SERVICE MANUAL

Machine: X-90
Manual No: 005872
Edition: 2003B

The content in the manual is protected by the Copyright Act and may not be copied either in full or part
without written approval. The material has undergone carefull review with regards to its correctness.
We reserve the right to make alterations.
In the event of conflict between the Swedish and English edition, the Swedish edition will take
precedence.
Modifications and updates will be distributed via ATLET AB Service Manual Change.

Approved 2003-08-14:

Bo Tranefors
After Sales Support

Ola Möller
Technical Documentation

ATLET SERVICE MANUAL X-90

 Table of Contents
Side 2

Edition 2003B

1 General information and technical data

Introduction ......................................................................................................................1.1
General information X-90 series ..........................................................................1.1
How to use the manual....................................................................................................1.2
Symbol key ...........................................................................................................1.2
Tips before next step .......................................................................................................1.3
Lifting points .........................................................................................................1.3
Safety risks when working on fork trucks .............................................................1.4
Environmentally hazardous waste – environment ................................................1.4
Handling ...............................................................................................................1.5
Trouble shooting ...................................................................................................1.5
Type designations............................................................................................................1.6
Dimensions and weights ...............................................................................................1.10
Dimensions XJN / XSN .....................................................................................1.10
Dimensions XML ................................................................................................1.11
Dimensions XLL .................................................................................................1.12
Dimensions XTF .................................................................................................1.13
Component specification ..............................................................................................1.14
Tightening torque .........................................................................................................1.17
Conversion table ................................................................................................1.18
Bolt types and tensile grades .............................................................................1.19
Lubrication chart and recommended intervals...........................................................1.20
Lubrication chart XJN / XSN / XML ...................................................................1.20
Lubrication chart XTF .........................................................................................1.22
Lubrication chart XLL .........................................................................................1.24
Symbol explanations, lubrication chart ...............................................................1.25
Recommended oil and grease types ..................................................................1.26
Recommended replacement ..............................................................................1.26
Colour codes and technical descriptions....................................................................1.27
Colour of the truck in accordance with NCS colour codes .................................1.27
Colour codes for Atlet wiring diagrams ..............................................................1.27
Designations for electrical components .............................................................1.28
Technical abbreviations ......................................................................................1.29

ATLET SERVICE MANUAL X-90

 Table of Contents
Side 3

Edition 2002A

2 Special tools
List of tools ...................................................................................................................... 2.1

Edition 2002A

3 Service
Introduction ..................................................................................................................... 3.1
Service inspection list .................................................................................................... 3.2
Chassis ................................................................................................................ 3.2
Drive unit ............................................................................................................. 3.3
Mast ..................................................................................................................... 3.4
Steering ............................................................................................................... 3.5
Brake ................................................................................................................... 3.5
Hydraulic system ................................................................................................. 3.6
Electrical system .................................................................................................. 3.7
Code explanations .......................................................................................................... 3.8
Chassis ................................................................................................................ 3.8
Mast ..................................................................................................................... 3.9
Drive unit ............................................................................................................. 3.9
Steering ............................................................................................................. 3.10
Brake unit .......................................................................................................... 3.10
Hydraulic system ............................................................................................... 3.11
Electrical system ................................................................................................ 3.12

ATLET SERVICE MANUAL X-90

 Table of Contents
Side 4

Edition 2002A

4 Chassis
Introduction ......................................................................................................................4.1
Machine cover ......................................................................................................4.1
Tightening torque .................................................................................................4.2
Overhead guard ...................................................................................................4.3
Panels ..................................................................................................................4.3
Castor wheel.....................................................................................................................4.4
Description ...........................................................................................................4.4
Dismantling ..........................................................................................................4.4
Dismantling ..........................................................................................................4.5
Assembly ..............................................................................................................4.5
Adjusting the angle of the truck ............................................................................4.6
Driver’s seat .....................................................................................................................4.7
Description ...........................................................................................................4.7
Settings ................................................................................................................4.7
Replacing the battery rollers ..........................................................................................4.9
Replacing the load wheel, bogie wheel .......................................................................4.10
Dismantling ........................................................................................................4.10
Assembly ............................................................................................................4.10
Replacing the load wheel, single wheel.......................................................................4.11
Dismantling ........................................................................................................4.11
Assembly ............................................................................................................ 4.11

ATLET SERVICE MANUAL X-90

 Table of Contents
Side 5

Edition 2002A

5 Drive unit
Introduction ..................................................................................................................... 5.1
Dismantling and assembling the drive unit .................................................................. 5.2
Gearbox............................................................................................................................ 5.5
First service ......................................................................................................... 5.5
Preventive maintenance ...................................................................................... 5.5
Drive motor, general instructions .................................................................................. 5.6
Storage of machines and motors ......................................................................... 5.6
First service ......................................................................................................... 5.6
Preventive maintenance ...................................................................................... 5.6
Dismantling, assembling the motor ..................................................................... 5.7
Reconditioning the motor............................................................................................... 5.8
Series motor, older type, used together with MOS-90 ......................................... 5.8
Separate field-magnetised motor, new type, used together with Sepex. ........... 5.10
Motor bearings ................................................................................................... 5.12
Brush holders .................................................................................................... 5.12
Overhaul of commutator and replacing the carbon brushes .............................. 5.12
Stator housing .................................................................................................... 5.14
Assembly ........................................................................................................... 5.14
Reasons for burned motors: .............................................................................. 5.14
Trouble shooting chart ................................................................................................. 5.15

ATLET SERVICE MANUAL X-90

 Table of Contents
Side 6

Edition 2003B

6 Mast
Introduction ......................................................................................................................6.1
General ................................................................................................................6.1
Fork creep.........................................................................................................................6.2
All trucks with masts. ............................................................................................6.2
Dismantling and assembling the masts ........................................................................6.2
General ................................................................................................................6.2
Assembling, dismantling older models .................................................................6.2
Assembling, dismantling new models ..................................................................6.2
Mast system older models ..............................................................................................6.3
Adjusting the brass lugs .......................................................................................6.3
Adjusting the mast top ..........................................................................................6.3
Dismantling the DTFV mast .................................................................................6.4
Dismantling the TFV mast ....................................................................................6.6
Dismantling the TV mast ......................................................................................6.8
Dismantling the DT mast ....................................................................................6.10
Dismantling the T mast ......................................................................................6.12
Mast system new model................................................................................................6.14
Adjusting the mast ..............................................................................................6.14
Dismantling the DTFV mast ...............................................................................6.14
Dismantling TFV mast, new model ....................................................................6.16
Dismantling TV mast, new model .......................................................................6.18
Dismantling T mast, new model .........................................................................6.20
Fork carriage ..................................................................................................................6.22
Adjusting, older models ......................................................................................6.22
Adjusting, new models .......................................................................................6.23
Dismantling ........................................................................................................6.23
Dismantling the fork carriage XTF ......................................................................6.24
Assembling the fork carriage XTF ......................................................................6.26
Checking the fork carriage XTF truck .................................................................6.26
Overload clutch ..................................................................................................6.27
Forks ...............................................................................................................................6.28
Adjusting forged forks ........................................................................................6.28
Adjusting welded forks .......................................................................................6.28
Fork test .............................................................................................................6.29
Checking the lift chains.................................................................................................6.31

ATLET SERVICE MANUAL X-90

 Table of Contents
Side 7

Regular maintenance ........................................................................................ 6.32

Re-fitting the chains ........................................................................................... 6.32
Straddle lift..................................................................................................................... 6.33
Adjusting (=>2002w49) ...................................................................................... 6.33
Dismantling and adjusting, TV, TFV, DTFV (=>2002w49) ................................. 6.34
Straddle lift (2002w50=>) ................................................................................... 6.36
Side stabilisers .............................................................................................................. 6.37
Dismantling and assembling (=>2002w45) ....................................................... 6.37
Assembling (=>2002w45) .................................................................................. 6.38
Checking the side stabiliser (=>2002w45) ......................................................... 6.39
Adjusting the side stabilisers (=>2002w45) ....................................................... 6.39
Side stabilisers (2002w46=>) ............................................................................ 6.40
Push rods....................................................................................................................... 6.41
Adjusting XLL .................................................................................................... 6.41
Lift cylinders .................................................................................................................. 6.43
Adjusting the cylinder attachment in the mast, older version ............................ 6.43
Adjusting cylinder attachment, newer version ................................................... 6.44
Trouble shooting chart ................................................................................................. 6.45

ATLET SERVICE MANUAL X-90

 Table of Contents
Side 8

Edition 2002A

7 Steering
Introduction ......................................................................................................................7.1
Mechanical steering.........................................................................................................7.1
Main shaft, general ...............................................................................................7.1
Steering column, dismantling and assembling .....................................................7.1
Steering chain steering column – intermediate gear, dismantling ........................7.3
Steering chain intermediate gear – drive unit, dismantling ...................................7.3
Steering chains, assembly ...................................................................................7.3
Intermediate gear, dismantling .............................................................................7.4
Intermediate gear, assembly ................................................................................7.4
Mechanical steering with auxiliary servo (Keltronic) ...................................................7.5
Servo motor, dismantling ......................................................................................7.5
Replacing the carbon brushes .............................................................................7.6
Servo sensor, general ..........................................................................................7.6
Servo sensor, inspection and trouble shooting ....................................................7.6
Servo sensor, measurement check ......................................................................7.7
Control unit, general .............................................................................................7.8
Control unit, settings ..........................................................................................7.10
Control unit, check .............................................................................................7.11
Electronic steering (ACC) .............................................................................................7.13
Servo steering unit, functions .............................................................................7.13
Servo steering unit, settings ...............................................................................7.14
Factory setting, electric steering ........................................................................7.16
Servo steering unit, diagnostics .........................................................................7.16
Trouble shooting .................................................................................................7.17
Check tachometer ..............................................................................................7.18
Servo motor, replacing carbon brushes .............................................................7.19

ATLET SERVICE MANUAL X-90

 Table of Contents
Side 9

Edition 2002A

8 Hydraulic system
Functional description.................................................................................................... 8.1
Introduction .......................................................................................................... 8.1
XSN / XJN / XML / XTF trucks ............................................................................. 8.1
XLL truck ............................................................................................................. 8.3
Hydraulic system – general regulations ....................................................................... 8.4
Installation ........................................................................................................... 8.4
Connections ......................................................................................................... 8.4
Start up ................................................................................................................ 8.4
Installation instruction for pipe couplings ............................................................. 8.5
Hydraulic oil, changing/draining ........................................................................... 8.8
Oil change ........................................................................................................................ 8.9
XSN / XJN / XML / XTF trucks ............................................................................ 8.9
XLL truck ............................................................................................................. 8.9
Air filter, replacing......................................................................................................... 8.10
XSN / XJN / XML / XTF trucks ........................................................................... 8.10
XLL truck ........................................................................................................... 8.10
Filter insert, replacing................................................................................................... 8.11
XSN / XJN / XML / XTF trucks ........................................................................... 8.11
Hydraulic unit XLL truck ............................................................................................... 8.12
Hydraulic unit XLL, dismantling ......................................................................... 8.12
Motor for hydraulic unit XLL, dismantling and assembling ................................ 8.12
Repair of lift motor and replacement of carbon brushes, XLL truck ................... 8.13
Lowering valve, dismantling and assembling .................................................... 8.13
Overflow valve, adjusting ................................................................................... 8.13
Valves, XSN / XJN / XML / XTF ..................................................................................... 8.14
Lowering brake valve, general ........................................................................... 8.14
Lowering brake valve, dismantling and assembling .......................................... 8.14
Setting the lowering brake valve ....................................................................... 8.15
Hose rupture valve, general .............................................................................. 8.16
Hose rupture valve, dismantling and assembling .............................................. 8.16
Setting the hose rupture valve ........................................................................... 8.17
Hydraulic valve, general ............................................................................................... 8.18
Hydraulic valve, dismantling and assembling .................................................... 8.18
Hyrdaulic motor XJN / XJN........................................................................................... 8.20
Dismantling ........................................................................................................ 8.20

ATLET SERVICE MANUAL X-90

 Table of Contents
Side 10

Stabiliser cylinders XSN / XJN......................................................................................8.22

Dismantling and assembling ..............................................................................8.22
Spring unit, dismantling and assembling ............................................................8.23
Dismantling and assembling, seals ....................................................................8.24
Hydraulic diagram..........................................................................................................8.25

ATLET SERVICE MANUAL X-90

 Table of Contents
Side 11

Edition 2002A

9 Lift cylinders
Introduction ..................................................................................................................... 9.1
Free-lift cylinder TFV / DTFV older model ..................................................................... 9.2
Dismantling and assembling ................................................................................ 9.2
Dismantling and assembling to: W-9638 ............................................................. 9.2
Dismantling and assembling from: W-9639 ......................................................... 9.4
Free-lift cylinder TFV / DTFV new model....................................................................... 9.6
Dismantling and assembling ................................................................................ 9.6
Dismantling and assembling ................................................................................ 9.6
Lift cylinder TV/ TFV/ DTFV older model ...................................................................... 9.8
Dismantling and assembling ................................................................................ 9.8
Dismantling and assembling to: W-9638 ............................................................. 9.9
Dismantling and assembling from: W-9638 ....................................................... 9.10
Lift cylinder TV/ TFV/ DTFV new model...................................................................... 9.12
Dismantling and assembling .............................................................................. 9.12
Dismantling and assembling .............................................................................. 9.14
Lift cylinder 100 DT / 125 DT to: W-9638 ..................................................................... 9.15
Dismantling and assembling .............................................................................. 9.15
Dismantling and assembling .............................................................................. 9.17
Lift cylinder 100 DT / 125 DT from: W-9639................................................................. 9.18
Dismantling and assembling .............................................................................. 9.18
Dismantling and assembling .............................................................................. 9.18
Lift cylinder 100 T / 125 T.............................................................................................. 9.20
Dismantling and assembling .............................................................................. 9.20
Dismantling and assembling .............................................................................. 9.21
Lift cylinder 160 T new model ...................................................................................... 9.22
Dismantling and assembling .............................................................................. 9.22
Dismantling and assembling .............................................................................. 9.22
Lift cylinder, straddle lift ............................................................................................... 9.24
Dismantling and assembling, (P/N 057869) ...................................................... 9.24
Dismantling and assembling .............................................................................. 9.24
Dismantling and assembling, (P/N 060061) ...................................................... 9.26
Dismantling and assembling .............................................................................. 9.26
Lift cylinders XLL .......................................................................................................... 9.28
Dismantling and assembling .............................................................................. 9.28
Dismantling and assembling .............................................................................. 9.28

ATLET SERVICE MANUAL X-90

 Table of Contents
Side 12

Bleeding the cylinders...................................................................................................9.30

Bleeding TV/ TFV/ DTFV to: W-9638 .................................................................9.30
Bleeding models from: W-9639 ..........................................................................9.30

ATLET SERVICE MANUAL X-90

 Table of Contents
Side 13

Edition 2003B

10 Electrical system
Introduction ................................................................................................................... 10.1
Safety procedures ......................................................................................................... 10.2
Routine test of the insulation resistance .................................................................... 10.3
Introduction ........................................................................................................ 10.3
Routines for insulation testing of all truck models. ............................................ 10.3
Insulation test of a newly charged battery mounted in the truck: ....................... 10.3
Battery maintenance ..................................................................................................... 10.4
Truck driver’s responsibility ............................................................................... 10.4
Foreman’s responsibility .................................................................................... 10.4
Checking of the battery fluid .............................................................................. 10.4
Drive motor .................................................................................................................... 10.5
Dismantling and assembling .............................................................................. 10.5
Replacing the drive motor cable ........................................................................ 10.5
Fork drive motor, XTF truck ......................................................................................... 10.6
Dismantling and assembling .............................................................................. 10.6
Replacing the carbon brushes ........................................................................... 10.6
Replacing the coupling between motor and gear. ............................................. 10.6
Electric cable to fork drive motor, replacing ....................................................... 10.6
Speed controller to machine number X14000 (MOS 90) ............................................ 10.8
Description ......................................................................................................... 10.8
Dismantling of speed controller ......................................................................... 10.8
Microswitches, complete check ......................................................................... 10.8
Microswitches, simple check ............................................................................. 10.9
Microswitches, replacing ................................................................................... 10.9
Speed controller, adjusting .............................................................................. 10.10
Thottle, replacing ............................................................................................. 10.11
Speed control, complete check ........................................................................ 10.11
Speed control, simple check ............................................................................ 10.11
Speed controller from machine number X14000 (SEPEX) ...................................... 10.12
Description ....................................................................................................... 10.12
Dismantling of speed controller ....................................................................... 10.12
Speed controller, adjusting .............................................................................. 10.12
Drive regulator............................................................................................................. 10.14
Dismantling, assembling the drive regulator .................................................... 10.14
Drive regulator MOS 90............................................................................................... 10.15
Safety procedures ........................................................................................... 10.15

ATLET SERVICE MANUAL X-90

 Table of Contents
Side 14

Checking the failsafe system, drive regulator ..................................................10.16

Settings, drive regulator ...................................................................................10.16
Settings for checking/fault finding of drive regulator ........................................10.18
Input status, drive regulator ..............................................................................10.19
Trouble shooting chart, drive regulator .............................................................10.20
Connections and voltage values ......................................................................10.30
Drive regulator Curtis/Sepex 1243 version 4324.......................................................10.31
Introduction ......................................................................................................10.31
General description ..........................................................................................10.31
Technical description ........................................................................................10.31
Hand terminal ...................................................................................................10.33
Special program ...............................................................................................10.35
Adjusting instructions .......................................................................................10.35
Factory settings ................................................................................................10.36
Possibility of separate adjustments: .................................................................10.40
Parameter selection M1 - M4 ...........................................................................10.40
Function and Installation checking ............................................................................10.41
Trouble shooting by means of LED: .................................................................10.42
Trouble shooting by means of Test menu ........................................................10.44
Brake function ..................................................................................................10.45
Left foot switch .................................................................................................10.45
Specifications ...................................................................................................10.45
Side stabilisers.............................................................................................................10.46
Adjusting ..........................................................................................................10.47
Wiring diagram .............................................................................................................10.48

ATLET SERVICE MANUAL X-90

 Table of Contents
Side 15

Edition 2002A

11 Brake system
Brake system to machine number X 14000 ................................................................ 11.1
Description ......................................................................................................... 11.1
Brake unit .......................................................................................................... 11.3
Brake drum ........................................................................................................ 11.3
Brake shoes, replacing ...................................................................................... 11.4
Dismantling, older version ................................................................................. 11.4
Dismantling, new version ................................................................................... 11.4
Master cylinder .................................................................................................. 11.6
Brake cylinder .................................................................................................... 11.6
Brake fluid and bleeding .................................................................................... 11.7
Hand brake wire, replacing on older version with wire through brake shoes .... 11.7
Hand brake wire, replacing on new versions with wire that stops at the brake shoes
11.8
Adjusting of the brake pedal’s push rod and height ........................................... 11.8
Adjusting the brake, older version ................................................................... 11.10
Adjusting the brake, new version ......................................................................11.11
Adjusting the foot brake ................................................................................... 11.12
Emergency brake system ................................................................................ 11.12
Hydraulic unit, emergency brake to W 9640 .................................................... 11.12
Hydraulic unit, emergency brake from W 9640 ............................................... 11.13
Pressure switch, version to W 9640 ................................................................ 11.14
Pressure switch, version from W 9640 to W 9735 ........................................... 11.14
Pressure switch version from W9735 for X 14000 .......................................... 11.15
Adjusting the spring brake cylinder .................................................................. 11.15
Trouble shooting chart, hydraulic unit .............................................................. 11.16
Brake system from machine number X 14000 .......................................................... 11.17
Description ....................................................................................................... 11.17
Dismantling/assembling, brake pedal .............................................................. 11.18
Electric brake 1 stage, 1 disc ........................................................................... 11.18
Dismantling/assembling, electric brake ........................................................... 11.18
Adjusting the electric brake ............................................................................. 11.20
Left-foot switch............................................................................................................ 11.21
Dismantling, assembling the left-foot switch .................................................... 11.21
Adjusting the left-foot switch ............................................................................ 11.21
Preventive maintenance .................................................................................. 11.21

ATLET SERVICE MANUAL X-90

 Table of Contents
Side 16

ATLET SERVICE MANUAL X-90

 SERVICE MANUAL

Machine: X-90

Manual nr: 005872

Edition 2003B
General information and technical data

1.1 Introduction................................................................................................................... 1.1

1.1.1 General information X-90 series ...................................................................................1.1

1.2 How to use the manual ................................................................................................ 1.2

1.2.2 Symbol key ...................................................................................................................1.2

1.3 Tips before next step ................................................................................................... 1.3

1.3.1 Lifting points .................................................................................................................1.3
1.3.2 Safety risks when working on fork trucks ....................................................................1.4
1.3.3 Environmentally hazardous waste – environment ........................................................1.4
1.3.4 Handling ........................................................................................................................1.5
1.3.5 Trouble shooting ...........................................................................................................1.5

1.4 Type designations ........................................................................................................ 1.6

1.5 Dimensions and weights ........................................................................................... 1.10

1.5.1 Dimensions XJN / XSN .............................................................................................1.10
1.5.2 Dimensions XML .......................................................................................................1.11
1.5.3 Dimensions XLL .........................................................................................................1.12
1.5.4 Dimensions XTF .........................................................................................................1.13

1.6 Component specification........................................................................................... 1.14

1.7 Tightening torque ...................................................................................................... 1.17

1.7.1 Conversion table .........................................................................................................1.18
1.7.2 Bolt types and tensile grades ......................................................................................1.19

ATLET SERVICE MANUAL X-90

ATLET SERVICE MANUAL X-90
1.8 Lubrication chart and recommended intervals ....................................................... 1.20
1.8.1 Lubrication chart XJN / XSN / XML ........................................................................ 1.20
1.8.2 Lubrication chart XTF ................................................................................................ 1.22
1.8.3 Lubrication chart XLL ................................................................................................ 1.24
1.8.4 Symbol explanations, lubrication chart ...................................................................... 1.25
1.8.5 Recommended oil and grease types ............................................................................ 1.26
1.8.1 Recommended replacement ........................................................................................ 1.26

1.9 Colour codes and technical descriptions ................................................................ 1.27

1.9.2 Colour of the truck in accordance with NCS colour codes ........................................ 1.27
1.9.1 Colour codes for Atlet wiring diagrams ..................................................................... 1.27
1.9.2 Designations for electrical components ...................................................................... 1.28
1.9.3 Technical abbreviations .............................................................................................. 1.29

ATLET SERVICE MANUAL X-90

ATLET SERVICE MANUAL X-90
 General information and technical data 1.1

Edition 2003B

1 General information and technical data

00000000

1.1 Introduction
This manual describes the service procedures for ATLET Sit-on stackers in the X-
90 series. Use the manual for quick and correct service of respective truck models.

Warning!
If the truck is rebuilt after delivery or supplemented in such a manner that
safety may be affected, ATLET AB or its authorised representative should be
contacted.
The electrical system must never be rewired in any form after delivery without
written authorisation from ATLET AB, since this may change the measured and
applicable EMC.
The content of this service 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. We reserve the right to make
alterations. In the event of inconsistent information in the Swedish and translated
editions, it is the Swedish edition that applies.
Amendments and updates will be distributed by ATLET AB to subscribers.
0Truck model modifications and updates will be distributed via AT LET AB Service Man ual Change to ensur e rap id and corr ect service.

1.1.1 General information X-90 series

Quality, flexibility and operating safety are three absolute requirements for
intensive and cost-effective materials handling. What characterises the Sit-on
stacker “X-90” is its small size, large capacity and first-rate economy, and it ensures
satisfactory comfort during long transportation routes.
The truck has been developed with the driver’s working environment in focus. This
has given the machine very good ergonomics.
The Sit-on stacker is mainly intended to handle loads of 1.6-2 tons up to lifting
heights of 6 metres, and for driving distances of up to 50m.
Service-friendliness has been an important aspect of the development work, where
these solutions have now reduced the time consumed for service and repair work.
Since Atlet products are continuously improved, customised or introduced in
special versions, some variants may not be included in this manual. In which case
they will be included in the next update. Important information will be distributed
via Parts & Service News between updates.

Introduction ATLET SERVICE MANUAL

1.2 General information and technical data

1.2 How to use the manual

The manual is arranged according to the same principles as ATLET 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, Masts (section 6)
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.

1.2.2 Symbol key

Warning!
Used with risk of personal injury.

Important!
Used with risk of damage to machine.

 Note!
Used for general observation.

ATLET SERVICE MANUAL How to use the manual

 General information and technical data 1.3

1.3 Tips before next step

0

1.3.1 Lifting points

[Link]

Figure 1.1 Lifting points

figure 1.1 shows where the permitted lifting points are placed on the truck. Lifting
points B and D are marked with decals representing a lifting hook. The lifting holes
in the outer mast (point A) should be used when lifting masts or machines with free-
view masts.
The lifting strap is placed round the upper mast strut (point C) when lifting other
machines with mast type T, DT.
The lifting point (point B) underneath the component box should be used when
lifting the complete XLL machine.
Lifting point for jack (point D).

Warning!
The machine must never be lifted from the overhead guard.

Tips before next step ATLET SERVICE MANUAL

1.4 General information and technical data

1.3.2 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.
• Tools must never be placed on the battery.
The drive wheel should always be lifted up free from the floor during service work
to prevent the vehicle from moving. The vehicle must not rest solely on the jack, but
must be secured by some form of blocking.
Ensure that straps, wires or chains have a sufficient lifting capacity before lifting the
truck.
To prevent injuries caused by crushing when working on electric trucks, the battery
plug should always be pulled out when working on and around the mast and
hydraulic unit. The mast or hydraulic unit can be actuated due to an electrical fault
or a 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).
When working on and around the mast and hydraulic unit, they must be locked by
using the mast lock, wooden blocks or some other appropriate means.
No other persons should be in the vicinity of the truck when it is test run in
conjunction with repair work, in view of the risk of accidents or near-accidents
caused by the truck making an unexpected manoeuvre.
The system should not be pressurised, e.g. the pump motor shut off and the forks
down, when dismantling parts of the hydraulic system.
All metal objects such as watches and rings should be removed when working on
the electrical system, or in its immediate vicinity. A short-circuit from such objects
can result in serious burn injuries.

1.3.3 Environmentally hazardous waste – environment

Atlet AB takes care of the environment. Waste material in conjunction with repairs,
maintenance, cleaning, or scrapping, should be collected and disposed of in an
environment-friendly way and in accordance with the directives of respective
countries. Such work must only be carried out in areas intended for this purpose.
Environmentally hazardous waste, such as oil filters, batteries, hydraulic hoses and
electronics, can have a negative effect on the environment, or health, if handled
incorrectly. Recyclable material should be taken care of by specialised authorities.

ATLET SERVICE MANUAL Tips before next step

 General information and technical data 1.5

1.3.4 Handling
Make sure that you have all the essential tools close at hand before starting work.
Before cabling or other electrical components are disconnected, check the colour
codes and check for damage to cables or connections.
When complex components are repaired and dismantled, make sure that you have
good control of the different component parts to avoid the risk of confusion.
When repairing or maintaining sensitive components, make sure that you use clean
tools and work on a clean work surface.
Dismantle, inspect and adjust components according to the prescribed routines. See
respective sections for detailed information.
Make sure that gaskets and O-rings, etc. are replaced with new parts each time they
are dismantled.
Use the screws and bolts specified in the spare parts catalogue. Tighten according
to instructions. In those cases where the tightening torque is not stated, refer to the
table of standard tightening torques, section1.7.
Always use ATLET original spare parts to improve operational reliability and
compliance with the warranty.

1.3.5 Trouble shooting

A large number of components are often replaced even though they are in good
condition. This leads to unnecessarily high maintenance costs.
Take this into consideration when you suspect a faulty component, and do not
replace it immediately. First check the surrounding equipment and carry out
complete trouble shooting routines. Make sure you know the reason for the fault
before replacing a component.

Tips before next step ATLET SERVICE MANUAL

1.6 General information and technical data

1.4 Type designations

Table 1.1
Truck type X Junior, Senior

XTF Junior, Senior

XML Junior, Senior

XLL Junior, Senior

Designations X Standard

XTF Telescopic forks

XML Medium lift

XLL Low lift

JN Junior

SN Senior

Load capacity X 1250, 1600, 2000 kg

XTF 1000 kg

XML 1600, 2500 kg

XLL 2000 kg

Frame type XJN 1250 ST, SDT, SDT-S, STV, STFV,

SDTFV, STV-S, STFV-S,
SDTFV-S, STV-H, STFV-H,
SDTFV-H, BTV, BTFV,
BDTFV.

XSN 1250 ST, SDT, SDT-S, STV, STFV,

SDTFV, STV-S, STFV-S,
SDTFV-S, STV-H, STFV-H,
SDTFV-H, BTV, BTFV,
BDTFV.

XSN 2000 STV, STFV, SDTFV, STV-S,

SDTFV-S, STV-H, STFV-H,
SDTFV-H, BTV, BTFV,
BDTFV.

XTF/JN 1000 T, TFV, DT, DTFV

XTF/SN 1000 T, TFV, DT, DTFV

XML/JN 1600 ST

XML/SN 1600 ST, ST-H

XML/SN 2500 ST

Battery size Min Junior 230 Ah, Senior 385 Ah

Max Junior 370 Ah, Senior 540 Ah

ATLET SERVICE MANUAL Type designations

 General information and technical data 1.7

Type designations (example):

125 STV S 360 / 225 / 40 / ... ...

Load capacity/10

Narrow track S
Wide track B

Telescopic mast T
Telescopic free lift mast TF
Dual telescopic mast DT
Dual telescopic free lift mast DTF

Free visibility mast   V

Stabilisers S
Adjustable straddle legs H

Lifting height in cm
Battery Ah/5
Battery charger Ampere
Model type XJN, XSN, XTF, XML, XLL
XJN = Junior     XSN = Senior
SM 023.1e

Figure 1.2 Type designation

Type designations ATLET SERVICE MANUAL

1.8 General information and technical data

ATLET AB MÖLNLYCKE SWEDEN

MODELL
MODEL 1
MODELL
MODELE

SERIE NR.
SERIAL NO. 2
SERIEN NR.
NOMERO DESERIE

TILLV. ÅR
YEAR OF MANUF. 3
BAUJAHR
AN DE FABR

TILLÅTEN LAST
ACTUAL CAPACITY
Q WIRKLICHE TRAGFÄHIGKEIT
CAPACITE EFFECTIVE

D
H
TYNGDPUNKTSAVSTÅND LYFTHÖJD
LOAD CENTRE DISTANCE LIFTHEIGHT
LASTSCHWERPUNKT HUBHÖHE
DISTANCE DE CENTRE
HAUTEUR DE LEVEE

H MM D MM Q KG

BATTERISPÄNNING VOLT-DC
BATTERY VOLTAGE
BATTERIESPANNUNG
TENSION DE LA BATTERIE

VIKT UTAN BATTERI KG

WEIGHT WITHOUT BATTERY
GEWICHT OHNE BATTERIE
MASSE SANS BATTERIE

MINSTA BATTERIVIKT
KG
MINIMUM BATTERY WEIGHT
MINDESTGEWICHT DER BATTERIE
MASSE MINIMAL DE LA BATTERIE

MAXIMAL BATTERIVIKT KG
MAXIMUM BATTERY WEIGHT
HÖCHSTGEWICHT DER BATTERIE
MASSE MAXIMAL DE LA BATTERIE

pA 73.4

Figure 1.3 Type designation

1. Type designation.
2. Serial numbers from and including serial number 20001 are also specified in
the version issue.
3. Year of manufacture, week, and warranty period in months (only Sweden).

ATLET SERVICE MANUAL Type designations

 General information and technical data 1.9

SM 024.1

Figure 1.4 The serial number is stamped on the left side of the mast,
see arrow (XLL: left side on back of fork carriage).

Type designations ATLET SERVICE MANUAL

1.10 General information and technical data

1.5 Dimensions and weights

0

1.5.1 Dimensions XJN / XSN

H6

H4
H3
H5
900
375

H2
H1
L2
L3
L4 L1
L

R2
B1
S
B

OK 351

Figure 1.5 XJN / XSN

ATLET SERVICE MANUAL Dimensions and weights

 General information and technical data 1.11

1.5.2 Dimensions XML

H6

H3
H4
H5
900
375

H1
L2
L3
L4 L1
L

R2

B1
B

OK 354

Figure 1.6 XML

Dimensions and weights ATLET SERVICE MANUAL

1.12 General information and technical data

1.5.3 Dimensions XLL

900
375

H4
H1
L2
L3
L4 L1
L

R2

B1
B

OK 355

Figure 1.7 XLL

ATLET SERVICE MANUAL Dimensions and weights

 General information and technical data 1.13

1.5.4 Dimensions XTF

H6

H4
H3
H5
900
375

H2
H1
H7
L2
L3
L4 L1
L

R2

B1

B2
V
B

U L1

OK 353

Figure 1.8 XTF

Dimensions and weights ATLET SERVICE MANUAL

1.14 General information and technical data

1.6 Component specification

Table 1.2 Drive motor

Drive motor
(See also section 5, Drive motor)

Manufacture Bosch / Iskra

Output 2,0 kW

Table 1.3 Gearbox

Gearbox
(See also section 5, Gearbox)

Manufacture Atlet

Gear ratio (standard) 17,4:1

Oil volume 0,75 litres

Table 1.4 Hydraulic unit XSN / XJN / XML / XTF

Hydraul unit (motor and pump) XSN / XJN / XML / XTF
(See also section 8, Hydraulic unit)

Manufacture Bosch

Output 3,0 kW

Flow at:
15 Mpa 13 litres/min
10 Mpa 16 litres/min

Tank volume 23 litres

Table 1.5 Hydraulic unit XLL

Hydraulic unit (motor and pump) XLL
(See also section 8, Hydraulic unit)

Manufacture Smith

Output 2,0 kW

Max pressure 150 bar

Flow at:
15 Mpa 4,9 litres
10 Mpa 6,1 litres

Tank volume 0,6 litres

ATLET SERVICE MANUAL Component specification

 General information and technical data 1.15

Table 1.6
Control system for motor

Manufacture Sevcon Curtis

Type Transistor MOS-90 1243 Sepex

Voltage 24 24 V

Table 1.7
Battery

Voltage 24 V

Capacity range JN: 230-370 Ah

SN: 385-540

Table 1.8
Steering servo unit Keltronic

Manufacture Keltronic

Voltage 24 V

Tolerance +20% / - 30% V

Current capacity Peak 50A cont. 30A A

Table 1.9
Servo motor X-90

Manufacture Schabmüller

Voltage 24 V

Output 400 W

Nominal current 25 A

Component specification ATLET SERVICE MANUAL

1.16 General information and technical data

Table 1.10
Steering servo unit ACC (*)

Manufacture Atlas Copco Fly By Wire

Control

Voltage 24 V

Tolerance 16-30 V

Switch frequency 16 kHz

Current capacity 30 A

Table 1.11
Servo motor ACC (*) X-90

Manufacture MET

Voltage 24 V

Output 240 W

Torque 0,78 Nm

Nominal current 12,3 A

Resistance 0,123 Ohm

Table 1.12
Fuses

Control fuses 2 pcs. 8 A

Pump motor fuse 1 250 A

pcs.

Drive motor fuse 150 / 160 A

1 pcs

Servo motor fuse 1 25 A

pcs, ACC *

Servo motor fuse 1 35 A

pcs, Keltronic

Telescopic Forks 30 A
(XTF)

* = Atlas Copco Controls

ATLET SERVICE MANUAL Component specification

 General information and technical data 1.17

1.7 Tightening torque

0

Table 1.13 Tightening torque, through hole

DIM Tensile grade

4,6 8,8 10,9 12,9

Nm Nm Nm Nm

M4 1,1 2,9 4,0 4,9

M5 2,2 5,7 8,1 9,7

M6 3,7 9,8 14 17

M8 8,9 24 33 40

M10 17 47 65 79

M12 30 81 114 136

M14 48 128 181 217

M16 74 197 277 333

M18 103 275 386 463

M20 144 385 541 649

The tightening torque in the table above are standard values. In some cases a
specific tightening torque is specified in respective sections. If no tightening torque
is specified in the service instructions, the values shown in the table above apply.

Tightening torque ATLET SERVICE MANUAL

1.18 General information and technical data

Table 1.14
Tightening torque: Pipe thread / metric thread:

Metric fine thread Whitworth pipe MA (Nm) with MA (Nm) with elastic
thread ring

M10 x 1 G 1/8" 25 10

M12 x 1.5 30 20

M14 x 1.5 G 1/4" 50 30

M16 x 1.5 G 3/8" 80 35

M18 x 1.5 90 40

M20 x 1.5 G 1/2" 130 50

M22 x 1.5 150 60

M26 x 1.5 250 70

M27 x 1.5 G 3/4" 250 80

M27 x 2 250 90

G 1" 350 140

M33 x 2 400 140

M42 x 2 G 11/4" 600 240

M48 x 2 G 11/2" 800 300

1.7.1 Conversion table

Table 1.15
Newton metre Kilopond metre Poundforce inch Poundforce foot
(Nm) (kpm) (lbg x in) (lbf x ft)

1 0,10 8,85 0,74

9,81 1 86,80 7,23

0,11 0,01 1 0,08

1,36 0,14 12,00 1

ATLET SERVICE MANUAL Tightening torque

 General information and technical data 1.19

1.7.2 Bolt types and tensile grades

Table 1.16
Figure Bolt type Designation Tensile grade

M6S Hexagon screw 8,8

10,9

MC6S Hexagon hole screw 8,8

10,9
12,9

MF6S Hexagon hole screw, 10,9

countersunk

MCS Slotted screw 4,6

MVBF Oval head 4,6

countersunk screw

Marking with the manufacturer’s trademark, including the tensile grade, is

compulsory for screws 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 1.9 Example of marking

Tightening torque ATLET SERVICE MANUAL

1.20 General information and technical data

1.8 Lubrication chart and recommended intervals

0

1.8.1 Lubrication chart XJN / XSN / XML

A I

B J

C K

D L

E M

P N

F O

H
A/B- Service

Yearly Service
SM 025.2e

Figure 1.10 Lubrication chart

ATLET SERVICE MANUAL Lubrication chart and recommended intervals

 General information and technical data 1.21

Table 1.17
Location Explanation Location Explanation

A Mast profile roller I Mast and fork carriage

surfaces, slide surfaces,
and grease nipples in
frame and on fork
carriage

B Lift chains, all J Thrust rollers – all

C Fork carriage, thrust K Shaft

rollers

D Fork carriage – slide L Hydraulic oil, check/change

surfaces

E Bogie axle (unloaded) M Brake fluid, check/change

F Steering joint N Steering servo sensor, bearing

(only Keltronic)

G Steering chain, top, O Gearbox oil, check/change

bottom

H Speed controller’s P Stabilisers – moving parts of

torsion springs cylinders and spring unit

Important!
All torsion springs in the machine should be lubricated during each service.
For explanation of symbols, see section1.8.4.

Lubrication chart and recommended intervals ATLET SERVICE MANUAL

1.22 General information and technical data

1.8.2 Lubrication chart XTF

B K

C L

D
M

E
N

O
G

H P

I
Q

J
A/B - Service

Yearly Service
SM 026.1e

Figure 1.11 Lubrication chart XTF

ATLET SERVICE MANUAL Lubrication chart and recommended intervals

 General information and technical data 1.23

Table 1.18
Location Explanation Location Explanation

A Mast profile roller surfaces, slide J Mast and fork carriage

surfaces, and grease nipples in
frame and on fork carriage

B Lift chains, all K Mast

C Fork carriage – thrust rollers L Thrust rollers and

shaft journal washer

D Fork carriage – slide surfaces M Chain pulley, shaft

E Forks, rollers, slide surfaces N Hydraulic oil

F Chains Fork driving O Brake fluid

G Steering joint P Steering servo sensor,

bearing
(Keltronik)

H Angle gear Q Gearbox

I Steering chains

Important!
All torsion springs in the machine should be lubricated during each service.
For explanation of symbols, see section1.8.4.

Lubrication chart and recommended intervals ATLET SERVICE MANUAL

1.24 General information and technical data

1.8.3 Lubrication chart XLL

E L

F N

G O

A/B- Service

Yearly Service

SM 027.1e

Figure 1.12 Lubrication chart XLL

ATLET SERVICE MANUAL Lubrication chart and recommended intervals

 General information and technical data 1.25

Table 1.19
Location Explanation Location Explanation

E Bogie – axle L Brake fluid

(unloaded)

F Steering joint M Hydraulic oil

G Steering chain, top, N Steering servo

bottom sensor, bearing
(only Keltronic)

H Speed controller’s O Gearbox oil

torsion springs

Important!
All torsion springs in the machine should be lubricated during each service.
For explanation of symbols, see section1.8.4.

1.8.4 Symbol explanations, lubrication chart

Table 1.20
Symbol Explanation Symbol Explanation

Hydraulic oil Hydraulic oil, change

Gearbox oil Gearbox oil, change

Brake fluid Brake fluid, change

Grease Chain spray

Chain spray / oil Only cold store version

Applicable in general for the symbols:

• Unfilled symbol = Check / lubrication
• Filled symbol = Change

Lubrication chart and recommended intervals ATLET SERVICE MANUAL

1.26 General information and technical data

1.8.5 Recommended oil and grease types

0

Table 1.21
Brand Gearbox oil Hydraulic oil Grease, Worm gear Brake
As per API As per ISO VG 32, ball oil fluid
grade VG 15 bearings (Only ATF) DOT 4
GL-5

Normal / Normal Cold store

Cold store (32) (15)

BP BP Energear Bartran BP Bartran Energrea BP-Energol BP

Hypo. SHF-S 32 HV 15 se SGXP 150 Super Disc
80 W/90 EP LC 2 Brake Fluid

Castrol Hypoy C Hyspin Hydraulic LMX Alpha syn

80 W/90 SHS 32 oil OM 15 T 220
Or: Hyspin
AWH 15

Mobil Mobilube DTE 13 M Flowrex 1 Mobilple GLY

HD 85 W/90 SHS 32 x 48 goyle 30

Shell Spirax Tellus oil Tellus oil Retinax Tivela WB

HD 85 W/90 TX 32 T 15 EP 2

Statoil Gear way G5 SHS 32 J 26 Uniway Snäck-

/Exxon 80 W/90 LiX 625 växelolja
375 S

Texaco Geartex EP- Rando oil Rando oil Hytex Synlube

C 80 W/90 HDZ 32 HDZ 15 EP 2 CLP 220

Important!
Do not mix different lubricants – definitely not synthetic oil with mineral oil!

1.8.1 Recommended replacement

Hoses should be replaced after 5 years, since they are perishable.

ATLET SERVICE MANUAL Lubrication chart and recommended intervals

 General information and technical data 1.27

1.9 Colour codes and technical descriptions

1.9.2 Colour of the truck in accordance with NCS colour

codes
0

Table 1.22
Machine colour Designation

Yellow NCS 0070-Y20R

Medium grey NCS 7000

Dark grey NCS 8000

1.9.1 Colour codes for Atlet wiring diagrams

Table 1.23
Code Cable colour

BE Beige

BL Blue

BN Brown

GN Green

GR Grey

OR Orange

P Pink

R Red

SB Black

VO Violet

W White

Y Yellow

 Note!
Two-colour cables are shown with both colour codes separated by a slash.
Example: blue/yellow cable is shown with colour code BL/Y.

Colour codes and technical descriptions ATLET SERVICE MANUAL

1.28 General information and technical data

1.9.2 Designations for electrical components

First letter
Table 1.24
Code Designation

A Component or function without its

own letter in list

C Contactor

D Diode

E Electronic component

F Fuse

I Indicator

L Light

M Motor

P Plug

R Relay

S Switch

T Terminal

V Valve

W Audible warning

Second letter
Table 1.25
Code Designation

B Brake

C Control system

E Emergency function

F Forward

H Hour

K Key

L Lowering

M Manouvre

P Pump

R Reverse

S Speed

Example SL = Switch for Lowering function

ATLET SERVICE MANUAL Colour codes and technical descriptions

 General information and technical data 1.29

1.9.3 Technical abbreviations

Table 1.26
Magnitude Unit Designation

Current Ampere A

Voltage Volt V

Resistance Ohm Ω
Output Watt W

Torque Newton metre Nm

Pressure Pascal Pa

Table 1.27
Prefix

1000 kilo k

1000 000 Mega M

Colour codes and technical descriptions ATLET SERVICE MANUAL

1.30 General information and technical data

ATLET SERVICE MANUAL Colour codes and technical descriptions