S Ervice Manual: E Series

Service Manual
CBE
12 T 12 F
15 T 15 F
16 T 16 F
16 TL 16 FL
18 T 18 F
18 TL 18 FL
20 T 20 F
E Series
036-0403-03 02/2003
PAGINA INTENZIONALMENTE BIANCA
INTENTIONALLY LEFT BLANK
PAGE INTENTIONNELLEMENT BLANCHE
WEIß SEITE
PÁGINA INTENCIONALMENTE BLANCA

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Electric SERVICE MANUAL
page 3
CESAB S.p.a. reserves all rights of

reproduction of this handbook
The text and the numbering system

may not be used in other printed matter,
reprinted or translated, whether entirely
or in part, without written authorization
from
CESAB reserves the right to make any

necessary modifications without obligation
to promptly update this handbook.
Copyright by
CESAB S.p.A
via Persicetana Vecchia, 10 40132 Bologna - Italy
Tel. (0039) 051.20 54 11
Fax (0039) 051.72 80 07
E-mail: cesab@cesab.it
BOLOGNA’S FACTORY, AFTER SALES SERVICE

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page 4
SERVICE MANUAL Electric
INDEX
TECHNICAL DATA page 4
MAIN COMPONENTS page 9
OPERATOR’S SEAT page 10
Pedals page 10
Foot drive direction page 10
Drive direction lever on steering column page 10
Battery cover page 11
Load handling commands page 11
Control valve version page 11
DASHBOARD page 12
Dashboard indicators page 12
Dashboard connection page 14
IDENTIFICATION AND LOAD PLATES page 15
SERVICE MANUAL: HYDRAULIC & MECHANICAL SECTION page 16
HIDRAULIC DIAGRAM page 17
Hydralic system 3 and 4 wheels page 18
Oil filter page 19
Hydraulic oil replacing page 20
Replacing of the pump page 20
STEERING CONTROL page 21
3 wheels page 22
4 wheels page 23
POWER STEERING page 24
Power steering hydraulic diagram page 25
REDUCTION GEAR VIEW page 26
Reduction gear page 27
Replacing of the reduction gear page 28
BRAKE SYSTEM page 29
Brake pedal page 30
Parking brake release instructions page 30
Brake effect page 31
Brake discks page 32
Replacing of the wheel brake cylinder 1st way page 33
Replacing of the wheel brake cylinder 2nd way page 34
3 WHEELS STEERING AXLE page 35
4 WHEELS STEERING AXLE page 36
CONTROL VALVE page 37
ELECTRICAL MOTOR page 38
Electrical motor characteristics page 38
FRONT AND REAR WHEELS page 39
MAST GROUPS page 40
Triple mast section page 41
Central displacement cylinder with braking effect on the lifting page 42
Side cylinder with braking effect on the lowering page 43
Description of the cylinder components page 44
Cylinder checking methods page 45
LUBRICATION OF LIFTING EQUIPMENT page 46
GUIDE ROLLERS AND GUIDE SHOES REPLACING page 48
Guide shoes fork carriage replacing page 49
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page 5
MAST CHAINS INSPECTION page 50

CHECKING THE CHAINS page 50
POSITIONING THE FORK MOUNTING CARRIAGE page 50
FORKS page 51
LIFTING OF THE TRUCK page 52
OIL AND GREASE SPECIFICATIONS page 53
TYRE TIGHTENING TORQUES page 53
RUNNING IN MAINTENANCE page 54
MAINTENANCE TIMES page 55
SERVICE MANUAL: ELECTRIC & ELECTRONIC SECTION page 58
FUNCTIONAL PERFORMANCES page 59
PROTECTIONS page 59
GENERAL PRECAUTIONS page 60
ELECTRICAL MOTOR CHARACTERISTIC page 61
ELECTRONIC PANEL CHARACTERISTICS page 62
CONNECTION OF THE AUXILIARY CIRCUIT - B1S UNIT page 63
TRANSDUCER STEERING-WHEEL WITH POTENTIOMETER page 66
LAY OUT LOGIC CONNECTORS page 68
REDUCTION SPEED page 70
CONNECTION OF THE POWER CIRCUIT - B1S UNIT page 71
Power circuit page 72
Release braking page 75
Potentiometer configuration page 76
CONNECTION OF ELECTRIC CIRCUIT - UNIT HP 350A page 77
LIFTING POWER CIRCUIT page 79
Potentiometer configuration page 80
AUXILIARY CARD page 81
Electric diagram of the auxiliary card page 82
Connection page 83
POWER FUSE BOX page 84
CONTACTOR CONNECTION page 85
GENERAL DESCRIPTION OF FUNCTIONS OF THE CONSOLE page 86
Console description: keyboard page 87
PARAMETER MODIFICATION UNIT B1 page 88
Warnings relevant on the dashboard and console page 89
PARAMETER MODIFICATIONS UNIT HP350 page 91
Warnings relevant on the dashboard and console page 92
ADJUSTMENT TABLE -B1S (traction) page 93
ADJUSTMENT TABLE - HP 350 (lifting) page 93
ELECTRICAL DIAGRAMS page 94
SERVICE MANUAL: SAFETY INFORMATIONS page 98
SAFETY INFORMATION page 99
Electric parts page 100
Welding page 101
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TECHNICAL DATA
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page 7
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page 9
MAIN COMPONENTS
Control valve
Logic units
Orbitrol
Pedals
Lifting/steering motor
Counterweigth
Steering axle
Hydraulic oil tank Battery
Electric fan
Main contactor
Traction logic unit
Direction contactors Lifting logic unit
Service pump
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page 10
OPERATOR'S SEAT
PEDALS
FOOT DRIVE DIRECTION

(Standard version)
- Forward direction (D)
- Backward direction (E)
- Service brake pedal (C)
- Parking and emergency brake pedal (A)
A B C D E
DRIVE DIRECTION LEVER ON STEERING

F
COLUMN (Alternative version)
1
o Direction selector lever (F)
2
é 1 Forward direction
o 0 Neutral
ê 2 Backward direction
Single drive pedal (G)
G
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page 11
BATTERY COVER
1. Handle for a better opening / closing.

2. Hook without key lock.
3. Bigger opening for battery plug and battery cable.
1 2 3
- Battery plug fixing position
Behind the battery plug fixed on the frame there is a thickness in

order to improve the operation of connection/disconnection.
1
Thickness (1)
LOAD HANDLING COMMANDS
CONTROL VALVE VERSION

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page 12
DASHBOARD
1 2 3 4 5 6 1) Battery charge indicator

2) Parking brake ON warning light
3) Lifting motor temperature warning light
4) Brake fluid low warning light
5) Worn lifting motor brushes warning light
6) Worn drive motor brushes
7) Electronic hour meter
8) Left drive motor temperature warning
light
9) Lifting equipment disabled due to flat
battery
10)Dead man light
11)Drive diagnostics
7 8 9 10 11 12 13 14 15 12)Electronic control unit temperature
warning light
13)Lift diagnostics
14)Right drive motor temperature warning
light
15)Steering indicator light
DASHBOARD INDICATORS
1 1) Battery charge indicator
Consists of a series of LEDs, green (5), orange (3) and red (2), arranged to
indicate the battery charge level in a simple and clear manner. When the
battery is 70% discharged, one of the red LEDs begins flashing, indicating that
the battery must be recharged (reserve). When the battery is 80% discharged,
both red LEDs flash alternately, indicating that the lifting equipment cannot be
used.
2 2) Parking brake ON warning light
3 3) Lifting motor temperature warning light

lights up when the temperature is too high; a short break, to allow cooling, is
sufficient to restore all initial potential.
4 4) Brake fluid low warning light

This warning light comes ON when the level of brake fluid in the tank has
reached the minimum level.
5 5) Worn lifting motor brushes warning light
6 6) Worn drive motor brushes warning light

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page 13
7 7) Electronic hour meter

The hour meter provides work time readings in fractions of an hour. It is
activated by insertion of the ignition key. Makes it possible to programme
work on the basis of battery life and facilitates the calculation of servicing
periods.
8 8) Left drive motor temperature warning light

9 9) Lifting equipment disabled due to flat battery
10 10)Dead man light
11 11)Drive diagnostics
12 12)Electronic control unit temperature warning light

Lights up when the temperature is too high. This warning light indicates that
the electronic control has reached an extremely high temperature; under these
conditions, to return within the maximum temperature limits, the electronic
control gradually reduces (to zero) the maximum current supplied and, as a
result, truck performance. A short break, to allow cooling, is sufficient to
restore all initial potential.
13 13)Lift diagnostics
14 14)Right drive motor temperature warning light

15 15)Steering indicator light

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page 14
DASHBOARD CONNECTION
CONNECTOR CN2 CONNECTOR CN3
1. Not used 1. Cursor of the steering potentiometer

2. Right traction motor temperature 2. Not used
3. Temperature of the traction logic unit 3. Parking brake
4. Lifting logic unit temperature 4. Brake oil level indicator
5. Left traction motor temperature 5. Wear indicator of the lifting motor
6. Positive of the traction diagnostic LED 6. Wear indicator of the right traction motor
7. Negative of the traction diagnostic LED 7. Wear indicator of the left traction motor
8. Positive of the lifting diagnostic LED 8. Dead man
9. Negative of the lifting diagnostic LED 9. Not used
10. Not used 10. Input test battery 48Volt
11. Lifting block with battery discharge 11. Not used
12. Negative 12. input of the KEY
13. Not used
14. Negative
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page 15
PLATE
A LOAD PLATE
B IDENTIFICATION PLATE
According to the dimension of the truck the

plate A can be located in differents plates
IDENTIFICATION PLATE LOAD PLATE

It identifies the lift truck technical data It identifies the load capacity with a load center
of 500 mm ( except for different indications )
ATTACHMENT OR SPECIAL CONDITION OF USE
MODEL Type MOTOR RATED CAPACITY B A
kW kg TYRES SERIAL N°
SERIAL N° DRAW-BAR PULL (1h)

CENTER OF LOAD DISTANCE mm
N LIFT HEIGHT
mm
BATTERY MASS SERVICE MASS
kg kg Without
min. max. Battery kg
MANUFACT. YEAR TENSION

V
Cod. 0312004
Cod. 0312005
DERATED CAPACITY Kg
CARRELLI ELEVATORI S.p.A.

via Persicetana vecchia, 10
40132 - Bologna - Italia CAPACITY PLATE
SERVICE MANUAL
Hydraulic & Mechanical

section
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page 17
HIDRAULIC DIAGRAM
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page 18
HYDRALIC SYSTEM 3 AND 4 WHEELS
Control valve
Manometer connection
Priority valve
Drain tube
Hydraulic oil filter
Hydraulic oil tank

Lowering valve
AGIP ARNICA 46
21 litres
The correct position of the valve is showen

on the picture
control valve tank
0,5 Bar
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page 19
OIL FILTER
The hydraulic lift oil tank is located under the

platform..
The filter cartridge (A) is beneath the screw cap
C A (C).
To check and change the oil, position the

truck at a standstill and on a flat surface,
with the mast tilted backwards and the forks
lowered.
D After the first 50 hours of work

- first filter change
After the first 500 hours of work
- second filter change.
Every 250 hours
- check the level of oil in the tank using the
dip-stick (D);
B - check and clean the tank breather valve filter
(B).
Every 2 000 hours
- replace the oil and the filter.
E
To change the oil and the filter:
- remove the tank cap (C) and the filter,
release the oil tank drainage pipe (E), then
allow all the oil to drain out into an
appropriate container. Move to the start
position and press the brake pedal to ensure
the complete emptying of the system;
- fit a new filter (D) after checking the state of

the seals;
- secure the drainage pipe again and fill with
new oil.
- After testing, check that there are no oil
leaks.
HYDRAULIC OIL: AGIP type ARNICA 46

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page 20
HYDRAULIC OIL REPLACING
B
C
The tank does not have the drain plug. Two different procedures can be used to replace the hydraulic oil:
1) To discharge the hydraulic oil it is possible to use a pump connected to the hole for the oil level rod
(point A).
2) It is possible olso to disconnect the drain hose of the control valve from the tank and put it on a external case.
By pressing the brake pedal (corrispond to the minimum RpM of the lifting pump) the oil flow out.
Pay attention that the pump must not work without oil.
REPLACING OF THE PUMP
1) After replacing the pump we suggest to help it for taking the oil during the first time of working by blowing
air compresser in the the hole for the oil level rod (point A). Maximum pressure usable 0.5 Bar.
2) It is also possible to use the connection D for the manometer for filling the main hose C with oil in order to
avoid that the pump turns without oil during the first time of working.
Tightening torque 45 +/- 5 Nm

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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.
The exceeding oil is sent to the control valve for other functions.
When the steering wheel is turned the steering unit “measures” a volume of oil proportional to the above
rotation and sends it into the steering cylinder.
Every 250 hours

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

- replace the hydraulic system tubing.
Power steering pressure setting

The max power steering pressure must be 90 Bar
In order to set the power steering pressure, the following operation are necessary:
1 - Fit a manometer on the priority valve (A);
2 - In order reach the adjusting screw (B) remove the cap (by allen wrench) positioned in the upper
side of the orbitrol (power steering unit);
- screw in to increase the pressure
- screw out to decrease the pressure
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page 22
3 WHEELS
LOAD
SENSOR
L
è
R
è LOAD
SENSOR
è
è
L
è
R
The 3 wheels uses a static orbitrol. It means that the oil ORBITROL
reaches the load sensor on the priority valve only when
the steering is moving.
Load
Oil inlet sensor
Valve for the
maximum
pressure
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page 23
4 WHEELS
R
LOAD L
SENSOR L
è
R
è LOAD
SENSOR
è
è
L
è
R
The 4 wheels uses a dinamic orbitrol. It means that the

ORBITROL
oil reaches always the load sensor on the priority valve.
Oil inlet Valve for the Load

maximum sensor
pressure
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page 24
POWER STEERING
For setting the pressure remove the cup and adjust the Allen screw
PRESSURE SETTING
90-100 BAR
Adjusting:
Screw in = highter pressure
Screw out = lower pressure
OSPC 50 LS STATIC ORBITROL
OSPF 80 LS DINAMIC ORBITROL

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page 25
POWER STEERING HYDRAULIC DIAGRAM
STEERING CYLINDER
ORBITROL
TO THE CONTROL VALVES
PRIORITY
VALVE
PUMP
FILTER
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page 26
REDUCTION GEAR VIEW

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page 27
REDUCTION GEAR
The brake discs are working oil-bathed inside the reduction gear unit.
The oil used is the AGIP - ATF II D.
For filling or drain the oil use the magnetic plug.
A - PLUG FOR OIL LEVEL AND OIL FILLING
B - OIL DRAIN PLUG
After the first 50-100 hours

- replace the oil.
Every 250 hours
- check the oil level, when cold, with the truck on a flat surface, and if necessary top up. Use transmission
oil such as AGIP-ATF II D or equivalent. The correct level is obtained when the oil starts to escape
from the hole (A).
- check that there are no oil leaks.
Every 1 000 hours
- change the oil.
Every 12 months for occasional use
- change the oil.
Changing the oil in the reduction gears:

- carefully clean the area around the oil filling and draining
caps; place a suitable container below the drain cap
0,2 and then remove both the filling and the draining caps
2L
and allow the oil to drain out completely;
- clean any ferrous residues from the magnetic cap (B)
and replace it;
- pour fresh oil into the hole (A) until it starts overflowing
(approximately 0.22 litre) then replace the cap;
- when filling is complete, clean any overflow. After
a short functioning period, check the oil level again.
To improve the oil flow, it is advisable to empty

the reduction gears after running the truck for a
few minutes to warm them up.
Do not fill with more oil than necessary to ensure

correct functioning of the reduction gears.
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page 28
REPLACING OF THE REDUCTION GEAR
- Lift the truck

- Remove the wheel from the reduction gear.
- Remove the cable for the parking brake and
the tube for the oil brake system.
- Put a shim under the electric motor.
Tube for the oil brake system.
Cable for the parking brake.
. Remove the screws for fixing the group (gear-

motor).
After replacing the reduction gear it is necessary

to replace also the pinion.
Pinion
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page 29
BRAKE SYSTEM
BRAKE TUBE
BRAKE PEDAL
BRAKE OIL TANK
aproximatly 1mm
Clearence of the brake

pedal in neutral position
The brake system uses the SERVICE BRAKE CONTROL

AGIP BRAKE FLUID DOT 4 Every 250 hours
This one is used only in the brake system and not - check that the liquid level in tank has not dropped;
in the reduction gear. if so, check the system.
The brake oil tank is located in the front side of - control the pedal functioning, that must be smooth
the machinebelow the dashboard. and with no jamming;
After pressing the pedal the pressure of the oil Every 2 000 hours
moves the brake cylinder in order to create the - change the braking system liquid.
brake effect Every 4 000 hours
- replace brake hoses.
Warning light (4) on dashboard
When the liquid in the brake tank is too low,
the warning light comes ON.
If the warning light (4) comes ON,
check that there are no leaks in the system.
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page 30
BRAKE PEDAL
J K
PARKING BRAKE
X
The foot parking brake operates by the same

discs as the service brake.
J) Release lever
V K) Parking brake pedal
Y V) Microswitch
W W)Brake block anchor
X) Pedal adjusting screw
Y) Release adjusting screw
PARKING BRAKE CONTROL AND

ADJUSTMENT
Every 500 hours

- check the parking brake travel which should
correspond to 4 notches. If necessary,
adjust the appropriate screws (X);
- check the condition of the stay bolt cables

and the anchors.
PARKING BRAKE RELEASE

INSTRUCTIONS
To block the truck with the parking brake it is

necessary
to press the Parking brake pedal (K).
The system remain blocked disabling also all
the electrical
functions of the truck.
To release the parking brake system it is
necessary to
pull the Parking brake release lever (J).
Remove the foot from the pedal and release
the lever.
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page 31
BRAKE EFFECT
Main piston
Pad
Brake pin
Fulcrum
Brake cylinder
Oil brake tube

Parking brake cable
Wheel cylinder
Oil area
Spring
Disks group
The brake effect is activated when the brake cylinder of the reduction gear is moving. It moves when the
parking brake pedal or the brake pedal is pressed.
When the brake pedal is pressed the oil moves the wheel cylinder which, by pressing against the side surface
of the reduction gear, moves the wheel brake cylinder. This turns around the fulcrum and presses against the
brake pin that pushes the pad. The pad push the main piston that close the brake discks, obtaining the braking
effect.
When the brake pedal is released the springs pushing the main piston in the neutral position, freeing the discks.
The same moviment around the fulcrum is created by pressing the parking brake pedal that moves
mechanically the brake cylinder.
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page 32
BRAKE DISCKS
Reduction gear body
Plate disck
Gear 1
Gear 2
Pinion
The brake effect starts when the wheel brake cylinder is

moving. The brake cylinder press the free cylinder and the
pad. The pin is used in order to block the pad that
Wheel brake
otherwise would turn with the brake disckes.
cylinder
The Pinion turns on the Gear 2 where are fixed the Gear1
and the brake disck.
Free rod pin The brake disckes have many teeth on the external
Pad diameter in order to bolck the them on the reduction gear
body. The counter disckes have many teeth on the internal
Pin diameter in order to block Gear1. Consequently after
pressing the brake pedal all the disckes are pressed and
the Grear1 is stopped by means of the counter diskes.
The spring are used for replacing the neutral position of
the Gear 1.
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page 33
REPLACING OF THE WHEEL BRAKE CYLINDER
A B C D A: Wheel E: Metal parking brake cable

B: Reduction gear F: Oil brake hose
C: Electric motor G: Threaded bar M8
D: Wheel brake cylinder H: Threaded bar M14
(see page 34)
For replacing the wheel brake cylinder D it is possible to proceed in two different ways.
1st WAY
1) lift the truck
E F D
2) remove the cable E and the hose F (picture 1)
3) remove the wheel A
4) replace the three screws used for fixing the

reduction gear to the electric motor with
three threaded bar M8 (pictures 2) or
Picture 1 three longer screews.
E 5) Move away the electric motor C in order to

create enough space between the two
components.
6) Replace the wheel brake cylinder by

dismounting the clip of the pin.
7) Reassemble the parts.

Picture 2
Be carefully do not damage the pinion during

the coupling of the motor and the reduction
gear.
Picture 3
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page 34
2nd WAY
To replace the brake cylinder it is enougth to

E F D proceed as follows:
1) lift the truck
2) remove the cable E and the hose F
3) remove the wheel A (see previous page)
4) remove the screws that fixed the gear box to the

frame
5) fix the bar G in a higther hole of the frame that will be

G like guide in order to help you to keep out the
reduction gear (5-10 cm) from the frame just to
have enougth space to change the brake cylinder.
6) repeat the procedure in the opposit direction to fit

again the components.
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page 35
3 WHEELS STEERING AXLE
Control of steering unit

The steering unit (D) does not require greasing or lubrication.
Every 2 000 hours
- check and if necessary adjust the wheel hub bearings.
24 daNm
Old fixing of the steering potentiometer
New fixing of the steering potentiometer

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page 36
4 WHEELS STEERING AXLE

Steering axle check
Every 500 hours
- lubricate the steering gear joints using the appropriate grease nipples (I);
- check the steering angles.
Every 2.000 hours
- check and if it is necessary, adjust the wheel hub bearings.
Max steering angle (internal wheel B = 80°)

End stroke setting (adjustment):
take the cylinder to the internal end stroke, then operate on the special screws putting
them on the spindles. Then screw in the adjusting screws till when you obtain the desired steering angle
B = 80°
If any abnormal consumption of the wheel tread is observed, the following controls should be made:
- check the parallelism of the steered wheels;
- check that the steering angle of the wheels is the same in both directions.
B = 80° Standard
ANGLE MEASURED BY THE AXLE FRAME TO THE
INTERNAL WHEEL THROUGH A SPECIAL DEVICE
I
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page 37
CONTROL VALVE
4°Way Sideshift Tilting Lifting
Maximum lifting valve

Maximum function
pressure
valves pressure
PRESSURE SETTING
TRUCK MAST TYPE LIFTING TILTING SIDESHIFT

TON PRESSURE PRESSURE PRESSURE
1,2 H<4350mm MAX ~ 160 MAX ~ 130 MAX ~ 110
1,2 H>4350mm MAX ~ 180 MAX ~ 130 MAX ~ 110
1,5-1,6 H<4350mm MAX ~ 190 MAX ~ 140 MAX ~ 120
1,5-1,6 H>4350mm MAX ~ 210 MAX ~ 140 MAX ~ 120
1,8-2,0 H<4350mm MAX ~ 220 MAX ~ 160 MAX ~ 130
1,8-2,0 H>4350mm MAX ~ 250 MAX ~ 160 MAX ~ 130
All the pressure values must be considered approximate

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page 38
ELECTRIC MOTOR
MAINTENANCE
Every 500 hours check the wear brushes
Every 500 hours check the commutator conditions
ELECTRIC MOTOR CHARACTERISTICS

TRACTION MOTORS: SCHABMÜLLER (P/NO 0058007)
V 48 Service S2 -60’
A 108 IP 20
RPM 2160 IS F
KW 4,2 SERIE
LIFTING MOTOR: SCHABMÜLLER (P/NO 0058026)

V 48 Service S3 -13%
A 244
RPM 1530
KW 9,5 SERIE
Lifting pump 17 LT/MIN
< 50%
L
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page 39
FRONT AND REAR WHEELS
SE
PN
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page 40
MAST GROUPS
The mast profile - CESAB design - with double stiffening flange is characterised by a high flexural and torsional
strength.
It allows wide visibility thanks to the reduced dimensions of the profile itself.
Cylinders are single-acting type.
The sideshift system has been housed inside the profiles.
The mast group is a roller type with a variable centre distance (i.e. a fixed roller is fitted on the outer mast and a
mobile one on the inner mast, instead of a number of mobile rollers only on the inner mast). This solution ensures
better grip and stability on operation.
Other features: side plays adjustable from outside. Plastic guide shoes. Roller bearings with grease nipples, ball
joints on axle couplings and tilt cylinders.
Lifting cylinders:
Duplex mast: TV 2 side cylinders
FFL 2 side cylinders
2 central cylinders
Triplex mast TV 2 side cylinders

FFL 2 side cylinders
2 central cylinders
Grease nipple Adjusting screw Shoe Roller

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page 41
TRIPLE MAST SECTION
Fork carriage
Internal
section bar
Intermediate
section bar
External
section bar
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page 42
CENTRAL DISPLACEMENT CYLINDER WITH BRAKING EFFECT ON THE LIFTING
The oil flows into the cylinder from

Rod the “Oil inlet” when the control valve
is operated.
Cap Flowing through channels 1, 2 and 3, it
Bleeder fills chamber A until the inner oil pres-
screw sure exerts an upward force against
the surface C. The outward sliding of
the rod is, thus, set off. This move-
ment is enacted by the oil flow from
chamber A to chamber B through the
above mentioned channels.
At the end of the expanding process
Chamber A channels 1 and 2 are plugged by the
cap. Therefore, since the oil flowing
between the two chambers passes only
through channel 3, it has a lower ca-
pacity. The outcome is a slowing-down
or “Braking effect”.
The downward sliding of the rod is
Channels 1-2 allowed by the opening of the “Oil
inlet” circuit, so that the oil can be
Unidirectional
valves D-E retrieved into the tank by means of
the control valve.
Channels 3
At the beginning of this phase cham-
ber A contains no oil. A more constant
filling is allowed by the two unidirec-
tional valves D and E that, when
Chamber B open, permit avoiding jolts.
Once beyond the cap, the oil flow
between the two chambers passes
through channels 1 and 2, which are
now open.
Surface C
Oil inlet
>
Safety valve
Unidirectional
< valves D-E
ton.1,2-2,0 T/F
page 43
SIDE CYLINDER WITH BRAKING EFFECT ON THE LOWERING
Channel A
(to the central
Chamber B
cylinder)
bleeder The oil flows into the cylinder from
screw the “Oil inlet” when the control valve
is operated.
Flowing through chamber B and chan-
nel A it fills first the central cylinders,
then chamber A through hole F and
Rod the unidirectional valve C.
The oil exerts thus an upward force
against the surface D, which sets off
the outward sliding of the rod.
This movement is allowed by the oil
flow from chamber A to chamber B
Chamber A through hole F and the guide ring.
blender The downward sliding of the rod is
screw allowed by the opening of the “Oil
inlet” circuit, so that the oil can be
retrieved into the tank by means of
the control valve.
In this phase the oil flows between the
two chambers only through the hole F,
as valve C is closed.
The downward speed of the rod re-
mains constant until hole F is closed
Chamber A by profile E. The remarkable reduc-
tion of oil flow has a slowing-down or
Surface D “Braking effect”.
Hole F
Profile E
Guide ring Chamber B
Safety valve
Unidirectional
valve C
>
Oil inlet
ton.1,2-2,0 T/F
page 44
DESCRIPTION OF THE CYLINDER COMPONENTS
The cylinder pistons are single-acting types (fig. A).
In these cylinders a seal (1) has been fitted on the

6
piston (2) that works on the inner surface of the
5 cylinder liner (3).
4 The rod guide is made by the plug (4) and by the

piston through anti-friction rings (5).
7 The dust control ring (6) prevents any dirt and water
from penetrating the cylinder.
Slight leakages that may occur are directed to the

tank through the drain pipe connected to the pipe
THRUST coupling (7).
DIAM-
ETER
3 The drain pipe shall reach the oil tank (fig. B)
A small quantity of oil will always remain in the loop

formed by the pipe before connecting to the tank. It
acts as a trap and constantly moisturizes the cylinder
liner, when it is completely closed (fig. B).
2
5
Fig. A Fig. B
ton.1,2-2,0 T/F
page 45
CYLINDER CHECKING METHODS
1ST CHECK
Remove the drain pipe from the cylinder (fig. C)
Lift the cylinder some times to end stroke, so as to

discharge any oil residual.
Put a load on the forks and lift it by at least 200 mm.
After 10 minutes, measure the amount by which the

load has lowered. A drop of a few millimetres is quite
normal, as in the distributor there are always some
leakages.
Now, lift the cylinder to its end stroke, if no oil leaks
from the drain pipe coupling, it means that the load
lowering is only due to the leakages on the distributor.
Fig. C
In the presence of leakages, it will be necessary to
replace the seal. Should this be the case, inspect the
cylinder liner.
2nd CHECK
(To be carried out if the 1st inspection has been
successful and after seal replacement).
Remove the drain pipe from the cylinder.
Lift the cylinder some times to end stroke, so that all

the possible remaining oil is discharged.
Put a load on the forks. Lift and lower it for 10 minutes,

making sure that the limit stop is never reached.
Lift the cylinder to end stroke.
If any leakages should be still present, the cylinder is

damaged and then it must be replaced.
ton.1,2-2,0 T/F
page 46
LUBRICATION OF LIFTING EQUIPMENT

D Masts
After the first 50 hours
E
- adjust the guide shoes adjusting the Allen screw (D)
For the adjustment use a 0.2-0.5 mm thickness gauge, inserted
from below and up to the centre of the Allen screw (D) passing
behind the roller (E).
Every 50-100 hours

- lubricate with grease the mast sliding guides
A - lubricate the tilting jacks and the mast connections.
A) Tilting jacks 2+2 grease nipples
B) Mast connections 1+1 grease nipples
Every 250 hours

- adjust the guide shoes;
- grease the mast guide rollers (E)
Every 2 000 hours

- check the condition of the guide rollers (E); they must turn freely
without jamming and not show excessive wear.
A
Fork carriage and sideshift unit
After the first 50 hours
- adjust the guide shoes adjusting the Allen screw (G)
For the adjustment use a 0.2-0.5 mm thickness gauge, inserted
from below and up to the centre of the Allen screw (G) passing
behind the roller (H).
Every 50 hours
B - lubricate the sideshift guides with with grease through the grease
nipples.
Every 250 hours

- lubricate the fork positioning pins and notches with grease.
- grease the fork carriage guide rollers (F)
F - adjust the guide shoes
G
Every 2 000 hours
- check the condition of the guide rollers; they must turn freely without
jamming and not show excessive wear.
H
ton.1,2-2,0 T/F
page 47
C C) Sideshift unit
(upper part)
3 grease nipples
(lower part)
without grease nipplesexcessive wear.
C Make sure that:
- the lifting chain stay bolts are free of defects and that the
adjusting nuts are locked by the appropriate cotter pins (A);
E - the fork carriage (B) safety end stops are present and tightly
E
fixed.
- the collars (C) are present and tightly fixed.
Every 500 hours

- check that there is a clearance (D); of 0.5 to 3 mm between
D the collar and external lifting jack cylinder.
- check that there self-lockin nuts (E) are tight.
Locking torques:
- collar self-locking nuts 0.8-1.2 daNm
SAFETY FORK CARRIAGE END STOP
The lifting unit is equipped with a mechanical safety end stop,

to avoid the accidental escape of the fork carriage from the botton
of the mast.
G The end stops (A) consists of two Allen bolts. To remove the
SKD051
fork carriage, first of all unscrew the end stops.

ton.1,2-2,0 T/F
page 48
GUIDE ROLLERS AND GUIDE SHOES REPLACING
Guide rollers and guide shoes Mast-Fork carriage replacing
In order to carry out the job proceed as follows:
1) remove the two forks from the carriage

Picture 1
Picture 1
2) disconnect the two sideshift hoses on the fork carriage (Picture 1)
3) tie the fork carriage with a belt (Picture 2)
4) remove the safety clip of the chain pin on the carriage (Picture 3)
5) remove the nut stopping the chain pin with a tools as shown in Picture
4. After that put the two chains in the opposit side in order to have more
Picture 2 space.
6) remove the two Allen screws (Picture 5)
7) remove the complete fork carriagefrom the bottom
8) remove the guide shoes with two screw drivers (Picture 6) and screw
out the Allen a screw G (see page 46) in order to give the possibility
at the new guide shoes to go inside completely.
Picture 3
9) remove the snap ring A and take out the guide roller (Picture 7)
10) reassembly all parts in the opposit sequency and adjust the guide shoes
as showen at page 49.
Picture 4
A
Picture 5 Picture 6 Picture 7
ton.1,2-2,0 T/F
page 49
GUIDE SHOES FORK CARRIAGE REPLACING

C
In order to carry out the job proceed as follows:
B 1) remove one of the two side bars B from the fork carriage (Picture 8)
Picture 8
2) take out the mobile plate C (Picture 8)
3) replace the upper and lower guide shoes D-E (Picture 9)

D
4) please note to introduce the shims F as necessary in order to have a
correct clearence of the mobile plate C on the fork carriage
E
Picture
Picture 7
9 5) reassembly all parts in the opposit sequency and lubricate the guide
shoes as showen at page 46.
B
Picture 10
C
D
F B
A
ton.1,2-2,0 T/F
page 50
MAST CHAINS INSPECTION
CHECKING THE CHAINS:
Every 500 hours (anyway, chains are to be checked every 3 months)

- check the condition of the chains which in any case must not be faulty, worn out or damaged.
Every 1 000 hours

- remove the chains, clean them thoroughly, refit them inverting the original working position and
lubricate them.
Every 10 000 hours

- replace the chains and the fixing tie rods
Use of original CESAB chains will guarantee that the safety requirements stated by the regulations
in force are complied with.
POSITIONING THE FORK MOUNTING CARRIAGE
Every 500 hours

- After testing the chains as described above, with the truck on an even surface and the mast in a vertical
position, check the position of the fork carriage plate, as follows:
- remove the forks, completely lower the fork carriage and measure the height (X), comparing it with
the value shown in the table, correspondig to the capacity in kg of the truck.
(e.g. the correct value of (X) for a truck with a capacity of 2000 kg (class II B), must be 152 ±5
mm).
X = 76 mm (A)
X = 152 mm (B)
ton.1,2-2,0 T/F
page 51
FORK INSPECTIONS
General criteria
FORKS Fork arms in use must be inspected at intervals of not more
than 1 000 hours, and whenever a defect or permanent deformation
is detected. If the truck is subject to intensive use, more frequent
inspections may be required.
Inspection
Fork arm inspection must be carried out carefully by trained personnel
to detect any damage, failure, deformation, etc., which may impair
safe use.
Surface cracks
The fork arm must be thoroughly examined visually for cracks giving
G G special attention to the heel (D) and top (E) and bottom (F) hooks.
If necessary, the forks may be subjected to a non-destructive crack
E E detection process.
Difference in height of fork tips
Check the difference in height between the blade tips on each pair
of forks, this must not be more than 3% of blade length with the
forks fitted on the fork plate.
F F Positioning lock
D D Check that the fork positioning lock (G) is in good working order.
Legibility of marking
If the fork arm marking is not clearly legible, it must be renewed
by the original fork supplier.
Fork wear control
The fork arm blade and shank must be thoroughly checked for wear,
paying special attention to the area around the heel (D). When maximum
wear is detected, with thickness reduced to 90% of the original,
the fork arm must be replaced.
Fork mounting wear control
The horizontal supporting surface of the top hook (E) and the contact
surfaces of both hooks (E) and (F) must be checked for wear and
any damage.
WITHDRAWAL OF THE FORKS FROM SERVICE

Any fork with defects revealed during the above controls must be
withdrawn from service.
<= FORVARD - BACKWARD=>
MAST GROUP TILTING SETTING
2°30 FORWARD
6° BACKWARD
Check to carry out every 500 h
N.B. 1 tilting degree corresponds to a 17.4 mm movement on 1 mt.
1° = 17,4 mm
ton.1,2-2,0 T/F
page 52
LIFTING OF THE TRUCK
If the truck is equipped with mudguard extensions, chains can

only be hooked by previously disassembling the extensions
themselves.
HOOKS ATTACHMENT POINTS FOR LIFTING THE

TRUCK
The hooking points are shown on the carriage with the symbol
shown on the side (see figure).
A
LIFTING OF THE FORKLIFT TRUCK
To lift the truck the following equipment must be used:
A- CHAINS: ø 8 mm - Degree 8 - UNI EN 818-2

B
B- HOOKS: for 2 t - UNI/ISO 7597
LIFTING OF THE FORKLIFT TRUCK WITH CABIN

To lift the truck with cabin the following equipment must be used:
A- CHAINS: ø 8 mm - Degree 8 - UNI EN

818-2
C C B- HOOKS: for 2 t - UNI/ISO 7597
C- N° 2 upper brackets to hold the chains.
A It is important to remember that the chain length must be

A
sufficient to lift the truck in a horizontal position, with the lifting
angles (ß) £ 45° with respect to the vertical lifting line.
Ensure that the chain is protected where it comes into contact
B with edges, then arrange the chains on the truck so that it
remains in a horizontal position during the entirely lifting operation.
Make sure that there are no personnel in the vicinity of the
truck, before carrying out the lifting operation.
If any maintenance operations need to be performed on the truck
in a raised position, the vehicle must be rested on appropriate
supports, sufficient to bear the overall weight of the vehicle,
keeping the chains taut.
ton.1,2-2,0 T/F
page 53
OIL AND GREASE SPECIFICATIONS
TYRE TIGHTENING TORQUES

ton.1,2-2,0 T/F
page 54
RUNNING IN MAINTENANCE
LEGENDA
'
In the maintenance table indicating a visual
control and cleaning of the parts indicated.
&
In the maintenance table indicating the
replacement of the parts indicated.
" In the maintenance table indicating

lubrication of the parts indicated.
,
Inthemaintenancetableindicatingtightening
or adjustment of the parts indicated.
The servicing periods are divided into hours,

considering an average working day of 8 hours
of effective operation.
If the truck is used on average for less than
8 hours per day, refer to the schedules expressed
in days/months
ton.1,2-2,0 T/F
page 55
MAINTENANCE TIMES
ton.1,2-2,0 T/F
page 56
MAINTENANCE TIMES
ton.1,2-2,0 T/F
page 57
MAINTENANCE TIMES
SERVICE MANUAL
Electric & Electronic

section
ton.1,2-2,0 T/F
page 59
Functional performances
- Very good control at low speed.

- Diagnostic with indication by means of led.
- Able to be formed via console.
- Internal timer visible from the console.
- Storage of the last 5 alarms with the relative value of the timer and temperature visible from the console.
- Tester by means of the console to verify in real time of the main parameters, such as input, motor voltage, battery.
- Arc less operation of the remote control switches.
- Internal coil suppression (within logic).
- High efficiency of motor and battery due to high frequency switching.
Protections
- Battery reversal:
It is important to observe the connections shown in order to prevent damage.
The logic is internally protected from reverse battery polarity.
- Connection errors:
All inputs are protected against incorrect connections.
The remote control switches have a rating of 3Amps, however they are protected from overload and short
circuits.
- Termal protection:
When the temperature is more than 80°C the maximum current is reduced in proportion to the increase in
temperature. The temperature can never exceed 85° C.
- Discharged battery:
When the battery is discharged the lifting speed is reduced by 60%. The other functions remain unchanged.
- External agents:
The chopper is protected from the dust and from the liquids spray , is completely sealed.
- Safety from accidental operation:
Starting the machine, requires a precise sequence of operations otherwise the machine will not start. The start
sequence has to be initiated after the key and the micro seat are active.
- Safety from uncontrolled movements:
The remote control switches remain open if:
- The power is not in use.
- The accelerator voltage does not fall below (minimum memorized value 2 volt).
- The logic is not in perfect order.
- A direction microswitche is ever closed.
General precautions see page 60.

ton.1,2-2,0 T/F
page 60
General precautions
- Do not connect the chopper to a battery with a nominal voltage different to the voltage stated from the one on
the unit plate. If the battery voltage is higher it may cause the MOS failure.
If the battery voltage is less the unit will not run .
- During the battery recharging no units must be connected to the battery as, the unit can be
damaged by the overvoltages generated by the charge-battery.
- Supply the unit only with traction battery, do not use rectifier outputs or power supplies.
- With key switched off, the filter capacitors could remain charged for some minutes. For work in surely working
conditions, we suggest you
. to disconnect the battery and with resting machine and inserted key wait some seconds till when
the display will be completely off;
or
. short circuit the capacitors through a resistor (56 Ohm 1W) across B+ and B- chopper power
connections.
- Before carrying out any arc-weldings on the trucks, disconnect the battery and short-circuit the unit between
positive (+) and negative (-).
ton.1,2-2,0 T/F
page 61
ELECTRICAL MOTOR CHARACTERISTIC
TRACTION MOTOR: SCHABMÜLLER (P/NO 0058007)

V 48 Service S2
A 108 IP 20
RPM 2160 IS F
KW 4,2 SERIE
LIFTING MOTOR: SCHABMÜLLER (P/NO 0058026)

V 48 Service S3 -13%
RPM 1530
KW 9,5 SERIE
Lifting pump 17 LT/MIN
ton.1,2-2,0 T/F
page 62
ELECTRONIC PANEL CHARACTERISTICS
Technical specifications B1S (traction) HP 350 (lifting)
Nominal voltage (Variation): 48V (30 - 60) 48V (30 - 60)
Max. current: : 350A + 350A 350A
Operating frequency: 18KH 18KHz
Working ambient temperature: -30°C / +40°C -30°C / +40°C
Max. attainable temperature

from chopper body: 85°C 85°C
Microprocessor Logic unit.

ton.1,2-2,0 T/F
page 63
CONNECTION OF THE AUXILIARY CIRCUIT - B1S UNIT

ton.1,2-2,0 T/F
page 64
The traction logic unit is symmetric. It means that the right side is complitly the same to the left side.
It is fixed using 6 screws located in different position in order to avoid any problem during the assembling.
For each connector corrispond a letter which it is not written on the logic unit.
CONNECTOR "A"
It is the diagnostic LED connected on the display. The flashing alarm code and the alarm written on the console are
manage from the same electric circuit inside the logic.
After switching the truck on there is a test on the dashboard for checking all the LEDs. It means that in case of alarm
showed on the dashboard it is necessary to wait the end of the start testing before counting.
CONNECTOR "B"
It is the connector for the console
CONNECTOR "E"
In this connector arrive 48 Volt from the key in the PIN 1. These 48 Volt are used to feed the logic unit but are
used also to control the microswitches(PIN5 connector G) and the coil of the contactors (PIN2 connector E).
It menas that a bridge inside the chopper conects the PIN1 and PIN2 (for the coils) and PIN5 connector G for
controlling the microswithes.
The logic unit controls all the negative signals, the positive is taken from the key.
Only the maing contactor does not have the positive in common but is controlled directly from the logic unit.
CONNECTOR "F"
In this connector arrived the signal from the brake pedal.
ton.1,2-2,0 T/F
page 65
CONNECTOR "G"
In this connector arrive the signals from the microswitches and the travel potentiometer. In the PIN5 arrive the
48Volt.
The parking brake is connected in series to the travel microswitches. For this reason it can be used like EMERGY
BOTTON.
CONNECTOR "H"
In this connector goes out the signal for the temperature LED.
CONNECTOR "L"
In this connector arrive the signals from the steering potentiometer. The cables start from the logic unit and reach
the printed card located in the front side of the machine, go throught two resistence (the cursor remain free) and
reach the potentiometer fixed on the axle.
The steering potentiometer is usedto inform the logic unit of the real position of the bach wheels in order to control
the traction motors.
When the potentiometer reaches 70° the traction logic unit

controls the motor in order to stop completely one motor
according to the direction. In this case the truck turn around the
point B. If the stroke of the poentiometer increases the motor that
was stopped start running in the opposite direction and the truck
start turning around the point A.
ton.1,2-2,0 T/F
page 66
Transducer steering-wheel with potentiometer
The potentiometer should have the following characteristics:

- Resistance between 2,2 Kohm (see P/No. in spare parts book).
- The potentiometer supply is ~ 7 ÷7,6 V.- The potentiometer should be installed in a way that in the "zero position"
(straighthened weels) the output voltage is 2.5V. The potentiometer has to be fitted so that when the trolley turns
clockwise the voltage increases.
R10
680 Ohm
RIGHT
STEERING
POTENTIOMETER
LEFT
R8
220 Ohm
ton.1,2-2,0 T/F
page 67
In the connecctor CN2 are located the two resistences connected in series to the positive and negative of the steering
potentiometer.
They are used for safetly reason.
AUXILIARY CARD
R10 R8
680 Ohm 220 Ohm
STEERING
POTENTIOMETER
VERDE GRIGIO
NERO ROSSO
GIALLO NERO
GRIGIO
ROSA
This truck controls the motors according to the position of the seteering potentiometer.
AUXILIARY CARD
R10
A 680 Ohm ~ 7 ÷7,6 V.
RIGHT
STEERING C
POTENTIOMETER
LEFT 0 V
B R8
220 Ohm
By means of the two resistences and the connection wires, in the points A and B there are respectively ~ 6,5÷5,5
(A) and ~ 0,4 ÷0,8V (B).In case of a wire disconnected the logic unit goes in alarm.
ton.1,2-2,0 T/F
page 68
LAY OUT LOGIC CONNECTORS
D1R
(VMNR) +SHR
+B D2R
(-SHR)
(-SHL)
-B D2L
(VMNL) +SHL
D1L
NTFR E9 F1 M. SEDILE
PTFR E8 F3 IN AUX,
NTASX E7
NTISX E6 G1 NPOT
NTADX E5 G2 CPOT
NTIDX E4 G3 PPOT
NTIND E3 G4 NPOT
PT E2 G5 CMM
+CH IN E1 G6 MF
G7 MI
// D2 G8 MA
// D1
H1 IN AUX. AM
// C3 H2 OUT AUX.
// C2 H3 PT
// C1
J1 //
UP/DOWN B8 J2 //
F. SELEC B7
-BATT B6 L1 -BATT
+12 B5 L2 CPOTST
NCLTXD B4 L3 -BATT
PCLTXD B3 L4 POS, ST.
NCLRXD B2 L5 D0
PCLRXD B1 L6 D1
L7 D2
+LED A2 L8 D3
-LED A1 L9 D4
ton.1,2-2,0 T/F
page 69
Connector of the right side

A1 -LED Negative of the diagnostic LED
A2 +LED Positive of the diagnostic LED
B1-B8 CONSOLE Console connnection B6(+12Volt) B5(GND)
C1-C3 // Not used
D1-D2 // Not used
E1 +KEY Input of the Key.
E2 PT Positive of the direction contactors
E3 NTAD Negative forward remote control switc right motor
E4 NTAS Negative forward remote control switc left motor
E5 // Not used
E6 NTIL Negative backward remote control switch left motor
E7 NTID Negative backward remote control switch right motor
E8 PTFR Positive brake contactor
E9 NTFR Negative brake contactor
Connector of the left side
F1 MF Micro foot-brake (+VB)

F2 // Not used
G1 NPOT Negative potentiometer (-VB)
G2 CPOT Central Potentiometer
G3 PPOT Positive Potentiometer
G4 // Not used
G5 CMM Common Micro (+VB)
G6 MSED Micro seat (+VB)
G7 MI Backward micro switch
G8 MA Forward micro switch
H1 // Not used
H2 TEMPERATURA Signal of temperature light on display
H3 // Not used
I1-I2 // Not used
L1 -BAT Negative
L2 CPOTST Cursor of the steering potentiometer
L3 // Not used
L4 8V Max voltage on the potentiometer. (aprox. between 7.2-8 Volt)
L5-L9 // Not used
ton.1,2-2,0 T/F
page 70
REDUCTION SPEED
The logic unit is equipped with a reduction speed (CUT BACK
SPEED).
In this configuration there is a free connector (connector n°1 in
fig. 5) which permits to modify the electric circuit in order to
enable or disable the reduction speed of the truck :
1
A. When the connector 1 is free the reduction of speed is
disabled.
Fig. 5 In this configuration the truck reaches the max. speed value, which
is previously set by the operator (SPEED LIMIT).
B. When the connector is plugged by means of bridge 2, the

1 reduction speed is enabled.
A
The CUT BACK SPEED is adjustable:
- VALUE 9 corresponds to the minimum reduction (high speed).

- VALUE 0 corresponds to the maximum reduction (low speed).
2 B
ton.1,2-2,0 T/F
page 71
CONNECTION OF THE POWER CIRCUIT - B1S UNIT

ton.1,2-2,0 T/F
page 72
POWER CIRCUIT
The electrical diagram shows the power circuit of the truck and also the internal components of the traction logic
unit. Eight numbers are present and they corrispond to the PINS which are present on the logic.
The chopper for the traction controls two motors and with two electrical circuits that are complitly the same.
Keeping the point number 5 as referent point it is possible to identify the two separete circuits. Left and right.
For a easer comprension of the power circuit it is better to identify the components that are inside the logic unit and
the components that are outside.
In the next diagrams they are divided by means of a line.

ton.1,2-2,0 T/F
page 73
INTERNAL COMPONENTS
Picture 1
INTERNAL COMPONENTS
Picture 2
ton.1,2-2,0 T/F
page 74
Picture 1
After switching the truck ON, 48 Volt arrived to the couple of resistence sconnected in serie and with the
same value: 1K2 5W.
In this case the value of the voltage on the line VMN (it means on the PINS 3 or 8) is 24 Volt.
It means that between the PINS 3 (positive) and 4 (negative) connecting a digital multimeter you read 24 Volt.
The same between the PINS 8 and 4.
Picture 2
It is possible to consider only half power circuit given that the two circuits are the same and they work in pairs.
For ex. we consider the left part of the circuit.
Pressing the accelerator pedal for exemple in backward direction the contactor for the direction is closed and
immediatly the 24Volt go to negative through the direction contactors, traction motors and main contactor.
When the logic unit reads that the 24 Volt are connected to the negative it controls the coil of the main
contactor that in this situation is closed.
Now the battery is connected directly to the motor and the current goes throught the MOS.
According to the position of the traction potentiometer the logic

unit control the signal that arrived to the Gate of the MOS.
In this condition the MOS controls the power signal creatin a
sequence of impulse.
V
Low speed
High speed
t
PERIOD
ton.1,2-2,0 T/F
page 75
RELEASE BRAKING
After releasing the accelerator pedal the direction contactor are inverted and the main contactor is open.The
current start running in the circuit as showed in the above picture.
The current goes through the MOS and for this reason it is possible to control the brake effect with the
console.
The two diodes connected between the two resistences are used for charging the battery when the accelerator pedal
is released.
ton.1,2-2,0 T/F
page 76
POTENTIOMETER CONFIGURATION
Drive potentiometer
Green : 5V
Black : 0 ÷ 5 V with pressed pedal
Yellow: 0V
Green Green
)
4.5KOhm
é 1.2KOhm Red Black
)
ç
Yellow Yellow
)
Steering potentiometer
Green : ~ 7 ÷7,6 V.
Black : ~ 4 V with max. steering angle
righthand + 90°
2,5 V with straight wheel
~ 1 V with max. steering angle
lefthand - 90°
Yellow : 0 V
Grey Green
)
Red
2,2 KOhm ç ) Black
Black Yellow
)
ton.1,2-2,0 T/F
page 77
CONNECTION OF ELECTRIC CIRCUIT - UNIT HP 350A
A1 K LED
A3 A LED
B1
B2
B3
B4 CONSOLE
B5
B6
B7
B8
48 V
C1 C POT
C2 N POT
C3 P POT
D1 CH IN
D2 CH OUT
48 V
E1 AB POT
E2 3RD S Battery discharge lifting block signal
E3 2ND S
E4 MF
(from dashboard, connector CN2 pin 11)
E5 BLOCCO Backward direction negative signal (connected to the left motor
E6 1ST S
E7 4RD S
direction contactor)
E8 NTIS
E9 NTAS
Forward direction negative signal (connected to the left motor

direction contactor)
ton.1,2-2,0 T/F
page 78
LEGEND
NTAS = FORWARD DIRECTION(connected to the traction logic unit) E9
NTIS = BACKWARD DIRECTION(connected to the traction logic unit) E8
Negative signal for steering wheel of following contactors of left-hand motor
4TH S = 5th lever microswitch positive E7
1ST S = Tilting microswitch positive E6
BLOCCO = Discharged battery (connected to the the dashboard) E5
MF = Signal for power steering of braking pedal E4
2ND S = Sideshift microswitch positive E3
3RD S = 4th lever positive E2
AB POT = Lifting microswitch positive E1
+ CH OUT = Key outcoming positive (+ 48 V) D2
+ CH IN = Key incoming positive (+ 48 V) D1
P POT = Lifting potentiometer positive (+ 12 V) C3
N POT = Lifting potentiometer negative (0 V) C2
C POT = Lifting potentiometer slider C1

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page 79
LIFTING POWER CIRCUIT
The lifting motor turns in one single direction. For this reason it
does not need contactors.
It is connected directly to the battery and the speed is controled
by the MOS in the lifting logic unit.
Low speed
High speed
t
PERIOD
The lifting logic unit receives the imput from the controlvalve
microswiches and controls the motor speed.
Only during the lifting the motor is controlled by a
potentiometer for changing the motor RpM.
For all the other function the RpM are set with the
console.Starting from the tilting it is possible to set the
following parameters:
1° Speed course
2° Speed course
3° Compensation
The firsts two parameter control thr motor RPM are the tens
and the units of the same value.
Compensation is used to obtain the same speed with or
without load on the forks. It menas that this parameter works
only according to the consume of Ampere.
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page 80
POTENTIOMETER CONFIGURATION
Lifting potentiometer
1 1.Green : 12 V
2
2. Black : 0 ÷ 10 V readable on the console
(function tester)
3 3.Yellow : 0 V
1 Green
Black
5 KOhm
2
ç
Yellow
3
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page 81
AUXILIARY CARD
The auxiliary card is located on the front side of the machine in the left corner and it controlls the reverse light end
the brake lights, horn.
L H) horn fuse 5A
I) auxiliary system fuse 5A
I L) 24V power supply board fuse 6,3A
H M)head-lights and lighting system fuse 5A
N) stop light fuse 5A
M O) reverse light fuse 5A
N O
The auxiliary card is an electric power converter that creates a + 24 V potential pole between the + 48 V positive
battery pole and negative battery pole.
The back lights will be supplied to 24 V by the tension between the + 48 V positive battery pole and this + 24 V
potential pole.
Avoid any kind of connection between the negative battery pole and this + 24 V potential pole
The converter power is designed for the standard lights only
It is not possible use the card for other applications
The only device that could be supplied is, if need be, an electronic backward alarm buzzer provided by Cesab.
Vbatt-Vauxiliary card=Vlamp(=Vo)
48Volt-24Volt=24Volt for the lights
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page 82
ELECTRIC DIAGRAM OF THE AUXILIARY CARD

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page 83
CONNECTION
On the card arrived four cables with different dimension:
P1 Brown 1.5mmq Key output (+48 V)

P2 Brown 0.5mmq Horn output (+48 V)
P3 Free (+48 V)
P4 Blue 1.5mmq Battery negative (-)
P5 Brown 2.5mmq Battery positive (+48 V)
1 P2
P4 P1 1 P5
1 P3
Connectors:
1. CN1 lights output connector

2. CN2 this connector collects the steerig potentiometer signals
and is a link for several other signals (see previous page ).
2 1
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page 84
POWER FUSE BOX
The power box fuse is located next to the battery connector.
POWER FUSE BOX
From the battery connector the positive arrived to the power fuxes box where are located the fuse for the auxiliary
card, traction logic unit and lifting logic unit.
FUSE DESCRIPTION
1. Traction fuse 300 Amp

2. Lifting fuse 160 Amp
3. Fuse for the auxiliary card 32 Amp
2 1 3
The fuses N°. 1 and 2 have special technical features so replace them with original spare parts.
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page 85
CONTACTOR CONNECTION
MAIN CONTACTOR
DIRECTION CONTACTORS
The contactors have special technical features so replace them with original spare parts.
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page 86
GENERAL DESCRIPTION OF FUNCTIONS OF THE CONSOLE
HOUR METER
The hour meter appears in the second line of the display when the chopper is connected. The hour meter has a
sensitivity of one minute and a full scale value of 65,535hours . It shows the hours only.
ALARM DISPLAY
The console features the possibility to read the last five alarm messages stored in the chopper and displayed together
with the time of occurrence, the number of times the alarm was sent and the temperature value at the time of the
alarm.
PARAMETER PROGRAMMING
The chopper parameters can be displayed and programmed via the keyboard, in real time and with operating
machine, thereby making it possible to set the chopper easily.
TESTER
It makes it possible to display the state of the chopper analogue and digital values and thereby to have a useful
tool for the analysis of chopper operation and external cables.
SAVE
It makes it possible to store all values relating to the parameters and the chopper hardware configuration into the
console with a program which can be selected from the keyboard.
RESTORE
It makes it possible to program a chopper with the parameters contained in a program generated by a SAVE.
ACCELERATOR MAX. STROKE PROGRAMMING
It allows to program the accelerator max. stroke.
STEER TABLE
It allows to configurate the chopper for the truck tipe and the pitch on which it is fitted
CONSOLE CONNECTION
+ -
The connection has to be made with resting machine.

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page 87
CONSOLE DESCRIPTION
KEYBOARD
Description of key functions:
ROLL1 = Allows selection of an option or the next menu item.
ROLL2 = Allows select of an option or the previous menu item.
ENTER = Allows confirmation of selected options.
OUT = Retains the current function.
PARAM = Allows an increase in the parameters or selects the type of connected I/O.
SET = Allows a reduction in the parameters or selects the type of connected I/O.
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page 88
PARAMETER MODIFICATION UNIT B1S
ACCELERATION Acceleration time, that is the minimum time during which motor voltage
varies from minimum to maximum
INVERS BRAKING Braking basic current to be used when in reverse. A value related to the
accelerator plus a fixed increase for each second must be added
RELEASE BRAKING Release braking current
PEDAL BRAKING Release braking current with pedal braking pressed
CUT BACK SPEED Speed reduction with input in (L9)
BRAKE CUT BACK Max speed reduced with braking pedal pressed
CURVE CUT BACK Active speed reduced with steering angle more than 70°
COMPENSATION Speed compensation (motor tension) related to current when speed

reductions are operating
BRAKING MODULATION Measures the effect of the accelerator with increase of the braking current in
reverse. By depressing the accelerator when in reverse the higher value of
the parameter, the sharper will be the braking
TRACTION I MAX Fixes the maximum current for the chopper bothduring running and
braking. All current levels are expressed in a percentage of this value
CREEP SPEED Fixes the minimum voltage value applied to the motor with speed
engaged. It makes it possible to obtain a faster response when starting
WEAK DROPOUT Not used
SPEED LIMIT Maximum speed
PLUG CURRENT Emergency braking current in inversion

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page 89
DESCRIPTION OF THE WARNINGS RELEVANT TO THE DIAGNOSTIC

LED PLACED ON THE DASHBOARD AND TO THE CONSOLE
UNIT B1S
1 FLASH = WATCH-DOG, EEPROM KO - Replace the complete unit B1S.
2 FLASHES = INCORRECT START - Incorrect sequence by starting; check:

- Microswitch for Forwards/Backwards directions;
- Wiring.
3 FLASHES = RIGHT VMN LOW, LEFT VMN LOW, RIGHT VMN HIGH,
LEFT VMN HIGH, BRAKE CONTACT OPEN- check:
- Motor isolation (R - L) and relevant wirings;
- Direction contactor, brake contactor and relevant cables.
- Unit B1S.
4 FLASHES = PEDAL WIRE KO-check:

- Accelerator potentiometer negative cut off;
- Accelerator potentiometer fault
VACC NOT OK - check:
- Traction potentiometer positive cut off ;
- Traction Potentiometer damaged or not more adjusted;
BAD STEERING POTENTIOMETER O SETT
- Steering Potentiometer (could be damaged or not more adjusted);
- Steering Potentiometer wiring;
5 FLASHES = RGT STBY I HIGH, LEFT STBY I HIGH, RIGHT I= 0 EVER,

LEFT I= 0 EVER) - replace the unit B1S.
6 FLASHES = DRIVER SHORTED, COIL SHORTED - check:

- Contactors coils and wirings;
- Unit B1S.
7 FLASHES = TH.PROTECTION - The temperature of the unit B1S exceeds 75°.

If the warning appears in cold conditions, replace unit B1S.
8 FLASHES = RIGHT CONT OPEN, LEFT CONT OPEN- check:

- Direction contactors and relevat tips;
- Motor and relevant wirings;
- Unit B1S.
ton.1,2-2,0 T/F
page 90
9 FLASHES = RIGHT CONT CLOSED, LEFT CONT CLOSED, BRAKE CONT CLOSED
check:
- Brake contactor stuck;
- Direction contactor (too slow by opening);
- Unit B1S.
CONTINUOUS FLASHING = Battery discharged.
FIX LED ON = Double running requests.
LEGEND
R = Righthand.
L = Lefhand.
I = Current.
V ACC = Potentiometer voltage.
VMN = Control signal: >1/3 < 2/3 of battery voltage.
CON - CONT = Contactor.
CON - COND = Conduction.
DIR = Direction.
ton.1,2-2,0 T/F
page 91
PARAMETER MODIFICATIONS UNIT HP350
ACCELER.DELAY Pump motor acceleration time.
EV. ACCELER DELAY not utilized.
DECELER DELAY Pump motor deceleration time
EV.DECELER DELAY not utlized.
AUXILIARY TIME not utilized.
IMAX Maximum chopper current.
HYD SPEED COARSE Coarse power steering speed + 10%
HYD SPEED FINE Fine power steering speed + 1%
HYDRO COMPENS Compensation in current for power steering request.
CREEP SPEED Minimal acceleration threshold.
WEAK DROPOUT Threshold of current for opening the weakening contactor.
HYDRO TIME Steering power delay time.
1ST SPEED COARSE Tilting speed, coarse adjustment + 10%.
1ST SPEED FINE Tilting speed, fine adjustment + 1%.
1ST SPEED COMP. Compensation of tilting speed.
2ND SPEED COARSE Sideshift speed, coarse adjustment + 10%.
2ND SPEED FINE Sideshift speed, fine adjustment + 1%.
2ND SPEED COMP. Compensation of sideshift speed.
3RD SPEED COARSE 4th-way speed , coarse adjustment + 10%.
3RD SPEED FINE 4th-way speed, fine adjustment + 1%.
3RD SPEED COMP. 4th-way compensation speed.
4TH SPEED COARSE 5th-way speed, coarse adjustment + 10%.
4TH SPEED FINE 5th-way speed, fine adjustment + 1%.
4TH SPEED COMP. 5th-way speed compensation.
MIN. VALVE VOLT. Not utilized.
MAX. VALVE VOLT. Not utilized.

ton.1,2-2,0 T/F
page 92
DESCRIPTION OF THE WARNINGS RELEVANT TO THE DIAGNOSTIC

LED PLACED ON THE DASHBOARD AND TO THE CONSOLE
UNIT HP350
1 FLASH = EEPROM DATA KO, EEPROM PAR. KO, EEPROM CONF.KO,

EEPROM OFF-LINE, CHOPPER NO CONF., WATCH DOG
- Replace unit HP350.
2 FLASHES = INCORRECT START - Incorrect sequence by starting; check: - Control

valve microswitches;
-Wiring.
3 FLASHES = NO FULL COND, VMNLOW - check:

-Motor isolation and relevant wirings;
-Unit HP350.
4 FLASHES = VACC NOT OK - check:

-Potentiometer (could be damaged or not more adjusted);
-Potentiometer wiring.
5 FLASHES = I HIGH, I= 0 EVER - replace the unit HP350.
6 FLASHES = DRIVER SHORTED, COIL SHORTED

-Replace Unit HP350.
7 FLASHES = TH.PROTECTION - The temperature of the unit HP350 exceeds 80°. If

the warning appears in cold conditions, replace unit HP350.
CONTINUOUS FLASHING = Battery discharged.

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page 93
ADJUSTMENT TABLE -B1S (traction)
ADJUSTMENT TABLE - HP 350 (lifting)

ton.1,2-2,0 T/F
page 94
ELECTRICAL DIAGRAM - 3 WEELS- FOOT PEDAL

ton.1,2-2,0 T/F
page 95
ELECTRICAL DIAGRAM - 3 WEELS-HAND DIRECTION

ton.1,2-2,0 T/F
page 96
ELECTRICAL DIAGRAM - 4 WEELS- FOOT PEDAL

ton.1,2-2,0 T/F
page 97
ELECTRICAL DIAGRAM - 4 WEELS-HAND DIRECTION

SERVICE MANUAL
Safety
Informations
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page 99
SAFETY INFORMATION
Work clothes
1. Gloves
2. Overalls
3. Accident-prevention shoes
4. Work glasses
Work place
The work place must be lighted and aired.

The area around the truck must not create obstacles
On the paviment must not be presents signs of oil or grease substances (danger of sliding).
Lifting the truck
It is obligatory to lift the front wheels with caps before doing any job to avoid the risch of accidend.
1. Block the steered wheels with chocks (A).

2. Tilt the mast back and place blocks under their base.
B
3. Tilt the mast forwards: the direction weels must be lifted and
free to rotate
To carry out correctly all the lifting operation of the truck
it is neccesary to have the follwing tools:
. a hydraulic jack to 5 ton

. metal or hard wood caps
before putting the caps below the must, check the inclination of the floor, the truck must be parked on a flat,
horizontal surface.
ton.1,2-2,0 T/F
page 100
ELECTRIC PART
It is obligatory to disconnect the battery before doing any job to avoid the risch of accidend.
- Do not connect the chopper to a battery with a nominal voltage different to the voltage stated from the one on
the unit plate. If the battery voltage is higher it may cause the MOS failure.
If the battery voltage is less the unit will not run .
- During the battery recharging no units must be connected to the battery as, the unit can be
damaged by the overvoltages generated by the charge-battery.
- Supply the unit only with traction battery, do not use rectifier outputs or power supplies.
- With key switched off, the filter capacitors could remain charged for some minutes. For work in surely working
conditions, we suggest you
. to disconnect the battery and with resting machine and inserted key wait some seconds till when
the display will be completely off;
or
. short circuit the capacitors through a resistor (56 Ohm 1W) across B+ and B- chopper power
connections.
Do not wear jewel, necklaces, watches,...ect becease they can be the cause of short circuit.
Charging of the battery
Do not smocke ( danger of explosion )

It is neccessary to swicth the battery charger off before disconnecting the battery.
Also little spark can cause the battery to explode
In order to fill in the battery or control the level of the acid it is necessary to wear gloves and glasses.
It is prohibited to smoke.
ton.1,2-2,0 T/F
page 101
Welding
It is suggests to wear a leather overall, gloves and mask.
It is obligatory to wear gloves and glasses during the grinding of the parts caused the projection of matallic particles.
To make sure that these two operations are feasible inside the working area where you are.
If these operations are carried out on a truck pay attention to cover the battery in order to avoid any danger of
explosion.
To make sure that around the working area there are not any infiammable product.
Before carrying out any arc-weldings on the trucks, disconnect the battery and short-circuit the unit
between positive (+) and negative (-).
WEIß SEITE

WEIß SEITE

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

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Service Manual

INTENTIONALLY LEFT BLANK

PAGE INTENTIONNELLEMENT BLANCHE

PÁGINA INTENCIONALMENTE BLANCA

CESAB S.p.a. reserves all rights of

The text and the numbering system

CESAB reserves the right to make any

BOLOGNA’S FACTORY, AFTER SALES SERVICE

MAST CHAINS INSPECTION page 50

Hydraulic oil tank Battery

Direction contactors Lifting logic unit

FOOT DRIVE DIRECTION

DRIVE DIRECTION LEVER ON STEERING

Single drive pedal (G)

1. Handle for a better opening / closing.

- Battery plug fixing position

Behind the battery plug fixed on the frame there is a thickness in

LOAD HANDLING COMMANDS

CONTROL VALVE VERSION

1 2 3 4 5 6 1) Battery charge indicator

2 2) Parking brake ON warning light

3 3) Lifting motor temperature warning light

4 4) Brake fluid low warning light

5 5) Worn lifting motor brushes warning light

6 6) Worn drive motor brushes warning light

7 7) Electronic hour meter

8 8) Left drive motor temperature warning light

9 9) Lifting equipment disabled due to flat battery

10 10)Dead man light

12 12)Electronic control unit temperature warning light

14 14)Right drive motor temperature warning light

15 15)Steering indicator light

CONNECTOR CN2 CONNECTOR CN3

1. Not used 1. Cursor of the steering potentiometer

According to the dimension of the truck the

IDENTIFICATION PLATE LOAD PLATE

SERIAL N° DRAW-BAR PULL (1h)

MANUFACT. YEAR TENSION

CARRELLI ELEVATORI S.p.A.

Hydraulic & Mechanical

HYDRALIC SYSTEM 3 AND 4 WHEELS

Hydraulic oil tank

The correct position of the valve is showen

control valve tank

The hydraulic lift oil tank is located under the

To check and change the oil, position the

D After the first 50 hours of work

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

HYDRAULIC OIL: AGIP type ARNICA 46

HYDRAULIC OIL REPLACING

REPLACING OF THE PUMP

Tightening torque 45 +/- 5 Nm

Every 250 hours

G Every 10 000 hours

Power steering pressure setting

The 4 wheels uses a dinamic orbitrol. It means that the

Oil inlet Valve for the Load

OSPC 50 LS STATIC ORBITROL