Service Manual
CBD 4.0 4.5 5.0
Cargo Range
CARGO
BT Svenska AB Per Wärmlund
4.0
< Tillbaka till Index
INTERNAL COMBUSTION
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SERVICE MANUAL
page 3
CESAB S.p.a. reserves all rights of reproduction of this handbook
The text and the numbering system may not be used in other printed matter, reprinted or translated, translated, whether entirely or in part, without 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
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SERVICE MANUAL
INTERNAL COMBUSTION
INDEX DATA SHEET....... SHEET........... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ....... ... p.
6
OPERATOR’S OPERATOR’ S SEAT SEAT ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ .... p. Foott peda Foo pedals ls ver versio sionn - Han Handd dire directi ction on lev lever er ver versio sionn .... ........ ....... ....... ........ ........ ....... ....... ........ ....... ....... ........ .... p. Pedals Ped als ver versio sionn - Ser Servic vicee bra brake ke .... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ...... .. p.
8 8 8
DASHBOARD........... DASHBOARD....... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ...... .. Dashbo Das hboard ard ind indica icator tor .... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ...... .. Parkin Par kingg swi switch tch .... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ....... ... Tru ruck ck sta start rt up up .... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ...... Set of lev levers ers .... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ...... .. Openin Ope ningg engin enginee compa compartm rtment ent... ....... ........ ....... ....... ....... ....... ........ ....... ....... ....... ....... ........ ....... ....... ....... ....... ........ ....... ....... ....... ..... Capaci Cap acity ty pla plates tes .... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ......
p. p. p. p. p. p. p.
9 9 11 11 12 12 12
ENDOTHERMIC ENGIN ENDOTHERMIC ENGINE E ....... ...... ...... ...... ...... ...... ..... ..... ...... ..... ..... ..... ..... ...... ..... ..... ...... ..... ..... ...... ..... ..... ...... ..... ..... ...... ..... ..... ...... ..... JOHN JOH N DEE DEERE RE ENG ENGINE INE.... ........ ........ ........ ....... ....... ........ ....... ....... ....... ....... ........ ....... ....... ........ ....... ....... ........ ....... ....... ....... ....... ........ .... Topp opping ing up with coola coolant....... nt........... ....... ....... ........ ........ ........ ........ ........ ....... ....... ........ ........ ........ ........ ........ ....... ....... ........ ........ ........ ...... .. Air fil filter ter - Cyclo Cyclone ne pref prefilte ilterr .... ........ ........ ........ ........ ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ...... ... Engi En gine ne ru runn nnin ingg-in in .... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ....... ...
p. p. p. p. p.
13 13 14 15 15
ELECTRONIC HYDROSTATIC TRANSMISSION...... TRANSMISSION........ .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. p. Exampl Exa mplee of a clo closed sed loo loopp hyd hydros rostat tatic ic tra transm nsmiss ission ion ... ....... ........ ........ ....... ....... ........ ....... ....... ........ ........ ....... ... p. Opera Ope ratio tionn of of the the var variab iable le dis displa place cemen mentt pump pump wit withh axia axiall pist pistons ons .... ........ ........ ........ ........ ........ ...... p. Operat Ope ration ion of the ele electr ctroni onicc hydr hydrost ostati aticc sys system tem ... ...... ....... ....... ...... ...... ...... ...... ...... ...... ....... ....... ...... ...... ...... ...... ..... p. Descr Des cript iption ion of the mai mainn fun functi ctions ons .... ........ ........ ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ...... .. p.
16 17 18 19 20
................... ............................... ............................... ................................ ............................... .................... ..... p. HYDRAULIC DIAGRAM ...
22
HYDROSTA HYDROST ATIC PUMP ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ....... ... p.
23
HYDRAULIC MOTOR HYDRAULIC MOTOR.... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ....... ... p. HYDROSTA HYDROST ATIC TRANSMISSION MAINTENANCE... MAINTENANCE ..... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. p. Replac Rep lacing ing the fil filter ter an andd chan changin gingg the the tran transmi smissi ssion on oil oil... ...... ...... ....... ....... ...... ...... ...... ...... ...... ...... ...... ....... .... p.
25 28 28
BRAKES............. BRAKES......... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ .... p. Diag Di agra ram m of the the serv servic icee brak brakee and and the par parki king ng bra brake ke sys syste tems ms ... ..... ..... ...... ...... ...... ..... ..... ...... ...... ... p. Checki Che cking ng the ser servic vicee bra brake ke .... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ....... ... p. Releas Rel easing ing the bra brake kess for for the tru truck ck tow towing ing .... ........ ....... ....... ....... ....... ........ ....... ....... ....... ....... ........ ....... ....... ....... ....... ...... p.
29 29 30 30
ELECTRIC SYSTE ELECTRIC SYSTEM M ... ....... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ....... ... p. Batt Ba tter eryy .... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ....... ... p. Electr Ele ctric ic com compon ponent entss .... ........ ....... ....... ........ ........ ....... ....... ........ ........ ....... ....... ........ ........ ....... ....... ........ ........ ....... ....... ........ ........ ....... ....... .... p. Fusee hol Fus holdin dingg pan panel el .... ........ ........ ........ ....... ....... ........ ........ ....... ....... ........ ........ ....... ....... ........ ........ ....... ....... ........ ........ ....... ....... ........ ........ ...... p. Engine Eng ine act actuat uator or .... ........ ........ ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ...... p. Rotary Rot ary / linear linear pot potent entiom iomete eterr .... ....... ....... ........ ....... ....... ....... ....... ........ ....... ....... ....... ....... ........ ....... ....... ....... ....... ........ ....... ....... ...... .. p. Wiringg diagram ..... Wirin ................... ............................... ................................. ................................ ................................. .............................. ............. p. Rear Re ar lig light htin ingg sy syst stem em .... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ...... .. p.
31 31 32 32 33 34 35/b 36
INTERNAL COMBUSTION
SERVICE MANUAL
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MENUS AND PARAMETERS FOR THE TCS SYSTEM....... SYSTEM........... ...... ...... ...... ....... ...... ...... ...... ...... .... p. 37 CALI CA LIBR BRA ATI TION ON .... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ...... p. 38 Calibr Cal ibrati ation on and fir first st sta start rt up of the tra transm nsmiss ission ion sys system tem .... ....... ...... ....... ....... ...... ...... ....... ....... ...... ....... .... p. 40 DISP DI SPLA LAY Y .... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ...... .. p. 44 PUMP PU MP CU CUST STOM OMIZ IZED ED .... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ...... .. p. 45 ENGI EN GINE NE CU CUST STOM OMIZ IZED ED .... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ....... ... p. 46 FAUL AULT T DETECTED / INFO / PH-PARAM. / EPROM RESET ................ ............................. ............. p. 47/B/C Troubles Tr oubles occuring while calibrating ................................................................... ..................................................................... p. 47C Syst Sy stem em fa faul ults ts an andd fai failu lure ress .... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ...... .. p. 53 Tro roub uble lesh shoo ootiting ng .... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ...... p. 55 WHEELS / TYRES........ TYRES............ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ...... .. p. Safety Saf ety of whe wheels els and rim rimss whil whilee usin usingg the the tru truck ck ... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ..... .. p.
56 56
STEERING STEERI NG UNIT UNIT ... ....... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ...... Steer Ste ering ing con contro troll .... ........ ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ........ ...... Power Pow er ste steeri ering ng dia diagra gram m .... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ .... Steeri Ste ering ng axl axlee .... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ...... Adjust Adj usting ing the bea bearin rings gs .... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ....... ...
p. p. p. p. p.
57 57 57 58 59
HYDRAULIC HYDRA ULIC DISTRIB DISTRIBUTOR UTOR ... ..... ..... ...... ..... ..... ...... ..... ..... ...... ...... ..... ..... ...... ...... ..... ..... ...... ..... ..... ...... ...... ..... ..... ...... ...... ..... ..... ..... p.
60
MASTS........... MASTS....... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ...... p. Lubric Lub ricati ation on .... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ .... p. Instal Ins tallat lation ion che checks cks saf safety ety sp speci ecific ficati ation onss ... ....... ....... ...... ...... ...... ....... ....... ...... ...... ...... ...... ....... ....... ...... ...... ...... ....... ....... ... p. Descri Des cripti ption on of of the cyl cylind inder er comp compone onents nts... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ........ ....... ....... ...... .. p. Cylind Cyl inder er inspec inspectio tionn proced procedure ures...... s.......... ........ ........ ........ ........ ........ ....... ....... ........ ........ ........ ........ ........ ........ ........ ........ ....... ..... .. p. Chains Cha ins ins inspec pectio tionn .... ........ ........ ........ ........ ........ ........ ....... ....... ....... ....... ........ ........ ........ ........ ........ ....... ....... ........ ........ ........ ........ ........ ....... ..... p. Forks For ks ins inspec pectio tionn .... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ .... p.
61 63 64 65 66 67 67
LIFTING LIFTI NG THE THE TRUCK TRUCK .... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ .... p.
68
TABLES ... ....... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ....... ... p. Table for oil and grease specifications specifications................. ................................... .................................... ............................. ........... p. Tyre pres pressure sure,, tighte tightening ning torqu torques es ............... .............................. .............................. .............................. .......................... ........... p. Tab able le for for the the tru truck ck mai maint nten enan ance ce dur durin ingg the the runn runnin ingg-in in sta stage ge .... ........ ........ ........ ........ ........ ........ ........ .... p. Tab able le for for th thee main mainte tena nanc ncee sch sched edul ulee .... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ....... ... p.
69 69 69 70 70
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T E C H N I C A L D A T A
4 , 0 4 , 5 5 , 0 t -
-
S E R V I C E M A N U A L
C O I M N T B E U R S N T A I L O N
INTERNAL COMBUSTION
SERVICE MANUAL
CAPACITY DIAGRAM (with SE tyres and duplex H=4000)
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SERVICE MANUAL
INTERNAL COMBUSTION
CAPACITY DIAGRAM (with SE tyres and duplex H=4000) 4.0 T
4.5 T
5.0 T
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INTERNAL COMBUSTION
FOOT PEDALS VERSION C
B
A
Pedals consist of: - two travel pedals, one forward pedal (A) and one reverse pedal (B) - a service brake pedal (C)
HAND DIRECTION LEVER VERSION D 1 o
Lever of direction selector (D)
2
o
1 forward speed 0 neutral 2 reverse speed
One travel pedal (E) E
C
BALANCED PEDAL VERSION Forward pedal ( F) Brake pedal ( C) Reverse pedal ( G)
G
C
F
SERVICE BRAKE Foot service brake ( C) controls a hydrostatic braking in the first part of the stroke by means of the electronic control unit; if fully pressed, it engages the oil-bath disc brakes (over the front driving wheels).
SERVICE MANUAL
INTERNAL COMBUSTION
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DASHBOARD During ordinary operation, all warning lights in the dashboard are to be off.
1
2
3 4 5 6 7
8
15
9
10 11
12 13
C
14
B
A
1) Fuel gauge 2) Water temperature indicator 3) Fuel level warning light 4) Generator warning light 5) Glow plug warning light (Diesel engine) 6) Parking brake-on warning light 7) Oil pressure warning light 8) Indicator light (optional) 9) Electronic hour counter 10) Water temperature warning light 11) Transmission oil temperature warning light 12) Hydraulic oil filter clogged warning light 13)Warning light (not used) 14) Warning light (not used) 15) Warning light indicating air filter clogged A) Parking switch; B) Electronic failure warning light
If the warning light blinks during ordinary operation, this indicates a failure in the electronic control unit; the vehicle will stop. C) Ignition key D) Emergency push-button; it acts as an emergency brake. CAUTION The vehicle could instantaneously stop if buttons (A) and (D) are pressed; never press those buttons during the truck ordinary operation.
D
DASHBOARD INDICATORS 1) Fuel gauge 2) Coolant temperature level
Indicates the coolant temperature. The pointer must never reach the red sector; the working temperature corresponds to 95 °C. 3) Fuel level warning light
1
The fuel level warning light turns on when approx. 5.5 l of fuel are left in the tank.
2
4) Generator warning light
3
4
That warning light is to be off when the engine is running. If not, it indicates that the alternator does not supply any current for the battery or the electric system charge. This may be caused by the breaking of the belt that drives the alternator pulley, or by a failure of the alternator.
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5
5) Glow plug warning light (Diesel engine).
6
6) Parking brake on warning light
7
8 9
INTERNAL COMBUSTION
This warning light turns on when the ignition key is in position ( 1); when the ignition temperature is reached, the warning light will automatically turn off.
7) Engine oil pressure warning light
During ordinary operation, this warning light is to be off. If it turns on, immediately check the oil level in the engine. That warning light could turn on when the engine is idling and hot, due to a lesser lubricant viscosity, even if no failure has occurred.
8) Direction indicator on warning light (optional) 9) Electronic hour counter
It indicates the working hours and hour fractions of your truck; it is controlled by the contact key and has the function to simplify scheduled maintenance programming.
10
10)Coolant temperature warning light
It indicates the engine overheating. Should it turn on, stop the vehicle immediately. Check the correct operation of the radiator fan, the water pump and the coolant level in the radiator.
11
11)Transmission oil temperature warning light
It indicates that the temperature limits required for the correct operation of the pump and the hydrostatic engine have been exceeded. Should it turn on, stop working and determine the reasons for the overtemperature transmission oil. Check the oil level and that the radiator is clean and in good operating conditions.
12
12)Transmission oil filter clogged warning light (replace filter)
13
13)Warning light (not used)
14
14)Warning light (not used)
15
15)Air filter clogged warning light (replace filter)
SERVICE MANUAL
INTERNAL COMBUSTION
A: B: 1
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PARKING SWITCH ELECTRONIC FAILURE WARNING LIGHT
position 1 - Travel enabled Switch A in position 1 enables the truck to travel. (green warning light B and warning light 6 on the dashboard are on);
A
brakes are engaged, but will automatically be released if the control pedal is pressed (warning lights B and 6 turn off).
B
position 2 - Parking - start up Switch A in position 2 (green warning light B off) starting of
the engine is possible. Travel blocked to prevent any accidents Brakes are engaged (parking condition).
2 A
HYDROSTATIC BRAKING Lift the travel pedals or the accelerator to enable the hydrostatic braking (adjustable) until the truck stops. A proper device engages the brakes if control pedals are not actuated within a short period. When reoperating the control pedal, brakes will be automatically released.
B
TRUCK START UP -
the operator must be seated parking switch A in position 2 (parking) turn the key to position 1 (ignition on) turn the key to position 2 (glow plugs on) turn the key to position 3 (starter contact) to start the engine once the engine has started up, turn the parking switch A to position 1. - select the foward or reverse direction. The truck is ready to travel.
1
2
If the start up procedure has not been correctly performed, the truck will not start up. If so, repeat the procedure above.
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SET OF LEVERS - LOAD HANDLING
N
L K
INTERNAL COMBUSTION
K) Lifting control (yellow). L) Tilt control lever (green). M )Control lever of the sideshift or other devices (red). N) Available (if existing; black)
M
OPENING ENGINE COMPARTMENT COVER I Before lifting the engine compartment cover, turn the ignition key to pos.0. Unlock with the key (I) and turn the handle (C). Lift the cover by using the special handle (L) An air spring (J) facilitates the complete lifting of the cowling.
L C
J
LOAD PLATE It identifies the load capacity with a load center of 500 mm (except for different indications)
IDENTIFICATION PLATE It identifies the lift truck technical data
ATTACHMENT OR SPECIAL CONDITION OF USE MODEL Type
MOTOR
RATED CAPACITY kW
SERIAL N°
TYRES
kg
DRAW-BAR PULL (1h) LIFT HEIGHT mm
N
BATTERY MASS kg min. MANUFACT. YEAR
SERVICE MASS Without Battery kg
kg max.
TENSION
A
SERIAL N°
CENTER OF LOAD DISTANCE mm
B
V 5 0 0 2 1 3 0 . d o C
4 0 0 2 1 3 0 . d o C
DERATED CAPACITY Kg CARRELLI ELEVATORI S.p.A. via Persicetana vecchia, 10 40132 - Bologna - Italia
CESAB LDT Bevan Way Smethwick - Warley West Midla 1ds B66 1BZ
CAPACITY PLATE
INTERNAL COMBUSTION
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JOHN DEERE 4045 D ENGINE No. cylinders
4 in line
Bore
106 mm
Travel
127 mm
Swept volume
4500 cm³
Compression ratio
17,6:1
SAE J1349 power
58 kW - 2000 rpm
Maximum torque
310 Nm a 1200 rpm
Maximum speed (with load)
2000 rpm
Cooling
water
Injection
direct
Injection pump
rotary
Induction Electrical system Lubrication Oil sump (capacity) Alternator Starter motor
atmospheric 12 V forced 13,3 L including filter 12 V - 65 A 2 KW
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INTERNAL COMBUSTION
TOPPING UP WITH COOLANT Every 50 hours - Make sure the coolant level is up to the radiator cap (B). The caps of the tank and radiator must be removed only when the engine is cold. Every 250 hours - clean the radiator outside.
B
Every 2,000 hours - replace the coolant mixture; check the freezing point of the coolant mixture, especially when driving areas with cold weather. The truck is supplied with a 50% mixture of coolant. If you want to vary the mixture, refer to the values stated in the table below.
ANTIFREEZE APPLICATION RANGE 10%
20%
30%
40%
50%
% VOLUME OF ANTIFREEZE
-4°C
-10°C
-17°C
-24°C
-40°C
FREEZING TEMPERATURE
101°C
102°C
104°C
106°C
109°C
BOILING TEMPERATURE
SERVICE MANUAL
INTERNAL COMBUSTION
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AIR FILTER The air suction filter for the fuel supply is composed of two filtering elements. Every 250 hours
- Clean the element outside the filter (the element inside is not to be cleaned). The filter is to be cleaned also when relevant warning light (15) on the dashboard turns on. Every 3 cleaning cycles
- replace the element inside the filter Every 6 cleaning cycles, or once a year - replace the element outside the filter. Disassembling and cleaning the filter
- release the cover fastening screws and remove the filter cartridge; - clean with compressed air (MAX. 5 bar pressure) from the inside towards the outside; - check that no tear is t o be found. Never hit the cartridge against hard surfaces. Never use any mixture of water and detergent to clean the filter. When reassembling the filter cover, make sure that the dust emptying opening is turned downwards.
CYLONE PREFILTER A
B Every 8 hours
- clean the cyclone prefilter. C
Cleaning the cyclone prefilter - loosen wing-nut (A); - remove cover (B) ; - remove tank (C) ;
- empty the tank and reassemble.
ENGINE RUNNING-IN During the running-in period, the engine may consume more oil than usual. It is recommended that the oil level be checked every 8 working hours, with engine standstill for at least 10 minutes. Do not use the engine at its peak RPM until it has reached its working temperature.
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INTERNAL COMBUSTION
HYDROSTATIC TRANSMISSION Hydrostatic transmission consists of a variable displacement pump, which is controlled by the thermal engine and which delivers oil towards two hydraulic motors that drive the front wheels. The hydraulic connections of both motors allow a proportional di vision of the oil flow generated by the hydrostatic tr ansmission, so as to support the outer wheel while turning; that kind of transmission acts as the differential transmission.
The control and adjustment of the electronic transmission are made by
a control unit (Total Control System) that drives t he following: · thermal engine · hydrostratic pump · hydraulic motors · parking brakes by means of sensors:
· · · ·
potentiometers (on the accelerator pedal, the brake/inching pedal and the mast lever) switches (on the tilt levers and sideshift, the forward/reverse gearshift lever and to engage the parking brake) potentiometer detecting the pump displacement sensor of the thermal engine speed of rotation
and by means of actuators:
· · · ·
proportional solenoid valves of the hydrostatic pump (displacement adjustment) actuator on the thermal engine (adjustment of the fuel pump or the carburettor) solenoid valve for the displacement shifting of the hydraulic motors solenoid valve for the parking brakes release Control unit Portable terminal
Solenoid valve for displacement shifting of hydraulic motors
Accelerator pedal
Parking brake switch
Brake / inching pedal
Potentiometer on mast lever
Running direction selector
Thermal engine speed sensor
Hydrostatic pump
Solenoid valve for parking brake release Thermal engine actuator
Failure warning light
INTERNAL COMBUSTION
SERVICE MANUAL
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EXAMPLE OF A CLOSED LOOP HYDROSTATIC TRANSMISSION
Basic system - pump / motor
The system is equipped with two max. pressure valves, one on each side of the high pressure circuit. There function is to protect the hydrostatic transmission (pump and motor) from overloads.
On the hydraulic motor, and on the pump there are some internal oil leakage (for lubri cation and cooling). This oil is brought back to the tank.
f i t . t i u c r i c
An integrated auxiliary pump is used for restoring of the lost oil. The system is completed by an pressure reducing valve, to control the charge pressure.
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SERVICE MANUAL
INTERNAL COMBUSTION
OPERATION OF THE VARIABLE DISPLACEMENT PUMP WITH AXIAL PISTONS The capacity of the pump is depending of the rpm, and of the displacement, which can be changed in continuity. By increasing the tilting of the plate, the capacity increases from 0, to the max. value.
Tilt 0°
On tilt 0°, it corresponds to 0 mm of stroke, therefore 0 capacity. (machine stopped)
If the tilting plate of the pump is positioned beyond the neutral point, the oil flow direction will be inverted.
INTERNAL COMBUSTION
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SERVICE MANUAL
page 19
OPERATION OF THE ELECTRONIC HYDROSTATIC SYSTEM
4
1
18
5
2 14
3 15
13
17
10
16
9
8 11
3
12 6 7
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Thermal engine Hydrostatic pump Hydraulic motors (dual-displacement motors) with built-in parking brake Boost pump (charge pump) Solenoid valves adjusting the pump displacement (proportionella > 0-5V) TCS control unit Accelerator pedal (0-5V) Direction selector (steering-wheel operated reverse gear with simple pedals or acting directly on the double/swaying pedal system) Actuator of the thermal engine Sensor for the motor speed of rotation Sensor for the hydrostatic pump displacement (magnet potentiometer) Brake pedal (0-5V, 0-95% av rörelsen=hydrostatbroms. 95-100% = parkeringsbroms) Solenoid valve to release the brakes on the motors Parking brake switch Solenoid valve for the displacement shifting of the hydrauli c motors (second speed) Fault warning light Service pump potentiometer/microswitches on the mast lever, the tilt system, the sideshift and any auxiliary devices. (lyftpotentiometer > 0-5V)
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SERVICE MANUAL
INTERNAL COMBUSTION
DESCRIPTION OF THE MAIN FUNCTIONS TRUCK TRAVEL The thermal engine may only be started if the parking brake is on.
The system allows the pump to increase the displacement (truck motion) only if: - the motor is running - the parking brake is off - the running selector is not in neutral position. Should one of those conditions not be true, the actuation of the accelerator pedal will only result in thermal engine speeding up. The position of the accelerator pedal - through the thermal engine and the hydrostatic pump affects the truck speed, i.e. each position of the pedal potentiometer corresponds to the following preset values, according to the setting values programmed in the control unit: - speed of the thermal engine - pump displacement. ACCELERATION / DECELERATION The truck acceleration depends on the speed
with which the accelerator pedal is pressed and on the parameters set in the control unit. BRAKING / INCHING The brake pedal has two functions: 1) hydrostatic braking (the
pump displacement cancels itself out) with a strength depending on the pedal stroke; 2) “inching” function, that can be obtained by simultaneously pressing the brake pedal and the accelerator pedal. PUMP DISPLACEMENT The displacement of the hydrostatic pump depends on the stroke
of the accelerator pedal (and on the stroke of the brake pedal in the “inching” function). The accelerator pedal also determines the rate of rotation of the thermal engine (by means of the actuator). ANTISTALL FUNCTION During the truck ordinary operation, if the power required by
the hydrostatic transmission exceeds the power that may be supplied to the thermal engine, the pump displacement will be automatically reduced to avoid the engine to stall. PARKING BRAKE The parking brake is engaged by pressing a switch located next to the
distributor levers. When the parking brake is on, the accelerator pedal is disabled (the thermal engine accelerates, but the truck cannot run). If the parking brake is engaged while the truck is running, the driving wheels will be automatically locked. Therefore, avoid engaging the parking brake while the truck is running, unless you are in an emergency condition. CONSTANT SPEED When using the mast levers, tilt system and sideshift, the thermal
engine automatically accelerates to meet the request for additional power; the pump displacement will be simultaneously reduced to ensure that the truck speed is kept constant.
INTERNAL COMBUSTION
SERVICE MANUAL
RUNNING DIRECTION May be selected through the steering-wheel operated reverse
gear (for simple pedals) or the forward/reverse pedals (for the double and swaying pedal system). If the lever of the steering-wheel operated reverse gear is shifted to the neutral position while the truck is running (or the accelerator pedal is released in case of double pedal system), the truck will hydrostatically brake. If the running direction is reversed while the truck is running, a hydrostatic braking will occur, which will be immediately followed by the acceleration in the opposite running direction. PARAMETER SETTING Most part of the transmission operation parameters may be set
via portable terminal. CALIBRATION The system sensors and actuators (pedals, motor actuator, etc.) are to be
calibrated using the portable terminal. FAULT DETECTION A warning light located beside the distributor lever indicates the
system faults (the warning light starts blinking). If the failure concerns the hydrostatic pump, the truck will immediately stop. DIAGNOSTICS The portable terminal, which is connected to the control unit, allows to
detect and to store any system fault. DISPLAY The display of the portable terminal allows to view the information about the
transmission operation (thermal engine speed, pump displacement, and so on). THERMAL ENGINE OPTIMIZATION The thermal engine operation (rate of rotation)
is optimized according to the truck speed the operator needs. SPEED DECREASE (OPTIONAL) The truck speed may be decreased for example in
case of transmission oil overtemperature. DISPLACEMENT SHIFTING The hydraulic motor displacement is automatically shifted
and is controlled by the control unit.
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OIL FILTER
OIL RADIATOR
H Y D R A U L I C D I A G R A M
S
EXCHANGE VALVE
INTERNAL COMBUSTION
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HYDROSTATIC PUMP PUMP Mod. POCLAIN PV75 SA Displacement Boost pump displacement Max. pressure measured in M1 or M2 (stall) Boost pressure measured in M3 Drain pressure measured in T1 or T2 (cold pump) or after temperature stabilization Vacuum pressure (absolute pr., measured in S) EXCHANGE UNIT Valve setting
Boost pump
75.5 cc/rev 13.9 cc/rev 450 Bar 24-30 Bar max. 5 Bar max. 2.8 Bar 0.8 Bar
22 Bar
INTERNAL COMBUSTION
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page 23
HYDROSTATIC PUMP PUMP Mod. POCLAIN PV75 SA Displacement Boost pump displacement Max. pressure measured in M1 or M2 (stall) Boost pressure measured in M3 Drain pressure measured in T1 or T2 (cold pump) or after temperature stabilization Vacuum pressure (absolute pr., measured in S)
75.5 cc/rev 13.9 cc/rev 450 Bar 24-30 Bar max. 5 Bar max. 2.8 Bar 0.8 Bar
EXCHANGE UNIT Valve setting
22 Bar
Boost pump
Solenoid valves
Displacement adjusting plate Actuator To motors Pump displacement potentiometer Hydrostatic pump
The pump displacement is controlled by two proportional solenoid valves which are fed by the boost pressure and controlled by the control unit through an electric signal. The spool shift of the solenoid valves controls the pressure over the two chambers of a piston servocontrol that is mechanically coupled to the pump plate; the difference in pressure between the two chambers determines the piston shift, i.e. the displacement shifting. The pump displacement is then detected by a rotary potentiometer sending a signal proportional to the plate shift. The electric control through the solenoid valves and the potentiometer represents a feedbacked circuit for the adjustment of the pump displacement. A sensor detecting the speed of rotation is to be found as well.
DRAIN INLET T1 (from the exchange unit) 1 1/16 - 12 UN - 2B
POTENTIOMETER MEASURING THE PUMP DISPLACEMENT
M2
M3
M1
MECHANICAL ZERO ADJUSTMENT
POTENTIOMETER CONNECTOR A
HIGH PRESSURE (to motors)
B
HIGH PRESSURE
MOTOR SIDE
SENSOR FOR THE SPEED OF ROTATION
DRAIN OUTLET T2 (to the radiator)
BOOST VALVE HIGH PRESSURE DETECTION SOCKET 9/16 - 18 UNF - 2B
BOOST PRESSURE SOCKET M 3
-
-
S E R V I C E M A N U A L
SERVOVALVES FOR THE DISPLACEMENT ADJUSTMENT S CHARGE PUMP INLET PORT (FROM THE OIL FILTER) 1 5/16 - 12 UN - 2B SERVOVALVE CONNECTOR
1 1/16 - 12 UN - 2B
M 2
p a g e 2 4
4 , 0 4 , 5 5 , 0 t
7/8 - 14 UN - 2B
HIGH PRESSURE DETECTION SOCKET M1
9/16 - 18 UNF - 2B
C O I M N T B E U R S N T A I L O N
SERVOVALVE PRESSURE SOCKET 2 M 5
7/16 - 20 UNF - 2B
SERVOVALVE PRESSURE SOCKET 1 M 4
INTERNAL COMBUSTION
7/16 - 20 UNF - 2B
SERVICE MANUAL
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HYDRAULIC MOTOR Motors Poclain MS 082 (dual-displacement; radial pistons) Maximum displacement Minimum displacement Maximum pressure Theoretical torque Maximum speed Brake Braking torque Number of pistons Brake driving pressure (measured in x) Displacement shifting driving pressure (measured in y) Drain pressure (measured in 1) with cold motor after temperature stabilization
934 cc/rev 467 cc/rev 450 Bar 1485 Nm (max. displacement) 140 RPM multidisc type max. 4060 Nm 10 12-30 Bar 10-30 Bar max. 3 Bar max. 1.5 Bar
INTERNAL COMBUSTION
SERVICE MANUAL
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HYDRAULIC MOTOR Motors Poclain MS 082 (dual-displacement; radial pistons) Maximum displacement Minimum displacement Maximum pressure Theoretical torque Maximum speed Brake Braking torque Number of pistons Brake driving pressure (measured in x) Displacement shifting driving pressure (measured in y) Drain pressure (measured in 1) with cold motor after temperature stabilization
wheel hub
cylinder unit
distributor
934 cc/rev 467 cc/rev 450 Bar 1485 Nm (max. displacement) 140 RPM multidisc type max. 4060 Nm 10 12-30 Bar 10-30 Bar max. 3 Bar max. 1.5 Bar
brake
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SERVICE MANUAL
INTERNAL COMBUSTION
The hydraulic motor is of “slow” type. Due to its radial pistons, it is characterized by a high displacement/rev (if compared to engines with axial pistons) so it produces a high torque at a low speed rate, with no reduction gear between the engine and the wheel hub.
The engine is also equipped with an oil-bath mult idisc brake that is normally engaged (wheel locked) by the pre-load of a Belleville washer (negative brake); the brake is hydraulically released by means of a solenoid valve controlled by the control unit : when the solenoid is fed, the valve opens and the fuel boost pr essure on the brake piston releases the brake. The multidisc brake on the motor is used only for the truck parking and emergency braking; on the other hand, service breaking is a hydrostatic one. The motor-brake unit is fully lubricated by the transmission oil (oil dripping from the hydraulic motor). Gearshifting.
The vehicle is equipped with a dual-displacement engine. The second speed is obtained by an internal selector that disables half cylinders, thus halving the effective displacement . This selector is hydraulically actuated - through a 24 bar boost pressure - by the gearshift solenoid valve, which in turn is controlled by the electronic control unit. When the engine is started, it is at its max. displacement (934 cc), so that it can generate the max. possible torque. Pump displacement gradually increases, speeding up the truck itself. When the pump reaches its max. displacement (75 cc) the control unit controls the gearshifting by decreasing engine displacement from 934 cc to 467 cc and simultaneously reducing pump displacement from 75 cc to 35 cc. Truck speed may be then increased by gradually upshifting the hydrostatic pump displacement (up to 75 cc).
C O I M N T B E U R S N T A I L O N A.R.
HIGH PRESSUREINLETS
X Y
NEGATIVE BRAKE DRIVING
DISPLACEMENT SHIFTING DRIVING
M16 X1.5
M14 X 1.5
Y
1
X
DRAINHOLE M18 X 1. 5
HOLE FOR BRAKE MECHANICAL UNLOCKING
S E R V I C E M A N U A L
M16 X 2
p a g e 2 7
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INTERNAL COMBUSTION
HYDROSTATIC TRANSMISSION MAINTENANCE The transmission system and hoisting system have the same oil tank, which is provided with one filter.
A
B
D
C
Components of the transmission system: A) Oil level disptick B) Oil bleeding hole C) Hydraulic oil filter unit D) Oil filling hole
To reach to the above components, unlock the battery support and rotate it. Maintenance consists of the oil change and filter replacement in order to keep the circuit clean.
REPLACING THE FILTER AND CHANGING THE TRANSMISSION OIL After 50 hours
- First transmission filter replacement.
4 , 0 4 , 5 5 , 0 t -
-
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SERVICE MANUAL
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INTERNAL COMBUSTION
HYDROSTATIC TRANSMISSION MAINTENANCE The transmission system and hoisting system have the same oil tank, which is provided with one filter.
A
B
C
Components of the transmission system: A) Oil level disptick B) Oil bleeding hole C) Hydraulic oil filter unit D) Oil filling hole
To reach to the above components, unlock the battery support and rotate it.
D
Maintenance consists of the oil change and filter replacement in order to keep the circuit clean.
REPLACING THE FILTER AND CHANGING THE TRANSMISSION OIL After 50 hours
- First transmission filter replacement. After 500 hours
T
- Second transmission filter replacement; - First oil change for the transmission/hoisting systems. Then, every 2,000 hours
- transmission filter replacement; - oil change for the transmission/hoisting systems.
The oil change is to be performed once a year. The filter is to be changed also when it gets clogged - warning light (12) on the dashboard on; in that case, replace the filter cartridge immediately. To replace the filter, do the following: - re move plug (A) and extract the filter
- insert the new cartridge and close. To change the oil in the tank for the transmission and hoisting systems, do the following:
-
change the oil while the engine is still hot; remove plugs (A ) and ( T) and let the fluid flow out; carefully clean the oil tank; fill the tank with clean oil up to the max. level marked on dipstick (A) after fastening drain plug (T) . only use the oil types mentioned in the specifications section in this manual; do not use oil that deteriorated due to a long storage.
After replacing the filter and changing the transmission oil: - start up the engine, let it idle for about 5-10 minutes while the vehicle is standstill; - check the oil level; top up, when required.
SERVICE MANUAL
INTERNAL COMBUSTION
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BRAKES The brake pedal has two different functions: - braking (if it is used alone) - “inching” function if it is used simultaneously with the accelerator pedal. The brake pedal stroke is divided into two configurable intervals: 0 to 95 % of the whole stroke: hydrostatic braking. The control unit reduces the pump displacement according to a programmed ramp. The braking effect is proportional to the pedal stroke. 95 to 100 % of the whole stroke: mechanical braking. The pump displacement cancels itself out in about 1.5 secs and the negative brakes get engaged. During ordinary operation, if the truck is slowed down and stopped, the mechanical brakes act automatically (after approx. 0.5 secs) on motors. Press the accelerator pedal again to release the brake and to speed up. When the mechanical brake is engaged, the relevant warning light on the dashboard turns on. The braking effect may also be obtained by releasing the accelerator pedal (hydrostatic braking) or by reversing the running direction (hydrostatic reverse braking, more efficient than the mere hydrostatic braking). A
B S
S
DIAGRAM OF THE SERVICE BRAKE AND PARKING BRAKE SYSTEMS S
C D E F
G I
H
A) Hydraulic motor B) Brake unit C) Solenoid valve D) Tank E) Electronic control unit F) Hydrostatic transmission G) Service brake pedal H) Parking switch I) Potentiometer
Every 4,000 hours
H
- replace solenoid valve ( C) for the brake control. Every 10,000 hours
- replace brake hoses ( S).
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INTERNAL COMBUSTION
CHECKING THE SERVICE BRAKE The disc brakes are in oil-bath; they make use of the same oil as the traction hydraulic motors. The disc brake unit is composed of 11 discs and 11 counterdiscs. The total disc thickness is: min. 31.5 mm, max. 34 mm. Every 250 hours
- check the pedal operation; the pedal has to be free from any obstacle; - check the brake wear;
RELEASING THE BRAKES FOR THE TRUCK TOWING In case of breakdown, previously release the brake discs inside the two traction units to tow the truck. Brake release
Position appropriate tool ( M), code 1996086, one for each brake unit; tighten screw (N) into hole (L) on the brake unit; keep tool ( M) locked and tighten nut (O) until the brakes unlock.
M
L N
O
SERVICE MANUAL
INTERNAL COMBUSTION
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ELECTRIC SYSTEM Every 500 hours
- check the push-buttons wiring and operation; - check the operation of the microswitches located on the pedals; Every 1,000 hours
- inspect wiring and connections; check if the cable terminals are properly tightened and the cable insulation is intact.
P
WARNING:
DISCONNECT THE TRUCK BATTERY BEFORE SERVICING THE ELECTRIC SYSTEM AND THE ELECTRONIC EQUIPMENT. Q
BATTERY Battery (P) is located under the engine bonnet; before servicing, always disconnect safety connector ( Q). Every 500 hours
- clean the battery poles and terminals; - grease and tighten the terminals; Every 1,000 hours
- check the earth connections. Every 4,000 hours
- replace the battery. The battery supplied has a min. 100 Ah capacitance. If the battery is a maintenance-free one, inspect as follows: Every 50 hours
- check the electrolyte level and density; top up with distilled water, if necessary. The battery is to be recharged when its voltage has decreased by 1.7V or the electrolyte thickness is under 1.16 kg/dm 3. When the truck is running, never disconnect the battery cables, so as to avoid dangerous voltage peaks to the alternator diodes.
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SERVICE MANUAL
INTERNAL COMBUSTION
ELECTRIC COMPONENTS FUSE HOLDING PANEL Lift the engine bonnet to reach to the fuse panel, which is located below the support of the distributor controls. The panel is composed of a fuse block ( A), of some relays ( B) and optional intermittance ( C). Disassemble the protecting panel to replace the component. A
B C Fuse specifications 1- F1 -alternator, starter 2- F2 -horn 5- F5 -system protection 6- F6 -injection pump 11-F11-glow plug switch 15-F15-rear lights - reverse light 16-F16-rear lights - brake/stop light
40A 5 A 7.5 A 5 A 7.5 A 5 A 5 A the other fuses are intended for optional systems Before replacing a fuse, make sure that the problem generating fuse burning has been solved. Relays E1 - start up E2 - brake validation E3 - speed increase E4 - reverse speed validation E5 - forward speed validation E6 - brake/stop light E8 - rear light E9 - glow plug warning light
E3-E4-E5-E6-E8-E9 RELAIS TYPE CODE
the other fuses are intended for optional systems
E1-E2 RELAIS TYPE CODE
SERVICE MANUAL
INTERNAL COMBUSTION
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ENGINE ACTUATOR The engine actuator is controlled by TCS control unit; it adjusts the Diesel engine injection pump. The engine actuator is composed of an electric motor controlling t he control shaft of the pump tie rod and of a potentiometer detecting the shaft rotation and generating a feedback electric signal (voltage). When calibrating, the control unit correlates the actuator stroke (r otation) measured by the potentiometer with the thermal engine speed of rotation, measured by the sensor located on the hydrostatic pump. The unit composed of the actuator and the rev sensor is a feedback system intended for adjusting the engine speed.
injection pump tie rod
actuator support
max. rpm adjusting screw
min. rpm adjusting screw
K A L B
E U L B
N W O R B
W O L L E Y
D E R
page 33
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SERVICE MANUAL
INTERNAL COMBUSTION
ROTARY POTENTIOMETER (on the accelerator and brake pedals)
resistance: 2.5 kohm electric stroke: 54° mechanica mech anicall stroke: stroke: 60°
LINEAR POTENTIOMETER (on the mast lever)
resistance: 5 kohm electric stroke: 10 mm mechanica mech anicall stroke: 12.5 mm yellow
red green yellow
red
green
AMP CONNECTOR (on control unit)
type: 144-796-1 55-pin
John Deere Motor
Page 35
CBD 4,0 - 5,0 PERKINS
35b
CBD 4,0 - 5,0 PERKINS
35b
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SERVICE MANUAL REAR LIGHT DIAGRAM
INTERNAL COMBUSTION
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REAR LIGHT DIAGRAM
LEGEND
LS1 LS2 LR1 LR2 IL1 IL2
= = = = = =
Left stop-light 12V - 10W Right stop-light 12V - 10W Left backup light 12V - 10W Right backup light 12V - 10W Left lighting system (OPTIONAL) Right lighting system (OPTIONAL)
INTERNAL COMBUSTION
INTERNAL COMBUSTION
SERVICE MANUAL
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MENUS AND PARAMETERS FOR THE TCS SYSTEM The parameters for the transmission control are composed of submenus and may be viewed and modified through the portable terminal (code 0058039), that may be connected to the control unit .
För att programmera en lös TCS-box: Anslut Pin 18 och 55 till BAnslut Pin 19 och 37 till B+
The [ENTER] key is used for selecting a menu or submenu and for the confi rmation of a parameter numeric value. The [ESC] key is used for quitting a menu or submenu or for deleting the last character entered. The [+] and [-] keys are used for moving through the menu list or increasing and decreasing the numeric value of a parameter. Use the numeric keypad to enter the parameter values; use the [.] key for decimal places.
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SERVICE MANUAL
INTERNAL COMBUSTION
The main menus are listed below:
N. Menu
1
Functions
CALIBRATION
to calibrate potentiometers and transmission actuators (pedals, distributor, engine actuator, ...) 2 DISPLAY to display the information on the transmission (thermal engine speed, pump displacement, antistall function, ...) 3 PUMP CUSTOMIZED to customize the transmission (more or less prompt breaking and acceleration) 4 ENGINE CUSTOMIZED to customatize the thermal engine control (higher or lower acceleration of the thermal engine, engine speed when the tilt system and the sideshift are on, ...) 5 FAULT DETECTED to display the system faults 6 INFORMATION software versions 7 PH PARAMETERS (password) configuration of the system operation parameters 8 EEPROM RESET (password) to reset the control unit memory 9 MOTOR SHIFTING (password) configuration of the parameters controlling the displacement shifting of the hydraulic motors 10 ACTUATOR PID (password) configuration of the actuator feedback parameters
1) CALIBRATION The CALIBRATION menu is used. That menu has two functions: · when the parking brake is locked and the “calibration status” parameter is “not locked” , it allows the calibration and configuration of the system elements (calibrating mode); · when the parking brake is not locked or the “calibration status” parameter is “locked”, that menu allows to view the output voltages of the system sensors and the state of some components (display mode). After any calibration, release and engage the parking brake again to exit from the “calibration status” mode and return to the standard operating mode.
INTERNAL COMBUSTION
SERVICE MANUAL
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CALIBRATION MENU N. SUBMENU A travel pedal
CALIBRATION MODE calibration of the travel pedal
B
calibration of the brake pedal
C
brake/inching pedal mast lever
calibration of the mast lever
D engine calibration
calibration of the actuator-thermal
E
calibration of the pump in neutral position limiting of the truck max. forward speed limiting of the truck max. revers speed limiting of the truck max.speed
pump neutral
F
max. forward speed G max. reverse speed H reduced speed I
L M N O
P Q
number of teeth
definition of the number of teeth per engine rev (speed sensor in the thermal engine) power supply measures the supply voltage of the control unit sensor excitation measures the supply voltage of the sensors multi disc brake definition of the type of brake used parking brake set definition of the brake pedal position in which the mechanical pedal is engaged pump pot. inverted definition of the connections type of the pump potentiometer calibration status lock or unlock the calibration menu
DISPLAY MODE display of the voltage supplied by the potentiometer for the travel pedal display of the voltage supplied by the potentiometer for the brake pedal display of the voltage supplied by the potentiometer for the mast lever display of the voltage supplied by the engine potentiometer for the actuator display of the voltage supplied by the potentiometer for the hydrostatic pump display of the truck forward speed (as a percentage of the max. speed) display of the truck reverse speed (as a percentage of the max. speed) display if the truck reduced speed is activated (enable / disable) display of the number of teeth/rev
measures the supply voltage of the control unit measures the supply voltage of the sensors type of brake used displays the brake pedal position in which the mechanical brake is locked displays the connections type of the pump potentiometer status of the calibration menu
For the TCS correct operation, the voltage values read by the potentiometers in the pedals, the mast system and the motor actuator must not exceed the limits set. If the mechanical limit stops of the potentiometer are not properly adjusted, the voltage supplied by t he potentiometers and exceeding the range of values allowed by the control unit disables the calibration procedure. That trouble may also occur after a correct calibration if, for whatever reason, the limit stop is modified.
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SERVICE MANUAL
INTERNAL COMBUSTION
CALIBRATION AND FIRST START UP OF THE TRANSMISSION SYSTEM The system calibration is to be performed when the thermal engine is stopped. The following are to be calibrated: · · · ·
Potentiometer for the travel pedal (TRAVEL PEDAL) Potentiometer for the brake pedal (BRAKE/INCHING PEDAL) Potentiometer for the mast lever (MAST LEVER) Feedback potentiometer for the hydrostatic pump (PUMP NEUTRAL)
While calibrating, check the parameters below: · Max. trans speed (truck max. speed) 100 % · Number of teeth (number of teeth per speed sensor) 9 · Multidisc brake (brake present) present · Parking brake set (brake setting) 95 % Calibration also includes the actuator setting while the thermal engine is running (ENGINE CALIBRATION). For the engine calibration, do the following: · · · · · ·
Lift the truck onto the shim blocks Fill the hydraulic circuit and bleed the air Engage the parking brake Select the neutral position (through the steering-wheel operated reverse gear) Start up the engine and wait for the stabilization of the fuel boost pressure Adjust the engine min. and max. RPM through the actuator limit stop screws (the limit stops are to be obtained on the actuator support, not on the injection pump). The engine RPM is to be measured through the “engine speed” parameter in the “DISPLAY” menu. · Calibrate the actuator (ENGINE CALIBRATION) · Press the accelerator pedal; the actuator has to rotate clockwise and the voltage of the feedback potentiometer in the actuator has to increase (such voltage may be measured in the “engine calibration” parameter in the “calibration” menu after engaging the parking brake). Once the calibration procedure is over, check the transmission operation (wheels must be up): · Release the parking brake · Position the steering-wheel operated reverse gear to forward gear · Gradually press the forward pedal: wheels should slowly rotate forwards. CAUTION: the hydraulic motors must not rotate quickly when wheels are up. When wheels rotate forwards, check that the voltage of the pump feedback potentiomet er increases from 2.5 to 5 volts (for the voltage detection, use “pump neutral” parameter in the “calibration” menu). Check the correct operation under the following conditions: - mast lifting, sideshift and tilt operation, etc.: if the relevant levers are adjusted, the thermal engine will accelerate. - forward/reverse speed and braking - parking brake: if engaged, the travel pedal will be disabled (the engine RPM will increase, but the truck wheels will be locked) - emergency button.
INTERNAL COMBUSTION
SERVICE MANUAL
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A) TRAVEL PEDAL CALIBRATION For calibrating, voltages are not to exceed the following ranges (voltages may be detected in display mode): pedal in its min. position 0,35 - 2,4 volts pedal in its max. position 2,6 - 4,65 volts (the supply voltage of all sensors is of 5 Volts)
(7 - 48 % of the supply voltage) (52 - 93 % of the supply voltage)
SEE THE “DIAGRAM FOR USING CONSOLE” SECTION “CALIBRATION”
B) BRAKE/INCHING CALIBRATION Allows to define the voltage values corresponding to the min. and max. positions of the brake pedal (and the “inching” function). For calibrating, voltages are not to exceed the following ranges: pedal in its min. position 0,35 - 2,4 volts pedal in its max. position 2,6 - 4,65 volts
(7 - 48 % of the supply voltage) (52 - 93 % of the supply voltage)
SEE THE “DIAGRAM FOR USING CONSOLE” SECTION “CALIBRATION”
C) MAST LEVER CALIBRATION Allows to define the voltage values corresponding to the maximum and minimum positions of the mast lever. For calibrating, voltages are not to exceed the following ranges: lever in neutral position lever fully pulled
0,25 - 2,3volts 2,4 - 4,65 volts
(5 - 46 % of the supply voltage) (48 - 93 % of the supply voltage)
SEE THE “DIAGRAM FOR USING CONSOLE” SECTION “CALIBRATION”
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SERVICE MANUAL
INTERNAL COMBUSTION
D) ENGINE CALIBRA CALIBRATION TION Allows to match the actuator angular position (voltage of the actuator feedback potentiometer) with the engine speed of rotation values. For calibration, voltages are not to exceed the following ranges: actuator in its min. position 0.3 .35 5 - 2,4 2,4 volts (7 - 40 40 % of the supply voltage) actu ac tuat ato or in it itss ma max. x. po possit itio ion n 2.60 2. 60 - 4.6 4.65 5 vol volts ts (5 (52 2 - 93 % of th thee su sup pply volt ltaage) Such values may be viewed if the t he parking brake is engaged. SEE THE “DIAGRAM FOR USING CONSOLE” SECTION “CALIBRATION”
The control unit automatically controls the actuator by bringing it i t to its minimum and maximum positions (that are determined by the mechanical limit stops located l ocated on the actuator support). With respect to the min. and max. positions, TCS reads the min. and max. RPM RP M as well as some intermediate values. The limit stops are to be obtained obtain ed on the actuator, not on the injection pump.
E) PUMP NEUTRAL CALIBRATION Allows to define the voltage corresponding to the t he neutral displacement position of the hydrostatic pump (feedback ( feedback potentiometer). The voltage value must not exceed the following range: r ange: 2.48 to 2.52 volts. (In display mode and when the truck is running, the voltage value must vary. When the wheels rotate forwards, the potentiometer voltage must tend to 5 Volts Volts and remain constant). SEE THE “DIAGRAM FOR USING CONSOLE” SECTION “CALIBRATION”
F) MAX FORWARD SPEED This parameter (expressed as a percentage percentage of the truck forward max. speed) limits the travel speed. This parameter may be modified (in calibration mode).
G) MAX REVERSE SPEED This parameter (expressed as a percentage of the truck reverse max. speed) limits limi ts the travel speed. This parameter may be modified (in calibration mode).
H) REDUCED SPEED This parameter expressed if the truck reduced speed is activated (enable / disable). This parameter may be modified (in calibration mode).
INTERNAL COMBUSTION
SERVICE MANUAL
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I) NUMBER OF TEETH This parameter defines the number of pulses (per rev of the thermal engine) engi ne) sent by the speed sensor to the control unit.
L) POWER SUPPLY Displays the supply voltage of the t he control unit: battery voltage (12 Volts). Volts).
M) SENSOR EXCITATION This parameter displays the t he voltage supplied by the control cont rol unit to the t he sensors. Correct value: 5 Volts. Volts.
N) MULTI DISC BRAKE This parameter defines whether whether the multidisc brake is fitted or not (the multidisc brake is an on/off brake, i.e. it is not gradual).
O) PARKING BRAKE SET This parameter defines the stroke str oke of the brake pedal necesary to engage the mechanical brake. The st andard value is 95%. It is suggested that this value val ue be not changed. Limit values: 90 to 95%.
P) PUMP POT. INVERTED This parameter defines the connections type of the pump potentiometer. This parameter is present with the Hall potentiometer software only only..
Q) CALIBRATION C ALIBRATION STATUS STATUS This parameter enables or disables the calibration mode.
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2) DISPLAY This menu displays the transmission data. Press [ENTER] to display a data (e.g. thermal t hermal engine speed). Hold down the key to display data in sequence.
ENGINE SPEED Real speed of the thermal engine (expressed in RPM). RPM) .
PUMP DISPLACEMENT Pump displacement required by TCS (expressed in cc). Warning: Warning: this is the displacement control sent by the control unit to the pump, so the value displayed may be different from the real displacement.
ENGINE COMMAND Speed of the thermal engine required by TCS (in RPM).
ANTISTALL Indicates whether the antistall function is enabled or not (enable/disable).
PARKING BRAKE Displays whether the negative brakes are set or not (set/not set).
BRAKE SWITCH Displays whether the parking brake switch is set or not (set/not set).
MAST ENGINE COMMAND Speed of the thermal engine required requir ed by TCS (in RPM) when the mast is actuated.
PUMP FEED-BACK Actual displacement of the pump (expressed in cc). This is the displacement measured by the potentiometer located on the pump.
DIRECTION SWITCH Displays the running direction controlled by the pedal microswitches or the steering-wheel operated reverse gear (neutral/forward/rev (neutral/forward/reverse). erse).
MAST SWITCH Displa Dis plays ys the the state state of of the dis distrib tributo utorr micros microswit witche chess
1 = tilt/s tilt/side ideshi shift ft (set/ (set/not not set) set)..
CONSTANT SPEED Displays the constant speed function enabling enabli ng when the mast is actuated while the truck is running r unning (set/not set).
REDUCED SPEED Displays the reduced speed function enabled (the travel speed is limited to a preset percentage value of the max. speed). Optional.
NEUTRAL DRIFT Displays the value difference between the theorical and real pump potentiometer value (i n mV). This parameter is present with wit h the Hall potentiometer software only. only.
INTERNAL COMBUSTION
SERVICE MANUAL
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3) PUMP CUSTOMIZED Allows to set the parameters for the control of the hydrostatic pump. This parameter is to be used to modify the acceleration and deceleration of the truck. Enable the program to modify such values (calibration status - not locked).
TRAVEL PEDAL INC. (sekunder från neutral till full utvinkling) This parameter defines how long the pump takes to reach its max. displacement when the travel pedal is fully pressed (the higher the value of this parameter, the lesser the acceleration of the truck).
TRAVEL PEDAL DEC. (sekunder från full utvinkling till neutral) This parameter defines how long the pump takes to reach its neutral displacement mode when the travel pedal is released (the higher the value of this parameter, the lesser the deceleration of the truck during the hydrostatic braking).
SENSITIVITY This parameter defines the sensitivity of the pump control when varying the pedal stroke (this value is expressed as a percentage of the pump max. displacement control).
INCHING PEDAL INC. This parameter defines how long the pump takes to reach its max. displacement when the inching pedal is instantaneously released after it has been fully pressed in conjunction with the travel pedal.
INCHING PEDAL DEC. This parameter defines how long the pump takes to range from the max. displacement to the neutral displacement when the inching pedal is instantaneously pressed after fully pressing the travel pedal.
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page 45
3) PUMP CUSTOMIZED Allows setting of the parameters who controls the hydrostatic pump. These parameters is used to modify the acceleration and deceleration of the truck. First the modification of these parameters must enabled (calibration status - not locked).
TRAVEL PEDAL INC. (sekunder från neutral till full utvinkling) This parameter defines how long time it takes for the pump to reach its max. displacement when the travel
TRAVEL PEDAL DEC. (sekunder från full utvinkling till neutral) This parameter defines how long time it takes for the pump to reach its neutral displacement mode when the travel pedal is released (higher value of this parameter = softer decceleration of the truck during the hydrostatic braking).
HARD BRAKING RATIO This parameter (%) changes the release braking value (travel pedal dec.) according to the following table: Braking times of the truck function of the two parameters “Travel pedal dec” (s) and “Hard braking ratio” (%)
Travel pedal dec. (s) Hard braking ratio (%) 0 17 50 67 83 100
2
5
7
10
Låg hastighet
2 1.7 1.6 1.3
5 3.8 2.8 2.5 2.3 2.1
7 5 3.1 2.5
10 6.5 3.6 2.9
Hög hastighet
0=Samma bromskraft vid alla hastigheter. 100=Hårdare broms vid hög hastighet.
SENSITIVITY This parameter defines the sensitivity of the pump control when changing the pedal position (this value is expressed as a percentage of the pump max. displacement control).
INCHING PEDAL INC. This parameter defines how long time it takes for the pump to reach its max. displacement when the inching pedal is instantaneously released after it has been fully pressed in conjunction with the travel pedal.
INCHING PEDAL DEC. This parameter defines how long time it takes for the pump to range from the max. displacement to the neutral position when the inching pedal is instantaneously pressed after fully pressing the travel pedal.
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4) ENGINE CUSTOMIZED Allows setting of the parameters who controls the thermal engine . Do not modify the standard values.
TRAVEL PEDAL INC. (sekunder från tomgång till fullgas) This parameter defines how long time it takes for the actuator to achieve its stroke when the travel pedal is fully pressed (the higher the value of this parameter, the longer the time the thermal engine takes to range from its min. RPM to its max. RPM).
TRAVEL PEDAL DEC. (sekunder från fullgas till tomgång) This is the same as the previous parameter (the time it takes for the thermal engine to range from its min. speed to its max. speed).
MAST INC. This parameter defines the time it takes for the actuator to achieve its stroke when the lifting lever is pulled (higher value of this parameter = longer time for the thermal engine to range from its min. RPM to its max. RPM).
MAST DEC. This parameter is similar to the previous one (time it takes for the engine to range from its max. RPM to its min. RPM when the lifting lever is released).
MAST FIXED CMD 1 MAST FIXED CMD 2 Parameter that defines the thermal engine speed rate when one of the auxiliary devices of the hydraulic valve unit is activated (tilt , sideshift, 4th way, 5th way). The engine RPM is increased to a value, according to the parameter set. Standard value is 30 - 40%. Ex:
engine min. speed: 700 rpm; engine max. speed: 2500 rpm usable range: 700 - 2500 = 1800 rpm parameter (mast fixed cmd): 25 % If the engine operates at a speed higher than 1100 rpm and the hydraulic lever is acti vated, the actuator will bring the engine rpm to: 1100 + (2500 - 700)x0.25 = 1550 rpm.
Do not increase the speeds set to avoid dangerous manoeuvres. Stroke of the sideshift: 2 -2.5 sec Tilting: 4.5 - 5 sec
MAST MAXIMUM CMD (Available from 2001) Parameter which defines the max thermal motor rpm when the lifting is started. By activating the lever, the motor speed increases step by step until the max value set.
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5) FAULT DETECTED Displays the system faults.
- FAULT OCCURRING NOW Press [ENTER] to display the current fault.
- FAULT SINCE START UP Press [+] and [-] to display the last five faults occurred.
FAULTS MESSAGES SHOW ON THE CONSOLE “Excitation Sensor”
The exitation voltage of the sensor is < 2V or > 5.5V.
“Power Supply”
The supply voltage of TCS control unit is < 9.5V or > 32V for more than 2 sec. long.
“Travel Pedal Sensor”
The signal (voltage) of the travel pedal potentiometer has exceeded the limits set while calibrating.
“Break/Inching Pedal Sensor”
The signal (voltage) of the brake pedal potentiometer has exceeded the limits set while calibrating.
“Mast Lever Sensor”
The signal (voltage) of the mast lever has exceeded the limits set while calibrating.
“Actuator Sensor”
The signal (voltage) of the feedback potentiometer has exceeded the limits set while calibrating.
“Error on Actuator control loop” >20% error, for more than 0.5 secs, between the actuator setpoint and the
potentiometer feedback “Error on pump control loop”
>20% error, for more than 0.5 secs, between the pump control signal and the potentiometer feedback signal in the pump.
“Feed bak error”
Pump feed back is < 0.25V or > 4.75V.
“Neutral out of range”
During the calibration the pump neutral is out the limits fixed.
“Pump neutral drift too high”
The difference between the pump in neutral calibration function and the pump in neutral while the values are not fed is >341 mV
“Feedback moves too fast”
The pump feedback changes too fast in comparison with the real change of the pump displacement.
“Eeprom error at address”
One parameter at least is outside the field of acceptable values.
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“Direction switches error”
The TCS control unit takes contemporarily the forward and reverse gear (running mode) started..
“Other Default”
Other faults.
6) INFORMATION Displays the SOFTWARE version
7) PH PARAMETERS - PASSWORD Enter the password (4 numbers) with the digital key and then valid (enter). Press the key / esc then [+] and [-] in order to haves access to the rest of the menu.
- PUMP NEUTRAL OFFSET This parameter is made to offset pump feedback
- ENABLE LIMIT CHANGE During the calibration of the pedals, the auxilary’s levers and the actuator, it is possible that the minimal values and maximal values abtained on the potentiometer are not conform to the limit fixed by the programm. It is possible to modify theses limits. In the menu calibration, authorise the mode calibration. Go into the menu “PH PARAMETERS” and into the under menu “ENABLE LIMIT CHANGE”. It is necessary to be in “NOT LOCKED”.
- INVERSION BRAKING This function is made to have a braking action if direction switch is set in the reverse position during the translation of the machine. The brake action will be proportionnal to the position of the travel pedal.
- INVERSION DESPLACEMENT This parameter set the inversion time range from: 0 - 10 cc
- DISABLE PUMP DELAY Parameter which defines the time of delay of the negative brakes starting up (standard values 30 cycles). It is the delay for the brakes starting up after the pump has reset its displacement. In order to have the brakes started up in a shortime, for example in ramp, reduce the value (min 5 max 45 cycles)
- REGULATOR OFFSET This is the acceptable difference between the ordered engine speed and the measured engine speed. If this value is exceeded, the antistall function is active.
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- ANTISTALL COEF Coefficient apply to the action of antistall function. The parameter change from 3 to 8. Bigger is the values more is the desplacement decrease.
- DERIVEE ANTISTALL Definition of the derived gain for the antistall action. The parameter is a variable number from 10 to 30. Bigger is the number, bigger is the sensibility at the RPM variation on antistall.
- FULL STROKE CMD Compensation of the electric stroke used on the recopy potentiometer of the pump. The parameter is a number (never vary it) 1488
- ENGINE DELAY INC This parameter is made to take into account the reaction time of the couple actuator/engine in order to activate the antistall at the right moment. It avoids to put the antistall function all the time.
- ENGINE DELAY DEC This value is the complementary value of engine delay dec. It is take into account during the engine deceleration.
8) EPROM RESET This menu is made to reset the data of the EEPROM
- PASSWORD Enter the password (4 numbers) with the digital key and then valid (enter). Press the key / esc then [+] and [-] in order to haves access to the rest of the menu.
- ALL EEPROM RESET A press on the key (ENT) cancel the list of the statistics.
- FAULT LIST RESET A press on the key (ENT) cancel the list of the detected defaults.
TROUBLES OCCURRING WHILE CALIBRATING The voltage values read by the transmission potentiometers (pedals, hoisting, etc.) must not exceed the limits set. If there is some wiring failure or the mechanical limit stops of the potentiometers are not properly adjusted, the voltage they supply will exceed the allowable range for the control unit, thus preventing the calibration procedure. In that case, the terminal will display one of the following messages (while calibrati ng or in the “fault detected” alarm menu): travel pedal position out of range brake/inching pedal sensor mast lever sensor actuator position out of range feed-back error
travel pedal brake pedal mast lever thermal engine actuator hydrostatic pump potentiometer
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SERVICE MANUAL
INTERNAL COMBUSTION
1) TRAVEL PEDAL travel pedal position out of range
(error message)
release the parking brake
select the TRAVEL PEDAL submenu
(the terminal will range from the CALIBRATION MODE to the DISPLAY MODE)
(the terminal will display the voltage - expressed in volts - that is supplied from the otentiometer in the travel pedal)
yes
voltage = 0 volt?
no
check the potentiometer wiring
hold down the [ENTER] key and check if voltage changes when the pedal is pressed
does voltage change? yes
press the [ENTER] key to measure the min. and max. voltage supplied by the potentiometer
adjust the mechanical limit stop of the pedal so that the voltage does not exceed the ranges set (see “travel calibration”)
Calibrate the travel pedal.
no
check the potentiometer wiring
INTERNAL COMBUSTION
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2) BRAKE/INCHING PEDAL brake/inching position out of range
release the parking brake
(error message)
(the terminal will range from the CALIBRATION MODE to the DISPLAY MODE)
select the BRAKE/ INCHING PEDAL submenu
(the terminal will display the voltage in volts, that is supplied by the brake pedal potentiometer)
yes
voltage = 0 volt?
no
check the potentiometer wiring
hold down the [ENTER] key and check if voltage changes when the pedal is pressed
does voltage change? yes
press the [ENTER] key to measure the min. and max. voltage supplied by the potentiometer
adjust the mechanical limit stops of the pedal so that the voltage does not exceed the ranges set (see “travel calibration”)
Calibrate the brake pedal.
no
check the potentiometer wiring
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INTERNAL COMBUSTION
3) MAST LEVER mast lever sensor out of range
(error message)
release the parking brake
select the MAST LEVER submenu
(the terminal will range from the CALIBRATION MODE to the DISPLAY MODE)
(the terminal will display the voltage in volts, that is supplied by the mast lever)
yes
voltage = 0 volt ?
no
check the potentiometer wiring
Hold down the [ENTER] key and check whether voltage changes when the lever is pulled
does voltage change? yes
no
press [ENTER] to measure the min. and max. voltage supplied the potentiometer
Adjust the shims of the potentiometer support bracket so that the voltage does not exceed the ranges set (see “mast lever calibration”). If the lever is shifted forward from its middle position (for the forks lowering) voltage is not to decrease. Calibrate the mast lever.
check the electrical connections by of the potentiometer
INTERNAL COMBUSTION
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4) THERMAL ENGINE ACTUATOR actuator position out of range
release the parking brake
(error message)
(the terminal will switch from the CALIBRATION MODE to the DISPLAY MODE)
select the ENGINE CALIBRATION submenu
yes
voltage = 0 volts?
(the terminal will display the voltage, in volts, supplied by the potentiometer of of the actuator) (engage the parking brake and no press the accelerator pedal)
check the electrical con nections of the actuator
hold down the [ENTER] key and check if voltage changes while the actuator rotates
does voltage change? yes
no
press the [ENTER] key to measure the min. and max. voltage supplied by the actuator potentiometer
check the actuator electrical connections
adjust the length of the tie rod so that voltage does not exceed the ranges set (see “engine calibration”)
Calibrate the actuator.
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INTERNAL COMBUSTION
5) POTENTIOMETER IN THE HYDROSTATIC PUMP feed-back error
(error message)
release the parking brake
(the terminal will range from the CALIBRATION MODE to the DISPLAY MODE)
select the PUMP NEUTRAL submenu
yes
voltage = 0 volts or 5 volts ?
(the terminal will display the voltage, in volts, that is supplied by the potentiometer in the hydrostatic pump) no
check the potentiometer electrical connections
voltage = 2.48 ¸ 2.52 volts ?
yes
no
engage the parking brake, switch to CALIBRATION mode and calibrate the pump potentiometer to zero
- check the potentiometer wiring - lift the truck on the shim blocks, electrically disconnect the pump solenoid valves and start up the engine: if the pump supplies some oil, the trouble is a hydraulic or mechanical type (mechanical maladjustment of the pump plate positioning in neutral displacement) - after disconnecting the valves, if the pump supplies some oil, switch off the engine and hold down the [ENTER] key in order to read the voltage, until a 2.5 volt value is obtained.
engage the parking brake, switch to CALIBRATION mode and calibrate the pump potentiometer zero.
INTERNAL COMBUSTION
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SYSTEM FAULTS AND FAILURES Any system failure is signalled by the blinking warning light located beside the distributor levers. The blinking intermittence indicates the failure importance. The kind of fault is displayed in the FAULT DETECTED menu (“FAULT OCCURRING NOW” submenu). If the warning light blinks slowly (0.5 Hz) the fault is not very important; the machine is able to work. Error message
travel pedal sensor
Cause
Cure
- the signal (voltage) of the travel pedal - check the potentiometer wiring potentiometer has exceeded the limits - check if the voltage values at the set while calibrating pedal limit stop do not exceed - connector disconnected or wrong wiring the limits preset - adjust the pedal limit stops - calibrate the pedal again - (see page 41)
- the signal (voltage) of the brake pedal brake/inching pedal potentiometer has exceeded the limits set - as above (see page 41) sensor while calibrating - connector disconnected or wrong wiring
mast lever sensor
actuator sensor
error on actuator control loop
This message may be displayed if the accelerator is pressed (green light on) when the engine is off and the brake is unlocked power supply out of range
- the signal (voltage) of the mast lever has exceeded the limits set while calibrating - as above (see page 41) - connector disconnected or wrong wiring - the signal (voltage) of the feedback potentiometer has exceeded the limits set while calibrating - connector disconnected or wrong wiring.
- as above (see page 42)
- >20% error, for more than 0.5 secs, between the actuator setpoint and the potentiometer feedback - connector disconnected or wrong wiring.
- check the actuator wiring - check theactuator potentiometer output signal (if you press the accelerator pedal, the actuator shall rotate forward and the voltage - measured in “engine calibration” when the brake is released - shall increase)
- the supply voltage of TCS control unit is not included in the 9.5 - 48 volts range
- check the supply voltage value
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INTERNAL COMBUSTION
If the warning light blinks quickly (1 Hz) the fault is serious; the machine stops.
Error message
Cause
Cure
excitation voltage
- wrong value of the supply voltage of the potentiometers and microswitches
- check that the voltage is equal to 5 volts ± 5%
feedback error
- wrong signal of the feedbackk potentiometer in the hydrostatic pump
- check that the feedback potentiometer voltage is equal to 2.5 ± 0.15 volts when the pump is in neutral displacement mode (see page 42)
neutral out of range
- wrong signal of the feedback potentiometer in the hydrostatic pump when the latter is in neutral displacement mode
- check the potentiometer calibration (PUMP NEUTRAL) - check that the feedback potentiometer voltage is equal to 2.5 ± 0.15 volts when the pump is in neutral displacement mode (see page 42)
error on pump control loop
- >20% error, for more than 0.5 secs, between the pump control signal and the potentiometer feedback signal in the pump
- check the pump wiring (potentiometer and solenoid valves) - check that the feedback potentiometer voltage properly changes while controlling the solenoid valves - measure the min. and max. voltage of the pump potentiometer and check that the control max. value is kept constant during the forward and reverse running mode (when the wheels turn forwards, the potentiometer voltage has to tend to 5 volts) (when the machine is running in the pump neutral calibration function)
INTERNAL COMBUSTION
SERVICE MANUAL
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TROUBLESHOOTING Fault
Possible cure
- check the parking brake operation (DISPLAY-BRAKE SWITCH (set-not set) menu)
The thermal engine works correctly but the pump is faulty
- check the operation of the speed selector (pedals with steeringwheel operated reverse gear) or the microswitches on the other pedals DISPLAY-DIRECTION SWITCH (neutral forward reverse menu)
- check the signal on the speed sensor (on the pump) (DISPLAY-ENGINE SPEED menu - check if the value displayed is acceptable)
The pump works correctly but the thermal engine is faulty
- check the signal of the feedback potentiometer (on the pump) (CALIBRATION menu (display mode)-PUMP NEUTRAL)
- check the actuator operation (CALIBRATION (display mode) - ENGINE CALIBRATION menu)
- check the mast potentiometer signal and wiring (of the potentiometer and microswitches) The pump and engine work correctly, but the engine does not accelerate when the distributor levers are actuated
(CALIBRATION (display mode)-MAST LEVER CALIBRATION menu)
- check if the potentiometer is fitted (TCS parameter) (CALIBRATION menu, MAST LEVER, mast sensor presence (1) menu)
if the fault warning light is off: - check the signal of the speed sensor (DISPLAY-ENGINE SPEED menu (check if the value displayed is acceptable)
The pump and thermal engine do not work
if the warning light blinks slowly: - check the signal of the travel pedal (CALIBRATION - TRAVEL PEDAL CALIBRATION menu)
if the warning light blinks quickly: - check the supply voltage of the sensors (5 volts) (CALIBRATION - SENSOR EXCITATION menu)
- control unit supply voltage (CALIBRATION - POWER SUPPLY menu)
- signal of the pump potentiometer (CALIBRATION menu (display mode)-PUMP NEUTRAL)
- wiring of the pump potentiometer (CALIBRATION menu (display mode)-PUMP NEUTRAL )
- wiring of the pump displacement control solenoid valves (VISUAL INSPECTION)
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page 56
WHEELS / TYRES SAFETY OF WHEELS AND RIMS WHILE USING THE TRUCK “TYRES” are to be replaced when the tyre tread is under 1.6 mm. “SUPERELASTIC” tyres are to be replaced when the tyre tread reaches the “60 J” mark, which is printed on the tyre side.
WHEEL TIGHTENING TORQUE Driving wheels 50 daNm Steering wheels 37 daNm
TYRE TYPE
SIZE
DOM
FRONT
250-15 300-15
400-450 500
REAR
250-15
400-450-500
FRONT
250-15 300-15
400-450 500
REAR
250-15
400-450-500
(SEG) - TWIN SUPERELASTIC
FRONT
7.00-15 8.25-15
400-450 500
TWIN PNEUMATIC
FRONT
7.00-15 8.25-15
400-450 500
SUPERELASTIC (SE)
PNEUMATIC (PN)
Tyre pressures for Front tyre pressure Front tyre pressure Re ar tyre pres sure
ordinary wheels: 9.5 bar 400-450 7.5 bar 500 9.5 ba r 400-450-500
Tyre pressures for dual wheels: Fr ont tyre pr ess ur e 9.25 b ar 4 00 -4 50 Front tyre pressure 7 bar 500
SERVICE MANUAL
INTERNAL COMBUSTION C
B A
F
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STEERING CONTROL The hydraulic steering unit uses the same oil as the hoisting unit. Orbitrol (A), located on the steering column, sends the control f rom pump (G) to the steering cylinder.
CHECKING THE SYSTEM SEALING AND CLEANING THE POWER STEERING SYSTEM Every 250 hours
G
- Check the whole system for any possible leakage; before servicing, release the system pressure. Every 4,000 working hours - replace hoses (F) connecting Orbitrol to the steering cylinder. Every 10,000 working hours
- replace the system pipes. Adjusting the power steering pressure
The max. pressure of the power steering is to be equal to 105 Bar Do the following to adjust the power steering pressure: 1 - Install a pressure gauge in (C) the power steering; 2 - With a socket head spanner, remove the cap located in the Orbitrol upper part to reach the adjusting screw ( B) (power steering unit); - tighten to increase pressure - loosen to decrease pressure
POWER STEERING DIAGRAM
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INTERNAL COMBUSTION
STEERING AXLE Steering axle check Every 500 hours - lubricate the steering gear joints using the appropriate grease nipples ( D), (E) and (F); - check the steering angles. Every 2.000 hours - check and if it is necessary, adjust the wheel hub bearings. Every 500 ore check the angles Max steering angle (internal wheel
78°)
≅
If any abnormal consumption of the wheel tread is observed, the following controls should be made:
- check the parallelism of the steered wheels; - check that the steering angle of the wheels is the same in both directions.
B = 78° ANGLE MEASURED BY THE AXLE FRAME TO THE INTERNAL WHEEL THROUGH A SPECIAL DEVICE
D E
D
F
ENDSTROKE SETTING SCREW
G
STEERING AXLE
INTERNAL COMBUSTION
SERVICE MANUAL
BEARING ADJUSTMENT Steering wheel bearings require an adjustment once a year. Steering wheels
-
lift the steering wheels remove cap (1); remove check pin (4); fasten the nut with a torque setting of 6 dNm; turn the hub of 2-3 turns in both senses; unfasten nut (3) and retighten with a 2-1 daNm torque; check that the wheels slide correctly (max. rolling final torque: 0.2 dNm) and that there is no side play (maximum axial play of 0.05 mm); reassemble the check pin; reassemble the cap (1); lower the wheels again and check that all nuts fixing the wheel disk (5) to hub (2) are well tightened.
5 2 1
4 3
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SERVICE MANUAL
INTERNAL COMBUSTION
HYDRAULIC DISTRIBUTOR Nominal capacity 80 l/min 3 - 4 - 5 section
235 ± 5 Bar pressure relief valve
A
P: T: A,B:
P
T
inlet =3/4 BPS drain outlet = 3/4 BPS doors = 1/2 BPS
B
150 Bar tilt pressure relief valve
150 Bar sideshift pressure relief valve Hollow dowels for the capacity adjustment:
Tilt Ø 2.25 mm (in the upper nipple) Sideshift Ø 2.5 mm
5th WAY
4th WAY
TRAVEL
TILT
MAST
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INTERNAL COMBUSTION
page 61
MAST GROUPS The mast profile - CESAB design - with double stiffening flange is characterised by a high
flexural and torsional strength. It allows wide visibility thanks to the reduced dimensions of the profile itself. Cylinders are single-acting type. The sideshift system has been housed inside the profiles. The mast group is a roller type with a variable centre distance (i.e. a fixed roller is fitted on the outer mast and a mobile one on the inner mast, instead of a number of mobile rollers only on the inner mast). This solution ensures better grip and stability on operation. Other features: side plays adjustable from outside. Plastic guide shoes. Roller bearings with
grease nipples, ball joints on axle couplings and tilt cylinders. Lifting cylinders:
Duplex mast:
Triplex mast
VT 2 side cylinders FFL 2 central cylinders (two small FFL side cylinders, and a central lifting one, old version) (two small FFL side cylinders, and two side lifting cylinder diplacement type, old version) VT 2 side cylinders FFL 2 side cylinders 2 central cylinders
Grease nipple
Adjusting screw
Shoe
Roller
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SERVICE MANUAL
TRIPLE MAST SECTION Fork carriage
Internal section bar
Intermediate section bar
External section bar
INTERNAL COMBUSTION
SERVICE MANUAL
INTERNAL COMBUSTION
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page 63
LUBRICATION D Masts
E
After the first 50 hours
- adjust the guide shoes through socket head screw (D). Use a 0.2 - 0.5 mm thickness gauge; fit it from the bottom upwards to socket head screw (D) centre, passing behind roller (E) and creeping on the outer mast. Every 50-100 hours
- Grease the mast sliding guides - through the grease nipples, lubricate the articulations of the tilt cylinders and of frame coupling.
A
Every 250 hours
- adjust the guide shoes; - grease mast guide rollers (E). Every 2,000 hours
- inspect mast guide rollers (E); they have to rotate freely and not to be too worn out. A) tilt cylinders
2+2 grease nipples B) mast coupling
1+1 grease nipples B
Fork mounting carriage and sideshift After the first 50 hours
- adjust the guide shoes through socket head screw (G). Use a 0.2 - 0.5 mm thickness gauge, fit it from the bottom upwards up to socket head screw (G), going behind roller (H). F
G
Every 50 hours
- lubricate the sideshift guides through the grease nipples. Every 250 hours
H
- grease the pins and the fork positioning slots; - adjust the guide shoes; - grease the guide rollers of carriage (F).
4,0 - 4,5 - 5,0 t
SERVICE MANUAL
page 64
Every 2,000 hours
C
- check the conditions of the guide rollers; they have to rotate freely and not to be too worn out. C) Sideshift (upper part) 2 grease nipples (lower part) no grease nipple
INSTALLATION CHECKS SAFETY SPECIFICATIONS
C
Make sure that:
E
- the hoisting chain stretchers are not faulty and the adjusting nuts are locked by counternuts and check pins (A); - safety limit stops (B) of the fork mounting carriage are fitted and tightened up; - stop collars (C) are fitted and tightened up;
E
Every 500 hours
D
- check that distance (D) between the collar and the mast outer cylinder ranges from 0.5 mm to 3 mm; - check if self-locking nuts (E) are tightened up. Tightening torques
- Nuts of the stop collars: 0.8 to 1.2 daNm
SAFETY LIMIT STOPS OF THE FORK MOUNTING CARRIAGES A
B
The mast unit is equipped with a mechanical safety limit stop to prevent the accidental removal of the fork mounting carriage from the mast downwards. Limit stops (A) consist of two socket head screws with counternut. Loosen limit stops ( A) before disassembling the fork mounting carriage.
INTERNAL COMBUSTION
INTERNAL COMBUSTION
SERVICE MANUAL
DESCRIPTION OF THE CYLINDER COMPONENTS The cylinder pistons are single-acting types (fig. A).
6 5 4 7
In these cylinders a seal ( 1) has been fitted on the piston (2) that works on the inner surface of the cylinder liner (3). The rod guide is made by the plug ( 4) and by the piston through anti-friction rings ( 5). The dust control ring ( 6) prevents any dirt and water from penetrating the cylinder. Slight leakages that may occur are directed to the tank through the drain pipe connected to the pipe coupling (7).
THRUST DIAMETER
3
The drain pipe shall reach the oil tank (fig. B) A small quantity of oil will always remain in the loop formed by the pipe before connecting to the tank. It acts as a trap and constantly moisturizes the cylinder liner, when it is completely closed (fig. B).
2 5 1
Fig. A
Fig. B
4,0 - 4,5 - 5,0 t
page 65
4,0 - 4,5 - 5,0 t
page 66
SERVICE MANUAL CYLINDER CHECKING METHODS 1ST CHECK
Remove the drain pipe from the cylinder (fig. C) Lift the cylinder some times to end stroke, so as to discharge any oil residual. Put a load on the forks and lift it by at least 200 mm. After 10 minutes, measure the amount by which the load has lowered. A drop of a few millimetres is quite normal, as in the distributor there are always some leakages. Now, lift the cylinder to its end stroke, if no oil leaks from the drain pipe coupling, it means that the load lowering is only due to the leakages on the distributor. Fig. C
In the presence of leakages, it will be necessary to replace the seal. Should this be the case, inspect the cylinder liner. 2nd CHECK
(To be carried out if the 1 st inspection has been successful and after seal replacement). Remove the drain pipe from the cylinder. Lift the cylinder some times to end stroke, so that all the possible remaining oil is discharged. Put a load on the forks. Lift and lower it for 10 minutes, making sure that the limit stop is never reached. Lift the cylinder to end stroke. If any leakages should be still present, the cylinder is damaged and then it must be replaced.
INTERNAL COMBUSTION
4,0 - 4,5 - 5,0 t
SERVICE MANUAL
INTERNAL COMBUSTION
page 67
CHAIN INSPECTION Every 500 hours (anyway, chains are to be checked every 3 months) - chains are not to be faulty or worn out. To check if the chain links are worn out, use the appropriate ruler; remember that chains must be replaced when, in a portion corresponding to 34 pitches, only 33 pitches are found. Every 1,000 hours - disassemble the chains, carefully clean them, reassemble reversing their original work position, and grease. Every 10,000 hours - replace the chains and the fastening tie rods. Use of original CESAB chains will guarantee that the safety requirements stated by the regulations in force are complied with.
FORK INSPECTION (to be performed every 1,000 hours) G
-
G E
E
F
F D
D
-
Surface cracks particularly in D/E/F Height difference of the tips (is to be < 3% than the fork length) Positioning latch (G) Punching is to be clear Forkmeasure(maximum wear =10%of the originalthickness) particularly in point D Wear of the fork fastening devices on the carriage (EF)
TABLE ISO 2328 - 1993
Rate
X = 203 mm
lifting load (kg)
"X" (± 5)
IB
0
÷
999
114 mm
II B
1 000
÷
2 500
152 mm
III B
2 501
÷
4 999
203 mm
IV B
5 000
÷
8 000
254 mm
VB
8 001
÷
10 999
257 mm
4,0 - 4,5 - 5,0 t
SERVICE MANUAL
page 68
LIFTING OF THE TRUCK
HOOKS ATTACHMENT POINTS FOR LIFTING THE TRUCK To lift the truck the following equipment must be used:
A
A- CHAINS: dia. 13 mm - Degree T (8) - UNI
9425 B
C
LIFTING OF THE FORKLIFT TRUCK WITH CABIN
C
A
A B
B- HOOKS: for 5.4 t - UNI/ISO 7597
A- CHAINS: dia. 13 mm - Degree T (8) - UNI
9425 B- HOOKS: for 5.4 t - UNI/ISO 7597 C- N° 2 upper brackets to hold the chains.
INTERNAL COMBUSTION
AGIP ARNICA 46
ISO - L - HV FZG tests to stage 11
MOBIL ANTICONGELANTE
-
MOBIL DELVAC 1300 SUPER SAE 15W-40
API CD-SF CCMC-D3 (SHPDO)-PD1 MIL-L-2104D MIL-L-46152B
20 ÷ 40 SAE
-
MOBILGREASE SPECIAL
Lithium base ASTM 275÷305 NLGI N.2 dropping point 180°
Hydraulic system, lifting, power steering and hydrostatic transmission Cooling liquid DIESEL engine Mast chain lubrication Mast securing joints - sideshift unit - steering joint - general lubrication with grease nipples
AGIP ARNICA 22
ISO - L - HV FZG tests to stage 10
MOBILTEMP SHC 100
Thickening Infusible ASTM 265÷295 NLGI N.2 Dropping point >260°
Hydraulic system, lifting and power steering units Mast securing joints - sideshift unit - steering joint - general lubrication with grease nipples mast guides
9,5 bar 400-450 7,5 bar 500
FRONT tyres
9,2 bar
REAR tyres
37 daNm
steered wheels
50 daNm
driven wheels
5
14,3 daNm 11 daNm
engine fixing PERKINS Front / Rear engine fixing to chassis
40 daNm 0,8÷1,2 daNm 77 daNm
bolts securing mast jack collar self-locking nuts counterweight blocking screws
engine oil and cartridge
clearances engine values
fan belt and alternator belt
general bolt a nd nuts
wheel torque (1) (1) During the first 500 w orning hours, check the torque every 50 hours
mast guide pads
oil filter
transmission oil filter
transmission oil
8
50
250
500
1 000
2 000
4 000
10 000
1/-
7/-
-/1
-/3
-/6
-/12
-/24
-/60
mast guide pads
carriage - sideshift unit slides
mast rollers and chain rollers
tilting jacks supply t ubes
fork positioning pins
mast guides, mast and jack fixing
lifting jack collars
fork carriage position
forks
mast tilting
mast secured to chassis
lifting chains
chain securing bolts
high pressure hydraulic hoses
system seal and connections
1/-
7/-
-/1
-/3
-/6
-/12
-/24
-/60
chassis - cleaning
bolts in general
fuel tank cleaning
fuel tank control
driver’s seat
wheels - hub bearings
tyre inspection and wheel tightness
tyre pressures
steering system and tubing seal hoses from orbitrol to steering jack rear axle and weheel hub bearings
steering lock
pedals in general - linkage
brake commands solenoid valve
1/-
7/-
-/1
-/3
-/6
-/12
-/24
-/60
#
cooling liquid
fuel filter cartridge
air filter
dusty environment air filter
cyclone prefilter
water and oil radiator (external cleaning) water and oil radiator in dusty environments
fan belt and alternator belt
engine oil and filter cartridge
engine supports
engine linkage and fuel connections
fexible fuel and water hosing DIESEL engine injection pressure control
DIESEL engine valve clearance PETROL and LPG engine valve clearance
PETROL and LPG engine spark plugs
LPG system control
LPG bottle hose and safety valve LPG pressure reducer
pushbuttons - pedal microswitches
cable terminals - cable sheaths
battery electrolyte level and density replacement battery terminals and poles
system seal
transmissin oil filter
transmissin oil
complete unit
Totaldokument BT Cargo CBD 40-50 Var 250:e timme Pos
Kontroll av:
Pos
Kontroll av:
Pos
Kontroll av:
0:0 0:1 0:2 0:3 0:4 0:5 0:6 0:7 0:8 0:9
2:0 2:1 2:2
Grupp 2 Hydrostatik Läckage Funktion
5:6 5:7 5:8
Batteri, fasts ättning Säkringar Batterivätskenivå
3:0 3:1 3:2 3:3 3:4 3:5 3:6
Grupp 3 Bromsar/hjul Däck/hjul Lufttryck d äck Hjulbultar/hjullager Färdbroms, funktion/l äckage Parkeringsbroms, funktion Pedall änkage
6:0 6:1 6:2 6:3
Grupp 6 Hydraulik Slangar/r ör Ventilreglage/l änkage Oljenivå
0:10 0:11
Grupp 0 Hel maskin Dörrar/luckor Motviktsinf ästning Förarskydd/hytt Skyltar/dekaler Förarmiljö Stol/mattor Pedalgummin Torkare/spolare Provk örning test av samtliga funktioner Smörjning enligt schema Tvätt/rengöring
1:0 1:1 1:2 1:3 1:4 1:5 1:6 1:7 1:8 1:9
Grupp 1 Motor Missljud/läckage Gaspedal/reglage Luft filter, kontroll Kylvätska, nivå/fryspunkt Remmar, kontroll Motorolja, byte Motoroljefilter, byte Br änslesystem, l äckage Glödning
4:0 4:1 4:2 4:3
Grupp 4 Styrning Styrleder/Styrspindlar Styrcylinder, fasts ättning Styrlagring/upph ängning
7:0 7:1 7:2 7:3 7:4 7:5
Grupp 7 Arbetsfunktion Lyftstativ, inf ästning Gaf flar Lyftkedjor Laststöd Lyft-/tiltcylindrar
5:0 5:1 5:2 5:3 5:4 5:5
Grupp 5 Elsystem Belysning/k örriktningsvisare Instrument/kontrollampor Signalhorn P-broms-/Backalarm Timmätare, avl äsning
Var 500:e timme tillkommer: 0:0 Grupp 0 Hel maskin 0:12 Bultar/Muttrar, fasts ättning
Var 1000:e timme tillkommer: 0:0 Grupp 0 Hel maskin 0:13 Br änsletank, reng öring
Var 2000:e timme tillkommer: 0:0 Grupp 0 Hel maskin 0:14 Ram, kontroll av sprickor
1:0 1:10 1:11 1:12
Grupp 1 Motorer Br änslefilter, byte Luft filter, byte Motorf ästen
1:0 1:13 1:14
1:0 1:15
Grupp 1 Motorer Kylvätska, byte
5:0 5:9 5:10 5:11
Grupp 5 Elsystem Batteripoler reng./infettning Färdväljare/länkage Microbrytare
Grupp 4 Styrning Slangar, kontroll Styrtryck, kontroll
CBD/CBG 15-50 Chassie/hel maskin © BT Svenska AB 01/06
Grupp 1 Motor Remmar, byte Ventilspel, kontroll
2:0 2:3
Grupp 2 Hydrostatik Bultar, kontroll/fasts ättning
4:0 4:4 4:5
3:0 3:7
Grupp 3 Bromsar/hjul Hjullager infettning
5:0 5:13
Grupp 5 Elsystem Laddning, kontroll
5:0 5:12
Grupp 5 Elsystem Kablage/anslutningar
6:0 6:4
Grupp 6 Hydraulik Andningsfilter, reng./byte
6:0 6:5 6:6 6:7 6:8
Grupp 6 Hydraulik Hydraultryck, kontroll Hydraulolja, byte Retur filter, byte Sug filter, rengöring/byte
7:0 7:6
Grupp 7 Arbetsfunktion Gaf flar, gaffeltest
Sida 5
Cargo Range CESAB S.p.A via Persicetana Vecchia, 10 40132 Bologna - Italy Tel. (0039) 051.20 54 11 Fax (0039) 051.72 80 07 E-mail:
[email protected]
Code 036 2001-2
GB
Issue 11/2000
CONSOLE MAP
press press+
PRESS ENTER
Calibration Travel Peda l Don't touch teh tra vel pedal ('EN T')
Calibration Travel Peda l Forwa rd completed (ENT)
press+
Calibration Travel Peda l Don't touch th e tra vel pedal ('EN T')
Calibration Travel Peda l Completed
Calibration
Reverse completed (ENT)
ENTER Travel Peda l
Calibration Travel Peda l If Forward switch select it ('EN T')
Calibration Travel Peda l Push slowly travel pedal
Calibration Travel Peda l Full depression in Forwa rd (press a key)
Calibration Travel Peda l Rest P osition OK (press a key)
ENTER
Calibration Travel Peda l If Reverse switch select it ('EN T')
Calibration Travel Peda l Push slowly travel pedal
Calibration Travel Peda l Full depression in Reverse (press a key)
Calibration Travel Peda l Rest P osition OK (press a key)
ENTER
press+
Calibration Max. forwa rd speed
Calibration Pum p pot. inverted
Calibration Pa rking brake set
Calibration Sensor excita tion
Calibration Power supply
Calibration Number of teeth
Calibration Reduce speed
Calibration Ma x. reverse speed
Calibration Multi-disk bra ke
Display En gine speed
ENTER
press+
ENTER Display ESC P ump displacement
press+
Display Enginecomman d
press+
press+
Display P ump feed-ba ck press+
Display Mastsw itch press+
Display Reduced speed press+
ENTER
ENTER
ENTER
ESC
ESC
ESC
ENTER
ENTER
ESC
ESC
Display Constant speed press+
ESC
Display Direction sw itch press+
ENTER
Display Mast engine Cmd press+
ENTER ESC
Display B rake switch press+
ESC
Display Antistall press+
ENTER
Display Pa rking brake
ESC
Display Neutral drift
ENTER
ESC
ENTER
ESC
ENTER
ESC
n
press+
press+
Pr ess+
Pr ess+
n
PARAMETER
CBD 4.0-4.5-5.0 JOHN DEERE ENGINE SETTING VALUE MAST PRESENCE ACTUATOR PRESENCE CLUTCH PRESENCE REDUCE SPEED MAX FORWARD SPEED MAX REVERSE SPEED NUMBER OF TEETH MULTI DISK BRAKE POWER SUPPLY SENSOR EXITATION PARKING BRAKE SET PUMP POT. INVERTED
TRAVEL PEDAL INC TRAVEL PEDAL DEC. SENSITIVITY INCHING PEDAL INC. INCHING PEDAL DEC.
TRAVEL PEDAL INC TRAVEL PEDAL DEC. MAST INC. MAST DEC. MAST FIXED CDM 1 MAST FIXED CDM 2
YES/NO YES/NO YES/NO 10% - 100% 10% - 100% 1 - 200 PRESENT / NOT PRESENT
70% - 95%
# #
YES YES NO DISABLE 100% 100% 9 PRESENT 12 VOLT 5 VOLT 95% ENABLE
3 - 8 SEC 3 - 6 SEC 10% - 90% 3 - 7 SEC 1,5 - 2,5 SEC
4 4,5 50% 4 2
0,5 - 2 SEC 0,3 - 2 SEC 0,3 - 2 SEC 0,3 - 2 SEC 0% - 100% 0% - 100%
1,8 1,5 1 1 30% 20%
# ONLY THESE VALUES CAN BE MODIFIED
CBD 4.0-4.5-5.0 PERKINS ENGINE SETTING VALUE MAST PRESENCE ACTUATOR PRESENCE CLUTCH PRESENCE REDUCE SPEED MAX FORWARD SPEED MAX REVERSE SPEED NUMBER OF TEETH MULTI DISK BRAKE POWER SUPPLY SENSOR EXITATION PARKING BRAKE SET PUMP POT. INVERTED
TRAVEL PEDAL INC TRAVEL PEDAL DEC. SENSITIVITY INCHING PEDAL INC. INCHING PEDAL DEC.
TRAVEL PEDAL INC TRAVEL PEDA DEC. MAST INC. MAST DEC. MAST FIXED CDM 1 MAST FIXED CDM 2
YES/NO YES/NO YES/NO 10% - 100% 10% - 100% 1 - 200 PRESENT / NOT PRESENT
70% - 95%
# #
YES YES NO DISABLE 100% 100% 9 PRESENT 12 VOLT 5 VOLT 95% ENABLE
3 - 8 SEC 3 - 6 SEC 10% - 90% 3 - 7 SEC 1,5 - 2,5 SEC
4 4,5 50% 4 2
0,5 - 2 SEC 0,3 - 2 SEC 0,3 - 2 SEC 0,3 - 2 SEC 0% - 100% 0% - 100%
1,8 1,5 1 1 30% 20%
# ONLY THESE VALUES CAN BE MODIFIED
LEGEND DESCRIPTION
ENGLISH
DEUTSCH
FRANCAIS
ESPAÑO L
4' via 5' via abilitazione attiva abilitazione freni abilitazione parcheggio acceleratore alternatore anomalia centralina attuatore arresto motore batteria bobina brandeggio candele candelette chiave chiave avviamento clacson comandi luci supplem. comando elettroventola comando fanali stop conn.batteria cruscotto dispositivo candelette elettrovalvole marcia elettroventola emergenza fanali retromarcia fanali stop freno freno pedale freno stazionamento indicatore riserva gas
4th valve 5th valve enable on brakes enable parking enable accelerator pedal alternator logic unit defect actuator motor stop battery coil tilting spark plugs glow plugs key start key horn additional lights controls electric fan control stop lights control battery connector dashboard glow plugs device speed electrovalves electric fan emergency reversing lights stop lights brake pedal brake parking brake LPG reserve indicator
4.Steuerkreis 5.Steuerkreis Freigabe ein Bremsenfreigabe Festellfreigabe Fahrpedal Lichtmaschine Logikeinheitsdefekt Aktuator Motorstop Batterie Spule Neigung Zundkerzen Glühkerzen Schlüssel Anlaßschlüssel Hupe Zusatzbeleuchtungssteuerung Elektroflügelsteuerung Stoplichtesteuerung Batteriestecker Armaturenbrett Glühkerzevorrichtung Gangelektroventile Elektroflügelrad Notstand Rückfahrscheinwerfer Stoplichte Bremse Bremspedal Festellbremse GPL Reserveanzeiger
4.ème levier 5.ème levier abilitation activée abilitation des freins abilitation de stationnement pédale accélérateur alternateur anomalie d’unité logique actionneur arrêt du moteur batterie bobine inclinaison bougies d’allumage bougies de chauffage clé clé de démarrage klaxon commandes lumières suppl. commande électro-ventilateur commande feus de stop connecteur batterie panneau de commande dispositif bougie de chauffage electrovannes de marche électro-ventilateur urgence feus de marche arrière feus de stop frein frein pédale frein de stationnement indicateur réserve GPL
4a.leva 5a.leva habilitación activada habilitación de los frenos habilitación de aparcamiento pedal acelerador alternador anomalía unidad lógica actuador parada del motor batería bobina inclinación bujías bu jías incandescente llave llave de arranque claxon mandos luces adicionales mando electroventilador mando faroles de stop enchufe batería salpicadero dispositivo bujia incandescente electroválvulas de marcha electroventilador emergencia faroles de marcha atras faroles de stop freno freno pedal freno de aparcamiento indicador reserva GPL
LEGEND DESCRIPTION
ENGLISH
DEUTSCH
FRANCAIS
ESPAÑO L
SW cofano temp.olio trasmis. temperatura acqua termico traslatore uomo presente ventola motore ventole vista posteriore
bonnet switch oil temperature transmission water temperature thermal sensor sideshift deadman device motor fan fan rear view
Schutzhaubeschalter Öltemperaturgetriebe Wassertemperatur Wärmesensor Seitenschieber Totmann-schalter Motorflügel Flügelräder Rücksicht
interrupteur coffre temperature d’huile transmis. temperature d’eau senseur thermique déplacement lateral Homme mort ventilateur moteur ventilateur vue arrière
interruptor cofre temperatura aceite transmisión temperatura agua sensor térmico desplazador lateral conductor presente motor ventilador ventilador vista rasera
COLORI arancio azzurro bianco blu giallo grigio marrone nero rosa rosso verde viola
COLOURS orange blue white dark blue yellow grey brown black pink red green purple
FARBEN Orange Hellblau Weiß Blau Gelb Grau Braun Schwarz Rose Rot Grun Violett
COULEURS orange bleu blanc bleu jaune gris marron noir rose rouge vert violet
COLORES anaranjado azul blanco azul amarillo gris marron negro rosa rojo verde violeta
LEGEND DESCRIPTION
ENGLISH
DEUTSCH
FRANCAIS
ESPAÑO L
SW cofano temp.olio trasmis. temperatura acqua termico traslatore uomo presente ventola motore ventole vista posteriore
bonnet switch oil temperature transmission water temperature thermal sensor sideshift deadman device motor fan fan rear view
Schutzhaubeschalter Öltemperaturgetriebe Wassertemperatur Wärmesensor Seitenschieber Totmann-schalter Motorflügel Flügelräder Rücksicht
interrupteur coffre temperature d’huile transmis. temperature d’eau senseur thermique déplacement lateral Homme mort ventilateur moteur ventilateur vue arrière
interruptor cofre temperatura aceite transmisión temperatura agua sensor térmico desplazador lateral conductor presente motor ventilador ventilador vista rasera
COLORI arancio azzurro bianco blu giallo grigio marrone nero rosa rosso verde viola
COLOURS orange blue white dark blue yellow grey brown black pink red green purple
FARBEN Orange Hellblau Weiß Blau Gelb Grau Braun Schwarz Rose Rot Grun Violett
COULEURS orange bleu blanc bleu jaune gris marron noir rose rouge vert violet
COLORES anaranjado azul blanco azul amarillo gris marron negro rosa rojo verde violeta
BT Cargo Teknikutbildning
Programmering av TCS-systemet BT Cargo CBD/CBG 2.5-5.0
BT Cargo Teknikutbildning
Programmering av TCS-systemet BT Cargo CBD/CBG 2.5-5.0
F1
F2
F3
F4
A
B
C
D
E
/
(
1
2
3
F
G
H
I
J
*
)
4
5
6
K
L
M
N
O
-
#
7
8
9
P
Q
R
S
T
=
0
W
X
+
U CTRL
Z
Per Wärmlund / Avd. service
,
V SHIFT
ESC BKSP
.
Y
SPACE ENTER
BT Cargo Teknikutbildning Main Menu
Programmering av TCS-systemet BT Cargo CBD/CBG 2.5-5.0
Connect the console and turn the key without starting Press ENTER to select the main menu ENTER
Calibration
Calibration of the potentiometers and the transmission actuators (pedals, control valve, engine actuator, etc.)
+ Display information on the transmission (engine RPM, transmission displacement, micro switches status, etc.)
Display
+ Pump Customised
Personalization of the transmission behavior
+ Engine Customised
Personalization of the engine setting
+ Fault Detected
System fault display
+ Information
Software version
+ Ph Parameters
Not accessible (Password only)
+ Eeprom reset
+
Not accessible (Password only)
End of list 2.5 - 3.5t
Motor Shifting
Not accessible (Password only)
+ Actuator Pid
+
Not accessible (Password only)
End of list 4.0 - 5.0t
Sida 1
BT Cargo Teknikutbildning
Programmering av TCS-systemet BT Cargo CBD/CBG 2.5-5.0
Calibration First operation to be carried out to release the program
ENTER
Calibration
ENTER
Calibration Calibration Status
- + Calibration Travel Pedal
ENTER
Calibration calibration Status locked
Configuration accelerator pedal potentiometer
ENTER
+ N.B. With the program locked it is possible to read the sensor values..
Calibration Travel pedal Don’t touch the travel pedal (’ENT’)
Select the parking brake
Calibration Calibration Status not locked
switch and press
+
ESC Calibration Travel Pedal If Forward switch select it (’ENT’)
ENTER
R Operate the forward switch lever or depress E T the twin forward. Pedal N E to close switch
Calibration Travel Pedal Forward complete (ENT)
Press a key
Calibration Travel Pedal Full depression in Forward (Press a key)
ENTER
Calibration Travel Pedal Forward complete (ENT)
ENTER
Calibration Travel pedal. Don’t touch the travel pedal (’ENT’)
Calibration Travel Pedal If Reverse switch select it (’ENT’)
ENTER
ENTER
Calibration Travel Pedal Reverse complete (ENT) R E T N E
Operate the reverse switch lever or depress the twin reverse. Pedal to close switch
ESCAPE
Calibration Brake / inching pedal
Configuration brake pedal potentiometer
ENTER
+
Calibration Travel Pedal Completed
Calibration Brake / inching pedal Rest reading (press a key)
Calibration Travel Pedal Reverse complete (ENT)
ENTER
Min value stored,
Press a key
Calibration Brake inching pedal Full depression (press a key)
Press a key
Calibration Travel Pedal Ful depression in reverse (Press a key)
Completely press the pedal, keep it pressed Calibration ENTER Brake / inching pedal completed
ESC Ended configuration of the brake pedal,
To page 3 Calibration Mast Lever
Sida 2
Programmering av TCS-systemet BT Cargo CBD/CBG 2.5-5.0
BT Cargo Teknikutbildning Calibration From page 2 Calibration Mast Lever Configuration of the lifting potentiometer,
ENTER
Calibration Mast lever
Calibration Mast lever Mast sensor presence YES (1) NO (0)
Press 1
Calibration Mast lever Rest reading (Press a key)
+
Min. Value stored
Calibration Mast lever Full depression (press a key)
Press a key
Pull the lifting lever to the end stroke, keep it pulled, ENTER
ESCAPE Ended configuration of the lifting potentiometer
ACQUISITION TO BE CARRIED OUT WITH THE ENGINE ON
Calibration Engine Calibration
Calibration Mast lever completed
+ Acquisition of the neutral pump position
Calibration Pump Neutral
ENTER
+ Calibration max.forward speed
Calibration Pump neutral Completed
Ended acquisition of the neutral pump positi on
May be Modified
+ Calibration Max.reverse speed
+ LIST FOR 2.5-3.5t NOT MODIFY
Calibration Parking brake set
+
Standard value 850 RPM
Calibration Mini engine set
+
Standard value 2250 RPM
Calibration Maxi engine speed
+
FUNCTION TO BE CARRIED OUT WITH THE ENGINE ON
May be Modified
NOT MODIFY
Calibration Pump pot.inverted
+ Back to calibration
LIST FOR 4.0-5.0t
ESCAPE
May be Modified
Calibration Reduce speed
+
Calibration Engine calibration
NOT MODIFY
Ended acquisition of the min. and max RPM of the engine,
Calibration Number of teeth
+
Engine Calibration End of engine calibration
NOT MODIFY
Acquisition of the min.and max. RPM of the engine
ENTER
Engine Calibration Lowest engine speed Reading.......
Then the engine starts to accelerate by itself
ESCAPE
Calibration Power supply
+
Calibration Engine Calibration Reading... (8 values)
NOT MODIFY
Engine Calibration Highest engine speed Reading.....
Calibration Sensor excitation
+
NOT MODIFY
Calibration Multi disc brake
+
NOT MODIFY
Calibration Parking brake set
+
NOT MODIFY
Calibration Pump pot.inverted
+
Back to calibration
Sida 3
BT Cargo Teknikutbildning Display Menu
Programmering av TCS-systemet BT Cargo CBD/CBG 2.5-5.0 ENTER
Display Engine Speed
+
ESC
+
ESC
Display pump displacement
ENTER
Display Engine command
Calibration
+ ENTER
+ +
ESC
+
ESC
ENTER
Display Parking brake
Displays information of the engine and hydrostat pump HOLD DOWN THE ENTER KEY TO DISPLAY DATA IN SEQUENCE
Display Brake switch
+
Display Mast engine Cmd
+ Display Pump feed-back
+ Display Neutral drift
ENTER ESC ENTER ESC ENTER
+ +
ESC
Display Mast switch
Display Reduced speed
ENTER
ESC
Display Direction switch
+
List for 4.0 - 5.0t
ENTER ESC
Display Antistall
Display
ENTER
Display Constant speed
ENTER
+
ENTER
ENTER
ESC
ESCAPE
Display the engine RPM requested by the logic unit Display the status of the function (enable / disable) Display the status of the negative brakes (enable / disable) Display the status of the parking brake switch (set / not set)
Display the engine RPM with the lifting lever pulled Display the real pump displacement (cc) by the potentiometer Display the status of the direction switches (neutral / forward / backward) Display the status of the control valve switches 1=tilting / sideshift (set / not set)
ENTER ESC
Display the constant driving speed function status with the lifting activated (set / not set) Display the reduced speed function status (enable / disable)
Display the difference of the pump potentiometer signal from the theoretical value (in mV)
List for 2.5 - 3.5t
Display Actuator feed back
+
Display Power supply
ENTER ESC ENTER
+
ESC
+
ESC
Display Sensor excitation
ESCAPE
Display the pump displacement requested by the logic unit (cc)
ESC
ESC
ENTER
Display the real engine RPM
Display Neutral drift
ENTER
ENTER ESC
Display the signal of the engine actuator in volts Display the voltage of the logic unit (enable / disable) Display the sensor voltage supplied by the logic unit Display the difference of the pump potentiometer signal from the theoretic value (in mV)
Sida 4
BT Cargo Teknikutbildning Pump Customised Section
Calibration status has to be un locked to release the parameters for Calibration modification Calibration status
ENTER ESC
ENTER
Calibration Calibration status Locked
+
Calibration Calibration status Not Locked
ESC
Calibration travel Pedal
ESCAPE ESC
Pump acceleration time Pump Customised ENTER Pump Customised Travel pedal Inc. Travel pedal Inc. 5.0 Seconds
Display
+
Select the Parking brake switch and press
- +
ENTER
Calibration
+
Programmering av TCS-systemet BT Cargo CBD/CBG 2.5-5.0
ESC
Pump Customised
ENTER
+
Set the requested value by typing it directly with the keyboard numbers or pressing + 0 ENTER ( N.B. Quicker acceleration, lower value, slower acceleration, higher value)
ESCAPE Pump Customised Travel pedal Inc. 5.0 Seconds
Pump deceleration time (Braking) Pump Customised Travel pedal Dec. ENTER
+ Hard braking ratio
ENTER
Pump Customised Travel pedal Dec. 5.0 Seconds Set the requested value by typing it directly with the keyboard numbers or pressing + 0 ENTER ( N.B. Stronger brake, lower value softer brake, higher value)
ESCAPE Pump Customised Travel pedal Dec. 5.0 Seconds
Pump Customised Sensitivity
Not Modified
Pump Customised Inching pedal Inc.
Not Modified
+ +
ESCAPE Pump Customised Inching pedal Dec.
Pump Customised Hard braking ratio 00%
ENTER Not Modified
See page 14
ESCAPE Pump Customised Hard braking ratio 00%
Sida 5
BT Cargo Teknikutbildning Engine Customised Section
Programmering av TCS-systemet BT Cargo CBD/CBG 2.5-5.0
Calibration status has to be un locked to release the parameters for Calibration modification Calibration status
ENTER
Calibration Calibration status Locked
+
- +
ENTER ENTER
Calibration Calibration status Not Locked
ESC
Calibration travel Pedal
Calibration
+
Select the Parking brake switch and press
ESCAPE
Display
+
Engine Customised Travel pedal Inc.
+
Pump Customised
+
Engine Customised
Engine Customised Travel pedal Dec.
ENTER
+ Engine Customised Mast Inc.
Set the requested value by typing it directly, or by the +0- ENTER (N.B. More RPM higher value less RPM lower value)
+ Engine Customised Mast Dec.
Engine Customised Mast fixed Cmd. 1 45%
+
Engine Customised ENTER Mast fixed Cmd. 1 Engine RPM Tilting
+
ENTER
Engine Customised Mast fixed Cmd. 1 ESCAPE 45% Set the requested value by typing it directly, or by the +0- ENTER (N.B. More RPM higher value less RPM lower value)
ESCAPE Engine Customised ENTER Mast fixed Cmd. 2
Engine RPM Sideshift
Engine Customised Mast fixed Cmd. 2 45%
ENTER Engine Customised
ESCAPE Mast fixed Cmd. 2 45%
Sida 6
BT Cargo Teknikutbildning Alarms Section “Fault Detected”
Programmering av TCS-systemet BT Cargo CBD/CBG 2.5-5.0
DISPLAY CONSOLE
ENTER
Calibration
+ Display
+ Pump Customised
+
ENTER To display the
Engine Customised
+ Fault Detected
Fault Detected Fault occuring now Press ENTER to display the faults
faults in real time Fault detected Fault occuring now No default
+
+
C S E
No alarms
Fault detected Fault occuring now Actuator sensor Alarm present
ENTERTo display the ESC
stored alarms (faults) Fault detected (max 5) Fault Detected Fault since startup Fault since startup Start of the list
+
To read the alarms
Fault detected Example:- Fault since startup Neutral out of range
+ ESC Fault detected
Fault since startup End of the list
Sida 7
BT Cargo Teknikutbildning
Programmering av TCS-systemet
Här är huvudmenyerna:
N
Meny
Funktion
1
CALIBRATION
Kalibrering av sensorer och potentiometrar. Visning av aktuella spänningar (Calibration Status = Locked)
2
DISPLAY
to display the information on the transmission (thermal engine speed, pump displacement, anitstall function,....)
3
PUMP CUSTOMIZED
to customize the transmission (more or less prompt braking and acceleration)
4
ENGINE CUSTOMIZED
to customize the thermal engine control (higher or lower acceleration of the thermal engine, engine speed when the tilt system and the sideshift are on,...)
5
FAULT DETECTED
to display the system faults
6
INFORMATION
software versions
7
PH PARAMETERS (password)
configuration of the system operation parameters
8
EEPROM RESET (password)
to reset the control unit memory
9
MOTOR SHIFTING(password)
configuration of the parameters controlling the displacement Shifting of the hydraulic motors
10 ACTUATOR PID (password)
configuration of the actuator feedback parameter
1 CALIBRATION The CALIBRATION menu has two functions: Calibrating mode when the parking brake is locked and the “calibration status” parameter is “not locked”, it allows the calibration and configuration of the system. Display mode when the parking brake is not locked or the “calibration status” parameter is “locked” this menu views the output voltages of the system sensors and the state of some components. After calibration, release and engage the parking brake again to exit from the “calibration status” mode and return to the standard operating mode.
Sida 8
BT Cargo Teknikutbildning
Programmering av TCS-systemet
CALIBRATION MENU N
SUBMENU
CALIBRATION MODE
DISPLAY MODE
A
Travel pedal
calibration of the travel pedal
B
brake / inching pedal calibration of the brake pedal
display of the voltage supplied by the potentiometer for the brake pedal
C
mast lever
calibration of the mast lever
display of the voltage supplied by the potentiometer for the mast lever
D
engine calibration
calibration of the actuator-thermal display of the voltage supplied by the potentiometer for the actuator
E
pump neutral
calibration of the pump in neutral position
display of the voltage supplied by the potentiometer for the hydrostatic pump
F
max forward speed
limiting of the truck max forward speed
display of truck forward speed (as a percentage of the max speed)
G
max reverse speed
limiting of the truck max reverse speed
display of the truck reverse speed (as a percentage of the max speed)
H
parking brake set
definition of the brake pedal position in which the mechanical pedal is engaged
displays the brake pedal position in which the mechanical brake is locked
I
min engine speed
definition of the minimum engine RPM
displays the minimum engine RPM
L
max engine speed
definition of the maximum engine RPM
displays the maximum engine RPM
M
pump pot. Inverted
definition of the connections type of the pump potentiometer
displays the connections type of the pump potentiometer
N
calibration status
validations and invalidation of the calibration menu
status of the calibration menu
O
reduced speed
limiting of the truck max. Speed
P
number of teeth
R
power supply
S
sensor excitation
T
multi disc brake
definition of the number of teeth Per engine rev (speed sensor in The thermal engine measures the supply voltage of Control unit measures the supply voltage of Sensors definition of the type of brake Used
displays if the truck reduced speed is (Enable / disable) display of the number of teeth/rev
display of the voltage supplied by the potentiometer for the travel pedal
measures the supply voltage of the control unit measures the supply voltage of the sensors type of brake used
For the TCS to operate correctly, the voltage values read by the potentiometers in the pedals, the mast system and the motor actuator must not exceed the limits set. If the mechanical limit stops of the potentiometer are not properly adjusted, the voltage supplied by the potentiometer is exceeded. The range of values allowed by the control unit disables the calibration procedure. Trouble may also occur after a correct calibration if, for whatever reason, the limit stop is modified.
Sida 9
BT Cargo Teknikutbildning
Programmering av TCS-systemet
CALIBRATION AND FIRST START UP OF THE TRANSMISSION SYSTEM The system calibration is to be performed when the thermal engine is stopped. The following are to be calibrated: Potentiometer for the travel pedal (TRAVEL PEDAL) Potentiometer for the brake pedal (BRAKE / INCHING PEDAL) Potentiometer for the mast lever (MAST LEVER) Potentiometer for the hydrostatic pump (PUMP NEUTRAL) While calibrating, check the parameters below: Max. forward speed (truck max speed) Max reverse speed (truck max speed) Parking brake set (brake setting) Min engine speed(minimum engine RPM) Max engine speed (maximum engine RPM) Pump pot. Inverted (with Potentiometer Hall effect only)
100% 100% 95% 850 2250 Enable
Calibration also includes the actuator setting while the thermal engine is running (ENGINE CALIBRATION). For the engine calibration do the following: Lift the truck onto the blocks fill the hydraulic circuit and bleed the air from the system engage the parking brake select the neutral position (through the steering-wheel operated reverse gear) start up the engine and wait for the stabilization of the boost pressure adjust the engine min and max RPM through the actuator limit stop screws (the limit stops are to be obtained on the actuator support, not on the injection pump). The engine RPM is to be measured through the “engine speed”parameter in the “DISPLAY” menu. Calibrate the actuator (ENGINE CALIBRATION) Press the accelerator pedal; the actuator has to rotate clockwise and the voltage of the feedback potentiometer in the actuator has to increase (such voltage may be measured in the “engine calibration” parameter in the “calibration” menu after engaging the parking brake). Once the calibration procedure is over, check the transmission operation (wheels must be jacked up): Release the parking brake position the steering column switch to forward gear gradually press the forward pedal: wheels should slowly rotate forward
CAUTION: the hydraulic motors must not rotate quickly when wheels are jacked up When wheels rotate forward, check that the voltage of the pump feedback potentiometer increases from 2.5 to 5 volts (for the voltage reading use “pump neutral” parameter in the “calibration” menu). Check the correct operation under the following conditions: - mast lifting, sideshift and tilt operation, etc., : if the relevant levers are adjusted, the thermal engine will accelerate - forward / reverse speed and braking - parking brake: if engaged, the travel pedal will be disabled (the engine RPM will increase, but the truck wheels will be locked) - emergency button.
Sida 10
BT Cargo Teknikutbildning
Programmering av TCS-systemet
SEE THE DIAGRAM FOR USING CONSOLE SECTION “CALIBRATION” A) TRAVEL PEDAL CALIBRATION For calibrating, voltages are not to exceed the following ranges (voltages may be read in display mode). Pedal in its min. position 0,35 - 2,4 volts Pedal in its max.position 2,6 - 4,65 volts (the supply voltage of all sensors is of 5 volts)
(7 - 48% of the supply voltage) (52 - 93% of the supply voltage)
B) BRAKE / INCHING CALIBRATION Defines the voltage values corresponding to the min. and max. positions of the brake pedal ( and the “ inching” function. For calibrating, voltages are not to exceed the following ranges: Pedal in its min. position 0,35 - 2,4 volts Pedal in its max. position 2,6 - 4,65 volts
(7 - 48 % of the supply voltage) (52 - 93% of the supply voltage)
C) MAST LEVER CALIBRATION Defines the voltage values corresponding to the maximum and minimum positions of the mast lever. For calibrating, voltages are not to exceed the following ranges: Lever in neutral position 0,35 - 2,3 volts (7 - 46 % of the supply voltage) Lever fully pulled 2,4 - 4,65 volts (48 - 93% of the supply voltage)
D) ENGINE CALIBRATION Matches the actuator position angle (voltage of the actuator feedback potentiometer) with the engine speed value. For calibration, voltages are not to exceed the following ranges: Actuator in its min. position 0,35 - 2,4 volts (7 - 48 % of the supply voltage) Actuator in its max. position 2,6 - 4,65 volts (52 - 93% of the supply voltage) Such values may be viewed if the parking brake is engaged. The control unit automatically controls the actuator by bringing it to its minimum and maximum positions (that are determined by the mechanical limit stops located on the actuator support). With respect to the min.and max. Positions, TCS reads the min.and max RPM as well as some intermediate values. The limit stops are to be obtained on the actuator, not on the injection pump.
E) PUMP NEUTRAL CALIBRATION Defines the voltage corresponding to the neutral displacement position of the hydrostatic pump (feedback potentiometer). The voltage value must not exceed the following range 2.48 to 2.52 volts. (In display mode and when the truck is running, the voltage value must vary. When the wheels rotate forward, the potentiometer voltage must rise to 5 volts and remain constant).
Sida 11
BT Cargo Teknikutbildning
Programmering av TCS-systemet
SEE THE DIAGRAM FOR USING CONSOLE SECTION “CALIBRATION” F) MAX FORWARD SPEED This parameter (expressed as a percentage of the truck’s forward max. speed) limits the travel speed. This parameter may be modified (in calibration mode).
G) MAX REVERSE SPEED This parameter (expressed as a percentage of the truck’s reverse max speed) limits the travel speed. This parameter may be modified (in calibration mode).
H) PARKING BRAKE SET This parameter defines the stroke of the brake pedal necessary to engage the mechanical brake. The standard value is 95%. It is suggested that this value is not changed. Limit values: 90 to 95%.
I) MIN ENGINE SPEED This parameter defines the minimum engine RPM (standard value 850).
L) MAX ENGINE SPEED This parameter defines the maximum engine RPM (standard value 2250)
M) PUMP POT. INVERTED This parameter defines the type of connections at the pump potentiometer. This parameter is present with the Hall potentiometer software only.
N) CALIBRATION STATUS This parameter enables or disables the calibration mode.
O) REDUCED SPEED This parameter expressed if the truck reduced speed is activated (enable / disable). This parameter may be modified (in calibration mode).
P) NUMBER OF TEETH This parameter defines the number of pulse per revolution of the thermal engine sent by the speed sensor to the control unit.
R) POWER SUPPLY Displays the supply voltage of the control unit: battery voltage (12 volts)
S) SENSOR EXCITATION This parameter displays the voltage supplied by the control unit to the sensors. Correct value: 5 volts.
T) MULTI DISC BRAKE this parameter defines whether the multidisc brake is fitted or not (the multidisc brake is an on/off brake, i.e. It is not gradual.
Sida 12
BT Cargo Teknikutbildning
Programmering av TCS-systemet
2) DISPLAY This menu displays the transmission data. Press ENTER to display data (e.g. Thermal engine speed). (Hold down the key to display data in sequence)
ENGINE SPEED Real speed of the thermal engine (expressed in RPM)
PUMP DISPLACEMENT Pump displacement required by TCS (expressed in cc). Warning: this is the displacement control sent by the control unit to the pump, so the value displayed may be different from the real displacement.
ENGINE COMMAND Speed of the thermal engine required by TCS (in RPM).
ANTISTALL Indicates whether the anitstall function is enabled or not (enable / disable).
PARKING BRAKE Displays whether the negative brakes are set or not (set / not set).
BRAKE SWITCH Displays whether the parking brake switch is set or not (set / not set)
MAST ENGINE COMMAND Speed of the thermal engine required by TCS (in RPM) when the mast is actuated.
PUMP FEED-BACK Actual displacement of the pump (expressed in cc). This is the displacement measured by the potentiometer located on the pump.
DIRECTION SWITCH Displays the running direction controlled by the pedal micro-switches or the steering-wheel operated reverse gear (neutral / forward / reverse).
MAST SWITCH Displays the state of the valve bank microswitches 1 = tilt / sideshift (set / not set)
CONSTANT SPEED. Displays the constant speed function enabling when the mast is actuated while the truck is running (set / not set).
REDUCED SPEED Displays if the reduced speed function is enabled (the trvel speed is limited to a preset percentage value of the max. speed). optional
ACTUATOR FEED BACK Displays the engine actuator signal in Volts. Increases during acceleration and vice versa.
POWER SUPPLY Displays the voltage supply to the control unit: battery voltage (12V) Must be between 9,5 and 48,5 Volt.
SENSOR EXCITATION Displays the voltage supply to the sensors. Correct value 5 Volt.
NEUTRAL DRIFT Displays the difference in value between the theoretical and real pump potentiometer value (in mV) This parameter is present with the Hall potentiometer software only.
Sida 13
BT Cargo Teknikutbildning
Programmering av TCS-systemet
3) PUMP CUSTOMIZED Sets the parameters for the control of the hydrostatic pump. This parameter is used to modify the acceleration and deceleration of the truck. Enable the program to modify such values (calibration status - not locked).
TRAVEL PEDAL INC. This parameter defines how long the pump takes to reach its max displacement when the travel pedal is fully pressed (the higher the value of this parameter, the less the acceleration of the truck).
TRAVEL PEDAL DEC. This paramter defines how long the pump takes to reach its neutral displacement mode when the travel pedal is released (the higher the value of this parameter, the less the deceleration of the truck during the hydrostatic braking).
HARD BRAKING RATIO This parameter (%) changes the release braking value (travel pedal dec) as the following table:
Braking times of the truck function of the two parameters “Travel pedal dec” (s) and Hard braking ratio”(%) Travel pedal dec (s)
2
5
7
10
0
2
5
7
10
17
1.7
3.8
5
6.5
50
-
2.8
-
-
67
1.6
2.5
3.1
3.6
83
-
2.3
-
-
100
1.3
2.1
2.5
2.9
Bromskraft vid låg hastighet
Hard braking ratio (%)
Bromskraft vid hög hastighet
SENSITIVITY This parameter defines the sensitivity of the pump control when varying the pedal stroke (this value is expressed as a percentage of the pump max. displacement control).
INCHING PEDAL INC This parameter defines how long the pump takes to reach it’s max. displacement when the inching pedal is instantaneously released after it has been fully pressed in conjunction with the travel pedal.
INCHING PEDAL DEC. This parameter defines how long the pump takes to range from the max. Displacement to the neutral displacement when the inching pedal is instantaneously pressed after fully pressing the travel pedal.
Sida 14
BT Cargo Teknikutbildning
Programmering av TCS-systemet
4) ENGINE CUSTOMIZED Sets the parameters for the thermal engine control. Do not modify the standard values.
TRAVEL PEDAL INC. This parameter defines how long the actuator takes to achieve its stroke when the travel pedal is fully pressed (the higher the value of this parameter, the longer the time the thermal engine takes to range from its min RPM to its max RPM.)
TRAVEL PEDAL DEC. This is the same as the previous parameter (the time the thermal engine takes to range from its min speed to its max. Speed.)
MAST INC. This parameter defines the time the actuator takes to achieve its stroke when the mast lever is fully pulled back. (The higher the value of this parameter, the longer the time the thermal engine takes to range from its min RPM to its max RPM)
MAST DEC. This parameter is similar to the previous one (time the engine takes to range from its max RPM to its min. RPM when the mast lever is released).
MAST FIXED CMD 1 MAST FIXED CMD 2 Parameters that define the thermal engine speed rate when one of the auxiliary devices of the hoisting unit is actuated (tilt unit, sideshift, 4th way, 5th way). When one of the value levers is actuated (except for the mast lever) the engine speed increases by a quantity proportional to the parameter setting. Standard value is 30 - 40 % Ex: Engine min speed: 700 rpm; engine max.speed: 2,500rpm usable range: 2,500 - 700 = 1,800rpm parameter (mast fixed cmd): 25% If the engine operates at a speed higher than 1,100rpm and the distributor is actuated, the actuator will bring the engine rpm to: 1,100 + (2,500 - 700) x 0.25 = 1,500rpm Do not increase the speeds set to avoid dangerous manoeuvres. Stroke of the sideshift: 2 - 2.5secs Tilting: 4.5 - 5 secs
MAST MAXIMUM CMD (Available from 2001) Parameter which defines the max thermal motor rpm when the lifting is started. By activating the lever, the motor speed increases step by step until the max value set.
Sida 15
BT Cargo Teknikutbildning
Programmering av TCS-systemet
5) FAULT DETECTED Displays the system faults.
- FAULT OCCURRING NOW Press enter to display the current fault
- FAULT SINCE START UP Press (+) and (-) to display the last five faults occurred
- FAULT MESSAGES SHOWN ON THE CONSOLE “Excitation Sensor”
The excitation voltage of the sensor is <2V or >5.5V
“Power Supply”
The supply voltage of TCS control unit is <9.5V or >32V for more than 2 secs long
“Travel Pedal Sensor”
The signal (voltage) of the travel pedal potentiometer has exceeded the limits set while calibrating
“Brake / Inching pedal Sensor“
The signal (voltage) of the brake pedal potentiometer has exceeded the limits set while calibrating
“Mast lever Sensor”
The signal (voltage) of the mast lever has exceeded the limits set while calibrating
“Actuator Sensor”
The signal (voltage) of the feedback potentiometer has exceed the limits set while calibrating
“Error on Actuator control loop”
>20% error, for more than 0.5secs, between the actuator setpoint and the potentiometer feedback
“Error on pump control loop”
>20% error, for more than 0.5 secs, between the pump control signal and the potentiometer feedback signal in the pump.
“Feed back error“
Pump feed back is <0.25V or >4.75V
“Neutral out of range”
During calibration the pump neutral is outside of the fixed limits
“Pump neutral drift too high”
The difference between the pump in neutral calibration function and the pump in neutral while the values are fed is >341 mV
“Feedback moves too fast”
The pump feedback changes too fast in comparison with the real change of the pump displacement.
“Eeprom error at address”
One parameter at least is outside of the field of acceptable values
“Direction switches error”
The TCS control unit takes contemporarily the forward and reverse gear (running mode) started
“Other default”
Other faults
6) INFORMATION Displays the SOFTWARE version
Sida 16
BT Cargo Teknikutbildning
Programmering av TCS-systemet
7) PH PARAMETERS - PASSWORD Enter the password (4 numbers) with the digital key and then valid (enter). Press the key / esc then (+) or (-) in order to have access to the rest of the menu - PUMP NEUTRAL OFFSET This parameter is used to offset pump feedback
- ENABLE LIMIT CHANGE During the calibration of the pedals, the auxiliary levers and the actuator, it is possible that the minimum and maximum values obtained on the potentiometer do not conform to the limits fixed by the programme. It is possible to modify these limits. In the menu calibration, authorise the mode calibration. Go into the menu “PH PARAMETERS”and into the menu “ENABLE LIMIT CHANGE”. It is necessary to be in “NOT LOCKED”
- INVERSION BRAKING This function is used to have a braking action if the direction switch is set to the reverse position during the operation of the machine (plug braking) The braking action will be proportional to the position of the travel pedal.
- INVERSION DISPLACEMENT This parameter sets the inversion time range from 0 - 10 seconds
- DISABLE PUMP DELAY Parameter which defines the time delay of the negative brakes releasing (standard values 30 cycles). It is the delay for the brakes releasing after the pump has reset its displacement. In order to have the brakes release in a short time, for example on a ramp, reduce the value (min 5 max 45 cycles).
- REGULATOR OFFSET This is the acceptable difference between the requested engine speed and the measured engine speed. If this value is exceeded, the antistall function is active
- ANTISTALL COEF coefficient applied to the action of the anitstall function. The parameter change from 3 to 8 The higher the value the more the displacement will decrease
- DERIVE ANTISTALL Definition of the derived gain for the antistall action. The parameter is a variable number from 10 - 30 The higher the number the more sensitive antistall is to RPM variations
- FULL STROKE CMD Compensation of the electric stroke used on the position potentiometer of the pump swashplate The parameter is a number (never vary it) 1488
- ENGINE DELAY INC
This parameter is used to take into account the reaction time of the engine actuator in order to activate the anitistall at the right moment. It avoids unnecessary operations of the antistall functions.
- ENGINE DELAY DEC This value is the complementary value of engine delay dec. It is to take into account during the engine deceleration This paramter is the time taken for engine deceleration.
Sida 17
BT Cargo Teknikutbildning
Programmering av TCS-systemet
8) EPROM RESET This menu is used to reset the data of the EEPROM
- PASSWORD Enter the password (4 numbers) with the digital key and then press enter. Press the key / esc then (+) or (-) in order to have access to the rest of the menu
- ALL EEPROM RESET Press the enter key to cancel the list of statistics
- FAULT LIST RESET Press the enter key to cancel the list of the detected faults.
Sida 18
BT Cargo Teknikutbildning
Programmering av TCS-systemet
TROUBLES OCCURRING WHILE CALIBRATING The voltage values read by the transmission potentiometer (pedals, hoisting, etc.) Must not exceed the limits set. If there is some wiring failure or the mechanical limit stops of the potentiometers are not properly adjusted, the voltage they supply will exceed the allowed range for the control unit, thus preventing the calibration procedure. In that case, the terminal will display one of the following messages (while calibrating or in the “fault detected” alarm menu). Travel pedal position out of range Brake/inching pedal sensor Mast lever sensor Actuator position out of range Feed back error
Travel pedal Brake pedal Mast lever Thermal engine actuator Hydrostatic pump potentiometer
1) TRAVEL PEDAL
Yes
Travel pedal position out of range
(Error message)
Release the parking brake
The terminal will switch from the CALIBRATION MODE to the DISPLAY MODE
Select the TRAVEL PEDAL submenu
The terminal will display the voltage that is supplied from the potentiometer in the travel pedal
Voltage = 0 volts?
No
Hold down the [ENTER] key and check if voltage changes when the pedal is pressed
Check the potentiometer wiring
Yes
Does voltage change? No
Press the [ENTER] key to measure the min. and max. Voltage supplied by the potentiometer
Check the potentiometer wiring
Adjust the mechanical limit stop of the pedal so that the voltage does not exceed the ranges set (see “travel calibration”)
Calibrate the travel pedal
Sida 19
BT Cargo Teknikutbildning
Programmering av TCS-systemet
TROUBLES OCCURRING WHILE CALIBRATING 2) BRAKE/INCHING PEDAL Brake/inching position out of range
(Error message)
Release the parking brake
The terminal will switch from the CALIBRATION MODE to the DISPLAY MODE
Select the BRAKE/INCHING PEDAL submenu
Yes
Voltage = 0 volts?
The terminal will display the voltage that is supplied from the brake pedal potentiometer
No
Hold down the [ENTER] key and check if voltage changes when the pedal is pressed
Check the potentiometer wiring
Yes
Does voltage change? No
Press the [ENTER] key to measure the min. and max. Voltage supplied by the potentiometer
Check the potentiometer wiring
Adjust the mechanical limit stop of the pedal so that the voltage does not exceed the ranges set (see “travel calibration”)
Calibrate the brake pedal
Sida 20
BT Cargo Teknikutbildning
Programmering av TCS-systemet
TROUBLES OCCURRING WHILE CALIBRATING 3) MAST LEVER Mast lever sensor out of range
(Error message)
Release the parking brake
The terminal will switch from the CALIBRATION MODE to the DISPLAY MODE
Select the MAST LEVER submenu
Yes
Voltage = 0 volts?
The terminal will display the voltage that is supplied from the mast lever potentiometer
No
Hold down the [ENTER] key and check if voltage changes when the pedal is pressed
Check the potentiometer wiring
Yes
Does voltage change? No
Press the [ENTER] key to measure the min. and max. Voltage supplied by the potentiometer
Check the potentiometer wiring
Adjust the shims of the potentiometer support bracket so that the voltage does not exceed the ranges set (see “mast lever calibration”) If the lever is moved forward from its middle position (for forks lowering) voltage is not to decrease.
Calibrate the mast lever
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BT Cargo Teknikutbildning
Programmering av TCS-systemet
TROUBLES OCCURRING WHILE CALIBRATING 4) THERMAL ENGINE ACTUATOR Actuator position out of range
(Error message)
Release the parking brake
The terminal will switch from the CALIBRATION MODE to the DISPLAY MODE
Select the ENGINE CALIBRATION submenu
Yes
Voltage = 0 volts?
The terminal will display the voltage that is supplied by the potentiometer of the actuator Engage the parking brake No and press the accelerator pedal
Hold down the [ENTER] key and check if voltage changes while the actuator rotates
Check the electrical connections of the actuator
Yes
Does voltage change? No
Press the [ENTER] key to measure the min. and max. Voltage supplied by the actuator potentiometer
Check the actuator electrical connections
Adjust the length of the tie rod so that the voltage does not exceed the ranges set (see “engine calibration”) Calibrate the actuator
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BT Cargo Teknikutbildning
Programmering av TCS-systemet
TROUBLES OCCURRING WHILE CALIBRATING 5) POTENTIOMETER IN THE HYDROSTATIC PUMP Feed back error
(Error message)
Release the parking brake
The terminal will switch from the CALIBRATION MODE to the DISPLAY MODE
Select the PUMP NEUTRAL submenu
Yes
Check the potentiometer electrical connections
Voltage = 0 volts or 5 volts
Yes
The terminal will display the voltage that is supplied by the potentiometer in the hydrostatic pump
No
Voltage = 2.48 - 2.52 volts No
Engage the parking brake, switch to CALIBRATION mode and clibrate the pump potentiometer to zero.
Check the potentiometer wiring, lift the truck onto blocks, electrically disconnect the pump solenoid valves and start up the engine: If the pump supplies some oil, the trouble is hydraulic or mechanical (mechanical maladjustment of the pump plate positioning in neutral) After disconnecting the valves, if the pump supplies some oil, switch off the engine and hold down the [ENTER] key in order to read the voltage, until a 2.5 volt value is obtained
Engage the parking brake, swich to CALIBRATION mode and clibrate the pump potentiometer zero.
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BT Cargo Teknikutbildning
Programmering av TCS-systemet
SYSTEM FAULTS AND FAILURES Any system failure is signalled by the flashing warning light located beside the valve bank levers. The frequency indicated the failure importance. The kind of fault is displayed in the FAULT DETECTED menu (FAULT OCCURRING NOW SUBMENU).
If the warning light blinks slowly (0.5Hz) the fault is not very important; the machine is able to drive.
Error message
Cause
Cure
Travel pedal sensor
The signal voltage of the travel pedal potentiometer has exceeded the limits set while calibrating. Connector disconnected or wrong wiring.
Check the potentiometer wiring. Check if the voltage values at the pedal stop do not exceed the preset limits. Adjust the pedal limit stop. Calibrate the pedal again.
Brake/inching pedal sensor
The signal voltage of the brake pedal potentiometer has exceeded the limits set while calibrating. Connector disconnected or wrong wiring.
Check the potentiometer wiring. Check if the voltage values at the pedal stop do not exceed the preset limits. Adjust the pedal limit stop. Calibrate the pedal again.
Mast lever sensor
The signal voltage of the mast lever potentiometer has exceeded the limits set while calibrating. Connector disconnected or wrong wiring.
Check the potentiometer wiring. Check if the voltage values at the lever stop do not exceed the preset limits. Adjust the lever limit stop. Calibrate the lever again.
The signal voltage of the feedback potentiometer has exceeded the limits set while calibrating. Connector disconnected or wrong wiring.
Check the potentiometer wiring. Check if the voltage values at the actuator stop do not exceed the preset limits. Adjust the actuator limit stop. Calibrate the actuator again.
.20% error, for more than 0.5 secretary.. Between the actuator set point and the potentiometer feed back. Connector disconnected or wrong wiring.
Check the actuator wiring. Check the actuator potentiometer output signal. If you press the accelerator pedal, the actuator will rotate forward and the voltage measured in engine calibration when the brake is released will increase.
The supply voltage of TCS control unit is not within the 9.5 - 48 volt range.
Check the supply voltage value.
Actuator sensor
Error on actuator control loop This message may be displayed if the accelerator is pressed(green light on) when the engine is off and the brake is unlocked.
Power supply out of range
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BT Cargo Teknikutbildning
Programmering av TCS-systemet
SYSTEMFEL OCH FELMEDDELANDEN Om varningslampan blinkar snabbt (1hz) är felet allvarligt, och maskinen går ej att köra!
FELMEDDELANDE
ORSAK
KONTROLLERA
Felaktig matningsspänning till sensorer och microbrytare.
- Att spänningen ligger på 5 volt +/- 5%
Fel signal från feedback-potentiometern på pumpen.
- Att spänningen från feedbackpotentiometern ligger på 2.5 +/0.15 volt när pumpen står i neutralläge.
Fel signal från feedback-potentiometern på pumpen, med pumpen i neutralläge.
- Att spänningen från feedbackpotentiometern ligger på 2.5 +/0.15 volt när pumpen står i neutralläge.
Fel signal från feedback-potentiometern på pumpen. Avvikelsen mellan feedback signalen och det förväntade värdet tillbaka till TCS kontrollen är >20%, i mer än 0.5 sec.
- Kablaget till feedbackpotentiometern och EDC kontrollen.
Excitation voltage
Feedback error
Neutral out of range
Error on pump control loop
- Att feedback signalen ändrar sig när man ökar körhastigheten. - Att Min och Max spänningen från feedback potentiometern är konstant, och att värdet är lika varje gång. Spänningen skall stiga till upp emot 5 volt.
Sida 25
