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Service Manual

CBE
2.5
3.0
3.0L
3.5

Cargo Range

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BT Svenska AB
Per Wrmlund

Electric

2,5 - 3,0 - 3,5 t

SERVICE MANUAL

page 3

reserves all rights of reproduction of this handbook

The text and the numbering system may


not be used in other printed matter, reprinted
or translated, whether entirely or in part, without
written authorization from

CESAB reserves the right to make any necessary


modifications without obligation to promptly update
this handbook.

Copyright by
CESAB
CARRELLI ELEVATORI S. p. A.

BOLOGNAS FACTORY, AFTER SALES SERVICE

2,5 - 3,0 - 3,5 t


page 4

SERVICE MANUAL

Electric

MECHANICAL SECTION

DATA SHEET

page 6-7

DRIVERS PLACE

page 8-9

DASHBOARD

page 10-11

TRUCK LOAD CAPACITY

page 12

TRACTION UNIT
Disassemble the reduction unit
Oil change

page 13
page 14
page 15

BRAKES
Service brake system
Service brake function description
Parking brake system

page 16
page 16
page 17
page 18

ELECTRIC MOTORS

page 19

WHEELS/TYRES

page 20

STEERING GROUP
Bearing adjustment
Power steering description and maintenance
Filter and power steering oil
Steering axle

page 21
page 21
page 22
page 22
page 23

LIFTING UNIT
Hydraulic control valves
Hydraulic system diagram

page 24
page 24
page 25

MASTS
Triplex mast section
Mast lubrication and settings

page 26
page 27
page 28-29

MAST LIFTING UNITS


Description of the cylinder component parts
Checking the chains
Checking the forks
Mast tilting setting

page 30
page 31
page 32
page 33
page 33

Electric

SERVICE MANUAL

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page 5

ELECTRICAL SYSTEM
Components Description
Accelerator pedal
Battery and battery charger

page 34
page 34
page 34
page 35

TRUCK LIFTING

page 36

TABLES
Oil and grease specifications
Tyre pressure tightening torques
Running in maintenance table
Maintenance table

page 37
page 37
page 37
page 38
page 39-41

ELECTRICAL SECTION
TECHNICAL FEATURES

page 43

FUNCTIONAL PERFORMANCES
Protection
General precautions

page 44
page 45
page 46

GENERAL DESCRIPTION OF FUNCTION OF THE CONSOLE

page 47

CONSOLE DESCRIPTION

page 48

ELECTRONIC CONTROL PANEL LAYOUT

page 49

POWER CIRCUIT DIAGRAM

page 50

OPERATING CURRENT DIRECTION

page 51-52

INPUT CONNECTION

page 53

TRACTION POTENTIOMETER

page 54

LIFTING POTETNTIOMETER

page 55

PARAMETER CHANGE DESCRIPTION

page 56

TESTER MENU DESCRIPTION

page 57

ALARMS MENU DESCRIPTION

page 58-59

ADJUSTMENTS TABLE

page 60

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page 6

SERVICE MANUAL
Electric

Electric

SERVICE MANUAL

2,5 - 3,0 - 3,5 t


page 7

2,5 - 3,0 - 3,5 t

SERVICE MANUAL

page 8

Electric

PEDALS
FOOT DRIVE DIRECTION
(Standard version)
- Forward direction (D)
- Backward direction (E)
- Service brake pedal (C)
- Parking and emergency brake pedal (A)
- Parking brake release lever (B)
A

DRIVE DIRECTION LEVER ON STEERING


COLUMN (Alternative version)

1
o
2

Direction selector lever (F)


1 Forward direction
0 Neutral
2 Backward direction

Single drive pedal (G)


G

Key (H)
Emergency push button (P)

SERVICE MANUAL

Electric

Battery cover lifting

I
J

Press the lever (J), lift the cover using the appropriate
handle (I); complete lifting is facilitated by the use
of an air spring.
After opening the battery cover, it is possible to
remove the rear compartment cover.

Battery connector (H)


Inside the battery cover

Levers unit

L
K

K) Lifting control lever


L) Tilting control lever
M) Sideshift control lever
N) Device control lever (optional)

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page 9

2,5 - 3,0 - 3,5 t

SERVICE MANUAL

page 10

10

11

12

13

14

15

16

Electric

1) Battery charge indicator


2) Parking brake ON warning light
3) Low brake fluid level warning light
4) Lifting motor temperature warning light
5) Worn lifting motor brushes warning light
6) Worn drive motor brushes
7) Not used
9) Electronic hour meter
10)Drive motor temperature warning light
11)Control valves functions locked due to flat battery (no connected)
12)Dead man device warning light
13)Electronic control unit temperature warning light
14)Drive and lifting diagnostics led (see electrical section)
15)Not used
16)Not used

DASHBOARD CONTROLS
1

1) Battery charge indicator


This consists of 3 green LEDS, 4 orange LEDS and 3 red LEDs,
With battery charged the right green LED becomes on and while
the battery discharges, the LEDS will be separately on from
right side to left side.
When the battery is 80% discharged, the first red LED on the
left begins to flash showing that the battery must be recharged
(reserve). At the same time, the warning light (11) comes ON.
2) Parking brake ON warning light

3) Brake fluid low warning light


4) Lifting motor temperature warning light
lights up when the temperature is 150C
5) Worn lifting motor brushes warning light (see chapter DRIVE
AND LIFTING MOTOR BRUSHES)

10

6) Worn drive motor brushes (see chapter DRIVE AND LIFTING


MOTOR BRUSHES)

9) Electronic hour meter


It is activated by insertion of the ignition key.
It shows the hours and the tenth
10)Drive motor temperature warning light
lights up when the temperature is 150C

Electric

SERVICE MANUAL

11

11) Control valves functions locked due to flat battery (no connected)

12

12)dead man device pilot light


the pilot light comes ON, when the driver leaves the driving seat

13

13)Electronic control unit temperature warning light; it lights


up, when the temperature is 75 C (electrical section)

14

14)Drive and lifting diagnostic led (see electrical section)

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page 11

SERVICE MANUAL

Electric

LOAD PLATE
It identifies the load capacity with a load center
of 500 mm (except for different indications)
ATTACHMENT OR SPECIAL CONDITION OF USE

TYRES

SERIAL N

CENTER OF LOAD DISTANCE mm

LIFT HEIGHT
mm

A
Cod. 0312005

page 12

DERATED CAPACITY Kg

CAPACITY PLATE

IDENTIFICATION PLATE
It identifies the lift truck technical data
MODEL Type

MOTOR

RATED CAPACITY
kW

SERIAL N

kg

DRAW-BAR PULL (1h)


N

BATTERY MASS
kg
min.

MANUFACT. YEAR

SERVICE MASS
Without
Battery kg

kg
max.
TENSION
V

Cod. 0312004

2,5 - 3,0 - 3,5 t

CARRELLI ELEVATORI S.p.A.


via Persicetana vecchia, 10
40132 - Bologna - Italia

CESAB LDT
Bevan Way
Smethwick - Warley
West Midla 1ds B66 1BZ

Electric

SERVICE MANUAL

2,5 - 3,0 - 3,5 t


page 13

2
3

The traction gear unit is consisted of:


1) Right hand reduction gear
2) Oil bath brakes
3) Differential gear
4) Electrical motor
5) Left hand reduction gear

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page 14

SERVICE MANUAL

Electric

7 screws

Disassemble the reduction unit


- Park the lift truck on a level ground. Engage the parking brake and disconnect the battery;
- Disassemble the mast;
- Lift the front part of the lift truck and set the special shims under the side
panels of the chassis;
- Remove the front wheels;
- Disconnect the tie rods of the parking brake, the service brake oil pipe, the
motor cables etc;
- Keep the reduction unit in lifted position;
- Remove the fastening screws located on the chassis (tightening torque setting of 45 daNm).

SERVICE MANUAL

Electric

2,5 - 3,0 - 3,5 t


page 15

OIL CHANGE
Type of oil MOBIL-FLUID 422SAE 80W
or equivalent (see oil table).
After the first 50-100 hours
- change the oil.
Every 250 hours
- remove the front wheels.
Check the oil level, when it is cold.
Every 1.000 hours or 12 months
- change the oil.

E
F

OIL CHANGE
C

INSTRUCTION

- Place the lift truck on a flat floor with the parking brake on.
- Lift the front part of the lift truck and remove the wheels.
- Disconnect the battery connector.
- Changing the oil in the reduction gears.
- Carefully clean the area around the oil filling (E) and draining caps
(F); place a suitable container below the drain cap and then remove
both the filling and the draining caps and allow the oil to drain
out completely.
- Clean any ferrous residues from the magnetic cap (F) and replace
it.
- Pour fresh oil into the hole (E) until it starts overflowing from
(E).
After a short functioning period, check the oil level again.
- The oil quality for each reduction is approximately 1 L.
- Breather (C).

2,5 - 3,0 - 3,5 t

SERVICE MANUAL

page 16

SERVICE BRAKE SYSTEM DIAGRAM

A) Reduction gear (right) and braking unit


B) Parking brake command
C) Bleeding screw
D) Electric drive motor
E) Brake pump
F) Tank
G) Service brake pedal
H) Reduction gear (left)

D
G

SERVICE BRAKE CONTROL


The disk brake is in an oil bath and it acts on
both of the front wheels; the brake uses the same
oil as the drive reduction unit.

OIL BRAKE TANK (F)

OBS! Olja typ SAE 80W i bromssystemet!

Gioco

CHECK SERVICE
BRAKE

Electric

Electric

SERVICE MANUAL

2,5 - 3,0 - 3,5 t


page 17

DISKS AND
COUNTER DISKS
DIFFERENTIAL
BRAKE

BRAKE
COUNTER
DISK

EXTERNAL
BRAKE
DISKS

CENTRAL
BRAKE DISKS

SERVICE
BRAKE
OIL INLET

PARKING BRAKE
LEVER

External brake disks thickness


Central brake counter disk thickness
Max wear on each side
Brake counter disks thickness
Differential brake disk thickness
Differential brake counter disk thickness

2,75 2,85
3,60 3,70
0,45
2,95 3,05
1,57 1,63
1,37 1,43

mm
mm
mm
mm
mm
mm

(n 2)
(n 1)
(n 1)
(n 2)
(n 2)

2,5 - 3,0 - 3,5 t

SERVICE MANUAL

page 18

PARKING BRAKE DIAGRAM

I) Release lever
L) Parking brake pedal
M M)Microswitch
N) Brake block anchor
O) Pedal adjusting screw
P) Release adjusting screw

P
N

PARKING BRAKE CONTROL AND


ADJUSTMENT
Every 500 hours
- Check the clearance shown on the drawing
A with the parking brake pedal released
A
- Check the parking brake stroke which
should correspond to 4 notches ( L pedal).
If it necessary, act on the adjusting screw
(O)
- With the front wheels lifted adjust the cable
so that the same ones at 1st notch are
free, on the contrary, at the 2nd notch
Leva.tif
are blocked.
Rr ej justerskruven p armen!
Press the parking brake pedal some times
Spel med nya lameller = 0,3mm
and check if the clearance is still the same.
Vid ett spel av 5-6mm r
lamellerna utslitna.

PARKING BRAKE RELEASE


INSTRUCTIONS
The dimension of the parking brake is sufficient
to guarantee blocking of the truck, even with nominal
load in the travelling position, on gradients of 22%
as required by the ISO 6292-2 standards.

Electric

SERVICE MANUAL

Electric

MAINTENANCE
Every 500 hours
Every 500 hours

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page 19

check the wear brushes


check the commutator conditions

CBE 2.5-3.0
(Svart drivmotor)
TRACTION MOTOR (Schabmller)
LIFTING MOTOR (Schabmller)
V 80
Kw 15,5
V 80
Kw 14
A 210
Ecc. sep
A 210
Ecc. serie
Rpm/min. 1650
IP 20
Rpm/min. 2150
IP 20
Service S2
Classe IS H
Service S3 18%
Classe IS H
N poles 4
N brushes 8
N poles 4
N brushes 8
Pump

(Silverfrgad drivmotor)

22,5 LiT/min.

CBE 3.0L-3.5

TRACTION MOTOR (Lucci)


V 80
Kw 16
A 230
Ecc. sep
Rpm/min. 1360
IP 20
Service S2
Classe IS H
N poles 4
N brushes 8

LIFTING MOTOR (Leroy somer)


V 80
Kw 17
A 240
Ecc. serie
Rpm/min. 2550
IP 20
Service S3 30%
Classe IS F
N poles 4
N brushes 8
Pump

19 LiT/min.

LENGTH OF ORIGINAL BRUSHES

< 50%

New

TYPE OF MOTOR

L = 40 mm

DRIVE MOTOR BRUSHES

L = 32 mm

LIFTING MOTOR BRUSHES

2,5 - 3,0 - 3,5 t

SERVICE MANUAL

page 20

Electric

STANDARD TYRES

THE SAFETY OF RIMS AND WHEELS FOR FORKLIFT TRUCKS


PNEUMATIC tyres must be replaced when the tread is less than 1.6 mm. SUPERELASTIC
tyres must be replaced when the tread reaches the 60J indicator printed on the side.
Replacement of CUSHION tyres is recommended when they reach a thickness of
20 or 30 mm.

PNEUMATIC TYRES PRESSURES


Front
10 BAR
Rear

CU
CUSHION

10 BAR

SE
SUPERELASTIC

TIGHTENING TORQUE
Driving tyres
19 daNm
Steering tyres
24 daNm

PN
PNEUMATIC

TYRES TYPE

CUSHION
(C)

SUPERELASTIC
(SE)

PNEUMATIC
(PN)
SUPERELASTIC
Twin Tyres

DIMENS.

VERSION

FRONT.

559x229x406

250-300-300L-350

REAR

457x152x308

250-300-300L-350

FRONT

23x9-10
23x10-12

250
300-300L-350

REAR

18x7-8

250-300-300L-350

FRONT.

23x9-10

250

REAR.

18x7-8

250

FRONT

6.50-10

250- 300- 300L-350

Electric

SERVICE MANUAL

2,5 - 3,0 - 3,5 t


page 21

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
4

1
3

2,5 - 3,0 - 3,5 t

SERVICE MANUAL

page 22

STEERING CONTROL
The steering uses the same oil as the lifting by means a priority valve, so that a sufficient
oil flow to the power steering is always assured.
The oil capacity is checked by the Ls signal (load - sersing) coming from the steering
unit and it occurrs so that the oil capacity sent to the power steering is equal to its
actual request.
The exceeding oil is sent to the control valve for other functions.
When the steering wheel is turned the steering unit measures a volume of oil proportional
to the above rotation and sends it into the steering cylinder.
The steering unit returns automatically in it neutral position when the manoeuvre is finished
(see hydraulic diagram page 25).

POWER STEERING SEAL CONTROL AND CLEANING

Every 250 hours


- check the entire system to identify any leak; any
intervention must be carried out without pressure in
the system.
Every 4 000 working hours
- replace hoses (G) connecting the orbitrol device to
the steering jack.
Every 10 000 hours
- replace the hydraulic system tubing.
Power steering pressure setting
The max power steering pressure must be 90 Bar

In order to set the power steering pressure, the following operation are necessary:
1 - Fit a manometer on point (A) of the motor;
2 - In order reach the adjusting screw (B) remove the cap (by allen wrench) positioned
in the upper side of the orbitrol (power steering unit);
- screw in to incroase the pressure
- screw out to decrease the pressure

Electric

2,5 - 3,0 - 3,5 t

SERVICE MANUAL

Electric

page 23

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 80)
End stroke setting (adjustment):
take the cylinder to the internal end stroke, then operate on the special screws putting
them on the spindles. Then screw in the adjusting screws till when you obtain the
desired steering angle B = 80
If any abnormal consumption of the wheel tread is observed, the following controls
should be made:
- check the parallelism of the steered wheels;
- check that the steering angle of the wheels is the same in both directions.
B = 80 Standard
85 Max angle accepted
ANGLE MEASURED BY THE AXLE FRAME TO THE
INTERNAL WHEEL THROUGH A SPECIAL DEVICE
D
E

A=Lnklager
F
D

END STROKE
SETTING SCREW

STEERING AXLE

2,5 - 3,0 - 3,5 t

SERVICE MANUAL

page 24

Electric

HYDRAULIC CONTROL VALVES

Max pressure valve

CBE 2.5-3.0 = 190 bar


CBE 3.0L-3.5 = 210 bar

Max pressure tilting valve 130 BAR

Max pressure sideshift valve 130 BAR

LIFTING EQUIPMENT OIL AND FILTER


B
D

The hydraulic lift oil tank is located under the platform.


The filter cartridge (D) (15 ) is beneath the screw cap (B).
After the first 50 hours of work
- first filter change
After the first 500 hours of work
- second filter change.
Every 250 hours
- check the level of oil in the tank using the dipstick (A);
- check and clean the tank breather valve filter (C).
Every 2 000 hours
- replace the oil and the filter.
To change the oil and the filter:
- remove the filling cap (B), extract the filter;
- remove the drain cap (E); drain out all the oil into an appropriate
container then replace the drain cap and tighten firmly;
- fit a new filter (D) after checking the state of the seals;
- Fill the tank with approx. 35 liters oil through
the filter until the dipstick notch (max level).

Lyft

Tilt

Sideshift

Electric

Styrcylinder

A
B

Prioriteringsventil

SERVICE MANUAL

HYDRAULIC DIAGRAM

A=Slangbrottsventiler
B=Snkbromsventil
C=Tiltls

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page 25

2,5 - 3,0 - 3,5 t

SERVICE MANUAL

page 26

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:
VT 2 side cylinders
FFL 2 central cylinders (with displacement cylinders)
1 short central cylinder
Triplex mast

VT 2 side cylinders
FFL 2 side cylinders
1 short central cylinder

Grease nipple

Adjusting screw

Shoe

Roller

Electric

Electric

SERVICE MANUAL

TRIPLE MAST SECTION

Fork carriage

Internal
section bar

Intermediate
section bar

External
section bar

2,5 - 3,0 - 3,5 t


page 27

2,5 - 3,0 - 3,5 t

SERVICE MANUAL

page 28

LUBRICATION OF LIFTING EQUIPMENT


D

Masts
After the first 50 hours
- adjust the guide shoes adjusting the Allen screw
(D)
For the adjustment use a 0.2-0.5 mm thickness
gauge, inserted from below and up to the centre
of the Allen screw (D) passing behind the roller
(E).
Every 50-100 hours
- lubricate with grease the mast sliding guides
- lubricate the tilting jacks and the mast connections.
A) Tilting jacks
2+2 grease nipples
B) Mast connections 1+1 grease nipples

Every 250 hours


- adjust the guide shoes;
- grease the mast guide rollers (E)
Every 2 000 hours
- check the condition of the guide rollers (E);
they must turn freely without jamming and not
show excessive wear.

F
G

Fork carriage and sideshift unit


After the first 50 hours
- adjust the guide shoes adjusting the Allen screw
(G)
For the adjustment use a 0.2-0.5 mm thickness
gauge, inserted from below and up to the centre
of the Allen screw (G) passing behind the roller
(H).
Every 50 hours
- lubricate the sideshift guides with with grease
through the grease nipples.
Every 250 hours
- lubricate the fork positioning pins and notches
with grease.
- grease the fork carriage guide rollers (F)
- adjust the guide shoes
Every 2 000 hours
- check the condition of the guide rollers; they
must turn freely without jamming and not show
excessive wear.

Electric

SERVICE MANUAL

Electric

C) Sideshift unit
(upper part)
3 grease nipples
(lower part)
without grease nipplesexcessive wear.

Make sure that:


C

- the lifting chain stay bolts are free of defects


and that the adjusting nuts are locked by the
appropriate cotter pins (A);
- the fork carriage (B) safety end stops are present
and tightly fixed.

- the collars (C) are present and tightly fixed.

Every 500 hours


- check that there is a clearance (D); of 0.5 to
3 mm between the collar and external lifting
jack cylinder.
- check that there self-lockin nuts (E) are tight.
Locking torques:
- collar self-locking nuts 0.8-1.2 daNm

A
B

SAFETY FORK CARRIAGE END STOP


The lifting unit is equipped with a mechanical safety
end stop, to avoid the accidental escape of the
fork carriage from the botton of the mast.
The end stops (A) consists of two Allen bolts. To
remove the fork carriage, first of all unscrew the
end stops.

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page 29

2,5 - 3,0 - 3,5 t


page 30

SERVICE MANUAL

DESCRIPTION OF THE CYLINDER COMPONENTS


The cylinder pistons are single-acting types (fig. A).

6
5
4
7

THRUST
DIAMETER

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).

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

Electric

Electric

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 1st inspection has been
successful and after seal replacement).
Remove the drain pipe from the cylinder.
Lift the cylinder some times to end stroke, so that all
the possible remaining oil is discharged.
Put a load on the forks. Lift and lower it for 10 minutes,
making sure that the limit stop is never reached.
Lift the cylinder to end stroke.
If any leakages should be still present, the cylinder is
damaged and then it must be replaced.

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page 31

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page 32

SERVICE MANUAL

Electric

CHECKING THE CHAINS:


Every 500 hours
- check the condition of the chains which in any case must not be worn or damaged.
To check the links for wear, use the appropriate gauge, paying attention that, when
33 links are counted in a space corresponding to 34, the chains must be replaced.
Every 1 000 hours
- remove the chains, clean them thoroughly, refit them inverting the original working
position and lubricate them.
Every 10 000 hours
- replace the chains and the fixing tie rods

POSITIONING THE FORK MOUNTING CARRIAGE


Every 500 hours
- After testing the chains as described above, with the truck on an even surface and
the mast in a vertical position, check the position of the fork carriage plate, as follows:
- remove the forks, completely lower the fork carriage and measure the height (X),
comparing it with the value shown in the table, correspondig to the capacity in kg
of the truck.
(e.g. the correct value of (X) for a truck with a capacity of 2000 kg (class II B),
must be 152 5 mm).

TABLE ISO 2328 - 1993

Rate

X = 203 mm

Lifting power (kg) "X" ( 5)

IB

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

SERVICE MANUAL

Electric

Inspection
Fork arm inspection must be carefully carried out by
trained personnel to detect any damage, failure, deformation,
etc., which may impair safety use.

F
D

page 33

FORK INSPECTIONS
General criteria
Fork arms in use must be inspected at intervals of not
more than 1 000 hours and whenever a defect or permanent
deformation is detected. If the truck is subject to intensive
use, more frequent inspections may be required.

G
E

2,5 - 3,0 - 3,5 t

Surface cracks
The fork arm must be thoroughly examined visually for cracks
giving special attention to the heel (D) and top (E) and bottom
(F) hooks.
If necessary, the forks may be subjected to a non-destructive
crack detection process
Difference in height of fork tips
Check the difference in height between the blade tips on each
pair of forks, this must not be more than 3% of blade length
with the forks fitted on the fork plate.
Positioning lock
Check that the fork positioning lock (G) is in good working
order.

MAST GROUP TILTING SETTING


230 FORWARD
10 BACKWARD
8

STANDARD
2M VT
3M FFL
3M VT - 2M FFL

Check to carry out every 500 h


N.B. 1 tilting degree corresponds to a 17.4 mm
movement on 1 mt.

2,5 - 3,0 - 3,5 t


page 34

SERVICE MANUAL

Electric

COMPONENTS DESCRIPTION
E

D) Traction and lifting module


F) Panel cooling fan
I) Fuses

E) Contactor
G) Air conveior
L) Converter 80/24 (120W standard)
ACCELERATOR PEDAL
Set the potentiometer
Position the tester set in OHM between the green
and the red wire.
Set the potentiometer
from 12 to 12.5 KOHM (pedal released)
from 7 to 7.5 KOHM (pedal pressed)

180 mm

Height adjustment screw

SERVICE MANUAL

Electric

BATTERY AND BATTERY CHARGER


General indications for battery maintenance
Every 50 working hours - measure electrolyte density.
Approximate density data
For a temperature of 15 C
- a density of 1.12 to 1.13 kg/dm3 indicates that the battery is flat;
- a density of 1.25 to 1.26 kg/dm3 indicates that the battery is charged (battery capacity
increased: 1.29 to 1.30 kg/dm3).

BATTERY CHARGING WARNINGS


Before charging the battery, verify that the room is well aerated. Open the battery compartment door.
Make sure that all electrical connections (electrical cable terminals, battery terminals, plugssockets, etc.) are well attached and in good condition.
- Do not open either remove battery filling caps.
- Never top up before and while charging the battery.
- Do not smoke, do not stay close to naked flames and do not cause sparks next to
batteries
- Do not use the battery while it is being charged
- Do not lean metal tools on the battery while under charge
- Never repair the battery while under charge
- Check that during the charging phase, the electrolyte temperature is kept below
50C.

BATTERY WEIGHTS AND CAPACITY

STANDARD
BATTERY WEIGHT

STANDARD 80V
BATTERY CAPACITY

CBE 2.5

1 547 kg

500-640 Ah

CBE 3.0

1 547 kg

500-640 Ah

CBE 3.0L-3.5

1872 kg

625-800 Ah

2,5 - 3,0 - 3,5 t


page 35

2,5 - 3,0 - 3,5 t

SERVICE MANUAL

page 36

Electric

HOOKS ATTACHMENT POINTS FOR LIFTING


THE TRUCK
B

To lift the truck the following equipment must be used:


A- CHAINS: dia. 10 mm - Degree T (8) - UNI 9425
B- HOOKS: for 3,2 t - UNI/ISO 7597

- 45

LIFTING OF THE FORKLIFT TRUCK WITH CABIN


A- CHAINS: dia. 10 mm - Degree T (8) - UNI 9425

B- HOOKS: for 3,2 t - UNI/ISO 7597


C- N 2 upper brackets to hold the chains.

SERVICE MANUAL

Electric

OIL AND GREASE SPECIFICATIONS


TIPO USATO
TYPE USED
TYP

SPECIFICHE
SPECIFICATIONS
EIGENSCHAFTEN

AGIP ARNICA 46

ISO - L - HV
Prove FZG
fino a stadio 11 (*)

MOBIL-FLUID 422
SAE 80 W

API GL4
MIL-L-2105D
+additivo per freni a
bagno dolio (***)

MOBILGREASE SPECIAL

Base LITIO
ASTM 275 305
NLGI N.2
Gocciolamento
180 (**)

Q.T
QTY.
MENGE

FOR NORMAL ENVIRONMENTS


PARTS TO BE LUBRICATED

30 L

Hydraulic system, lifting and power steering

1 L
+
1 L

Transmission reduction gears

Hydraulic brake system tank

Mast securing joints - Sideshift unit - Steering joint


- General lubrication with grease nipples

(*) ISO-L-HV FZG tests to stage 11 / ISO-L-HV FZG-Pr fung bis


Stufe 11
(**) Lithium base ASTM 275-305 NLGI Nr.2 Dropping point 180
Lithiumbasis ASTM 275 305 NLGI Nr.2 Tropfpunkt 180
(***) add brake additive to oil bath / Zus tze f r lbad-Bremsen
zuf gen

TYRE PRESSURES TIGHTENING TORQUES


PNEUMATIC TYRE PRESSURES
10

bar

FRONT Tyres

10

bar

REAR Tyres

WHEEL TORQUE
24 daNm

Steered wheels

19 daNm

Driven wheels

DRIVE UNIT TORQUE


8 daNm

securing of electric motor to the reduction


gears

45 daNm

securing of axles to the chassis

31 daNm

wheel hub central screw

11 daNm

reduction gear tank screws

8 daNm

Oil filling and draining cap

VARIOUS TORQUES
40 daNm
0,8 1,2 daNm
30 daNm

mast securing U-bolts


Jack collar self-locking nuts
Counterweight locking screws

2,5 - 3,0 - 3,5 t


page 37

2,5 - 3,0 - 3,5 t

SERVICE MANUAL

page 38

RUNNING IN MAINTENANCE
50

500

# at # hours for MEDIUM/INTENSE USE

7/-

-/3

at # days/months FOR OCCASIONAL


USE
LIFTING UNIT - MASTS

mast guide pads

 

lifting oil filter

TRANSMISSION REDUCTION GEARS

transmission reduction gear oil

HYDROGUIDE

filter change

CHASSIS AND COMMANDS




bolts in general

wheel tightness (1)

(1) During the first 500 working hours, check


tightness every 50 hours.
LEGENDA

In the maintenance table indicating a visual control


cleaning of the parts indicated.
and

In the maintenance table indicating the


of the parts indicated.
 replacement
table indicating lubrication
parts indicated.
ofIn thethemaintenance

 or adjustment of the parts indicated.

In the maintenance table indicating tightening

Electric

Totaldokument
BT Cargo CBE 25-35
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
0:10

3:0
3:1
3:2
3:3
3:4
3:5
3:6
3:7

Grupp 3 Bromsar/hjul
Dck/hjul
Lufttryck dck
Hjulbultar/hjullager
Frdbroms, funktion/lckage
Parkeringsbroms
Bromsvtskeniv
Pedallnkage/pedalspel

4:0
4:1
4:2
4:3

Grupp 4 Styrning
Styrleder/Styrspindlar
Styrcylinder, faststtning
Styrlagring/upphngning

5:9
5:10
5:11
5:12
5:13
5:14
5:15
5:16
5:17
5:18

Acc. pedal/fartreglage
Microbrytare
Kontaktorer/kontakter
Skringar
Batterivtskeniv
Batteri, smuts/lckage
Batterianslutningar
Batteripoler reng./infettning
Batterihandskar, kontroll
Kylflktar, kontroll

0:11

Grupp 0 Hel maskin


Drrar/luckor
Motviktsinfstning
Frarskydd/hytt
Batterilsning
Skyltar/dekaler
Frarmilj
Stol/mattor
Pedalgummin
Torkare/spolare
Provkrning test av
samtliga funktioner
Smrjning enligt schema

1:0
1:1
1:2

Grupp 1 Motorer
Missljud
Faststtning/infstning
Grupp 2 Kraftverfring
Oljeniv
Faststtning

Grupp 5 Elsystem
Belysning/krriktningsvisare
Instrument/kontrollampor
Signalhorn
P-broms-/Backalarm
Timmtare, avlsning
Frdvljare/lnkage
Kablar/anslutningar
Startfrekvens

Grupp 6 Hydraulik
Slangar/rr
Ventilreglage/lnkage
Andningsfilter/ventilatorer
Oljeniv

2:0
2:1
2:2

5:0
5:1
5:2
5:3
5:4
5:5
5:6
5:7
5:8

6:0
6:1
6:2
6:3
6:4
7:0
7:1
7:2
7:3
7:4
7:5

Grupp 7 Arbetsfunktion
Lyftstativ
Gafflar
Lyftkedjor
Laststd
Lyft-/tiltcylindrar

Var 500:e timme tillkommer:


0:0
Grupp 0 Hel maskin
0:12 Bultar/Muttrar, faststtning

Var 1000:e timme tillkommer:


2:0
Grupp 2 Kraftverfring
2:3
Drivaxel, oljebyte

Var 2000:e timme tillkommer:


0:0
Grupp 0 Hel maskin
0:13 Ram, kontroll av sprickor

1:0
1:3
1:4
1:5
1:6
1:7

Grupp 1 Motorer
Drivmotor, renblsning
Drivmotorkol, kontroll
Pumpmotorkol, kontroll
Pumpmotor, renblsning
Motorer, isolationsprov

3:0
3:8
3:9

Grupp 3 Bromsar/hjul
Hjullager infettning
Bromsvtska byte

1:0
1:8

Grupp 1 Motorer
Kolfjdrar, styrka

6:0
6:5

Grupp 6 Hydraulik
Andningsfilter, reng./byte

4:0
4:4
4:5

Grupp 4 Styrning
Slangar, kontroll
Styrtryck, kontroll

5:0
5:19

Grupp 5 Elsystem
Batteri, isolationsprov

5:0
5:20
5:21

Grupp 5 Elsystem
Batteribelastningsprov
Motorstrm, mtning

6:0
6:6
6:7
6:8

Grupp 6 Hydraulik
Hydraultryck, kontroll
Hydraulolja, byte
Sugfilter, rengring/byte

7:0
7:6

Grupp 7 Arbetsfunktion
Gafflar, gaffeltest

Sida 2

CBE 12-50
Chassie/hel maskin

SERVICE MANUAL
Electrical section

Electric

SERVICE MANUAL
TECHNICAL FEATURES

ELECTRONIC PANEL - COMBI SEM 3


Tension

80 V

Field max. current

50 A

Armature max current

500 A

Pump max current

500 A

Armature working frequency

16 KHz

Field working frequency

1 KHz

Pump working frequency

16 KHz

Working ambient temperature

-30C / +40C

Max. attainable temperature


from chopper body

85C

2,5 - 3,0 - 3,5 t


page 43

2,5 - 3,0 - 3,5 t


page 44

SERVICE MANUAL

FUNCTIONAL PERFORMANCES
- Very good control at low speed.
- Reduction of the max. speed: max. speed in both directions can be set by using the
programming console.
- Regenerative braking based on deceleration ramps, on release, on reversal and on
partial accelerator release.
- Speed check down a slope: the motor speed follows the accelerator pedal automatically
setting the regenerative braking, in case the motor speed exceeds the desired one.
- Up start without roll-back also without use of an electric brake (electrobrake).
- Anti rolldown function; key On chopper checks the traction motor speed; in case it
is moving, without direction request from the operator, it carries out automatically
a braking and checks the down a slope by very low speed (function useful for safety
also without truck driver on).
- In the pump section the selected lower speed prevails.
- Diagnostic with indication by means of led.
- Able to be formed via console.
- Internal timer visible from the console.
- Storage of the last 5 alarms with the relative value of the timer and temperature
visible from the console.
- Tester by means of the console to verify in real time of the main parameters, such as
input, motor voltage, battery.
- Arc less operation of the remote control switches.
- Internal coil suppressor (within logic).
- High efficiency of motor and battery due to high frequency switching.

Electric

Electric

SERVICE MANUAL

2,5 - 3,0 - 3,5 t


page 45

PROTECTIONS
- Battery reversal:
It is important to observe the connections shown in order to prevent damage.
The logic is internally protected from reverse battery polarity.
- Connection errors:
All inputs are protected against incorrect connections.
The remote control switches have a rating of 2Amps, however they are protected from overload and short
circuits.
- Thermal protection:
When the temperature is more than 75 C the maximum current is reduced in proportion to the increase in
temperature. The temperature can never exceed 85 C.
- Discharged battery:
When the battery is discharged the lifting speed is reduced by 60%. The other function remain unchanged.
- External agents:
The chopper is protected from the dust and from the liquids spray is completely sealed.
- Safety from accidental operation:
Starting the machine, requires a precise sequence of operations otherwise the machine will not start. The start
sequence has to be initiated after the key and the micro seat are active.
- Safety from uncontrolled movements:
The remote control switches remain open if:
-

The power is not in use.


The accelerator voltage does not fall below (minimum memorized value 2 volt).
The logic is not in perfect order.
A direction microswitch is ever closed.

2,5 - 3,0 - 3,5 t


page 46

SERVICE MANUAL

GENERAL PRECAUTIONS
- Do not connect the chopper to a battery with a nominal voltage different to the voltage stated
from the one on the unit plate. If the battery voltage is higher it may cause the MOS failure.
If the battery voltage is lower, the unit will not run .
- During the battery recharging no units must be connected to the battery as, the unit can be
damaged by the overvoltages generated by the charge-battery.
- Supply the unit only with traction battery, do not use rectifier outputs or power supplies.
- With key switched off, the filter capacitors could remain charged for some minutes. To work
in safety working conditions, we suggest you as follows
.

disconnect the battery with the key on and wait till when the display is
completely off;
or

. short circuit the capacitors through a resistor (56 Ohm 1W) across B+ and Bchopper power connections.
- Before carrying out any arc-welding on the trucks, disconnect the battery and short-circuit
the unit between positive (+) and negative (-).

Electric

Electric

SERVICE MANUAL

GENERAL DESCRIPTION OF FUNCTION OF THE CONSOLE


HOUR METER
The hour meter appears in the second line of the display when the chopper is connected. The
hour meter has a sensitivity of one minute and a full scale value of 65,535hours . It shows the
hours only.
ALARM DISPLAY
The console features the possibility to read the last five alarm messages stored in the chopper
and displayed together with the time of occurrence, the number of times the alarm was sent and
the temperature value at the time of the alarm.
PARAMETER PROGRAMMING
The chopper parameters can be displayed and programmed via the keyboard, in real time and
with operating machine, thereby making it possible to set the chopper easily.
TESTER
It makes it possible to display the state of the chopper analogue and digital values and thereby
to have a useful tool for the analysis of chopper operation and external cables.
SAVE
It makes it possible to store all values relating to the parameters and the chopper hardware
configuration into the console with a program which can be selected from the keyboard.
RESTORE
It makes it possible to program a chopper with the parameters contained in a program
generated by a SAVE.
ACCELERATOR MAX. STROKE PROGRAMMING
It allows to program the accelerator max. stroke.

2,5 - 3,0 - 3,5 t


page 47

2,5 - 3,0 - 3,5 t


page 48

SERVICE MANUAL

Electric

CONSOLE DESCRIPTION
KEYBOARD
Description of key functions:

ROLL 1

= Allows selection of an option or the next menu item

ROLL 2

= Allows select of an option or the previous menu item

ENTER

= Allow confirmation of selected options

OUT

= Retains the current function

PARAM

= Allows an increase in the parameters or selects the type of connected I/O

SET

= Allows a reduction in the parameters or selects the type of connected I/O

Electric

Remouve the plastic cap


and connect the console

F1

F6
F5
F4

C
F0

A=Anslutningsplint A p panelen

B=Anslutningsplint B p panelen
C=Anslutning fr fltlindningen

5 A
2 A
20 A

F4) horn fuse


F5) electrofan fuse
F6) reverse and stop light fuse

5 A
3 A
5 A

page 49

D=Backljusrel

2,5 - 3,0 - 3,5 t

Poewr fuse
F0) traction and lifting motors fuse 500 A
Auxiliary fuses
F1) key fuse
F2) contactors fuse
F3) converter 80/24 fuse

SERVICE MANUAL

F3

ELECTRONIC PANEL LAY-OUT

F2

2,5 - 3,0 - 3,5 t


page 50

SERVICE MANUAL

PUMP
MOTOR

POWER CIRCUIT DIAGRAM

TRACTION MOTOR

Electric

Electric

SERVICE MANUAL
OPERATING CURRENT DIRECTION

FORWARD DIRECTION

FORWARD DIRECTION BRAKING

2,5 - 3,0 - 3,5 t


page 51

2,5 - 3,0 - 3,5 t


page 52

SERVICE MANUAL

BACKWARD DIRECTION

BACKWARD DIRECTION BRAKING

Electric

Electric

SERVICE MANUAL

2,5 - 3,0 - 3,5 t


page 53

INPUT CONNECTION

KEY
key

Key switch (+VB)

cm
rev
forw

=
=
=

Common switch (+VB)


Backward switch
Forward switch

seat
hb

=
=

Seat switch
Parking brake switch

plc
nlc
pb

=
=
=

Main contactor positive


Main contactor negative
Brake switch

acc. pot .
1 st speed

=
=

Traction potentiometer
Tilting switch

2 nd speed
3 rd speed
lift

=
=
=

Sideshift switch
4 Th lever switch
Lifting switch

4 th speed
lift pot
lcc

=
=
=

5 Th lever switch
Lifting potentiometer
Main contactor

led

Diagnostic led

2,5 - 3,0 - 3,5 t

SERVICE MANUAL

page 54

TRACTION POTENTIOMETER

Green

111

5KOhm
7KOhm

109

Red

Yello

)
)

110

By the console on TESTER menu select, ACCELERATOR function:


Accelerator pedal released

~ 0,6 0,8 Volt

Accelerator pedal pressed

~ 7,5 7,7 Volt

Verified these values, carry out the PROGRAM VACC function to acquire the
traction potentiometer signals (see attached diagram for using the console).

Electric

SERVICE MANUAL

Electric

LIFTING POTENTIOMETER

137

5 KOhm

135
136

By the console on TESTER menu select, LIFTING CONTROL


Lifting lever at rest - 0 Volt
Lifting lever pulled ~ 4.5 Volt
Verified these values, carry out the SET PUMP ACC MIN e MAX function to acquire the
lifting potentiomer signal (see attached diagram data acquisition lifting potentiometer).

2,5 - 3,0 - 3,5 t


page 55

2,5 - 3,0 - 3,5 t


page 56

SERVICE MANUAL

Electric

PARAMETER CHANGE DESCRIPTION


(t) means traction (p) means pump
ACCELER. DELAY (t)
=
DECELER DELAY (t)
=
RELEASE BRAKING (t) =
PEDAL BRAKING (t)
=
INVERS BRAKING (t)
=
CUTBACK SPEED (t)
=
MAX SPEED FORW (t)
=
MAX SPEED BACK (t)
=
TRACTION I MAX (t)
=
ARMA. NOM. CURR. (t) =
WEAK DROPOUT (t) =
FIELD NOM. CURR. (t) =
CREEP SPEED (t)
=
SEAT MICRO DELAY
=
SPEED LIMIT (p)
=
PUMP I MAX (p)
=
PU. ACCELER DELAY (p) =
PU. DECELER DELAY (p) =
PUMP CREEP (p)
=
COMPENSATION (p)
=
1ST SPEED COARSE (p) =
1ST SPEED FINE (p)
=
1ST SPEED COMP (p)
=
2ND SPEED COARSE (p) =
2ND SPEED FINE (p)
=
2ND SPEED COMP (p)
=
3RD SPEED COARSE (p) =
3RD SPEED FINE (p)
=
3RD SPEED COMP (p)
=
4TH SPEED COARSE (p) =
4TH SPEED FINE (p)
=
4TH SPEED COMP (p)
=
HYD SPEED COARSE (p) =
HYD SPEED FINE (p)
=
HYD SPEED COMP (p)
=
HYDRO TIME (p)
=

Traction motor acceleration time


Traction motor deceleration time
Braking current by releasing the accelerator
Braking current with pressed braking pedal
Braking current on inversion
Max speed reducton with input on
Forward max speed
Backward max speed
Traction max current
Armature nominal current
Weakening threshold current
Field nominal current OBS! Viktigt att se upp med typ av drivmotor!
Min. acceleration threshold
Seat microsiwtch delay
Lifting max speed
Lifting max current
Motor pump acceleration delay
Motor pump deceleration delay
Min. lifting acceleration threshold
Lifting speed compensation
Tilting speed, coarse adjustment + 10%
Tilting speed, fine adjustement + 1%
Tilting speed compensation
Sideshift speed, coarse adjustment + 10%
Sideshift speed, fine adjustment + 1%
Sideshift speed compensation
4th way speed, coarse adjustment + 10%
4th way speed, fine adjustment + 1%
4th way speed compensation
5th way speed, coarse adjustment + 10%
5th way speed, fine adjustment + 1%
5th way speed compensation
Power steering speed, coarse adjust. + 10%
Power steering speed, fine adjust. + 1%
Power steering speed compensation
Power steering time

Electric

SERVICE MANUAL
TESTER MENU DESCRIPTION

BATTERY VOLTAGE
TR MOTOR VOLTAGE
PU MOTOR VOLTAGE
TRAC. CURRENT
PUMP CURRENT
FIELD VOLTAGE
FIELD CURRENT
TR CHOPPER TEMP
PU CHOPPER TEMP
ACCELERATOR
LIFTING CONTROL
ENABLE SWITCH
SEAT SWITCH
FORWARD SWITCH
BACKWARD SWITCH
BRAKE SWITCH
HAND BRAKE
CUTBACK SPEED
1ST SPEED SWITCH
2ST SPEED SWITCH
3ST SPEED SWITCH
4TH SPEED SWITCH
LIFTING SPEED
BATTERY CHARGE

battery tension value


traction motor tension (armature)
pump motor tension
traction motor current (armature)
pump mototr current
traction motor field tension
traction motor field current
traction chopper temperature
pump chopper temperature
traction potentiometer value (tensione and percentage)
lifting potentiometer value (tensione and percentage)
not used (must be connected to + BV)
seat microswitch
ON/+VB=input on
OFF/GND=input off
forward microswitch
ON/+VB=input on
OFF/GND=input off
backward microswitch
ON/+VB=input on
OFF/GND=input off
brake microswitch
ON/+VB=input on
OFF/GND=input off
parking brake switch
ON/+VB=input on
OFF/GND=input off
traction speed reduction switch
ON/+VB=input on
OFF/GND=input off
tilting microswitch
ON/+VB=input on
OFF/GND=input off
side-shift microswitch
ON/+VB=input on
OFF/GND=input off
4 way microswitch
ON/+VB=input on
OFF/GND=input off
5 way microswitch
ON/+VB=input on
OFF/GND=input off
lifting microswitch
ON/+VB=input on
OFF/GND=input off
battery charge value (percentage)

2,5 - 3,0 - 3,5 t


page 57

2,5 - 3,0 - 3,5 t


page 58

SERVICE MANUAL

Electric

ALARM MENU DESCRIPTION


ALARMS DESCRIPTION OF THE DIAGNOSTIC LED
PLACED ON THE DASHBOARD AND THE CONSOLE
1 FLASH

2 FLASHES =

SYSTEM CHECK KO, EEPROM KO - Replace the complete unit.


INCORRECT START - Incorrect sequence by starting; check:
-Logic unit.

3 FLASHES =

CAPACITOR CHARGE - Replace the complete unit.


VMN NOT OK, V FIELD NOT OK - Check:
-Traction motor connection, isolation and cables.
-Logic unit.
PUMP VMN LOW- check:
-Lifting motor connection, isolation and cables.
-Logic unit.

4 FLASHES =

VACC NOT OK, PEDAL WIRE NOT OK - check:


-Traction potentiometer connection and relevant wires.
-Potentiometer damaged.
-Carry out the function PROGRAM VACC
PUMP VACC NOT OK - Check:
-Lifting potentiometer connection and relevant wires.
-Potentiometer damaged.
-Carry out the function SET PUMP ACC MIN on the ADJUSTMENT menu.

5 FLASHES =

STBY I HIGH, I= 0 EVER, HIGH FIELD CURRENT,


PUMP STBY I HIGH, PUMP I= 0 EVER - Replace the complete unit.
NO FIELD CURRENT - Check :
-Field traction motor cables connection.
-Logic unit.

6 FLASHES =

DRIVER SHORTED, COIL SHORTED, CONTACTOR DRIVE, CONTACTOR


CLOSED - Check:
-Main contactor stuck
-Contactor coils and relevant wires.
-Logic unit.
LOGIC FAILURE - Replace the complete unit.

Electric

SERVICE MANUAL

2,5 - 3,0 - 3,5 t


page 59

7 FLASHES =

TH.PROTECTION, PUMP TEMPERATURE - The unit temperature of (traction


system or lifting sistem) exceeds 75. If the alarm occurrs in cold conditions, replace
the complete unit.

8 FLASHES =

HAND BRAKE - Check:


-Parking brake microswitch and wires.
-Logic unit.

CONTINUOUS FLASHING = BATTERY LOW - Charge the battery.


FIX LED ON =

FORW+BACK - Double running requests. Check:


-Direction microswitches and wires.
-Logic unit.

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

Code 036 2002-0

GB

Issue 08/1999

CONSOLE MAP

DIAGRAM FOR USING THE CONSOLE-COMBI SEM 3


Manufacturer's name
CBE 2,5 - 3,5
CESAB

Press ENTER to select


the main menu

Model/configuration and
program version of the unit

COMBI SEM 3 CE 1.07


80V 500A 00000

Tension/power and
hour meter value

Press ROLL
to change the
parameters

Press
ROLL

SEAT SWITCH
FORWARD SWITCH
BACKWARD SWITCH
BRAKE SWITCH
HAND BRAKE
CUTBACK SPEED
1ST SPEED SWITCH
2ST SPEED SWITCH
3ST SPEED SWITCH
4TH SPEED SWITCH
LIFTING SPEED
BATTERY CHARGE

Use

PARAM

SET
to c hange
the values

Press
OUT

Program number
Program version stored

YES=ENTER

NO=OUT

Press ENTER

READING...

RUN ALL PARAMETERS

OVERWRITE DATA?

Press
OUT

RUN ALL PARAMETERS

(seat microswitch)
ON/OFF
(forward microswitch)ON/OFF
(backward microswitch)ONOFF
(brake microswitch) ON/OFF
(parking brake switch)ON/OFF
(speed reduction switch)ONOFF
(tilting microswitch) ON/OFF
(side-shift microswitch)ON/OFF
(4 way microswitch) ON/OFF
(5 way microswitch) ON/OFF
(lifting microswitch) ON/OFF
(battery charge)
%

Select the requested program from 1 to 31 where you


save the setting values by using ROLL

SELECT. Mod.00
FREE / COMBI SEM 3
Confirm ENTER

READING...

LIFTING
SPEED LIMIT
3RD SPEED COARSE
PUMP I MAX
3RD SPEED FINE
PU. ACCELER. DELAY 3RD SPEED COMP.
PU. DECELER DELAY 4TH SPEED COARSE
PUMP CREEP
4TH SPEED FINE
COMPENSATION
4TH SPEED COMP.
1ST SPEED COARSE HYD. SPEED COARSE
1ST SPEED FINE
HYD. SPEED FINE
1ST SPEED COMP.
HYD. SPEED COMP.
2ND SPEED COARSE HYDRO TIME
2ND SPEED FINE
2ND SPEED COMP.

BATTERY VOLTAGE (battery tension)


Volt
TR MOTOR VOLTAGE (trac. motor tension) Volt
PU MOTOR VOLTAGE (pump motor tension)Volt
TRAC. CURRENT
(trac. motor current) A m p
PUMP CURRENT
(pump mototr current)A m p
FIELD VOLTAGE
(field tension)
Volt
FIELD CURRENT
(field current)
Amp
TR CHOPPER TEMP (trac. chopper temp.) C
PU CHOPPER TEMP (pump chopper temp.)C
ACCELERATOR
(traction potentiometer)V - %
LIFTING CONTROL (lifting potentiometer) V - %
ENABLE SWITCH
(enable micoswitch) OFF

Press ENTER to select the function to


acquire on the console all the setting/
configuration parameters of the
module

Press
ROLL

Press OUT to
return to the

main menu

TRACTION
ACCELER. DELAY
DECEL. DELAY
RELEASE BRAKING
PEDAL BRAKING
INVERS. BRAKING
CUT BACK SPEED
MAX SPEED FORW
MAX SPEED BACK
TRACTION I MAX
ARMA. NOM. CURR.
WEAK DROPOUT
FIELD NOM. CURR.
CREEP SPEED
SEAT MICRO DELAY

Press ENTER to select


the function of electrical
device control

MAIN MENU
SAVE PARAM.

Press
OUT

Press
ROLL

values

MAIN MENU
TESTER

MAIN MENU

PARAMETER CHANGE
Press ENTER to select setting
Press
ROLL
to change
the functions

ARE YOU SURE?


YES=ENTER NO=OUT

CONNECTED TO:
COMBI SEM 3 CE 1.07

Connection moment
between console and
COMBI SEM

Description which appearsonly when


some values are modified

Console program version

CONSOLE V.1.0

Display Console

1-CONNECT THE CONSOLE TO MODULE COMI SEM


2-TURN THE KEY ON

Press ENTER to select the function to


RESTORE the parameters on the
module saved on the console by a
SAVE function

If NO press OUT

ARE YOU SURE?

Select the requested program from 1 to 31 where you save


the setting values by using ROLL
If YES press
ENTER

YES=ENTER NO=OUT

NONE
00000h #00 0C

No alarms
stored

( PRESS OUT )

OUT

MAIN MENU
STEER TABLE

Function not
used

YES=ENTER NO=OUT

ENTER

ARE YOU SURE?

Press ENTER if you want


to modify this value

VACC SETTINGS
0.0
10.0

Max. Value

ENTER

YES=ENTER NO=OUT

OUT

ARE YOU SURE?

If NO press OUT

Press OUT

Min. Value

If YES press ENTER

CLEAR LOGBOOK

Press OUT

MIN
0.0

VACC
--

MAX
0.0

Press the acceleration


pedal slowly until the
max. stroke

Press ENTER to select the


function to acquire the
potentiometer signals

MAIN MENU
PROGRAM VACC

Press
ROLL

OUT

MAX 5 alarms stored

LOGBOOK CLEARED

RUN ALL PARAMETERS

OUT

V ACC NOT OK
23h 2 25 C

Press
ROLL

HOUR METER
N ALARMS
TEMPERATURE

Press ENTER to select


the function to read the
stored alarms

STORING...

Alarm code

Program number
Program version stored

MAIN MENU
ALARM

SELECT: Mod.00
H2 REGENER

Confirm with
ENTER

Press
ROLL

MAIN MENU
RESTORE PARAM.

YES=ENTER NO=OUT

Press OUT

MIN
0.0

PED.FORW
PED.BACK

MAX
10.0

JUNE 1999

A=Stesbrytare+Fram/Back pverkade

CBE 2,5 - 3,5

DIAGRAM FOR USING THE CONSOLE


Function -AUXILIARY TIMEReach the function ALARMS from the main menu
MAIN MENU
ALARMS

V ACC NOT OK
23h 2 25 C

Press
ENTER

Press PARAM
SET
simultaneously

* CESAB MENU *
SPECIAL ADJUST.

SET CURRENT
500 A

Press
ROLL

STARTING CONSOLE
DESCRIPTION

SET PUMP CURRENT


500 A

Press
ROLL

0=Lng frdrjning, 9=Kort frdrjning

Auxiliary Time = Frdrjning vid kriktningsvxling

Press
ENTER

SET FIELD CURR.


50 A

Press
ROLL

SEM 2
OFF
Press
ROLL

* CESAB MENU *
HARDWARE SETTING

AUXILIARY TIME
LEVEL = 7

Press

PARAM
SET
to change the value
low value=inversion softer
high value=inversion stronger

ARE YOU SURE?

Press
OUT

COMBISEM 3 CE 1.25
80V
500A 00000

Press OUT
to escape

Press
ROLL

YES=ENTER NO=OUT

SEPTEMBER 1999

CBE 2,5 - 3,5

DIAGRAM FOR USING THE CONSOLE


Function -CLEAR EEPROMReach the function ALARMS from the main menu

Press
ENTER

V ACC NOT OK
23h 2 25 C

Press PARAM
SET
simultaneously

Anvnds vid uppgradering


av mjukvaran till ny version.

* CESAB MENU *
SPECIAL ADJUST.
Press
ROLL

* CESAB MENU *
HARDWARE SETTING

Press
ROLL

* CESAB MENU *
READ RAM
Press
ROLL

in den tillbaka.

* CESAB MENU *
READ EEPROM
Press
ROLL

Spara den gamla parameterlistan frst, och ladda sedan

* CESAB MENU *
CLEAR EEPROM

Press
ENTER

ARE YOU SURE?


YES=ENTER NO=OUT

Press
ENTER

MAIN MENU
ALARMS

EEPROM CLEARED!
KEY OFF, PLESED
SWITCH OFF - SWITCH ON THE KEY

MAY 2000

CBE 2,5 - 3,0 - 3,5

DATA ACQUISITION LIFTING POTENTIOMETER


-Connect the console to the module COMBI SEM 3
-Turn the key on

Anvnds fr att lra panelen min och

Display Consolle

CESAB
CONSOLE V.1.0

Manufacturer's name
Console program version
Connection moment between
console and COMBI SEM3

CONNECTED TO:
COMBI SEM3 CE 1.07

max positionerna fr lyftpotentiometern.

Type and program version of module

COMBI SEM3 CE 1.07


80V 500A 00000

Tension/power and hour meter value

PRESS SIMULTANEOUSLY

ROLL

PARAM

WILL BE DISPLAYED
CONFIG. MENU
SET MODEL
Press
ROLL

CONFIG. MENU
SET OPTIONS
Press
ROLL

Minimum
value of lifting
potentiometer

CONFIG. MENU
ADJUSTMENT

SET PUMP ACC MIN


0,6 V

Press ENTER to select


the menu of the
ACQUISITIONS

Press
OUT

Value at rest

Press Enter

Press
ROLL

Maximun voltage
value stored

SET PUMP ACC MAX


0,0 V
Value at rest

Press OUT
keeping the lever pulled

Pull the lifting lever


untill the mechanic end
stroke

ARE YOU SURE?


YES=ENTER NO=OUT

SET PUMP ACC MAX


4,6 V

Press ENTER to
confirm or OUT

JUNE 1999

SET PUMP ACC MAX


4,5 V
Press
Enter

Pull the lifting lever till when the


microswitch will be closed

SET PUMP ACC MIN


0,5 V
Press ENTER to
confirm or OUT

SET PUMP ACC MIN


0,0 V

Maximum
value of lifting
potentiometer

Minimun voltage
value stored

Press OUT
keeping the
lever pulled

ARE YOU SURE?


YES=ENTER NO=OUT

PARAMETER

CBE 2,5 - 3,0


SETTING VALUE
MODULE COMBI SEM3 (EPROM CE1.34)
motors: traction SCHABMLLER lifting SCHABMLLER
(Svart drivmotor)

PARAMETER
ACCELER. DELAY
DECELER DELAY
RELEASE BRAKING
PEDAL BRAKING
INVERS BRAKING
CUTBACK SPEED
BRAKE CUTBACK
MAX SPEED FORW
MAX SPEED BACK
TRACTION I MAX
ARMA. NOM. CURR.
WEAK DROPOUT
FIELD NOM. CURR.
CREEP SPEED
SEAT MICRO DELAY
SPEED LIMIT
PUMP I MAX
PU. ACCELER DELAY
PU. DECELER DELAY
PUMP CREEP
COMPENSATION
1ST SPEED COARSE
1ST SPEED FINE
1ST SPEED COMP
2ND SPEED COARSE
2ND SPEED FINE
2ND SPEED COMP
3RD SPEED COARSE
3RD SPEED FINE
3RD SPEED COMP
4TH SPEED COARSE
4TH SPEED FINE
4TH SPEED COMP
HYD SPEED COARSE
HYD SPEED FINE
HYD SPEED COMP
HYDRO TIME

DESCRIPTION
min/max
Traction motor acceleration time
1-9
Traction motor deceleration time
0-9
Braking current by releasing the accelerator 0-6
Braking current with pressed braking pedal 0-7
Braking current on inversion
0-7
Max speed reducton with input on
0-9
Speed reduction with pressed braking pedal 2-9
Forward max speed
0-7
Backward max speed
0-7
Traction max current
0-9
Armature nominal current
3-7
Weakening threshold current
0-6
Field nominal current OBS! Viktigt!
0-0
Min. acceleration threshold
0-3
Seat microsiwtch delay
0-9
Lifting max speed
0-9
Lifting max current
0-9
Motor pump acceleration delay
5-9
Motor pump deceleration delay
3-7
Min. lifting acceleration threshold
4-6
Lifting speed compensation
5-9
1-1
Tilting speed, coarse adjustment + 10%
0-9
Tilting speed, fine adjustement + 1%
Tilting speed compensation
2-7
0-9
Sideshift speed, coarse adjustment + 10%
0-9
Sideshift speed, fine adjustment + 1%
Sideshift speed compensation
0-9
0-9
4th way speed, coarse adjustment + 10%
0-9
4th way speed, fine adjustment + 1%
4th way speed compensation
0-9
0-9
5th way speed, coarse adjustment + 10%
0-9
5th way speed, fine adjustment + 1%
5th way speed compensation
0-9
Power steering speed, coarse adjust. + 10% 0-1
0-9
Power steering speed, fine adjust. + 1%
Power steering speed compensation
3-7
Power steering time
0-9

* AUXILIARY TIME

Delay on inversion direction

0-9

VALUE

4
5
2
6
3
0
2
7
7
9
3
3
0
2
5
7
9
9
5
5
6
1
4
2
1
6
0
0
0
0
0
0
0
0
1
5
2
3

NOVEMBER 2000

CBE 3,0L - 3,5


SETTING VALUE
MODULE COMBI SEM3 (EPROM CE1.34)
motors: traction LUCCHI lifting LEROY SOMER
(Silverfrgad drivmotor)

PARAMETER
ACCELER. DELAY
DECELER DELAY
RELEASE BRAKING
PEDAL BRAKING
INVERS BRAKING
CUTBACK SPEED
BRAKE CUTBACK
MAX SPEED FORW
MAX SPEED BACK
TRACTION I MAX
ARMA. NOM. CURR.
WEAK DROPOUT
FIELD NOM. CURR.
CREEP SPEED
SEAT MICRO DELAY
SPEED LIMIT
PUMP I MAX
PU. ACCELER DELAY
PU. DECELER DELAY
PUMP CREEP
COMPENSATION
1ST SPEED COARSE
1ST SPEED FINE
1ST SPEED COMP
2ND SPEED COARSE
2ND SPEED FINE
2ND SPEED COMP
3RD SPEED COARSE
3RD SPEED FINE
3RD SPEED COMP
4TH SPEED COARSE
4TH SPEED FINE
4TH SPEED COMP
HYD SPEED COARSE
HYD SPEED FINE
HYD SPEED COMP
HYDRO TIME

DESCRIPTION
min/max
Traction motor acceleration time
1-9
Traction motor deceleration time
0-9
Braking current by releasing the accelerator 0-6
Braking current with pressed braking pedal 0-7
Braking current on inversion
0-7
Max speed reducton with input on
0-9
Speed reduction with pressed braking pedal 2-9
Forward max speed
0-9
Backward max speed
0-9
Traction max current
0-9
Armature nominal current
3-7
Weakening threshold current
0-6
Field nominal current OBS! Viktigt!
4-4
Min. acceleration threshold
0-3
Seat microsiwtch delay
0-9
Lifting max speed
0-9
Lifting max current
0-9
Motor pump acceleration delay
5-9
Motor pump deceleration delay
3-7
Min. lifting acceleration threshold
0-4
Lifting speed compensation
7-9
0-1
Tilting speed, coarse adjustment + 10%
0-9
Tilting speed, fine adjustement + 1%
Tilting speed compensation
4-8
0-9
Sideshift speed, coarse adjustment + 10%
0-9
Sideshift speed, fine adjustment + 1%
Sideshift speed compensation
0-9
0-9
4th way speed, coarse adjustment + 10%
0-9
4th way speed, fine adjustment + 1%
4th way speed compensation
0-9
0-9
5th way speed, coarse adjustment + 10%
0-9
5th way speed, fine adjustment + 1%
5th way speed compensation
0-9
Power steering speed, coarse adjust. + 10% 0-1
0-9
Power steering speed, fine adjust. + 1%
Power steering speed compensation
3-7
Power steering time
0-9

* AUXILIARY TIME

Delay on inversion direction

0-9

VALUE

4
5
4
6
5
0
2
9
9
9
3
3
4
2
5
6
9
9
5
0
8
1
2
8
2
8
2
0
0
0
0
0
0
1
1
7
2
7

NOVEMBER 2000

LEGEND
DESCRIPTION

ENGLISH

DEUTSCH

FRANCAIS

ESPAOL

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
Glhkerzen
Schlssel
Anlaschlssel
Hupe
Zusatzbeleuchtungssteuerung
Elektroflgelsteuerung
Stoplichtesteuerung
Batteriestecker
Armaturenbrett
Glhkerzevorrichtung
Gangelektroventile
Elektroflgelrad
Notstand
Rckfahrscheinwerfer
Stoplichte
Bremse
Bremspedal
Festellbremse
GPL Reserveanzeiger

4.me levier
4a.leva
5.me levier
5a.leva
abilitation active
habilitacin activada
abilitation des freins
habilitacin de los frenos
abilitation de stationnement
habilitacin de aparcamiento
pdale acclrateur
pedal acelerador
alternateur
alternador
anomalie dunit logique
anomala unidad lgica
actionneur
actuador
arrt du moteur
parada del motor
batterie
batera
bobine
bobina
inclinaison
inclinacin
bougies dallumage
bujas
bougies de chauffage
bu jas incandescente
cl
llave
cl de dmarrage
llave de arranque
klaxon
claxon
commandes lumires suppl. mandos luces adicionales
commande lectro-ventilateur mando electroventilador
commande feus de stop
mando faroles de stop
connecteur batterie
enchufe batera
panneau de commande
salpicadero
dispositif bougie de chauffage dispositivo bujia incandescente
electrovannes de marche
electrovlvulas de marcha
lectro-ventilateur
electroventilador
urgence
emergencia
feus de marche arrire
faroles de marcha atras
feus de stop
faroles de stop
frein
freno
frein pdale
freno pedal
frein de stationnement
freno de aparcamiento
indicateur rserve GPL
indicador reserva GPL

LEGEND
DESCRIPTION

ENGLISH

indicatore temperatura ac water temperature indicator


intas.filtro aria
air filter clogging
intas.filtro olio
oil filter clogging
intas.filtro olio idraul.
hydraulic oil filter clogging
inversore
inversor lever
inversore manuale
drive direction lever
livello carburante
fuel level
liv.liquido freni
brake fluid level
luci posteriori
back lights
luci retromarcia
reversing lamps
marcia avanti
forward speed
marcia indietro
backward speed
marcia lenta
slow speed
mot.trazione
traction motor
motore avviamento
starter motor
motore idroguida
power steering motor
motore pompa
pump motor
pedale freno
brake pedal
pedaliera
pedals
pedaliera doppia
double pedals
pompa
pump
pompa iniezione
injection pump
post combustione
afterburning
potenziometro sollev.
lifting potentiometer
pressione olio motore
motor oil pressure
pressostato freni
brakes press.switch
pulsante clacson
horn push button
pulsante emergenza
emergency.pushbutton
rel avviamento
starter relay
riserva gas
LPG reserve
scatola acc.
speed box
sensore velocita
speed sensor
sollevamento
lifting
spia candelette
glow plugs warning light

DEUTSCH

FRANCAIS

ESPAOL

Wassertemperaturanzeiger
Luftfilterverstopfung
lfilterverstopfung
Hydrauliklfilterverstopfung
Umschaltung
Handumschaltung
Treibstoffstand
Bremsflssigkeitsstand
Rcklichte
Rckfahrlampen
Vorwrtsgang
Rckwrtsgang
langsamer Gang
Fahrmotor
Anlamotor
Hydrolenkungsmotor
Pumpenmotor
Bremsepedal
Pedale
Doppelpedal
Pumpe
Einspritzungspumpe
Nachverbrennung
Hubpotentiometer
lmotordruck
Bremsdruckschalter
Hupeknopf
Notdruckknopf
Anlarelais
GPL Reserve
Fahrschalter
Geschwindigkeitsensor
Hub
Glhkerzenwarnlampe

indicateur temperature de lea indicador temperatura del agua


encrassement filtre air
obstruccin filtro aire
encrassement filtre huile
obstrucci filtro aceite
encrassement filtre huile hydr. obstruccin filtro aceite hidr.
inverseur de direction
palanca de inversin
inverseur de direction
palanca de inversin
niveau carburant
nivel carburante
jauge dhuile de freins
nivel aceite frenos
lumires arrires
luces traseras
ampoule marche arrire
lampara de marcha atrs
marche avant
marcha adelante
marche arrire
marcha atrs
marche lente
marcha lenta
moteur de traction
motor de traccin
dmarreur
motor de arranque
moteur direction assiste
motor servodireccin
moteur pompe
motor bomba
pdale du frein
pedal del freno
jeu de pdales
juego de pedales
pdales double
pedales doble
pompe
bomba
pompe dinjection
bomba inyeccin
postcombustion
postcombustin
potentiomtre dlvation
potencimetro levantamiento
pression dhuile moteur
presin aceite motor
pressostat freins
presstato frenos
poussoir klaxon
pulsador de claxon
poussoir durgence
pulsador de emergencia
relais dmarreur
rel arranque
rserve GPL
reserva GPL
boitier du vitesse
caja aceleradores
senseur de vitesse
sensor de velocidad
lvation
levantamiento
voyant bougies de chauffage luz testigo bujas incandescen.

LEGEND
DESCRIPTION

ENGLISH

DEUTSCH

FRANCAIS

ESPAOL

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
ltemperaturgetriebe
Wassertemperatur
Wrmesensor
Seitenschieber
Totmann-schalter
Motorflgel
Flgelrder
Rcksicht

interrupteur coffre
temperature dhuile transmis.
temperature deau
senseur thermique
dplacement lateral
Homme mort
ventilateur moteur
ventilateur
vue arrire

interruptor cofre
temperatura aceite transmisin
temperatura agua
sensor trmico
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
Wei
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