SA - OMNI (GB) - V1.2 - Pag 1 - 225

Content
General Information
Operating instructions
Safety
Product description
Lifecycle
Initial commissioning
Mechanical parts
Hydraulics
Electrical equipment
Setup work
Diagnosis
Optional equipment
OMNI 120/140 AC
Service manual
OMNI 120/140 AC
Version 1.2, 12.07.2006 EN
All rights reserved. Any duplication of this technical documentation, regardless of the method, is forbidden
without the prior written permission of DAMBACH Lagersysteme GmbH, even in excerpt.
We reserve the right to make changes without prior notice. The original document was created in German
(the local language of the manufacturer). All translations are copies of the original document.
Copyright 2006 by
DAMBACH Lagersysteme GmbH & Co. KG

Adolf-Dambach-Straße
D-76571 Gaggenau
Telephone +49-7225-64-01
Fax: +49-7225-64-188
Internet: http://www.dambach.de
E-mail: info@dls.dambach.de
Table of Content
Chapter 1
General Information ...................................................................................................1
1.1 Notes on the complete documentation ....................................................................2
1.1.1 Service manual ......................................................................................................... 2
1.2 Preventative maintenance .........................................................................................3
1.2.1 General maintenance instructions ......................................................................... 3
1.2.2 After the first 100 and 500 operating hours ........................................................... 4
1.2.3 Daily maintenance before driving........................................................................... 4
1.2.4 Maintenance and lubrication intervals ................................................................... 5
1.2.5 General maintenance plan....................................................................................... 6
1.2.6 Maintenance plan swivel/traverse fork................................................................... 9
1.2.7 Maintenance plan telescopic fork......................................................................... 10
1.2.8 Lubrication equipment........................................................................................... 11
1.2.9 General lubrication schedule ................................................................................ 12
1.2.10 Lubrication schedule swivel/traverse fork........................................................... 13
1.2.11 Lubrication schedule telescopic fork................................................................... 14
1.2.12 Lift chains ............................................................................................................... 15
1.2.13 Toothed belt lift sensor (if present) ...................................................................... 15
1.2.14 Hydraulic hoses ..................................................................................................... 15
1.2.15 Required special tools ........................................................................................... 16
1.3 Spare parts ................................................................................................................18
Chapter 2
Operating instructions.............................................................................................19
Chapter 3
Safety ........................................................................................................................21
3.1 General safety instructions .....................................................................................22
3.2 Safety symbols used ................................................................................................23
3.3 Instructions for maintenance ..................................................................................27
3.3.1 General safety instructions, maintenance and repairs....................................... 27
3.3.2 Parking the vehicle ................................................................................................ 28
3.3.3 Before performing work on the vehicle................................................................ 28
3.3.4 Putting the vehicle into operation ........................................................................ 28
3.3.5 Warning and instruction signs on the vehicle..................................................... 29
3.3.6 Conditions of use ................................................................................................... 29
3.3.7 Safety regulations for operation ........................................................................... 30
3.3.8 Personnel requirements ........................................................................................ 32
3.4 Load capacity............................................................................................................33
3.4.1 Area of application ................................................................................................. 33
3.4.2 Terms ...................................................................................................................... 33
3.4.3 vehicle geometry .................................................................................................... 35
3.4.4 Load capacity tables acc. to vehicle geometry"” on page 3-35......................... 36
3.4.5 Additional lift height h9 ......................................................................................... 38
3.4.6 Influence of the vehicle geometry on the load capacity..................................... 39
3.5 Electrostatic dangers ...............................................................................................40
3.5.1 Work instructions on the handling of electrostatically endangered components
or assemblies (EGB) .............................................................................................. 40
3.6 Inspections................................................................................................................41
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3.6.1 At the operator end ................................................................................................ 41
Chapter 4
Product description ................................................................................................. 43
4.1 Assembly arrangement............................................................................................44
4.1.1 Components of the E system ................................................................................ 44
4.2 Components in the drive compartment (rear view)...............................................45
4.3 Swivel/traverse fork..................................................................................................46
4.3.1 Functioning ............................................................................................................. 46
4.4 Telescopic fork .........................................................................................................48
4.4.1 Functioning ............................................................................................................. 48
4.5 Technical data...........................................................................................................50
4.5.1 Technical vehicle data ........................................................................................... 50
4.5.2 Adjusting and test values ...................................................................................... 50
4.5.3 Type structure......................................................................................................... 53
4.5.4 Fuses ....................................................................................................................... 54
Chapter 5
Lifecycle.................................................................................................................... 55
5.1 Safety.........................................................................................................................56
5.1.1 Qualification............................................................................................................ 58
5.1.2 Securing the freight and truck .............................................................................. 59
5.2 Disassembly work ....................................................................................................60
5.2.1 Removing the battery ............................................................................................. 61
5.2.2 Shutting down the hydraulic system .................................................................... 61
5.3 Overview transport options.....................................................................................62
5.3.1 Transport types ...................................................................................................... 62
5.4 Standing transport ...................................................................................................63
5.5 Lying transport .........................................................................................................64
5.5.1 Establishing the transport state............................................................................ 64
5.5.2 Safely load the OMNI 120/140 AC.......................................................................... 65
5.5.3 OMNI Unloading...................................................................................................... 67
5.6 Container loading .....................................................................................................68
5.6.1 Required tools ........................................................................................................ 68
5.6.2 Weight overview approx. values ........................................................................... 69
5.6.3 Size determination for container shipping........................................................... 70
5.6.4 Corrosion protection .............................................................................................. 71
5.6.5 Preparation and pole disassembly ....................................................................... 72
5.6.6 Loading and securing of boxes ............................................................................ 74
5.6.7 Loading and securing of chassis.......................................................................... 75
5.6.8 Loading and securing pole with cab .................................................................... 77
5.6.9 Loading and securing disassembled attachment ............................................... 86
5.6.10 Unloading the components, pole assembly and commissioning...................... 86
5.6.11 Depreserving........................................................................................................... 86
5.7 Assembly work on-site ............................................................................................89
5.7.1 Assembling the hydraulic system ........................................................................ 89
5.7.2 Prepare the brakes for commissioning ................................................................ 91
5.7.3 Battery installation ................................................................................................. 92
II Version 1.2, 12.07.2006

Chapter 6
Initial commissioning...............................................................................................93
6.1 General ......................................................................................................................94
6.2 Individual components.............................................................................................95
6.3 Basic unit...................................................................................................................96
6.4 Lift frame ...................................................................................................................97
6.5 Load lifting device (LLD)..........................................................................................98
6.6 Battery equipment ....................................................................................................99
6.7 Hydraulics ...............................................................................................................100
6.7.1 Pump aggregate ................................................................................................... 100
6.7.2 Hydraulic system ................................................................................................. 100
6.8 Inspections..............................................................................................................101
6.9 Supplied documentation........................................................................................102
6.9.1 Documentation behind driver's seat in storage box (plastic cover) ............... 102
Chapter 7
Mechanical parts ....................................................................................................103
7.1 Safety instructions .................................................................................................104
7.1.1 Working under lifted frame.................................................................................. 104
7.1.2 Working at dangerous heights............................................................................ 107
7.1.3 Gas-pressure springs .......................................................................................... 107
7.2 Torque values for screwed connections ..............................................................108
7.3 Ground requirements .............................................................................................109
7.3.1 Evenness .............................................................................................................. 111
7.4 Vehicle guidance ....................................................................................................114
7.4.1 Rail guidance ........................................................................................................ 114
7.4.2 Overview of guide rail variants ........................................................................... 119
7.4.3 Lateral floor rail forces of OMNI.......................................................................... 120
7.4.4 Induction guidance .............................................................................................. 121
7.4.5 Aisle detection...................................................................................................... 122
7.4.6 Aisle end stop....................................................................................................... 122
7.4.7 Placement of floor magnets ................................................................................ 123
7.4.8 Routing the guide wire......................................................................................... 124
7.4.9 Guide wire routing and wire design ................................................................... 126
7.4.10 Safety regulations and tolerances for narrow aisle .......................................... 127
7.5 Lift frame and cabin................................................................................................130
7.5.1 Chassis and lift frame .......................................................................................... 130
7.5.2 Backward tilting of the mast ............................................................................... 132
7.5.3 Guide rollers pole / cabin and auxiliary lift / load carriage............................... 134
7.6 Chassis ....................................................................................................................138
7.6.1 Lateral guidance (RG-rail guided vehicles) ....................................................... 138
7.6.2 Perform crack detection at chassis.................................................................... 139
7.7 Load axles and load wheels ..................................................................................140
7.7.1 Load axle<and multiple disc brake..................................................................... 140
7.8 Load wheel ..............................................................................................................141
7.8.1 Testing of brake effectiveness of the load wheel brake system...................... 142
7.8.2 Dismounting of the brake .................................................................................... 143
7.8.3 Checking the release play and the lining thickness ......................................... 144
Version 1.2, 12.07.2006 III

7.8.4 Exchanging the brake plates ............................................................................... 146
7.8.5 Visual check of the load wheel brake ................................................................. 147
7.9 Mechanically released spring-loaded brake (magnet brake) .............................148
7.9.1 Components of the magnetic brake ................................................................... 149
7.9.2 Adjustment of the air gap .................................................................................... 150
7.9.3 Minimum brake lining thickness ......................................................................... 151
7.9.4 Adjusting the brake action .................................................................................. 151
7.9.5 Brake test .............................................................................................................. 152
7.10 Traction drive..........................................................................................................153
7.10.1 Removal and installation of the drive aggregate............................................... 153
7.11 Swivel/traverse fork................................................................................................155
7.11.1 Adjustment of the tooth backlash....................................................................... 155
7.11.2 Adjustment of the swivel chains ......................................................................... 159
7.12 Telescopic fork .......................................................................................................161
7.12.1 Standard telescopic fork (TF) .............................................................................. 162
7.12.2 Flat telescopic fork (FTF) ..................................................................................... 163
7.12.3 Auxiliary lift pole................................................................................................... 164
7.12.4 Mechanical design of the telescope .................................................................. 166
7.13 Fork test ..................................................................................................................175
7.14 Lift chains................................................................................................................177
7.14.1 INSPECTION.......................................................................................................... 177
7.14.2 LIFT CHAIN LUBRICATION .................................................................................. 182
7.14.3 LIFT CHAIN REPLACEMENT ............................................................................... 183
7.15 "Master Speed Plus" testing instruction..............................................................186
Chapter 8
Hydraulics............................................................................................................... 189
8.1 General information ...............................................................................................190
8.1.1 Preparation, assembly and putting into operation of the FFZ hydraulics ...... 190
8.2 Torques ...................................................................................................................193
8.3 Description of the hydraulic system.....................................................................194
8.3.1 General features ................................................................................................... 194
8.3.2 Pump aggregate ................................................................................................... 194
8.3.3 Hydraulic plans ..................................................................................................... 196
8.4 Hydraulic installation in the bogie ........................................................................198
8.5 Hydraulic installation in the rear of the vehicle...................................................199
8.5.1 Rear view............................................................................................................... 199
8.5.2 Top view ................................................................................................................ 200
8.6 Tank .........................................................................................................................201
8.6.1 Oil fill...................................................................................................................... 201
8.6.2 Emptying the tank ................................................................................................ 201
8.6.3 Cleaning the tank.................................................................................................. 202
8.6.4 Re-filling the tank ................................................................................................. 203
8.6.5 Checking the hydraulic oil level.......................................................................... 203
8.7 Filler and breather ..................................................................................................204
8.7.1 Level control ......................................................................................................... 204
8.7.2 Checking the filter ................................................................................................ 205
8.8 Return flow filter .....................................................................................................206
8.8.1 Checking the filter ................................................................................................ 206
IV Version 1.2, 12.07.2006

8.9 Pump........................................................................................................................207
8.9.1 Putting the pump into operation......................................................................... 207
8.9.2 Removing the pump unit ..................................................................................... 208
8.10 Lift module block ....................................................................................................209
8.10.1 Proportional valve with priority direction 2Y30................................................. 209
8.10.2 Swiveling and sideshift........................................................................................ 210
8.10.3 Synchronous swiveling/sideshift ....................................................................... 211
8.10.4 Main lift/Auxiliary lift ............................................................................................ 212
8.10.5 Auxiliary lift movement........................................................................................ 212
8.10.6 Return flow pressure control valve .................................................................... 213
8.10.7 Lift module block H3 ............................................................................................ 214
8.11 Lift cylinders (main and auxiliary lift) ...................................................................215
8.11.1 Design of the cylinders........................................................................................ 215
8.11.2 Bleeding the cylinder ........................................................................................... 216
8.11.3 Replacing the sealing .......................................................................................... 217
8.11.4 Removing and installing the main lift cylinder.................................................. 219
8.11.5 Replacing the lower cylinder rod guide ............................................................. 220
8.11.6 Pipe-break protection / Load-lowering valve..................................................... 221
8.11.7 Emptying the lift cylinder .................................................................................... 224
8.12 Hydraulic installation of the traverse fork (RFZ) .................................................225
8.12.1 Side view ............................................................................................................... 225
8.12.2 Front view ............................................................................................................. 226
8.12.3 Setting the shock valves (sideshift) ................................................................... 227
8.12.4 Setting the load stabilizer valve (swiveling) ...................................................... 228
8.12.5 Swivel cylinder ..................................................................................................... 230
8.12.6 Replacing the sealing .......................................................................................... 231
8.13 Drawings of hydraulic components......................................................................232
8.13.1 Lift module of combined block KPL ................................................................... 232
8.13.2 Hydraulic control unit .......................................................................................... 233
8.13.3 Hydraulic installation in the bogie...................................................................... 234
Chapter 9
Electrical equipment ..............................................................................................237
9.1 Block diagram of the control concept ..................................................................238
9.2 CAN bus description ..............................................................................................239
9.2.1 CAN bus features ................................................................................................. 239
9.3 Components of the control systems ....................................................................241
9.3.1 General information concerning the components ............................................ 241
9.3.2 Drive compartment processing unit (DPU)........................................................ 241
9.4 Structure of the DPU ..............................................................................................242
9.5 Cabin processing unit (CPC) .................................................................................243
9.5.1 Function of the CPC............................................................................................. 243
9.5.2 Structure of the CPC ............................................................................................ 243
9.5.3 Plug arrangement distributor board cabin ........................................................ 244
9.5.4 Control panel processing unit (CPU) and APE.................................................. 245
9.6 Control panel...........................................................................................................246
9.6.1 Fixing of the control panel .................................................................................. 247
9.6.2 Disassembly / assembly of the control panel right side .................................. 248
9.6.3 Disassembly / Assembly of the control panel left side .................................... 252
9.6.4 Structure of the APE ............................................................................................ 255
9.7 Operation of the APE..............................................................................................256
9.7.1 Displays and menus on the APE ........................................................................ 256
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9.7.2 Basic display......................................................................................................... 256
9.7.3 Key functions in editable menus ........................................................................ 258
9.7.4 Information display .............................................................................................. 259
9.7.5 Control panel test page........................................................................................ 260
9.7.6 Service menu ........................................................................................................ 261
9.8 Brakes......................................................................................................................267
9.8.1 Braking system description ................................................................................ 267
9.8.2 Spring-loaded brake system ............................................................................... 267
9.8.3 Load brake system ............................................................................................... 268
9.8.4 Actuation of the load wheel brake ...................................................................... 268
9.8.5 Setting of the load wheel brake........................................................................... 268
9.8.6 Electrical braking system .................................................................................... 269
9.8.7 General emergency stop...................................................................................... 270
9.8.8 Functional emergency stop................................................................................. 270
9.9 Driving .....................................................................................................................271
9.9.1 Drive speeds ......................................................................................................... 271
9.9.2 Masterspeed and Masterspeed Plus (option) .................................................... 272
9.9.3 Adjustment of driving motion and electrical brake ........................................... 273
9.10 Steering ...................................................................................................................274
9.11 Triggering of the hydraulic system.......................................................................276
9.11.1 Triggering of the pump unit................................................................................. 276
9.11.2 Proportional valve ................................................................................................ 277
9.12 Functional relations ...............................................................................................280
9.12.1 Driving ................................................................................................................... 280
9.12.2 Manual steering .................................................................................................... 281
9.12.3 Lifting / lowering the main lift.............................................................................. 281
9.12.4 Lifting/lowering the auxiliary lift ......................................................................... 282
9.12.5 Sideshift right / left ............................................................................................... 283
9.12.6 Swiveling right / left.............................................................................................. 283
9.12.7 Automatic synchronous swiveling right / left .................................................... 284
9.13 Aisle detection and storage zones .......................................................................285
9.13.1 Aisle detection (standard and optional) ............................................................. 285
9.13.2 Wire guidance with aisle detection (IGwoA) ...................................................... 288
9.14 Release of options via code numbers ..................................................................289
9.15 Aisle end stop (option)........................................................................................... 290
9.16 Functional description ........................................................................................... 291
9.16.1 GESI with manual reset (code 0 activated) ........................................................ 291
9.16.2 GESI with auto-reset (code 8 activated) ............................................................. 292
9.16.3 GESI with positioning set-up (distance measurement) .................................... 293
9.17 IG (induction guidance) ........................................................................................294
9.17.1 System overview IG (induction guidance) ......................................................... 294
9.17.2 Tasks of the IG ...................................................................................................... 295
9.17.3 Operation of the IG ............................................................................................... 296
9.17.4 Safety concept of the emergency stop diamond............................................... 297
9.17.5 Wire signal control ............................................................................................... 298
9.17.6 Steering angle control.......................................................................................... 299
9.17.7 Mechanical lock device (claw, if available) ........................................................ 299
9.17.8 Actual driving speed control ............................................................................... 299
9.17.9 Full speed release ................................................................................................ 299
9.17.10 Overview of emergency stop conditions ........................................................... 300
9.17.11 Diagnosis .............................................................................................................. 300
9.17.12 Setting the IG ........................................................................................................ 300
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9.18 Interface to PPS connection (personnel protection system) .............................304
9.18.1 General information ............................................................................................. 304
9.18.2 ATLET-High-rise stacker with control system SECAN 2 .................................. 305
9.19 Automatic swiveling / sideshift synchronization.................................................306
9.19.1 Geometric adjustment ......................................................................................... 306
9.19.2 Hydraulic adjustment........................................................................................... 312
9.20 ***Battery discharge monitor.................................................................................314
9.21 Hour meters.............................................................................................................315
9.22 Cut-outs ...................................................................................................................316
9.22.1 Lifting cut-offs and lowering cut-outs (optional) .............................................. 316
9.22.2 Sideshift cut-out (second stacking depth)......................................................... 317
9.22.3 Driving cut-outs.................................................................................................... 317
9.23 Sensor units main lift .............................................................................................318
9.23.1 Laser odometer .................................................................................................... 318
9.23.2 Reference switch 0,3 m........................................................................................ 323
9.23.3 Startup and check of the main lift sensor units ................................................ 324
9.24 Sensor units actual value steering .......................................................................325
9.24.1 Overview of sensor elements.............................................................................. 325
9.24.2 Adjustment of the steering sensor unit ............................................................. 326
9.25 Sensor bearing drive- and steering motor (control system) ..............................332
9.25.1 Sensor bearing on the drive motor..................................................................... 332
9.25.2 Sensor bearing of the steering motor ................................................................ 335
9.26 Temperature sensor drive and pump motor ........................................................337
9.26.1 Drive motor ........................................................................................................... 337
9.26.2 Pump motor .......................................................................................................... 337
9.27 Sensor unit auxiliary lift (version B) .....................................................................338
9.28 Sensor unit sideshift ..............................................................................................340
9.29 Sensor unit swiveling.............................................................................................343
9.30 Controlling the hydraulic system..........................................................................345
9.30.1 Introduction .......................................................................................................... 345
9.30.2 Overview: Control of hydraulic functions by software modules ..................... 345
9.30.3 Fault analysis hydraulic functions ..................................................................... 347
9.31 Control of the hydraulic system (HR1200-1400) ..................................................348
9.31.1 Valve overview ..................................................................................................... 348
9.31.2 Overview: usage of the valves for individual movements ............................... 349
9.31.3 Cyclograms (from the hydraulic point of view) ................................................. 351
Chapter10
Setup work ..............................................................................................................357
10.1 Service menu / Setting parameter.........................................................................358
10.1.1 Abbreviations used for parameter types ........................................................... 358
10.1.2 Abbreviations in parameter display texts .......................................................... 359
10.1.3 Division of the parameters in levels ................................................................... 359
10.1.4 Minimum and maximum values .......................................................................... 360
10.2 List of the service menu.........................................................................................361
10.2.1 M 01: Control panel .............................................................................................. 362
10.2.2 M 02: Sideshift ...................................................................................................... 363
10.2.3 M 03: Turn ............................................................................................................. 364
10.2.4 M 04: Auxiliary lift................................................................................................. 365
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10.2.5 M 05: main lift........................................................................................................ 366
10.2.6 M 06: Driving ......................................................................................................... 367
10.2.7 M 07: Steering ....................................................................................................... 368
10.2.8 M 08: Synchronous main and auxiliary lift......................................................... 369
10.2.9 M 09: Traverse synchronous hydraulic .............................................................. 370
10.2.10 M 10: Sync. swivel geometry ............................................................................... 371
10.2.11 M 11: Pump ........................................................................................................... 371
10.2.12 M 12: Lifting cut-out (activation by code) .......................................................... 372
10.2.13 M 13: Drive cut-out (activation by code) ............................................................ 373
10.2.14 M 14: Lowering cut-out (activation by code) ..................................................... 374
10.2.15 M 15: Option codes 0-15 ...................................................................................... 375
10.2.16 M 16: Option codes 16-29 .................................................................................... 376
10.2.17 M 17: IG (induction guidance) ............................................................................. 377
10.2.18 M 18: Battery ......................................................................................................... 378
10.2.19 M 19: Hour meters ................................................................................................ 378
10.2.20 M 20: Load sensors .............................................................................................. 379
10.2.21 M 21: MasterSpeed ............................................................................................... 379
10.2.22 M 22: PPS (personal protection system) ............................................................ 379
Chapter 11
Diagnosis................................................................................................................ 381
11.1 Visual check of electronics components .............................................................382
11.2 Fuse check ..............................................................................................................383
11.3 CAN check...............................................................................................................384
11.3.1 Structural design .................................................................................................. 384
11.3.2 Procedure for fault analysis for CAN interference ............................................ 385
11.4 System messages ..................................................................................................387
11.4.1 Fault types............................................................................................................. 387
11.4.2 Online help ............................................................................................................ 389
11.4.3 Boot-up fault ......................................................................................................... 389
11.5 Operational messages ........................................................................................... 391
11.5.1 General remarks on operating messages .......................................................... 391
11.5.2 Operational messages CPU................................................................................. 399
11.6 Inputs, outputs. Noter ............................................................................................401
11.6.1 General remarks about inputs, outputs, flags ................................................... 401
11.6.2 Abbreviations of inputs, outputs and flags ....................................................... 402
11.6.3 Abbreviations in parameter display texts .......................................................... 402
11.6.4 Digital inputs ......................................................................................................... 404
11.6.5 Digital outputs ...................................................................................................... 408
11.6.6 Analog outputs ..................................................................................................... 410
11.6.7 Analog inputs........................................................................................................ 410
11.6.8 Digital flag ............................................................................................................. 411
11.6.9 Analog flag ............................................................................................................ 412
11.6.10 Condition flag (MZ) ............................................................................................... 414
11.7 State analysis and operating states .....................................................................416
11.7.1 State analysis........................................................................................................ 416
11.7.2 Table of states ...................................................................................................... 417
Chapter 12
Optional equipment ............................................................................................... 425
12.1 PPS laser scanner installation ..............................................................................426
12.2 End of aisle stop.....................................................................................................430
12.2.1 Placement of floor magnets ................................................................................ 430
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List of Figures.........................................................................................................433
List of Tables ..........................................................................................................437
Version 1.2, 12.07.2006 IX

X Version 1.2, 12.07.2006
General Information
Chapter index
Chapter 1
General Information
Chapter index
1.1 About the Manufacturer ............................................................. 2

1.2 Notes on the complete documentation ...................................... 3
1.3 Preventative maintenance ......................................................... 4
1.4 Spare parts .............................................................................. 19
Version 1.2, 12.07.2006 1-1

General Information
Notes on the complete documentation
1.1 Notes on the complete documentation
1.1.1 Service manual
This service manual is an advance version and only intended for training service
personnel.
§ Note
Only ATLET or a specially-trained person authorized by
ATLET who is authorized to carry out the appropriate
tasks may carry out the activities described in these in-
structions.
In your interests, ATLET tries to continually improve its products. For this reason,
we reserve the right to make technical changes which may deviate from the infor-
mation in these service instructions without prior notice.
1-2 Version 1.2, 12.07.2006

General Information
Preventative maintenance
1.2 Preventative maintenance
1.2.1 General maintenance instructions
A thorough and professional maintenance service is one of the most important re-
quirements for a safe use of the OMNI 120/140 AC. Neglect of regular mainte-
nance may cause a breakdown of the vehicle, and also presents a danger to
persons and operation.
The indicated servicing intervals are based on single-shift operation under normal
operating conditions. For applications in dusty environments, or involving large
temperature fluctuations or multiple-shift operation, the servicing intervals must be
shortened accordingly.
The following requirements must be adhered to:
• Only the manufacturer's spare parts are subject to our quality control. To en-
sure safe and reliable operation, use only ATLET spare parts.
• Old parts and replaced equipment must be disposed of properly in accor-
dance with the applicable environmental protection regulations.
• Any alteration of the unit, especially of the safety equipment, is forbidden.
• In no case may the working speeds of the equipment be changed.
For additional information, please see:

• Manufacturer's documentation
Version 1.2, 12.07.2006 1-3

General Information
1.2.2 After the first 100 and 500 operating hours
Measures after 100 and 500 operating hours to reduce wear in the break-in phase.
After 100 operating hours
Check wheel nuts with a torque wrench to make sure they are tight and tighten
if necessary.
Check the hydraulic connections to make sure they are leakproof, tighten if nec-
essary.
Check the state of the lift chain on the lift frame and the load lifting device; adjust
if necessary.
Check load-bearing wheels for damage/flattening/wear
Check guide wheels for damage/flattening/wear
After 500 operating hours
Check the ring gear and steering pinion of the steering system for play. If you
detect abnormal play, inform ATLET service.
Replace the hydraulic oil and the hydraulic filter.
1.2.3 Daily maintenance before driving
Check brake performance

Check steering performance
Check function of all instruments
Check lift chains, straight plates and suspension baffle for damage
Check lift/lower hydraulic function
Check function of push/swivel
Check drive gears for noise
Check hydraulic hoses for leakage
Check hydraulic oil for oil level
Check tires for damage
Charge battery after each discharge
Check electrolyte level toward the end of the charging, refill if necessary
1-4 Version 1.2, 12.07.2006

General Information
1.2.4 Maintenance and lubrication intervals
The following maintenance checklist indicates the operations to be performed and

the respective intervals to be observed. The servicing intervals are defined as fol-
lows:
W1 = every 50 operating hours, but at least once per week
M3 = every 500 operating hours, but at least every 3 months
The servicing intervals apply for normal conditions of use in one-shift operation.
Under more difficult conditions or with multi-shift operation, the intervals may need
to be shorter.
Version 1.2, 12.07.2006 1-5

General Information
1.2.5 General maintenance plan
Component Description W1 M3 M6 M12

Chassis/super- Check all load-bearing elements for damage z
structure:
Check all bolted connections z
Check the readability of the instruction labels, type plates z
and warning signs; replace them if necessary
Drive unit: Check the gears for noises and leakage z
Check transmission oil level, refill if necessary z
Check the play of the swiveling bolster bearing play z
Change the gear oil z
Wheels: Check for wear and damage z
Check bearings and secure attachment z
Steering system: Check the steering wheel play z
Check steering for function and adjustment z
Check the wheel position indicator for proper functioning
and correct adjustment
z
Check hydraulic components for function and leaks, re-
place if necessary
z
Check the ring gear and the steering pinion of the steering z
transmission for wear and lubricate
Inductively-guided vehicles:
Check steering angle limit for function and adjustment (if
present)
z
Check steering function "manual" and "automatic" z
Brake system: Check performance and adjustment z
Check brake wear (load-bearing wheel brake) z
Check brake mechanics (spring tension brake), adjust or z
replace if necessary
Check brake cable z
1-6 Version 1.2, 12.07.2006

General Information

Hydr. system: Performance check z
Check all connections for leakage and damage z
Check the hydraulic cylinders for leakage, damage and se- z
cure attachment
Check the oil level z
Check the hose run for correct functioning and damage z
Check the breather filter on the hydraulic oil reservoir z z
Change the breather filter on the hydraulic oil reservoir z
Change hydraulic oil and filter cartridge z
Check the pressure relief valves for correct functioning z
Check the hydraulic hoses for leakage and damage z
Check clogging indicator z
Electrical system: Check deflection of static charge (if present) z
Performance check z
Check all cables for secure connection and damage z
Check the cable runs for correct functioning and damage z
Check the warning installation for correct functioning z
Check the electronic boards for tight seat and cleanliness z
Check the sensors for secure attachment, damage, clean-
liness and proper functioning, replace if necessary
z
Check the instruments and displays for correct functioning z
Check contactors and relays; replace wearing parts if nec-
essary
z
Check the functioning and correct labeling of the operating z
elements
Check switches and solenoids for secure attachment and z
correct functioning
Check the toothed belt for the lifting sensors for damage
and correct tension
z
Check the fuses for correct amperage z
Electric motors: Check carbon brush wear drive motor, pump motor, main
lift, replace if necessary
Check the motors for secure attachment z
Check carbon brush wear, auxiliary pump unit, replace if
necessary
Vacuum out housing of all motors, check collector for wear
Version 1.2, 12.07.2006 1-7

General Information

Battery: Check the acid level z
Check acid density, acid level and cell voltage z
Check the battery cables for damage; renew if necessary z
Clean the battery connections; check for tight fitting z
Check the battery covers for smooth operation and satis-
factory condition
z
Check the terminals for secure attachment and apply
grease
z
Lifting device: Check performance, wear and adjustment
Check the lift frame bearing z
Visual check of the rollers, stops and runner surfaces pro- z
files, replace if necessary
Check the lift chains and chain guides for wear; adjust and
grease
z
Check the protective equipment for damage and secure at-
tachment, replace if necessary
z
Check the mast sections for lateral play and parallelism z
Load lifting device: Perform checks in accordance with separate checklist
Operator's place: Check all load-bearing elements and the driver's seat sup- z
port for damage
Check the overhead guard and glass shields for damage z
Check rails, doors, barriers for correct functioning and
damage
z
Check the emergency lowering device (vehicles with a
height of more than 2.5 m)
z
Lubrication Grease the vehicle in accordance with the lubrication z
schedule
Measurements Check the driving speed, the braking behaviour and brak-
ing distance
z
Check the lifting and lowering speeds of the main and aux-
iliary lift frames
z
Inductively-guided vehicles:
Measure the current in the guide wire and adjust if neces-
sary
z
Check safety and cut-out devices, end-of-aisle safety
equipment (GESI) and aisle exiting
z
Check the driving behavior on the IG wire and the maxi- z
mum deviation; adjust if necessary(g)
Check the aligning mode on the IG wire during engaging in
the aisle(g)
z
Check the electrical system for a grounding fault z
Check IG emergency stop z
Tab. 1-1: Maintenance plan
1-8 Version 1.2, 12.07.2006

General Information
1.2.6 Maintenance plan swivel/traverse fork

Mechanical parts Check all load-bearing elements for damage z
Check the fork tines and fork carrier for wear and damage z
Check the hose and cable runs for correct functioning and z
damage
Check the lift chains and chain guides; adjust and grease z
Check the gear wheels and toothed rack for wear and dam- z
age; grease if necessary
Check bearings, guide elements, and stops for wear and z
damage; grease if necessary
Hydr. system Performance check z
Check the hydraulic cylinders for leakage, damage and se-
cure attachment
z
Check the hydraulic motor for leakage, damage and se- z
cure attachment
Electrical system Performance check z
Check the sensors for fastening, damage, cleanliness and
proper functioning
z
Check switches and switch cams for secure attachment
and correct functioning
z
Check the toothed belt for the lifting sensors for damage z
and correct tension
Lubrication Grease the swivel/traverse fork in accordance with the lu-
brication schedule
z
Measurements Check the swiveling and traversing speeds z
Tab. 1-2: Maintenance list swivel/traverse fork
Version 1.2, 12.07.2006 1-9

General Information
1.2.7 Maintenance plan telescopic fork

Mechanical parts Check all load-bearing elements for damage z
Check bearings, guide elements, and stops for wear and
damage; grease if necessary
z
Check the lift chains and chain guides; adjust and grease z
Check lateral play, parallelism and deflection of the fork
tines
z
Check and adjust equal running of both fork tines z
Adjust tension of the transport chains z
Check the fork tines and fork carrier for wear and damage z
Hydr. system Performance check z
Check the hydraulic cylinders for leakage, damage and se-
cure attachment
z
Check the hydraulic motor for leakage, damage and se- z
cure attachment
Electrical system Performance check z
Check the sensors for fastening, damage, cleanliness and
proper functioning
z
Check switches and switch cams for secure attachment z
and correct functioning
Check the toothed belt for the lifting sensors for damage z
and correct tension
Lubrication Grease the telescopic fork in accordance with the lubrica-
tion schedule
z
Measurements Check traverse speed z
Tab. 1-3: Maintenance list telescopic fork
1-10 Version 1.2, 12.07.2006

General Information
1.2.8 Lubrication equipment
Consumption-type materials
Consumption-type materials must always be handled properly and in accordance

with the manufacturer's instructions.
Improper handling is injurious to health, life, and environment. Consumption-type

materials must be stored in adequate containers. They might be flammable and,
therefore, must not come into contact with hot components or open fire.
When filling up consumption-type materials, use clean containers only. Consump-

tion-type materials of different qualities may not be mixed.
Avoid spilling. Spilt liquid must be removed immediately using a suitable binding
agent, and the mixture of consumption-type material and binding agent is to be
disposed of according to the regulations.
Reference values oils
Code Designation Area of application

A HLP 46, DIN 51524 Hydraulic systems
B API GL4 SAE 80-90 Gears
E Grease, DIN 51825 Lubrication
G Chain spray Chains
Tab. 1-4: Oils
Reference values lubricants
Drop-
Saponifica- Worked penetr. at NLG 1- Service tempera-
Code ping
tion 25°C class ture°C
point °C
E Lithium 185 265-295 2 -35/+120
F - - 310-340 1 -52/+100
Tab. 1-5: Greases
Version 1.2, 12.07.2006 1-11

General Information
1.2.9 General lubrication schedule
Fig. 1-1: Lubrication pointsOMNI 120/140 AC
Ite
Description Code Quantity Remark
m
1 Slide surface E as needed Gear
2 Bleed screw - Gears
3 Filler neck B approx. 7 liters Gears
4 Slide surfaces E as needed Guide
5 Chain G as needed Load chain
6 Filler neck A approx. 80 liters Hydraulic aggregate
7 Drain hose - Hydraulic aggregate
1-12 Version 1.2, 12.07.2006

General Information
1.2.10 Lubrication schedule swivel/traverse fork
Fig. 1-2: Lubrication points swivel/traverse fork
Ite
m
1 Slide surfaces E as needed Guides
2 Grease nipple E as needed
3 Slide surfaces E as needed
4 Grease nipple E as needed
5 Chain G as needed
6 Chain G as needed Auxiliary lifting chain
Version 1.2, 12.07.2006 1-13

General Information
1.2.11 Lubrication schedule telescopic fork
Fig. 1-3: Lubrication points telescopic fork, example
Ite
m
1 Slide surfaces E as needed Guides
2 Chain G as needed Auxiliary lifting chain
3 Grease nipple (4×) E as needed Bearing drive shaft
4 Slide surfaces E as needed Guides on the middle part
5 Chains (4×) E as needed Ground tackle for middle part and
exterior part
1-14 Version 1.2, 12.07.2006

General Information
1.2.12 Lift chains
The lift chains wear rapidly if not lubricated. The intervals in the maintenance
checklist apply to normal duty. If requirements are higher (dust, temperature), lu-
brication is required more often. To lubricate the lift chains, the prescribed chain
spray must be used as instructed. The external application of grease does not pro-
vide sufficient lubrication.
1.2.13 Toothed belt lift sensor (if present)
The quality of the toothed belts and the toothed belt pulleys influences the safety
of the lift sensors and the reliability of switching (off) lifting and thus the required
stability. The correct tension of the toothed belts is also a safety factor. ATLET
spare parts must be used when replacing the toothed belts.
1.2.14 Hydraulic hoses
When replacing hydraulic components, also replace the hoses in this hydraulic
system. During safety checks, all hoses must be checked for noticeable damage
and replaced if necessary. Use only genuine ATLET hoses.
Version 1.2, 12.07.2006 1-15

General Information
1.2.15 Required special tools
Parts Num-
Tool Usage
ber
Service connector with R1/8“
M16x2 screw connection
R1/4“
for plug connector
Manufacturer: Parker
Extension tube with M16x2

screw connection
Length: 2 meters
„Serviceman“ test set for SC510-01

testing the hydraulic pres-
sure, the temperature, the
flow and the rotation in hy-
draulic and pneumatic sys-
tems
Sealing pliers for AMP AMP 654148-1 or

connections
AMP 654149-1
Type Mate-N-Lok
1-16 Version 1.2, 12.07.2006

General Information
Parts Num-
Tool Usage
ber
Extraction tool for extract- AMP 876047-1
ing Mate-N-Lok-contact
pins
Sealing pliers for AMP RS 446-816

connections
Type Sub-Min D
Extraction tool for extract- RS 446-822

ing Sub-Min D plug pins
Sealing pliers for Molex RS 162-3351

connections
Type Mini Fit
Extraction tool for extract- RS 215-5900

ing Mini-Fit plug pins
PC software application for

downloading and pro-
gramming all forklift truck
TI06 Teach-In top
TI07 Teach-In bottom
G20 End ahead top 300
G21 End ahead bottom 300
G22 Height
R08 Braking ramp lift
5400
30
R09 Braking ramp lower 20
parameters to a laptop.
R10 Accel. ramp lift 20
R1 1 Accel. ramp lower 15
V08 Speed max lift 100
V09 Speed max lower 100
V10 Slowspeed lift 64
V11 Slowspeed lower 29
I04 Current min lift 120
I05 Current max lift 490
I06 Current min lower 200
I07 Current max lower 500
D00 RPM max lift 2500
D01 RPM min lift 2500
D02 RPM Prop. lift 950
D03 RPM Prop. lower 550
V30 Switch speed RPM Prop. 17
F1 F2 F3 F4 F5 F6
Tab. 1-6: Table of special tools
Version 1.2, 12.07.2006 1-17

General Information
Spare parts
1.3 Spare parts

Spare parts are listed in a separate manual. Always specify the following when or-
dering spare parts
• specification of the vehicle

• model number of the vehicle
• serial number of the vehicle
1
2
3
10
Fig. 1-4: Type plate

1 Modell
2 Serial No.
3 Yera of manufactury
4 Load centre distance
5 Battery voltage
6 Weight without battery
7 Minimum battery weight
8 Maximum battery weight
9 Liftheight
10 Actual capacity
1-18 Version 1.2, 12.07.2006

Chapter index
Chapter 2
Chapter index
This chapter contains the operating instructions.
Version 1.2, 12.07.2006 2-19

Chapter index
2-20 Version 1.2, 12.07.2006

Safety
Chapter index
Chapter 3
Safety
Chapter index
3.1 General safety instructions ...................................................... 24

3.2 Safety symbols used ............................................................... 25
3.3 Instructions for maintenance ................................................... 29
3.4 Load capacity .......................................................................... 35
3.5 Electrostatic dangers ............................................................... 42
3.6 Inspections .............................................................................. 43
Version 1.2, 12.07.2006 3-21

Safety
General safety instructions
3.1 General safety instructions

Always carry out a daily test under operating conditions before putting the vehicle
into operation.
• Check the safety equipment as well as all protective and safety switches for
correct function before putting the vehicle into operation.
• The safety equipment must not be put out of operation or removed.
• Check all warning and device labels for cleanliness and perfect condition.
• The battery must be securely fastened in the battery compartment.
• The weight of the battery must match the weight specified on the vehicle's
type plate.
If the vehicle exhibits damage or errors that compromise safety or danger-free us-
age, it may not be put into service. This also applies if repairs or changes are made
to the forklift truck or settings are changed on the vehicle without the acceptance
and cooperation of authorized employees.
Use of theOMNI for purposes other than those intended is not permitted. This ap-
plies, e.g. for following types of use:
• in areas where there is a danger of fire and explosion by dust and gaseous
air.
• as towing vehicle for trailers.
• for towing other vehicles.
3-22 Version 1.2, 12.07.2006

Safety
Safety symbols used
3.2 Safety symbols used

For better orientation and unambiguous indication of special danger points, we
have used the following pictograms:
§ Note
This symbol designates text with additional and impor-
tant notes.
Note
This symbol designates text with additional information
Note
This symbol warns about severe injury or life-threaten-
ing dangers and/or possible high property damage.
You yourself or bystanders can be severely or mortally
injured and/or you can cause high property damage if
you ignore this safety warning.
Note
This symbol warns about danger of falling from all
heights greater than 1m and about places at which one
can sink.
Note
This symbol warns about caustic materials and/or liquids
with which you can come into contact when working on
the vehicle.
Version 1.2, 12.07.2006 3-23

Safety
Safety symbols used
Note
This symbol warns about slipping on wet or oily surfac-
es.
Note
This symbol warns about the drawing-in of body parts or
work clothing in rollers or presses
Note
This symbol warns about dangers due to electrical cur-
rent in rooms or during handling of products such as,
e.g. machines, tools, etc.
This symbol indicates a dangerous situation as a conse-
quence of which slight bodily injuries or property dam-
age can occur due to non-observance of the behavior
rules.
Note
This symbol warns about danger due to flammable ma-
terials in rooms e.g. storage rooms or storage cabinets
with flammable contents or when handling products
such as, e.g. tanks, machines, etc.
This symbol indicates a dangerous situation with flam-
mable materials as a consequence of which bodily inju-
ries or property damage can occur due to non-
observance of the behavior rules.
An indication of hazardous substances with flammable
properties (chemicals [materials], preparations and re-
sults) is only permissible in accordance with ANSI
Z129.1-1988.
3-24 Version 1.2, 12.07.2006

Safety
Safety symbols used
Note
This symbol warns about hot surfaces such as hot ma-
chine parts, tanks and materials, but also hot liquids,
which cannot always be perceived. If such a safety
marking is affixed to a component, use caution.
Hot surfaces should be indicated as of a temperature
above 45 °C (coagulation of egg white) and can thus
cause burns to people.
Note
This symbol warns about cold in work rooms (e.g. refrig-
erated storage in which frozen goods are stored).
Note
This symbol indicates areas in which there is sometimes
a high acoustic pressure level.
See accident prevention guideline BGV B3 "Noise".
Note
This symbol warns about lingering under lifted loads.
Note
This symbol warns about hand injuries.
Hand injuries are the most common consequence of oc-
cupational accidents.
Warning, keep hands away from places which display
this warning sign!
There is a danger that hands can be crushed, drawn in
or otherwise injured.
Version 1.2, 12.07.2006 3-25

Safety
Safety symbols used
Note
This symbol warns about stumbling points on traffic
routes.
Normally routes can be traveled without danger without
having to look constantly at the floor. However, in order
to equalize height differences between workplaces,
steps may be built in.
Even temporary stumbling places such as, e.g. cables or
other lines must be marked as such.
3-26 Version 1.2, 12.07.2006

Safety
Instructions for maintenance
3.3 Instructions for maintenance
3.3.1 General safety instructions, maintenance and repairs
Note
Observe the safety instructions of the service manual
and the operating instructions.
Service personnel or even uninvolved persons may oth-
erwise be seriously injured or even killed.
Motorized vehicles can be a source of danger if maintenance and care are ne-
glected. Therefore, maintenance and inspection must be carried out at suitably
short intervals and trained personnel and appropriate company regulations must
exist.
Note
Observe all valid national and local safety regulations
for maintenance and repair work!
Service personnel or even uninvolved persons may oth-
erwise be seriously injured or even killed.
; Carry out work only according to the test and maintenance plan.
; Only have work carried out at the vehicle by authorized personnel.
; Keep flame retardants at the ready, do not use an open flame to test fill lev-
els or to test for leakages.
; For cleaning, use groundwater-neutral, non-flammable cleansers. Only

clean over an oil separator. Protect electrical systems against humidity.
; Keep workspace and battery chargers clean, dry and well-ventilated.

; Do not allow oil to penetrate the ground or sewer systems. Dispose of used
oil in a used oil recycling facility. Oil filters and desiccants must be treated
as special waste. Adhere to the regulations of the responsible authorities.
; Neutralize spilled battery liquid immediately and wash with a lot of water.
; Keep vehicle clean in order to make finding loose or defective parts easier.
; Keep load capacity and type plate, warning and instruction signs legible.
; Changes to or modifications of the unit by the licensee or operator are not
permitted without the express written permission of ATLET.
; The reliability, safety, and suitability of the ATLET vehicles can only be guar-
anteed if original ATLET spare parts are used.
Version 1.2, 12.07.2006 3-27

Safety
3.3.2 Parking the vehicle
; Apply brakes until the vehicle stops.

; Completely lower the fork carrier.
; Switch off the vehicle and remove the ignition key.
; When parking on inclines then put the steering mechanism into park posi-
tion .
3.3.3 Before performing work on the vehicle
; Press the EMERGENCY OFF switch.

; Disconnect the battery plug connection.
; Secure the vehicle against rolling away and lowering.
; During work on the lift frame, fork carriers or lift pole, a blocking according
to the service instructions is absolutely necessary in order to prevent inad-
vertent lowering.
; Carry out functional checks only with sufficient room to move so as not to
endanger yourself and other people.
3.3.4 Putting the vehicle into operation
; Carry out a function check of the safety equipment.

; Take your seat on the driver's seat.
; Carry out a function check of the lifting device, speed regulation, steering,
warning equipment and brakes.
3-28 Version 1.2, 12.07.2006

Safety
3.3.5 Warning and instruction signs on the vehicle
Check the warning and instruction signs attached to the vehicle during periodic
maintenance work for completeness and legibility.
• Clean dirty signs.

• Replace defective or missing signs.
The designation and arrangement of the warning and instruction signs on the ve-
hicle is described in the spare parts manual.
3.3.6 Conditions of use
Ambient temperature
The permissible ambient temperature for operation must be between +5 °C and

+40 °C.
Note
When the truck is continually operated at temperatures
below 0°C, the hydraulic system should be filled with
special hydraulic oil. Special equipment and a special
approval are required for industrial trucks that are to be
operated in cold stores or at extreme fluctuations of tem-
perature or humidity.
Interior use
The OMNI is only intended for interior use in closed and dry rooms such as ware-
houses. The floor surface and load capacity should be designed in accordance
with the intended use.
Exterior use
Outdoor use is forbidden!
Version 1.2, 12.07.2006 3-29

Safety
3.3.7 Safety regulations for operation
General information
• Always make sure that there are no persons located under a lifted load or
under lifted forks,
• and that there are no persons in the danger zone of moving parts.
Loads
• The maximum permissible load to be lifted is indicated on the type plate and
the load capacity diagram attached to the vehicle, depending on the lift
height.
• A load may not be lifted lopsided since during operation, e.g. when lowering,
collisions with the cabin or other components may occur.
Driving
• Driving behavior must always be adjusted to the load, the floor covering, the
driving direction and the visibility. Special care must be taken if there may
be people or vehicles in the area.
§ Note
When using in storage aisles, a safety distance on both
sides of at least 90 mm must be observed, in accor-
dance to DIN 15185 Part 2. If this is not possible due to
limitations within the system, then a special approval is
required in Germany acc. to §4 Regulations on Place of
Work and §3 Accident Prevention Regulations of the
German VBG 1.
Parking
If the OMNI is parked, the following points must be observed:
• The fork and lifting equipment must be lowered.

• The hand brake is automatically activated and closed.
• The start key must be removed.
• Depending on the parking situation, the unit must be sufficiently lighted.
3-30 Version 1.2, 12.07.2006

Safety
Battery
Care and charging of the battery is according to the safety instructions of the man-
ufacturer.
• In particular, no work on the battery may be carried out without protective

equipment.
• No conductive objects may be placed over the battery pole or its connec-
tions.
Version 1.2, 12.07.2006 3-31

Safety
3.3.8 Personnel requirements
The operation of storage units, storage systems and their components assumes extensive knowledge of
their functioning and the dangers they present. Before operating or maintaining the storage unit, the op-
erator must have the following qualifications:
Personnel Responsible for Qualification

• Must be at least 18 years of age
• Trained in first aid and in a position to admin-
ister it.
• Informed about the potential dangers of indus-
trial trucks. Knowledge and understanding of
all safety-related instructions, sources of dan-
ger and safety measures.
• Trained and instructed according to the be-
havior measures in case of fault.
Operating personnel Proper operation • In possession of the bodily and mental capac-
ities to carry out their responsibilities, tasks
and activities on the OMNI.
• Has read, understood and can apply all of the
documentation, especially these operating in-
structions.
• Trained via an activity-related training by AT-
LET or by a person authorized by ATLET for
operation and authorized by the licensee.
• All qualifications named for the operating per-

sonnel
• Trained for and in possession of up-to-date
knowledge about work on the mechanics,
All care, fault detec- electrical, control and hydraulic systems of in-
tion and mainte- dustrial trucks.
Maintenance per-
nance described in • In a position to read and understand circuit di-
sonnel agrams and hydraulic diagrams.
these operating in-
structions. • Informed about the potential dangers of work-
ing on industrial trucks.
• Trained via an activity-related training by AT-
LET or by a person authorized by ATLET for
maintenance and authorized by the licensee.
Fig. 3-1: Responsibility and qualifications of the personnel
3-32 Version 1.2, 12.07.2006

Safety
Load capacity
3.4 Load capacity

The load capacity is one of the most important features of the order-picking stack-
er; in comparison to the competition however, this is mainly for safety reasons. In
case of overloading, there is a danger of tilting over as well as the risk of structural
breaks at supporting parts of the order-picking stacker.
3.4.1 Area of application
This technical information sets the load capacity of our order-picking stackers. The
values set here are the maximum permissible values. If a higher value is indicated
in a company contract then a written permission for this deviation must be provid-
ed by the department head of the FFZ-TB. This must be sent to the customer to-
gether with the declaration of conformity. Without a written permission for this
deviation, the final acceptance dept. must not approve the vehicle and dispatch
must be refused.
This technical information is binding for all departments.
3.4.2 Terms
Nominal Lifting Capacity
Acc. to En 1726 No. 3.6.1, nominal lifting capacity for industrial trucks with large
lift height.
The nominal lifting capacity is the load in kg authorized by the manufacturer and
that the type of industrial truck is able to transport or to lift under the following set
conditions. In setting the load Q, the following conditions apply:
• the load center of gravity G in the standardized load center of gravity dis-
tance of D = 600 mm
• load Q lifted perpendicular to the normal lifting height
• industrial truck equipped with a double lifting frame in which the maximum
lift height is the same as the standard lift height. When equipping the indus-
trial truck with another lift frame, the load capacity must be related to a dou-
ble lifting frame with a standard lifting height.
Actual load capacity (EN1726-1:1998 No. 3.7)
The largest load in kg permitted by the manufacturer taking into account the at-
tachment, lift height and load center of gravity, that the industrial truck is able to
transport or to lift in proper use and under defined conditions.
The actual load capacity may vary by the various types and the height of the lift
frame and the various distances of the load center of gravity.
Version 1.2, 12.07.2006 3-33

Safety
Load capacity
Standard lifting height (EN1726-1:1998 No. 3.8)
Lift height H in millimeters, measured from the floor to the load contact surface of
the fork tines or platform. The following height is set:
H=3300 mm for all industrial trucks except for pallet-stacking trucks and high-lift
trucks
3-34 Version 1.2, 12.07.2006

Safety
Load capacity
3.4.3 vehicle geometry
The maximum permissible load capacity related to one Europallet 1200×1200 with a loading height of
h16=1200 mm. The table values of the lifting capacities are based on vehicles configured as follows:
Type se- Type se- Type se- Type se- Type se-
Veh. type ries 1000 ries 1200 ries 1400 ries 1400 ries 1600
Parameter AC 48V AC 80V AC 80V AC 80V DC 80V
2005
Wheelbase Y 1765 mm 1950 mm 2070 mm 2000 mm 2200 mm
Pivot load-bearing wheel axle l8 1125 mm 1187 mm 1187 mm 1253 mm 1178 mm
Swivel radius R 210 mm 215 mm 215 mm 215 mm 215 mm

(without spacer)
Boom width B 170 mm 180 mm 180 mm 180 mm 180 mm
Width of load-bearing wheel 1450 mm 1450 mm 1450 mm 1450 mm 1450 mm

axle b2
Width of forestructure b15 1510 mm 1510 mm 1510 mm 1510 mm 1510 mm
Cabin width b14 1480 mm 1480 mm 1480 mm 1480 mm 1480 mm
Auxiliary lift h9 1600 mm 1500 mm 1500 mm 1800 mm 1500 mm
Safety clearance S1 125 mm 125 mm 125 mm 125 mm 125 mm
Safety clearance S2 140 mm 130 mm 130 mm 130 mm 130 mm
Theor. AST 1760 mm 1760 mm 1760 mm 1760 mm 1760 mm
Min. weight of battery 1087kg 1520kg 1830kg 1830kg 2130kg
Tab. 3-1: Vehicle configuration for determining the load capacity tables with ZT pole
Fig. 3-2: vehicle geometry
Version 1.2, 12.07.2006 3-35

Safety
Load capacity
3.4.4 Load capacity tables acc. to vehicle geometry"” on page 3-35
1000 AC 1200 AC 1400 AC 1600 DC

Installation height h1
Carrying load [kg]
Carrying load [kg]
Carrying load [kg]
Carrying load [kg]

Lift height htot
Lift height htot
Lift height htot
Lift height htot

[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
2200 4000 1000 2250 4000 1200 N/A N/A N/A N/A N/A N/A
2450 4500 1000 2500 4500 1200 N/A N/A N/A N/A N/A N/A
2700 5000 1000 2750 5000 1200 3000 5000 1400 3000 5000 1600
2950 5500 1000 3000 5500 1200 3250 5500 1400 3250 5500 1600
3200 6000 1000 3250 6000 1200 3500 6000 1400 3500 6000 1600
3450 6500 800 3500 6500 1200 3750 6500 1400 3750 6500 1600
3700 7000 700 3750 7000 1200 4000 7000 1400 4000 7000 1600
3950 7500 600 4000 7500 1200 4250 7500 1400 4250 7500 1600
4250 8000 1100 4500 8000 1300 4500 8000 1600
4500 8500 1000 4750 8500 1300 4750 8500 1600
4750 9000 800 5000 9000 1150 5000 9000 1500
5000 9500 700 5250 9500 1150 5250 9500 1500
5250 10000 600 5500 10000 1000 5500 10000 1400
5500 10500 500 5750 10500 1000 5750 10500 1400
5750 11000 350 6000 11000 700 6000 11000 1250
6250 11500 700 6250 11500 1250
6500 12000 1100
6750 12500 1100
7000 13000 1000
7250 13500 900
7500 14000 700
7750 14500 600
Tab. 3-2: Basic load capacity for vehicles acc. to Tab.: 3-1 on page 3-35 with ZT pole
3-36 Version 1.2, 12.07.2006

Safety
Load capacity
1200 AC 1400 AC 2005 1 1400 AC 1600 DC

Carrying load [kg]
Carrying load [kg]
Carrying load [kg]
Carrying load [kg]

Lift height htot
Lift height htot
Lift height htot
Lift height htot

[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
2500 6000 1200 N/A N/A N/A N/A N/A N/A N/A N/A N/A
2750 6750 1200 2750 6300 1400 2750 6000 1400 N/A N/A N/A
3000 7500 1200 3000 7050 1400 3000 6750 1400 N/A N/A N/A
3250 8250 1050 3250 7800 1400 3250 7500 1400 3250 7500 1600
3500 9000 900 3500 8550 1200 3500 8250 1300 3500 8250 1600
3750 9750 750 3750 9300 1200 3750 9000 1200 3750 9000 1600
4000 10500 400 4000 10050 1000 4000 9750 1000 4000 9750 1500
4250 10800 1000 4250 10500 850 4250 10500 1350
4500 11550 800 4500 11250 700 4500 11250 1250
4750 12300 700 4750 12000 1150
5000 13050 700 5000 12750 1050
5250 13800 600 5250 13500 850
5500 14550 600

Tab. 3-3: Load capacity for vehicles acc. to Tab.: 3-1 on page 3-35 with DT pole
1
Load capacity at a free lift of h9 = 1800 mm
h1 [mm] h1 [mm] h9 [mm] of htot [mm] to htot [mm] Q [kg]

5500 7200 1800 0 9000 1400
5500 8450 1800 9001 10250 1200
5500 9700 1800 10251 11500 1000
5500 10700 1800 11501 12500 800
5500 11700 1800 12501 13500 700
5500 12700 1800 13501 14500 600
Tab. 3-4: Permissible load capacity HiRacker 1400 DT (h1=5500mm) from stability trials
Version 1.2, 12.07.2006 3-37

Safety
Load capacity
3.4.5 Additional lift height h9
The additional lift height h9 also influences the load capacity.
With increasing installation height of the auxiliary lift pole, the bending moment remains constant over the
entire lifting range at the same load distance and same swivel radius. The shear also remains constant.
However, when stacking, accelerating and braking the vehicle, the additional forces caused by the accel-
eration change when the load is lifted. Additionally, the static deflection of the free lift pole increases and
the swing behavior is shifted to smaller frequencies with larger amplitudes.
h9
1500 1600 1700 1800 1900 2000 2100 2200 2400 2600
Type
CF11 N/A 1000 900 800 700 600 500 N/A N/A N/A
BF12 1200 1200 1200 1200 1100 1050 950 900 600 400
BF15 1600 1600 1500 1400 1250 1150 1050 900 700 500
BF15V 1600 1600 1600 1600 1500 1400 1300 1200 1000 900
Tab. 3-5: Permissible load capacity of the SSG depending on the lift height h9
The restriction of the reduction in load capacity by a larger lift height of the free lift may be partially solved
by a lifting cut-out in the free lift. To do this, the free lift is switched off when loading at a height smaller
than 1500 mm or 1600 mm. The remaining lift height of the free lift is only enabled when a total lifting
height is reached in which the device load capacity is smaller or equal to the load capacity of the free lift.
3-38 Version 1.2, 12.07.2006

Safety
Load capacity
3.4.6 Influence of the vehicle geometry on the load capacity
In case of changes to one of the following dimensions vis-à-vis the values listed in
Tab.: 3-1 on page 3-35, the permissible load capacity also changes:
• dimension under load wheels b15

• wheelbase Y
• stacking depth l6
• pallet width b12
• distance pivot load-bearing wheel axle l8
• additional lift height h9
Version 1.2, 12.07.2006 3-39

Safety
Electrostatic dangers
3.5 Electrostatic dangers
3.5.1 Work instructions on the handling of electrostatically endan-

gered components or assemblies (EGB)
ATLET QM-System
DIN EN ISO 9001
industrial truck technical office (FFZ-TB)
Purpose
These work instructions describe the safe handling with elecrostatically endan-
gered components or assemblies (EGB).
Area of validity
These work instructions are valid for all staff that work with electrostatically endan-
gered components or assemblies (in particular FFZ-TB, FFZ-WMT, KD, FER-
LAG,SR).
Procedure
Fig. 3-3: Symbol (Reference: DIN 4002)
A personal electrostatic discharge can destroy sensitive components. Correct

packaging and grounding regulations must therefore be observed. Always ob-
serve the following safety measures.
• Transport plug-in boards in electrostatically secure containers or bags.

Appropriate packages are marked with the symbol shown above and are
usually also labeled, e.g.: „Attention: Electrostatic sensitive devices“.
• Keep electrostatically sensitive parts in their container until they reach an
electrostatically safe workplace.
• Only touch electrostatically endangered parts when it is ensured that they
are well grounded.
• Wear antistatic gloves!
• Store electrostatically endangered parts in protective packaging or on anti-
static mats
3-40 Version 1.2, 12.07.2006

Safety
Inspections
3.6 Inspections
3.6.1 At the operator end
In accordance with the safety ordinance, the licensee must ensure that a compe-
tent person write up and document an evaluation of the dangers for the use of the
vehicle. Dangers that result from operation must be avoided by means of suitable
measures. The proper use must be ensured. The inspections and maintenance
work/intervals prescribed by the manufacturer must be carried out in accordance
to the instructions.
Initial commission- Before initial commissioning, the OMNI 120/140 AC must be inspected by a qual-
ing ified and authorized person in accordance with DIN EN 1726Inspections"” on page
6-101.
Recurring inspec- For accident prevention during operation of the industrial truck, a safety check
tion must be carried out once annually according to the stipulations of the manufactur-
er by competent persons and to be documented accordingly. For these inspec-
tions, ATLET has a special safety service with appropriately-trained employees.
Inspection sticker
Note
Inform yourself about the applicable national inspection
regulations.
As a visual indicator, an inspection sticker is placed on the vehicle after successful

inspection. This sticker indicates in which month of which year the next inspection
must occur.
jährliche Prüfung
gemäß UVV
nächste Prüfung
5 6 7 8 9
4
10
3
1112
12
letzte Prüfung
Fig. 3-4: Inspection sticker
Version 1.2, 12.07.2006 3-41

Safety
Inspections
3-42 Version 1.2, 12.07.2006

Product description
Chapter index
Chapter 4
Product description
Chapter index
4.1 Assembly arrangement ........................................................... 46

4.2 Components in the drive compartment (rear view).................. 47
4.3 Swivel/traverse fork ................................................................. 48
4.4 Telescopic fork ........................................................................ 50
4.5 Technical data ......................................................................... 52
Version 1.2, 12.07.2006 4-43

Product description
Assembly arrangement
4.1 Assembly arrangement
Note
Overview of the mechanical components, see Operating
Instructions.
4.1.1 Components of the E system
5
1
2
6
3
7
Fig. 4-1: Components of the E system
1 Sensor technology main lift pole (if available)

2 Sensor technology auxiliary lift (10-helix tandem potentiometer) (version A) or cable
control potentiometer (version B)
3 Sensor technology sideshift (10-helix tandem potentiometer)
4 Sensor technology swivel (3-helix tandem potentiometer)
5 Control panel with processing unit control panel (CPU) and APE
6 Cabin processing unit (CPC) under the driver's seat
7 Drive compartment processing unit (DPU)
8 Battery
4-44 Version 1.2, 12.07.2006

Product description
Components in the drive compartment (rear view)
4.2 Components in the drive compartment (rear

view)
19 17 16 15
1
2 14
3
13
7 8 9 11 12
Fig. 4-2: Components in the drive compartment
1 Lift module block 11 Steering motor with gears

2 Hydraulic container 12 AC controller pump
3 Emergency lowering key 13 AC controller steering
4 Return flow filter 14 AC controller driving
6 Incremental encoder for steering 15 Drive compartment processing unit (DPU)
7 AC drive motor 16 Main contactor
8 Spring force brake 17 CMP (central minus point)
9 Brake loosening screws 19 Pressure sensor
Version 1.2, 12.07.2006 4-45

Product description
Swivel/traverse fork
4.3 Swivel/traverse fork
4.3.1 Functioning
The swivel/traverse fork allows stackable load units to be directly picked up from
or set down on the ground, either laterally or from the front. During transport runs,
the fork is swiveled through 90°, with the tines pointing either to the left or the right
of the travel direction. Inside the narrow aisles, stacking operations can be carried
out on either side of the racks.
7
2
Fig. 4-3: Swivel/traverse fork

1 Auxiliary lift pole
2 Hydraulic motor
3 Sideshift frame
4 Traversing carriage
5 Fork tines
6 Fork carrier
8 Auxiliary lifting chain
4-46 Version 1.2, 12.07.2006

Product description
The load lifting device consists of the traversing carriage for the horizontal side
movement and the auxiliary lifting mast with fork carrier and fork which can be
swiveled by 180°. The auxiliary mast is a central mast with a cylinder and a load
chain. The traversing motion of the traversing carriage is handled by a hydraulic
motor which drives a toothed shaft. Its gears grip in two toothed racks mounted on
the front end. The traversing carriage is guided by two adjustable guide rollers on
the top and bottom in U profiles. These rollers absorb the moment of tilt. A sup-
porting roller on the middle rail of the carrier absorbs the vertical forces. Two hy-
draulic cylinders connected by chains effect the swiveling motion of the auxiliary
lift pole around the auxiliary lifting cylinder’s axis of rotation.
All end positions are reached smoothly thanks to proportional valve controllers.
With an additional button on the control panel, swiveling and traversing can be trig-
gered simultaneously (up to a fork height of 500 mm) outside the narrow aisles.
After 180° angle of rotation, the motion switches off in the end position.
Version 1.2, 12.07.2006 4-47

Product description
Telescopic fork
4.4 Telescopic fork
4.4.1 Functioning
With a telescopic fork, stacked load units can be picked up or put down left or right.
The required aisle width is very narrow (pallet length + 2x safety distance). The
lowest stack height must be more than 250 mm with the telescopic fork since the
lowered height is 300 mm. Optionally, a flat telescopic fork (FTF) with lowest stack-
ing height of 100 mm can be attached. Only pallets can be picked up which are
open to the bottom. The unobstructed drive-in height must be at least 100 mm.
Fig. 4-4: Telescopic fork

2 Fork tines
3 Load carriage
4 Ground tackles
4-48 Version 1.2, 12.07.2006

Product description
Telescopic fork
The telescopic fork consists of the auxiliary lift pole and the load carriage with the
fork tines mounted on them. The auxiliary lift pole can be delivered as a simple or
double telescopic mast with free lift. The auxiliary lift cylinder causes the lift move-
ment; for the double poles with free lift in two stages.
The feed motion of the telescopic fork is generated by a hydraulic motor and trans-
ferred by ground tackles. All end positions are driven to softly and switched off
electrically by proportional valve controls. In addition, they are stopped mechani-
cally.
For transport drives, the telescopic fork must be in the middle position, the feed
motion switches off automatically in this setting. The control lamp (R4) indicates
that the middle setting has been reached. The end setting and the middle setting
are driven to smoothly.
Version 1.2, 12.07.2006 4-49

Product description
Technical data
4.5 Technical data
4.5.1 Technical vehicle data
An overview of the design data is located in the Operating Instructions. The actual
values may differ depending upon the vehicle design. They can be found in the
customer order. A sample excerpt is located in the appendix.
4.5.2 Adjusting and test values
Designation Unit 1200 AC 1400 AC

Vehicle
Dead weight (without load) approx. kg
Driving speed km/h IG: 8.0-9.0 IG: 8.0-9.0

RG: 10.0 RG: 10.0
with/without load
Main lift raising with/without load m/s 0.4 0.4
Main lift lowering with/without load m/s 0.4 0.4
Auxiliary lift raising with/without load m/s 0.25 0.25
Auxiliary lift lowering with/without load m/s 0.36 0.36
Lateral traversing with/without load m/s 0.25 0.25
Swiveling through 180° with load s 10 10
Synchronous swivel/pushing s approx. 12 approx. 12

180°/dead-center position
Traction drive
Gears I 19.07 19.07
- Gear oil quantity l 7 7
- Drive plate M16 screws Nm 186 186
Drive motor
- Power (KB 60 min) kW 7 7
Brake
Spring-loaded brake on the drive motor
Brake disc thickness (nominal size) mm 13.0 13.0
Brake disc thickness (minimum size) mm 8.5 8.5
Air gap mm 0.3 - 0.6 0.3 - 0.6
Max. braking distance with/without load m
4-50 Version 1.2, 12.07.2006

Product description
Technical data

Load wheel brake
Brake disc thickness (nominal size) mm 2 mm (x5) 2 mm (x7)
Brake disc thickness (minimum size) mm 1.4 1.4
Air gap mm 1.0-1.25 1.5-1.75
Max. braking distance with/without load m
Wheels / axles (drive)
Wheel diameter max. mm 406 406
Wheel nut Nm 140 140
Wheels / axles (load wheel)
Wheel diameter max. mm 300 380
Wheel nut Nm *) *)
*) Groove nut set to required play for conical roller bearing

+ secured
Lift frame
Screw connection chassis M20 / 10.9. Nm 520 520
Hydraulics
Basic unit
Pressure liquid H-LP 46 DIN H-LP 46 DIN

51.524 51.524
Oil fill quantity: Tank / hydr. system l / max 90/130 90/140
Max. overpressure bar 210 210
Pump unit cm³ 25 25
Pump motor kW 22.3 22.3
Return flow filter µma 3 3
Air filter µma 3 3
Steering drive
Steering motor kW 1.2 1.2
Steering gears I 44.44 44.44
Version 1.2, 12.07.2006 4-51

Product description
Technical data

Electric system
Battery voltage V 80 80
Control voltage V 24 24
On-board power supply Two-wire system Two-wire system
Fuse ratings See Operating In- See Operating In-

structions structions
Tab. 4-1: Adjusting and test values
4-52 Version 1.2, 12.07.2006

Product description
Technical data
4.5.3 Type structure
Designation 1200 AC 1400 AC

Load capacity 1200 kg 1400 kg
Load center of gravity B Pal. 1200 x 1200, LSP Pal. 1200 x 1200, LSP
600 mm 600 mm
Chassis y, z, H, m, B RG 1950, 280, 60, 1200 2070, 280, 60, 1200

mm mm
Chassis y, z, H, m, B IG 1950, 280, 60, 1200 2070, 280, 60, 1200

mm mm
L2 / XD dimension (1200 x 1200) RG + IG Wa = 2266/ 3560/ 1180 Wa = 2386 / 3680/ 1180

mm mm
Load wheels (diameter x width) 2 x diameter 300 x 157 2 x diameter 380 x 152
mm mm
Motor 7 KW standing AC tech- 7 KW standing AC tech-

nology nology
Gears i = 19.07, Pmax = i = 19.07, Pmax =

40,000 N 40,000 N
Drive wheels (diameter x width) 1 x diameter 406 x 178 1 x diameter 406 x 178
mm mm
Driving control / GESI AC controller 80 V, AC controller 80 V,

DPU computer, GESI- DPU computer, GESI-
DAMBACH DAMBACH
Lift frame ZT ZT-2 cylinder front ZT-2 cylinder front
Lift frame DT ZT-2 cylinder front ZT-2 cylinder front
Lift height h3 / h9 ZT up to 8,000 mm up to 10,000 mm
Lift height h3 DT up to 8,250 mm up to 9,750 mm
Lift height htot = h3 + h9 ZT htot = 9,500 mm htot = 11,500 mm
Lift height htot DT htot = 9,750 mm htot = 11,250 mm
Lift cylinder diameter K / Z ZT 2 x diameter 55 / 75 ZT 2 x diameter 55 / 75

mm mm
from 43:7500
60/92 mm
Lift cylinder diameter K / Z DT 2 x diameter 70/92 DT 2 x diameter 70/92

mm mm
SSG-BF 12 / BF15 hs = 40 mm hs = 50 mm
AST (1200 x 1200) AST - RG ??? SA 75 AST 3 1600 SA 75 AST 3
AST (1200 x 1200) AST - IG ??? SA 125 AST 3 = 1700 SA 125 AST 3 =
??? mm ??? mm
Free lift h9 SSG 1,500 up to 1,800 mm 1,500 up to 1,800 mm
Free lift cylinder SSG 55 mm 60 mm
Version 1.2, 12.07.2006 4-53

Product description
Technical data
Designation 1200 AC 1400 AC

Hoist control - electr. / hydr. AC / SECAN / propor- AC / SECAN / propor-
tional valves tional valves
Hydraulic aggregate ??? KW / 2200 1/min / 13.5 KW / 2200 1/min /

21.5 cm³ 21.5 cm³
Electronic control 4 computers DPU, 4 computers DPU,

CPC, CPU, APE with CPC, CPU, APE with
SECAN bus SECAN bus
Steering manual / automatic Electrical steering with Electrical steering with

AC controller, AC steer- AC controller, AC steer-
ing motor ing motor
Guide RG / IG-S RG diameter 95, 140, RG diameter, 95, 140,

180 x 50 180 x 50
IG-S with 1 x sensor IG-S with 1 x sensor
front, 1 x sensor rear front, 1 x sensor rear
Brake system 3-wheel / magnetic 3-wheel / magnetic

brake / electr. load brake / electr. load
wheel brake / counter- wheel brake / counter-
current / GESI / coast- current / GESI / coast-
ing brake ing brake
Battery voltage 80 V 2 trays 80 V 2 trays
Battery capacity 560 / 560 Ah 700 Ah
Battery weight 1,580 kg 1,830 kg
Battery tray dimension L 707 mm 824 mm
Battery tray dimension B 520 mm 533 mm
Battery tray dimension H with pockets 864 mm 864 mm
Circuit A A
1200 ZT + DT 1400 ZT
1400 DT
Tab. 4-2: Type structure
4.5.4 Fuses
Note
Power and control fuses, see Operating Instructions.
4-54 Version 1.2, 12.07.2006

Lifecycle
Chapter index
Chapter 5
Lifecycle
Chapter index
5.1 Safety .......................................................................................58

5.2 Disassembly work ....................................................................62
5.3 Overview transport options.......................................................64
5.4 Standing transport ....................................................................65
5.5 Lying transport..........................................................................66
5.6 Container loading .....................................................................70
5.7 Assembly work on-site .............................................................91
Version 1.2, 12.07.2006 5-55

Lifecycle
Safety
5.1 Safety
DANGER!
Injuries and death due to tipping or falling parts
• Heed relevant safety regulations for the transport of ma-

chine components. Wear safety clothing.
In case of emergency, press EMERGENCY OFF switch.

Administer first aid and summon a doctor.
§ Note
For safety reasons, the OMNI may only be transported
by the manufacturer's service personnel.
Moving loads, unloading and reloading
• Transport may only be performed by a qualified transport company heeding

the guidelines for the transport of machine parts and after training by AT-
LET.
• Unloading processes and subsequent transport on customer premises may
only be performed by qualified personnel under the supervision of a ATLET
service employee insofar as no other agreements have been made.
• For the transport of the OMNI and its components, suitable lifts and indus-
trial trucks must be provided by the licensee. Heed the transport weight in
connection with the load limits of the vehicles. For the necessary lifting and
loading capacities of components, see the shipping data.
• Only use lifting equipment (e.g. crane) and attachment equipment, e.g. ca-
ble with a load capacity which is appropriate for the overall weight of the ma-
chine (heed safety loading). The overall weight of the respective vehicle on
the type plate serves as an orientation. Depending on additional equipment,
the weight can vary.
• Only use undamaged cables, attachment chains and straps. Never shorten
these with knots or screws. Absolutely heed that a higher load capacity
must be selected depending on the angle of attachment.
5-56 Version 1.2, 12.07.2006

Lifecycle
Safety
• To adhere to the maximum load capacity of the cable, the angle between
the load and cable should remain as close as possible to 90°, even if addi-
tional cables should be necessary.
• The OMNI is equipped with attachment points and screw in threads for ap-
propriate transport equipment (ring eyes/load clamps). Screw in load eyes
must be attached so that they are not twisted.
• The attachment equipment must be attached in such a way that it will not
damage any parts of the vehicle when the vehicle is lifted.
• Avoid abrupt falling or hard setting down of the OMNI and its components
in order to prevent possible warping or bending of machine parts.
• Hydraulic components such as hoses and valves must be handled with spe-
cial care.
• To protect against leaks, suitable aids such as square-shaped timbers, hard
rubber plates, etc. must be used.
• Heed the transport instructions on the packaging units.
Version 1.2, 12.07.2006 5-57

Lifecycle
Safety
5.1.1 Qualification
§ Note
The OMNI may be loaded, transported and unloaded
only by trained and authorized personnel (training ac-
cording to the guideline VDI2700a).
Fig. 5-1: Proof of training; example
5-58 Version 1.2, 12.07.2006

Lifecycle
Safety
5.1.2 Securing the freight and truck
The following prerequisites apply to the proper and safe loading:
• enclosed truck
• equipped with wooden floor
• corresponding fastening options, e.g. fastening eyes
• sliding tarpaulin (Edscha tarpaulin®)
Fig. 5-2: Requirements of the truck

1 Sliding tarpaulin
2 Fastening eyes
Version 1.2, 12.07.2006 5-59

Lifecycle
Disassembly work
5.2 Disassembly work
§ Note
For safety reasons, the OMNI may only be assembled
and disassembled by the manufacturer's authorized ser-
vice personnel. Unauthorized changes or additions to,
structural changes to the machine or to the accessory
equipment or to the controller endanger operational
safety and can cause severe personal injury and proper-
ty damage.
For personal injury or machine damage as well as de-
fects which arise by not following these instructions and
the safety instructions, ATLET makes no guarantee and
assumes no liability.
DANGER!
Severe injuries and even death due to falling parts
and remaining energy in the electric and hydraulic
system and tools used.
• Heed relevant safety regulations for the assembly of
machines, safety clothing
• Electric and hydraulic systems must always be dis-
charged properly.
• Ensure that the escape routes and rescue equipment
provided are accessible.
• Lay cables and hoses so that they are protected from
damage.
5-60 Version 1.2, 12.07.2006

Lifecycle
Disassembly work
5.2.1 Removing the battery
Purpose Preparatory measures same as for loading and subsequent transport.
Park the vehicle safely.

Uninstall the battery.

• Operating instructions
5.2.2 Shutting down the hydraulic system
When disassembling the hydraulic system, proceed in reverse order of the assem-
bly. Fig.: 5-33 on page 5-89 and Fig.: 5-34 on page 5-90
Procedure Remove the filler neck.

Attach the cap.
Close the unit spherical valve of the pump aggregate, the handle must be cross-
ways to the pipe.
Uninstall the front and rear IG sensors (applies only to vehicles with IG guide).
If necessary, detach the load lifting device.
; The vehicle is decommissioned.
Version 1.2, 12.07.2006 5-61

Lifecycle
Overview transport options
5.3 Overview transport options

The OMNI can be transported as follows:
• Vertical: for trucks up to 3,950 mm (provided that the customer has suffi-
cient space to store the fork lift).
• Horizontal: for trucks up to 3,950 mm
• with detached pole: if the truck provides only minimum storage space or for
container shipping.
5.3.1 Transport types
Depending upon the installation height of the lift frame and the local conditions at
the location, the transport can be performed in three different ways:
• Standing with assembled lift frame and load lifting device (for trucks starting
at 3,950 mm)
For information see Standing transport"” on page 5-63
• Standing with disassembled lift frame and load lifting device (for great instal-
lation heights or if only a little storage space is available in the truck).
For information see Standing transport"” on page 5-63 and Preparation and
pole disassembly"” on page 5-72
• Lying with assembled lift frame and disassembled load lifting device de-
signed for transport frame
For information see Lying transport"” on page 5-64
• Container shipment
For information see Container loading"” on page 5-68
Note
Perform the disassembly measures before loading. Ob-
serve the measures in Disassembly work"” on page 5-60
5-62 Version 1.2, 12.07.2006

Lifecycle
Standing transport
5.4 Standing transport

If the transport is performed with a vehicle according to the illustration, no assem-
bly work is required on the OMNI. The OMNI is simply driven onto the loading ar-
ea, secured and moved out again at the destination. No cranes are required for
unloading.
Fig. 5-3: Vertical transport with appropriate truck
Version 1.2, 12.07.2006 5-63

Lifecycle
Lying transport
5.5 Lying transport

For the horizontal transport, the OMNI must be partially disassembled. The OMNI
is laid onto the loading area and the pole is secured by a safety stand. Unloading
requires 2 cranes or a special crane with two hooks. Form fit (fixed stop) must be
heeded.
Fig. 5-4: Sample images
5.5.1 Establishing the transport state
Before the actual transport, the OMNI must be brought into a safe transport state
using the following measures.
Uninstall the battery.

Remove the front and rear aisle guide wheels. With lying transport always,
since this is not otherwise possible.
Remove the load lifting device, if necessary.
5-64 Version 1.2, 12.07.2006

Lifecycle
Lying transport
5.5.2 Safely load the OMNI 120/140 AC.
DANGER!
Injuries and death due to tipping or falling parts
• Heed relevant safety regulations for the transport of ma-
chine components. Wear safety clothing.
Purpose Prevention of damage to the OMNI 120/140 AC and to the transport vehicle during
loading. The transport can now be carried out.
2
Fig. 5-5: Attachment points
1 Lift frame attachment points
2 Vehicle frame attachment points
Procedure Use only attachment equipment with sufficient load capacity. Observe the vehi-
cle weight information on the type plate of the vehicle and the specification
about the greatest acceptable weight of the attachment equipment.
Version 1.2, 12.07.2006 5-65

Lifecycle
Lying transport
Two crane gears or a special crane with two hooks are required for loading and
unloading.
Attach the crane gear at the attachment points on the lift frame and on the ve-
hicle frame.
; The OMNI 120/140 AC can now be lifted safely with the crane.
Fig. 5-6: Lift device and turn

1 Attachment point on the pole
2 Attachment point on the vehicle frame
Park vehicle safely.
Drive pole to the lower end position and secure.
Fasten attachment equipment. Make sure that no vehicle parts can be damaged
during lifting.
Lift OMNI carefully and put in the position shown in Fig.: 5-6 on page 5-66.
Deposit OMNI in the vehicle and secure.
5-66 Version 1.2, 12.07.2006

Lifecycle
Lying transport
1 2 3
Fig. 5-7: Loading situation truck

1 Pieces of wood 300 × 300 × 300 (2×)
2 Wooden block
3 Pieces of wood 140 × 90 × 200 (2×)
5.5.3 OMNI Unloading
The procedure for unloading is identical to the loading but in reverse order.
Version 1.2, 12.07.2006 5-67

Lifecycle
Container loading
5.6 Container loading

The OMNI is usually disassembled into the following parts:
• Drive unit - chassis

• Pole with cabin and possible attachment depending on size
• Forks on a pallet
• Hoods in a sturdy box
• Small parts in a small box.
In case of a container shipment, a 40´ HC container is required, otherwise a tilt

trailer (height: 2.60 meters, length: 13.60 meters)
Prerequisites
• Ensure that the container is horizontal or tilted slightly to the front.

• Suitable spacers (e.g. wooden blocks) must be used between the individual
load units.
5.6.1 Required tools
The following tools are required:
• Straps for securing the load (4 x pole+cab, 3-4 x chassis, 1-2 x for each box)
• 2 jacks (carrying capacity 3 t)
• 2 cranes for lifting the pole with the cab
• Suitable hoisting means (no chains!)
• Support material (wooden blocks, square-shaped timbers)
• Edge protection material
• 1 stacker for lifting the chassis
• 1 hand lift truck for moving the pallets with boxes
• 3 heavy-duty rollers (carrying capacity 3 t)
• Torque wrench (580 Nm)
5-68 Version 1.2, 12.07.2006

Lifecycle
Container loading
5.6.2 Weight overview approx. values
H1 max. 4 m ZT pole
Pole + cab 2.7 t
Chassis 1.7 t
Attachment and sideshift frame 1.0 t
Battery see type plate
H1 < 4 m ZT pole
Pole + cab 2.4 t
Chassis 2.5 t
H1 > 4 m ZT pole
Pole + cab 3.5 t
Chassis 2.5 t
H1 max. 3.75 m 1400 ZT ZT pole

Pole + cab 3.5 t
Chassis 2.5 t
1400 DT DT
4.0 t
2.5 t
1.5 t
see type plate
Tab. 5-1: Weight overview
Version 1.2, 12.07.2006 5-69

Lifecycle
Container loading
5.6.3 Size determination for container shipping
Tilted vehicles
Length:h1 + l8 (+1000 mm for battery + 1000 mm for hoods)
Height: Chassis length*
Width: b6, b2, or b15 (depending on the model)
Standing vehicles
Length:Chassis length* + l8
Height: h1
Pole disassembled
Length:Chassis length* + h1 + l8 (+1000 mm for battery)
Height: Floor up to upper edge of battery cover
Chassis lengths
Hi-Racker 1000AC: 2,500 mm
Hi-Racker 1200AC: 2,800 mm
Hi-Racker 1400AC: 2,900 mm (ZT pole) / 3000 mm (DT pole)
Hi-Racker 1600DC: 3,200 mm
* +100 mm with divided control panel
5-70 Version 1.2, 12.07.2006

Lifecycle
Container loading
5.6.4 Corrosion protection
Parts
The following parts must be protected against corrosion. The parts marked with *
must be depreserved at the destination. See “Depreserving” on page 5-86.
• Turning ring gear drive unit*

• Pump unit battery compartment*
• Sideshift motor
• Lift cylinder (non-chromed surfaces)*
• Grease pole profile*
• Battery roller track (if present)
• Connector surfaces pole to chassis and the thread*
• All (anchor) chain bolts & fasteners
• Surface for lift platform / included plates for attachment*
• Bearing block on the potentiometer
• Sensor unit clamp
• All guide/supporting roller bearings*
• Lift cylinder setting pieces
• Spring brake blank surfaces
• Base plate drive
• Foot switch/cabin
• Driver's seat fastening plate*
• Lift frame connector element*
• Drive shaft swivel/traverse arm
• Toothed rack*
• All open screws and threads
• Aluminium fastening return flow filter*
• Fastening of sensor including cover*
• Sensor unit in the main lift incl. cover*
• Fastening of IG sensor
Container
The following measures must be carried out in the container:
• Dehumidifier
• Close ventilation in container
Version 1.2, 12.07.2006 5-71

Lifecycle
Container loading
5.6.5 Preparation and pole disassembly
Lift main lift until inner pole is above the first transverse beam
Use mast cut-out (Fig.: 5-10 on page 5-73)
Lower main lift onto pole safeguard
Straighten drive wheel
Switch off the vehicle
Remove battery from vehicle
Prepare vehicle for transport as described in the Operating Instructions
Disconnect hydraulic connections underneath cab and close them
Disconnect pole cable connection
Hang pole on crane with straps
Place second strap around the pole foot and hang on fork lift
Loosen the pole screws
Lift pole and ensure that the second strap is tensioned
Align pole horizontally and place it on suitable wooden blocks
If necessary, attach existing plain washer plates with cable ties at pole foot
(Caution: do not mix up left and right side)
Lash cab onto pole (belt fastening illustrations Mastfuß.jpg, Gurt über Kab-
ine.jpg
Fig. 5-8: Strap mounting on pole foot
5-72 Version 1.2, 12.07.2006

Lifecycle
Container loading
Fig. 5-9: Strap mounting at cab

Securely attach disconnected pole cable at pole.
Fig. 5-10: Secure pole cable
Version 1.2, 12.07.2006 5-73

Lifecycle
Container loading
5.6.6 Loading and securing of boxes
Place boxes in the container using a stacker and hand lift truck and secure them
with ratchet straps
Fig. 5-11: Secure boxes

If ratchet straps are tensioned over sharp edges, a suitable edge protection
must be placed underneath to avoid damaging the straps.
Fig. 5-12: Edge protection
5-74 Version 1.2, 12.07.2006

Lifecycle
Container loading
5.6.7 Loading and securing of chassis
Move forks under the chassis on the rear side (Caution: Do not damage sensor
technology on the left and right at the bottom of the chassis)
Slowly lift chassis with fork lift
Fig. 5-13: Lift chassis

Place chassis in the container
Unscrew brake loosening screws from the motor plate and screw them into the
spring-loaded brake until the chassis can be moved.
Fig. 5-14: Loosen brake

1 Brake loosening screws in the motor plate
2 Screw locations (2x across from one another)
Version 1.2, 12.07.2006 5-75

Lifecycle
Container loading
Move chassis into the container

Unscrew brake loosening screws from the spring-loaded brake again and screw
it into the motor plate
Secure chassis with ratchet straps
Fig. 5-15: Secured chassis

5-76 Version 1.2, 12.07.2006

Lifecycle
Container loading
5.6.8 Loading and securing pole with cab
Preparation (only for assembled attachment)
Before placing in the container, brace the auxiliary lift pole between the master
profile and the free-lift pole with wood angles.
Fig. 5-17: Brace auxiliary lift pole
Version 1.2, 12.07.2006 5-77

Lifecycle
Container loading
Procedure
The pole is placed on wooden blocks at both ends. The wooden blocks for the first
end of the pole (moved first into the container) must be able to ensure that the pole
can be moved on heavy-duty rollers across the wooden blocks. After removing the
heavy-duty rollers, the first end of the pole must rest on the wooden blocks.
Fig. 5-18: Pole on wooden blocks

Place wooden blocks in the container for the first end of the pole.
Important note!
If the wooden blocks consist of several blocks, they must
by attached to each other with nails.
Position a suitable lifting gear above and below the cab on the pole
5-78 Version 1.2, 12.07.2006

Lifecycle
Container loading
Below the cab on the left side: Place rectangular timber between pole and lifting
gear so that the power supply chain is not damaged.
Fig. 5-19: Protect power supply chain

Lift pole horizontally.
Fig. 5-20: Lift pole
Version 1.2, 12.07.2006 5-79

Lifecycle
Container loading
Move first end of the pole into the container.
Fig. 5-21: Move first end of the pole into the container
Place first end of the pole on the heavy-duty rollers; the first lifting gear becomes
free.
Fig. 5-22: Place first end of the pole
5-80 Version 1.2, 12.07.2006

Lifecycle
Container loading
Remove the first lifting gear and move pole further into the container.
Fig. 5-23: Remove first lifting gear

Straighten pole in the container and place the second end of the pole onto
heavy-duty rollers.
Fig. 5-24: Second end of the pole on heavy-duty rollers
Version 1.2, 12.07.2006 5-81

Lifecycle
Container loading
Remove second lifting gear.

Move pole further into the container on the heavy-duty rollers until the first end
of the pole is beyond the wooden blocks.
Fig. 5-25: Continue moving pole into the container
Fig. 5-26: End of pole beyond the wooden blocks
5-82 Version 1.2, 12.07.2006

Lifecycle
Container loading
Lift first end of the pole on the left and right using jacks.
Remove heavy-duty rollers.
Place first end of the pole on wooden blocks.
Important note!
Lift second end of the pole on the left and right using jacks.
Remove heavy-duty rollers.
Place second end of the pole on wooden blocks.
Important note!
Fig. 5-27: Place second end of the pole
Version 1.2, 12.07.2006 5-83

Lifecycle
Container loading
Secure lower pole end on the pole foot plates and on the front end with tension
belt.
Fig. 5-28: Secure lower end of the pole

Secure upper end of the pole with ratchet straps.
Fig. 5-29: Secure upper end of the pole
5-84 Version 1.2, 12.07.2006

Lifecycle
Container loading
Version 1.2, 12.07.2006 5-85

Lifecycle
Container loading
5.6.9 Loading and securing disassembled attachment
If the attachment is separately loaded from the vehicle, it is secured on a pallet.

• Loading and securing disassembled attachment, see Loading and securing of
boxes"” on page 5-74
5.6.10 Unloading the components, pole assembly and commission-

ing
The procedure is performed as described in Preparation and pole disassembly"”

on page 5-72 to Loading and securing disassembled attachment"” on page 5-86,
although in reverse order.
5.6.11 Depreserving
The parts marked on the list (Corrosion protection"” on page 5-71) must be depre-
served. Typically, the OMNI is preserved with the preservation agent OKS 2100.
In this case, OKS 2611 should be used for depreservation.
Important note!
The vehicle may not be depreserved with a steam blast-
er.
DANGER!
Risk of fire and danger when swallowing
• The instructions from the manufacturer must be ob-
served.
In case of emergency, administer first aid and summon a
doctor.
5-86 Version 1.2, 12.07.2006

Lifecycle
Container loading
Fig. 5-31: Preservation compound OKS datasheet
Version 1.2, 12.07.2006 5-87

Lifecycle
Container loading
Fig. 5-32: Preservation compound OKS safety data sheet
5-88 Version 1.2, 12.07.2006

Lifecycle
Assembly work on-site
5.7 Assembly work on-site

The assembly of the vehicle on-site must be performed by the manufacturer's
trained personnel. If several vehicles are delivered, it must be checked that the
load lifting device, the lift frame and the chassis (the serial number must be iden-
tical) are assembled only with identical serial numbers.
DANGER!
Risk of injury by slipping on spilled oil
• Remove spilled oil immediately
• Pay close attention
In case of emergency, administer first aid and summon a
doctor.
The Hi-Racker may be commissioned only of the following measures have been
performed:
5.7.1 Assembling the hydraulic system
Purpose The supply of the vehicle with hydraulic oil is reestablished.
Fig. 5-33: Hydraulic system

1 Cap
2 Filler neck
Version 1.2, 12.07.2006 5-89

Lifecycle
Procedure Remove the cover from the aggregate container.

Remove the cap.
Install the breather filter.
Check the hydraulic oil level.
Fig. 5-34: Hydraulic system - pipework

1 Spherical unit valve
Open the spherical unit valve of the pump aggregate. The handle must be
crossways to the pipe.
Install the front and rear IG sensors (applies only to vehicles with IG guide).
Attach the load lifting device.
; The hydraulic aggregate is operational
5-90 Version 1.2, 12.07.2006

Lifecycle
5.7.2 Prepare the brakes for commissioning
DANGER!
Danger of crushing by automatic movement of the
load wheel
• Do not linger in the movement and danger zone.
Purpose Place the OMNI 120/140 AC in an operationally reliable state.
Fig. 5-35: - Front view
Procedure Check whether the brake loosening screws at the spring-loaded brake are
screwed out.
If necessary, remove the brake loosening screws with nuts and screw them into
the appropriate boreholes in the base plate.
If necessary, place load wheel brake in operating state.
Reattach the cover of the aggregate space.
; The brakes are operational
Version 1.2, 12.07.2006 5-91

Lifecycle
5.7.3 Battery installation
DANGER!
Danger of crushing by automatic movement of the
drive wheel
• Before the connection, press EMERGENCY OFF

switch.

Purpose Establish the power supply for the OMNI 120/140 AC.
Procedure Install the battery.

Attach any additional weights according to the separate sign and fasten them.
Observe min/max battery weight according to the type plate.
Secure battery.
; The vehicle is supplied with current and can now be commissioned.
5-92 Version 1.2, 12.07.2006

Chapter index
Chapter 6
Chapter index
6.1 General.....................................................................................96
6.2 Individual components..............................................................97
6.3 Basic unit ..................................................................................98
6.4 Lift frame ..................................................................................99
6.5 Load lifting device (LLD).........................................................100
6.6 Battery equipment ..................................................................101
6.7 Hydraulics...............................................................................102
6.8 Inspections .............................................................................103
6.9 Supplied documentation .........................................................104
Version 1.2, 12.07.2006 6-93

General
6.1 General
§ Note
The initial commissioning of the vehicle must be per-
formed according to these instructions. In addition, the
operating instructions must be observed. The assembly
on-site, the commissioning and the introduction of the
operator must be performed by trained personnel from
ATLET.
Before commissioning, check the vehicle and equipment
for completeness and flawless condition. The operator
must perform a risk and danger analysis prior to com-
missioning. For this purpose, vehicle and operating ar-
eas must be examined to rule out any danger to the
operator or any other persons.
6-94 Version 1.2, 12.07.2006

Individual components
6.2 Individual components

All components that are not affixed to the vehicle in the delivery state (so-called
individual components) are listed on the delivery note.
The following are supplied:
• 1 Bridge for battery support

• 1 Protective molding (optional)
• Various connecting screws (supplied in the box)
• Covers (supplied in the box)
• 1 Air filter for oil tank
• Emergency lowering device (supplied in the box)
• Components for special equipment
Version 1.2, 12.07.2006 6-95

Basic unit
6.3 Basic unit
Note
For IG vehicles that are not shipped standing, the IG
sensor is disassembled under the cab. To be able to
move the vehicle, the sensor must be connected at least
electrically with the connector after setting up the vehi-
cle.
The sensors of IG vehicles are at risk due to their low ground clearance, particu-
larly when driving on ramps.
After setting up the vehicle

Remove plastic bands and square-shaped timbers of the cab fastening.
Adjust the switch for aisle detection and aisle end stop on the load side of the
chassis to the correct height and alignment with the floor magnets (ground dis-
tance 40 mm).
Remove protective molding from cab railing and attach it to the load wheel
housings.
Remove oil tank cap and install air filter (see Operating Instructions).
Open hydraulic valve under the battery (lever longitudinal to the pipe, see Op-
erating Instructions).
Check oil level in the drive gear (see Operating Instructions).
Check leakage-proofness of entire vehicle.
Check whether the lowering device is properly stored underneath the driver's
seat.
6-96 Version 1.2, 12.07.2006

Lift frame
6.4 Lift frame
Note
If several vehicles are delivered at the same time, en-
sure that the serial number of chassis, lift frame and load
lifting device match.
For delivery with disassembled lift frame

Fasten pole screws with specified torque (See “Adjusting and test values” on
page 4-50.).
Check lift frames for correct slope (See “Backward tilting of the mast” on page 7-
132.).
Connect hydraulic lines to lift cylinder.
Route electric cable harness in the chassis and in the cable tray if the drive com-
partment.
Version 1.2, 12.07.2006 6-97

Load lifting device (LLD)
6.5 Load lifting device (LLD)
Note
If several vehicles are delivered at the same time, en-
sure that the serial numbers of chassis, lift frame and
load lifting device match.
For delivery with disassembled load lifting device (LLD)

Place LLD on wooden blocks.
Place LLD on suspended beam at the front cab side and fasten and tighten with
the supplied M 16 screws. If necessary, use existing plain washer plates.
Check free hoisting mast in longitudinal direction of vehicle with level for hori-
zontal position.
Note
The vertical position results from the alignment of
toothed shaft and toothed rack and cannot be changed.
Tighten the 4 fixing screws M 16 with 170 Nm torque.

Secure with pins
Remove the sealing plugs of the hydraulic lines of attachment and cab.
Connect the tubings according to the marking.
Connect cable of cab and LLD
6-98 Version 1.2, 12.07.2006

Battery equipment
6.6 Battery equipment
Note
The use of acid batteries is described in the Operating
Instructions.
The weight of the battery and, if necessary, defined additional weights is absolute-
ly required for the structural ability of the vehicle.
If additional battery weights are planned, they must be properly installed prior to
operating the vehicle and secured with screws.
The specified battery weight is entered on the vehicle type plate (See “Spare parts”
on page 1-18.). Other battery weights are not permissible.
If necessary, install additional weights.

Install bridge for battery support.
Insert the battery.
Insert left and right battery shutters.
Connect battery cable to battery pole.
Couple battery socket with vehicle plug.
Check battery for charging state and water level (see Operating Instructions of
the battery manufacturer).
If necessary, insert lateral battery covers.
Note
Moving the vehicle without battery power is described in
the Operating Instructions.
Version 1.2, 12.07.2006 6-99

Hydraulics
6.7 Hydraulics
6.7.1 Pump aggregate
Note
To prevent damage to the pump, perform a thorough
commissioning.
For commissioning
Switch on the vehicle.
Activate main lift for a few seconds, watch for noises from the pump.
Note
In case of insufficient pump performance or atypical
pump noises (cavitation noise), immediately switch off
the pump motor and determine the cause.
Switch off the vehicle.
6.7.2 Hydraulic system
After putting the pump into operation

Check all pipe connections for leakages, particularly the cab/LLD connection.
Vent main and auxiliary lift cylinder (See “Bleeding the cylinder” on page 8-
216.).
Check the function of the slack chain switch.
Check the function of the lift sensor technology and toothed belts (if present).
Check operating states and emergency off circuits in aisle and apron.
; The vehicle is now ready for operation.
6-100 Version 1.2, 12.07.2006

Inspections
6.8 Inspections
For safe operation of the order-picking stacker, adhere to the appropriate require-
ments for the floor and the rack (the vehicle was designed for the requirements
agreed upon with the licensee).
During commissioning, a person authorized by ATLET must drive the vehicle un-
loaded and unloaded in all rack aisles at different heights (or other driving areas
which may be used). Here the aisle-end functions (GESI) must also be checked:
• Braking to a stop
• Braking to vcreep
• Braking to distance measurement
The shifting heights and the speeds permissible for these must be checked for or-
derly assignment while driving. If the vehicle tends to large vibration amplitudes or
if the safety distances on location do not permit operation without danger, then the
driving speed and/or the shift heights must be reduced by the person named
above. All parameter changes during commissioning must be reported to ATLET
immediately. If nevertheless operation without danger is not possible, the vehicle
may not be put into operation. Transfer to the customer is prohibited. In this case
ATLET must be informed immediately.
The requirements of DIN 15125 are minimum requirements and should be under-
run. At lift heights above ten meters, these must be underrun. The rack tolerance
requirements in DIN 15125 must also be adhered to or underrun.
Version 1.2, 12.07.2006 6-101

Supplied documentation
6.9 Supplied documentation

The product documentation is compiled by the manufacturer dependent upon the
order and supplied with the vehicles as follows:
6.9.1 Documentation behind driver's seat in storage box (plastic

cover)
• Operating Instructions
• CE certificate
• VDMA brochure
• Acceptance certificate (settings)
• Detailed electrical wiring diagram
§ Note
The documents listed must be kept with the vehicle.
6-102 Version 1.2, 12.07.2006

Mechanical parts
Chapter index
Chapter 7
Mechanical parts
Chapter index
7.1 Safety instructions ................................................................. 106

7.2 Torque values for screwed connections ................................ 110
7.3 Ground requirements ............................................................ 111
7.4 Vehicle guidance ................................................................... 116
7.5 Lift frame and cabin ............................................................... 132
7.6 Chassis.................................................................................. 140
7.7 Load axles and load wheels .................................................. 142
7.8 Load wheel ............................................................................ 143
7.9 Mechanically released spring-loaded brake (magnet brake). 150
7.10 Traction drive......................................................................... 155
7.11 Swivel/traverse fork ............................................................... 157
7.12 Telescopic fork ...................................................................... 163
7.13 Fork test ................................................................................ 177
7.14 Lift chains .............................................................................. 179
7.15 "Master Speed Plus" testing instruction................................. 188
Version 1.2, 12.07.2006 7-103

Mechanical parts
Safety instructions
7.1 Safety instructions
7.1.1 Working under lifted frame
DANGER!
When work is to be performed under the lifted frame,
the inner pole and the cabin must be securely pro-
tected against lowering.
The following measures can be taken to secure the lift frame:
• attach sufficiently strong chains to the lift frame straps (varnish and attach-
ments may be damaged)
• place sufficiently strong supporting frames between floor trough and inner
pole
• use the hoist frame locking device (only available for newer vehicles)
DANGER!
Triggering hydraulic functions as well as closing the
main water cock do not provide reliable safety !
7-104 Version 1.2, 12.07.2006

Mechanical parts
Safety instructions
Hoist frame lock device
3
2
Fig. 7-1: Hoist frame lock device
1 Right outer pole 3 Securing screw

2 Hoist frame lock device
The lift frame lock device is attached to the right-hand outer frame. The securing
screw prevents undesired engaging of the hoist frame lock device during opera-
tion of the vehicle.
DANGER!
Carefully check the lift frame lock device for damages
and proper connection before using it.
The lift frame lock device does not directly act upon the cabin but supports the in-
ner pole. When work is performed on the cabin lifting system or if the system is
damaged (e.g. lifting chains), the cabin must first be completely lowered.
Version 1.2, 12.07.2006 7-105

Mechanical parts
Safety instructions
Activating the hoist frame lock device
To activate the hoist frame lock device

lift the cabin until the lower edge of the inner pole is above the hoist frame lock
device
use an open-ended wrench to unscrew and remove the securing screw. Keep
the screw
Fig. 7-2: Loosen the hoist securing screw

tilt up the hoist frame locking device until it stops
carefully lower the cabin until the inner pole rests on the hoist frame locking de-
vice.
Deactivating the locking device
lift the cabin

tilt back the hoist frame locking device
insert and tighten the securing screw
DANGER!
Do not start the vehicle when the securing screw has
been removed.
7-106 Version 1.2, 12.07.2006

Mechanical parts
Safety instructions
7.1.2 Working at dangerous heights
DANGER!
Risk of falling when working at dangerous heights
• Secure against falling with lifebelt and safety line.
• Use secure ladders.
• Secure ladders against tipping and slipping.
Leave the lifted cabin via emergency lowering device in
emergency situations (-> operating instructions).
DANGER!
Persons lingering below the worker have to protect
themselves against falling parts by wearing a protec-
tive helmet.
7.1.3 Gas-pressure springs
Gas-pressure springs are installed, e.g. in the control panel and in the cabin cab-
inets.
DANGER!
Gas-pressure springs are highly energized.
• Never open the gas-pressure springs.
• Defective gas-pressure springs must be exchanged
completely.
Version 1.2, 12.07.2006 7-107

Mechanical parts
Torque values for screwed connections
7.2 Torque values for screwed connections

Refer to operating instructions.
7-108 Version 1.2, 12.07.2006

Mechanical parts
Ground requirements
7.3 Ground requirements

7.3.0.1 Specification
The use of narrow aisle lifts has special requirements Observing the following
ground values is of fundamental importance for the function of the narrow aisle lift
and is therefore a part of the storage system technology. We request that you pay
special attention to this. We recommend that you exclude these regulations of your
order to claims from the floor and control manufacturer.
The floor must meet the following specifications:
Requirements
Concrete quality / subsoil Reinforced concrete with quality of at least
B25
Electrostatic dissipation Earth leakage resistance R, measured

acc. to DIN 51953 of max. 106 Ohm
Floor covering High non-slip texture, dry and even sur-

face, braking ability of the fork-lift vehicle
Screed
acc. to DIN 15810; friction coefficient of
Vulkollan µ = 0.4 - 0.5.
Strength of floor covering Acc. to DIN 18560, part 7 (screed in build-

ing construction) High-duty screed acc. to
group II middle: Vulkollan tire equipment
Mineral-oil resistance Oil loss from the vehicles is possible.

This requirement is met by all building ma-
terials except bitumen.
Compression strength 12 N/mm² acc. to DIN 1164
Tolerances Observance of the tolerances listed below

depending on DIN 15185, Part 1 is an ab-
solute requirement.
Tab. 7-1: Ground requirements
Version 1.2, 12.07.2006 7-109

Mechanical parts
Ground requirements
7.3.0.2 Measurement tolerances
Transverse to the aisle, the maximum deviation may have the following values over the entire passage
width acc. to DIN 15185, Part 1:
Transverse
1,000 mm 1,500 mm 2,000 mm
gauge length1
Dimensional (2.0) 1.5 mm (2.5) 2.0 mm (3.0) 2.5 mm
tolerance2
(total value):
Upper (+)/ r(1.0) 0.75 mm r(1.25) 1.0 mm r(1.5) 1.25 mm

lower (-)
tolerance2
Tab. 7-2: Measurement tolerances

1)
Intermediate values must be interpolated
2)
Values is brackets are valid forOMNI 100 AC
Longitudinal to the aisle, the maximum deviation may have the following values over the entire passage
length acc. to DIN 15185, Part 1:
Transverse
1m 2m 3m 4m 15 m 50 m 100 m
gauge length1
Measurement toler- 2 mm 3 mm 4 mm 5 mm 9 mm 15 mm 15 mm
ances
(total value):
Upper (+)/ r1.0 mm r1.5 mm r2.0 mm r2.5 mm r4.5 mm r7.5 mm r7.5 mm

lower (-)
dimension
Tab. 7-3: Measurement tolerances
1)
Intermediate values must be interpolated
2) Values is brackets are valid forOMNI 100 AC
7-110 Version 1.2, 12.07.2006

Mechanical parts
Ground requirements
7.3.1 Evenness
7.3.1.1 Basics
The evenness of the floor is a basic requirement for the secure use of OMNI par-
ticularly when using in narrow passages with high shelves.
Inclination of standing vehicle (static inclination))
An unevenness of 2.5 mm between the two vehicles (1150 mm medium distance)

already causes an inclination of 30 mm at 14 m height.
Swings when running (dynamic swings)
When driving, there are additional negative influences that result from the play of
the components, the dynamic vehicle movement and the combination of uneven-
ness in the longitudinal and transverse direction. Experience shows that you can
take a factor of 3 ... 4 to the inclination of the standing vehicle. The load to the pole
is correspondingly high, as well as the body panels and even the electronic com-
ponents. For this reason, uneven floors present a high safety risk
E
S = H ----
D
Fig. 7-3: Inclination
Rack Height difference between the load wheels E (mm)

height
H (m) 3 4 5 6 7 8 9 10 11 12
6 12 17 21 25 29 33 37 41 46 50
6.5 13 18 22 27 31 36 40 45 49 54
Version 1.2, 12.07.2006 7-111

Mechanical parts
Ground requirements
Rack Height difference between the load wheels E (mm)

height
H (m) 3 4 5 6 7 8 9 10 11 12
7 14 19 24 29 34 39 43 48 53 58
7.5 16 21 26 31 36 41 47 52 57 62
8 17 22 28 33 39 44 50 55 61 66
8.5 18 23 29 35 41 47 53 59 64 70
9 19 25 31 37 43 50 56 62 68 74
9.5 20 26 33 39 46 52 59 66 72 79
10 21 28 34 41 48 55 62 69 76 83
10.5 22 29 36 43 51 58 65 72 80 87
11 23 30 38 46 53 61 68 76 83 91
11.5 24 32 40 48 56 63 71 79 87 95
12 25 33 41 50 58 66 74 83 91 99
12.5 26 34 43 52 60 69 78 86 95 103
13 27 36 45 54 63 72 81 90 99 108
Tab. 7-4: Dependence of static and dynamic inclination
The table shows the static inclination of a fork lift presupposing that the pole is rigid. The values arising
for the dynamic swing when driving are based on a vehicle with a distance of 1.45 m between the load
wheels.
7-112 Version 1.2, 12.07.2006

Mechanical parts
Ground requirements
7.3.1.2 Checking floor evenness
For high-bay systems, the check is normally by means of cross-section leveling

survey along the 3 tracks. The test points are one meter apart. Transverse to the
track, the test points are at the distance of the load-wheel track.
In the longitudinal direction, each of the 3 tracks are checked and evaluated
In the aisle longitudinal direction, a check can also be made with a straight edge
and measuring key. The 3 consecutive test points are thereby taken into consid-
eration and evaluated.
A more simple and exact test can be carried out using the "electronic profiler". This
is a device that runs on the tracks and that continuously records with a graph re-
corder both the difference in height of the 3 tracks to each other as well as the un-
evenness along the tracks electronically and with a precision of 0.1 mm.
The floor should be checked immediately after manufacture and an appropriate

acceptance certificate should be written up.
The following literature can be recommended for the manufacture and checking of
the floor:
• Special Printing: Industriebau (3) Mai 94, 40. Jahrgang, Duraplan

• Böhl-Boden, Regale, Leitlinien, VDI Report No. 1003/1992
Version 1.2, 12.07.2006 7-113

Mechanical parts
Vehicle guidance
7.4 Vehicle guidance
7.4.1 Rail guidance
- low lateral guide rail
Fig. 7-4: Lateral guide rail
For the standard rail guidance, the distance of the guide rollers to the floor mea-
sures 30 to 50 mm. In this case, guide rails with a height of 100 mm are used
(L100).
For the low rail guidance, the distance of the guide rollers to the floor measures >
10 mm. In this case, guide rails with a max. height of 45 mm and measuring forks
are used. The pallet can be lifted off of the ground if the distance of outer edge
guide rollers b6 (between the rails) is 160 mm less than the distance between the
deposited pallets Ast.
A high rail guidance is possible using an UNP 100 rail which is anchored with small
plates (see next page).
§ Note
The rollover and stability tests performed according to
machinery directive MRL 98/37 EG have shown that our
vehicle types Hi-Racker 1400 AC and Hi-Racker 1600
DC may be used only with standard rail guidance (height
of 100 mm).
The low rail guidance can be used only for our vehi-
cles OMNI 100 AC and 120 AC; provided that the cab
lift h3 = 8,000 mm
7-114 Version 1.2, 12.07.2006

Mechanical parts
Vehicle guidance
The following rail guidance variants are available:

• Standard guide rail: L-profile 100 [L100 x 65 x 9; DIN 1045]
• The following profiles for the low rail guidance are available upon request:
U-profile U65 [U65 x 42; DIN 1026]
or alternatively L-profile L65 [L65 x 50 x 7; DIN 1029]
§ Note
Atlet is neither responsible nor liable for applications that
deviate from the aforementioned guidelines.
Lined guide rail C-profile
Fig. 7-5: Lined guide rail C-profile
Clean the floor, no floor lining required
Version 1.2, 12.07.2006 7-115

Mechanical parts
Vehicle guidance
U-rail UNP 100 (DIN 1026)
Fig. 7-6: U-rail UNP 100 (DIN 1026)
Front floor lining is not required if passage matches the dimension between the
guide rails.
L-rail 100 x 65 x 9 (standard)
Fig. 7-7: L-rail 100 x 65 x 9 (standard)
Simple assembly since the screw connection is done via the branch.
7-116 Version 1.2, 12.07.2006

Mechanical parts
Vehicle guidance
The load unit can be placed on the floor directly behind the guide rail if the distance
of outer edge guide rollers b6 (between the rails) is 160 mm less than the distance
between the deposited pallets Ast.
Version 1.2, 12.07.2006 7-117

Mechanical parts
Vehicle guidance
As a drive-in aid, a mechanical guide bend (left figure) or a mechanical drive-in

guide (right figure) should be installed at the beginning of the aisle.
The forces that occur are absorbed by using a correspondingly narrow keying at
the loading process.
To protect against possible deformation, it is recommended to fill the area behind

the guide rail with concrete.
7-118 Version 1.2, 12.07.2006

Mechanical parts
Vehicle guidance
7.4.2 Overview of guide rail variants
Fig. 7-10: Overview of guide rail variants
Version 1.2, 12.07.2006 7-119

Mechanical parts
Vehicle guidance
7.4.3 Lateral floor rail forces of OMNI
Drive-in and aisle situation
F1
vmax=
12 km/h
Rear
F1 Aisle situation
Aisle drive-in situation

F2
15°
Floor rail
vcentr.=
2.5 km/h
Rear
Fig. 7-11: Drive-in and aisle situation
Rail loading through lateral forces
Lateral forces that must be absorbed by the guide rails occur when driving into the
aisle. These occurring compressive forces are dependent upon the mass of the
vehicle and the speed driven. Depending on the vehicle type, the max. values in
the mounting area F2 are approx. 10 - 20 KN daN and in the route F1 approx. 5 to
10 KN. The thrusts of the guide rails must be welded and the stop face must be
even. Ensure sufficient and safe keying.
7-120 Version 1.2, 12.07.2006

Mechanical parts
Vehicle guidance
7.4.4 Induction guidance
Fig. 7-12: Sensors for scanning the guide wire for induction guidance
1 1 x front
2 1 x rear
For the induction guidance or even the guide wire guidance, the instantaneous ve-
hicle position is determined via sensors. The vehicle software processes these
values and transfers the corresponding control values for automatic steering cor-
rection to the vehicle steering. For safety reasons, an additional mechanical lock
is installed at the steering ring.
This constrained vehicle guidance relieves the operator of any steering work and
allows him to specifically concentrate on the stacking and picking work.
Advantages of induction guidance
• No rails on the warehouse floor

• No concrete pedestals required
• Pallets can be placed on the warehouse floor
• Clean warehouse floor (the floor can be cleaned)
• Less expensive with respect to the complete warehouse layout
Version 1.2, 12.07.2006 7-121

Mechanical parts
Vehicle guidance
7.4.5 Aisle detection
For the steering to be locked and the aisle program or safety check to be activated,
the device must "recognize" the aisle.
For this reason, the Atlet are equipped with sensor that are installed in the front
and rear section of the stacker and recognize the magnets placed in the ware-
house floor. The floor magnets are located in every single aisle.
This solution has already been implemented in over 3,500 installations.
For the guide wire guidance, the aisle detection is implemented or switched via the
guide wire. Advantage:
• fast
• safe
• no additional sensors
A system that is switched via photodiodes can be installed as an option. These

sensors are mounted on both sides of the stacker and send a light beam onto re-
flectors at the guide rails.
However, this light beam does not provide the same safety value as the floor mag-
nets since they can become dirty or even affected by other light sources. This so-
lution should be used only in existing systems.
7.4.6 Aisle end stop
The electronic aisle end stop is a mandated safety equipment for narrow aisle ve-
hicles which prevents them from leaving the work aisle during fast speed. This pro-
vides a meaningful protection of the people and other vehicles located in the cross
aisle.
At the end of every aisle, the vehicle is slowed down either to creep speed or to
standstill. Only after braking or standstill is it possible to restart the vehicle in both
directions after a visual inspection of the front perimeter by the driver.
The aisle end stop is carried out only via sensors in the front and rear area of the
OMNI and via floor magnets.
7-122 Version 1.2, 12.07.2006

Mechanical parts
Vehicle guidance
7.4.7 Placement of floor magnets
Magnets Stop
for positioning n
DIA no. 177833 S Braking distance + l8 +b12/2
max. 1,000 mm in front
of the stop position Warning! With vxmax = 10.5 km/h
1) = 7,200 mm
Installation crossways to
driving direction
b12/2 Rectangular magnet GESI
North
South
L8
Filling compound
Round magnet
aisle detection Aisle detection
DIA no. 177833
Important:
For GESI magnet, north pole
must always be installed at top!
Check for round magnet:

North-north repulsion
North pole
backward
forward
GESI
GESI
South pole
b = 2,000 for forward system direction

Filling compound (in load direction)
b = 150 for backward system direction
b = 2,000 for forward/backward sys-

tem direction
N: North pole (top countersink)

S: South pole (bottom countersink)
690 5th track

110 4th track
220 3rd track
280 2nd track
170 1st track
Interchanging aisle
1st rack column
Fig. 7-13: Placement of floor magnets
Version 1.2, 12.07.2006 7-123

Mechanical parts
Vehicle guidance
7.4.8 Routing the guide wire
Guide wire course A (continuous course in row)
Rack
2 wires
Angular cutting
for wire routing
1 wire
2 wires
Frequency generator:
220 V / 50 Hz
Fig. 7-14: Guide wire course A (continuous course in row)
Guide wire course A is recommended for short and up to 4 - 5 aisles.
Maximum wire length = 1,000 m.
Frequency generator with 8 outputs and inputs.
Possible wire frequencies: 5.2 - 5.7 - 6.25 - 7.0 - 10.0 kHz.
Wire current 35 mA.
7-124 Version 1.2, 12.07.2006

Mechanical parts
Vehicle guidance
Guide wire course B (separate course parallel guidance)
Course 8
Rack
Course 3
Angular cutting
for wire routing
Course 2
max. 8 wires Course 1
max. 8 wires
Frequency generator:
220 V / 50 Hz
Fig. 7-15: Guide wire course B (separate course parallel guidance)
Guide wire course B is recommended for long and more than 5 aisles.
Maximum wire length = 1,000 m.
Frequency generator with 8 outputs and inputs.
Possible wire frequencies: 5.2 - 5.7 - 6.25 - 7.0 - 10.0 kHz.
Wire current 35 mA.
Version 1.2, 12.07.2006 7-125

Mechanical parts
Vehicle guidance
7.4.9 Guide wire routing and wire design
The guide wires are

Course A Filling compound routed in a groove
that is at least 10 mm
deep and sealed.
max. 2 guide wires
The groove required for

Course B Filling compound the guide wire is cut ac-
cording to the adjacent
sketch. After inserting
and tensioning the guide
wire, the groove is sealed
even with the floor.
Guide wire:
plastic-sheathed copper
strand: HO5VK, 0.75
mm2, blue, Ø ~ 2.5 mm.
Max. 8 guide wires.
Fig. 7-16: Guide wire routing and wire design
7-126 Version 1.2, 12.07.2006

Mechanical parts
Vehicle guidance
7.4.10 Safety regulations and tolerances for narrow aisle
Tolerance Tolerance description Rack class

"Man high" "Man down"
A Deviation for each compartment grid 3 3

At Deviation of rack length accumulated per com- 3n 3n
partment grid
B-Bn Offset of opposite supports on both sides of an 10 10

aisle, added for the number of shelves "n" mea- or or
sured near to floor 1.0n 0.5n
c Plumb-line deviation of stand in x and z-direction x z x z
10 10 10 10
or H/500 or H/500 or H/350 or H/750
D Nominal size of stand depth (single or double 3 3

rack)
E Deviation of aisle width 5 5

EFÜ Distance between mechanical line guidance on +4/-0 +4/-0
entire length for length of 1 m
(b6) 2 2
F Deviation from nominal straightness of an aisle 5 5
G Deviation of induction and mechanical line guid-
ance from center line on the entire length
5 5
K Deviation of top edge of first rack support from
floor in reference to system floor level
5 5
K1 - Kn Deviation of system floor level to all higher rack 10 or
supports as well as their individual rack supports
K/400 5
to each other
Kmax Deviation between top rack support to floor in ref- 15 10

erence to system floor level
l Deviation of rack supports in the same compart- 5 5

ment in y-direction
m Height deviation of top edge of mechanical line 5 5

guidance to floor in reference to system floor lev-
el
n Deflection of rack support (under load) L/200 max. 10 mm
Note: "K" refers to the tolerance deviation within each horizontal storage level, usually a rack support within a line.
The system reference level is usually assumed to be the highest point of the concrete slab, whereby the rack sys-
tem can be leveled.
Tolerance data apply to assembled, but not loaded rack installations.
Tab. 7-5: Overview of tolerances
Version 1.2, 12.07.2006 7-127

Mechanical parts
Vehicle guidance
y-direction
x-direction
z-direction
7-128 Version 1.2, 12.07.2006

Mechanical parts
Vehicle guidance
Fig. 7-17: Allocations to tolerance description

The following standards must be observed: ZH 1/428; DIN 15184; RAL 614/2;
FEM 10.3.01
Version 1.2, 12.07.2006 7-129

Mechanical parts
Lift frame and cabin
7.5 Lift frame and cabin
7.5.1 Chassis and lift frame
5 6
4
1
Fig. 7-18: Chassis and lift frame
1 Ball head joint of the pull rod 4 Rear screw connection of the pull rod
2 Plain washer plates 5 Pull rod
3 Screwed connection for connecting 6 Flattened part for engaging an open-
the hoist frame ended wrench
The pole connection is via screws, torque 360 Nm.
Note
Screws must be lubricated with oil or MoS2 grease be-
fore tightening.
The correct sideward tilting of the pole is assured by the use of plain washer
plates.
The thickness of the plain washer plates (in mm) provided by the factory is
stamped onto the chassis at the spots marked “xx“. It must not be changed.
7-130 Version 1.2, 12.07.2006

Mechanical parts
OMNI 140 AC, h3 > 8.000 mm
For cabin lift heights above 8,000 mm, the OMNI 140 AC can be equipped with
pull rods connecting the chassis frame with the lift frame.
Fig. 7-19: Tie rods
1 Pull rod
Version 1.2, 12.07.2006 7-131

Mechanical parts
7.5.2 Backward tilting of the mast
The lift frame is equipped with a defined backward tilting and an allowed tolerance
at the factory.
Note
After collisions or overload situations on the lift frame the
backward tilting must be checked.
The values for backward tilting, which depend on the height of the hoist frame, can
be taken from the following table:
h1 [mm] Backward tilting X [mm]

2250 10
2500 11
2750 12
3000 13
3250 14
3500 15
3750 16
4000 17
4250 18
4500 20
4750 21
5000 22
5250 23
5500 24
5750 25
6000 26
6250 27
Tab. 7-6: Backward tilting
According to the drawing, lateral tilting of the hoist frame may not exceed /- ±5 mm.
7-132 Version 1.2, 12.07.2006

Mechanical parts
max. +/- 5 mm x
h1
Fig. 7-20: Permissible lateral tilting
Version 1.2, 12.07.2006 7-133

Mechanical parts
7.5.3 Guide rollers pole / cabin and auxiliary lift / load carriage
The inner pole is supported by the outer pole via 6 guide rollers:
• 2 guide rollers at the top of the outer pole

• 2 guide rollers at the rear of the outer pole
• 2 guide rollers at the bottom of the inner pole
The cabin is supported by the inner pole via 6 guide rollers:
• 2 lateral guide rollers at the top of the cabin

• 2 lateral guide rollers at the bottom of the cabin
• 1 rear guide roller at the top of the cabin
• 1 rear guide roller at the bottom of the cabin
The load carriage is supported by the auxiliary lift pole via 4 guide rollers:
• 2 lateral guide rollers at the top of the load carriage

• 2 lateral guide rollers at the bottom of the load carriage
7-134 Version 1.2, 12.07.2006

Mechanical parts
Rear guide rollers
The guidance principle of inner pole, the cabin and the auxiliary lift the same.
Note
The rear rollers are adjusted and fixed on factory site. A
readjustment on customer’s site is not necessary.
Fig. 7-21: Rear guide roller
1 Ma=75 Nm 2 Loctite® 222
Version 1.2, 12.07.2006 7-135

Mechanical parts
Lateral guide rollers
The adjustment of the correct hoist frame clearance is effected by inserting or re-
moving shims below the hoist frame rollers. The shims are available in different
sizes.
WARNING!
Only use shims with a maximum size of 3.5 mm for
the hoist frame rollers.
Note
Chippings in the area of the guide profiles indicate that
the clearance of 0.5 mm is too tight.
5 1
5
4
Fig. 7-22: Lateral guide roller
1 Loctite® 222 4 Loctite® 222

2 Ma=290 Nm 5 Ma=75 Nm
3 Compensation disks
7-136 Version 1.2, 12.07.2006

Mechanical parts
Slide pieces main and auxiliary lift
The slide pieces at the lower hoist frame rollers prevent rattling noises when the
lifting gear is lowered.
Setting the side pieces

Loosen the counter-nut
Using the screw, adjust the slide piece until it lies on the guide profile.
Retighten the slide piece
1 2 3 4
Fig. 7-23: Slide piece
1 Guide profile 3 Lock nut

2 Slide pieces 4 Screw
Version 1.2, 12.07.2006 7-137

Mechanical parts
Chassis
7.6 Chassis
7.6.1 Lateral guidance (RG-rail guided vehicles)
The appropriate roller spacing for the respective spacing between the guide rails
is set by removing or inserting plain washer plates .
When adjusting the spacing make sure that
• the middle of the load does not result in different stacking depths depending
on the sideshift direction. If required, remove the plain washer plates at the
side with the larger distance and place under the other side .
• all 4 guide rollers sit evenly and without excess pressure on the guide rails
• the vehicle moves straight ahead properly in the aisle; otherwise, the vulkol-
lan tires of the wheels will wear prematurely
Fig. 7-24: Setting the roller spacing
1 Plain washer plates
7-138 Version 1.2, 12.07.2006

Mechanical parts
Chassis
7.6.2 Perform crack detection at chassis
Crack detection according to dye penetration test
DANGER!
Danger of life from frame break
• Immediately stop using the vehicle if tears or breaks are
visible on the frame!
§ Note
The crack detection based on the dye penetration test
may be performed only by trained and authorized ser-
vice personnel.
After every maintenance work on the frame or once a year as part of the mainte-
nance, the frame and all load-bearing parts must be checked for damages using
the dye penetration test. The crack detection based on the dye penetration test
may be performed only by trained and authorized service personnel.
Procedure
Remove the paint.

Spray on testing agent.
Spray on coloring agent.
Perform visual inspection.
Remove testing agent.
Paint test points.
Version 1.2, 12.07.2006 7-139

Mechanical parts
Load axles and load wheels
7.7 Load axles and load wheels
7.7.1 Load axle<and multiple disc brake
12
11
10
1
9 2
8
3
7
4
Fig. 7-25: Load axle and Multiple disc brake
1 Roller bearing 7 Roller bearing

2 Locking plate 8 Nilos ring
3 Shaft nut 9 Distance ring
4 Cover 10 Screw
5 Screw 11 Screw
6 Load-bearing wheel 12 Wheel brake
7-140 Version 1.2, 12.07.2006

Mechanical parts
Load wheel
7.8 Load wheel
16 17
1
15
14
13
2
12
11
3
10
4
9
7 6
Fig. 7-26: Load wheel and load brake
1 Power supply of brake 10 Cover

2 Distance bush 11 Wheel axle
3 Wheel support 12 Locking plate
4 Fixing screw of brake to chassis 13 Hexagonal socket fixing screw
5 Load wheel brake 14 Grease chamber
6 Fixing screw multiple toothing 15 Wear mark
7 Conical roller bearing 16 Fixing screw toothed gear
8 Nilos ring 17 Load wheel (vulkollan tire)
9 Tighten nut on the wheel axle
Version 1.2, 12.07.2006 7-141

Mechanical parts
Load wheel
The load wheels must be replaced

• if the consumption of the vulkollan tire is more than 10% of the new tire pe-
rimeter (wear mark on the tire
• if the vulkollan tires are worn unevenly
• if the vulkollan surfaces are damaged
WARNING!
Always replace both load wheels!
7.8.1 Testing of brake effectiveness of the load wheel brake system
deactivate spring pressure system

check load brake system for correct function and resolution
In case of no or improper actuation of the load wheel brake
• visual check of the actuation unit, replacement if necessary

• inspection of the wire connections of the actuation unit
• current measurement of the control
7-142 Version 1.2, 12.07.2006

Mechanical parts
Load wheel
7.8.2 Dismounting of the brake
Fig. 7-27: LRB with wheel

park the vehicle and render it safe
disconnect the brake electrically
jack up the vehicle
; the load wheel is released (2-3mm)
screw out the hexagon socket head
remove the cover
unlock the fixing nut
remove the locking plate
remove the load wheel using an extractor
remove the fixing screws
remove the load wheel brake
Note
The fixing screws are secured with Loctite.
Lay down the brake onto a clean surface, otherwise dirt gets into the magnetic
part.
Version 1.2, 12.07.2006 7-143

Mechanical parts
Load wheel
7.8.3 Checking the release play and the lining thickness
To check the clearance and the thickness of the lining of the friction
plates
The following illustration shows a brake with 5 friction plates. There are also
brakes used, that contain more friction plates (7 blades OMNI 140).
8 1
7
2
6
3
5
4
Fig. 7-28: Brake (cross-section)
1 Brass washer 5 Locking bolt

2 Disk 6 Aluminum end plate
3 Distance bush 7 Anchor plate
4 Disk 8 Friction linings
7-144 Version 1.2, 12.07.2006

Mechanical parts
Load wheel
Procedure Remove brake (See “Dismounting of the brake” on page 7-143.)

Connect brake electrically to 24V DV supply (see type plate of the brake)
; The brake is aerated
Check lining thickness Permissible wear: b = 4.2 mm in total or 0.6 mm per fric-
tion plate.
Check release play with feeler gauge at two positions, shifted by 180° If the per-
missible release play of 2.25 mm is reached or exceeded it can be readjusted
to 1.0-1.25 mm by removing the shims (2) and/or (4).
Fig. 7-29: LRB
Version 1.2, 12.07.2006 7-145

Mechanical parts
Load wheel
7.8.4 Exchanging the brake plates
Remove brake (See “Dismounting of the brake” on page 7-143.)

Loosen the holding screws and remove the distance bolts and the disks from
the brake together with the washers
Place the screws together with the washers around the brake (see Fig.: 7-30 on
page 7-146)
Fig. 7-30: LRB with loosened screws

Remove the aluminum end plate
Remove the anchor plate
Remove friction plates in order outer friction plate - inner friction plate - outer
friction plate - inner friction plate - outer friction plate
Remove the brass washer
check magnet and coil housing for damages
remove dust from magnet and coil housing with paper towel
7-146 Version 1.2, 12.07.2006

Mechanical parts
Load wheel
Fig. 7-31: Single parts LRB

Assembly is carried out in reverse order.
WARNING!
New friction plates may only be changed as a com-
plete set. The exchange must be performed on both
load wheels.
7.8.5 Visual check of the load wheel brake
Each 1000 operating hours dismount the brakes and perform the following work:
check electrical connections for damages

check gear plates of the hub for damages
check for correct release play
check for sufficient lining thickness
make visual check of the friction plate surfaces for damages
check magnet and coil housing for damages
§ Note
Never repair parts of the brake. Exchange with new
original parts.
Version 1.2, 12.07.2006 7-147

Mechanical parts
Mechanically released spring-loaded brake (magnet brake)
7.9 Mechanically released spring-loaded brake

(magnet brake)
All vehicle types are equipped with a magnetically released spring-loaded brake
(“magnetic brake“) on the traction drive.
The brake can be released mechanically if an electrically release of the brake is

no longer possible (e.g. after a power supply failure).
Note
Releasing of the magnetic brake -> operating instruc-
tions.
7-148 Version 1.2, 12.07.2006

Mechanical parts
7.9.1 Components of the magnetic brake
10 1
2
9
Fig. 7-32: Design of the magnetic brake
1 Adjustment ring 6 Safety ring

2 Magnet 7 Adjusting sleeve
3 Anchor plate 8 Spring
4 Brake disk (with brake linings) 9 Electrical connection
5 Hub 10 Fixing screw
Version 1.2, 12.07.2006 7-149

Mechanical parts
7.9.2 Adjustment of the air gap
The air gap scan be adjusted via three adjusting sleeves .
Stipulated value: s = 0.3 mm
3 1
Fig. 7-33: Setting the air gap
1 Brake linings 3 Adjustment ring

2 Adjusting sleeve
WARNING!
The air gap s may not be larger than 0.6 mm; other-
wise, the brake cannot be released reliably.
After the air gap has been adjusted, the braking force
must be readjusted.
7-150 Version 1.2, 12.07.2006

Mechanical parts
7.9.3 Minimum brake lining thickness
Brake linings (Pos. 1 in Fig.: 7-33 on page 7-150) are stuck to the top and bottom
side of the brake disk.
DANGER!
If the thickness b of the brake disk is below 8.5 mm,
the brake disk must be replaced. After exchange re-
adjust brake action.
7.9.4 Adjusting the brake action
The brake action of the spring-loaded brake can be adjusted via the adjusting ring
by using a special wrench:
Unscrew the setting ring

; Effectiveness of the brakes is reduced
Screw in the setting ring
; Effectiveness of the brakes increases
Fig. 7-34: Setting the air gap
1 Adjustment ring
Version 1.2, 12.07.2006 7-151

Mechanical parts
DANGER!
Dimension „y“ must not exceed 10 mm.
The correct values for braking the vehicle can be taken from the acceptance cer-
tificate supplied with the vehicle.
Note
In the case of vehicles equipped with a load wheel
brake, the spring-loaded brake is always adjusted and
tested with the load wheel brake activated.
7.9.5 Brake test
Always carry out brake tests as follows:
• with lowered main lift and only slightly lifted auxiliary lift
• with maximum load, protected against sliding
• at first with low, then maximum driving speed
Note
Test operating brake: release the foot switch
Test emergency brake: open one cabin barrier
DANGER!
The demanded stopping distance according to the
sign “braking test data“ in the cabin may not be ex-
ceeded. The vehicle may only be operated with prop-
erly working brake system.
The braking test according to the acceptance certificate can only be performed by
service staff equipped with a suitable deceleration gauge.
7-152 Version 1.2, 12.07.2006

Mechanical parts
Traction drive
7.10 Traction drive
7.10.1 Removal and installation of the drive aggregate
For removal of the drive aggregate
6 3
Fig. 7-35: Drive aggregate
1 Drive motor 5 Fairing plate

2 Steering motor 6 Screws of the drive bearer plate
3 Incremental transmitter 7 Brake
Electrically disconnect drive motor, steering motor, brakes, potentiometer (ver-

sion A under the drive plate) and incremental transmitter
Slightly lift the rear of the vehicle with a hydraulic jack and secure it properly
Version 1.2, 12.07.2006 7-153

Mechanical parts
Traction drive
Fig. 7-36: Traction drive

Secure traction drive with lifting gear (weight approx. 210 kg; Fig.: 7-36 on page
7-154)
Remove the fairing plate from the traction drive
Loosen the screws of the drive support plate
Carefully lower down the rear of the vehicle
Carefully pull out the complete drive unit towards the rear and roll it aside on the
drive wheel
; Installation is in the reverse order of steps.
Torque of the screws: 186 Nm
Note
For disassembly of the drive aggregate, see the spare
parts catalogue.
For level of gear oil and mounting of the drive wheel, see
the operating instructions.
7-154 Version 1.2, 12.07.2006

Mechanical parts
7.11 Swivel/traverse fork
7.11.1 Adjustment of the tooth backlash
1
2
7
3
Fig. 7-37: Sideshift drive
1 Nut 5 Eccentric bush

2 Eccentric bush 6 Nut
3 Pinion shaft 7 Toothed rack
4 Grease nipple
The correct tooth flank clearance between the teeth of the pinion shaft and the
toothed racks is 0.2 mm.
Version 1.2, 12.07.2006 7-155

Mechanical parts
To adjust the tooth flank clearance:

Measure the tooth flank clearance at the upper and the lower toothed rack using
a feeler gauge.
Loosen the nuts
Using a hook wrench, turn the eccentric bushes until the tooth flank clearance
is 0.2 mm at the upper and the lower toothed rack
Retighten the nuts.
Check the tooth flank clearance at the upper and the lower toothed rack
Note
The toothed racks are greased according to the lubrica-
tion schedule in the operating instructions. The bearing
of the pinion shaft is greased via the grease nipple ac-
cording to the lubrication schedule in the operating in-
structions.
7-156 Version 1.2, 12.07.2006

Mechanical parts
Sideshift frame
13
12 1
11
10 2
3
9
4
7
5
Fig. 7-38: Bar sideshift
1 Wearing bars 8 Screw

2 Wearing bars 9 Holding strap 0.5 (not visible in pic-
ture)
3 Power supply chain 10 Plug
4 Holding strap 0.5 (not visible in pic- 11 Stop
ture)
5 Stop 12 Screw
6 Dowel pin 13 Screw
7 Screw
The screwed connection connects the sideshift frame with the cabin. The lateral
stops mechanically limit the lateral sideshift movement.
DANGER!
Never operate the vehicle without the lateral stops.
Version 1.2, 12.07.2006 7-157

Mechanical parts
Wearing bars
The supporting rollers of the sideshift arm run on replaceable wearing bars.
Note
The screws of the wearing bars are secured with Loctite
241.
The wearing bars are comprised of several pieces. They can therefore be re-
placed when the sideshift arm is mounted.
The lock nuts of the middle wearing bars can be locked through the installation
holes .
The lower multilayer wearing bars are underlaid with a holding strap for vertical
alignment of the sideshift arm and the auxiliary lift pole.
7-158 Version 1.2, 12.07.2006

Mechanical parts
7.11.2 Adjustment of the swivel chains
Setting of the swivel cylinder and swivel chain for SSG-EF 12/16 -
swivel/traverse fork
1
6
5
2
159 mm
16 mm
In all end positions:

extended:
retracted:
4 mm play
4
I II 3
1 Chain 4 Piston stroke 151 mm

2 Setting path 2 ... 18 mm 5 Chain anchor
3 Swivel cylinder 6 Stop pole
Procedure Move the free hoisting mast left and right against the stop.
Set the position of the swivel cylinder in such a way that the respective end po-
sitions have a play of 4 mm. The setting is made using the chain anchor. Ob-
serve the setting gauge of the cylinder rod:
• extended: 159 mm
• retracted: 16 mm
A setting path of 2-18 mm is possible at the chain anchor.
Version 1.2, 12.07.2006 7-159

Mechanical parts
If the pole does not set itself to 90° or against the stop then the causes are as fol-
lows:
• Piston II is at the stop at the rear in the cylinder. In this case, turn in the chain
anchor. Observe a dimension of 16 mm.
• Piston I is at the stop at the rear in the cylinder. In this case, turn out the
chain anchor. Observe a dimension of 159 mm.
• or proceed in reverse order.
Note
In case of a chain length over 3%, this must always be
replaced.
Chain length ¾“ 4×4:
normal 9 Gl.= 171.45 mm
lengthened 9 Gl. = 176.59
7-160 Version 1.2, 12.07.2006

Mechanical parts
Telescopic fork
7.12 Telescopic fork
Note
For operation of the telescopic fork refer to the operating
instructions.
The telescopic fork is available in two versions with different dimensions:
• Standard telescopic fork (TF)

• Flat telescopic fork (FTF).
Dimension TF FTF
Fork length 1,200 mm 1,200 mm
Fork width 180 mm 180 mm
Fork thickness 60 mm 60 mm
Fork height, lowered 300 mm 180 mm
Min. stacking height 250 mm 130 mm
Free pallet drive-in height min. 100 mm min 100 mm
The telescopic forks (TF, FTF) are driven via chains by a hydraulic motor.
Version 1.2, 12.07.2006 7-161

Mechanical parts
Telescopic fork
7.12.1 Standard telescopic fork (TF)
With standard telescopic forks (TF), the hydraulic motor is installed below the fork
tines.
5
1
3 2
Fig. 7-39: Standard telescopic fork (TF)
1 Auxiliary lift pole 4 Lifting chains

2 Fork tines 5 Auxiliary lift cylinder
3 Load carriage
7-162 Version 1.2, 12.07.2006

Mechanical parts
Telescopic fork
Fig. 7-40: Hydraulic motor standard telescopic fork
1 Fork tines 2 Hydraulic motor
7.12.2 Flat telescopic fork (FTF)
With the flat telescopic fork (FTF), the hydraulic motor is installed laterally above
the fork tines. Thus, lower stacking heights can be attained with FTF.
Fig. 7-41: Flat telescopic fork (FTF)
1 Hydraulic motor
Version 1.2, 12.07.2006 7-163

Mechanical parts
Telescopic fork
7.12.3 Auxiliary lift pole
Two versions of the auxiliary lift pole are available for TF and FTF:
• Single pole (E pole)

• Double pole (Z pole)
Single pole (E pole)
Fig. 7-42: Single hoist frame
1 Lift cylinder 2 Load carriage
With the single pole, only one lift cylinder lifts the load carriage via a chain.
7-164 Version 1.2, 12.07.2006

Mechanical parts
Telescopic fork
Double pole (Z pole)
Fig. 7-43: Double pole
1 Outer lift cylinder 2 Inner lift cylinder
The double pole is equipped with 3 cylinders:
• As with the single pole, the center cylinder lifts the load carriage via a chain
until it reaches the installation height of the Z pole.
• The two outer cylinders then lift the center Z hoist frame segment until it
reaches the maximum lifting height.
Auxiliary lifting cylinder
The auxiliary lifting cylinders are identical to the auxiliary hoist cylinders for the
swivel/traverse fork.
Version 1.2, 12.07.2006 7-165

Mechanical parts
Telescopic fork
7.12.4 Mechanical design of the telescope
5 1
4
2
3
Fig. 7-44: Power transmission of telescope
1 Drive shaft 5 Base

2 Chain between hydraulic motor and 6 Center part
drive shaft
3 Tensioning device 7 Fork tines
4 Hydraulic motor 8
Power transmission between the drive shaft and the fork tines is via four chains.
• 4 chains between base and fork tines (2 chains for each tine)
• 2 chains between drive shaft and center part (1 chain for each tine)
• 1 chain between hydraulic motor and drive shaft
7-166 Version 1.2, 12.07.2006

Mechanical parts
Telescopic fork
4
2 3
6
1 7
5 9
8
10
11
19
18
17
16
13
12
14
15
15
20
Fig. 7-45: Design of telescope
1 Counter stroke for middle section 11 Chain bolts, fixing for chain lower
part/fork tines
2 Endless chain between drive shaft 12 Stops for fork tines
and center part
3 Assembly hole 13 Hydraulic motor
4 Base 14 Drive shaft
5 Chain between hydraulic motor and 15 Flange bearing for drive shaft
drive shaft
6 Stops for center part 16 Console for drive shaft with auto-
matic chain adjuster for endless
chain drive shaft/middle section
7 Chain between base and fork tines 17 Counterstop for fork tine
8 Chain adjuster for chain under sec- 18 Belt adjuster guide for endless chain
tion/fork tines drive shaft/middle section
9 Center part 19 Guide rail
Version 1.2, 12.07.2006 7-167

Mechanical parts
Telescopic fork
10 Fork tines 20 Tensioning element
7-168 Version 1.2, 12.07.2006

Mechanical parts
Telescopic fork
Chain between base and fork tines
3
2
Fig. 7-46: Drive schematic
1 Chain adjuster 4 Chain bolts

2 Chain between base and fork tines
The chain is fixed to the fork tine by means of a bolt and is guided via a roller on
the center part to the chain tensioner on the telescope base.
Adjusting the chain between base and fork tines
1 2 3
Fig. 7-47: Chain adjuster
1 Lock nut 3 Chain adjuster

2 Belleville spring
The belleville springs in the chain tensioner keep the chain tensioned.
Note
Use the lock nut to set theadjusting range of the
belleville springs to approx. 5 mm.
Version 1.2, 12.07.2006 7-169

Mechanical parts
Telescopic fork
If the adjusting range of the springs has been exhausted by lengthening of the
chain, one double chain link must be removed.
Exchange the chain if the adjusting range has exhausted up again.
Exchanging the chain between the base and the fork tines
1 2 3
Fig. 7-48: Fork telescope
1 Chain adjuster 3 Chain bolts

2 Belleville spring
Contract the spring assembly with the counter nut

; The chain is loosened
Loosen the chain at the bolts of the chain adjuster and at the chain bolts
Take the chain off and dispose of it properly
Use chain spray to lubricate the new chain
Fix the chain at the chain bolts and at the chain adjuster
Adjust the chain as described above
Chain between drive shaft and center part
3
2
1 Toothed rack on center part 3 Drive shaft

2 Tensioning block 4 Chain drive shaft and center part
The drive shaft drives the center part of the telescope via an endless chain .
7-170 Version 1.2, 12.07.2006

Mechanical parts
Telescopic fork
6
3
Fig. 7-50: Components of the bearing of the drive shaft
1 Tensioning block 5 Screw

2 Ratchet 6 Pressure spring
3 Tensioning spring 7 Tensioning roller
4 Set screw
The chain is held via a toothed rack at the middle section. The chain adjuster holds
the chain tightly.
Adjusting the tension of the chain between the drive shaft and
the center part
The springs automatically adjust the tensioning block when the chain lengthens.
The spring causes the tensioning block to engage in the new position.
The tensioning roller exerts pressure on the chain and provides the correct ten-
sioning.
The clamping pressure of the spring is set via the set screw.
Exchanging the chain between the drive shaft and the center
part
The chain must be exchanged when it is broken or when it can no longer be cor-
rectly tensioned by means of the tensioning roller .
Version 1.2, 12.07.2006 7-171

Mechanical parts
Telescopic fork
To exchange the chain

Unscrew the screw
Remove the spring
Use a screwdriver to push the ratchet down to release the tensioning block
Remove the stops
Fig. 7-51: Fork telescope
1 Stops for fork tines 2 Stops for center part
Move the fork tines to the side until the toothed rack no longer engages in the
chain
Fig. 7-52: Middle section with toothed rack
1 Toothed rack 2 Center part
Fret one bolt of the chain and knock out

Separate the chain
Attach the new chain to one end of the old chain
Pull out the old chain
; The new chain is pulled in
Connect both ends of the new chain with the supplied clinch bolt
Remount the spring and screw
Adjust the chain tension as described above
7-172 Version 1.2, 12.07.2006

Mechanical parts
Telescopic fork
Primary drive hydraulic motor / drive shaft
1
4
1 Drive shaft 3 Tensioning device

2 Chain between hydraulic motor and 4 Hydraulic motor
drive shaft
The hydraulic motor drives the drive shaft via the chain.
Adjusting the chain between the hydraulic motor and the drive
shaft
1
3
2
Fig. 7-54: Drive shaft
1 Sprocket (to the 2nd fork tine) 4 Sprocket (to the 1st fork tine)
2 Tensioning element 5 Drive shaft
3 Sprocket (to the hydraulic motor)
Version 1.2, 12.07.2006 7-173

Mechanical parts
Telescopic fork
The chain can be tensioned by means of the tensioning device (Fig.: 7-53 on page
7-173, item 3).
Adjusting the fork tine positions

The sprockets are connected force-closed via the tensioning element.
If the fork tines have been displaced in relation to each other by external forces,
their position can be corrected by means of the tensioning element as follows:
Unscrew the Allen screws of the tensioning element

Align the fork tines via the sprocket
Tighten the Allen screws of the tensioning element crosswise (torque: 14 Nm)
Note
If the vehicle is delivered with telescopic forks, observe
the settings according to service menu *M02 "Tele-
scope".
7-174 Version 1.2, 12.07.2006

Mechanical parts
Fork test
7.13 Fork test

Inspection protocol for fork tine test
CAUTION!
Fork tines should always be replaced in pairs since it can be assumed that
damage to one fork tine always shows or will show similar damage to the oth-
er tine.
Note
Sometimes fork tines are used for special applications with deviating angle di-
mensions. Please check prior to inspection.
Com. no.: Fork tine dimensions:

Stacker type: Width [mm]:
Serial no.: Thickness [mm]:
Tine length [mm]:
Suspension:
Wear Okay
n
Nominal thickness N-10% Not okay
Replacement required! Remark:
Wear range
Surface cracks Okay

Crack indication Not okay
Fork hook
Replacement required! Remark:
Internal
kink
Height differences of tine tip Okay

L Fork tines
Acceptable: hmax = ------ Not okay
L 66 L
Align fork tine: h= ------ to ------ Remark:
66 L 33 1 2
Replace fork tine: h> ------
66
L:=tine length [mm] h
Version 1.2, 12.07.2006 7-175

Mechanical parts
Fork test
Tine bend Ruler Okay

L
Acceptable: k= ------ Not okay
66 L L
Align fork tine: k= ------ to ------ Remark:
66 L 33 K
Replace fork tine: k> ------
66
L:=tine length [mm]
Bend position
Angle Okay
Ideal state 90°: d=707 mm Not okay
Acceptable tolerance: d=695-713 mm Remark:
Align fork tine: d=714-730 mm D
500
Replace fork tine: d>730 mm
500
Blocking Okay
Not okay
Remark:
Tip damage Okay

Not okay
Remark:
Bending/wear of fork hook Bend

Okay
Not okay
Remark:
Result
Fork tines okay Name of tester:

Fork tines not okay Date:
Scrap/replacement
Repair Signature:
7-176 Version 1.2, 12.07.2006

Mechanical parts
Lift chains
7.14 Lift chains

Lift chains are highly important components on fork lift trucks. The chain system
on your pole was designed for efficient, reliable transmission of lifting force from
hydraulic cylinder to the forks. Safe, uninterrupted use of your lift truck depends
on the proper care and maintenance of the lift chains.
Most complaints of unsatisfactory chain performance can be traced directly to in-

adequate maintenance. Highly stressed precision chains require periodic mainte-
nance to deliver maximum service life.
7.14.1 INSPECTION
After every 100 hours of truck operation, lift chains should be inspected and lubri-
cated. When used in an extremely corrosive environment, inspect chains every 50
working hours. During inspection, check for the following:
Wear
As the chain flexes on and oft the pulleys, the joints very gradually wear.
The "stretch"a chain develops in service is due to material being worn off pins out-
side diameter and pitch hole inside diameter on the inside plates.
Fig. 7-55: Check chain length
Version 1.2, 12.07.2006 7-177

Mechanical parts
Lift chains
Chain wear can be measured by using a 106440 wear scale or a steel tape (Refer
to Illustration 7.5-1). When chains have elongated 3%, as represented on scale
UA (0.75 in. or 1 in. pitch chain) or scale "B" (0.625 in. pitch chain) of the wear
scale, they should be discarded. On chain with 0.75 in (19 mm) between pins, for
example, 12 in. (305 mm) of chain contains 16 pitches or links.
When 16 pitches measure 12.375 in. (314 mm) the chain should be replaced. On
chain with 0.625 in (16 mm) between pins, 20 pitches or links equal 12.5 in (318
mm). When 20 pitches measure 12.875 in. (327 mm) the chain should be re-
placed. Crown currently uses 0.625 in (16 mm) pitch (20 left in 12.5 in. (8 mm),
0.75 in (19 mm) pitch (16 left in 12 in. [and 1 in. pitch (12 left in 12 in. [305 mm])
chain.
When checking chain wear, be sure to measure a segment of chain that operates
over a pulley. Do not repair chains by cutting out the worn section and splicing in
a new piece. If part of a chain is worn, replace both of the lift chains.
Rust and Corrosion
Chains used on lift trucks are highly stressed precision components. It is very im-
portant that "as-manufactured" ultimate strength and fatigue strength be main-
tained throughout the chain.
Corrosion will cause a major reduction in the load-carrying capacity of lift chain or
roller chain because corrosion causes sideplate cracking.
It is extremely important to protect lift chains from corrosion, whether in service or

in storage. The initial factory prelube on chains is an excellent rust and corrosion
inhibitor. Factory lube is applied in a hot dip tank to insure complete penetration
into the joint. Do not steam clean or degrease new chains. After the chain has
been placed in service, factory lube must be supplemented by a maintenance lu-
brication program.
Refer to applicable lubrication and adjustment section for your particular truck se-
ries and/or the lubrication information later in this section.
Fig. 7-56: Chain link with corrosion and corrosion tears
7-178 Version 1.2, 12.07.2006

Mechanical parts
Lift chains
Heavy motor oil serves both as a joint lubricant and corrosion inhibitor. During in-
spection, carefully examine external chain surfaces for the presence of an oily film.
Under certain operating or environmental conditions it may be necessary to oh
chains more frequently than 100 hour intervals. In all cases, the external surface
of the chain must be protected a film of oil.
Corroded chains should be inspected for cracked plates. Outside plates are par-
ticularly susceptible to stress corrosion cracking. If chains are heavily rusted or
corroded they should he removed from the pole for thorough inspection for
cracked plates. If plates are cracked, both chains on the truck must be replaced.
Oil chains when they are reinstalled on the pole.
Cracked Plates
The most common cause of plate cracking is fatigue failure. Fatigue is a phenom-
enon that affects most metals and many plastics. After many repeated heavy loads
the plates may crack and the chains will eventually break.
Fig. 7-57: Chain link with fatigue cracks
Fatigue cracks are almost always found through the pitch holes perpendicular to
the pitch line. (Fig.: 7-57 on page 7-179) Contrast this failure mode to the random
failures caused by stress-corrosion cracking. (Fig.: 7-56 on page 7-178) It any fa-
tigue cracks are discovered during planned maintenance (PM) inspections; both
lift chains should be replaced. Many apparently sound plates will be on the verge
of cracking, making chain failure very likely.
Tight Joints
All joints in lift chain should flex freely. Tight joints resist flexure, increase internal
friction, thus increasing chain tension required to lift a given bad. Increased ten-
sion accelerates wear and fatigue problems. Fig.: 7-58 on page 7-179.
Fig. 7-58: Tight chain links
Version 1.2, 12.07.2006 7-179

Mechanical parts
Lift chains
Tight joints in lift chains can be caused by:

• Bent pins or plates,
• Rusty joints,
• Peened plate edges.
Oil rusty chains and replace chains that appear bent or peened. Peening of plate
edges may be caused by worn pulleys, unusually heavy loads, or chain sliding
past a guide or obstruction in the pole.
Protruding or Turned Pins
Heavily loaded chains operating with little tube generate tremendous friction be-
tween pin and plates (pin and bushing in roller chain). In extreme cases, the fric-
tional torque in the joint can actually turn pins in the press-fit outside plates.
If chain is allowed to operate in this condition, the pins slowly work out of the chain,
causing chain failure. Turned pins can be quickly spotted because the flats on the
"V" heads are no longer in line. Refer to Fig.: 7-59 on page 7-180, pin has turned
45°. Chains with turned or protruding pins should be replaced immediate
Never attempt to repair the chain by driving pins back into the chain
Fig. 7-59: Protruding or Turned Pins
7-180 Version 1.2, 12.07.2006

Mechanical parts
Lift chains
Chain Side Wear
A continuous wear pattern on pin heads and outside plates indicates misalign-
ment. Misalignment can be caused by two different factors: unequal chain tension
or nonalignment between pulleys and chain anchors.
Unequal Chain Tension
When a lift chain is installed or adjusted, care should be taken to "bad" the chains
evenly. When changing fork heel height or platform height for example, the chain
anchors should be loosened until both forks come in contact with the floor. At this
point both chains should display the same tension or slack. The lower chain an-
chor nuts should be rotated as that they are tightened with the same number of
revolutions. When the desired height setting is achieved the upper (chain side)
lock nut with lock washer should secure the setting.
Non-Alignment of Lifting Components
Non-alignment of the pulley and chain due to misshimming of the pole or bent or
damaged mast or cylinder components can also contribute 10 chain side wear. A
check for this condition is to place the truck on a level area in your maintenance
area. After supporting the fork carriage, disconnect each end of the lift chain at the
chain anchor and visually inspect its alignment with the anchor slots.
Version 1.2, 12.07.2006 7-181

Mechanical parts
Lift chains
7.14.2 LIFT CHAIN LUBRICATION
The most important consideration in held maintenance of lift chains is LUBRICA-

TION. Hard working, heavily loaded chains cannot be expected to give satisfacto-
ry wear life without scheduled periodic relubrication. Like all bearing surfaces, the
precision-manufactured, hardened-steel joint wearing surfaces require a film of oil
between mating parts to prevent rapid wear.
• Maintaining an oil film on all chain surfaces will:

• Minimize joint wear (chain stretch).
• Prevent corrosion.
• Reduce the possibility of pin turning.
• Minimize tight joints in roller chain.
• Promote smooth, quiet chain action.
• Lower chain tension by reducing internal friction in the chain system.
Heavy motor oil is an excellent chain lubricant-even used oil drained from lift truck
engines is adequate for lubricating exposed lift chains.
Laboratory wear tests show SAE 40011 to have greater ability to prevent wear
than SAE 10 oh. Also, SAE 40 oil is superior to hydraulic fluid or automatic trans-
mission fluid. Generally, the heaviest (highest viscosity) oil that will penetrate the
joint is the best.
Lab wear testing shows dry film lubes to be less effective in preventing joint wear
than fluid petroleum based products.
Some aerosol spray lubes are effective and are more convenient and less messy
than applying motor oils.
Whatever method is used, the oil must penetrate the chain joint 10 prevent wear.
Applying oil to external surfaces will prevent rust, but 011 must flow into the live
bearing surfaces for maximum wear life. (Fig.: 7-60 on page 7-183)
Apply oil to chains with a narrow paint brush. A plastic liquid detergent bottle
makes a handy lube applicator. Flood the chain with oh over its entire length every
lube-inspection period.
Frequency of relube will vary with operating conditions and environment. The best
estimate of tube period is 100 hours actual operating truck time. Trucks parked
outdoors, used in freezers or trucks in extremely severe service, may require more
frequent relube to maintain an Oil film on all chain surfaces.
In dusty operating conditions, lubed chains will gather dust. Even under these con-
ditions wear life will be greatly improved by periodic lubrication. Joints may acquire
a "paste "made up of oh and dirt, but joint wear will still be much less??????? if
the chain is allowed to run dry with metal-to-metal contact between pins and
plates.
7-182 Version 1.2, 12.07.2006

Mechanical parts
Lift chains
In dusty operating conditions leaf chain can be more effectively relubricated. The
multiple plate construction of leaf chain provides more paths for the lube to reach
the pin (Fig.: 7-60 on page 7-183). At 100 hour intervals, clean chains to remove
accumulation of dirt - relubricate immediately. (Do not steam clean chains)
Lubricant
7.14.3 LIFT CHAIN REPLACEMENT
The first step in chain replacement is to find the chain part number in your service
manual parts list.
An important factor in ordering replacement chain from the truck manufacturer is

that special chains may be specified for your truck with certified minimum ultimate
strength.
If the unit is equipped with two strands, replace chains as a pair. It will be virtually
impossible to maintain uniform loading between the strands if a new chain is put
into service opposite an old chain. The joints in the old chain will have worn
through the hardest layer of the case-hardened pin. Therefore, the wear rate on
the old chain will be greater than that on the new chain, greatly complicating the
problem of maintaining equal chain tension.
The new chain will wear more slowly, causing it to bear the major portion of the
bad, resulting in premature wear and fatigue failure.
Never steam clean or degrease new chains. The manufacturer's grease is effec-
tive in reducing wear and corrosion. If the original factory lube is dried out or wiped
oft, soak the new chain in heavy engine for at least 0.5 hour prior to installing on
truck.
After the old chains have been stripped from the pole, very carefully inspect chain
anchors and sheaves. Broken, cracked, or worn anchors must be replaced. Re-
place worn sheaves, and check sheave bearings for wear. Do not paint new re-
placement chain before or after It has been installed. Paint will help prevent
corrosion, but will prevent oil from reaching the pin surface for good joint lubrica-
tion.
Version 1.2, 12.07.2006 7-183

Mechanical parts
Lift chains
Install the new chains, using new anchor pins. Old pins may contain invisible fa-
tigue cracks that could lead to pin failure. After chains have been connected to the
anchors, adjust chain tension to obtain proper fork or platform bower height.
Correct chain installation and pole adjustment will increase chain service life.
Chain Anchors and Pulleys
An inspection of the chain system should include a dose examination of chain an-
chors, anchor tension devices and pulleys.
Check chain anchors for wear, breakage, and radial misalignment. Anchors with
worn or broken fingers should be replaced. Anchors should be adjusted to elimi-
nate twisting or other misalignment in the chain. When chain is misaligned, bad is
not distributed uniformly between the plates-prolonged operation will result in pre-
mature fatigue failure.
Pulleys with badly worn flanges and outside diameter should be replaced. Heavy
flange wear indicates chain misalignment. Investigate cause by checking chain
tension and pole shimming.
Leaf Chain Disconnect
To minimize the risk of damaging (cracking, etc.) the chain, refer to the following
when disconnecting leaf chain.
Equipment Required:
• A sturdy work surface with an opening slightly greater than the pin diameter,
and should be thick enough to allow the pin to extend beneath the work sur-
face as it is driven through the bottom pin link plate.
• A support ring (flat washer) with an inside diameter slightly greater than the
pin diameter and a height equal to the head height of the pin.
• Grinding wheel.
• Pin punch with a diameter slightly less than the pin diameter, hammer or
pressing equipment.
Disconnect Procedures: (ILLUSTRATION 7.5-8)
1. Grind the top head of the pin flash with the pin link plate. Be careful not to
grind or damage the pin link plate.
2. Position the support ring over opening of the work surface. The support ring
serves to support the bottom pin link plate and avoids damage to chain com-
ponents while driving the pin through the chain.
3. Stand the chain on its side and seat pin in the support ring.
4. Remove the pin through the top pin link plate.
7-184 Version 1.2, 12.07.2006

Mechanical parts
Lift chains
Grinding wheel
Pin link plate
Grind pin flush
with link plate
Support ring Work surface

Knock out opening
Version 1.2, 12.07.2006 7-185

Mechanical parts
"Master Speed Plus" testing instruction
7.15 "Master Speed Plus" testing instruction

Setting and test of the "Master Speed Plus" control with vmax/2.5
reversing curve
vmax to h3 D1 test curve h3

Q
Table:
[(kg]
forw. backw. Q forward (560 mm)
Corner point 1 1400 6000 7000 1400 6000
Ç 1200 6300 7250 1300 6500
Behavior 1000 6700 7400 1200 7000
Linear 800 7100 7600 1100 7500
È 600 7400 7800 1000 8000
Corner point 2 0 8500 8500 900 8500
Tab. 7-7: Master Speed Plus parameter
Adjustment test
If the top values of the aforementioned parameters Q and h3 are reached, the
speed vx must change to 2.5 km/h forward and backward travel. The stability is ful-
ly reached according to the D1 test curve.
Load capacity label
1,400 kg to htot = 7,500 mm
1,300 kg to htot = 8,500 mm
1,150 kg to htot = 9,500 mm
1,000 kg to htot = 10,000 mm
Reversing height level vmax/v2.5
Forward
htot = 7,500 mm to 1,400 kg corner point 1
htot = 7,800 mm to 1,200 kg Ç

htot = 8,200 mm to 1,000 kg
htot = 8,600 mm to 800 kg
htot = 8,900 mm to 600 kg È

htot = 10,000 mm to 0 kg corner point 2
7-186 Version 1.2, 12.07.2006

Mechanical parts
Reversing height level vmax/v2.5
Backward
htot = 8,500 mm to 1,400 kg corner point 1
htot = 8,750 mm to 1,200 kg Ç

htot = 8,900 mm to 1,000 kg
htot = 9,100 mm to 800 kg
htot = 9,300 mm to 600 kg È

htot = 10,000 mm to 0 kg corner point 2
Version 1.2, 12.07.2006 7-187

Mechanical parts
7-188 Version 1.2, 12.07.2006

Hydraulics
Chapter index
Chapter 8
Hydraulics
Chapter index
8.1 General information ............................................................... 192

8.2 Torques ................................................................................. 195
8.3 Description of the hydraulic system....................................... 196
8.4 Hydraulic installation in the bogie .......................................... 200
8.5 Hydraulic installation in the rear of the vehicle ...................... 201
8.6 Tank ...................................................................................... 203
8.7 Filler and breather ................................................................. 206
8.8 Return flow filter .................................................................... 208
8.9 Pump ..................................................................................... 209
8.10 Lift module block ................................................................... 211
8.11 Lift cylinders (main and auxiliary lift) ..................................... 217
8.12 Hydraulic installation of the traverse fork (RFZ) .................... 227
8.13 Drawings of hydraulic components ....................................... 234
Version 1.2, 12.07.2006 8-189

Hydraulics
General information
8.1 General information
8.1.1 Preparation, assembly and putting into operation of the FFZ

hydraulics
Impurities within the hydraulics system is the most frequent cause of faults and
breakdowns.
The rules and measures listed in the following for the avoidance and removal of
dirt within the hydraulics system must always be observed during production, stor-
age, installation and commissioning. Non-observance impairs the functionality of
FFZ devices.
8.1.1.1 Types of impurities
• Metal particles: Chippings, welding beads, wear

• Silicate particles: Blasted sand, dust
• Elastomer: wear to the sealings
• Organic fibers
• Rust
• Water
8.1.1.2 General rules
• The VDI regulations (VDI 3027) for commissioning and maintenance of oil-
hydraulic systems must be observed.
• Components to be replaced (valves, lines, etc.) must meet the requirements
and be intended for the purpose planned by ATLET. Additionally, the in-
structions from the manufacturer of the component must be observed.
• Mount systems in clean environment and pay attention to cleanliness.
• During breaks in work or at the end of a shift, all openings must be closed
with stops.
• When cleaning, only use non-linting fabric or special paper.
• Pipe lines and tank must be cleaned from dirt, cinder, sand, chippings, etc.
before installation.
• Heat-bent or welded pipes must be pickled, rinsed and oiled.
• Seal the tank against external dirt.
• Sealing agent such as hemp, mastic or sealing band is not permitted.
8-190 Version 1.2, 12.07.2006

Hydraulics
General information
• To achieve a high level of stiffness, hose lines should be avoided between

valves and consumers when possible.
• Connection lines between consumers and valves should be kept as short
as possible .
• Sealing surfaces must satisfy the requirements of the manufacturer of the
component.
• If proportional valves are mounted on a consumer then the valve piston
should not be in the movement of direction of the components .
• The stipulated maximum temperatures and pressures for the hydraulic oil
must be observed and checked when putting into operation.
• Pilot pressures, e.g. for proportional valves, must be observed.
• The hydraulic system must be bled. depending on the design of the compo-
nents, these must be bled at their highest points. Draining off the tank pipe
should be avoided.
Version 1.2, 12.07.2006 8-191

Hydraulics
General information
8.1.1.3 Measures
Valves
Store valves packaged when possible or at least closed with stops. Only remove
the stops immediately before installation.
Fresh oil
• Make sure that the barrel or storage tank lid is sealed tightly.
• Only fill the FFZ tanks with filtered fresh oil (10µm absolute filter).
• Keep filler lines clean and always close them when not in use.
Lines
• Immediately before assembly, you should clean:

tubes with compressed air
and rinse pipes with a suitable pipe cleaning unit (cold cleaner, compressed
air).
• Line ends that can not be connected immediately must be closed.
FFZ tank
• The tank must be carefully and completely cleaned before filling and sealed
against external dirt.
• The inside surfaces of the plate tank must be coated with corrosion protec-
tion.
• Regulations regarding surface preparation, cleaning and color coating must
be observed.
Cylinder
• All lift cylinders must be rinsed before installing into the FFZ; the tightness
is thereby also checked.
an appropriate cylinder test and rinsing stand comprises:
• A hydraulic power unit, reversing or double filter and load lifting device to
load the cylinder.
8-192 Version 1.2, 12.07.2006

Hydraulics
Torques
8.2 Torques
Note
If no other tightening torques are specified in the manu-
facturer's documentation, tighten screw connections us-
ing the values in the table.
The values listed under „Steel“ apply to the following surface protection:
• phosphated and oiled or

• galvanized and chromated.
Cone packing con-

Connection Size Stud end with thread
nection
L=light Torque, stainless

Torque, steel [Nm]
H=heavy steel 1.4571 [Nm]
6-L 15 18
8-L 15 35
10-L 25 35
12-L 35 70
15-L 45 90
18-L 85 90
22-L 110 180
28-L 130 310
35-L 215 450
42-L 330 540
6-H 25 55
8-H 40 55
10-H 50 80
12-H 60 80
14-H 75 115
16-H 80 115
20-H 120 180
25-H 170 310
30-H 250 450
38-H 350 540
Tab. 8-1: Torques of the cone packing connection and stud end with thread
Version 1.2, 12.07.2006 8-193

Hydraulics
Description of the hydraulic system
8.3 Description of the hydraulic system
DANGER!
Also observe the safety instructions from Mechanical
parts"” on page 7-103 !
For all assembly work at the hydraulic system
• Switch off the vehicle
• Pull the battery plug
• Close the main tap under the battery
• Lower the main and auxiliary lift to the lower end posi-
tion
8.3.1 General features
• The speed of all movements can be adjusted continuously by the pump

speed and/or current regulating valve
• Direction of the movements is controlled by control valves
• Optimized efficiency by energy recovery by lowering the main lift
• Standard synchronous swiveling and pushing in the apron
8.3.2 Pump aggregate
The unit is mounted lying down under the battery. An AC-controller supplies the
three-phase a.c. motor with energy and allows the speed to be adjusted continu-
ously.
The pump must be carefully put into operation
• after loading / transport of the vehicle

• after replacing the pump
• after actions within the hydraulic system in the area around the pump
• when the pump makes abnormal noises (cavitation noise)
8-194 Version 1.2, 12.07.2006

Hydraulics
Note
For putting the pump into operation, see Chapter 5.10.1
Putting the Pump into Operation“.
Depending on the operating state, the electrical machine can work as a motor or
as a generator.
Motor operation
• Lifting the main lift

• Lifting the auxiliary lift
• Sideshift/swivel/synchronous swivel
Generator operation
• Lowering the main lift (crawling speed to maximum speed)
The pump works here as a hydraulic motor and drives the electric motor that feeds
energy back into the battery via the AC-controller.
Low lowering speeds of the main lift (below the crawling speed) are controlled by
a hydraulic flow regulator to ensure a minimum speed of the unit.
WARNING!
Increased wear to the pump
• Speeds under 200 rpm damage the pump.
Version 1.2, 12.07.2006 8-195

Hydraulics
8.3.3 Hydraulic plans
The hydraulic plan shown in the following presents an overview of the principle design of the hydraulic
system. There may be deviations from this depending on the model of the vehicle.
main lift
free lift
side drive
Fig. 8-1: Hydraulic plan without swiveling and tine adjustment
8-196 Version 1.2, 12.07.2006

Hydraulics
main lift
free lift
swivel
side drive
adjustment
Tine
Fig. 8-2: Hydraulic plan with swiveling and tine adjustment
Version 1.2, 12.07.2006 8-197

Hydraulics
Hydraulic installation in the bogie
8.4 Hydraulic installation in the bogie
H3(H1) 5 R P1 P2
2. B10
2
H3(H2)
H3(R)
H3(B)
H3(R1)
H3(A)
3
H3(P)
RF
7
A1
2Y30
B1
2Y36
R2
R1
6
2Y3
D
1
H1
2Y34
2Y35
5
H2
2Y33
2Y32
P
R
H9
Fig. 8-3: Top view of the bogie
1 Main cylinder 5 Filler and breather

2 Main tap H6 6 Lift module block H3
3 Pump aggregate H2 (pump + motor) 7 Tank H1
4 Return line filter H18
8-198 Version 1.2, 12.07.2006

Hydraulics
Hydraulic installation in the rear of the vehicle
8.5 Hydraulic installation in the rear of the vehicle
8.5.1 Rear view
1
6
Fig. 8-4: Side view of the tank control unit
1 Manometer clogging indicator of re- 5 Tank

turn line filter H18
2 Return line filter H18 6 Hexagon spanner for the emergency
lowering function
3 Tank clip 7 Filler and breather H26
4 Tube for emptying tank 8 Lift module block H3
Version 1.2, 12.07.2006 8-199

Hydraulics
Hydraulic installation in the rear of the vehicle
8.5.2 Top view
10
9
1
8
2
2Y31 2Y36 2Y30
2Y34 2Y52
2Y35
2Y49
2Y33
2Y32
2Y37
2Y53
3
7
6 5 4
Fig. 8-5: Lift module block
1 Tank clip 6 Screw connection (G1/2) for filling

tank via return line filter by pump
2 Emergency lowering screw of auxil- 7 Emergency lowering screw of main lift
iary lift
3 Tank clip 8 Lift module block H3
4 Return line filter H18 9 Filler and breather H26
5 Manometer clogging indicator of re- 10 Tank
turn line filter H18
8-200 Version 1.2, 12.07.2006

Hydraulics
Tank
8.6 Tank
Oil tank, breather, return line filter and the lift module block form one unit.

• Situation of tank installation Top view"” on page 8-200
8.6.1 Oil fill
Oil volume (pressure liquid) in the tank: 90 liters
Total volume of oil (tank+hydraulic system): up to approx. 160 liters
Pressure liquid: acc. to ISO VG 46 (Shell Tellus Oil T 46)
WARNING!
Incorrect pressure liquids may result in decreased
performance or damage to the hydraulic compo-
nents.
• Never mix the various types of oil together.
Oil-mixtures tend to form froth and sludge after drop-out of the additive . De-
creased lubricity can result in damage at the pump and the cylinder bearing sur-
faces.
8.6.2 Emptying the tank
Note
Always replace oil when warmed up to ensure that it
flows off quickly and completely.
Lower the main and auxiliary lift to the lower end position
Switch off the vehicle and pull the battery plug
Remove the cap of the filler and breather
Hold the oil drain pipe in a suitably sized (at least 60 liters), flat container
Version 1.2, 12.07.2006 8-201

Hydraulics
Tank
Remove and store the sealing plug from the oil drain pipe
Let the oil run off completely
Open the bleeder screw of the main and auxiliary lift cylinder and the emergen-
cy lowering screw of the main lift and auxiliary lift (Fig.: 8-5 on page 8-200; pos.
2 and 7) in order to also empty these
Note
The tank can be emptied more quickly when you con-
nect the drain hose to an external pump and suck off the
oil. Using this method, even higher oil vessels (canis-
ters, barrels) can be used.
Once more close the bleeder screws from the main and auxiliary lift cylinders
as well as the emergency lowering screw
Close the oil drain pipe and fix to the tank
Dispose of the oil in an environmental-friendly manner
8.6.3 Cleaning the tank
The tank has to be cleaned when the oil in the tank is heavily soiled, e.g. after a
break in the return line filter.
Empty the tank

Dismount the tank attachments
Remove the tank
Rinse the tank with hydraulic oil
8-202 Version 1.2, 12.07.2006

Hydraulics
Tank
8.6.4 Re-filling the tank
Note
For cleaning, always pump the oil through the return line
filter into the tank.
If the hydraulic circuit has been re-filled then ventilate the main and auxiliary lift
cylinders and put the pump into operation.

• Screw connection for filling the tank in Top view"” on page 8-200
8.6.5 Checking the hydraulic oil level
Note
Refer to Operating Instructions, Chapter F8.
Version 1.2, 12.07.2006 8-203

Hydraulics
Filler and breather
8.7 Filler and breather
§ Note
Never operate the vehicle without filler and breather.
4 1
Max.
Maximum
3
2
Minimum
Min.
Fig. 8-6: Filler and breather
1 Screw cap 3 Gauze filter

2 Chain 4 Air filter
The filler and breather with a fineness of 3 µma prevents dirt from entering the tank
from the ambient air.

• For assembly, refer to the operating instructions.
8.7.1 Level control
With the main and auxiliary lift lowered, the oil level in the gauze filter must be be-
tween the minimum and maximum mark.
8-204 Version 1.2, 12.07.2006

Hydraulics
Filler and breather
8.7.2 Checking the filter
A dirty filler and breather generates underpressure in the tank when lifting the main
or auxiliary lift. This results in an increased noise level and premature wear to the
pump aggregate.
Note
The filter must be replaced at the latest when replacing
the hydraulic oil.
Lift the cabin at maximum speed

With the pump running, remove the screw cap of the filter
; If the noise level of the pump is reduced considerably then the filter is dirty
and must be replaced.
Version 1.2, 12.07.2006 8-205

Hydraulics
Return flow filter
8.8 Return flow filter

The return flow filter cleans the oil flowing back into the tank with a fineness of
10 µma.
8.8.1 Checking the filter
Fig. 8-7: Return flow filter
1 Clogging indicator 2 Filter cartridge
When the pointer of the clogging indicator is in the red when lowering the main lift
at maximum speed then screw off the filter cartridge and replace it completely .
WARNING!
Break of filter with subsequent damage within the en-
tire hydraulic system
• Replace the filter on time.
8-206 Version 1.2, 12.07.2006

Hydraulics
Pump
8.9 Pump
The pump unit is installed under the battery.
When lowering the main lift, valves 2Y35 and 2Y52 must be open. The pump is
fed with oil via current controller 2Y31. The pump motor becomes a generator in
this operating state and feeds energy back into the battery via the lift control.
To avoid damages to the pump, the speed when lowering within the lower speed
range is not controlled via the pump control but via current controller 2Y31.
DANGER!
Oil can spray out at high pressure and result in seri-
ous injury.
• In case of initial commissioning or replacement of the
hydraulic components, maintain a suitable safety dis-
tance.
• Close all coverings before switching on. Erect protec-
tive walls.
8.9.1 Putting the pump into operation
The pump must be put back into operation after
• erecting the vehicle at the location of the customer

• replacing the pump
• work in the hydraulic system
• replacing the oil
DANGER!
Damage to the pump
• If the pump makes atypical noises (cavitation noise)
then switch off the pump motor, search for the cause
and alleviate it.
Version 1.2, 12.07.2006 8-207

Hydraulics
Pump
Preparations
To put into operation, make sure that
• the vehicle is ready for operation

• ball valve H6 under the battery is opened
• the tank transport lock is removed and the breather is mounted
• the oil level in the tank is correct; refill if required
• the bleed screw and emergency drain plug are closed
Switching on the pump
Only switch on the pump for a short time and observe the running noise
First run the LLD functions and then lift the main lift
If you are in doubt then connect the manometer to the test connector of the main
lift module block and check the correct development of pressure
Note
Ventilate the main lift and free lift cylinder thoroughly.
Bubble-free feed of the pump can be controlled by sep-
arating the manometer from the test hose and holding
the hose in a container.
8.9.2 Removing the pump unit
Switch off the vehicle and remove the battery plug

Remove the battery (refer to Operating Instructions)
Electrically disconnect the pump motor
Close ball valve H6 (directly in front of the pump)
Unscrew the hydraulic connections at the pump
Attach sealing plugs at the bleed pipe (DN 6) and at the pressure lines
Unscrew the fixing screws of the unit
Remove the unit (weight of the unit approx. 23 kg without motor)
; Installation is in the reverse order of steps.
8-208 Version 1.2, 12.07.2006

Hydraulics
Lift module block
8.10 Lift module block

Lift module block H3 on the tank has the following job:
• control of all speeds of the attachment

• control of the creep speed of the main lift for lifting/lowering
• limiting the pressure for all hydraulic movements (except load wheel brake)
8.10.1 Proportional valve with priority direction 2Y30
2Y42 2Y43
2Y40 2Y41
Priority circuit
Prioritärkreis
Secondary circuit 2Y30

Sekundärkreis
tozum
tank Tank
Fig. 8-8: Flow divider
The 3-way proportional valve 2Y30 guarantees the supply of the priority circuit
with a defined amount of oil and distributes the remaining oil to the secondary cir-
cuit.
The valve is normally closed, i.e. when not flowing, the priority circuit is closed and
the secondary circuit opens. When supplying with maximal current(Imax), the prior-
ity circuit is fully opened and the secondary circuit is closed.
Version 1.2, 12.07.2006 8-209

Hydraulics
Lift module block
The regulated oil flow is independent of the pressure at all three paths. Valve 2Y30
controls the amount of oil flowing through the priority circuit. If the amount of oil
flowing through decreases or stops entirely (e.g. turning against the stop), then the
valve opens the priority circuit independently (hydro-mechanical) as if there is a
supply of 600 mA (Ima) and completely closes the secondary circuit.
Note
All movements that depend on the priority circuit must be
taught in underneath the mechanical stop (mechan. end
position of the movement, e.g. auxiliary lift).
8.10.2 Swiveling and sideshift
Note
Directional valve 2Y40...43, see figure in Hydraulic in-
stallation of the traverse fork (RFZ)"” on page 8-225.
The flow divider with priority circuit 2Y30 controls the speed of swivel and sideshift.
The priority direction is swivel and the secondary direction is sideshift.
Swivelling motions
2Y36 and 2Y37 are activated for swiveling. Either 2Y40 or 2Y41 is activated, de-
pending on the swivel direction. To control the flow of oil, 2Y30 is activated suitably
to the swivel speed selected (control range: Imin to Imax). The remaining amount of
oil is led back via secondary circuit 2Y30 (sideshift) to the tank.
Sideshift movement
2Y36 and 2Y37 are activated for sideshift. Either 2Y42 or 2Y43 is activated, de-
pending on the sideshift direction. There is maximum flow at 2Y30 at the beginning
(Imax). The entire amount of oil is led back via priority circuit 2Y30 (swivel) to the
tank. The current is then continuously reduced until Imin is reached. During this, the
secondary circuit of 2Y30 is supplied with an increasing amount of oil. The side-
shift movement is accelerated up to the maximum speed.
Note
When braking the sideshift movement, the procedure is
reversed.
To exactly set the movements, the shock and load sta-
bilizer valve of the attachment must be set (Setting the
shock valves (sideshift)"” on page 8-227).
8-210 Version 1.2, 12.07.2006

Hydraulics
Lift module block
8.10.3 Synchronous swiveling/sideshift
The synchronous movement is controlled by the speed of the pump for synchro-
nous swiveling (service menu M07, D12, D06), as well as the setting of Imin and
Imax of the proportional valve with priority control 2Y30 (service menu M07, I10,
I11).
When synchronous movement is selected:
• the pump starts at minimum speed (acc. to service menu M07; D12)
• 2Y37 is opened
• 2Y31 is constantly operated (acc. to service menu M07; I10). This ensures
that the remaining amount of oil is led back to the pump and not to the tank.
• Swiveling starts at minimum speed
• The flow at 2Y30 is increased from Imin to Imax
• The speed of the pump is increased to the maximum (acc. to service menu
M07; D06). This supplies the secondary circuit with oil.
• 2Y36 is opened and the sideshift movement begins. The delay (offset) for
2Y36 can be set in service menu M07; V21.

• The exact setting of the synchronous movement is in Adjustment of the swivel
chains"” on page 7-159.
Version 1.2, 12.07.2006 8-211

Hydraulics
Lift module block
8.10.4 Main lift/Auxiliary lift
Lift main lift
The lift speed of the main lift movement is controlled by the speed of the pump.
Lower main lift
The lowering speed of the main lift movement is controlled by proportional valve
2Y31. When the main lift is lowered at maximum speed then the speed should be
controlled by the pump which then functions as a generator. Otherwise, energy re-
covery does nor function The speed at which the control is transmitted from pro-
portional valve 2Y31 to the pump is set by service menu M04; V30.
8.10.5 Auxiliary lift movement
Lift auxiliary lift
The speed of the auxiliary lift movement is controlled by proportional valve 2Y30.
2Y32 is opened.
At the start of the movement, 2Y30 is increasingly fed with current and the pump
runs at minimum speed for lifting the auxiliary lift. After running up to the maximum
speed, 2Y30 remains completely open (current Imax) and the speed of the pump is
continuously increased to the maximum speed.
Lower auxiliary lift
The lowering speed of the auxiliary lift movement is controlled by proportional

valve 2Y49. 2Y33 is opened.
Synchronous lifting of main lift and auxiliary lift:
The amount of oil is controlled via proportional valve 2Y30 between the main lift
and the auxiliary lift proportionally by activating the master switch L2 (to the left of
the console segment). The setting must be made so that the auxiliary lift move-
ment at the upper stop has reached its end position at approx. 6 m main lift .
8-212 Version 1.2, 12.07.2006

Hydraulics
Lift module block
8.10.6 Return flow pressure control valve
To set the pressure control valve for the return flow of the oil
• Connect the manometer at the minimess connection (Fig.: 8-9 on page 8-

214; pos. 5)
• Pull plug from 2Y32
• Activate lift of auxiliary lift
§ Note
The pressure must be set to the value listed in the ac-
ceptance certificate.
Version 1.2, 12.07.2006 8-213

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DAMBACH Lagersysteme GmbH & Co. KG

Version 1.2, 12.07.2006 I

II Version 1.2, 12.07.2006

Version 1.2, 12.07.2006 III

IV Version 1.2, 12.07.2006

Version 1.2, 12.07.2006 V

VI Version 1.2, 12.07.2006

Version 1.2, 12.07.2006 VII

VIII Version 1.2, 12.07.2006

List of Tables ..........................................................................................................437

Version 1.2, 12.07.2006 IX

1.1 About the Manufacturer ............................................................. 2

Version 1.2, 12.07.2006 1-1

1.1 Notes on the complete documentation

1.1.1 Service manual

1-2 Version 1.2, 12.07.2006

1.2 Preventative maintenance

1.2.1 General maintenance instructions

The following requirements must be adhered to:

For additional information, please see:

Version 1.2, 12.07.2006 1-3

1.2.2 After the first 100 and 500 operating hours

After 100 operating hours

After 500 operating hours

1.2.3 Daily maintenance before driving

 Check brake performance

1-4 Version 1.2, 12.07.2006

1.2.4 Maintenance and lubrication intervals

The following maintenance checklist indicates the operations to be performed and

W1 = every 50 operating hours, but at least once per week

M3 = every 500 operating hours, but at least every 3 months

M6 = every 1000 operating hours, but at least every 6 months

M12 = every 2000 operating hours, but at least every 12 months

Version 1.2, 12.07.2006 1-5

1.2.5 General maintenance plan

Component Description W1 M3 M6 M12

1-6 Version 1.2, 12.07.2006

Component Description W1 M3 M6 M12

Version 1.2, 12.07.2006 1-7

Component Description W1 M3 M6 M12

1-8 Version 1.2, 12.07.2006

1.2.6 Maintenance plan swivel/traverse fork

Component Description W1 M3 M6 M12

Version 1.2, 12.07.2006 1-9

1.2.7 Maintenance plan telescopic fork

Component Description W1 M3 M6 M12

1-10 Version 1.2, 12.07.2006

1.2.8 Lubrication equipment

Consumption-type materials must always be handled properly and in accordance

Improper handling is injurious to health, life, and environment. Consumption-type

When filling up consumption-type materials, use clean containers only. Consump-

Reference values oils

Code Designation Area of application

B API GL4 SAE 80-90 Gears

E Grease, DIN 51825 Lubrication

G Chain spray Chains

Tab. 1-4: Oils

Reference values lubricants

Tab. 1-5: Greases

Version 1.2, 12.07.2006 1-11

1.2.9 General lubrication schedule

Check brake performance