Atlet OP Series OPM OPH OPC & OPS Service Manual – PDF DOWNLOAD
DESCRIPTION:
Atlet OP Series OPM OPH OPC & OPS Service Manual – PDF DOWNLOAD
Machine: OP
Manual nr: 005949
Introduction:
This manual describes the service procedures for ATLET picking trucks in the OP series. Use the manual for quick and correct service of respective truck models. You may find contradictions in the manual compared to the models supplied due to optional designs and the like.
General information, OP series:
Picking trucks in the OP series include OPM, OPH, OPC and OPS.
Picking trucks in the OP series include OPM, OPH, OPC and OPS.
How to use the manual :
The manual is arranged according to the same principles as ATLET’s spare part catalogues, i.e. a system consists of 12 sections, where sections 4 -12 contain information limited to a specific part of the truck. For example, Chassis (section 4) and Hydraulic System (section 8). Sections 1 – 3 in this manual contain more comprehensive information regarding technical data, general service, instructions and tools. The main principle for extra accessories is to place them under the respective sections. Otherwise they are placed under section 12 “Miscellaneous”. For this reason section 12 is not always included in the Service Manual. For specific problems or information about procedures, look in the main index for the correct section.
Safety instructions:
When the truck is lifted using a jack, make sure you secure it with blocks. The truck must not rest on the jack, while work is carried out. Ensure that straps, wires or chains have a sufficient lifting capacity before lifting the truck. Pull out the battery plug before working on the electrical system. Ensure that the drive wheel runs free of the floor before trouble shooting. The system should not be pressurised, e.g. the pump motor shut off and the forks down, when dismantling parts of the hydraulic system.
When the truck is lifted using a jack, make sure you secure it with blocks. The truck must not rest on the jack, while work is carried out. Ensure that straps, wires or chains have a sufficient lifting capacity before lifting the truck. Pull out the battery plug before working on the electrical system. Ensure that the drive wheel runs free of the floor before trouble shooting. The system should not be pressurised, e.g. the pump motor shut off and the forks down, when dismantling parts of the hydraulic system.
General safety risks when working on fork trucks:
Extreme importance must be placed on precautionary measures to avoid accidents during all work on the vehicle.
A general rule is to always implement preventive measures that are adapted to the type of vehicle to be worked on. The general rules below must always be observed:
• Smoking or naked flames are strictly forbidden as there is a risk of explosion in
the vicinity of batteries and while working on gas equipped vehicles.
• The battery should always be protected during grinding work.
• The fire regulations for the building should also be observed.TABLE OF CONTENTS:
A general rule is to always implement preventive measures that are adapted to the type of vehicle to be worked on. The general rules below must always be observed:
• Smoking or naked flames are strictly forbidden as there is a risk of explosion in
the vicinity of batteries and while working on gas equipped vehicles.
• The battery should always be protected during grinding work.
• The fire regulations for the building should also be observed.TABLE OF CONTENTS:
Atlet OP Series OPM OPH OPC & OPS Service Manual – PDF DOWNLOAD
01....................................................................................... 1 1 General information and technical data............................................. 1 1.1 Introduction................................................................. 5 1.2 General information, OP series............................................... 6 1.3 How to use the manual........................................................ 7 1.3.1 History................................................................ 7 1.3.2 Symbol key............................................................. 8 1.4 Tips before next step........................................................ 9 1.4.1 Lifting points......................................................... 9 1.4.2 Safety instructions.................................................... 10 1.4.3 General safety risks when working on fork trucks....................... 10 1.4.4 Environmentally hazardous waste - environment.......................... 11 1.4.5 Handling............................................................... 11 1.4.6 Trouble shooting....................................................... 12 1.5 Data OP...................................................................... 13 1.6 Dimensions and weights....................................................... 17 1.6.1 Dimensions OP.......................................................... 17 1.7 Overview of motor compartment................................................ 18 1.8 Component specification...................................................... 19 1.9 Tightening torque............................................................ 21 1.9.1 Conversion table....................................................... 22 1.9.2 Bolt types and tensile grades.......................................... 22 1.10 Lubrication chart........................................................... 24 1.10.1 Lubrication chart OP.................................................. 24 1.10.2 Symbol explanations, lubrication chart................................ 25 1.11 Recommended oil and grease types............................................ 26 1.12 Colour of the truck in accordance with NCS colour codes..................... 27 1.13 Colour codes for Atlet’s wiring diagrams.................................... 28 1.14 Designations for electrical components...................................... 29 1.15 Technical abbreviations..................................................... 30 1.16 Recommended replacement..................................................... 31 02....................................................................................... 33 2 Special tools...................................................................... 33 2.1 List of tools................................................................ 37 03....................................................................................... 39 3 Service............................................................................ 39 3.1 Introduction................................................................. 41 3.2 Service inspection list...................................................... 42 3.2.1 Chassis................................................................ 42 3.2.2 Mast................................................................... 43 3.2.3 Drive unit............................................................. 44 3.2.4 Steering............................................................... 45 3.2.5 Brake.................................................................. 45 3.2.6 Hydraulic system....................................................... 46 3.2.7 Electrical system...................................................... 47 3.3 Code explanations............................................................ 48 3.3.1 Chassis................................................................ 48 3.3.2 Mast................................................................... 49 3.3.3 Drive unit............................................................. 49 3.3.4 Steering............................................................... 49 3.3.5 Brake unit............................................................. 50 3.3.6 Hydraulic system....................................................... 50 3.3.7 Electrical system...................................................... 51 04....................................................................................... 53 4 Chassis............................................................................ 53 4.1 Introduction................................................................. 55 4.2 Replacing the load wheel..................................................... 56 05....................................................................................... 59 5 Drive unit......................................................................... 59 5.1 Introduction................................................................. 61 5.2 Dismantling, assembling the drive unit....................................... 62 5.3 Drive motor, general instructions............................................ 63 5.3.1 Storage of machines and motors......................................... 63 5.3.2 First service.......................................................... 63 5.3.3 Preventive maintenance................................................. 63 5.3.4 Dismantling, assembling the motor...................................... 64 5.4 Reconditioning the motor..................................................... 66 5.4.1 Brush holders.......................................................... 66 5.4.2 Motor bearings......................................................... 66 5.4.3 Overhaul of commutator and replacing the carbon brushes................ 66 5.4.4 Reasons for burned motors.............................................. 68 5.4.5 Stator housing......................................................... 68 5.4.6 Assembly............................................................... 68 5.5 Insulation test.............................................................. 69 5.6 Gearbox...................................................................... 70 5.6.1 First service.......................................................... 70 5.6.2 Preventive maintenance................................................. 70 5.7 Replacing the gears in the gearbox........................................... 71 5.8 Replacing the drive wheel.................................................... 73 5.9 Replacing the drive shaft seal............................................... 74 5.10 Trouble shooting chart...................................................... 75 06....................................................................................... 77 6 Mast............................................................................... 77 6.1 Introduction................................................................. 79 6.2 Erecting the mast............................................................ 80 6.3 Adjusting the mast........................................................... 84 6.3.1 Adjusting the mast top................................................. 84 6.3.1 Adjusting the side thrust in mast...................................... 84 6.4 Dismantling and assembling the mast, general................................. 85 6.5 Dismantling the driver’s platform............................................ 86 6.6 Dismantling the inner mast................................................... 88 6.7 Lift chains.................................................................. 89 6.7.1 Adjusting.............................................................. 89 6.7.2 Adjusting the chain tension sensor..................................... 89 6.7.3 Regular maintenance.................................................... 90 6.7.4 Re-fitting the chains.................................................. 90 6.7.5 Checking the lift chains............................................... 90 6.8 Fork test.................................................................... 92 6.9 Trouble shooting chart....................................................... 94 07....................................................................................... 95 7 Steering........................................................................... 95 7.1 Introduction................................................................. 97 7.2 Servo steering unit.......................................................... 98 7.2.1 Functions.............................................................. 98 7.2.2 Servo steering unit, settings.......................................... 99 7.2.3 Factory setting, electric steering.....................................101 7.2.4 Servo steering unit, diagnostics.......................................102 7.2.5 Trouble shooting.......................................................103 7.3 Steering control.............................................................104 7.3.1 Check tachometer.......................................................104 7.3.2 Replacing the tachometer...............................................104 7.4 Steering servo motor.........................................................106 7.4.1 Steering servo motor, replacing carbon brushes.........................106 7.4.2 Replacing the steering servo motor.....................................106 08.......................................................................................109 8 Hydraulic system...................................................................109 8.1 Introduction.................................................................111 8.2 Replacement of the hydraulic filter..........................................112 8.3 Draining the tank............................................................113 8.3.1 Checking the hydraulic oil level.......................................114 8.4 Hose rupture valve...........................................................115 8.4.1 Hose rupture valve, dismantling and assembling.........................115 8.4.2 Setting the hose rupture valve.........................................116 8.5 Hydraulic valve, general.....................................................117 8.5.1 Functional description, hydraulic valve................................117 8.5.2 Function of the coils..................................................118 8.5.3 Checking the lowering speed............................................119 8.5.4 Adjusting the lifting-lowering function from OP- 1429..................119 8.5.5 Adjusting the regulator, electric valve to OP-1429.....................120 8.5.6 Adjusting the hydraulic lowering speed valve in the hydraulic valve....122 8.5.7 Adjusting the working pressure.........................................122 8.6 Lift motor...................................................................123 8.6.1 Dismantling of the lift motor OPH, OPS, OPC............................123 8.6.2 Dismantling the lift motor OPM.........................................125 8.7 Checking the lift motor OPH..................................................127 8.8 Hydraulic diagram............................................................127 09.......................................................................................131 9 Lift cylinders.....................................................................131 9.1 Dismantling and assembling...................................................133 9.2 Dismantling and assembling...................................................134 9.2.1 Adjusting the lift cylinders...........................................134 10.......................................................................................135 10 Electrical system.................................................................135 10.1 Safety procedures...........................................................139 10.2 Battery maintenance.........................................................140 10.2.1 Truck driver’s responsibility.........................................140 10.2.2 Foreman’s responsibility..............................................140 10.2.3 Checking of the battery fluid.........................................140 10.3 Drive motor.................................................................141 10.4 Electrical panel............................................................142 10.4.1 Front of the electrical panel.........................................142 10.4.2 Back of the electrical panel..........................................143 10.5 Switches and sensors........................................................144 10.5.1 Replacing the 1.2 metre switch........................................144 10.5.2 Replacing the magnet switch...........................................145 10.5.3 Replacing the gate contact switch.....................................145 10.5.4 Optical aisle sensor, rail guidance...................................146 10.6 Transistor system Curtis 1243...............................................147 10.6.1 Technical description.................................................147 10.6.2 Hand terminal.........................................................150 10.6.3 Special program.......................................................152 10.6.4 Special Diagnostics...................................................152 10.6.5 Programming...........................................................152 10.6.6 Adjustment instructions...............................................153 10.6.7 Function and Installation checking....................................157 10.6.8 Trouble shooting by means of LED......................................159 10.6.9 Trouble shooting by means of Test menu................................161 10.6.10 Specifications.......................................................162 10.7 Regulator, electric valve...................................................163 10.8 Wiring diagram..............................................................164 11.......................................................................................165 11 Speed control and brake systems...................................................165 11.1 Control lever...............................................................167 11.1.1 Replacing the speed controller........................................167 11.1.2 Replacing the lifting/lowering switch.................................168 11.1.3 Replacing the green button............................................168 11.1 Electric brake..............................................................169 11.1.1 Electric brake 1 stage, 1 disc........................................169 11.2 Adjusting the electric brake................................................171
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PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.V