p320 Powered Pallet

Repair manual 7572516-040
P320, P322.
www.cesab.it
Publication
Date Changes
number
2014-08-11 7572516-040 Completely new issue.
2015-03-01 7572516-040 Updated version
Chapter 5: Parameters 111, 211 and 1061 updated
2015-10-01 7572516-040 Chapter 9: Chassis - 9.4 Updated tables for suspension.
Chapter 13: Steering system - Updated
Liste der Modelle:

Model T-Code Valid from serial number
P320, P322 1010 6304531-
© Cesab T-Code(s): 1010

Repair manual: Contents Model(s): P320, P322
Publication Number: 7572516-040 Date: 2015-10-01 Valid from serial number: 6304531-
1. Contents
2. General introduction...................................................................................... 2–1
2.1 How to use this manual ............................................................................... 2–1
2.2 Warning levels and symbols ........................................................................ 2–2
2.3 Pictograms................................................................................................... 2–3
3. General safety rules....................................................................................... 3–1
3.1 Work safety.................................................................................................. 3–1
3.2 Electrical systems ........................................................................................ 3–3
3.3 Safe lifting.................................................................................................... 3–4
3.4 Truck modifications...................................................................................... 3–5
4. Operation and connection sequences ......................................................... 4–1
4.1 Battery is connected .................................................................................... 4–3
4.2 Login via keypad.......................................................................................... 4–3
4.3 Tiller arm lowered for driving ....................................................................... 4–4
4.4 Driving in fork direction ................................................................................ 4–4
4.5 Driving in the drive wheel direction .............................................................. 4–5
4.6 Neutral position braking............................................................................... 4–5
4.7 Reverse braking .......................................................................................... 4–6
4.8 Mechanical braking...................................................................................... 4–6
4.9 Emergency reversal..................................................................................... 4–7
4.10 Fork lifting .................................................................................................. 4–7
4.11 Fork lowering ............................................................................................. 4–8
5. Parameters...................................................................................................... 5–1
5.1 General parameters..................................................................................... 5–1
5.1.1 Show/change parameters .............................................................. 5–2
5.2 Operator parameters ................................................................................... 5–3
5.2.1 Overview ........................................................................................ 5–3
5.2.2 Connection to logged-in operator ................................................... 5–4
5.3 General service parameters ........................................................................ 5–7
5.3.1 Overview ........................................................................................ 5–7
5.3.2 Description ..................................................................................... 5–8
5.4 Service parameters, travel functions ......................................................... 5–17
5.4.1 Overview ...................................................................................... 5–17
5.4.2 Description ................................................................................... 5–18
5.5 Service parameters, hydraulic functions.................................................... 5–27
5.5.1 Description ................................................................................... 5–28
5.6 Factory parameters ................................................................................... 5–29
5.6.1 Overview ...................................................................................... 5–29
5.6.2 Description ................................................................................... 5–30
5.7 Calibration parameters .............................................................................. 5–55
5.7.1 Overview ...................................................................................... 5–55
5.8 Calibration ................................................................................................. 5–58
5.8.1 Steering angle calibration “1” ....................................................... 5–59
5.8.2 Calibration “2” (Not applicable)..................................................... 5–59
5.8.3 Calibration of weight measuring "3".............................................. 5–60
5.8.6 Calibration of weight measuring "6".............................................. 5–61
6. Installation and commissioning ................................................................... 6–1
6.1 Transporting the truck.................................................................................. 6–1
6.2 Transporting the fork carriage ..................................................................... 6–1
© Cesab 1– 1 T Code(s): 1010

6.3 Lifting the truck ............................................................................................ 6–2

6.3.1 Lift using an eye bolt ...................................................................... 6–2
6.3.2 Lift using a jack............................................................................... 6–3
6.4 Battery installation ....................................................................................... 6–4
6.4.1 Safety for battery handling ............................................................. 6–4
6.4.2 Installing the battery ....................................................................... 6–5
6.5 Using PIN codes.......................................................................................... 6–6
6.5.1 General........................................................................................... 6–6
6.5.2 PIN code for resetting after a collision............................................ 6–6
6.5.3 Programming PIN codes ................................................................ 6–7
6.5.4 PIN code defaults ........................................................................... 6–9
6.6 Setting parameters .................................................................................... 6–10
6.6.1 Setting collision sensor parameters (option) ................................ 6–10
6.6.2 Setting battery parameters ........................................................... 6–10
6.7 Function check .......................................................................................... 6–11
7. Maintenance ................................................................................................... 7–1
7.1 Introduction.................................................................................................. 7–1
7.2 Maintenance instructions............................................................................. 7–1
7.2.1 Cleaning and washing .................................................................... 7–1
7.2.2 High-pressure washers .................................................................. 7–2
7.2.3 Degreasing agents ......................................................................... 7–2
7.2.4 Cleaning the exterior ...................................................................... 7–2
7.2.5 Cleaning the chain.......................................................................... 7–3
7.2.6 Cleaning the motor compartment ................................................... 7–3
7.2.7 Electric components ....................................................................... 7–3
7.3 Oil and grease specification ........................................................................ 7–4
7.4 Symbols....................................................................................................... 7–5
7.5 Periodic maintenance .................................................................................. 7–7
8. Troubleshooting............................................................................................. 8–1
8.1 Towing a defective truck.............................................................................. 8–1
8.2 Auxiliary functions........................................................................................ 8–2
8.2.1 Emergency driving mode................................................................ 8–2
8.3 Error code history ........................................................................................ 8–3
8.3.1 Extended error log.......................................................................... 8–4
8.4 Error code system ....................................................................................... 8–5
8.5 Error codes .................................................................................................. 8–6
8.6 Service information.................................................................................... 8–77
8.7 Digital input/output status .......................................................................... 8–79
8.7.1 Test mode “9” – ............................................................................ 8–79
8.7.2 Test mode “12” – Expansion unit SEU (option). ........................... 8–80
8.8 Built-in test function for the tiller arm ......................................................... 8–81
8.8.1 Display test................................................................................... 8–81
8.8.2 Speed control ............................................................................... 8–81
8.8.3 Safety reversing ........................................................................... 8–81
8.8.4 Controls for lifting/lowering ........................................................... 8–81
8.8.5 Sensilift......................................................................................... 8–82
8.8.6 Keypad ......................................................................................... 8–82
9. Chassis C0000................................................................................................ 9–1
9.0.1 Overview ........................................................................................ 9–1
9.1 Hatches, covers C0340 ............................................................................... 9–2
9.1.1 Overview ........................................................................................ 9–2
9.1.2 Replacing the service cover ........................................................... 9–3
© Cesab 1– 2 T Code(s): 1010

9.1.3 Replacing the side cover ................................................................ 9–4

9.1.4 Replacing the cover (without gate) ................................................. 9–5
9.1.5 Replacing the gate cover................................................................ 9–6
9.1.6 Replacing the emblem cover.......................................................... 9–7
9.1.7 Replacing the upper cover ............................................................. 9–8
9.1.8 Replacing the steering adapter cover............................................. 9–9
9.1.9 Replacing the rubber seals........................................................... 9–10
9.2 Fork frame C0380...................................................................................... 9–13
9.2.1 Overview fork frame ..................................................................... 9–13
9.2.2 Replacing the fork carriage .......................................................... 9–14
9.2.3 Checking the fork carriage ........................................................... 9–17
9.2.4 Replacing the torsion tube-linkage-wheel fork ............................. 9–18
9.2.5 Checking the torsion tube-linkage-wheel fork .............................. 9–23
9.2.6 Replacing the roller on the torsion tube........................................ 9–24
9.2.7 Weld the push rod ........................................................................ 9–25
9.3 Battery compartment parts C0390............................................................. 9–29
9.3.1 Battery lock, fixed ......................................................................... 9–29
9.3.2 Battery lock, quick ........................................................................ 9–30
9.4 Drive unit suspension C0450..................................................................... 9–31
9.4.1 Overview ...................................................................................... 9–31
9.4.2 Overview, ..................................................................................... 9–33
9.4.3 Replacing the drive unit suspension............................................. 9–36
9.4.4 Relieving spring force using the special tool ................................ 9–48
9.4.5 Tensioning spring force using the special tool ............................. 9–50
9.4.6 Adjusting the tool.......................................................................... 9–51
9.4.7 Replacing the initial pressure spring ............................................ 9–52
9.4.8 Replacing the PowerTrak spring .................................................. 9–53
9.4.9 Replacing the PowerTrak cylinder................................................ 9–54
9.5 Platform including fixing points C0560 ...................................................... 9–55
9.5.1 Overview, Standard and Cold store ............................................. 9–55
9.5.2 Overview, platform ....................................................................... 9–56
9.5.3 Replacing the platform ................................................................. 9–57
9.5.4 Replacing the gas spring.............................................................. 9–61
9.5.5 Checking the gas spring............................................................... 9–63
9.5.6 Replacing the spring..................................................................... 9–64
9.5.7 Adjusting platform suspension ..................................................... 9–65
9.5.8 Replacing the platform inductive position sensor ......................... 9–66
9.5.9 Checking the position sensor (B120), std platform....................... 9–68
9.5.10 Adjusting the presence sensor ................................................... 9–68
9.5.11 Fixed side guard......................................................................... 9–69
9.5.12 Overview .................................................................................... 9–69
9.5.13 Replacing the fixed side guard ................................................... 9–70
9.5.14 Photo cells, fixed side guard ...................................................... 9–72
9.5.15 Overview, platform with fixed side guard.................................... 9–73
9.5.16 Replacing a platform with fixed side guard................................. 9–74
9.5.17 Checking the position sensor (B120), fixed side guards ............ 9–75
9.5.19 Adjusting platform suspension ................................................... 9–76
9.5.20 Back guard ................................................................................. 9–77
9.5.21 Overview .................................................................................... 9–77
9.5.22 Replacing the back guard........................................................... 9–78
9.5.23 Checking the position sensor (B120), back guard...................... 9–79
9.5.25 Adjusting platform suspension ................................................... 9–80
© Cesab 1– 3 T Code(s): 1010

9.6 Operator protection C0840 ........................................................................ 9–81

9.6.1 Gate.............................................................................................. 9–81
9.6.2 Replacing the gate ....................................................................... 9–82
9.6.3 Replacing the gate damper .......................................................... 9–84
9.6.4 Replacing the gate damper .......................................................... 9–85
9.6.5 Replacing the pad ........................................................................ 9–86
9.6.6 Replacing the gate bar ................................................................. 9–88
9.6.7 Checking the gate bar .................................................................. 9–88
9.6.8 Replacing the upper inductive position sensor ............................. 9–89
9.6.9 Checking the upper inductive position sensor B121 .................... 9–89
9.6.10 Replacing the lower inductive position sensor ........................... 9–90
9.6.11 Checking the lower inductive position sensor B122 ................... 9–90
9.7 Signs, warnings, labels C0850 .................................................................. 9–91
10. Motors C1000.............................................................................................. 10–1
10.1 Electric pump motor C1710 ..................................................................... 10–1
10.1.1 Overview .................................................................................... 10–1
10.1.2 Replacing the pump motor ......................................................... 10–3
10.1.3 Replacing the carbon brushes.................................................... 10–5
10.2 Steering motor C1730 ............................................................................. 10–7
10.2.1 Overview .................................................................................... 10–7
10.2.2 Replacing the steering motor ..................................................... 10–9
10.3 Motor control fans .................................................................................. 10–10
10.3.1 Overview .................................................................................. 10–10
10.3.2 Replacing the motor control fans.............................................. 10–11
10.4 Drive motor ............................................................................................ 10–12
10.4.1 Tightening torques – Drive motor ............................................. 10–12
10.5 1.8, 2.5 kW ............................................................................................ 10–13
10.5.1 Overview .................................................................................. 10–13
10.5.2 Connecting wiring harness 1.8 - 2.5 kW................................... 10–14
10.5.3 Replacing the drive motor 1.8, 2.5 kW ..................................... 10–15
10.6 2.8 KW ................................................................................................... 10–17
10.6.1 Overview .................................................................................. 10–17
10.6.2 Connecting wiring harness, 2.8 kW .......................................... 10–18
10.6.3 Replacing the motor 2.8 kW ..................................................... 10–19
10.6.4 Replacing the temperature sensor ........................................... 10–21
10.6.5 Replacing the RPM sensor....................................................... 10–22
10.6.6 Replacing the speed sensor toothed wheel ............................. 10–24
10.6.7 Cleaning ................................................................................... 10–25
11. Transmission/Drive gear C2000................................................................ 11–1
11.1 Description............................................................................................... 11–1
11.2 Gears ....................................................................................................... 11–2
11.2.1 Small gear .................................................................................. 11–2
11.2.2 Overview .................................................................................... 11–2
11.2.3 Large gear .................................................................................. 11–3
11.2.4 Overview .................................................................................... 11–3
11.3 Replacing the drive gear.......................................................................... 11–4
11.4 Oil check and oil change, large gear ....................................................... 11–7
11.4.1 Draining oil ................................................................................. 11–7
11.4.2 Checking/refilling oil ................................................................... 11–8
11.4.3 Replacing the steering bearing................................................... 11–9
11.5 Oil check and oil change, small gear ..................................................... 11–10
11.5.1 Draining oil ............................................................................... 11–10
11.5.2 Checking/refilling oil ................................................................. 11–11
© Cesab 1– 4 T Code(s): 1010

11.5.3 Replacing the steering bearing................................................. 11–12

11.5.4 Replacing studs ........................................................................ 11–12
11.6 Replacing the wheel hub seal................................................................ 11–14
12. Brake system/Wheels C3000..................................................................... 12–1
12.1 Brake system C3100 ............................................................................... 12–1
12.1.1 Description ................................................................................. 12–1
12.2 Parking brake - C3370............................................................................. 12–2
12.2.1 Overview .................................................................................... 12–2
12.2.2 Checking the parking brake gap (adjustable brakes only) ......... 12–4
12.2.3 Checking the parking brake gap (only for the small
brake 21Nm in standard configuration) ................................................ 12–4
12.2.4 Adjustment of the parking brake gap.......................................... 12–5
12.2.5 Emergency release of the parking brake.................................... 12–6
12.2.6 Replacing the parking brake....................................................... 12–7
12.2.7 Checking the emergency stop/parking brake ............................. 12–8
12.2.8 Replacing the friction disc .......................................................... 12–9
12.2.9 Replacing the brake hub .......................................................... 12–11
12.2.10 Cleaning the parking brake .................................................... 12–12
12.3 Drive wheel ............................................................................................ 12–13
12.3.1 Replacing the drive wheel ........................................................ 12–14
12.4 Castor wheel.......................................................................................... 12–16
12.4.1 Replacing the castor wheel assembly ...................................... 12–17
12.4.2 Checking the castor wheels ..................................................... 12–18
12.4.3 Replacing the castor wheel (single) ......................................... 12–18
12.4.4 Replacing the castor wheel (twin wheel) .................................. 12–20
12.5 Fork wheels ........................................................................................... 12–22
12.5.1 Replacing single wheels ........................................................... 12–23
12.5.2 Replacing the bogie wheel ....................................................... 12–25
12.6 Wheel wear............................................................................................ 12–27
13. Steering system C4000.............................................................................. 13–1
13.1 Steering arm C4110 ................................................................................ 13–1
13.1.1 Overview .................................................................................... 13–1
13.1.2 Replacing the keypad C9420 ..................................................... 13–2
13.1.3 Replacing the tiller arm cover ..................................................... 13–3
13.1.4 Replacing the upper cover C4110.............................................. 13–4
13.1.5 Replacing the tiller arm handle................................................... 13–6
13.1.6 Replacing the logic card ............................................................. 13–7
13.1.7 Checking the handle................................................................... 13–9
13.1.8 Update the software ................................................................... 13–9
13.1.9 Replacing the signal button/switch ........................................... 13–10
13.1.10 Replacing the lift/lower button ................................................ 13–11
13.1.11 Replacing the button .............................................................. 13–12
13.1.12 Replacing the symbol disc - support arm lift/fork lift ............... 13–13
13.1.13 Replacing the safety reversing switch .................................... 13–14
13.2 Steering arm C4110 .............................................................................. 13–15
13.2.1 Overview steering arm manual steering................................... 13–15
13.2.2 Overview steering arm power steering ..................................... 13–16
13.2.3 Replacing the tiller arm (manual and power steering) .............. 13–17
13.2.4 Replacing the tiller arm suspension (manual and power
steering) ............................................................................................. 13–20
13.2.5 Replacing the safety switch (manual and power steering) ....... 13–22
13.2.6 Replacing the steering yoke ..................................................... 13–24
© Cesab 1– 5 T Code(s): 1010

13.3 Tiller arm, E-man ................................................................................... 13–26

13.3.1 Overview, tiller arm E-man ....................................................... 13–27
13.3.2 Replacing the tiller arm cover (E-man) ..................................... 13–28
13.3.3 Replacing the upper cover (E-man) ......................................... 13–29
13.3.4 Replacing the tiller arm handle (E-man) ................................... 13–31
13.3.5 Replacing the safety switch (E-man) ........................................ 13–32
13.3.6 Replacing the tiller arm (E-Man)............................................... 13–33
13.4 Power steering....................................................................................... 13–35
13.4.1 Safety ....................................................................................... 13–35
13.4.2 Overview .................................................................................. 13–35
13.5 Steering angle sensor C4350 ................................................................ 13–36
13.5.1 Replacing the steering angle sensor servo unit ....................... 13–37
13.5.2 Replacing the steering damper ................................................ 13–38
13.5.3 Calibrating the steering damper/reference sensor ................... 13–40
13.5.4 Steering adapter (power steering) ............................................ 13–41
13.5.5 Replacing the gas strut - height adjustment ............................. 13–42
13.5.6 Replacing the lock - height adjustment .................................... 13–44
13.5.7 Checking the lock - height adjustment ..................................... 13–45
13.5.8 Replacing the steering adapter (power steering) ..................... 13–46
13.5.9 Replacing the steering bearing (power steering)...................... 13–47
13.5.10 Replacing the mechanical stop of the steer axle
(power steering) .................................................................................. 13–49
13.6 Mechanical steering............................................................................... 13–51
13.6.1 Overview .................................................................................. 13–51
13.6.2 Steering adapter, mech. steering ............................................. 13–52
13.6.3 Replacing the steering adapter (fixed) ..................................... 13–53
13.6.4 Replacing the steering angle sensor ........................................ 13–54
13.6.5 Replacing the steering bearing - mechanical steering ............. 13–56
13.6.6 Replacing the mechanical stop of the steer axle...................... 13–58
14. Electrical system C5000 ............................................................................ 14–1
14.1 General .................................................................................................... 14–1
14.1.1 Truck firmware applications........................................................ 14–1
14.2 Menus ...................................................................................................... 14–2
14.2.1 Menu navigation ........................................................................ 14–2
14.2.2 Menu information........................................................................ 14–4
14.2.3 Show hour counter values.......................................................... 14–4
14.2.4 Show error codes ....................................................................... 14–4
14.2.5 Show part numbers for software/hardware ................................ 14–5
14.2.6 Built-in test A5 (A5) .................................................................... 14–5
14.2.7 Show collisions........................................................................... 14–5
14.2.8 Show/change parameters .......................................................... 14–5
14.2.9 Emergency driving mode............................................................ 14–6
14.2.10 Calibration ................................................................................ 14–6
14.2.11 Show/change PIN code ............................................................ 14–6
14.3 Battery C5110.......................................................................................... 14–7
14.3.1 Battery replacement ................................................................... 14–7
14.3.2 Charging the battery ................................................................... 14–9
14.4 Li-ion battery (Hoppecke) ...................................................................... 14–11
14.4.1 Resetting/restarting the battery ................................................ 14–11
14.5 Inspecting the battery ............................................................................ 14–11
14.6 Electric panel: ........................................................................................ 14–12
14.6.1 Overview .................................................................................. 14–12
© Cesab 1– 6 T Code(s): 1010

14.7 Motor control [T1] (ACT) ........................................................................ 14–13

14.7.1 General..................................................................................... 14–13
14.7.2 Replacing the motor control ..................................................... 14–14
14.7.3 Replacing the pump contactor.................................................. 14–15
14.7.4 Replacing the main contactor ................................................... 14–17
14.8 Horn C5160 ........................................................................................... 14–21
14.8.1 Horn [P4] .................................................................................. 14–21
14.9 Control system....................................................................................... 14–22
14.9.1 Direction selector/speed regulator............................................ 14–22
14.9.2 Safety reversing ....................................................................... 14–22
14.9.3 Battery indicator ....................................................................... 14–22
14.9.4 Hour meter ............................................................................... 14–23
14.9.5 Lifting and lowering control - support arm/fork lift..................... 14–23
14.9.6 Signal buttons........................................................................... 14–23
14.9.7 Option buttons .......................................................................... 14–23
14.9.8 Display...................................................................................... 14–24
14.9.9 Keypad/ID unit.......................................................................... 14–25
14.9.10 Weighing system .................................................................... 14–25
14.9.11 Pressure equalization ............................................................. 14–25
14.9.12 Logic card (A5) ....................................................................... 14–26
14.10 Work function harness/fuse ................................................................. 14–27
14.10.1 Fuse panel overview .............................................................. 14–27
14.11 Sending units and sensors C5800....................................................... 14–29
14.11.1 Inductive sensors ................................................................... 14–29
14.11.2 Position sensor ....................................................................... 14–29
14.11.3 Steering reference sensor ...................................................... 14–30
14.11.4 Pressure sensor ..................................................................... 14–31
14.11.5 Pulse transducer .................................................................... 14–31
14.12 Safety sensor....................................................................................... 14–32
14.12.1 Emergency switch off [S21] .................................................... 14–32
14.12.2 Photocell................................................................................. 14–32
15. Hydraulic system C6000............................................................................ 15–1
15.1 General .................................................................................................... 15–1
15.2 Hydraulic hygiene .................................................................................... 15–1
15.2.1 Washing ..................................................................................... 15–1
15.2.2 Packaging................................................................................... 15–2
15.2.3 Handling ..................................................................................... 15–2
15.2.4 Storage....................................................................................... 15–2
15.2.5 Work procedures ........................................................................ 15–3
15.3 Hydraulic system ..................................................................................... 15–4
15.3.1 Overview .................................................................................... 15–4
15.3.2 Hydraulic unit.............................................................................. 15–5
15.3.3 Tightening torques for hydraulic unit .......................................... 15–6
15.3.4 Replacing the hydraulic unit ....................................................... 15–7
15.3.5 Tank ........................................................................................... 15–9
15.3.6 Changing oil ............................................................................. 15–10
15.3.7 Replacing the tank.................................................................... 15–12
15.3.8 Valve unit.................................................................................. 15–13
15.3.9 Hydraulic pump ........................................................................ 15–14
15.3.10 Replacing the hydraulic pump ................................................ 15–15
15.3.11 Replacing the return filter ....................................................... 15–16
15.3.12 Replacing the valve coil.......................................................... 15–17
15.3.13 Replacing the flow control valve ............................................. 15–18
© Cesab 1– 7 T Code(s): 1010

15.3.14 Pressure limitation .................................................................. 15–19

15.3.15 Replacing the pressure limiting valve ..................................... 15–19
15.3.16 Adjusting pressure limitation .................................................. 15–20
15.3.17 Replacing the pressure sensor............................................... 15–22
15.3.18 Lift cylinder ............................................................................. 15–23
15.3.19 Replacing lift cylinders............................................................ 15–24
15.4 Hydraulic connections ........................................................................... 15–26
15.4.1 Quick change connector........................................................... 15–26
16. Mast C7000 ................................................................................................. 16–1
17. Peripherals C8000 ...................................................................................... 17–1
18. Options/Extra equipment C9000............................................................... 18–1
18.1 Overview.................................................................................................. 18–1
18.2 Spider expansion unit .............................................................................. 18–2
18.3 I_Site, previously T.W.I.S ........................................................................ 18–3
18.4 DC/DC converter ..................................................................................... 18–4
18.5 Collision sensor ....................................................................................... 18–5
18.6 Integrated battery charger C5170............................................................ 18–6
18.6.1 Overview .................................................................................... 18–6
18.6.2 Description ................................................................................. 18–6
18.6.3 Connecting the battery charger .................................................. 18–7
18.7 E-bar ........................................................................................................ 18–8
18.7.1 Overview .................................................................................... 18–8
18.7.2 E-bar accessories....................................................................... 18–9
18.7.3 Fire extinguisher ....................................................................... 18–10
19. Instructions for disposal ........................................................................... 19–1
19.1 General .................................................................................................... 19–1
19.2 Marking of plastics ................................................................................... 19–1
19.2.1 General marking of products and packaging.............................. 19–1
19.2.2 Marking according to the manufacturer’s standards .................. 19–2
19.3 Pressure vessels ..................................................................................... 19–3
19.3.1 Gas dampers.............................................................................. 19–3
19.4 Sorting categories.................................................................................... 19–4
20. Electrical components and wiring diagrams........................................... 20–1
20.1 Electric components ................................................................................ 20–1
20.2 Component location................................................................................. 20–3
20.3 Wiring diagrams.................................................................................... 20–18
20.3.1 List of symbols.......................................................................... 20–18
20.3.2 Wiring diagram P300 overview - std platform........................... 20–19
20.3.3 Wiring diagram P300 overview - fixed platform ........................ 20–20
20.3.4 Wiring diagram P300 overview - accessories .......................... 20–21
20.3.5 Wiring diagram ......................................................................... 20–22
21. Hydraulics schematics .............................................................................. 21–1
21.1 Component list......................................................................................... 21–1
21.2 Component location................................................................................. 21–2
21.2.1 Valve unit.................................................................................... 21–5
21.3 Hydraulics schematics ............................................................................. 21–6
21.3.1 P320, 322 ................................................................................... 21–6
22. Tools............................................................................................................ 22–1
22.1 AMP contacts .......................................................................................... 22–1
22.2 MQS contacts .......................................................................................... 22–2
© Cesab 1– 8 T Code(s): 1010

22.3 CPC contacts........................................................................................... 22–4

22.4 Other tools ............................................................................................... 22–5
23. Service data and grease specifications ................................................... 23–1
23.1 General tightening torques ...................................................................... 23–1
23.2 Oil and grease specification .................................................................... 23–2
24. Technical data ............................................................................................ 24–1
24.1 Basic data ................................................................................................ 24–1
© Cesab 1– 9 T Code(s): 1010

© Cesab 1 – 10 T Code(s): 1010

Repair manual: General introduction Model(s): P320, P322
2. General introduction
2.1 How to use this manual
The repair manual is divided into chapters containing the following
information:
• General safety rules.
• Operation and connection sequences – This chapter provides a basic
description of the main functions of the truck and their interdependencies.
• Parameters – This chapter provides a basic description of the truck
parameters.
• Installation – This chapter describes the preparatory work that is to be
done before the truck is used for the first time.
• Maintenance – This chapter provides an overview of periodic
maintenance.
• Troubleshooting – This chapter describes the action you should take
when the truck is completely or partially malfunctioning. It also describes
the cause of the problem together with suggested remedies.
• C Codes – This chapter describes the various truck systems, e.g. the
hydraulic system and includes descriptions of system parts and the
necessary service procedures. These descriptions are divided according
to Cesab's C code system.
• Instructions for disposal – This chapter specifies the proper sorting
categories for the materials used in the various truck components.
• Wiring diagram – This chapter provides information on electrical
components and wiring diagrams.
• Hydraulic diagram – This chapter provides information on hydraulic
components and hydraulic diagrams.
• Tools – This chapter provides a list of the special tools required.
• Service data and grease specifications – This chapter contains
information on general tightening torques and an oil and grease
specification.
• Technical data.
© Cesab 2– 1 T Code(s): 1010

2.2 Warning levels and symbols

The following warning levels and symbols are used in the repair manual:
DANGER!
Indicates a dangerous situation that – if not avoided – will cause death or
serious bodily injury.
WARNING
Indicates a dangerous situation that – if not avoided – will cause a slight or
minor bodily injury.
CAUTION
Indicates a dangerous situation that – if not avoided – will cause a slight or
minor bodily injury.
Note:
Used in connection with actions that can cause material damage but not
bodily injury.
Note:
Used to attract attention and to give information about various actions.
© Cesab 2– 2 T Code(s): 1010

2.3 Pictograms
Symbol Procedure Symbol Procedure
Visual inspection of
condition, wear and loose Component replacement.
connections.
Cleaning Measurement
Check of fluid level and Check that bolts, nuts, etc.

check for leaks. are tightened to torque.
Listening for noise. Lubrication, application.
Check of functions. Calibration
Adjustment Welding
Disassembly/removal Assembly/installation
© Cesab 2– 3 T Code(s): 1010

Symbol Procedure Symbol Procedure
Open Close
Refilling Emptying
Update
An example of another type of pictogram is “Cut cable ties”:
Additional information under the pictogram can, for example, indicate the
number of cable ties to be cut.
— Slut på avsnittet —
© Cesab 2– 4 T Code(s): 1010

Repair manual: General safety rules Model(s): P320, P322
3. General safety rules

Only personnel trained in servicing and repair of this type of truck are
authorised to carry out service and repair activities.
3.1 Work safety

To make work safer and prevent accidents, always keep the following in
mind:
• Keep the maintenance work site clean. Oil and water on the floor will make
it slippery.
• Use the correct working posture. Service work often involves sitting on
your knees or bending over forwards. Try sitting on a toolbox, for example,
to relieve the strain on your knees and back.
• Loose items and jewellery can get caught in moving parts of the truck. So
never wear loose articles or jewellery while working on the truck.
• Exercise caution and always follow applicable local regulations when
working at high heights.
• Use the correct tools for the work you are carrying out.
• Keep all tools well maintained.
• Make sure that all safety equipment including guards and covers are
properly secured and that they work as intended before starting the repair
work. If a guard or cover must be removed in order to perform the repair
work, extra care must be taken, and when the repair work is finished the
guard or cover must be refitted.
• Relieve the system pressure slowly before starting work on the truck’s
hydraulic system.
• Use paper or a stiff piece of cardboard when checking for possible oil
leaks. Do not use your hands.
© Cesab 3– 1 T Code(s): 1010

• Drive unit oil and the hydraulic system oil may be hot.
DANGER!
Risk of burn injury.
Hot drive unit and hydraulic oil.
Allow the truck to cool down before changing the oil.
• Only fill the hydraulic system with new and clean oil.
DANGER!
The hydraulic system can be damaged.
If the oil is contaminated, the hydraulic components will suffer damage.
Always use new and clean oil in the hydraulic system.
• Store and transport changed oil according to applicable local directions.
• Do not flush solvents, etc. down the drain unless they are intended to be
disposed of in this way.
Follow local disposal regulations.
• Disconnect the battery prior to performing any welding work on the truck.
Note:
The battery could be damaged.
When welding with an electric welding unit, the current may enter the battery.
The battery must be disconnected.
• Prior to welding or grinding on painted surfaces, be sure to remove the
paint at least 100 mm around the welding/grinding area by using
sandblasting equipment or paint remover.
DANGER!
Harmful gasses.
Heated paint gives off harmful gases.
Remove all paint within 100 mm of the welding/grinding site.
© Cesab 3– 2 T Code(s): 1010

3.2 Electrical systems

When working on the electrical system of the truck, remember the following:
• Never wear loose items or jewellery when working with the truck.
DANGER!
Short-circuiting/Burn injury.
Short circuits and burn injuries can occur if metal objects come into contact
with live electrical connections when working on the truck's electrical
system.
Remove wristwatches, rings and other metal objects beforehand.
• Always use insulated tools when working on the electrical system.
• Always disconnect the battery before opening any covers to drive units or
the electrical system.
• Always disconnect the battery prior to welding work using an electric
welding unit. The welding current may damage the battery.
• Always disconnect the battery when carrying out maintenance or repair
work on the truck unless otherwise stated in this repair manual.
• Clean electric motors using a rag or a vacuum cleaner.
• Clean electrical panels, electronic cards, contactors, contacts, magnetic
valves, etc. with a dampened cloth and a cleaning agent that will not
damage the part.
Note:
Risk of short-circuiting that may damage electrical components.
Do not break the warranty seal on the logic cards.
© Cesab 3– 3 T Code(s): 1010

3.3 Safe lifting

All lifting must be carried out on a level, non-slip and stable surface. Asphalt
surfaces should be avoided if possible.
To prevent the truck moving while it is being lifted, it must not be lifted with
anyone on the platform or with the tiller arm in the lowered position.
If the drive wheel, which is braked, is being lifted the other wheels must be
chocked to stop the truck from moving.
Select the lifting point so that the lift is as light as possible, for example one
corner at a time. If the truck has marked lifting points on the lower part of the
chassis, these must be used to ensure balanced lifting.
Make sure the surface where the jack is placed is clean and free of oil and
grease.
Make sure your hands and the jack lever are free of grease and oil.
Only use the lever supplied with the jack. If the lever is too short, more
exertion than is necessary will be required. If the lever is too long, there is a
risk that the jack will be overloaded.
DANGER!
Risk of crushing since a poorly supported truck could fall down.
Never work under a truck that is not supported by trestles and secured by a
lifting device.
Support the truck:
• as close to the lifted part of the chassis as possible in order to reduce the
falling height if the truck should collapse
• so the truck cannot move.
Never support the jack on trestles to achieve a higher lift.
Never work under a raised truck without it being properly supported on
trestles.
© Cesab 3– 4 T Code(s): 1010

3.4 Truck modifications

Any modification of the truck must be approved beforehand. No modification
of truck may be performed that may influence the capacity, stability and safety
of the truck without prior written approval from the manufacturer, its
representative or successor.
In the case of the manufacturer no longer being in business and there being
no successor, the user of the truck may arrange for modifications on the
precondition that the user:
• makes sure that an engineer with expert knowledge of industrial trucks
and their safety designs, tests and implements the modification,
• files all documentation of the designs, tests and implementation of the
modification,
• approves and makes the applicable changes to the capacity plate,
adhesive labels, markings and operator’s manual and
• affixes a permanent and well visible sign to the truck stating how the truck
has been modified, together with the date of the modification and the
name and address of the company that carried out the modification work.
© Cesab 3– 5 T Code(s): 1010

© Cesab 3– 6 T Code(s): 1010

Repair manual: Operation and connection sequences Model(s): P320, P322
4. Operation and connection sequences
This section provides a basic description of the main functions of the truck.
The terms below are used in the description of the truck’s main functions.
• Event – Use of one of the truck's main functions is referred to as an event.
• Prior event – Indicates an event which must have taken place immediately
before the current event in order for the latter to be performed correctly.
• Action(s) – An action that the driver must perform in order for an event to
happen.
• Influencing elements – Conditions that must be fulfilled in order for an
event to happen. Certain parameter settings may also affect the outcome
of the event.
• Resulting conditions – Describe the key events that can be checked in
order to confirm a function.
Note that resulting conditions indicate what is assumed to occur when there
is no error state.
Text within square brackets [ ] refer to the electrical component names in the
truck's electrical diagram.
{High} means ˜ 24 V and {low} means ˜ 0 V unless otherwise specified.
© Cesab 4– 1 T Code(s): 1010

Symbols on keypad and display
Symbol Description
ON button
This button is used to start the truck
and confirm entered settings during
PIN code management
OFF button
Error code
Battery charge as a percentage
Parameter
Hour meter
© Cesab 4– 2 T Code(s): 1010

4.1 Battery is connected
Event Connection of battery

Preceding event -
Action(s) Connect battery [X1, G1]

Main power fuse OK [F1]
Influencing
Current circuit fuses [F50, F51, F52, F53]
elements
Resulting
Login possible.
conditions
4.2 Login via keypad
Event Logging in
Preceding event Battery is connected
Log in with PIN code and press the ON button
Action(s)
[S223]
Emergency stop not actuated [S21]
Influencing elements Drive position sensor deactivated [B60]
Input [T1:INP TILL. ARM IN DRIV. POS] is {low}
Battery indicator lamp lights. The main display
[P6] shows the hour meter for 5 seconds,
Resulting conditions followed by battery status (% of full charge)
The mechanical brake [Q1] must remain actuated
[T1:OUT.BRAKE RELEASE] {high}
© Cesab 4– 3 T Code(s): 1010

4.3 Tiller arm lowered for driving
Event Tiller arm lowered for driving

Preceding event Logging in
Action(s) Lower tiller arm
Influencing elements Tiller arm in drive position sensor [B60].

Tiller arm in drive position sensor activates [B60]
[T1:INP.TILLER ARM IN DRIVE POS] {high}.
Resulting conditions Main contactor output goes {low} [T1:OUT.MAIN
CONTACTOR].
The main contactor closes [Q10].
4.4 Driving in fork direction
Event Driving in fork direction

Preceding event Tiller arm lowered for driving
Action(s) Move the speed control [L1] in the fork direction.

Hall element in speed control [A5:S310-S318]
Influencing elements
Parameter settings
[T1:OUT.BRAKE RELEASE] goes {low}
Brake coil [Q1] is energised, mechanical brake is
Resulting conditions released
Pulsed current is fed to the drive motor in
proportion to the position of the speed control
© Cesab 4– 4 T Code(s): 1010

4.5 Driving in the drive wheel direction
Event Driving in the drive wheel direction

Preceding event Tiller arm lowered for driving
Action(s) Move the speed control [L1] in the drive wheel direction.
Influencing Direction indicator's Hall element [A5:S300-S308]

elements Parameter settings
[T1:OUT.BRAKE RELEASE] goes {low}
Resulting Brake coil [Q1] is energised, mechanical brake is
conditions released. Pulsed current is fed to the drive motor in
proportion to the speed control’s movement
4.6 Neutral position braking
Event Neutral braking

Preceding event Driving in fork or drive wheel direction
Allow the speed control [L1] to return to the neutral
Action(s)
position.
Influencing
Parameter settings
elements
The drive motor [M1] functions as a generator and
converts the kinetic energy of the truck into electrical
energy via the motor control [T1]. This reduces the
Resulting
velocity of the truck.
conditions The excess energy is fed back to the battery [G1].
The mechanical brake engages when the truck stops
completely. [T1:OUT.BRAKE RELEASE] goes {high}
© Cesab 4– 5 T Code(s): 1010

4.7 Reverse braking
Event Reverse braking

The speed control [L1] is moved to the opposite driving
Action(s)
direction.
Influencing elements Parameter settings
The drive motor [M1] functions as a generator and
converts the kinetic energy of the truck into electrical
energy via the motor control [T1]. This reduces the
velocity of the truck.
Resulting conditions The excess energy is fed back to the battery [G1].
The mechanical brake engages when the truck stops
completely. [T1:OUT.BRAKE RELEASE] goes
{high}
4.8 Mechanical braking
Event Mechanical braking

Action(s) Raise or lower the tiller arm
Influencing
Tiller arm in drive position sensor [B60]
elements
Input [T1:INP TILL. ARM IN DRIV. POS] goes {low}
Resulting Brake reduction until the truck is stationary
conditions Brake coil [Q1] is deactivated, mechanical brake is
engaged [T1:OUT.BRAKE RELEASE] goes {high}
© Cesab 4– 6 T Code(s): 1010

4.9 Emergency reversal
Event Emergency reversal

Preceding event Driving in the drive wheel direction
When driving in the drive wheel direction, the emergency
Action(s)
reversal button is pressed
Influencing
Emergency reversal
elements
The Hall sensor [A5:S317] is immediately activated.
The card [A5] interprets this signal as a command to
the motor control [T1] to run the drive motor at a
Resulting
reduced speed in the fork direction as long as the
conditions
button is depressed. The normal drive command
signal received from [L1] is blocked until [L1] is
released and returns to neutral position.
4.10 Fork lifting
Event Fork lifting

Preceding event Switched on (PIN code login)
Action(s) Press the button for fork lift

Main contactor [Q10].
Pump contactor [Q25].
Fuse [F1].
Influencing elements Fork lifting button
Battery status OK (>20% charge left)
Lift height limit S31 [B61] [T1:INP.LIFT LIMIT] not
activated
[T1:OUT.PUMP CONTACTOR] goes {low}
Resulting conditions Pump contactor [Q25] is activated
Pump motor [M3] starts.
© Cesab 4– 7 T Code(s): 1010

4.11 Fork lowering
Event Fork lowering

Preceding event Fork lifting
Action(s) Press the fork lowering button

Fork lowering button
Influencing elements
Main contactor [Q10]
[T1:OUT. LOWER VALVE] goes {low}, proportional
Resulting conditions
valve [Q4] opens.
© Cesab 4– 8 T Code(s): 1010

Repair manual: Parameters Model(s): P320, P322
5. Parameters
5.1 General parameters

The truck's control system can store a number of different parameters. These
are used to configure the truck according to the task to be performed. The
parameters are divided into groups:
- Operator parameters – The driver parameters (1-100) are used to
adapt the truck’s characteristics to a specific driver or task. Up to 10
operator parameter profiles can be stored.
- Service parameters – The service parameters (range 101–1000) are
used to adapt the truck's performance/response and cover all other
parameters not covered by the operator parameters.
- Factory parameters – (range 1001-1250). Truck-specific parameters.
- Calibration parameters – (range 1251-1300) store the value
generated on the calibration of valves, weight indication, etc. These
can be changed manually.
Operator parameters are displayed and changed only for a selected operator,
but if a CAN service key is connected, the parameters for all operators can be
displayed and changed. Operator parameters can be changed by the
operator if the truck's program is set up for this.
The service parameters can be changed once a suitable CAN service key or
PDA/PC has been connected to the truck.
Factory parameters can ONLY be changed after a specially configured PDA/
PC has been connected to the truck.
© Cesab 5– 1 T Code(s): 1010

5.1.1 Show/change parameters
1: Ensure that the truck is switched off. Connect the CAN key or enter the
PIN code. Note: Do not press the ON button.
2: Press and then release the horn button. “Info“ is shown on the display.
3: Move between menus by turning the speed control several times.
4: “Par” is shown on the display.
5: Press the horn button to select. The parameter symbol lights up.
6: By pressing the speed control repeatedly, you can move through the
parameter list.
See section "5.1 General parameters".For setting parameters.
To show a parameter, release the speed control when the required parameter
is shown on the display. Press the horn button to change the parameter.
© Cesab 5– 2 T Code(s): 1010

5.2 Operator parameters
5.2.1 Overview
Par. Description
1 Max. speed in fork direction
2 Maximum speed in drive wheel direction
3 Acceleration
4 Deceleration
Maximum speed, platform loaded, safety gate
5
lowered
6 Maximum speed, platform not loaded
7 (Not applicable)
© Cesab 5– 3 T Code(s): 1010

5.2.2 Connection to logged-in operator

The operator parameters can be adjusted individually to the available log-in
profiles. The parameter’s connection to the operator is done by a combination
of operator and parameter numbers where the single digit always
corresponds to the parameter.
Operator Parameter
profile range
1 1–7
2 11 – 17
3 21 – 27
4 31 – 37
5 41 – 47
6 51 – 57
7 61 – 67
8 71 – 77
9 81 – 87
10 91 – 97
Description of operator parameters
Parameters 1, 2, 5, 6 and 7 – Maximum travel speed

These three parameters are used to limit the maximum travel speed for the
operator profile that is logged on.
Defa Incre
Par. Description Min. Max. Unit
ult ment
1 Max. speed in fork direction 30 100 100 5 %
Maximum speed in drive wheel
2 30 100 100 5 %
direction
Maximum speed, platform
5 30 100 100 5 %
loaded, safety gate lowered
Maximum speed, platform up
6 30 100 100 5 %
and gates down.
7 (Not applicable)
The maximum travel speed can also be limited by factory parameter #1044
and it is always the lowest speed for a parameter that is the limiting one.
© Cesab 5– 4 T Code(s): 1010

Description of operator parameters

#1 - Speed, Fork direction
Adjusts the maximum speed of the truck in the fork wheel direction, with gates
up and operator on the platform
#2 - Speed, drive wheel direction
Adjusts the maximum speed of the truck in the drive wheel direction, with
gates up and operator on the platform
#5 - Speed, gates down
Adjusts the maximum speed of the truck for this application, with gates down
and operator on the platform
#6 - Speed, platform up and gates down.
Adjusts the truck’s maximum speed when the operator is not on the platform,
platform is up and the gates down, i.e. when the operator walks alongside the
truck.
# 7 - (Not applicable)
© Cesab 5– 5 T Code(s): 1010

Parameters 3 and 4 – Acceleration/Deceleration

These two parameters can be used to get a smoother acceleration/
retardation where the application or operator profile so requires.
Defa Incre
ult ment
3 Acceleration 10 100 100 5 %
4 Deceleration 40 100 100 5 %
#3 - Acceleration
The lower the parameter value, the more time is needed to accelerate to the
maximum speed.
#4 - Deceleration
Defines plug braking force when speed control [L1] returns to the neutral
position. The lower the value of parameter, the longer it takes to reduce
speed.
100% = 2.0 m/s2
© Cesab 5– 6 T Code(s): 1010

5.3 General service parameters

Before any service parameter can be changed, the CAN service key must be
connected to the contact [X41].
5.3.1 Overview
Note:
Changing specific truck parameters changes the truck's driving properties.
Do not change any parameter values without the necessary know-how.
Par. Description
101 Service intervals
102 Operator access
103 Start-up - alternative
104 Automatic logout/min
105 Collision sensor X level
106 Collision sensor Y level
107 Battery adjustment, Ah
109 Battery type, built-in charger
110 Battery size, built-in charger
111 Reset following a collision
112 Clear application data
© Cesab 5– 7 T Code(s): 1010

5.3.2 Description
Parameter 101/104 – Service/Log-out

Defa Incre
ult ment
101 Service intervals 0 0 2000 50 h
104 Time to automatic log-out 0 20 20 1 min.
#101 - Service interval

This parameter determines the time value (in hours) to the next service from
0 to 2000 hours in increments of 50 hours. Whenever this value is changed,
the timer is reset and will start to count the truck activity time. On reaching the
set value, code “S - 0h” is shown on the display and the red LED flashes.
If the value is set as '0', no service interval is given
#104 - Time to automatic log-out
Gives the time, in minutes, before automatic log-out if the truck is inactive.
If the value is set as ‘0’, logout takes place after 4 hours.
Parameter 102 - Operator access
Defa Incre
ult ment
102 Operator access 1 3 10 1
#102 - Operator access

Specifies which login method should be used and if the operator will have the
possibility of changing the operator parameter settings.
Values 1 and 2 = Key
Values 3 and 4 = Keypad with 100 PIN codes. See section "6.5 Using PIN
codes".
Values 5 and 6 = Keypad with DHU
Values 7 and 8 = ID unit
Values 9 and 10 = SA2
Odd values = Operator parameters are open and can be changed by the
operator.
Even values = Operator parameters can only be changed with a CAN key
connected.
© Cesab 5– 8 T Code(s): 1010

Parameter 103 - Start-up display

Defa Incre
ult ment
103 Start-up display 1 2 5 1
#103 - Start-up display

Sets which value is shown on the display when the truck is started.
When the truck is started, one of the truck's 5 values is shown on the hour
meter display "H" (hour meter display) for 5 seconds. After the menu has
disappeared, the battery capacity is continuously shown in the numeric field
at the same time as the battery indicator is lit.
The truck control system stores five different time values. "Value 2 -
Operating time" is the default value on the start-up display.
Hour meter values Display
Value 1 = (A) Key time

The total time the truck has been in use
Value 2 = (B) Operating time

Combined time during which the pump or drive motor has
been in operation.
Default display.
Value 3 = (C) Drive motor time

The total time the drive motor has been in operation.
Value 4 = (D) Pump motor time

Total time the pump motor has been in operation.
Value 5 = (S) Remaining time until next service.

Parameter 101 controls the initial value.
© Cesab 5– 9 T Code(s): 1010

Parameter 105/106 - Collision sensor sensitivity for X/Y (Optional)

Defa Incre
ult ment
Collision sensor X-degree
105 0 0 100 1
of sensitivity
Collision sensor Y-degree
106 0 0 100 1
of sensitivity
#105 - Collision sensor X sensitivity degree

Indicates the degree of sensitivity for what should be interpreted as a frontal/
rear-end impact. 0 = Collision sensor not activated
The collision sensor can also be used in combination with DHU. In such
cases, the parameters should not be set in the truck. Collision monitoring is
instead administrated via I_Site.
This parameter must be set during truck installation. See the chapter “Setting
collision sensor parameters (option)”
#106 - Collision sensor Y sensitivity degree
Indicates the degree of sensitivity for what should be interpreted as a side
impact. 0 = Collision sensor not activated
The collision sensor can also be used in combination with DHU. In such
cases, the parameters should not be set in the truck. Collision monitoring is
instead administrated via I_Site.
This parameter must be set during truck installation. See the chapter “Setting
collision sensor parameters (option)”
© Cesab 5 – 10 T Code(s): 1010

Parameter 107 – Battery size

Defa Incre
ult ment
107 Battery size 1 12 20 1
# 107 - Battery size

Specifies what type of battery the truck is equipped with.
The parameter can be used to compensate for different ways of driving by:
• increasing the value to discharge the battery even more.
• reducing the value if the battery is discharged too much.
In order to set the meter for battery charge level, consideration must be given
to the following:
• Acid density when the battery is fully charged; to check the quality of the
battery. This value should be between 1.27 and 1.29.
Please note that the acid density may vary between different kinds of
battery.
• When the lifting capacity is disabled (battery 80% discharged), the value
must be close to (but not below) 1.14.
Refer to the table below for recommended parameter settings.
© Cesab 5 – 11 T Code(s): 1010

Lead/acid
Parameter 107 Gel battery
battery
1
2
Slight
3 581-650 Ah
discharge
4 480-580 Ah
5 381-480 Ah
6 281-380 Ah
7 ≤ 280 Ah
8
9
10
11 ≥ 601 Ah
12 401-600 Ah
13 210-400 Ah
14 ≤ 209 Ah
15
16
Deeper 17
discharge 18
19
20
DANGER!
Battery service life will be reduced if the value of parameter 107 is set too high.
The standard setting of parameter 107 is set for normal truck handling. Other
applications may require a different setting of parameter 107. Check that the
parameter setting is the correct one using the instructions below.
© Cesab 5 – 12 T Code(s): 1010

Verifying parameter settings for freely ventilated batteries (lead-acid

batteries)
1. Charge the battery.
2. Use the truck in its normal application until the battery indicator shows a
discharged battery (0% on the display).
3. Disconnect the battery from the truck and allow it to rest for at least two
minutes.
Note:
Do not charge or discharge during this time.
4. Measure the specific gravity of the electrolyte at ambient temperature.
If the specific gravity is below 1.15 g/cm3, the parameter value must be
reduced.
If the value is considerably higher than 1.15 g/cm3 the risk of damage to the
battery is reduced. At the same time, the operating time of the truck is
reduced. If extended operating time is desired, then increase the parameter
value by no more than one unit.
Note:
Each change should be followed up by a new verification of the parameter
setting.
Verifying the parameter setting for valve-regulated batteries (Exide)

1. Charge the battery.
2. Operate the truck in its normal application until the battery indicator
indicates a discharged battery (0% in the display).
3. Disconnect the battery from the truck and allow it to rest for at least two
hours.
Note:
Do not allow any charging or discharging during this time.
4. Measure the battery voltage at room temperature.
If the voltage is less than Uend (see the table below) the parameter value
must be reduced. If the value is considerably higher than Uend the risk of
damage to the battery is reduced. At the same time, however, the operating
time of the truck decreases. If extended operating time is desired, then
increase the parameter value, but maximum by one unit.
Note:
Each change should be followed up by a new verification of the parameter
setting.
Battery type Battery voltage while resting,

Uend
Exide 24.24 V
© Cesab 5 – 13 T Code(s): 1010

Parameters 109/110 - Built-in charger (option)

Defa Incre
ult ment
Battery type, built-in
109 0 0 3 1
charger
Battery size, built-in
110 100 100 350 1 Ah
charger
#109 - Battery type, built-in charger

Sets the type of battery in case of built-in charger. This parameter has no use
unless there is a built-in charger.
#0 = No charging
#1 = Lead/acid battery
#2 = Hawker Evolution battery
#3 = Exide gel battery
#110 - Battery type, built-in charger (Optional)

Sets the battery size used with the built-in charger so the correct charging
current is chosen. For Hawker Evolution only the sizes 134 Ah, 174 Ah and
201 Ah are approved. This parameter has no use unless there is a built-in
charger.
© Cesab 5 – 14 T Code(s): 1010

Parameter 111 - Reset procedure after collision (option)

Defa Incre
ult ment
Resetting procedure after
111 0 0 3 1
collision
#111 - Reset procedure after collision

Specifies the condition for how the truck is to be taken into operation again
after the collision sensors have been triggered.
Value 0 default = Horn sounds immediately upon collision and then every 5
seconds until the truck is reset
Value Function
0 Default setting
The operator can reset the truck; only if the
1
collision sensor is handled from the truck
2 Activates sounding of the horn every 5 seconds
3 Options 1 and 2 combined.
The PIN code to be activated for resetting can be found in operator profile 1
and special block 10. Page 6–10
© Cesab 5 – 15 T Code(s): 1010

Parameter 112 - Clear application data
Defa Incre
ult ment
112 Erase application data 0 0 2 1
#112 - Clear application data

Specifies whether information from the histogram/collision sensor is to be
deleted at login.
Value Function
0 Do not clear
1 Clear histogram at start-up
2 Clear collision log at start-up
The histogram data consists of the logged motor temperature, motor control
and steering motor in the form of a histogram. You clear this data by setting
parameter 112 =1. This is useful when transferring the truck from one client
to another.
The collision log is a log with the 10 latest collisions are stored together with
the operator PIN code. You clear this data by setting parameter 112 =2.
© Cesab 5 – 16 T Code(s): 1010

5.4 Service parameters, travel functions
5.4.1 Overview
Par. Description
201 Braking force when reversing the travel direction
202 Maximum speed Turtle mode activated
203 (Not applicable)
207 Operation –walk alongside truck
208 Reduction of max. speed with forks fully lowered
Min. fork lifting height to exit reduced speed via parameter
209
208
220 Min. steering angle for initiation of speed reduction
222 Max. speed at full speed reduction
223 Max. steering angle for full speed reduction
250 Min. steering resistance (TFD) in drive wheel direction
251 Max. steering resistance (TFD) in drive wheel direction
252 Min. steering resistance (TFD) in fork direction
253 Max. steering resistance (TFD) in fork direction
© Cesab 5 – 17 T Code(s): 1010

5.4.2 Description
Parameter 201 – Deceleration when reversing
Defa Incre
ult ment
Deceleration when
201 70 100 100 5 %
reversing
#201 – Deceleration when reversing

Sets how hard the truck will brake when the speed control is turned in the
opposite direction, and used to get a smoother deceleration where the
application requires this for all operator profiles.
100% = 2.5 m/s2
Parameter 201 is set to 70% on all trucks with forks shorter than 1500 mm
and a small battery compartment.
Parameter 202 – Maximum speed Turtle mode activated
Defa Incre
ult ment
Maximum speed Turtle
202 0.5 4.0 6.0 0.5 km/h
mode activated
#202 - Maximum speed Turtle mode activated

Sets the maximum speed when Turtle mode is activated
.
© Cesab 5 – 18 T Code(s): 1010

Parameter 203 - (Not applicable)
© Cesab 5 – 19 T Code(s): 1010

Parameter 207 - Operation, walk alongside truck
Defa Incre
ult ment
Operation –walk alongside
207 0 0 1 1
truck
#207 - Operation, walk alongside truck

This parameter is used to activate/deactivate the possibility of the operator
operating the truck with the tiller arm while walking alongside the truck (i.e.
not standing on the platform).
Value Function
0 Activated
1 Deactivated
Parameter 208 - Reduction of max. speed with forks fully lowered

Option
Defa Incre
ult ment
Reduction of max. speed with
208 0.5 12.5 12.5 0.5 km/h
forks fully lowered
#208 - Reduction of max. speed with forks fully lowered

Reduces maximum speed when the forks are fully lowered. This option
requires that a pressure sensor is installed. This is beneficial when you are
operating on a smooth floor and do not want to scrape the forks.
© Cesab 5 – 20 T Code(s): 1010

Parameter 209 - Min. fork lifting height to exit reduced speed via
parameter 208
Defa Incre
ult ment
Min. fork lifting height to exit
209 reduced speed via parameter 10 10 50 1 ms
208
#209 - Min. fork lifting height to exit reduced speed via parameter 208
The required lifting time that the hydraulic pump must be active/lift the forks
above the floor (in increments of 20 ms) to exit reduced speed via parameter
208.
Parameter 211 - Automatic speed reduction (built-in)
Defa Incre
ult ment
Automatic speed reduction
211 25 25 100 5 %
(built-in)
#211 - Automatic speed reduction (built-in)

Specifies automatic speed reduction when the light beam is broken for more
than 500 ms. As a percentage of maximum speed reduction for this
application.
The light beam must be broken for more than 500 ms in order for the feet to
be detected as outside the platform.
If travel speed is 6 km/h or more, the truck does not stop.
© Cesab 5 – 21 T Code(s): 1010

Parameter 220 - Min. steering angle for initiation of speed limitation
Defa Incre
ult ment
Min. steering angle for
220 1 5 10 1 °
initiation of speed limitation
# 220 - Min. steering angle for initiation of speed limitation

This parameter is used to set when speed reduction during cornering should
begin. Set in degrees between 1 and 10º
Note: A lower angle produces a milder nature during cornering.
This parameter is set (default) to 10° on LPE.
14
10°
12
5°
10
1°
8
Y
6
0
0 20 40 60 80 100
X
X= Steering angle
Y= Max. speed
© Cesab 5 – 22 T Code(s): 1010

Parameter 222 - Max. speed at full speed limitation
Defa Incre
ult ment
See
Max. speed at full speed
222 2.5 the 6.3 1 km/h
limitation
table
# 222 - Max. speed at full speed limitation

This parameter is used to determine the speed when full speed limitation is
achieved during cornering. Set in km/h and is dependent on the wheel base
of the truck; see the table below.
Note: A higher speed here produces gentler braking, but a higher curve
speed.
Parameter 222
Wheel base (dm)
(km/h)
15 4.8
16 5.0
17 5.1
18 5.3
19 5.4
20 5.6
dm 21 5.7
22 5.9
Wheel base (dm) 23 6.0
24 6.2
25 6.3
14
6,3 Km/h
12
4,5 Km/h
2,5 Km/h
10
8
Y
6
0
0 20 40 60 80 100
X
X= Steering angle
Y= Max. speed
© Cesab 5 – 23 T Code(s): 1010

Parameter 223 - Max. steering angle for full speed limitation
Defa Incre
ult ment
Max. steering angle for full
223 30 60 75 1 °
speed limitation
# 223 - Max. steering angle for full speed limitation

This parameter is used to set when speed reduction during cornering should
end. Set in degrees between 30 and 75º
Note: A higher value produces gentler braking, but allows a higher curve
speed quote far into the turn.
This parameter is set (default) to 75° on LPE.
14
30°
12
50°
10 75°
8
Y
6
0
0 20 40 60 80 100
X
X= Steering angle
Y= Max. speed
© Cesab 5 – 24 T Code(s): 1010

TFD (Tactile Feedback Device)

All trucks with power steering also have a TFD. The TFD is used to both
measure the tiller arm angle and to produce resistance in the tiller arm. This
resistance is set with parameters 250-253. 100% = 1000 mA, 0% = 0 mA. If
min. parameter 250 or 252 is set to a higher value than max. parameter 251
or 253, the lowest value will be used.
Parameter 250 - Min. steering resistance (TFD) in drive wheel direction
Defa Incre
ult ment
Min. steering resistance
250 0 20 100 5 %
(TFD) in drive wheel direction
# 250 - Min. steering resistance (TFD) in drive wheel direction

This parameter is used to set the minimum steering resistance in the drive
wheel direction.
Parameter 251 - Max. steering resistance (TFD) in drive wheel direction
Defa Incre
ult ment
Max. steering resistance
251 0 100 100 5 %
(TFD) in drive wheel direction
251 (TFD) in drive wheel direction 0 60 100 5 %
(E-Man only)
# 251 - Max. steering resistance (TFD) in drive wheel direction

This parameter is used to set the maximum steering resistance in the drive
wheel direction.
© Cesab 5 – 25 T Code(s): 1010

Parameter 252 - Min. steering resistance (TFD) in fork direction
Defa Incre
ult ment
Min. steering resistance
252 0 20 100 5 %
(TFD) in fork direction
# 252 - Min. steering resistance (TFD) in fork direction

This parameter is used to set the minimum steering resistance in the fork
direction.
Parameter 253 - Max. steering resistance (TFD) in fork direction
Defa Incre
ult ment
253 0 100 100 5 %
(TFD) in fork direction
# 253 - Max. steering resistance (TFD) in fork direction

This parameter is used to set the maximum steering resistance in the fork
direction.
© Cesab 5 – 26 T Code(s): 1010

5.5 Service parameters, hydraulic functions
Par. Description
311 Load weight
312 Pressure equalization
499 (Not applicable - for field test software only)
© Cesab 5 – 27 T Code(s): 1010

5.5.1 Description
Parameter 311 - Load weight
Defa Incre
ult ment
311 Load weight 0 1 1 1 kg
Parameter 311 - Load weight

Weight indication of load weight in kg. Lifting or lowering, the load weight is
only shown in full 100s of kg in the display.
Value Function
0 Off
1 On
Parameter 312 – Pressure equalization
Defa Incre
ult ment
312 Pressure equalization 0 0 5 1 20 ms
Parameter 312 – Pressure equalization

Activates and controls a pressure equalization pulse after a lift. This is to
equalize the pressure, and to get a better measurement of the load weight.
Set to 0 to switch off the function (standard). If it is set to a higher value than
0, the duration of the lowering pulse will be a multiple of the parameter value
20 ms. The truck must have a pressure sensor to enable the function.

This parameter is only used for field test software
© Cesab 5 – 28 T Code(s): 1010

5.6 Factory parameters

The truck's factory parameters are preset in the truck during production at the
factory. Factory parameters can only be changed using the TruckCom
software application.
Note:
Remember that a change of specific truck parameters changes the truck's
properties. Do not change any parameter values without the necessary
know-how. Only authorised service technicians with personal TruckCom
user identities have the rights to change factory settings. The parameters
should only be changed when a specific need for this arises.
The user ID and time of changing parameters will be logged in the logic card
housed in the tiller arm handle.
5.6.1 Overview
Par. Description
1001 Truck type
1002 Non-configurable option
1003-
Optional functions FUNC1 - FUNC8
1042
1044 Master maximum speed
1045 Battery type
1051 Inactivate hydraulic functions
1060 Handling during cornering
1061 Tiller arm
1101 Built-in charger
1102 Controls for hydraulic function
1103 Protective gates
1106 Sensor, forks in top position
1107 Type of control
1108 Truck type
1110 BDI
1111 Platform
1113 Protective overhead guard
1115 Fan
© Cesab 5 – 29 T Code(s): 1010

5.6.2 Description
Parameter 1001 - Type of truck
Defa Incre
ult ment
1001 Truck type 0 0 158 1
Parameter 1001 - Type of truck

This parameter is used to set which truck type the program is to adapt
operational data for.
Value Function
0 Unknown truck type
2 LPE200
3 LPE220
4 LPE250
5 (Not applicable)
© Cesab 5 – 30 T Code(s): 1010

Parameter 1002 - Non-configurable options
Defa Incre
ult ment
1002 Non-configurable option 0 1 7 1
#1002 - Non-configurable options

3 different functions are accessible via parameter 1002. These functions are
either active or inactive. The functions do not require any further adjustment
and are thus referred to as non-configurable options.
Value Function
0 No optional function
1 CLICK-2-CREEP
2 TURTLE
3 CLICK-2-CREEP and TURTLE
4 SAFETY REVERSING HORN
5 SAFETY REVERSING HORN and CLICK-2-CREEP
6 SAFETY REVERSING HORN and TURTLE
SAFETY REVERSING HORN, CLICK-2-CREEP and
7
TURTLE
Parameters 1003-1042 – Optional functions
Defa Incre
ult ment
1003 Optional function 1 0 0 21 1
1004 Optional function 1Arg1 0 0 255 1
© Cesab 5 – 31 T Code(s): 1010

Defa Incre
ult ment
© Cesab 5 – 32 T Code(s): 1010

Parameters #1003-1042
Factory parameters # 1003 to 1042 - configurable optional functions

Parameters #1003 to #1042 are reserved in the truck’s control system for
extra truck options and/or special product modifications. The parameters
configure and control the Spider expansion unit (SEU) that must be fitted to
the truck, in some cases it is enough to have an empty I/0 in the motor control.
This method of implementation enables use of the standard program. This
eliminates the need for any special program.
Normally, these parameters are configured by the manufacturer when the
truck is modified or customised. It is advisable to upload the parameter
settings from the truck when carrying out any modification. If the main control
unit [A2] has been replaced, the original parameter settings can be
transferred to the new unit, thus ensuring that special options function
correctly.
Factory parameter nos. #1003, #1008, #1013, #1018, #1023, #1028, #1033
and #1038 can be adjusted to allow up to a maximum of 8 pre-programmed
"Basic options" to be activated and configured to suit a specific special option
or customisation.
Activation of optional functions

The system can use up to eight configurable optional functions
simultaneously. Each configurable function is controlled by five factory
parameters. During activation, an index parameter (#1003, #1008, #1013,
#1018, #1023, #1028, #1033, #1038) must first be set to a value equivalent
to an optional function. Linked to each index parameter are four parameters
that can be modified to configure the optional function.
• The index parameter is allocated one optional function (optional function is
determined).
• Each optional function can have up to 4 arguments associated with it.
Each argument holds a value which can be changed to configure the
function (optional function is configured).
• If the value of an argument is outside of the highest or lowest permitted
value, an error code is generated and the option cannot be used.
The error code cannot be eliminated until the argument is given a
permissible value.
© Cesab 5 – 33 T Code(s): 1010

Base option 1 - Option button controls SEU output

Argument #1 Selection of SEU unit 1 or 2
Values Meaning
0 option is handled by SEU unit 1 (A36)
1 option is handled by SEU unit 2 (the second SEU unit)
Argument #2 Selection of SEU digital output
Values Meaning Pin no.
0 activates digital output 1 (1.6 A) on SEU 16
Argument #3 Selection of option button
Values Meaning
0 activated by option button 2 or 5
1 activated by option button 1
Argument #4 Type of switching

Values Meaning
0 activated when the button is pressed
1 option is toggled when button is pressed
© Cesab 5 – 34 T Code(s): 1010

Basic option 2 - Reduced driving speed via SEU inputs

Values Meaning
Argument #2 Selection of SEU digital input
0 activates digital input 1 (1 mA) on SEU 5
Argument #3 Speed limitation as a percentage of max. speed
Values Meaning
Max. speed adjustable from 0-100%
0-100
(driving is not possible when value = 0)
Argument #4 Speed range
Values Meaning
0 Affects only high speed range
1 Affects only low speed range
2 Affects both speed ranges
© Cesab 5 – 35 T Code(s): 1010

Basic option 3 - Truck movement activates SEU output

Values Meaning
Argument #2 Selection of SEU digital output
Pin
Values Meaning
no.
© Cesab 5 – 36 T Code(s): 1010

Basic option 3 - Truck movement activates SEU output

Argument #3 Selection of activation movement
Driving
Driving Fork Fork
Values drive wheel
fork direction lifting lowering
direction
1 X
2 X
3 X X
4 X
5 X X
6 X X
7 X X X
8 X
9 X X
10 X X
11 X X X
12 X X
13 X X X
14 X X X
15 X X X X
16
17 X
18 X
19 X X
20 X
21 X X
22 X X
23 X X X
24 X
25 X X
26 X X
27 X X X
28 X X
29 X X X
30 X X X
31 X X X X
Argument #4 Output switching mode
Values Meaning
0 Output continuously on
1 Output switches at 1 Hz
© Cesab 5 – 37 T Code(s): 1010

Basic option 4 - Activate main contactor by SEU input

Values Meaning
0 activated by digital input 1 (1 mA) on SEU 5
2 activated by digital input 3 (1 mA) on SEU 3 33
Argument #3 Hold time in minutes
Values Meaning
Contactor is held from 0 to 30 minutes after the digital input is
0-30
activated
Argument #4 Not used
© Cesab 5 – 38 T Code(s): 1010

Basic option 5 - Activate lifting/lowering by SEU input

Values Meaning
Argument #2 Selection of SEU digital inputs
Lift - SEU digital input 1 on SEU 5
0 Lower - SEU digital input 2 on SEU 19
Lowering block - SEU digital input 3 on SEU 33
Argument #3 Enable/disable lowering block
Values Meaning
0 Lowering block disabled
1 Lowering block enabled
Argument #4 Selection of fork/support arm
Values Meaning
0 Selects fork lifting/lowering
1 Selects support arm lifting/lowering
© Cesab 5 – 39 T Code(s): 1010

Basic option 6 - Lift height limitation by SEU input and override

Values Meaning
Argument #2 Selection of SEU digital input for limitation switch
Argument #3 Selection of option button for override function
Values Meaning
8 no override possible
Argument #4 Selection of time interval for override function
Values Meaning
0 open button must be held depressed for override
1-15 value corresponds to time in seconds, e.g. value 1 = 1 second
© Cesab 5 – 40 T Code(s): 1010

Basic option 11 - Automatic height preselector

Values Meaning
Argument #2 Selection of option button for automatic lift and lowering movement
Values Meaning
0 option not activated by option button
6 activated by option button 1.6 or 2.5
7 activated by option button 2.5 or 3.4
Argument #3 Selection of SEU digital inputs/outputs
photocell - digital input 1 on SEU 5
lowest position - digital input 2 on SEU 19
highest position - digital input 3 on SEU 33
0
external lift button - digital input 4 on SEU 6
external lower button - digital input 5 on SEU 20
lamp - digital output 1 on SEU 16
1
2
3
© Cesab 5 – 41 T Code(s): 1010

Basic option 11 - Automatic height preselector

Argument #4 Engagement/disengagement of external lift/lower button

Values Meaning
0 external lift/lower button disengaged
1 external lift/lower button engaged
Basic option 13 – Activate SEU outputs on login

Values Meaning
Argument #2 Selection of SEU digital output Pin no.
Argument #4 SEU output's connection mode

Values Meaning
0 Output continuously on
© Cesab 5 – 42 T Code(s): 1010

Basic option 14 – Activate restrictions on hydraulics via operator profiles

Argument #1 Not used. SEU unit not required
Argument #2 Selection of operator profile

Values Meaning
1 Operator profile 1
2 Operator profile 1-2
Connecting restrictions. The values in argument #3 can be combined
Argument #3
through addition, e.g. value 1 + value 8 = value 9
Values Meaning
1 Block the lift/pressurising of hydraulic function 1
2 Block the lowering/depressurising of hydraulic function 1
© Cesab 5 – 43 T Code(s): 1010

Basic option 15 – Activate restrictions on hydraulics via SEU inputs

Values Meaning
Connecting restrictions. The values in argument #3 can be combined
Argument #3
through addition, e.g. value 1 + value 8 = value 9
Values Meaning
Argument #4 Override button
Values Meaning
0 Option button 2 or 5 has override function
1 Option button 1 has override function
7 Option button 3 or 4 has override function
8 No override possible
© Cesab 5 – 44 T Code(s): 1010

Parameter 1044 - Master maximum speed
Defa Incre
ult ment
1044 Master maximum speed 0.5 12.5 12.5 0.5 km/h
#1044 - Master maximum speed

Sets the maximum speed for the application. The speed can never exceed
the value of this parameter, regardless of the settings of the other
parameters.
Parameter 1045 - Type of battery in the truck
Defa Incre
ult ment
1045 Type of battery in the truck 0 0 1 1
# 1045 - Type of battery in the truck

Specifies the type of battery found in the application.
Value Function
0 Lead/acid battery
1 Li-ion battery from Hoppecke
© Cesab 5 – 45 T Code(s): 1010

Parameter 1051 - Inactivate hydraulic functions
Defa Incre
ult ment
Inactivate hydraulic
1051 0 0 255 1
functions
#1051 - Inactivate hydraulic functions

Block one or more hydraulic functions when the operator is not standing on
the platform. The value is determined by the binary number system and is
primarily used by the manufacturer for different options.
To disable all hydraulic functions when the operator leaves the platform, enter
the value 255.
Value Function
Bit 0 1st hydraulic function, lift
Bit 1 2nd hydraulic function, lift
Bit 2 3rd hydraulic function, lift
Bit 3 4th hydraulic function, lift
Bit 4 1st hydraulic function, lower
Bit 5 2nd hydraulic function, lower
Bit 6 3rd hydraulic function, lower
Bit 7 4th hydraulic function, lower
© Cesab 5 – 46 T Code(s): 1010

Parameter 1060 – Progressive steering
Defa Incre
ult ment
Progressive steering -
1060 15 15 25 1 dm
wheel base
# 1060 - Progressive steering

This value is set based on the truck's wheel base (measured between the
drive wheel and fork wheel) and controls the deflection between the tiller
arm position and the drive wheel position. It is progressive steering that is
adapted to the length of the truck. The deflection is dependent on:
· Tiller arm position
· Truck's wheel base
· Truck's current travel speed
As a result, steering is less sensitive at high travel speeds and/or with shorter
wheel bases.
Parameter 1061 – Tiller arm - power steering
Defa Incre
ult ment
1061 Tiller arm - power steering 0 0 1 1
# 1061 – Tiller arm - power steering

Specifies the type of tiller arm fitted on the truck (power steering only)
Value Function
0 Short tiller arm (E-Man), used in trucks with fixed side guards.
1 Standard tiller arm.

© Cesab 5 – 47 T Code(s): 1010

Parameter 1101 - Built-in charger
Defa Incre
ult ment
1101 Built-in battery charger 0 0 2 1
#1101 - Built-in charger

Indicates if there is a battery charger on the application. If there is a battery
charger, parameters 109 and 110 must also be set.
Battery charger, special version with extra sensor:
Some countries have a breaker for each socket. If it is not switched on, the
BCU will not detect whether it is connected or not. To prevent the risk of the
truck being started and driven off with the mains cable connected to the wall,
the "UK" version has an extra sensor that measures whether the mains cable
is in its parked position in the battery compartment.
Value Function
0 No battery charger
1 Battery charger present
Battery charger present, special version with
2
extra sensor (see above)
© Cesab 5 – 48 T Code(s): 1010

Parameter 1102 - Controls for hydraulic function
Defa Incre
ult ment
1102 Controls for hydraulic function 1 1 4 1
#1102 - Controls for hydraulic function
Value Function
The rear lifting and lowering control is connected
1 to the second hydraulic function, while the front
control is connected to the first hydraulic function
The rear lifting and lowering control is connected
to the first hydraulic function, while the front
2
control is connected to the second hydraulic
function
Both lifting and lowering controls are connected
3 to the first hydraulic function. There is no second
hydraulic function.
The analogue lifting and lowering control is
connected to the first hydraulic function, while the
4
front control is connected to the second hydraulic
function.
© Cesab 5 – 49 T Code(s): 1010

Parameter 1103 – Safety gate
Defa Incre
ult ment
1103 Safety gate 0 0 1 1 Bool
# 1103 – Safety gate

Indicates if there is a safety gate on the application.
Value Function
0 No safety gate
1 Safety gate present
Parameter 1106 - Sensor for top position
Defa Incre
ult ment
1106 Sensor for top position 0 0 1 1
#1106 - Sensor for top position

Indicates whether there is a sensor for fork top position mounted at the top
Value Function
0 The truck has no sensor for top position
1 The truck has a sensor for fork top position
Parameter 1107 - Steering
Defa Incre
ult ment
1107 Steering 0 0 1 1
Parameter 1107 - Steering

Specifies what type of steering the truck is equipped with.
Value Function
0 Manual control
1 Power steering
© Cesab 5 – 50 T Code(s): 1010

Parameter 1108 - Truck type (Model)
Defa Incre
ult ment
1108 Truck type 0 0 3 1
#1108 - Truck type (Model)

Indicates what type of truck (speed) is current for this application
Value Function
0 6 km/h
1 8 km/h
2 10 km/h
3 12.5 km/h
#1108 - Truck type (Model)

This parameter is set automatically for trucks types with only model. For
trucks with several models, this parameter must agree with parameter 1001,
otherwise error code 2.503 will be generated.
Value #1001 Model #1108

0 Unknown truck type
0
2 LPE200 1
2
1
3 LPE220
2
4 LPE250 3
5 (Not applicable)
© Cesab 5 – 51 T Code(s): 1010

Value #1001 Model #1108


© Cesab 5 – 52 T Code(s): 1010

Parameter 1110 – Reset voltage for BDI
Defa Incre
ult ment
1110 BDI 24.8 25.2 27.0 0.1 V
#1110 – Reset voltage for BDI

After the battery is charged to full capacity, BDI is reset to 100% provided that
battery voltage comes up to the pre-programmed reset value. If the reset
voltage value is not reached, it could be due to a voltage drop between the
battery and the logic card.
In case of reset problems:
• Charge the battery to full capacity following the instructions in the
operator's manual.
• Then drive the truck for at least 25 seconds before logging out.
• BDI is only set to 100% if the battery has been disconnected/reconnected.
• Check the voltage across the battery compared to the voltage between
wires 20 and 40 on the tiller arm logic card (A5)
• A voltage drop between the battery and the logic card (A5) could be
caused by poor contacts/connections or a loose connection in the battery
connector.
Parameter 1111 - Platform
Defa Incre
ult ment
1111 Platform 0 0 4 1
#1111 - Platform
Indicates the type of platform fitted to the application.
Value Function
0 No platform
1 Platform (folding up)
2 Platform (staying down)
3 Platform (backrest)
4 Platform (built in)
© Cesab 5 – 53 T Code(s): 1010

Parameter 1113 - Overhead guard
Defa Incre
ult ment
1113 Protective overhead guard 0 0 1 1 Bool
#1113 - Overhead guard

Indicates if there is a overhead guard on this application.
Value Function
0 No overhead guard
1 Protective overhead guard
Parameter 1115 – Cooling fan
Defa Incre
ult ment
1115 Cooling fan 0 0 1 1 Bool
# 1115 – Cooling fan

Indicates if there is a cooling fan on this application.
Value Function
0 No cooling fan
1 Cooling fan
© Cesab 5 – 54 T Code(s): 1010

5.7 Calibration parameters
5.7.1 Overview
See section "5.8 Calibration". for calibration instructions.
Par. Description
1251 Steering motor calibration
1252 Steering motor potentiometer
1253 Steering offset
1271 Start value for load weight
1272 End value for load weight
© Cesab 5 – 55 T Code(s): 1010

Parameter 1251 - Steering motor calibration
Defa Incre
ult ment
Steering motor calibration
1251 -1000 0 1000 1 mV
Analogue offset/mV
Parameter 1251 - Steering motor calibration

Offset adjustment of analogue setpoint for steering. Value set during calibration.
Parameter 1252 - Steering motor potentiometer
Defa Incre
ult ment
Steering motor calibration
1252 4000 5000 6000 1 mV
Checksum/mV
Parameter 1252 - Steering motor potentiometer

Sum of the analogue steering potentiometers' inputs. Value set during calibration.
Parameter 1253 - Steering offset
Defa Incre
ult ment
Steering offset
1253 -300 0 300 1 °/10
Calibration/(degrees/10)
Parameter 1253 - Steering offset

Fine adjustment of steering (zero)
-300: 30 degrees to the left
300: 30 degrees to the right
© Cesab 5 – 56 T Code(s): 1010

Parameter 1271 – Start value for load weight
Defa Incre
ult ment
1271 Start value for load weight 0 500 1499 1 mV
Parameter 1271 – Start value for load weight

Indicates the start value for load weight in mV. Value set during calibration.
Parameter 1272 – End value for load weight
Defa Incre
ult ment
1272 End value for load weight 1500 1500 3500 1 mV
Parameter 1272 – End value for load weight

Indicates the end value for load weight in mV. Value set during calibration.
© Cesab 5 – 57 T Code(s): 1010

5.8 Calibration
No. Function
1 Steering
2 (Not applicable)
3 Weight calculation
4 (Not applicable)
5 (Not applicable)
6 Weight calculation
© Cesab 5 – 58 T Code(s): 1010

5.8.1 Steering angle calibration “1”

The calibration function is used for calibration of the steering angle (steering
angle potentiometer). Calibration sets the centre position of steering (straight
ahead). The CAN service key must be connected in order to perform
calibration.
The following situations may require this calibration to be done.
• When the steering angle potentiometer has been disconnected or
replaced.
• The truck does not steer straight ahead when the steering unit points
straight ahead. May also require adjustment of parameter 1253.
• Display of error code 5.582 or 5.586.
Before carrying out this calibration, check that the reference sensor (B17)
works and is correctly set.
Method
1. Place the steering unit in the straight-ahead position and maintain this
position.
2. Ensure that the truck is switched off. Connect the CAN key.
3. Press and then release the horn button. “Info“ is shown on the display.
4. Turn the speed control several times until “CAL” is shown on the display. The
parameter symbol lights.
5. Press the horn button to select.
6. Turn the speed control to move between the calibration modes.
7. Press the horn button to select steering motor calibration, "1".
8. In calibration mode, “push” will be shown on the display until you press one
of the two horn buttons.
9. “Done” is shown on the display. The setting has now been stored.
10. Switch off the truck by pressing the OFF button.
If the actual steering position must be “trimmed” (fine-tuned), see parameter
#1253.
The calibration process affects the following parameters:
• Analogue offset (parameter 1251)
• Checksum (parameter 1252)
These parameters must not be adjusted manually after calibration.
5.8.2 Calibration “2” (Not applicable)
© Cesab 5 – 59 T Code(s): 1010

5.8.3 Calibration of weight measuring "3"
Method
1: Ensure that the truck is switched off. Connect the CAN key.
3: Turn the speed control several times until “CAL” is shown on the display.
The parameter symbol lights.
4: Press the horn button to select.
5: Turn the speed control to move between the calibration modes.
– Calibrate weight measuring "3"
If there is no menu "3" it due to the fact that there is no pressure sensor on
this truck model, and therefore a calibration is not needed.
7: Make sure there is not load on the forks, press the horn button and keep
it pressed until the first lifting/lowering sequence is over.
8: Use the speed control to select the weight for the load for which you are
calibrating. Press the horn button to select. Move the steering arm to the
neutral position, move it down and enter the fork under the load.
Minimum 1000kg and maximum 2500kg.
9: Press the horn button again, and keep it pressed until the sequence is
done, and that "donE" is displayed.
10: The calibration is now complete.
© Cesab 5 – 60 T Code(s): 1010

5.8.6 Calibration of weight measuring "6"

This calibration is only carried out when the battery is not mounted in the
truck.
Method
1: Ensure that the truck is switched off. Connect the CAN key.
3: Turn the speed control several times until “CAL” is shown on the display.
The parameter symbol lights.
5: Turn the speed control to move between the calibration modes.
– Calibrate weight measuring "6"
If there is no menu "6" it due to the fact that there is no pressure sensor on
this truck model, and therefore a calibration is not needed.
7: Set the value/weight of the battery. Use the speed control to select the
weight of the battery. Press the horn button to select.
8: Make sure there is not load on the forks, press the horn button and keep
it pressed until the first lifting/lowering sequence is over.
9: Use the speed control to select the weight for the load for which you are
calibrating. Press the horn button to select. Move the steering arm to the
neutral position, move it down and enter the fork under the load.
Minimum 1000kg and maximum 2500kg.
10: Press the horn button again, and keep it pressed until the sequence is
done, and that "donE" is displayed.
11: The calibration is now complete.
© Cesab 5 – 61 T Code(s): 1010

© Cesab 5 – 62 T Code(s): 1010

Repair manual: Installation and commissioning Model(s): P320, P322
6. Installation and commissioning

This chapter describes the work that is necessary before the truck can be put
into use.
6.1 Transporting the truck

When transporting the truck on a lorry or the like, the truck must be properly
anchored with stropping (A). Use inserts and sheets of shock-absorbing
material to prevent damage to the truck during lashing and transport.
6.2 Transporting the fork carriage

When transporting the fork carriage alone, you must properly anchor all loose
parts. Cables and any hoses must be secured so they cannot come loose or
be damaged. The entire fork carriage must then be anchored on a load pallet
or another suitable support for transport.
© Cesab 6– 1 T Code(s): 1010

6.3 Lifting the truck
6.3.1 Lift using an eye bolt

When lifting the whole truck, use an eye bolt that is screwed into the hole
marked in front of the tiller arm.
Eye bolt: M20

LT Class 8
© Cesab 6– 2 T Code(s): 1010

6.3.2 Lift using a jack

Select the lifting point so that the lift is as light as possible, for example one
corner at a time. The whole rear frame can be used for lifting with a jack.
Make sure the surface where the jack is placed is clean and free of oil and
grease.
Make sure your hands and the jack lever are free of grease and oil.
Only use the lever supplied with the jack. If the lever is too short, more
exertion than is necessary will be required. If the lever is too long, there is a
risk that the jack will be overloaded.
WARNING!
Risk of tipping.
The truck may tip over if it is lifted incorrectly.
Always lift the truck when it has been fastened to the forks of the lifting truck
and its centre of gravity between the forks.
• Only lift the truck at the indicated lifting points using suitable lifting
equipment.
WARNING!
Risk of tipping.
The truck may tip over if it is lifted in the wrong places.
Always lift the truck in the indicated lifting points.
© Cesab 6– 3 T Code(s): 1010

6.4 Battery installation
6.4.1 Safety for battery handling

Keep the following safety precautions in mind when working with the battery.
• Always use safety equipment to protect the eyes, face and skin while
checking or handling batteries.
Note:
Parameter 107 must always be checked and adapted to the battery installed
in the truck. The parameter setting depends on battery type, truck type,
battery size and the truck application.
Note:
Only change to a battery that complies with the data given on the truck
identification plate. The weight of the battery affects the stability and braking
capacity of the truck. Information on the minimum permitted battery weight is
on the truck identification plate.
DANGER!
Risk of moving the centre of gravity.
A battery weight that is too low gives impaired stability and braking capacity.
The battery weight must be in accordance with the information on the truck’s
identification plate.
DANGER!
Battery acid causes burns. If battery acid gets onto your skin or clothes,
immediately flush the area with cold water. If you get battery acid in the face
or the eyes, flush the area with cold water and immediately seek medical
assistance.
• Ensure there is a shower and an eye bath nearby in case an accident
happens.
• Batteries generate explosive gases. Never use an open flame or other
sources of ignition in close vicinity to a battery.
• Do not place tools or other metal objects on the battery. This can cause a
short-circuit and even an explosion.
• Gel batteries are only intended for use at room temperature within the
interval +15 to +30°C. Otherwise, there is a risk of the battery being
damaged or its service life being shortened.
© Cesab 6– 4 T Code(s): 1010

6.4.2 Installing the battery

DANGER!
To prevent the battery from falling down when it is released from the lifting
device, prepare trestles or other suitable supports of the right height to
support it. Check the height of the supporting material before releasing the
lifting hook.
The battery to be installed in the truck must be the right size. If the battery is too
small in terms of size and weight, it can seriously affect the truck's braking ability
and truck stability when lifting goods. See the truck's identification plate for the
correct battery data.
1: Park the truck, and open the battery door.

2: Lift the battery into place using an approved lifting device and a suitable
battery lifting yoke or lifting loops. Check that the cables are not pinched
when the battery is lifted into place. Use a battery changing table if
changing the battery from the side.
3: Fit the battery lock.
4: Check the electrolyte level. Top up with deionized water as necessary.
5: Connect the battery cables/battery connector.
DANGER!
Check that the polarity is correct when connecting the battery cables.
Compare the markings on the cables with those on the battery terminals. An
incorrectly connected battery may cause short-circuiting.
6: Close the battery compartment cover.
7: Check or set the battery parameters. Page 5–11
© Cesab 6– 5 T Code(s): 1010

6.5 Using PIN codes
6.5.1 General
PIN codes can be used e.g. to link different operator experience levels to
specific truck characteristics – Operator profiles.
Operator parameters can be adjusted individually for up to ten different
operator profiles.
The PIN codes are organised in blocks and profiles. Each block can hold ten
operator profiles, each with its own PIN code.
In order to use the PIN codes in a block, the block must first be activated.
By default, block 0 (zero) is always active, which means that the truck has 3
ready-to-use operator profiles from the beginning. Page 6–9
PIN codes can be activated or changed according to the preferences of the
operator. An operator profile is activated upon normal log-in by all PIN codes
whose block number is activated.
6.5.2 PIN code for resetting after a collision

If the truck has stopped as a result of a collision, it needs to be reset by
entering a special PIN code. This PIN code must be programmed by a
service technician during installation. Page 6–8
The PIN code to be activated can be found in operator profile 1 and special
block 10. The default value of the PIN code is 0000. This must be changed to
the PIN code selected by the service technician.
Note:
The PIN code cannot contain the same combination of digits as any of the
other programmed PIN codes.
With parameter #111, it is possible to change how reset after collision is
carried out. Page 5–15
© Cesab 6– 6 T Code(s): 1010

6.5.3 Programming PIN codes

Note:
There are two possible methods for programming PIN codes.
The first and the simplest is to use TruckCom, which provides clear
instructions.
The other alternative is to use the truck keypad.
If the truck is configured to handle PIN codes, 100 different PIN codes can be
programmed.
The first time a block is activated, all PIN codes in the block are set to “0000”.
If a block with PIN codes not set to “0000”, is deactivated and later
reactivated, the PIN codes with other values than “0000” will again be valid.
Use of PIN code “0000” is permitted, but it means that the position is
deactivated. It is never possible to log in with PIN code “0”.
The truck program stores a standard set of PIN codes as indicated in the
table in the section “PIN code defaults”.
Note:
The truck program will not accept attempts to program PIN codes that have
already been set. The previous code will be restored.
When a PIN code is programmed, there is a check to ensure that it is not used
elsewhere in the table, regardless of whether the block is active or inactive.
The PIN code setting menu is used for managing PIN codes; the menu can
only be accessed when a service key is connected.
© Cesab 6– 7 T Code(s): 1010

To start programming, proceed as follows:
1. Ensure that the truck is switched off. Connect the CAN service key to
connector [X41]. Enter the PIN code.
3. Turn the speed control several times until “Pin” is shown on the display.
4. Press and then release the horn button to select.
5. Select programming commands from the table below:
Function Programming Comments
Blocks 1-9 are
deactivated. The original
PIN codes are reset
Restore factory settings. Press 1 + ON button
according to the Default
assignment of PIN codes
table.
b = Block 0-9
Upon activation of a PIN
Activate a new PIN
Press 2 + b + ON button code's block, the codes
code's block.
already stored become
available again.
b = Block 0-9
No codes will be deleted.
Deactivate a PIN code's
Press 3 + b + ON button They will be available
block
again when the PIN code's
block is reactivated.
Press 4 + b + P + NNNN + ON button
b = Block 0-9
Note:
P = Operator profile 1-10
The block that should apply must first be activated (see
NNNN = PIN code
function 2 in the table above).
Note:
Programming a new If the PIN code is correct, the code is shown for 3 seconds,
It is only possible to assign
PIN code followed by the text "donE" for 2 seconds. It is possible to
one digit to an operator
enter a new PIN code within these 5 seconds by pressing a
profile. As a result,
key on the keyboard.
operator profile 10 should
If the PIN code is wrong, the display shows “Err”. If you press
be assigned as 0 (zero).
the red button, the new PIN code is not saved.
PIN code programming
for truck reset after Press 6 + NNNN + ON button NNNN = PIN code
collision
6. Switch off the truck by pressing the OFF button.

PIN code programming is now complete. Verify that programming has been
done correctly by logging in using one of the new PIN codes.
For PIN code management via TruckCom, refer to the TruckCom manual.
Note:
It is important to ensure the correct operator profile is activated when a
specific PIN code is entered. This is especially important when an operator
profile has been set to apply for a specific truck application.
© Cesab 6– 8 T Code(s): 1010

6.5.4 PIN code defaults

The PIN codes are factory set so that only block 0/operator profiles 1 – 9 are
activated.
Note:
Service personnel are urged to keep notes on activated blocks, changed
PIN codes and special operator profile settings.
Default assignment of PIN codes
Operator 10
Note:
profile 1 2 3 4 5 6 7 8 9
Entered
no. as 0
Block 0 0001 0002 0003 0004 0005 0006 0007 0008 0009 0000
Block 1 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 2 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 3 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 4 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 5 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 6 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 7 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 8 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 9 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 10 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
The factory-set operator profiles are classified as follows:

Profile Characteristic Remarks
1 Standard profile –
2 Beginner profile –
Operator parameters set to
3 Advanced profile
max. values
© Cesab 6– 9 T Code(s): 1010

6.6 Setting parameters

This chapter covers only those parameters that need to be set upon
commissioning of the truck and which, as a result, require a more detailed
description. For information about other parameters, refer to the chapter
“Parameters”
Check to make sure all parameters are set to the desired values in terms of
• speed - Page 5–3
• acceleration - Page 5–3
• deceleration - Page 5–3
• collision sensor - Page 5–10
• battery - Page 5–11
Note:
When checking or setting parameters, remember to note down the truck's
specific parameter values, for example in a truck report. This separate
information on truck-specific parameters can come in handy, e.g. in case of
downtime, since the information is not available elsewhere.
6.6.1 Setting collision sensor parameters (option)

Collision sensitivity parameters must be set during truck installation.
If there is a collision sensor installed on the CAN bus, it registers when the
truck bumps into something. If a collision exceeds a certain force, set by
parameters 105 and 106, it is interpreted as a collision, and the truck travel
speed is reduced to creep speed, a signal is heard and error code 8.001 is
displayed.
Information about the collision is stored in the truck's internal memory. The
last ten registered collisions can be read directly from the display together
with operator identity via the PIN code. Additional information is available via
TruckCom, where collision levels and time indications can also be read.
6.6.2 Setting battery parameters

The following parameters must be set or checked on battery installation.
Note:
Even if the battery comes with the truck from the factory, the parameters
must be set or checked.
See section " # 107 - Battery size".
© Cesab 6 – 10 T Code(s): 1010

6.7 Function check
c a b a b c
j d
l
k m
h
f
Prior to putting the truck into use/after service, check the following items:
Pos. Inspection point Procedure
a Operating control Check functionality
b Hydraulic functions Check functionality
c Horn Check functionality
d Steering Check functionality
e Platform Brake switch Check functionality
f Brakes Check functionality
g Chassis Inspect for any damage, remove dirt etc.
h Wheels Inspect for any damage, remove dirt etc.
i Fork carriage Inspect for any damage, remove dirt etc.
Check that the sensor is correctly set and that it
j Lift height limit sensor disconnects before the lift strikes the mechanical
stop.
k Battery Inspect the battery acid level and charge level
l Battery locking Check functionality
m Emergency switch off Check functionality
© Cesab 6 – 11 T Code(s): 1010

© Cesab 6 – 12 T Code(s): 1010

Repair manual: Maintenance Model(s): P320, P322
7. Maintenance
7.1 Introduction
To maintain a high level of truck safety and to minimise downtime, all the
points specified in the service programme must be carried out.
The intervals specified are those that fulfil the truck manufacturer's
requirements for a truck used in standard applications. The local operating
environment may require service intervals that differ from those specified.
Once a truck's service intervals have been determined, the hour recorder is
primarily used for determining when servicing is to be carried out.
To maintain truck safety, only spare parts approved by the truck manufacturer
may be used for servicing and repairs.
During the truck's warranty period: If repairs/servicing have been carried

out by non-authorised personnel, or if non-approved spare parts are used,
the truck warranty ceases to be valid.
7.2 Maintenance instructions
7.2.1 Cleaning and washing

Cleaning and washing the truck is an important factor in maintaining truck
reliability.
• Carry out general cleaning and washing each week.
Note:
Risk of short circuiting.
Risk of damage to the electrical system.
Disconnect the battery before washing by pulling out the battery connector.
© Cesab 7– 1 T Code(s): 1010

7.2.2 High-pressure washers

High-pressure washers may only be used on metal surfaces.
Under no circumstances may high-pressure washers be used in the truck's
motor compartment.
When using a high-pressure washer, the jet must be directed in such a way
that it does not damage electric cables, electric sensors, hydraulic hoses or
decals.
Lifting chains, piston rods and end pieces of hydraulic cylinders, ball and
roller bearings – including those that are fully enclosed – must not be
exposed to the jet, as there is a risk that water may penetrate and cause
corrosion.
After washing with a high-pressure washer, all the truck bearings and chains
must be lubricated/greased as specified in the maintenance instructions.
7.2.3 Degreasing agents

When using degreasing agents, only environmentally-friendly cold
degreasing agents may be used, such as those that are designed for general
vehicle cleaning and do not damage paintwork, plastic components, cables,
hydraulic hoses or decals.
7.2.4 Cleaning the exterior

• Remove rubbish, etc. from the wheels daily
• Degreasing agents can be used as needed, in line with the previous
section.
• Rinse off loose grime using tepid water.
Note:
Seizing, corrosion.
Risk of damage to mechanical parts.
Once washed, the truck should be lubricated as set out in the maintenance
instructions.
© Cesab 7– 2 T Code(s): 1010

7.2.5 Cleaning the chain

We recommend you to replace a chain that is very dirty.
Dirty chains should be cleaned before they are lubricated, e.g. by washing
with solvent such as diesel or petrol.
The chain should be blown dry using compressed air and lubricated directly
after cleaning.
Note:
Exercise care with degreasing agents as these can contain abrasives.
7.2.6 Cleaning the motor compartment

• Cover electric motors, connectors and valves prior to washing.
Note:
Risk of damage to the electrical system.
Electrical components must not be washed with high-pressure washers.
• Clean the motor compartment using a well-known degreasing agent,
diluted to a suitable concentration
• Rinse off loose grime using tepid water.
7.2.7 Electric components

• Clean electric motors using vacuum cleaner or a rag.
• Clean electric panels, logic cards, contactors, connectors, magnetic
valves, etc. with a rag moistened with water and a suitable detergent.
Note:
Risk of damage to electrical components.
Do not break the warranty seals on the logic cards.
© Cesab 7– 3 T Code(s): 1010

7.3 Oil and grease specification
Specification 1000 3000

Lubricant type
> -15°C < -15°C
B Hydraulic oil See table below See table below X
Synthetic base hypoid oil
C Transmission oil SAE 75W-90 X1
Class API-GL5
D Grease See table below See table below X
Grafloscon Grafloscon
E Grease X
A-G1 (Klüber) A-G1 (Klüber)
F Grease Gletmo 805 Gletmo 805 X
F Grease Rembrandt EP2 Rembrandt EP2 X
1. The drive gear oil is only replaced during the first 1000-hour service.
Ambient
Pos. Viscosity class Usage
temperature
ISO VG 32
B 0°C-40 C ° ISO 6743-4 category HM Hydraulic system
DIN 51524 part 2 = HLP
ISO VG 27.5
B -35°C-40°C ISO 6743-4 category HV Hydraulic system
DIN 51524 part 3 = HVLP
Ambient
Pos. Viscosity class Recommended products*
temperature
> -40°C
D VG 15 Klüberoil 4UH 1-15, Klüber Lubrication
< -30°C
> -30°C Klüberoil 4UH 1-68N, Klüber Lubrication
D VG 68
< +5°C Anticorit LBO 160 TT, Fuchs DEA
Klüberoil 4UH 1-150N, Klüber Lubrication
> +5°C
D VG 150 Anticorit LBO 160, Fuchs DEA
< +45°C Rexoil, Rexnord Kette
> +45°C
D VG 220 Klüberoil 4UH 1-220N, Klüber Lubrication
< +80°C
© Cesab 7– 4 T Code(s): 1010

7.4 Symbols
Symbol Procedure Symbol Procedure Symbol Procedure

Visual inspection of
Component
condition, wear and Listening for noise.
replacement.
loose connections.
Cleaning Measurement Check of functions.
Check of fluid level and Check tightening of

Lubrication, application.
check for leaks. bolts, nuts, etc.
© Cesab 7– 5 T Code(s): 1010

© Cesab 7– 6 T Code(s): 1010

7.5 Periodic maintenance

DANGER!
Risk of personal injury and material and property damage.
Note: For trucks with power steering, the truck battery must be disconnected
when working on the drive gear/ drive wheel. The drive wheel will automatically
return to the original position when the truck is started.
© Cesab 7– 7 T Code(s): 1010

1
Pos 1 Pos 2 Pos 3
Pos 4 Pos 5 Pos 6
Pos 7 Pos 8 Pos 9

1000
Pos. Type Point Instruction Procedure 3000 h2 OK
h1
Preparation Pick up the truck
Check that the truck functions normally. Instructions at

1 Operator controls X
Page 6–11
Page 11–9
2 Drive gear Listen for abnormal noise in the drive gear bearing X
Page 11–12
3 Motor Listen for abnormal noise in the motor bearing Page 10–12 X
Check the photo cell (built-in) to ensure it cuts out if a foot is

4 Photo cell, built-in Page 14–32 X
outside the platform.
Raise the forks to the top.
Lift the truck and support it on trestles so that the wheels are
Preparation in the air.
Switch off the truck and pull out the battery connector.
Remove the platform.
Replace
5 Platform Inspect the platform for crack formation and other damage. X
Page 9–55
6 Chassis Inspect the chassis for crack formation and other damage. X
Replace seal
7 Drive gear Check the drive gear for leaks X
Page 11–14
Replace
8 Drive gear Change the drive gear oil3 Page 11–7 X
Page 11–10
9 Drive wheel Clean the drive wheel from strings and other dirt X
Continued...
1. Every 1000 hours
2. Every 3000 hours
3. Note: The drive gear oil is only replaced during the first 1000-hour service.
M
Pos 10 Pos 11 Pos 12

1000 3000
Pos. Type Point Instruction Procedure OK
h1 h2
Check that the drive wheel is not worn.
10 Drive wheel Drive wheel D = 230 min. size 15mm Page 12–14 X
Drive wheel D = 250 min. size 12,5mm
11 Drive wheel Torque tighten the wheel bolts M12=83Nm, M14=135Nm X
12 Castor wheel Clean the castor wheel from strings and other dirt X
Check that the castor wheel is not worn.

Castor wheel D = 150 Single min. size 10mm
Page 12–18
13 Castor wheel Castor wheel D = 150 TWIN min. size 10mm X
Page 12–20
Castor wheel D = 125 TWIN min. size 5mm
Castor wheel D = 125 Single min. size 7.5mm
Check that the castor wheel is properly attached and that it Replace
14 Castor wheel X
rotates and pivots freely. Page 12–17
Replace
15 Fork wheels Check the fork motor's attachment. X
Page 12–22
16 Linkage Check that the wheel fork can move back and forth Page 9–18 X
17 Fork wheels Clean the fork wheels from strings and other dirt X
Check that the fork wheels are not worn.

18 Fork wheels X
Fork wheels D = 85 min. size 5mm
Continued...
1. Every 1000 hours
2. Every 3000 hours
Pos 22 Pos 23
Pos 24

3000
Pos. Type Point Instruction Procedure 1000 h1 OK
h2
Replace
19 Wheel fork Check that the bushings in the wheel fork are not worn out X
Page 12–27
20 Linkage Inspect the linkage for crack formation and other damage. X
Inspect the fork carriage for crack formation and other

21 Fork carriage X
damage.
22 Beams, chassis Lubricate the beams. Lubricant F. Page 7–4 X
Replace
Check that the height adjuster runs freely and the gas spring
23 Tiller arm: Page 13–54 X
is able to bear the weight of the tiller arm.
Page 13–53
24 Truck traction Clean the drive motor. Instructions on Page 10–25 X
25 Brakes Clean the brakes, wipe with a rag. Instructions on Page 7–1 X
Check that the brakes are fitted tightly. Instructions on

26 Brakes X
Page 12–8
Clean the inside of the brake. Use compressed air to carefully
27 Brakes blow away the brake dust inside the brake. Instructions on X
Page 7–1
Continued...
1. Every 1000 hours
2. Every 3000 hours
M

Procedur 3000
Pos. Type Point Instruction 1000 h1 OK
e h2
Cooling flange, Clean the heatsink of the electric panel by blowing carefully
28 X
electric panel with compressed air Instructions on Page 7–1
Measuring the air gap 30 Nm. 0.15-0.5 mm between the Replace

29 Brakes X
pressure disc and the magnet housing. 21 Nm. 0.15-0.65 mm Page 12–7
30 Steering motor Clean the steering motor. Instructions on Page 7–1 X
Clean the electric panel, wiping it with a rag. Instructions on

31 Electric panel: X
Page 7–1
Check that there is no leakage from hydraulic hoses and hose

32 Hydraulic system X
couplings.
Replace
33 Lift cylinder Inspect the air cylinders for leaks Page 15– X
24
Replace
34 Lift cylinder Check the attachment of the air cylinders Page 15– X
24
Check the steering motor's attachment.
35 Steering motor X
Tightening torque 26 ± 3 Nm.
36 Steering motor Check that the steering motor is not damaged. X
Continued...
1. Every 1000 hours
2. Every 3000 hours

Pos. Type Point Instruction Procedure 1000 h1 3000 h2 OK
Check the drive motor's attachment.
Drive motor 1.8/2.5 KW T=7±1 Nm, to be done cross-wise in 2
37 Truck traction steps X
Drive motor 2.5 KW T=9.5 Nm, to be done cross-wise in 2
steps
38 Truck traction Check that the drive motor is not damaged. X
39 Truck traction Check the speed sensor's attachment. X
40 Drive gear Check the drive gear's attachment. X
41 Electric panel: Check the electric panel's attachment. X
Motor mounts Inspect the engine mounts/PowerTrak for crack formation and Replace
42 X
PowerTrak other damage. Page 9–31
43 Electric panel: Inspect the contactor electrical connections X
44 Electric panel: Inspect the cable connections on the electric panel. X
Check all wiring harnesses (including their attachment

45 Wiring harness devices and contacts) for wear, damage and proper X
attachment.
Continued
1. Every 1000 hours
2. Every 3000 hours
Pos 52
Pos 53 Pos 54
1000 3000
h1 h2
46 Truck traction Inspect the cable connections of the drive motor. X
47 Steering motor Inspect the cable connections of the steering motor. X
Steering motor Replace

48 Inspect the steering motor pinion X
pinion Page 10–9
49 Gear ring Carefully clean the gear ring. (Power steering, option) X
Lubricate the gear ring (Power steering, option) Lubricant E

50 Gear ring X
Page 7–4
Lower the truck to the ground and connect the battery
connector
Preparation
Lower the forks and relieve the pressure in the hydraulic
system
Replace
51 Hydraulic system Change the hydraulic oil, Lubricant B Page 7–4 X
Page 15–10
52 Hydraulic system Clean the tank, instructions at Page 7–1 X
Replace
53 Tank Inspect the tank for crack formation and other damage. X
Page 15–9
Replace
54 Hydraulic system Clean the tank, instructions at Page 7–1 X
Page 15–16
Continued...
1. Every 1000 hours
2. Every 3000 hours

1000 3000
h1 h2
55 Hydraulic system Replace the oil filter, instructions at Page 15–16 X
Battery
Check that the battery complies with the truck specification,
56 Battery X
see the serial number plate
Inspect the connections of the battery (T=25±2 Nm), truck and

57 Battery X
charger.
Inspect the battery wiring harness/cable protection between

58 Battery X
the fork carriage and chassis. Replace if damaged.
Check the electrolyte level. Top up with deionized water as

59 Battery X
necessary.
60 Battery Verify that the cell and pole protectors are not damaged. X
61 Battery Check the fluid density and temperature X
62 Battery Clean the battery. X
Inspect the battery lock; shim the rubber lugs until they lock
63 Battery locking X
the battery. Page 9–29
Continued
1. Every 1000 hours
2. Every 3000 hours

Procedur 1000
Pos. Type Point Instruction 3000 h2 OK
e h1
Subsequent checks
DANGER!
Note: For trucks with power steering, the truck battery
must be disconnected when working on the drive gear/
drive wheel. The drive wheel will automatically return to
the original position when the truck is started.
64 Fork carriage Check the lateral play of the fork carriage at the rollers X
Check the operation of the brake microswitch in the upper

Page 13–
65 Tiller arm: and lower brake positions. The lower position means that you X
32
have to press down to activate the switch.
Page 13–
66 Tiller arm: Check the play and return travel in the tiller arm. X
15
67 Operator controls Check the function of the safety reversing Page 14–22 X
68 Platform Check for correct operation of the platform switch Page 9–66 X
Page 9–89
69 Gate Check the function of the gate switch X
Page 9–90
70 Fork carriage Check that the fork lift height limiter functions X
71 E-bar Check the locking of the E-bar X
72 Display Inspect the error log and operating hours. Page 14–4 X
Continued
1. Every 1000 hours
2. Every 3000 hours
Pos 73 Pos 74
Procedur 1000 3000
Pos. Type Point Instruction OK
e h1 h2
Replace
Inspect all signs and adhesive labels to ensure they are intact.
73 Adhesive labels adhesive X
See section "9.7 Signs, warnings, labels C0850".
labels.
74 Operator controls Check the operation of the operator controls Page 8–81 X
End
1. Every 1000 hours
2. Every 3000 hours
© Cesab 7 – 26 T Code(s): 1010

Repair manual: Troubleshooting Model(s): P320, P322
8. Troubleshooting
If the error cannot be remedied through troubleshooting, contact the supplier
for more information.
8.1 Towing a defective truck

The towed truck shall always have an operator who can steer and apply the
brake when towing using a tow-truck and tow-rope.
Always remove the load before towing or transporting the truck to the
specified repair site.
Tow or transport a defective truck as follows:
• Start the truck, move the tiller arm to the drive position and push the truck
by hand.
DANGER!
The truck can start to roll when the parking brake function is disabled.
Never leave the truck with the parking brake disconnected, chock the wheels
in a satisfactory manner.
Tow using a tow truck and tow wagon:
1. Lift the truck onto the tow wagon. See the instructions under Lifting a
truck.
2. Connect the truck to the wagon.
3. Drive with care.
4. Lift off the truck according to the instructions under Lifting a truck.
© Cesab 8– 1 T Code(s): 1010

8.2 Auxiliary functions
8.2.1 Emergency driving mode

If the truck for some reason stops operating and remains immobile in an
unsuitable place, it is possible to active the emergency travel mode to move
the truck out of the way (max. 1.3 km/h). In this mode, it is possible to lower
and lift the forks.
1. Ensure that the truck is switched off. Enter your PIN code.
3. Turn the speed control several times until “Ed” is shown on the display.
5. All lamps flash and “SLO” is shown on the display.
It is now possible to drive the truck, but exercise extreme caution. It is not
possible to brake suddenly by raising the steering unit.
If the truck is on an incline, be even more careful when using the emergency
travel mode. If you apply too much throttle, there is a risk the truck will roll
away. To stop the truck, turn the sped control in the opposite drive direction.
NOTE:
Some errors block emergency travel mode. You then cannot obtain
information on the error.
© Cesab 8– 2 T Code(s): 1010

8.3 Error code history

Up to 50 of the most recent error code events can be stored in a log along
with the hour meter reading when the error occurred. The error code log
displays error codes in chronological order starting with the most recent error
code.
The 10 latest error codes show extended information if you look at them in
TruckCom. See section "8.3.1 Extended error log".
Do as follows to display the error code log:
1. Ensure that the truck is switched off. Connect the CAN key or enter the
3. Press and then release the horn button to select the "Info" menu.
4. Turn the speed control several times until “E” is shown on the display.
The error code symbol lights up.
6. The most recent error is then displayed. The display alternates between
the error code and the hour counter reading when the error occurred. If
the error code log contains more than one error code, the codes can be
displayed by repeatedly pressing the speed control.
7. Switch off the truck by pressing the OFF button or return to the previous
menu by selecting "ESC".
The display of error code history is now complete.
© Cesab 8– 3 T Code(s): 1010

8.3.1 Extended error log

The 10 latest error codes in the error code log contain extended information.
Data 1, 9-15 only for the manufacturer. Access to the error log is through
TruckCom.
Data Description Resolution Unit Standard value

Motor, hydraulic control and machine
1 - -
status
2 Battery voltage 1 mV
3 True speed 0.1 km/h
4 Motor temperature 1 °C
5 Temperature [T1] ACT/ACC 1 °C
6 Signal from pressure sensor 1 mV
7 Signal from PowerTrack sensor 1 mV
Difference between the set angle of Only for trucks with
8 5.493E-3 °
the servo and the true one servo
Only for trucks
8 Signal from steering angle sensor 1 mV
without servo
9 Signal to [T1] ACT/ACC Only data for Cesab
10 Signal from [T1] ACT/ACC Only data for Cesab
11 Signal to servo Only data for Cesab
12 Signal from servo Only data for Cesab
13 Generic data depending on error type Only data for Cesab
© Cesab 8– 4 T Code(s): 1010

8.4 Error code system

See the tables below for an explanation of the error code system.
Structure Description
X.YZZ Example: 3.510
X (3) Group. Indicates which truck system is affected by the
error.
YZZ (510) Sequential number
Group. Description
1 Not used.
2 Main Control Unit (A5)
3 Drive system
4 Hydraulic system
5 Steering system:
6 Not used.
7 Not used.
8 Option/auxiliary system
9 Not used.
© Cesab 8– 5 T Code(s): 1010

8.5 Error codes

Please note that some error codes are saved in the log and disappear from
the display, while other error codes remain on the display and require that the
truck be switched off and then on again for the error code to disappear.
Truck
Code Description Error cause(s) Procedure
behaviour
Parameters set 1: New software 1: Check parameters
to default has been
• Check that factory parameters
values. loaded in the
are set according to the truck
At start-up, it was truck, adding a
configuration.
detected that one new
or more parameter, or • Check that other parameters
2:002 parameters were Not influenced it has changed are set correctly.
not within the parameter 2: Replace A5:
acceptable limit values
intervals; they • See section "13.1.6 Replacing
2: Corrupt the logic card".
have therefore
memory A5
been reset to
default values
1: Copy the truck configuration
using TruckCom
1: Hardware (T1
• See the separate manual for
or A5) has
TruckCom.
been
Backup copies replaced. 2: Copy the truck configuration
do not match. using TruckCom
2: Software has
Backup copy in been updated • See the separate manual for
2:004 secondary unit Not influenced to an older TruckCom.
(T1) does not version
match data in 3: Replace T1
primary unit (A5) 3: Corrupt
• See section "14.7.2 Replacing
memory T1
the motor control".
4: Corrupt
4: Replace A5
memory A5
the logic card".
Everything is
stopped at • Create a truck report. Send a
once, the report to the manufacturer.
Internal Internal program
2:005 parking brake is
program error error A5 • Update the truck software to the
activated, and
the main latest version.
contactor opens
© Cesab 8– 6 T Code(s): 1010

Truck
behaviour
1: Connect the battery connector.
1: Battery 2: Check battery voltage
connector • Check the voltage using the
disconnected built-in test procedure and
from truck that comparing with value from
Saving to is started
memory failed. external volt meter
Saving to 2: Voltage loss • Check connectors, joints and
memory failed on supply to splices for damage or corrosion.
2:006 because low Not influenced A5
• Check fuses F1 and F50
battery voltage. 3: The battery is
Battery voltage defective 3: Inspect the battery.
below 15 V at the
4: Battery 4: Check parameters
time of saving
parameter • Check that factory parameters
#107 has an are set according to the truck
erroneous configuration.
value
• Check that other parameters
are set correctly.
• Create a truck report. Send a
Internal report to the manufacturer.
Internal program
2:007 program error Not influenced
error • Update the truck software to the
A5
latest version.
Internal program
A5
latest version.
Internal program
A5
latest version.
© Cesab 8– 7 T Code(s): 1010

Truck
behaviour
1: Check the CAN bus
• Check that CAN is intact in
terms of wiring harness,
resistance and connectors.
Disconnect the battery. Check
that the resistance between
(X41:3) and (X41:4) is 54 - 66
ohms.
• Check that the CAN wiring
harness is not pinched.
Measure resistance between
1: Error on CAN the chassis and CAN contact.
bus wiring or Limit value >24 kOhm
CAN connections 2: Check for loose connections
communication 2: Loose • Switch on the truck, and pull
warning. connections
2:010 Not influenced carefully in the branches of the
A5 has received
3: Defective CAN wiring harness to find any loose
too may
node connections, and note when/if
erroneous signals
the error code appears.
4: Software
failure 3: Check the CAN node
• Deactivate and disconnect the
option unit connected to the
CAN wiring (e.g. K110,B90,T14
and A36/A37). Activate and
then connect them one by one
to identify which unit produces
the communication error.
4: Update the truck software
• Update the truck software
package to the latest available
version.
New software.
New software
installed. In order
to look in the New software Logged in the error log to see
2:011 Not influenced
error code log to installed when the software was updated
see when new
software was
installed.
© Cesab 8– 8 T Code(s): 1010

Truck
behaviour
1: Create a truck report. Send a
report to the manufacturer.
Creep speed, 1: Internal
• Update the truck software to the
Internal blocked lifting/ program error
2:080 latest version.
program error lowering 2: Manufacturing
movement 2: Replace A5:
defect in A5
the logic card".
1: Check parameters
Configuration
error. Creep speed, • Check that factory parameters
Truck blocked lifting/ Incorrect value for are set according to the truck
2:102
configuration lowering parameter 1102 configuration.
does not match movement
parameter 1102
are set correctly.
Creep speed, • Create a truck report. Send a
Internal blocked lifting/ Internal program report to the manufacturer.
2:180
program error lowering error • Update the truck software to the
movement latest version.
1: Check the sensor signal
• Check that the distance
between the sensor and the
opposite part is correct.
• Check that there is no dirt or
foreign objects on the sensor
• Inspect cabling.
1: High signal
from both • Measure the signals from the
B119 and sensor with a volt meter and
Incorrect signal B120 verify using TruckCom or the
combination from built-in test that the signal is
2:281 Creep speed 2: Constantly
platform position correct
sensor. high signal at
inputs 2: Check the signal to the unit
(T1:101) and • Compare the signals from the
(T1:97) sensor with the input signal (use
a volt meter and verify using
TruckCom or the built-in test
that the signals are the same)
• Check the pins on the unit and in
the connector
• Replace the unit if you cannot
get it to work properly
© Cesab 8– 9 T Code(s): 1010

Truck
behaviour
1: Handling error - no action
1: Platform • Inspect cabling.

loaded • Measure the signals from the
The platform
sensor has been 2: Constantly sensor with a volt meter and
activated for more high signal verify using TruckCom or the
2:282 Creep speed built-in test that the signal is
than 5 minutes from B119
without any truck correct
activity. 3: Constantly
high signal at 3: Check the signal to the unit
inputs T1:101 • Compare the signals from the
sensor with the input signal (use
the connector
© Cesab 8 – 10 T Code(s): 1010

Truck
behaviour
1: High signal • Measure the signals from the
from both sensor with a volt meter and
Incorrect signal B121 and verify using TruckCom or the
combination from B122 built-in test that the signal is
2:284 Creep speed
the gate position 2: Constantly correct
sensor high signal at 2: Check the signal to the unit
inputs (T1:88)
and (T1:96) • Compare the signals from the
sensor with the input signal (use
the connector
1: Charge the battery.
2: Check battery voltage
1: The battery is • Check the voltage using the

discharged built-in test procedure and
comparing with value from
2: Voltage loss external volt meter
Everything is
on supply to
A5 • Check connectors, joints and
Low battery voltage stopped at once,
splices for damage or corrosion.
below 16.8 Volts for the parking brake 3: The battery is
2:501
more than 2 is activated, and defective • Check fuses F1 and F50
seconds the main
contactor opens 4: Battery 3: Inspect the battery.
parameter 4: Check parameters
#107 has an
erroneous • Check that factory parameters
value are set according to the truck
configuration.
are set correctly.
© Cesab 8 – 11 T Code(s): 1010

Truck
behaviour
1: A5 is replaced using TruckCom
and/or • See the separate manual for
Everything is erroneous TruckCom.
stopped at once, value for
Truck type not set
the parking brake factory 2: Check parameters.
2:502 Parameter 1001 is
is activated, and parameters
incorrectly set
the main
contactor opens 2: Incorrect value are set according to the truck
for parameter configuration.
1001 • Check that other parameters
are set correctly.
1: A5 is replaced using TruckCom
and/or
erroneous • See the separate manual for
Wrong truck model Everything is TruckCom.
set. stopped at once, value for
Parameter 1108 is the parking brake factory 2: Check parameters.
2:503 parameters
wrongly set in is activated, and
combination with the main
2: Wrong value are set according to the truck
1001 contactor opens
for parameter configuration.
1108 and/or
1001 • Check that other parameters
are set correctly.
© Cesab 8 – 12 T Code(s): 1010

Truck
behaviour
1: Charge the battery
2: Check the voltages in T1
• Check the voltage using a volt
meter (Measuring point F50 - B-
) and compare with the
TruckCom value “Battery
Voltage” (Node:ACT, Analogue
I/O) (Limit values?) (TBD)
1: The battery is meter (Measuring point F1 - B-)
discharged and compare with the
2: Voltage loss TruckCom value “Battery
on pre-supply Voltage” (Node:ACT, Analogue
The battery voltage Everything is I/O) (Limit values?) If the
to the capacitors in stopped at once, to T1
contactor is open, there is
T1 is below 16.0 the parking brake 3: The battery is
2:504
Volt when the main is activated, and
several volts of difference --
defective normal. If the contactor is
contactor must be the main
closed contactor opens 4: Battery closed, voltage should match
parameter the point over +XX
#107 has an • Check the connectors, joints
erroneous and splices
value
• Check that any extra equipment
is connected in accordance with
our recommendation.
3: Inspect the battery.
4: Check parameters
configuration.
are set correctly.
© Cesab 8 – 13 T Code(s): 1010

Truck
behaviour
(X41:3) and (X41:4) is 54 - 66
ohms.
1: Error on CAN the chassis and CAN contact.
bus wiring or Limit value >24 kOhm
Everything is connection
2: Check for loose connections
A5 has received stopped at once, 2: Loose
the parking brake connections • Switch on the truck, and pull
2:511 too may
is activated, and carefully in the branches of the
erroneous signals the main 3: Defective CAN wiring harness to find any loose
contactor opens node connections, and note when/if
4: Software the error code appears.
failure 3: Check the CAN node
• Deactivate and disconnect the
option unit connected to the
CAN wiring (e.g. K110,B90,T14
and A36/A37). Activate and
then connect them one by one
to identify which unit produces
the communication error.
latest version.
© Cesab 8 – 14 T Code(s): 1010

Truck
behaviour
(X41:3) and (X41:4) is 54 - 66
ohms.
the chassis and CAN contact.
Limit value >24 kOhm
2: Check parameters.
1: Error on CAN
bus wiring or
configuration.
connection
2: Wrong setting
are set correctly.
Everything is for parameter
No return signal 3: Check K110 (DHU/TWIS)
stopped at once, 102
from K110 (DHU/
the parking brake
2:515 TWIS) within 0.6
is activated, and
3: No connection • Check that the DHU's green
seconds after
the main with K110 LED is lit. If the LED is not lit:
logging on Check the DHU's feed voltage =
contactor opens 4: Loose
battery voltage
connections
• Check that it is possible to
5: Software
connect TruckCom to the DHU.
failure
If it is possible to connect them,
check the DHU's configuration.
If there is a power supply but no
communication, check the CAN
bus. If it still not possible to
communicate with the DHU,
replace the unit.
4: Check for loose connections
• Switch on the truck, and pull
carefully in the branches of the
wiring harness to find any loose
connections, and note when/if
the error code appears.
latest version.
© Cesab 8 – 15 T Code(s): 1010

Truck
behaviour
A5 has an incorrect 1: Check whether contact X203
box address. Everything is is short circuited. If a jumper is
There is a jumper/ stopped at once,
fitted, remove it.
short circuit in the parking brake Box address error on
2:516
contact X203 is activated, and A5 2: Replace A5
between pin 1 and the main
0 V internally on contactor opens • See section "13.1.6 Replacing
the A5 card. the logic card".
1: Check parameters
configuration.
are set correctly.
2: Replace A5
1: New software the logic card".
has been
loaded in the 3: Set new checksum
truck, adding a • If the problem with the check
Everything is new sum occurs directly in
The checksum of
stopped at once, parameter, or connection with the software
the parameter
the parking brake it has changed update, proceed as follows:
2:520 values does not
is activated, and the parameter
match the • Change the value of one
the main limit values
parameter values. parameter in each category,
contactor opens
2: Corrupt operator parameters, service
memory circuit parameters and calibration
3: Checksum parameters.
error • Save the changes and restart
the truck.
• Reset the values you changed
in the previous step back to their
original values.
• Restart the truck.
• The program will have
performed a new checksum
calculation.
© Cesab 8 – 16 T Code(s): 1010

Truck
behaviour
1: Check the Hall sensors
• Check with TruckCom or the
built-in test that the Hall sensors
Incorrect power
Plug braking to work the way they should.
supply to the Hall
stop, then the
sensors. Incorrect power • A Hall sensor that is being
parking brake is
2:522 High (or low) signal supply to the Hall influenced should give a low
activated and the
from all Hall sensors. signal.
main contactor
sensors A5:S300-
opens
S318 • Replace A5 if the Hall sensors
have an error function. See
section "13.1.6 Replacing the
logic card".
Everything is
Internal memory
stopped at once, 1: Replace A5
(FRAM or RAM) is
the parking brake • Corrupt
2:523 faulty Reading from • See section "13.1.6 Replacing
or writing to
is activated, and memory circuit
the main the logic card".
memory failed
contactor opens
1: Update the truck software.
A5 does not have The truck cannot Software download • Update the truck entire software
2:525
any truck software be started interrupted package to the latest available
version.
1: Check contactor
• Check the function of the main
contactor and that there is no
Contactor points in connection between the points.
the main contactor
fused • Check that there is no short-
Everything is circuit that can cause improper
High voltage over
stopped at once, Contactor points in
the capacitor bank power supply.
the parking brake the main contactor
2:540 internally in the
is activated, and are fused. Q10:3, • If this voltage does not increase
motor control unit
the main Q10:4 when the main contactor pulls
on the secondary
contactor opens and the voltage is close to
side of the
connector when it battery voltage (measured via
is open precharge in), it is a sign that the
contactor points in the main
contactor are fused.
• Replace the contactor.
© Cesab 8 – 17 T Code(s): 1010

Truck
behaviour
1: Check contactor
• Check the function of the main
contactor and that there is no
connection between the points.
Contactor points for • Check that there is no short-

steering servo and circuit that can cause improper
Everything is power supply.
pump etc. in the
stopped at once, Contactor points in
main contactor are
the parking brake the main contactor • On this side of the main
2:541 fused.
is activated, and are fused. Q10:1, contactor, there is no PTC
Voltage on this
the main Q10:2 resistor that can precharge any
side is measured
contactor opens capacitor bank. So, this voltage
through the
steering servo. drops towards zero when the
main contactor is open. Check
that the voltage drops at least 1
V over 5 seconds before trying
to pull the main contactor again.
• Replace the contactor.
1: Check fuses
• Check if there is any contact on
the fuse. Replace the fuse if it is
defective.
2: Check contactor
• Check the contactor's function
1: Fuse F1 and that there is a connection
Main contactor defective between the points [Q10:3] and
Everything is
ordered to close [Q10:4].
stopped at once,
but stays open. 2: Poor or no
the parking brake • Check that there is no short-
2:560 Low voltage on the connection
is activated, and circuit that can cause improper
secondary side of between the
the main
the contactor when points. power supply.
contactor opens
it is closed
3: Broken wiring • Replace the contactor.
3: Check wiring after the break.
• Disconnect the battery
• Using instruments, check that
there is no break in any wire.
• Measure and check the voltage
with the functions activated
© Cesab 8 – 18 T Code(s): 1010

Truck
behaviour
1: Check fuses
• Check if there is any contact on
the fuse. Replace the fuse if it is
defective.
2: Check contactor
• Check the contactor's function
1: Fuse F53 and that there is a connection
Main contactor defective between the points [Q10:1] and
Everything is
ordered to close [Q10:2].
stopped at once,
but stays open. 2: Poor or no
the parking brake • Check that there is no short-
2:561 Low voltage on the connection
is activated, and circuit that can cause improper
secondary side of between the
the main
the contactor when points. power supply.
contactor opens
it is closed
3: Broken wiring • Replace the contactor.
1: Check the Hall sensors
• Check with TruckCom or the
built-in test for the Hall sensors
Plug braking to that they work the way they
The Hall element
stop, then the
for the speed should. A Hall sensor that is
main contactor
2:580 control gives a A5 defective being influenced should give a
opens and the
signal (active low) low signal.
parking brake is
when it should not
activated • Replace A5 if the Hall sensors
logic card".
© Cesab 8 – 19 T Code(s): 1010

Truck
behaviour
1: Let go of the control, and wait
for four seconds
2: Check the speed control
• Check the spring function
• Check that the speed control is
not seized
The speed control 1: Control
manipulated. • Check that the plastic cover
was not in the
neutral position at
where the spring is attached is
2: The speed intact.
start-up The truck cannot
control does
3:001 One or more Hall be driven, other 3: Check the Hall sensors
elements for the functions OK
not spring
speed control give back to neutral • Check with TruckCom or the
an active signal at position. built-in test for the Hall sensors
start 3: A5 defective that they work the way they
should. A Hall sensor that is
being influenced should give a
low signal.
• Replace A5 if the Hall sensors
logic card".
© Cesab 8 – 20 T Code(s): 1010

Truck
behaviour
2: Check the cooling
• Check the cooling flanges of the
transistor regulator, motor and
steering motor as well as the
battery charger and fans and
filters for accumulations of dirt
and dust. Too much dust and dirt
cause the cooling not to work
properly.
• Check that the fans work when
The temperature the speed control is activated
1: Cooling is
sensor in the motor (fans behind T1 and motor fan)
The motor control reduced or the
control power stage
3:080 is limiting the temperature • Check that the fan on charger
is outside the limit
values. Above
voltage. sensor is T14 works when the charging
130°C defective. begins, i.e. when the mains
cable is connected
• Check the signal from the
temperature sensors for T1 and
T13 and from B1 using the built-
in test or TruckCom. Determine
if the temperature signals are
plausible relative to the real
temperatures of the
components. If not, replace
T1,T13 or replace B1 with a
repair kit.
© Cesab 8 – 21 T Code(s): 1010

Truck
behaviour
properly.
the speed control is activated
The motor 1: Cooling is
(fans behind T1 and motor fan)
temperature sensor Creep speed and reduced or the
3:081 is outside of limit motor control temperature • Check that the fan on charger
values. Above limits the voltage. sensor is T14 works when the charging
210°C. defective. begins, i.e. when the mains
cable is connected
temperatures of the
repair kit.
Creep speed, 1: Internal 1: Create a truck report. Send a
Motor control program error report to the manufacturer.
blocked lifting/
3:100 warning. Unknown
lowering 2: Software 2: Update the truck software to
warning
movement failure the latest version.
Creep speed, • Replace T1
Incorrect checksum
blocked lifting/
3:120 for the motor Motor control corrupt • See section "14.7.2 Replacing
lowering
control parameters the motor control".
movement
The strength of the
current through the • Replace T1
horn is more than Defective transistor
3:127 Not influenced • See section "14.7.2 Replacing
200mA even on the output
though the output the motor control".
is deactivated
© Cesab 8 – 22 T Code(s): 1010

Truck
behaviour
The strength of the
current through the
output to the fans is • Replace T1
Defective transistor
3:128 more than 200mA Not influenced • See section "14.7.2 Replacing
on the output
even though the the motor control".
output is
deactivated
1: Check for overcurrent or short
circuit:
• Check the ohms and the
Hardware amperes of the component,
protection in T1 compare them to the setpoint
detects a short values if they outside the
circuit in the output
accepted range.
for the horn. The High power
3:140 current through the Not influenced consumption or • Check the connections and
horn is above the short circuit wiring harness for short-circuit.
valid limit value.
Maximum value = • Check that the component does
500mA, continuous not seize or is jammed.
value = 300mA • If points 1-3 are OK, it indicates
that the output stage is short
circuited - Replace the power-
supplying component
circuit:
accepted range.
for the fans. The High power
3:141 current through the Not influenced consumption or • Check the connections and
fan is above the short circuit wiring harness for short-circuit.
valid limit value.
Maximum value = • Check that the component does
2.5A, continuous not seize or is jammed.
value = 1.5A • If points 1-3 are OK, it indicates
supplying component
© Cesab 8 – 23 T Code(s): 1010

Truck
behaviour
1: Check the rotational speed
sensor
T1 detects to high • Disconnect the B11. Check that
speed for the • Defective there are no metal fragments on
3:225 Creep speed
motor, more than component B11 sensor points.
5000 rpm
• Check that the toothed wheel on
the motor axle is clean, intact
and properly mounted.
(X41:3) and (X41:4) is 54 - 66
ohms.
1: Error on CAN Measure resistance between
bus wiring or the chassis and CAN contact.
connection Limit value >24 kOhm
2: Incorrect value 2: Check parameters.
Motor control start- The truck cannot for parameter
3:303 • Check that factory parameters
up failed be started 1001
3: No power configuration.
supply
4: Wrong kind of are set correctly.
motor control
for the activated functions
4: Replace T1
the motor control".
© Cesab 8 – 24 T Code(s): 1010

Truck
behaviour
Everything is
stopped at once, 1: Replace T1
the parking brake Defective motor
3:500 Internal error in T1 • See section "14.7.2 Replacing
is activated, and control
the main the motor control".
contactor opens
Everything is
Error in T1 when the parking brake Defective motor
3:502 • See section "14.7.2 Replacing
saving parameters is activated, and control
contactor opens
Everything is
stopped at once, 1: Update the truck software
Unknown error in the parking brake No software • Update the truck entire software
3:505
T1 is activated, and compatibility package to the latest available
the main version.
contactor opens
Motor control 2: Check battery voltage
detects excessively 1: Battery • Check the voltage using the
low battery voltage discharged built-in test procedure and
at start-up. The truck cannot
3:506 2: Voltage loss comparing with value from
Battery voltage be started
below 15.3V after on supply to external volt meter
10 seconds from T1 • Check connectors, joints and
power-on splices for damage or corrosion.
Everything is
the parking brake Defective motor
3:507 Internal error in T1 • See section "14.7.2 Replacing
is activated, and control
contactor opens
© Cesab 8 – 25 T Code(s): 1010

Truck
behaviour
Everything is 1: Error on CAN (X41:3) and (X41:4) is 54 - 66
CAN
stopped at once, bus wiring or
communication ohms.
the parking brake connection
3:511 problem between
T1 and A5, A5 gets
is activated, and • Check that the CAN wiring
the main 2: CAN module harness is not pinched.
no signals from T1
contactor opens in A5 defective Measure resistance between
2: Replace A5
the logic card".
Everything is Disconnect the battery. Check
CAN
stopped at once,
communication 1: Error on CAN that the resistance between
the parking brake
3:512 problem between bus wiring or (X41:3) and (X41:4) is 54 - 66
is activated, and
A5 and T1, T1 gets connection ohms.
the main
no signals from A5
contactor opens • Check that the CAN wiring
© Cesab 8 – 26 T Code(s): 1010

Truck
behaviour
Everything is 1: Error on CAN (X41:3) and (X41:4) is 54 - 66
CAN stopped at once, bus wiring or ohms.
communication the parking brake connection
3:514
problem, A5 cannot is activated, and • Check that the CAN wiring
send to T1 the main 2: CAN module harness is not pinched.
contactor opens in A5 defective Measure resistance between
2: Replace A5
the logic card".
Everything is The ground for
stopped at once, speed sensor and
Signal ground in T1
the parking brake temperature sensor
3:520 out of valid range
is activated, and is connected to
??V (TBD)
the main chassis, battery- or
contactor opens battery+
The amperage
Everything is
through the output
to the brake (Q1) is
the parking brake Defective transistor
3:523 more than 200mA • See section "14.7.2 Replacing
is activated, and on the output
even though the the motor control".
the main
output is
contactor opens
deactivated
The amperage
through the output Everything is
to the main stopped at once, 1: Replace T1
contactor (Q10) is the parking brake Defective transistor
more than 200mA is activated, and on the output
even though the the main the motor control".
output is contactor opens
deactivated
sensor
T1 detects to high The drive is • Disconnect the B11. Check that
speed for the stopped • Defective there are no metal fragments on
3:525
motor, more than immediately with component B11 sensor points.
6000 rpm the parking brake
© Cesab 8 – 27 T Code(s): 1010

Truck
behaviour
1: Check the motor
• Disconnect motor wiring
including sensor wires.
• Insulation test. Check that the
coils are not electrically
connected to the chassis.
Replace M1 if the motor is not
isolated
2: Check the motor wiring
1: Short circuit in harness
Hardware in T1 motor
detects a short
Everything is • Visual check of the motor wiring
stopped at once, harness. Check that there is no
circuit in the power 2: Short circuit in
the parking brake contact between the pole
3:540 stage and a phase- motor wiring
is activated, and connections on the motor/motor
to-phase short harness
the main control. Search for contact and
circuit, phase B-
contactor opens 3: Short circuit in
and phase B+ damaged insulation on the
power stage wiring harness.
• Disconnect the motor wiring
harness at the motor control and
the motor and measure the
ohms of the wiring harness
between the phases and verify
that there is no contact.
3: Replace T1
the motor control".
circuit:
amperes of the component,
compare them to the setpoint
values if they outside the
Too many amperes The drive is accepted range.
High power
to the speed stopped
3:542 consumption or • Check the connections and
sensor, limit value immediately with
short circuit wiring harness for short-circuit.
68 mA the parking brake
• Check that the component does
not seize or is jammed.
• If points 1-3 are OK, it indicates
supplying component
© Cesab 8 – 28 T Code(s): 1010

Truck
behaviour
circuit:
Hardware • Check the ohms and the
protection in T1 amperes of the component,
detects a short compare them to the setpoint
circuit in the output values if they outside the
Everything is
to the brake (Q1)
stopped at once, accepted range.
The current High power
the parking brake
3:545 through the brake consumption or • Check the connections and
is activated, and
exceeds the limit short circuit wiring harness for short-circuit.
the main
values. Maximum
contactor opens • Check that the component does
value = 5.95A,
continuous value = not seize or is jammed.
3A • If points 1-3 are OK, it indicates
supplying component
circuit:
Everything is
circuit or current
stopped at once, accepted range.
through the main High power
the parking brake
3:546 contactor (Q10) consumption or • Check the connections and
is activated, and
exceeds valid limit short circuit wiring harness for short-circuit.
the main
values. Maximum
contactor opens • Check that the component does
value = 2.5A,
1.5A • If points 1-3 are OK, it indicates
supplying component
Everything is
Hardware
stopped at once, Components are
protection in T1
the parking brake using too much
3:547 detects a short •
is activated, and power or wiring is
the main short circuited.
“High Side driver”
contactor opens
© Cesab 8 – 29 T Code(s): 1010

Truck
behaviour
The amperage to The drive is 1: Broken wiring for the activated functions
speed sensor (B11) stopped
3:560 2: Check the rotational speed
is below the 6mA immediately with 2: Defective
limit value the parking brake component sensor
• Disconnect the B11. Check that
there are no metal fragments on
B11 sensor points.
1: Check wiring and component
after the break
• Visually inspect the wiring
harness
Everything is
The amperage is • Using instruments, check that
stopped at once,
below the limit 1: Low power there is no break in any wire
the parking brake
3:563 value 100mA on consumption
is activated, and • Check the ohms and the
the output to brake or break
the main amperes of the component,
(Q1)
contactor opens
values and replace if they are
outside the accepted range.
• Reconnect the battery. Measure
and check the voltage for the
activated functions.
© Cesab 8 – 30 T Code(s): 1010

Truck
behaviour
after the break
harness
Everything is
The amperage is • Using instruments, check that
stopped at once,
below the limit 1: Low power there is no break in any wire
the parking brake
3:564 value 100mA on consumption
is activated, and • Check the ohms and the
the output to brake or break
the main amperes of the component,
(Q10)
contactor opens
circuit:
accepted range.
Power supply to 1: High power • Check the connections and
The drive is consumption
B11 out of valid wiring harness for short-circuit.
stopped or short circuit.
3:584 range. External
12V outside of valid
immediately with • Check that the component does
the parking brake 2: Defective not seize or is jammed.
range: 10V - 14V
motor control.
supplying component
2: Replace T1
the motor control".
© Cesab 8 – 31 T Code(s): 1010

Truck
behaviour
1: Check the motor
• Disconnect motor wiring
including sensor wires.
• Insulation test. Check that the
coils are not electrically
connected to the chassis.
Replace M1 if the motor is not
isolated
2: Check the motor wiring
Software in T1
1: Short circuit in harness
detects too high a
current in the motor • Visual check of the motor wiring
power stage and The drive is harness. Check that there is no
2: Short circuit in
also high current stopped contact between the pole
3:586 motor wiring
phase-phase, immediately with connections on the motor/motor
phase B- and the parking brake harness
control. Search for contact and
phase B+. The 3: Short circuit in damaged insulation on the
current is 150% of power stage
maximum current.
wiring harness.
• Disconnect the motor wiring
harness at the motor control and
the motor and measure the
ohms of the wiring harness
between the phases and verify
that there is no contact.
3: Replace T1
the motor control".
• Check the voltage using the
Everything is 1: Voltage loss built-in test procedure and
stopped at once, on supply to comparing with value from
Battery voltage the parking brake T1 external volt meter
3:587
exceeds 33 V is activated, and
the main 2: Battery • Check connectors, joints and
contactor opens defective splices for damage or corrosion.
© Cesab 8 – 32 T Code(s): 1010

Truck
behaviour
1: Charge the battery.
meter (Measuring point F50 - B-
) and compare with the
TruckCom value “Battery
Voltage” (Node:ACT, Analogue
I/O) (Limit values?) (TBD)
1: The battery is meter (Measuring point F1 - B-)
discharged and compare with the
2: Voltage loss TruckCom value “Battery
on power Voltage” (Node:ACT, Analogue
Everything is I/O) (Limit values?) If the
stopped at once, supply to T1
contactor is open, there is
Battery voltage is the parking brake 3: The battery is
3:589
below 12 V is activated, and
several volts of difference --
defective normal. If the contactor is
the main
contactor opens 4: Battery closed, voltage should match
parameter # the point over +XX
107 has an • Check the connectors, joints
erroneous and splices
value
• Check that any extra equipment
is connected in accordance with
our recommendation.
4: Check parameters
configuration.
are set correctly.
© Cesab 8 – 33 T Code(s): 1010

Truck
behaviour
1: Broken wiring • Measure and check the voltage

2: Defective
The drive is 2: Check the rotational speed
The change component
stopped sensor
3:590 exceeds 1000 rpm
immediately with 3: Change in
in 20 ms
the parking brake surface friction • Disconnect the B11. Check that
combined with there are no metal fragments on
slippage B11 sensor points.
3: Drive carefully if there is a risk
of slipping
sensor
Improbable motor The drive is • Disconnect the B11. Check that
rpm stopped 1: Defective there are no metal fragments on
3:591
Rpm over 15000 immediately with component B11 sensor points.
rpm the parking brake
Internal electrical The drive is 1: Replace T1
fault. stopped 1: Defective
Sensor offset is too immediately with motor control
high the parking brake the motor control".
© Cesab 8 – 34 T Code(s): 1010

Truck
behaviour
Signal error B11. with the functions activated
The drive is 1: Broken wiring
Loss of channel A
stopped
3:593 in the rotational 2: Check the rotational speed
immediately with 2: Defective
speed sensor
the parking brake component sensor
detected
B11 sensor points.
Signal error B11. with the functions activated
The drive is 1: Broken wiring
Loss of channel B
stopped
3:594 in the rotational 2: Check the rotational speed
immediately with 2: Defective
speed sensor
the parking brake component sensor
detected
B11 sensor points.
© Cesab 8 – 35 T Code(s): 1010

Truck
behaviour
1: Intensive use of the truck. Let
the truck cool down.
properly.
1: Intensive use
of the truck • Check that the fans work when
The drive is the speed control is activated
The motor control 2: Cooling is
stopped (fans behind T1 and motor fan)
3:596 unit temperature reduced or the
immediately with
exceeds +110°C. temperature • Check that the fan on charger
the parking brake
sensor is T14 works when the charging
defective. begins, i.e. when the mains
cable is connected
temperatures of the
repair kit.
© Cesab 8 – 36 T Code(s): 1010

Truck
behaviour
properly.
1: Intensive use
The drive is the speed control is activated
stopped (fans behind T1 and motor fan)
3:597 temperature reduced or the
immediately with
exceeds +180°C. temperature • Check that the fan on charger
the parking brake
cable is connected
temperatures of the
repair kit.
Internal 5V outside
Everything is
of valid range:
4.12V - 5.88V or
the parking brake 1: Defective
3:598 internal 15V • See section "14.7.2 Replacing
voltage outside
is activated, and motor control
valid range: 10.56V
contactor opens
- 19V
© Cesab 8 – 37 T Code(s): 1010

Truck
behaviour
circuit:
Voltage regulator Creep speed, accepted range.
1: High power
for analogue blocked lifting/
3:599 consumption • Check the connections and
sensors out of valid lowering
range: 4V - 6V movement or short circuit wiring harness for short-circuit.
supplying component.
Lifting/lowering
control is not in
neutral position at
Blocked lifting/
start-up. Lifting is 1: Control 1: Let go of the control, and wait
4:001 lowering
prevented until the
movement
manipulated for four seconds
lifting/lowering
controller is back in
the neutral position.
1: Check parameters
Signal from the 1: Incorrect value
sensilift are set according to the truck
for parameter
potentiometer Blocked lifting/ configuration.
1102
4:102 detected even lowering • Check that other parameters
though parameter movement 2: Error in
are set correctly.
1102 does not have hydraulic
the value 4. controls 2: Replacement of the hydraulic
control. See section
"13.1 Steering arm C4110".
© Cesab 8 – 38 T Code(s): 1010

Truck
behaviour
1: Check the analogue sensors
• Check that the sensor has a 5V
or 24V power supply
(depending on the component)
• Compare the measured output
from the sensor with the
corresponding value in
The signal from the 1: Defective TruckCom or built-in test. If the
pressure sensor B4 Creep speed,
component, values are the same and are out
4:180 is out of valid blocked lifting
range: 0.3 V - 4.86 movement
short circuit or of the valid range, it indicates an
V wire cut off error in the sensor or the wiring
harness. Repair or replace the
component.
• If the values are not the same, it
points to an error in T1. Replace
T1
the motor control".
Current through the
Everything is
output to the
PowerTrak valve 1: Defective
the parking brake
4:231 (Q58) is more than transistor on • See section "14.7.2 Replacing
is activated, and
200 mA even the output. the motor control".
the main
though the output
contactor opens
is deactivated.
The current Everything is
through output stopped at once, 1: Replace T1
1: Defective
exceeds 200mA to the parking brake
4:232 transistor on • See section "14.7.2 Replacing
the pump contactor is activated, and
(Q25) when it is not the main the output. the motor control".
active. contactor opens
Everything is
Current through the
Q70 output is more 1: Defective
the parking brake
4:233 than 200 mA even transistor on • See section "14.7.2 Replacing
is activated, and
though the output the output. the motor control".
the main
is inactive.
contactor opens
Everything is
Current through the
Q4/Q40 output is 1: Defective
the parking brake
4:234 more than 200 mA transistor on • See section "14.7.2 Replacing
is activated, and
even though the the output. the motor control".
the main
output is inactive.
contactor opens
© Cesab 8 – 39 T Code(s): 1010

Truck
behaviour
Everything is
Current through the
Q41/Q23 output is 1: Defective
the parking brake
4:235 more than 200 mA transistor on • See section "14.7.2 Replacing
is activated, and
even though the the output. the motor control".
the main
output is inactive.
contactor opens
Plug braking to
Too high a current
stop, then the
measured in the
parking brake is
4:236 Q59 output when it 1: 1:
activated and the
is not active
main contactor
(exceeds 200 mA)
opens
circuit:
Lowering valve compare them to the setpoint
(Q4/Q40) output is values if they outside the
short circuited or
accepted range.
too high a current Blocked lifting/ 1: High power
4:243 through the output. lowering consumption • Check the connections and
Valid limit values - movement or short circuit. wiring harness for short-circuit.
maximum value =
2.5 A, continuous • Check that the component does
value = 1.5 A not seize or is jammed.
supplying component
circuit:
Valve coil (Q41/ compare them to the setpoint
Q23) output is values if they outside the
short circuited or
accepted range.
too high a current Blocked lifting/ 1: High power
4:244 through the output. lowering consumption • Check the connections and
Valid limit values - movement or short circuit. wiring harness for short-circuit.
maximum value =
2.5 A, continuous • Check that the component does
value = 1.5 A not seize or is jammed.
supplying component
© Cesab 8 – 40 T Code(s): 1010

Truck
behaviour
circuit:
PowerTrak drain amperes of the component,
valve (Q58) output compare them to the setpoint
is short circuited or values if they outside the
too high a current accepted range.
Creep speed, 1: High power
through the valve
4:245 blocked lifting consumption • Check the connections and
output Valid limit
movement or short circuit. wiring harness for short-circuit.
values - maximum
value = 2.5 A, • Check that the component does
1.5 A
supplying component
circuit:
Hardware • Check the ohms and the
protection in T1 amperes of the component,
detects a short compare them to the setpoint
circuit in the output values if they outside the
Q25 (pump
accepted range.
contactor). The Blocked lifting/ 1: High power
4:246 current through the lowering consumption • Check the connections and
contactor (Q25) is movement or short circuit wiring harness for short-circuit.
above the valid
limit value. • Check that the component does
Maximum value = not seize or is jammed.
2.5 A, continuous • If points 1-3 are OK, it indicates
value = 1.5 A
supplying component
© Cesab 8 – 41 T Code(s): 1010

Truck
behaviour
circuit:
Hardware
protection in T1 • Check the ohms and the
detects a short amperes of the component,
circuit in output compare them to the setpoint
Q70 values if they outside the
(decompression accepted range.
Creep speed, 1: High power
locking valve) or
4:247 blocked lifting consumption • Check the connections and
current through the
movement or short circuit wiring harness for short-circuit.
valve output
exceeds the limit • Check that the component does
values. Maximum not seize or is jammed.
value = 2.5 A,
continuous value = • If points 1-3 are OK, it indicates
1.5 A that the output stage is short
supplying component
Filler valve
(PowerTrak Q59)
Creep speed,
output is short
4:248 blocked lifting 1: 1:
circuited or too high
movement
a current through
the output
after the break
harness
Too low a current
on the PowerTrak • Using instruments, check that
Creep speed, 1: Low power there is no break in any wire
valve output (Q58).
4:561 blocked lifting consumption
Current exceeds • Check the ohms and the
movement or break
the limit value 100 amperes of the component,
mA.
© Cesab 8 – 42 T Code(s): 1010

Truck
behaviour
after the break
harness
Current too low on • Using instruments, check that
pump contactor Blocked lifting/ 1: Low power there is no break in any wire
4:562 output (Q22,Q25, lowering consumption
Q52) - limit value movement or break • Check the ohms and the
100 mA amperes of the component,
after the break
harness
Too low a current • Using instruments, check that
on decompression Creep speed, 1: Low power there is no break in any wire
4:563 locking valve blocked lifting consumption
output (Q70) - limit movement or break • Check the ohms and the
value 100 mA amperes of the component,
© Cesab 8 – 43 T Code(s): 1010

Truck
behaviour
after the break
harness
Too low a current • Using instruments, check that

Blocked lifting/ 1: Low power there is no break in any wire
on valve output
4:565 lowering consumption
(Q23 - Q41) - limit • Check the ohms and the
movement or break
value 100 mA amperes of the component,
Current on filler Creep speed,
4:566 valve (Powertrak) blocked lifting 1: 1:
output is too low movement
© Cesab 8 – 44 T Code(s): 1010

Truck
behaviour
properly.
1: Intensive use
The temperature in the speed control is activated
the steering motor 2: Cooling is
5:035 Not influenced (fans behind T1 and motor fan)
power stage reduced or the
exceeds 68°C. temperature • Check that the fan on charger
cable is connected
temperatures of the
repair kit.
© Cesab 8 – 45 T Code(s): 1010

Truck
behaviour
for the activated functions
2: Check the reference sensor
• Steer slightly to the right so that
the gear ring is correctly
positioned in relation to the
reference sensor.
• Cut off power to the truck.
• Check the clearance between
the sensor and the gear ring
Reference sensor 1: Broken wiring
error, amperes
elevation using a feeler gauge.
5:080 Not influenced 2: Defective Nominal measurement: 1.5 mm
below limit value
500µA component Note: Risk of personal injury if
power is restored to the truck
while work is performed on the
gear ring.
• Restore power to the truck.
• Check if there is any power
supply to B17, 9.8 - 13.5V
between wires 95 and 97.
• If there is a power supply,
replace B17.
• Check if there is a short circuit
between wires 95 and 97, but
also between wire 95 and the
rest of the electrical system.
• If there is no power supply or
short circuit, replace the T13
© Cesab 8 – 46 T Code(s): 1010

Truck
behaviour
reference sensor.
Nominal measurement: 1.5 mm
Power supply to Note: Risk of personal injury if
reference sensor power is restored to the truck
outside of valid while work is performed on the
1: Defective gear ring.
5:081 range. It should be Not influenced
9.8 - 13.5V
component
between the wires
95-97. • Check if there is any power
supply to B17, 9.8 - 13.5V
• If there is a power supply,
replace B17.
• Check if there is a short circuit
between wires 95 and 97, but
also between wire 95 and the
© Cesab 8 – 47 T Code(s): 1010

Truck
behaviour
1: Avoid steering the truck when
stationary
2: Checking the steerability of the
drive unit.
1: Intensive • Check why the drive wheel
steering with cannot be turned with the help of
stationary the steering motor in the
Overloaded
truck following places.
steering motor to
5:135 Creep speed
80% of maximum 2: Turning of • Steering motor
capacity. drive wheel • Gears of the steering motor
was
prevented. • Gears
• Steering bearings
• Crown wheel/ steering motor
gear
• Drive wheel/surface
© Cesab 8 – 48 T Code(s): 1010

Truck
behaviour
circuit:
accepted range.
• Check the connections and
wiring harness for short-circuit.
Error in power that the output stage is short
supply to brake coil
1: High power
consumption circuited - Replace the power-
in (A83). Current
or short circuit supplying component.
differs from
5:136 Creep speed
requested current 2: Low power 2: Check wiring and component
by 100 mA and consumption after the break
current exceeds 2
or break • Disconnect the battery
A.
harness
there is no break in any wire
© Cesab 8 – 49 T Code(s): 1010

Truck
behaviour
1: Check the analogue sensor
• Check that the sensor has a 5V
or 24V power supply
(depending on the component)
The signal for the • Compare the measured output
steering angle from the sensor with the
sensor is out of corresponding value in
permitted range 1: Defective TruckCom or built-in test. If the
(only for component, values are the same and are out
5:180 Creep speed
mechanical short circuit or of the valid range, it indicates an
steering, not power wire cut off error in the sensor or the wiring.
steering) Permitted
Repair or replace the
range: 0.18V -
4.86V
component.
• If the values are not the same, it
points to an error in T1. Replace
the T1. See section
"14.7.2 Replacing the motor
control".
© Cesab 8 – 50 T Code(s): 1010

Truck
behaviour
reference sensor.
Note: Risk of personal injury if
gear ring.
supply to B17, 9.8 - 13.5V
1: The clearance between wires 95 and 97.
between • If there is a power supply,
reference replace B17.
sensor and
When B17 • Check if there is a short circuit
crown wheel is
indicates 0 between wires 95 and 97, but
wrong
5:182 degrees, A83 must Creep speed also between wire 95 and the
lie in the interval +/- 2: Defective rest of the electrical system.
7 degrees component
3: Erroneous short circuit, replace the T13
steering angle
2: See above
signal
3: Check the steering angle
sensor
• Check the wiring between T13
and A83 for short circuit or
disruption - repair or replace the
wiring.
• Digital PWM signal from A83
cannot be measured, use an
A83 that works as a reference.
• Compare the steering angle
with the steering angle that is
indicated by the system via
Service Information Mode 13 or
TruckCom - If it does not seem
to be the same, check the
mechanical fastening of the
steering arm and make a new
steering angle calibration.
© Cesab 8 – 51 T Code(s): 1010
Truck
behaviour
Everything is
stopped at once,
Steering motor
the parking brake
5:301 control power stage 1: TBD 1: TBD
is activated, and
defective
the main
contactor opens
meter (Measuring points wires
40 and 23 at T13), and compare
with the value from TruckCom
“DC Bus Voltage” Compare with
battery voltage.
• Check the connectors, joints
and splices.
• Check fuse F53
1: Voltage loss
on supply to 2: Check the CAN bus
Everything is T13
stopped at once, • Check that CAN is intact in
the parking brake 2: Error on CAN terms of wiring harness,
5:303 Start of T13 failed
is activated, and bus wiring or resistance and connectors.
the main connections Disconnect the battery. Check
contactor opens that the resistance between
3: No software
(X41:3) and (X41:4) is 54 - 66
compatibility
ohms.
• Update the truck entire software
package to the latest available
version.
© Cesab 8 – 52 T Code(s): 1010

Truck
behaviour
meter (Measuring points wires
40 and 23 at T13), and compare
1: Voltage loss with the value from TruckCom
on supply to “DC Bus Voltage” Compare with
T13 battery voltage.
Everything is
stopped at once, 2: The battery is • Check the connectors, joints
Voltage below valid the parking brake defective and splices.
5:320
level: 12V is activated, and • Check fuse F53
the main
3: Battery
contactor opens parameter # 2: Inspect the battery.
107 has an
erroneous 3: Check parameters
value • Check that factory parameters
configuration.
are set correctly.
drive unit.
• Check why the drive wheel
cannot be turned with the help of
the steering motor in the
1: Turning of following places.
Everything is
drive wheel
was • Steering motor
stopped at once,
Overloaded the parking brake prevented. • Gears of the steering motor
5:325
steering motor is activated, and 2: Intensive
the main • Gears
steering with
contactor opens • Steering bearings
stationary
truck • Crown wheel/ steering motor
gear
2: Avoid steering the truck when
stationary
© Cesab 8 – 53 T Code(s): 1010

Truck
behaviour
properly.
1: Intensive use
Everything is of the truck • Check that the fans work when
The temperature in stopped at once, the speed control is activated
the steering motor the parking brake 2: Cooling is
5:326 (fans behind T1 and motor fan)
power stage is activated, and reduced or the
exceeds 85°C. the main temperature • Check that the fan on charger
contactor opens sensor is T14 works when the charging
cable is connected
temperatures of the
repair kit.
1: No software 1: Update the truck software
compatibility
Everything is 2: Wrong latest version.
The internal stopped at once, electronic unit
2: Check the P/N of the electronic
parameters in the the parking brake in the motor
5:335 unit.
steering motor are is activated, and servo in
erroneous the main connection 3: Replace T13
contactor opens with change • See section "10.2.2 Replacing
3: Defective the steering motor".
electronic unit
© Cesab 8 – 54 T Code(s): 1010

Truck
behaviour
1: No software 1: Update the truck software
compatibility
Everything is 2: Wrong latest version.
The internal stopped at once, electronic unit
2: Check the P/N of the electronic
parameters in the the parking brake in the motor
5:336 unit.
steering motor are is activated, and servo in
erroneous the main connection 3: Replace T13
contactor opens with change • See section "10.2.2 Replacing
3: Defective the steering motor".
electronic unit
© Cesab 8 – 55 T Code(s): 1010

Truck
behaviour
reference sensor.
gear ring.
supply to B17, 9.8 - 13.5V
1: Defective • If there is a power supply,

Everything is replace B17.
stopped at once, component
T13 reports an • Check if there is a short circuit
the parking brake 2: Turning of
5:337 error during
is activated, and drive wheel between wires 95 and 97, but
reference run
the main was also between wire 95 and the
contactor opens rest of the electrical system.
prevented.
short circuit, replace the T13.
See section "10.2.2 Replacing
the steering motor".
drive unit.
following places.
• Steering motor
• Gears of the steering motor
• Gears
gear
© Cesab 8 – 56 T Code(s): 1010

Truck
behaviour
Everything is
Temperature in stopped at once,
steering motor the parking brake
5:380 1: TBD 1: TBD
exceeds high is activated, and
temperature the main
contactor opens
CAN Everything is Disconnect the battery. Check
communication stopped at once,
1: Error on CAN that the resistance between
problems between the parking brake
5:414 bus wiring or (X41:3) and (X41:4) is 54 - 66
A5 and T13. T13 is activated, and
does not get any the main connections ohms.
commands from A5 contactor opens • Check that the CAN wiring
CAN resistance and connectors.
communication Everything is Disconnect the battery. Check
problems between stopped at once,
A5 and T13. A5 the parking brake
gets no responses is activated, and
from T13 or the main connections ohms.
answers are contactor opens • Check that the CAN wiring
corrupted harness is not pinched.
© Cesab 8 – 57 T Code(s): 1010

Truck
behaviour
CAN Everything is Disconnect the battery. Check
communication stopped at once,
problems between the parking brake
A5 and T13. A5 is activated, and
gets no response the main connections ohms.
from T13. contactor opens • Check that the CAN wiring
Everything is Disconnect the battery. Check
CAN stopped at once,
communication the parking brake
problems between is activated, and
A5 and T13 the main connections ohms.
contactor opens • Check that the CAN wiring
© Cesab 8 – 58 T Code(s): 1010

Truck
behaviour
built-in test procedure and
comparing with value from
external volt meter
• Check connectors, joints and
1: Voltage loss splices for damage or corrosion.
on supply to
Everything is • Check fuses F1 and F50
T1
stopped at once,
Voltage above limit the parking brake 2: Voltage
5:421
of 39V is activated, and measurement • Check the voltage using a volt
the main error in T13 meter (Measuring points wires
contactor opens 40 and 23 at T13), and compare
3: The battery is
with the value from TruckCom
defective
“DC Bus Voltage” Compare with
battery voltage.
• Check the connectors, joints
and splices.
• Check fuse F53
Everything is 1: Replace M6
Current exceeds 1: Short circuit in
stopped at once, • See RM for instructions (TBD)
limit value 95 A. steering motor
the parking brake
5:422 Short circuit in 2: Replace T13
is activated, and 2: Short circuit in
steering motor
the main power stage • See section "10.2.2 Replacing
power stage.
contactor opens
the steering motor".
Everything is
stopped at once,
Internal program the parking brake 1: Software 1: Update the truck software to
5:435
error is activated, and failure the latest version.
the main
contactor opens
Everything is 1: Replace M6
stopped at once, 1: Interruption in
Interruptions in one servo motor • See RM for instructions (TBD)
the parking brake
5:436 or more phases in
is activated, and 2: Interruption in 2: Replace T13
T13/M6
the main power stage
contactor opens • See RM for instructions (TBD)
© Cesab 8 – 59 T Code(s): 1010

Truck
behaviour
Everything is
1: Defective
1: Replace M6
stopped at once, components
T13 detects an internally in • See RM for instructions (TBD)
the parking brake
5:437 erroneous signal M6
is activated, and 2: Replace T13
from Hall sensor
the main 2: Erroneous in-
contactor opens • See RM for instructions (TBD)
signal
Everything is
T13 detects a stopped at once,
problem with the parking brake 1: Internal error 1: Replace the T13 or the
5:438
voltage is activated, and in electronics complete unit (TBD)
measurement the main
contactor opens
Everything is 1: Update the truck software
stopped at once,
Unknown steering the parking brake 1: No software • Update the truck software to the
5:500 latest version.
motor error is activated, and compatibility
the main
contactor opens
Everything is 1: Create a truck report.
stopped at once,
Internal program the parking brake 1: Internal • Send a report to the
5:501 manufacturer.
error is activated, and program error
the main
contactor opens
1: Check parameters
Everything is
A5 detects T13 • Check that factory parameters
stopped at once,
even though 1: Incorrect value
the parking brake are set according to the truck
5:502 parameter 1107 is for parameter
set for mechanical
is activated, and configuration.
the main 1107
steering 1: Check that other parameters
contactor opens
are set correctly.
© Cesab 8 – 60 T Code(s): 1010

Truck
behaviour
1: Check the power supply to the
steering angle sensor
wiring.
Everything is 1: Defective
stopped at once, • Measure the voltage between
Power supply to component,
the parking brake wires 91 and 94. Set point: 4.5V
5:520 A83 outside of valid short circuit or
range: 4.5V-5.5V
is activated, and - 5.5V
the main internal error
contactor opens in T13 • If the voltage is too high -
replace T13
• If the voltage is too low - open
splice A83 and measure output
4 on T13. If the voltage is too
low - replace T13, otherwise
replace A83
sensor
wiring.
T13 detects a short

Everything is 1: Defective • Digital PWM signal from A83
stopped at once, cannot be measured, use an
circuit between component,
the parking brake A83 that works as a reference.
5:540 steering angle short circuit or
is activated, and
sensor signals 1 internal error • Compare the steering angle
the main
and 2 in T13 with the steering angle that is
contactor opens
© Cesab 8 – 61 T Code(s): 1010

Truck
behaviour
reference sensor.
gear ring.
supply to B17, 9.8 - 13.5V
Everything is 1: Defective • If there is a power supply,
stopped at once, component replace B17.
Reference run not
the parking brake
5:580 terminated within 2: Turning of
is activated, and • Check if there is a short circuit
15 seconds drive wheel
the main between wires 95 and 97, but
contactor opens was prevented also between wire 95 and the
drive unit.
following places.
• Steering motor
• Gears of the steering motor
• Gears
gear
© Cesab 8 – 62 T Code(s): 1010

Truck
behaviour
sensor
wiring.
Steering angle component,
5:582 signal 1 and 2 out short circuit or
is activated, and
of valid range internal error • Compare the steering angle
the main
contactor opens in T13 with the steering angle that is
sensor
• Check steering angle signal 1
between pin 3 (contact A83) and
pin 5 (contact T13)
Everything is 1: Defective wiring.
stopped at once,
the parking brake • Digital PWM signal from A83
5:583 signal 1 out of valid short circuit or
is activated, and cannot be measured, use an
range internal error
the main A83 that works as a reference.
contactor opens in T13
© Cesab 8 – 63 T Code(s): 1010

Truck
behaviour
sensor
• Check steering angle signal 2
between pin 4 (contact A83) and
pin 13 (contact T13)
Everything is 1: Defective wiring.
stopped at once,
the parking brake • Digital PWM signal from A83
5:584 signal 2 out of valid short circuit or
is activated, and cannot be measured, use an
range internal error
the main A83 that works as a reference.
contactor opens in T13
Everything is 1: Update the truck software
stopped at once,
Incorrect • Update the truck software to the
the parking brake 1: No software
5:585 configuration of latest version.
steering motor
is activated, and compatibility
the main
contactor opens
© Cesab 8 – 64 T Code(s): 1010

Truck
behaviour
sensor
wiring.
Sums of steering component,
5:586 angle signals 1 and short circuit or
is activated, and
2 out of valid range internal error • Compare the steering angle
the main
contactor opens in T13 with the steering angle that is
1: Resetting truck after collision
Collision sensor
has registered 2: Check parameters
1: Collision
collision levels • Check that factory parameters
8:001 outside set limit Creep speed 2: Parameters
values as defined 105 and 106
configuration.
by parameters 105 set too low.
and 106. • Check that other parameters
are set correctly.
The truck was
intentionally taken
8:002 Creep speed 1: TBD 1: Not implemented in I-site
out of service via
I_site
1: Check parameters
1: Option
Argument error in Not influenced. • Check that factory parameters
argument
option. Invalid The alarming are set according to the truck
8:003 error,
configuration in one option does not configuration.
or more options. work. parameters
1003 - 1042 • Check that other parameters
are set correctly.
© Cesab 8 – 65 T Code(s): 1010

Truck
behaviour
1: Check your option buttons
Not influenced. • Check the function of the option

All option buttons buttons via the built-in test
One or more option are non- mode, Service Information
1: Option button
buttons on A5 is functional until mode 9 or TruckCom.
8:004 pressed
activated at start- the option button
up. that is influenced during start-up • If there is still a signal from a
is not influenced seemingly uninfluenced button,
any more. the button must be checked for
jamming or unwanted
connection.
CAN Disconnect the battery. Check
8:010 problem with the Not influenced bus wiring or (X41:3) and (X41:4) is 54 - 66
built-in charger T14 connections ohms.
at start-up
CAN Disconnect the battery. Check
8:011 problem with the Not influenced bus wiring or (X41:3) and (X41:4) is 54 - 66
built-in charger connections ohms.
T14.
© Cesab 8 – 66 T Code(s): 1010

Truck
behaviour
1: Check the battery charger
cables.
• Disconnect the battery by
T14 detects no disconnecting the connector
1: Battery not
battery, voltage and power cable from the
8:020 Not influenced connected to
below valid level: charger.
6V charger
• Measure the ohms on red and
black cable from T14 to X1.
Replace the cables in case of
breakage.
T14 detects
excessively low
battery voltage 1: The battery is
8:021 Not influenced 1: Inspect the battery.
when charging. defective
Voltage below valid
level: 19.8V
T14 detects
excessively high
battery voltage 1: The battery is
8:022 Not influenced 1: Inspect the battery.
when charging. defective
Voltage above valid
level: 34.8V
1: Inform the client that the truck
T14 detects should be stored in normal
1: Truck used in
excessively low ambient temperatures to avoid
8:023 Not influenced cold
temperature when unnecessary wear and tear of
charging. environments.
the battery and other
components.
© Cesab 8 – 67 T Code(s): 1010

Truck
behaviour
properly.
the speed control is activated
T14 has reduced 1: Cooling is
(fans behind T1 and motor fan)
the charging reduced or the
8:024 current to 0A Not influenced temperature • Check that the fan on charger
because of high sensor is T14 works when the charging
temperature. defective. begins, i.e. when the mains
cable is connected
temperatures of the
repair kit.
1: No software • Update the truck software to the
Internal error in compatibility latest version.
T14 2: Defective 2: Replace the T14
component
• See section "18.6 Integrated
battery charger C5170".
1: Check parameters
1: Battery
The main charging • Check that factory parameters
parameters
time is exceeded are set according to the truck
109 and 110
8:028 by 5-11 hours Not influenced configuration.
incorrectly set.
depending of • Check that other parameters
battery capacity. 2: The battery is
are set correctly.
defective
© Cesab 8 – 68 T Code(s): 1010

Truck
behaviour
1: Check parameters
1: Battery
parameters
Charged capacity are set according to the truck
109 and 110
8:029 exceeds battery Not influenced configuration.
incorrectly set.
capacity. • Check that other parameters
2: The battery is
are set correctly.
defective
1: Check parameters
Communication • Check that factory parameters
with charger T14 1: Incorrect value
8:030 exists, but factory Not influenced for parameter
parameter 1101 is
configuration.
1101
not activated. • Check that other parameters
are set correctly.
Saving parameter 1: No software
8:031 Not influenced • Update the truck software to the
in T14 failed. compatibility
latest version.
1: Check parameters
Wrong battery type 1: Battery • Check that factory parameters
selected via parameters are set according to the truck
parameters 109 109 and 110 configuration.
and 110. incorrectly set.
are set correctly.
CAN Creep speed,
communication blocked lifting/
problems between lowering
A5 and A36/A37 movement connections ohms.
© Cesab 8 – 69 T Code(s): 1010

Truck
behaviour
CAN Creep speed,
communication blocked lifting/
problems between lowering
A5 and A36/A37 movement connections ohms.
CAN
communication
8:112 Not influenced bus wiring or (X41:3) and (X41:4) is 54 - 66
problems between
A5 and B90 connections ohms.
1: Check parameters
Argument error in Creep speed, • Check that factory parameters
option. Invalid blocked lifting/ 1: Argument are set according to the truck
8:123
configuration in one lowering error option configuration.
or more options. movement
are set correctly.
© Cesab 8 – 70 T Code(s): 1010

Truck
behaviour
Creep speed, Disconnect the battery. Check
CAN blocked lifting
communication movement If
error with li-ion CAN key
battery connected - connections ohms.
creep speed • Check that the CAN wiring
Temperature in the Creep speed, 1: Let the battery cool down
8:131 li-ion battery is too blocked lifting 1:
high movement
1: No action.
1: Regenerative • Check the voltage using the
Creep speed, braking with built-in test procedure and
Current in the li-ion fully-charged
8:132 blocked lifting comparing with value from
battery is too high battery.
movement external volt meter
2: • Check connectors, joints and
Li-ion battery Creep speed, 1: Move the truck to a warmer
8:133 temperature below blocked lifting 1: area
permitted level movement
Creep speed, 1: Defective 1: Contact the battery
Defective hardware
8:134 blocked lifting sensor in the manufacturer.
in the li-ion battery
movement module.
1: Communication 1: Contact the battery
Internal CAN Creep speed, problem manufacturer.
8:135 problem in the li-ion blocked lifting between
battery movement modules in the
battery.
1: A module in 1: Restart the battery.
the battery has
Creep speed,
Overvoltage in the been switched
8:136 blocked lifting
li-ion battery
movement
off because its
voltage is too
high.
© Cesab 8 – 71 T Code(s): 1010

Truck
behaviour
1: Overvoltage, undervoltage,
Battery cells Creep speed, 1: Some battery temperature too high,
8:137 deactivated by blocked lifting functions are temperature too low. Let the
internal monitoring movement not working. battery rest and then restart
the battery.
Creep speed, 1: Battery built-in test procedure and
Low battery voltage discharged
8:138 blocked lifting comparing with value from
in the li-ion battery
movement 2: Voltage drop. external volt meter
• Check connectors, joints and
1: Check parameters
1: Battery
Wrong battery type Creep speed, parameter
8:139 selected via blocked lifting 1045 has
parameter 1045 movement
configuration.
incorrect
setting. • Check that other parameters
are set correctly.
Start-up problem
Creep speed, • Create a truck report. Send a
between truck and 1: Internal
8:140 blocked lifting report to the manufacturer.
li-ion battery during
movement
program error
start. • Update the truck software to the
latest version.
© Cesab 8 – 72 T Code(s): 1010

Truck
behaviour
1: Lower the platform or lower the
gate.
2: Move the gate to a defined
position
3: Lower the gate for stacking
above 1.8 meters in order to
1: The gate is not have three escape routes
lowered when
the platform is 1: Check the sensor signal
The position of the raised.
gate in combination • Check that the distance
with the platform 2: Gate in an between the sensor and the
Driving or lifting opposite part is correct
gATE position and height undefined
stopped
sensor (SPE, position • Check that there is no dirt or
SWE) is not
3: Gate raised foreign objects on the sensor
permitted
when stacking • Inspect cabling.
above height
limit 1.8 m • Measure the signals from the
sensor with a volt meter and
verify using TruckCom or the
built-in test that the signal is
correct.
2: See above
3: See above
1: Move the platform to a defined
position
1: Check the sensor signal and/
or adjust the platform
The platform is 1: Platform in opposite part is correct
StOP lowered but not Driving stopped undefined • Check that there is no dirt or
loaded position foreign objects on the sensor
• Measure the signals from the
sensor with a volt meter and
verify using TruckCom or the
built-in test that the signal is
correct.
© Cesab 8 – 73 T Code(s): 1010

Truck
behaviour
1: Return the emergency stop
switch to the normal position
and restart the truck
Everything is 1: Emergency 2: Check the circuit of the
stopped at once, stop activated
Emergency stop emergency stop
the parking brake
ESO circuit open, low 2: Open
voltage on T1:114
is activated, and • Check that the emergency stop
the main electrical is in the normal position
contactor opens circuit
• Check fuse F51
• Check wiring and S21 after the
break
Travel speed
reduced because of
Reduced travel Reduced speed activated Click-2-
SLO 1:
speed and acceleration Creep, turtle or
emergency drive
mode.
1: After service is complete, enter
S-0h Time for service Not influenced Time for service a new or the same value in
parameter 101
1: Keep the feet inside the truck
profile.
2: Check the foot protection
1: A foot is sensor
A foot is indicated
outside of the truck breaking the • Check whether the light source
Foot Driving stopped light barrier
profile (sensor is misdirected
B124/B125) 2: Signal error • Check the wiring harness for a
break
• Check whether dirt or another
object is blocking the light
1: The tiller arm
The tiller arm comes down
Fold UP comes down too Driving stopped before the 1: Raise the arm.
quickly after start. motor control
unit is running.
© Cesab 8 – 74 T Code(s): 1010

Truck
behaviour
The power stage in and dust. Too much dust and dirt
T1 shows a high cause the cooling not to work
temperature.
properly.
The temperature 1: Intensive use
exceeds 85°C.
The motor control of the truck • Check that the fans work when
reduces the the speed control is activated
Hot maximum (fans behind T1 and motor fan)
temperature sensor reduced or the
accelerating temperature • Check that the fan on charger
shows a high
voltage linearly T14 works when the charging
temperature. sensor is
The motor defective. begins, i.e. when the mains
temperature cable is connected
exceeds +150°C
temperatures of the
repair kit.
© Cesab 8 – 75 T Code(s): 1010

Truck
behaviour
1: Inform the client that the truck
should be stored in normal
ambient temperatures to avoid
unnecessary wear and tear of
the battery and other
components.
The power stage of steering motor as well as the
the motor control is battery charger and fans and
very cold. filters for accumulations of dirt
The motor control
1: Truck used in and dust. Too much dust and dirt
unit temperature is
below -20°C
cold cause the cooling not to work
The motor control environments properly.
reduces the
The motor 2: Cooling is • Check that the fans work when
Cold maximum
temperature sensor reduced or the the speed control is activated
accelerating
shows a low temperature (fans behind T1 and motor fan)
voltage linearly
temperature
sensor is
The motor • Check that the fan on charger
defective.
temperature is T14 works when the charging
below begins, i.e. when the mains
-35°C cable is connected
temperatures of the
repair kit.
© Cesab 8 – 76 T Code(s): 1010

8.6 Service information

The truck has a service information mode that is a useful aid for
troubleshooting. To activate:
1. Connect the CAN service key to [X41] and log in.
2. The battery status symbol lights up.
3. Press the horn button [S18] repeatedly to select the desired mode in the
8 4 2 1 service information mode.
Note!
All truck functions work as normal when the service information mode is
active. Care should be taken when operating the truck and reading the
display at the same time.
Data Flashing symbol Description Resolution Unit Standard value

- BDI 10 % 0-100
Depending on
battery type.
1 Battery voltage 0.1 V
Compare with the
real battery voltage
Battery voltage, the value
indicated in an
2 approximate value of 1 A 0-450A
motor and pump
voltages.
Set speed sent to [T1]
from A5. Positive value in -12.5 - 12.5 km/h
3 the drive wheel direction. 0.1 km/h (depending on truck
Negative value in the fork type)
direction.
Speed value from the
speed sensor. Positive -12.5 - 12.5 km/h
4 value in the drive wheel 0.1 km/h (depending on truck
direction. Negative value type)
in the fork direction.
Forks or support arms,
lifting or lowering
5 1 % 0-100%
command. 100% shown
for on/off checked signals
Pressure sensor 1
(hydraulic pressure).
6 0.001 V 0.5-4.5V
“nonE” is shown if no
pressure sensor exists.
Pressure sensor 2
(hydraulic pressure).
7 0.001 V 0.5-4.5V
pressure sensor exists.
© Cesab 8 – 77 T Code(s): 1010

Data Flashing symbol Description Resolution Unit Standard value

± 1,5 ° A higher
Sensor leaning angle.
value will activate
8 “nonE” is shown if no 0.1 °
the decompression
sensor exists.
locking
Digital I/0 for A5 and [T1].
9 See description in “Test - - -
mode “9” –” on page 79
10 TBD - - -
Maximum value for

collision sensor X and Y.
11 0.1 G 0 G - 10 G
sensor exists.
SEU digital I/0. See
description in “Test mode
“12” – Expansion unit
12 - - -
SEU (option).” on
page 80 “nonE” is shown
if no SEU exists.
13 Steering angle 1 ° 0-90°
14 Drive motor temperature 1 °C ?
15 [T1] temperature 1 °C ?
© Cesab 8 – 78 T Code(s): 1010

8.7 Digital input/output status
8.7.1 Test mode “9” –
In this mode, the digital inputs and outputs are tested by checking specific
segments on the display according to the following tables.
1
6 7 2
5 3
8
1 2 3 4 4
Position:
1. Digital input of A5 [A5]
2. Digital input/output of A5 [A5]
3. Transistor regulator inputs
4. Transistor regulator inputs
1 – 8: Reference to segment
Digit 1, A5 digital in Digit 2, A5 digital in/out
Segment Description Segment Description
1 1 Option button 6
1 1 Rear button up
2 Option button 5 2 Rear button down
6 7 2 3 Option button 4 6 7 2 3 Front button up
4 Option button 1 4 Front button down
5 Option button 2 5 Main contactor
5 3 6 Option button 3
5 3 6 Horn input
8 7 A5 address (node ID) 8 7 Brake output
4 8 - 4 8 Pump
Digit 3, [T1] digital in Digit 4, [T1] digital in

Top position sensor not
1 1
active (B61)
1 1 Input 9
2 Steering arm active (B60) 2 Input 10

6 7 2 3
Operator on platform 6 7 2 3 Input 11
[B119]
4 Input 4 4 Input 12
5 3 5 Input 5 5 3 5 Input 13
8 6 Platform up (B120) 8 6 Input 14
4 7 Gate up (121) 4 7 Motor encode, channel A
8 Gate down (B122) 8 Motor encode, channel B
© Cesab 8 – 79 T Code(s): 1010

8.7.2 Test mode “12” – Expansion unit SEU (option).
In this mode, the digital inputs and outputs are tested by checking specific
segments on the display according to the following tables.
1
6 7 2
5 3
8
1 2 3 4 4
Position:
1. SEU 0 inputs
2. SEU 0 outputs
3. SEU 1 inputs
4. SEU 1 outputs
1 – 8: Reference to segment
Digit 1, SEU 0 digital in Digit 2, SEU 0 digital out

1 1 In 1
1 1 Out 1
2 In 2 2 Out 2
6 7 2 3 In 3 6 7 2 3 Out 3
4 In 4 4 Out 4
5 In 5 5
5 3 6 In 6
5 3 6
8 7 In 7 8 7
4 8 In 8 4 8
Digit 3, SEU 1 digital in Digit 4, SEU 1 digital out

1 1 In 1
1 1 Out 1
2 In 2 2 Out 2
6 7 2 3 In 3 6 7 2 3 Out 3
4 In 4 4 Out 4
5 In 5 5
5 3 6 In 6
5 3 6
8 7 In 7 8 7
4 8 In 8 4 8
© Cesab 8 – 80 T Code(s): 1010

8.8 Built-in test function for the tiller arm

1: Make sure the battery is connected.
2: Check that the truck is switched off. Press the OFF button.
3: Connect the CAN key or enter the PIN code. Note: Do not press the ON
button.
5: Press and release the horn button to select the "Info" menu.
6: Turn the speed control several times until “tESt” is shown on the display.
7: Press the horn button and release it to enter the test mode.
8: The first one you arrive at is the display test. Press on the button/function
you want to test to proceed. In this mode, the 2 LEDs on the keypad
flash.
8.8.1 Display test

The digital display [A6] can be tested to verify all the segments of the display
function correctly. A moving 8 tests all the segments of the display.
8.8.2 Speed control

The Hall elements are tested by moving the speed control all the way back
and forth. Follow these steps to test the Hall elements:
Move the rocker from the neutral position to begin the test. This is visualised
as number X Y when the rocker is moved in the fork direction and X-Y when
the rocker is moved in the drive wheel direction. X is the total number of Hall
elements that are affected by the magnet and Y is the number of existing Hall
elements. At full movement in both directions 9-9 or 9 9 is shown when all Hall
elements are OK.
8.8.3 Safety reversing

Press the button for safety reversing “Er 1” is shown in the display
8.8.4 Controls for lifting/lowering

Press a button for lifting / lowering in order to start the test. “L1”, “L2”, “L3” or
“L4” is shown in the display depending on which button has been pressed.
© Cesab 8 – 81 T Code(s): 1010

8.8.5 Sensilift
Move the sensilift rocker from the neutral position to begin the test. The
analogue value from the sensilift potentiometer is shown in mV.
8.8.6 Keypad
Press a number to start testing the keypad. “b1” up to “b11” is shown in the
display depending on which button is pressed. The numbers 0-9 are shown
as “b0” to “b9”. The red button “b10” and the green button “b11”
9: Switch off the truck by pressing the OFF button or return to the previous
menu by pressing the horn button.
© Cesab 8 – 82 T Code(s): 1010

Repair manual: Chassis C0000 Model(s): P320, P322
9. Chassis C0000
9.0.1 Overview
f c
Pos. Component Notes

1 Battery compartment Page 9–29
2 Fork body Page 9–13
3 Drive unit suspension Page 9–31
4 Platform Page 9–55
5 Gate Page 9–81
© Cesab 9– 1 T Code(s): 1010

9.1 Hatches, covers C0340
9.1.1 Overview
5
3
4
2

1 Service cover Page 9–3
2 Side cover Page 9–4
3 Gate cover Page 9–6
4 Emblem cover Page 9–7
5 Upper cover Page 9–8
© Cesab 9– 2 T Code(s): 1010

9.1.2 Replacing the service cover
Removing the service cover
1: Undo the screws and fold up the cover at the top edge. Then carefully lift
it up from the rubber strip.
Fitting the service cover
1: Position the cover at the bottom edge, fold it in and screw it into place.
© Cesab 9– 3 T Code(s): 1010

9.1.3 Replacing the side cover
Removing the side cover
• Remove the service cover. Page 9–3

1: Undo the screws and remove the cover.
Fitting the side cover
1: Hook the side cover into the upper cover and install.
Note: Make sure the washers are seated in the rubber grommets
2: Screw the cover into place.
• Fit the service cover. Page 9–3
© Cesab 9– 4 T Code(s): 1010

9.1.4 Replacing the cover (without gate)
Removing the cover (without gate)
• Remove the rubber seals. Page 9–10

Fitting the cover (without gate)
1: Position the cover and screw it in place.

• Fit the rubber seals. Page 9–11
© Cesab 9– 5 T Code(s): 1010

9.1.5 Replacing the gate cover
Remove the gate cover
• Remove the rubber seals. Page 9–10

Fitting the gate cover

• Fit the rubber seals. Page 9–11
© Cesab 9– 6 T Code(s): 1010

9.1.6 Replacing the emblem cover
Removing the emblem cover
• Removing the side covers Page 9–4

1: Undo the snap lock and move the cover downwards
Fitting the emblem cover
1: Insert the pins in the holes and press the snap lock so that it engages.
Note: Fitting is easier if you handle one side at a time.
• Fitting the side covers. Page 9–4
© Cesab 9– 7 T Code(s): 1010

9.1.7 Replacing the upper cover
Removing the upper cover
• Remove the emblem cover. Page 9–7

Fitting the upper cover

2: Fit the CAN socket guard
• Fit the emblem cover Page 9–7
© Cesab 9– 8 T Code(s): 1010

9.1.8 Replacing the steering adapter cover
Removing the steering adapter cover
• Removing the cover (without gate). Page 9–5

• Removing the gate cover. Page 9–6
1: Undo the screw, turn the cover to the left and pull it down.
2: Open the cover by moving the rear part downwards.
Fitting the steering adapter cover
1: Fit the cover around the steering adapter. The rear part is approx. 1 cm
longer.
2: Assemble the parts, guide the cover into the groove and turn it to the right
to screw it in place.
• Fitting the cover (without gate). Page 9–5
• Fitting the gate cover. Page 9–6
© Cesab 9– 9 T Code(s): 1010

9.1.9 Replacing the rubber seals
Removing the rubber seals
1: Use your fingers or carefully use a screwdriver to remove the seals

around the gate bar and steering adapter.
© Cesab 9 – 10 T Code(s): 1010

Fitting the rubber seals
Step 1
Step 2
Step 3 Step 4
© Cesab 9 – 11 T Code(s): 1010

1: Fit the seals at the gates. Make sure that the seal is properly positioned
with the notches for the lugs in the covers.
2: Press the seal into place at the front and rear edge, with the line facing
the right direction.
Note: Line should always face the operator. On trucks without gate, there is a
line on each side of the seal.
3: Then press the sides into place using your fingers or a plastic drift.
4: Use a plastic tool to ensure the cover is situated in the groove.
5: Make sure that the rubber ring does not fold together.
• Turn to the right and left and raise and lower 3 times to check that the seal
is in place.
© Cesab 9 – 12 T Code(s): 1010

9.2 Fork frame C0380
9.2.1 Overview fork frame
a d
z b e
c
f
h g
u vxy
i j
k
l
t
s
r m
q p n
o
Pos. Description Pos. Description

a Shaft o Shaft
b Bushing p Bushing
c Spring pin q Spring pin
d Wheel fork r Roller
e Bushing s Locking plate
f Spring pin t Washer
g Shaft u Roller
h Push rod v Circlip
i Screw x Washer
j Shaft y Steering
k Bushing z Battery cover lock
l Torsion tube
m Spring pin
n Shaft
© Cesab 9 – 13 T Code(s): 1010

9.2.2 Replacing the fork carriage
Removing the fork carriage
Step 1 Step 2, 3 Step 4
Step 5 Step 6
Step 7
Step 8 Step 9 Step 10
© Cesab 9 – 14 T Code(s): 1010

Step 11 Step 12
• Open the motor compartment. Page 9–2

• Remove the battery from the truck. Page 14–7
1: Lift the truck and support it on trestles so that the chassis does not tip
over when the fork carriage is removed.
2: Remove the screws of the emergency stop bracket and move it aside so
the fork carriage can be lifted out.
3: Remove the hydraulic hose bracket.
4: Remove the fork carriage stop.
5: Lift the fork carriage halfway. Only use a lifting device that is suitable for
this work.
6: Remove the lug (lifting height limiter).
7: Remove the battery connector bracket.
8: Remove the bracket of the battery wiring harness in the battery tray.
9: Remove the bracket of the battery wiring harness inside the chassis.
10: Pull the battery wiring harness out of the battery tray.
11: Lift the fork carriage until the fork wheels hang freely. Only use a lifting
device that is suitable for this work.
Note: Check that the torsion tubes have free clearance under the truck. If not,
move the fork wheels backwards so that the torsion tubes have free
clearance during the lift.
12: Lift away the fork carriage. Only use a lifting device that is suitable for this
work.
© Cesab 9 – 15 T Code(s): 1010

Fitting the fork carriage
Step 1 Step 3
Step 2
© Cesab 9 – 16 T Code(s): 1010

Step 10 Steps 11, 12
1: Lift the fork carriage into place. Only use a lifting device that is suitable
for this work.
2: Lower the fork carriage halfway.
3: Insert the battery wiring harness into the battery tray.
4: Fit the lug (lifting height limiter).
5: Lower the fork carriage, taking care to ensure the guide pins on the lift
cylinders enter the guide holes.
Note: Check that the battery wiring harness and the guides in the fork
carriage are not pinched/seated crookedly when fitting the chassis.
6: Remove the blocks and lower the truck.
7: Fit the battery connector bracket.
8: Fit the bracket of the battery wiring harness in the battery tray.
9: Fit the bracket of the battery wiring harness inside the chassis.
10: Fit the fork carriage stop.
11: Fit the emergency stop bracket.
12: Fit the hydraulic hose bracket.
• Lift the battery into place and connect the battery connector.
• Close the motor compartment. Page 9–2
9.2.3 Checking the fork carriage

Make sure that the fork carriage runs freely up and down in the chassis and
that the lifting height limiter is correctly fitted.
© Cesab 9 – 17 T Code(s): 1010

9.2.4 Replacing the torsion tube-linkage-wheel fork
Removing the torsion tube-linkage-wheel fork
Step 1 Step 2
Step 3 Step 4
© Cesab 9 – 18 T Code(s): 1010

Step 5 Step 6
Step 7
Step 7
Step 8
© Cesab 9 – 19 T Code(s): 1010

1: Lift the forks all the way and support on trestles.

2: Switch off the truck
3: Undo the fork carriage stop.
4: Tap out the spring pin of the linkage attachment.
5: Tap out the linkage shaft.
6: Remove the plate stop.
7: Pull out the shaft using a puller hammer.
8: Tap out the spring pin of the torsion tube and the wheel fork.
© Cesab 9 – 20 T Code(s): 1010

Fitting the torsion tube-linkage-wheel fork
3 2
1 1
2
Steps 1, 2, 3 Steps 4, 5 6
2
1
Steps 7, 8 Step 9
© Cesab 9 – 21 T Code(s): 1010

1
Steps 10, 11 Step 12
1
2
2
Steps 13, 14 Step 15
© Cesab 9 – 22 T Code(s): 1010

1: Fit the wheel fork and push rod.

2: Tap in the shaft.
3: Tap in the spring pin.
4: Fit the torsion tube and push rod.
7: Position the linkage.
9: Position the stop plate and screw it in place.
Note: The pin must be flush with the bottom edge.
12: Fit the wheel fork stop.
13: Lift up the fork frame.
14: Remove the blocks.
15: Lower the forks.
9.2.5 Checking the torsion tube-linkage-wheel fork

Make sure that the fork carriage runs freely up and down in the chassis.
© Cesab 9 – 23 T Code(s): 1010

9.2.6 Replacing the roller on the torsion tube
Removing the roller on the torsion tube

• Remove the linkage. Page 9–18
1: Tap out the spring pin and shaft.
2: Remove the roller.
Fit the roller on the torsion tube
1: Fit the roller.

2: Tap the shaft and spring pin into place.
Fit the linkage. Page 9–21
© Cesab 9 – 24 T Code(s): 1010

9.2.7 Weld the push rod

Welding must be carried out in accordance with ISO 5817. Weld class C
Step 1 Step 2
Step 3 Step 4
287 287
X X
L ±1,5
19
Step 5
© Cesab 9 – 25 T Code(s): 1010

Step 6 Step 7
303 +1,5
-0
(Q)
2x
Step 8
2 Contact between wheel fork and fork tip
Q see table
© Cesab 9 – 26 T Code(s): 1010

U
Battery Fork length
Machine type measurement Q (mm)
compartment (mm)
(mm)
LPE250 342 2350 750 19.5
LPE250 342 2150 750 19.5
LPE250 245 2100 330 19.5
LPE250 342 1150 330 19.5
LPE250 245 1150 330 19.5
LPE250 197 1150 330 19.5
LPE250 342 800 330 19.5
LPE 200/220 245 2350 750 19.5
LPE 200/220 342 2150 750 19.5
LPE 200/220 342 1150 330 9.5
LPE 200/220 197 1150 330 9.5
LPE 200/220 245 1000 330 9.5
LPE 200/220 197 1000 330 9.5
4 c (x2)
a3 c (x2)
Steps 9, 10 Step 11
© Cesab 9 – 27 T Code(s): 1010

• Remove the fork carriage and position it in such a way as you have access
to replace the push rod. Page 9–14
Note: Make sure the fork carriage is properly secured so that it cannot tip
over.
• Remove the linkage. Page 9–18
1: Fit the wheel fork and front push rod.
2: Fit the fork.
3: Tap in the shaft and lock it in place with the spring pin.
4: Fit the torsion tube in the fork carriage.
5: Cut the push rod to the correct length. L (push rod) = X-287 as measured
in the fork's home position.
6: Position the push rod in the fork carriage.
7: Fit the push rod in the torsion tube, tap in the shaft and lock it in place
with the spring pin.
8: Check that all parts are properly positioned.
9: Secure with a tack weld – one on each side of the V-joint.
10: Weld the front push rod and the push rod together.
11: Turn the fork carriage and weld the top. Weld through the hole on the top
of the fork.
• Fit the fork carriage. Page 9–16
© Cesab 9 – 28 T Code(s): 1010

9.3 Battery compartment parts C0390
9.3.1 Battery lock, fixed
Overview
d
c
b
a

a Screw
b Washer
c Plate
d Plate
e Nut
Description
The fixed battery lock is screwed into the chassis and locks the battery into
place. It is used when the battery is charged in the truck instead of being
replaced.
© Cesab 9 – 29 T Code(s): 1010

9.3.2 Battery lock, quick
Overview
c
k
b d
j
e
f
g

a Spring
b Nut
c Magnet
d Damper
e Washer
f Screw
g Frame
h Shim
i Stopper
j Rivet
k Handle
Description
The quick battery lock is screwed into place in the chassis and clamps the
battery into place. The lock is released by pulling the handle towards you and
then pulling it up. Battery replacement Page 6–4
© Cesab 9 – 30 T Code(s): 1010

9.4 Drive unit suspension C0450

Small drive unit suspension, with and without servo
9.4.1 Overview
a
b
c
g d
h
i
Pos. Description Note

a Rod
b Upper lug
c Initial spring
d PowerTrak spring
e Lower lug
f Upper bracket
g Driver
h Drive gear bracket
i Lower bracket
© Cesab 9 – 31 T Code(s): 1010

Table showing suspension/PT cylinder power steering
a b c d e f g h i j
6/8/8 6/8/7.5 400 650 LPE200/220 197 Lead Black White Blue
6/8/8 6/8/7.5 450 680 LPE200/220 245 Lead Black White Green
6/8/8 6/8/7.5 500 720 LPE200/220 342 Lead Black White Orange
6/8/8 6/8/7.5 330 590 LPE200/220 197/245 Li-ion Black White Yellow
Table showing suspension/PT cylinder mechanical steering
a b c d e f g h i j
6/8/8 6/8/7.5 400 650 LPE200/220 197 Lead Black White Blue
6/8/8 6/8/7.5 450 680 LPE200/220 245 Lead Black White Green
6/8/8 6/8/7.5 500 720 LPE200/220 342 Lead Black White Orange
6/8/8 6/8/7.5 330 590 LPE200/220 197/245 Li-ion Black White Yellow
a Speed without load

b Speed with max. load
c Minimum drive wheel load (0 kg load)
d Max. drive wheel load (Max. load)
e Truck type
f Battery compartment
g Battery type
h PowerTrak cylinder
i PowerTrak spring
j Initial spring
© Cesab 9 – 32 T Code(s): 1010

9.4.2 Overview,
Large drive unit suspension, with and without servo
a
b
zy y z
x x
c
d
h
0 0
00

a Rod
b Upper lug
c Initial spring
d PowerTrak spring
e Lower lug
f Upper bracket
g Driver
h Drive gear bracket
i Lower bracket
© Cesab 9 – 33 T Code(s): 1010

Table showing suspension/PT cylinder power steering
a b c d e f g h i j
12.5 11 440 1150 LPE250 245/342 Lead Green Yellow Black
12.5 11 390 1090 LPE250 245 Li-ion Green Yellow Blue
10 9 330 740 LPE200/220 197/245 Li-ion Grey Red Blue
10 9 440 820 LPE200/220 245/342 Lead Grey Red Green
10 9 380 780 LPE200 197 Lead Grey Red Black
10 9 300 740 LPE200 197/245 Li-ion Grey Red Blue
Table showing suspension/PT cylinder mechanical steering
a b c d e f g h i j
12.5 7 440 710 LPE250 245/342 Lead Grey Red Green
12.5 7 320 740 LPE250 245 Li-ion Grey Red Blue
10 8/7.5 430 820 LPE200/220 245/342 Lead Grey Red Green
10 8 360 660 LPE200 197 Lead Grey Red Black
10 8/7.5 310 740 LPE200/220 197/245 Li-ion Grey Red Blue
a Speed without load

b Speed with max. load
c Minimum drive wheel load (0 kg load)
d Max. drive wheel load (Max. load)
e Truck type
f Battery compartment
g Battery type
h PowerTrak cylinder
i PowerTrak spring
j Initial spring
© Cesab 9 – 34 T Code(s): 1010

Description
Lower drive wheel pressure without

load
Higher drive wheel pressure with load
The PowerTrak system is a well-proven design used to keep the drive wheel
pressure towards the floor at an optimal level regardless of load. The
PowerTrak system is mounted linearly on bearings and contains fewer
moving parts compared to its predecessor. In addition, tiller arm mounting
has been integrated in the upper bracket. With mechanical steering, the
vertical movements of the drive unit are absorbed by the bearings between
the driver and the steering rod so that the truck operator does not feel these
in the tiller arm.
The principle of this system is that hydraulic pressure applied on the fork
cylinders is proportional to the fork load when the forks are raised.
When the pressure from the fork lift cylinder increases, the pressure in the
PowerTrak cylinder also increases. This increases the downward force on
the drive wheel.
© Cesab 9 – 35 T Code(s): 1010

9.4.3 Replacing the drive unit suspension
Removing the small drive unit suspension
Step 1 Step 2
Step 3 Step 4 Power steering Step 4 Mechanical steering
© Cesab 9 – 36 T Code(s): 1010

Step 5 Step 5
X2
X4
X4
• Remove the battery. Page 6–4

• Remove the gate. Page 9–82
• Remove the platform. Page 9–57
• Remove the steering damper (power steering). Page 13–38
• Remove the steering angle sensor (mechanical steering). Page 13–54
• Remove the servo motor. Page 10–7
• Remove the drive gear. Page 11–4
1: Remove the spacer rings on the rods.
Note: This must be done before the motor is removed.
© Cesab 9 – 37 T Code(s): 1010

2: Undo the wiring harness clips in the water trough.

3: Disconnect the connector (X65)
4: Remove the steer axle and pull the entire tiller arm straight up.
5: Detach the hydraulic hose of the drive unit suspension.
Note: Make sure the hydraulic system has been depressurised before
removing the hose.
Note: Do not forget to seal the hydraulics to prevent foreign objects from
entering the system.
Note: Dismantling the hydraulic coupling. See section " Dismantling the
quick change connector".
6: Screw out the screws through the battery wall. The fork carriage must be
raised and lowered to gain access to all drive unit suspension screws.
Note: Use an overhead crane or another suitable lifting device to lift the fork
carriage when removing the screws.
7: Lift out the entire drive unit suspension and place it on a suitable work
surface.
Note: Use an overhead crane or another suitable lifting device to lift away the
drive unit suspension.
© Cesab 9 – 38 T Code(s): 1010

Fitting the small drive unit suspension
0 0
Step 3
Step 1 Step 2
Step 7 Step 8 Mechanical steering Step 8 Power steering

T=23 Nm T=50 Nm T=80 Nm
© Cesab 9 – 39 T Code(s): 1010

Step 9 Step 10
Step 11 Step 12
1: Lift the entire drive unit suspension into the truck.

Note: Use an overhead crane or another suitable lifting device to lift the drive
unit suspension into place.
2: Use a stud/guide pin M8x65 in the lower holes to facilitate fitting.
3: Guide in the lower lugs and guide pins on the rear of the suspension in
the battery wall.
4: Screw in the lower screws.
5: Support the drive unit suspension on trestles.
6: Use a jack to adjust the upper lugs.
© Cesab 9 – 40 T Code(s): 1010

7: Screw in the screws through the battery wall. The fork carriage must be
raised and lowered to gain access to and tighten all drive unit suspension
screws.
carriage when fitting the screws.
8: Fit the steer axle to the tiller arm.
9: Connect the connector (X65)
10: Fasten the wiring harness clips in the water trough.
11: Attach the hydraulic hose of the drive unit suspension.
12: Remove the spacer rings.
Note: Remove the rings once everything has been refitted.
• Fit the drive gear. Page 11–6
• Fit the servo motor. Page 10–9
• Fit the steering damper (power steering). Page 13–39
• Fit the steering angle sensor (mechanical steering). Page 13–55
• Fit the gate. Page 9–83
• Install the platform. Page 9–59
• Fit the battery. Page 14–7
© Cesab 9 – 41 T Code(s): 1010

Removing the large drive unit suspension
Step 1 Step 2
Step 2
Step 3 Step 4 Power steering Step 4 Mechanical steering
Step 5
© Cesab 9 – 42 T Code(s): 1010

Step 6 Step 6
• Remove the gate. Page 9–82

• Remove the servo motor. Page 10–7
• Remove the battery. Page 14–7
1: Remove the spacer rings on the rods.
Note: This must be done before the motor is removed.
2: Undo the wiring harness clips in the water trough.
3: Disconnect the connector (X65)
© Cesab 9 – 43 T Code(s): 1010

4: Remove the steer axle and pull the entire tiller arm straight up.
5: Undo the screws of the electric panel and move it aside.
6: Detach the hydraulic hose of the drive unit suspension.
Note: Make sure the hydraulic system has been depressurised before
removing the hose.
Note: Do not forget to seal the hydraulics to prevent foreign objects from
entering the system.
Note: Dismantling the hydraulic coupling. See section " Dismantling the
quick change connector".
7: Screw out the screws through the battery wall. The fork carriage must be
raised and lowered to gain access to all drive unit suspension screws.
carriage when removing the screws.
8: Lift out the entire drive unit suspension and place it on a suitable work
surface.
Note: Use an overhead crane or another suitable lifting device to lift away the
drive unit suspension.
© Cesab 9 – 44 T Code(s): 1010

Fitting the large drive unit suspension
0 0
Step 3
Step 1 Step 2
Step 8 Mechanical steering Step 8 Power steering

Step 7 T=23 Nm T=50 Nm T=80 Nm
© Cesab 9 – 45 T Code(s): 1010

Step 12 Step 13
1: Lift the entire drive unit suspension into the truck.

Note: Use an overhead crane or another suitable lifting device to lift the drive
unit suspension into place.
2: Use a stud/guide pin M8x65 in the lower holes to facilitate fitting.
3: Guide in the lower lugs and guide pins on the rear of the suspension in
the battery wall.
4: Screw in the lower screws.
5: Support the drive unit suspension on trestles.
6: Use a jack to adjust the upper lugs.
7: Screw in the screws through the battery wall. The fork carriage must be
raised and lowered to gain access to and tighten all drive unit suspension
screws.
carriage when fitting the screws.
8: Fit the steer axle to the tiller arm.
© Cesab 9 – 46 T Code(s): 1010

9: Connect the connector (X65)

10: Fasten the wiring harness clips in the water trough.
11: Attach the hydraulic hose of the drive unit suspension.
12: Remove the spacer rings.
13: Reposition the electric panel and screw it in place.
• Fit the servo motor. Page 10–9
• Fit the steering angle sensor. Page 13–55
• Fit the steering adapter. Page 13–53
• Fit the battery. Page 14–7
• Fit the gate. Page 9–83
© Cesab 9 – 47 T Code(s): 1010

9.4.4 Relieving spring force using the special tool
Step 4 Step 5
© Cesab 9 – 48 T Code(s): 1010

• Remove the drive unit suspension Page 9–36

Note: Do not forget to fit the semi-circular spacers on the shafts before
starting work.
Note: Fix the suspension over the edge of a table or similar using a clamp;
make sure that it is firmly in place and cannot fall down.
1: Fit the tool.
Note: Use the same screws that secure the suspension in the chassis.
2: Using the tool, compress the drive unit suspension just enough to free
the semi-circular spacers.
Warning! Do not use a power tool or similar when compressing with the tool,
only hand tools are permitted
3: Remove the semi-circular spacers by turning the screw through the
semi-circular spacer towards the shaft.
4: Undo the screws and washers at the top of the shafts.
5: Relieve spring force using the tool.
Note: Use a plastic mallet to carefully knock loose the upper bracket if it
sticks when removing.
Note: Make sure that all spring force compression is gone before removing
the tool.
© Cesab 9 – 49 T Code(s): 1010

9.4.5 Tensioning spring force using the special tool
Step 1 Step 2
Step 3 Step 4
Step 6 Step 7
Step 5
© Cesab 9 – 50 T Code(s): 1010

1. Fit the springs and the upper bracket to the drive unit suspension.
Note: Do not use pressing tools or similar if the upper bracket sticks. There is
a "risk of damage to the seals and the bushings". Use a plastic mallet to
carefully knock the bracket straight down over the bars.
2. Fit the tool.
3: Compress the drive unit suspension so much that the semi-circular
spacers fit onto the shafts.
4: Fit the semi-circular spacers on the shafts.
5: Fit washers and screws to the top of the shafts.
6: Relieve spring force with the tool so that the semi-circular spacers are
clamped in place
7: Remove the tool.
• Fit the drive unit suspension. Page 9–36
9.4.6 Adjusting the tool.

It is possible to adjust the tool inertia to prevent the tool springing back when
compressing the drive unit suspension.
1. Undo the nut, adjust the screw in/out to make the screw suitably stiff to
prevent the tool springing back, then tighten the nut again.
Step 1 Step 1
© Cesab 9 – 51 T Code(s): 1010

9.4.7 Replacing the initial pressure spring
Removing the initial pressure spring
Step 1 Step 2
• Relieve spring force using the special tool Page 9–48
1: Lift off the top of the drive unit suspension bracket.
2: Remove the initial pressure springs.
Fitting the initial pressure spring
Step 1 Step 2
1: Fit the initial pressure springs
2: Lift the top of the drive unit suspension bracket into place.
• Tension spring force using the special tool. Page 9–50
© Cesab 9 – 52 T Code(s): 1010

9.4.8 Replacing the PowerTrak spring
Removing the PowerTrak spring
Step 1 Step 2

2: Remove the PowerTrak spring.
Fitting the PowerTrak spring
Step 1 Step 2
1: Fit the PowerTrak spring.

© Cesab 9 – 53 T Code(s): 1010

9.4.9 Replacing the PowerTrak cylinder
Removing the PowerTrak cylinder

2: Remove the circlip and lower the cylinder.
Fitting the PowerTrak cylinder
1: Move the cylinder up into the top bracket and fit the circlip.
© Cesab 9 – 54 T Code(s): 1010

9.5 Platform including fixing points C0560
9.5.1 Overview, Standard and Cold store
a
b c
h
m
k i
l

a Inductive sensor
b Bracket
c Spring
d Bracket
e Shim (T=1 mm)
f Bracket
g Tube
h Spring
i Washer
j Screw
k Bushing
l Damper
m Ball screw
© Cesab 9 – 55 T Code(s): 1010

9.5.2 Overview, platform
Pos. Description Notes

a Screw
b Carpet
b Platform
c Stop screw
© Cesab 9 – 56 T Code(s): 1010

9.5.3 Replacing the platform
Removing the platform
Step 2 Step 3
50 mm
Steps 4, 5 Step 6
Step 7
Step 8
© Cesab 9 – 57 T Code(s): 1010

Step 9
Step 10
Step 11
1: Remove the service cover. Page 9–3

2: Disconnect the platform sensor connector.
3: Undo the screws securing the platform.
4: Position a block or the like (50 mm wide) between the floor plate and the
casting. Facilitates removal/fitting.
5: Remove the platform from the truck.
6: Detach the bracket to relieve the pressure in the gas spring.
7: Use a screwdriver or similar tool to undo the spring lock at the bottom of
the gas spring.
8: Loosen the screw holding the shaft lock plate in position.
9: Remove the lock.
10: Tap out the shaft.
11: Remove the platform.
© Cesab 9 – 58 T Code(s): 1010

Fitting the platform
Step 1 Step 2
Step 5.6
Step 3.4
50 mm
Step 7
© Cesab 9 – 59 T Code(s): 1010

Step 8.9 Step 10
1: Guide the platform into the chassis.

Note: Make sure the spacer rings remain in place when refitting.
2: Fit the shaft.
3: Fit the locking plate.
4: Screw the locking plate into place.
5: Fit the gas spring.
6: Tighten the gas spring bracket.
7: Open the platform with a crowbar or similar tool (using one of the fitting
screw holes). Position the block as illustrated.
8: Guide in the platform.
9: Screw the platform into place.
10: Connect the platform sensor connector.
© Cesab 9 – 60 T Code(s): 1010

9.5.4 Replacing the gas spring
Removing the gas spring
Step 3
Step 2
50 mm
Step 6
Steps 4, 5
Step 7
Step 8
© Cesab 9 – 61 T Code(s): 1010

1: Remove the service cover. Page 9–3

3: Undo the screws securing the platform.
4: Position a block or the like (50 mm wide) between the floor plate and the
casting. Facilitates removal/fitting.
5: Remove the platform from the truck.
6: Remove the block.
7: Detach the bracket to relieve the pressure in the gas spring.
the gas spring.
© Cesab 9 – 62 T Code(s): 1010

Fitting the gas spring
50 mm
Step 1.2
Step 3
Step 4.5
Step 6
1: Fit the new gas spring, making sure it is fitted in the right direction.
2: Tighten the gas spring bracket.
3: Open the platform with a crowbar or similar tool (using one of the fitting
screw holes). Position the block as illustrated.
4: Guide in the platform.
5: Screw the platform into place.
6: Connect the platform sensor connector.
9.5.5 Checking the gas spring

Check that the platform springs back like it should.
© Cesab 9 – 63 T Code(s): 1010

9.5.6 Replacing the spring
Removing the platform suspension
Step 3
Step 1
Step 2
• Remove the gas spring of the platform. Page 9–61

1: Remove the nut on the top of the platform bracket.
2: Remove the spring and bolt from the platform bracket.
3: Remove the spring.
© Cesab 9 – 64 T Code(s): 1010

Fitting the platform suspension
Step 1, Lubricant type E

Step 2
Step 4
Step 3
1: Lubricate the bolt with lubricant type E. Page 23–2

2: Fit the spring on the bolt.
3: Fit the spring and bolt in the platform bracket.
4: Position the nut and screw it in place.
• Fitting the gas spring. Page 9–63
9.5.7 Adjusting platform suspension
mm
1: Adjust the suspension so that the play between the sleeve and the screw
is 7 mm +0.5/-0.2.
© Cesab 9 – 65 T Code(s): 1010

9.5.8 Replacing the platform inductive position sensor
Removing the platform inductive position sensor (B119)
Steps 1, 2

2: Detach the cable bracket and remove the sensor.
Fitting the platform inductive position sensor (B119)
Step 1, 2
1: Fit the sensor and cable bracket.

2: Connect the sensor connector.
© Cesab 9 – 66 T Code(s): 1010

Removing the lower platform inductive position sensor (B120)
• Remove the platform. “Page 9–57

1: Remove the spring of the detection plate.
2: Move the plate rearwards and remove the sensor.
Fitting the lower platform inductive position sensor (B120)
1: Fit the sensor.

2: Move the detection plate back into position.
3: Fit the spring.
• Fitting the platform. Page 9–59
© Cesab 9 – 67 T Code(s): 1010

9.5.9 Checking the position sensor (B120), std platform

When checking the presence sensor, the weight must be positioned all the
way out on the platform. With a load of 30 kg, there should be no detection.
With a load of 40 kg, there should be detection.
9.5.10 Adjusting the presence sensor
• Check the platform suspension. Page 9–65

1: Use shims (a) to maintain minimal play (b)
© Cesab 9 – 68 T Code(s): 1010

9.5.11 Fixed side guard
9.5.12 Overview
b
d
c
e
f
g
h
l i
j

a Cushion Left
b Cushion Right
c Plate
d Plate
e Cover
f Cover
g Cover
h Cover
i Cover plate
j Cover plate
k Cover plate
l Plate
© Cesab 9 – 69 T Code(s): 1010

9.5.13 Replacing the fixed side guard
Removing the fixed side guard
Step 1 Steps 2, 3 Step 4
Step 5 Step 6

1: Loosen and remove the storage cover screws.
2: Loosen and remove the nuts and bolts through the chassis.
3: Disconnect connector B125 left, B124 right
4: Detach and remove the side cover.
5: Loosen and remove the side guard screws.
6: Loosen the lock nut and screw in the bolt to release the side guard.
© Cesab 9 – 70 T Code(s): 1010

Fitting the side guard
Steps 1, 2 Step 3 Step 4
Step 5 Step 6
1: Screw the side guard into place in the chassis.

2: Connect connector B125 left, B124 right
3: Fasten the side screws.
4: Fit the side cover.
5: Fit the storage cover.
6: Adjust the side guard so it does not rattle. Then tighten the lock nut.
© Cesab 9 – 71 T Code(s): 1010

9.5.14 Photo cells, fixed side guard
Overview, positioning
B120
B124
B125

B124 Photo cell receiver
B125 Photo cell transmitter
© Cesab 9 – 72 T Code(s): 1010

9.5.15 Overview, platform with fixed side guard
b
b
f
g
h
d

a Screw
b Carpet
b Floor Cold store
c Plate
d Frame
e Nut
f Shaft
g Plate
h Screw
© Cesab 9 – 73 T Code(s): 1010

9.5.16 Replacing a platform with fixed side guard
Removing a platform with fixed side guard
Step 1 Steps 2, 3

1: Disconnect the connector (B119)
2: Remove the bolts and lift out the platform.
Fitting a platform with fixed side guard
Step 1 Step 2
1: Position the platform and screw it into place.

2: Connect the connector (B119)
© Cesab 9 – 74 T Code(s): 1010

9.5.17 Checking the position sensor (B120), fixed side guards


© Cesab 9 – 75 T Code(s): 1010

mm 1 mm 2
1: mm1: Adjust the suspension so that the play between the sleeve and the
screw is 6 mm +0.2/-0.
2: mm2: Adjust the suspension so that the play between the sleeve and the
screw is 7.5 mm +0/-0.3.
© Cesab 9 – 76 T Code(s): 1010

9.5.20 Back guard
9.5.21 Overview
b
c
d
e
f

a Back rest
b Storage compartment
c Platform
d Sensor
e Platform suspension
f Mounting screw
g Mounting screw
© Cesab 9 – 77 T Code(s): 1010

9.5.22 Replacing the back guard
Removing the back guard
b
Step 1

1: Remove the back guard by removing the screws (a and b) and
disconnecting the presence sensor B119 (c).
Fitting the back guard
b
Step 1
1: Fit the back guard with the screws, a and b (T=109 ±27Nm), and connect
the presence sensor B119 (c).
© Cesab 9 – 78 T Code(s): 1010

9.5.23 Checking the position sensor (B120), back guard


© Cesab 9 – 79 T Code(s): 1010

mm
1: Adjust the suspension so that the play between the sleeve and the screw
is 7 mm +0.5/-0.2.
© Cesab 9 – 80 T Code(s): 1010

9.6 Operator protection C0840
9.6.1 Gate
Overview
a
e
b f
c

a Bearing block
b Damper
c Gate bar
d Pad
e Upper position sensor B121
f Lower position sensor B122
© Cesab 9 – 81 T Code(s): 1010

9.6.2 Replacing the gate
Removing the gate assembly
xz
Step 1 Step 2
Steps 3, 4

1: Disconnect the sensor connectors (B121 and B122).
2: Detach the water trough from the gate bracket.
3: Undo the screws securing the gate in the chassis.
4: Remove the gate and bracket.
© Cesab 9 – 82 T Code(s): 1010

Fitting the gate assembly
4
1
Step 1.2 T=23 Nm Step 3
xz
Step 4 T=2.8 Nm Step 5
1: Fit the gate and bracket on the chassis.

2: Tighten the screws, being sure to follow the correct sequence. Press the
gate forwards while tightening.
3: Connect the sensor connectors (B121 and B122).
4: Screw the water trough into place on the gate bracket.
5: Lubricate the locking lug with lubricant type A. Page 23–2
© Cesab 9 – 83 T Code(s): 1010

9.6.3 Replacing the gate damper

Applies to gate damper with part no. 7569855
Removing the gate damper
Steps 1, 2

the gas spring.
2: Remove the damper.
Fitting the gate damper
1: Fit the gas spring, making sure it is fitted in the right direction.
© Cesab 9 – 84 T Code(s): 1010

9.6.4 Replacing the gate damper

Applies to gate damper with part no. 7577717
Removing the gate damper
Steps 1, 2

the gas spring.
2: Remove the damper.
Fitting the gate damper
1: Fit the gas spring, making sure it is fitted in the right direction.
© Cesab 9 – 85 T Code(s): 1010

9.6.5 Replacing the pad
Removing the pad
Step 1 Step 2
Step 3
1: Remove the pad using a screwdriver or a similar tool.

2: Drill away the blind rivet securing the pad holder in the gate bar.
3: Pull off the pad bracket
© Cesab 9 – 86 T Code(s): 1010

Fitting the pad
Step 1 Step 2
Step 3
1: Thread the pad holder onto the gate bar.

2: Fasten the pad holder using a blind rivet.
3: Press the pads in place
© Cesab 9 – 87 T Code(s): 1010

9.6.6 Replacing the gate bar
Removing the gate bar
X4
• Remove the gate damper. Page 9–84

1: Remove the bearing block.
2: Remove the gate bar.
Fitting the gate bar
X4
1: Lubricate the bearing races with lubricant type A Page 23–2

2: Fit the gate bar and screw the bearing blocks into place.
• Fit the gate damper. Page 9–84
9.6.7 Checking the gate bar

After fitting, the gate bar must be free from mechanical catches and rotate to
its lower position through its own weight.
© Cesab 9 – 88 T Code(s): 1010

9.6.8 Replacing the upper inductive position sensor
Removing the upper inductive position sensor
1
2
2
1 2
• Remove the gate bar Page 9–88
1: Remove the lower bearing block.
2: Disconnect the sensor (B121) connector.
3: Unscrew the upper sensor (B121).
Fitting the upper inductive position sensor
2
1: Fasten the sensor
2: Connect the sensor (B121) connector.
• Fit the gate bar. Page 9–88
9.6.9 Checking the upper inductive position sensor B121

The sensor must send an output signal equal to supply voltage when the gate
is raised. Permitted supply voltage = 10-60 V
© Cesab 9 – 89 T Code(s): 1010

9.6.10 Replacing the lower inductive position sensor
Removing the lower inductive position sensor
1
• Remove the gate bar Page 9–88
1: Disconnect the sensor (B122) connector.
2: Unscrew the lower sensor (B122).
Fitting the lower inductive position sensor
1: Fasten the lower sensor.

2: Connect the sensor connector.
• Fit the gate bar. Page 9–88
9.6.11 Checking the lower inductive position sensor B122

The sensor must send an output signal equal to supply voltage when the gate
is lowered. Permitted supply voltage = 10-60 V
© Cesab 9 – 90 T Code(s): 1010

9.7 Signs, warnings, labels C0850

Overview
d
e

a Identification plate
b Serial number
c Snowflake
d Hydraulic oil Cold store
e Hydraulic oil
© Cesab 9 – 91 T Code(s): 1010

© Cesab 9 – 92 T Code(s): 1010

Repair manual: Motors C1000 Model(s): P320, P322
10. Motors C1000
The truck motors are the drive motor, the pump motor for the hydraulics, the
steering motor for rotating the drive unit (steering) and three cooling fans.
10.1 Electric pump motor C1710

The pump motor is a compound motor, a stator winding in series with the rotor
winding and an additional stator winding in parallel with these.
10.1.1 Overview
Pos. Component Note

a Motor
b Brush bridge
c Carbon brush
© Cesab 10 – 1 T Code(s): 1010

Tightening torque
a
Pos. Tightening torque

a 8.5 ± 0.5 Nm
b 10 +2/-0 Nm
© Cesab 10 – 2 T Code(s): 1010

10.1.2 Replacing the pump motor
Removing the pump motor
Step 1 Step 2
• Remove the hydraulic unit. Page 15–7

1: Loosen and remove the screws holding the motor in the valve block.
2: Lift the motor straight up.
© Cesab 10 – 3 T Code(s): 1010

Fitting the pump motor
Step 1 Step 2
Step 3 T=10 Nm
+2/-0 Nm
1: Rotate the connection assembly so the parts align.

2: Fit the motor.
Note: Check that the O-ring is in place and is undamaged.
3: Screw the motor to the valve block.
• Fit the hydraulic unit. Page 15–8
© Cesab 10 – 4 T Code(s): 1010

10.1.3 Replacing the carbon brushes
Removing the carbon brushes
Step 4
• Remove the pump motor. Page 10–3

1: Undo the nuts of the electrical connections.
2: Carefully lift the top cover straight up.
3: Carefully tap out the rotor.
4: Detach and remove the carbon.
© Cesab 10 – 5 T Code(s): 1010

Fitting the carbon brushes
Step 1 Step 3
Step 2
Step 4 T= 8.5 Nm ±0.5 Nm
1: Fit and connect the carbon.

2: Fit the rotor. Hold out the carbon to facilitate fitting.
3: Turn the cover upside down and insert it in the motor.
Note: Fit the spring washer in the cover before fitting the motor.
4: Tighten the nuts of the electrical connections.
• Fit the pump motor. Page 10–4
© Cesab 10 – 6 T Code(s): 1010

10.2 Steering motor C1730

The steering motor is made up of three main components mounted as a unit
on the bottom plate of the motor compartment:
• steering motor electronics,
• the motor, which is a brushless synchronous motor with permanently
magnetised rotor,
• a two-stage planetary gear, which has a gear wheel on its output shaft in
direct contact with the gear ring on the drive gear
10.2.1 Overview
c
d
Pos. Component Note

a Motor
b Seal
c Electronic circuit board
d Gearbox
e Gear wheel
f Nut
© Cesab 10 – 7 T Code(s): 1010

Tightening torque
c
Pos. Tightening torque
a 9 Nm
b 33 Nm (+ centre punch mark)
c 23 Nm
© Cesab 10 – 8 T Code(s): 1010

10.2.2 Replacing the steering motor
Removing the steering motor
y z

1: Disconnect the connector
2: Remove the screw and pull the steering motor straight up
Fitting the steering motor
y z
Step 1 Step 1 T=26±3 Nm Step 2
1: Fit the steering motor and screw it into place.

2: Connect the connector
© Cesab 10 – 9 T Code(s): 1010

10.3 Motor control fans

There are two cooling fans in the truck's motor compartment:
a: Two axial fans that cool the motor control, designated [M12] and [M13].
10.3.1 Overview
a b

a Motor control [T1] (ACT)
b Fan
© Cesab 10 – 10 T Code(s): 1010

10.3.2 Replacing the motor control fans
Removing the motor control fans
Step 3
Step 1 Step 2
• Remove the electric panel. Page 14–14
2: Detach the brackets from the panel plate.
3: Remove the screws securing the fan.
Fitting the motor control fans
Step 1
Step 2 Step 3
1: Screw the fan into place.
2: Attach the brackets to the panel plate.
• Fit the electric panel. Page 14–14
© Cesab 10 – 11 T Code(s): 1010

10.4 Drive motor

The drive motor is a brushless, short-circuited, three-phase asynchronous
motor.
The motor has the following for monitoring:
• a thermoelement that measures motor temperature
• a sensor that measures direction of rotation and speed
10.4.1 Tightening torques – Drive motor

The drive motor tightening torques are depicted in the figure below:
a
d
2.8 KW 1.8, 2.5 KW
Pos. Tightening torque Notes

a 9.5 Nm Applied in two stages, crosswise
b 13 +2/-1Nm
c 6 ±1 Nm
d 7 ± 1 Nm Applied in two stages, crosswise
© Cesab 10 – 12 T Code(s): 1010

10.5 1.8, 2.5 kW
10.5.1 Overview
b c d
e
f
g
a h
i

a Speed sensor
b N-shield
c Rotor
d Toothed wheel
e Power cable U
f Power cable V
g Power cable W
h B1
i B11
j Fixing screw
Holds the motor
k Motor screw
together
© Cesab 10 – 13 T Code(s): 1010

10.5.2 Connecting wiring harness 1.8 - 2.5 kW
© Cesab 10 – 14 T Code(s): 1010

10.5.3 Replacing the drive motor 1.8, 2.5 kW
Removing the drive motor
3X
Step 1 Step 2
Step 3 Step 4 Steps 5, 6
• Remove the parking brake. Page 12–7

• Thoroughly clean the area round the drive motor. Page 10–25
1: Unscrew the motor cables U, V, W
2: Disconnect the connectors (B1, B11)
3: Detach the cable bracket at the speed sensor, or cut off the strap.
4: Remove the screws securing the motor.
5: Undo the screws (k) holding the motor together so they sit loose, but not
removed.
6: Pull the motor straight up.
© Cesab 10 – 15 T Code(s): 1010

Fitting the drive motor
Step 1 Step 2 T=7 ±1 Nm Step 3
3X
Step 4 T=6 ±1 Nm Step 5
1: Lower the motor in the drive gear, taking care so as not to damage the
spline on the drive shaft.
Note: Make sure the screws (k) holding the motor together are tightened
loosely.
2: Screw in the motor and the screws (k).
3: Connect the connectors (B1, B11)
4: Screw the motor cables U, V, W in place.
5: Screw the cable bracket into place at the speed sensor, of fit a new strap.
• Fit the parking brake. Page 12–8
© Cesab 10 – 16 T Code(s): 1010

10.6 2.8 KW
10.6.1 Overview
d
b
e

a Rotor
b B11
c Toothed wheel
d N-shield
e B1
f Fixing screw
g Power cable W
h Power cable V
i Power cable U
© Cesab 10 – 17 T Code(s): 1010

10.6.2 Connecting wiring harness, 2.8 kW
© Cesab 10 – 18 T Code(s): 1010

10.6.3 Replacing the motor 2.8 kW
Removing the motor 2.8 kW
Step 4 Step 5

• Thoroughly clean the area round the drive motor. Page 10–25
1: Unscrew the motor cables U, V, W
2: Disconnect the connectors (B1, B11)
3: Detach the cable bracket on the plate securing the connection terminal.
4: Remove the screws securing the motor.
5: Pull the motor straight up.
© Cesab 10 – 19 T Code(s): 1010

Fitting drive motor 2.8 kW
Step 1 Step 2 T=9.5 Nm Step 3
Step 4 T=13 +2/-1 Nm Step 5
1: Lower the motor in the drive gear, taking care so as not to damage the
spline on the drive shaft.
2: Screw the motor into place.
3: Connect the connectors (B1, B11)
4: Screw the motor cables U, V, W in place.
5: Screw the cable bracket into place at the connection terminal.
© Cesab 10 – 20 T Code(s): 1010

10.6.4 Replacing the temperature sensor

It is not possible to replace the motor's internal temperature sensor. If a fault
occurs with the temperature sensor the internal sensor is replaced by an
external sensor.
Step 1 Step 2 Steps 3, 4, 5

1: Clean the surface where the new temperature sensor will be mounted.
2: Position the temperature sensor as shown in the illustration:
3: Apply plastic steel over the sensor. The entire sensor must be covered.
4: Affix the steel plastic and the sensor with masking tape and allow to set.
5: Remove the masking tape.
The temperature sensor should now be firmly positioned and entirely covered
by the plastic steel.
© Cesab 10 – 21 T Code(s): 1010

10.6.5 Replacing the RPM sensor
Removing the RPM sensor
z x
Step 1 y
Step 2
z z x
x
y y
Step 3 Step 4

1: Remove the screw.
2: Pull out the sensor.
3: Disconnect the connector (B11)
4: Detach the sensor's cable connection from the motor.
© Cesab 10 – 22 T Code(s): 1010

Fitting the RPM sensor
z x
Step 2
Step 1 Step 2
z x
y
z x
Step 3 y
Step 4
1: Check the O-ring seal of the new sensor.
2: Position the sensor and screw it into place.
3: Fit the sensor's cable connection to the motor.
4: Connect the connector (B11)
© Cesab 10 – 23 T Code(s): 1010

10.6.6 Replacing the speed sensor toothed wheel
Removing the speed sensor toothed wheel
Step 1 Step 2
• Remove the motor. Page 10–15

• Remove the speed sensor. Page 10–22
• Remove the brake hub. Page 12–11
1: Remove the circlip at the toothed wheel.
2: Remove the toothed wheel. If needed, use a puller and save the key.
© Cesab 10 – 24 T Code(s): 1010

Fitting the speed sensor toothed wheel
Step 1 Step 2
1: Fit the toothed wheel.

2: Fit the circlip
Note: Make sure it is in the right direction (so it presses down the toothed
wheel ) on 1.8 kW and 2.5 kW
• Fit the brake hub. Page 12–11
• Fit the speed sensor. Page 10–23
• Fit the motor. Page 10–16
10.6.7 Cleaning
To assure proper truck operation, it is important to keep the motor clean.
Make sure the motor and motor compartment are free from dust and other
contaminants.
If the motor windings and internal compartments are dry, use a vacuum
cleaner with a suitable nozzle to clean the motor.
The use of water or other liquids is not recommended as these may damage
the insulation and cause stray currents.
Use of compressed air to clean motors is not recommended as the
compressed air presses dirt into the bearings and thereby shortens the
service life of the motors.
© Cesab 10 – 25 T Code(s): 1010

© Cesab 10 – 26 T Code(s): 1010

Repair manual: Transmission/Drive gear C2000 Model(s): P320, P322
11. Transmission/Drive gear C2000
11.1 Description
The drive gear is a two-stage angle gear that is integrated with the motor and
brake assembly in a complete drive unit. The drive gear is fitted to the chassis
with bolts. At the top edge of the gear, the steering bearing and a gear ring
for the steering motor (option) are fitted.
These service instructions cover descriptions of service performed on site at
the customer. A complete reconditioning of the drive gear must be performed
in the workshop by trained technicians.
© Cesab 11 – 1 T Code(s): 1010

11.2 Gears
11.2.1 Small gear
Description Value
Gear ratio 18.39
Oil quality 0.9 litres
Drive wheel Ø 230
11.2.2 Overview
a e

a Transmission housing
b Motor bearing and packing box
c Steering bearings
d Seal and cover ring
e Stud bolt M12x1.5
© Cesab 11 – 2 T Code(s): 1010

11.2.3 Large gear
Description Value
Gear ratio 16.96
Oil quality 1.05 litres
Drive wheel Ø 250
11.2.4 Overview
b e

a Seal and cover ring
b Transmission housing
c Motor bearing and packing box
d Steering bearings
e Stud bolt M14x1.5
© Cesab 11 – 3 T Code(s): 1010

11.3 Replacing the drive gear
Removing the drive gear
Step 1 Step 2
Step 3 Step 4
Step 5 Step 6
© Cesab 11 – 4 T Code(s): 1010

• Remove the platform Page 9–57

1: Set the drive wheel as per the illustration.
2: Switch off the truck and disconnect the battery connector
DANGER!
when working on the drive gear/ drive wheel. The drive wheel will
automatically return to the original position when the truck is started.
• Remove the motor. Page 10–12
3: Loosen and remove the gear screws.
4: Lift the truck 100 mm and support it on trestles.
DANGER!
5: Remove the gear from the truck.
6: Mark the position of the steering bearing.
© Cesab 11 – 5 T Code(s): 1010

Fitting the drive gear
Step 1 Step 2
Step 3 Step 4
1: Lift the gear into place.

Note: Turn the wheel towards you (rearwards) to facilitate the lift.
2: Rotate the steering bearing to the right position; see marking.
3: Lower the truck and position the gear.
4: Fasten the screws.
• Fit the motor. Page 10–16
© Cesab 11 – 6 T Code(s): 1010

11.4 Oil check and oil change, large gear
11.4.1 Draining oil
Step 1 Step 2
Step 3 T=20 Nm

1: Undo and remove the oil plug on the lower part of the gear housing.
2: Drain all old oil into a suitable receptacle.
3: Clean away dirt and metal shavings from the oil plug before fitting.
© Cesab 11 – 7 T Code(s): 1010

11.4.2 Checking/refilling oil
Step 1 Step 2
Step 3
1: Remove the oil filler plug on the upper part of the gear housing.
2: Top up with oil up to the lower edge of the hole to reach the correct level.
Page 23–2
3: Screw in the plug.
© Cesab 11 – 8 T Code(s): 1010

11.4.3 Replacing the steering bearing
Removing the steering bearing
Step 1 Step 2

1: Loosen and remove the steering bearing screws.
2: Lift away the steering bearing.
Fitting the steering bearing
Step 1 Step 1
1: Position the steering bearing and screw it into place.

Note: Check that the bearing rotates before fitting it in the truck.
© Cesab 11 – 9 T Code(s): 1010

11.5 Oil check and oil change, small gear
11.5.1 Draining oil
Step 1 Step 2 Step 3 T=20 Nm

1: Undo and remove the oil plug on the lower part of the gear housing.
2: Drain all old oil into a suitable receptacle.
3: Clean away dirt and metal shavings from the oil plug before fitting.
© Cesab 11 – 10 T Code(s): 1010

11.5.2 Checking/refilling oil
Step 2 Step 3
1: Remove the oil filler plug on the upper part of the gear housing.
2: Top up with oil up to the lower edge of the hole to reach the correct level.
Page 23–2
3: Screw in the plug.
© Cesab 11 – 11 T Code(s): 1010

11.5.3 Replacing the steering bearing
Step 1 Step 2

1: Loosen and remove the steering bearing screws.
2: Lift away the steering bearing.
Step 1 Step 1
1: Position the steering bearing and screw it into place.

Note: Check that the bearing rotates before fitting it in the truck.
11.5.4 Replacing studs

The drive wheel is fixed to the hub with five studs, conical washers and nuts.
© Cesab 11 – 12 T Code(s): 1010

Loctite XXX
Step 1 Steps 2, 3 T=35 Nm
• Remove the drive wheel. Page 12–14

1: Remove the damaged studs.
– Use a stud tool to remove any studs with damaged threads.
– For broken studs, there are two methods:
Method 1: Drill a hole in the centre of the stud and remove it using a bolt
extractor.
Method 2: If the stud will not come loose with a bolt extractor, it will have
to be drilled out
– Drive a centre punch as close to the centre of the stud as possible
– Drill a pilot hole through the stud using a 5 mm bit
– Drill out the screw with a drill.
– Try to remove the stud remains using pliers, etc. If that does not work,
remove the remains by clearing the threads with a tap.
2: Apply Loctite® 270 to the stud thread.

3: Use the stud tool to fit the new stud and tighten to 35 Nm.
• Fit the drive wheel. Page 12–15
© Cesab 11 – 13 T Code(s): 1010

11.6 Replacing the wheel hub seal
Removing the seal
• Remove the drive wheel. Page 12–14

1: Remove the cover ring using a screwdriver or similar.
2: Remove the seal using a screwdriver or similar.
© Cesab 11 – 14 T Code(s): 1010

Fitting the seal
Step 1 Step 2
1: Fit a new seal. Tap lightly to get it into the right position.
2: Fit a new cover ring. Tap it lightly into place.
• Fit the drive wheel. Page 12–15
© Cesab 11 – 15 T Code(s): 1010

© Cesab 11 – 16 T Code(s): 1010

Repair manual: Brake system/Wheels C3000 Model(s): P320, P322
12. Brake system/Wheels C3000
12.1 Brake system C3100
12.1.1 Description
The truck has three different types of brake:
• travel brake,
• parking brake,
• emergency brake.
Travel brake
• Regenerative motor braking using the drive motor.
Parking brake
The brake [Q1] is a single stage electromechanical spring-loaded brake that
is released when the magnetic coil is energised. This brake serves as a
parking brake and emergency brake.
The parking brake is activated/is active as follows:
• The parking brake is applied automatically when the truck stops during
operation. The brake is released when the truck moves off.
• The parking brake remains active after the main power has been switched
on.
Emergency brake
Emergency braking of the truck takes place in the event of a fault with the
steering system or a serious fault in the electrical system.
The parking brake on the drive motor is the main emergency brake.
Motor braking can operate during emergency braking provided there is a
supply voltage.
© Cesab 12 – 1 T Code(s): 1010

12.2 Parking brake - C3370

DANGER!
Risk of brake function being lost.
When work is done in the brake system, there is a risk of brake function being
partly or completely lost.
Only the actions described in this section may be carried out on the parking
brake.
12.2.1 Overview
1 9
2
3
5
6

1 Screw
2 Wiring harness
3 Magnet housing
4 Guard
5 Locking screw
6 Hub
7 Friction disc
8 Pressure disc
9 Sleeved screw M5x40
© Cesab 12 – 2 T Code(s): 1010

Technical data
Description Standard Cold storage Standard/coldstore Unit

Brakes Non-CCV CCV Non-CCV / CCV
Nominal brake torque 21 30 Nm
Nominal air gap 0.2 (+015 -0.05) 0.2 ±0.05 mm
Maximum gap before adjustment 0.651 0.5 mm
Coil resistance 7.68 Ohm at 20ºC 6.261 Ohm at 20ºC Ohms
1. The standard brake 21Nm is not adjustable, it is replaced when the maximum gap is reached.
© Cesab 12 – 3 T Code(s): 1010

12.2.2 Checking the parking brake gap (adjustable brakes only)

1: Switch off the truck and disconnect the truck battery
2: Open the motor compartment. Page 9–2
3: Check that the parking brake is applied.
4: Use a feeler gauge to check that the air gap between the brake unit's
magnet housing and the movable pressure disc does not exceed 0.5
mm(30Nm) 0.65 mm (21Nm) or less than 0.15 mm at any place.
5: Adjust the gap if it does not fall within accepted limits. Page 12–5
12.2.3 Checking the parking brake gap (only for the small brake
21Nm in standard configuration)
If the brake has an air gap that cannot be adjusted, the rotating friction disc
must be replaced with a new one before the maximum air gap is exceeded.
3: Check that the parking brake is applied.
4: Use a feeler gauge to check that the air gap between the brake unit's
magnet housing and the movable pressure disc does not exceed 0.65
mm or less than 0.15 mm at any place.
5: If the air gap is not within the permitted values, the brake must be
cleaned or the friction disc replaced. Page 12–12
© Cesab 12 – 4 T Code(s): 1010

12.2.4 Adjustment of the parking brake gap
1: Undo the screws

2: Carefully turn the lock screw using a combination spanner.
• Turn the screw clockwise to lessen the gap if it is too large.
• Turn the screw counter-clockwise to increase the gap if it is too small.
• 1/6 of a turn changes the gap about 0.15 mm.
3: Torque tighten the screws to 11.3±1.2 Nm
Check the gap and repeat the adjustment if needed.
© Cesab 12 – 5 T Code(s): 1010

12.2.5 Emergency release of the parking brake

Note:
An emergency release of the brakes should only be performed when the
truck needs to be moved in connection with work for service and repairs.
If it is necessary to perform an emergency brake release manually:
3: To perform an emergency brake release, gradually screw in the two
sleeved screws M5×40 evenly.
4: Connect the battery.
5: Move the truck with great caution.
6: Disconnect the battery.
DANGER!
The sleeved screws must be removed in order to engage the parking brake.
7: Unscrew the two sleeved screws gradually.
8: Connect the battery and check that the parking brake engages.
© Cesab 12 – 6 T Code(s): 1010

12.2.6 Replacing the parking brake
Removing the parking brake

When the load is relieved from the parking brake friction disc or if the brake is
released mechanically and removed from the truck, the truck may move
unintentionally.
Step 1 Step 2 Step 3 Step 4
• Open the service cover. Page 9–3

1: Disconnect the connector (Q1) to the brake.
2: Remove the dust guard.
3: Fit the sleeved screws.
4: Remove the brake.
© Cesab 12 – 7 T Code(s): 1010

Fitting the parking brake
Step 1 Step 2 Step 3 Step 4

T=11.3 ±1.2 Nm
1: Fit the brake to the hub, be careful so that the splines are not damaged in
the process
2: Remove the sleeved screws.
3: Fit the dust guard.
4: Fit the connector (Q1).
DANGER!
Be careful when test driving after performing operations on the truck parking
brake.
The sleeved screws must be removed in order to engage the parking brake.
12.2.7 Checking the emergency stop/parking brake

Check that the truck brakes to a safe stop using the mechanical spring brake
when you press the emergency stop switch.
© Cesab 12 – 8 T Code(s): 1010

12.2.8 Replacing the friction disc
Removing the friction disc

1: Place the brake assembly on a clean, dry work bench with the magnet
housing facing downwards.
2: Remove the immovable pressure disk.
3: Lift out the friction disc..
© Cesab 12 – 9 T Code(s): 1010

Fitting the friction disc
Step 1 Step 2
1: Place the friction disc on the revolving pressure disk.

2: Place the fixed pressure disc on top of the friction disc, making sure the
screw holes are correctly positioned.
© Cesab 12 – 10 T Code(s): 1010

12.2.9 Replacing the brake hub
Removing the brake hub
Step 2
Step 1
• Remove the brakePage 12–7.
1: Remove the circlip
2: Remove the hub
Note: If the hub is stuck, you will need to use a puller to remove it.
Fitting the brake hub
Step 1 Step 2
1: Fit the hub carefully.

Note: Carefully knock the hub onto the shaft.
2: Fit the circlip
• Fit the brake. Page 12–8
© Cesab 12 – 11 T Code(s): 1010

12.2.10 Cleaning the parking brake

1: Remove the parking brake. Page 12–7
2. Place the parking brake on a workbench with the magnet housing facing
downwards.
3. Remove the immovable pressure disk.
4. Lift out the friction disc.
5. Clean the brake using compressed air. Clean from the inside outwards.
6. If there are particles that cannot be cleared away with compressed air,
these may be carefully scraped away.
7. Place the friction disc on the revolving pressure disk.
8. Place the immovable pressure disk on top of the friction disc, making
sure the screw holes are correctly positioned.
9. Check that the friction disc is centred in relation to the magnet housing.
10. Reinstall the parking brake. Page 12–7
Note:
It is extremely important that an air gap of min. 0.15mm is maintained all
around the brake. If the prescribed measurement cannot be maintained after
cleaning or adjustment, the brake must be replaced
11: Repeat the cleaning as necessary until a 0.15 mm feeler gauge can be
inserted. Measure the air gap between the magnet housing of the brake
unit and the movable pressure disc. Measuring must be done around the
entire pressure disc, both on the inside and the outside.
© Cesab 12 – 12 T Code(s): 1010

12.3 Drive wheel
Overview

1 Wheels
2 Washer
3 Nut
© Cesab 12 – 13 T Code(s): 1010

12.3.1 Replacing the drive wheel
Removing the drive wheel
Step 1 Step 2
Step 3 Step 4

1: Set the drive wheel as per the illustration.
2: Switch off the truck and disconnect the battery connector
DANGER!
3: Support the truck with trestles, etc
DANGER!
4: Disassemble the drive wheel.
© Cesab 12 – 14 T Code(s): 1010

Fitting the drive wheel
Step 1 Step 2 (T=83Nm M12)

(T=135Nm M14)
1: Fit the drive wheel and screw it on tight.

2: Lower the truck
DANGER!
DANGER!
Please be careful to check that everything is correctly fitted and also that the
gears / drive wheel may turn freely before the truck has power
© Cesab 12 – 15 T Code(s): 1010

12.4 Castor wheel

Overview
01 01
02 02
03 03

1 Single wheel
1 Twin wheels
2 Shaft set
3 Single wheel
3 Twin wheels
© Cesab 12 – 16 T Code(s): 1010

12.4.1 Replacing the castor wheel assembly
Removing the castor wheel assembly
3X
80 mm
Step 1 Step 2

2: Remove the castor wheel
Fitting the castor wheel assembly
3X
Step 1 Step 2
1: Fit the castor wheel

2: Lower the truck to the ground
© Cesab 12 – 17 T Code(s): 1010

12.4.2 Checking the castor wheels

Check that the castor wheels rotate freely.
12.4.3 Replacing the castor wheel (single)
Removing the castor wheel (single)
Step 1 Step 2
Step 3
• Remove the castor wheel assembly Page 12–17

1: Remove the nut from the wheel axle
2: Pull out the wheel axle
3: Remove the wheel
© Cesab 12 – 18 T Code(s): 1010

Fitting the castor wheel (single)
Step 2
Step 3
Step 1 T=160Nm
1: Fitting the wheel

Note: Do not forget to refit the washers.
2: Fit the wheel axle
3: Fit the nut on the wheel axle
• Removing the castor wheel assembly. Page 12–17
© Cesab 12 – 19 T Code(s): 1010

12.4.4 Replacing the castor wheel (twin wheel)
Removing the twin wheels
Step 1 Step 2
Step 3
• Remove the castor wheel assembly Page 12–17

1: Remove the nut from the wheel axle
2: Pull out the wheel axle
3: Remove the wheel
© Cesab 12 – 20 T Code(s): 1010

Fitting twin wheels
Step 2 Step 3
T=160Nm
Step 1

3: Fit the nut on the wheel axle
• Removing the castor wheel assembly. Page 12–17
© Cesab 12 – 21 T Code(s): 1010

12.5 Fork wheels

Overview
© Cesab 12 – 22 T Code(s): 1010

12.5.1 Replacing single wheels
Removing single wheels
170mm
Step 1 Step 2
1
2 Steps 3, 4
1: Remove the lock on the wheel axle

3: Knock out the wheel axle
4: Remove the wheel
© Cesab 12 – 23 T Code(s): 1010

Single wheel installation
1
2
2 2 170mm
1 Steps 1, 2 Step 3
Step 4

3: Lower the truck
4: Fit the locking on the wheel axle
© Cesab 12 – 24 T Code(s): 1010

12.5.2 Replacing the bogie wheel
Removing the bogie wheel
170mm
Step 1
Step 2
Step 3

2: Remove the wheel screw
3: Remove the wheel
© Cesab 12 – 25 T Code(s): 1010

Fitting the bogie wheel
Step 1 Step 2
Step 2
Max. 0,5mm
1
2
2 170mm
Step 3 Step 4

2: Insert and tighten the wheel screw
3: Centre the wheels with shims
Note: The wheels must be centred with a maximum play of 0.5 mm
4: Lower the truck
© Cesab 12 – 26 T Code(s): 1010

12.6 Wheel wear
Normal Minimum
Type mm
dimensions, mm (H) dimensions, mm
Drive wheel D = 250 25 12.5
Drive wheel D = 230 30 15
Castor wheel D = 150
20 10
Twin
Castor wheel D = 150 20 10
10 5
Twin
15 7.5
Single
Support arm wheel D =
10 5
85
© Cesab 12 – 27 T Code(s): 1010

© Cesab 12 – 28 T Code(s): 1010

Repair manual: Steering system C4000 Model(s): P320, P322
13. Steering system C4000
13.1 Steering arm C4110
13.1.1 Overview

a Tiller arm:
b Handle
© Cesab 13 – 1 T Code(s): 1010

13.1.2 Replacing the keypad C9420
Removing the keypad
Step 1
1: Detach the keypad and disconnect it from the logic card
Fitting the keypad
Step 1
1: Connect the keypad and screw it in position
© Cesab 13 – 2 T Code(s): 1010

13.1.3 Replacing the tiller arm cover
Removing the tiller arm cover
Step 1 Step 1
1: Fit the cover on the front of the tiller arm. It is held with catches on each
side.
Fitting the tiller arm cover
Step 1
1: Refit the cover.
© Cesab 13 – 3 T Code(s): 1010

13.1.4 Replacing the upper cover C4110
Removing the upper cover
Step 2 Step 3
• Remove the keypad. Page 13–2

1: Remove the screws holding the upper cover and keep hold of the upper
cover to prevent damage to the cable to the logic board
2: Disconnect the CAN connection to the logic card
© Cesab 13 – 4 T Code(s): 1010

Fitting the upper cover
x5
Step 1 Step 2
2 3
x4
4 1
Step 3 Step 4
1: Connect the CAN bus connection to the logic card

2: Press together the upper and the lower parts, and turn the screws five complete
turns. Start with the left side, and then proceed with the right side.
3. Turn the screws crosswise as depicted below a further four complete turns (a
total of nine turns, which corresponds to 1 Nm).
4. Check that there is no space between the tiller arm and the steering head.
5: Make sure that the control can be moved back and forth without difficulty, and
that the control returns to the neutral position.
If the control shows signs of being difficult to move: Re-adjust the screws
according to step 3.
6: Fit the cover at the front of the steering arm.
• Fit the keypad. Page 13–2
© Cesab 13 – 5 T Code(s): 1010

13.1.5 Replacing the tiller arm handle
Removing the tiller arm handle
Step 1 Step 1
• Remove the upper cover. Page 13–4

1: Remove the cable bracket/handle in the tiller arm.
Fitting the tiller arm handle
Step 1 “std” T=12 Nm Step 1
1: Fit the handle/cable bracket.

Note: Mount the wiring harness so that it does not get pinched.
• Fit the upper cover. Page 13–5
© Cesab 13 – 6 T Code(s): 1010

13.1.6 Replacing the logic card
Removing the logic card

Warning!
Static electricity!
Risk of static discharge that can damage the electronics.
Make sure you take the necessary steps to prevent static electricity, ESD
protection, before starting work on the steering module.
1: Remove the screws holding the cover over the logic card and carefully lift
away the cover.
Hint: Hold a finger between the cover and the shaft for the speed control
buttons to prevent the speed control assembly from falling down.
2: Lift off the speed control assembly
3: Pull out the logic card, and pull off the connectors.
© Cesab 13 – 7 T Code(s): 1010

Fitting the logic card
1: Fit the new logic card in place and connect it.

2: Check the cable connection on the logic card and that the connectors are
correctly connected.
3: Fit the speed control assembly in position. Hook the ends of the spring
around two the lugs in the cover
4: Fit the cover in place and screw it down. Make sure the conduit entry is
intact and correctly positioned.
© Cesab 13 – 8 T Code(s): 1010

13.1.7 Checking the handle

Test drive the truck and check the functions of the handle Page 14–22
13.1.8 Update the software

If a new logic card without software has been installed, use TruckCom to
download software and reset the parameters.
See the TruckCom manual.
© Cesab 13 – 9 T Code(s): 1010

13.1.9 Replacing the signal button/switch
Removing the signal button/switch
• Remove the logic card. Page 13–7

1: Remove the button using a screwdriver as illustrated.
2: Remove the connection for the switch on the logic card
3: Press out the switch from its bracket
Fitting the signal button/switch

1: Fit the new switch and connect the cable to the logic card
2: Align the button with the catch and secure it by hand.
• Fit the logic card Page 13–8
© Cesab 13 – 10 T Code(s): 1010

13.1.10 Replacing the lift/lower button
Removing the lift/lower button
A A

1: Remove the button by placing a screwdriver in the holes (A).
2: Unscrew the plate securing the arm and remove the arm.
Fitting the lift/lower button

1: Press the springs together and fit the button in place. Snap the button in
place by hand.
© Cesab 13 – 11 T Code(s): 1010

13.1.11 Replacing the button
Removing the push button

1. Press out the button laterally with the fingers.
2. Position a screwdriver as illustrated and carefully pry out the button.
3. Unscrew the button-holder and arm.
Fitting the push button

1: Fit the button holder and arm.
2: Position the button and press it into place by hand.
© Cesab 13 – 12 T Code(s): 1010

13.1.12 Replacing the symbol disc - support arm lift/fork lift
Removing the symbol disc, support arm lift/fork lift
1. Pry off the lift control buttons using a thin screwdriver and switch the
positions with the rear buttons.
Fitting the symbol disc, support arm lift/fork lift

1: Make sure the lips catch when the new buttons are inserted.
2: See parameter 1102 for more information.
2. Start the truck and make sure the change is correct.
© Cesab 13 – 13 T Code(s): 1010

13.1.13 Replacing the safety reversing switch
Removing the safety reversing switch
Step 1 Step 2
1: Loosen the screws until the switch brackets come loose.

2: Remove the button by unhooking the catches on both sides.
Fitting the safety reversing switch
Step 1 Step 2
1: Fit the button, ensuring that all component parts follow along.
2: Tighten the screws.
© Cesab 13 – 14 T Code(s): 1010

13.2 Steering arm C4110
13.2.1 Overview steering arm manual steering
4 6
5
3
1 7
8
9
10
11
12
13
14
16
15

1 Cover
2 Steering yoke
3 Roller
4 Spring
5 Bushing
6 Shaft
7 Bracket
8 Plate
9 Screw
10 Sensor
11 Damper
12 Plate
13 Cover
14 Screw
15 Bar
16 Cover
© Cesab 13 – 15 T Code(s): 1010

13.2.2 Overview steering arm power steering
4
6
3 5
1 7
8
9
10
11
12
17
14 13
16
15

1 Cover
2 Steering yoke
3 Roller
4 Spring
5 Shaft
6 Bushing
7 Bracket
8 Plate
9 Screw
10 Sensor
11 Damper
12 Plate
13 Cover
14 Screw
15 Bar
16 Cover
17 Push button
© Cesab 13 – 16 T Code(s): 1010

13.2.3 Replacing the tiller arm (manual and power steering)
Removing the tiller arm
Step 4
• Remove the tiller arm handle. Page 13–6

1: Remove the dampers.
2: Remove the shaft lock.
3: Remove the spring stop.
4: Knock out the shaft and lay the arm down.
© Cesab 13 – 17 T Code(s): 1010

Fitting the tiller arm
© Cesab 13 – 18 T Code(s): 1010

1: Fit the spring stop.

2: Fit the tiller arm.
Note: Move the arm obliquely forward so that is suspended from the spring
ends.
3: Press the arm in place
4: Tap in the shaft, leaving the adjuster wheel outside.
5: Fold down the arm, adjust the shaft so the hole points straight up and tap
in the shaft.
6: Fit the shaft lock and screw it in tight.
7: Fit the dampers.
• Fit the tiller arm handle. Page 13–6
© Cesab 13 – 19 T Code(s): 1010

13.2.4 Replacing the tiller arm suspension (manual and power

steering)
Removing the tiller arm suspension
Step 1
• Remove the tiller arm. Page 13–17

1: Lift out the spring package.
Make a note of which is the left side and which is the right side of the plastic
roller, marked H and V respectively
© Cesab 13 – 20 T Code(s): 1010

Fitting the tiller arm suspension
Step 1
1: Fit the spring package into the yoke

Note: Make sure that the spring holder is turned the correct way, the
markings H (right) and V (left) in the fork direction
Fit into the groove of the spring holder so that it is led onto the bushings, turn
a quarter turn upwards
• Fit the tiller arm. Page 13–18
© Cesab 13 – 21 T Code(s): 1010

13.2.5 Replacing the safety switch (manual and power steering)
Removing the safety switch
• Removing the tiller arm suspension. Page 13–20

1: Unscrew and remove the sensor bracket
2: Disconnect connector B60
3: Remove the sensor from the snap lock
© Cesab 13 – 22 T Code(s): 1010

Fitting the safety switch
Step 2 Step 3
1: Fit the sensor in the snap lock

2: Connect the connector B60
3: Fit and screw tight the sensor bracket to the yoke.
• Fitting the steering arm suspension. Page 13–21
© Cesab 13 – 23 T Code(s): 1010

13.2.6 Replacing the steering yoke
Removing the steering yoke
Step 1 Step 2
• Remove the gas strut. Page 13–42 (Power steering)

• Remove the cover around the steering adapter Page 9–9 (Manual)
• Remove the safety switch. Page 13–22
• Remove the safety switch (E-man). Page 13–32
1: Remove the bolt and nut of the height adjustment to ease the removing
of the rear screws. (Power steering)
2: Remove the screws and lift the yoke straight up, taking care not to
damage the wiring harness.
© Cesab 13 – 24 T Code(s): 1010

Fitting the steering yoke
Step 1 T=30 Nm Step 2 T=5 Nm
1: Fit and screw on the yoke in the steering adapter.

Note: Be careful with the wiring harness so that it does not get pinched
between the yoke and the steering adapter.
2: Fit the height adjustment and screw it in tight
• Fit the safety switch. Page 13–23
• Fit the safety switch (E-man). Page 13–32
• Install the gas spring Page 13–43
• Fit the cover around the steering adapter. Page 9–9
© Cesab 13 – 25 T Code(s): 1010

13.3 Tiller arm, E-man

a Tiller arm:
b Handle
© Cesab 13 – 26 T Code(s): 1010

13.3.1 Overview, tiller arm E-man
17
2
22 4
3 6
5
10
7 8 9
21 20
19
14
11
12
13
18
17
16 15
Pos. Component Note

1 Cover
2 Cover
3 Pin
4 Spring
5 Damper
6 Push button
7 Screw
8 Sensor
9 Bracket
10 Clamp
11 Shaft
12 Screw
13 Screw
14 Spring
15 Screw
16 Cover
17 Steering yoke
18 Cover
19 Bushing
20 Screw
21 Cover
22 Cover
© Cesab 13 – 27 T Code(s): 1010

13.3.2 Replacing the tiller arm cover (E-man)
Removing the tiller arm cover (E-man)
Step 1 Step 2
1: Remove the cover.

2: Remove the cover.
Fitting the tiller arm cover (E-man)
Step 1 Step 2 T=1 Nm
1: Refit the cover.

2: Refit the cover. Insert the guide pins when fitting the covers.
© Cesab 13 – 28 T Code(s): 1010

13.3.3 Replacing the upper cover (E-man)
Removing the upper cover (E-man)
Step 1 Step 2
• Remove the keypad. Page 13–2

• Remove the tiller arm cover (E-man). Page 13–28
1: Remove the screws holding the upper cover and keep hold of the upper
cover to prevent damage to the cable to the logic board
2: Disconnect the CAN connection to the logic card
© Cesab 13 – 29 T Code(s): 1010

Fitting the upper cover (E-man)
x5
Step 1 Step 2
2 3
x4
4 1
Step 3 Step 4
1: Connect the CAN bus connection to the logic card

2: Press together the upper and the lower parts, and turn the screws five
complete turns. Start with the left side, and then proceed with the right
side.
3. Turn the screws crosswise as depicted below a further four complete
turns (a total of nine turns, which corresponds to 1 Nm).
4. Check that there is no space between the tiller arm and the steering
head.
5: Make sure that the control can be moved back and forth without difficulty,
and that the control returns to the neutral position.
If the control shows signs of being difficult to move: Re-adjust the screws
according to step 3.
• Fit the keypad. Page 13–2
• Fit the tiller arm cover (E-man). Page 13–28
© Cesab 13 – 30 T Code(s): 1010

13.3.4 Replacing the tiller arm handle (E-man)
Removing the tiller arm handle (E-man)
Step 1 Step 1

1: Remove the cable bracket/handle in the tiller arm.
Fitting the tiller arm handle (E-man)
Step 1 “E-Man” T=9.8 Nm Step 1

Apply Loctite 243 on the screw.
1: Fit the handle/cable bracket.

Note: Mount the wiring harness so that it does not get pinched.
© Cesab 13 – 31 T Code(s): 1010

13.3.5 Replacing the safety switch (E-man)
Removing the safety switch (E-man)
Step 1 Step 1

1: Remove the switch.
Fitting the safety switch (E-man)
Step 1 Step 1
1: Install the switch.

© Cesab 13 – 32 T Code(s): 1010

13.3.6 Replacing the tiller arm (E-Man)
Removing the tiller arm (E-man)
Step 1 Step 1
Step 2 Step 3

1: Remove the spring, unhooking it from the bracket. Make sure that the
spring does not fly off.
2: Remove the shafts.
3: Remove the tiller arm bracket.
© Cesab 13 – 33 T Code(s): 1010

Fitting the tiller arm (E-man)
Step 3 Step 4
1: Fit the tiller arm bracket.

2: Fit the spring.
3: Fit the shaft on the right side in the fork direction.
4: Fit the shaft on the left side in the fork direction.
Note: Press the tiller arm bracket downwards to fit the shaft. Do not use any
tools. Use hand force only when fitting so as not to damage the bushings.
© Cesab 13 – 34 T Code(s): 1010

13.4 Power steering

The steering system is electric and uses a "Steer-By-Wire" design. There is
no mechanical contact between the handle and the steered drive wheel.
Steering is progressive, which means that when the truck is operated at low
speed the steering wheel gearing ratio is higher than at high speeds. This
allows the truck to be operated in a safe and efficient manner.
13.4.1 Safety
Note: If the drive wheel is not in the home position “straight ahead” 0° when
the truck is started, it will return to the home position automatically. This is
important to remember when performing service and repairs when cover are
removed and when working in the motor compartment.
13.4.2 Overview
2
3
4

1 Steering damper
2 Servo motor
3 Steering angle sensor
4 Gear ring
© Cesab 13 – 35 T Code(s): 1010

13.5 Steering angle sensor C4350

The steering angle reference sensor [B17] is used as a reference for 0° for
the 360° steering. It is located on the drive unit house.
The sensor signal changes status when the drive wheel is positioned so that
the truck moves straight forward/back = 0°.
Steering is calibrated through a reference search when the truck is started.
Each time the signal from the reference sensor changes status, there is a
check that steering angle is 0°.
The reference sensor is also monitored in that the drive wheel may not be
turned by more than 180°, plus a certain tolerance, between each sensor
status change.
© Cesab 13 – 36 T Code(s): 1010

13.5.1 Replacing the steering angle sensor servo unit
Removing the steering angle sensor

2: Remove the screw securing the sensor.
3: Pull the sensor straight up.
Fitting the steering angle sensor
1: Fit the sensor and screw on tight.

© Cesab 13 – 37 T Code(s): 1010

13.5.2 Replacing the steering damper
Removing the steering damper
Steps 1, 2

2: Remove the steering damper
© Cesab 13 – 38 T Code(s): 1010

Fitting the steering damper
Step 1 Step 2
Step 3 Steps 4, 5
1: Lubricate the hole at the bottom of the shaft with Klüberplex® BEM 34-
132
2: Lubricate the entire journal on the steering damper with lubricant type H.
Page 23–2
3: Fit the rubber bushing on the journal.
4: Fit the steering damper and screw it on tight
Note: when refitting, check that the steering axle fits properly before
screwing the steering damper on tight.
© Cesab 13 – 39 T Code(s): 1010

13.5.3 Calibrating the steering damper/reference sensor

The sensor signal changes status when the drive wheel is positioned so that
the truck moves straight forward/back = 0°.
Steering is calibrated through a reference search when the truck is started.
Each time the signal from the reference sensor changes status, there is a
check that steering angle is 0°.
© Cesab 13 – 40 T Code(s): 1010

13.5.4 Steering adapter (power steering)
overview
3
5
4
2
6
8
7
11
10
12
14
13

1 Steering pin
2 Nut
3 Steering adapter
4 Screw
5 Push button
6 Lever
7 Bushing
8 Screw
9 Spring
10 Shaft
11 Bushing
12 Shaft
13 Stopper
14 Pin
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13.5.5 Replacing the gas strut - height adjustment
Removing the gas strut - height adjustment
Step 3
• Remove the cover to the steering adapter. Page 9–9

1: Lift the tiller arm to the uppermost position.
2: Compress the gas strut, press down with your hand until it is possible to
turn the gas strut outwards.
Note: The gas strut is only inserted into the steering adapter.
Note: Do not let go of the gas strut, let it carefully expand upwards
the gas strut.
© Cesab 13 – 42 T Code(s): 1010

Fitting the gas strut - height adjustment
Step 1 Step 2
1: Fit the gas strut onto the ball screw

2: Compress the gas strut by hand and turn it under the steering adapter
and let it carefully expand upwards.
• Fit the cover around the steering adapter. Page 9–9
© Cesab 13 – 43 T Code(s): 1010

13.5.6 Replacing the lock - height adjustment
Removing the lock - height adjustment
Steps 1, 2, 3
• Remove the cover around the steering adapter. Page 9–9

1: Undo and remove the bolt and nut that hold the arm.
2: Pull out the guide pin from the brass sleeve.
3: Lower the complete arm.
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Fitting the lock - height adjustment
Step 1, 2 T=5 Nm
1: Push the arm up into the steering adapter and fit the guide pin in the
brass sleeve.
2: Fit the arm and screw it on tight.
• Fit the cover to the steering adapter. Page 9–9
13.5.7 Checking the lock - height adjustment

Check that the tiller arm can be lifted and lowered and that the lock does not
seize in the steering adapter.
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13.5.8 Replacing the steering adapter (power steering)
Removing the steering adapter
Step 1 Step 2
• Remove the steering yoke. Page 13–24

1: Unscrew and remove the guide pin
2: Press the height adjustment button and pull the steering adapter straight
up
Fitting the steering adapter
Step 1 T=45 Nm
1: Fit the steering adapter by pressing in the height adjustment button and
screwing the guide pin into place. T=45 Nm, use loctite 243.
• Fit the steering yoke. Page 13–25
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13.5.9 Replacing the steering bearing (power steering)
Step 1 Step 2
Step 3 Step 4
• Remove the steering adapter (power steering). Page 13–46

1: Unscrew the nut that locks the steering shaft
2: Knock the shaft straight up. Use a rubber mallet or other suitable tool.
3: The upper steering bearing is removed upwards.
4: Lower bearing, remove the circlip and knock out the bearing.
© Cesab 13 – 47 T Code(s): 1010

Step 1 Step 2
1: Fit the lower steering bearing and the circlip

2: Fit the upper steering bearing.
3: Fit the steering shaft
4: Screw on the nut that locks the steering shaft. T=80 Nm
• Fit the steering adapter (power steering). Page 13–46
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13.5.10 Replacing the mechanical stop of the steer axle (power

steering)
Removing the mechanical stop of the steer axle (power steering)
Step 1 Step 2
• Remove the steering adapter (power steering). Page 13–46

3: Remove the ball screw.
4: Remove the spring pin.
5: Remove the mechanical stop.
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Fitting the mechanical stop of the steer axle (power steering)
1: Fit the mechanical stop, ensuring it ends up facing the right way.
2: Fit the spring pin.
3: Fit the ball screw.
5: Screw on the nut that locks the steering shaft.
• Fit the steering adapter (power steering). Page 13–46
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13.6 Mechanical steering
13.6.1 Overview
1
2

1 Steering angle sensor
2 Driver
3 Steering ring
© Cesab 13 – 51 T Code(s): 1010

13.6.2 Steering adapter, mech. steering

1 Steering adapter
2 Screw
3 Shaft
4 Pin
5 Stopper
6 Washer
7 Nut
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13.6.3 Replacing the steering adapter (fixed)
Removing the steering adapter
Step 3
• Remove the steering yoke. Page 13–24

1: Loosen the screws and pull the adapter straight up
Fitting the steering adapter
Step 1
1: Fit and screw on the steering adapter

• Fit the steering yoke. Page 13–25
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13.6.4 Replacing the steering angle sensor
Removing the steering angle sensor
Step 3
Step 1 Step 2
x2
Step 4 Step 5

1: Turn the tiller arm 90 degrees
2: Disconnect the connector B13
3: Remove the shaft stop screw
4: Unscrew the bracket.
5: Unscrew the sensor and remove the wire clip at the back
© Cesab 13 – 54 T Code(s): 1010

Fitting the steering angle sensor
Step 1 Step 1
Steps 2, 3, 4 Step 5
1: Fit and turn the sensor so that the screw is centred in the screw holes.
2: Fit the sensor bracket and the cable clamp in the angled plate
3: Fit and screw on the sensor on to the steering axle.
4: Screw down the angled bracket securely
5: Connect the connector B13
• Refit the service casing. Page 9–3
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13.6.5 Replacing the steering bearing - mechanical steering
Step 4 Step 5
• Remove the steering adapter (mechanical steering). Page 13–53

3: Turn the driver to the side.
4: The upper steering bearing is removed upwards.
5: Lower bearing, remove the circlip and knock out the bearing.
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1: Fit the lower steering bearing and the circlip

2: Fit the upper steering bearing.
3: Turn back the driver
• Fit the steering adapter (mechanical steering). Page 13–53
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13.6.6 Replacing the mechanical stop of the steer axle
Removing the mechanical stop of the steer axle
Step 1 Step 2
Step 3 Step 4
• Remove the steering adapter (mechanical steering). Page 13–53

3: Remove the spring pin.
4: Remove the mechanical stop.
© Cesab 13 – 58 T Code(s): 1010

Fitting the mechanical stop of the steer axle
Step 1 Step 2
1: Fit the mechanical stop.

2: Fit the spring pin.
• Fit the steering adapter (mechanical steering). Page 13–53
© Cesab 13 – 59 T Code(s): 1010

© Cesab 13 – 60 T Code(s): 1010

Repair manual: Electrical system C5000 Model(s): P320, P322
14. Electrical system C5000
14.1 General
The electrical system in the AC powered trucks consists of a number of
electronic modules, A5-T1, which communicate with each other via two
separate CANs (Controller Area Network). Communication is active as long
as the truck is switched on.
The following electronic units are housed in the tiller arm:
[A5] integrated control panel A5
The following electronic modules are housed in the chassis:
[T1] motor control ACT
The input signals for the various truck functions are received by the electronic
modules are both digital (switches and sensors) and analogue
(potentiometers and sensors).
Likewise, the output signals for the various truck functions received by the
electronic modules are both digital (valves, drive wheel brakes, etc.) and
analogue (proportional valves).
14.1.1 Truck firmware applications

The truck firmware for the truck consists of a complete firmware package for
all logic cards installed in the truck.
The firmware package file consists of a configuration file, with the .ini format,
which describes the various applications for each logic card.
© Cesab 14 – 1 T Code(s): 1010

14.2 Menus
The speed control is used for menu navigation.
To select a menu item, press and release the horn button.
Menu item "ESC" always returns you to the previous menu.
If logged in without CAN key or TruckCom, only a limited number of menus
are available.
14.2.1 Menu navigation

Proceed as follows if you only want to view the different truck settings:
1. Ensure that the truck is switched off. Connect the CAN key or enter the
3. Move between menus by turning the speed control several times.
4. Press and release the horn button to select which menu to view.
5. Turn the speed control several times to move between the different
positions in the selected menu.
6. If logged in without CAN key or TruckCom, only a limited number of
menus are available and unavailable menus are not shown.
The following are not shown:
- Calibration (CAL)
- PIN code menu (Pin)
- Collision sensor log (c)
- Service mode (Ser)
7. Switch off the truck by pressing the OFF button or return to the previous
See the menu overview on the next page.
© Cesab 14 – 2 T Code(s): 1010

Menu overview
Log on using horn
Parameter set/ PIN code menu Escape

Info menu Emergency drive Calibrate
view “CAL” “Pin” “ESC”
“InFo” “Ed” “Cal”
“PAr” Truck resets
Starts truck in
First parameter 1st calibrate Enter PIN code
emergency drive
“1” function edit function
mode. All LEDs
are flashing “1”
Last parameter Last calibrate

“XXXX” function
“X”
Escape Escape
“ESC” “ESC”
Back to prev menu Back to prev menu
Part number Build in test ICH Escape

Hour meter display Error log display Shock lockout log
display “tESt” “ESC”
“H” “E” “c”
“Pn” Back to prev menu
A time “A” Software part no Display test Latest shock PIN

Latest error “1”
Total key on time “SPn” Walking 8 “1”
B time “b” Oldest error “XX” Hardware part no Oldest shock PIN
Throttle
Active time (XX max 50) “HPn” “10”
Accessible to
the operator
C time “c” Escape Escape
Machine no Emergency
Drive avtive time “ESC” “ESC”
“no” Reverese
Back to prev menu Back to prev menu
D time “d” Only accessible

Hydraulic active Hardware serial no Lift/Lower with the CAN key,
time “HSn” operator
S time “S” Escape

“ESC” Sensilift
Time to service
Back to prev menu
Escape
“ESC” Keyboard
Back to prev menu
Escape by
pressing horn
© Cesab 14 – 3 T Code(s): 1010

14.2.2 Menu information

An explanation/description of the various menus is found below.
For access and navigation among the menus. Page 14–2
14.2.3 Show hour counter values

1: “H” is shown on the display.
2: Press the horn button to select. The hour counter symbol is lit.
3: You can obtain the following information by pressing the speed control
repeatedly:
- Total time (A)
- Total operating time (b)
- Total operating time drive motor (c)
- Total operating time hydraulic motor (d)
- Time until service (S)
4: To show an hour meter value, release the speed control when the
required hour meter symbol is shown on the display. The hour meter
value in question is shown on the display.
5: Switch off the truck by pressing the OFF button or return to the previous
14.2.4 Show error codes

Note: Max. 50 error codes are stored
1: “E” is shown on the display.
repeatedly:
- Latest error code (1)
- Next error code, etc. (2)
- Last error code (XX, max 50)
4: To show an error code, release the speed control when the required error
code is shown on the display.
© Cesab 14 – 4 T Code(s): 1010

14.2.5 Show part numbers for software/hardware

1: “Pn” is shown on the display.
repeatedly:
- SPn - Software package
- HPn - Logic card
- no - Machine number
- HSn . Logic card serial number
4: To show a part number, release the speed control when the required part
number is shown on the display.
14.2.6 Built-in test A5 (A5)

See section "8.8 Built-in test function for the tiller arm".
14.2.7 Show collisions

If there is a collision sensor installed on the CAN bus, it registers when the
truck bumps into something. Information about the collision is stored in the
truck's internal memory. The last ten registered collisions can be read directly
from the display together with operator identity via the PIN code. Additional
information is available via TruckCom, where collision levels and time
indications can also be read.
1: “c” is shown on the display.
3: By pressing the speed control repeatedly, you can see the last 10
collisions.
If a 5-digit PIN code is shown, the first digit is shown and then the other 4
digits are shown.
14.2.8 Show/change parameters

1: “Par” is shown on the display.
2: Press the horn button to select. The parameter symbol lights up.
3: By pressing the speed control repeatedly, you can move through the
parameter list.
See section "5.1 General parameters".For setting parameters.
To show a parameter, release the speed control when the required parameter
is shown on the display. Press the horn button to change the parameter.
© Cesab 14 – 5 T Code(s): 1010

14.2.9 Emergency driving mode

See section "8.2.1 Emergency driving mode". for more information
14.2.10 Calibration
See section "5.8 Calibration". for more information
14.2.11 Show/change PIN code

See section "6.5 Using PIN codes". for more information
© Cesab 14 – 6 T Code(s): 1010

14.3 Battery C5110
14.3.1 Battery replacement

DANGER!
Risk of short-circuiting.
An incorrectly connected battery may cause short-circuiting.
The polarity must be correct. Compare the markings on the cables with those
on the battery terminals.
Note:
Make sure the battery’s minimum and maximum weights comply with those
on the truck type plate.
Check the electrolyte level in the battery. Normally, the level should be
around 10-15 mm above the cell plates.
Replacement using a battery changing table.

1: Open the cover of the battery compartment.
2: Move the truck close to the battery changing table.
If the battery is not installed, do as follows:
–Connect a temporary cable between the truck and battery.
–Move the truck to the battery changing table.
–Disconnect the temporary cable.
3: Release the catch and roll the battery over to the battery changing table.
4: Move the truck close to the new battery.
5: Push the battery in place and lock the battery.
6: Connect the battery connector.
7: Reposition the cover over the battery compartment.
8: If the truck is not to be used straight away, you must check to ensure that
logout has taken place.
© Cesab 14 – 7 T Code(s): 1010

Replacement using lifting gear

DANGER!
To prevent the battery from falling down when it is released from the lifting
device, prepare trestles or other suitable supports of the right height to
support it. Check the height of the supporting material before releasing the
lifting hook.
1. Open the cover of the battery compartment.
2. When removing, pull out the battery connector and release the catch
3. Lift the battery in/out using an approved lifting device and a suitable
battery lifting yoke or lifting straps.
4. Lift the battery so that it just goes free.
5. Move the battery sideways and place it down.
6. When installing, connect the battery cables/battery connector and lock
the battery.
DANGER!
Check that the polarity is correct when connecting the battery cables.
Compare the markings on the cables with those on the battery terminals. An
incorrectly connected battery may cause short-circuiting.
7. Close the battery compartment cover.
8. If the truck is not to be used straight away, you must check to ensure that
logout has taken place.
© Cesab 14 – 8 T Code(s): 1010

14.3.2 Charging the battery
DANGER!
Always wear safety goggles and protective gloves when checking the
battery!
DANGER!
When charging the battery it is absolutely forbidden to smoke or use a naked
flame.
DANGER!
The battery case contains corrosive acid. Spilled fluid on the skin must
immediately be removed. Wash with soap and plenty of water.
If the fluid was in contact with your eyes, they should immediately be washed
with eye wash and a doctor should be contacted.
DANGER!
Risk of explosion.
During the charging process oxygen and hydrogen gases are always formed
in the battery. A short-circuit, an open flame or a spark near the battery may
cause an explosion.
Always switch off the charging current BEFORE removing the battery
connector. Provide good ventilation, especially if the battery is charged in a
confined area.
Use an automatic battery charger intended for charging traction truck
batteries.
The charger shall have an automatic maintenance charging feature for a
certain period after the main charging period has been completed. This
eliminates the risk of overcharging the battery and the need to monitor the
charging procedure is reduced to a minimum.
The charger shall have a minimum charging current as indicated in the
following table:
Battery (Ah) Charger (A)
300 – 480 50 – 70
480 – 730 80 – 110
730 – 900 130 – 150
© Cesab 14 – 9 T Code(s): 1010

Before charging
1: Park the truck in the assigned charging area.

2: Switch off the truck.
3: Open the battery door and let it remain open during the whole charging
time. Ensure nothing hinders ventilation above the battery.
4: Separate the battery connectors.
5: Rinse off and dry the battery.

6: Make sure the charger unit is switched off.
7: Connect the battery charger to the battery charging socket.
8: Start the charger.
During charging
9: After a couple of minutes, check that the charger indicates the correct
charge; see the charger's manual.
After charging
10: Make sure that the ammeter indicates an insignificant or no reading and
that the maintenance charging lamp is on, if fitted.
11: Switch off the battery charger.
12: Disconnect the battery charger connector from the charging connector of
the battery.
DANGER!
The terminals can otherwise be damaged inside and result in a subsequent
short-circuit.
Do not pull the cables to disconnect from the charger.
13: Check the fluid level and top up with distilled water if needed. The fluid
level should be around 10 - 15 mm above the cell plates.
For detailed instructions, please see the instructions provided by the battery
manufacturer.
© Cesab 14 – 10 T Code(s): 1010

14.4 Li-ion battery (Hoppecke)
14.4.1 Resetting/restarting the battery

If error codes are generated or the battery lamp does not light with a steady
green glow, the battery can be restarted.
1: Disconnect the battery yoke

Note: the yoke must be removed from the battery.
2: Disconnect the CAN connector X111.
3: Wait until the light goes out.
4: Connect the CAN connector.
5: Wait until the lamp on the battery shows steady green.
6: Reconnect the battery yoke.
14.5 Inspecting the battery

1: Check that a green lamp is lit on the battery. This indicates that
everything is OK.
2: Check the attachment of the brackets.
3: Check electrical connections on the CAN wiring harness.
4: Check the attachment of the battery lock.
5: Check that the covers have been refitted properly.
© Cesab 14 – 11 T Code(s): 1010

14.6 Electric panel:
14.6.1 Overview

a Motor controller:
b Main contactor
c Pump contactor
© Cesab 14 – 12 T Code(s): 1010

14.7 Motor control [T1] (ACT)
14.7.1 General
Drive/pump motor output control is done via transistor regulators, ACT or
ACC.
The regulators contain software for drive motor and pump motor output
control. They are configured for their function during programming with
TruckCom via the truck's CAN service socket.
The transistor regulators have dedicated internal monitoring of CAN
communication, DC voltage levels, their own temperature and motor
temperature.
Any malfunctions are recorded via internal monitoring and are sent via the
CAN to A5, where the error code is registered and subsequently displayed
on the display [A6].
The regulators have a green LED to indicate status:
• Start-up – LED flashes twice
• Normal operation – LED remains lit
• Error – LED flashes or is unlit.
Power is fed via two copper bars B+ and B-. B+ is secured with a fuse.
© Cesab 14 – 13 T Code(s): 1010

14.7.2 Replacing the motor control
Removing the motor control

Note:
This action requires access to TruckCom!
Step 1 Step 2

1: Detach the cable connections, the plate and the connector on the panel.
2: Remove the screws and guide the panel out of the truck.
Fitting the motor control
T1
T2
Step 1 Step 2 Step 2 T1 = 7.5 Nm, T2 = 9

Nm
1: Position the panel and screw it in place.
2: Attach the cable connections, the plate and the connector on the panel.
© Cesab 14 – 14 T Code(s): 1010

14.7.3 Replacing the pump contactor
Removing the pump contactor
• Remove the service cover Page 9–3

1: Loosen and remove the connection nuts.
2: Remove the cable and plate.
3: Remove the fuse holder.
4: Loosen and remove the nuts of the connections.
5: Guide out the pump contactor.
© Cesab 14 – 15 T Code(s): 1010

Fitting the pump contactor
Step 4 Step 5 Step 6 T = 9 Nm

2: Guide in the pump contactor.
3: Screw the pump contactor into place.
4: Fit the fuse holder.
5: Fit the cable and plate.
6: Tighten the nuts of the connections.
© Cesab 14 – 16 T Code(s): 1010

14.7.4 Replacing the main contactor
Removing the main contactor
Step 7 Step 8
© Cesab 14 – 17 T Code(s): 1010


1: Disconnect and move aside the wiring harness.
2: Undo the nuts of the electrical connections.
3: Loosen and remove the plate.
4: Remove the fuses and cable.
5: Disconnect the connector and unscrew the motor control.
6: Move aside the motor control.
7: Undo the screws securing the main contactor.
8: Guide out the main contactor.
© Cesab 14 – 18 T Code(s): 1010

Fitting the main contactor
Step 7 Step 8
© Cesab 14 – 19 T Code(s): 1010

1: Guide in the main contactor.

2: Screw the main contactor into place.
3: Move the motor control back into position.
4: Connect the connector and screw the electric panel into place.
5: Fit the fuses and cable.
6: Fit the plate.
7: Tighten the nuts of the connections.
8: Connect the wiring harness.
© Cesab 14 – 20 T Code(s): 1010

14.8 Horn C5160
14.8.1 Horn [P4]
+ (2) - (1)
Pos. Description
a Horn (P4)
The horn [P4] is supplied battery voltage to connection ‘+’. Control is handled
via T1 output X112:XX, “HORN”. When the output is low, the horn sounds.
[G1]
[F51] + -
[T1]
2 1
39
X112-xx
© Cesab 14 – 21 T Code(s): 1010

14.9 Control system
14.9.1 Direction selector/speed regulator

Travel direction and speed are selected by rotating the speed contract in the
required direction with an angle equivalent to the required speed. The speed
control signal is processed to emulate a potentiometer, even though there are
discrete sensor steps.
When navigating in menus, the speed control is used to move between
different positions.
14.9.2 Safety reversing

When ERB is depressed, at least one specific Hall element is activated.
Since the Hall elements are also used for rpm control, they are continually
monitored.
14.9.3 Battery indicator

Each time you start the truck, the operation time is shown for a few seconds in
the numeric field. At the same time the hour meter indicator is lit. After it goes
out, the battery capacity is continuously shown in the numeric field at the same
time as the battery indicator is lit.
When the battery indicator symbol lights, the battery capacity can be read in %
in the numeric field of the display:
• 100% = Fully charged battery
• 0% = Discharged battery
When the field shows 10% capacity, the symbol starts to flash.
Charge the battery when the symbol flashes to save the battery.
If you continue to use the truck without charging the battery, the lift function is
shut down when the field shows 0% capacity. The truck can still be driven, so
that it can be taken to the charging station.
© Cesab 14 – 22 T Code(s): 1010

14.9.4 Hour meter

Total operating time (b) is shown by default in the display. The following
information can also be displayed by accessing the menu system. Page 14–4
- Total time (A)
- Total operating time (b)
- Total operating time drive motor (c)
- Total operating time hydraulic motor (d)
- Time until service (S)
14.9.5 Lifting and lowering control - support arm/fork lift

Lifting and lowering is controlled by 2 controls that are integrated in the
handle. Factory parameter #1102 determines which hydraulic function the 2
controls have. Connect a PDA or PC and use TruckCom to change the
parameter.
14.9.6 Signal buttons

Fixed buttons on each side of the handle. Activation of either of these buttons
will activate the horn in normal mode. If the CAN key is connected during
login, the signal button is used to come to the desired position in the service
information. See section "8.6 Service information".
14.9.7 Option buttons

There are six option buttons in the handle, all of which can be used for
different options.
© Cesab 14 – 23 T Code(s): 1010

14.9.8 Display
The display is a four-digit, seven segment numeric information display with
coloured LED symbols, together with a menu-based information system as
the primary communication tool between the operator/technician and the
truck.
In logged-in mode, the display is always lit and shows battery capacity in the
numeric field while the battery indicator is lit.
General
A keypad and a numeric information display with coloured LED symbols are
used together with a menu-based information system as the primary
communication tool between the operator/technician and the truck.
In logged-in mode, the display is always lit and shows battery capacity in the
numeric field while the battery indicator is lit.
Symbols on keypad and display

Symbol Description
ON button
This button is used to start the truck
and confirm entered settings during
PIN code management
OFF button
Error code
Battery charge as a percentage
Parameter
Hour meter
© Cesab 14 – 24 T Code(s): 1010

14.9.9 Keypad/ID unit
Pos. Name: Note

a Keypad
14.9.10 Weighing system

By setting parameter 311 to 1, you can get an estimated load weight based
on hydraulic pressure. The display automatically shows the load weight in
increments of 100 kg if the forks are lowered shorter than 500 ms. The load
weight is shown on the display for 4 seconds.
14.9.11 Pressure equalization

Activates and controls a pressure equalization pulse after a lift. This is to
equalize the pressure, and to get a better measurement of the load weight.
Set to 0 via parameter 312 to switch off the function (standard). If it is set to
a higher value than 0, the duration of the lowering pulse will be a multiple of
the parameter value 20 ms. The truck must have a pressure sensor to enable
the function.
© Cesab 14 – 25 T Code(s): 1010

14.9.12 Logic card (A5)
Electronic
Ferdinand card A5
1 Electronic Card
X200 1 dig in (horn)

22 hall sensors
X201 1 dig in (horn)
6 dig in (option buttons)

X203 1 dig in (second CAN ID)
Display control X300
X205 2 ana in
Power Supply Keyboard/

BDM
CAN Smart Access
X100 X202 X204
Connecto
Type Pin Function
r
X100 Tyco MQS 2X4 pin Supply from truck and CAN
X200, X201 AMP MTE 1x2 pin Horn
Tyco AMP or MPE-
X202 2x3 pin BDM
GARRY
X203 AMP 2x8 pin Option buttons
X204 BERG 1x10 pin Keypad
X205 AMP MTE 1x4 pin
X300 AMP 1x6 pin Display
© Cesab 14 – 26 T Code(s): 1010

14.10 Work function harness/fuse
14.10.1 Fuse panel overview
F50
F51
F52
F53
F2
F1
Description Fuse Protects (function) I (A)

F1 Truck traction 175
F2 Pump motor 125
Electric circuit T1, T13, A5,
F50 Flat pin 7.5
K110, B90
F51 Flat pin Fans M12, M13, Horn P4 7.5
Inductive sensors, B61, B119-
F52 Flat pin 7.5
B122,
F53 Flat pin Servo motor 20
Option DC/DC converter (T7,
F54 Flat pin
T8)
© Cesab 14 – 27 T Code(s): 1010

Fuses
The fuses are of the type "FKS" flat pin fuses. The rated current is printed on
the top of the fuses and is also indicated by the colour coding of the fuse
body.
a
3.6
19 5
(13.2)
19.7
6.5
5.2 0.62
(4.1) 3.5
14.5 3.8
17
The fuses' measurements, in mm, without given tolerances a = rated current.
Rated current
Colour Remarks
(A)
3 Violet –
5 Light brown –
7.5 Brown
10 Red –
15 Blue –
20 Yellow –
25 White Brown print
30 Light green –
Fuse colour coding
© Cesab 14 – 28 T Code(s): 1010

14.11 Sending units and sensors C5800
14.11.1 Inductive sensors

Inductive sensors are affected by metallic objects that are moved into the
sensor's active area.
The sensors used in this truck have protection against incorrect polarity and
have short-circuit protected outlets.
When inductive sensors are energised, they have a short start-up time, ≤50
ms.
14.11.2 Position sensor

Active area
The sensors have an active area, 25 × 25 mm, which is marked with the
symbol:
The sensitivity of the sensors is such that metallic objects within the area
0 – 6.5 mm are detected.
To avoid erroneous detection, there should be a free area around the
sensor’s active area:
d2
a sa
d1
Pos. Description Min. Nom. Max. Unit

a Active area – 25×25 – mm
sa Detection guaranteed 3 – 5 mm
d1 37.5 – – mm
Free area
d2 24 – – mm
© Cesab 14 – 29 T Code(s): 1010

14.11.3 Steering reference sensor

Active area
The sensors have an active area, 12 x 12 mm, at the end of the cylindrical
body.
The sensitivity of the sensors is such that metallic objects within the area
0 – 1.6 mm are detected.
To avoid erroneous detection, there should be a free area around the
sensor’s active area:
d2
a sa
Pos. Description Min. Nom. Max. Unit

a Active area – 12×12 – mm
sa Detection guaranteed 0 – 1.65 mm
d2 Free area 6 – – mm
© Cesab 14 – 30 T Code(s): 1010

14.11.4 Pressure sensor

Properties
The output voltage range is 0.5 V – 4.5 V in the pressure range 0 – 25 MPa
(250 bar).
14.11.5 Pulse transducer

The pulse transducers have two outputs, channels, where each channel
transmits a pulse train when the sensor shaft rotates.
Pulse ratio: During a period, the channel is high 50% ±10% of the time:
Vout
t
Pulse ratio = 50%
Phase ratio: One complete pulse is considered 360° and one channel's
pulses are always offset 90° ±30° in relation to the other's. The design of the
sensor determines how many such pulses are emitted by the sensor during
one revolution of the shaft.
Which of the channels, ‘A’ or ‘B’, that is first, is determined by the shaft's
direction of rotation.
360°
A
B
90°
Phase ratio with anticlockwise rotation as seen from the steering wheel side.
Channel ‘B’ goes high 90° before channel ‘A’.
© Cesab 14 – 31 T Code(s): 1010

14.12 Safety sensor
14.12.1 Emergency switch off [S21]
When the emergency switch off [S21] is depressed, the main contactor [Q10]
is opened. This is indicated on the truck central information display.
The user must log out before the truck can be activated again. If the truck is
started while the emergency switch off depressed, the emergency switch off
must be pulled up before the truck can be started.
The truck battery circuits are still live even if the emergency switch off is
depressed.
When working on the electrical system, the battery must be mechanically
disconnected.
14.12.2 Photocell
Transmitter/receiver photo cell = a transmitter sends light to a separate
receiver; activated when the light beam is interrupted.
© Cesab 14 – 32 T Code(s): 1010

Repair manual: Hydraulic system C6000 Model(s): P320, P322
15. Hydraulic system C6000

15.1 General
Always take the following safety precautions prior to commencing work on the
truck's hydraulic systems:
• Lower the forks completely and hold the button depressed another 5-10
seconds to relieve system pressure.
• Use paper or a stiff piece of cardboard when checking for possible oil leaks.
Do not use your hand.
• Be careful since the oil in the transmission and hydraulic systems can be
scalding hot.
WARNING!
Risk of burns if hot transmission oil or hydraulic oil gets onto the skin.
Allow the truck to cool down before changing the oil.
15.2 Hydraulic hygiene

Note:
Risk of malfunction.
If impurities get into the hydraulic system, there is a risk of malfunctions in
part or all of the hydraulic system. There is also a risk of severe damage to
components.
For all work on the hydraulic system, the following instructions must be
followed.
Note:
Use only new and clean oil when refilling the hydraulic oil system. If the oil
is contaminated, the hydraulic components will suffer damage.
15.2.1 Washing
Hydraulic components, including hydraulic hoses and pipes, must be cleaned
with a filtered washing fluid using a method suitable for the components
concerned.
The washing fluid must have purity code 19/16/13 in accordance with
ISO4406:1999 or 16/13 in accordance with ISO4406:1987.
Blowing clean with dry filtered air may be done when this is the only practical
method to carry out cleaning.
© Cesab 15 – 1 T Code(s): 1010

15.2.2 Packaging
After cleaning, all openings must be sealed with protective plugs. Connecting
surfaces must be protected against handling damage and dirt penetration.
Completely dry components can be packed in plastic bags or boxes with lids.
The packaging (protective plugs, masking, plastic bag, etc.) must not be
removed until immediately before the component is to be fitted in a workplace
suitable for handling hydraulic components.
Tape must never be used without cleaning afterwards.
Protective plugs must be stored in plastic bags or boxes with lids until they are
used.
After use, discard the plugs and plastic bags.
15.2.3 Handling
Hydraulic components must be handled and transported with the greatest
care.
Transportation packaging must be used throughout the entire handling chain.
This packaging must be clean and free from dust, etc.
15.2.4 Storage
Hydraulic components must be handled and stored so that:
• no rusting can occur
• dust and dirt particles are shielded out
• no mechanical deformation can occur
© Cesab 15 – 2 T Code(s): 1010

15.2.5 Work procedures

When working on the hydraulic system, great cleanliness must be observed
so that no impurities can enter the system.
No work that generates particles may be carried out in the same workplace
or close to where work is being carried out on the hydraulic system.
The service technician must ensure that the components to be used are
carefully deburred and cleaned.
Couplings for pipe ends or other openings must never be removed until the
part is to be fitted to the receiving component.
Note:
All hydraulic components that have not been cleaned, e.g. pipe couplings and
nipples, must be blown clean before fitting.
© Cesab 15 – 3 T Code(s): 1010

15.3 Hydraulic system
15.3.1 Overview

a Lift cylinders
b Hydraulic hose to left lift cylinder
c PowerTrak cylinder
d Hydraulic hose to PowerTrak
e Hydraulic unit
f Hydraulic hose to right lift cylinder
g Hydraulic tank
Description
The hydraulic system consists of a hydraulic unit with contactor-controlled
DC motor for lifting and an On/Off-controlled solenoid valve for lowering. The
lowering flow and thereby the lowering speed is regulated hydraulically by a
flow control valve. The PowerTrak cylinder has a constant connection to the
lift cylinders and will thereby always have the same pressure as these. Its
speed during filling and emptying is limited by a restrictor.
© Cesab 15 – 4 T Code(s): 1010

15.3.2 Hydraulic unit
a
g
b h
c
d i
j
e k

a Connector kit
b Pressure limiting valve
c Flow control valve
d Lowering valve
e Lowering valve coil
f Motor
g Valve unit
h PowerTrak restrictor
i Non-return valve
j WEO insert
k Pump
l Return filter
m Suction strainer
© Cesab 15 – 5 T Code(s): 1010

15.3.3 Tightening torques for hydraulic unit
b e
i
f
h
g
Pos. Torque Tolerance

a 25 Nm +10/-0 Nm
b 35 Nm +7/-5 Nm
c 10 Nm +2/-0 Nm
d 8.5 Nm ±0.5 Nm
e 35 Nm +7/-5 Nm
f 30 Nm +7/-6 Nm
g 4 Nm +2/-0 Nm
h 10 Nm +5/-0 Nm
i 65 Nm +5/-0 Nm
j 4 Nm +1/-0 Nm
© Cesab 15 – 6 T Code(s): 1010

15.3.4 Replacing the hydraulic unit
Removing the hydraulic unit
z x
Step 1 Step 2
Step 3
• Remove the side covers. Page 9–4

1: Detach and disconnect all connections.
2: Loosen and remove the screw securing the clamp across the hydraulic
unit.
3: Move the clamp aside and remove the unit.
© Cesab 15 – 7 T Code(s): 1010

Fitting the hydraulic unit
z x
Step 1 Step 2
Step 3
1: Lift the unit into place and fit the clamp.

2: Screw into place.
3: Connect and mount all connections.
• Fit the side covers. Page 9–4
© Cesab 15 – 8 T Code(s): 1010

15.3.5 Tank

a Air filter with splash guard
b Tank 1.8 litres
The hydraulic oil tank is welded from two halves of PP (Polypropylene).
© Cesab 15 – 9 T Code(s): 1010

15.3.6 Changing oil
Draining oil
Steps 1, 2
• Remove the tank. Page 15–12

1: Suction or pour out the oil into a suitable receptacle.
2: Clean and wipe out the tank and check it for defects.
• Fit the tank. Page 15–12
© Cesab 15 – 10 T Code(s): 1010

Topping up with oil
Steps 1, 2 Step 3
1: Remove the cover on the filler pipe.

2: Fill with new oil.
Note: Only use new oil approved for the application.
3: Refit the cover on the filler pipe.
© Cesab 15 – 11 T Code(s): 1010

15.3.7 Replacing the tank
Removing the tank
Step 1 Step 2

1: Loosen and remove the screws holding the tank in the valve block.
2: Pull the tank straight down.
Fitting the tank
Step 1 Step 2
1: Fit the tank, making sure the O-ring is in the correct position.
2: Screw the tank into place.
© Cesab 15 – 12 T Code(s): 1010

15.3.8 Valve unit

Overview

a Pressure limiting valve
b Lowering valve
c Pressure sensor/plug
d PowerTrak hose connection
e Non-return valve
f Air cylinder connection
g Lift cylinder
© Cesab 15 – 13 T Code(s): 1010

15.3.9 Hydraulic pump

Overview
Description
The hydraulic pump is an outer gear pump driven directly by the pump motor.
© Cesab 15 – 14 T Code(s): 1010

15.3.10 Replacing the hydraulic pump
Removing the hydraulic pump
Step 1 Step 2
• Remove the filter. Page 15–16

1: Loosen and remove the screws holding the pump in the block.
2: Lift the pump straight up.
Fitting the hydraulic pump
Step 1 Step 2 T=20+5/-0 Nm
1: Fit the pump, making sure the O-ring is in the correct position.
2: Screw the pump into place.
• Fit the filter. Page 15–16
© Cesab 15 – 15 T Code(s): 1010

15.3.11 Replacing the return filter
Removing the return filter
Step 1 Step 2
• Remove the tank. Page 15–12

1: Loosen and unscrew the suction strainer.
2: Remove the return filter by pulling it straight down.
Fitting the return filter
Step 1 Step 2
1: Press the return filter straight up on the pipe.

2: Screw the suction strainer into place, tightening by hand until you reach
the stop.
• Fit the tank. Page 15–12
© Cesab 15 – 16 T Code(s): 1010

15.3.12 Replacing the valve coil
Removing the valve coil
• Open the service cover Page 9–3

2: Undo the nut and pull the magnetic coil straight out.
Fitting the valve coil
Step 1 Step 2 T=4+1-0 Nm Step 3

1: Fit the magnetic coil.
2: Screw the nut into place.
© Cesab 15 – 17 T Code(s): 1010

15.3.13 Replacing the flow control valve
Removing the flow control valve
Step 1 Step 2
• Remove the return filter. Page 15–16

1: Unscrew the return filter pipe.
2: Unscrew the valve.
Fitting the flow control valve
Step 1 T = 5 +3-0 Nm Step 2 T = 5 +10-0 Nm
1: Screw the valve into place.

2: Screw the return filter pipe into place.
Note: Screw on by hand.
• Fit the return filter. Page 15–16
© Cesab 15 – 18 T Code(s): 1010

15.3.14 Pressure limitation

To protect the system against overpressure, there is a pressure
limiting valve integrated in the hydraulic unit. The pressure limiter only
limits the pressure the pump works towards and is set to a level above
the pressure equivalent to the rated load.
15.3.15 Replacing the pressure limiting valve
Removing the pressure limiting valve
Step 1
1: Loosen and unscrew the valve.
Fitting the pressure limiting valve
Step 1 T=65+5-0 Nm
1: Screw the valve into place.
• Adjusting the pressure limiting valve Page 15–20
© Cesab 15 – 19 T Code(s): 1010

15.3.16 Adjusting pressure limitation

The truck should be able to lift the rated load to the top at normal lift speed.
The pressure limiting valve may need adjusting if:
• The valve is replaced
• The complete hydraulic unit is replaced
In either of the above cases, proceed as follows:
• Verify that the truck is able to lift the rated load.
• If the truck is able to lift the rated load, add another 15% to the forks and
check that the truck is not able to lift the load.
The pressure limiting valve may also need adjustment if the truck lift speed is
abnormally low and no other fault can be found in the hydraulic system.
a b
Step 1, 5 T=10+5-0 Nm Steps 2, 4 Step 3
© Cesab 15 – 20 T Code(s): 1010

Method
1: Loosen the locking nut (a) by screwing it anti-clockwise.
2: Place a rated load on the forks and check that the truck can lift this weight
to the top position.
3: Place the rated load +15% on the forks and check that the truck is not
able to lift it.
4: If point 2 or 3 is not satisfied, adjust as described below.
To reduce the lifting capacity – turn the adjuster (b) anti-clockwise
To increase the lifting capacity – turn the adjuster (b) clockwise
5: Tighten the locking nut (a) clockwise. Hold the adjusting screw (a) with
an Allen key while tightening the locking nut.
© Cesab 15 – 21 T Code(s): 1010

15.3.17 Replacing the pressure sensor
Removing the pressure sensor
Step 1

1: Loosen and unscrew the sensor.
Fitting the pressure sensor
Step 1 T=35+7-5 Nm
1: Screw the sensor into place.
• Fitting the service cover. Page 9–3
© Cesab 15 – 22 T Code(s): 1010

15.3.18 Lift cylinder
Two plunger cylinders are used for fork carriage lifting.
© Cesab 15 – 23 T Code(s): 1010

15.3.19 Replacing lift cylinders
Removing the lift cylinder, right side

1: Lift the fork carriage so that the lift cylinder is freed and place trestles
under the forks for support. Hold the lowering button depressed another
5-10 second to relieve the pressure in the system.
2: Remove the clamp holding the cylinder.
3: Lift the cylinder straight up and move it out.
4: Disconnect the hydraulic hose. Page 15–26
© Cesab 15 – 24 T Code(s): 1010

Fitting the lift cylinder, right side
1: Connect the hydraulic hose. Page 15–26

2: Fit the cylinder in the chassis.
Note: If a new cylinder is fitted, fit the spring pin before fitting it in the
chassis.
3: Fit the clamp and attach the cylinder.
4: Lower the fork carriage, making sure the pin goes into the fork carriage.
Removing the lift cylinder, left side

• Remove the transistor panel. Page 14–14
• See points 1-4. Page 15–24
Fitting the lift cylinder, left side

• See points 1-4. Page 15–25
• Fit the transistor panel. Page 14–14
© Cesab 15 – 25 T Code(s): 1010

15.4 Hydraulic connections
15.4.1 Quick change connector
Connecting the quick change connector
1. Place the assembly stop (1) on the male fitting and make sure that the
dismantling ring (2) runs freely in the groove.
2. Push the male fitting into the female fitting until the assembly stop
makes contact with the female fitting.
3. The connector is now connected and locked. Test-pull the handle to
check that the connector is correctly fitted.
© Cesab 15 – 26 T Code(s): 1010

Dismantling the quick change connector
1. Remove the assembly stop (with the aid of a screwdriver or similar tool).
2. Push the male fitting all the way into the female fitting.
3. Pull the male fitting out of the female fitting.
4. Refit the assembly stop on the male fitting.
5. Place protective plugs on the valve and hose.
© Cesab 15 – 27 T Code(s): 1010

© Cesab 15 – 28 T Code(s): 1010

Repair manual: Mast C7000 Model(s): P320, P322
16. Mast C7000
© Cesab 16 – 1 T Code(s): 1010

Repair manual: Mast C7000 Model(s): P320, P322
© Cesab 16 – 2 T Code(s): 1010

Repair manual: Peripherals C8000 Model(s): P320, P322
17. Peripherals C8000
© Cesab 17 – 1 T Code(s): 1010

Repair manual: Peripherals C8000 Model(s): P320, P322
© Cesab 17 – 2 T Code(s): 1010

Repair manual: Options/Extra equipment C9000 Model(s): P320, P322
18. Options/Extra equipment C9000

18.1 Overview
c b a
g
e

a DC/DC converter, 24-12V
b I_Site antenna
c Power cable BCU
d SEU
e Built-in charger (BCU)
f Collision sensor
g I_Site main unit
© Cesab 18 – 1 T Code(s): 1010

18.2 Spider expansion unit

The spider expansion unit, called SEU, allows the main logic card to handle
a greater number of inputs and outputs. The SEU does not have its own truck
controller logic, which means that a defective SEU can be replaced without
the replacement affecting any truck functions.
The SEU is used for modification of the truck to meet special customer
requirements. .
Electronic
card
Truck Log
System
Spider
Extra/Customised
Expansion
function(s)
Unit
CAN bus
Pump
controller
CAN service
connector
Motor
Controller
The picture above shows how the SEU is used to allow a greater number of
functions to be controlled via the CAN bus. SEU has a 42-pin, multi-pin
contact that manages all inputs, outputs, CAN and power supply signals.
© Cesab 18 – 2 T Code(s): 1010

18.3 I_Site, previously T.W.I.S

I_Site is a system that collects data from the trucks.
I_Site is available in two different versions:
• I_Site including a DHU/DHU2 and an antenna.
• I_Site including a DHU/DHU2 and an antenna and a collision sensor.
The data handling unit (DHU) receives data from the truck and transfers it to
a central server at a set interval. The data is then accessible to users with an
authorised code via a website. No hardware installation is required at the
customer site. Communication is via the GSM 900/1800 network for the DHU.
DHU2 is also approved for UMTS FDDI/ VIII 900/ 1900/ 2100 MHz.
Reports can be viewed showing information such as the following:
• Truck usage
• Operator utilisation
• Battery consumption and charging behaviour
• Hour meter readings
If the system includes a collision sensor, the following collision data can be
viewed:
• Operator involved in collision
• Severity of collision
• Error codes generated by a collision
• When the collision occurred and how long the truck had been in use before
the collision
Collision sensitivity and the post-collision resetting procedure can be
programmed separately for each individual truck.
For instructions on installation, configuration, setup and troubleshooting, see
the separate I_Site manual.
© Cesab 18 – 3 T Code(s): 1010

18.4 DC/DC converter

The truck can be equipped with a DC/DC converter to supply power to equipment
such as a PC, scanner, etc. The converter on the input side is protected against
polarity reversal, short circuit and thermal overload. The chassis is not live, and
the in/outputs are galvanically separated. The output sits on the E-bar profile.
Pos. Component Note

a DC/DC converter
© Cesab 18 – 4 T Code(s): 1010

18.5 Collision sensor

If a collision sensor is installed on the CAN bus, this registers when the truck
bumps against something. If an impact exceeds a certain level, specified by
parameters 105 and 106, this is counted as a collision.
Pos. Component Note

a Collision sensor
© Cesab 18 – 5 T Code(s): 1010

18.6 Integrated battery charger C5170

(For P320 only)
18.6.1 Overview
Pos. Component Note

a BCU - Built-in battery charger
b Power cable
18.6.2 Description
The built-in battery charger is a CAN-controlled battery charger. It starts
charging as soon as it is connected to a power socket. The BCU always
keeps the ICH [A5] informed of its status over the CAN bus. The ICH [A5]
switches off the truck as soon as charging starts. It is not possible to log while
the BCU is connected to alternating current.
Three parameters are used to activate and configure the BCU. One factory
parameter (#1101) for whether there is a charger or not. Page 5–29 Two
service parameters (#109-#110) that determine battery size and battery type.
Page 5–7
© Cesab 18 – 6 T Code(s): 1010

18.6.3 Connecting the battery charger
b e
f
c
d
Pos. Description
a B - Black cable
b B + Red cable
c - Black cable
d + Red cable
e CAN connection
f Power supply
© Cesab 18 – 7 T Code(s): 1010

18.7 E-bar
18.7.1 Overview
b
c

a Load protection
b Fixed E-bar
c Rotating E-bar
© Cesab 18 – 8 T Code(s): 1010

18.7.2 E-bar accessories

Use the E-bar profile for quick and easy installation of optional accessories,
such as a computer equipment, scanner, writing tablet, etc. The accessories
are then easily accessible from the operator's position.
Accessories can be fixed with standard brackets. The brackets can be used
on all trucks with E-bar profile, making it easy to move equipment between
the trucks.
• Use the screws on the brackets of each accessory to adjust the

accessories for the most comfortable operating position.
NOTE:
To prevent accidents, make sure all fastening screws are securely tightened.
DANGER!
To prevent accessories from coming loose and eliminate the risk of
accidents, only use specially approved mounting brackets for the E-bar.
DANGER!
Never mount accessories where they will reduce safety.
© Cesab 18 – 9 T Code(s): 1010

18.7.3 Fire extinguisher

The truck can be fitted with a fire extinguisher. Useful in areas where
flammable materials are handled, always at hand in case of fire.
Two versions of fire extinguisher are available:

Type Size Standard Market
Countries following EU
Standard ABC 2 kg EN3
regulations
Countries following
USA ABC 2 kg ANSI/UL711 & ANSI/UL299
American regulations
A = Combustible material such as paper, wood, cardboard and plastic.
B = Ignitable or combustible fluids such as petrol, kerosene, grease and oil.
C = Electrical equipment such as devices, cables and power sockets.
In the event of fire, the powder extinguisher should be employed as
follows:
1: Remove the safety catch.
2: Aim the nozzle at the base of the flames
3: Press the handle down
© Cesab 18 – 10 T Code(s): 1010

Regular checks of the fire extinguisher – truck operator

• Check regularly that the pressure gauge indicator is in the green field. If
the indicator is in the red field, the fire extinguisher is not fit for use and
must be recharged.
• Recharge the extinguisher immediately after use. Contact an authorised
service company.
• Make sure that the extinguisher is checked once a year by a qualified
service engineer (from an authorised service company for fire protection)
and that a workshop review is carried out every 10 years.
NOTE:
Only material/parts approved by the manufacturer may be used.
Inspection of fire extinguisher during service inspection of the truck
The fire extinguisher must be checked once a year in connection with
servicing of the truck.
• Check that the pressure gauge indicator is in the green field. If the
indicator is in the red field, the fire extinguisher is not fit for use and must
be recharged.
• Check that the fire extinguisher is intact and in working order and is in the
correct location in the truck.
• If the fire extinguisher does not appear to function satisfactorily, make sure
that an authorised service company is contacted.
© Cesab 18 – 11 T Code(s): 1010

© Cesab 18 – 12 T Code(s): 1010

Repair manual: Instructions for disposal Model(s): P320, P322
19. Instructions for disposal

19.1 General
The disposal instructions were developed to support our company's objective
of protecting the environment. By recycling materials, resources can be
utilised more efficiently, while reducing emissions.
The instructions below indicate the proper sorting category for the materials
used in the various truck components. To achieve optimum sorting, all
components should be disassembled to a level corresponding to the sorting
categories.
19.2 Marking of plastics
19.2.1 General marking of products and packaging

Markings on plastics consist of three arrows, a number and usually also a
designation of the plastic material used. This example shows the marking for
polypropylene.
• 01: PET – Polyethylene terephthalate
• 02: PE-HD – Polyethylene with high density
• 03: PVC – Polyvinyl chloride
• 04: PE-LD – Polyethylene with low density
• 05: PP - Polypropylene
• 06: PS – Polystyrene
• 07: O – Other
© Cesab 19 – 1 T Code(s): 1010

19.2.2 Marking according to the manufacturer’s standards

Standards: 58-02-001, 58-02-003 and 58-02-004.
A few examples of markings are given here. For more information, please
refer to the standards above.
The product material and trade name of each item are indicated between
arrows. Example: >PP<.
Abbreviations
• ABS: acrylonitrile/butadiene/styrene
• HDPE: High Density Polyethylene
• LDPE: Low Density Polyethylene
• PA: Polyamide
• PA6: Amide resin 6
• PA66: Amide resin 66
• PBT: Polybutylene terephtalate
• PC: Polycarbonate
• PET: Polyethylene terephtalate
• PMMA: Plexiglas
• POM: Polyoxymethylene, Polyformaldehyde
• PP: Polypropylene
• PUR: Polyurethane
Marking examples
Products made from a single substance
ABS (acrylonitrile/butadiene/polystyrene):
>ABS<
Polyurethane:
>PUR<
Plastic compounds
A compound based on acrylonitrile/butadiene/polystyrene and carbonate
plastic:
>ABS+PC<
Filled or reinforced materials
Polypropylene with 30% mineral powder:
>PP-MD30<
© Cesab 19 – 2 T Code(s): 1010

19.3 Pressure vessels

Pressure vessels sent for recycling/destruction must have been
depressurised beforehand and, if possible, opened.
Examples of existing pressure vessels are gas dampers and accumulators
used in hydraulic systems.
19.3.1 Gas dampers

WARNING!
Gas dampers have extremely high internal pressure. To prevent injury,
always follow the instructions of the manufacturer.
Wear safety goggles when disassembling springs.
To allow the gas to escape, only open and disassemble gas dampers as
recommended by the manufacturer. An example of how to perform this is
given for "Stabilus Lift-O-Mat/Inter-stop":
2 1
ca 20 mm
1: Drill or cut a hole in the cylinders, approximately 20 mm from the bottom.

2: Drill or cut a hole in the recess at the piston rod end.
© Cesab 19 – 3 T Code(s): 1010

19.4 Sorting categories

• Plastic and rubber material
• Iron/steel (including bolts, washers and nuts)
• Oils
• Oil filters
• Oil-polluted material
• Electronic parts (including switches and sensors)
• Wires
• Hazardous waste
• Complex materials - large amounts in several categories but non-
combustible and not hazardous
• Combustible material, including small plastic and rubber parts
• Please return batteries to the manufacturer.
Component Category Comments
Chassis Iron/steel
Iron/steel
Inspection covers, sheet metal
Handle: >ABS<
Sort according to the material
Inspection covers, plastic Plastic
marking
Forks and frames Iron/steel
Iron/steel, including any gas
Operator's platforms dampers Be sure to depressurise dampers
Mats, cushions: combustible
Roofs and overhead guards Iron/steel
Iron/steel
Gates and operator protective
Plastic handles: >PA<
devices
Crush protectors: >PMMA<
Oil
Hydraulic hoses: Oil-polluted Ensure that the system has been
material depressurised.
Oil tank: >PP< Carefully drain all oil.
Hydraulic unit
Motor, valves: Electronic Any accumulators should be
components emptied of gas and if possible
Pump: Iron/steel opened.
Accumulator: Iron/steel
Motor: Electronic components
Travel motors Wires
Parking brake: Hazardous waste
Iron/steel Carefully drain all oil
Drive gears
Oil Hazardous waste
If the tread and hub cannot be
Tread: Plastic according to marking
Wheels separated, then sort the wheel as
Hub: Iron/steel
complex material
© Cesab 19 – 4 T Code(s): 1010

Component Category Comments

Electronic components
Tiller arms Wires Be sure to depressurise dampers
Iron/steel, also gas dampers
PCBs, motor control, SEU
expansion unit, contactors:
Electrical system Hazardous waste
Wires
Small batteries Hazardous waste
Hazardous waste.
Because of the chemical content in
fluorescent tubes, do not break
Fluorescent tubes them.
Used fluorescent tubes must be
packaged and transported according
to local regulations.
Mast beams, rollers, cylinders,
hydraulic pipes: Iron/steel
Hydraulic hoses: Oil-polluted ()
Wires Oil-polluted components should be
Mast
Sensors/switches: Electronic handled as hazardous waste
components
Plastic components: According to
marking or as combustible waste
Chargers and connectors
Wires
© Cesab 19 – 5 T Code(s): 1010

© Cesab 19 – 6 T Code(s): 1010

Repair manual: Electrical components and wiring diagrams Model(s): P320, P322
20. Electrical components and wiring diagrams
20.1 Electric components

The following table shows a summary of the electrical components in this
truck.
Schemat
Des. Function Component type Other Picture ic chart
7523203
Electronic circuit
A5 Control of truck functions (A5) 14 9,10,11
board
Electronic circuit
A36 Expansion unit (SEU)
board
A83 TFD (Torque feedback device) Steering damper 5 5
Drive motor
B1 Temperature sensor 2 2
temperature sensor
B4 Load detection Pressure sensor 2
B5 Hydraulic pressure PowerTrack Pressure sensor
B11 Pulse transformer Speed sensor 2 2
B13 Steering angle sensor Potentiometer 4
Inductive limit
B17 Drive wheel centring reference 2 5
switch
Inductive limit
B60 Drive position sensor 12 3
switch
Inductive limit
B61 Fork lift limiter 6 3
switch
B90 Collision registration Collision sensor Option 8 14
Inductive limit
B119 Platform down monitoring 3 6,7,8
switch
Inductive limit
B120 Monitoring that platform is not folded up 3 6.8
switch
Inductive limit
B121 Gates up monitoring 4 6
switch
Inductive limit
B122 Gates down monitoring 4 6
switch
B124 Monitoring, fixed side guards Photo cell receiver 8
Photo cell
B125 Monitoring, fixed side guards 8
transmitter
B130 Monitoring, UK head connector BCU Sensor 12
F Fuse (External equipment) Fuse 1
F1 Main fuse Fuse 175 A 7 1
F2 Fuse Fuse 125 A 7 1
F50 Fuse Fuse 7.5 A 7 1
© Cesab 20 – 1 T Code(s): 1010

Schemat
Des. Function Component type Other Picture ic chart
7523203
F53 Fuse Fuse 20 A 7 1
F54 Fuse Fuse 7.5 A 1.13
G1 Main power source Battery 24 V 6 1
G10 Battery Li-ion Option 16
Electronic circuit
K110 Data Handling Unit (DHU) Option 9 15
board
M1 Truck traction Motor 2 2
M3 Pump motor Motor 1
M6 Steering motor Motor 2 5
M12 Motor control cooling Fan 1 3
M13 Motor control cooling Fan 1 3
P4 Horn Horn 10 3
P6 Display of truck functions Display 13 10
Electromagnetic
Q1 Mechanical brake 2 3
brake
Q4 Fork lowering – hydraulic control Proportional valve 3
Q10 Main contactor Contactor 1 1
Q25 Fork lifting (Pump motor activation) Contactor 1 1
Q58 Powertrack, emptying valve Valve
Q59 Powertrack, filling valve Valve
S18:1 /
Button for sound signal (left/right) Switch 13 10
S18:2
S21 Emergency switch off Switch 11 3
S206 Creep function Switch Option 10
Key pad - Smart
S223 Log in with PIN code - Smart card 15 11
card
1,2,3,4,6,7
T1 Lift, drive and peripherals control (ACT) Motor controller: 1
,8.12
T7 DC/DC converter, 24V/12V Circuit board Option 10 13
T8 DC/DC converter, 24V/24V Circuit board Option 10 13
Electronic circuit
T13 Steering motor 2 5
board
T14 Charger onboard BCU Charger Option 8 12
T20 Antenna, T.W.I.S Antenna 11 15
X10 Connector piece for H-contactor Port 1
X23 Socket, DC/DC converter Port 10 13
X41 External CAN communication Port 6 9
X65 Tiller arm: Port 5 9
X1 Battery contact Port 6 1
© Cesab 20 – 2 T Code(s): 1010

20.2 Component location
Picture 1
[M12] [T1]
[M13]
[Q10]
[Q25]
© Cesab 20 – 3 T Code(s): 1010

Picture 2
[Q1]
[T13]
[M6]
M6
[B11]
[M1]
[B17]
© Cesab 20 – 4 T Code(s): 1010

Picture 3
[B119]
[B120]
© Cesab 20 – 5 T Code(s): 1010

Picture 4
[B121]
[B122]
© Cesab 20 – 6 T Code(s): 1010

Picture 5
[X65] [A83]
© Cesab 20 – 7 T Code(s): 1010

Picture 6
[G1]
[X1]
[B61]
© Cesab 20 – 8 T Code(s): 1010

Picture 7
[F50]
[F51]
[F52]
[F53]
[F2]
[F1]
© Cesab 20 – 9 T Code(s): 1010

Picture 8
[T14]
[B90]
© Cesab 20 – 10 T Code(s): 1010

Picture 9
[K110]
© Cesab 20 – 11 T Code(s): 1010

Picture 10
[X23]
[T8]
[P4]
[T7]
© Cesab 20 – 12 T Code(s): 1010

Picture 11
[T20]
[S21]
© Cesab 20 – 13 T Code(s): 1010

Picture 12
[B60]
© Cesab 20 – 14 T Code(s): 1010

Picture 13
[P6] [S18:2]
[S18:1]
© Cesab 20 – 15 T Code(s): 1010

Picture 14
[X100]
[A5]
© Cesab 20 – 16 T Code(s): 1010

Picture 15
© Cesab 20 – 17 T Code(s): 1010

20.3 Wiring diagrams
20.3.1 List of symbols
Symbol Description Symbol Description

Truck battery. Horn
Fuse Emergency switch off NC
Sensor, inductive NO Switch, pressure (weight)

operated
DC motor Sensor, inductive NC
Contactor Variable resistor (potentiometer)
Brake coil (normally applied) Pressure switch NO
Coil for the hydraulic solenoid Multi-pin connector

valve
Pressure sensor, analogue NO = Normally open

P NC = Normally closed
© Cesab 20 – 18 T Code(s): 1010

© Cesab
Publication Number: 7572516-040

Repair manual: Electrical components and wiring diagrams
1
1
F1 T1, MOTOR CONTROLLER

1 125A
9 5 5 50
INP. B+ 24 VDC INP. PRESSURE LIFT (91)
F51 B4
S21
7,5A 21 24 41 P
(114) INP. +24 V, “HIGH SIDE DRIVER” OUT. GND (113)
8
35
ESO M12 (119) OUT. FAN
32
B13
M13
27
Q10 OUT. +5V (93)
B60
30
57
(87) INP. TILL ARM IN DRIVE POS.
F52 B61
8 7,5A 22 49 70
(95) INP. LIFT LIMIT INP.STEER SENSOR (101)
20.3.2 Wiring diagram P300 overview - std platform

B119
F50 65
(101) INP. MAN ON PLATFORM
7,5A
1 20
B120
56
(97) PLATFORM NOT FOLDED UP
F53 B121
20A 58
(88) INP. GATES UP
2
DISPLAY B122 OUT. U
A5, TILLER ARM CARD 3
P6 59
(96) INP. GATES DOWN DRIVE MOTOR OUT. V M1
(X1) (X300) 4
OUT. W
32
Date: 2015-10-01
32
(118) OUT. MAIN CONTACTOR
20 – 19
40
30 30 61
KEYBOARD (115) OUT. +24V, “HIGH SIDE DRIVER” INP. CH A (104)
SMART CARD (X204) SPEED SENSOR
S223 Q4
20 38 60
A5:S322 (FORK LOWER) (108) OUT. LOWER VALVE OUT. +5V (85) B11
Rd Bu
Hall F2 SPEED SENSOR
125A Q1
8 31 64 Bk Wh
A5:S323 (FORK LIFT) (117) OUT. BRAKE RELEASE OUT. NEGATIVE (105)
Hall SPEED/THERMAL SENSOR
Q25 B1
T13, EPS 33 Gn
A5:S300-S308, A5:S310-S318 (DRIVE) 23 (116) OUT. PUMP CONTACTOR
(8) INP. +24VDC Rd
Hall Hall 6
1 23
(16) INP. +24VDC 20 63
X1 (84) INP. ENABLE INP. THERMAL SENSOR (92)
A5:S320
(106) CAN resistor 120 Ohm

(DRIVE MOTOR)
Hall
95
+ OUT. SUPPLY +12V (3) 6 62
B17 INP. CH B (103)
-
A5:S321
Hall
Valid from serial number: 6304531-

96 SPEED SENSOR
Hall INP.REF. SWITCH (11)
X1
97
40 OUT. SUPPLY 0V (12)
(100) CAN L
(99) CAN H
S18:1 20
(X200:1) INP. INP. +24VDC 20
(6) ENABLE 40
HORN 1 (X100)
Rd
40
(X200:2) OUT. 0V Gn
Model(s): P320, P322

HORN 1
Og M3
S18:2 119 119 120
(X201:1) INP. Bk
HORN 2
Wh
OUT.COIL - (9)
(X201:2) OUT. 0V Bu 20 20
OUT.COIL + (1)
HORN 2
CAN H 119 119 X41
(2) CAN H
T Code(s): 1010
S206 (X100) 1
120 120 40
(X2:1/2) INP. TURTLE CAN L (10) CAN L OUT. U 2
(X100) 40 STEER 3
(7) INP. 0V
MOTOR
OUT. V M6
4
(X2:1/3) OUT. 0V INP.0V 40 40
(15) INP. 0V OUT. W
TURTLE (X100)
119 120
119 119
120 120
40 40
© Cesab

1
1
F1 T1, MOTOR CONTROLLER

1 9 125A
5 5 50
INP. B+ 24 VDC INP. PRESSURE LIFT (91)
F51 B4
7,5A S21
21 24 41 P
(114) INP. +24 V, “HIGH SIDE DRIVER” OUT. GND (113)
8
35
32 ESO M12 (119) OUT. FAN
B13
M13
27
Q10 OUT. +5V (93)
B60
20.3.3 Wiring diagram P300 overview - fixed platform

30 57
(87) INP. TILL ARM IN DRIVE POS.
F52 B61
8 7,5A 22 49 70
(95) INP. LIFT LIMIT INP.STEER SENSOR (101)
B119
F50 65
(101) INP. MAN ON PLATFORM
7,5A
1 20
B120
56
(97) PLATFORM NOT FOLDED UP
F53 B121
20A 58
(88) INP. GATES UP
2
Date: 2015-10-01
DISPLAY B122 OUT. U
A5, TILLER ARM CARD 59 3
P6 DRIVE MOTOR OUT. V M1
(96) INP. GATES DOWN
20 – 20
(X1) (X300) 4
OUT. W
32 32
(118) OUT. MAIN CONTACTOR
40
30 30 61
KEYBOARD (115) OUT. +24V, “HIGH SIDE DRIVER” INP. CH A (104)
SMART CARD (X204) SPEED SENSOR
S223 Q4
20 38 60
A5:S322 (FORK LOWER) (108) OUT. LOWER VALVE OUT. +5V (85) B11
Rd Bu
Hall F2 SPEED SENSOR
125A Q1
8 31 64 Bk Wh
A5:S323 (FORK LIFT) (117) OUT. BRAKE RELEASE OUT. NEGATIVE (105)
Hall SPEED/THERMAL SENSOR
Q25 B1
T13, EPS 33 Gn
A5:S300-S308, A5:S310-S318 (DRIVE) 23 (116) OUT. PUMP CONTACTOR
(8) INP. +24VDC Rd
1 Hall Hall 6
23
(16) INP. +24VDC 20 63
X1 (84) INP. ENABLE INP. THERMAL SENSOR (92)
A5:S320
(DRIVE MOTOR)
(106) CAN resistor 120 Ohm

Hall
95
+ OUT. SUPPLY +12V (3) 6 62
G1 B17 INP. CH B (103)
-
A5:S321
96 SPEED SENSOR
Hall INP.REF. SWITCH (11)
X1
97
40 OUT. SUPPLY 0V (12)
(100) CAN L
(99) CAN H
S18:1 20 20
(X200:1) INP. INP. +24VDC (6) ENABLE
HORN 1 (X100) 40

Rd
40
(X200:2) OUT. 0V Gn
HORN 1
Og M3
S18:2 119 119 120
(X201:1) INP. Bk
HORN 2
Wh
OUT.COIL - (9)
(X201:2) OUT. 0V Bu 20 20
OUT.COIL + (1)
T Code(s): 1010
HORN 2
CAN H 119 119 X41
(2) CAN H
S206 (X100) 1
CAN L 120 120 (10) CAN L 40

(X2:1/2) INP. TURTLE OUT. U 2
(X100) 40
(7) INP. 0V STEER OUT. V M6 3
MOTOR
(X2:1/3) OUT. 0V INP.0V 40 40 (15) INP. 0V
4
OUT. W
TURTLE (X100)
119 120
119 119
120 120
40 40
© Cesab

OPTIONS
20.3.4 Wiring diagram P300 overview - accessories

ON BOARD CHARGER
G10, Li-Ion BATTERY
MAINS CONNECTOR
BATTERY CONNECTOR IN MACHINE
DC/DC CONVERTER
(T7=24V/12V, T8=24V/24V 1 + + + OUT. B+ (POLE BOLT)
X23
25 26 40 - -
Date: 2015-10-01
INP. +24 VDC OUT. 12V/24V - OUT. B- (POLE BOLT)
T14
T7 / T8 1(Rd)
20 – 21
40 41 B+
INP. 0VDC OUT. 0V OUT. POS.CHARGER
JUMPER
CONNECTOR
40 (Bk) + B+ OUT
OUT. NEG.CHARGER
F54
7,5A 119 1 (1) CHARGER COMM.
(3) CAN H
BATTERY
1 1 (2) CHARGER COMM. MODULES
120 2 CHARGER
(4) CAN L CONNECTOR
3 (3)
40 DHU/SHOCK SENSOR 4 (4)

B90, SHOCK SENSOR

40 - B-
(2) INP. 0V
119
CAN H (3)
20 20 J1
(1) INP. +24V (X111:7) INP. ENABLE
120
CAN L (4)
J1
(X111:8) INP. ENABLE

K110, DHU 119
(X111:3) CAN H
40
(8) INP. 0V
119 120
CAN H (2) (X111:4) CAN L
20
(1) INP. +24V
T20 120
CAN L (3)
T Code(s): 1010
INP. ANTENNA
119
120
20.3.5 Wiring diagram
PROD A
7523203
1/16
© Cesab 20 – 22 T Code(s): 1010

PROD A
7523203
2/16
© Cesab 20 – 23 T Code(s): 1010

PROD A
7523203
3/16
© Cesab 20 – 24 T Code(s): 1010

PROD A
7523203
4/16
© Cesab 20 – 25 T Code(s): 1010

PROD A
7523203
5/16
© Cesab 20 – 26 T Code(s): 1010

PROD A
7523203
6/16
© Cesab 20 – 27 T Code(s): 1010

PROD A
7523203
7/16
© Cesab 20 – 28 T Code(s): 1010

PROD A
7523203
8/16
© Cesab 20 – 29 T Code(s): 1010

PROD A
7523203
9/16
© Cesab 20 – 30 T Code(s): 1010

PROD A
7523203
10/16
© Cesab 20 – 31 T Code(s): 1010

PROD A
7523203
11/16
© Cesab 20 – 32 T Code(s): 1010

PROD A
7523203
12/16
© Cesab 20 – 33 T Code(s): 1010

PROD A
7523203
13/16
© Cesab 20 – 34 T Code(s): 1010

PROD A
7523203
14/16
© Cesab 20 – 35 T Code(s): 1010

PROD A
7523203
15/16
© Cesab 20 – 36 T Code(s): 1010

PROD A
7523203
16/16
© Cesab 20 – 37 T Code(s): 1010

© Cesab 20 – 38 T Code(s): 1010

Repair manual: Hydraulics schematics Model(s): P320, P322
21. Hydraulics schematics

21.1 Component list
Pos. Type of component Designation Picture Remarks

a Lift cylinder F1 1 Fork carriage lift
b Lift cylinder F2 1 Fork carriage lift
Increases the pulling capacity with a
c PowerTrak cylinder PT 1
loaded machine
d Pressure sensor M (B4) 1 Pressure sensor/Cavity plug
e Solenoid valve Q4 1, 2 Solenoid valve, lowering
f Flow control valve 2
g Return filter 2
Coarse filtering of oil, pump suction
h Suction strainer 2
side
j Tank 3
k Air filter 3 Tank ventilation
l Pump M 2 Hydraulic pressure
Limitation of max. hydraulic pressure,
n Pressure limiting valve 2
250 bar
o Non-return valve 2
p PowerTrak restrictor 2 Ø1.1
© Cesab 21 – 1 T Code(s): 1010

21.2 Component location
Picture 1
e
d
a b
© Cesab 21 – 2 T Code(s): 1010

Picture 2
n p
f
e o
e l
© Cesab 21 – 3 T Code(s): 1010

Picture 3
© Cesab 21 – 4 T Code(s): 1010

21.2.1 Valve unit

Overview

a Pressure limiting valve Max. 250 bar
b Lowering valve Q4
c Pressure sensor/plug M
d PowerTrak hose connection PT
e Non-return valve
f Lift cylinder F2
g Lift cylinder F1
© Cesab 21 – 5 T Code(s): 1010

21.3 Hydraulics schematics
21.3.1 P320, 322
a b c d
F1 F2 PT M
(WEO 1/4”) (WEO 1/4”) (WEO 1/4”) (G 1/4”)
Q4
Dia 1.1
e
p
o Max 250 Bar
n
f
l
M
g
k h
© Cesab 21 – 6 T Code(s): 1010

Repair manual: Tools Model(s): P320, P322
22. Tools
22.1 AMP contacts
PT = Power Timer (4.8, 5.8, 6.3 mm)
JPT = Junior Power Timer (2.8 mm)
MPT = Micro Power Timer (1.5 mm)
Tools Number Usage

213296 (JPT, PT) Pin/sleeve removal tool
213298 (MPT) Pin/sleeve removal tool
1=163787 (JPT) Tool for crimping sleeves

2=163788 (JPT)
1=213336 (MPT)
2=213337 (MPT)
1
2
1=213336 (JPT) Tool for crimping pins
2=213549 (JPT) For 0.5–2.5 mm2
1
2
© Cesab 22 – 1 T Code(s): 1010

22.2 MQS contacts
Tools Number Usage

257841 MQS Basic toolbox.
The box contains:

1 pair crimping pliers
1 pair stripping pliers
25 x splice sleeves 0.5-1.5 mm2
2x complete 2, 3, 4, 6, 8 and 12-pin
connectors (male and female) with
prewired cables and splicing sleeves.
Please use to replace damaged connectors
on the truck.
© Cesab 22 – 2 T Code(s): 1010

Tools Number Usage

257842 MQS refill box.
Use to refill the “MQS 257843 Complete
toolbox”.
The refill box contains:

200 x sleeves 0.2-0.5 mm2
200 x SWS sleeves 0.2-0.5 mm2
400 x SWS sleeves 0.5-0.75 mm2
100 x Clean body sleeves 0.5-0.75 mm2
200 x SWS pins 0.2-0.5 mm2
400 x SWS pins 0.5-0.75 mm2
1200 x seals
200 x blind plugs
and connectors
257843 MQS Complete toolbox.
Contains 4 pliers with tools:

MQS SWS 0.25-0.5 mm2
MQS SWS 0.5-0.75 mm2
MQS Std&Clean body 0.25-0.5 mm2
MQS Std&"Clean body" 0.5-0.75 mm2
Puller for 2, 3, 4, 6, 8 and 12-pin male and

female connectors.
© Cesab 22 – 3 T Code(s): 1010

22.3 CPC contacts
Tools Number Usage

1=213336 (CPC) Crimping tool (sleeves only)
2=213338 (CPC)
1
2
183593 Pin/sleeve removal tool
© Cesab 22 – 4 T Code(s): 1010

22.4 Other tools
Tools Usage
7513225 Service instrument (CAN)
1=7521083 Service instrument

1 2=163793 (CASTOR USB)
for programming
219730 Hydraulic pressure gauge
1/4" — 254526 Plugs (male part) for valves with WEO type
3/8" — 254527 quick change connector
1/2" — 254528
© Cesab 22 – 5 T Code(s): 1010

Tools Usage
1/4" — 254529 Plugs (female part) for hydraulic hoses with
3/8" — 254530 WEO type quick change connector
1/2" — 254531
7541426 Eye bolt M20 LT class 8,

lifting capacity of max. 6 tonnes
651154 Support block
651279 Motor suspension mounting tool,

including spacers.
(V08-18302 +
V08-18255)
© Cesab 22 – 6 T Code(s): 1010

Repair manual: Service data and grease specifications Model(s): P320, P322
23. Service data and grease specifications
23.1 General tightening torques

Millimetre threads M3 to M24. The following applies in the case of good
conditions, e.g. steel against steel.
Galvanised, Untreated,
not oiled screws oiled screws
Strength class: Strength class:
Dimension
8.8 10.9 12.9 8.8 10.9 12.9
1.1 1.6 2.0 M3 1, 2 1.7 2.1
2.8 3.8 4.7 M4 2.9 4.0 4.9
5.5 7.7 9.3 M5 5.7 8.1 9.7
9.5 13 16 M6 9.8 14 17
23 32 38 M8 24 33 40
45 62 76 M10 47 65 79
78 109 130 M12 81 114 136
123 174 208 M14 128 181 217
189 266 320 M16 197 277 333
370 519 623 M20 385 541 649
638 898 1075 M24 665 935 1120
Tightening torque ‘T’ (Nm)

Note:
Experience has shown that if the torque wrench is adjusted to the values for untreated
screws, the correct torque value for galvanised screws will also be obtained. Do not
tighten more than the values indicated in the table, otherwise the screws can be
destroyed.
© Cesab 23 – 1 T Code(s): 1010

Repair manual: Service data and grease specifications Model(s): P320, P322
23.2 Oil and grease specification
Specification Use
Lubricant type
> -15°C < -15°C
S213366 S213366
A Grease Bearings and bushes
Q8 Rubens WB Q8 Rubens WB
Synthetic base hypoid oil
C Transmission oil SAE 75W-90 Gears
Class API-GL5
D Grease See table below See table below Chains
Grafloscon Grafloscon
E Grease Gear ring
A-G1 (Klüber) A-G1 (Klüber)
F Grease Gletmo 805 Gletmo 805 Beams, rib
F Grease Rembrandt EP2 Rembrandt EP2 Beams, flanges
Staburags Staburags
G Grease Steering bearings
NBU 8EP NBU 8EP
H Grease Klüberplex BEM 34-132 Steer axle/steering damper
Ambient
Pos. Viscosity class Usage
temperature
ISO VG 32
B 0°C-40°C ISO 6743-4 category HM Hydraulic system
DIN 51524 part 2 = HLP
ISO VG 27.5
B -35°C-40°C ISO 6743-4 category HV Hydraulic system
DIN 51524 part 3 = HVLP
Ambient
Pos. Viscosity class Recommended products*
temperature
> -40°C
D VG 15 Klüberoil 4UH 1-15, Klüber Lubrication
< -30°C
> -30°C Klüberoil 4UH 1-68N, Klüber Lubrication
D VG 68
< +5°C Anticorit LBO 160 TT, Fuchs DEA
Klüberoil 4UH 1-150N, Klüber Lubrication
> +5°C
D VG 150 Anticorit LBO 160, Fuchs DEA
< +45°C Rexoil, Rexnord Kette
> +45°C
D VG 220 Klüberoil 4UH 1-220N, Klüber Lubrication
< +80°C
* Equivalent products from another manufacturer may be used.
© Cesab 23 – 2 T Code(s): 1010

Repair manual: Technical data Model(s): P320, P322
24. Technical data
24.1 Basic data
Specifications P320 P322

1.1 Manufacturer Cesab Cesab Cesab Cesab Cesab
1, 2 Model P320 P320 P320 P322 P322
1.3 Drive unit Electric Electric Electric Electric Electric
Identification
1.4 Driving mode Standing/walking

1.5 Lifting capacity/rated load Q kg 2000 2000 2000 2200 2200
1.6 Load centre distance c mm 600 600 600 600 600
Load centre distance, centre support arm
1.7 x mm 913/957* 913/957* 913/957* 913/957* 913/957*
wheel to fork back, fork lifting/lowering
1.8 Wheel base, forks lifted/lowered y mm 1362/1406* 1362/1406* 1362/1406* 1410/1454* 1410/1454*
2.1 Weight with battery kg 718 718 718 826 826
Weight
Axle load, with load, drive/caster/fork

2.2 kg 466/585/4667 466/585/4667 466/585/4667 679/834/1513 679/834/1513
wheels
Axle load, without load, drive/caster/fork
2.3 kg 284/294/140 284/294/140 284/294/140 289/311/126 289/311/126
wheels
3.1 Drive/caster/fork wheels Vulkollan®*/Vulkollan®/Vulkollan®
3.2 Wheel size, front mm Ø230x70 Ø230x70 Ø250x75 Ø230x70 Ø250x75
3.3 Wheel size, rear mm Ø85x95 Ø85x95 Ø85x95 Ø85x95 Ø85x95
Wheels
3.4 Further wheels (dimensions) mm Ø125x50* Ø125x50* Ø125x50* Ø125x50* Ø125x50*

Wheels, number front/rear (x=drive
3.5 1x+2/2 or 4 1x+2/2 or 4 1x+2/2 or 4 1x+2/2 or 4 1x+2/2 or 4
wheels)
3.6 Track width, front b10 mm 500 500 500 500 500
3.7 Track width, rear b11 mm 370 370 370 370 370
4.4 Lift h3 mm 120 1) 1201) 1201) 1201) 1201)
Lift height h23 mm 205 1) 2051) 2051) 2051) 2051)
4.8 Platform height h7 mm 190 190 190 190 190
4.9 Tiller arm height in driving position, min/
max h14 mm 1100/1413 1100/1413 1100/1413 1100/1413 1100/1413
Manual control h14 mm 1201/1413 1201/1413 1201/1413 1201/1413 1201/1413
Power steering, highest position
h14 mm 1101/1313 1101/1313 1101/1313 1101/1313 1101/1313
Power steering, lowest position
4.15 Height, lowered forks h13 mm 85 85 85 85 85
Dimensions
4.19 Total length l1 mm 1816* 1816* 1816* 1864* 1864*

4.20 Length to fork back l2 mm 666* 666* 666* 714* 714*
4.21 Overall width b1 mm 730 730 730 730 730
s/e/
4.22 Fork dimensions mm 78/180/1150* 78/180/1150* 78/180/1150* 78/180/1150* 78/180/1150*
l
4.25 Width over fork b5 mm 550* 550* 550* 550* 550*
4.32 Ground clearance, wheelbase centre m1 mm 30 30 30 30 30
Path requirements for pallet size
4.33 Ast mm 2430* 2430* 2430* 2477* 2477*
1000*1200, long-side handling
Path requirements for pallet size
4.34 Ast mm 2277* 2277* 2277* 2324* 2324*
800*1200, short-side handling
4.35 Turning radius Wa mm 1585* 1585* 1585* 1632* 1632*
© Cesab 24 – 1 T Code(s): 1010


5.1 Speed with/without load
Manual control km/h 6.0/6.0 8.0/8.0 8.0/10.0 7.5/8.0 7.5/10.0
Power steering km/h 6.0/6.0 8.0/8.0 9.0/10.0 8.0/8.0 9.0/10.0
Performance
5.2 Lift speed with/without load m/s 0.05/0.08 0.05/0.08 0.05/0.08 0.05/0.07 0.05/0.07
5.3 Lowering speed with/without load m/s 0.11/0.09 0.11/0.09 0.11/0.09 0.11/0.08 0.11/0.08
Max. gradient capability, with/without
5.8 % 8/18 8/18 8/18 8/18 8/18
load
5.9 Acceleration time (over 10 m) s 5.7 5.7 5.7 5.0 5.0
5.10 Travel brake Electromagnetic
6.1 Drive motor S2 @ 60 min kW 1.8 2.5 2.5 2.5 2.5
Electric motor
6.2 Lifting motor S3 10% kW 2.2 2.2 2.2 2.2 2.2

6.4 Battery voltage/nominal capacity K5 V/Ah 24/300* 24/300* 24/300* 24/400* 24/400*
6.5 Battery weight kg 241 241 241 305 305
Battery dimensions
Changing the
Lifting out To the side Li-ion
battery
Dimensions
Battery
Small Medium Large/din Small Medium Large/din Small Medium
compartment
Wheelbase, forks lifted/
1.9 y mm 1406/1362 1454/1410 1551/1507 1466/1422 1514/1470 1608/1564 1406/1362 1554/1410
lowered
4.19 Total length
with platform up/down l1 mm 1816/2266 1864/2314 1961/2411 1876/2326 1924/2374 2021/2471 1816/2266 1864/2314
with backrest l1 mm 2440 2488 2585 2500 2548 2645 2440 2488
with fixed side guards l1 mm 2276 2324 2420 2336 2384 2480 2276 2324
4.20 Length to fork back
with platform up/down l2 mm 666/1116 714/1164 811/1261 726/1176 774/1224 871/1321 666/1116 714/1164
with backrest l2 mm 1290 1338 1435 1350 1398 1495 1290 1338
with fixed side guards l2 mm 1126 1174 1270 1186 1234 1330 1126 1174
4.35 Turning radius, forks lifted
with platform up/down Wa mm 1585/2049 1632/2096 1727/2193 1644/2108 1691/2156 1786/2252 1585/2049 1632/2096
with backrest Wa mm 2221 2269 2365 2281 2329 2425 2221 2269
with fixed side guards Wa mm 2059 2106 2202 2118 2166 2261 2059 2106
Battery voltage/nominal 24/225- 24/375- 24/225- 24/375-
6.4 V/Ah 24/400 24/400 24/100-150 24/200
capacity K5 300 600 300 600
6.5 Battery weight, min-max kg 175-285 265-350 375-485 175-285 265-350 375-485 126/90 90/102
© Cesab 24 – 2 T Code(s): 1010

© Cesab 24 – 3 T Code(s): 1010

Service data

Truck traction Type Brushless, three-phase asynchronous motor
Result kW 1.8 2.5 2.5 2.5 2.5
Duty cycle S2 60 min
Weight kg 13 18 18 18 18
Brakes Type Single stage electromechanical spring-loaded brake
Brake force Nm 21 30 30 30 30
Result W 18.75 23 23 23 23
Resistance, coil 7.68 6.26 6.26 6.26 6.26
Nominal clearance in applied position mm 0.2
Minimum brake disc thickness mm Breaks when the friction material is completely worn
Thickness of new brake disc mm 7.5
Horn Resistance Ohm
Pump contactor Resistance Ohm 29±10%
Lowering valve resistance Ohm 21
Fan Resistance Ohm
Speed sensor Normal current consumption
Main contactor Resistance Ohm 52±10%
Gearbox Type Two-stage angle gear
Gear ratio 18.39 18.39 16.96 18.39 16.96
Oil volume l 0.9 0.9 1.05 0.9 1.05
Oil type See section "23.2 Oil and grease specification".
Hydraulic system Result kW 2.2
Duty cycle % S3=5%, S2=2 min
Min. carbon brush length mm 9
Nominal commutator diameter mm 42
Minimum commutator diameter mm 39
Pressure at rated load bar 170 170 170 185 185
Overflow pressure bar ~15% over pressure at rated load
Pump flow l/min 10 l/min at 10 bar. 6 l/min at 200 bar
Usable tank volume l 1.6
Oil type, normal temperature, <-15°C See section "23.2 Oil and grease specification".
Power steering, Brushless, permanently magnetised, three-phase
Type
motor (option) synchronous motor
Result kW 240
Torque constant Nm/A 0.06
Max. current A 45
Continuous current A 13
Rotational speed rpm 3250
Minimum carbon brush length mm N/A
Minimum commutator diameter mm N/A
Resistance, armature Ohm N/A
© Cesab 24 – 4 T Code(s): 1010

© Cesab 24 – 5 T Code(s): 1010

© Cesab 24 – 6 T Code(s): 1010

Cesab Carelli Elevatori Spa Bologna, Italy

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Repair manual 7572516-040

Liste der Modelle:

© Cesab T-Code(s): 1010

© Cesab 1– 1 T Code(s): 1010

6.3 Lifting the truck ............................................................................................ 6–2

© Cesab 1– 2 T Code(s): 1010

9.1.3 Replacing the side cover ................................................................ 9–4

© Cesab 1– 3 T Code(s): 1010

9.6 Operator protection C0840 ........................................................................ 9–81

© Cesab 1– 4 T Code(s): 1010

11.5.3 Replacing the steering bearing................................................. 11–12

© Cesab 1– 5 T Code(s): 1010

13.3 Tiller arm, E-man ................................................................................... 13–26

© Cesab 1– 6 T Code(s): 1010

14.7 Motor control [T1] (ACT) ........................................................................ 14–13

© Cesab 1– 7 T Code(s): 1010

15.3.14 Pressure limitation .................................................................. 15–19

© Cesab 1– 8 T Code(s): 1010

22.3 CPC contacts........................................................................................... 22–4

© Cesab 1– 9 T Code(s): 1010

© Cesab 1 – 10 T Code(s): 1010

© Cesab 2– 1 T Code(s): 1010

2.2 Warning levels and symbols

© Cesab 2– 2 T Code(s): 1010

Symbol Procedure Symbol Procedure

Check of fluid level and Check that bolts, nuts, etc.

Listening for noise. Lubrication, application.

Check of functions. Calibration

© Cesab 2– 3 T Code(s): 1010

Symbol Procedure Symbol Procedure

An example of another type of pictogram is “Cut cable ties”:

© Cesab 2– 4 T Code(s): 1010

3. General safety rules

3.1 Work safety

© Cesab 3– 1 T Code(s): 1010

© Cesab 3– 2 T Code(s): 1010

3.2 Electrical systems

© Cesab 3– 3 T Code(s): 1010

3.3 Safe lifting

© Cesab 3– 4 T Code(s): 1010

3.4 Truck modifications

© Cesab 3– 5 T Code(s): 1010

© Cesab 3– 6 T Code(s): 1010

4. Operation and connection sequences

© Cesab 4– 1 T Code(s): 1010

Symbols on keypad and display

Battery charge as a percentage

© Cesab 4– 2 T Code(s): 1010

4.1 Battery is connected

Event Connection of battery

Action(s) Connect battery [X1, G1]

4.2 Login via keypad

© Cesab 4– 3 T Code(s): 1010

4.3 Tiller arm lowered for driving

Event Tiller arm lowered for driving

Action(s) Lower tiller arm

Influencing elements Tiller arm in drive position sensor [B60].

4.4 Driving in fork direction

Event Driving in fork direction

Action(s) Move the speed control [L1] in the fork direction.