cbd&cbg 25manual.pdf

CBD/G

2.53.03.5

Service Manual

Cargo Range

CARGO 2.5

< Tillbaka till Index

Per Wärmlund

BT Svenska AB Per Wärmlund

SERVICE MANUALpage 3

INTERNALCOMBUSTION

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

BOLOGNA’S FACTORY, AFTER SALES SERVICE

CESAB S.p.a. reserves all rights ofreproduction of this handbook

The text and the numbering systemmay not be used in other printed matter,reprinted or translated, whether entirelyor in part, without written authorizationfrom

CESAB reserves the right to make anynecessary modifications without obligationto promptly update this handbook.

Copyright byCESAB S. p. A.


2,5 - 3,0 - 3,5 tINTERNAL

COMBUSTION

INDEX

TECHNICAL DATA ............................................................................................. p. 6

OPERATOR’S SEAT .......................................................................................... p. 8Pedals version ................................................................................................... p. 8Service brake .................................................................................................... p. 8

DASHBOARD ..................................................................................................... p. 9Dashboard indicator .......................................................................................... p. 9Parking switch ................................................................................................... p. 11Truck start up ..................................................................................................... p. 11Set of levers - Load handling.............................................................................. p. 12Capacity plates ................................................................................................. p. 12

ENDOTHERMIC ENGINE .................................................................................. p. 13KUBOTA ENGINE ............................................................................................. p. 13Kubota engine data ........................................................................................... p. 14Continental engine data ..................................................................................... p. 15Oil change and engine oil filter replacement ....................................................... p. 16Topping up with coolant...................................................................................... p. 16Air filter .............................................................................................................. p. 17Cyclone prefilter ................................................................................................. p. 17Engine running-in ............................................................................................... p. 17

ELECTRONIC HYDROSTATIC TRANSMISSION .............................................. p. 18Example of a closed loop hydrostatic transmission ............................................ p. 19Operation of the variable displacement pump with axial pistons ......................... p. 20Operation of the electronic hydrostatic system ................................................... p. 21Description of the main functions ....................................................................... p. 22

HYDRAULIC DIAGRAM ...................................................................................... p. 24

HYDROSTATIC PUMP ......................................................................................... p. 26

HYDRAULIC MOTOR........................................................................................... p. 28HYDROSTATIC TRANSMISSION MAINTENANCE............................................... p. 30

Replacing the filter and changing the transmission oil ......................................... p. 30

BRAKES ............................................................................................................. p. 31Diagram of the service brake and the parking brake systems ............................ p. 31Checking the service brake ............................................................................... p. 32Releasing the brakes for towing of the truck....................................................... p. 32

ELECTRIC SYSTEM ............................................................................................ p. 33Battery ............................................................................................................... p. 33Electric components .......................................................................................... p. 34Fuse holding panel ............................................................................................ p. 34


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Engine actuator ................................................................................................. p. 35Potentiometer and microswitches ...................................................................... p. 35Rotary / Linear potentiometer ............................................................................. p. 36Wiring diagrams ................................................................................................ p. 37

MENUS AND PARAMETERS FOR THE TCS SYSTEM ..................................... p. 39

CALIBRATION ..................................................................................................... p. 40Calibration and first start up of the transmission system ..................................... p. 42

DISPLAY.............................................................................................................. p. 45PUMP CUSTOMIZED .......................................................................................... p. 46ENGINE CUSTOMIZED ....................................................................................... p. 47FAULT DETECTED ............................................................................................. p. 48INFORMATION / PH PARAMETERS .................................................................... p. 49EPROM RESET .................................................................................................. P. 50

Troubles occuring while calibrating ...................................................................... p. 50System faults and failures .................................................................................. p. 56Troubleshooting ................................................................................................. p. 58

WHEELS / TYRES .............................................................................................. p. 59Safety of wheels and rims while using the truck .................................................. p. 59

STEERING UNIT ................................................................................................ p. 60Steering control ................................................................................................. p. 60Steering axle ..................................................................................................... p. 61Bearings adjustment .......................................................................................... p. 62

HYDRAULIC DISTRIBUTOR ............................................................................. p. 63

MASTS ................................................................................................................ p. 64Description of the cylinder components .............................................................. p. 66Cylinder inspection procedures.......................................................................... p. 67Lubrication ........................................................................................................ p. 68Installation checks safety specifications ............................................................. p. 69Safety limit stops of the fork mounting carriages ................................................ p. 69Chains inspection .............................................................................................. p. 70Fork inspection ................................................................................................. p. 70

LIFTING THE TRUCK ........................................................................................ p. 71Hooking points .................................................................................................. p. 71

TABLES .............................................................................................................. p. 72Table for oil and grease specifications................................................................ p. 72Table for the truck maintenance during the running-in stage ................................ p. 73Table for the maintenance schedule ................................................................... p. 74

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2,5 - 3,0 - 3,5 tINTERNAL

COMBUSTION

FOOT PEDALS VERSION

Pedals consist of:- two travel pedals, one forward pedal (A)

and one reverse pedal (B)- a service brake pedal (C)

One travel pedal (E)

HAND DIRECTION LEVER VERSION

Lever of direction selector (D)

1 forward speed0 neutral2 reverse speed

1

o2

�

�

o

D

CB

A

EC

G

C F

BALANCED PEDAL VERSIONForward pedal (F)Reverse pedal (G)Brake pedal (C)

SERVICE BRAKEFoot service brake (C) controls a hydrostatic brakingin the first part of the stroke by means of the electroniccontrol unit; if fully pressed, it engages the oil-bath discbrakes (over the front driving wheels).


INTERNALCOMBUSTION

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

DASHBOARDDuring ordinary operation, all warning lights in the dashboard are to be off.

9 13121110

15

14

865 74321

1 2

4

3

1) Fuel gauge2) Water temperature indicator3) Fuel level warning light4) Generator warning light5) Glow plug warning light (Diesel engine)6) Parking brake-on warning light7) Oil pressure warning light8) Indicator light (optional)9) Electronic hour counter10)Water temperature warning light11)Transmission oil temperature warning light12)Hydraulic oil filter clogged warning light13)Warning light (not used)14)Warning light (not used)15)Warning light indicating air filter clogged

A) Parking switch;B) Electronic failure warning light

If the warning light blinks during ordinary operation, this indicatesa failure in the electronic control unit; the vehicle will stop.

C) Ignition keyD) Emergency push-button; it acts as an emergency brake.

CAUTIONThe vehicle could instantaneously stop if buttons (A) and (D)are pressed; never press those buttons during the truck ordinaryoperation.

DASHBOARD INDICATORS1) Fuel gauge

2) Coolant temperature levelIndicates the coolant temperature.The pointer must never reach the red sector; the working temperaturecorresponds to 95 °C.

3) Fuel level warning lightThe fuel level warning light turns on when approx. 5.5 l of fuelare left in the tank.

4) Generator warning lightThat warning light is to be off when the engine is running. If not,it indicates that the alternator does not supply any current for thebattery or the electric system charge. This may be caused by thebreaking of the belt that drives the alternator pulley, or by a failureof the alternator.

D

BC

A


2,5 - 3,0 - 3,5 tINTERNAL

COMBUSTION

5) Glow plug warning light (Diesel engine).This warning light turns on when the ignition key is in position (2);

6) Parking brake on warning light

7) Engine oil pressure warning lightDuring ordinary operation, this warning light is to be off.If it turns on, immediately check the oil level in the engine. That warninglight could turn on when the engine is idling and hot, due to a lesserlubricant viscosity, even if no failure has occurred.

8) Direction indicator on warning light (optional)

9) Electronic hour counterIt indicates the working hours and hour fractions of your truck; it is controlledby the contact key and has the function to simplify scheduled maintenanceprogramming.

10)Coolant temperature warning lightIt indicates the engine overheating. Should it turn on, stop the vehicleimmediately.Check the correct operation of the radiator fan, the water pump and thecoolant level in the radiator.

11)Transmission oil temperature warning lightIt indicates that the temperature limits required for the correct operationof the pump and the hydrostatic engine have been exceeded.Should it turn on, stop working and determine the reasons for the overtemperaturetransmission oil.Check the oil level and that the radiator is clean and in good operatingconditions.

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

13)Warning light (not used)

14)Warning light (not used)

15)Air filter clogged warning light (replace filter)

8

7

9

10

11

5

6

12

13

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15


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

A: PARKING SWITCHB: ELECTRONIC FAILURE WARNING LIGHT

position 1 - Travel enabledSwitch A in position 1 enables the truck to travel (greenwarning light B and warning light 6 on the dashboard are on);brakes are engaged, but will automatically be released if the controlpedal is pressed (warning lights B and 6 turn off).

position 2 - Parking - start upSwitch A in position 2 (green warning light B off) starting ofthe engine is possible. Travel blocked to prevent any accidents. Brakes are engaged (parking condition).

HYDROSTATIC BRAKINGLift the travel pedals or the accelerator to enable the hydrostatic braking(adjustable) until the truck stops.The brakes are engaged if the control pedals are not actuated within a short period of time. When reoperating the control pedal, brakeswill be automatically be released.

TRUCK START UP

- the operator must be seated- parking switch A in position 2 (parking)- turn the key to position 1 (ignition on)- turn the key to position 2 (glow plugs on)- turn the key to position 3 (starter contact) to start the engine- once the engine has started up, turn the parking switch

A to position 1.- select the foward or reverse direction. The truck is ready to travel.

If the start up procedure has not been correctly performed, the truckwill not start up. If so, repeat the procedure above.

1 2

B

A

2

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2,5 - 3,0 - 3,5 tINTERNAL

COMBUSTION

A B

CAPACITY PLATE

ATTACHMENT OR SPECIAL CONDITION OF USE

TYRES SERIAL N°

CENTER OF LOAD DISTANCE mmLIFT HEIGHTmm

DERATED CAPACITY Kg

Co

d. 0

3120

05

Co

d. 0

3120

04

CARRELLI ELEVATORI S.p.A.via Persicetana vecchia, 10

40132 - Bologna - Italia

MODEL Type MOTOR RATED CAPACITY

SERIAL N° DRAW-BAR PULL (1h)

SERVICE MASSBATTERY MASS

MANUFACT. YEAR TENSION

kW kg

N

WithoutBattery kg

kgmin.

kgmax.

V

J

SET OF LEVERS - LOAD HANDLING

K) Lifting control (yellow).L) Tilt control lever (green).M)Control lever of the sideshift or other devices (red).N) Available (if existing; black)

OPENING ENGINE COMPARTMENT COVER

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

LOAD PLATEIt identifies the load capacity with a load centerof 500 mm (except for different indications) IDENTIFICATION PLATE

It identifies the lift truck technical data

CESAB LDTBevan Way

Smethwick - WarleyWest Midla 1ds B66 1BZ

K

L

M

N

C

L

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

ENGINE KUBOTA 3300 - E

1 - Intake manifold2 - Speed control lever3 - Engine stop lever4 - Shut off solenoid5 - Fuel feed pump6 - Cooling fan7 - Engine hook8 - Oil filter cartridge9 - Fuel filter plug

10 - Oil filler plug11 - Exhaust manifold12 - Alternator13 - Starter14 - Fan belt15 - Oil pressure switch16 - Flywheel17 - Oil drain plug18 - Oil pan


2,5 - 3,0 - 3,5 tINTERNAL

COMBUSTION

KUBOTA V 3300 ENGINE

No. cylinders 4 in line

Bore 98 mm

Travel 110 mm

Swept volume 3318 cm‡

Compression ratio 22,6:1

SAE J1349 power 46 kW

Maximum torque230 Nm

at 1600 rpm

Maximum speed (withload)

2200 rpm

Cooling water

Injection indirect

Injection pump in line

Induction atmospheric

Electrical system 12 V

Lubrication forced

Oil sump (capacity)13,2 L

including filter

Alternator 540 W - 45 A

Starter motor 2.5 kW


INTERNALCOMBUSTION

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

CONTINENTAL TM 27 ENGINE

No. cylinders 4 in line

Bore 91 mm

Travel 103,5 mm

Swept volume 2700 cm‡

Compression ratio 8:1

SAE J1349 power 43 kW

Maximum torque200 Nm

at 1500 rpm

Maximum speed (withload)

2400 rpm2200 rpm

Cooling water

Feeding LPG

Induction atmospheric

Electrical system 12 V

Lubrication forced

Oil sump (capacity) 4 L

Alternator 12 V - 65 A

Starter motor 1.4 kW


2,5 - 3,0 - 3,5 tINTERNAL

COMBUSTION

OIL CHANGE AND ENGINE OIL FILTER REPLACEMENT

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

CHANGING OIL AND FILTERAfter the first 50 hours: change oil and filter of the engineand thenevery 50 hours: check oil engine levelevery 250 hours: change oil and filter of the engine

To replace the oil and the filter, proceed as follows:-with the engine hot, remove filling cap, then unscrew the drain plug and allow the oilto drain out.-Unscrew the engine filter cartridge.-Fit the new filter and tighten it, paying particular attention to the position of the seal thatshould be previously oiled.-Tighten the drain plug and fill the oil sump up to the Max level on the dip-stick.

TOPPING UP WITH COOLANT

Every 50 hours- Make sure the coolant level is up to the radiator cap (B).

The caps of the tank and radiator must be removed only whenthe engine is cold.

Every 250 hours- clean the radiator outside.

Every 2000 hours- replace the coolant mixture; check the freezing point of the coolant mixture, especially whendriving areas with cold weather.

The truck is supplied with a 50% mixture of coolant. If you want to varythe mixture, refer to the values stated in the table below.

B

ANTIFREEZE APPLICATION RANGE

10% 20% 30% 40% 50% % VOLUME OF ANTIFREEZE

-4 C -10 C -17 C -24 C -40 C FREEZING TEMPERATURE

101 C 102 C 104 C 106 C 109 C BOILING TEMPERATURE


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

AIR FILTER

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

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

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

CYLONE PREFILTER

Every 8 hours- clean the cyclone prefilter.

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

ENGINE RUNNING-INDuring the running-in period, the engine may consume more oil thanusual. It is recommended that the oil level be checked every 8 workinghours, with engine at stand still for at least 10 minutes.

Do not use the engine at its peak RPM until it has reached its workingtemperature.

A B

C

A


2,5 - 3,0 - 3,5 tINTERNAL

COMBUSTION

The control and adjustment of the electronic transmission are made bya control unit (Total Control System) that drives the following:· thermal engine· hydrostratic pump· hydraulic motors· parking brakes

by means of sensors:· potentiometers (on the accelerator pedal, the brake/inching pedal and the mast lever)· switches (on the tilt levers and sideshift, the forward/reverse gearshift lever and to engage the parking

brake)· potentiometer detecting the pump displacement· sensor of the thermal engine speed of rotationand by means of actuators:· proportional solenoid valves of the hydrostatic pump (displacement adjustment)· actuator on the thermal engine (adjustment of the fuel pump or the carburettor)· solenoid valve for the displacement shifting of the hydraulic motors· solenoid valve for the parking brakes release

HYDROSTATIC TRANSMISSION

Hydrostatic transmission consists of a variable displacement pump, which iscontrolled by the thermal engine and which delivers oil towards two hydraulicmotors that drive the front wheels.The hydraulic connections of both motors allow a proportional division of theoil flow generated by the hydrostatic transmission, so as to support the outerwheel while turning; that kind of transmission acts as the differential transmission.

PortableTerminal

Travel pedal

Parking brake switch

Potentiometer onmast lever

Thermal enginespeed sensor

Hydrostaticpump Thermal engine actuator

Solenoid valve for parkingbrake release

Failure warninglight

Running directionselector

Brake/inchingpedal

Control unit


INTERNALCOMBUSTION

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

circ

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if

EXAMPLE OF A CLOSED LOOP HYDROSTATIC TRANSMISSION

Basic system - pump / motor

An integrated auxiliary pump is used for restoring of the lost oil. The system is completedby an pressure reducing valve, to control the charge pressure.

The system is equipped with two max. pressure valves, one on each side of the high pressure circuit.There function is to protect the hydrostatic transmission (pump and motor) from overloads.

On the hydraulic motor, and on the pump there are some internal oil leakage (for lubrication and cooling). This oil is brought back to the tank.


2,5 - 3,0 - 3,5 tINTERNAL

COMBUSTION

The capacity of the pump is depending of the rpm, and of the displacement, which can be changed in continuity.By increasing the tilting of the plate, the capacity increases from 0, to the max. value.

On tilt 0°, it corresponds to 0 mmof stroke, therefore 0 capacity.(machine stopped)

If the tilting plate of the pump is positionedbeyond the neutral point, the oil flow directionwill be inverted.

OPERATION OF THE VARIABLE DISPLACEMENT PUMP WITH AXIALPISTONS


INTERNALCOMBUSTION

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

OPERATION OF THE ELECTRONIC HYDROSTATIC SYSTEM

1 Thermal engine2 Hydrostatic pump3 Hydraulic motors with built-in parking brake4 Boost pump (charge pump)5 Solenoid valves adjusting the pump displacement (proportionella > 0-5V)6 TCS control unit7 Accelerator pedal (0-5V)8 Direction selector (steering-wheel operated reverse gear with single pedal or acting directly on the

double/swaying pedal system)9 Actuator of the thermal engine10 Sensor for the motor speed of rotation11 Sensor for the hydrostatic pump displacement (magnet potentiometer)12 Brake pedal (0-5V, 0-95% av rörelsen=hydrostatbroms. 95-100% = parkeringsbroms)13 Solenoid valve to release the brakes on the motors14 Parking brake switch15 Fault warning light16 Service pump17 potentiometer/microswitches on the mast lever, the tilt system, the sideshift and any auxiliary

devices. (lyftpotentiometer > 0-5V)

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2,5 - 3,0 - 3,5 tINTERNAL

COMBUSTION

DESCRIPTION OF THE MAIN FUNCTIONS

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

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

ACCELERATION / DECELERATION The truck acceleration depends on the speedwith which the accelerator pedal is pressed and on the parameters set in the control unit.

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

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

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

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

CONSTANT SPEED When using the mast levers, tilt system and sideshift, the thermalengine automatically accelerates to meet the request for additional power; the pumpdisplacement will be simultaneously reduced to ensure that the truck speed is kept constant.


INTERNALCOMBUSTION

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

RUNNING DIRECTION May be selected through the steering-wheel operated reversegear (for simple pedals) or the forward/reverse pedals (for the double and swaying pedalsystem). If the lever of the steering-wheel operated reverse gear is shifted to the neutralposition while the truck is running (or the accelerator pedal is released in case of double pedalsystem), the truck will hydrostatically brake. If the running direction is reversed while thetruck is running, a hydrostatic braking will occur, which will be immediately followed by theacceleration in the opposite running direction.

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

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

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

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

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

THERMAL ENGINE OPTIMIZATION The thermal engine operation (rate of rotation)is optimized according to the truck speed the operator needs.

SPEED DECREASE (OPTIONAL) The truck speed may be decreased for example incase of transmission oil overtemperature.

Exchange valve, 19bar

OljefilterH

YD

RA

UL

IC D

IAG

RA

M

MagnetventilBroms

Prioriterings-ventil

OrbitrolStyrning

Gaspedal

Fram&Back

Broms

S

(återfyllnad av systemet, kompensation för läckolja)

A A=Bypasskruv för bogsering

Per Wärmlund

Per Wärmlund

Per Wärmlund


INTERNALCOMBUSTION

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

HIGH PRESSURE CIRCUIT

LOW PRESSURE CIRCUIT

BY-PASS VALVE2 BAR

RETURNLIFTINGOIL

TRANSMISSIONSUCTION

AUXILIARY SERVICECHECKING POINT

DRAINAGEMOTEURS

RETURNTRANSMISSIONOIL

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LIFTINGSUCTION

EXCHANGE VALVE

OIL RETURN TOTANK

NEGATIVE BRAKEELECTROVALVE

BOOST PRESSURE CHECK POINT

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HIGH PRESSURE CHECK POINT

HIGH PRESSURE CHECK POINT

TEMP


2,5 - 3,0 - 3,5 tINTERNAL

COMBUSTION

The pump displacement is controlled by two proportional solenoid valves which are fed bythe boost pressure and controlled by the control unit through an electric signal. The spool shiftof the solenoid valves controls the pressure over the two chambers of a piston servocontrolthat is mechanically coupled to the pump plate; the difference in pressure between the twochambers determines the piston shift, i.e. the displacement shifting.The pump displacement is then detected by a rotary potentiometer sending a signal proportionalto the plate shift.The electric control through the solenoid valves and the potentiometer represents a feedbackedcircuit for the adjustment of the pump displacement.A sensor detecting the speed of rotation is to be found as well.

HYDROSTATIC PUMP

PUMP Mod. POCLAIN PV75 SA (Eaton, USA)Displacement 75.5 cc/revBoost pump displacement 13.9 cc/revMax. pressure measured in M1 or M2 (stall) 450 BarBoost pressure measured in M3 24-30 BarDrain pressure measured in T1 or T2 max. 5 Bar(cold pump) or after temperature stabilization max. 2.8 BarVacuum pressure (absolute pr., measured in S) 0.8 Bar

EXCHANGE UNITValve setting 19 Bar

Boost pump

Solenoid valves

Actuator

Hydrostaticpump

Pump displacementpotentiometer

Displacement adjustingplate

To motors

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DRAIN INLETT1

(from the exchange unit)

1 1/16 - 12 UN - 2B

POTENTIOMETERMEASURING THE PUMP

DISPLACEMENT POTENTIOMETERCONNECTOR

M

2

M

3

M

1

BHIGH PRESSURE

MOTORSIDE

PROPORTIONALSERVOVALVES FORTHE DISPLACEMENTADJUSTMENT S

CHARGE PUMP INLET PORT(FROM THE OIL FIL

TER)1 5/16 - 12 UN - 2B

SERVOVALVE CONNECTORSENSOR FOR THE SPEED OFR

O

T

A

TION

DRAIN OUTLETT2

(to the radiator)

1 1/16 - 12 UN - 2B

HIGH PRESSURE DETECTION SOCKETM 2 9/16 - 18 UNF - 2B

BOOST PRESSURE SOCKETM 3 7/8 - 14 UN - 2B

HIGH PRESSURE DETECTION SOCKETM 1 9/16 - 18 UNF - 2B

BOOST V

A

L

V

E

S

E

R

V

O

V

A

L

VE PRESSURE SOCKET 2M 5

7/16 - 20 UNF - 2B

AHIGH PRESSURE

(to motors)

S

E

R

V

O

V

A

L

VE PRESSURE SOCKET 1M 4

7/16 - 20 UNF - 2B

MECHANICAL ZEROADJUSTMENT

< 0-5V (2,5V i mittläget)


2,5 - 3,0 - 3,5 tINTERNAL

COMBUSTION

HYDRAULIC MOTOR

Motors Poclain MS 05 (radial pistons)

Maximum displacement 468 cc/revMaximum pressure 450 BarTheoretical torque 740 NmMaximum speed 240 RPMBrake multidisc typeBraking torque max. 3060 NmNumber of pistons 8Brake driving pressure (measured in x) 12-30 BarDisplacement shifting driving pressure (measured in y) 10-30 BarDrain pressure (measured in 1) with cold motor max. 3 Bar

after temperature stabilization max. 1.5 Bar

wheelhub

cylinderunit

distributor brake


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The hydraulic motor is of “slow” type. Due to its radialpistons, it is characterized by a high displacement/rev (ifcompared to engines with axial pistons) so it produces ahigh torque at a low speed rate, with no reduction gearbetween the engine and the wheel hub.

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

Braking release hole- M12 x 1,75

R, L High pression inlet - 3/4 GAS1 Drain hole 3/8 GASX Negative brake pilote 1/4 GAS


2,5 - 3,0 - 3,5 tINTERNAL

COMBUSTION

HYDROSTATIC TRANSMISSION MAINTENANCE

The transmission system and hoisting system have the same oil tank, which is provided with onefilter.

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T

Components of the transmission system:A) Oil level dipstickB) Oil bleeding holeC) Hydraulic oil filter unitD) Oil filling hole

Maintenance consists of the oil change and filter replacement inorder to keep the circuit clean.

REPLACING THE FILTER AND CHANGING THETRANSMISSION OILAfter 50 hours

- First transmission filter replacement.After 500 hours

- Second transmission filter replacement;- First oil change for the transmission/hoisting systems.

Then, every 2,000 hours- transmission filter replacement;- oil change for the transmission/hoisting systems.

The oil change is to be performed once a year. The filter is to be changed also when it getsclogged - warning light (12) on the dashboard on; in that case, replace the filter cartridgeimmediately.

To replace the filter, do the following:- re move plug (C) and extract the filter- insert the new cartridge and close.

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

After replacing the filter and changing the transmission oil:- start up the engine, let it idle for about 5-10 minutes while the vehicle is standstill;- check the oil level; top up, when required.

A CB D


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BRAKES

The brake pedal has two different functions:- braking (if it is used alone)- “inching” function if it is used simultaneously with the accelerator pedal.

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

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

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

DIAGRAM OF THE SERVICE BRAKEAND PARKING BRAKE SYSTEMS

A) Hydraulic motorB) Brake unitC) Solenoid valveD) TankE) Electronic control unitF) Hydrostatic transmissionG) Service brake pedalH) Parking switchI) Potentiometer

Every 4,000 hours- replace solenoid valve (C) for the brake control.

Every 10,000 hours- replace brake hoses (S).

B

C

F

D

E

G

H

A

I

SS

S

H


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COMBUSTION

LN O

M

CHECKING THE SERVICE BRAKE

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

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

Every 250 hours- check the pedal operation; the pedal has to be free from any obstacle;- check the brake wear;

RELEASING THE BRAKES FOR THE TRUCK TOWING

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

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


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P

Q

ELECTRIC SYSTEM

Every 500 hours- check the push-buttons wiring and operation;- check the operation of the microswitches located on the pedals;

Every 1000 hours- inspect wiring and connections; check if the cable terminals are properly tightened

and the cable insulation is intact.

WARNING:DISCONNECT THE TRUCK BATTERY BEFORE SERVICINGTHE ELECTRIC SYSTEM AND THE ELECTRONIC EQUIPMENT.

BATTERYBattery (P) is located under the engine bonnet; before servicing, alwaysdisconnect safety connector (Q).Every 500 hours

- clean the battery poles and terminals;- grease and tighten the terminals;

Every 1,000 hours- check the earth connections.

Every 4,000 hours- replace the battery.

The battery supplied has a min. 100 Ah capacitance.

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

Every 50 hours- check the electrolyte level and density; top up with distilled water,

if necessary.The battery is to be recharged when its voltage has decreased by1.7V or the electrolyte thickness is under 1.16 kg/dm3.

When the truck is running, never disconnect the battery cables,so as to avoid dangerous voltage peaks to the alternator diodes.


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COMBUSTION

ELECTRIC COMPONENTS

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

Fuse specifications1 F1 alternator, starter 40A2 F2 horn 5 A5 F5 system protection 7.5 A7 F7 alternator 7.5 A8 F8 engine stop 5 A11 F11 glow plug 5 A15 F15 rear lights - reverse light 5 A16- F16-rear lights - brake/stop light 5 Athe other fuses are intended for optional systems

Before replacing a fuse, make sure that the problem generating fuse burning has been solved.

RelaysE1 - start upE2 - brake validationE3 - glow plug warning light (diesel engine)E4 - reverse speed validationE5 - forward speed validationE6 - brake/stop rear lightE8 - reverse rear light

the other fuses are intended for optional systems

A

CB

RELAIS TYPE RELAIS TYPE

CODE CODE

E3-E4-E5-E6-E8-E9 E1-E2


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ENGINE ACTUATOR

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

WARNING - POTENTIOMETERS AND MICROSWITCHES

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

BLU

E

BLA

CK

BR

OW

N

RE

D

YE

LLO

W

A

C

C

A B

C

C B

DC

C

BRAKE PEDALTRAVEL PEDAL


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COMBUSTION

ROTARY POTENTIOMETER(on the accelerator and brake pedals) resistance: 2.5 kohm

electric stroke: 54°mechanical stroke: 60°

LINEAR POTENTIOMETER(on the mast lever) resistance: 5 kohm

electric stroke: 10 mmmechanical stroke: 12.5 mm

AMP CONNECTOR type: 144-796-1(on control unit) 55-pin

redgreen

yellow

yellow

red

green


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MENUS AND PARAMETERS FOR THE TCSSYSTEM

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

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

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

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

Use the numeric keypad to enter the parameter values; use the [.] key for decimal places.

För att programmera en lös TCS-box:

Anslut Pin 19 och 37 till B+Anslut Pin 18 och 55 till B-


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COMBUSTION

The main menus are listed below:

N. Menu Functions

1 CALIBRATION to calibrate potentiometers and transmission actuators (pedals,distributor, engine actuator, ...)

2 DISPLAY to display the information on the transmission (thermal engine speed,pump displacement, antistall function, ...)

3 PUMP CUSTOMIZED to customize the transmission (more or less prompt breaking andacceleration)

4 ENGINE CUSTOMIZED to customatize the thermal engine control (higher or lower accelerationof the thermal engine, engine speed when the tilt system and thesideshift are on, ...)

5 FAULT DETECTED to display the system faults6 INFORMATION software versions7 PH PARAMETERS (password) configuration of the system operation parameters8 EEPROM RESET (password) to reset the control unit memory

1) CALIBRATION

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

· when the parking brake is locked and the “calibration status” parameter is “not locked” , it allows thecalibration and configuration of the system elements (calibrating mode);

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

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

Per Wärmlund


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CALIBRATION MENU

N. SUBMENU CALIBRATION MODE DISPLAY MODEA travel pedal calibration of the travel pedal display of the voltage supplied by the

potentiometer for the travel pedalB brake/inching calibration of the brake pedal display of the voltage supplied by the

pedal potentiometer for the brake pedalC mast lever calibration of the mast lever display of the voltage supplied by the

potentiometer for the mast leverD engine calibration calibration of the actuator-thermal display of the voltage supplied by the

engine potentiometer for the actuatorE pump neutral calibration of the pump in neutral display of the voltage supplied by the

position potentiometer for the hydrostatic pumpF max. forward limiting of the truck max. display of the truck forward speed

speed forward speed (as a percentage of the max. speed)G max. reverse limiting of the truck max. display of the truck reverse speed

speed reverse speed (as a percentage of the max. speed)H parking brake set definition of the brake pedal displays the brake pedal position in which

position in which the mechanical the mechanical brake is lockedpedal is engaged

I min engine speed definition of the minimum engine displays the minimun engine RPMRPM (tomgång)

L max engine speed definition of the maximum engine displays the maximum engine RPMRPM (fullvarv)

M pump pot. inverted definition of the connections type displays the connections type(*) of the pump potentiometer of the pump potentiometerN calibration status lock or unlock the calibration status of the calibration menu

menu

(*) With Hall potentiometer software only

For the TCS correct operation, the voltage values read by the potentiometers in the pedals, the mastsystem and the motor actuator must not exceed the limits set. If the mechanical limit stops of thepotentiometer are not properly adjusted, the voltage supplied by the potentiometers and exceedingthe range of values allowed by the control unit disables the calibration procedure.That trouble may also occur after a correct calibration if, for whatever reason, the limit stop ismodified.


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COMBUSTION

CALIBRATION AND FIRST START UP OF THE TRANSMISSION SYSTEM

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

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

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

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

· Lift the truck onto the shim blocks· Fill the hydraulic circuit and bleed the air· Engage the parking brake· Select the neutral position (through the steering-wheel operated reverse gear)· Start up the engine and wait for the stabilization of the fuel boost pressure· Adjust the engine min. and max. RPM through the actuator limit stop screws (the limit stops are to be obtained

on the actuator support, not on the injection pump). The engine RPM is to be measured through the “enginespeed” parameter in the “DISPLAY” menu.

· Calibrate the actuator (ENGINE CALIBRATION)· Press the accelerator pedal; the actuator has to rotate clockwise and the voltage of the feedback potentiometer

in the actuator has to increase (such voltage may be measured in the “engine calibration” parameter in the“calibration” menu after engaging the parking brake).

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

CAUTION: the hydraulic motors must not rotate quickly when wheels are up.When wheels rotate forwards, check that the voltage of the pump feedback potentiometer increases from 2.5 to5 volts (for the voltage detection, use “pump neutral” parameter in the “calibration” menu).Check the correct operation under the following conditions:

- mast lifting, sideshift and tilt operation, etc.: if the relevant levers are adjusted, the thermal enginewill accelerate.- forward/reverse speed and braking- parking brake: if engaged, the travel pedal will be disabled (the engine RPM will increase, but the truckwheels will be locked)

- emergency button.


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A) TRAVEL PEDAL CALIBRATION

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

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

SEE THE “DIAGRAM FOR USING CONSOLE”SECTION “CALIBRATION”

B) BRAKE / INCHING CALIBRATION

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

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

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


C) MAST LEVER CALIBRATION

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


lever in neutral position 0,35 - 2,3volts (7 - 46 % of the supply voltage)lever fully pulled 2,4 - 4,65 volts (48 - 93 % of the supply voltage)


D) ENGINE CALIBRATION

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

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

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

Vid 2-pedal system:Se till att max positionerna är lika för fram och back!


2,5 - 3,0 - 3,5 tINTERNAL

COMBUSTION


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

E) PUMP NEUTRAL CALIBRATION

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

The voltage value must not exceed the following range: 2.49 to 2.51 volts.(In display mode and when the truck is running, the voltage value must vary. When the wheels rotate forwards, thepotentiometer voltage must tend to 5 Volts and remain constant).


F) MAX FORWARD SPEEDThis parameter (expressed as a percentage of the truck forward max. speed) limits the travel speed. This parametermay be modified (in calibration mode).

G) MAX REVERSE SPEEDThis parameter (expressed as a percentage of the truck reverse max. speed) limits the travel speed. This parametermay be modified (in calibration mode).

H) PARKING BRAKE SETThis parameter defines the stroke of the brake pedal necesary to engage the mechanical brake. The standardvalue is 95%. It is suggested that this value be not changed. Limit values: 90 to 95%.

I) MIN ENGINE SPEEDThis parameter defines the minimum engine RPM (standard value 850).

L) MAX ENGINE SPEEDThis parameter defines the maximum engine RPM (standard value 2250).

M) PUMP POT. INVERTEDThis parameter defines the connections type of the pump potentiometer.This parameter is present with the Hall potentiometer software only.

N) CALIBRATION STATUSThis parameter enables or disables the calibration mode.


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2) DISPLAY

This menu displays the transmission data.Press [ENTER] to display a data (e.g. thermal engine speed). Hold down the key to display data in sequence.

ENGINE SPEEDReal speed of the thermal engine (expressed in RPM). (9 pulser/varv)

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

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

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

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

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

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

PUMP FEED-BACKActual displacement of the pump (expressed in cc). This is the displacement measured by the potentiometerlocated on the pump.

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

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

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

ACTUATOR FEED BACKDisplays the engine actuator signal in Volt. Increase during the acceleration and vice versa.

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

SENSOR EXCITATIONDisplays the voltage supply of the sensor. Correct value 5 Volt.

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


2,5 - 3,0 - 3,5 tINTERNAL

COMBUSTION

3) PUMP CUSTOMIZED

Allows setting of the parameters who controls the hydrostatic pump.These parameters is used to modify the acceleration and deceleration of the truck.First the modification of these parameters must enabled (calibration status - not locked).

TRAVEL PEDAL INC. (sekunder från neutral till full utvinkling)This parameter defines how long time it takes for the pump to reach its max. displacement when the travel pedal is fully pressed ( higher value of this parameter = softer acceleration of the truck).

TRAVEL PEDAL DEC. (sekunder från full utvinkling till neutral)This parameter defines how long time it takes for the pump to reach its neutral displacement mode when the travel pedal is released (higher value of this parameter = softer decceleration of the truck during thehydrostatic braking).

HARD BRAKING RATIOThis parameter (%) change the release braking value (travel pedal dec.) according to the following table:

Braking times of the truck function of the two parameters“Travel pedal dec” (s) and “Hard braking ratio” (%)

Travel pedal dec. (s) 2 5 7 10

Hard braking ratio (%)0 2 5 7 1017 1.7 3.8 5 6.550 - 2.8 - -67 1.6 2.5 3.1 3.683 - 2.3 - -100 1.3 2.1 2.5 2.9

SENSITIVITYThis parameter defines the sensitivity of the pump control when changing the pedal position (this value is expressed as a percentage of the pump max. displacement control).

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

INCHING PEDAL DEC.This parameter defines how long time it takes for the pump to range from the max. displacement to the neutral position when the inching pedal is instantaneously pressed after fully pressing the travel pedal.

Låg hastighet

Hög hastighet

0=Samma bromskraft vid alla hastigheter. 100=Hårdare broms vid hög hastighet.


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4) ENGINE CUSTOMIZEDAllows setting of the parameters who controls the thermal engine . Do not modify the standard values.

TRAVEL PEDAL INC. (sekunder från tomgång till fullgas)This parameter defines how long time it takes for the actuator to achieve its stroke when the travel pedal is fully pressed (the higher the value of this parameter, the longer the time the thermal engine takes to range from its min. RPM to its max. RPM).

TRAVEL PEDAL DEC. (sekunder från fullgas till tomgång)This is the same as the previous parameter (the time it takes for the thermal engine to range from its min. speed to its max. speed).

MAST INC.This parameter defines the time it takes for the actuator to achieve its stroke when the lifting lever is pulled(higher value of this parameter = longer time for the thermal engine to range from its min. RPM to its max. RPM).

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

MAST FIXED CMD 1

MAST FIXED CMD 2Parameter that defines the thermal engine speed rate when one of the auxiliary devices of the hydraulic valve unit is activated (tilt , sideshift, 4th way, 5th way).The engine RPM is increased to a value, according to the parameter set. Standard value is 30 - 40%.

Ex: engine min. speed: 700 rpm; engine max. speed: 2500 rpmusable range: 700 - 2500 = 1800 rpmparameter (mast fixed cmd): 25 %

If the engine operates at a speed higher than 1100 rpm and the hydraulic lever is activated, the actuator will bring the engine rpm to: 1100 + (2500 - 700)x0.25 = 1550 rpm.

Do not increase the speeds set to avoid dangerous manoeuvres.Stroke of the sideshift: 2 -2.5 secsTilting: 4.5 - 5 secs

MAST MAXIMUM CMD (Available from 2001)Parameter which defines the max thermal motor rpm when the lifting is started. By activating the lever, themotor speed increases step by step until the max value set.


2,5 - 3,0 - 3,5 tINTERNAL

COMBUSTION

5) FAULT DETECTED

Displays the system faults.

- FAULT OCCURRING NOWPress [ENTER] to display the current fault.

- FAULT SINCE START UPPress [+] and [-] to display the last five faults occurred.

FAULTS MESSAGES SHOW ON THE CONSOLE

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

“Power Supply” The supply voltage of TCS control unit is < 9.5V or > 32V for more than2 sec. long.

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

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

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

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

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

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

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

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

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

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

“Eeprom error at address” One parameter at least is outside the field of acceptable values.


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“Direction switches error” The TCS control unit takes contemporarily the forward and reverse gear(running mode) started..

“Other Default” Other faults.

6) INFORMATION

Displays the SOFTWARE version

7) PH PARAMETERS

- PASSWORD (4567 or 4321)Enter the password (4 numbers) with the digital key and then valid (enter).Press the key / esc then [+] and [-] in order to haves access to the rest of the menu.

- PUMP NEUTRAL OFFSETThis parameter is made to offset pump feedback

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

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

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

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

- REGULATOR OFFSETThis is the acceptable difference between the ordered engine speed and the measured engine speed.If this value is exceeded, the antistall function is active.

Per Wärmlund

Per Wärmlund


2,5 - 3,0 - 3,5 tINTERNAL

COMBUSTION

- ANTISTALL COEFCoefficient apply to the action of antistall function.The parameter change from 3 to 8.Bigger is the values more is the desplacement decrease.

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

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

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

- ENGINE DELAI DECThis value is the complementary value of engine delay dec. It is take into account during the engine deceleration.

8) EPROM RESET

This menu is made to reset the data of the EEPROM

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

- ALL EEPROM RESETA press on the key (ENT) cancel the list of the statistics.

- FAULT LIST RESETA press on the key (ENT) cancel the list of the detected defaults.

TROUBLES OCCURRING WHILE CALIBRATING

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

travel pedal position out of range travel pedalbrake/inching pedal sensor brake pedalmast lever sensor mast leveractuator position out of range thermal engine actuatorfeed-back error hydrostatic pump potentiometer


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1) TRAVEL PEDAL

travel pedal position out of range (error message)

release the parking brake (the terminal will range fromthe CALIBRATION MODE to theDISPLAY MODE)

select the (the terminal will display theTRAVEL PEDAL submenu voltage - expressed in volts - that

is supplied from the otentiometerin the travel pedal)

yes voltage = 0 volt? no

check the hold down the [ENTER] key andpotentiometer wiring check if voltage changes when

the pedal is pressed

does voltage change?

yes no

press the [ENTER] key to check the potentiometer wiringmeasure the min. and max. voltagesupplied by the potentiometer

adjust the mechanical limit stop ofthe pedal so that the voltage doesnot exceed the ranges set(see “travel calibration”)

Calibrate the travel pedal.

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2,5 - 3,0 - 3,5 tINTERNAL

COMBUSTION

2) BRAKE/INCHING PEDAL

brake/inching position out of range (error message)


select the BRAKE/ (the terminal will display the voltage inINCHING PEDAL submenu volts, that is supplied by the brake

pedal potentiometer)

yes voltage = 0 volt? no

check the hold down the [ENTER] key and potentiometer wiring check if voltage changes when

the pedal is pressed


yes no

press the [ENTER] key to check the potentiometer wiringmeasure the min. and max. voltagesupplied by the potentiometer

adjust the mechanical limit stops ofthe pedal so that the voltage doesnot exceed the ranges set(see “travel calibration”)

Calibrate the brake pedal.

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�

�

�


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3) MAST LEVER

mast lever sensor out of range (error message)


select the (the terminal will display theMAST LEVER submenu voltage in volts, that is supplied

by the mast lever)

yes voltage = 0 volt ? no

check the potentiometer Hold down the [ENTER] key andwiring check whether voltage changes

when the lever is pulled


yes no

press [ENTER] to measure the check the electrical connectionsmin. and max. voltage supplied by of the potentiometerthe potentiometer

Adjust the shims of thepotentiometer support bracket sothat the voltage does not exceedthe ranges set (see “mast levercalibration”).If the lever is shiftedforward from its middle position(for the forks lowering) voltage isnot to decrease.

Calibrate the mast lever.

�

�

�

�

�

� �

�

�


2,5 - 3,0 - 3,5 tINTERNAL

COMBUSTION

4) THERMAL ENGINE ACTUATOR

actuator position out of range (error message)

release the parking brake (the terminal will switch from theCALIBRATION MODE to the DISPLAYMODE)

select the ENGINE (the terminal will display the voltage, CALIBRATION submenu in volts, supplied by the potentiometer of

of the actuator)

yes voltage = 0 volts? no

check the electrical con- hold down the [ENTER] key and nections of the actuator check if voltage changes while the

actuator rotates


yes no

press the [ENTER] key to measure check the actuator electrical connectionsthe min. and max. voltage suppliedby the actuator potentiometer

adjust the length of the tie rod sothat voltage does not exceedthe ranges set(see “engine calibration”)

Calibrate the actuator.

� �

�

�

�

�

�

�

�

(engage theparking brake andpress theaccelerator pedal)


INTERNALCOMBUSTION

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

5) POTENTIOMETER IN THE HYDROSTATIC PUMP

feed-back error (error message)

release the parking brake (the terminal will range from theCALIBRATION MODE to theDISPLAY MODE)

select thePUMP NEUTRAL submenu (the terminal will display the

voltage, in volts, that is suppliedby the potentiometer in thehydrostatic pump)

yes voltage = 0 volts or 5 volts ? no

check the potentiometer voltage = 2.48 ̧ 2.52 volts ? electrical connections

yes no

engage the parking brake,switch to CALIBRATION modeand calibrate the pumppotentiometer to zero

�

�

�

�

�

� �

�

- check the potentiometer wiring- lift the truck on the shim blocks,

electrically disconnect the pumpsolenoid valves and start up theengine: if the pump supplies someoil, the trouble is a hydraulic ormechanical type (mechanicalmaladjustment of the pump platepositioning in neutraldisplacement)

- after disconnecting the valves, if thepump supplies some oil, switch offthe engine and hold down the[ENTER] key in order to read thevoltage, until a 2.5 volt value isobtained.

engage the parking brake, switchto CALIBRATION mode andcalibrate the pump potentiometerzero.


2,5 - 3,0 - 3,5 tINTERNAL

COMBUSTION

SYSTEM FAULTS AND FAILURES

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

Error message Cause Cure

- the signal (voltage) of the travel pedalpotentiometer has exceeded the limitsset while calibrating

- connector disconnected or wrong wiringtravel pedal sensor

brake/inching pedalsensor

mast lever sensor

actuator sensor

error on actuatorcontrol loop

This message may bedisplayed if theaccelerator is pressed(green light on) whenthe engine is off and thebrake is unlocked

power supply out ofrange

- check the potentiometer wiring- check if the voltage values at the

pedal limit stop do not exceedthe limits preset

- adjust the pedal limit stops- calibrate the pedal again- (see page 51)

- the signal (voltage) of the brake pedalpotentiometer has exceeded the limits setwhile calibrating

- connector disconnected or wrong wiring

- as above (see page 52)



- the signal (voltage) of the mast lever hasexceeded the limits set while calibrating

- connector disconnected or wrong wiring

- the signal (voltage) of the feedbackpotentiometer has exceeded the limits setwhile calibrating

- connector disconnected or wrong wiring.

- >20% error, for more than 0.5 secs,between the actuator setpoint and thepotentiometer feedback

- connector disconnected or wrong wiring.

- check the actuator wiring- check theactuator potentiometer

output signal (if you press theaccelerator pedal, the actuatorshall rotate forward and thevoltage - measured in “enginecalibration” when the brake isreleased - shall increase)

- check the supply voltage value- the supply voltage of TCS control unitis not included in the 9.5 - 48 volts range


INTERNALCOMBUSTION

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

excitation voltage

feedback error

neutral out ofrange

error on pumpcontrol loop

If the warning light blinks quickly (1 Hz) the fault is serious; the machine stops.


- wrong value of the supplyvoltage of the potentiometers andmicroswitches

- check that the voltage is equal to 5 volts± 5%

- wrong signal of the feedbackkpotentiometer in the hydrostaticpump

- check that the feedback potentiometervoltage is equal to 2.5 ± 0.15 voltswhen the pump is in neutraldisplacement mode (see page 55)

- wrong signal of the feedbackpotentiometer in the hydrostaticpump when the latter is inneutral displacement mode

- check the potentiometer calibration(PUMP NEUTRAL)

- check that the feedback potentiometervoltage is equal to 2.5 ± 0.15 voltswhen the pump is in neutral displacementmode (see page 55)

- >20% error, for more than 0.5secs, between the pump controlsignal and the potentiometerfeedback signal in the pump

- check the pump wiring(potentiometer and solenoid valves)

- check that the feedback potentiometervoltage properly changes whilecontrolling the solenoid valves

- measure the min. and max. voltage ofthe pump potentiometer and check thatthe control max. value is kept constantduring the forward and reverse runningmode (when the wheels turn forwards,the potentiometer voltage has to tendto 5 volts) (when the machine is runningin the pump neutral calibration function)


2,5 - 3,0 - 3,5 tINTERNAL

COMBUSTION

if the fault warning light is off:- check the signal of the speed sensor

(DISPLAY-ENGINE SPEED menu (check if the valuedisplayed is acceptable)

if the warning light blinks slowly:- check the signal of the travel pedal

(CALIBRATION - TRAVEL PEDAL CALIBRATION menu)if the warning light blinks quickly:- check the supply voltage of the sensors (5 volts)

(CALIBRATION - SENSOR EXCITATION menu)- control unit supply voltage

(CALIBRATION - POWER SUPPLY menu)- signal of the pump potentiometer

(CALIBRATION menu (display mode)-PUMPNEUTRAL)

- wiring of the pump potentiometer(CALIBRATION menu (display mode)-PUMPNEUTRAL )

- wiring of the pump displacement control solenoid valves(VISUAL INSPECTION)

The thermal engine works correctlybut the pump is faulty

The pump works correctly but thethermal engine is faulty

The pump and engine work correctly,but the engine does not acceleratewhen the distributor levers areactuated

The pump and thermal engine do notwork

Fault Possible cure

- check the parking brake operation (DISPLAY-BRAKE SWITCH(set-not set) menu)

- check the operation of the speed selector (pedals with steering-wheel operated reverse gear) or the microswitches on the otherpedals DISPLAY-DIRECTION SWITCH (neutral forwardreverse menu)

- check the signal on the speed sensor (on the pump)(DISPLAY-ENGINE SPEED menu - check if the valuedisplayed is acceptable)

- check the signal of the feedback potentiometer (on thepump)(CALIBRATION menu (display mode)-PUMPNEUTRAL)

- check the actuator operation(CALIBRATION (display mode) - ENGINECALIBRATION menu)

- check the mast potentiometer signal and wiring (of thepotentiometer and microswitches) -(CALIBRATION (display mode)-MASTLEVER CALIBRATION menu)

- check if the potentiometer is fitted (TCS parameter)(CALIBRATION menu, MAST LEVER, mast sensor presence(1) menu)

TROUBLESHOOTING


INTERNALCOMBUSTION

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

WHEELS / TYRES

SAFETY OF WHEELS AND RIMS WHILE USING THE TRUCK“TYRES” are to be replaced when the tyre tread is under 1.6 mm.“SUPERELASTIC” tyres are to be replaced when the tyre tread reaches the“60 J” mark, which is printed on the tyre side.

WHEEL TIGHTENING TORQUEDriving wheels 17 daNmSteering wheels 24 daNm

SUPERELASTIC (SE)

PNEUMATIC (PN)

T YRE T YPE SIZEAIR

PRESSIO NT YPE

SUPERELAST IC( SE)

F RO NT7 . 0 0 - 1 2

2 7 X1 0 - 1 22 . 5

3 . 0 - 3 . 5

REAR 6 . 5 0 - 1 02 . 5 - 3 . 0 - 3 . -

5

PNEUM AT IC( PN)

F RO NT

7 . 0 0 - 1 22 7 X1 0 - 1 2 ( 1 6

PR)2 7 X1 0 - 1 2 ( 2 0

PR)

9 b a r8 b a r

1 0 b a r

2 . 53 . 0 - 3 . 5

REAR 6 . 5 0 - 1 0 7 , 7 5 b a r2 . 5 - 3 . 0 - 3 . -

5

T W INSUPERELAST IC

( SEG )F RO NT 7 . 0 0 - 1 2

2 . 53 . 0 - 3 . 5

T W INPNEUM AT IC

( PNG )REAR 7 . 0 0 - 1 2 9 b a r

2 . 53 . 0 - 3 . 5


2,5 - 3,0 - 3,5 tINTERNAL

COMBUSTION

CHECKING THE SYSTEM SEALING AND CLEANINGTHE POWER STEERING SYSTEMEvery 250 hours - Check the whole system for any possible leakage; before servicing,

release the system pressure.Every 4,000 working hours- replace hoses (D) connecting Orbitrol to the steering cylinder.Every 10,000 working hours- replace the system pipes.

Adjusting the power steering pressureThe max. pressure of the power steering is to be equal to 100 Bar

POWER STEERINGCIRCUIT DRAWING

A

D

B

PRIORITY VALVE(C)

D

STEERING CONTROL

The steering uses the same oil as the lifting by means a priority valve, so that a sufficientoil flow to the power steering is always assured.The oil capacity is checked by the Ls signal (load - sersing) coming from the steeringunit and it occurrs so that the oil capacity sent to the power steering is equal to itsactual 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 proportionalto the above rotation and sends it into the steering cylinder.

Do the following to adjust the power steering pressure:1 - Install a pressure gauge in (C) the power steering;2 - With a socket head spanner, remove the cap located in the Orbitrol upper part to reach the

adjusting screw (B) (power steering unit);- screw in to increase pressure- screw out decrease pressure


INTERNALCOMBUSTION

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

STEERING AXLE

Every 500 hours- lubricate the steering gear joints using the appropriate grease nipples (C);- check the steering angles.

Every 2.000 hours- check and if it is necessary, adjust the wheel hub bearings.

Every 500 ore check the angles

Max steering angle (internal wheel ≅ 75°)

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

B = 75° STANDARD VALUE80° MAX VALUE WITH PN85° MAX VALUE WITH SE

ANGLE MEASURED BY THE AXLE FRAME TO THE INTERNALWHEEL THROUGH A SPECIAL DEVICE

END STROKESETTING SCREW

STEERING AXLE

G

C

CC

C


2,5 - 3,0 - 3,5 tINTERNAL

COMBUSTION

BEARING ADJUSTMENT

Steering wheel bearings require an adjustment once a year.

Steering wheels- lift the steering wheels- remove cap (1);- remove toothed washer(4);- fasten the nut with a torque setting of 6 dNm;- turn the hub of 2-3 turns in both senses;- unfasten nut (3) and retighten with a 2-1 daNm torque;- check that the wheels slide correctly (max. rolling final torque: 0.2 dNm)

and that there is no side play (maximum axial play of 0.05 mm);- reassemble the toothed washer;- reassemble the cap (1);- lower the wheels again and check that all nuts fixing the rim are well tightened.

1

2

4

5

3


INTERNALCOMBUSTION

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

HYDRAULIC DISTRIBUTOR

Nominal capacity 80 l/min3 - 4 - 5 section

Lifting potentiometer

Max lifting pression 235 ± 5 Bar

Relief valve pressionTilting 180 BarSide shift 150 Bar

Microswitch

Nipple 1/2 Gas

Restrictor Ø 2 mm


2,5 - 3,0 - 3,5 tINTERNAL

COMBUSTION

MAST GROUPS

The mast profile - CESAB design - with double stiffening flange is characterised by a highflexural 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 theouter mast and a mobile one on the inner mast, instead of a number of mobile rollers only onthe inner mast). This solution ensures better grip and stability on operation.

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

Lifting cylinders:Duplex mast: VT 2 side cylinders

FFL 2 central cylinders1 central cylinders for the FFL

Triplex mast VT 2 side cylindersFFL 2 side cylinders

1 central cylinders for the FFL

Grease nipple Adjusting screw Shoe Roller


INTERNALCOMBUSTION

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

TRIPLE MAST SECTION

Fork carriage

Internalsection bar

Intermediatesection bar

Externalsection bar


2,5 - 3,0 - 3,5 tINTERNAL

COMBUSTION

6

4

5

3

1

2

5

DIAMETRODISPINTA

7

Fig. A Fig. B

In these cylinders a seal (1) has been fitted on thepiston (2) that works on the inner surface of thecylinder liner (3).

The rod guide is made by the plug (4) and by thepiston through anti-friction rings (5).

The dust control ring (6) prevents any dirt and waterfrom penetrating the cylinder.

Slight leakages that may occur are directed to thetank through the drain pipe connected to the pipecoupling (7).

The drain pipe shall reach the oil tank (fig. B)

A small quantity of oil will always remain in the loopformed by the pipe before connecting to the tank. Itacts as a trap and constantly moisturizes the cylinderliner, when it is completely closed (fig. B).

DESCRIPTION OF THE CYLINDER COMPONENTSThe cylinder pistons are single-acting types (fig. A).


INTERNALCOMBUSTION

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

Fig. C

CYLINDER CHECKING METHODS

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

Lift the cylinder some times to end stroke, so as todischarge 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 theload has lowered. A drop of a few millimetres is quitenormal, as in the distributor there are always someleakages.Now, lift the cylinder to its end stroke, if no oil leaksfrom the drain pipe coupling, it means that the loadlowering is only due to the leakages on the distributor.

In the presence of leakages, it will be necessary toreplace the seal. Should this be the case, inspect thecylinder liner.

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

Remove the drain pipe from the cylinder.

Lift the cylinder some times to end stroke, so that allthe 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 isdamaged and then it must be replaced.


2,5 - 3,0 - 3,5 tINTERNAL

COMBUSTION

LUBRICATION

Masts

After the first 50 hours- adjust the guide shoes through socket head screw (D).

Use a 0.2 - 0.5 mm thickness gauge; fit it from the bottom upwardsto socket head screw (D) centre, passing behind roller (E) andcreeping on the outer mast.

Every 50-100 hours- Grease the mast sliding guides- through the grease nipples, lubricate the articulations of the tilt cylinders

and of frame coupling.

Every 250 hours- adjust the guide shoes;- grease mast guide rollers (E).

Every 2000 hours- inspect mast guide rollers (E); they have to rotate freely and not

to be too worn out.

A) tilt cylinders2+2 grease nipples

B) mast coupling1+1 grease nipples

Fork mounting carriage and sideshift

After the first 50 hours- adjust the guide shoes through socket hallen screw (D).

Use a 0.2 - 0.5 mm thickness gauge, fit it from the bottom upwardsup to socket hallen screw (D), going behind roller (E).

Every 50 hours- lubricate the sideshift guides through the grease nipples.

Every 250 hours- grease the pins and the fork positioning slots;- adjust the guide shoes;- grease the guide rollers of carriage (F).

D

E

B

D

F

E

A


INTERNALCOMBUSTION

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

Every 2,000 hours- check the conditions of the guide rollers; they

have to rotate freely and not to be too wornout.

C) Sideshift(upper part) 2 grease nipples(lower part) no grease nipple

INSTALLATION CHECKSSAFETY SPECIFICATIONS

Make sure that:- the hoisting chain stretchers are not faulty and

the adjusting nuts are locked by counternuts andcheck pins (F);

- safety limit stops (A) of the fork mounting carriageare fitted and tightened up;

- stop collars (D) are fitted and tightened up;

Every 500 hours- check that distance (D) between the collar and

the mast outer cylinder ranges from 0.5 mm to3 mm;

- check if self-locking nuts (B) are tightened up.

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

SAFETY LIMIT STOPS OF THE FORKMOUNTING CARRIAGESThe mast unit is equipped with a mechanical safetylimit stop to prevent the accidental removal of thefork mounting carriage from the mast downwards.Limit stops (A) consist of two socket head screwswith counternut. Loosen limit stops (A) beforedisassembling the fork mounting carriage.

C

D

B

D

A

F


2,5 - 3,0 - 3,5 tINTERNAL

COMBUSTION

CHAIN INSPECTION

Every 500 hours (anyway, chains are to be checked every 3 months)- chains are not to be faulty or worn out.

To check if the chain links are worn out, use the appropriate ruler; remember thatchains must be replaced when, in a portion corresponding to 34 pitches, only33 pitches are found.

Every 1,000 hours- disassemble the chains, carefully clean them, reassemble reversing their original

work position, and grease.Every 10,000 hours

- replace the chains and the fastening tie rods.

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

G

F

D D

F

EE

G

FORK INSPECTION(to be performed every 1000 hours)

- Surface cracks particularly in D/E/F- Height difference of the tips (is to be < 3% than the fork

length)- Positioning latch (G)- Punching is to be clear- Fork measure (maximum wear = 10% of the original thickness)

particularly in point D- Wear of the fork fastening devices on the carriage (E-

F)

X = 152 mm (2,5T)203 mm (3,0 - 3,5T)

TABLE ISO 2328 - 1993

Rate lifting load (kg) "X" (– 5)

I B 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

V B 8 001 10 999 257 mm


INTERNALCOMBUSTION

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

LIFTING OF THE FORKLIFT TRUCKWITH CABIN

A- CHAINS: dia. 13 mm - Degree T (8) - UNI9425

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

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

HOOKS ATTACHMENT POINTS FORLIFTING THE TRUCK

To lift the truck the following equipment must beused:

A- CHAINS: dia. 13 mm - Degree T (8) - UNI9425

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

AA

B

C C

A

B

LIFTING OF THE TRUCK

TRUCK WEIGHTON THE AXLE WITH OUT

LOAD(FRONT / REAR)

2.5 t 4050 kg 2070 / 1980 kg

3.0 t 4600 kg 2100 / 2500 kg

3.5 t 5160 kg 2260 / 2900 kg


2,5 - 3,0 - 3,5 tINTERNAL

COMBUSTION

OIL AND GREASE SPECIFICATIONS

TYRE PRESSURES TIGHTENING TORQUES

FOR NORMAL ENVIRONMENTS

USED TYPE SPECIFICATIONS QTY.PARTS INVOLVED

AGIP ARNICA 46 ISO - L - HVFZG tests to stage 11

39 LHydraulic system, lifting, power steering andhydrostatic transmission

MOBIL ANTICONGELANTE - - Cooling liquid

MOBIL DELVAC 1300SUPER SAE 15W-40

API CD-SF CCMC-D3(SHPDO)-PD1 MIL-L-2104D

MIL-L-46152B- DIESEL engine

20 ÷ 40 SAE - - Mast chain lubrication

MOBILGREASE SPECIALLithium base

ASTM 275 305 NLGI N.2dropping point 180

-Mast securing joints - sideshift unit - steeringjoint - general lubrication with grease nipples

FOR COLD CLIMATES AND COLD-STORAGE CELLS

PARTS INVOLVED

AGIP ARNICA 22 ISO - L - HVFZG tests to stage 10

39 LHydraulic system, lifting and power steeringunits

MOBILTEMP SHC 100Thickening Infusible

ASTM 265 295 NLGI N.2Dropping point >260

-Mast securing joints - sideshift unit - steeringjoint - general lubrication with grease nipples -mast guides

TYRE PRESSURES

9,5 bar7,5 bar

400-450500

FRONT tyres

9,25bar

REAR tyres

WHEEL TORQUE

37 daNm steered wheels

50 daNm driven wheels

DRIVE UNIT TORQUE

27 daNm engine fixing to chassis

VARIOUS TORQUES

40 daNm bolts securing mast

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

77 daNm counterweight blocking screws


INTERNALCOMBUSTION

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

RUNNING IN MAINTENANCE

The servicing periods are divided into hours, consideringan average working day of 8 hours of effective operation.If the truck is used on average for less than 8 hours perday, refer to the schedules expressed in days/months

LEGEND

In the maintenance table showing a visualcontrol and cleaning of the parts indicated.

In the maintenance table showing thereplacement of the parts indicated.

In the maintenance table showing lubrificationof the parts indicated.

In the maintenance table showing tighteningor adjustment of the parts indicated.

50 500 #at # hours for MEDIUM/INTENSEUSE

7/- -/3 #at # days/months FOROCCASIONAL USE

ENGINES

engine oil and cartridge

clearances engine values

fan belt and alternator belt

CHASSIS AND CONTROLS

general bolt and nuts

wheel torque (1)

(1) During the first 500 worning hours, checkthe torque every 50 hours

LIFTING UNIT - MASTS

mast guide pads

oil filter


transmission oil filter

transmission oil


2,5 - 3,0 - 3,5 tINTERNAL

COMBUSTION

MAINTENANCE TIMES

8 50 250 500 1 0002

0004

00010

000 #at # hours for MEDIUM/INTENSEUSE

1/- 7/- -/1 -/3 -/6 -/12 -/24 -/60 #at # days/monthsFOR OCCASIONAL USE

mast guide pads

carriage - sideshift unit slides

mast rollers and chain rollers

tilting jacks supply tubes

fork positioning pins

mast guides, mast and jack fixing

lifting jack collars

fork carriage position

forks

mast tilting

mast secured to chassis

lifting chains

chain securing bolts

high pressure hydraulic hoses

system seal and connections


INTERNALCOMBUSTION

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

MAINTENANCE TIMES

8 50 250 500 1000 2000 4000 10 000 #afteri # hours FORMEDIUM/INTENSE USE

1/- 7/- -/1 -/3 -/6 -/12 -/24 -/60 #after # days/months FOROCCASIONAL USE

CHASSIS AND COMMANDS

chassis - cleaning

bolts in general

fuel tank cleaning

fuel tank control

driver’s seat

wheels - hub bearings

tyre inspection and wheel tightness

tyre pressures

steering system and tubing seal

hoses from orbitrol to steering jack

rear axle and weheel hub bearings

steering lock

pedals in general - linkage

brake commands solenoid valve


2,5 - 3,0 - 3,5 tINTERNAL

COMBUSTION

MAINTENANCE TIMES

8 50 250 500 1 000 2 000 4 00010000

#at # hours for MEDIUM/INTENSEUSE

1/- 7/- -/1 -/3 -/6 -/12 -/24 -/60 #at # days/months FOR OCCASIONUSEENGINE

cooling liquid

fuel filter cartridge

air filter

dusty environment air filter

cyclone prefilter

water and oil radiator (external cleaning)

water and oil radiator in dustyenvironments

fan belt and alternator belt

engine oil and filter cartridge

engine supports

engine linkage and fuel connections

fexible fuel and water hosing

DIESEL engine injection pressure control

DIESEL engine valve clearance

PETROL and LPG engine valveclearance

PETROL and LPG engine spark plugs

LPG system control

LPG bottle hose and safety valve

LPG pressure reducer


INTERNALCOMBUSTION

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

MAINTENANCE TIMES

8 50 250 500 1000 2000 4000 10000 #at # hours for MEDIUM/INTENSEUSE

1/- 7/- -/1 -/3 -/6 -/12 -/24 -/60 #ati # days/months forOCCASIONAL USE

ELECTRIC SYSTEM

pushbuttons - pedal microswitches

cable terminals - cable sheaths

battery electrolyte level and density -replacement

battery terminals and poles


system seal

transmissin oil filter

transmissin oil

complete unit

Var 2000:e timme tillkommer:0:0 Grupp 0 Hel maskin0:14 Ram, kontroll av sprickor

1:0 Grupp 1 Motorer1:15 Kylvätska, byte

4:0 Grupp 4 Styrning4:4 Slangar, kontroll

4:5 Styrtryck, kontroll

5:0 Grupp 5 Elsystem5:13 Laddning, kontroll

6:0 Grupp 6 Hydraulik6:5 Hydraultryck, kontroll

6:6 Hydraulolja, byte

6:7 Returfi lter, byte

6:8 Sugfi lter, rengöring/byte

7:0 Grupp 7 Arbetsfunktion7:6 Gaffl ar, gaffeltest

Var 1000:e timme tillkommer:0:0 Grupp 0 Hel maskin0:13 Bränsletank, rengöring

1:0 Grupp 1 Motor1:13 Remmar, byte

1:14 Ventilspel, kontroll

2:0 Grupp 2 Hydrostatik2:3 Bultar, kontroll/fastsättning

3:0 Grupp 3 Bromsar/hjul3:7 Hjullager infettning

5:0 Grupp 5 Elsystem5:12 Kablage/anslutningar

6:0 Grupp 6 Hydraulik6:4 Andningsfi lter, reng./byte

BT Cargo CBD 2.5-3.5Var 250:e timme

Pos Kontroll av:

0:0 Grupp 0 Hel maskin0:1 Dörrar/luckor

0:2 Motviktsinfästning

0:3 Förarskydd/hytt

0:4 Skyltar/dekaler

0:5 Förarmiljö

0:6 Stol/mattor

0:7 Pedalgummin

0:8 Torkare/spolare

0:9 Provkörning test av

samtliga funktioner

0:10 Smörjning enligt schema

0:11 Tvätt/rengöring

1:0 Grupp 1 Motor1:1 Missljud/läckage

1:2 Gaspedal/reglage

1:3 Luftfi lter, kontroll

1:4 Kylvätska, nivå/fryspunkt

1:5 Remmar, kontroll

1:6 Motorolja, byte

1:7 Motoroljefi lter, byte

1:8 Bränslesystem, läckage

1:9 Glödning

Pos Kontroll av:

2:0 Grupp 2 Hydrostatik2:1 Läckage

2:2 Funktion

3:0 Grupp 3 Bromsar/hjul3:1 Däck/hjul

3:2 Lufttryck däck

3:3 Hjulbultar/hjullager

3:4 Färdbroms, funktion/läckage

3:5 Parkeringsbroms, funktion

3:6 Pedallänkage

4:0 Grupp 4 Styrning4:1 Styrleder/Styrspindlar

4:2 Styrcylinder, fastsättning

4:3 Styrlagring/upphängning

5:0 Grupp 5 Elsystem5:1 Belysning/körriktningsvisare

5:2 Instrument/kontrollampor

5:3 Signalhorn

5:4 P-broms-/Backalarm

5:5 Timmätare, avläsning

Pos Kontroll av:

5:6 Batteri, fastsättning

5:7 Säkringar

5:8 Batterivätskenivå

6:0 Grupp 6 Hydraulik6:1 Slangar/rör

6:2 Ventilreglage/länkage

6:3 Oljenivå

7:0 Grupp 7 Arbetsfunktion7:1 Lyftstativ, infästning

7:2 Gaffl ar

7:3 Lyftkedjor

7:4 Laststöd

7:5 Lyft-/tiltcylindrar

Var 500:e timme tillkommer:0:0 Grupp 0 Hel maskin0:12 Bultar/Muttrar, fastsättning

1:0 Grupp 1 Motorer1:10 Bränslefi lter, byte

1:11 Luftfi lter, byte

1:12 Motorfästen

5:0 Grupp 5 Elsystem5:9 Batteripoler reng./infettning

5:10 Färdväljare/länkage

5:11 Microbrytare

Totaldokument

Var 2000:e timme tillkommer:0:0 Grupp 0 Hel maskin0:13 Ram, kontroll av sprickor

1:0 Grupp 1 Motorer1:17 Kylvätska, byte

4:0 Grupp 4 Styrning4:4 Slangar, kontroll

4:5 Styrtryck, kontroll

5:0 Grupp 5 Elsystem5:13 Laddning, kontroll

6:0 Grupp 6 Hydraulik6:5 Hydraultryck, kontroll

6:6 Hydraulolja, byte

6:7 Returfi lter, byte

6:8 Sugfi lter, rengöring/byte

7:0 Grupp 7 Arbetsfunktion7:6 Gaffl ar, gaffeltest

Var 1000:e timme tillkommer:1:0 Grupp 1 Motor1:14 Remmar, byte

1:15 Tändinställning

1:16 Tändstift, byte

2:0 Grupp 2 Hydrostatik2:3 Bultar, kontroll/fastsättning

3:0 Grupp 3 Bromsar/hjul3:7 Hjullager infettning

5:0 Grupp 5 Elsystem5:12 Kablage/anslutningar

6:0 Grupp 6 Hydraulik6:4 Andningsfi lter, reng./byte

Var 500:e timme tillkommer:0:0 Grupp 0 Hel maskin0:12 Bultar/Muttrar, fastsättning

1:0 Grupp 1 Motorer1:11 Luftfi lter, byte

1:12 Motorfästen

1:13 Ventilspel, kontroll

5:0 Grupp 5 Elsystem5:9 Batteripoler reng./infettning

5:10 Färdväljare/länkage

5:11 Microbrytare

BT Cargo CBG 2.5-3.5Var 250:e timme

Pos Kontroll av:

0:0 Grupp 0 Hel maskin0:1 Dörrar/luckor

0:2 Motviktsinfästning

0:3 Förarskydd/hytt

0:4 Skyltar/dekaler

0:5 Förarmiljö

0:6 Stol/mattor

0:7 Pedalgummin

0:8 Torkare/spolare

0:9 Provkörning test av

samtliga funktioner

0:10 Smörjning enligt schema

0:11 Tvätt/rengöring

1:0 Grupp 1 Motor1:1 Missljud/läckage

1:2 Gaspedal/reglage

1:3 Luftfi lter, kontroll

1:4 Kylvätska, nivå/fryspunkt

1:5 Remmar, kontroll

1:6 Motorolja, byte

1:7 Motoroljefi lter, byte

1:8 Gasolsystem, funktion

Pos Kontroll av:

1:9 Gasolsystem, läckage

1:10 Tändsystem, kondition

2:0 Grupp 2 Hydrostatik2:1 Läckage

2:2 Funktion

3:0 Grupp 3 Bromsar/hjul3:1 Däck/hjul

3:2 Lufttryck däck

3:3 Hjulbultar/hjullager

3:4 Färdbroms, funktion/läckage

3:5 Parkeringsbroms, funktion

3:6 Pedallänkage

4:0 Grupp 4 Styrning4:1 Styrleder/Styrspindlar

4:2 Styrcylinder, fastsättning

4:3 Styrlagring/upphängning

5:0 Grupp 5 Elsystem5:1 Belysning/körriktningsvisare

Pos Kontroll av:

5:2 Instrument/kontrollampor

5:3 Signalhorn

5:4 P-broms-/Backalarm

5:5 Timmätare, avläsning

5:6 Batteri, fastsättning

5:7 Säkringar

5:8 Batterivätskenivå

6:0 Grupp 6 Hydraulik6:1 Slangar/rör

6:2 Ventilreglage/länkage

6:3 Oljenivå

7:0 Grupp 7 Arbetsfunktion7:1 Lyftstativ, infästning

7:2 Gaffl ar

7:3 Lyftkedjor

7:4 Laststöd

7:5 Lyft-/tiltcylindrar

Totaldokument

Issue 11/2000

CESAB S.p.Avia Persicetana Vecchia, 10 40132 Bologna - Italy

Tel. (0039) 051.20 54 11Fax (0039) 051.72 80 07E-mail: [email protected]

GB

Cargo Range

Code 036 2005-1

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CalibrationTravel PedalIf Reverse switchselect it ('ENT')

CalibrationTravel PedalPush slowly travelpedal

CalibrationTravel PedalFull depression inReverse (press a key)

CalibrationTravel PedalReverse completed(ENT)

CalibrationTravel PedalCompleted

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DisplayMast switch

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DisplayEngine speed

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DisplayPump displacement

DisplayEngine command

DisplayParking brake

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DisplayPower supply

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DisplaySensor exitation

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PARAMETER

CBG 2.5-3.0-3.5CONTINENTAL ENGINE

SETTING VALUE

&$/,%5$7,21�6(&7,21 $&&(77$%/(�9$/8( 67$1'$5'�9$/8(

MAST PRESENCE YES/NO YESMAX FORWARD SPEED 10% - 100% 100%MAX REVERSE SPEED 10% - 100% 100%MIN ENGINE SPEED 850MAX ENGINE SPEED 2200MULTI DISK BRAKE PRESENT / NOT PRESENT PRESENTPARKING BRAKE SET 80% - 95% 95%PUMP POT. INVERTED ENABLE

3803�&86720,=(' $&&(77$%/(�9$/8( 67$1'$5'�9$/8(

TRAVEL PEDAL INC # 2,5 - 4 SEC 3TRAVEL PEDAL DEC. # 3 - 4 SEC 3,5SENSITIVITY 10% - 70% 50%INCHING PEDAL INC. 4 - 6 SEC 4INCHING PEDAL DEC. 1,5 - 2,5 SEC 2

(1*,1(�&86720,=(' $&&(77$%/(�9$/8( 67$1'$5'�9$/8(

TRAVEL PEDAL INC 0,5 - 3 SEC 1,8TRAVEL PEDAL DEC. 0,3 - 2 SEC 1,3MAST INC. 0,5 - 2 SEC 1MAST DEC. 0,8 - 2 SEC 1MAST FIXED CDM 1 0% - 100% 30%MAST FIXED CDM 2 0% - 100% 30%

# ONLY THESE VALUES CAN BE MODIFIED

CBD 2.5-3.0-3.5KUBOTA ENGINESETTING VALUE

&$/,%5$7,21�6(&7,21 $&&(77$%/(�9$/8( 67$1'$5'�9$/8(

MAST PRESENCE YES/NO YESMAX FORWARD SPEED 0% - 100% 100%MAX REVERSE SPEED 0% - 100% 100%NUMBER OF TEETH 1 - 200 9MULTI DISK BRAKE PRESENT / NOT PRESENT PRESENTPARKING BRAKE SET 80% - 95% 95%PUMP POT. INVERTED ENABLE / DISABLE ENABLE

3803�&86720,=(' $&&(77$%/(�9$/8( 67$1'$5'�9$/8(

TRAVEL PEDAL INC # 2.5 - 4 SEC 3TRAVEL PEDAL DEC. # 3 - 4 SEC 3,5SENSITIVITY 10% - 70% 50%INCHING PEDAL INC. 4 - 6 SEC 4INCHING PEDAL DEC. 1.5 - 2.5 SEC 2

(1*,1(�&86720,=(' $&&(77$%/(�9$/8( 67$1'$5'�9$/8(

TRAVEL PEDAL INC 0,5 - 2 SEC 1,2TRAVEL PEDAL DEC. 0,3 - 2 SEC 1MAST INC. 0,3 - 2 SEC 1MAST DEC. 0,3 - 2 SEC 1MAST FIXED CDM 1 0% - 100% 30%MAST FIXED CDM 2 0% - 100% 30%

# ONLY THESE VALUES CAN BE MODIFIED

LEGEND

DESCRIPTION ENGLISH DEUTSCH FRANCAIS ESPAÑOL

4' via 4th valve 4.Steuerkreis 4.ème levier 4a.leva5' via 5th valve 5.Steuerkreis 5.ème levier 5a.levaabilitazione attiva enable on Freigabe ein abilitation activée habilitación activadaabilitazione freni brakes enable Bremsenfreigabe abilitation des freins habilitación de los frenosabilitazione parcheggio parking enable Festellfreigabe abilitation de stationnement habilitación de aparcamientoacceleratore accelerator pedal Fahrpedal pédale accélérateur pedal aceleradoralternatore alternator Lichtmaschine alternateur alternadoranomalia centralina logic unit defect Logikeinheitsdefekt anomalie d’unité logique anomalía unidad lógicaattuatore actuator Aktuator actionneur actuadorarresto motore motor stop Motorstop arrêt du moteur parada del motorbatteria battery Batterie batterie bateríabobina coil Spule bobine bobinabrandeggio tilting Neigung inclinaison inclinacióncandele spark plugs Zundkerzen bougies d’allumage bujíascandelette glow plugs Glühkerzen bougies de chauffage bu jías incandescentechiave key Schlüssel clé llavechiave avviamento start key Anlaßschlüssel clé de démarrage llave de arranqueclacson horn Hupe klaxon claxoncomandi luci supplem. additional lights controls Zusatzbeleuchtungssteuerung commandes lumières suppl. mandos luces adicionalescomando elettroventola electric fan control Elektroflügelsteuerung commande électro-ventilateur mando electroventiladorcomando fanali stop stop lights control Stoplichtesteuerung commande feus de stop mando faroles de stopconn.batteria battery connector Batteriestecker connecteur batterie enchufe bateríacruscotto dashboard Armaturenbrett panneau de commande salpicaderodispositivo candelette glow plugs device Glühkerzevorrichtung dispositif bougie de chauffage dispositivo bujia incandescenteelettrovalvole marcia speed electrovalves Gangelektroventile electrovannes de marche electroválvulas de marchaelettroventola electric fan Elektroflügelrad électro-ventilateur electroventiladoremergenza emergency Notstand urgence emergenciafanali retromarcia reversing lights Rückfahrscheinwerfer feus de marche arrière faroles de marcha atrasfanali stop stop lights Stoplichte feus de stop faroles de stopfreno brake Bremse frein frenofreno pedale pedal brake Bremspedal frein pédale freno pedalfreno stazionamento parking brake Festellbremse frein de stationnement freno de aparcamientoindicatore riserva gas LPG reserve indicator GPL Reserveanzeiger indicateur réserve GPL indicador reserva GPL

LEGENDDESCRIPTION ENGLISH DEUTSCH FRANCAIS ESPAÑOL

indicatore temperatura ac water temperature indicator Wassertemperaturanzeiger indicateur temperature de l’ea indicador temperatura del aguaintas.filtro aria air filter clogging Luftfilterverstopfung encrassement filtre à air obstrucción filtro aireintas.filtro olio oil filter clogging Ölfilterverstopfung encrassement filtre huile obstrucció filtro aceiteintas.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 inversióninversore manuale drive direction lever Handumschaltung inverseur de direction palanca de inversiónlivello carburante fuel level Treibstoffstand niveau carburant nivel carburanteliv.liquido freni brake fluid level Bremsflüssigkeitsstand jauge d’huile de freins nivel aceite frenosluci posteriori back lights Rücklichte lumières arrières luces traserasluci retromarcia reversing lamps Rückfahrlampen ampoule marche arrière lampara de marcha atrásmarcia avanti forward speed Vorwärtsgang marche avant marcha adelantemarcia indietro backward speed Rückwärtsgang marche arrière marcha atrásmarcia lenta slow speed langsamer Gang marche lente marcha lentamot.trazione traction motor Fahrmotor moteur de traction motor de tracciónmotore avviamento starter motor Anlaßmotor démarreur motor de arranquemotore idroguida power steering motor Hydrolenkungsmotor moteur direction assistée motor servodirecciónmotore pompa pump motor Pumpenmotor moteur pompe motor bombapedale freno brake pedal Bremsepedal pédale du frein pedal del frenopedaliera pedals Pedale jeu de pédales juego de pedalespedaliera doppia double pedals Doppelpedal pédales double pedales doblepompa pump Pumpe pompe bombapompa iniezione injection pump Einspritzungspumpe pompe d’injection bomba inyecciónpost combustione afterburning Nachverbrennung postcombustion postcombustiónpotenziometro sollev. lifting potentiometer Hubpotentiometer potentiomètre d’élévation potenciómetro levantamientopressione olio motore motor oil pressure Ölmotordruck pression d’huile moteur presión aceite motorpressostato freni brakes press.switch Bremsdruckschalter pressostat freins presóstato frenospulsante clacson horn push button Hupeknopf poussoir klaxon pulsador de claxonpulsante emergenza emergency.pushbutton Notdruckknopf poussoir d’urgence pulsador de emergenciarelè avviamento starter relay Anlaßrelais relais démarreur relé arranqueriserva gas LPG reserve GPL Reserve réserve GPL reserva GPLscatola acc. speed box Fahrschalter boitier du vitesse caja aceleradoressensore velocita’ speed sensor Geschwindigkeitsensor senseur de vitesse sensor de velocidadsollevamento lifting Hub élévation levantamientospia 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 cofretemp.olio trasmis. oil temperature transmission Öltemperaturgetriebe temperature d’huile transmis. temperatura aceite transmisióntemperatura acqua water temperature Wassertemperatur temperature d’eau temperatura aguatermico thermal sensor Wärmesensor senseur thermique sensor térmicotraslatore sideshift Seitenschieber déplacement lateral desplazador lateraluomo presente deadman device Totmann-schalter Homme mort conductor presenteventola motore motor fan Motorflügel ventilateur moteur motor ventiladorventole fan Flügelräder ventilateur ventiladorvista posteriore rear view Rücksicht vue arrière vista rasera

COLORI COLOURS FARBEN COULEURS COLORESarancio orange Orange orange anaranjadoazzurro blue Hellblau bleu azulbianco white Weiß blanc blancoblu dark blue Blau bleu azulgiallo yellow Gelb jaune amarillogrigio grey Grau gris grismarrone brown Braun marron marronnero black Schwarz noir negrorosa pink Rose rose rosarosso red Rot rouge rojoverde green Grun vert verdeviola purple Violett violet violeta

Programmering av TCS-systemetBT Cargo CBD/CBG 2.5-5.0

A B C D E

F G H I J

K L M N O

P Q R S T

U V W X Y

Z

F1 F2 F3 F4

/ (

* )

- #

+,

=.

CTRLSHIFT

ESC

BKSPSPACE ENTER

1 2 3

4 5 6

7 8 9

0

Per Wärmlund / Avd. service

BT Cargo Teknikutbildning

Main Menu

Connect theconsole and turn thekey without starting

Press ENTERto select themain menu

Calibration

Display

PumpCustomised

EngineCustomised

FaultDetected

Information

Ph Parameters

Eeprom reset

Motor Shifting

Actuator Pid

Calibration of the potentiometers and the transmission actuators (pedals,control valve, engine actuator, etc.)

Display information on the transmission (engine RPM, transmissiondisplacement, micro switches status, etc.)

Personalization of the transmission behavior

System fault display

Software version

Not accessible (Password only)




Personalization of the engine setting

Sida 1

ENTER

+

+

+

+

+

+

+

+

+

+

End of list 4.0 - 5.0t

End of list 2.5 - 3.5t



To page 3Calibration Mast Lever

Sida 2

Calibration

ENTER

ENTER

ENTER

-

CalibrationCalibration Status

First operationto be carriedout to releasethe program

+

Calibrationcalibration Statuslocked

Select theparking brake

switch andpress +

CalibrationCalibration Statusnot locked

ESC

CalibrationTravel Pedal

Configurationaccelerator pedalpotentiometer

ENTER

Press a key

ENTER

ENTER ENTER

EN

TE

R

Press a keyENTER

ENTER

ESCAPE

ENTERPress a key

CalibrationTravel pedalDon’t touch thetravel pedal (’ENT’)

ENTER

ENTER

CalibrationTravel PedalIf Forward switchselect it (’ENT’)

Operate the forwardswitch lever or depressthe twin forward. Pedalto close switch

Operate the reverseswitch lever or depressthe twin reverse. Pedalto close switch

EN

TE

R

CalibrationTravel PedalForward complete(ENT)

CalibrationTravel PedalReverse complete(ENT)

Calibration TravelPedalFull depression inForward (Press a key)

Calibration TravelPedalFul depression inreverse (Press a key)

CalibrationTravel PedalForward complete(ENT)

Calibration Travelpedal. Don’t touchthe travel pedal(’ENT’)

CalibrationTravel PedalIf Reverse switchselect it (’ENT’)

CalibrationTravel PedalReverse complete(ENT)

CalibrationTravel PedalCompleted

+

CalibrationBrake / inchingpedal

Configurationbrake pedalpotentiometer Calibration

Brake / inching pedalRest reading(press a key)

Min value stored, CalibrationBrake inching pedalFull depression(press a key)

Completely pressthe pedal,keep it pressed Calibration

Brake / inchingpedal completed

Ended configuration of the brake pedal,

+ ESC

N.B. With the programlocked it is possible toread the sensor

values..

Calibration



Sida 3

From page 2Calibration Mast Lever

CalibrationMast lever

Configuration of thelifting potentiometer,

ENTER

Pressa key

ENTER

CalibrationMast leverMast sensor presenceYES (1) NO (0)

Press 1 CalibrationMast leverRest reading(Press a key)

Min. Valuestored Calibration

Mast leverFull depression(press a key)

Pull the lifting lever tothe end stroke, keep itpulled,

CalibrationMast levercompletedEnded configuration of the

lifting potentiometer

+

+

+

+

+

+

+

+

+

+

+

+

++ + +

CalibrationEngine Calibration

CalibrationPump Neutral

Acquisition ofthe neutralpump position

ENTER

CalibrationPump neutralCompleted

Ended acquisitionof the neutralpump position

ACQUISITION TO BE CARRIED OUTWITH THE ENGINE ON

Calibrationmax.forward speed

CalibrationMax.reverse speed


CalibrationMini engine set

CalibrationMaxi engine speed

CalibrationPump pot.inverted

CalibrationPump pot.inverted

FUNCTION TO BE CARRIED

OUT WITH THE ENGINE ON

CalibrationEngine calibration

Engine CalibrationLowest engine speedReading.......

Engine CalibrationHighest engine speedReading.....

CalibrationEngine CalibrationReading...(8 values)

Engine CalibrationEnd of enginecalibration

Ended acquisitionof the min. and maxRPM of the engine,

ESCAPE

ESCAPE

Acquisition of themin.and max.RPM of the engine

ENTER

Then the enginestarts to accelerateby itself

May be Modified

May be Modified

May be Modified

Standardvalue2250 RPM

Standardvalue850 RPM

NOT MODIFY

NOTMODIFY

NOTMODIFY

NOTMODIFY

NOTMODIFY

NOTMODIFY NOT MODIFY NOT MODIFY

ESCAPE

Back to calibration Back to calibration

CalibrationReduce speed

CalibrationNumber of teeth

CalibrationPower supply

CalibrationSensor excitation

CalibrationMulti disc brake


LIST FOR 4.0-5.0tLIST FOR 2.5-3.5t

Calibration



Sida 4

DisplayEngine Speed

Displaypump displacement

DisplayEngine command

DisplayAntistall

DisplayParking brake

DisplayBrake switch

DisplayMast engine Cmd

DisplayPump feed-back

DisplayDirection switch

DisplayMast switch

DisplayConstant speed

DisplayActuator feed back

DisplayReduced speed

DisplayPower supply

DisplaySensor excitation


Display the real engine RPM

Display the pump displacementrequested by the logic unit (cc)

Display the engine RPMrequested by the logic unit

Display the status of thefunction (enable / disable)

Display the status of the negativebrakes (enable / disable)

Display the status of the parkingbrake switch (set / not set)

Display the engine RPMwith the lifting lever pulled

Display the real pump displacement(cc) by the potentiometer

Display the status of the direction switches(neutral / forward / backward)

Display the status of the control valve switches1=tilting / sideshift (set / not set)

Display the constant driving speed functionstatus with the lifting activated (set / not set)

Display the signal of the engineactuator in volts

Display the voltage of the logicunit (enable / disable)

Display the sensor voltage supplied by thelogic unit

Display the difference of the pump potentiometersignal from the theoretic value (in mV)

ENTER

ENTER

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

Displays informationof the engine andhydrostat pump

Calibration

Display

ESCAPE

ESCAPE

ENTER

ESC

ENTER

ESC

ENTER

ESC

ENTER

ESC

ENTER

ESC

ENTER

ESC

ENTER

ESC

ENTER

ESC

ENTER

ESC

ENTER

ESC

ENTER

ESC

ENTER

ESC

ENTER

ESC

ENTER

ESC

ENTER

ESC

ENTER

ESC

ENTER

ESC


Display the reduced speed functionstatus (enable / disable)

Display the difference of the pump potentiometersignal from the theoretical value (in mV)

List for

4.0 - 5.0t

List for

2.5 - 3.5t

DisplayMenu

HOLD DOWN THE ENTERKEY TO DISPLAY DATA INSEQUENCE



ENTER

ENTER

ENTER

ENTER

ENTER

ENTER

ENTER

ENTER +

+

++

+

+

+

+

ESCAPE

ESC

ESC

ESC

ESCAPE

ESCAPE

ESCAPE

ESCAPE

ESC

Calibrationtravel Pedal

CalibrationCalibration status

CalibrationCalibration statusLocked

CalibrationCalibration statusNot Locked

-

Display

PumpCustomised

Pump CustomisedTravel pedal Inc.

Pump CustomisedTravel pedal Dec.

Pump CustomisedInching pedal Dec.

Pump CustomisedInching pedal Inc.

Pump CustomisedSensitivity

Pump CustomisedTravel pedal Inc.5.0 Seconds

Pump CustomisedTravel pedal Inc.5.0 Seconds

Pump CustomisedTravel pedal Dec.5.0 Seconds

Pump CustomisedTravel pedal Dec.5.0 Seconds

Sida 5

Set the requested value bytyping it directlywith the keyboard numbersor pressing + 0 -

( N.B. Stronger brake,lower valuesofter brake, higher value)

ENTER

Set the requested value by typing it directlywith the keyboard numbers or pressing + 0 -

( N.B. Quicker acceleration, lowervalue, slower acceleration, higher value)ENTER

Pump accelerationtime

Pump decelerationtime (Braking)

Not Modified

Not Modified

Not Modified

Select the Parking brakeswitch and press

Calibration statushas to be un lockedto release theparameters formodification

Pump CustomisedSection

Pump CustomisedHard brakingratio 00%

Pump CustomisedHard brakingratio 00%

Hard braking ratio

Calibration

See page 14



ENTER

ENTER

ENTER

ENTER

ENTER ENTER

ENTER

ENTER +

+

ESCAPE

ESCAPE

ESCAPE

ESCAPE

ESC

Calibrationtravel Pedal

CalibrationCalibration status

CalibrationCalibration statusLocked

CalibrationCalibration statusNot Locked

-

Display

PumpCustomised

EngineCustomised

+

+

+

+

++

+

+

Select the Parking brakeswitch and press

Calibration statushas to be un lockedto release theparameters formodification

Engine CustomisedTravel pedal Inc.

Engine CustomisedMast fixed Cmd. 1

Engine CustomisedMast fixed Cmd. 145%


Engine CustomisedMast fixed Cmd. 2



Engine CustomisedMast Dec.

Engine CustomisedMast Inc.

Engine CustomisedTravel pedal Dec.

Set the requested value by typing itdirectly, or by the +0-(N.B. More RPM higher value less RPMlower value)

ENTER

Set the requested value by typing itdirectly, or by the +0-(N.B. More RPM higher value less RPMlower value)

ENTER

Engine RPMTilting

Engine RPMSideshift

Sida 6

Engine CustomisedSection

Calibration



Calibration

Display

PumpCustomised

EngineCustomised

FaultDetected

Fault DetectedFault occuring now

Fault DetectedFault since startup

Sida 7

ENTER

+

+

+

++ +

+

+

DISPLAY CONSOLE

Pressto display the faults

ENTER

ENTER

ENTER To display thefaults in real time Fault detected

Fault occuring nowNo default

ES

C

ESC

ESC

No alarms

Fault detectedFault occuring nowActuator sensor

Alarm present

Fault detectedFault since startupStart of the list

To display thestored alarms (faults)(max 5)

To readthe alarms

Fault detectedFault since startupNeutral out of range

Fault detectedFault since startupEnd of the list

Alarms Section“Fault Detected”

Example:-



Här är huvudmenyerna:

1 CALIBRATION

The CALIBRATION menu has two functions:

Cwhen the parking brake is locked and the “calibration status” parameter is “not locked”, it allows thecalibration and configuration of the system.

Dwhen the parking brake is not locked or the “calibration status” parameter is “locked” this menuviews the output voltages of the system sensors and the state of some components.

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

alibrating mode

isplay mode

N Meny Funktion

1 CALIBRATION Kalibrering av sensorer och potentiometrar. Visning av aktuellaspänningar (Calibration Status = Locked)

2 DISPLAY to display the information on the transmission (thermal engine speed,pump displacement, anitstall function,....)

3 PUMP CUSTOMIZED to customize the transmission (more or less prompt braking andacceleration)

4 ENGINE CUSTOMIZED to customize the thermal engine control (higher or lower accelerationof the thermal engine, engine speed when the tilt system and thesideshift are on,...)

5 FAULT DETECTED to display the system faults

6 INFORMATION software versions

7 PH PARAMETERS (password) configuration of the system operation parameters

8 EEPROM RESET (password) to reset the control unit memory

Sida 8

9 MOTOR SHIFTING(password) configuration of the parameters controlling the displacementShifting of the hydraulic motors

10 ACTUATOR PID (password) configuration of the actuator feedback parameter

BT Cargo Teknikutbildning Programmering av TCS-systemet

CALIBRATION MENU

N SUBMENU CALIBRATION MODE DISPLAY MODE

A Travel pedal calibration of the travel pedal display of the voltage supplied by thepotentiometer for the travel pedal

B brake / inching pedal calibration of the brake pedal display of the voltage supplied by thepotentiometer for the brake pedal

C mast lever calibration of the mast lever display of the voltage supplied by thepotentiometer for the mast lever

D engine calibration calibration of the actuator-thermal display of the voltage supplied by thepotentiometer for the actuator

E pump neutral calibration of the pump in neutral display of the voltage supplied by theposition potentiometer for the hydrostatic pump

F max forward speed limiting of the truck max display of truck forward speedforward speed (as a percentage of the max speed)

G max reverse speed limiting of the truck max display of the truck reverse speedreverse speed (as a percentage of the max speed)

H parking brake set definition of the brake pedal displays the brake pedal position inposition in which the mechanical which the mechanical brake is lockedpedal is engaged

I min engine speed definition of the minimum engine displays the minimum engine RPMRPM

L max engine speed definition of the maximum engine displays the maximum engine RPMRPM

M pump pot. Inverted definition of the connections type displays the connections typeof the pump potentiometer of the pump potentiometer

N calibration status validations and invalidation of the status of the calibration menucalibration menu

For the TCS to operate correctly, the voltage values read by the potentiometers in the pedals, the mastsystem and the motor actuator must not exceed the limits set. If the mechanical limit stops of thepotentiometer are not properly adjusted, the voltage supplied by the potentiometer is exceeded. The rangeof values allowed by the control unit disables the calibration procedure.Trouble may also occur after a correct calibration if, for whatever reason, the limit stop is modified.

Sida 9

O reduced speed limiting of the truck max. Speed displays if the truck reduced speed is(Enable / disable)

P number of teeth definition of the number of teeth display of the number of teeth/revPer engine rev (speed sensor inThe thermal engine

R power supply measures the supply voltage of measures the supply voltage ofControl unit the control unit

S sensor excitation measures the supply voltage of measures the supply voltage of theSensors sensors

T multi disc brake definition of the type of brake type of brake usedUsed


CALIBRATION AND FIRST START UP OF THE TRANSMISSION SYSTEM

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

Potentiometer for the travel pedal (TRAVEL PEDAL)

Release the parking brakeposition the steering column switch to forward geargradually press the forward pedal: wheels should slowly rotate forward

When wheels rotate forward, check that the voltage of the pump feedback potentiometer increases from2.5 to 5 volts (for the voltage reading use “pump neutral” parameter in the “calibration” menu).Check the correct operation under the following conditions:

- mast lifting, sideshift and tilt operation, etc., : if the relevant levers are adjusted, the thermal enginewill accelerate

- forward / reverse speed and braking- parking brake: if engaged, the travel pedal will be disabled (the engine RPM will increase, but thetruck wheels will be locked)

- emergency button.

CAUTION: the hydraulic motors must not rotate quickly when wheels are jacked up

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

While calibrating, check the parameters below:

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

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

Lift the truck onto the blocks

fill the hydraulic circuit and bleed the air from the system

engage the parking brake

select the neutral position (through the steering-wheel operated reverse gear)

start up the engine and wait for the stabilization of the boost pressure

adjust the engine min and max RPM through the actuator limit stop screws (the limit stops are to beobtained on the actuator support, on the injection pump). The engine RPM is to be measuredthrough the “engine speed”parameter in the “DISPLAY” menu.

Calibrate the actuator (ENGINE CALIBRATION)

Press the accelerator pedal; the actuator has to rotate clockwise and the voltage of thefeedback potentiometer in the actuator has to increase (such voltage may be measured in the“engine calibration” parameter in the “calibration” menu after engaging the parking brake).

Once the calibration procedure is over, check the transmission operation (wheels must be jacked up):

not

Sida 10


A) TRAVEL PEDAL CALIBRATION

B) BRAKE / INCHING CALIBRATION

C) MAST LEVER CALIBRATION

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

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

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


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

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

For calibrating, voltages are not to exceed the following ranges:Lever in neutral position 0,35 - 2,3 volts (7 - 46 % of the supply voltage)Lever fully pulled 2,4 - 4,65 volts (48 - 93% of the supply voltage)

Matches the actuator position angle (voltage of the actuator feedback potentiometer) with the enginespeed value.

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

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

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

Defines the voltage corresponding to the neutral displacement position of the hydrostatic pump (feedbackpotentiometer).

The voltage value must not exceed the following range 2.48 to 2.52 volts.(In display mode and when the truck is running, the voltage value must vary. When the wheels rotateforward, the potentiometer voltage must rise to 5 volts and remain

D) ENGINE CALIBRATION

E) PUMP NEUTRAL CALIBRATION

constant).

Sida 11

SEE THE DIAGRAM FOR USING CONSOLESECTION “CALIBRATION”


Sida 12

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

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

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

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

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

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

This parameter enables or disables the calibration mode.

This parameter expressed if the truck reduced speed is activated (enable / disable). This parameter maybe modified (in calibration mode).

This parameter defines the number of pulse per revolution of the thermal engine sent by the speed sensorto the control unit.

Displays the supply voltage of the control unit: battery voltage (12 volts)

This parameter displays the voltage supplied by the control unit to the sensors. Correct value: 5 volts.

this parameter defines whether the multidisc brake is fitted or not (the multidisc brake is an on/off brake,i.e. It is not gradual.

F) MAX FORWARD SPEED

G) MAX REVERSE SPEED

H) PARKING BRAKE SET

I) MIN ENGINE SPEED

L) MAX ENGINE SPEED

M) PUMP POT. INVERTED

N) CALIBRATION STATUS

O) REDUCED SPEED

P) NUMBER OF TEETH

R) POWER SUPPLY

S) SENSOR EXCITATION

T) MULTI DISC BRAKE

SEE THE DIAGRAM FOR USING CONSOLESECTION “CALIBRATION”


2) DISPLAY

This menu displays the transmission data.Press ENTER to display data (e.g. Thermal engine speed).

(Hold down the key to display data in sequence)

Real speed of the thermal engine (expressed in RPM)

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

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

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

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

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

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

Actual displacement of the pump (expressed in cc). This is the displacement measured by thepotentiometer located on the pump.

Displays the running direction controlled by the pedal micro-switches or the steering-wheel operatedreverse gear (neutral / forward / reverse).

Displays the state of the valve bank microswitches 1 = tilt / sideshift (set / not set)

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

Displays if the reduced speed function is enabled (the trvel speed is limited to a preset percentagevalue of the max. speed). optional

Displays the engine actuator signal in Volts. Increases during acceleration and vice versa.

Displays the voltage supply to the control unit: battery voltage (12V)Must be between 9,5 and 48,5 Volt.

Displays the voltage supply to the sensors. Correct value 5 Volt.

Displays the difference in value between the theoretical and real pump potentiometer value (in mV)This parameter is present with the Hall potentiometer software only.

ENGINE SPEED

PUMP DISPLACEMENT

ENGINE COMMAND

ANTISTALL

PARKING BRAKE

BRAKE SWITCH

MAST ENGINE COMMAND

PUMP FEED-BACK

DIRECTION SWITCH

MAST SWITCH

CONSTANT SPEED

REDUCED SPEED

ACTUATOR FEED BACK

POWER SUPPLY

SENSOR EXCITATION

NEUTRAL DRIFT

Sida 13


3) PUMP CUSTOMIZED

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

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

This paramter defines how long the pump takes to reach its neutral displacement mode when thetravel pedal is released (the higher the value of this parameter, the less the deceleration of the truckduring the hydrostatic braking).

This parameter (%) changes the release braking value (travel pedal dec) as the following table:

Travel pedal dec (s) 2 5 7 10

Hard braking ratio (%)

0 2 5 7 10

17 1.7 3.8 5 6.5

50 - 2.8 - -

67 1.6 2.5 3.1 3.6

83 - 2.3 - -

100 1.3 2.1 2.5 2.9

TRAVEL PEDAL INC.

TRAVEL PEDAL DEC.

HARD BRAKING RATIO

Braking times of the truck function of the two parameters“Travel pedal dec” (s) and Hard braking ratio”(%)

SENSITIVITY

INCHING PEDAL INC

INCHING PEDAL DEC.

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

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

This parameter defines how long the pump takes to range from the max. Displacement to the neutraldisplacement when the inching pedal is instantaneously pressed after fully pressing the travel pedal.

Sida 14


Bromskraft vid låghastighet

Bromskraft vid höghastighet

4) ENGINE CUSTOMIZED

Sets the parameters for the thermal engine control. Do not modify the standard values.

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

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

This parameter defines the time the actuator takes to achieve its stroke when the mast lever is fullypulled back. (The higher the value of this parameter, the longer the time the thermal engine takes torange from its min RPM to its max RPM)

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

Parameters that define the thermal engine speed rate when one of the auxiliary devices of the hoistingunit is actuated (tilt unit, sideshift, 4th way, 5th way).When one of the value levers is actuated (except for the mast lever) the engine speed increases by aquantity proportional to the parameter setting. Standard value is 30 - 40 %

Ex: Engine min speed: 700 rpm; engine max.speed: 2,500rpmusable range: 2,500 - 700 = 1,800rpmparameter (mast fixed cmd): 25%If the engine operates at a speed higher than 1,100rpm and the distributor is actuated, theactuator will bring the engine rpm to: 1,100 + (2,500 - 700) x 0.25 = 1,500rpm

Do not increase the speeds set to avoid dangerous manoeuvres.Stroke of the sideshift: 2 - 2.5secsTilting: 4.5 - 5 secs

(Available from 2001)Parameter which defines the max thermal motor rpm when the lifting is started. By activating the lever,the motor speed increases step by step until the max value set.

TRAVEL PEDAL INC.

TRAVEL PEDAL DEC.

MAST INC.

MAST DEC.

MAST FIXED CMD 1

MAST FIXED CMD 2

MAST MAXIMUM CMD

Sida 15


5) FAULT DETECTED

- FAULT OCCURRING NOW

- FAULT SINCE START UP

- FAULT MESSAGES SHOWN ON THE CONSOLE

Displays the system faults.

Press enter to display the current fault

Press (+) and (-) to display the last five faults occurred

The excitation voltage of the sensor is <2V or >5.5V

The supply voltage of TCS control unit is <9.5V or >32V for morethan 2 secs long

The signal (voltage) of the travel pedal potentiometer hasexceeded the limits set while calibrating

The signal (voltage) of the brake pedal potentiometer hasexceeded the limits set while calibrating

The signal (voltage) of the mast lever has exceeded the limitsset while calibrating

The signal (voltage) of the feedback potentiometer has exceedthe limits set while calibrating

>20% error, for more than 0.5secs, between the actuator setpointand the potentiometer feedback

>20% error, for more than 0.5 secs, between the pump controlsignal and the potentiometer feedback signal in the pump.

Pump feed back is <0.25V or >4.75V

During calibration the pump neutral is outside of the fixed limits

“ The difference between the pump in neutral calibration functionand the pump in neutral while the values are fed is >341 mV

The pump feedback changes too fast in comparison with the realchange of the pump displacement.

One parameter at least is outside of the field of acceptable values

“Excitation Sensor”

“Power Supply”

“Travel Pedal Sensor”

“Brake / Inching pedal Sensor“

“Mast lever Sensor”

“Actuator Sensor”

“Error on Actuator control loop”

“Error on pump control loop”

“Feed back error“

“Neutral out of range”

Pump neutral drift too high”

“Feedback moves too fast”

“Eeprom error at address”

Sida 16

“Direction switches error”

“Other default”

The TCS control unit takes contemporarily the forward and reverse gear(running mode) started

Other faults

6) INFORMATION

Displays the SOFTWARE version


7) PH PARAMETERS

- PASSWORD

PUMP NEUTRAL OFFSET

- ENABLE LIMIT CHANGE

- INVERSION BRAKING

- INVERSION DISPLACEMENT

- DISABLE PUMP DELAY

- REGULATOR OFFSET

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

-This parameter is used to offset pump feedback

During the calibration of the pedals, the auxiliary levers and the actuator, it is possible that the minimumand maximum values obtained on the potentiometer do not conform to the limits fixed by the programme.It is possible to modify these limits.In the menu calibration, authorise the mode calibration. Go into the menu “PH PARAMETERS”and intothe menu “ENABLE LIMIT CHANGE”.It is necessary to be in “NOT LOCKED”

This function is used to have a braking action if the direction switch is set to the reverse position during theoperation of the machine (plug braking)The braking action will be proportional to the position of the travel pedal.

This parameter sets the inversion time range from 0 - 10 seconds

Parameter which defines the time delay of the negative brakes releasing (standard values 30 cycles). It isthe delay for the brakes releasing after the pump has reset its displacement. In order to have the brakesrelease in a short time, for example on a ramp, reduce the value (min 5 max 45 cycles).

This is the acceptable difference between the requested engine speed and the measured engine speed.If this value is exceeded, the antistall function is active

Sida 17

- ANTISTALL COEF

- DERIVE ANTISTALL

- FULL STROKE CMD

- ENGINE DELAY INC

coefficient applied to the action of the anitstall function.The parameter change from 3 to 8The higher the value the more the displacement will decrease

Definition of the derived gain for the antistall action. The parameter is a variable number from 10 - 30The higher the number the more sensitive antistall is to RPM variations

Compensation of the electric stroke used on the position potentiometer of the pump swashplateThe parameter is a number (never vary it) 1488

This parameter is used to take into account the reaction time of the engine actuator in order to activate theanitistall at the right moment. It avoids unnecessary operations of the antistall functions.

This value is the complementary value of engine delay dec. It is to take into account during the engine decelerationThis paramter is the time taken for engine deceleration.

- ENGINE DELAY DEC


8) EPROM RESET

- PASSWORD

- ALL EEPROM RESET

- FAULT LIST RESET

This menu is used to reset the data of the EEPROM

Enter the password (4 numbers) with the digital key and then press enter.Press the key / esc then (+) or (-) in order to have access to the rest of the menu

Press the enter key to cancel the list of statistics

Press the enter key to cancel the list of the detected faults.

Sida 18


Sida 19


1) TRAVEL PEDAL

Travel pedal position out of range

Release the parking brake

Select theTRAVEL PEDAL submenu

Voltage = 0 volts?

Check the potentiometer wiringHold down the [ENTER] key andcheck if voltage changes whenthe pedal is pressed

Does voltage change?

Press the [ENTER] key tomeasure the min. and max.Voltage supplied by thepotentiometer

Adjust the mechanical limit stop ofthe pedal so that the voltage doesnot exceed the ranges set(see “travel calibration”)

Check the potentiometer wiring

Yes No

No

Yes

(Error message)

The terminal will display thevoltage that is suppliedfrom the potentiometer inthe travel pedal

Calibrate the travel pedal

The terminal will switch from theCALIBRATION MODE to theDISPLAY MODE

The voltage values read by the transmission potentiometer (pedals, hoisting, etc.) Must not exceed the limits set. Ifthere is some wiring failure or the mechanical limit stops of the potentiometers are not properly adjusted, the voltagethey supply will exceed the allowed range for the control unit, thus preventing the calibration procedure. In thatcase, the terminal will display one of the following messages (while calibrating or in the “fault detected” alarmmenu).

Travel pedal position out of range Travel pedalBrake/inching pedal sensor Brake pedalMast lever sensor Mast leverActuator position out of range Thermal engine actuatorFeed back error Hydrostatic pump potentiometer


Sida 20


2) BRAKE/INCHING PEDAL

Brake/inching position out of range


Select theBRAKE/INCHING PEDAL submenu

Voltage = 0 volts?




Adjust the mechanical limit stop ofthe pedal so that the voltage doesnot exceed the ranges set(see “travel calibration”)


Yes No

No

Yes

(Error message)

The terminal will display thevoltage that is suppliedfrom the brake pedalpotentiometer

Calibrate the brake pedal



Sida 21


3) MAST LEVER

Mast lever sensor out of range


Select theMAST LEVER submenu

Voltage = 0 volts?





Yes No

No

Yes

(Error message)

The terminal will display thevoltage that is suppliedfrom the mast leverpotentiometer

Calibrate the mast lever

Adjust the shims of thepotentiometer support bracket sothat the voltage does not exceedthe ranges set (see “mast levercalibration”) If the lever is movedforward from its middle position(for forks lowering) voltage is notto decrease.



Sida 22


4) THERMAL ENGINE ACTUATOR

Actuator position out of range


Select theENGINE CALIBRATION submenu

Voltage = 0 volts?

Check the electrical connectionsof the actuator

Hold down the [ENTER] key andcheck if voltage changes while theactuator rotates


Press the [ENTER] key tomeasure the min. and max.Voltage supplied by theactuator potentiometer

Check the actuator electricalconnections

Yes No

No

Yes

(Error message)


The terminal will display thevoltage that is suppliedby the potentiometer ofthe actuator

Calibrate the actuator

Adjust the length of the tie rod sothat the voltage does not exceedthe ranges set (see “enginecalibration”)

Engage theparking brakeand press theacceleratorpedal


Sida 23


5) POTENTIOMETER IN THE HYDROSTATIC PUMP

Feed back error


Select thePUMP NEUTRAL submenu

Voltage = 0 volts or 5 volts

Check the potentiometerelectrical connections

Voltage = 2.48 - 2.52 volts

Yes No

No

Yes

(Error message)


The terminal will display thevoltage that is suppliedby the potentiometer in thehydrostatic pump

Check the potentiometer wiring, liftthe truck onto blocks, electricallydisconnect the pump solenoidvalves and start up the engine: Ifthe pump supplies some oil, thetrouble is hydraulic or mechanical(mechanical maladjustment of thepump plate positioning in neutral)After disconnecting the valves, if thepump supplies some oil, switch offthe engine and hold down the[ENTER] key in order to read thevoltage, until a 2.5 volt value isobtained

Engage the parking brake,switch to CALIBRATIONmode and clibrate thepump potentiometer tozero.

Engage the parking brake, swich toCALIBRATION mode and clibratethe pump potentiometer zero.


Sida 24

SYSTEM FAULTS AND FAILURES

Any system failure is signalled by the flashing warning light located beside the valve bank levers.The frequency indicated the failure importance.The kind of fault is displayed in the FAULT DETECTED menu (FAULT OCCURRING NOW SUBMENU).If the warning light blinks slowly (0.5Hz) the fault is not very important; the machine is able to drive.


Travel pedal sensor

The signal voltage of the travel pedalpotentiometer has exceeded the limits setwhile calibrating.Connector disconnected or wrong wiring.

The signal voltage of the brake pedalpotentiometer has exceeded the limits setwhile calibrating.Connector disconnected or wrong wiring.

The signal voltage of the mast leverpotentiometer has exceeded the limits setwhile calibrating.Connector disconnected or wrong wiring.

The signal voltage of the feedbackpotentiometer has exceeded the limits setwhile calibrating.Connector disconnected or wrong wiring.

Check the potentiometerwiring.Check if the voltage values atthe pedal stop do not exceedthe preset limits.Adjust the pedal limit stop.Calibrate the pedal again.

Check the potentiometerwiring.Check if the voltage values atthe pedal stop do not exceedthe preset limits.Adjust the pedal limit stop.Calibrate the pedal again.

Check the potentiometerwiring.Check if the voltage values atthe lever stop do not exceedthe preset limits.Adjust the lever limit stop.Calibrate the lever again.

Check the potentiometerwiring.Check if the voltage values atthe actuator stop do notexceed the preset limits.Adjust the actuator limit stop.Calibrate the actuator again.

Brake/inching pedal sensor

Mast lever sensor

Actuator sensor

Error on actuator controlloop

This message may bedisplayed if the acceleratoris pressed(green light on)when the engine is off andthe brake is unlocked.

.20% error, for more than 0.5 secretary..Between the actuator set point and thepotentiometer feed back.Connector disconnected or wrong wiring.

Check the actuator wiring.Check the actuatorpotentiometer output signal. Ifyou press the acceleratorpedal, the actuator will rotateforward and the voltage -measured in engine calibrationwhen the brake is released -will increase.

Power supply out of range The supply voltage of TCS control unit isnot within the 9.5 - 48 volt range.

Check the supply voltage value.


Sida 25

SYSTEMFEL OCH FELMEDDELANDEN

Om varningslampan blinkar snabbt (1hz) är felet allvarligt, och maskinen går ej att köra!

FELMEDDELANDE ORSAK KONTROLLERA

Excitation voltage

Felaktig matningsspänning till sensoreroch microbrytare.

- Att spänningen ligger på 5 volt+/- 5%

Feedback error

Fel signal från feedback-potentiometernpå pumpen.

Fel signal från feedback-potentiometernpå pumpen, med pumpen i neutralläge.

- Att spänningen från feedback-potentiometern ligger på 2.5 +/-0.15 volt när pumpen står ineutralläge.

Neutral out of range

- Att spänningen från feedback-potentiometern ligger på 2.5 +/-0.15 volt när pumpen står ineutralläge.

Error on pump control loop

Fel signal från feedback-potentiometernpå pumpen. Avvikelsen mellan feedbacksignalen och det förväntade värdettillbaka till TCS kontrollen är >20%, i merän 0.5 sec.

- Kablaget till feedback-potentiometern och EDCkontrollen.

- Att feedback signalen ändrarsig när man ökar körhastigheten.

- Att Min och Max spänningenfrån feedback potentiometern ärkonstant, och att värdet är likavarje gång. Spänningen skallstiga till upp emot 5 volt.


Sida 26

FELSÖKNING

Typ av fel Möjlig orsak

Motorn går men ingen drivning.Pumpen vinklar inte ut, varkenframåt eller bakåt.

Kontrollera p-broms brytarens funktion i menyn: "DISPLAY /BRAKE SWITCH" (set / not set).

Kontrollera fram&back brytarnas funktion i menyn: "DISPLAY /DIRECTION SWITCH" (neutral / forward / reverse).

Drivningen fungerar och pumpenvinklar ut, men motorn varvarinte upp.

Kontrollera varvtalssensorns funktion i menyn: "DISPLAY/ENGINESPEED" - värdet skall vara relevant till det verkliga motorvarvet.

Kontrollera feedback signalen från pump-potentiometern i menyn:"CALIBRATION / PUMP NEUTRAL" (calibration status = locked)

Kontrollera gasmotorn funktion i menyn: "CALIBRATION / ENGINECALIBRATION" (calibration status = locked)

Drivningen fungerar och motornvarvar upp vid körning.Inget gaspådrag när mananvänder hydraulfunktionerna.

Kontrollera lyftpotentiometerns funktion i menyn:"CALIBRATION / MAST LEVER / MAST SENSOR PRESENCE"(Yes=1/ No=0)

(calibration status = locked)

Kontrollera Tilt/Aux brytarnas funktion i menyn: "DISPLAY / MASTSWITCH" (set / not set).

Kontrollera lyftpotentiometerns funktion i menyn:"CALIBRATION/MAST LEVER"

Varken drivning eller gaspådragfungerar.

Om varningslampan är släckt:

:

:

Kontrollera varvtalssensorns funktion i menyn: "DISPLAY/ENGINESPEED" - värdet skall vara relevant till det verkliga motorvarvet.

(calibration status = locked)

Kontrollera spänningsmatningen till TCS enheten i menyn:

Kontrollera feedback signalen från pump-potentiometern i menyn:"CALIBRATION / PUMP NEUTRAL" (calibration status = locked)

Om varningslampan blinkar sakta

Om varningslampan blinkar snabbt

Kontrollera signalen från gaspedalen i menyn: "CALIBRATION/TRAVEL PEDAL CALIBRATION" .

Kontrollera spänningsmatningen till sensorerna i menyn:"DISPLAY / SENSOR EXCITATION" (5 volt).

"DISPLAY / POWER SUPPLY"

Kontrollera kablaget till EDC-kontrollen.


cbd&cbg 25manual.pdf

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