Why does the CESAB Forklifts battery run down rapidly during the work period?
A CESAB Forklifts battery might drain quickly due to several reasons: * The battery's capacity may not be sufficient for the work being done; consider moderating current consumption or charging more frequently. * An old battery may need replacement. * The battery might not be fully charged; in this case, check the battery charger.
What to do if my CESAB Forklifts battery runs down rapidly and the truck is slow with low voltage?
If your CESAB Forklifts battery is draining fast, the truck is moving slowly with low voltage, and the electrolyte is heating up, it could be due to excessive current consumption. Check the load lifted by the truck. It could also be that the truck motor is overloaded, especially when going uphill; lubricate and check the motor's mechanical parts. Another cause could be a battery charger with high current at the end of charge; check the battery charger.
What to do if my CESAB Forklifts battery runs down rapidly and the electrolyte density is too low during charging?
If the electrolyte density is too low because of acid leakage, attempt to restore it by adding acid if a trickle charge does not increase the density.
What causes density not being the same, contacts shorting to earth and current leakage in CESAB Forklifts?
Uneven density, contacts shorting to earth, and current leakage in CESAB Forklifts can stem from several issues. It could be due to faulty insulation of an electrical device in the truck or battery; examine the insulation. The battery may have cracked cells or dirty elements; clean the case and elements. The metal case may have faulty insulation; renew the insulating coating. Also, eliminate too high and/or continuous intermediate current sockets.
Why does my CESAB Forklifts battery run down rapidly with low voltage and high water consumption?
If your CESAB Forklifts battery is running down rapidly, showing low voltage, acid heats up, density isn't the same, density is too low while charging, charge voltage is too low and there's high water consumption, it is likely due to plates short circuiting in some battery elements. Replace the faulty elements.
Illustrates the external views of the forklift truck with two different perspectives.
Details the truck models, their load capacities, control methods, and supply voltages.
Shows the format and location of the chassis serial number for different vehicle types.
Explains how to read identification and load capacity plates, detailing technical data and load specifications.
Provides guidance on understanding operating procedures, explanations, and point operations within the manual.
Defines key terms and cautions for important operational matters and safety.
Lists common abbreviations used in the manual with their meanings.
Explains the purpose of illustrations in depicting work methods on the machine.
Explains the use of SI units and provides conversion rates between conventional and SI units.
Offers general instructions for safe and skillful operation, including handling parts and waste disposal.
Provides information on the hazardous nature of battery materials and the importance of recycling.
Details safety instructions and procedures for jacking up the vehicle.
Lists the weights of various components of the forklift truck by vehicle model.
Provides instructions and cautions for towing the forklift truck safely.
Outlines procedures for inspecting electrical parts, including multimeter usage and measurement results.
Presents tables for preloading and maximum torque values for metric coarse and fine thread screws.
Specifies lubricants, capacities, and types applicable to different vehicle parts.
Explains the necessity and intervals for periodic inspection and maintenance by specialized technicians.
Defines methods for inspection: Inspect/correct/replace, Measure/correct/adjust, Clean, Tighten.
Details the replacement cycle for various components based on operating hours or truck life.
Specifies battery casing dimensions and minimum required weight with casing for different vehicle models.
Details service standards for battery electrolyte, insulation resistance, and voltage.
Explains the Battery Charge Indicator, including diagnostic LED and charge indicator functionality.
Covers battery discharge voltage, status indicator management, and parameter customization.
Manages indicator reset for partial charges, specifying minimum recharge percentage.
Determines the voltage threshold for signaling 0% residual charge and electrolyte density requirements.
Sets the voltage threshold for signaling 100% charge, influencing the discharge curve.
Parameter to determine the reset curve, affecting how the discharge curve is adjusted.
Procedure to follow if the battery indicator on the display has not reset after a charge cycle.
Explains how to use ADJUST BATTERY and ADJUST CAPACITOR parameters for precise battery discharge indication.
Procedure to set the voltage measured for the battery elements, affecting the indicator's accuracy.
Provides a table of defects, causes, and remedies for common battery issues.
Details electrolyte level, electrolyte transparency, and fluid density checks using a hydrometer.
Explains how state of charge is measured by electrolyte density and provides discharge limits.
Discusses factors influencing lead-acid battery capacity like discharge rate, electrolyte gravity, and temperature.
Provides general information on gel batteries, their maintenance, discharge, and charge procedures.
Describes how to set parameters for GEL batteries to ensure correct charge reading and avoid damage.
Introduces the truck's traction & lifting logic units, their self-diagnosis function, and analyzer mode.
Lists power fuses, fuses (+Vb), contactors, and armrest opt fuses with their ratings.
Details procedures for inspecting traction/lifting units, including insulation resistance measurement.
Guides on inspecting boards, harnesses, connectors, and pins, emphasizing careful measurement.
Describes the connectors and pin assignments for the traction logic unit.
Details connectors and pin assignments for the lifting logic unit.
Lists connector pin assignments and descriptions for the I/O board.
Details connectors and pin assignments for the armrest card, including joysticks and potentiometers.
Lists connector pin assignments for the Mhyrio unit, including CAN-BUS and console inputs.
Shows connector pin assignments for the contactor group, including fuses and relays.
Details connector pin assignments for the dashboard interface.
Compares specifications of Traction Logic Unit ACE-2 and Lifting Logic Unit ACE-2.
Explains methods using a clamp amperometer or multimeter to check motor phase balancing.
Details procedures for checking lifting motor phase balancing using a clamp amperometer or multimeter.
Provides steps for removing and installing logic units, including thermic transmission paste application.
Outlines procedures for removing and installing the I/O control board.
Describes the Mhyrio logic unit's function and removal/installation steps.
Details the procedure for removing and installing the contactor group.
Explains inspection methods for power supply contactors and fuses, including resistance measurement.
Provides steps for removing and installing the dashboard display.
Details components of the armrest card and the removal/installation procedure.
Describes the fuse box, its location, and the function of each fuse.
Explains how to check and adjust the accelerator potentiometer (P2) installation and acquisition.
Details the procedure for adjusting brake pedal play and checking the speed reduction switch.
Outlines the procedure for checking and adjusting the parking brake limit switch.
Explains how to check and adjust the lifting potentiometer and microswitch positions.
Lists required adjustments after replacing components like I/O BOARD, LOGIC UNITS, DASHBOARD, etc.
Introduces the instrument panel's function in displaying vehicle information through changing screens.
Provides a map and instructions for navigating the User Menu on the dashboard.
Explains the User Menu's accessibility and its ability to modify parameters, including password insertion notes.
Details the procedure for inserting the password to access the User Menu.
Lists and describes functions like HOUR METER, TRIP, CLOCK, ALARMS, and DISPLAY SETTING.
Explains how to access and view hour meter information, including working, traction, and service hours.
Describes how to view trip information and reset the hours count.
Details how to modify hours, date, and explains the clock icon's flashing behavior.
Guides on setting and activating alarms, including the clock icon's behavior.
Explains how to disable alarms, including the clock icon's flashing and the use of the OUT button.
Covers setting the hour meter display mode and visualization options.
Describes how to select the desired language for the user menu display.
Explains how to set and select the desired visualization for steering direction.
Introduces the Service Menu for assistance, maintenance, and rental activities.
Details the Service Menu's functions and access, including password insertion notes.
Outlines the procedure for inserting the service menu password, including error handling.
Provides a flowchart of the Service Menu structure and navigation.
Lists and describes functions like SOFTWARE VERSION, PARAMETER CHANGE, TRUCK CONFIGURATION, etc.
Explains how to view software versions of boards and logic units.
Shows the menu map for accessing software versions of various truck components.
Guides on changing program parameters for Traction and Material Handling functions.
Details the procedure for accessing and modifying advanced parameters for Traction and Material Handling.
Provides a map of parameter changes for Traction and Material Handling, basic and advanced.
Explains how to view and modify traction system parameters like turtle cutback and curve cutback.
Explains how to view and modify hydraulic system parameters for mechanical and electro-proportional versions.
Describes how to view error codes and memorized alarms in real time.
Provides a map for navigating the Alarms menu, including READ and CLEAR functions.
Explains the learning function for memorizing settings and indicating battery voltage.
Details how to identify and acquire the truck serial number, requiring repetition after component replacement.
Describes the procedure for accelerator potentiometer acquisition, including repeated steps if data is not memorized.
Outlines the procedure for lifting potentiometer acquisition, applicable to electro-proportional versions.
Explains how to set the voltmeter inside the traction logic unit for reading battery voltage.
Describes setting the voltmeter for battery voltage reading, potentially requiring serial number acquisition repeat.
Details steering potentiometer acquisition in the central position for straight wheels.
Explains steering potentiometer acquisition in the right limit switch position.
Describes steering potentiometer acquisition in the left limit switch position.
Guides on resetting MCB, ARMREST, TRACTION, MHYRIO, PUMP, and DISPLAY components.
Provides a map for navigating the Default Reset menu.
Details recoverable errors generated by incorrect starting procedures or control sequences.
Provides steps for checking connectors and terminals, including proper disconnection and contact pressure checks.
Basic preliminary step before troubleshooting, involving battery plug disconnection.
Outlines procedures for continuity check, short circuit check, and visual inspection of wire harnesses and connectors.
Details procedures for checking truck, battery, and motor insulation resistance.
Describes how to check the state of the motors, specifically focusing on phase continuity.
Illustrates the wiring harness connections for the mechanic distributor system.
Shows the wiring diagram for the electric distributor system.
Lists error codes, their specifications, error modes, and corresponding pages for troubleshooting.
Provides general information and specifications for the drive motor, including type, power, and voltage.
Details motor type, power, voltage, current, frequency, insulation class, and RPM.
Illustrates the components of the drive motor, labeling parts like cover, elastic ring, and engine body.
Provides a step-by-step procedure for removing the gearmotor unit, including torque specifications.
Details specific disassembly and assembly steps for removing the gearmotor unit.
Explains the encoder's function in generating feedback signals for motor status and rotation.
Outlines the procedure for replacing the traction temperature sensor, including required tools and drying time.
Provides general information and specifications for the lifting motor.
Details motor type, dimensions, power, voltage, current, frequency, and insulation class.
Illustrates the components of the lifting motor, labeling parts like cover, elastic ring, and engine body.
Provides a step-by-step procedure for removing and installing the lifting motor, including torque specifications.
Details the procedure for replacing the encoder, including dismantling and assembly steps.
Provides a general overview and torque specifications for the transmission unit.
Lists load capacity, total reduction ratio, and tyre sizes for the drive unit.
Illustrates the components of the drive unit, showing exploded views of parts.
Details the step-by-step procedure for disassembling and reassembling the rear axle and drive unit, including torque values.
Illustrates and labels the components of the steering system, including motor, pump, and orbitrol.
Presents the hydraulic circuit diagram for the mechanical distributor version of the steering system.
Shows the hydraulic circuit diagram for the electro-proportional distributor version.
Details specifications for the power steering orbitrol, including type, capacity, and pressure.
Provides procedures for removing and installing the priority valve, including torque specifications.
Offers general information and torque specifications for the hydraulic motor.
Outlines the steps for removing and installing the hydraulic motor.
Provides general information and diagrams for the steering potentiometer unit.
Details the procedure for removing and installing the steering potentiometer.
Lists hydraulic-related troubleshooting symptoms, possible causes, and recommended actions.
Provides a general overview and specifications for the brake system.
Lists specifications for service brake, parking brake, brake wheel, and brake shoe.
Details the procedure for disassembling and reassembling the parking brake, including inspection and adjustment.
Outlines the steps for disassembling and reassembling the brake group, with torque specifications.
Provides a detailed procedure for disassembling and reassembling brake shoes and the brake cylinder.
Explains the procedure for removing and installing the brake pedal, including torque specifications.
Covers brake pump play adjustment and brake fluid system bleeding procedures.
Explains the function of the brake fluid tank warning light and how to verify it.
Provides information on tyre types, pressure, tightening torques, and a detailed tyre table.
Shows an exploded view of the forklift's body and frame components.
Details the procedure for removing and installing the battery cover, including torque specifications.
Outlines the steps for removing and installing the overhead guard, including torque specifications.
Provides the procedure for removing and installing the counterweight, including bolt sequences and torque.
Explains the procedure for removing and installing the operator's seat.
Presents the hydraulic circuit diagram for systems with lever control valves.
Shows the hydraulic circuit diagram for systems with electric control valves.
Illustrates the components of the steering system.
General overview of the steering system.
Details the hydraulic system layout for lever control valve configurations.
Describes the hydraulic system layout for electric control valve configurations.
Shows components related to the 2M TV mast.
Illustrates components for the 3M TV mast.
Shows components for the 2M FFL mast.
Illustrates components for the 3M FFL mast.
Provides procedures for removing and installing the hydraulic oil and filter, including torque specifications.
Details the procedure for performing oil leak tests on lifting and tilting cylinders.
Outlines the procedure for testing lifting cylinders for oil leaks.
Describes the procedure for testing tilting cylinders for oil leaks and adjusting angles.
Shows an exploded view of the components for the 2M TV mast.
Illustrates the components for the 3M TV mast.
Shows components related to the 2M TV (FW) mast.
Illustrates components for the 3M FFL (FSW) mast.
Shows exploded views of fork carriage components for various mast types.
Illustrates chains and rollers for different mast types, side view.
Shows chains and rollers for different mast types, central view.
Details the procedure for removing and installing the mast, including torque specifications.
Provides specific operational points for mast removal and installation procedures.
Outlines the procedure for removing and installing mast connection bushings, with lubrication remarks.
Details disassembly and installation steps for mast connection bushings.
Provides procedures for removing and installing primary cylinder supply pipes for a 2M TV mast.
Outlines the procedure for removing and installing third way system supply pipes for a 2M TV mast.
Details installation steps for pipes, emphasizing compliance with sizing and preventing rotation.
Describes the procedure for removing and installing third way system pulleys for a 2M TV mast.
Outlines the procedure for removing and installing third way system chains for a 2M TV mast.
Details disassembly and inspection steps for chains and split pins.
Provides procedures for removing and installing primary cylinder supply pipes for a 3M FFL mast.
Outlines the procedure for removing and installing third way system supply pipes for a 3M FFL mast.
Details installation steps for pipes, emphasizing compliance with sizing and preventing rotation.
Describes the procedure for removing and installing third way system pulleys for a 3M FFL mast.
Outlines the procedure for removing and installing third way system chains for a 3M FFL mast.
Details disassembly and installation steps for chains and split pins.
Covers inspection and adjustment of roller pads and bearings, including clearance checks.
Details inspection and adjustment procedures for mobile mast pads, including clearance and thickness checks.
Provides methods for inspecting chain links for wear and adjusting chain tension.
Presents a table detailing lifting load capacities and corresponding 'X' dimensions based on ISO standards.
Outlines procedures for removing and inspecting fork arms, including checks for cracks, wear, and positioning.
Provides general information and diagrams for lifting cylinders, showing standard and optional configurations.
Details specifications for side/rear and central lifting cylinders, including model, bore, and parachute valve settings.
Illustrates the components of the 2M TV lifting cylinder, showing standard and optional parts.
Shows the components of the 3M TV side lifting cylinders.
Illustrates the components of the 2M FFL side/rear lifting cylinder.
Shows the components of the 3M FFL side/rear lifting cylinder.
Illustrates components for central cylinders in 2M FFL and 3M FFL configurations.
Details the procedure for removing and installing side/rear cylinders, including bleeding air and checking oil levels.
Provides specific disassembly steps for pipe-hose clips and fixing bolts.
Outlines procedures for disassembling, inspecting, and reassembling central cylinder gaskets.
Details the procedure for disassembling, inspecting, and reassembling side cylinder gaskets for 2M FFL.
Provides procedures for disassembling, inspecting, and reassembling side cylinder gaskets for 3M FFL.
Outlines steps for disassembling, inspecting, and reassembling tilt cylinder gaskets, including torque values.
Provides general information about the oil pump.
Details oil pump type, name, transmission, capacity, and theoretical displacement.
Illustrates the components of the oil pump.
Details the procedure for disassembling and reassembling the service pump, including torque specifications and notes.
Explains how to test the oil pump's discharge performance by cylinder operation and checks.
Provides performance data for lifting and tilting masts under various load conditions.
Provides a general overview and diagrams of the mechanical control valve, including 3-way and 4-way types.
Illustrates the general layout of a 3-way control valve.
Shows the general layout of a 4-way control valve.
Details the hydraulic circuit and specifications for the mechanical control valve.
Outlines the procedure for disassembling and reassembling the mechanical control valve, with notes on adjustments.
Details disassembly of lever pins and microswitch adjustments for the control valve.
Explains the procedure for adjusting the relief valve pressure for lifting, tilting, and side shift functions.
Provides performance data for lifting and tilting masts, including tolerances and standard values.
Describes the lift lock unlocking bolt and its operation, with notes on tightening.
Provides general information and diagrams for electric control valves used with minilever and joysticks.
Illustrates the components of the electric control valve system.
Details the hydraulic circuit and specifications for the electric control valve.
Outlines the procedure for disassembling and reassembling the electric control valve, with notes and cautions.
Explains the procedure for adjusting the pressure relief valve, emphasizing careful adjustment to prevent damage.
Describes the lift lock unlocking bolt and its operation, with notes on proper tightening.
Presents the wiring diagram for various optional systems installed on the truck.
Details the procedure for removing and installing the flash beacon, including wiring connections.
Outlines the procedure for removing and installing the reverse acoustic warning system.
Provides steps for removing and installing working lights, including fuse and wiring connections.
Explains the procedure for removing and installing the complete lighting system, including bulbs and wiring.
Introduces the programmer's function for updating logic units and cards on the truck.
Explains the meaning of function buttons, choices, and screen indicators used with the programmer.
Details the procedure for connecting the programmer to the truck via CAN-BUS.
Outlines the steps for connecting the programmer via serial connection for programming cards.
Guides on using the AUTO mode for software updates, where the programmer automatically recognizes the truck.
Explains how to use the MANUAL mode for selecting truck family and software versions for installation.
Describes how to create a file on the SD card for saving operator profile parameters.
Details how to load saved operator profile parameters from the SD card onto the truck.
Explains how to delete files from the SD card that were created with the SAVE function.
Lists programmer messages, their descriptions, and potential causes or required actions.
Details the serial connection procedure for the MCB main control board.
Provides steps for accessing the serial connector on the armrest card.
Outlines the procedure for removing the display unit and accessing its serial connector.
Guides on downloading, preparing, and installing new software onto the programmer SD card.
Provides detailed technical specifications for traction motor and pump motor, including power, voltage, current, and RPM.
Shows a diagram of the auxiliary wiring harness and lists connector descriptions.
Lists connector pin assignments, terminal details, and descriptions for various truck components.
Presents schematic diagrams illustrating the electric system of the forklift.
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