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INTERNAL
COMBUSTION
SERVICE MANUAL
page 3

CESAB S.p.a. 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 S. p. A.

BOLOGNA’S FACTORY, AFTER SALES SERVICE

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INDEX
TECHNICAL DATA .............................................................................................. p. 6
OPERATOR’S SEAT ........................................................................................... p. 8
Foot pedals version ........................................................................................... p. 8
Hand direction lever version ............................................................................... p. 8
Balanced pedals version ................................................................................... p. 8
Service brake .................................................................................................... p. 8
DASHBOARD ..................................................................................................... p. 9
Dashboard indicator .......................................................................................... p. 9
Parking switch ................................................................................................... p. 11
Truck start up ..................................................................................................... p. 11
Set of levers - Load handling.............................................................................. p. 12
Capacity plates ................................................................................................. p. 12
ENGINE DATA ..................................................................................................... p. 13
KUBOTA 3300 E ENGINE ................................................................................. p. 14
GM 3,0 L4 ENGINE ........................................................................................... p. 15
TOYOTA 4 Y ENGINE ........................................................................................ p. 16
Oil change and engine oil filter replacement ....................................................... p. 17
Topping up with coolant ...................................................................................... p. 17
Air filter .............................................................................................................. p. 18
Cyclone prefilter ................................................................................................. p. 18
Engine running-in ............................................................................................... p. 18
ELECTRONIC HYDROSTATIC TRANSMISSION ................................................. p. 19
Example of a closed loop hydrostatic transmission ............................................ p. 20
Operation of the variable displacement pump with axial pistons ......................... p. 21
Operation of the electronic hydrostatic system ................................................... p. 22
Description of the main functions ....................................................................... p. 23
HYDRAULIC DIAGRAM KUBOTA - GM................................................................ p. 25
HYDRAULIC DIAGRAM TOYOTA ........................................................................ p. 26
HIGH PRESSURE CIRCUIT KUBOTA - GM ......................................................... p. 27
LOW PRESSURE CIRCUIT KUBOTA - GM ......................................................... p. 27
HIGH PRESSURE CIRCUIT TOYOTA .................................................................. p. 28
LOW PRESSURE CIRCUIT TOYOTA .................................................................. p. 28
HYDROSTATIC PUMP ......................................................................................... p. 29
HYDRAULIC MOTOR ........................................................................................... p. 31
HYDROSTATIC TRANSMISSION MAINTENANCE............................................... p. 33
Replacing the filter and changing the transmission oil ......................................... p. 33
BRAKES ............................................................................................................. p. 34
Diagram of the service brake and the parking brake systems ............................ p. 34
Checking the service brake ............................................................................... p. 35
Releasing the brakes for the truck towing ........................................................... p. 35
ELECTRIC SYSTEM............................................................................................ p. 36
Battery ............................................................................................................... p. 36
Electric components .......................................................................................... p. 37
Electrical contol panel ........................................................................................ p. 37
Fuse characteristics .......................................................................................... p. 37
Relay characteristics ......................................................................................... p. 37
Engine actuator ................................................................................................. p. 38
Rotary / Linear potentiometer ............................................................................. p. 39
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Kubota Wiring diagrams .................................................................................... p. 40

GM Wiring diagrams ......................................................................................... p. 41
Toyota Wiring diagrams ..................................................................................... p. 42
MENUS AND PARAMETERS FOR THE TCS SYSTEM ...................................... p. 43
CALIBRATION ..................................................................................................... p. 44
Calibration and first start up of the transmission system ..................................... p. 46
DISPLAY .............................................................................................................. p. 49
PUMP CUSTOMIZED .......................................................................................... p. 50
ENGINE CUSTOMIZED ....................................................................................... p. 51
FAULT DETECTED ............................................................................................. p. 52
INFORMATION / PH PARAMETERS .................................................................... p. 53
EPROM RESET .................................................................................................. P. 54
Troubles occurring while calibrating ................................................................... p. 54
System faults and failures .................................................................................. p. 56
Troubleshooting ................................................................................................. p. 58
WHEELS / TYRES ............................................................................................... p. 63
Safety of wheels and rims while using the truck .................................................. p. 63
STEERING UNIT .................................................................................................. p. 64
Steering control ................................................................................................. p. 64
Steering axle ...................................................................................................... p. 65
Bearings adjustment .......................................................................................... p. 66
HYDRAULIC DISTRIBUTOR ................................................................................ p. 67
MAST GROUPS .................................................................................................. p. 68
Central displacement cylider with braking effect on the lifting.............................. p. 70
Side cylider with braking effect on the lowering .................................................. p. 71
Description of the cylinder components .............................................................. p. 72
Cylinder checking methods ................................................................................ p. 73
Lubrication ........................................................................................................ p. 74
Installation checks safety specifications ............................................................. p. 75
Safety limit stops of the fork mounting carriages ................................................ p. 75
Mast chains inspection ...................................................................................... p. 76
Fork inspection ................................................................................................. p. 77
LIFTING THE TRUCK ........................................................................................... p. 78
L.P.G. SYSTEM .................................................................................................... p. 79
GM engine LPG system ..................................................................................... p. 79
GM engine adjustment.................................................................................................. p. 82
GM engine initial timing adjustment............................................................................. p. 83
Toyota engine LPG system ................................................................................ p. 84
Toyota LPG regulator ......................................................................................... p. 86
Toyota engine adjustment.............................................................................................. p. 87
Toyota engine initial timing adjustment........................................................................ p. 88
LPG bottle ..................................................................................................................... p. 89
TABLES ............................................................................................................... p. 90
Table for the grease specifications..................................................................... p. 90
Table for the truck maintenance during the running-in stage ................................ p. 91
Table for the maintenance schedule ................................................................... p. 92
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TECHNICAL DATA
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OPERATOR'S SEAT

FOOT PEDALS VERSION

B
C A
FOOT DRIVE DIRECTION
(Standard version)
- Forward direction (A)
- Reverse direction (B)
- Service brake pedal (C)

HAND DIRECTION LEVER VERSION

D (ON STEERING COLUMN)

1 Direction selector lever (D)

o é 1 forward speed
2
o 0 neutral
ê 2 reverse speed

Single drive pedal (E)

E
C

BALANCED PEDAL VERSION

Forward pedal (F)
Reverse pedal (G)
G Brake pedal (C)

C F

SERVICE BRAKE
Foot service brake (C) controls a hydrostatic braking in the first part of the stroke by means of the electronic
control unit; if fully pressed, it engages the oil-bath disc brakes (over the front driving wheels).
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DASHBOARD
During ordinary operation, all warning lights in the dashboard are to be off.
1 2 3 4 5 6 7 8 1) Fuel gauge
2) Water temperature indicator
3) Fuel level warning light
15 4) Generator warning light
5) Glow plug warning light (Diesel engine)
6) Parking brake-on warning light
7) Oil pressure warning light
9 10 11 12 13 14
8) Indicator light (optional)
9) Electronic hour counter
10)Water temperature warning light
11)Transmission oil temperature warning light
12)Hydraulic oil filter clogged warning light
13)Warning light (not used)
14)Warning light (not used)
15)Warning light indicating air filter clogged
A
A) Parking switch;
B) Electronic failure warning light
C B If the warning light blinks during ordinary operation, this indicates
a failure in the electronic control unit; the vehicle will stop.
C) Ignition key
D) Emergency push-button; it acts as an emergency brake.
D
CAUTION
The vehicle could instantaneously stop if buttons (A) and (D)
are pressed; never press those buttons during the truck ordinary
operation.

DASHBOARD INDICATORS
1 1)Fuel gauge

2 2) Coolant temperature level

Indicates the coolant temperature. The pointer must never reach the red sector;
the working temperature corresponds to 95 °C.

3 3) Fuel level warning light

The fuel level warning light turns on when approx. 5.5 l of fuel are left in the tank.

4 4) Generator warning light

That warning light is to be off when the engine is running. If not, it indicates that
the alternator does not supply any current for the battery or the electric system
charge. This may be caused by the breaking of the belt that drives the alternator
pulley, or by a failure of the alternator.
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5 5) Glow plug warning light (Diesel engine).

This warning light turns on when the ignition key is in position (2);

6 6) Parking brake on warning light

7 7) Engine oil pressure warning light

During ordinary operation, this warning light is to be off.
If it turns on, immediately check the oil level in the engine. That warning light could
turn on when the engine is idling and hot, due to a lesser lubricant viscosity, even
if no failure has occurred.

8 8) Direction indicator on warning light (optional)

9 9) Electronic hour counter

It indicates the working hours and hour fractions of your truck; it is controlled
by the contact key and has the function to simplify scheduled maintenance programming.

10 10)Coolant temperature warning light

It indicates the engine overheating. Should it turn on, stop the vehicle immediately.
Check the correct operation of the radiator fan, the water pump and the coolant
level in the radiator.

11 11)Transmission oil temperature warning light

It indicates that the temperature limits required for the correct operation of the
pump and the hydrostatic engine have been exceeded.
Should it turn on, stop working and determine the reasons for the overtemperature
transmission oil.
Check the oil level and that the radiator is clean and in good operating conditions.

12 12)Transmission oil filter clogged warning light (replace filter)

13 13)Warning light (not used)

14 14)Warning light (not used)

15 15)Air filter clogged warning light (replace filter)

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A: PARKING SWITCH
1 B: ELECTRONIC FAILURE WARNING LIGHT (RED)
A C: RUN ENABLED WARNING LIGHT (GREEN)
E D: EMERGENCY PUSH-BUTTON WARNING LIGHT (RED)
C E: YELLOW LIGHT (OFF, NOT USED)

B D GM ENGINE
position 1 - parking - start up
2 Rotary switch A in position 1 (green warning light C off) allows
A
the engine start and disables the traction to prevent any accidental
start up; brakes are engaged (parking condition).
E position 2 - running enabling
C
Rotary switch A in position 2 enables the truck running (green warning
light C and warning light 6 in the dashboard are on); brakes are
B D engaged, but will automatically be released if the control pedal is
pressed (warning lights C and 6 turn off).
3
A KUBOTA AND TOYOTA ENGINE
position 3 - parking - start up
E Rotary switch A in position 3 allows the engine start and disables
the traction to prevent any accidental start up; brakes are engaged
(parking condition).
B
position 4 - running enabling
Rotary switch A in position 4 enables the truck running; brakes
4 are engaged, but will automatically be released if the control pedal
A is pressed.
E
HYDROSTATIC BRAKING
Lift the travel pedals or the accelerator to enable the hydrostatic braking
B (adjustable) until the truck stops.
A proper device engages the brakes if control pedals are not actuated
within a short period. When reoperating the control pedal, brakes will
be automatically released.

IGNITION KEY
0 fitting;
0 1 1 power supply
2 2 glow plug on
3 3 ignition contact and automatic return to position 1.

TRUCK START UP
- the operator must be seated
- parking rotary switch A in position P (park).
- fit the key and turn it to position 1 (power supply on)
- turn the key to position 2 (glow plug on)
- turn the key to position 3 to start the engine
P - once the engine has started up, release the key which will turn back
to position 1 and turn the rotary parking switch A to position R
(run).
- select the foward or reverse direction ; the truck is ready to travel.
R
If the start up procedure has not been correctly performed, the truck
will not start up. If so, repeat the procedure above.
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L
SET OF LEVERS - LOAD HANDLING
M
K) Lifting control lever ( yellow marking )
L) Tilting control lever (green marking )
K N M)Control lever for sideshifting or other devices ( red marking )
N) Available ( black marking, if present )

OPENING ENGINE COMPARTMENT COVER

Before lifting the engine compartment cover, turn the ignition key to
pos.0.
Unlock with the key (I) and turn the handle (C).
I
Lift the cover by using the special handle (L)
L An air spring (J) facilitates the complete lifting of the cowling.

LOAD PLATE
It identifies the load capacity with a load center
IDENTIFICATION PLATE
of 500 mm (except for different indications)
It identifies the lift truck technical data
ATTACHMENT OR SPECIAL CONDITION OF USE
MODEL Type MOTOR RATED CAPACITY
TYRES SERIAL N° kW kg

SERIAL N° DRAW-BAR PULL (1h)

CENTER OF LOAD DISTANCE mm
LIFT HEIGHT N
mm

BATTERY MASS SERVICE MASS

kg kg Without
A B min. max. Battery kg
MANUFACT. YEAR TENSION
V
Cod. 0312005

Cod. 0312004

DERATED CAPACITY Kg

CARRELLI ELEVATORI S.p.A. CESAB LDT

via Persicetana vecchia, 10 Bevan Way
CAPACITY PLATE 40132 - Bologna - Italia Smethwick - Warley
West Midla 1ds B66 1BZ
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ENGINE DATA
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KUBOTA 3300 E ENGINE

1 - Engine stop lever

2 - Fuel filter plug
3 - Oil filter cartridge
4 - Starter
5 - Cooling fan
6 - Alternator
7 - Intake manifold
8 - Shut off solenoid
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GM 3,0 L4 ENGINE

1- Alternator
2 - Fan belt
3 - Oil filter cartridge
4 - Sparks
5 - Ignition distributor
6 - Starter
7 - Cooling fan support
8 - Igniction coil
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TOYOTA 4 Y ENGINE

11

6 10

1
3

8 7

1 - Alternator
2 - Starter
3 - Oil filter cartridge
4 - Cooling fan
5 - Fan belt
6 - Sparks
7 - Ignition distributor
8 - Service pump (lifting & steering pump)
9 - Air governer
10- Oil level disptick
11- Carburetor
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OIL CHANGE AND ENGINE OIL FILTER REPLACEMENT

The oil level in the sump is checked with the dip-stick, making sure that the level is between the MIN and
MAX notches.
If it is necessary to top up, use the same oil as that used for filling.

CHANGING OIL AND FILTER

After the first 50 hours:
change oil and filter of the engine and then
every 50 hours:
check oil engine level
every 250 hours:
change oil and filter of the engine

To replace the oil and the filter, proceed as follows:

- with the engine hot, remove filling cap, then unscrew the discarge cap and allow the oil to drain out.
- Unscrew the engine filter cartridge.
- Fit the new filter and tighten it, paying particular attention to the position of the seal that should be
previously oiled.
- Tighten the drain cap and fill the oil sump up to the Max level on the dip-stick.

TOPPING UP WITH COOLANT

Every 50 hours
- Make sure the coolant licks up the radiator plug (B).
B -Check the level of the cooling liquid in the expansion tank (A) with
the MIN level indicator.
The plugs of the tank and radiator must only be removed when
the engine is cold.

Every 250 hours

- clean the outside of the radiator.

Every 2,000 hours

- change the cooling liquid
- check the density, if possible, at the start of the cold season.
The truck is delivered with the antifreeze diluted 50%. To change
the percentage dilution , follow the values in the table below.
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AIR FILTER

The air suction filter for the fuel supply is composed of two filtering
elements.
Every 250 hours
- Clean the element outside the filter (the element inside is not to be
cleaned).
The filter is to be cleaned also when relevant warning light (15) on
A the dashboard turns on.
Every 3 cleaning cycles
- replace the element inside the filter
Every 6 cleaning cycles, or once a year
- replace the element outside the filter.

Disassembling and cleaning the filter

- release the cover fastening screws and remove the filter cartridge;
- clean with compressed air (MAX. 5 bar pressure) from the inside
towards the outside;
- check that no tear is to be found.
Never hit the cartridge on hard surfaces.
Never use any mixture of water and detergent to clean the
filter.

When reassembling the filter cover, make sure that the dust
emptying opening is turned downwards.

CYLONE PREFILTER
A B
Every 8 hours
- clean the cyclone prefilter.

Cleaning the cyclone prefilter

C - loosen wing-nut (A);
- remove cover (B);
- remove tank (C);
- empty the tank and reassemble.

ENGINE RUNNING-IN
During the running-in period, the truck should be used at 60-
80 % of its power for the first 50-100 working hours.
During the running-in period, the engine may consume more oil than
usual. It is recommended that the oil level be checked every 8 working
hours, with engine standstill for at least 10 minutes.

Do not use the engine at its peak RPM until it has reached its working
temperature.
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ELECTRONIC HYDROSTATIC TRANSMISSION

Hydrostatic transmission consists of a variable displacement pump, which

is controlled by the thermal engine and which delivers oil towards two
hydraulic motors that drive the front wheels.
The hydraulic connections of both motors allow a proportional division of
the oil flow generated by the hydrostatic transmission, so as to support the
outer wheel while turning; that kind of transmission acts as the differential
transmission.

The control and adjustment of the electronic transmission are made by

a control unit (Total Control System) that drives the following:
· thermal engine
· hydrostratic pump
· hydraulic motors
· parking brakes
by means of sensors:
· potentiometers (on the accelerator pedal, the brake/inching pedal and the mast lever)
· switches (on the tilt levers and sideshift, the forward/reverse gearshift lever and to engage the parking
brake)
· potentiometer detecting the pump displacement
· sensor of the thermal engine speed of rotation
and by means of actuators:
· proportional solenoid valves of the hydrostatic pump (displacement adjustment)
· actuator on the thermal engine (adjustment of the fuel pump or the carburettor)
· solenoid valve for the displacement shifting of the hydraulic motors
· solenoid valve for the parking brakes release

Control unit

Portable
Terminal

Travel pedal

Parking brake switch Brake/inching

pedal
Potentiometer on
mast lever
Running direction
selector
Thermal engine
speed sensor
Failure warning
light
Solenoid valve for parking
Hydrostatic brake release
pump Thermal engine actuator
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EXAMPLE OF A CLOSED LOOP HYDROSTATIC TRANSMISSION

Basic system - pump / motor

The pump is equipped with two pressure relief valves on the relevant high pressure sides.The
valves have the function to protect the hydrostatic transmission (pump and motor) from any
overloads.

In the hydraulic motor and the pump, oil drips are collected in the tank.
circuit.tif

An integrated auxiliary pump acts as a fuel boost pump for the system restoration of the oil
dripped from the pump and the motor. The sytem is also equipped with a boost pressure control
valve.
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OPERATION OF THE VARIABLE DISPLACEMENT PUMP WITH AXIAL

PISTONS

The pump delivery is proportional to the rate of rotation

and the displacement and may be varied continuously.
The pump delivery increases from 0 to its max. value
depending on the plate tilt angle.

Tilt 0
corresponds to stroke 0
so to delivery 0
(standstill machine)

If the pump tilted plate is positioned beyond the

neutral point, the pump direction will be
automatically reversed.
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OPERATION OF THE ELECTRONIC HYDROSTATIC SYSTEM

4
3

ê
17 1
ê
5 ê 13

2 16
14 10
15
9

8
11
3

12

6
7

le
1 Thermal engine
2 Hydrostatic pump
3 Hydraulic motors with the parking brake
4 Boost pump
5 Solenoid valves adjusting the pump displacement
6 TCS control unit
7 Accelerator pedal
8 Direction selector (steering-wheel operated reverse gear with simple pedals or acting directly on the
double/swaying pedal system)
9 Actuator of the thermal engine
10 Sensor for the motor speed of rotation
11 Sensor for the hydrostatic pump displacement
12 Brake pedal
13 Solenoid valve to release the brakes on the motors
14 Parking brake switch
15 Fault warning light
16 Service pump
17 potentiometer/microswitches on the mast lever, the tilt system, the sideshift and any auxiliary
devices.
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DESCRIPTION OF THE MAIN FUNCTIONS

TRUCK TRAVEL The thermal engine may only be started if the parking brake is on.
The system allows the pump to increase the displacement (truck motion) only if:
- the motor is running
- the parking brake is off
- the running selector is not in neutral position.
Should one of those conditions be not true, the actuation of the accelerator pedal will only
result in thermal engine speeding up.

The position of the accelerator pedal - through the thermal engine and the hydrostatic pump -
affects the truck speed, i.e. each position of the pedal potentiometer corresponds to the
following preset values, according to the setting values programmed in the control unit:
- speed of the thermal engine
- pump displacement.

ACCELERATION / DECELERATION The truck acceleration depends on the speed

with which the accelerator pedal is pressed and on the parameters set in the control unit.

BRAKING / INCHING The brake pedal has two functions: 1) hydrostatic braking (the
pump displacement cancels itself out) with a strength depending on the pedal stroke; 2) “inching”
function, that can be obtained by simultaneously pressing the brake pedal and the accelerator
pedal.

PUMP DISPLACEMENT The displacement of the hydrostatic pump depends on the stroke
of the accelerator pedal (and on the stroke of the brake pedal in the “inching” function). The
accelerator pedal also determines the rate of rotation of the thermal engine (by means of the
actuator).

ANTISTALL FUNCTION During the truck ordinary operation, if the power required by
the hydrostatic transmission exceeds the power that may be supplied to the thermal engine,
the pump displacement will be automatically reduced to avoid the engine stall.

PARKING BRAKE The parking brake is engaged by pressing a switch located next to the
distributor levers. When the parking brake is on, the accelerator pedal is disabled (the thermal
engine accelerates, but the truck cannot run). If the parking brake is engaged while the truck
is running, the driving wheels will be automatically locked. Therefore, avoid engaging the
parking brake while the truck is running, unless you are in an emergency condition.

CONSTANT SPEED When using the mast levers, tilt system and sideshift, the thermal
engine automatically accelerates to meet the request for additional power; the pump
displacement will be simultaneously reduced to ensure that the truck speed is kept constant.
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RUNNING DIRECTION May be selected through the steering-wheel operated reverse

gear (for simple pedals) or the forward/reverse pedals (for the double and swaying pedal
system). If the lever of the steering-wheel operated reverse gear is shifted to the neutral
position while the truck is running (or the accelerator pedal is released in case of double pedal
system), the truck will hydrostatically brake. If the running direction is reversed while the
truck is running, a hydrostatic braking will occur, which will be immediately followed by the
acceleration in the opposite running direction.

PARAMETER SETTING Most part of the transmission operation parameters may be set
via portable terminal.

CALIBRATION The system sensors and actuators (pedals, motor actuator, etc.) are to be
calibrated using the portable terminal.

FAULT DETECTION A warning light located beside the distributor lever indicates the
system faults (the warning light starts blinking). If the failure concerns the hydrostatic pump,
the truck will immediately stop.

DIAGNOSTICS The portable terminal, which is connected to the control unit, allows to
detect and to store any system fault.

DISPLAY The display of the portable terminal allows to view the information about the
transmission operation (thermal engine speed, pump displacement, and so on).

THERMAL ENGINE OPTIMIZATION The thermal engine operation (rate of rotation)

is optimized according to the truck speed the operator needs.

SPEED DECREASE (OPTIONAL) The truck speed may be decreased for example in
case of transmission oil overtemperature.
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HYDRAULIC DIAGRAM KUBOTA - GM

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HYDRAULIC DIAGRAM - TOYOTA

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HIGH PRESSURE CIRCUIT KUBOTA - GM

BOOST PRESSION
CHECK POINT

å å

OIL RETURN TO
TANK NEGATIVE BRAKE
ELECTROVALVE

LOW PRESSURE CIRCUIT

RETURN
LIFTING
TRANSMISSION
OIL
>

SUCTION

KUBOTA
>

AUXILIARY SERVICE
>

CHECKING POINT >

> LIFTING
SUCTION

> >
> > RETURN
RETURN
TRANSMISSION GM
> TRANSMISSION OIL
OIL

RETURN
DRAINAGE
LIFTING
MOTEURS
OIL

>
AUXILIARY SERVICE >
CHECKING POINT
>
>
>

>
>

> >
>
DRAINAGE TRANSMISSION
MOTEURS SUCTION LIFTING
SUCTION
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page 28

HIGH PRESSURE CIRCUIT TOYOTA

MAXIMUM
PRESSION
CHECK POINT
å

å
å

OIL RETURN TO
TANK NEGATIVE BRAKE
ELECTROVALVE

LOW PRESSURE CIRCUIT TOYOTA

RETURN
LIFTING
OIL

â
à
â
AUXILIARY SERVICE
CECKING POINT
à à
à à

à
à
à

DRAINAGE
MOTEURS

TRANSMISSION
RETURN SUCTION
TRANSMISSION OIL
BY-PASS VALVE
2 BAR
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page 29

HYDROSTATIC PUMP
PUMP Mod. POCLAIN PV75 SA
Displacement 75.5 cc/rev
Boost pump displacement 13.9 cc/rev
Max. pressure measured in M1 or M2 (stall) 450 Bar
Boost pressure measured in M3 24-30 Bar
Drain pressure measured in T1 or T2 max. 5 Bar
(cold pump) or after temperature stabilization max. 2.8 Bar
Vacuum pressure (absolute pr., measured in S) 0.8 Bar

EXCHANGE UNIT
Valve setting 19 Bar

Boost pump

Solenoid valves

Displacement adjusting
plate
Actuator

To motors
Pump displacement
potentiometer
Hydrostatic
pump

The pump displacement is controlled by two proportional solenoid valves which are fed by
the boost pressure and controlled by the control unit through an electric signal. The spool shift
of the solenoid valves controls the pressure over the two chambers of a piston servocontrol
that is mechanically coupled to the pump plate; the difference in pressure between the two
chambers determines the piston shift, i.e. the displacement shifting.
The pump displacement is then detected by a rotary potentiometer sending a signal proportional
to the plate shift.
The electric control through the solenoid valves and the potentiometer represents a feedbacked
circuit for the adjustment of the pump displacement.
A sensor detecting the speed of rotation is to be found as well.
 POTENTIOMETER
MEASURING THE PUMP POTENTIOMETER
CONNECTOR MECHANICAL ZERO
DISPLACEMENT ADJUSTMENT
M2 M3 M1
DRAIN INLET
T1 (from the exchange unit)
1 1/16 - 12 UN - 2B
page 30

A
2,5 - 3,0 - 3,5 t

HIGH PRESSURE
B (to motors)
HIGH PRESSURE

MOTOR
SIDE
PROPORTIONAL
SERVOVALVES FOR
THE DISPLACEMENT
ADJUSTMENT
S
CHARGE PUMP INLET PORT
(FROM THE OIL FILTER)
SENSOR FOR THE SPEED OF 1 5/16 - 12 UN - 2B
DRAIN OUTLET ROTATION SERVOVALVE CONNECTOR
T2 (to the radiator)
1 1/16 - 12 UN - 2B

BOOST VALVE
HIGH PRESSURE DETECTION SOCKET
M2 9/16 - 18 UNF - 2B

BOOST PRESSURE SOCKET

M3 7/8 - 14 UN - 2B
SERVICE MANUAL

HIGH PRESSURE DETECTION SOCKET

M1 9/16 - 18 UNF - 2B

SERVOVALVE PRESSURE SOCKET 2 SERVOVALVE PRESSURE SOCKET 1

M5 7/16 - 20 UNF - 2B
INTERNAL

M4 7/16 - 20 UNF - 2B
COMBUSTION
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HYDRAULIC MOTOR
Motors Poclain MS 05 (radial pistons) KUBOTA - GM TOYOTA
ENGINE ENGINE
Maximum displacement 468 cc/rev 560 cc/rev
Maximum pressure 450 Bar 450 Bar
Theoretical torque 740 Nm 890 Nm
Maximum speed 240 RPM 200 RPM
Brake multidisc type multidisc type
Braking torque max. 3060 Nm max. 3060 Nm
Number of pistons 8 8
Brake driving pressure (measured in x) 12-30 Bar 12-30 Bar
Displacement shifting driving pressure (measured in y) 10-30 Bar 10-30 Bar
Drain pressure (measured in 1) with cold motor max. 3 Bar max. 3 Bar
after temperature stabilization max. 1.5 Bar max. 1.5 Bar

wheel cylinder distributor brake

hub unit
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The hydraulic motor is of “slow” type. Due to its radial

pistons, it is characterized by a high displacement/rev (if
compared to engines with axial pistons) so it produces a
high torque at a low speed rate, with no reduction gear
between the engine and the wheel hub.

The engine is also equipped with an oil-bath multidisc brake that is normally engaged
(wheel locked) by the pre-load of a Belleville washer (negative brake); the brake is
hydraulically released by means of a solenoid valve controlled by the control unit: when
the solenoid is fed, the valve opens and the fuel boost pressure on the brake piston
releases the brake.
The multidisc brake on the motor is used only for the truck parking and emergency
braking; on the other hand, service breaking is a hydrostatic one.
The motor-brake unit is fully lubricated by the transmission oil (oil dripping from the
hydraulic motor).

R, L High pression inlet - 3/4 GAS

1 Drain hole 3/8 GAS
X Negative brake pilote 1/4 GAS

Braking release hole- M12 x 1,75

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HYDROSTATIC TRANSMISSION MAINTENANCE

The transmission system and hoisting system have the same oil tank, which is provided with one
filter.
Components of the transmission system:
A) Oil level disptick
B) Oil bleeding hole
C) Hydraulic oil filter unit
D) Oil filling hole

Maintenance consists of the oil change and filter replacement in

order to keep the circuit clean.
B A D C

REPLACING THE FILTER AND CHANGING THE

TRANSMISSION OIL
After 50 hours
- First transmission filter replacement.
After 500 hours
- Second transmission filter replacement;
- First oil change for the transmission/hoisting systems.
Then, every 2,000 hours
- transmission filter replacement;
á - oil change for the transmission/hoisting systems.
T

The oil should be changed at least once a year. The filter is to be changed also when it gets
clogged. When the warning light (12) on the dashboard is on replace the filter cartridge immediately.

To replace the filter, do the following:

- re move plug (C) and extract the filter
- insert the new cartridge and close.

To change the oil in the tank for the transmission and hoisting systems, do the following:
- change the oil while the engine is still hot;
- remove plugs (A) (C) and (T) and let the fluid flow out;
- carefully clean the oil tank;
- fill the tank with clean oil up to the max. level marked on dipstick (A) after fastening drain plug (T).
- only use the oil types mentioned in the specifications section in this manual;
- do not use oil that deteriorated due to a long storage.

After replacing the filter and changing the transmission oil:

- start up the engine, let it idle for about 5-10 minutes while the vehicle is standstill;
- check the oil level; top up, when required.
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BRAKES
The brake pedal has two different functions:
- braking (if it is used alone)
- “inching” function if it is used simultaneously with the accelerator pedal.

The brake pedal stroke is divided into two configurable intervals:

0 to 95 % of the whole stroke: hydrostatic braking. The control unit reduces the pump
displacement according to a programmed ramp. The braking effect is proportional to the
pedal stroke.
95 to 100 % of the whole stroke: mechanical braking. The pump displacement cancels
itself out in about 1.5 secs and the negative brakes get engaged.

During ordinary operation, if the truck is slowed down and stopped, the mechanical brakes
act automatically (after approx. 0.5 secs) on motors. Press the accelerator pedal again to
release the brake and to speed up.
When the mechanical brake is engaged, the relevant warning light on the dashboard turns on.

The braking effect may also be obtained by releasing the accelerator pedal (hydrostatic braking)
or by reversing the running direction (hydrostatic reverse braking, more efficient than the mere
hydrostatic braking).

DIAGRAM OF THE SERVICE BRAKE

AND PARKING BRAKE SYSTEMS

A) Hydraulic motor
B) Brake unit
C) Solenoid valve
D) Hydraulic tank
E) Electronic control unit
F) Hydrostatic transmission
G) Service brake pedal
H) Parking switch
I) Potentiometer
S) Hoses of brake

Every 4,000 hours

- replace solenoid valve (C) for the brake control.
H

Every 10,000 hours

- replace brake hoses (S).
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CHECKING THE SERVICE BRAKE

The disc brakes are in oil-bath; they make use of the same oil as the traction hydraulic
motors.

The disc brake unit is composed of 11 discs and 11 counterdiscs. The total disc
thickness is: min. 27 mm, max. 34 mm.

Every 250 hours

- check the pedal operation; the pedal has to be free from any obstacle;
- check the brake wear;

RELEASING THE BRAKES FOR THE TRUCK TOWING

In case of breakdown, previously release the brake discs inside the two traction units
to tow the truck.

Brake release
Position appropriate tool (M), code 1996086 (M12 x 1,75), one for each brake unit;
tighten screw (N) into hole (L) on the brake unit; keep tool (M) locked and tighten
nut (O) until the brakes unlock.

L
N O
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ELECTRIC SYSTEM
Every 500 hours
- check the push-buttons wiring and operation;
- check the operation of the microswitches located on the pedals;

Every 1000 hours

- inspect wiring and connections; check if the cable terminals are properly tightened
and the cable insulation is intact.

WARNING:
DISCONNECT THE TRUCK BATTERY BEFORE SERVICING
THE ELECTRIC SYSTEM AND THE ELECTRONIC EQUIPMENT.
P
BATTERY
Battery (P) is located under the engine bonnet; before servicing, always
disconnect safety connector (Q).
Q Every 500 hours
- clean the battery poles and terminals;
- grease and tighten the terminals;
Every 1,000 hours
- check the earth connections.
Every 4,000 hours
- replace the battery.

The battery supplied has a min. 100 Ah capacitance.

If the battery is a maintenance-free one, inspect as follows:

Every 50 hours
- check the electrolyte level and density; top up with distilled water,
if necessary.
The battery is to be recharged when its voltage has decreased by
1.7V or the electrolyte thickness is under 1.16 kg/dm3.

When the truck is running, never disconnect the battery cables,

so as to avoid dangerous voltage peaks to the alternator diodes.
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ELECTRIC COMPONENTS

ELECTRICAL CONTROL PANEL

Lift the engine bonnet to reach to the fuse panel,
which is located below the support of the distributor
controls.
The panel is composed of a fuse block (A), of
some relays (B) and optional intermittance (C).
Disassemble the protecting panel to replace the
component.

B C
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ENGINE ACTUATOR

C D

YELLOW
BROWN
C

BLACK

BLUE

RED
The engine actuator is controlled by TCS control unit; it adjusts the Diesel engine injection pump.
The engine actuator is composed of an electric motor controlling the control shaft of the pump tie
rod and of a potentiometer detecting the shaft rotation and generating a feedback electric signal
(voltage).
When calibrating, the control unit correlates the actuator stroke (rotation) measured by the
potentiometer with the thermal engine speed of rotation, measured by the sensor located on the
hydrostatic pump. The unit composed of the actuator and the rev sensor is a feedback system
intended for adjusting the engine speed.

WARNING - POTENTIOMETERS AND MICROSWITCHES

To avoid compromising the functional characters of the truck, fixing or adjusting of the potentiometers
(D), the micrositches (B), the mechanical stops (C) and the accelerator control tie-rod (D), is
forbidden.

A A B
C
C

C
C B

BRAKE PEDAL
TRAVEL PEDAL
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ROTARY POTENTIOMETER
(on the accelerator and brake pedals) resistance: 2.5 kohm
electric stroke: 54°
mechanical stroke: 60°

LINEAR POTENTIOMETER
(on the mast lever) resistance: 5 kohm
electric stroke: 10 mm
mechanical stroke: 12.5 mm

yellow

red red

green
yellow
green

AMP CONNECTOR type: 144-796-1

(on control unit) 55-pin
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KUBOTA V 3300-E ENGINE

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GM 3,0 L4 ENGINE
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TOYOTA 4 Y ENGINE
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MENUS AND PARAMETERS FOR THE TCS

SYSTEM
The parameters for the transmission control are composed of submenus and may be viewed
and modified through the portable terminal (code 0058039), that may be connected to the
control unit .

The [ENTER] key is used for selecting a menu or submenu and for the confirmation of a
parameter numeric value.

The [ESC] key is used for quitting a menu or submenu or for deleting the last character
entered.

The [+] and [-] keys are used for moving through the menu list or increasing and decreasing
the numeric value of a parameter.

Use the numeric keypad to enter the parameter values; use the [.] key for decimal places.
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The main menus are listed below:

N. Menu Functions

1 CALIBRATION to calibrate potentiometers and transmission actuators (pedals,

distributor, engine actuator, ...)
2 DISPLAY to display the information on the transmission (thermal engine speed,
pump displacement, antistall function, ...)
3 PUMP CUSTOMIZED to customize the transmission (more or less prompt breaking and
acceleration)
4 ENGINE CUSTOMIZED to customatize the thermal engine control (higher or lower acceleration
of the thermal engine, engine speed when the tilt system and the
sideshift are on, ...)
5 FAULT DETECTED to display the system faults
6 INFORMATION software versions
7 PH PARAMETERS (password) configuration of the system operation parameters
8 EEPROM RESET (password) to reset the control unit memory

CALIBRATION

The CALIBRATION menu is used. That menu has two functions:

· when the parking brake is locked and the “calibration status” parameter is “not locked” , it allows the
calibration and configuration of the system elements (calibrating mode);
· when the parking brake is not locked or the “calibration status” parameter is “locked”, that menu
allows to view the output voltages of the system sensors and the state of some components (display mode).

After any calibration, release and engage the parking brake again to exit from the “calibration status” mode and
return to the standard operating mode.
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CALIBRATION MENU

N. SUBMENU CALIBRATION MODE DISPLAY MODE

A travel pedal calibration of the travel pedal display of the voltage supplied by the
potentiometer for the travel pedal
B brake/inching calibration of the brake pedal display of the voltage supplied by the
pedal potentiometer for the brake pedal
C mast lever calibration of the mast lever display of the voltage supplied by the
potentiometer for the mast lever
D engine calibration calibration of the actuator-thermal display of the voltage supplied by the
engine potentiometer for the actuator
E pump neutral calibration of the pump in neutral display of the voltage supplied by the
position potentiometer for the hydrostatic pump
F max. forward limiting of the truck max. display of the truck forward speed
speed forward speed (as a percentage of the max. speed)
G max. reverse limiting of the truck max. display of the truck reverse speed
speed revers speed (as a percentage of the max. speed)
H parking brake set definition of the brake pedal displays the brake pedal position in which
position in which the mechanical the mechanical brake is locked
pedal is engaged
I min engine speed definition of the minimum engine displays the minimun engine RPM
RPM
L max engine speed definition of the maximum engine displays the maximum engine RPM
RPM
M pump pot. inverted definition of the connections type displays the connections type
(*) of the pump potentiometer of the pump potentiometer
N calibration status validations and invalidation of the status of the calibration menu
calibration menu

(*) With Hall potentiometer software only

For the TCS correct operation, the voltage values read by the potentiometers in the pedals, the mast
system and the motor actuator must not exceed the limits set. If the mechanical limit stops of the
potentiometer are not properly adjusted, the voltage supplied by the potentiometers and exceeding
the range of values allowed by the control unit disables the calibration procedure.
That trouble may also occur after a correct calibration if, for whatever reason, the limit stop is
modified.
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CALIBRATION AND FIRST START UP OF THE TRANSMISSION SYSTEM

The system calibration is to be performed when the thermal engine is stopped. The following are to be calibrated:

· Potentiometer for the travel pedal (TRAVEL PEDAL)

· Potentiometer for the brake pedal (BRAKE/INCHING PEDAL)
· Potentiometer for the mast lever (MAST LEVER)
· Feedback potentiometer for the hydrostatic pump (PUMP NEUTRAL)

While calibrating, check the parameters below:

· Max. forward speed (truck max. speed) 100 %
· Max. reverse speed (truck max. speed) 100 %
· Parking brake set (brake setting) 95 %
· Min engine speed (minimum engine RPM) 850
· Max engine speed (maximum engine RPM) 2250
· Pump pot. inverted (with potentiometer Hall effect only) Enable

Calibration also includes the actuator setting while the thermal engine is running (ENGINE CALIBRATION). For
the engine calibration, do the following:

· Lift the truck onto the shim blocks

· Fill the hydraulic circuit and bleed the air
· Engage the parking brake
· Select the neutral position (through the steering-wheel operated reverse gear)
· Start up the engine and wait for the stabilization of the fuel boost pressure
· Adjust the engine min. and max. RPM through the actuator limit stop screws (the limit stops are to be obtained
on the actuator support, not on the injection pump). The engine RPM is to be measured through the “engine
speed” parameter in the “DISPLAY” menu.
· Calibrate the actuator (ENGINE CALIBRATION)
· Press the accelerator pedal; the actuator has to rotate clockwise and the voltage of the feedback potentiometer
in the actuator has to increase (such voltage may be measured in the “engine calibration” parameter in the
“calibration” menu after engaging the parking brake).

Once the calibration procedure is over, check the transmission operation (wheels must be up):
· Release the parking brake
· Position the steering-wheel operated reverse gear to forward gear
· Gradually press the forward pedal: wheels should slowly rotate forwards.

CAUTION: the hydraulic motors must not rotate quickly when wheels are up.
When wheels rotate forwards, check that the voltage of the pump feedback potentiometer increases from 2.5 to
5 volts (for the voltage detection, use “pump neutral” parameter in the “calibration” menu).
Check the correct operation under the following conditions:
- mast lifting, sideshift and tilt operation, etc.: if the relevant levers are adjusted, the thermal engine
will accelerate.
- forward/reverse speed and braking
- parking brake: if engaged, the travel pedal will be disabled (the engine RPM will increase, but the truck
wheels will be locked)
- emergency button.
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A) TRAVEL PEDAL CALIBRATION

For calibrating, voltages are not to exceed the following ranges (voltages may be detected in display mode):

pedal in its min. position 0,35 - 2,4 volts (7 - 48 % of the supply voltage)
pedal in its max. position 2,6 - 4,65 volts (52 - 93 % of the supply voltage)
(the supply voltage of all sensors is of 5 Volts)

SEE THE “DIAGRAM FOR USING CONSOLE”

SECTION “CALIBRATION”

B) BRAKE / INCHING CALIBRATION

Allows to define the voltage values corresponding to the min. and max. positions of the brake pedal (and the
“inching” function).

For calibrating, voltages are not to exceed the following ranges:

pedal in its min. position 0,35 - 2,4 volts (7 - 48 % of the supply voltage)
pedal in its max. position 2,6 - 4,65 volts (52 - 93 % of the supply voltage)

SEE THE “DIAGRAM FOR USING CONSOLE”

SECTION “CALIBRATION”

C) MAST LEVER CALIBRATION

Allows to define the voltage values corresponding to the maximum and minimum positions of the mast lever.

For calibrating, voltages are not to exceed the following ranges:

lever in neutral position 0,35 - 2,3volts (7 - 46 % of the supply voltage)

lever fully pulled 2,4 - 4,65 volts (48 - 93 % of the supply voltage)

SEE THE “DIAGRAM FOR USING CONSOLE”

SECTION “CALIBRATION”

D) ENGINE CALIBRATION

Allows to match the actuator angular position (voltage of the actuator feedback potentiometer) with the engine
speed of rotation values.

For calibration, voltages are not to exceed the following ranges:

actuator in its min. position 0,35 - 2,4 volts (7 - 48 % of the supply voltage)
actuator in its max. position 2,6 - 4,65 volts (52 - 93 % of the supply voltage)
Such values may be viewed if the parking brake is engaged.
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SEE THE “DIAGRAM FOR USING CONSOLE”

SECTION “CALIBRATION”

The control unit automatically controls the actuator by bringing it to its minimum and maximum positions (that are
determined by the mechanical limit stops located on the actuator support). With respect to the min. and max.
positions, TCS reads the min. and max. RPM as well as some intermediate values.
The limit stops are to be obtained on the actuator, not on the injection pump.

E) PUMP NEUTRAL CALIBRATION

Allows to define the voltage corresponding to the neutral displacement position of the hydrostatic pump (feedback
potentiometer).

The voltage value must not exceed the following range: 2.48 to 2.52 volts.
(In display mode and when the truck is running, the voltage value must vary. When the wheels rotate forwards, the
potentiometer voltage must tend to 5 Volts and remain constant).

SEE THE “DIAGRAM FOR USING CONSOLE”

SECTION “CALIBRATION”

F) MAX FORWARD SPEED

This parameter (expressed as a percentage of the truck forward max. speed) limits the travel speed. This parameter
may be modified (in calibration mode).

G) MAX REVERSE SPEED

This parameter (expressed as a percentage of the truck reverse max. speed) limits the travel speed. This parameter
may be modified (in calibration mode).

H) PARKING BRAKE SET

This parameter defines the stroke of the brake pedal necesary to engage the mechanical brake. The standard
value is 95%. It is suggested that this value be not changed. Limit values: 90 to 95%.

I) MIN ENGINE SPEED

This parameter defines the minimum engine RPM (standard value 850).

L) MAX ENGINE SPEED

This parameter defines the maximum engine RPM (standard value 2250).

M) PUMP POT. INVERTED

This parameter defines the connections type of the pump potentiometer.
This parameter is present with the Hall potentiometer software only.

N) CALIBRATION STATUS
This parameter enables or disables the calibration mode.
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DISPLAY
This menu displays the transmission data.
Press [ENTER] to display a data (e.g. thermal engine speed). Hold down the key to display data in sequence.

ENGINE SPEED
Real speed of the thermal engine (expressed in RPM).

PUMP DISPLACEMENT
Pump displacement required by TCS (expressed in cc). Warning: this is the displacement control sent by the
control unit to the pump, so the value displayed may be different from the real displacement.

ENGINE COMMAND
Speed of the thermal engine required by TCS (in RPM).

ANTISTALL
Indicates whether the antistall function is enabled or not (enable/disable).

PARKING BRAKE
Displays whether the negative brakes are set or not (set/not set).

BRAKE SWITCH
Displays whether the parking brake switch is set or not (set/not set).

MAST ENGINE COMMAND

Speed of the thermal engine required by TCS (in RPM) when the mast is actuated.

PUMP FEED-BACK
Actual displacement of the pump (expressed in cc). This is the displacement measured by the potentiometer
located on the pump.

DIRECTION SWITCH
Displays the running direction controlled by the pedal microswitches or the steering-wheel operated reverse
gear (neutral/forward/reverse).

MAST SWITCH
Displays the state of the distributor microswitches 1 = tilt/sideshift (set/not set).

CONSTANT SPEED
Displays the constant speed function enabling when the mast is actuated while the truck is running (set/not set).

ACTUATOR FEED BACK

Displays the engine actuator signal in Volt. Increase during the acceleration and vice versa.

POWER SUPPLY
Displays the voltage supply of the contol unit: battey voltage (12 V). Must be between 9,5 and 48,5 Volt.

SENSOR EXCITATION
Displays the voltage supply of the sensor. Correct value 5 Volt.

NEUTRAL DRIFT
Displays the value difference between the theorical and real pump potentiometer value (in mV).
This parameter is present with the Hall potentiometer software only.
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PUMP CUSTOMIZED

Allows to set the parameters for the control of the hydrostatic pump.
This parameter is to be used to modify the acceleration and deceleration of the truck.
Enable the program to modify such values (calibration status - not locked).

TRAVEL PEDAL INC.

This parameter defines how long the pump takes to reach its max. displacement when the travel pedal is fully
pressed (the higher the value of this parameter, the lesser the acceleration of the truck).

TRAVEL PEDAL DEC.

This parameter defines how long the pump takes to reach its neutral displacement mode when the travel pedal
is released (the higher the value of this parameter, the lesser the deceleration of the truck during the hydrostatic
braking).

HARD BRAKING RATIO

This parameter (%) change the release braking value (travel pedal dec.) as the follow table:

Braking times of the truck function of the two parameters

“Travel pedal dec” (s) and “Hard braking ratio” (%)

Travel pedal dec. (s) 2 5 7 10

Hard braking ratio (%)

0 2 5 7 10
17 1.7 3.8 5 6.5
50 - 2.8 - -
67 1.6 2.5 3.1 3.6
83 - 2.3 - -
100 1.3 2.1 2.5 2.9

SENSITIVITY
This parameter defines the sensitivity of the pump control when varying the pedal stroke (this value is expressed
as a percentage of the pump max. displacement control).

INCHING PEDAL INC.

This parameter defines how long the pump takes to reach its max. displacement when the inching pedal is
instantaneously released after it has been fully pressed in conjunction with the travel pedal.

INCHING PEDAL DEC.

This parameter defines how long the pump takes to range from the max. displacement to the neutral displacement
when the inching pedal is instantaneously pressed after fully pressing the travel pedal.
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ENGINE CUSTOMIZED
Allows to set the parameters for the thermal engine control. Do not modify the standard values.

TRAVEL PEDAL INC.

This parameter defines how long the actuator takes to achieve its stroke when the travel pedal is fully pressed
(the higher the value of this parameter, the longer the time the thermal engine takes to range from its min. RPM
to its max. RPM).

TRAVEL PEDAL DEC.

This is the same as the previous parameter (time the thermal engine takes to range from its min. speed to its
max. speed).

MAST INC.
This parameter defines the time the actuator takes to achieve its stroke when the mast lever is fully up (the
higher the value of this parameter, the longer the time the thermal engine takes to range from its min. RPM to
its max. RPM).

MAST DEC.
This parameter is similar to the previous one (time the engine takes to range from its max. RPM to its min.
RPM when the mast lever is released).

MAST FIXED CMD 1

MAST FIXED CMD 2

Parameter that defines the thermal engine speed rate when one of the auxiliary devices of the hoisting unit is
actuated (tilt unit, sideshift, 4th way, 5th way).
When one of the distributor levers is actuated (except for the mast lever) the engine speed increases by a
quantity proportional to the parameter set. Standard value is 30 - 40%.
Ex: engine min. speed: 700 rpm; engine max. speed: 2,500 rpm
usable range: 2,500 - 700 = 1,800 rpm
parameter (mast fixed cmd): 25 %
If the engine operates at a speed higher than 1,100 rpm and the distributor is actuated, the actuator will bring
the engine rpm to: 1,100 + (2,500 - 700)x0.25 = 1,550 rpm.

Do not increase the speeds set to avoid dangerous manoeuvres.

Stroke of the sideshift: 2 -2.5 secs
Tilting: 4.5 - 5 secs

MAST MAXIMUM CMD (Available from 2001)

Parameter which defines the max thermal motor rpm when the lifting is started. By activating the lever, the
motor speed increases step by step until the max value set.
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FAULT DETECTED

Displays the system faults.

- FAULT OCCURRING NOW

Press [ENTER] to display the current fault.

- FAULT SINCE START UP

Press [+] and [-] to display the last five faults occurred.

FAULTS MESSAGES SHOW ON THE CONSOLE

“Excitation Sensor” The exitation voltage of the sensor is < 2V or > 5.5V.

“Power Supply” The supply voltage of TCS control unit is < 9.5V or > 32V for more than
2 sec. long.

“Travel Pedal Sensor” The signal (voltage) of the travel pedal potentiometer has exceeded the
limits set while calibrating.

“Break/Inching Pedal Sensor” The signal (voltage) of the brake pedal potentiometer has exceeded the
limits set while calibrating.

“Mast Lever Sensor” The signal (voltage) of the mast lever has exceeded the limits set while
calibrating.

“Actuator Sensor” The signal (voltage) of the feedback potentiometer has exceeded the limits
set while calibrating.

“Error on Actuator control loop” >20% error, for more than 0.5 secs, between the actuator setpoint and the
potentiometer feedback

“Error on pump control loop” >20% error, for more than 0.5 secs, between the pump control signal and
the potentiometer feedback signal in the pump.

“Feed bak error” Pump feed back is < 0.25V or > 4.75V.

“Neutral out of range” During the calibration the pump neutral is out the limits fixed.

“Pump neutral drift too high” The difference between the pump in neutral calibration function and the
pump in neutral while the values are not fed is >341 mV

“Feedback moves too fast” The pump feedback changes too fast in comparison with the real change of
the pump displacement.

“Eeprom error at address” One parameter at least is outside the field of acceptable values.
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“Direction switches error” The TCS control unit takes contemporarily the forward and reverse gear
(running mode) started..

“Other Default” Other faults.

INFORMATION

Displays the SOFTWARE version

PH PARAMETERS

- PASSWORD
Enter the password (4 numbers) with the digital key and then valid (enter).
Press the key / esc then [+] and [-] in order to haves access to the rest of the menu.

- PUMP NEUTRAL OFFSET

This parameter is made to offset pump feedback

- ENABLE LIMIT CHANGE

During the calibration of the pedals, the auxilary’s levers and the actuator, it is possible that the minimal values and
maximal values abtained on the potentiometer are not conform to the limit fixed by the programm. It is possible to
modify theses limits.
In the menu calibration, authorise the mode calibration. Go into the menu “PH PARAMETERS” and into the
under menu “ENABLE LIMIT CHANGE”.
It is necessary to be in “NOT LOCKED”.

- INVERSION BRAKING
This function is made to have a braking action if direction switch is set in the reverse position during the translation
of the machine.
The brake action will be proportionnal to the position of the travel pedal.

- INVERSION DESPLACEMENT
This parameter set the inversion time range from: 0 - 10 cc

- DISABLE PUMP DELAY

Parameter which defines the time of delay of the negative brakes starting up (standard values 30 cycles). It is the
delay for the brakes starting up after the pump has reset its displacement. In order to have the brakes started up
in a shortime, for example in ramp, reduce the value (min 5 max 45 cycles)

- REGULATOR OFFSET
This is the acceptable difference between the ordered engine speed and the measured engine speed.
If this value is exceeded, the antistall function is active.
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- ANTISTALL COEF
Coefficient apply to the action of antistall function.
The parameter change from 3 to 8.
Bigger is the values more is the desplacement decrease.

- DERIVEE ANTISTALL
Definition of the derived gain for the antistall action. The parameter is a variable number from 10 to 30.
Bigger is the number, bigger is the sensibility at the RPM variation on antistall.

- FULL STROKE CMD

Compensation of the electric stroke used on the recopy potentiometer of the pump.
The parameter is a number (never vary it) 1488

- ENGINE DELAI INC

This parameter is made to take into account the reaction time of the couple actuator/engine in order to activate the
antistall at the right moment. It avoids to put the antistall function all the time.

- ENGINE DELAI DEC

This value is the complementary value of engine delay dec. It is take into account during the engine deceleration.

EPROM RESET

This menu is made to reset the data of the EEPROM

- PASSWORD
Enter the password (4 numbers) with the digital key and then valid (enter).
Press the key / esc then [+] and [-] in order to haves access to the rest of the menu.

- ALL EEPROM RESET

A press on the key (ENT) cancel the list of the statistics.

- FAULT LIST RESET

A press on the key (ENT) cancel the list of the detected defaults.

TROUBLES OCCURRING WHILE CALIBRATING

The voltage values read by the transmission potentiometers (pedals, hoisting, etc.) must not exceed the limits set.
If there is some wiring failure or the mechanical limit stops of the potentiometers are not properly adjusted, the
voltage they supply will exceed the allowable range for the control unit, thus preventing the calibration procedure.
In that case, the terminal will display one of the following messages (while calibrating or in the “fault detected”
alarm menu):

travel pedal position out of range travel pedal

brake/inching pedal sensor brake pedal
mast lever sensor mast lever
actuator position out of range thermal engine actuator
feed-back error hydrostatic pump potentiometer
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1) TRAVEL PEDAL

travel pedal position out of range (error message)

ê
release the parking brake (the terminal will range from
the CALIBRATION MODE to the
DISPLAY MODE)

ê
select the (the terminal will display the
TRAVEL PEDAL submenu voltage - expressed in volts - that
is supplied from the otentiometer
in the travel pedal)
ê
yes voltage = 0 volt? no

ê ê
check the hold down the [ENTER] key and
potentiometer wiring check if voltage changes when
the pedal is pressed

ê
does voltage change?

yes no

ê ê
press the [ENTER] key to check the potentiometer wiring
measure the min. and max. voltage
supplied by the potentiometer

ê
adjust the mechanical limit stop of
the pedal so that the voltage does
not exceed the ranges set
(see “travel calibration”)

Calibrate the travel pedal.

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2) BRAKE/INCHING PEDAL

brake/inching position out of range (error message)

ê
release the parking brake (the terminal will range from
the CALIBRATION MODE to the
DISPLAY MODE)

ê
select the BRAKE/ (the terminal will display the voltage in
INCHING PEDAL submenu volts, that is supplied by the brake
pedal potentiometer)
ê
yes voltage = 0 volt? no

ê ê
check the hold down the [ENTER] key and
potentiometer wiring check if voltage changes when
the pedal is pressed

ê
does voltage change?

yes no

ê ê
press the [ENTER] key to check the potentiometer wiring
measure the min. and max. voltage
supplied by the potentiometer

ê
adjust the mechanical limit stops of
the pedal so that the voltage does
not exceed the ranges set
(see “travel calibration”)

Calibrate the brake pedal.

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3) MAST LEVER

mast lever sensor out of range (error message)

ê
release the parking brake (the terminal will range from
the CALIBRATION MODE to the
DISPLAY MODE)

ê
select the (the terminal will display the
MAST LEVER submenu voltage in volts, that is supplied
by the mast lever)

ê
yes voltage = 0 volt ? no

ê ê
check the potentiometer Hold down the [ENTER] key and
wiring check whether voltage changes
when the lever is pulled

ê
does voltage change?

yes no

ê ê
press [ENTER] to measure the check the electrical connections
min. and max. voltage supplied by of the potentiometer
the potentiometer

ê
Adjust the shims of the
potentiometer support bracket so
that the voltage does not exceed
the ranges set (see “mast lever
calibration”).
If the lever is shifted
forward from its middle position
(for the forks lowering) voltage is
not to decrease.

Calibrate the mast lever.

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4) THERMAL ENGINE ACTUATOR

actuator position out of range (error message)

ê
release the parking brake (the terminal will switch from the
CALIBRATION MODE to the DISPLAY
MODE)

ê
select the ENGINE (the terminal will display the voltage,
CALIBRATION submenu in volts, supplied by the potentiometer of
of the actuator)
ê (engage the
yes voltage = 0 volts? no parking brake and
press the
accelerator pedal)
ê ê
check the electrical con- hold down the [ENTER] key and
nections of the actuator check if voltage changes while the
actuator rotates

ê
does voltage change?

yes no

ê ê
press the [ENTER] key to measure check the actuator electrical connections
the min. and max. voltage supplied
by the actuator potentiometer

ê
adjust the length of the tie rod so
that voltage does not exceed
the ranges set
(see “engine calibration”)

Calibrate the actuator.

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5) POTENTIOMETER IN THE HYDROSTATIC PUMP

feed-back error (error message)

ê
release the parking brake (the terminal will range from the
CALIBRATION MODE to the
DISPLAY MODE)

ê
select the
PUMP NEUTRAL submenu (the terminal will display the
voltage, in volts, that is supplied
by the potentiometer in the
ê hydrostatic pump)
yes voltage = 0 volts or 5 volts ? no

ê ê
check the potentiometer voltage = 2.48 ¸ 2.52 volts ?
electrical connections

yes no
ê ê
engage the parking brake, - check the potentiometer wiring
switch to CALIBRATION mode - lift the truck on the shim blocks,
and calibrate the pump electrically disconnect the pump
potentiometer to zero solenoid valves and start up the
engine: if the pump supplies some
oil, the trouble is a hydraulic or
mechanical type (mechanical
maladjustment of the pump plate
positioning in neutral
displacement)
- after disconnecting the valves, if the
pump supplies some oil, switch off
the engine and hold down the
[ENTER] key in order to read the
voltage, until a 2.5 volt value is
obtained.

ê
engage the parking brake, switch
to CALIBRATION mode and
calibrate the pump potentiometer
zero.
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page 60

SYSTEM FAULTS AND FAILURES

Any system failure is signalled by the blinking warning light located beside the distributor levers.
The blinking intermittence indicates the failure importance.
The kind of fault is displayed in the FAULT DETECTED menu (“FAULT OCCURRING NOW”
submenu).
If the warning light blinks slowly (0.5 Hz) the fault is not very important; the machine is able
to work.

Error message Cause Cure

- the signal (voltage) of the travel pedal - check the potentiometer wiring
potentiometer has exceeded the limits - check if the voltage values at the
set while calibrating pedal limit stop do not exceed
travel pedal sensor
- connector disconnected or wrong wiring the limits preset
- adjust the pedal limit stops
- calibrate the pedal again
- (see page 51)

- the signal (voltage) of the brake pedal

brake/inching pedal potentiometer has exceeded the limits set
sensor while calibrating - as above (see page 52)
- connector disconnected or wrong wiring

- the signal (voltage) of the mast lever has

mast lever sensor exceeded the limits set while calibrating - as above (see page 53)
- connector disconnected or wrong wiring

- the signal (voltage) of the feedback

potentiometer has exceeded the limits set
actuator sensor while calibrating - as above (see page 54)
- connector disconnected or wrong wiring.

- >20% error, for more than 0.5 secs, - check the actuator wiring
error on actuator between the actuator setpoint and the - check theactuator potentiometer
control loop potentiometer feedback output signal (if you press the
- connector disconnected or wrong wiring. accelerator pedal, the actuator
This message may be
shall rotate forward and the
displayed if the
voltage - measured in “engine
accelerator is pressed calibration” when the brake is
(green light on) when released - shall increase)
the engine is off and the
brake is unlocked

power supply out of - the supply voltage of TCS control unit - check the supply voltage value
range is not included in the 9.5 - 48 volts range
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If the warning light blinks quickly (1 Hz) the fault is serious; the machine stops.

Error message Cause Cure

- wrong value of the supply - check that the voltage is equal to 5 volts
excitation voltage voltage of the potentiometers and ± 5%
microswitches

- wrong signal of the feedbackk - check that the feedback potentiometer

potentiometer in the hydrostatic voltage is equal to 2.5 ± 0.15 volts
feedback error pump when the pump is in neutral
displacement mode (see page 55)
- wrong signal of the feedback - check the potentiometer calibration
potentiometer in the hydrostatic (PUMP NEUTRAL)
pump when the latter is in - check that the feedback potentiometer
neutral out of neutral displacement mode voltage is equal to 2.5 ± 0.15 volts
range when the pump is in neutral displacement
mode (see page 55)

- >20% error, for more than 0.5 - check the pump wiring
secs, between the pump control (potentiometer and solenoid valves)
signal and the potentiometer - check that the feedback potentiometer
error on pump feedback signal in the pump voltage properly changes while
control loop controlling the solenoid valves
- measure the min. and max. voltage of
the pump potentiometer and check that
the control max. value is kept constant
during the forward and reverse running
mode (when the wheels turn forwards,
the potentiometer voltage has to tend
to 5 volts) (when the machine is running
in the pump neutral calibration function)
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TROUBLE SHOOTING

Fault Possible cure

- check the parking brake operation (DISPLAY-BRAKE SWITCH

(set-not set) menu)
The thermal engine works correctly - check the operation of the speed selector (pedals with steering-
but the pump is faulty wheel operated reverse gear) or the microswitches on the other
pedals DISPLAY-DIRECTION SWITCH (neutral forward
reverse menu)
- check the signal on the speed sensor (on the pump)
(DISPLAY-ENGINE SPEED menu - check if the value
displayed is acceptable)
- check the signal of the feedback potentiometer (on the
The pump works correctly but the
pump)
thermal engine is faulty
(CALIBRATION menu (display mode)-PUMP
NEUTRAL)
- check the actuator operation
(CALIBRATION (display mode) - ENGINE
CALIBRATION menu)
- check the mast potentiometer signal and wiring (of the
potentiometer and microswitches) -
The pump and engine work correctly, (CALIBRATION (display mode)-MAST
but the engine does not accelerate LEVER CALIBRATION menu)
when the distributor levers are - check if the potentiometer is fitted (TCS parameter)
actuated (CALIBRATION menu, MAST LEVER, mast sensor presence
(1) menu)
if the fault warning light is off:
- check the signal of the speed sensor
(DISPLAY-ENGINE SPEED menu (check if the value
displayed is acceptable)
if the warning light blinks slowly:
The pump and thermal engine do not - check the signal of the travel pedal
work (CALIBRATION - TRAVEL PEDAL CALIBRATION menu)
if the warning light blinks quickly:
- check the supply voltage of the sensors (5 volts)
(CALIBRATION - SENSOR EXCITATION menu)
- control unit supply voltage
(CALIBRATION - POWER SUPPLY menu)
- signal of the pump potentiometer
(CALIBRATION menu (display mode)-PUMP
NEUTRAL)
- wiring of the pump potentiometer
(CALIBRATION menu (display mode)-PUMP
NEUTRAL )
- wiring of the pump displacement control solenoid valves
(VISUAL INSPECTION)
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WHEELS / TYRES
SAFETY OF WHEELS AND RIMS WHILE USING THE TRUCK
“TYRES” are to be replaced when the tyre tread is under 1.6 mm.
“SUPERELASTIC” tyres are to be replaced when the tyre tread reaches the “60 J” mark, which is printed
on the tyre side.
WHEEL TIGHTENING TORQUE
Driving wheels 17 daNm
Steering wheels 24 daNm

SUPERELASTIC (SE)

PNEUMATIC (PN)
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page 64

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.

B A CHECKING THE SYSTEM SEALING AND CLEANING

THE POWER STEERING SYSTEM
Every 250 hours
D - Check the whole system for any possible leakage; before servicing,
release the system pressure.
Every 4,000 working hours
- replace hoses (D) connecting Orbitrol to the steering cylinder.
Every 10,000 working hours
- replace the system pipes.
Adjusting the power steering pressure
The max. pressure of the power steering is to be equal to 100 Bar

Do the following to adjust the power steering pressure:

1 - Install a pressure gauge in (C) the power steering;
2 - With a socket head spanner, remove the cap located in the Orbitrol upper part to reach the
adjusting screw (B) (power steering unit);
- screw in to increase pressure
- screw out decrease pressure

PRIORITY VALVE D
(C)

POWER STEERING
CIRCUIT DRAWING
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STEERING AXLE

Every 500 hours

- lubricate the steering gear joints using the appropriate grease nipples (C);
- 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 ≅ 75°)

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 = 75° STANDARD VALUE

C 80° MAX VALUE WITH PN
C
85° MAX VALUE WITH SE
C ANGLE MEASURED BY THE AXLE FRAME TO THE INTERNAL
WHEEL THROUGH A SPECIAL DEVICE

END STROKE
SETTING SCREW

STEERING AXLE
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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 toothed washer(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 toothed washer;
- reassemble the cap (1);
- lower the wheels again and check that all nuts fixing the rim are well tightened.

4
1
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page 67

HYDRAULIC DISTRIBUTOR

Nominal capacity 80 l/min

3 - 4 - 5 section

Relief valve pression

Tilting 180 Bar
Side shift 150 Bar

Max lifting pression 235 ± 5 Bar

Nipple 1/2 Gas

Microswitch Lifting potentiometer

Restrictor Ø 2 mm
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page 68

MAST GROUPS
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: TV 2 side cylinders
FFL 2 side cylinders
1 central cylinder for the FFL

Triplex mast TV 2 side cylinders

FFL 2 side cylinders
1 central cylinder for the FFL

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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CENTRAL DISPLACEMENT CYLINDER WITH BRAKING EFFECT ON THE LIFTING

The oil flows into the cylinder from the

Rod “Oil inlet” when the control valve is oper-
ated.
Cap
Blender Flowing through channels 1, 2 and 3, it
screw fills chamber A until the inner oil pressure
exerts an upward force against the sur-
face C. The outward sliding of the rod is,
thus, set off. This movement is enacted
by the oil flow from chamber A to cham-
ber B through the above mentioned chan-
nels.
Chamber A
At the end of the expanding process
channels 1 and 2 are plugged by the cap.
Therefore, since the oil flowing between
the two chambers passes only through
channel 3, it has a lower capacity. The
outcome is a slowing-down or “Braking
Channels 1-2 effect”.
Unidirectional
The downward sliding of the rod is al-
valves D-E
lowed by the opening of the “Oil inlet”
Channels 3
circuit, so that the oil can be retrieved into
the tank by means of the control valve.
At the beginning of this phase chamber A
contains no oil. A more constant filling is
Chamber B allowed by the two unidirectional valves
D and E that, when open, permit avoid-
ing jolts.
Once beyond the cap, the oil flow be-
tween the two chambers passes through
Surface C
channels 1 and 2, which are now open.
Oil inlet
>

Safety valve

Unidirectional
< valves D-E
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SIDE CYLINDER WITH BRAKING EFFECT ON THE LOWERING

Channel A
(to the central
Chamber B The oil flows into the cylinder from the
cylinder)
blender “Oil inlet” when the control valve is oper-
screw ated.

Flowing through chamber B and channel

A it fills first the central cylinders, then
chamber A through hole F and the unidi-
Rod rectional valve C.
The oil exerts thus an upward force
against the surface D, which sets off the
outward sliding of the rod.

This movement is allowed by the oil flow

Chamber A from chamber A to chamber B through
blender hole F and the guide ring.
screw The downward sliding of the rod is al-
lowed by the opening of the “Oil inlet”
circuit, so that the oil can be retrieved into
the tank by means of the control valve.

In this phase the oil flows between the

two chambers only through the hole F, as
valve C is closed.
The downward speed of the rod remains
Chamber A constant until hole F is closed by profile
E. The remarkable reduction of oil flow
Surface D has a slowing-down or “Braking effect”.
Hole F

Profile E

Guide ring Chamber B

Safety valve
Unidirectional
valve C
>

Oil inlet
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DESCRIPTION OF THE CYLINDER COMPONENTS

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

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

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
DIAMETRO coupling (7).
DI
SPINTA
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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LUBRICATION

Masts

After the first 50 hours

D - adjust the guide shoes through socket head screw (D).
Use a 0.2 - 0.5 mm thickness gauge; fit it from the bottom upwards
to socket head screw (D) centre, passing behind roller (E) and
creeping on the outer mast.
E
Every 50-100 hours
- Grease the mast sliding guides
- through the grease nipples, lubricate the articulations of the tilt cylinders
and of frame coupling.

Every 250 hours

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

Every 2000 hours

- inspect mast guide rollers (E); they have to rotate freely and not
to be too worn out.

A) tilt cylinders
2+2 grease nipples
B) mast coupling
B 1+1 grease nipples

Fork mounting carriage and sideshift

After the first 50 hours

- adjust the guide shoes through socket hallen screw (D).
Use a 0.2 - 0.5 mm thickness gauge, fit it from the bottom upwards
up to socket hallen screw (D), going behind roller (E).

Every 50 hours
- lubricate the sideshift guides through the grease nipples.
D
Every 250 hours
- grease the pins and the fork positioning slots;
- adjust the guide shoes;
- grease the guide rollers of carriage (F).
F
E
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Every 2,000 hours

- check the conditions of the guide rollers; they
have to rotate freely and not to be too worn
out.
C
C) Sideshift
(upper part) 2 grease nipples
(lower part) no grease nipple

INSTALLATION CHECKS
D SAFETY SPECIFICATIONS

Make sure that:

- the hoisting chain stretchers are not faulty and
B
the adjusting nuts are locked by counternuts and
check pins (F);
- safety limit stops (A) of the fork mounting carriage
are fitted and tightened up;
- stop collars (D) are fitted and tightened up;

Every 500 hours

- check that distance (D) between the collar and
the mast outer cylinder ranges from 0.5 mm to
3 mm;
D - check if self-locking nuts (B) are tightened up.

Tightening torques
- Nuts of the stop collars: 0.8 to 1.2 daNm

SAFETY LIMIT STOPS OF THE FORK

MOUNTING CARRIAGES
The mast unit is equipped with a mechanical safety
limit stop to prevent the accidental removal of the
F fork mounting carriage from the mast downwards.
Limit stops (A) consist of two socket head screws
with counternut. Loosen limit stops (A) before
disassembling the fork mounting carriage.
A
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page 76

MAST CHAINS INSPECTION

CHECKING THE CHAINS:

Every 500 hours (anyway, chains are to be checked every 3 months)
- check the condition of the chains which in any case must not be faulty, worn out 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

Use of original CESAB chains will guarantee that the safety requirements stated by the regulations
in force are complied with.

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 2000 kg (class II B), must be 152 ±5
mm).

X = 76 mm (A)
X = 152 mm (B)
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FORKS

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

Inspection
Fork arm inspection must be carefully carried out by
F F trained personnel to detect any damage, failure, deformation,
D D etc., which may impair safety use.

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.
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LIFTING THE TRUCK

HOOKS ATTACHMENT POINTS FOR

LIFTING THE TRUCK

To lift the truck the following equipment must be

used:
A
A- CHAINS: dia. 13 mm - Degree 8 - UNI EN
818-2

B B- HOOKS: for 5.4 t - UNI/ISO 7597

ß ≤ 45° concerning the lifting vertical line

C C LIFTING OF THE FORKLIFT TRUCK

WITH CABIN

A- CHAINS: dia. 13 mm - Degree 8 - UNI EN

A A
818-2

B B- HOOKS: for 5.4 t - UNI/ISO 7597

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

ß ≤ 45° concerning the lifting vertical line

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GM ENGINE LPG SYSTEM

A B

A= Liquid gas cylinder

B= Liquid gas cylinder stopcock
G C= Safety valve (max 15 bar)
C D= Water fitting for vaporiser heating
F E= Vaporiser
F= Liquid gas filter valve
G= Air filter
D H= Carburetor
I= Rpm setting (done by Cesab)
E
L= Connection of carburetor vacuum to
H filter valve
M = Connection of carburetor vacuum to
N L rpm adjuster
N = Connection of carburetor vacuum to
distributor to change spark advance
M
I

Vapour pressure curves

(switch from liquid to gaseous state)

bar

8
o
pan

7
GPL
Pro

4
The liquid gas is a mixture of propane and butane
no
ta

3
in varying percentages. The higher the percentage
Bu

2 of propane, the higher the vapour pressure (pressure

1 being equal), the better the system will work.
0

°C
-30 -20 -10 0 +10 +20 +30
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LIQUID GAS INLET

AT VAPORISER

udt2

VACUUM D ATMOSPHERIC C
PRESSURE

FILTER VALVE
The liquid gas flows in through filter A which traps all impurities (replace every 1000 hours).
Liquid gas flow is interrupted by valve B (the pressure of the liquid gas keeps this valve
closed: active safety)
The vacuum of the carburetor, connected through hole C, acts on diaphragm D and causes
valve B to open.

L I

AT THE
CARBURETOR

E F G ATMOSPHERIC PRESSURE

VAPORISER (shown in operating position)

By means of primary valve E, the liquid gas becomes gaseous, passing from 6-8 bar to
0.5 bar, with heat absorption.
Valve E maintains a pressure of 0.5 bar in chamber F.
Valve E is operated by diaphragm G. The secondary valve H (this opens at 0.038 bar)
is controlled by diaphragm I which is affected by the carburetor vacuum (active safety).
L = manual control for opening valve H.
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A E

GASEOUS LPG INLET

AIR INLET

Butano

udt4

CARBURETTOR (here shown in fully open position)

The liquid gas is metered by valve A controlled by the vacuum operating on piston B.

udt3

D
F

D = CO adjustment at minimum rpm (completely screw up and then unscrew by 3 full turns)
E = CO adjustment at peak rpm. Switching from R (open)to C (closed), the percentage of
gas is reduced.
F = adjustment of minimum rpm
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page 82

GM ENGINE ADJUSTMENT

MAX. RPM ADJUSTMENT

Turn the adjusting screw bushing (A) clockwise or counterclockwise of approximately 90 degrees until you
reach the correct maximum RPM, around 2400 RPM.
In order to regulate the adjusting screw bushing you have to screw out the safety screw (C).

HUNTING ADJUSTMENT
If hunting is observed, i.e. the irregular variation of the minimum and maximum engine RPM, you have to
proceed as following:

1) Turn the adjusting screw (B) clockwise (increase of the maximum engine RPM without load lower then 100
RPM) or counterclockwise (increase of the maximum engine RPM without load highter then 100 RPM)
until you toget the correct running of the engine.

2) Check the eventually hunting with load and repeat the precedent point if it is necessary.

3) Verify thet the maximum RPM are not changed (2400 RPM, in case set the adjustiing screw bushing A
again).

4) Plunb the adjusting screw to theadjusting screw bushing to prevent the screw from moving during engine
vibrations.
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GM ENGINE INITIAL TIMING ADJUSTMENT

ADVANCE CONNECTOR

Fig. A Fig. B

1) With the engine shut-off, plug the advance connector P/N 0994425 to the distributor (see picture A).

2) Start the engine and run at slow idle, 500 RPM.

3) Connect the alligator clip to the battery positive (+) but only after starting the engine, otherwise this will
cause the distributor module to fail.
This connection removes the built in electronic advance from the distributor module.

4) Connect the stroboscopic gun to the N° 1 spark plug wire (fan side, back side).

5) Check the timing on the crankshaft pulley in relation to the pointer on the timing cover that has to be of 4
degrees (see picture B).

6) In order to adjust the timing you have to screw out the distributor fixing screw and turn the distributor on the
appropriate side.
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page 84

TOYOTA ENGINE LPG SYSTEM

Fig. 1

The liquid LPG from the LPG cylinder is taken into the regulator for filtration of foreign metters by the built-in
filter. The filtered LPG is then sent to the pressure reduction chamber, where it is vaporized into gas which is
sucked into the engine through the carburator. The engine cooling water is led to the regulator as the heat source
for LPG vaporization.

Carburator

This carburator functions to mix the LPG after

pressure reduction in the regulator with the air
at an appropriate ratio and lead the mixture
into he cylinder. A negative pressure type
power valve is built in to improve the perfor-
mance in a heavily loaded state. The carburator
body is integrated with a venturi tube.

Specification:
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Idling speed (minimum RPM adjustment)

1) Warm up the engine

cooling water temperature: 80°C or above

engine oil temperature: 70°C or above
hydraulic oil temperature: 50°C or above

2) Connect an engine revolution counter

3) Inspect the idling speed (750 RPM)

A
4) If the idling speed does not satisfy the standard,
turn the Air adjust screw A.
If the idling speed cannot be adjusted to the standard Idle adjust screw B
value, first turn the idle screw B counterclockwise until
to reach the highest engine RPM, now adjust the air
adjusting screw A in order to find 750 RPM.
Turn idle adjusting screw B slowly clockwise to find
the opening where the speed starts to drop, and turn it
counterclockwise by 45° from that position.
The above adjustment attains the standard idling speed
and CO value.

In any case it is possible to adjust the CO value trough

the power adjust screw C (the standard value is 2% at
minimum RPM).

C
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TOYOTA LPG REGULATOR

Regulator

The regulator for the gasoline engine correspond to a Idle adjust screw B
part of the carburator. It is supllies the LPG fuel to the
engine while maintaining the vaporized LPG after
pressure reduction at a constant pressure level.
The regulator is made very compact since the filter
and solenoid separated.
The LPG in the liquid phase is vaporized by taking Filter
the heat of vaporization from the engine cooling water.
The regulator consist of chamber A where the LPG
starts to vaporize, chamber B for reducing the pressure
of the vaporized LPG (primary pressure reduction
chamber), chamber C (secondary pressure reduction Solenoid valve
chamber) where the pressure is further educed to
near the atmospheric pressure to supply the fuel
according to the negative pressure at the venturi in the
carburator, and chamber D that forcibly supplies fuel
at the time of the engine starting or idling.

Specification:

Filter

The filter is set to 10 µm and two types of materials

are used inside with rubber paking for sealing in-
between (see Fig. 1).

Solenoid valve
Fig. 1
A solenoid valve integrated with the regulator is
installed between the filter and the chamber B. Fig. 2
The LPG switch (see page 80 and 83), installed on
the regulator support, starts and stop the LPG supply.
A slide valve is located inside the solenoid valve. The
current flowing in the coil generates a magnetic force
to attact the slide valve toward the solenoid against
the spring force, opening the path.
When no current flows, the spring forces the valve
seat to close the path.
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Idle adjust screw

Fig. 1 LPG switch

TOYOTA ENGINE ADJUSTMENT

Max. RPM adjustment

1) Warm up the engine

cooling water temperature: 80°C or above
engine oil temperature: 70°C or above
hydraulic oil temperature: 50°C or above
2) Connect an engine revolution counter.
3) Inspect the maximum speed (2450 RPM)
4) Loosen the safety bolt (C), turn the adjusting screw
bushing (A) counterclockwise if the maximum RPM
are exeeded from the standard value or turn it
clockwise if the maximum RPM are less that the
standard.
A C
If it is necessary keep loked the screw (B) with a plain B
screwdriver.
5) Check the eventually hunting with load and repeat the
precedent point.

Hunting adjustment

If hunting is observed, i.e. the irregular variation of the

minimum and maximum engine RPM, you have to proceed
as following:

1) Turn the adjusting screw (B) clockwise to reduce the

hunting.
2) Verify that the maximum RPM are not changed (in
case set the adjusting screw bushing (A) again).
3) Plumb the adjusting screw to the adjusting screw (B)
to prevent the screw from moving during engine
vibration.
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TOYOTA ENGINE INITIAL TIMING ADJUSTMENT

Vacuum pipe

(Engine speed sensor connector)

Distributor set bolt

Fig. 1 Fig. 2

1) Warm up the engine

cooling water temperature: 80°C or above

engine oil temperature: 70°C or above
hydraulic oil temperature: 50°C or above

2) Connect the stroboscopic gun to the n° 1 spark plug wire

3) Disconnect the vacuum pipe (see Fig. 1)

4) Check the timing on the crankshaft pulley in relation to the pointer on the timing cover that has to be of
7 degreese (see Fig. 2)

5) In order to adjust the timing loosen the distributor set bolt (see Fig. 1) and turn the distributor on the
appropriate side

6) Tighten the set bolt and connect the vacuum pipe

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page 89

LPG BOTTLE

The LPG bottle is not supplied with the truck. For correct truck operation, you should request and use
only bottles designed for VEHICLES, with an INTERNAL FEED PIPE. These bottles are available from
authorized suppliers, whose fitting and maintenance instructions must be scrupulously followed. Secure the
bottle to the support on the truck. Position the bottle so that the internal feed tube points downwards
(ask the bottle supplier for advice).

TAP

INTERNAL
FEED PIPE

FILTER

FLEXIBLE GAS
HOSE FITTING
BOTTLE TYPE B
TAP

INTERNAL
FEED PIPE
FLEXIBLE GAS
HOSE FITTING
FILTER

BOTTLE TYPE A
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OIL AND GREASE SPECIFICATIONS

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page 91

RUNNING IN MAINTENANCE TIME TABLE

LEGEND

' In the maintenance table showing a visual

control and cleaning of the parts indicated .
The servicing periods are divided into hours, considering
an average working day of 8 hours of effective operation.
If the truck is used on average for less than 8 hours per

& I n the maintenance table showing the day, refer to the schedules expressed in days/months
replacement of the parts indicated.

" In the maintenance table showing lubrification

of the parts indicated.

, In the maintenance table showing tightening

or adjustment of the parts indicated.
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MAINTENANCE TIMES TABLE

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MAINTENANCE TIMES TABLE

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MAINTENANCE TIMES TABLE

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MAINTENANCE TIMES
SERVICE MANUAL

250300 350
 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

Code 036 2005-3 GB Issue 11/2002