Service Manual

CBE
4.0
4.5
5.0
DC Version

Cargo Range

CARGO 4.0

BT Svenska AB
Per Wrmlund

< Tillbaka till Index

Electric

SERVICE MANUAL

4,0 - 4,5 - 5,0 t

page 3

reserves all rights of reproduction of this handbook

The text and the numbering system may

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

CESAB reserves the right to make any necessary

modifications without obligation to promptly update
this handbook.

Copyright by
CESAB
CARRELLI ELEVATORI S. p. A.

4,0 - 4,5 - 5,0 t

SERVICE MANUAL

Electric

INDEX

page 4

MECHANICAL SECTION
DATA SHEET

page 7

DRIVERS PLACE
Load handling commands

page 8
page 9

DASHBOARD

page 10

TRUCK LOAD CAPACITY

page 12

TRACTION UNIT

page 13

DISASSEMBLE THE REDUCTION UNIT

page 14

OIL CHANGE

page 15

BRAKES
Service brake system
Parking brake system

page 16
page 16
page 18

ELECTRIC MOTORS

page 19

WHEELS/TYRES

page 20

STEERING GROUP
Power steering diagram
Filter and power steering oil
Steering axle
Bearing adjustment

page 21
page 21
page 22
page 23
page 24

LIFTING UNIT
Hydraulic control valves
Hydraulic system diagram with distributor
Lifting unit with electrovalves
Hydraulic system diagram with electrovalves
Filter and lifting oil

page 25
page 25
page 26
page 27
page 29
page 30

MASTS
Triplex mast section
Mast lubrication and settings

page 31
page 32
page 33

MAST LIFTING UNITS

Description of the cylinder component parts
Checking the chains
Checking the forks - Mast tilting setting

page 35
page 35
page 37
page 38

ELECTRICAL SYSTEM
Description of components
Accelerator pedal - Battery and battery charger

page 39
page 39
page 40

TRUCK LIFTING

page 41

TABLES

page 42

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SERVICE MANUAL
INDEX

Running in maintenance table

Maintenance table

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page 5

page 43
page 44

ELECTRICAL SECTION
TECHNICAL FEATURES

page 48

ELECTRICAL MOTORS FEATURES

page 48

FUNCTIONAL PERFORMANCES
Protection
General precautions

page 49
page 49
page 50

CONSOLE DESCRIPTION

page 52

ELECTRONIC CONTROL PANEL LAYOUT

page 53

CONTACTORS PANEL

page 54

COMPONENTS PANEL

page 55

ELECTRICAL CIRCUIT CONNECTION - TRACTION MODULE H3D

Configuration of the traction potentiometer

page 56
page 58

SETTING VALVES TRACTION MODULE H3D

page 59

ALARMS DESCRIPTION - TRACTION MODULE H3D

page 60

ADJUSTMENTS TABLE TRACTION MODULE H3D

page 62

ELECTRICAL CIRCUIT CONNECTION - LIFTING MODULE H2P

Lifting potentiometer configuration

page 63
page 65

SETTING VALUE - LIFTING MODULE H2P

page 66

ALARMS DESCRIPTION - LIFTING MODULE H2P

page 67

ADJUSTMENTS TABLE LIFTING MODULE H2P

page 68

ELECTRICAL CIRCUIT CONNECTION - LIFTING MODULE HPRC

page 69

WIRING DIAGRAM INPUT SIGNALS - LIFTING MODULE HPRC

(fingertips version)

page 70

WIRING DIAGRAM INPUT SIGNALS - LIFTING MODULE HPRC

(joystick version)

page 71

WIRING DIAGRAM OUTPUT SIGNALS - FOR ELECTROVALVES

page 72

FUNCTION DESCRIPTION OF ELECTROVALVES AND HPRC MODULE

HPRC module configuration (version with fingertips-joystick)

page 73
page 73

SETTING VALUES - LIFTING MODULE HPRC

page 74

ALARMS DESCRIPTION - LIFTING MODULE HPRC

page 75

ADJUSTMENTS TABLE

page 77

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SERVICE MANUAL
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SERVICE MANUAL

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page 8

Electric

DRIVER'S PLACE
PEDALS

FOOT DRIVE DIRECTION

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

DRIVE DIRECTION LEVER ON STEERING

COLUMN (Alternative version)

1
o
2

Direction selector lever (F)

1 Forward direction
o 0 Neutral
2 Backward direction

Single drive pedal (G)

Emergency push button (P)

Battery connector (H)

Inside the battery cover

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SERVICE MANUAL

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DRIVER'S PLACE

page 9

LOAD HANDLING COMMANDS

There can be three types of commands for load handling

FINGERTIPS VERSION (A)

LEVER VERSION (B)

JOYSTICK VERSION (C)

All the functions will be explained on the "LIFTING GROUP" paragraph

SERVICE MANUAL

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DASHBOARD

page 10

10

11

12

13

14

15

16

1) Battery charge indicator

2) Parking brake ON warning light
3) Low brake fluid level warning light
4) Lifting motor temperature warning light
5) Worn lifting motor brushes warning light
6) Worn drive motor brushes
7) Not used
9) Electronic hour meter
10)Drive motor temperature warning light
11)Lifting speed reduction due to flat battery
12)Dead man device warning light
13)Electronic control unit temperature warning light
14)Drive diagnostics
15)Lifting diagnostics
16)Not used

DASHBOARD CONTROLS
1

1) Battery charge indicator

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

Electric

3) Brake fluid low warning light

4) Lifting motor temperature warning light
lights up when the temperature is 150C

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

AND LIFTING MOTOR BRUSHES)
6

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

MOTOR BRUSHES)

9) Electronic hour meter

It is activated by insertion of the ignition key.
It shows the hours and the tenth

10

10)Drive motor temperature warning light

lights up when the temperature is 150C

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SERVICE MANUAL

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DASHBOARD

page 11

11

11)Lifting speed is reduced due to flat battery the lifting speed is reduced by 60%

12

12)dead man device pilot light

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

13

13)Electronic control unit temperature warning light; it lights

up, when the temperature is 80C electrical selection

14

14)Drive diagnostics (see electrical selection)

15

15)Lifting diagnostics (see electrical selection)

SERVICE MANUAL

page 12

Electric

TRUCK LOAD CAPACITY

LOAD PLATE
It identifies the load capacity with a load center
of 500 mm (except for different indications)
ATTACHMENT OR SPECIAL CONDITION OF USE

TYRES

SERIAL N

CENTER OF LOAD DISTANCE mm

LIFT HEIGHT
mm

Cod. 0312005

DERATED CAPACITY Kg

CAPACITY PLATE

IDENTIFICATION PLATE
It identifies the lift truck technical data
MODEL Type

MOTOR

RATED CAPACITY
kW

SERIAL N

kg

DRAW-BAR PULL (1h)

N

BATTERY MASS
kg
min.

MANUFACT. YEAR

SERVICE MASS
Without
Battery kg

kg
max.
TENSION
V

Cod. 0312004

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CESAB LDT
Bevan Way
Smethwick - Warley
West Midla 1ds B66 1BZ

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TRACTION UNIT

page 13

The traction gear unit is consisted of:

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

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SERVICE MANUAL

Electric

DISASSEMBLE THE REDUCTION UNIT

8 screws

Disassemble the reduction unit

- Park the lift truck on a level ground. Engage the parking brake and disconnect the battery;
- Disassemble the mast;
- Lift the front part of the lift truck and set the special shims under the side
panels of the chassis;
- Remove the front wheels;
- Disconnect the tie rods of the parking brake, the service brake oil pipe, the
motor cables etc;
- Keep the reduction unit in lifted position;
- Remove the fastening screws located on the chassis (tightening torque setting of 55 daNm).

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OIL CHANGE

page 15

Type of oil MOBIL-FLUID 422SAE 80W

or equivalent (see oil table).
After the first 50-100 hours
- Change the oil
Every 250 hours
- Check the oil level, when it is cold.
Every 1.000 hours or 12 months
- Change the oil

OIL CHANGE

INSTRUCTION

- Place the lift truck on a flat floor with the

parking brake on.
- Disconnect the battery connector.
- Changing the oil in the reduction gears.
- Carefully clean the area around the oil filling
(A) and draining caps (B); place a suitable
container below the drain cap and then remove
both the filling and the draining caps and allow
the oil to drain out completely.
- Clean any ferrous residues from the magnetic
cap (B) and replace it.
- Pour fresh oil into the hole (A) until it starts
overflowing from (C).
After a short functioning period, check the oil
level again.
- The oil quality for each reduction is approximately
1,5 L.

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BRAKE

page 16

SERVICE BRAKE SYSTEM DIAGRAM

A) Reduction gear (right) and braking unit

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

D
G

SERVICE BRAKE CONTROL

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

OIL BRAKE TANK (F)

OBS! Olja typ SAE 80W i bromssystemet!

Gioco

CHECK SERVICE
BRAKE

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SERVICE MANUAL

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BRAKE

page 17

DIFFERENTIAL
BRAKE

BRAKE DISKS

SERVICE
BRAKE
OIL INLET

12345
12345
12345
12345
1234
1234
1234
1234
1234
1234
BRAKE
COUNTER
DISKS

PARKING BRAKE
LEVER

Brake disks thickness

Max. wear
Brake counter disk thickness
Differential brake disk thickness
Max wear

3,8 mm (n 2)
0,4 mm
9 mm (n 2)
1,8 mm (n 1)
0,2 mm

SERVICE MANUAL

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BRAKE

page 18

PARKING BRAKE DIAGRAM

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

P
N

PARKING BRAKE CONTROL AND

ADJUSTMENT
Every 500 hours
- Check the clearance shown on the drawing
A with the parking brake pedal released
A
- Check the parking brake stroke which
should correspond to 4 notches ( L pedal).
If it necessary, act on the adjusting screw
(O)
- With the front wheels lifted adjust the cable
so that the same ones at 1st notch are
free, on the contrary, at the 2nd notch
Leva.tif
are blocked.
Rr ej justerskruven p armen!
Press the parking brake pedal some times
Spel med nya lameller = 0,3mm
and check if the clearance is still the same.
Vid ett spel av 5-6mm r
lamellerna utslitna.

PARKING BRAKE RELEASE

INSTRUCTIONS
The dimension of the parking brake is sufficient
to guarantee blocking of the truck, even with nominal
load in the travelling position, on gradients of 22%
as required by the ISO 6292-2 standards.

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Electric

MAINTENANCE
Every 500 hours
Every 500 hours

SERVICE MANUAL

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ELECTRIC MOTORS

page 19

check the wear brushes

check the commutator conditions

TRACTION MOTOR
V 80
Kw 18
A 250
Ecc. serie
Rpm/min. 1400
IP 20
Service S2
Classe IS H
N poles 4
N brushes 8

LIFTING MOTOR
V 80
Rpm/min. 1800
Service S3 15%
N poles 4

Kw 17
Ecc. serie
Classe IS H
N brushes 8

Lifting pump
27 LiT/min.

POWER STEERING MOTOR

V 80
Kw 2
Rpm/min. 1370
Service S3 58%
Classe IS H
N poles 4
N brushes 4
Power steering pump
14 Lit/min.

LENGTH OF ORIGINAL BRUSHES

< 50%

New

TYPE OF MOTOR

L = 32 mm

DRIVE MOTOR BRUSHES

L = 30 mm

LIFTING MOTOR BRUSHES

L = 32 mm

STEERING MOTOR BRUSHES

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page 20

SERVICE MANUAL
WHEELS/TYRES
STANDARD TYRES

THE SAFETY OF RIMS AND WHEELS FOR FORKLIFT TRUCKS

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

PNEUMATIC TYRES PRESSURES

Front
9,5 BAR
8,5 BAR (twin tyres)
Rear

10 BAR

TIGHTENING TORQUE
Driving tyres
50 daNm
Steering tyres
37 daNm

CU
CUSHION

SE
SUPERELASTIC

PN
PNEUMATIC

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SERVICE MANUAL

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STEERING GROUP

page 21

POWER STEERING SEAL CONTROL AND CLEANING

B
A

Every 250 hours

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

Power steering pressure setting

The max power steering pressure must be 105 Bar
In order to set the power steering pressure the following operations are necessary:
1- Connect a manometer on point A of the power steering
2- Remove the cap (with allen screw) on the top of the orbitrol, in order to reach
the setting screw (B)
- Screw in to increase the pressure -Screw out to decrease the pressure

POWER STEERING
DIAGRAM

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STEERING GROUPE

page 22

POWER STEERING OIL AND FILTER

The power steering oil pump (F) and the tank (G)
are located beneath the drivers platform.
The filter cartridge (D) is beneath the screw cap
(B).

G
D
A

After the first 50 hours of work

- first filter change
After the first 500 hours of work
- second filter change.
Every 250 hours
- check the level of oil in the tank using the dipstick
(A);
- check and clean the tank breather valve filter
(C).
Every 2.000 hours
- replace the oil and the filter.
To change the oil and the filter:
- remove the front dashboard, disconnect the
delivery tube (E) and place it in a special container;
- with the key inserted press the brake pedal to
drain the oil from the hydroguide system.;
- to avoid problems, remove the feet from the
brake pedal as soon as oil drainage is complete.
- replace the filter (D) after controlling the state
of the washers;
- Reconnect the feed pipe (E) and fill the tank
with approx. 18 liters oil through the filter.
Verify the oil level (0 - 20 mm higher than
the lower notch) by using the dipstick.
- After testing, check that there are no oil leaks.

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SERVICE MANUAL

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STEERING GROUPE

page 23

STEERING AXLE
Steering axle check
Every 500 hours
- lubricate the steering gear joints using the appropriate grease nipples (D), (E) and
(F);
- check the steering angles.
Every 2.000 hours
- check and if it is necessary, adjust the wheel hub bearings.
Every 500 ore check the angles
Max steering angle (internal wheel 78)
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 = 78
ANGLE MEASURED BY THE AXLE
FRAME TO THE INTERNAL WHEEL
THROUGH A SPECIAL DEVICE

D
E

F
D

END STROKE
SETTING SCREW

STEERING AXLE

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SERVICE MANUAL
STEERING UNIT

page 24

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

5
2

4
3

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SERVICE MANUAL

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LIFTING UNIT

page 25

HYDRAULIC CONTROL VALVES

Lever control version

Max pressure valve 220 BAR

Max pressure tilting valve

150 BAR

Max pressure sideshift valve 150 BAR

MANOMETER CONNECTION POINT FOR HYDRAULIC PRESSURE

CONTROL

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page 26

SERVICE MANUAL
LIFTING UNIT

HYDRAULIC DIAGRAM WITH CONTROL VALVES

LIFTING

TILTING

SIDESHIFT

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SERVICE MANUAL

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LIFTING UNIT

page 27

LIFTING UNIT WITH ELECTROVALVES

Version with fingertips control and joystick
It is consisted of:
1 - Double 24V upstroke ON/OFF electrovalve
Proportional electrovalve for the downstroke
2 - Two 24V ON/OFF tilting control electrovalves
3 - Two 24V ON/OFF sideshift control electrovalves
The movements speed is according to the lifting motor rpm number.

Pressure gauge
connection for sideshift
tilting pressure survey

Sideshift electrovalve

Tilting electrovalve

Pressure survey valve

220 Bar

Tilting sideshift 160-bar

pressure reducing valve

Safety valve for load lowering

in case of failure of the
electrovalve

Downstroke speed
adjusting screw

Lifting electrovalve

Pressure gauge connection for lifting max.

pressure survey

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SERVICE MANUAL
LIFTING UNIT

page 28

NOTES
1) Before connecting/disconnecting a hydraulic system equipped with rapid action couplings,
release the pressure of the circuit by pressing a metal bit on the spool of the corresponding
solenoid valve (point A).
2) In case of failure of the load downstroke proportional electrovalve, the emergency
downstroke of the load can be activated by slightly tightening the socket head screw B
that is normally at the limit stop and completely loose. Once the failure has been rectified,
the lift truck can be restored to its standard operation and socket screw B must be completely
loosened.

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SERVICE MANUAL

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LIFTING UNIT

page 29

HYDRAULIC DIAGRAM WITH ELECTROVALVES

LIFTING

TILTING

SIDESHIFT

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LIFTING UNIT

page 30

LIFTING EQUIPMENT OIL AND FILTER

The lifting oil tank is positioned inside the rear
compartment
The filter cartridge (D) (20 ) is beneath the screw
cap (B).
B
A
D
C

After the first 50 hours of work

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

- turn the wheels completely to obtain access and

remove the drain cap (E); drain out all the oil
into an appropriate container then replace the
drain cap and tighten firmly;

- fit a new filter (D) after checking the state of

the seals;
- Fill the tank with approx. 35 liters oil through
the filter until the dipstick notch (max level).
Min. level for triplex mast groups is 10-15 mm
lower than the notch.
Min. level for duplex mast groups is 50 mm lower
than the notch

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MAST GROUPS

page 31

The mast profile - CESAB design - with double stiffening flange is characterised by a high
flexural and torsional strength.
It allows wide visibility thanks to the reduced dimensions of the profile itself.
Cylinders are single-acting type.
The sideshift system has been housed inside the profiles.
The mast group is a roller type with a variable centre distance (i.e. a fixed roller is fitted on the
outer mast and a mobile one on the inner mast, instead of a number of mobile rollers only on
the inner mast). This solution ensures better grip and stability on operation.
Other features: side plays adjustable from outside. Plastic guide shoes. Roller bearings with
grease nipples, ball joints on axle couplings and tilt cylinders.
Lifting cylinders:
Duplex mast:
VT 2 side cylinders
FFL 3 central cylinders
(two small FFL side cylinders, and a central lifting one)
Triplex mast

VT 2 side cylinders
FFL 2 side cylinders
2 central cylinders

Grease nipple

Adjusting screw

Shoe

Roller

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SERVICE MANUAL

page 32

MAST GROUPS

TRIPLE MAST SECTION

Fork carriage

Internal
section bar

Intermediate
section bar

External
section bar

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MAST GROUPS

page 33

LUBRICATION OF LIFTING
EQUIPMENT

Masts
Every 50-100 hours
- lubricate with grease the mast sliding guides
- lubricate the tilting jacks and the mast connections.
A) Tilting jacks
2+2 grease nipples
B) Mast connections
1+1 grease nipples

F
D

Fork carriage and sideshift unit

Every 50 hours
- lubricate the sideshift guides with grease through
the grease nipples.
Every 250 hours
- lubricate the fork positioning pins and notches
with grease.
C) Sideshift unit
(upper part)
3 grease nipples
(lower part)
without grease nipples

Fork carriage shoes and rollers:

After the first 50 hours
- adjust the guide shoes adjusting the Allen screw
(D).
For the adjustment use a 0.2 - 0.5 mm thickness
gauge, inserted from below and up to the centre
of the Allen screw (D) passing behind the roller
(E).
Every 250 hours
- adjust the guide shoes;
- grease the Fork carriage guide rollers (F).
Every 2 000 hours
- check the condition of the guide rollers; they
must turn freely without jamming and not show
excessive wear.

SERVICE MANUAL

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MAST GROUPS

page 34

Lifting side jack collars:

A

Every 500 hours

- check that there is a clearance (C) of 0.5 to
3 mm between the collar and the external lifting
jack cylinder.
- check that the self-locking nuts (B) are tight.
B

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

Mast guide shoes and rollers:

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

Every 250 hours

- adjust the guide shoes;
- grease the mast guide rollers (E).
Every 2 000 hours
- check the condition of the mast guide rollers
(E); they must turn freely without jamming and
not show excessive wear.

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MAST LIFTING UNIT

page 35

DESCRIPTION OF THE CYLINDER COMPONENTS

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

6
5
4
7

THRUST
DIAMETER

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

piston (2) that works on the inner surface of the
cylinder liner (3).
The rod guide is made by the plug (4) and by the
piston through anti-friction rings (5).
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
coupling (7).

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
1

Fig. A

Fig. B

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page 36

SERVICE MANUAL
MAST LIFTING UNIT
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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SERVICE MANUAL

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MAST GROUPS

page 37

CHECKING THE CHAINS:

Every 500 hours
- check the condition of the chains which in any case must not be worn or damaged.
To check the links for wear, use the appropriate gauge, paying attention that, when
33 links are counted in a space corresponding to 34, the chains must be replaced.
Every 1 000 hours
- remove the chains, clean them thoroughly, refit them inverting the original working
position and lubricate them.
Every 10 000 hours
- replace the chains and the fixing tie rods

203 mm

POSITIONING THE FORK MOUNTING

CARRIAGE
Every 500 hours
- check the position of the fork mounting carriage.
Position is correct when the carriage (with the
mast upright) in its lowest position is at a distance
of 203 mm from the lower edge of the fixed
mast.

SERVICE MANUAL

4,0 - 4,5 - 5,0 t

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

G
E

F
D

Electric

MAST GROUPS

page 38

Inspection
Fork arm inspection must be carefully carried out by trained
personnel to detect any damage, failure, deformation, 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.

MAST GROUP TILTING SETTING

230 FORWARD
10 BACKWARD
Check to carry out every 500 h
N.B. 1 tilting degree corresponds to a 17.4 mm
movement on 1 mt.

Electric

SERVICE MANUAL

4,0 - 4,5 - 5,0 t

ELECTRIC SYSTEM

page 39

COMPONENTS DESCRIPTION

A) Traction module
B

B) Lifting module
C) Contactors

D) Control cooling fan

E) Components panel
D

Every 500 hours

- Check and clean the electronic control space

ELECTRONIC PANEL FUNCTION DESCRIPTION, TROUBLE SHOOTING,

CONSOLE USE: SEE "ELECTRIC SECTION"

4,0 - 4,5 - 5,0 t

page 40

SERVICE MANUAL
ELECTRICAL SECTION

Electric

ACCELERATOR PEDAL
Set the potentiometer
Position the tester set in OHM between the green
and the red wire.
Set the potentiometer
from 12 to 12.5 KOHM (pedal released)
from 7 to 7.5 KOHM (pedal pressed)

180 mm

Height adjustment screw

BATTERY AND BATTERY CHARGER

General indications for battery maintenance
Every 50 working hours - measure electrolyte density.
Approximate density data
For a temperature of 15 C
- a density of 1.12 to 1.13 kg/dm3 indicates that the battery is flat;
- a density of 1.25 to 1.26 kg/dm3 indicates that the battery is charged (battery capacity increased: 1.29 to 1.30
kg/dm3).
BATTERY CHARGING WARNINGS
Before charging the battery, verify that the room is well aerated. Open the battery compartment door.
Make sure that all electrical connections (electrical cable terminals, battery terminals, plugs-sockets, etc.) are well
attached and in good condition.
- Do not open either remove battery filling caps.
- Never top up before and while charging the battery.
- Do not smoke, do not stay close to naked flames and do not cause sparks next to batteries
- Do not use the battery while it is being charged
- Do not lean metal tools on the battery while under charge
- Never repair the battery while under charge
- Check that during the charging phase, the electrolyte temperature is kept below 50C.

Electric

SERVICE MANUAL

4,0 - 4,5 - 5,0 t

TRUCK LIFTING

page 41

HOOKS ATTACHMENT POINTS FOR

LIFTING THE TRUCK

To lift the truck the following equipment must be

used:
A- CHAINS: dia. 13 mm - Degree T (8) - UNI
9425
B- HOOKS: for 5.4 t - UNI/ISO 7597

LIFTING OF THE FORKLIFT TRUCK

WITH CABIN
B

A- CHAINS: dia. 13 mm - Degree T (8) - UNI

9425
A

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

C- N 2 upper brackets to hold the chains.

4,0 - 4,5 - 5,0 t

SERVICE MANUAL

page 42

TABLE

OIL AND GREASE SPECIFICATIONS

TIPO USATO
TYPE USED
TYP

SPECIFICHE
SPECIFICATIONS
EIGENSCHAFTEN

AGIP ARNICA 46

ISO - L - HV
Prove FZG
fino a stadio 11 (*)

MOBIL-FLUID 422
SAE 80 W

API GL4
MIL-L-2105D
+additivo per freni a
bagno dolio (***)

MOBILGREASE SPECIAL

Base LITIO
ASTM 275 305
NLGI N.2
Gocciolamento
180 (**)

Q.T
QTY.
MENGE

FOR NORMAL ENVIRONMENTS

PARTS TO BE LUBRICATED

21 L

Hydraulic system, lifting and power steering

1 L
+
1 L

Transmission reduction gears

Hydraulic brake system tank

Mast securing joints - Sideshift unit - Steering

joint - General lubrication with grease nipples

(*) ISO-L-HV FZG tests to stage 11 / ISO-L-HV FZG-Pr fung bis

Stufe 11
(**) Lithium base ASTM 275-305 NLGI Nr.2 Dropping point 180
Lithiumbasis ASTM 275 305 NLGI Nr.2 Tropfpunkt 180
(***) add brake additive to oil bath / Zus tze f r lbad-Bremsen
zuf gen

TYRE PRESSURES TIGHTENING TORQUES

PNEUMATIC TYRE PRESSURES
9,5

bar

FRONT Tyres

10

bar

REAR Tyres

8,25

bar

FRONT - Twin tyres

WHEEL TORQUE
37 daNm

Steered wheels

50 daNm

Driven wheels

DRIVE UNIT TORQUE

11 daNm

securing of electric motor to the reduction

gears

55 daNm

securing of axles to the chassis

31 daNm

wheel hub central screw

11 daNm

reduction gear tank screws

8 daNm

Oil filling and draining cap

VARIOUS TORQUES
40 daNm
0,8 1,2 daNm
40 daNm

mast securing U-bolts

Jack collar self-locking nuts
Counterweight locking screws

Electric

Electric

SERVICE MANUAL

4,0 - 4,5 - 5,0 t

TABLE

page 43

RUNNING IN MAINTENANCE

50

500

# at # hours for MEDIUM/INTENSE USE

7/-

-/3

# at # days/months FOR OCCASIONAL USE

LIFTING UNIT - MASTS

mast guide pads

 

lifting oil filter

TRANSMISSION REDUCTION GEARS

transmission reduction gear oil

POWER STEERING

filter change




b o lt s in g e n e r a l

w h e e l t ig h t n e s s ( 1 )

( 1 ) D u r in g t h e f ir s t 5 0 0 w o r k in g h o u r s , c h e c k
t ig h t n e s s e v e r y 5 0 h o u r s .
LEGENDA

In the maintenance table indicating a visual control

cleaning of the parts indicated.
 and

In the maintenance table indicating the

of the parts indicated.
 replacement
table indicating lubrication
parts indicated.
ofIn thethemaintenance

 or adjustment of the parts indicated.

In the maintenance table indicating tightening

Totaldokument
BT Cargo CBE 40-50 DC
Var 250:e timme
Pos

Kontroll av:

Pos

Kontroll av:

Pos

Kontroll av:

0:0
0:1
0:2
0:3
0:4
0:5
0:6
0:7
0:8
0:9
0:10

3:0
3:1
3:2
3:3
3:4
3:5
3:6
3:7

Grupp 3 Bromsar/hjul
Dck/hjul
Lufttryck dck
Hjulbultar/hjullager
Frdbroms, funktion/lckage
Parkeringsbroms
Bromsvtskeniv
Pedallnkage/pedalspel

4:0
4:1
4:2
4:3

Grupp 4 Styrning
Styrleder/Styrspindlar
Styrcylinder, faststtning
Styrlagring/upphngning

5:9
5:10
5:11
5:12
5:13
5:14
5:15
5:16
5:17
5:18

Acc.pedal/fartreglage
Microbrytare
Kontaktorer/kontakter
Skringar
Batterivtskeniv
Batteri, smuts/lckage
Batterianslutningar
Batteripoler reng./infettning
Batterihandskar, kontroll
Kylflktar, kontroll

0:11

Grupp 0 Hel maskin

Drrar/luckor
Motviktsinfstning
Frarskydd/hytt
Batterilsning
Skyltar/dekaler
Frarmilj
Stol/mattor
Pedalgummin
Torkare/spolare
Provkrning test av
samtliga funktioner
Smrjning enligt schema

1:0
1:1
1:2

Grupp 1 Motorer
Missljud
Faststtning/infstning
Grupp 2 Kraftverfring
Oljeniv
Faststtning

Grupp 5 Elsystem
Belysning/krriktningsvisare
Instrument/kontrollampor
Signalhorn
P-broms-/Backalarm
Timmtare, avlsning
Frdvljare/lnkage
Kablar/anslutningar
Startfrekvens

Grupp 6 Hydraulik
Slangar/rr
Ventilreglage/lnkage
Andningsfilter/ventilatorer
Oljeniv

2:0
2:1
2:2

5:0
5:1
5:2
5:3
5:4
5:5
5:6
5:7
5:8

6:0
6:1
6:2
6:3
6:4
7:0
7:1
7:2
7:3
7:4
7:5

Grupp 7 Arbetsfunktion
Lyftstativ
Gafflar
Lyftkedjor
Laststd
Lyft-/tiltcylindrar

Var 500:e timme tillkommer:

0:0
Grupp 0 Hel maskin
0:12 Bultar/Muttrar, faststtning

Var 1000:e timme tillkommer:

2:0
Grupp 2 Kraftverfring
2:3
Drivaxel, oljebyte

Var 2000:e timme tillkommer:

0:0
Grupp 0 Hel maskin
0:13 Ram, kontroll av sprickor

1:0
1:3
1:4
1:5
1:6
1:7
1:8
1:9

Grupp 1 Motorer
Drivmotor, renblsning
Drivmotorkol, kontroll
Pumpmotorkol, kontroll
Pumpmotor, renblsning
Styrpumpmotorkol, kontroll
Styrpumpmotor, renblsning
Motorer, isolationsprov

3:0
3:8
3:9

Grupp 3 Bromsar/hjul
Hjullager infettning
Bromsvtska byte

1:0
1:10

Grupp 1 Motorer
Kolfjdrar, styrka

6:0
6:5

Grupp 6 Hydraulik
Andningsfilter, reng./byte

4:0
4:4
4:5

Grupp 4 Styrning
Slangar, kontroll
Styrtryck, kontroll

5:0
5:19

Grupp 5 Elsystem
Batteri, isolationsprov

5:0
5:20
5:21

Grupp 5 Elsystem
Batteribelastningsprov
Motorstrm, mtning

6:0
6:6
6:7
6:8

Grupp 6 Hydraulik
Hydraultryck, kontroll
Hydraulolja, byte
Sugfilter, rengring/byte

7:0
7:6

Grupp 7 Arbetsfunktion
Gafflar, gaffeltest

CBE 12-50
Chassie/hel maskin
BT Svenska AB 01/06

Sida 3

SERVICE MANUAL
Electrical section

SERVICE MANUAL

4,0 - 4,5 - 5,0 t

Electric

Electrical section

page 48

TECHNICAL FEATURES

ELECTRONIC PANEL

Trac. Unit

Lifting Unit

H2B

H2P

HPRC

(distributor)

(electrovalves)

Tension

80 V

80 V

80 V

Max. current

1000A

500A

500 A

Operatin frequency

18 KHz

18 KHz

18KHz

Working ambient temperature

-30C / +40C

-30C / +40C

-30C / +40C

85C

85C

Max. attainable temperature

from chopper body
Microprocessor unit logic

ELECTRICAL MOTOR FEATURE

TRACTION MOTOR

POWER STEERING MOTOR

V 80

KW 18

V 80

A 250

SERIE

RPM 1370

RPM 1400

IP 20

SERVICE S3 58%

IS H

SERVICE S2

IS H

POLES N4

BRUSHES N4

POLES N4

BRUSHES N8

LIFTING MOTOR
V 80

KW 17
SERIE

RPM 1800
SERVICE S3 15%

IS H

POLES N4

BRUSHES N8

KW 2

Electric

SERVICE MANUAL

4,0 - 4,5 - 5,0 t

Electrical section

page 49

FUNCTIONAL PERFORMANCES
- Very good control at low speed.
- Diagnostic with indication by means of led.
- Able to be formed via console.
- Internal timer visible from the console.
- Storage of the last 5 alarms with the relative value of the timer and temperature visible from the console.
- Tester by means of the console to verify in real time of the main parameters, such as input, motor voltage, battery.
- Arc less operation of the remote control switches.
- Internal coil suppressor (within logic).
- High efficiency of motor and battery due to high frequency switching.

PROTECTIONS
- Battery reversal:
It is important to observe the connections shown in order to prevent damage.
The logic is internally protected from reverse battery polarity.
- Connection errors:
All inputs are protected against incorrect connections.
The remote control switches have a rating of 3Amps, however they are protected from overload and short
circuits.
- Thermal protection:
When the temperature is more than 80C the maximum current is reduced in proportion to the increase in
temperature. The temperature can never exceed 85 C.
- Discharged battery:
When the battery is discharged the lifting speed is reduced by 60%. The other function remain unchanged.
- External agents:
The chopper is protected from the dust and from the liquids spray is completely sealed.
- Safety from accidental operation:
Starting the machine, requires a precise sequence of operations otherwise the machine will not start. The start
sequence has to be initiated after the key and the micro seat are active.
- Safety from uncontrolled movements:
The remote control switches remain open if:
-

The power is not in use.

The accelerator voltage does not fall below (minimum memorized value 2 volt).
The logic is not in perfect order.
A direction microswitch is ever closed.

4,0 - 4,5 - 5,0 t

page 50

SERVICE MANUAL
Electrical section

Electric

GENERAL PRECAUTIONS
- Do not connect the chopper to a battery with a nominal voltage different to the voltage stated from the one on
the unit plate. If the battery voltage is higher it may cause the MOS failure.
If the battery voltage is lower, the unit will not run .
- During the battery recharging no units must be connected to the battery as, the unit can be
damaged by the overvoltages generated by the charge-battery.
- Supply the unit only with traction battery, do not use rectifier outputs or power supplies.
- With key switched off, the filter capacitors could remain charged for some minutes. To work in safety working
conditions, we suggest you as follows
.

disconnect the battery with the key on and wait till when the display is completely off;
or

. short circuit the capacitors through a resistor (56 Ohm 1W) across B+ and B- chopper power
connections.
- Before carrying out any arc-welding on the trucks, disconnect the battery and short-circuit the unit between
positive (+) and negative (-).

Electric

SERVICE MANUAL

4,0 - 4,5 - 5,0 t

Electrical section

page 51

GENERAL DESCRIPTION OF FUNCTION OF THE CONSOLE

HOUR METER
The hour meter appears in the second line of the display when the chopper is connected. The hour meter has a
sensitivity of one minute and a full scale value of 65,535hours . It shows the hours only.
ALARM DISPLAY
The console features the possibility to read the last five alarm messages stored in the chopper and displayed together
with the time of occurrence, the number of times the alarm was sent and the temperature value at the time of the
alarm.
PARAMETER PROGRAMMING
The chopper parameters can be displayed and programmed via the keyboard, in real time and with operating
machine, thereby making it possible to set the chopper easily.
TESTER
It makes it possible to display the state of the chopper analogue and digital values and thereby to have a useful
tool for the analysis of chopper operation and external cables.
SAVE
It makes it possible to store all values relating to the parameters and the chopper hardware configuration into the
console with a program which can be selected from the keyboard.
RESTORE
It makes it possible to program a chopper with the parameters contained in a program generated by a SAVE.
ACCELERATOR MAX. STROKE PROGRAMMING
It allows to program the accelerator max. stroke.
STEER TABLE
Type and pitch calibration of the truck

CONSOLE CONNECTION
HP - HPRC

Con
nec
tion

The connection has to be made with resting machine.

4,0 - 4,5 - 5,0 t

page 52

SERVICE MANUAL

Electric

Electrical section
CONSOLE DESCRIPTION
KEYBOARD
Description of key functions:

ROLL 1

= Allows selection of an option or the next menu item

ROLL 2

= Allows select of an option or the previous menu item

ENTER

= Allow confirmation of selected options

OUT

= Retains the current function

PARAM

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

SET

= Allows a reduction in the parameters or selects the type of connected I/O

Electric

SERVICE MANUAL

4,0 - 4,5 - 5,0 t

Electrical section

page 53

ELECTRONIC PANEL LAY-OUT

TRACTION
UNIT H3B

LIFTING UNIT
H2P 500 - HPRC

RELAYS FOR THE

ELECTRIC FAN
AND ELECTROVALVES

4,0 - 4,5 - 5,0 t

page 54

SERVICE MANUAL

Electric

Electrical section
CONTACTORS PANEL

LIFTING WEAKENING CONTACTOR SW 180

TRACTION WEAKENING CONTACTOR SW 180

POWER STEERING CONTACTOR SW 180

FORWARD CONTACTOR SW 202

BACKWARD CONTACTOR SW 202

BRAKE CONTACTOR SW 201

Electric

SERVICE MANUAL

4,0 - 4,5 - 5,0 t

Electrical section

page 55

COMPONENTS PANEL
FT
FS
FI
F1
F2
F3
F4
F5
RL1
CONV. 1
CONV. 2

= traction fuse 500 A

= lifting fuse 425 A
= power steering fuse 40 A
= horn fuse 5 A
= key fuse 5 A
= converter fuse for electric fans and electrovalves 5 A
= converter fuse for rear light and horn 20 A
= rear light fuse 5 A
= rear light relay
= converter 80/24 for light
= converter 80/24 for electric fans and electrovalves
CONV. 2

FT

FS

FI

F2
F3
F4

F5

F1

CONV. 1
RL1

SERVICE MANUAL

4,0 - 4,5 - 5,0 t

Electrical section

page 56

CONNECTION ELECTRICAL CIRCUIT

TRACTION UNIT H3D

+T

TFR

TAV

A1

A2

TIN
+ SH
- SH

RIT
TIT
PTFR
PT
NTIT
NTIN
NTFR
NTAV
NTID

5A
KEY
CMM

MFP
MSED
MF
MI
MA

VMN

Electric

Electric

SERVICE MANUAL

4,0 - 4,5 - 5,0 t

Electrical section

page 57

LEGEND

pin connector
CMM

common micro (+VB)

G5

MF

Pedal braking switch (+VB)

F5

M SED

Seat switch (+VB)

F4

MI

Backward switch (+VB)

F6

MA

Forward switch (+VB)

F7

NTFR

Negative brake contactor

C5

PTFR

Positive brake contactor

C1

NTIN

Negative backward contactor

C4

NTIT

Negative weakening contactor

C3

NTAV

Negative forward contactor

C6

PT

Positive contactors

C2

RIT

Traction field weakening resistor

TAV

Forward contactor

TIN

Backward contactor

TFR

Brake contactor

TIT

Weakening contactor

SERVICE MANUAL

4,0 - 4,5 - 5,0 t

Electric

Electrical section

page 58

ACCELERATOR POTENTIOMETER CONFIGURATION

Green

111 :

12 V

109 :
110 :

0 10 V with pedal pressed

0V

111

5KOhm
7KOhm

Red

Yellow

109

)
)

110

Electric

SERVICE MANUAL

4,0 - 4,5 - 5,0 t

Electrical section

page 59

SETTING VALUES
TRACTION MODULE H3D
ACCELER DELAY

Acceleration time, that is the minimum time during

0-9

which motor voltage changes from minimum to maximum.

INVERS BRAKING

Braking basic current to be used when in reverse. A value

0-9

related to the accelerator plus a fixed increase for each

second must be added.
RELEASE BRAKING

Release braking current.

0-9

PEDAL BRAKING

Release braking current with braking pedal pressed.

0-9

BRAKING MODULATION Measures the effect of the accelerator with increase of

0-9

the braking current in reverse. By pressing the accelerator

when in reverse the braking effect will be so sudden as the
higher value of the parameter
CURVE BRAKING

Not used

0-9

CURVE TIME

Not used

0-9

AUXILIARY TIME

Not used

0-9

BACKING TIME

Not used

0-9

CUT BACK SP. 1

Speed reduction with input in (F3).

0-9

CUT BACK SP. 2

Speed reduction with input in (F2).

0-9

CUT BACK SP. 3

Speed reduction with input in (F1).

0-9

COMPENSATION

Speed compensation (motor tension) related to current

0-9

when speed reductions are operating.

WEAK DROPOUT

Current threshold for the opening of the weakening

0-9

remote control switch.

MAXIMUM CURRENT

Fixes the maximum current for the chopper both during

0-9

running and braking. All current levels are expressed in

a percentage of this value.
CREEP SPEED

Fixes the minimum voltage value applied to the motor

0-9

with speed engaged. It makes it possible to obtain a faster

response when starting.
MAX SPEED FORWARD

Max speed in forward direction

MAX SPEED BACKWARD Max speed in backward direction

0-9
0-9

4,0 - 4,5 - 5,0 t

SERVICE MANUAL

Electric

Electrical section

page 60

DESCRIPTION OF THE WARNINGS RELEVANT TO THE

DIAGNOSTIC LED PLACED ON THE DASHBOARD AND
TO THE CONSOLE - TRACTION UNIT H3D
1 FLASH =

2 FLASHES =

Logic defect.(EEPROM DATA KO, EEPROM PAR KO, EEPROM CONF. KO,
EEPROM OFF-LINE, CHOPPER NO CONF,WATCH- DOG) - Replace the
complete unit.
Incorrect sequence by starting. (INCORRECT START) check:
- Microswitch for forward/Backward directions;

- Wiring.
3 FLASHES =

Failure on the VMN test. (VMN LOW, NO FULL COND) check:

- Motor isolation and relevant wirings;
- Direction contactor stuck.
- Unit H3D.
4 FLASHES =
High potentiometer signal at rest (VACC NOT OK) check:
- Traction potentiometer (could be damaged or no more adjusted);
- Traction potentiometer wiring.
5 FLASHES =
Failure on the current test. (I HIGH AT STAND, I= 0 EVER) replace the
unit H2B.
6 FLASHES =
Failure on the contactor pilot circuit. (DRIVER SHORTED, COIL
SHORTED) check:
- Contactors coils and wirings;
- Unit H3D.
7 FLASHES =
The temperature of the unit H3D exceeds 80C (TH.PROTECTION) If
the warning appears in cold conditions, replace unit H3D.
8 FLASHES =
Failure on the contacts or VMN signal high.(BRAKE CONT.OPEN,
DIR CONT OPEN, VMN HIGH) check:
- Direction, brake contactors and relevant tips;
- Motor and relevant wirings;
- Unit H3D.
9 FLASHES =
Contactor stuck (BRAKE CONT. CLOSED, DIR. CONT. CLOSED) check:
- Brake contactor stuck;
- Direction contactor (too slow by opening);
- Unit H3D.
CONTINUOUS FLASHING = Battery discharged.
FIX LED ON =
Double running requests.

Electric

SERVICE MANUAL

4,0 - 4,5 - 5,0 t

Electrical section

page 61

LEGEND

Right hand.

Left hand.

Current.

V ACC

Potentiometer voltage.

VMN

Control signal: >1/3 < 2/3 of battery voltage.

CON - CONT

Contactor.

CON - COND =

Conduction.

DIR

Direction.

4,0 - 4,5 - 5,0 t

SERVICE MANUAL

Electric

Electrical section

page 62

ADJUSTMENT TABLE

H3D Unit - Traction

PARAMETER
ACCELERATION DELAY

UNIT
Sec.

0
1
0.41 0.82

PROGRAMMED LEVEL
2
3
4
5
6
1.2
1.6
2
2.4
2.9

7
3.3

8
3.7

9
4.1

INVERS BRAKING

% IMax.

19

23

28

32

37

41

46

50

55

59

RELEASE BRAKING
PEDAL BRAKING

% IMax.
% IMax.

15
25

19
31

23
37

27
43

31
49

34
56

38
62

42
68

46
74

50
80

BRAKING MODUL
CURVE BRAKING

% IMax.
% IMax.

0
15

3
19

5
23

8
27

11
31

14
34

17
38

20
42

22
46

25
50

CURVE TIME
AUXILIARY TIME

Sec.
Sec.

0
0.1

0.2
0.5

0.3
2

0.4
4

0.6
7

0.8
9

1
12

1.2
14

1.6
17

2
20

BACKING TIME
CUTBACK SP. (1-2-3)

Sec.
% VBatt.

0.05
10

0.2
22

0,35
33

0.5
45

0.75
53

1
61

1.5
69

2
78

2.5
88

cont
100

COMPENSATION
WEAK DROPOUT
MAXIMUM CURRENT

K (I)
% IMax.
Amp.

0.1
10
750

0.2
20
778

0.3
30
806

0.4
40
833

0.5
0.6
0.7
50
60
70
861 889 916

0.8
80
944

CREEP SPEED
MAX SPEED FORW-BACK

% VBatt.
% VBatt.

0
10

1.9
22

3.9
33

5.9
45

7.8
53

9.8
61

0.9
1
90 100
972 1000

11.7 13.7 16.6 17.6

69
78
88 100

Electric

SERVICE MANUAL

4,0 - 4,5 - 5,0 t

Electrical section

page 63

CONNECTION ELECTRICAL CIRCUIT

LIFTING UNIT H2P
lever control valve version

+P
D1P
A1P
+P

A1
A2

K LED

A1P

A LED

B1
B2
B3
B4
B5
B6
B7
B6

CONSOLLE

RIP
D1P
TIP

C1
C2
C3

C POT

D1
D2

CH IN

E1
E2
E3
E4
E5
E6
E7
E8
E9

AB POT

N POT
P POT

CHOUT

3RD S
2ND S
BLOCCO

1ST S
4TH S

REAR
CONNECTOR G

4,0 - 4,5 - 5,0 t

SERVICE MANUAL

Electric

Electrical section

page 64

LEGEND
CONNECTOR

4th S

= 5th lever switch

E7

1st S

= tilting switch

E6

BLOCCO

= lifting speed reducer

E5

2nd S

= sideshift switch

E3

3nd S

= 4th lever speed

E2

AB POT

= lifting switch

E1

+CH OUT

= key outcoming positive (+80 V)

D2

+CH IN

= key incoming positive (+80 V)

D1

P POT

= lifting potentiometer positive (+12 V)

C3

N POT

= lifting potentiometer negative ( 0 V)

C2

C POT

= lifting potentiometer wiper

weakening contactor positve
weakening contactor negative

C1
G1
G3

Electric

SERVICE MANUAL

4,0 - 4,5 - 5,0 t

Electrical section

page 65

LIFTING POTENTIOMETER CONFIGURATION

137

12 V

135

0 10 V (drawing lever for lifting)

136

0V

137

5 KOhm

135
136

4,0 - 4,5 - 5,0 t

SERVICE MANUAL

Electric

Electrical section

page 66

SETTING VALUE
LIFTING UNIT H2P
ACCELER.DELAY

Pump motor acceleration time

0-9

EV. ACCELER DELAY

not used

0-9

DECELER DELAY

Pump motor deceleration time

0-9

EV.DECELER DELAY

not used

0-9

AUXILIARY TIME

not used

0-9

IMAX

Maximum chopper current.

0-9

HYD SPEED COARSE

Coarse power steering speed + 10%

0-9

HYD SPEED FINE

Fine power steering speed + 1%

0-9

HYDRO COMPENS

Compensation in current for power steering request

0-9

CREEP SPEED

Minimal acceleration threshold

0-9

WEAK DROPOUT

Threshold of current for opening the weakening contactor

0-9

HYDRO TIME

Steering power delay time

0-9

1ST SPEED COARSE

Tilting speed, coarse adjustment + 10%

0-9

1ST SPEED FINE

Tilting speed, fine adjustment + 1%

0-9

1ST SPEED COMP.

Compensation of tilting speed.

0-9

2ND SPEED COARSE

Sideshift speed, coarse adjustment + 10%

0-9

2ND SPEED FINE

Sideshift speed, fine adjustment + 1%

0-9

2ND SPEED COMP.

Compensation of sideshift speed

0-9

3RD SPEED COARSE

4th-way speed , coarse adjustment + 10%

0-9

3RD SPEED FINE

4th-way speed, fine adjustment + 1%

0-9

3RD SPEED COMP.

4th-way compensation speed.

0-9

4TH SPEED COARSE

5th-way speed, coarse adjustment + 10%

0-9

4TH SPEED FINE

5th-way speed, fine adjustment + 1%

0-9

4TH SPEED COMP.

5th-way speed compensation

0-9

MIN. VALVE VOLT.

Not used

0-9

MAX. VALVE VOLT.

Not used

0-9

Electric

SERVICE MANUAL

4,0 - 4,5 - 5,0 t

Electrical section

page 67

DESCRIPTION OF THE WARNINGS RELEVANT TO THE

DIAGNOSTIC LED PLACED ON THE DASHBOARD AND
TO THE CONSOLE - LIFTING UNIT H2P
1 FLASH

2 FLASHES =

EEPROM DATA KO, EEPROM PAR. KO, EEPROM CONF.KO,

EEPROM OFF-LINE, CHOPPER NO CONF., WATCH DOG replace complete unit.
INCORRECT START - Incorrect sequence by starting; check:
-Control valve microswitches;

-Wiring.
3 FLASHES =

NO FULL COND, VMNLOW - check:

- Motor isolation and relevant wirings;
- Unit H2P.

4 FLASHES =

VACC NOT OK - check:

- Potentiometer (could be damaged or not more adjusted);
- Potentiometer wiring.

5 FLASHES =

I HIGH, I= 0 EVER - replace the unit H2P.

6 FLASHES =

DRIVER SHORTED, COIL SHORTED - Replace Unit H2P.

- Replace Unit H2P

7 FLASHES =

TH.PROTECTION - The temperature of the unit H2P exceeds 80.+

If the warning appears in cold conditions, replace unit H2P.

CONTINUOUS FLASHING =

Battery discharged.

4,0 - 4,5 - 5,0 t

SERVICE MANUAL

page 68

Electric

Electrical section

ADJUSTMENT TABLE

Lifting H2P Unit

PARAMETER

UNIT

PROGRAMMEDLEVEL
2
3
4
5

ACCELERATION DELAY

Sec.

0.15

0.24 0.39

0.50 0.63 0.74 0.86 0.97 1.09 1.22

EV.ACCELERDELAY

Sec.

0.39

0.63

0.81 0.97 1.05

DECELERDELAY

Sec.

0.06

0.13 0.19

0.25

0.60

0.78 0.95 1.04 1.26

EV.DECELERDELAY

Sec.

0.30

AUXILIARY TIME

Sec.

0.1

0.5

I MAX. (500 A)

Amp.

250

SPEED COARSE (TUTTE)

% VBatt.

SPEED FINE (TUTTE)

COMPENSATION (TUTTE)

0.71
0.70

1.27 1.36 1.46 1.54

0.31 0.38 0.44

278

306

333

361

11

22

33

% VBatt.

1.2

2.4

K (I)

10

20

30

CREEPSPEED

% VBatt.

1.9

WEAK DROPOUT

% IMax.

10

20

HYDRO TIME

Sec.

0.5

MIN VALVE VOLT

% VBatt.

7.4

11.3

15.2

MAX VALVE VOLT

% VBatt.

56

60

64.5

70

0.50 0.56 0.62

1.36

1.43 1.53

12

14

17

20

388

416

444

472

500

44

55

66

77

88

100

3.6

4.8

6.05

7.3

8.5

9.7

10.9

40

50

60

70

80

90

100

3.9

5.9

7.8

9.8

11.7

13.7

16.6

17.6

30

40

50

60

70

80

90

100

12

14

17

20

19.2

23.1 27.0

31

35

39

43

74

83.5

92.5

97.5

78.5

88

Electric

SERVICE MANUAL

4,0 - 4,5 - 5,0 t

Electrical section

page 69

POWER CIRCUIT CONNECTION

LIFTING UNIT HPRC
electrovalve version (fingertips-joystick)

Diagnostic led and console connector

+P

A1P

D1P

+P

A1P

RIP
D1P
TIP

SERVICE MANUAL

4,0 - 4,5 - 5,0 t

Electric

Electrical section

page 70

ELECTRICAL DIAGRAM
INPUT SIGNAL
LIFTING UNIT HPRC
Fingertips version

HPRC UNIT

+ CH
I

FINGERTIPS

- VB
+ 5V
SIDESHIFT
TILTING
LIFTING
4th WAY

L
BLOCCO
+ TIP (G1)
+ MSED
P1
P2
P3
P4
+ TIP
MSED
BLOCCO
+CH

=
=
=
=
=
=
=
=

TILTING POTENTIOMETER
+ 24V
LIFTING POTENTIOMETER
SIDESHIFT POTENTIOMETER
4TH WAY POTENTIOMETER
WEAKENING CONTACTOR POSITIVE
SEAT MICROSWITCH
LIFTING SPEED REDUCTION
KEY POSITIVE

Electric

SERVICE MANUAL

4,0 - 4,5 - 5,0 t

Electrical section

page 71

ELECTRICAL DIAGRAM
INPUT SIGNAL
LIFTING UNIT HPRC
Joystick version

HPRC UNIT

+ CH
I
JOYSTICK
- VB
+ 5V

TILTING
LIFTING

TR. DX
MAN. SIM.
TR. SX

+ CH

L
BLOCCO
+ TIP (G1)
+ MSED
P1
P2
PB1
PB2
+ TIP
MSED
BLOCCO
+CH

=
=
=
=
=
=
=
=

+ 24V

TILTING POTENTIOMETER
LIFTING POTENTIOMETER
RIGHT SIDESHIFT PUSH BUTTON
LEFT SIDESHIFT PUSH BUTTON
WEAKENING CONTACTOR POSITIVE
SEAT MICROSWITCH
LIFTING SPEED REDUCTION
KEY POSITIVE

4,0 - 4,5 - 5,0 t

SERVICE MANUAL

Electric

Electrical section

page 72

LIFTING UNIT HPRC

Rear view unit HPRC
CONNECTOR G

OUTPUT ELECTROVALVES CONNECTION

HPRC
UNIT

+ 24 V

TIP (G3)
EV 1
EVP
EV3
EV4
EV5
EV6
EV7
EV8
- TIP

FORK LIFTING ELECTROVALVE

FORK LOWERING ELECTROVALVE
FORWARD TILTING ELECTROVALVE
BACKWARD TILTING ELECTROVALVE
LEFT SIDESHIFT ELECTROVALVE
RIGHT SIDESHIFT ELECTROVALVE
4th WAY ELECTROVALVE
4th WAY ELECTROVALVE
WEAKENING CONTACTOR NEGATIVE (CONNECTOR G3)

Electric

SERVICE MANUAL

4,0 - 4,5 - 5,0 t

Electrical section

page 73

FUNCTION DESCRIPTION OF ELECROVALVES

AND HPRC UNIT
The electrovalves group is consisted of:
LIFTING:

N1 double electrovalve 24 V
-one ON/OFF for lifting
-one proportional for lowering

TILTING:

N2 electrovalves 24 V ON/OFF

SIDESHIFT:

N2 electrovalves 24 V ON/OFF

Operation
Lifting:

operating the potentiometer P2 (backward movement) the unit logic will

open the electrovalve ON/OFF (EV1) and the lifting speed changes
according to the motor R.P.M.

Lowering:

operating the potentiometer P2 (forward movement) the unit logic will

open the proportional electrovalve (EVP) and the lowering speed
changes according to the proportional valve opening.

Tilting:

operating the potentiometer P1 the unit logic will open one of the two
electrovalves ON/OFF (EV3 - EV4) and the tilting speed changes
according to the motor R.P.M.

Sideshift:

operating the potentiometer P3 the unit logic will open one of the two
electrovalves ON/OFF (EV5 - EV6) and the sideshift speed changes
according to the motor R.P.M.

HPRC MODULE CONFIGURATION

Before setting up the new logic unit, it is necessary to configurate the version (fingertips or
joystick) and the potentiometers stroke (see diagram).

4,0 - 4,5 - 5,0 t

page 74

SERVICE MANUAL

Electric

Electrical section
SETTING VALUE
LIFTING UNIT HPRC

PU ACCELER.DEL.

Pump motor acceleration delay

0-9

PU DECELER DEL.

Pump motor deceleration delay

0-9

PUMP I MAX

Maximum chopper current

0-9

MAX SPEED FORW.

Max lifting speed

0-9

MAX SPEED BACK.

Max lowering speed

0-9

DOWN CREEP

Min. tension on the proportional electrovalve (lowering)

0-9

MIN SPEED UP

Min. lifting speed

0-9

2ND SPEED COARSE Tilting speed, coarse adjustment + 10%

0-9

2ND SPEED FINE

0-9

Tilting speed, fine adjustment + 1%

3RD SPEED COARSE Sideshift speed , coarse adjustment + 10%

0-9

3RD SPEED FINE

Sideshift speed, fine adjustment + 1%

0-9

4TH SPEED COARSE

4th-way speed, coarse adjustment + 10%

0-9

4TH SPEED FINE

5th-way speed, fine adjustment + 1%

0-9

1ST SPEED COMP.

Compensation of lifting speed

0-9

2ND SPEED COMP.

Compensation of tilting speed

0-9

3RD SPEED COMP.

Sideshift compensation speed.

0-9

4TH SPEED COMP.

4th-way speed compensation

0-9

CREEP SPEED

Minimal acceleration threshold for tilting, sideshift, 4th way

0-9

BY-PASS DROPOUT

Threshold of current for opening the weakening contactor

0-9

EV.ACCELER.DEL.

Proportional electrovalve acceleration delay

0-9

EV.DECELER.DEL.

Proportional electrovalve deceleration delay

0-9

Electric

SERVICE MANUAL

4,0 - 4,5 - 5,0 t

Electrical section

page 75

DESCRIPTION OF THE WARNINGS RELEVANT TO THE

DIAGNOSTIC LED PLACED ON THE DASHBOARD AND
TO THE CONSOLE - LIFTING UNIT HPRC
1 FLASH

EEPROM KO, MICRO ST

replace complete unit.

2 FLASHES =

INCORRECT START
Incorrect sequence by starting.
Correct sequence: micro seat,key,parking brake micro, hydraulic
function

3 FLASHES =

V JOY 1-2-3-4 NOT OK

The max value of the potentiometer is bigger than the stored value on
the module
- Carry out the procedure for potentiometer data acquisition on the
unit
- Change the unit

4 FLASHES =

Available for future alarms

5 FLASHES =

PUMP I=0 EVER - STBY I HIGH

- Change the unit
POS. EV NOT OK- No positive signal to electrovalves, check:
- Converter 24V (conv. 2)
- Change the unit

6 FLASHES =

DRIVER 1 KO, DRIVER 2 KO

Shortcircuit on the electrovalves circuit
DRIVE 1 KO- Lifting electrovalve (EV1 - EVP)
DRIVE 2 KO- Electrovalves for: tilting, sideshift, 4th way, 5 way
(EV 3-4-5-6-7-8).de Check:
-the electrovalves and relevant wiring
-change the unit

7 FLASHES =

PUMP TEMPERATURE - The temperature of the unit HPRC

exceeds 75.
If the warning appears in cold conditions, replace unit HPRC.

8 FLASHES =

PROG. JOY 1-2-3-4 NOT OK.

Min and max potentiometer signal are inverted.
- Carry out the procedure for potentiometer data acquisition on the
unit
- Change the unit

SERVICE MANUAL

4,0 - 4,5 - 5,0 t

Electrical section

page 76

ALARMS NO SHOWN ON THE CONSOLE AND ON THE

DIAGNOSTIC LED
DEFECT :

when you connect the battery, the lifting motor starts at max speed and the
functions do not work

CAUSE

shortcircuit of the power circuit on the unit HPRC

LEGEND
I
V

=
=

Current
Voltage

Electric

Electric

SERVICE MANUAL

4,0 - 4,5 - 5,0 t

Electrical section

page 77

ADJUSTMENT TABLE

PU. ACCELERATION DELAY

PARAMETER

ms

UNIT

127

236

384

512

PU. DECELER DELAY

ms

32

64

96

PUMP MAX

50

55

MAX SPEED FORW

%VBatt.

15

MAX SPEED BACK

%VBatt.

50

54

58

63

68

73

79

CREEP DOWN

% VBatt.

16

20

24

29

36

40

45

MIN SPEED UP

% VBatt.

11

15

18

20

2ND SPEED COARSE

%VBatt.

18

27

36

46

55

65

2ND SPEED FINE

% VBatt.

0,7

1,5

3RD SPEED COARSE

% VBatt.

18

27

36

46

55

65

74

84

93

3ND SPEED FINE

%VBatt.

0,7

1,5

4TH SPEED COARSE

%VBatt.

18

27

36

46

55

65

74

84

93

4TH SPEED FINE

%VBatt.

0,7

1,5

HYD SPEED COARSE

% VBatt.

18

27

36

46

55

65

74

84

93

HYD SPEED FINE

% VBatt.

0,7

1,5

1ST SPEED COMP

K (I)

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0,9

2ND SPEED COMP

K (I)

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0,9

3RD SPEED COMP

K (I)

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0,9

4TH SPEED COMP

K (I)

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0,9

HYD SPEED COMP

K (I)

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0,9

HYD TIME

sec.

0,5

12

14

17

20

CREEPSPEED

% Batt.

11

15

18

20

24

27

30

BYPASS DROPOUT

% IMax.

39

45

51

57

62

70

78

84

93

98

EV. ACCELER. DEL.

ms

128

256

384

512

640

768

896

1024

1152 1280

EV.DECELER.DEL.

ms

128

256

384

512

640

768

896

1024

1152 1280

23

640

768

896

1024

128

160

192

224

256

288

320

61

67

72

77

83

89

94

100

31

37

46

58

70

82

93

100

85

92

100

53

61

70

24

27

30

74

84

93

1152 1280

Cargo Range
CESAB S.p.A
via Persicetana Vecchia, 10 40132 Bologna - Italy
Tel.
(0039) 051.20 54 11
Fax
(0039) 051.72 80 07
E-mail: cesab@cesab.it

Code 036 2007-0

GB

Issue 06/1999

CONSOLE MAP

CBE 4,0 - 4,5 - 5,0

CONFIGURATION LIFTING MODULE HPRC

VERSION FOR JOYSTICK OR FINGERTIPS
-Connect the console to the module HPRC
-Turn the key on
Manufacturer's
Console display

CESAB
CONSOLE V.1.0

Type and program version

of the module

Console program
version

CONNECTED TO:
HPRC CESAB V.1.11

Connection moment between

console and HPRC

HPRC CESAB V.1.11

80V 500A 00000

Tension/power and hour meter value

PRESS SIMULTANEOUSLY

ROLL
Press
OUT

PARAM

WILL BE DISPLAYED
CONFIG. MENU
SET MODEL
Press
ROLL

CONFIG. MENU
SET OPTIONS

Press ENTER
to confirm
or OUT

Press ENTER
to select the menu of
the OPTIONS

ARE YOU SURE?

YES=ENTER NO=OUT

HOUR COUNTER
RUNNING
Press
ROLL

BATTERY CHECK
OFF

Press
ROLL
Press OUT

AUX. FUNCTION
ANALOG.
Press

PARAM

SET
to modify the configuration
ANALOG.= FINGERTIPS
MICROSWITCHES = JOYSTICK

JUNE 1999

CBE 4,0 - 4,5 - 5,0

HPRC LIFTING MODULE

DATA ACQUISITION OF POTENTIOMETERS OF FINGERTIPS

-Connect the console to the module HPRC and turn the key on
Display Consolle

CESAB
CONSOLE V.1.0

Manufacturer's name
Console program version
Connection moment between
console and HPRC

CONNECTED TO:
HPRC CESAB V.1.13

Repeat the acquisition operation for each lever

both forward and backward

HPRC CESAB V.1.13

80V 500A 00000

ROLL

MINIMUN
DOWN -0,4V
(forward)

Tension/power and hour meter value

MINIMUN
+0,4V
UP
(backward)

MAXIMUN
DOWN

PRESS SIMULTANEOUSLY

LEVER AT REST

Type and program version of module

PARAM

MAXIMUN
UP

WILL BE DISPLAYED
CONFIG. MENU
SET MODEL
Press
ROLL

CONFIG. MENU
SET OPTIONS
Press
ROLL

Min. value
1st potentiometer
forw. movement

CONFIG. MENU
ADJUSTMENT

MINIMUM DOWN 1
2,3 V

Press ENTER to select

the menu of the
ACQUISITIONS

Press
OUT

Value at rest;
it must be between 2,3V
and 2,7V; if not, set
mechanicaly

Press
ROLL

Press ENTER to
confirm or OUT

Press OUT
keeping the pressed lever

ARE YOU SURE?

YES=ENTER NO=OUT

Press ENTER to
confirm or OUT

= lifting
= tilting
= sideshift
= 4th way

MAXIMUM DOWN 1
0,5 V
Press
Enter

Voltage value stored

of the 1st
potentiometer

MAXIMUM DOWN 1
Press "forward"the 1st lever till
when you obtain a value less than
2,5 V
0,4 V from that one at rest
Value at rest

MINIMUM DOWN 1
2,1 V

1 pot./lever
2 pot./lever
3 pot./lever
4 pot./lever

Press Enter

MINIMUM DOWN 1
2,5 V

Max. value 1st

potentiometer
forw. movement

Voltage value stored

of the 1st
potentiometer

Press "forward"
the1st lever until the
mechanic end stroke

MAXIMUM DOWN 1
0,4 V

Press OUT
keeping the
pressed lever

ARE YOU SURE?

YES=ENTER NO=OUT

(Are you sure? Yes - No)

JUNE 1999

DIAGRAM FOR USING THE CONSOLE FOR UNIT H3D

Manufacturer's name
CBE 4,0 - 5,0
CESAB
Console program version
CONSOLE V.1.0
Display Console
TRACTION

Press ROLL
to change the
parameters

Press ENTER to select the

function of electrical device
control

Press
ROLL

Press
OUT

Press ENTER to select the function to

acquire on the console all the setting/
configuration parameters of the
module

MAIN MENU
SAVE PARAM.

SELECT. Mod.00
FREE / H3 REGENER
Confirm ENTER

READING...

0-9

>/<
Volt
600
Volt
C (-20100)
010 V
OFF-GND/ON
OFF-GND/ON
OFF-GND/ON
OFF-GND/ON
OFF-GND/ON

Press
OUT

+VB
+VB
+VB
+VB
+VB

Select the requested program from 1 to 31 where you

save the setting values by using ROLL

Program number
Program version stored

YES=ENTER

NO=OUT

Press ENTER

READING...

RUN ALL PARAMETERS

Use
PARAM
SET

to c hange
the values

0-9
0-9
0-9
0-9
0-9
0-9
0-9

OVERWRITE DATA?

Press
OUT

RUN ALL PARAMETERS

0-9

Press
ROLL

0-9
0-9
0-9
0-9

VMN 50%
Signal check
MOTOR VOLTAGE
Voltage to motor
MOTOR CURRENT
Current used by motor
BATTERY VOLTAGE Battery voltage
TEMPERATURE
Module temperature
ACCELERATOR
Check potentiometer stroke
FORWARD SWITCH
Check forward microswitch
BACKWARD SWITCH Check backward microswitch
CUT BACK SWITCH 1-2-3Check slow speed microswitches
BRAKE SWITCH
Check brake pedal microswitch
HANDLE/SEAT SW
Check seat microswitch

Press
ROLL

MAIN MENU
TESTER

Acceleration time
Current braking by inverting
Current braking by releasing
Current braking with pressed brake pedal
Current braking increase by inverting
with pressed accelerator pedal
CURVE BRAKING
Not used
CURVE TIME
Not used
AUXILIARY TIME
Time of auxiliary contactor
BACKING TIME
Not used
CUT BACK SP.1-2-3
Speed reduction with input on
COMPENSATION
Speed reduction compensation
WEAK DROPOUT
Threshold of the weakening output current
MAXIMUM CURRENT Maximum chopper current
CREEP SPEED
Minimum acceleration threshold
MAX SPEED FORW
Max. speed in forward direction
MAX SPEED BACK
Max. speed in backward direction

values

ACCELER. DELAY
INVERS. BRAKING
RELEASE BRAKING
PEDAL BRAKING
BRAKIG MODUL

MAIN MENU

PARAMETER CHANGE
Press ENTER to select setting
Press
ROLL
to change
the functions

main menu

Tension/power and
hour meter value

Press OUT to
return to the

YES=ENTER NO=OUT

ARE YOU SURE?

Connection moment
between console and H3D

H3 REGENER V.2.2
80V 1000A 00000

Press ENTER to select

the main menu

Description which appearsonly when

some values are modified

CONNECTED TO:
H3 REGENER V.2.2

Model/configuration and
program versionof the unit

1-CONNECT THE CONSOLE TO MODULE H3D

2-TURN THE KEY ON

Press ENTER to select the function to

RESTORE the parameters on the
module saved on the console by a
SAVE function

If NO press OUT

ARE YOU SURE?

Select the requested program from 1 to 31 where you save

the setting values by using ROLL
If YES press
ENTER

YES=ENTER NO=OUT

HOUR METER
N ALARMS
TEMPERATURE

NONE
00000h #00 0C

No alarms
stored

( PRESS OUT )

OUT

MAIN MENU
STEER TABLE

Function not
used

CLEAR LOGBOOK

YES=ENTER NO=OUT

ENTER

ARE YOU SURE?

Press ENTER if you want

to modify this value

VACC SETTINGS
0.0
10.0

Press OUT

MIN
0.0

Max. Value

YES=ENTER NO=OUT

Press OUT

ENTER

YES=ENTER NO=OUT

OUT

ARE YOU SURE?

If NO press OUT

Press OUT

Min. Value

If YES press ENTER

RUN ALL PARAMETERS

Press ENTER to select the

function to acquire the
potentiometer signals

MAIN MENU
PROGRAM VACC

Press
ROLL

STORING...

MAX 5 alarms stored

LOGBOOK CLEARED

OUT
OUT

INCORRECT START
23h 2 25 C

Press ENTER to select

the function to read the
stored alarms

Press
ROLL

Alarm code

Program number
Program version stored

MAIN MENU
ALARM

SELECT: Mod.00
H2 REGENER

Confirm with
ENTER

Press
ROLL

MAIN MENU
RESTORE PARAM.

VACC
--

MAX
0.0

Press the acceleration

pedal slowly until the
max. stroke

MIN
0.0

MAX
10.0

PED.FORW
PED.BACK

JUNE 1999

DIAGRAM FOR USING CONSOLE FOR UNIT HP 500

CBE 4,0 - 5,0
CESAB
Console program
CONSOLE
V1.0
Console display
LIFTING
version

Connection moment
between console and HP

CESAB
PUMP STD

Module program version

V.1.6
35

Press
ROLL

to change
the functions

Press ROLL
to change the
parameters

SELECT MENU
2 TESTER
Press
ROLL

Press ENTER to select the

functions of electrical device
control

SELECT MENU
3 SAVE

of all setting parameters of the

module B1

SELECT MENU
4 RESTORE

Confirm with
ENTER

If NO press OUT

function to RESTORE the

parameters on the module B1
saved on the console by a SAVE

Hour meter at the

moment of the alarm

INCORRECT START
23H
2
25 C

Number of times the

alarm appeared

No alarms
stored

Presence of alarms
stored MAX 5
ROLL

Temperature at the
moment of the alarm

Press OUT
Max. value

MIN.
0.01

ACCEL.

MIN.
4.99

MAX
4.99

Press ENTER if you want to modify this value

ACCEL.

MAX
0.01

Press ENTER

If NO press OUT

Press OUT

Alarm code

Press ENTER to select

the function to acquire the
potentiometer signals

ALARM NULL

WAIT!

If YES press ENTER

Press OUT

SELECT MENU
6 PROGRAM VACC

Select the requested program

from 1 to 10 where you save the

setting values by using ROLL

Min. value

Press
ROLL

Press ENTER to select the

function to read the stored
alarms

ARE YOU SURE?

SELECT MENU
5 ALARM

SELECT PROGRAM
PROGRAM 1 10

If NO press OUT

Confirm with
ENTER

WAIT!

If YES
press ENTER

Press ENTER to select the

Press
ROLL

Press
OUT

ARE YOU SURE?

Press
P ARAM

SET
to change
the values

Select the requested program from

1 to 10 where you save the setting
values by using ROLL

SELECT PROGRAM
PROGRAM 1 10

Press ENTER to select the acquisition

function on the console

Check signal for leakage towards -VB

>/<
Check signal for leakage towards +VB
>/<
Check of the input signals lifting/
lifting block
/ VB
ACCELER
Check potentiometer stroke
mV 5000
500A
CURRENT
Current used by the motor
TEMPERATURE
Module temperature
C (-20 100)
SPEED
(connector E 6-3-2-check of the input signals
tilting - sideshift - 4th way
/ VB
4TH SPEED E7 - HYDRO E4 Check of the input signals5th way - power steering / VB
BATTERY
Battery voltage
Volt & nominal
MOTOR VOLTAGE
Voltage to motor
Volt

Press
ROLL

0-9
0-9
0-9
0-9
0-9
0-9
0-9
0-9
0-9
0-9
0-9
0-9
0-9
0-9
0-9
0-9
0-9
0-9
0-9
0-9
0-9
0-9
0-9
0-9
0-9
0-9

VMN 30%
VMN 80%
DIRECTION E1 - E5

Press
OUT

Pump motor acceleration time

Not used
Pump motor deceleration time
Not used
Not used
Maximum chopper current
Not used
Not used
Not used
Minimum acceleration threshold
Threshold of the weakening output current
Power steering delay time
Tilting speed, coarse adjustment = 10%)
Tilting speed, fine adjustment = 1%)
Tilting speed compensation
Sideshift speed, coarse adjustment = 10%)
Sideshift speed, fine adjustment = 1%)
Sideshift speed compensation
4th way speed,coarse adjustment = 10%)
4th way speed, fine adjustment = 1%)
4th way speed compensation
5th way speed, coarse adjustment = 10%)
5th way speed, fine adjustment= 1%)
5th way speed compensation
Not used
Not used

Press
ROLL

Press ENTER to select the

setting parameters

ACCELER. DELAY
EV. ACCELER. DEL.
DECELER. DELAY
EV. DECELER. DEL.
AUXILIARY TIME
IMAX
HYD SPEED COARSE
HYD SPEED FINE
HYDRO COMPENS.
CREEP SPEED
WEAK DROPOUT
HYDRO TIME
IST. SPEED COARSE
IST. SPEED FINE
IST. SPEED COMP.
2ND. SPEED COARSE
2ND. SPEED FINE
2ND. COMP.
3RD. SPEED COARSE
3RD. SPEED FINE
3RD. COMP.
4TH. SPEED COARSE
4TH. SPEED FINE
4TH. COMP.
MIN. VALVE VOLT.
MAX VALVE VOLT

Press ENTER to select the main

menu

SELECT MENU
1 PROGRAM

Press OUT to
return to the
main menu

Hour meter value

Manufacturer's name
Chopper configuration

HP

DO YOU WANT
TO SAVE DATA?

Press ENTER to
confirm the values

Model name

Description that appears only when

some values are modified

ARE YOU SURE?

Slowly pull the lifting lever until

the max. stroke
If YES press ENTER

WAIT CONNECT:
B1 H2P HP CESAB

1-CONNECT THE CONSOLE TO THE MODULE HP500

2-TURN THE KEY ON

JUNE 1999

DIAGRAM FOR USING CONSOLE FOR UNIT HPRC

Manufacturer's name
CESAB
CBE 4,0 - 5,0
Console program version
CONSOLE V.1.0
Console display

LIFTING
HPRC CESAB V.1.13
80V
500A 00000

Tension/power and
hour meter value

Description that appears only when

some values are modified

ARE YOU SURE?

Press
ROLL

Press ENTER to select

setting values

to change the
functions

Press ROLL
to change the
parameters

Press ENTER to select the

function of electrical device
control

Press
OUT

Press
ROLL

MAIN MENU
TESTER

Press
ROLL

MAIN MENU
SAVE PARAM.

Press
ROLL

Press ENTER to select the function to

RESTORE the parameters on the module B1
saved on the console by a SAVE

Press
ROLL

Function not
used

OUT

OUT

SELECT: Mod.00
HPRC CESAB V

HOUR METER
N ALARMS
TEMPERATURE

NONE
00000h #00 0C

Press ENTER

Number program
Program version stored

Select the requested program from 1 to 31

where you the setting values by using ROLL

STORING...

If YES press ENTER

RUN ALL PARAMETERS

POS. EV. NOT OK

23h 2 25 C

OUT
OUT

CLEAR LOGBOOK

YES=ENTER NO=OUT

MAX 5 alarms stored

LOGBOOK CLEARED
( PRESS OUT )

ENTER

ARE YOU SURE?

OUT

ENTER

YES=ENTER NO=OUT

No alarms
stored

MAIN MENU
PROGRAM VACC

Press ENTER to select

the function to read
the stored alarms

Press
ROLL

NO=OUT

Alarm code

MAIN MENU
ALARM

READING...

(Are you sure? Yes - No)

C
0 100%

OVERWRITE DATA?

NO DATA FOR THIS

CHOPPER! (OUT)

YES=ENTER NO=OUT

Press
OUT

RUN ALL PARAMETERS

ARE YOU SURE?

If NO press OUT

Program number
Program version stored

YES=ENTER

Confirm with
ENTER

Press
PARAM
SET

to change
the values

0 - 100%
Amper
0 - 100%
0 24V
Volt
0 5V
0 5V
0 5V
0 5V
OFF-GND/ON +VB
OFF-GND/ON +VB
OFF-GND/ON +VB

Select the requested program from 1 to 31

where you savethe setting values using
ROLL

MAIN MENU
RESTORE PARAM.

Press
OUT

RUN ALL PARAMETERS

Confirm with
ENTER

Pump motor speed percentage

Pump motor current
Proportional electrovalve speed percentage
Proportional electrovalve voltage
Battery voltage
Lifting potentiometer voltage
Tilting potentiometer voltage
Sideshift potentiometer voltage
4th way potentiometer voltage
Seat microswitch
Sideshift microswitch, left hand movement
Sideshift microswitch,right hand movement
Function not used
Function not used
Temeperature inside the module
Battery charge percentage

SELECT. Mod.00
FREE / B1 CESAB

READING...

Press
ROLL

0-9
0-9
0-9
0-9
0-9
0-9
0-9
0-9
0-9
0-9
0-9
0-9
0-9
0-9
0-9
0-9
0-9
0-9
0-9
0-9
0-9

PUMP VOLTAGE
MOTOR CURRENT
PROP 1 SET POINT
PROP. EV. VOLTAGE
BATTERY VOLTAGE
ANALOG INPUT #1
ANALOG INPUT #2
ANALOG INPUT #3
ANALOG INPUT #4
DEAD MAN SWITCH
TRASL.LEFT SW.
TRASL. RIGHT SW.
OPTION 1 SW
OPTION 2 SW
TEMPERATURE
BATTERY CHARGE

Press ENTER to select the function to

SAVE the configuration and parameter
values of the module on the Console

Pump motor acceleration delay

Pump motor deceleration delay
Pump maximum current
Maximum upstroke speed
Maximum downstroke speed
Min. voltage on the proportional electrovalve
Min. upstroke speed
Tilting speed coarse adjustment
Tilting speed fine adjustment
Sideshift speed coarse adjustment
Sideshift speed fine adjustment
4th way speed coarse adjustment
4th way speed fine adjustment
Lifting speed compensation
Tilting speed compensation
Sideshift speed compensation
4th way speed compensation
Minimum pump voltage
Current BY PASS contactor opening
Proportional electrovalve acceleration delay
Proportional electrovalve deceleration delay

MAIN MENU
PARAMETER CHANGE

Press OUT to return

to the main menu

PU ACCELER. DEL.
PU DECELER DEL.
PUMP I MAX
MAX SPEED FORW.
MAX SPEED BACK.
DOWN CREEP
MIN SPEED UP
2ND SPEED COARSE
2ND SPEED FINE
3RD SPEED COARSE
3RD SPEED FINE
4TH SPEED COARSE
4TH SPEED FINE
1ST SPEED COMP
2ND SPEED COMP
3RD SPEED COMP
4TH SPEED COMP
CREEP SPEED
BY PASS DROPOUT
EV. ACCELER. DEL.
EV. DECELER. DEL.

YES=ENTER NO=OUT

Press ENTER to
select the main
menu

Connection moment
between console and HPRC

CONNECTED TO:
HPRC CESAB V.1.13

Type and program version

of the module

1-DISCONNECT CONNECTOR "B" FROM MODULE HPRC

2-CONNECT THE CONSOLE INTO THE CONNECTOR "B"
3-TURN THE KEY ON

MAIN MENU
STEER TABLE

Function not
used

JUNE 1999

PARAMETER

CBE 4,0 - 5,0

SETTING VALUE
UNIT H3D -TRACTIONPARAMETER
ACCELER. DELAY
INVERS. BRAKING
RELEASE BRAKING
PEDAL BRAKING
BRAKING MODUL
CURVE BRAKING
CURVE TIME
AUXILIARY TIME
BACKING TIME
CUT BACK SP.1

DESCRIPTION

VALUE

Acceleration time
Braking current on inversion
Braking current by releasing the accelerator
Braking current with pressed braking pedal
Increase of braking current on inversion with
pressed accelerator

Not used
Not used
Power steering delay
Not used
First speed reduction with input on

5
5
5
5
9

CUT BACK SP.2

Speed reduction with pressed braking pedal
CUT BACK SP.3
Third speed reduction with input on
COMPENSATION
Speed reduction compensation
WEAK DROPOUT
Current threshold for weakening opening
MAXIMUM CURRENTMaximum current of chopper
CREEP SPEED
Minimum threshold of acceleration
MAX SPEED FORW Max. speed in forward direction
MAX SPEED BACK Max speed in backward direction

7
2
5
6

0
9
5
6
1
2
9
9

NOVEMBER 2000

CBE 4,0 - 5,0

SETTING VALUE
UNIT HP500 - LIFTING(LEVER CONTROL VERSION)
PARAMETER
ACCELER. DELAY

DESCRIPTION
Motor pump acceleration time

VALUE
8

EV. ACCELER DELAY Not used

DECELER DELAY

Motor pump deceleration time

EV.DECELER DELAY

Not used

AUXILIARY TIME

Not used

I MAX

Max. chopper current

HYD SPEED COARSENot used

HYD SPEED FINE

Not used

HYD SPEED COMP

Not used

CREEP SPEED

Min. acceleration threshold

WEAK DROPOUT

Current threshold for weakening opening

HYDRO TIME

Not used

1ST SPEED COARSE

Tilting speed, coarse adjustment + 10%

1ST SPEED FINE

Tilting speed, fine adjustement + 1%

1ST SPEED COMP

Tilting speed compensation

2ND SPEED COARSE

Sideshift speed, coarse adjustment + 10%

2ND SPEED FINE

Sideshift speed, fine adjustment + 1%

2ND SPEED COMP

Sideshift speed compensation

3RD SPEED COARSE

4th way speed, coarse adjustment + 10%

3RD SPEED FINE

4th way speed, fine adjustment + 1%

3RD SPEED COMP

4th way speed compensation

4TH SPEED COARSE

5th way speed, coarse adjustment + 10%

4TH SPEED FINE

5th way speed, fine adjustment + 1%

4TH SPEED COMP

5th way speed compensation

MIN. VALVE VOLT

Not used

MAX VALVE VOLT

Not used

NOVEMBER 2000

CBE 4,0 - 5,0

SETTING VALUE
UNIT HPRC - LIFTING(FINGERTIPS AND JOYSTICK VERSION)
PARAMETER

DESCRIPTION

VALUE

PU ACCELER. DELAY Motor pump acceleration time

PU DECELER. DELAY Motor pump deceleration time

PUMP I MAX

Max. chopper current

MAX SPEED FORW.

Max. upstroke speed

MAX SPEED BACK.

Max. downstroke speed

DOWN CREEP

Min. voltage on the proportional electrovalve

MIN SPEED UP

Min. upstroke speed

2ND SPEED COARSE

Tilting speed, coarse adjustment + 10%

2ND SPEED FINE

Tilting speed, fine adjustment + 1%

3RD SPEED COARSE

Sideshift speed, coarse adjustment + 10%

3RD SPEED FINE

Sideshift speed, fine adjustment + 1%

4TH SPEED COARSE

4th way speed, coarse adjustment + 10%

4TH SPEED FINE

4th way speed, fine adjustment + 1%

HYD SPEED COARSE Not used

HYD SPEED FINE

Not used

1ST SPEED COMP

Lifting speed compensation

2ND SPEED COMP

Tilting speed compensation

3RD SPEED COMP

Sideshift speed compensation

4TH SPEED COMP

4th way speed compensation

HYD SPEED COMP

Not used

HYD TIME

Not used

CREEP SPEED

Min. acceleration threshold

BY PASS DROPOUT

Current threshold for weakening opening

EV. ACCELER DELAY Proportional electrovalve acceleration time

EV. DECELER DELAY Proportional electrovalve deceleration time

NOVEMBER 2000

CBE 4,0-5,0 - HPRC500

LEGEND
DESCRIPTION

ENGLISH

DEUTSCH

FRANCAIS

ESPAOL

4' via
5' via
abilitazione attiva
abilitazione freni
abilitazione parcheggio
acceleratore
alternatore
anomalia centralina
attuatore
arresto motore
batteria
bobina
brandeggio
candele
candelette
chiave
chiave avviamento
clacson
comandi luci supplem.
comando elettroventola
comando fanali stop
conn.batteria
cruscotto
dispositivo candelette
elettrovalvole marcia
elettroventola
emergenza
fanali retromarcia
fanali stop
freno
freno pedale
freno stazionamento
indicatore riserva gas

4th valve
5th valve
enable on
brakes enable
parking enable
accelerator pedal
alternator
logic unit defect
actuator
motor stop
battery
coil
tilting
spark plugs
glow plugs
key
start key
horn
additional lights controls
electric fan control
stop lights control
battery connector
dashboard
glow plugs device
speed electrovalves
electric fan
emergency
reversing lights
stop lights
brake
pedal brake
parking brake
LPG reserve indicator

4.Steuerkreis
5.Steuerkreis
Freigabe ein
Bremsenfreigabe
Festellfreigabe
Fahrpedal
Lichtmaschine
Logikeinheitsdefekt
Aktuator
Motorstop
Batterie
Spule
Neigung
Zundkerzen
Glhkerzen
Schlssel
Anlaschlssel
Hupe
Zusatzbeleuchtungssteuerung
Elektroflgelsteuerung
Stoplichtesteuerung
Batteriestecker
Armaturenbrett
Glhkerzevorrichtung
Gangelektroventile
Elektroflgelrad
Notstand
Rckfahrscheinwerfer
Stoplichte
Bremse
Bremspedal
Festellbremse
GPL Reserveanzeiger

4.me levier
5.me levier
abilitation active
abilitation des freins
abilitation de stationnement
pdale acclrateur
alternateur
anomalie dunit logique
actionneur
arrt du moteur
batterie
bobine
inclinaison
bougies dallumage
bougies de chauffage
cl
cl de dmarrage
klaxon
commandes lumires suppl.
commande lectro-ventilateur
commande feus de stop
connecteur batterie
panneau de commande
dispositif bougie de chauffage
electrovannes de marche
lectro-ventilateur
urgence
feus de marche arrire
feus de stop
frein
frein pdale
frein de stationnement
indicateur rserve GPL

4a.leva
5a.leva
habilitacin activada
habilitacin de los frenos
habilitacin de aparcamiento
pedal acelerador
alternador
anomala unidad lgica
actuador
parada del motor
batera
bobina
inclinacin
bujas
bu jas incandescente
llave
llave de arranque
claxon
mandos luces adicionales
mando electroventilador
mando faroles de stop
enchufe batera
salpicadero
dispositivo bujia incandescente
electrovlvulas de marcha
electroventilador
emergencia
faroles de marcha atras
faroles de stop
freno
freno pedal
freno de aparcamiento
indicador reserva GPL

LEGEND
DESCRIPTION

ENGLISH

DEUTSCH

FRANCAIS

ESPAOL

indicatore temperatura ac
intas.filtro aria
intas.filtro olio
intas.filtro olio idraul.
inversore
inversore manuale
livello carburante
liv.liquido freni
luci posteriori
luci retromarcia
marcia avanti
marcia indietro
marcia lenta
mot.trazione
motore avviamento
motore idroguida
motore pompa
pedale freno
pedaliera
pedaliera doppia
pompa
pompa iniezione
post combustione
potenziometro sollev.
pressione olio motore
pressostato freni
pulsante clacson
pulsante emergenza
rel avviamento
riserva gas
scatola acc.
sensore velocita
sollevamento
spia candelette

water temperature indicator

air filter clogging
oil filter clogging
hydraulic oil filter clogging
inversor lever
drive direction lever
fuel level
brake fluid level
back lights
reversing lamps
forward speed
backward speed
slow speed
traction motor
starter motor
power steering motor
pump motor
brake pedal
pedals
double pedals
pump
injection pump
afterburning
lifting potentiometer
motor oil pressure
brakes press.switch
horn push button
emergency.pushbutton
starter relay
LPG reserve
speed box
speed sensor
lifting
glow plugs warning light

Wassertemperaturanzeiger
Luftfilterverstopfung
lfilterverstopfung
Hydrauliklfilterverstopfung
Umschaltung
Handumschaltung
Treibstoffstand
Bremsflssigkeitsstand
Rcklichte
Rckfahrlampen
Vorwrtsgang
Rckwrtsgang
langsamer Gang
Fahrmotor
Anlamotor
Hydrolenkungsmotor
Pumpenmotor
Bremsepedal
Pedale
Doppelpedal
Pumpe
Einspritzungspumpe
Nachverbrennung
Hubpotentiometer
lmotordruck
Bremsdruckschalter
Hupeknopf
Notdruckknopf
Anlarelais
GPL Reserve
Fahrschalter
Geschwindigkeitsensor
Hub
Glhkerzenwarnlampe

indicateur temperature de leau

encrassement filtre air
encrassement filtre huile
encrassement filtre huile hydr.
inverseur de direction
inverseur de direction
niveau carburant
jauge dhuile de freins
lumires arrires
ampoule marche arrire
marche avant
marche arrire
marche lente
moteur de traction
dmarreur
moteur direction assiste
moteur pompe
pdale du frein
jeu de pdales
pdales double
pompe
pompe dinjection
postcombustion
potentiomtre dlvation
pression dhuile moteur
pressostat freins
poussoir klaxon
poussoir durgence
relais dmarreur
rserve GPL
boitier du vitesse
senseur de vitesse
lvation
voyant bougies de chauffage

indicador temperatura del agua

obstruccin filtro aire
obstrucci filtro aceite
obstruccin filtro aceite hidr.
palanca de inversin
palanca de inversin
nivel carburante
nivel aceite frenos
luces traseras
lampara de marcha atrs
marcha adelante
marcha atrs
marcha lenta
motor de traccin
motor de arranque
motor servodireccin
motor bomba
pedal del freno
juego de pedales
pedales doble
bomba
bomba inyeccin
postcombustin
potencimetro levantamiento
presin aceite motor
presstato frenos
pulsador de claxon
pulsador de emergencia
rel arranque
reserva GPL
caja aceleradores
sensor de velocidad
levantamiento
luz testigo bujas incandescen.

LEGEND
DESCRIPTION

ENGLISH

DEUTSCH

FRANCAIS

ESPAOL

SW cofano
temp.olio trasmis.
temperatura acqua
termico
traslatore
uomo presente
ventola motore
ventole
vista posteriore

bonnet switch
oil temperature transmission
water temperature
thermal sensor
sideshift
deadman device
motor fan
fan
rear view

Schutzhaubeschalter
ltemperaturgetriebe
Wassertemperatur
Wrmesensor
Seitenschieber
Totmann-schalter
Motorflgel
Flgelrder
Rcksicht

interrupteur coffre
temperature dhuile transmis.
temperature deau
senseur thermique
dplacement lateral
Homme mort
ventilateur moteur
ventilateur
vue arrire

interruptor cofre
temperatura aceite transmisin
temperatura agua
sensor trmico
desplazador lateral
conductor presente
motor ventilador
ventilador
vista rasera

COLORI
arancio
azzurro
bianco
blu
giallo
grigio
marrone
nero
rosa
rosso
verde
viola

COLOURS
orange
blue
white
dark blue
yellow
grey
brown
black
pink
red
green
purple

FARBEN
Orange
Hellblau
Wei
Blau
Gelb
Grau
Braun
Schwarz
Rose
Rot
Grun
Violett

COULEURS
orange
bleu
blanc
bleu
jaune
gris
marron
noir
rose
rouge
vert
violet

COLORES
anaranjado
azul
blanco
azul
amarillo
gris
marron
negro
rosa
rojo
verde
violeta