this must be
linked to one of the four driver categories. When a new driver is defined a new question is asked Driver
category? - at the end of the sequence. On delivery factory code 1/2222 is linked to AC Driver 1
category.
IMPORTANT! When delivered category 4 is set for the demonstration of the trucks maximum
capacity and should be readjusted if its to be used for practical operations.
Factory set values in the different performance categories.

Performance category
Travel speed
Crawl speed
Current limit Driving
Acceleration travel
Reduction brake, travel
Reversing brake, travel
100
40
100
80
90
75
80
40
90
70
75
70
50
40
80
60
70
70
100
50
100
100
100
100
Brake pedal, travel

Max. speed, reversing
Max. pump speed
Max. lowering speed
Acceleration pump
Soft hydraulics
Extra Steering 1.
Extra Steering 2.
100
100
100
100
100
0
100
100
100
80
100
100
100
0
90
90
90
80
90
100
90
1
80
80
100
100
100
100
100
0
100
100
The parameters that the driver can tune make up a percentage of the corresponding category parameters in
the category he/she has been placed in. For example, the top speed is set by:
Top speed = Machine parameter (see 2.1) Driver category% (see 2.2) Driver%
Example: Top speed = 12 km/h 90% 100% = 10.8 km/h
10.25
IMPORTANT! If the parameter Max. speed reverse is set lower than 100% it will also be
added to the above calculation example when reversing.
Driver parameters: Each driver can set his/her own performance profile; under the condition that
individual driver IDs are used. The performance profile is activated each time the driver starts the truck.
Follow the instructions to store your own performance profile.
1
Press the [S] key with the battery plug connected, but in the logged off mode.
Select 6 Driver parameters by pressing the [6] key, or scroll using the arrow keys. Press [ENT].
Enter your unique start code.
A parameter menu is displayed:

0. Exit
1. Max. travel speed
20 - 100%
2. Acceleration travel
20 - 100%
3. Reduction braking (motor brake) 0 - 100%
4. Reversing brake
50 - 100%
Default 100%
Default 100%
Default 70%
Default 70%
Move to the parameter you wish to change. Use the number keys to define a new value. Save the value
by pressing [ENT
Press 0. Exit when finished, followed by [ENT] to leave the menu.
Leave the service menu by pressing 0. Exit and [ENT].
Log on to the truck and test drive.
10.15
Fuses
Standard fuses
10.26
F1
F4
F5
F2 heavy
F3 heavy
F4
10A
5A
5A
250A
250A
20A
F6
10A
F7
5A
ATC internal fuses

Drive motor
Pump motor
Servo motor
Pump regulator (measurement point B+3)
Valve plate
Steering wheel indicator
Manoeuvre cold storage cab
Electric servo and end position switch
(measurement point B+4)
Drive regulator
Extra equipment not supplied by Atlet
Standard fuses
F8
F9
F10
F12
F14
5A
10A
5A
5A
5A
Fan door
ATC
B+ ref (see trouble shooting, warning low battery)
Charging circuit regulator
Emergency stop circuits
Fuses extra accessories
F11 heavy
F13
F15
F17
F21
F22
10.16
80A
A fuse box
with 8 fuses,
see wiring
diagram
074530
5A
5A
63A
5A
Main supply cold storage cab

Interior cold storage cab
Radio
Headlamp
Motor circuit, motorised battery rollers
Manoeuvre, motorised battery rollers
Horn
When connecting the horn the terminals on the terminal block should be turned towards you. Connected
according to the standard wiring diagram.
Setting the sound: A number of dipswitches labelled 1-5 can be found at the rear of the horn. The switches
are set so that 1-3 are closed and 4-5 are open. The tones obtained will then be 970 Hz for the horn and 2850
Hz for the buzzer. There is also a potentiometer screw that can be turned clockwise to the stop to give the
maximum sound level.
10.17
Warnings
The ATC display shows a warning message to the side of the described error conditions. Typical warning
conditions are when the temperature of a regulator or motor approaches a critical level. This results in
reduced power to the overheated unit. However, the truck remains operational. System temperatures under
-20C result in a power reduction and a warning condition. The warning message on the display disappears
once conditions return to normal.
Function
Warning
temperature
Stop temperature
Drive motor
Lift motor
Drive regulator
Lift regulator
Hydraulic oil temperature
145
145
85
85
60
165
165
125
125
65
10.27
10.18
Menu tree ATC
Service menu
1: Set language
Select language
1.0: Exit and return to "Service menu"
1.1 :English
1.2: Svenska
1.3: Deutsch
1.4: Francais
1.5: Custom lang.1
1.6: Custom lang.2
1.7: Text test OK
2: Local Service ( Password required )(2)
Local Service
2.1: Set drivercode
(2.1)
2.2: Run tests
Select test:
2.2.0: Exit and return to "Local service"
2.2.1: Drive test
Drive menu:
2.2.1.0: Exit and return to "Select test"
2.2.1.1: Drive inputs(2.2.1.1)
2.2.1.2: Set acceler. (2.2.1.2)
2.2.1.3: Drive outputs(2.2.1.3)
2.2.1.4: Set brake(2.2.1.4)
2.2.1.5: Regulator inp(2.2.1.5)
2.2.1.6: Brake test(2.2.1.6)
2.2.1.7: Calib. wheel(2.2.1.7)
2.2.1.8: Analog wheel(2.2.1.8)
2.2.2: Hydraul. test
Hydraul menu:
2.2.2.1: Hydr. inputs (2.2.2.1)
2.2.2.2: Read joyst. (2.2.2.2)
2.2.2.3: Pump tests (2.2.2.3)
2.2.2.4: Regulator inp (2.2.2.4)
2.2.2.5: Std. valves(2.2.2.5)
2.2.2.6: Opt. valves (2.2.2.6)
2.2.2.7: Hydr. lamps (2.2.2.7)
2.2.2.8: Calib. joyst.(2.2.2.8)
10.28
2.2.3: Options test

Options menu:
2.2.3.1: Optional inp. (2.2.3.1)
2.2.3.2: Optional outp (2.2.3.2)
2.2.3.3: Height encod.(2.2.3.3)
2.2.3.4: Temp. inputs (2.2.3.4)
2.2.3.5: Ext. temp. inp(2.2.3.5)
2.2.3.6: AC Regul. temp(2.2.3.6)
2.2.4: Misc. test
Misc. menu
2.2.4.1: Battery test (2.2.4.1)
2.2.4.2: Chassis test (2.2.4.2)
2.2.4.3: Horn test (2.2.4.3)
2.2.4.4: Custom test
Cust.Test menu
2.2.4.4.0: Exit to "Misc test"
2.2.4.4.1: Custom inputs (2.2.4.4.1
2.2.4.4.2: Custom output (2.2.4.4.2
2.2.4.4.3: Custom calibr (2.2.4.4.3
2.2.4.4.4: Custom spare (2.2.4.4.4
2.2.4.5: Spare
2.3: Log & counter
Log & counters
2.3.1: Read tmp. log (2.3.2)
2.3.2: Read err. log
(2.3.3)
2.3.3: Read total c
(2.3.3)
2.3.4: Read work. c
(2.3.4)
#4
2.4: Set time/date

Clock menu
2.4.1: Read time
(2.4.1)
2.4.2: Read date
(2.4.2)
2.4.3: Set time
(2.4.3)
2.4.4: Set date
(2.4.4)
2.4.5: Set date form
(2.4.5)
2.4.6: Set day of w
(2.4.6)
10.29
3: Atlet service ( Password required )

ATLET service
3.1: Set passwords
Password menu
3.1.0: Exit and return to "ATLET service"
3.1.1: Set ATLET code (3.1.1)
3.1.2: Set def. drive
(3.1.2)
3.1.3: Del one passw. (3.1.3)
3.1.4: Set local code (3.1.4)
3.1.5: Set def. local
(3.1.5)
3.1.6: Set cust. code (3.1.6)
3.1.7: Set def. cust.
(3.1.7)
3.1.8: Set passw. par. (3.1.8)
3.2: ATLET counters
Counters menu
3.2.1: Read custom
(4.4.1)
3.2.2: Read working (2.3.4)
3.2.3: Read total
(2.3.3)
3.2.4: Reset custom
(4.5.1)
3.2.5: Reaset working (3.2.5)
3.3: Set options
(3.3)
3.4: Settings menu
Select setting:
3.4.0 Exit and return to "ATLET service"
3.4.1: Performance
AC parameters
3.4.1.0: Exit and return to "Settings menu"
3.4.1.1: AC driver 1(3.4.1.X)
3.4.1.2: AC driver 2(3.4.1.X)
3.4.1.3: AC driver 3(3.4.1.X)
3.4.1.4: AC driver 4(3.4.1.X)
3.4.2: Set valves
3.4.2.0: Exit and return to "Settings menu"
3.4.2.1: Lift param. (3.4.2.X)
3.4.2.2: Ch 1 param (3.4.2.X)
3.4.2.3: Ch 2 param (3.4.2.X)
3.4.2.4: Ch 3 param (3.4.2.X)
3.4.2.5: Ch 4 param (3.4.2.X)
#6
3.4.3: Set battery

3.4.4: Set levelsyst.
(3.4.3)
(3.4.4)
3.5: Spare
3.6: Spare
10.30
3.7: Run tests

Select test:
3.7.1 Drive test
Drive menu:
3.7.1.1: Drive inputs(2.2.1.1)
3.7.1.2: Set acceler. (2.2.1.2)
3.7.1.3: Drive outputs(2.2.1.3)
3.7.1.4: Set brake(2.2.1.4)
3.7.1.5: Regulator inp(2.2.1.5)
3.7.1.6: Brake test(2.2.1.6)
3.7.1.7: Calib. wheel(2.2.1.7)
3.7.1.8: Analog wheel(2.2.1.8)
3.7.2: Hydraul.test
Hydraul menu:
3.7.2.1: Hydr. inputs (2.2.2.1)
3.7.2.2: Read joyst. (2.2.2.2)
3.7.2.3: Pump tests (2.2.2.3)
3.7.2.4: Regulator inp (2.2.2.4)
3.7.2.5: Std. valves(2.2.2.5)
3.7.2.6: Opt. valves (2.2.2.6)
3.7.2.7: Hydr. lamps (2.2.2.7)
3.7.2.8: Calib. joyst.(2.2.2.8)
3.7.3: Options test
Options menu:
3.7.3.1: Optional inp. (2.2.3.1)
3.7.3.2: Optional outp (2.2.3.2)
3.7.3.3: Height encod.(2.2.3.3)
3.7.3.4: Temp. inputs (2.2.3.4)
3.7.3.5: Ext. temp. inp(2.2.3.5)
3.7.3.6: AC Regul. temp(2.2.3.6)
10.31
3.7.4: Misc. test

Misc. Menu
3.7.4.1: Battery test (2.2.4.1)
3.7.4.2: Chassis test (2.2.4.2)
3.7.4.3: Horn test (2.2.4.3)
3.7.4.4: Custom test
3.7.4.4.0: Exit and return to "Misc test"
3.7.4.4.1: Custom inputs (2.2.4.4.1
3.7.4.4.2: Custom output (2.2.4.4.2
3.7.4.4.3: Custom calibr (2.2.4.4.3
3.7.4.4.4: Custom spare (2.2.4.4.4
3.7.4.5: Spare
#3
3.7.5: Acquisition
Acquision menu
3.7.5.1: Read data(3.7.5.1)
3.7.5.2: Print data(3.7.5.2)
3.7.5.3: Setup acq. 1(3.7.5.X)
3.7.5.4: Setup acq. 2(3.7.5.X)
3.7.5.5: Setup acq. 3(3.7.5.X)
3.7.5.6: Setup acq. 4(3.7.5.X)
3.7.5.7: Setup acq. 5(3.7.5.X)
3.7.5.8: Clear all acq.
3.7.5.9: Reset all acq.
3.7.6: Spare
3.7.7: Test any output (3.7.7)
3.7.8: Show inputs
(3.7.8)
3.7.9: System setup
#5
3.8: ATLET logbook

Log book menu:
3.8.1: Read tmp log
(2.3.1)
3.8.2: Read err. log
(2.3.2)
3.8.3: Read service
(3.8.3)
3.8.4: Sign service
(3.8.4)
3.8.5: Reset service
3.8.6: Reset tmp.log
3.8.7: Reset err.log
3.8.8: NVR upload
(3.8.8)
3.9: Set all def.
10.32
4: Custom serv.
Custom service
4.1: Unlock
(4.1)
4.2: Communication
(4.2)
4.3: Printout
Print Custom
4.3.0: Exit and return to "Custom service"
4.3.1: Print counters (4.3.X)
4.3.2: Print cus.log
(4.3.X)
4.3.3: Print tmp.log
(4.3.X)
4.3.4: Print srv.log
(4.3.X)
4.3.5: Print err. log
(4.3.X)
4.3.6: Print settings
(4.3.X)
4.3.7: Spare
4.3.8: Print all log
(4.3.X)
4.4:Readout
Read custom
4.4.1: Cust. counter
(4.4.1)
4.4.2: Cust. log
4.5: Reset custom ( password required )(4.5)
Reset custom
4.5.1: Cust. counter
4.5.2: Cust. log
#5
4.6: Show inputs
(3.7.8)
5: Startup
6: Driver param.
(6)
10.33
Comments:
#1
Removed in issue C
#2
Removed in issue B
#3
See document M330 for more information.
#4
Format code 1: dd-mon-yy

Format code 2: dd-mm-yyyy
Format code 3: mm-dd-yyyy
Format code 4: yyyy-mm-dd
#5 Line 1 shows "Ana.inp XCnn.pp" or "Dig.inp XCnn.pp" where nn is the connector number and pp is
pin number.
#6
Either select function by pressing key 1' to 5' or touch the joystick for the function.
#7 Asks for password and then goes thru options list ( 3.3), calibration of speed pedal ( 2.2.1.2) and
hydraulic levers ( 2.2.2.8).
10.34
10.18.1 Log of faults

ATC has a log containing the last found 30 faults. This can be servo faults, lift sensor faults, speed
controller faults, etc. Each fault is traced with the time and date.
All faults found by ATC are given a code. Significant error codes are shown on the displays lower row
until they are acknowledged by reading the fault log. Minor error codes are traced in the fault log
without being displayed. When reading the error code is translated to text.
10.18.2 Subinfo
Error codes with underlying subinfo menu. Read the fault log in the log and bring up subinfo by pressing
the I on the keyboard!
10.18.3 General instructions with all types of faults on trucks

in combination with a power failure.
ATC seems as if it does not work as it should, check the internal fuses F1, F4 and F5 in the ATC.
Check the nine measurement points in the form of insulation support under the instrument panel.
B+ should be B+ 48V when the battery plug is fitted.
B- should be B- 0V when the battery plug is fitted.
B+2 should be B+ 48V when the emergency stop is pulled up.
AGND (analogue earth) should be 0V.
B 12V should be 12V.
B 5V should be 5V.
B+3 should be B+ 48V when the truck is logged on.
B+4 should be B+ 48V when the truck is logged on.
B+5 should be B+ 48V when the truck is logged on and the servo is active.
If B+ or B- deviate, check the battery plug, electrical panel plug and associated cable connections.
If B+2 deviates, check the fuse F14 and the emergency stops SE1 and SE2. Also check that the
connectors K11 and K12 through the visual inspection of the contact strips and that the coils are not
short circuited and that the freewheel diodes across the coils are intact. Check the connectors cable
connections too.
If AGND deviates, check the connections between AGND measurement point and ATC XC1.10. If
AGND is broken it gives a calibration error. If AGND is not put out by ATC, change the ATC.
If B12V deviates, check the connections between B12V and ATC XC3.17. If B12V is broken the
indicating lamps will not light. Ensure that nothing loads 12V by pulling out all ATC connectors
except XC9, also disconnect the CAN bus, now check whether the ATC puts 12V out on pin XC3.17,
if not change the ATC.
If B+3 deviates, check the fuse F6 and connections from the key relay K3.30 to K3.87, if the relay
10.35
does not make check the coil resistance (should be approx. 300 ohm), the freewheel diode across both
relay coils and cable connections to the ATC XC1.17 and XC1.27. If the relay circuit is OK, check that
B+ 48V puts out on ATC XC1.17 and that the output XC4.23 draws to 0V when logging on, if not,
replace the ATC.
If B+4 deviates, make a check as set out above but on F7 and K6.30, K6.87
If B+5 deviates, go to trouble shooting electric servo.
If B+5V deviates, check that the cable connections between B5V and ATC XC1.11 are intact. Ensure
that nothing loads 5V by pulling out all ATC connectors except XC9, also disconnect the CAN bus,
now measure whether there is 5V on the measurement points or XC1.11, if not change the ATC.
10.19
Trouble shooting
10.19.1 Low temp drive or Low temp hydraulics - Warning on the display
Drive the truck at a reduced speed and

reduced load until the regulator has
warmed up to approx. 20 degrees for full
operating capacity.
Or
Drive the truck in a heated building until

the regulator has reached the temperature
for full operating capacity.
10.36
10.19.2 The truck and ATC are dead:

Is there 48V between B+ and Binsulators?
No
Check the battery, battery plug, electrical

panel plug and associated connections.
Yes
Is the electrical emergency stop in the

emergency stop position?
Pull up the button for the emergency stop.
Yes
No
Is B+ 48V on the insulator B+2?
No
Check the contactor circuits K11 and

K12. Check that the fuse F14 has not
failed and that the emergency stop
switches failed SE1 and SE2 are made to
48V. If the fuse has failed check the
contactor K10, K11 and K12 so that none
of the coils are short circuited and that the
freewheel diodes are intact.
Yes
Are the ATC internal fuses F1 and F5

intact?
Change the fuses.
No
Yes
Is the fuse F9 intact?
Change the fuse.
No
Yes
Is there B+ 48V to the ATC connectors

XC9.1 and XC9.2?
No
Check the cable routing between B+2 and

ATC and between B- and ATC.
Change the ATC!
10.37
10.19.3 Warning low battery in combination with E02 B+ on the chassis:

The battery supply shows 00% depending on a fault occurring before or after logging on. It is not possible
to lift after lowering.
Is the fuse F10 with fuse holder intact?
Change the fuse/fuse holder!
No
Yes
Is there a connection between B+2 and

XC9.5 in ATC?
Change the cable!
No
Yes
Does the truck seem OK otherwise?
No
Check the battery voltage and the battery

connections!
Yes
Change the ATC!
10.38
10.19.4 Electric steering:

E05 is a servo tacho fault, E06 is a servo motor fault, E07 is a servo regulator fault.
Do the faults occur together resulting in

the drive no longer working?
No
Check that the servos safety relay K4 is

made, if not, the probable fault lies with
one of the limit switches for the servo.
Check the red LEDs 2 and 3 in the servo
box, both the bistabile switches shall be
open when the drive unit is in the end
positions, otherwise closed.
Change the servo box!
Change the motor!
Yes
Is the green lamp on the servo box on?
No
Check the fuse F7 and measurement point

B+4, see the general instructions for a
power failure.
Check the tachometer and its cables. The

tachometer should give increasing
voltage with speed/wheel turning. If the
cables are okay, replace the tachometer,
or replace the servo box.
Yes
E05 or tacho fault logged?

Tip: Red LED ERROR 4 lights on the
control box if the fault occurs during
operations and the truck has not been
logged off. If the tacho fault arises when
the truck is logged off the fault is not
logged, error code E97 is shown.
Yes
No
E05 or servo motor fault logged?

Red LED Error 5 lit on the control box.
See Important comments below.
No
Yes
10.39
Check that the motor fuse F4 is intact.

Check that there is a low resistance
between the motors poles, the carbon
brushes should be made.
Check the motor cables.
Make a visual inspection of the servo
connector strips to ensure they are OK.
Check that the coil resistance is approx.
70 ohm and that the cables are OK.
Check that the freewheel diode across the
contactor coil is intact.
Continue
Change the servo box!

Change the servo motor!
IMPORTANT! Error codes E05 tacho fault, E06 servo motor fault and E07 servo regulator
fault are generally overwritten by error code E97.
IMPORTANT! If both the LEDs ERROR 4 and ERROR 5 are on, the servo box should be
replaced (E07).
10.40
10.19.5 Symptom: The pump motors speed gradually drops

(High temperature on the pump regulator)
Was the warning text High tmp hydrau
C visible on the display when the
symptom occurred?
Go to high pump motor temperature.
No
Yes
Check that the regulator fan works as it

should by first removing the battery plug
and then restarting the truck again.
Does the fan start within about 20

seconds?
Yes
Check that nothing obstructs the air flow

through the regulators heatsinks. If the
heatsinks are covered in dust or other
objects, clean under these!
No
Connect a voltmeter and repeat the

procedure to check the regulator fan!
..................................................................
Is the voltage at least B+ 48V for a few
seconds after the fan has started?
Yes
Change the fan!
No
Is there B+ 48V on the fan?
No
Check the cables between the fan

connector X26.1 and the ATC contact
XC5.19 carefully. If the cables are OK
and the truck has no other faults, change
the ATC!
Yes
Check the cables between the fan

connector X26.2 and the ATC contact
XC5.12 carefully. If the cables are OK
and the truck has no other faults, change
the ATC!
10.41
10.19.6 Symptom: The pump regulators status lamp flashes on and off
1. The truck shall be logged on.
Does the status lamp flash?
Yes
Look for an error code and go to the

related trouble shooting chart.
No (the status lamp is off)
2. Is there a supply voltage B+ 48V to the

regulators connector E2 K1.1
Go to point 5 below.
No
Yes
3. Battery voltage low?
Charge and check the battery!
Yes
No
4. Change the pump regulator!
5. B+ 48V at measurement point B+4?
No
Yes
6. Check the connection between B+4

and the regulators contact E2 K1.1
7. Change the drive regulator!
8. Is the fuse F7 intact?
Change the fuse.
No
Yes
10.42
9. Is the relay K6, B+48 on connection

K6.87 activated?
No
Change the relay!
Yes
10. Check the cable connection between

the measurement points B+4 and K6.87!
If none of the key relays K3 and K6 are

activated (the drive regulators status
lamp is also off). Check the coil
resistance, which should be about
300 ohm, that the freewheel diode across
the coils are intact and that there is a
supply via the ATC.
10.43
10.19.7 Symptom: Main connectors do not close once the truck is logged
on.
ATC is voltage fed.
Have any related error codes been
logged?
Yes
See the trouble shooting chart for

respective error codes!
No
B+ 48V to the main contactors coil?
No
Check that the emergency stop circuits

are intact!
Yes
B- to the main contactors negative side?
No
Check the connection between the main

connectors negative side and the ATC!
If these are OK, replace the ATC!

Perhaps the ATC does not put out B- to
the connectors coil.
Yes
Are the connectors coil and its freewheel

diode intact?
Change the connector/diode!
No
Yes
Change the regulator!
10.44
10.19.8 Symptom: The fuse for the power supply has failed.
The probable cause for a blown fuse is a
short circuit in the regulators power
stage or that the average current exceeds
the fuses rated current.
Change the fuse (with correct fuse value)

and restart!
Does the fuse fail just after the main

contactor has made?
Yes
Change the drive regulator/pump

regulator!
Tip: If the drive or pump motor fuse has
blown when starting the error code E97
or E98 is given with the subinfo: No
charge DC-bus E128.
No
Start the truck again!
Does the fuse fail again after the truck has

been running for some time?
Yes
Check that the mechanical torque in the

gearbox is not too great due to worn parts
or, e.g. that the pump jams.
If the truck has been run with a heavy

load and at a high speed and with many
stops and starts or in any other way
exceeded its limitations, try to reduce the
speed, load, acceleration and retardation
(braking).
Increased friction, increased load, high

speed and rapid starting/stopping increase
the average current from the regulator.
The truck may have been driven over its
maximum performance!
Warning! Always make sure that the regulators are correctly discharged by removing the
battery plug and waiting for 2 minutes before fuses are changed, risk for arcing.
10.45
10.19.9 Symptom: The drive regulators status lamp flashes on and off
1. The truck shall be logged on.
Does the status lamp flash?
Yes
Look for an error code and go to the

related trouble shooting chart.
No (the status lamp is off)
2. Is there a supply voltage B+ 48V to the

regulators connector E1 K1.1
No
Yes
3. Battery voltage low?
Charge and check the battery!
Yes
No
5. Does the servo work?
Yes
Check the connections between B+5 and

the regulators connector E1 K1.1
No
The steering probably has no supply

voltage or the safety system has tripped.
Go to the trouble shooting chart for the
electric servo.
A flashing status lamp means the drive

regulator has indicated a fault.
When the status lamp is off this means
that the drive regulator is not receiving
any supply voltage or that the internal
program has not been run.
Change the drive regulator!
10.46
10.19.10 Symptom: The drive motor only runs at a low speed with a ticking
noise.
Or the motor attempts to start, but cannot run or runs unevenly with a low torque.
1. Are the motor cables correctly
connected and make good contact
between the drive motor and the drive
regulator?
No
Tighten the connections or replace the

motor cables.
Yes
2. Switch the regulators. Note that in

most cases the drive and pump regulators
can be switched with each other for test
purposes. First check that the article
numbers correspond with each other.
IMPORTANT!
If you cannot switch the regulators go to
point 4.
No
If the fault moves to the pump motor

system, change the drive regulator that is
now fitted in the pump regulators place!
3. Is there still a fault with the drive motor

system.
Yes
4. Is the voltage on the motor cable

between M1.1 and M1.2 approx. 12V
DC?
No
Yes
5. Is the voltage at E1 K1.5 and E1 K1.6

approx. 4V DC with E1 K1.4 as a
reference when the motor rotates,
alternatively 0V or 8V DC when the
motor is at a standstill.
Yes
After checking the drive regulators

connections, change the drive regulator.
No
6. Is the voltage at M1.3 and M1.4

approx. 4 V DC with M1.2 as a reference
when the motor rotates? Alternatively 0V
or 8V DC when the motor is at a
standstill.
No
After checking the motors connector

connections, change the drive motor.
10.47
Yes
7. Look for the break/short circuit in the

cables between the drive regulator and
the drive motor M1.4 - E1 K1.5 and M1.3
- E1 K1.6 and between M1.3 and M1.4.
Both connectors are pulled out of their
connections on the motor and drive
regulator.
8. Is the voltage between the drive

regulator and the contact points E1 K1.3
and E1 K1.4 approx. 12V?
Yes
Check that there is not a break or short

circuit in the cables between the motor
contact and the drive regulator contact,
both connectors are pulled out of their
connections. Measure between E1 K1.3 E1 K1.4 and between M1.1 - E1K1.3 and
M1.2 - E1 K1.4.
No
10.48
10.19.11 Symptom: High pump motor temperature

1. Was the warning text High tmp
hydrau M visible on the display when
the symptom occurred?
No
Start using the truck again and ask the

truck driver to report any new warning
messages!
Yes
2. Does the machine housing fan work?
No
Yes
3. * Check that nothing obstructs the air

flow to the motor.
* If the motor is dirty, clean it!
* Let the truck rest until the temperature
has dropped!
* If the truck works above its specified
capacity the acceleration and speed must
be lowered or the current limit lowered.
4. Connect a voltmeter to the fan.

Is the voltage B+ 48V?
No
Check that the fuse F8 has not failed and

that the cables are intact!
Also check the thermostat if the truck is
in the cold store design!
Yes
5. Change the fan
IMPORTANT! If the truck is allowed to continue working despite the temperature warnings it
can result in an automatic stop of the drive motor system, the error codes will be E98 with
Hydraulics stopped subinfo will be motor temp too high e2 or controllers temp too high
e4 registered in the log. If the temperature is allowed to drop to the normal level again, the
truck will rum at full capacity again.
10.49
10.19.12 Symptom: The drive motors speed gradually drops

(High drive regulator temperature)
Was the warning text High tmp drive C
visible on the display when the symptom
occurred?
Go to, symptom: high drive motor temp.
No
Yes
Check that the regulator fan works as it

should by first removing the battery plug
and then restarting the truck again.
Does the fan start within about 20

seconds?
Yes
Check that nothing obstructs the air flow

through the regulators heatsinks. If the
heatsinks are covered in dust or other
objects, clean under these!
No
Connect a voltmeter and repeat the

procedure to check the regulator fan!
..................................................................
Is the voltage at least B+ 48V for a few
seconds after the fan has started?
Yes
Change the fan!
No
Is there B+ 48V on the fan?
No
Check the cables between the fan contact

X26.1 and the ATC contact XC5.19
carefully. If the cables are OK and the
truck has no other faults, change the
ATC!
Yes
Check the cables between the fan contact

X26.2 and the ATC contact XC5.12
carefully. If the cables are OK and the
truck has no other faults, change the
ATC!
10.50
10.19.13 Symptom: (High drive motor temperature)

1. Was the warning text High tmp drive
M visible on the display when the
symptom occurred?
No
Start using the truck again and ask the

truck driver to report any new warning
messages!
Yes
2. Does the machine housing fan work?
No
Yes
3. * Check that nothing obstructs the air

flow to the motor.
* If the motor is dirty, clean it!
* Let the truck rest until the temperature
has dropped!
* If the truck works above its specified
capacity the acceleration and speed must
be lowered or the current limit lowered.
4. Connect a voltmeter to the fan.

Is the voltage B+ 48V?
No
Check that the fuse F8 has not failed and

that the cables are intact!
Also check the thermostat if the truck is
in the cold store design!
Yes
Change the fan
IMPORTANT! If the truck is allowed to continue working despite the temperature warnings it
can result in an automatic stop of the drive motor system, the error codes will be E97 with
Drive stopped subinfo will be motor temp too high e2 or controllers temp too high e4
registered in the log. If the temperature is allowed to drop to the normal level again, the truck
will rum at full capacity again.
10.51
10.19.14 The pump motor only runs at a low speed with a ticking noise.
1. Are the motor cables correctly
connected and make good contact
between the pump motor and the pump
regulator?
No
Tighten the connections or replace the

motor cables.
Yes
2. Switch the regulators. Note that in

most cases the drive and pump regulators
can be switched with each other for test
purposes. First check that the article
numbers correspond with each other.
IMPORTANT!
If you can not switch the regulators go to
point 4.
3. Is there still a fault with the pump

motor system.
No
Change the pump regulator that is now

fitted in the drive regulators place!
Yes
4. Is the voltage on the motor cable

between M2.1 and M2.2 approx. 12V
DC?
No
Yes
5. Is the voltage at E2 K1.5 and E2 K1.6

approx. 4V DC with E2 K1.4 as a
reference when the motor rotates;
alternatively 0V or 8V DC when the
motor is at a standstill?
Yes
After checking the pump regulators

connections, change the pump regulator.
No
6. Is the voltage at M2.3 and M2.4

approx. 4 V DC with M2.2 as a reference
when the motor rotates; alternatively 0V
or 8V DC when the motor is at a
standstill?
No
After checking the motors connector

connections, change the pump motor.
Yes
10.52
7. Look for the break/short circuit in the

cables between the pump regulator and
the pump motor M2.4 E2 K1.5 and
M2.3 E2 K1.6 and between M2.3 and
M2.4. Both connectors are pulled out of
their connections on the motor and drive
regulator.
8. Is the voltage between the pump

regulator and the contact points E2 K1.3
and E2 K1.4 approx. 12V?
Yes
Check that there is not a break or short

circuit in the cables between the motor
contact and the pump regulator contact,
both connectors are pulled out of their
connections. Measure between E2 K1.3
E2 K1.4 and between M2.1 E2K1.3 and
M2.2 E2 K1.4.
No
9. Change the pump regulator!
10.53
10.19.15 Drive system stopped/ Hydraulics stopped Subinfo: Controller not

responding
Drive motor system:

Check that it is not the electric servo
system that is giving the alarm and is
caused by a break to the regulator see
section 10.19.4 Electric steering:
Check the CAN bus cables and

terminations between the ATC and motor
regulator extremely carefully. The most
probable cause is a break on one of the
four CAN bus wires.
Try changing the motor regulator or

switching the regulators.
Change the ATC!
10.54
10.19.16 Drive system stopped/ Hydraulics stopped Subinfo: Overcurrent e8

Overcurrent arises when the regulators
load impedance drops under a minimum
value. This is often caused by a short
circuit in the regulators output stage, in
the heavy cable connection between the
motor and regulator or in the motor.
Switch off the voltage, wait a few

seconds and switch on the voltage again.
Subinfo: Overcurrent e8
Finished!
No
Yes
Check the motor cables for a short circuit

between U-V, U-W and V-W, also check
that the phases are not short circuited or
have inferior insulation to the chassis!
In order to measure a short circuit in the

motor cables they must be unscrewed
from the insulation supports on both the
regulator and motor sides!
Subinfo: Overcurrent e8
Finished!
No
Yes
Change the motor!
10.55
10.19.17 Drive system stopped/ Hydraulics stopped Subinfo: DC bus too low
e64
10.19.18 Drive system stopped/Hydraulics stopped subinfo: No charge DC

bus e128
Error code E 97:
If the motor fuse for the drive motor has
blown when starting you receive the
message:
Drive stopped subinfo: No charge DC
bus e128
Error code E 98:

If the motor fuse for the hydraulic motor
has failed when starting you receive the
message:
Hydraulics stopped subinfo: No charge
DC bus e128
The fault appears when the regulators
software detects that the voltage between
the + and B- terminals is too low for the
regulator to be reliable.
Is the battery voltage low?
Charge the battery!
Yes
No
Does the fault appear when the regulator

is delivering high current to the motor?
Yes
Check the supply voltage between the

regulators + and B- terminal while
running. If the voltage is under 70% of
the nominal battery voltage, find the
voltage drop in the circuits that feed the
drive regulator.
(Minimum supply voltage is 22V).
No
Check the charging circuit. F12 R300 and

that the components are intact!
Check the connections to the regulators

B+, + and B- terminals. Tighten the nuts
to 15 Nm!
10.56
Check the trucks battery!
10.19.19 Drive system abnormal/ Hydraulics abnormal Subinfo: Controller

calib error. w256
Cut the voltage to the truck by pulling out
the battery plug, wait a few seconds and
then switch on the voltage again.
Warning code w 256 reappears after

restarting the regulator?
Yes
Change the pump or drive regulator

depending on the which warning code has
been logged!
No
Finished!

rev to default w512
Change the regulator if the fault arises
repeatedly during start up!
10.57
10.19.21 Drive system stopped/ Hydraulics stopped Subinfo: DC bus too

high. HW e16
The error occurs when the regulator
detects that the battery voltage is too high
for reliable regulator operation. This
condition normally arises when too much
energy has been regenerated (recovered)
to the battery or the resistance between
the regulator and battery is too high. The
battery voltage between the + and Bterminals on the regulator must not
exceed 60V DC.
Check the heavy cables between the

motor and the regulator and between the
regulator and the battery!
Check the line contactor, (connections

and connector strips)
The regulators measurement of the

supply voltage can be defective!
Is the above OK?
Yes
The requested brake torque can be too

high!
No
Rectify the cables and connector!
Reduce the amplitude for the brake

torque via ATC.
See the sections on the pedal brake,
reversing brake or reduction brake.
Change the battery!
10.58
10.19.22 Drive system stopped/ Hydraulics stopped Subinfo: ATC

contradictory. e2048
switch on the voltage again.
Error code 2048 reoccurs after a new

start?
Finished!
No
Yes
Check that the ATC works as it should!

temp sensor W2 or subinfo: sensor w4
switch on the voltage again.
The regulators temperature sensor can be

defective!
Warning code W2 drive regulator or W4

pump regulator logged after the truck
starts?
Finished!
No
Yes

been logged!
10.59
10.19.24 Drive system abnormal/ Hydraulics abnormal Subinfo: Speed signal

out of range. w 128
The ATC has sent a speed command to
the regulator, which exceeds the users
maximum speed parameter.
<Motor_HighSpeed>
The regulator limits the true speed to
<Motor_HighSpeed>.
Switch off the voltage to the ATC and

regulator by pulling out the battery plug!
Start the truck again!
Does the warning message reoccur after a

restart?
No
Finished!
Yes

been logged!
Change the ATC!
10.60
10.19.25 Drive system abnormal/ Hydraulics abnormal Subinfo: Motor temp

sens lost. w32: Motor temp sens shorted. w64
Check that the sensor is OK and not short
circuited. Check the cable connection
between the motor temperature sensor
and the regulator.
If the sensor is defective, change the

motor!
The sensor is measured in the 8 way

connector on the motor after the truck
side cables have been disconnected. If the
sensor is OK you should receive a value
of about 500 ohm at room temperature,
which is measured across pins 7 and 8 on
the connector. If the temperature is higher
the resistance will increase!
In order to check the cable connections,
loosen the 8 way contactor on the motor
and the 13 way contactor on the related
regulator. Measure across pins 7 and 8 on
the 8 way contactor, the resistance should
be infinite. Measure that the cables are
intact between pin 7 on the motor
contactor and regulator contactor, and pin
8 on the motor contactor and pin 4 on the
regulator contactor, the resistance should
be well under 0.5ohm.
If there is a cable fault (see the

explanation to the right), rectify of
change the cable!
The regulators temperature measurement

can be malfunctioning!
10.61
10.19.26 Subinfo: CAN too many errors. e256

Check that the CAN bus is not short
circuited or that the connector is broken.
Also check the termination resistors at the
ends are intact and maintain a value of
120 ohm!
The fault can arise when the CAN

interface on the regulator has discovered
too many communication errors in a
message across the CAN bus.
Is the CAN buss supply between E1

K1.1 and E1 K1.13 (applies to the drive
regulator) or E2 K1.1 and E2 K1.13
(applies to the pump regulator) less than
8V DC?
Yes
Check the CAN buss external supply and

change the cables if necessary.
The CAN bus is fed via ATC 12V,
connectors XC9.12 and XC9.7.
No
10.19.27 Subinfo: CAN watchdog time-out. e512

The fault arises when the regulator has
not received any control message from
the ATC under a period exceeding 70
milliseconds.
Does the same fault occur on more than

one regulator across the CAN-bus?
Yes
Check that the CAN bus is intact on all

nodes!
No
Check the function of the ATC!
10.62
10.20
Trouble shooting chart movement functions
10.20.1 Lift function does not work - other functions OK
If error code E10 (Joyst. fault), check the

lift lever function and recalibrate!
1. Does the pump rotate?
Go to point 7.
Yes
No
2. Does L light on the display for

hydraulic inputs on the service menu,
when the lift lever is activated?
No
Check the control cable for the lifts lever

and the linear lever. If the linear lever is
not working it should be replaced and
calibrated!
Yes
3. Is the lift stop activated? The symbol ^

is visible on the display when logging on
and LLi is not showing on the menu for
extra inputs.
Yes
If the truck is normally fitted with a lift

stop, check the sensor and its cables, the
signal is cut with a lift stop.
If the truck is not fitted with

a lift stop, check to see whether the
function has been accidentally selected in
the menu set options
No
Rectify or replace!
4. Is the remaining battery capacity less

than 20%?
Yes
Is the truck equipped with lifting cut-out,

in the event of a low battery lifting is
stopped when the capacity is under 20%.
Charge the battery!
No
10.63
5. Check that the lift stop with a low

battery has not been accidentally set to a
too high value! (the pump can be broken).
6. Follow the trouble shooting chart for

AC regulators!
7. B+ 48V valve plates connector P61.1?
Replace the valve plate cables!
No
Yes
8. Is the voltage between P61.1 and P61.2

< 27V with full lever movement? (only
needed to be checked if you can safely
say that the lowering function does not
work)
Go to point 10.
Yes
No
9. Replace the valve plate!
10. Breakage or short circuit in the coil

between P61.1 and P61.2?
Change the coil!
Yes
No
11. Is the cable connection between the

valve plate and ATC OK?
Change the ATC!
Yes
No
Change the cable!
10.64
10.20.2 The reach-in function does not work other functions OK
IMPORTANT!
When measuring voltage across the valve
coil the connector shall be connected to
the valve plate. In the event of breakage/
short circuit the connector should not be
connected.

linear lever function and recalibrate!
Go to point 5.
Yes
No
2. Does R = reach-in, light when the

linear lever is activated in the menu
hydraulic inputs?
No
Check the control cable for the lifts

linear lever and the linear lever. If the
linear lever is not working it should be
replaced and calibrated!
Yes
3. Is the symbol RS lit in the menu

hydraulic inputs?
No
Check that the level has not been

accidentally set to 0!
Yes
4. RS = Reach-in stop, shall only be lit

when the reach is in the fully retracted
position. Check the reach stop switch and
related cables. The signal is cut when the
reach stop is activated.
Change the valve plates cable!
No
Yes
10.65

< 27V when the reach-in lever is
activated?
Go to point 8.
Yes
No

Change the coil!
Yes
No

Change the ATC!
Yes
No
Change the cable!
10.66
10.20.3 The reach-out function does not work other functions OK

linear lever function and recalibrate!
Go to point 4.
Yes
No
2. Does E = reach-out, light when the

linear lever is activated in the menu
hydraulic inputs?
No
Check the control cable for the reachs

linear lever and the linear lever. If the
linear lever is not working it should be
replaced and calibrated!
Yes
3. Check that the level for the reach-out

has not been accidentally set to 0!
Change the valve plates cable!
No
Yes

< 27V when the reach-out lever is
activated?
Go to point 7.
Yes
No
10.67

Change the coil!
Yes
No

Change the ATC!
Yes
No
9. Change the cable!
10.68
IMPORTANT!
When measuring voltage across the valve
coil the connector shall be connected to
the lever. In the event of breakage/short
circuit measuring on the lever the
connector should not be connected.
10.20.4 The drive function does not work, one or two directions
IMPORTANT!
If the brakes are applied these will hold
the truck despite full power. Check that
the regulator works, a weak humming
noise should be audible.
1. Is the drive function lost in both

directions?
With error code E8, check analogue

sensor for accelerator and recalibrate!
No
Check in the menu drive inputs whether

either Fd or Bd lights when forward or
reverse directions are activated!
Yes
2. Does the motors electric brake release

when the left-foot switch is activated and
any travel direction is selected?
Yes
Check the accelerators analogue sensor

so that it goes from approx. 2V 4.95V.
If not check mechanism and possibly
replace the sensor!
No
3. Does the symbol SA light in the

menu drive inputs when the left-foot
switch is activated.
Yes
Go to point 5
No
4. Check the sensor for the left-foot

switch and related cables. The signal is
made when the left-foot switch is
activated!
5. Check that the brakes are not applied

and that the cables are intact!
6. Breakage/short circuit in the brake

coil?
Change the brakes!
Yes
10.69
No
7. B+ 48V voltage to the brakes when the

left-foot switch and travel direction are
selected?
Go to point 9.
No
Yes
8. Adjust or replace the brakes!
9. Brake switch OK?
Change the ATC!
Yes
No
Rectify!
10.70
10.20.5 Lowering of the forks does not work

or works at a low speed. Other hydraulic functions are OK.
If error code E10 joyst. fault, check the

sensor and recalibrate!
1. Does dD light = lower when lowering

is activated in the menu hydraulic inputs?
No
Check the control cable for the linear

lever and the linear lever, if the linear
lever is not working it should be replaced
and a new calibration done.
Yes
2. Check that the level for lowering has

not been accidentally set to 0!

less than 27V when lowering is
activated?
Go to point 5.
Yes
No

Yes
5. Breakage/short circuit in the coil

Change the coil!
Yes
No

Change the ATC!
Yes
No
7. Change the cable!

10.71
10.21
Trouble shooting chart battery stop

Indication
Cause
Worn rubber stop
Action
The speed for mast shift is set too

Reduce the reach-in speed.
high.
Mast reach does not work, mast The magnetic switch for the mast Check the function of the switch.
runs against the battery.
shift stop is defective.
Replace the switch!
The mast runs against the
The magnetic switch for the mast
Adjust according to the
battery.
reach stop is incorrectly
instructions!
adjusted.
10.72
10.22
Menu tree, leaves
DL1
Driver log 1, truck statistics without PC program
DL2
Driver log 2, truck statistics with a PC program, MDQS

( Davis Derby )
DL1
------
Symbol for a choise. Yes to the left and No to the right.

Number value that can variate.
10.73
2:
Local service
2.1
Set drivercode
Code
:
???????
Local service
1:Set drivercode
Note 1
User id:
?
Note 3
Driver category
1
Note 2
Old code:
????
Note 2
New code:
????
Note 2
Verify:
????
Password OK
2.2.1.1
Drive inputs
Drive menu:
1: Drive inputs
Note 8
10.74
2.2.1.2
Set acceler.
Drive menu:
2: Set acceler.
Release acceler.
and hit digitkey
Push acceler max
and hit digitkey
Calibration fail
Press Enter
2.2.1.3
Drive outputs
Drive menu:
3: Drive outputs
0 1 2 3 4 5 6 7
ExTrFoBaS1B1B2B3
Truck on lamp
0:Exit
0 1 2 3 4 5 6 7
Func. not
0 1 2 3 4 5 6 7
Func. not avail.
Speed limit 1
0:Exit 1:Toggle
Brake step 1
0:Exit
Brake step 2
0:Exit 1:Toggle
Func. not avail.

Press Enter
10.75
2.2.1.4
Set brake
Drive menu:
4: Set brake
Release brakeped
and hit digitkey
Push brake max
and hit digitkey
Calibration fail
Press Enter
2.2.1.5
Regulator ing.
Drive menu:
5:Regulator inp
Accel. Volt -.-Drive out
--%
2.2.1.6
Brake test
Drive menu:
6: Brake test
Brake Volt -.-Brake out
--%
10.76
2.2.1.7
Calib. wheel
Drive menu:
7: Calib. wheel
Pulses per rev.
-Indicate forward
Press Enter
Arrows for FWD
Indicate side
Press Enter
Arrows for side
2.2.1.8
Analog wheel
Drive menu:
8: Analog wheel
Wheel angle
xx
8: Analog wheel
2.2.2.1
Hydr. inputs
Hydraul. menu:
1:Hydr. inputs
Note 9
10.77
2.2.2.4
Regulator inp
Hydraul. menu:
4:Regulator inp
Lift
Volt x.yy
Pump Out
zz%
2.2.2.5
Std. valves
Hydraul. menu:
5: Std. valves
Only on
elektric
valve block
0 1 2 3 4 5 6 7
ExLiDoRiRoTiTo
10.78
Lift
0:Exit
1:Toggle
Lower
0:Exit
1:Toggle
Reach in
0:Exit 1:Toggle
Reach out
0:Exit 1:Toggle
Tilt in
0:Exit 1:Toggle
Tilt out
0:Exit 1:Toggle
2.2.2.6
Opt. valves
Only on
elektric
valve block
Hydraul. menu:
6: Opt. valves
0 1 2 3 4 5 6 7
ExSrSlRrRl
2.2.2.7
Hydr. lamps
Sideshift right
0:Exit
Sideshift left
0:Exit
Rotate
0:Exit
right
1:Toggle
Rotate
0:Exit
left
1:Toggle
Hydraul. menu:
7: Hydr. lamps
0 1 2 3 4 5 6 7
ExTiSiRo
Tilt lamp
0:Exit
Sideshift lamp
0:Exit
Rotate lamp
0:Exit 1:Toggle
10.79
2.2.2.8
Calib. joyst.
Hydraul. menu:
8: Calib. joyst.
Select joyst.
8: Calib joyst.
0,6,7,8,9
Channel Lift
Max and min
Channel Lift
and hit digitkey
OK ?
Calibration OK
Press Enter
Calibration fail
Press Enter
Channel 2
Max and min
Channel 2
and hit digitkey
OK ?
Calibration OK
Press Enter
10.80
Calibration fail
Press Enter
Select
channel
with digit
or with
lever
Channel 3
Max and min
Channel 3
and hit digitkey
OK ?
Calibration OK
Press Enter
Calibration fail
Press Enter
Channel 4
Max and min
Channel 4
and hit digitkey
OK ?
Calibration OK
Press Enter
Calibration fail
Press Enter
Channel 5
Max and min
Channel 5
and hit digitkey
OK ?
Calibration OK
Press Enter
Calibration fail
Press Enter
10.81
2.2.3.1
2.2.3.2
Optional inp.
Optional outp
Options menu:
1:Optional inp.
Note 10
Options menu:
2: Optional outp
0 1 2 3 4 5 6 7
ExSiSoFlSt
2.2.3.3
Height encod.
Func. not
avail.
Func. not
avail.
Flash light
0:Exit. 1:Toggle
Stright lamp
0:Exit. 1:Toggle
Options menu:
3: Height encod.
Note 11
2.2.3.4
Temp.inputs
Options menu:
1:Temp. inputs
Oil temp:
Dr: --C,Pu:
10.82
--C
--C
2.2.3.5
Ext. temp.inp
Options menu:
1:Ext. Temp.inp
ATC temp:
--C
T1
--C,T2 --C
2.2.3.6
AC Regul temp
Options menu:
6:AC Regul.temp
Regulator temp
Dr: --C,Pu: --C
2.2.4.1
Battery test
Misc menu:
1: Battery test
Batt. Volt --.-
2.2.4.2
Chassis test
Misc menu:
2: Chassis test
Limits: -.----.Chass. Volt --.-
2.2.4.3
Horn test
Misc menu:
3: Horn test
Horn
10.83
2.2.4.4.1
Custom inputs
Cust. test menu

1:Custom inputs
Prepared
for special.
Func. not avail.

Press Enter
2.2.4.4.2
Custom output
Cust. test menu

1: Custom output
Prepared
for special.
Func. not avail.

Press Enter
2.2.4.4.1
Custom calibr
Cust. test menu

1: Custom calibr
Prepared
for special.
Func. not avail.

Press Enter
2.2.4.4.1
Custom spare
Cust. test menu

1:Custom spare
Func. not avail.
Press Enter
10.84
Prepared
for special.
2.3.1
Read tmp. log
Log & counters

1:Read tmp. log
Hydr. oil Temp.
Hydr. oil
ON
If measuring
channel is
ON, is
shown for 1
second
Hydr. oil Temp.

56- 60C: -.-Hydr. oil Temp.
76C: -.--
Drive motor
temp
If measuring
channel is
ON, is
shown for 1
second
Drive motor
temp
Drive motor
temp
Drive motor
temp
Drive motor
temp
Drive motor
temp
10.85
Pump motor temp.

Pump motor t ON
Pump motor temp.
81- 90C: -.--h
Pump motor temp.
91-100C: -.--h
Pump motor temp.
101-110C: -.--h
Pump motor temp.
111-120C: -.--h
Pump motor temp.
120C: -.--h
ATLET Computer
56- 60C: -.--h
ATLET Computer
61- 65C: -.--h
ATLET Computer
66- 70C: -.--h
ATLET Computer
71- 75C: -.--h
ATLET Computer
76C: -.--h
10.86
Om
If
measuring
mtkanalen
channel
is
r pisvisas
ON,
under
shown1 for 1
sekund
second
Extra 1 Temp
Extra 1 Temp ON
Extra 1 Temp
56- 60C: -.--h
If measuring
channel is
ON, is
shown for 1
second
Extra 1 Temp
61- 65C: -.--h
Extra 1 Temp
66- 70C: -.--h
Extra 1 Temp
71- 75C: -.--h
Extra 1 Temp
76C: -.--h
Extra 2 Temp
Extra 2 Temp ON
Extra 2 Temp
81- 90C: -.--h
If measuring
channel is
ON, is
shown for 1
second
Extra 2 Temp
91-100C: -.--h
Extra 2 Temp
101-110C: -.--h
Extra 2 Temp
111-120C: -.--h
Extra 2 Temp
121C: -.--h
10.87
Dr regul. temp.
81- 90C: -.--h
DR regul. temp.
91-100C: -.--h
Dr regul. temp.
101-110C: -.--h
Dr regul. temp.
111-120C: -.--h
Dr regul. temp.
121C: -.--h
Pu regul. temp.
81- 90C: -.--h
Pu regul. temp.
91-100C: -.--h
Pu regul. temp.
101-110C: -.--h
Pu regul. temp.
111-120C: -.--h
Pu regul. temp.
121C: -.--h
10.88
2.3.2
Read err.log
Log & counters

2:Read err. log
Upp to 30 errors
are shown.
Latest error is
shown first. Use
arrows to
navigate.
30 :991228
10:14
i
01 :991012
08:33
2.3.3
Read total c
Log & counters

3:Read total c
Truck
Total :
---
Logged on
Total :
---
Sum of time
when any
function has
been active
Forward drive
Total :
--Backward drive
Total :
--Pump total
Total :
---
Pump 1
Total :
---
Pump 2
Total :
---
Pump 3
Total :
---
Pump 4
Total :
---
Pump 5
Total :
---
10.89
2.3.4
Read work. c
Log & counters

4:Read work. c
Truck
Time :
---
Logged on
Tid:
---
Forward drive
Time :
--Backward drive
Time :
---
10.90
Pump total
Time :
---
Pump 1
Time :
---
Pump 2
Time :
---
Pump 3
Time :
---
Pump 4
Time :
---
Pump 5
Time :
---
Sum of time
when any
function has
been active
2.4.1
Read time
Clock menu:
1: Read time
20:38:15
1: Read time
2.4.2
Read date
Clock menu:
2: Read date
02-03-
Date format
can be
changed.
2000
2.4.3
Set time
Clock menu:
3: Set time
Note 5
Time setting
XX:XX:XX
2.4.4
Set date
Clock menu:
4: Set date
Note 6
Date setting
XX-XX-XXXX
2.4.5
Set date form
Clock menu:
5: Set date
Date format
Note 7
Date form. set.

03-04-2000
2
2.4.6
Set day of w
Clock menu:
6: Set day of w
Wednesday
Set day 1-7,H,E
10.91
3:
3.1.1
Code :
ATLET service
???????
Password menu
6:Set ATLET code
Set ATLET code
Old code:
???????
New code:
???????
Verify :
???????
Password OK
3.1.2
Password menu
2:Set def. drive
Set def. drive
Reset all Passw?

0:No 1:Yes (No )
3.1.3
Password menu
3:Del. one passw
Del. one passw
User id:
?
Valid
ID ?
Id not found
10.92
Reset password ?
0:No 1:Yes (No )
Number of
digits depends
on setting
3.1.4
Set local code
Password menu
4:Set local code
Old code :
???????
New code :
???????
Verify :
???????
Password OK
3.1.5
Set def. local
Password menu
5:Set def. local
Reset passwords?
0:No 1:Yes (No )
3.1.6
Set cust. code
Password menu
6:Set cust. code
Old code :
???????
New code :
???????
Verify :
???????
Password OK
10.93
3.1.7
Set def. cust.
Password menu
5:Set def. cust.
Reset passwords?
0:No 1:Yes (No )
3.1.8
Set passw.par.
Password menu
8:Set passw.par.
Can be set
from 1 to 7
Id length:
1
Password length:
4
10.94
Can be set
from 0 to 7
3.2.5
Reset working
Counters menu
5:Reset working
Truck
0:No 1:Yes (No )
Logged on
0:No 1:Yes (No )
Forward drive
0:No 1:Yes (No )
Backward drive
0:No 1:Yes (No )
Pump total
0:No 1:Yes (No )
Pump 1
0:No 1:Yes (No )
Pump 2
0:No 1:Yes (No )
Pump 3
0:No 1:Yes (No )
Pump 4
0:No 1:Yes (No )
Pump 5
0:No 1:Yes (No )
10.95
3.3
Set options
ATLET service
3:Set options
Switch levelsys.
0:No 1:Yes (No )
Pulse levelsys.
0:No 1:Yes (No )
Lift limiting
0:No 1:Yes (No )
Yes / No
Lift lim restart

0:No 1:Yes (No )
Custom system
0:No 1:Yes (No )
Yes / No
Func. not awail.
Press Enter
Hydr. oil Temp.

0:No 1:Yes (No )
Yes / No
Warning oiltemp
60
Stop oil temp.
65
Drive motor Temp

0:No 1:Yes (No )
10.96
Pump motor temp

0:No 1:Yes (Yes)
Speed reduction.
0:No 1:Yes (Yes)
Batt. Level buzz
0:No 1:Yes (No )
Reach out creep
0:No 1:Yes (No )
Krocksensor
0:No 1:Yes (No )
Yes / No
Impact warn.lim.
40
Impact horn lim.
200
Impactflashlim.
200
Impact stop lim.
200
Impact sup. lim.
200
Timeout log off

0:No 1:Yes (No )
Yes / No
Logoff time (mi)
0
10.97
System supervis.
0:No 1:Yes (No )
Display logon-h.
0:No 1:Yes (No )
Transp. indicat.
0:No 1:Yes (No )
Battery shunt op
0:No 1:Yes (No )
Extra 1 Temp.
0:No 1:Yes (No )
Yes / No
Warning Extra T1
60
Stop Extra T1
65
Extra 2 Temp.
0:No 1:Yes (No )
Yes / No
Warning extra T2
100
Stop Extra T2
120
Summer time
0:No 1:Yes (Yes)
10.98
Show hight
0:No 1:Yes (Yes)
Yes / No
Feet inch height
0:No 1:Yes (No )
Seat switch opt.

0:No 1:Yes (No )
Wheel ind. opt.
0:No 1:Yes (Yes)
10.99
3.4.1.X
AC driver X
AC Parameters
AC driver X
Maximum speed
--Creep speed
--Acceleration dri
--Curr Limit Drive
--Reduc.brakes dri
--Reverse braking
--Pedal braking
--Max backw. speed
--Max pump speed
--Max lower speed
--Acc. pump
--Hydralic spare
--Steering spare 1
--Steering spare 2
---
10.100
X can be 1
to 4.
All values are
from 0 to 100
percent of
machine max
performance
Select joystick
3.4.2.X
Channel :
xxxxx:
1.
Lyft
2
2
3
3
4
4
Channel : zzzzz
1.
Lower
2
Extend
3
Tiltout
4
ShiftR
5
Open
Channel xxxxx
Press Enter
yyyyy
max level
---
yyyyy
min level
---
zzzzz
max level
---
zzzzz
min level
---
Channel can
be selected
by digit 1 to 5
or by touching
the lever.
Channel : yyyyy
1.
Raise
2
Retract
3
Tiltin
4
ShiftL
5
Close
Joyst. deadzone:
--yyyyyy acc:
--yyyyyy ret.:
--zzzzzz acc:
--zzzzzz ret.:
--Fetch B./Scalef.
--Pos. Motor close
--Neg. Motor close
---
10.101
3.4.3
Set battery
Select setting:
3:Stta batteri
Select 48V batt.
0:No 1:Yes (Yes)
Measured B+ (mV)
----Battery size(Ah)
--Pump size
(kW)
---
Utilisation (%)
--Chassis const. 1
--Chassis const. 2
--Low batt. level
--Lift stop level
--Spare 1
---
3.4.4
10.102
Set levelsyst
Select setting
4:Set levelsyst
See M403,
M404,
M405 resp.
M406.
3.7.5.1
Read data
Acquisition menu
1:Read data
Forward
0 0
3.7.5.2
Print data
Note 4
Acquisition menu
2: Print data
DP1000 printer ?
0:No 1:Yes (No )
Printing
please wait !
3.7.5.X
Setup acq. N
Acquisition menu
X:Setup acq. N
Pin to acquire ?
-
N is channel
between 1
and 5
See M330
for more info.
Size of bin(.1s)
Invert 0=No 1=Ye
--
3.7.7
Test any outp
Select test
7: Test any outp
Outputno: (0=ex)
0
Exit ?
--------------0:Exit 1:Toggle
On line 1
selected output
is diplayed.
10.103
3.7.8
Show inputs
Select test
8:Show inputs
Se Not 12
Dig.Input XC2:12
XXXXXXXXXXXXXX
3.8.3
Read service
Log book menu

3:Read service
Func. not avail.
Press Enter
3.8.4
Sign service
Log book menu

4:Signera serv.
Func. not avail.
Press Enter
3.8.8
NVR upload.
Log book menu

8:NVR upload
Load std. NVR ?
0:No 1:Yes (No )
Yes / No
Loading !!!!!!!
10.104
Terminated
automaticly.
3.9
Set all def.
ATLET service
9:Set all def.
Are you sure ?
0:No 1:Yes (No )
Yes/ No
Terminated
automaticly.
10.105
4.1
Custom service
1: Unlock
Unlock
Code :
???????
Code OK
Code :
Id not found.
4.2
Communication
Custom service
2:Communication
DL2
Press Enter
PSION COMM.
4.3.X
Print yyyyy
Func. not avail.

A Press Enter
Print custom
X:Print yyyyy
DP1000 printer?
0:No 1:Yes (No )
Printing
please wait !
10.106
X
1
2
3
4
5
6
7
8
yyyyyyy
counters
cus.log
tmp.log
serv.log
err.log
settings
spare
all log
4.4.1
Cust. counter
Read custom
1: Cust counter
ID
ON
N
MMDD HH:MM
ID
N
OFF MMDD HH:MM
ID
Drive:
ID
Lift:
ID
N
Logged:
N: user ID
Time for first
logon
Time for last
logoff.
-.--h
Sum of driving
time
-.--h
Sum of liftting
time
-.--h
Sum of logged
on time.
more ID
4.5
Reset custom
Custom service
5: Reset custom
Code :
???????
code OK
4.5.0
Code :
Id not found.
4
10.107
Service menu
6: Driver param
Driver param
Number of
digits depends
on setting
User id:
?
Number of
digits depends
on setting
Valid
ID ?
Code
Id not found
*
:
****
Valid
code ?
Id not found
Maximum speed
--Acceleration dri
--Reduc.brakes dri
--Reverse braking
--Hydralic spare
--Steering spare 1
--Steering spare 2
---
10.108
****
All values are

from 0 to 100
percent of
machine max
performance
Note Description
1
The number of ? are the same as Id-length set in 3.1.8
The number of ? are the same as password-length set in 3.1.8
Select driver category from 1 to 4 and make settings in 3.4.1.X
Stepping is done with the arrow buttons step by step,

with numbers 1..5 to beginning of data of each channel,
H-button to exit.
See M330 for more details.
Time setting: The keys Ent and down displays one more digit
every time they are pressed. Up arrow displays one less digit
every time it is pressed. Digits are entered as values.
Format is:
HH:MM:SS
HH Hours
MM Minutes
SS Seconds
Date setting: The keys Ent and down displays one more digit
every time they are pressed. Up arrow displays one less digit
every time it is pressed. Digits are entered as values.
Formatet r:
DD:MM:YYYY
DD Day
MM Month
YYYY Year
Date format:
1: dd-mon-yy
2: dd-mm-yyyy
3: mm-dd-yyyy
4: yyyy-mm-dd
10.109
Drive input-symbols:
UNS/URF/UTF
SaAFdBdMFP
LoFHiF<@><->S1S2
Sa: Safety switch ( Left foot )
A Aisle
Fd: Forward switch
Bd: Reverse switch
M: Fuse drive regulator
F: Fuse pump regulator
P: Fuse power-steering
LoF: Low fork height ( 1/2 meter )
HiF: High fork height (3 meter )
<@: Forks turned counter clockwise
@<: Forks turned clockwise
<-: Forks shifted left
->: Forks shifted right
S1: PS fault signal 1
UFS
SaAFdBdMFP
LoFHiF <-> S1S2
Sa: Safety switch ( Left foot )
A Aisle
Fd: Forward switch
Bd: Reverse switch
M: Fuse drive regulator
F: Fuse pump regulator
P: Fuse power-steering
LoF: Low fork height ( 1/2 meter )
HiF: High fork height (3 meter )
<@: Forks turned counter clockwise
@<: Forks turned clockwise
10.110
Hydralic inputs symbols, levers in one or the other end position
UNS 5-lever
l L reRE tiTI
S>SR <>SORSRO
or
d DriRI toTO
<SSL ><SC
l liftlever in lift position

d liftlever in lower position
L logic in lift position
D logic in lower position
ri reach lever in reach in position
ro reach lever in reach out position
RI logic in reach in position
RO logic in reach out position
ti tilt lever in tilt in position
to tilt lever in tilt out position
TI logic in tilt in position
TO logic in tilt uot position
S> sideshift lever in shift right position
<S sideshift lever in shift left position
SR logic in shift right position
SL logic in shift left position
<> fork spread lever in spread position
>< fork spread lever in close position
SO logic in fork spread position
SC logic in fork close position
RS Reachstop
RO Reach out
10.111
UNS 3- lever
L L I I xx
TB SB RB
xx
or
d D O O xx
TB SB RB
xx
L liftlever in lift position

D liftlever in lower position
I reach lever in reach in position
O reach lever in reach out position
I logic in reach in position
O logic in reach out position
xx in position 11 and 12 depends on selected function and can be:
TI tilt lever in tilt in position
TO tilt lever in tilt ut position
S> sideshift lever in shift right position
<S sideshift lever in shift left position
<@ fork spread lever in spread position
@> fork spread lever in close position
xx i position 15 och 16 beror p vald funktion och kan vara:
SR logic in shift right position
SL logic in shift left position
TB Tilt button
SB: sideshift button
RB fork spread button
RS Reachstop
10.112
UFS
l L
RE tiTO
<>SORSRO
or
d D
RI toTO
><SC

RI logic in reach in position
RO logic in reach out position
ti tilt lever in tilt in position
to tilt lever in tilt out position
<> fork spread lever in spread position
>< fork spread lever in close position
RS Reachstop
RO Reach out
10.113
URF
l L <-<-
@>@>
RSRO
or
d D->->
<@<@

-> sideshift lever in shift right position
<- sideshift lever in shift left position
-> logic in shift right position
<- logic in shift left position
@> rotation lever in clockwise position
<@ rotations lever in anti clockwise position
@> logic in clockwise position
<@ logic in anti clockwise position
RS Reachstop
RO Reach out
UTF
eller
l L <-<-
d D->->
RSRO
-> sideshift lever in shift right position
<- sideshift lever in shift left position
-> logic in shift right position
<- logic in shift left position
RS Reachstop
RO Reach out
10.114
10
Options input symbols, the same for UNS, UNE, URF / UTF
LLi
Seat:
St Ho
RSRIRO
LLi: Lift limit switch

St: Straight switch
Ho: Horn button
Seat:. Are not present on UNS/UTF etc.
RS: Reachstop
RI: Reach in
RO: Reach out
4
Level selection, common for all machines

Inputs:
LZ LC
Level(mm):xxxxxx
LZ: Zero set switch
LC: Level count switch, for switch level system
xxxxxx: Actual level in mm for puls level system
12
On line 1 is input connection pin on the ATC2 displayed.

On line 2 is an "analog" diplay of the voltage
10.115
10.23
Wiring diagram
The wiring diagrams are placed in number order at the end of section 10.
Description
Wiring Diagram
Wiring Diagram
Options
Circuit diagram
Machine
type
Reference
Document code
Issue
U**
U**
111239
111370
D.
C
U*S, U*F
111693
10.116
10.117
110703:E 1/1
111239:D 2/8
111239:D 3/8
111239:D 4/8
111239:D 5/8
111239:D 6/8
111239:D 7/8
111239:D 8/8
110703:E 1/1
111239:D 2/8
111239:D 3/8
111239:D 4/8
111239:D 5/8
111239:D 6/8
111239:D 7/8
111239:D 8/8
111370:C 9/23
111370:C 10/23
111370:C 11/23
111370:C 12/23
111370:C 13/23
111370:C 14/23
111370:C 15/23
111370:C 16/23
111370:C 17/23
111370:C 18/23
111370:C 19/23
111370:C 20/23
111370:C 21/23
111370:C 22/23
111370:C 23/23
110703:E 1/1
111239:D 2/8
111239:D 3/8
111239:D 4/8
111239:D 5/8
111239:D 6/8
111239:D 7/8
111239:D 8/8
111370:C 9/23
111370:C 10/23
111370:C 11/23
111370:C 12/23
111370:C 13/23
111370:C 14/23
111370:C 15/23
111370:C 16/23
111370:C 17/23
111370:C 18/23
Service Manual
U - AC Power Plus
Manual No: 005953
Section:11 Issue: A
11 Speed control and brake systems .............................................11.3

11.1 Speed control, U*S....................................................................................................................11.3
11.1.1 Dismantling the speed and brake controls, U*S ............................................................11.3
11.1.2 Inspection and adjustment of the speed control, U*S ....................................................11.4
11.1.3 Calibrating the controls ..................................................................................................11.4
11.2 Brake pedal, U*S.......................................................................................................................11.5
11.2.1 Adjusting and inspecting the brake pedal ......................................................................11.6
11.3 Left-foot switch, U*S ................................................................................................................11.8
11.3.3 Preventive maintenance .................................................................................................11.8
11.3.4 Adjusting the electric brake, 1 disc ................................................................................11.8
11.3.1 Dismantling, assembling the left-foot switch ................................................................11.8
11.3.2 Adjusting the left-foot switch ........................................................................................11.8
11.4 Trouble shooting......................................................................................................................11.10
11.1
11.2
11
Speed control and brake systems
11.1
Speed control, U*S
The speed and brake controls consists of a

bracket with two pedals and several sensors,
both digital and analogue.
The speed control has an analogue sensor (pos
58, fig. 11.1), which is connected to the ATC.
The sensor regulates the speed of the drive
motor. Two digital sensors are also fitted to the
speed control (pos 21), these send direction
signals to the ATC and determine in which
direction the drive motor shall rotate. As an
extra accessory the microswitches can be
replaced with hand operated switches, which
are then placed on the handle.
10
11
7
23
1
67
12
24
25
13
22
15 16
14
17
18
29
23
20
21
24
25
26
19
30
26
28
32
11.1.1
1
69
34
33
Lift up the foot plate under the pedals.
Undo the nuts on the machine housing

cover and lift it up.
Dismantle the securing bolts (pos 63,

fig. 11.1), which hold the pedal assembly
against the frame.
Swing the pedal assembly forward and
split the ribbon cable by pulling apart the
connector located behind the pedal
assembly.
70
29
72
Pull out the battery plug.
40
Dismantling the speed

and brake controls, U*S
41
71
42
63
54
62
53
35
31
35
36
24
54
36
24
25
25
60
53
58
25
59
24
25
39
60
59
24
25
58
52
39
H 270.2
61
56
48
56
57
Figure 11.1
IMPORTANT! Check that the

cables are not crushed.
11.3
11.1.2
Inspection and adjustment of the speed control, U*S
IMPORTANT! Measurements shall be made with the help of the ATC.
The speed control should be connected to the ATC.
Check that the return springs for the direction selectors (pos 12, fig. 11.1) have sufficient force to lift
the direction selectors to their upper position.
Go to DRIVE Inputs in the ATC. Check that the text: Fwd and Bwd appear and disappear on the
display when the direction selectors are pressed down.
Fwd = Forwards
Bwd = Reverse
This instruction only applies to software 3.22. The ATC language should be set to English in order to
follow the instructions below.
If necessary also refer to the related document, service manual Truck Computer.
11.1.3
Calibrating the drive controls
Start by checking that the moving aluminium plate (39 fig 11.1) is very close (approx. 0.5 mm) and
completely parallel with the SLOAN sensor when the pedal is fully pressed down. The procedure to
calibrate the pedal is identical with UNS-DC. The only difference is that the SLOAN sensor potentiometer
should be adjusted to give 2.0V with the pedal in the neutral position to give the best possible
characteristics. This voltage level should be checked with the ATC under the service menu ([S] button).
3: ATLET service
7: Run test
1: Drive tests
5: Regulator inputs
Read Accel.Volt. The voltage level can be adjusted if necessary using the trim potentiometer on the
sensor.
When the voltage level is right, calibrate the sensor on the accelerator by entering:
3: ATLET service
7: Run test
1: Drive tests
2: Set accelerator
Follow the instructions on the display.
11.4
When calibration has been completed return to ATLET service

7: Run test
1: Drive tests
5: Regulator inputs
and check that the values are the following:
accel volt
drive out
11.2
Accelerator
released
Accelerator fully pressed down
approx. 2.0 Volt

0
4.5 - 5.0
100%
Brake pedal, U*S
The brake pedal is fitted to the same bracket

and has one digital and one analogue sensor,
see fig. 11.1. The limit switch is an emergency
stop (forced braking), which is actuated when
the pedal is pressed down fully. This switch is
connected outside of ATC, see fig. 11.1, pos
42.
11.5
11.2.1
Adjusting and inspecting the brake pedal
Check the length of the spring assembly,

see measurement A, which should be
67 mm when the pedal is not actuated and
in its uppermost position.
Even the brake pedal must be calibrated,

this takes place in a way that is similar to
the accelerator. Start by checking that the
moving aluminium plate is very close
(approx. 0.5 mm) and completely parallel
with the SLOAN sensor when the pedal is
fully pressed down. Now check that the
voltage level from the brake sensor
(SLOAN) is about 2.0 V when the pedal is
fully released. In ATC step to:
3: Atlet service, 7: Run test, 1: Drive tests,

6: Brake test.
Read Brake Volt

4
If the voltage is not right, adjust on the

brake pedal sensor. When the voltage level
is right, calibrate the pedal using the menu:
3: Atlet service, 7: Run test, 1: Drive tests,

4: Set brake.
Follow the instructions on the display.
SM 022.1
Figure 11.2
When calibration has been completed return to:

6
3: Atlet service, 7: Run test, 1: Travel tests,

6: Brake test.
And check the values as set out in the table

below.
11.6
Brake
volt
Brake out
Brake pedal
fully released
Brake pedal fully pressed down
Special
settings for
UFS
approx. 2.0 Volt
4.5 5.0 Volt
500%
NOTE! when 100% is measured it gives the maximum
electric motor brake, further pedal movement has no
bearing on the electric motor brake.
At approx. 300%, the ATC shall activate the electric
magnetic brake that is mounted on the motors top end.
At approximately 450 - 500% the emergency brake
microswitch, which is activated by the brake pedal,
should be activated so that the electric magnetic brake
under all circumstances is switched on.
4.5 5.0
Volt
approx.
100%
The values above only apply if the last log on has been with a performance category where the parameter
pedal brake is set to 100%
11.7
11.3
Left-foot switch, U*S
The left-foot switch (pos 1) is located on the

floor to the left of the brake pedal and actuates
a microswitch. The left-foot switch has the
function of preventing the driver from coming
out of the machine housings profile and
thereby be injured in the event of a collision.
The left-foot switch also serves as an automatic
parking brake. If released while travelling, the
automatic control system will automatically
disengage and the brake will be actuated with a
degree of delay, (should not be used as a
brake).
5
3
7
11.3.1
Dismantling, assembling
the left-foot switch
When dismantling and assembling, see Figure

11.3
5
9
10
11.3.2
Adjusting the left-foot

switch
H 280.1
Figure 11.3
The microswitch is adjusted so that its roller

touches the shafts lower tip in the unactuated
position.
11.3.3
The shaft is lubricated with each preventive maintenance so that is runs easily and eliminates wear. The
shaft must be replaced if wear is so much that there is a risk that it can jam or that the microswitch roller is
no longer actuated by a good margin. Also lubricate the spring.
11.3.4
Adjusting the electric brake, 1 disc
The function of the electric brake is to act as a parking brake and emergency brake (not as a travel brake,
when there is a motor brake).
Assemble the electric brake and tighten the bolts. Check that the spacing (A) between the magnetic
section, see Figure 11.4 and the plate is 0.4 mm all round. During normal usage and normal conditions the
brake is virtually maintenance free. The braking force is not possible to adjust.
Adjustment of the spacing A is done as follows:
11.8
Loosen the bolts holding the brake a little

(pos 1).
Adjust the spacers (pos 2).
Tighten the bolts and measure the spacing,

A, as above.
SM 189.1
Figure 11.4
Connect the electrical connector to the brake and connect the battery plug.
Test the brakes by driving and test braking. The following braking distances applies:
Unloaded
Loaded
Braking distance
2.0 -2.5 metres
2.5 -3.0 metres
Measurement A
Min
Max
0.4 mm
0.8 mm
Braking distances are measured at max speed. Loaded means with the classified weight and a truck
equipped as standard.
The friction surfaces must be at least 1 mm thick. If not, the brake discs must be replaced.
11.9
11.4
Trouble shooting
Symptom: The brakes do not release.
Check the LED indications for faulty steering function: LED 4 and 5 on the ACC unit, error code
E05, E06 and E07 on the ATC display.
Check that the limit switch for the brake in the pedal unit functions.
If the brake still does not release, check that there is 48 volt on the brake connections on the drive
motor when the brake is released.
Also check that the left-foot brake SA functions under the menu drive inputs. If the switch does not
work, no pulsing is received from the drive motor!
11.10
Service Manual
U - AC Power Plus
Manual No: 005953
Section:12 Issue: A
12 Extra accessories .......................................................................12.3

12.1 Level selector ............................................................................................................................12.3
12.1.1 Setting the switch height preset .....................................................................................12.4
12.1.2 General height preselection ...........................................................................................12.4
12.1.3 Operating height preselection ........................................................................................12.4
Selection .............................................................................................................................12.4
Cancel.................................................................................................................................12.5
Lift......................................................................................................................................12.5
12.1.4 Usage example. ..............................................................................................................12.5
Ex.1: Collecting a load .......................................................................................................12.5
Ex.2: Just logged on. ..........................................................................................................12.5
Ex.3: Placing the load.........................................................................................................12.5
12.1.5 Pulse height preset. ........................................................................................................12.6
12.1.6 Operation. ......................................................................................................................12.6
Selection .............................................................................................................................12.6
Cancel.................................................................................................................................12.6
Lift......................................................................................................................................12.6
To change levels.................................................................................................................12.7
12.1.7 Checking settings ...........................................................................................................12.7
12.1.8 Usage example. ..............................................................................................................12.7
Ex.1: Collecting a load .......................................................................................................12.7
Ex.2: Just logged on. ..........................................................................................................12.7
Ex.3: Placing the load.........................................................................................................12.8
12.2 Height measurement instrument................................................................................................12.8
12.2.1 Technology ....................................................................................................................12.8
12.2.2 Settings ...........................................................................................................................12.8
12.2.3 Programming .................................................................................................................12.8
12.2.4 Setting the offset value ..................................................................................................12.9
12.2.5 Protecting the preset value .............................................................................................12.9
12.2.6 Setting COEFF ...............................................................................................................12.9
12.2.7 Setting dECPt .................................................................................................................12.9
12.2.8 Final test .........................................................................................................................12.9
12.2.9 Sensor .............................................................................................................................12.9
12.2.10 Adjusting the sensor .....................................................................................................12.9
12.2.11 Height indication on the display. ...............................................................................12.10
12.3 Wheel indicator. ......................................................................................................................12.10
12.4 Testing the wheel angle sensor and indicator..........................................................................12.10
12.5 Cab...........................................................................................................................................12.11
12.1
12.2
12
Extra accessories
12.1
Level selector
The driver selects collection and deposit levels

from the keyboard and then actuates the lifting
lever. The pump then starts and runs at a speed
corresponding to the lever movement. While
the forks are raised the ATC calculates the
levels as they are passed. When the selected
level is reached, the pump speed is reduced to a
preset speed and stops completely after the set
time. If collection has been selected, the ATC
now lowers the forks until the level is reached
again, this is done to improve accuracy when
positioning. When the lifting lever is placed in
the neutral position once the level has been
reached the selection is reset.
6
4
9 7
10 9
21
20
17
16
15
19
20
19
21
10
22
11
68
18
In addition, there is a stop that stops the system

when it has not been correctly reset or when an
invalid level has been selected.
16
66
69
70
15
63
38
If the system does not count, check that the

option has been set in set options. Check in
the service menu, options test, height preset
that LZ is not shown on the display, if LZ
is shown this means resetting is active, that is,
the switch has jammed or the cable from the
reset switch is broken.
67
32
31
73
64
65
71
72
33
34
1615
13
12
58
14
25
27
28
61
30
29
62
60
35
37
23
24
59
36
Figure 12.1
12.3
12.1.1
Setting the switch height preset
The option Switch level sys in Set options must be on.
The following variables are set in Set level sys so that the forks, with the customers greatest load,
stop at a suitable height for depositing.
Number of Levels should be set to the number of levels available.
Up pwm: (>500) defines the speed, after passing the output level with lift preset. This value should
be greater than 500, usually about 600.
Up time: (.1s) defines how long the lift shall continue after passing the collection level and is stated
in tenths of a second. Normal value is 6.
Wait time: (.1s) states how long the ATC should wait from when the depositing height has been
reached to when it should start lowering to the collection level and is stated in tenths of a second.
Normal is 4.
A sensor for resetting.
A magnetic sensor to count the levels and a magnet for each collection level.
A lowering valve with a constant flow.
10 Software version UNS 3.00 or later.

11 More than 300 mm between levels, and no greater accuracy than +/- 200 mm when depositing.
12.1.2
General height preselection
The driver selects collection and deposit levels from the keyboard and orders lift via the lift control. The
pump then starts and runs at a speed corresponding to the control movement. While the forks are raised the
ATC calculates the levels as they are passed. When the selected level is reached, the pump collection is
lowered until the preset collection (UP PWM) and then switches off completely after a set time (UP
TIME). If the collection has been selected, the ATC lowers the forks until the level is reached again. This is
done to improve accuracy when positioning. When the lifting lever is placed in the neutral position, once
the level has been reached, the preselection is completed (LEVEL REACHED).
In addition, immobilizers are fitted to prevent the system from being used, if it has not been correctly reset
or if an invalid level has been selected.
12.1.3
Operating height preselection
Selection
To select OUT, press O or for IN press I. The display shows:
Select level. Press the numbers for the level. If the forks are above the selected level the error message
Incorrect level! is shown and the selection is not approved.
If Ent is pressed instead of a number, with collection selected, the forks are lowered to the closest level.
This can be used to place the load.
As an option to Ent the lift/lower lever can be used. Use lift if a higher level is selected, and lower if a
lower level is selected.
If the forks have not activated the resetting sensor, after logging on, the display shows Syst. Not reset!
12.4
and the height preset cannot be activated.

If everything is correct the display shows Level: k:nn(mm) until the level is reach or you cancel the
operation. k is I for depositing or O for taking-out, nn is the selected level and mm is the current
level.
Cancel.
To cancel/reset a selection, move the lifting lever for a moment in the lowering direction. The display
shows Level CANCELLED!. NOTE! Cancel or the lower command, when the forks are close to a
sensor, can result in the miscalculation of the levels. In some instances the ATC will detect this and show
Sys. Not reset on the display. If this happens lower the forks to the resetting level so that the system is
restored.
You can also cancel using the lift command when placing a load.
Lift.
Pull the lift control until the pump stops. Now let the control return to the neutral position. A lift can be
cancelled, to then be continued, without losing the selection. With collection, the forks first go passed the
level, the pump stops, and then lowers to the right level.
When the control is in the neutral position and the level is reached the display shows Level reached!.
12.1.4
Usage example.
Ex.1: Collecting a load

1
The driver shall collect a load on level 3.
The driver presses O for the OUT level.
The driver presses 3 + E. The display shows Level:O03(00) where O03 means that he has
selected collection level number 3, 00 is the last passed level.
The driver actuates the lift control until the forks stop and the display shows Level reached!.
Ex.2: Just logged on.

The driver has just logged on, the forks are above the resetting level and the driver shall deposit the load on
level 5.
1
The driver presses I for depositing. The display shows Sys. Not reset.
The driver lowers the forks to the resetting level.
The driver presses I again for depositing and then 5 and E. The display shows Level: I05(00)
where O05 means that he has selected the depositing level 5, and 00 is the level last passed.
The driver actuates the lift control until the forks stop and the display shows Level reached!.
Ex.3: Placing the load.

The forks are on level 2 Depositing and driver needs to place the pallet in the pallet rack.
1
The driver presses O for collection.
The driver presses E as the level is correct. The display shows Level: O02(02) where O02
12.5
means that he has selected collection level 2, and 02 is the level on which the forks are at.
3
The forks are automatically lowered to the level.
12.1.5
Pulse height preset.
The driver selects a collection or depositing level from the keyboard and then actuates the lifting lever.
Pump will now run at the speed corresponding to the lifting levers movement. ATC counts the pulses from
the sensor and converts these to millimetres. The height is compared with the selected value and when the
distance to the select level is 400 mm or less, the pump speed is successively reduced until the level is
reached.
If the forks stop more than 10 mm too high, the ATC opens the lowering valve until the level is reached.
When the lifting lever is placed in the neutral position, once the level has been reached, the preselection is
completed.
The system must be reset before it can be used, i.e. the forks should pass the resetting sensor. If an
incorrect level is stated the preselection stops immediately.
Normally the level selection is used when lifting, but it can also be used for lowering, if the distance is less
than 400 mm. No lever movement is then required.
12.1.6
Operation.
Selection
To select collection, press O or for deposit press I. The display then shows:
Select level. Press the numbers for the level number. If the forks are above the selected level the error
message Incorrect level! is shown and the selection is not approved.
If O has been pressed, you can then press Ent instead of numbers, to lower the forks to the closest
collection level. This can be used to place the load.
The forks must have activated the resetting sensor since the last log on to use the system. Otherwise the
display shows Syst. Not reset.! And the system will not start.
If everything is correct the display shows kk:nnn (mmm) until the level is reached or you cancel the
operation. kk is the selected level number, nnn is the selected level in cm and mmm is the current
height of the forks.
Cancel.
To cancel/reset a selection, move the lifting lever for a moment to lowering. The display shows Level
CANCELLED!.
A preselection that results in lowering of the forks can be cancelled by a lift order.
Lift.
Pull the lift lever until the pump stops. Now let the lever return to the neutral position. You can cancel the
lift (stop) and then continue without the selection disappearing.
When the lever is moved to the neutral position and the level is reached the display shows Level
reached!.
12.6
To set levels
1
Select Local service from the service menu.
Select 4: Set levels A number of parameters are shown. If the displayed values are to be kept, press
Ent, otherwise change and press Ent.
IMPORTANT! Incorrect input cannot be corrected, you must first complete all the questions
and then restart!
The following parameters are asked for:

Level no.: (0=Ex) State the level to be changed.
Level 0 is used to quit.
Level: State the height for the level in cm.
12.1.7
Checking settings
This section describes how you check that the parameter Forkzero offset is set correctly.
1
Check that the mast is not tilted.
Lift with a low pump output to the height where the free lift ends and the final stroke shall starts, that
is before the measurement starts. Now measure the distance from the floor to the top of the forks.
12.1.8
Usage example.
Ex.1: Collecting a load

The driver shall collect a load on level 3.
1
The driver presses O for the collection level.
The driver presses 3 + Ent. The display shows, e.g. 03:200 (082) where 03 means the selected
level, 200 is the height the forks shall move to, in cm, and 082 is the current fork height, in cm.
The driver actuates the lift lever until the forks stop and the display shows Level reached!.
Ex.2: Just logged on.

The driver has just logged on. The forks are above the resetting level. The driver shall deposit a load on
level 5.
1
The driver presses I for depositing.
The display shows Sys. Not reset.
The driver lowers the forks to the resetting level.
The driver presses I again for depositing and 5 and Ent. The display shows 05:380 (008)
where 05 means the selected level, 380 is the height the forks shall move to, in cm, and 008 is
12.7
the current fork height, in cm.

5
The driver actuates the lift lever until the forks stop and the display shows Level reached!.
Ex.3: Placing the load.

The forks are on level 2 Depositing and driver needs to place the pallet in the pallet rack.
1
The driver presses O for collection.
The driver presses Ent as the level is correct. The display shows
The display shows 02:100 (110) where 02 means the selected level, 100 is the height the forks
shall move to, in cm, and 110 is the current fork height, in cm.
The forks are automatically lowered to the right level.
12.2
Height measurement instrument
As extra equipment the truck can be fitted with an instrument that shows the height of the forks in mm or
inches. Indication is only possible above the free lift position. All trucks with the height measurement
instrument must be equipped with a low fork indicator switch; this is because this indicator is used for both
low fork indication and resetting of the height measurement instrument. Lof does not need to be
activated in ATC.
12.2.1
Technology
The instrument is preset to work as a pulse counter. The pulses come to the instrument on two channels
with 90 mutual phase displacement. The phase displacement gives the instrument the possibility to
determine the forks direction of movement and in doing so count in the right direction. The pulses are
generated by means of a chain and unit (complete with a sprocket, block and two inductive sensors) placed
on the mast. Accuracy is +- 15 mm at a lifting height of 10 m.
12.2.2
Settings
The instrument has two setting modes, programming mode and operating mode. Programming mode is
accessed by pulling out the instruments mechanism from the casing 5-10 mm. This requires some force
and if you pull out the mechanism to far the feed to this is lost. If this happens slide in the mechanism until
the feed returns.
12.2.3
Programming
If the truck goes to a country that uses the metric system the instrument only needs to be locked once the
offset value has been set. In other cases modification to COEFF and dECPt must be done. dECPt = how
many decimals are used.
12.8
12.2.4
Setting the offset value
Place the forks exactly at the transition between free lift and final stroke. Measure the height to the top of
the forks, this is the offset height. Set the instrument in the programming mode, press P until the display
shows Prot, now press one of the 5 small buttons until no is displayed. Setting the instrument in
operating mode. Press P and set P1 to the offset height by stepping to the right value using the five small
buttons. Ex: If the offset is 182 cm, P1 should be set to 1.82 (m). Press P again and set P2 in the same way,
display P1 again and press RST until inst. offset is shown on the display.
12.2.5
Protecting the preset value
In order to protect the offset value from modification proceed as follows. Set the instrument in
programming mode and go to the Prot menu, press one of the 5 small buttons until YES,P1,P2 and RST are
shown on the display, if COEFF is not to be changed reset the instrument to the operating mode.
12.2.6
Setting COEFF
In programming mode press P repeatedly until COEFF is shown on the display. COEFF is used to recount
the number of pulses so that the right value is shown. With metric measurement COEFF should be 1.000,
but when the truck is used in USA this should be set to 3.935. Set this using the same buttons as used for
P1 and P2.
12.2.7
Setting dECPt
In programming mode go to the menu dECPt by pressing P repeatedly. Press one of the small round
buttons until a decimal appears after the decimal point. Reset the instrument to operating mode.
12.2.8
Final test
When all this has been done the height measurement can be test run, run the forks up and down over the
final stroke and check that the instrument counts in the right direction. Test a few times at the free lift
transition point to be sure that everything is fitted correctly. Compare the instruments height measurement
with that shown on the ATC display. It can happen that they sometimes differ by one, but this is OK,
however they should not differ more.
12.2.9
Sensor
The sensor is equipped with LEDs that flash with each pulse.
12.2.10 Adjusting the sensor

The sensors distance to the sprocket should be 0.8 tolerance 0.1.
12.9
12.2.11 Height indication on the display.

The system requires a height measuring sensor type pulse level sys. It can either be a wire sensor (older
trucks), or chain sensor. The option Show height should be activated. If you wish the height to be shown
in feet and inches activate the option Feet & inches height.
The system should be set under Atlet Service, Setting menu, Set level system. The sensors number of
pulses per metre should be defined and the height, in centimetres, above the floor when the counting of
pulses starts.
As soon as the sensor starts to count pulses the equivalent height is displayed. When the fork height has
been the same for 5 seconds or more the display dims.
12.3
Wheel indicator.
The system consists of an incremental sensor mounted in connection to the steering servos output axle and
an inductive sensor for synchronisation. On trucks with a 180 degree drive unit a sensor mounted in front
of the motor is used and on 360 degree drive units the sensor is located between the drive motor and the
pump motor.
The setting of the wheel indicator is done in Atlet Service, Run test, Drive tests and Calibrate wheel.
Pulses per revolution is the number of pulses delivered by the incremental sensor connected to the servo
systems axle with a complete revolution of the drive wheel. The value is calculated according to: The
sensors marking x 4 x mechanical reduction. (2000-05-10: 500 x 4 x teeth on the large cog/teeth on the
servo pinion = 5.5185 Total 11037). After this the display instrument shall be set to point straight laterally
towards the pedal side. This is done by means of the arrow keys. Press Enter. Now manoeuvre the
instrument to point straight sideways towards the seat side. Press Enter. Go to the menu Analogue wheel.
The drive wheel can be turned using the steering wheel. With a 180 degree drive unit calibration takes
place when the wheel is turned clockwise passed the straight position. With a 360 degree drive unit
calibration takes place with the wheel position straight to the side. Turn the steering wheel quickly.
While driving the systems angular value and passage straight ahead or to the side are monitored. If the
angular value does not correspond the error code 60 or 61 is shown.
12.4
Testing the wheel angle sensor and indicator
The system consists of an incremental sensor mounted in connection to the steering servos output axle and
an inductive sensor for synchronisation. On trucks with a 180 degree drive unit a sensor mounted in front
of the motor is used and on 360 degree drive units the sensor is located between the drive motor and the
pump motor.
The setting of the wheel indicator is done in Atlet Service, Run test, Drive tests and Calibrate wheel.
Pulses per revolution is the number of pulses delivered by the incremental sensor connected to the servo
systems axle with a complete revolution of the drive wheel. The value is calculated according to: The
sensors marking x 4 x mechanical reduction. (2000-05-10: 500 x 4 x teeth on the large cog/teeth on the
servo pinion = 5.5185 Total 11037). After this the display instrument shall be set to point straight laterally
towards the pedal side. This is done by means of the arrow keys. Press Enter. Now manoeuvre the
instrument to point straight sideways towards the seat side. Press Enter. Go to the menu Analogue wheel.
The drive wheel can be turned using the steering wheel. With a 180 degree drive unit calibration takes
place when the wheel is turned clockwise passed the straight position. With a 360 degree drive unit
calibration takes place with the wheel position straight to the side. Turn the steering wheel quickly.
12.10
While driving the systems angular value and passage straight ahead or to the side are monitored. If the
angular value does not correspond the error code 60 or 61 is shown.
12.5
Cab
In those cases where the truck is equipped with a cab, all fans and heaters should be kept clean. A dirty
heater gives inferior heat and can cause the thermal fuse to blow. The ventilation damper must never be
closed completely, as this can result in the thermal fuse blowing.
12.11
12.12

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Service Manual

General information and technical data

Drive and brake system

1 General information and technical data .....................................1.3

ATLET SERVICE MANUAL U - AC Power Plus

ATLET SERVICE MANUAL U - AC Power Plus

General information and technical data

How to use the manual

IMPORTANT! Used with the risk of damage to the machine.

ATLET SERVICE MANUAL U - AC Power Plus

ATLET SERVICE MANUAL U - AC Power Plus

S = Narrow (second letter)

Load capacity: UNS / UHS: 1400, 1600, 2000 kg

140, 160, 141, 200 DTFV

141, 200 DTFV

Approx. 450 Ah.

Approx. 600 Ah.

Approx. 750 Ah.

Approx. 900 Ah.

ATLET SERVICE MANUAL U - AC Power Plus

140 UNS, 160 UNS, 141 UNS, 200 UNS.

141 UHS, 200 UHS.

Type designations (example):

UNS / 140 DTFV R E 540

Clear view mast

Available battery combinations

ATLET SERVICE MANUAL U - AC Power Plus

(Also see section 5, Drive motor)

7.5 kW, S3 60% at 2500

UNS / UHS (Also see section 5, Electric brakes)

Lenze (1 stage 1 disc)

(Also see section 5, Gearbox)

See section 1.8

(Also see section 8, Hydraulic unit)

14 kW, S3 15% at 2300

Oil type normal environment

See section 1.9

ATLET SERVICE MANUAL U - AC Power Plus

Control system for motors

Capacity area UN / UH / UFS

Capacity area URF/UTF

Capacity area USS

Steering servo unit ACC

ATLET SERVICE MANUAL U - AC Power Plus

Conversion table torque

Pound force foot

ATLET SERVICE MANUAL U - AC Power Plus

Bolt types and tensile grades

Hexagon hole bolt

Hexagon hole bolt,

Square raised head

Marking and the manufacturer's trademark as

ATLET SERVICE MANUAL U - AC Power Plus

Lubrication chart U*S

ATLET SERVICE MANUAL U - AC Power Plus

Symbol key lubrication chart

Hydraulic oil and filter,

Gearbox oil, replace

Chain spray / oil

Only cold storage design

Mast profile, roller surfaces and slide

Fork carriage, slide surfaces for fork

Fork carriage, thrust rollers