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Service Manual Cargo Range CARGO 4.0 BT Svenska AB < Tillbaka till Index Per Wärmlund...
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 3 CESAB CARRELLI ELEVATORI S. p. A. reserves all rights of reproduction of this handbook The text and the numbering system may not be used in other printed matter, reprinted or translated, whether entirely or in part, without written authorization from CESAB reserves the right to make any necessary...
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 4 INDEX DATA SHEET page 6 DRIVER’S PLACE page 8 Load handling commands page 9 DASHBOARD page 10 BATTERY COVER AND REAR COMPARTMENT page 11 TRUCK LOAD CAPACITY page 12 TRACTION UNIT page 13...
4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 5 TABLES page 39 Oil and grease specifications - Tyre pressure tightening torques page 39 Running in maintenance table page 40 Maintenance table page 41 ELECTRICAL SECTION TECHNICAL FEATURES page 45 Electrical motor feature page 45...
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 7...
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 8 PEDALS FOOT DRIVE DIRECTION (Standard version) - Forward direction (D) - Backward direction (E) - Service brake pedal (C) - Parking and emergency brake pedal (A) - Parking brake release lever (B) DRIVE DIRECTION LEVER ON STEERING COLUMN (Alternative version) Direction selector lever (F)
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 9 LOAD HANDLING COMMANDS There can be three types of commands for load handling LEVER VERSION (A) FINGERTIPS VERSION(B) FUTURE CONFIGURATION MINI JOYSTICK VERSION (C) FUTURE CONFIGURATION All the functions will be explained on the "LIFTING GROUP" paragraph...
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 10 DASHBOARD 1) Battery charge indicator 2) Parking brake ON warning light 3) Low brake fluid level warning light 4) Lifting motor temperature warning light 5) Not used 6) Not used 7) Not used 9) Electronic hour meter...
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 11 12)“dead man device” pilot light the pilot light comes ON, when the driver leaves the driving seat 14)Drive diagnostics (see electrical selection) 15)Lifting diagnostics (see electrical selection) BATTERY COVER AND REAR COMPARTMENT COVER LIFTING Release the lock (I), then lift the battery cowling...
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 12 TRUCK LOAD CAPACITY LOAD PLATE It identifies the load capacity with a load center of 500 mm (except for different indications) ATTACHMENT OR SPECIAL CONDITION OF USE TYRES SERIAL N°...
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 13 TRACTION UNIT The traction gear unit is consisted of: 1) Right hand reduction gear 2) Oil bath brakes 3) Differential gear 4) Electrical motor 5) Left hand reduction gear...
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 14 DISASSEMBLE THE REDUCTION UNIT 8 screws Disassemble the reduction unit - Park the lift truck on a level ground. Engage the parking brake and disconnect the battery; - Disassemble the mast;...
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 15 OIL CHANGE Type of oil MOBIL-FLUID 422SAE 80W or equivalent (see oil table). After the first 50-100 hours - Change the oil Every 250 hours - Check the oil level, when it is cold. Every 1.000 hours or 12 months - Change the oil OIL CHANGE...
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 16 BRAKE SERVICE BRAKE SYSTEM DIAGRAM A) Reduction gear (right) and braking unit B) Parking brake command C) Bleeding screw D) Electric drive motor E) Brake pump F) Tank G) Service brake pedal H) Reduction gear (left) SERVICE BRAKE CONTROL...
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 18 PARKING BRAKE I) Release lever L) Parking brake pedal M)Microswitch N) Brake block anchor O) Pedal adjusting screw P) Release adjusting screw PARKING BRAKE CONTROL AND ADJUSTMENT Every 500 hours - Check the clearance shown on the drawing A with the parking brake pedal released...
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 19 ELECTRIC MOTOR TRACTION MOTOR V 54 (nominal) Kw 17 Frequency 78 Hz Rpm nominal max. 2260 (rpm/min) Service S2 Classe IS F N° poles 4 LIFTING MOTOR V 54 (nominal) Kw 18,6 Frequency...
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 20 STANDARD TYRES THE SAFETY OF RIMS AND WHEELS FOR FORKLIFT TRUCKS “PNEUMATIC” tyres must be replaced when the tread is less than 1.6 mm. “SUPERELASTIC” tyres must be replaced when the tread reaches the “60J” indicator printed on the side. Replacement of “CUSHION”...
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 21 STEERING CONTROL The steering uses the same oil as the lifting by means a priority valve, so that a sufficient oil flow to the power steering is always assured. The oil capacity is checked by the Ls signal (load - sersing) coming from the steering unit and it occurrs so that the oil capacity sent to the power steering is equal to its actual request.
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 22 STEERING AXLE Steering axle check Every 500 hours - lubricate the steering gear joints using the appropriate grease nipples (D), (E), (F) and (G); - check the steering angles. Every 2.000 hours - check and if it is necessary, adjust the wheel hub bearings.
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 23 BEARING ADJUSTMENT Steering wheel bearings require an adjustment once a year. Steering wheels lift the steering wheels remove cap (1); remove check pin (4); fasten the nut with a torque setting of 6 dNm; turn the hub of 2-3 turns in both senses;...
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 24 HYDRAULIC SYSTEM Lever control version SIDESHIFT LIFTING TILTING OIL FILTER OIL TANK PRESSURE CHECKING POINT...
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TILTING SIDE SHIFT STEERING CYLINDER LIFTING ORBITROL CONTROL VALVE PRIORITY VALVE MOTOR PUMP FILTER...
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 26 HYDRAULIC CONTROL VALVES Lever control version Max pressure valve 220 BAR Max pressure tilting valve 150 BAR Max pressure sideshift valve 150 BAR MANOMETER CONNECTION POINT FOR HYDRAULIC PRESSURE CONTROL...
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 27 LIFTING EQUIPMENT OIL AND FILTER The lifting and power steering oil tank is positioned inside the rear compartment The filter cartridge (D) is beneath the screw cap (B).
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 28 MAST GROUPS The mast profile - CESAB design - with double stiffening flange is characterised by a high flexural and torsional strength. It allows wide visibility thanks to the reduced dimensions of the profile itself. Cylinders are single-acting type.
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 29 TRIPLE MAST SECTION Fork carriage Internal section bar Intermediate section bar External section bar...
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 30 LUBRICATION OF LIFTING EQUIPMENT Masts Every 50-100 hours - lubricate with grease the mast sliding guides - lubricate the tilting jacks and the mast connections. A) Tilting jacks 2+2 grease nipples B) Mast connections 1+1 grease nipples...
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 31 Lifting side jack collars: Every 500 hours - check that there is a clearance (C) of 0.5 to 3 mm between the collar and the external lifting jack cylinder.
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 32 DESCRIPTION OF THE CYLINDER COMPONENTS The cylinder pistons are single-acting types (fig. A). In these cylinders a seal (1) has been fitted on the piston (2) that works on the inner surface of the cylinder liner (3).
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 33 CYLINDER CHECKING METHODS CHECK Remove the drain pipe from the cylinder (fig. C) Lift the cylinder some times to end stroke, so as to discharge any oil residual. Put a load on the forks and lift it by at least 200 mm.
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 34 CHECKING THE CHAINS: Every 500 hours - check the condition of the chains which in any case must not be worn or damaged. To check the links for wear, use the appropriate gauge, paying attention that, when 33 links are counted in a space corresponding to 34, the chains must be replaced.
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 35 FORK INSPECTIONS General criteria Fork arms in use must be inspected at intervals of not more than 1 000 hours and whenever a defect or permanent deformation is detected.
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 36 ELECTRIC COMPONENTS DESCRIPTION A) Emergency Switch B) Battery connector C) Traction module D) Lifting module E) Contactors F) Electric cooling fan G) Timer electric fan H) Converter DC/DC I) Fuses Components panel Every 500 hours...
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 37 BATTERY AND BATTERY CHARGER General indications for battery maintenance Every 50 working hours - measure electrolyte density. Approximate density data For a temperature of 15° C - a density of 1.12 to 1.13 kg/dm indicates that the battery is flat;...
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 38 TRUCK LIFTING HOOKS ATTACHMENT POINTS FOR LIFTING THE TRUCK To lift the truck the following equipment must be used: A- CHAINS: dia. 13 mm - Degree T (8) - UNI 9425 B- HOOKS: for 5.4 t - UNI/ISO 7597 LIFTING OF THE FORKLIFT TRUCK...
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 39 OIL AND GREASE SPECIFICATIONS FOR NORMAL ENVIRONMENTS TIPO USATO SPECIFICHE TYPE USED SPECIFICATIONS Q.T QTY. PARTS TO BE LUBRICATED EIGENSCHAFTEN MENGE ISO - L - HV AGIP ARNICA 46 Hydraulic system, lifting and power steering Prove FZG 21 L...
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 40 RUNNING IN MAINTENANCE after # hours FOR MEDIUM/INTENSE USE after # days/months FOR OCCASIONAL USE CHASSIS AND COMMANDS bolts in general wheel tightness (1) (1) During the first 500 working hours, check tightness every 50 hours.
4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 45 TECHNICAL FEATURES ELECTRONIC PANEL Traction Unit Lifting Unit AC3T AC3P Inverter for AC asyncronous 3-phase motors Regenerative braking functions Can-bus interface Digital control based upon a microcontroller Voltage Maximum current 450A (RMS*)
4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 46 OPERATIONAL FEATURES - Speed control. - Optimum behaviour an a slope due to the speed feedback: - the motor speed follows the accelerator, starting a regenerative braking if the speed overtakes the speed set point.
4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 47 DIAGNOSIS The microprocessor continually monitors the inverter and carries out a diagnostic procedure on the main functions. The diagnosis is made in 4 points 1) Diagnosis on key switch closing that checks: watchdog circuit, current sensor, capacitor charging, phase's voltages, contactor drives, can-bus interface, if the switch sequence for operation is correct and if the output of accelerator unit is correct.
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 48 PROTECTIONS - Battery polarity inversion: A MAIN CONTACTOR is fitted to protect the inverter against reverse battery polarity and for safety reasons. - Connection Errors: All inputs are protected against connection errors. - Thermal protection: If the chopper temperature exceeds 75°C, the maximum current is reduced in proportion to the thermal increase.
4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 49 GENERAL DESCRIPTION OF FUNCTION OF THE CONSOLE HOUR METER The hour meter appears in the second line of the display when the chopper is connected. It shows the real working hours.
4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 50 CONSOLE DESCRIPTION KEYBOARD Description of key functions: ROLL 1 = Allows selection of an option or the next menu item ROLL 2 = Allows select of an option or the previous menu item ENTER = Allow confirmation of selected options = Retains the current function...
4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 51 ELECTRIC COMPONENT LAY-OUT CONSOLE CONNECTION PUMP UNIT TRACTION AC3P UNIT AC3T LOGIC BOX ELECTROFAN TRACTION MOTOR See pag 52 ELECTROFAN...
4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 52 COMPONENTS PANEL DESCRIPTION CONVERTER FOR BACK LIGHT (STANDARD 140W) REVERSE LIGHT RELAY A-B FUSE HOLDER FOR LIGHT EQUIPMENT (OPTIONAL) C-D CONVERTER FOR LIGHT EQUIPMENT (OPTIONAL) BATTERY CONNECTOR R1-R2 ELECTROFAN RESISTOR ELECTROFANS TIMER R3 REVERSE RELAY RESISTOR...
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 54 LEGEND Common of FORWARD/ BACKWARD/ SR / PB / SEAT microswiches PARK Parking brake swicth FORWARD Forward direction request input. BACKWARD Backward direction request input. PPOT Acceleretor potentiometer positive. CPOT Acceleretor potentiometer wiper NPOT...
4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 55 ELECTRIC MOTORS ENCODER TRACTION MOTOR TRACTION BEARING ENCODER LIFTING MOTOR LIFTING BEARING ENCODER...
4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 56 ACCELERATOR POTENTIOMETER CONFIGURATION 111 : 4,2 V 109 : 0 ÷ 4,2 V with pedal pressed 110 : Green 5KOhm 7KOhm Yellow...
4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 58 PARAMETER CHANGE FUNCTION TRACTION MODULE AC3T ACC DELAY determines the acceleration ramp. RELEASE BRAKING controls the deceleration ramp when the travel request is released. INVERSION BRAKING controls the deceleration ramp when the direction switch is inverted during travel.
4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 59 TESTER FUNCTIONS TRACTION UNIT AC3T MOTOR VOLTAGE: this is the voltage supplied to the motor by the inverter; it is expressed as a percentage of the full voltage (which depends of the battery voltage). FREQUENCY: this is the frequency of the voltage and current supplied to the motor.
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4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 60 LIFTING UNIT AC3T MOTOR VOLTAGE: this is the voltage supplied to the motor by the inverter; it is expressed as a percentage of the full voltage (which depends of the battery voltage). FREQUENCY: this is the frequency of the voltage and current supplied to the motor.
4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 61 ALARMS FUNCTIONS TRACTION UNIT AC3T 1 FLASH = Logic defect.(EEPROM DATA KO, EEPROM PAR KO, EEPROM CONF. KO, EEPROM OFF-LINE, CHOPPER NO CONF, WATCH- DOG) - Replace the Unit logic AC3T. 2 FLASHES = Incorrect sequence by starting.
4,0 - 4,5 - 5,0 t SERVICE MANUAL A.C. VERSION Electric page 64 LIFTING UNIT AC3P PROGRAMMED LEVEL PARAMETER UNIT ACCEL. DELAY (*) Sec. DECEL. DELAY (**) Sec. MAX SPEED UP MIN SPEED UP 12.0 13.5 15.0 16.5 18.0 19.5 21.0 22.5 24.0 25.5...
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DIAGRAM FOR USING THE CONSOLE FOR UNIT AC3P 1-CONNECT THE CONSOLE TO MODULE AC3P 2-TURN THE KEY ON Manufacturer's name CBE 4.0-5.0 Console program version CONSOLE V.1.0 Display Console LIFTING è Description which appearsonly when Model/configuration and AC Power Connection moment CONNECTED TO: some values are modified program versionof the unit...
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DIAGRAM FOR USING THE CONSOLE FOR UNIT AC3T 1-CONNECT THE CONSOLE TO MODULE AC3T 2-TURN THE KEY ON CBE 4,0 - 5,0 Manufacturer's name CESAB Console program version CONSOLE V.1.0 TRACTION Display Console è Description which appearsonly when AC Power CONNECTED TO: Model/configuration and Connection moment...
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CBE 4,0 - 5,0 AC Power SETTING VALUE LIFTING MODULE AC3P PARAMETERS DESCRIPTION VALUE min. PU. ACCELER DEL determines the acceleration ramp PU. DECELERATION DEL determines the deceleration ramp MAX SPEED UP determines the maximum lifting speed with a 18Hz 95Hz 95Hz potentiometer control...
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CBE 4,0 - 5,0 AC Power SETTING VALUE TRACTION MODULE AC3T PARAMETERS DESCRIPTION VALUE min. ACC DELAY determines the acceleration ramp RELEASE BRAKING controls the deceleration ramp when the travel request is released INVERSION BRAKING controls the deceleration ramp when the direction switch is inverted during travel PEDAL BRAKING determines the deceleration ramp when the travel...
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LEGEND DESCRIPTION ENGLISH DEUTSCH FRANCAIS ESPAÑOL 4' via 4th valve 4.Steuerkreis 4.ème levier 4a.leva 5' via 5th valve 5.Steuerkreis 5.ème levier 5a.leva abilitazione attiva enable on Freigabe ein abilitation activée habilitación activada abilitazione freni brakes enable Bremsenfreigabe abilitation des freins habilitación de los frenos abilitazione parcheggio parking enable...
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LEGEND DESCRIPTION ENGLISH DEUTSCH FRANCAIS ESPAÑOL indicatore temperatura ac water temperature indicator Wassertemperaturanzeiger indicateur temperature de l’ea indicador temperatura del agua intas.filtro aria air filter clogging Luftfilterverstopfung encrassement filtre à air obstrucción filtro aire intas.filtro olio oil filter clogging Ölfilterverstopfung encrassement filtre huile obstrucció...
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LEGEND DESCRIPTION ENGLISH DEUTSCH FRANCAIS ESPAÑOL SW cofano bonnet switch Schutzhaubeschalter interrupteur coffre interruptor cofre temp.olio trasmis. oil temperature transmission Öltemperaturgetriebe temperature d’huile transmis. temperatura aceite transmisión temperatura acqua water temperature Wassertemperatur temperature d’eau temperatura agua termico thermal sensor Wärmesensor senseur thermique sensor térmico traslatore...
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