BT CBE 1.2-2.0 T/F Cargo Range Forklift Truck Service & Repair Manual

Service Manual CBE 1.2 T 1.2 F 1.5 T 1.5 F 1.6 T 1.6 F 1.6 TL 1.6 FL 1.8 T 1.8 F 1.8 TL 1.8 FL 2.0 T 2.0 F Cargo Range CARGO 1.2

SERVICE MANUAL page 2 Electric ton.1,2-2,0 T/F CESAB S.p.a. reserves all rights of reproduction of this handbook The text and the numbering system may not be used in other printed matter, reprinted or translated, whether entirely or in part, without written authorization from CESAB reserves the right to make any necessary modifications without obligation to promptly update this handbook. Copyright by CESAB S. p. A. BOLOGNA’S FACTORY, AFTER SALES SERVICE

SERVICE MANUAL page 3 Electric ton.1,2-2,0 T/F INDEX ELECTRICAL SECTION Electronic Panel Characteristics page 4 Functional Performance page 5 General Precautions page 6 Electrical Motors Characteristics page 7 General Description of Functions of the Console page 8 Console Description - Keyboard page 9 Connection of the Auxiliary Circuit - B1S Unit page 10 Connection of the Power Circuit - B1S Unit page 11 Potentiometer Configuration page 13 Contactor Connection page 15 Parameter Modification Unit B1S page 16 Description of the Warnings Relevant to the Diagnostic Led Placed on the Dashboard and to the Console - Unit B1S page 17 Connection of Electric Circuit HP 350 page 19 Lifting Potentiometer page 21 Parameter Modifications Unit HP350 page 22 Description of the Warnings Relevant to the Diagnostic Led Placed on the Dashboard and to the Console - Unit HP350 page 23 Adjustment Tables page 24 Dashboard page 25 MECHANICAL SECTION Explicative drawings/diagrams page 26

SERVICE MANUAL page 4 Electric ton.1,2-2,0 T/F ELECTRONIC PANEL CHARACTERISTICS Technical specifications B1S (traction) HP 350 (lifting) Nominal voltage (Variation): 48V (30 - 60) 48V (30 - 60) Max. current: : 350A + 350A 350A Operating frequency: 18KHz 18KHz Working ambient temperature: -30°C / +40°C -30°C / +40°C Max. attainable temperature from chopper body: 85° (80°= 100% motorström, 81°= 80% motorström, 85°= 0% motorström) Microprocessor Logic unit. OBS! Använd endast "Anderson" orginal laddhandske!

SERVICE MANUAL page 5 Electric ton.1,2-2,0 T/F Functional performances - Very good control at low speed. - Diagnostic with indication by means of led. - Able to be formed via console. - Internal timer visible from the console. - Storage of the last 5 alarms with the relative value of the timer and temperature visible from the console. - Tester by means of the console to verify in real time of the main parameters, such as input, motor voltage, battery. - Arc less operation of the remote control switches. - Internal coil suppression (within logic). - High efficiency of motor and battery due to high frequency switching. Protections - Battery reversal: It is important to observe the connections shown in order to prevent damage. The logic is internally protected from reverse battery polarity. - Connection errors: All inputs are protected against incorrect connections. The remote control switches have a rating of 3Amps, however they are protected from overload and short circuits. - Termal protection: When the temperature is more than 80°C the maximum current is reduced in proportion to the increase in temperature. The temperature can never exceed 85° C. - Discharged battery: When the battery is discharged the lifting speed is reduced by 60%. The other functions remain unchanged. - External agents: The chopper is protected from the dust and from the liquids spray , is completely sealed. - Safety from accidental operation: Starting the machine, requires a precise sequence of operations otherwise the machine will not start. The start sequence has to be initiated after the key and the micro seat are active. - Safety from uncontrolled movements: The remote control switches remain open if: - The power is not in use. - The accelerator voltage does not fall below (minimum memorized value 2 volt). - The logic is not in perfect order. - A direction microswitche is ever closed.

SERVICE MANUAL page 6 Electric ton.1,2-2,0 T/F General precautions - Do not connect the chopper to a battery with a nominal voltage different to the voltage stated from the one on the unit plate. If the battery voltage is higher it may cause the MOS failure. If the battery voltage is less the unit will not run . - During the battery recharging no units must be connected to the battery as, the unit can be damaged by the overvoltages generated by the charge-battery. - Supply the unit only with traction battery, do not use rectifier outputs or power supplies. - With key switched off, the filter capacitors could remain charged for some minutes. For work in surely working conditions, we suggest you . to disconnect the battery and with resting machine and inserted key wait some seconds till when the display will be completely off; or . short circuit the capacitors through a resistor (56 Ohm 1W) across B+ and B- chopper power connections. - Before carrying out any arc-weldings on the trucks, disconnect the battery and short-circuit the unit between positive (+) and negative (-).

SERVICE MANUAL page 7 Electric ton.1,2-2,0 T/F ELECTRICAL MOT OR CHARACTERISTIC TRACTION MOTOR: SCHABMÜLLER (P/NO 0057919) V 48 Service S2 A 108 IP 20 RPM 2160 IS F KW 4,2 (4,7) SERIE LIFTING MOTOR: SCHABMÜLLER (P/NO 0058026) V 48 Service S3 -13% RPM 1530 KW 9,5 SERIE Lifting pump 17 LT/MIN

SERVICE MANUAL page 8 Electric ton.1,2-2,0 T/F GENERAL DESCRIPTION OF FUNCTIONS OF THE CONSOLE HOUR METER The hour meter appears in the second line of the display when the chopper is connected. The hour meter has a sensitivity of one minute and a full scale value of 65,535hours . It shows the hours only. ALARM DISPLAY The console features the possibility to read the last five alarm messages stored in the chopper and displayed together with the time of occurrence, the number of times the alarm was sent and the temperature value at the time of the alarm. PARAMETER PROGRAMMING The chopper parameters can be displayed and programmed via the keyboard, in real time and with operating machine, thereby making it possible to set the chopper easily. TESTER It makes it possible to display the state of the chopper analogue and digital values and thereby to have a useful tool for the analysis of chopper operation and external cables. SAVE It makes it possible to store all values relating to the parameters and the chopper hardware configuration into the console with a program which can be selected from the keyboard. RESTORE It makes it possible to program a chopper with the parameters contained in a program generated by a SAVE. ACCELERATOR MAX. STROKE PROGRAMMING It allows to program the accelerator max. stroke. STEER TABLE It allows to configurate the chopper for the truck tipe and the pitch on which it is fitted CONSOLE CONNECTION The connection has to be made with resting machine. - +

SERVICE MANUAL page 9 Electric ton.1,2-2,0 T/F CONSOLE DESCRIPTION KEYBOARD ROLL1 = Allows selection of an option or the next menu item. ROLL2 = Allows select of an option or the previous menu item. ENTER = Allows confirmation of selected options. OUT = Retains the current function. PARAM = Allows an increase in the parameters or selects the type of connected I/O. SET = Allows a reduction in the parameters or selects the type of connected I/O. 176986BT Part nr: eller: 1997100R1CE

BT CBE 1.2-2.0 T/F Cargo Range Forklift Truck Service & Repair Manual

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