Service Manual

CBE

2.5
3.0
3.0L
3.5

Cargo Range

< Tillbaka till Index

BT Svenska AB
Per Wärmlund
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Electric SERVICE MANUAL
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.

BOLOGNA’S FACTORY, AFTER SALES SERVICE

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SERVICE MANUAL Electric

MECHANICAL SECTION

DATA SHEET page 6-7

DRIVER’S PLACE page 8-9

DASHBOARD page 10-11

TRUCK LOAD CAPACITY page 12

TRACTION UNIT page 13

Disassemble the reduction unit page 14
Oil change page 15

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

ELECTRIC MOTORS page 19

WHEELS/TYRES page 20

STEERING GROUP page 21

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

LIFTING UNIT page 24

Hydraulic control valves page 24
Hydraulic system diagram page 25

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

MAST LIFTING UNITS page 30

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

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

TRUCK LIFTING page 36

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

ELECTRICAL SECTION

TECHNICAL FEATURES page 43

FUNCTIONAL PERFORMANCES page 44

Protection page 45
General precautions page 46

GENERAL DESCRIPTION OF FUNCTION OF THE CONSOLE page 47

CONSOLE DESCRIPTION page 48

ELECTRONIC CONTROL PANEL LAYOUT page 49

POWER CIRCUIT DIAGRAM page 50

OPERATING CURRENT DIRECTION page 51-52

INPUT CONNECTION page 53

TRACTION POTENTIOMETER page 54

LIFTING POTETNTIOMETER page 55

PARAMETER CHANGE DESCRIPTION page 56

TESTER MENU DESCRIPTION page 57

ALARMS MENU DESCRIPTION page 58-59

ADJUSTMENTS TABLE page 60

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SERVICE MANUAL Electric

PEDALS

FOOT DRIVE DIRECTION

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

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

Single drive pedal (G)

Key (H)

Emergency push button (P)

P H
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Battery cover lifting

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

H
Battery connector (H)
Inside the battery cover

N
M
Levers unit
L
K K) Lifting control lever
L) Tilting control lever
M) Sideshift control lever
N) Device control lever (optional)
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SERVICE MANUAL Electric

1) Battery charge indicator

1 2 3 4 5 6 7 2) Parking brake ON warning light
3) Low brake fluid level warning light
4) Lifting motor temperature warning light
5) Worn lifting motor brushes warning light
6) Worn drive motor brushes
7) Not used
9) Electronic hour meter
10)Drive motor temperature warning light
11)Control valves functions locked due to flat battery (no connected)
9 10 11 12 13 14 15 16 12)Dead man device warning light
13)Electronic control unit temperature warning light
14)Drive and lifting diagnostics led (see electrical section)
15)Not used
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
2
the battery discharges, the LEDS will be separately on from
right side to left side.
When the battery is 80% discharged, the first red LED on the
left begins to flash showing that the battery must be recharged
3 (reserve). At the same time, the warning light (11) comes ON.

2) Parking brake ON warning light

4 3) Brake fluid low warning light

4) Lifting motor temperature warning light

lights up when the temperature is 150°C
5
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
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 150°C
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11 11) Control valves functions locked due to flat battery (no connected)

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 75° C (electrical section)

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

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SERVICE MANUAL Electric

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

ATTACHMENT OR SPECIAL CONDITION OF USE

TYRES SERIAL N°

CENTER OF LOAD DISTANCE mm

LIFT HEIGHT
mm

A
Cod. 0312005

DERATED CAPACITY Kg

CAPACITY PLATE

IDENTIFICATION PLATE
It identifies the lift truck technical data

MODEL Type MOTOR RATED CAPACITY

kW kg

SERIAL N° DRAW-BAR PULL (1h)

N

BATTERY MASS SERVICE MASS

kg kg Without
min. max. Battery kg

B MANUFACT. YEAR TENSION

V
Cod. 0312004

CARRELLI ELEVATORI S.p.A. CESAB LDT

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

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

7 screws

Disassemble the reduction unit

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

After the first 50-100 hours

- change the oil.

Every 250 hours

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

Every 1.000 hours or 12 months

- change the oil.

F F

OIL CHANGE INSTRUCTION

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

H B C A SERVICE BRAKE SYSTEM DIAGRAM

A) Reduction gear (right) and braking unit

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

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

OIL BRAKE TANK (F)

OBS! Olja typ SAE 80W i bromssystemet!

Gioco

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

CENTRAL
BRAKE DISKS

SERVICE
BRAKE
OIL INLET

PARKING BRAKE
LEVER

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

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

I L
PARKING BRAKE DIAGRAM

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

PARKING BRAKE CONTROL AND

ADJUSTMENT
Every 500 hours
- Check the clearance shown on the drawing
A 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.
Rör ej justerskruven på 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 är
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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MAINTENANCE
Every 500 hours check the wear brushes
Every 500 hours check the commutator conditions

(Svart drivmotor) CBE 2.5-3.0

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

Pump 22,5 LiT/min.

(Silverfärgad drivmotor)
CBE 3.0L-3.5
TRACTION MOTOR (Lucci) LIFTING MOTOR (Leroy somer)
V 80 Kw 16 V 80 Kw 17
A 230 Ecc. sep A 240 Ecc. serie
Rpm/min. 1360 IP 20 Rpm/min. 2550 IP 20
Service S2 Classe IS H Service S3 30% Classe IS F
N° poles 4 N° brushes 8 N° poles 4 N° brushes 8

Pump 19 LiT/min.

LENGTH OF ORIGINAL BRUSHES

< 50%
L
New TYPE OF MOTOR
L = 40 mm DRIVE MOTOR BRUSHES
L = 32 mm LIFTING MOTOR BRUSHES
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SERVICE MANUAL Electric

STANDARD TYRES

THE SAFETY OF RIMS AND WHEELS FOR FORKLIFT TRUCKS

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

PNEUMATIC TYRES PRESSURES

Front 10 BAR CU
CUSHION
Rear 10 BAR
←

SE
TIGHTENING TORQUE SUPERELASTIC
Driving tyres 19 daNm ←
Steering tyres 24 daNm
PN
PNEUMATIC
←

TYRES TYPE DIMENS. VERSION

FRONT. 559x229x406 250-300-300L-350

CUSHION
(C)
REAR 457x152x308 250-300-300L-350

23x9-10 250
FRONT
SUPERELASTIC 23x10-12 300-300L-350
(SE)
REAR 18x7-8 250-300-300L-350

FRONT. 23x9-10 250

PNEUMATIC
(PN)
REAR. 18x7-8 250

SUPERELASTIC
FRONT 6.50-10 250- 300- 300L-350
Twin Tyres
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BEARING ADJUSTMENT
Steering wheel bearings require an adjustment once a year.

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

3
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SERVICE MANUAL Electric

STEERING CONTROL

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

POWER STEERING SEAL CONTROL AND CLEANING

Every 250 hours

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

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

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

Max steering angle (internal wheel ≅ 80°)

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

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

B = 80° Standard
85° Max angle accepted

ANGLE MEASURED BY THE AXLE FRAME TO THE

INTERNAL WHEEL THROUGH A SPECIAL DEVICE
D

A=Länklager
F
D

END STROKE A
SETTING SCREW

STEERING AXLE
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SERVICE MANUAL Electric

HYDRAULIC CONTROL VALVES

Max pressure valve

CBE 2.5-3.0 = 190 bar
CBE 3.0L-3.5 = 210 bar

Max pressure tilting valve 130 BAR

Max pressure sideshift valve 130 BAR

LIFTING EQUIPMENT OIL AND FILTER

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

After the first 50 hours of work

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

To change the oil and the filter:

- remove the filling cap (B), extract the filter;
- remove the drain cap (E); drain out all the oil into an appropriate
container then replace the drain cap and tighten firmly;
- fit a new filter (D) after checking the state of the seals;
- Fill the tank with approx. 35 liters oil through
the filter until the dipstick notch (max level).
E
 Lyft Tilt Sideshift
Styrcylinder

Electric
A

B
C
A=Slangbrottsventiler
B=Sänkbromsventil

HYDRAULIC DIAGRAM
C=Tiltlås

SERVICE MANUAL
-

Prioriteringsventil

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SERVICE MANUAL Electric

The mast profile - CESAB design - with double stiffening flange is characterised by a high
flexural and torsional strength.
It allows wide visibility thanks to the reduced dimensions of the profile itself.
Cylinders are single-acting type.
The sideshift system has been housed inside the profiles.
The mast group is a roller type with a variable centre distance (i.e. a fixed roller is fitted on the
outer mast and a mobile one on the inner mast, instead of a number of mobile rollers only on
the inner mast). This solution ensures better grip and stability on operation.

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

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

Triplex mast VT 2 side cylinders

FFL 2 side cylinders
1 short central cylinder

Grease nipple Adjusting screw Shoe Roller

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TRIPLE MAST SECTION

Fork carriage

Internal
section bar

Intermediate
section bar

External
section bar
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SERVICE MANUAL Electric

LUBRICATION OF LIFTING EQUIPMENT

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

Every 50-100 hours

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

Every 250 hours

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

Every 2 000 hours

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

Fork carriage and sideshift unit

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

Every 50 hours
- lubricate the sideshift guides with with grease
F through the grease nipples.
G
Every 250 hours
- lubricate the fork positioning pins and notches
with grease.
H - grease the fork carriage guide rollers (F)
- adjust the guide shoes

Every 2 000 hours

- check the condition of the guide rollers; they
must turn freely without jamming and not show
excessive wear.
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C
C) Sideshift unit
(upper part)
3 grease nipples
(lower part)
without grease nipplesexcessive wear.

Make sure that:

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

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

E
and tightly fixed.

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

Every 500 hours

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

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

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

SAFETY FORK CARRIAGE END STOP

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

DESCRIPTION OF THE CYLINDER COMPONENTS

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

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

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

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

piston through anti-friction rings (5).

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

Slight leakages that may occur are directed to the

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

A small quantity of oil will always remain in the loop

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

2
5

Fig. A Fig. B
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CYLINDER CHECKING METHODS

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

Lift the cylinder some times to end stroke, so as to

discharge any oil residual.

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

After 10 minutes, measure the amount by which the

load has lowered. A drop of a few millimetres is quite
normal, as in the distributor there are always some
leakages.
Now, lift the cylinder to its end stroke, if no oil leaks
from the drain pipe coupling, it means that the load
lowering is only due to the leakages on the distributor.
Fig. C
In the presence of leakages, it will be necessary to
replace the seal. Should this be the case, inspect the
cylinder liner.

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

Remove the drain pipe from the cylinder.

Lift the cylinder some times to end stroke, so that all

the possible remaining oil is discharged.

Put a load on the forks. Lift and lower it for 10 minutes,

making sure that the limit stop is never reached.

Lift the cylinder to end stroke.

If any leakages should be still present, the cylinder is

damaged and then it must be replaced.
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SERVICE MANUAL Electric

CHECKING THE CHAINS:

Every 500 hours

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

Every 1 000 hours

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

Every 10 000 hours

- replace the chains and the fixing tie rods

POSITIONING THE FORK MOUNTING CARRIAGE

Every 500 hours

- After testing the chains as described above, with the truck on an even surface and
the mast in a vertical position, check the position of the fork carriage plate, as follows:
- remove the forks, completely lower the fork carriage and measure the height (X),
comparing it with the value shown in the table, correspondig to the capacity in kg
of the truck.
(e.g. the correct value of (X) for a truck with a capacity of 2000 kg (class II B),
must be 152 ±5 mm).

TABLE ISO 2328 - 1993

Rate Lifting power (kg) "X" (– 5)

IB 0 999 114 mm
II B 1 000 2 500 152 mm
III B 2 501 4 999 203 mm
IV B 5 000 8 000 254 mm
VB 8 001 10 999 257 mm

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

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

Difference in height of fork tips

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

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

MAST GROUP TILTING SETTING

2°30 FORWARD STANDARD

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

Check to carry out every 500 h

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

movement on 1 mt.
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SERVICE MANUAL Electric

COMPONENTS DESCRIPTION
E I
G

D) Traction and lifting module E) Contactor

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

ACCELERATOR PEDAL

Set the potentiometer

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

Set the potentiometer

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

180 mm

Height adjustment screw

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page 35

BATTERY AND BATTERY CHARGER

General indications for battery maintenance

Every 50 working hours - measure electrolyte density.

Approximate density data

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

BATTERY CHARGING WARNINGS

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

BATTERY WEIGHTS AND CAPACITY

STANDARD STANDARD 80V

BATTERY WEIGHT BATTERY CAPACITY

CBE 2.5 1 547 kg 500-640 Ah

CBE 3.0 1 547 kg 500-640 Ah

CBE 3.0L-3.5 1872 kg 625-800 Ah

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

page 36
SERVICE MANUAL Electric

Ï
HOOKS ATTACHMENT POINTS FOR LIFTING
THE TRUCK

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

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

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

ß - ≤ 45°
C
C

C C

LIFTING OF THE FORKLIFT TRUCK WITH CABIN

B B

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

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

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

 2,5 - 3,0 - 3,5 t
Electric SERVICE MANUAL
page 37

OIL AND GREASE SPECIFICATIONS

Q.T FOR NORMAL ENVIRONMENTS

TIPO USATO SPECIFICHE QTY.
TYPE USED SPECIFICATIONS MEN-
TYP EIGENSCHAFTEN GE
PARTS TO BE LUBRICATED
ISO - L - HV
AGIP ARNICA 46 Prove FZG 30 L Hydraulic system, lifting and power steering
fino a stadio 11 (*)
1 L
API GL4
MOBIL-FLUID 422 MIL-L-2105D
+ Transmission reduction gears
1 L
SAE 80 W +additivo per freni a
bagno d’olio (***) - Hydraulic brake system tank
Base LITIO
ASTM 275 305
Mast securing joints - Sideshift unit - Steering joint
MOBILGREASE SPECIAL NLGI N.2 -
Gocciolamento - General lubrication with grease nipples
180 (**)
(*) 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

10 bar FRONT Tyres

10 bar REAR Tyres

WHEEL TORQUE
24 daNm Steered wheels

19 daNm Driven wheels

DRIVE UNIT TORQUE

8 daNm securing of electric motor to the reduction
gears

45 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 mast securing U-bolts

0,8 1,2 daNm Jack collar self-locking nuts

30 daNm Counterweight locking screws

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

page 38
SERVICE MANUAL Electric

RUNNING IN MAINTENANCE

50 500 # at # hours for MEDIUM/INTENSE USE

at # days/months FOR OCCASIONAL
7/- -/3 #
USE

LIFTING UNIT - MASTS

 mast guide pads

  lifting oil filter

TRANSMISSION REDUCTION GEARS

 transmission reduction gear oil

HYDROGUIDE

  filter change

CHASSIS AND COMMANDS

 bolts in general

  wheel tightness (1)

(1) During the first 500 working hours, check

tightness every 50 hours.
LEGENDA

 and
In the maintenance table indicating a visual control
cleaning of the parts indicated.

 replacement
In the maintenance table indicating the
of the parts indicated.

ofIn thethemaintenance table indicating lubrication

parts indicated.

 or adjustment of the parts indicated.

In the maintenance table indicating tightening
 Totaldokument
BT Cargo CBE 25-35
Var 250:e timme

Pos Kontroll av: Pos Kontroll av: Pos Kontroll av:

0:0 Grupp 0 Hel maskin 3:0 Grupp 3 Bromsar/hjul 5:9 Acc. pedal/fartreglage
0:1 Dörrar/luckor 3:1 Däck/hjul 5:10 Microbrytare
0:2 Motviktsinfästning 3:2 Lufttryck däck 5:11 Kontaktorer/kontakter
0:3 Förarskydd/hytt 3:3 Hjulbultar/hjullager 5:12 Säkringar
0:4 Batterilåsning 3:4 Färdbroms, funktion/läckage 5:13 Batterivätskenivå
0:5 Skyltar/dekaler 3:5 Parkeringsbroms 5:14 Batteri, smuts/läckage
0:6 Förarmiljö 3:6 Bromsvätskenivå 5:15 Batterianslutningar
0:7 Stol/mattor 3:7 Pedallänkage/pedalspel 5:16 Batteripoler reng./infettning
0:8 Pedalgummin 5:17 Batterihandskar, kontroll
0:9 Torkare/spolare 4:0 Grupp 4 Styrning 5:18 Kylfläktar, kontroll
0:10 Provkörning test av 4:1 Styrleder/Styrspindlar
samtliga funktioner 4:2 Styrcylinder, fastsättning 6:0 Grupp 6 Hydraulik
0:11 Smörjning enligt schema 4:3 Styrlagring/upphängning 6:1 Slangar/rör
6:2 Ventilreglage/länkage
1:0 Grupp 1 Motorer 5:0 Grupp 5 Elsystem 6:3 Andningsfilter/ventilatorer
1:1 Missljud 5:1 Belysning/körriktningsvisare 6:4 Oljenivå
1:2 Fastsättning/infästning 5:2 Instrument/kontrollampor
5:3 Signalhorn 7:0 Grupp 7 Arbetsfunktion
2:0 Grupp 2 Kraftöverföring 5:4 P-broms-/Backalarm 7:1 Lyftstativ
2:1 Oljenivå 5:5 Timmätare, avläsning 7:2 Gafflar
2:2 Fastsättning 5:6 Färdväljare/länkage 7:3 Lyftkedjor
5:7 Kablar/anslutningar 7:4 Laststöd
5:8 Startfrekvens 7:5 Lyft-/tiltcylindrar

Var 500:e timme tillkommer: Var 1000:e timme tillkommer: Var 2000:e timme tillkommer:
0:0 Grupp 0 Hel maskin 2:0 Grupp 2 Kraftöverföring 0:0 Grupp 0 Hel maskin
0:12 Bultar/Muttrar, fastsättning 2:3 Drivaxel, oljebyte 0:13 Ram, kontroll av sprickor

1:0 Grupp 1 Motorer 3:0 Grupp 3 Bromsar/hjul 1:0 Grupp 1 Motorer

1:3 Drivmotor, renblåsning 3:8 Hjullager infettning 1:8 Kolfjädrar, styrka
1:4 Drivmotorkol, kontroll 3:9 Bromsvätska byte
1:5 Pumpmotorkol, kontroll 4:0 Grupp 4 Styrning
1:6 Pumpmotor, renblåsning 6:0 Grupp 6 Hydraulik 4:4 Slangar, kontroll
1:7 Motorer, isolationsprov 6:5 Andningsfilter, reng./byte 4:5 Styrtryck, kontroll

5:0 Grupp 5 Elsystem 5:0 Grupp 5 Elsystem

5:19 Batteri, isolationsprov 5:20 Batteribelastningsprov
5:21 Motorström, mätning

6:0 Grupp 6 Hydraulik

6:6 Hydraultryck, kontroll
6:7 Hydraulolja, byte
6:8 Sugfilter, rengöring/byte

7:0 Grupp 7 Arbetsfunktion

7:6 Gafflar, gaffeltest

CBE 12-50
Sida 2 Chassie/hel maskin
SERVICE MANUAL

Electrical section
 2,5 - 3,0 - 3,5 t
Electric SERVICE MANUAL
page 43

TECHNICAL FEATURES

ELECTRONIC PANEL - COMBI SEM 3

Tension 80 V
Field max. current 50 A
Armature max current 500 A
Pump max current 500 A
Armature working frequency 16 KHz
Field working frequency 1 KHz
Pump working frequency 16 KHz
Working ambient temperature -30°C / +40°C
Max. attainable temperature
from chopper body 85°C
 2,5 - 3,0 - 3,5 t

page 44
SERVICE MANUAL Electric

FUNCTIONAL PERFORMANCES

- Very good control at low speed.

- Reduction of the max. speed: max. speed in both directions can be set by using the
programming console.
- Regenerative braking based on deceleration ramps, on release, on reversal and on
partial accelerator release.
- Speed check down a slope: the motor speed follows the accelerator pedal automatically
setting the regenerative braking, in case the motor speed exceeds the desired one.
- Up start without roll-back also without use of an electric brake (electrobrake).
- Anti rolldown function; key On chopper checks the traction motor speed; in case it
is moving, without direction request from the operator, it carries out automatically
a braking and checks the down a slope by very low speed (function useful for safety
also without truck driver on).
- In the pump section the selected lower speed prevails.
- Diagnostic with indication by means of led.
- Able to be formed via console.
- Internal timer visible from the console.
- Storage of the last 5 alarms with the relative value of the timer and temperature
visible from the console.
- Tester by means of the console to verify in real time of the main parameters, such as
input, motor voltage, battery.
- Arc less operation of the remote control switches.
- Internal coil suppressor (within logic).
- High efficiency of motor and battery due to high frequency switching.
 2,5 - 3,0 - 3,5 t
Electric SERVICE MANUAL
page 45

PROTECTIONS

- Battery reversal:
It is important to observe the connections shown in order to prevent damage.
The logic is internally protected from reverse battery polarity.
- Connection errors:
All inputs are protected against incorrect connections.
The remote control switches have a rating of 2Amps, however they are protected from overload and short
circuits.
- Thermal protection:
When the temperature is more than 75° C the maximum current is reduced in proportion to the increase in
temperature. The temperature can never exceed 85° C.
- 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.
 2,5 - 3,0 - 3,5 t

page 46
SERVICE MANUAL 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 (-).
 2,5 - 3,0 - 3,5 t
Electric SERVICE MANUAL
page 47

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.
2,5 - 3,0 - 3,5 t

page 48
SERVICE MANUAL Electric

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
Remouve the plastic cap
and connect the console

F1

ELECTRONIC PANEL LAY-OUT

F2

F3

SERVICE MANUAL
F6
F5
F4

A C
F0

B A=Anslutningsplint A på panelen

Poewr fuse B=Anslutningsplint B på panelen

F0) traction and lifting motors fuse 500 A C=Anslutning för fältlindningen

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

D=Backljusrelä

page 49
Auxiliary fuses
F1) key fuse 5 A F4) horn fuse 5 A
F2) contactors fuse 2 A F5) electrofan fuse 3 A
F3) converter 80/24 fuse 20 A F6) reverse and stop light fuse 5 A
2,5 - 3,0 - 3,5 t
page 50
SERVICE MANUAL Electric
POWER CIRCUIT DIAGRAM
MOTOR
PUMP
TRACTION MOTOR
 2,5 - 3,0 - 3,5 t
Electric SERVICE MANUAL
page 51

OPERATING CURRENT DIRECTION

FORWARD DIRECTION

FORWARD DIRECTION BRAKING

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

page 52
SERVICE MANUAL Electric

BACKWARD DIRECTION

BACKWARD DIRECTION BRAKING

 2,5 - 3,0 - 3,5 t
Electric SERVICE MANUAL
page 53

INPUT CONNECTION

KEY
key = Key switch (+VB) acc. pot . = Traction potentiometer
cm = Common switch (+VB) 1 st speed = Tilting switch
rev = Backward switch 2 nd speed = Sideshift switch
forw = Forward switch 3 rd speed = 4 Th lever switch
seat = Seat switch lift = Lifting switch
hb = Parking brake switch 4 th speed = 5 Th lever switch
plc = Main contactor positive lift pot = Lifting potentiometer
nlc = Main contactor negative lcc = Main contactor
pb = Brake switch led = Diagnostic led
 2,5 - 3,0 - 3,5 t

page 54
SERVICE MANUAL Electric

TRACTION POTENTIOMETER

Green 111
)

Ï
5KOhm

7KOhm Red 109

Í )
Yello 110
)

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

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

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

Verified these values, carry out the “PROGRAM VACC” function to acquire the
traction potentiometer signals (see attached diagram for using the console).
 2,5 - 3,0 - 3,5 t
Electric SERVICE MANUAL
page 55

LIFTING POTENTIOMETER

137
3

5 KOhm

2 135
Í
1
136

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

Lifting lever at rest - 0 Volt

Lifting lever pulled ~ 4.5 Volt

Verified these values, carry out the “SET PUMP ACC MIN e MAX” function to acquire the
lifting potentiomer signal (see attached diagram “data acquisition lifting potentiometer”).
 2,5 - 3,0 - 3,5 t

page 56
SERVICE MANUAL Electric

PARAMETER CHANGE DESCRIPTION

(t) means traction (p) means pump

ACCELER. DELAY (t) = Traction motor acceleration time

DECELER DELAY (t) = Traction motor deceleration time
RELEASE BRAKING (t) = Braking current by releasing the accelerator
PEDAL BRAKING (t) = Braking current with pressed braking pedal
INVERS BRAKING (t) = Braking current on inversion
CUTBACK SPEED (t) = Max speed reducton with input on
MAX SPEED FORW (t) = Forward max speed
MAX SPEED BACK (t) = Backward max speed
TRACTION I MAX (t) = Traction max current
ARMA. NOM. CURR. (t) = Armature nominal current
WEAK DROPOUT (t) = Weakening threshold current
FIELD NOM. CURR. (t) = Field nominal current OBS! Viktigt att se upp med typ av drivmotor!
CREEP SPEED (t) = Min. acceleration threshold
SEAT MICRO DELAY = Seat microsiwtch delay
SPEED LIMIT (p) = Lifting max speed
PUMP I MAX (p) = Lifting max current
PU. ACCELER DELAY (p) = Motor pump acceleration delay
PU. DECELER DELAY (p) = Motor pump deceleration delay
PUMP CREEP (p) = Min. lifting acceleration threshold
COMPENSATION (p) = Lifting speed compensation
1ST SPEED COARSE (p) = Tilting speed, coarse adjustment + 10%
1ST SPEED FINE (p) = Tilting speed, fine adjustement + 1%
1ST SPEED COMP (p) = Tilting speed compensation
2ND SPEED COARSE (p) = Sideshift speed, coarse adjustment + 10%
2ND SPEED FINE (p) = Sideshift speed, fine adjustment + 1%
2ND SPEED COMP (p) = Sideshift speed compensation
3RD SPEED COARSE (p) = 4th way speed, coarse adjustment + 10%
3RD SPEED FINE (p) = 4th way speed, fine adjustment + 1%
3RD SPEED COMP (p) = 4th way speed compensation
4TH SPEED COARSE (p) = 5th way speed, coarse adjustment + 10%
4TH SPEED FINE (p) = 5th way speed, fine adjustment + 1%
4TH SPEED COMP (p) = 5th way speed compensation
HYD SPEED COARSE (p) = Power steering speed, coarse adjust. + 10%
HYD SPEED FINE (p) = Power steering speed, fine adjust. + 1%
HYD SPEED COMP (p) = Power steering speed compensation
HYDRO TIME (p) = Power steering time
 2,5 - 3,0 - 3,5 t
Electric SERVICE MANUAL
page 57

TESTER MENU DESCRIPTION

BATTERY VOLTAGE battery tension value

TR MOTOR VOLTAGE traction motor tension (armature)
PU MOTOR VOLTAGE pump motor tension
TRAC. CURRENT traction motor current (armature)
PUMP CURRENT pump mototr current
FIELD VOLTAGE traction motor field tension
FIELD CURRENT traction motor field current
TR CHOPPER TEMP traction chopper temperature
PU CHOPPER TEMP pump chopper temperature
ACCELERATOR traction potentiometer value (tensione and percentage)
LIFTING CONTROL lifting potentiometer value (tensione and percentage)
ENABLE SWITCH not used (must be connected to + BV)
SEAT SWITCH seat microswitch
ON/+VB=input on OFF/GND=input off
FORWARD SWITCH forward microswitch
ON/+VB=input on OFF/GND=input off
BACKWARD SWITCH backward microswitch
ON/+VB=input on OFF/GND=input off
BRAKE SWITCH brake microswitch
ON/+VB=input on OFF/GND=input off
HAND BRAKE parking brake switch
ON/+VB=input on OFF/GND=input off
CUTBACK SPEED traction speed reduction switch
ON/+VB=input on OFF/GND=input off
1ST SPEED SWITCH tilting microswitch
ON/+VB=input on OFF/GND=input off
2ST SPEED SWITCH side-shift microswitch
ON/+VB=input on OFF/GND=input off
3ST SPEED SWITCH 4° way microswitch
ON/+VB=input on OFF/GND=input off
4TH SPEED SWITCH 5° way microswitch
ON/+VB=input on OFF/GND=input off
LIFTING SPEED lifting microswitch
ON/+VB=input on OFF/GND=input off
BATTERY CHARGE battery charge value (percentage)
2,5 - 3,0 - 3,5 t

page 58
SERVICE MANUAL Electric

ALARM MENU DESCRIPTION

ALARMS DESCRIPTION OF THE DIAGNOSTIC LED

PLACED ON THE DASHBOARD AND THE CONSOLE

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

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

-Logic unit.

3 FLASHES = CAPACITOR CHARGE - Replace the complete unit.

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

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

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

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

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

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

CLOSED - Check:
-Main contactor stuck
-Contactor coils and relevant wires.
-Logic unit.
LOGIC FAILURE - Replace the complete unit.
 2,5 - 3,0 - 3,5 t
Electric SERVICE MANUAL
page 59

7 FLASHES = TH.PROTECTION, PUMP TEMPERATURE - The unit temperature of (traction

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

8 FLASHES = HAND BRAKE - Check:

-Parking brake microswitch and wires.
-Logic unit.

CONTINUOUS FLASHING = BATTERY LOW - Charge the battery.

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

-Direction microswitches and wires.
-Logic unit.
 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 2002-0 GB Issue 08/1999

CONSOLE MAP
 DIAGRAM FOR USING THE CONSOLE-COMBI SEM 3 1-CONNECT THE CONSOLE TO MODULE COMI SEM
2-TURN THE KEY ON
CESAB Manufacturer's name
CBE 2,5 - 3,5
CONSOLE V.1.0 Console program version Description which appearsonly when
Display Console some values are modified
è
Connection moment CONNECTED TO: Model/configuration and ARE YOU SURE? Press OUT to
between console and COMBI SEM 3 CE 1.07 program version of the unit YES=ENTER NO=OUT return to the
COMBI SEM ê é main menu
è COMBI SEM 3 CE 1.07 ç ç ç
Tension/power and
80V 500A 00000 hour meter value TRACTION LIFTING
Press ENTER to select ACCELER. DELAY SPEED LIMIT 3RD SPEED COARSE
the main menu ê DECEL. DELAY PUMP I MAX 3RD SPEED FINE
RELEASE BRAKING PU. ACCELER. DELAY 3RD SPEED COMP.
è MAIN MENU ç é
é è è PEDAL BRAKING PU. DECELER DELAY 4TH SPEED COARSE
PARAMETER CHANGE Press ENTER to select setting INVERS. BRAKING PUMP CREEP 4TH SPEED FINE
CUT BACK SPEED COMPENSATION 4TH SPEED COMP.
values MAX SPEED FORW 1ST SPEED COARSE HYD. SPEED COARSE
Press é MAX SPEED BACK 1ST SPEED FINE HYD. SPEED FINE Use é
TRACTION I MAX 1ST SPEED COMP. HYD. SPEED COMP. PARAM
ROLL ê Press ROLL ê
ê é ARMA. NOM. CURR. 2ND SPEED COARSE HYDRO TIME SET
é to change to change the WEAK DROPOUT 2ND SPEED FINE
to c hange

the functions parameters ê FIELD NOM. CURR. 2ND SPEED COMP.

the values

CREEP SPEED
SEAT MICRO DELAY
ê ç ç
MAIN MENU ç
BATTERY VOLTAGE (battery tension) Volt SEAT SWITCH (seat microswitch) ON/OFF
TESTER è è TR MOTOR VOLTAGE (trac. motor tension) Volt FORWARD SWITCH (forward microswitch)ON/OFF
Press ENTER to select PU MOTOR VOLTAGE (pump motor tension)Volt BACKWARD SWITCH (backward microswitch)ONOFF é
the function of electrical TRAC. CURRENT (trac. motor current) A m p BRAKE SWITCH (brake microswitch) ON/OFF
device control PUMP CURRENT (pump mototr current)A m p HAND BRAKE (parking brake switch)ON/OFF
ê
Press é
FIELD VOLTAGE (field tension) Volt CUTBACK SPEED (speed reduction switch)ONOFF
é FIELD CURRENT (field current) Amp 1ST SPEED SWITCH (tilting microswitch) ON/OFF Press
ROLL ê Press é TR CHOPPER TEMP (trac. chopper temp.) °C 2ST SPEED SWITCH (side-shift microswitch)ON/OFF OUT
ROLL PU CHOPPER TEMP (pump chopper temp.)°C 3ST SPEED SWITCH (4° way microswitch) ON/OFF
ê ACCELERATOR (traction potentiometer)V - % 4TH SPEED SWITCH (5° way microswitch) ON/OFF
LIFTING CONTROL (lifting potentiometer) V - % LIFTING SPEED (lifting microswitch) ON/OFF
é ê ENABLE SWITCH (enable micoswitch) OFF BATTERY CHARGE (battery charge) %
MAIN MENU
SAVE PARAM. è è SELECT. Mod.00
Select the requested program from 1 to 31 where you
Press ENTER to select the function to save the setting values by using ROLL
é é
ê
FREE / COMBI SEM 3
ç

acquire on the console all the setting/

Press configuration parameters of the Program number ê
OUT module Confirm ENTER Program version stored

ç
ç
ç

ç OVERWRITE DATA?
Press é é
ROLL READING... Press YES=ENTER NO=OUT
ê é ç RUN ALL PARAMETERS OUT

ç
Press ENTER
é READING...
ç ç
RUN ALL PARAMETERS
ç ç
ç

MAIN MENU ç ç
ç ç
RESTORE PARAM. é
é è è SELECT: Mod.00 Program number
Press ENTER to select the function to Program version stored
RESTORE the parameters on the H2 REGENER
module saved on the console by a
SAVE function Confirm with Select the requested program from 1 to 31 where you save é
ENTER the setting values by using ROLL ê
é
ç

If NO press OUT ARE YOU SURE?

If YES press é
Press é ENTER STORING...
ç YES=ENTER NO=OUT è è RUN ALL PARAMETERS
ROLL ê
é
ç ç
é OUT
ç

Alarm code
è è V ACC NOT OK OUT CLEAR LOGBOOK
MAIN MENU è
Press ENTER to select HOUR METER 23h 2 25 °C
ALARM the function to read the YES=ENTER NO=OUT
N° ALARMS
ç

stored alarms TEMPERATURE

MAX 5 alarms stored ENTER
ç
è
è

ENTER
é NONE LOGBOOK CLEARED ARE YOU SURE?
Press ç ç
ROLL No alarms 00000h #00 0°C ( PRESS OUT ) YES=ENTER NO=OUT
ê
ç

stored
ç

OUT OUT
ç ç ç

ç ç
Press OUT Press ENTER if you want
é ç ç to modify this value
é Press OUT
ç

ç
ç

MAIN MENU ç VACC SETTINGS MIN VACC MAX

PROGRAM VACC è 0.0 10.0 è 0.0 -- 0.0
Press ENTER to select the A
é é function to acquire the Min. Value Max. Value Press the acceleration
potentiometer signals pedal slowly until the
ç

max. stroke
Press é If YES press ENTER ARE YOU SURE? Press OUT MIN é MAX
ç

ROLL ê ç ç YES=ENTER NO=OUT ç 0.0 10.0

ê
If NO press OUT
ç ç
PED.FORW
MAIN MENU Function not
PED.BACK
ç JUNE 1999
STEER TABLE used
A=Sätesbrytare+Fram/Back påverkade
 CBE 2,5 - 3,5
DIAGRAM FOR USING THE CONSOLE
Function -AUXILIARY TIME-
Reach the function ALARMS from the main menu

MAIN MENU V ACC NOT OK

ALARMS è 23h 2 25 °C
Press
ENTER

Press PARAM é
ê ê
SET
simultaneously

* CESAB MENU *
SPECIAL ADJUST.

Press
ROLL é
ç

Press OUT Press

to escape * CESAB MENU * ENTER SET CURRENT
COMBISEM 3 CE 1.25
80V 500A 00000 ç HARDWARE SETTING è 500 A

Press é
ROLL
STARTING CONSOLE

ç
DESCRIPTION
SET PUMP CURRENT
500 A
Auxiliary Time = Fördröjning vid åkriktningsväxling é
Press
0=Lång fördröjning, 9=Kort fördröjning ROLL é
ç
SET FIELD CURR.
50 A

Press é
ROLL
ç

SEM 2
OFF

Press
ROLL é
é
ç

AUXILIARY TIME
Press PARAM é LEVEL = 7
SET ê
to change the value
low value=inversion softer
high value=inversion stronger Press
OUT
ç

ARE YOU SURE?

YES=ENTER NO=OUT

SEPTEMBER 1999
 CBE 2,5 - 3,5
DIAGRAM FOR USING THE CONSOLE
Function -CLEAR EEPROM-
Reach the function ALARMS from the main menu

MAIN MENU V ACC NOT OK

ALARMS è 23h 2 25 °C
Press
ENTER

Press PARAM é
ê ê
SET
simultaneously

Används vid uppgradering * CESAB MENU *

SPECIAL ADJUST.
av mjukvaran till ny version.
Press
ROLL é
Spara den gamla parameter-
listan först, och ladda sedan * CESAB MENU *
HARDWARE SETTING
in den tillbaka.
Press
ROLL é
ç

* CESAB MENU *
READ RAM

Press
ROLL é
ç

* CESAB MENU *
READ EEPROM

Press
ROLL é
Press
ç

ENTER
* CESAB MENU * ARE YOU SURE?
è
CLEAR EEPROM YES=ENTER NO=OUT

Press
ENTER
ç

EEPROM CLEARED!
KEY OFF, PLESED

SWITCH OFF - SWITCH ON THE KEY

MAY 2000
 CBE 2,5 - 3,0 - 3,5
DATA ACQUISITION LIFTING POTENTIOMETER
-Connect the console to the module COMBI SEM 3
-Turn the key on
Display Consolle Används för att lära panelen min och
CESAB Manufacturer's name
max positionerna för lyftpotentiometern.
Console program version
CONSOLE V.1.0
Connection moment between
CONNECTED TO: console and COMBI SEM3

COMBI SEM3 CE 1.07 Type and program version of module

COMBI SEM3 CE 1.07

è
80V 500A 00000 Tension/power and hour meter value

PRESS SIMULTANEOUSLY

é
ROLL é éPARAM
WILL BE DISPLAYED
CONFIG. MENU
SET MODEL
Press
ROLL é ê
é
CONFIG. MENU
SET OPTIONS Minimum Maximum
Press value of lifting Minimun voltage value of lifting
ROLL é ê potentiometer value stored potentiometer

CONFIG. MENU SET PUMP ACC MIN SET PUMP ACC MAX
è è è
ADJUSTMENT 0,6 V Press 4,5 V
Press ENTER to select ROLL é
Press
the menu of the ê Press Enter
Maximun voltage
OUT Press
ACQUISITIONS
SET PUMP ACC MIN Enter ê value stored

0,0 V
é Value at rest
SET PUMP ACC MAX
Pull the lifting lever till when the
ê microswitch will be closed 0,0 V
Value at rest
SET PUMP ACC MIN
é 0,5 V Pull the lifting lever
ê untill the mechanic end
Press OUT stroke
Press ENTER to ê keeping the lever pulled
confirm or OUT
ARE YOU SURE?
ê

YES=ENTER NO=OUT SET PUMP ACC MAX

4,6 V
Press OUT
keeping the
é ê lever pulled
Press ENTER to
confirm or OUT
ARE YOU SURE?
ê

YES=ENTER NO=OUT
JUNE 1999
PARAMETER
 CBE 2,5 - 3,0
SETTING VALUE
MODULE COMBI SEM3 (EPROM CE1.34)
motors: traction SCHABMÜLLER lifting SCHABMÜLLER
(Svart drivmotor)
PARAMETER DESCRIPTION min/max VALUE
ACCELER. DELAY Traction motor acceleration time 1-9 4
DECELER DELAY Traction motor deceleration time 0-9 5
RELEASE BRAKING Braking current by releasing the accelerator 0-6 2
PEDAL BRAKING Braking current with pressed braking pedal 0-7 6
INVERS BRAKING Braking current on inversion 0-7 3
CUTBACK SPEED Max speed reducton with input on 0-9 0
BRAKE CUTBACK Speed reduction with pressed braking pedal 2-9 2
MAX SPEED FORW Forward max speed 0-7 7
MAX SPEED BACK Backward max speed 0-7 7
TRACTION I MAX Traction max current 0-9 9
ARMA. NOM. CURR. Armature nominal current 3-7 3
WEAK DROPOUT Weakening threshold current 0-6 3
FIELD NOM. CURR. Field nominal current OBS! Viktigt! 0-0 0
CREEP SPEED Min. acceleration threshold 0-3 2
SEAT MICRO DELAY Seat microsiwtch delay 0-9 5
SPEED LIMIT Lifting max speed 0-9 7
PUMP I MAX Lifting max current 0-9 9
PU. ACCELER DELAY Motor pump acceleration delay 5-9 9
PU. DECELER DELAY Motor pump deceleration delay 3-7 5
PUMP CREEP Min. lifting acceleration threshold 4-6 5
COMPENSATION Lifting speed compensation 5-9 6
1ST SPEED COARSE Tilting speed, coarse adjustment + 10% 1-1 1
1ST SPEED FINE Tilting speed, fine adjustement + 1% 0-9 4
1ST SPEED COMP Tilting speed compensation 2-7 2
2ND SPEED COARSE Sideshift speed, coarse adjustment + 10% 0-9 1
2ND SPEED FINE Sideshift speed, fine adjustment + 1% 0-9 6
2ND SPEED COMP Sideshift speed compensation 0-9 0
3RD SPEED COARSE 4th way speed, coarse adjustment + 10% 0-9 0
3RD SPEED FINE 4th way speed, fine adjustment + 1% 0-9 0
3RD SPEED COMP 4th way speed compensation 0-9 0
4TH SPEED COARSE 5th way speed, coarse adjustment + 10% 0-9 0
4TH SPEED FINE 5th way speed, fine adjustment + 1% 0-9 0
4TH SPEED COMP 5th way speed compensation 0-9 0
HYD SPEED COARSE Power steering speed, coarse adjust. + 10% 0-1 0
HYD SPEED FINE Power steering speed, fine adjust. + 1% 0-9 1
HYD SPEED COMP Power steering speed compensation 3-7 5
HYDRO TIME Power steering time 0-9 2

* AUXILIARY TIME Delay on inversion direction 0-9 3

NOVEMBER 2000
 CBE 3,0L - 3,5
SETTING VALUE
MODULE COMBI SEM3 (EPROM CE1.34)
motors: traction LUCCHI lifting LEROY SOMER
(Silverfärgad drivmotor)
PARAMETER DESCRIPTION min/max VALUE
ACCELER. DELAY Traction motor acceleration time 1-9 4
DECELER DELAY Traction motor deceleration time 0-9 5
RELEASE BRAKING Braking current by releasing the accelerator 0-6 4
PEDAL BRAKING Braking current with pressed braking pedal 0-7 6
INVERS BRAKING Braking current on inversion 0-7 5
CUTBACK SPEED Max speed reducton with input on 0-9 0
BRAKE CUTBACK Speed reduction with pressed braking pedal 2-9 2
MAX SPEED FORW Forward max speed 0-9 9
MAX SPEED BACK Backward max speed 0-9 9
TRACTION I MAX Traction max current 0-9 9
ARMA. NOM. CURR. Armature nominal current 3-7 3
WEAK DROPOUT Weakening threshold current 0-6 3
FIELD NOM. CURR. Field nominal current OBS! Viktigt! 4-4 4
CREEP SPEED Min. acceleration threshold 0-3 2
SEAT MICRO DELAY Seat microsiwtch delay 0-9 5
SPEED LIMIT Lifting max speed 0-9 6
PUMP I MAX Lifting max current 0-9 9
PU. ACCELER DELAY Motor pump acceleration delay 5-9 9
PU. DECELER DELAY Motor pump deceleration delay 3-7 5
PUMP CREEP Min. lifting acceleration threshold 0-4 0
COMPENSATION Lifting speed compensation 7-9 8
1ST SPEED COARSE Tilting speed, coarse adjustment + 10% 0-1 1
1ST SPEED FINE Tilting speed, fine adjustement + 1% 0-9 2
1ST SPEED COMP Tilting speed compensation 4-8 8
2ND SPEED COARSE Sideshift speed, coarse adjustment + 10% 0-9 2
2ND SPEED FINE Sideshift speed, fine adjustment + 1% 0-9 8
2ND SPEED COMP Sideshift speed compensation 0-9 2
3RD SPEED COARSE 4th way speed, coarse adjustment + 10% 0-9 0
3RD SPEED FINE 4th way speed, fine adjustment + 1% 0-9 0
3RD SPEED COMP 4th way speed compensation 0-9 0
4TH SPEED COARSE 5th way speed, coarse adjustment + 10% 0-9 0
4TH SPEED FINE 5th way speed, fine adjustment + 1% 0-9 0
4TH SPEED COMP 5th way speed compensation 0-9 0
HYD SPEED COARSE Power steering speed, coarse adjust. + 10% 0-1 1
HYD SPEED FINE Power steering speed, fine adjust. + 1% 0-9 1
HYD SPEED COMP Power steering speed compensation 3-7 7
HYDRO TIME Power steering time 0-9 2

* AUXILIARY TIME Delay on inversion direction 0-9 7

NOVEMBER 2000
 LEGEND
DESCRIPTION ENGLISH DEUTSCH FRANCAIS ESPAÑOL

4' via 4th valve 4.Steuerkreis 4.ème levier 4a.leva

5' via 5th valve 5.Steuerkreis 5.ème levier 5a.leva
abilitazione attiva enable on Freigabe ein abilitation activée habilitación activada
abilitazione freni brakes enable Bremsenfreigabe abilitation des freins habilitación de los frenos
abilitazione parcheggio parking enable Festellfreigabe abilitation de stationnement habilitación de aparcamiento
acceleratore accelerator pedal Fahrpedal pédale accélérateur pedal acelerador
alternatore alternator Lichtmaschine alternateur alternador
anomalia centralina logic unit defect Logikeinheitsdefekt anomalie d’unité logique anomalía unidad lógica
attuatore actuator Aktuator actionneur actuador
arresto motore motor stop Motorstop arrêt du moteur parada del motor
batteria battery Batterie batterie batería
bobina coil Spule bobine bobina
brandeggio tilting Neigung inclinaison inclinación
candele spark plugs Zundkerzen bougies d’allumage bujías
candelette glow plugs Glühkerzen bougies de chauffage bu jías incandescente
chiave key Schlüssel clé llave
chiave avviamento start key Anlaßschlüssel clé de démarrage llave de arranque
clacson horn Hupe klaxon claxon
comandi luci supplem. additional lights controls Zusatzbeleuchtungssteuerung commandes lumières suppl. mandos luces adicionales
comando elettroventola electric fan control Elektroflügelsteuerung commande électro-ventilateur mando electroventilador
comando fanali stop stop lights control Stoplichtesteuerung commande feus de stop mando faroles de stop
conn.batteria battery connector Batteriestecker connecteur batterie enchufe batería
cruscotto dashboard Armaturenbrett panneau de commande salpicadero
dispositivo candelette glow plugs device Glühkerzevorrichtung dispositif bougie de chauffage dispositivo bujia incandescente
elettrovalvole marcia speed electrovalves Gangelektroventile electrovannes de marche electroválvulas de marcha
elettroventola electric fan Elektroflügelrad électro-ventilateur electroventilador
emergenza emergency Notstand urgence emergencia
fanali retromarcia reversing lights Rückfahrscheinwerfer feus de marche arrière faroles de marcha atras
fanali stop stop lights Stoplichte feus de stop faroles de stop
freno brake Bremse frein freno
freno pedale pedal brake Bremspedal frein pédale freno pedal
freno stazionamento parking brake Festellbremse frein de stationnement freno de aparcamiento
indicatore riserva gas LPG reserve indicator GPL Reserveanzeiger indicateur réserve GPL indicador reserva GPL
 LEGEND
DESCRIPTION ENGLISH DEUTSCH FRANCAIS ESPAÑOL

indicatore temperatura ac water temperature indicator Wassertemperaturanzeiger indicateur temperature de l’ea indicador temperatura del agua
intas.filtro aria air filter clogging Luftfilterverstopfung encrassement filtre à air obstrucción filtro aire
intas.filtro olio oil filter clogging Ölfilterverstopfung encrassement filtre huile obstrucció filtro aceite
intas.filtro olio idraul. hydraulic oil filter clogging Hydraulikölfilterverstopfung encrassement filtre huile hydr. obstrucción filtro aceite hidr.
inversore inversor lever Umschaltung inverseur de direction palanca de inversión
inversore manuale drive direction lever Handumschaltung inverseur de direction palanca de inversión
livello carburante fuel level Treibstoffstand niveau carburant nivel carburante
liv.liquido freni brake fluid level Bremsflüssigkeitsstand jauge d’huile de freins nivel aceite frenos
luci posteriori back lights Rücklichte lumières arrières luces traseras
luci retromarcia reversing lamps Rückfahrlampen ampoule marche arrière lampara de marcha atrás
marcia avanti forward speed Vorwärtsgang marche avant marcha adelante
marcia indietro backward speed Rückwärtsgang marche arrière marcha atrás
marcia lenta slow speed langsamer Gang marche lente marcha lenta
mot.trazione traction motor Fahrmotor moteur de traction motor de tracción
motore avviamento starter motor Anlaßmotor démarreur motor de arranque
motore idroguida power steering motor Hydrolenkungsmotor moteur direction assistée motor servodirección
motore pompa pump motor Pumpenmotor moteur pompe motor bomba
pedale freno brake pedal Bremsepedal pédale du frein pedal del freno
pedaliera pedals Pedale jeu de pédales juego de pedales
pedaliera doppia double pedals Doppelpedal pédales double pedales doble
pompa pump Pumpe pompe bomba
pompa iniezione injection pump Einspritzungspumpe pompe d’injection bomba inyección
post combustione afterburning Nachverbrennung postcombustion postcombustión
potenziometro sollev. lifting potentiometer Hubpotentiometer potentiomètre d’élévation potenciómetro levantamiento
pressione olio motore motor oil pressure Ölmotordruck pression d’huile moteur presión aceite motor
pressostato freni brakes press.switch Bremsdruckschalter pressostat freins presóstato frenos
pulsante clacson horn push button Hupeknopf poussoir klaxon pulsador de claxon
pulsante emergenza emergency.pushbutton Notdruckknopf poussoir d’urgence pulsador de emergencia
relè avviamento starter relay Anlaßrelais relais démarreur relé arranque
riserva gas LPG reserve GPL Reserve réserve GPL reserva GPL
scatola acc. speed box Fahrschalter boitier du vitesse caja aceleradores
sensore velocita’ speed sensor Geschwindigkeitsensor senseur de vitesse sensor de velocidad
sollevamento lifting Hub élévation levantamiento
spia candelette glow plugs warning light Glühkerzenwarnlampe voyant bougies de chauffage luz testigo bujías incandescen.
 LEGEND
DESCRIPTION ENGLISH DEUTSCH FRANCAIS ESPAÑOL

SW cofano bonnet switch Schutzhaubeschalter interrupteur coffre interruptor cofre

temp.olio trasmis. oil temperature transmission Öltemperaturgetriebe temperature d’huile transmis. temperatura aceite transmisión
temperatura acqua water temperature Wassertemperatur temperature d’eau temperatura agua
termico thermal sensor Wärmesensor senseur thermique sensor térmico
traslatore sideshift Seitenschieber déplacement lateral desplazador lateral
uomo presente deadman device Totmann-schalter Homme mort conductor presente
ventola motore motor fan Motorflügel ventilateur moteur motor ventilador
ventole fan Flügelräder ventilateur ventilador
vista posteriore rear view Rücksicht vue arrière vista rasera

COLORI COLOURS FARBEN COULEURS COLORES

arancio orange Orange orange anaranjado
azzurro blue Hellblau bleu azul
bianco white Weiß blanc blanco
blu dark blue Blau bleu azul
giallo yellow Gelb jaune amarillo
grigio grey Grau gris gris
marrone brown Braun marron marron
nero black Schwarz noir negro
rosa pink Rose rose rosa
rosso red Rot rouge rojo
verde green Grun vert verde
viola purple Violett violet violeta