Service Manual

CBE

25
30
30L
35

E Range

036-0402-02 08/1999
 PAGINA INTENZIONALMENTE BIANCA

INTENTIONALLY LEFT BLANK

PAGE INTENTIONNELLEMENT BLANCHE

WEIß SEITE

PÁGINA INTENCIONALMENTE BLANCA

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Electric SERVICE MANUAL
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reserves all rights of reproduction of this handbook

The text and the numbering system may

not be used in other printed matter, reprinted
or translated, whether entirely or in part, without
written authorization from

CESAB reserves the right to make any necessary

modifications without obligation to promptly update
this handbook.

Copyright by
CESAB
CARRELLI ELEVATORI S. p. A.

BOLOGNA’S FACTORY, AFTER SALES SERVICE

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MECHANICAL SECTION

DATA SHEET page 6-7

DRIVER’S PLACE page 8-9

DASHBOARD page 10-11

TRUCK LOAD CAPACITY page 12

TRACTION UNIT page 13

Disassemble the reduction unit page 14
Oil change page 15

BRAKES page 16
Service brake system page 16
Service brake function description page 17
Parking brake system page 18

ELECTRIC MOTORS page 19

WHEELS/TYRES page 20

STEERING GROUP page 21

Bearing adjustment page 21
Power steering description and maintenance page 22
Filter and power steering oil page 22
Steering axle page 23

LIFTING UNIT page 24

Hydraulic control valves page 24
Hydraulic system diagram page 25

MASTS page 26
Triplex mast section page 27
Mast lubrication and settings page 28-29

MAST LIFTING UNITS page 30

Description of the cylinder component parts page 31
Checking the chains page 32
Checking the forks page 33
Mast tilting setting page 33
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ELECTRICAL SYSTEM page 34

Components Description page 34
Accelerator pedal page 34
Battery and battery charger page 35

TRUCK LIFTING page 36

TABLES page 37
Oil and grease specifications page 37
Tyre pressure tightening torques page 37
Running in maintenance table page 38
Maintenance table page 39-41

ELECTRICAL SECTION

TECHNICAL FEATURES page 43

FUNCTIONAL PERFORMANCES page 44

Protection page 45
General precautions page 46

GENERAL DESCRIPTION OF FUNCTION OF THE CONSOLE page 47

CONSOLE DESCRIPTION page 48

ELECTRONIC CONTROL PANEL LAYOUT page 49

POWER CIRCUIT DIAGRAM page 50

OPERATING CURRENT DIRECTION page 51-52

INPUT CONNECTION page 53

TRACTION POTENTIOMETER page 54

LIFTING POTETNTIOMETER page 55

PARAMETER CHANGE DESCRIPTION page 56

TESTER MENU DESCRIPTION page 57

ALARMS MENU DESCRIPTION page 58-59

ADJUSTMENTS TABLE page 60

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PEDALS

FOOT DRIVE DIRECTION

(Standard version)
- Forward direction (D)
- Backward direction (E)
- Service brake pedal (C)
- Parking and emergency brake pedal (A)
- Parking brake release lever (B)
A B C D E

F
DRIVE DIRECTION LEVER ON STEERING
1
COLUMN (Alternative version)
o
2
Direction selector lever (F)
é
1 Forward direction
o
0 Neutral
ê 2 Backward direction

Single drive pedal (G)

Key (H)

Emergency push button (P)

P H
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Battery cover lifting

Press the lever (J), lift the cover using the appropriate
I handle (I); complete lifting is facilitated by the use
J
of an air spring.
After opening the battery cover, it is possible to
remove the rear compartment cover.

H
Battery connector (H)
Inside the battery cover

N
M
Levers unit
L
K K) Lifting control lever
L) Tilting control lever
M) Sideshift control lever
N) Device control lever (optional)
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1) Battery charge indicator

1 2 3 4 5 6 7 2) Parking brake ON warning light
3) Low brake fluid level warning light
4) Lifting motor temperature warning light
5) Worn lifting motor brushes warning light
6) Worn drive motor brushes
7) Drive motor temperature warning light
9) Electronic hour meter
10)Not used
11)Control valves functions locked due to flat battery (no connected)
9 10 11 12 13 14 15 12)Dead man device warning light
13)Drive and lifting diagnostics led (see electrical section)
14)Not used

DASHBOARD CONTROLS
1
1) Battery charge indicator
This consists of 3 green LEDS, 4 orange LEDS and 3 red LEDs,
With battery charged the right green LED becomes on and while
2 the battery discharges, the LEDS will be separately on from
right side to left side.
When the battery is 80% discharged, the first red LED on the
left begins to flash showing that the battery must be recharged
3
(reserve). At the same time, the warning light (11) comes ON.

2) Parking brake ON warning light

4
3) Brake fluid low warning light

4) Lifting motor temperature warning light

5 lights up when the temperature is 150°C

5) Worn lifting motor brushes warning light (see chapter “DRIVE

6 AND LIFTING MOTOR BRUSHES”)

6) Worn drive motor brushes (see chapter “DRIVE AND LIFTING

MOTOR BRUSHES”)

7 7) Drive motor temperature warning light

lights up when the temperature is 150°C

9) Electronic hour meter

9
It is activated by insertion of the ignition key.
It shows the hours and the tenth
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12 12)“dead man device” pilot light

the pilot light comes ON, when the driver leaves the driving seat

14 14)Drive and lifting diagnostic led (see electrical section)

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LOAD PLATE
It identifies the load capacity with a load center
of 500 mm (except for different indications)

ATTACHMENT OR SPECIAL CONDITION OF USE

TYRES SERIAL N°

CENTER OF LOAD DISTANCE mm

LIFT HEIGHT
mm

A
Cod. 0312005

DERATED CAPACITY Kg

CAPACITY PLATE

IDENTIFICATION PLATE
It identifies the lift truck technical data

MODEL Type MOTOR RATED CAPACITY

kW kg

SERIAL N° DRAW-BAR PULL (1h)

N

BATTERY MASS SERVICE MASS

kg kg Without
min. max. Battery kg

B MANUFACT. YEAR TENSION

V
Cod. 0312004

CARRELLI ELEVATORI S.p.A. CESAB LDT

via Persicetana vecchia, 10 Bevan Way
40132 - Bologna - Italia Smethwick - Warley
West Midla 1ds B66 1BZ
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The traction gear unit is consisted of:

1) Right hand reduction gear
2) Oil bath brakes
3) Differential gear
4) Electrical motor
5) Left hand reduction gear
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7 screws

Disassemble the reduction unit

- Park the lift truck on a level ground. Engage the parking brake and disconnect the battery;
- Disassemble the mast;
- Lift the front part of the lift truck and set the special shims under the side
panels of the chassis;
- Remove the front wheels;
- Disconnect the tie rods of the parking brake, the service brake oil pipe, the
motor cables etc;
- Keep the reduction unit in lifted position;
- Remove the fastening screws located on the chassis (tightening torque setting of 45 daNm).
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OIL CHANGE
Type of oil MOBIL-FLUID 422SAE 80W
or equivalent (see oil table).

After the first 50-100 hours

- change the oil.

Every 250 hours

- remove the front wheels.
Check the oil level, when it is cold.

Every 1.000 hours or 12 months

- change the oil.

F F

OIL CHANGE INSTRUCTION

- Place the lift truck on a flat floor with the parking brake on.
C - Lift the front part of the lift truck and remove the wheels.
- Disconnect the battery connector.
- Changing the oil in the reduction gears.
- Carefully clean the area around the oil filling (E) and draining caps
(F); place a suitable container below the drain cap and then remove
both the filling and the draining caps and allow the oil to drain
out completely.
- Clean any ferrous residues from the magnetic cap (F) and replace
it.
- Pour fresh oil into the hole (E) until it starts overflowing from
(E).
After a short functioning period, check the oil level again.
- The oil quality for each reduction is approximately 1 L.
- Breather (C).
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H B C A SERVICE BRAKE SYSTEM DIAGRAM

A) Reduction gear (right) and braking unit

B) Parking brake command
C) Bleeding screw
D) Electric drive motor
E) Brake pump
D F) Tank
G G) Service brake pedal
H) Reduction gear (left)

E F
SERVICE BRAKE CONTROL
The disk brake is in an oil bath and it acts on
both of the front wheels; the brake uses the same
oil as the drive reduction unit.

OIL BRAKE TANK (F)

Gioco

CHECK SERVICE
BRAKE
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DISKS AND
COUNTER DISKS
DIFFERENTIAL
BRAKE BRAKE
COUNTER
DISK
EXTERNAL
BRAKE
DISKS

CENTRAL
BRAKE DISKS

SERVICE
BRAKE
OIL INLET

PARKING BRAKE
LEVER

External brake disks thickness 2,75 ÷ 2,85 mm (n° 2)

Central brake counter disk thickness 3,60 ÷ 3,70 mm (n° 1)
Max wear on each side 0,45 mm
Brake counter disks thickness 2,95 ÷ 3,05 mm (n° 1)
Differential brake disk thickness 1,57 ÷ 1,63 mm (n° 2)
Differential brake counter disk thickness 1,37 ÷ 1,43 mm (n° 2)
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I L
PARKING BRAKE DIAGRAM

I) Release lever
O L) Parking brake pedal
M M)Microswitch
N) Brake block anchor
O) Pedal adjusting screw
P) Release adjusting screw
P
N

PARKING BRAKE CONTROL AND

ADJUSTMENT

Every 500 hours

- Check the clearance shown on the drawing
A A with the parking brake pedal released
- Check the parking brake stroke which
should correspond to 4 notches ( L pedal).
If it necessary, act on the adjusting screw
(O)
- With the front wheels lifted adjust the cable
so that the same ones at 1st notch are
Leva.tif
free, on the contrary, at the 2nd notch
are blocked.
Press the parking brake pedal some times
and check if the clearance is still the same.

PARKING BRAKE RELEASE

INSTRUCTIONS

The dimension of the parking brake is sufficient

to guarantee blocking of the truck.
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MAINTENANCE
Every 500 hours check the wear brushes
Every 500 hours check the commutator conditions

BLITZ 250 - 300

TRACTION MOTOR (Schabmüller) LIFTING MOTOR (Schabmüller)
V 80 Kw 15,5 V 80 Kw 14
A 210 Ecc. sep A 210 Ecc. serie
Rpm/min. 1650 IP 20 Rpm/min. 2150 IP 20
Service S2 Classe IS H Service S3 18% Classe IS H
N° poles 4 N° brushes 8 N° poles 4 N° brushes 8

Pump 22,5 LiT/min.

BLITZ 300L - 350

TRACTION MOTOR (Cesab) LIFTING MOTOR (Leroy somer)
V 80 Kw 16 V 80 Kw 17
A 230 Ecc. sep A 240 Ecc. serie
Rpm/min. 1360 IP 20 Rpm/min. 2550 IP 20
Service S2 Classe IS H Service S3 30% Classe IS F
N° poles 4 N° brushes 8 N° poles 4 N° brushes 8

Pump 19 LiT/min.

< 50%
L
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STANDARD TYRES

THE SAFETY OF RIMS AND WHEELS FOR FORKLIFT TRUCKS

“PNEUMATIC” tyres must be replaced when the tread is less than 1.6 mm. “SUPERELASTIC”
tyres must be replaced when the tread reaches the “60J” indicator printed on the side.
Replacement of “CUSHION” tyres is recommended when they reach a thickness of
20 or 30 mm.

PNEUMATIC TYRES PRESSURES

Front 10 BAR CU
CUSHION
Rear 10 BAR
←

SE
TIGHTENING TORQUE SUPERELASTIC
Driving tyres 19 daNm ←
Steering tyres 24 daNm
PN
PNEUMATIC
←
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BEARING ADJUSTMENT
Steering wheel bearings require an adjustment once a year.

Steering wheels
- lift the steering wheels
- remove cap (1);
- remove check pin (4);
- fasten the nut with a torque setting of 6 dNm;
- turn the hub of 2-3 turns in both senses;
- unfasten nut (3) and retighten with a 2-1 daNm torque;
- check that the wheels slide correctly (max. rolling final torque: 0.2 dNm)
and that there is no side play (maximum axial play of 0.05 mm);
- reassemble the check pin;
- reassemble the cap (1);
- lower the wheels again and check that all nuts fixing the wheel disk (5) to
hub (2) are well tightened.

3
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STEERING CONTROL

The steering uses the same oil as the lifting by means a priority valve, so that a sufficient
oil flow to the power steering is always assured.
The oil capacity is checked by the Ls signal (load - sersing) coming from the steering
unit and it occurrs so that the oil capacity sent to the power steering is equal to its
actual request.
The exceeding oil is sent to the control valve for other functions.
When the steering wheel is turned the steering unit “measures” a volume of oil proportional
to the above rotation and sends it into the steering cylinder.
The steering unit returns automatically in it neutral position when the manoeuvre is finished
(see hydraulic diagram page 25).

POWER STEERING SEAL CONTROL AND CLEANING

Every 250 hours

- check the entire system to identify any leak; any
intervention must be carried out without pressure in
B
the system.
Every 4 000 working hours
- replace hoses (G) connecting the orbitrol device to
the steering jack.
G
Every 10 000 hours
- replace the hydraulic system tubing.
Power steering pressure setting
The max power steering pressure must be 90 Bar

In order to set the power steering pressure, the following operation are necessary:
1 - Fit a manometer on point (A) of the motor;
2 - In order reach the adjusting screw (B) remove the cap (by allen wrench) positioned
in the upper side of the orbitrol (power steering unit);
- screw in to incroase the pressure
- screw out to decrease the pressure

A
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STEERING AXLE
Steering axle check
Every 500 hours
- lubricate the steering gear joints using the appropriate grease nipples (D), (E) and (F);
- check the steering angles.
Every 2.000 hours
- check and if it is necessary, adjust the wheel hub bearings.
Every 500 ore check the angles

Max steering angle (internal wheel ≅ 80°)

End stroke setting (adjustment):
take the cylinder to the internal end stroke, then operate on the special screws putting
them on the spindles. Then screw in the adjusting screws till when you obtain the
desired steering angle B = 80°

If any abnormal consumption of the wheel tread is observed, the following controls
should be made:
- check the parallelism of the steered wheels;
- check that the steering angle of the wheels is the same in both directions.

B = 80° Standard
85° Max angle accepted

ANGLE MEASURED BY THE AXLE FRAME TO THE

INTERNAL WHEEL THROUGH A SPECIAL DEVICE
D

F
D

END STROKE
SETTING SCREW

STEERING AXLE
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HYDRAULIC CONTROL VALVES

Max pressure valve 200 BAR

Max pressure tilting valve 130 BAR

Max pressure sideshift valve 130 BAR

LIFTING EQUIPMENT OIL AND FILTER

B
D The hydraulic lift oil tank is located under the platform.
The filter cartridge (D) (15 µ) is beneath the screw cap (B).

After the first 50 hours of work

A
C - first filter change
After the first 500 hours of work
- second filter change.
Every 250 hours
- check the level of oil in the tank using the dipstick (A);
- check and clean the tank breather valve filter (C).
Every 2 000 hours
- replace the oil and the filter.

To change the oil and the filter:

- remove the filling cap (B), extract the filter;
- remove the drain cap (E); drain out all the oil into an appropriate
container then replace the drain cap and tighten firmly;
- fit a new filter (D) after checking the state of the seals;
- Fill the tank with approx. 35 liters oil through
the filter until the dipstick notch (max level).
E
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HYDRAULIC DIAGRAM
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The mast profile - CESAB design - with double stiffening flange is characterised by a high
flexural and torsional strength.
It allows wide visibility thanks to the reduced dimensions of the profile itself.
Cylinders are single-acting type.
The sideshift system has been housed inside the profiles.
The mast group is a roller type with a variable centre distance (i.e. a fixed roller is fitted on the
outer mast and a mobile one on the inner mast, instead of a number of mobile rollers only on
the inner mast). This solution ensures better grip and stability on operation.

Other features: side plays adjustable from outside. Plastic guide shoes. Roller bearings with
grease nipples, ball joints on axle couplings and tilt cylinders.

Lifting cylinders:
Duplex mast: VT 2 side cylinders
FFL 2 central cylinders (with displacement cylinders)
1 short central cylinder

Triplex mast VT 2 side cylinders

FFL 2 side cylinders
1 short central cylinder

Grease nipple Adjusting screw Shoe Roller

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TRIPLE MAST SECTION

Fork carriage

Internal
section bar

Intermediate
section bar

External
section bar
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LUBRICATION OF LIFTING EQUIPMENT

D Masts
After the first 50 hours
E - adjust the guide shoes adjusting the Allen screw (D)
For the adjustment use a 0.2-0.5 mm thickness gauge, inserted
from below and up to the centre of the Allen screw (D) passing
behind the roller (E).

Every 50-100 hours

- lubricate with grease the mast sliding guides
- lubricate the tilting jacks and the mast connections.
A) Tilting jacks 2+2 grease nipples
A
B) Mast connections 1+1 grease nipples

Every 250 hours

- adjust the guide shoes;
- grease the mast guide rollers (E)

Every 2 000 hours

- check the condition of the guide rollers (E); they must turn freely
without jamming and not show excessive wear.

Fork carriage and sideshift unit

After the first 50 hours
- adjust the guide shoes adjusting the Allen screw (G)
For the adjustment use a 0.2-0.5 mm thickness gauge, inserted
from below and up to the centre of the Allen screw (G) passing
behind the roller (H).
B
Every 50 hours
- lubricate the sideshift guides with with grease through the grease
nipples.

Every 250 hours

- lubricate the fork positioning pins and notches with grease.
- grease the fork carriage guide rollers (F)
F - adjust the guide shoes
G
Every 2 000 hours
- check the condition of the guide rollers; they must turn freely without
jamming and not show excessive wear.
H
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C
C) Sideshift unit
(upper part)
3 grease nipples
(lower part)
without grease nipplesexcessive wear.

Make sure that:

C
- the lifting chain stay bolts are free of defects
and that the adjusting nuts are locked by the
appropriate cotter pins (A);

E - the fork carriage (B) safety end stops are present

E
and tightly fixed.

- the collars (C) are present and tightly fixed.

Every 500 hours

- check that there is a clearance (D); of 0.5 to
3 mm between the collar and external lifting
D
jack cylinder.

- check that there self-lockin nuts (E) are tight.

Locking torques:
- collar self-locking nuts 0.8-1.2 daNm

SAFETY FORK CARRIAGE END STOP

The lifting unit is equipped with a mechanical safety
A end stop, to avoid the accidental escape of the
B
fork carriage from the botton of the mast.
The end stops (A) consists of two Allen bolts. To
remove the fork carriage, first of all unscrew the
end stops.
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DESCRIPTION OF THE CYLINDER COMPONENTS

The cylinder pistons are single-acting types (fig. A).

In these cylinders a seal (1) has been fitted on the

6
piston (2) that works on the inner surface of the
5 cylinder liner (3).

4 The rod guide is made by the plug (4) and by the

piston through anti-friction rings (5).

7 The dust control ring (6) prevents any dirt and water
from penetrating the cylinder.

Slight leakages that may occur are directed to the

tank through the drain pipe connected to the pipe
THRUST coupling (7).
DIAM-
ETER
3 The drain pipe shall reach the oil tank (fig. B)

A small quantity of oil will always remain in the loop

formed by the pipe before connecting to the tank. It
acts as a trap and constantly moisturizes the cylinder
liner, when it is completely closed (fig. B).

2
5

Fig. A Fig. B
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CYLINDER CHECKING METHODS

1ST CHECK
Remove the drain pipe from the cylinder (fig. C)

Lift the cylinder some times to end stroke, so as to discharge any oil
residual.

Put a load on the forks and lift it by at least 200 mm.

After 10 minutes, measure the amount by which the load has lowered. A
drop of a few millimetres is quite normal, as in the distributor there are
always some leakages.
Now, lift the cylinder to its end stroke, if no oil leaks from the drain pipe
coupling, it means that the load lowering is only due to the leakages on
the distributor.

Fig. C In the presence of leakages, it will be necessary to replace the seal. Should
this be the case, inspect the cylinder liner.

2nd CHECK
(To be carried out if the 1st inspection has been successful and after seal
replacement).

Remove the drain pipe from the cylinder.

Lift the cylinder some times to end stroke, so that all the possible remaining
oil is discharged.

Put a load on the forks. Lift and lower it for 10 minutes, making sure that
the limit stop is never reached.

Lift the cylinder to end stroke.

If any leakages should be still present, the cylinder is damaged and then it
must be replaced.
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CHECKING THE CHAINS:

Every 500 hours

- check the condition of the chains which in any case must not be worn or damaged.
To check the links for wear, use the appropriate gauge, paying attention that, when
33 links are counted in a space corresponding to 34, the chains must be replaced.

Every 1 000 hours

- remove the chains, clean them thoroughly, refit them inverting the original working
position and lubricate them.

Every 10 000 hours

- replace the chains and the fixing tie rods

POSITIONING THE FORK MOUNTING CARRIAGE

Every 500 hours

- After testing the chains as described above, with the truck on an even surface and
the mast in a vertical position, check the position of the fork carriage plate, as follows:
- remove the forks, completely lower the fork carriage and measure the height (X),
comparing it with the value shown in the table, correspondig to the capacity in kg
of the truck.
(e.g. the correct value of (X) for a truck with a capacity of 3000 kg (class II B),
must be 203 ±5 mm).

X = 203 mm
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FORK INSPECTIONS
General criteria
Fork arms in use must be inspected at intervals of not
more than 1 000 hours and whenever a defect or permanent
deformation is detected. If the truck is subject to intensive
G G use, more frequent inspections may be required.

E E Inspection
Fork arm inspection must be carefully carried out by
trained personnel to detect any damage, failure, deformation,
etc., which may impair safety use.
F F
D D Surface cracks
The fork arm must be thoroughly examined visually for cracks
giving special attention to the heel (D) and top (E) and bottom
(F) hooks.
If necessary, the forks may be subjected to a non-destructive
crack detection process

Difference in height of fork tips

Check the difference in height between the blade tips on each
pair of forks, this must not be more than 3% of blade length
with the forks fitted on the fork plate.

Positioning lock
Check that the fork positioning lock (G) is in good working
order.

MAST GROUP TILTING SETTING

2°30 FORWARD STANDARD

10° BACKWARD 2M VT
8° “ 3M FFL
6° “ 3M VT - 2M FFL

Check to carry out every 500 h

N.B. 1 tilting degree corresponds to a 17.4 mm

movement on 1 mt.
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COMPONENTS DESCRIPTION
E I
G

D) Traction and lifting module E) Contactor

F) Panel cooling fan G) Air conveior
I) Fuses L) Converter 80/24 (120W standard)

ACCELERATOR PEDAL

Set the potentiometer

Position the tester set in OHM between the green
and the red wire.

Set the potentiometer

from 12 to 12.5 KOHM (pedal released)
from 7 to 7.5 KOHM (pedal pressed)

180 mm

Height adjustment screw

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BATTERY AND BATTERY CHARGER

General indications for battery maintenance

Every 50 working hours - measure electrolyte density.

Approximate density data

For a temperature of 15° C
- a density of 1.12 to 1.13 kg/dm3 indicates that the battery is flat;
- a density of 1.25 to 1.26 kg/dm3 indicates that the battery is charged (battery capacity
increased: 1.29 to 1.30 kg/dm3).

BATTERY CHARGING WARNINGS

Before charging the battery, verify that the room is well aerated. Open the battery compart-
ment door.
Make sure that all electrical connections (electrical cable terminals, battery terminals, plugs-
sockets, etc.) are well attached and in good condition.
- Do not open either remove battery filling caps.
- Never top up before and while charging the battery.
- Do not smoke, do not stay close to naked flames and do not cause sparks next to
batteries
- Do not use the battery while it is being charged
- Do not lean metal tools on the battery while under charge
- Never repair the battery while under charge
- Check that during the charging phase, the electrolyte temperature is kept below
50°C.

BATTERY WEIGHTS AND CAPACITY

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é
HOOKS ATTACHMENT POINTS FOR LIFTING
THE TRUCK

B To lift the truck the following equipment must be used:

A- CHAINS: dia. 10 mm - Degree T (8) - UNI 9425

B- HOOKS: for 3,2 t - UNI/ISO 7597

ß - ≤ 45°
C
C

C C

LIFTING OF THE FORKLIFT TRUCK WITH CABIN

B B

A- CHAINS: dia. 10 mm - Degree T (8) - UNI 9425

A
B- HOOKS: for 3,2 t - UNI/ISO 7597

C- N° 2 upper brackets to hold the chains.

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OIL AND GREASE SPECIFICATIONS

TYRE PRESSURES TIGHTENING TORQUES

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SERVICE MANUAL Electric
page 38

RUNNING IN MAINTENANCE

LEGENDA

' and cleaning of the parts indicated.

In the maintenance table indicating a visual control

& Inreplacement
the maintenance table indicating the
of the parts indicated.

" Inof thethemaintenance table indicating lubrication

parts indicated.

, or adjustment of the parts indicated.

In the maintenance table indicating tightening
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MAINTENANCE TIMES
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MAINTENANCE TIMES
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MAINTENANCE TIMES
SERVICE MANUAL

Electrical section
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Electric SERVICE MANUAL
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TECHNICAL FEATURES

ELECTRONIC PANEL - COMBI SEM 3

Tension 80 V
Field max. current 50 A
Armature max current 500 A
Pump max current 500 A
Armature working frequency 16 KHz
Field working frequency 1 KHz
Pump working frequency 16 KHz
Working ambient temperature -30°C / +40°C
Max. attainable temperature
from chopper body 85°C
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FUNCTIONAL PERFORMANCES

- Very good control at low speed.

- Reduction of the max. speed: max. speed in both directions can be set by using the
programming console.
- Regenerative braking based on deceleration ramps, on release, on reversal and on
partial accelerator release.
- Speed check down a slope: the motor speed follows the accelerator pedal automatically
setting the regenerative braking, in case the motor speed exceeds the desired one.
- Up start without roll-back also without use of an electric brake (electrobrake).
- Anti rolldown function; key On chopper checks the traction motor speed; in case it
is moving, without direction request from the operator, it carries out automatically
a braking and checks the down a slope by very low speed (function useful for safety
also without truck driver on).
- In the pump section the selected lower speed prevails.
- Diagnostic with indication by means of led.
- Able to be formed via console.
- Internal timer visible from the console.
- Storage of the last 5 alarms with the relative value of the timer and temperature
visible from the console.
- Tester by means of the console to verify in real time of the main parameters, such as
input, motor voltage, battery.
- Arc less operation of the remote control switches.
- Internal coil suppressor (within logic).
- High efficiency of motor and battery due to high frequency switching.
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PROTECTIONS

- Battery reversal:
It is important to observe the connections shown in order to prevent damage.
The logic is internally protected from reverse battery polarity.
- Connection errors:
All inputs are protected against incorrect connections.
The remote control switches have a rating of 2Amps, however they are protected from overload and short
circuits.
- Thermal protection:
When the temperature is more than 75° C the maximum current is reduced in proportion to the increase in
temperature. The temperature can never exceed 85° C.
- External agents:
The chopper is protected from the dust and from the liquids spray is completely sealed.
- Safety from accidental operation:
Starting the machine, requires a precise sequence of operations otherwise the machine will not start. The start
sequence has to be initiated after the key and the micro seat are active.
- Safety from uncontrolled movements:
The remote control switches remain open if:
- The power is not in use.
- The accelerator voltage does not fall below (minimum memorized value 2 volt).
- The logic is not in perfect order.
- A direction microswitch is ever closed.
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GENERAL PRECAUTIONS

- Do not connect the chopper to a battery with a nominal voltage different to the voltage stated
from the one on the unit plate. If the battery voltage is higher it may cause the MOS failure.
If the battery voltage is lower, the unit will not run .

- During the battery recharging no units must be connected to the battery as, the unit can be
damaged by the overvoltages generated by the charge-battery.

- Supply the unit only with traction battery, do not use rectifier outputs or power supplies.

- With key switched off, the filter capacitors could remain charged for some minutes. To work
in safety working conditions, we suggest you as follows

. disconnect the battery with the key on and wait till when the display is
completely off;
or
. short circuit the capacitors through a resistor (56 Ohm 1W) across B+ and B-
chopper power connections.

- Before carrying out any arc-welding on the trucks, disconnect the battery and short-circuit
the unit between positive (+) and negative (-).
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GENERAL DESCRIPTION OF FUNCTION OF THE CONSOLE

HOUR METER
The hour meter appears in the second line of the display when the chopper is connected. The
hour meter has a sensitivity of one minute and a full scale value of 65,535hours . It shows the
hours only.

ALARM DISPLAY
The console features the possibility to read the last five alarm messages stored in the chopper
and displayed together with the time of occurrence, the number of times the alarm was sent and
the temperature value at the time of the alarm.

PARAMETER PROGRAMMING
The chopper parameters can be displayed and programmed via the keyboard, in real time and
with operating machine, thereby making it possible to set the chopper easily.

TESTER
It makes it possible to display the state of the chopper analogue and digital values and thereby
to have a useful tool for the analysis of chopper operation and external cables.

SAVE
It makes it possible to store all values relating to the parameters and the chopper hardware
configuration into the console with a program which can be selected from the keyboard.

RESTORE
It makes it possible to program a chopper with the parameters contained in a program
generated by a SAVE.

ACCELERATOR MAX. STROKE PROGRAMMING

It allows to program the accelerator max. stroke.
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CONSOLE DESCRIPTION
KEYBOARD

Description of key functions:

ROLL 1 = Allows selection of an option or the next menu item

ROLL 2 = Allows select of an option or the previous menu item

ENTER = Allow confirmation of selected options

OUT = Retains the current function

PARAM = Allows an increase in the parameters or selects the type of connected I/O

SET = Allows a reduction in the parameters or selects the type of connected I/O
 Remouve the plastic cap
and connect the console
Electric

F1

F2

F3

F6
F5
F4

A
ELECTRONIC PANEL LAY-OUT

F0
SERVICE MANUAL

B
Poewr fuse
F0) traction and lifting motors fuse 500 A

Auxiliary fuses
F1) key fuse 5 A F4) horn fuse 5 A
page 49

F2) contactors fuse 2 A F5) electrofan fuse 3 A

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F3) converter 80/24 fuse 20 A F6) reverse and stop light fuse 5 A
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POWER CIRCUIT DIAGRAM

MOTOR
PUMP
TRACTION MOTOR
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OPERATING CURRENT DIRECTION

FORWARD DIRECTION

ARMATURE

FIELD

FORWARD DIRECTION BRAKING

ARMATURE

FIELD
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BACKWARD DIRECTION

ARMATURE

FIELD

BACKWARD DIRECTION BRAKING

ARMATURE

FIELD
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INPUT CONNECTION

KEY

key = Key switch (+VB) acc. pot . = Traction potentiometer

cm = Common switch (+VB) 1 st speed = Tilting switch
rev = Backward switch 2 nd speed = Sideshift switch
forw = Forward switch 3 rd speed = 4 Th lever switch
seat = Seat switch lift = Lifting switch
hb = Parking brake switch 4 th speed = 5 Th lever switch
plc = Main contactor positive lift pot = Lifting potentiometer
nlc = Main contactor negative lcc = Main contactor
pb = Brake switch led = Diagnostic led
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TRACTION POTENTIOMETER

Green 111
)

5KOhm

7KOhm Red 109

ç )
Yello 110
)

By the console on “TESTER” menu select, “ACCELERATOR” function:

Accelerator pedal released ~ 0,6 ÷ 0,8 Volt

Accelerator pedal pressed ~ 7,5 ÷ 7,7 Volt

Verified these values, carry out the “PROGRAM VACC” function to acquire the
traction potentiometer signals (see attached diagram for using the console).
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LIFTING POTENTIOMETER

137
3

5 KOhm

2 135
ç
1
136

By the console on “TESTER” menu select, “LIFTING CONTROL”

Lifting lever at rest - 0 Volt

Lifting lever pulled ~ 4.5 Volt

Verified these values, carry out the “SET PUMP ACC MIN e MAX” function to acquire the
lifting potentiomer signal (see attached diagram “data acquisition lifting potentiometer”).
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PARAMETER CHANGE DESCRIPTION

(t) means traction (p) means pump

ACCELER. DELAY (t) = Traction motor acceleration time

DECELER DELAY (t) = Traction motor deceleration time
RELEASE BRAKING (t) = Braking current by releasing the accelerator
PEDAL BRAKING (t) = Braking current with pressed braking pedal
INVERS BRAKING (t) = Braking current on inversion
CUTBACK SPEED (t) = Max speed reducton with input on
MAX SPEED FORW (t) = Forward max speed
MAX SPEED BACK (t) = Backward max speed
TRACTION I MAX (t) = Traction max current
ARMA. NOM. CURR. (t) = Armature nominal current
WEAK DROPOUT (t) = Weakening threshold current
FIELD NOM. CURR. (t) = Field nominal current
CREEP SPEED (t) = Min. acceleration threshold
SEAT MICRO DELAY = Seat microsiwtch delay
SPEED LIMIT (p) = Lifting max speed
PUMP I MAX (p) = Lifting max current
PU. ACCELER DELAY (p) = Motor pump acceleration delay
PU. DECELER DELAY (p) = Motor pump deceleration delay
PUMP CREEP (p) = Min. lifting acceleration threshold
COMPENSATION (p) = Lifting speed compensation
1ST SPEED COARSE (p) = Tilting speed, coarse adjustment + 10%
1ST SPEED FINE (p) = Tilting speed, fine adjustement + 1%
1ST SPEED COMP (p) = Tilting speed compensation
2ND SPEED COARSE (p) = Sideshift speed, coarse adjustment + 10%
2ND SPEED FINE (p) = Sideshift speed, fine adjustment + 1%
2ND SPEED COMP (p) = Sideshift speed compensation
3RD SPEED COARSE (p) = 4th way speed, coarse adjustment + 10%
3RD SPEED FINE (p) = 4th way speed, fine adjustment + 1%
3RD SPEED COMP (p) = 4th way speed compensation
4TH SPEED COARSE (p) = 5th way speed, coarse adjustment + 10%
4TH SPEED FINE (p) = 5th way speed, fine adjustment + 1%
4TH SPEED COMP (p) = 5th way speed compensation
HYD SPEED COARSE (p) = Power steering speed, coarse adjust. + 10%
HYD SPEED FINE (p) = Power steering speed, fine adjust. + 1%
HYD SPEED COMP (p) = Power steering speed compensation
HYDRO TIME (p) = Power steering time
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TESTER MENU DESCRIPTION

BATTERY VOLTAGE battery tension value

TR MOTOR VOLTAGE traction motor tension (armature)
PU MOTOR VOLTAGE pump motor tension
TRAC. CURRENT traction motor current (armature)
PUMP CURRENT pump mototr current
FIELD VOLTAGE traction motor field tension
FIELD CURRENT traction motor field current
TR CHOPPER TEMP traction chopper temperature
PU CHOPPER TEMP pump chopper temperature
ACCELERATOR traction potentiometer value (tensione and percentage)
LIFTING CONTROL lifting potentiometer value (tensione and percentage)
ENABLE SWITCH not used (must be connected to + BV)
SEAT SWITCH seat microswitch
ON/+VB=input on OFF/GND=input off
FORWARD SWITCH forward microswitch
ON/+VB=input on OFF/GND=input off
BACKWARD SWITCH backward microswitch
ON/+VB=input on OFF/GND=input off
BRAKE SWITCH brake microswitch
ON/+VB=input on OFF/GND=input off
HAND BRAKE parking brake switch
ON/+VB=input on OFF/GND=input off
CUTBACK SPEED traction speed reduction switch
ON/+VB=input on OFF/GND=input off
1ST SPEED SWITCH tilting microswitch
ON/+VB=input on OFF/GND=input off
2ST SPEED SWITCH side-shift microswitch
ON/+VB=input on OFF/GND=input off
3ST SPEED SWITCH 4° way microswitch
ON/+VB=input on OFF/GND=input off
4TH SPEED SWITCH 5° way microswitch
ON/+VB=input on OFF/GND=input off
LIFTING SPEED lifting microswitch
ON/+VB=input on OFF/GND=input off
BATTERY CHARGE battery charge value (percentage)
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ALARM MENU DESCRIPTION

ALARMS DESCRIPTION OF THE DIAGNOSTIC LED

PLACED ON THE DASHBOARD AND THE CONSOLE

1 FLASH = SYSTEM CHECK KO, EEPROM KO - Replace the complete unit.

2 FLASHES = INCORRECT START - Incorrect sequence by starting; check:

-Microswitch for forward/backward directions, lifting and wirings.
-Logic unit.

3 FLASHES = CAPACITOR CHARGE - Replace the complete unit.

VMN NOT OK, V FIELD NOT OK - Check:
-Traction motor connection, isolation and cables.
-Logic unit.
PUMP VMN LOW- check:
-Lifting motor connection, isolation and cables.
-Logic unit.

4 FLASHES = VACC NOT OK, PEDAL WIRE NOT OK - check:

-Traction potentiometer connection and relevant wires.
-Potentiometer damaged.
-Carry out the function PROGRAM VACC
PUMP VACC NOT OK - Check:
-Lifting potentiometer connection and relevant wires.
-Potentiometer damaged.
-Carry out the function SET PUMP ACC MIN on the ADJUSTMENT menu.

5 FLASHES = STBY I HIGH, I= 0 EVER, HIGH FIELD CURRENT,

PUMP STBY I HIGH, PUMP I= 0 EVER - Replace the complete unit.
NO FIELD CURRENT - Check :
-Field traction motor cables connection.
-Logic unit.

6 FLASHES = DRIVER SHORTED, COIL SHORTED, CONTACTOR DRIVE, CONTACTOR

CLOSED - Check:
-Main contactor stuck
-Contactor coils and relevant wires.
-Logic unit.
LOGIC FAILURE - Replace the complete unit.
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7 FLASHES = TH.PROTECTION, PUMP TEMPERATURE - The unit temperature of (traction

system or lifting sistem) exceeds 75°. If the alarm occurrs in cold conditions, replace
the complete unit.

8 FLASHES = HAND BRAKE - Check:

-Parking brake microswitch and wires.
-Logic unit.

CONTINUOUS FLASHING = BATTERY LOW - Charge the battery.

FIX LED ON = FORW+BACK - Double running requests. Check:

-Direction microswitches and wires.
-Logic unit.
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ADJUSTMENT TABLE

Programmed level
Parameter Value 0 1 2 3 4 5 6 7 8 9
ACCELER DELAY sec. 0,4 0,7 1,0 1,4 1,8 2,2 2,5 2,9 3,2 3,6
DECELER DELAY sec.* 16,5 17,1 17,7 18,3 18,9 19,5 20,1 20,7 21,3 21,9
RELEASE BRAKING sec.** 11,0 9,9 8,8 7,7 6,6 5,5 4,4 3,3 2,2 1,1
PEDAL BRAKING sec.** 9,0 8,1 7,1 6,1 5,1 4,1 3,2 2,3 1,5 0,6
INVERS BRAKING sec.** 11,0 9,9 8,8 7,7 6,6 5,5 4,4 3,3 2,2 1,1
CUTBACK SPEED %ACC 20 29 38 47 56 65 74 82 88 90
MAX SPEED FORW %FNC 100 86 75 66 58 51 45 41 38 36
MAX SPEED BACK %FNC 100 86 75 66 58 51 45 41 38 36
TRACTION IMAX %IMAX*** 82 84 85 85 89 91 93 96 98 100
ARMA NOM CURR %IMAX 33 36 39 42 44 47 50 53 56 58
WEAK DROP OUT %ANC 35 40 45 50 55 60 65 70 75 80
FIELD NOM CURR %INOM 69 75 81 87 94 100 106 112 119 125
CREEP SPEED %VBATT 2,4 3,5 4,7 5,9 7,1 8,2 9,4 10,6 11,8 12,9
SEAT MICRO DELAY sec. 0,5 0,8 1,0 1,2 1,4 1,7 1,9 2,2 2,4 2,7
PUMP I MAX %IMAX*** 50 56 61 67 72 78 83 89 94 100
PUMP ACC DELAY sec. 0,04 0,09 0,13 0,17 0,21 0,26 0,30 0,34 0,38 0,42
PUMP DEC DELAY sec. 0,06 0,13 0,19 0,26 0,32 0,38 0,45 0,51 0,57 0,64
PUMP CREEP %VBATT 0 10 12 14 16 18 20 22 23 25
1ST÷4TH SPEED COARSE %VBATT 0 10 20 30 40 50 60 70 80 90
1ST÷4TH SPEED FINE %VBATT 0,8 2,0 2,7 3,9 4,7 5,9 6,7 7,8 8,6 9,8
1ST÷4TH SPEED COMP. %VBATT# 14 19 28 37 43 48 54 60 65 71
HYD SPEED COARSE %VBATT 0 10 20 30 40 50 60 70 80 90
HYD SPEED FINE %VBATT 0,8 2,0 2,7 3,9 4,7 5,9 6,7 7,8 8,6 9,8
HYD SPEED COMP. %VBATT# 7 14 21 29 35 42 49 56 64 71
HYDRO TIME sec. 0 0,3 0,5 1,0 1,5 2,0 2,6 3,1 3,6 4,0
SPEED LIMIT %VBATT 47 53 59 65 71 76 82 88 94 100
COMPENSATION %VBATT# 0 4 8 12 17 21 25 29 36 40
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 Cargo Range
CESAB S.p.A
via Persicetana Vecchia, 10 40132 Bologna - Italy
Tel. (0039) 051.20 54 11
Fax (0039) 051.72 80 07
E-mail: cesab@cesab.it