ExTe Com 90 User manual

Art nr: AD00234_Eng REV-A © Copyright Exte fabriks AB.
AD00234 Eng
User Manual
Art nr: AD00234_Eng REV-A © Copyright Exte fabriks AB.
2021-06-16
CC-PILOT
Art nr: AD00234_Se REV-A © Copyright Exte fabriks AB.
Com 90
Com 90

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Art nr: AD00234_Eng REV-A © Copyright Exte fabriks AB.
Read through the entire manual and fully
understand the content before using the
system!
Bad or faulty mounting and handling can cause
interruptions, damages and personal injury.
Content: Page
Risks and warnings
Components locations and designations
Description of bunks, brake
Mounting of bunks
Mounting of stakes, compl. or only upper stake
Assembly of stakes and lashing arms
Mounting of hydraulic components Truck
Connection of hydraulic pump
Mounting of hydraulic components Trailer
Hydraulic schematic Truck, single stack block
Hydraulic schematic Trailer, double stack block
Schematic overview, Control system
Menu and function guide, CCpilot Control system
Emergency control
Alarms and warnings
Remote control, functions and operation
Loading and unloading
Control system components and connections
Basic circuit diagram
Oil recommendations and pre check
Adjusting pressures and lashing arm speeds
Control system check
Notes, hose length protocol
3
4
5-6
7
8
9-13
14-16
17
18-19
20
21
22
23-29
29
30
31-32
33-34
35-39
40
41
42-43
44-45
46
Can bus system
Manual
Translation from original manual.
Fabriks AB, Gundbergsvägen 6, 827 28 FÄRILA, SWEDEN
Tel: + 46(0)651-175 00
E-mail: [email protected]
www.exte.se
Com 90

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Art nr: AD00234_Eng REV-A © Copyright Exte fabriks AB.
Risks and warnings.
Always wear a HELMET when maneuvering
and staying close to the Com 90 system!
Always wear PROTECTIVE GLOVES and EYE
PROTECTION when maintaining and repairing
the Com 90 system!
Safety distance min. 5m when operating the
system.
Risk of falling load when maneuvering stakes
and lashing arms.
Hidden tree parts and other debrie
can get in motion!
Even maneuvering an empty vehicle can lead
to risks and surprising situations if you are
too close to the system!
ALWAYS load so that there is a motion
reserve for compression and settling of the
load to avoid the stakes reaching
end of stroke.
More information about emergency stop
functions on page 30.
EMERGENCY STOP
PULL
OR
PUSH
Stop
COM 90
COM 90
COM 90
COM 90
COM 90
COM 90
Min 5m!
!
!
x
!

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Art nr: AD00234_Eng REV-A © Copyright Exte fabriks AB.
Component locations and designations
1. Hydraulic pump.
2. High pressure filter.
3. Main pressure valve (150 Bar).
4. Direction valve block for single stack (truck).
5. Electrical terminal, I/O unit.
6. Distribution blocks with flow divider.
7. Electrical cable connector, female part.
8. Electrical cable connector, male part on cable.
9. Distribution blocks with flow divider (forward bunk pair).
10. -”- (rear bunk pair).
11. Direction valve block for dubble stack (trailer).
12. Electrical terminals, I/O units.
13. Control panel located in cabin.
14. Radio receiver.
15. Radio transmitter.
16. Quick couplings pressure and return.
17. Quick couplings pressure and return.
18. Termination connector (120 Ohm resistor, used only when driving without trailer if
not auto-termination is used).
2
2
15
9
4
6
3
7
18
17
814
13
16
1
10
11
12
5
Hook LEFT. Ring RIGHT.
COM 90
COM 90
COM 90
COM 90
COM 90
COM 90

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Art nr: AD00234_Eng REV-A © Copyright Exte fabriks AB.
Description of bunks
1. Bolster
2. Lower stake
3. Upper stake
4. Hook-rib
5. Ring-rib
6. Hydraulic cylinder
7. Sliding sleeve
8. Slide bearing plate
9. Rack
10. Pinion
11. Lashing arm
12. Locking element
13. Mounting plate
14. Securing plate
15. Clamp
16. Fastening plate
17. Screw w. nut
18. Inner frame stop
19. Screw w. nut
20. Brake housing
21. Friction pads
22. Rubber puck
23. Shim
24. Break pin
25. Rib
26. Hook / Ring
27. Locking Pin
The drawing shows Com 90 complete bunk with its different components.
Lashing arm
1
2
3
4
12
5
6
20
21
8
9
10
13
14
22
15
11
16
23
17
18
19
24 25 26
27
7

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Art nr: AD00234_Eng REV-A © Copyright Exte fabriks AB.
Brake
1
2
3
45
6
7
8
9
9
10
11
Included parts
1. Hydraulic cylinder
2. Brake housing
3. Washer
4. Snap-lock ring
5. Piston seal
6. Piston
7. Support plate
8. Support plate
9. Friction pad
10. Hydraulic line, Brake
11. Seal
Working principle:
Built-in to the upper stake is a brake device that brakes the stake thus enabeling lashing arm
maneuvering instead of stake movement.
When up or down movement is wanted on the stake, the “High speed” function is activated.
The hydraulic pressure to the brakes then significantly reduces to lower the friction against the stake
and enabeling the higher speed but still maintain a secure connection between hook and ring.
!NEVER use the high speed function when moving the
lashing arms!!
ONLY when moving the upper stake UP or DOWN.

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Art nr: AD00234_Eng REV-A © Copyright Exte fabriks AB.
1
4
7
2
5
6
3
10
8
9
Mounting of bunks
A
Important
In relation to the chassis´ frame
thickness, shim (10) must be used
in appropriate number to achieve
a flat contact surface between the
mounting plate (1) and fastening
plate (7). Gap between frame and
fastening plate, 3-4mm.
See fig. below.
The bunks must always be mounted to the chassis´ frame with a friction attachment (1) Mounting plate.
The friction attachment has a bolted inner stop (2) which must be adjusted to the correct frame width.
It is vital that the inner stop is adjusted correctly.
A slide plate (3) must be placed between the mounting plate and chassis´ frame.
There is a notch in the lower part of the bolster for centering on the chassi (A).
The bunk is fixed by a toothed securing plate (4) against the corresponding teeth in the bolster frame.
Please note that the plate is reversible, which makes it possible to flip the plate for a half
step adjustment.
Slide plunge (5) and spring (6) must be mounted in the fastening plate (7). The bunk is
fixated with the clamp (8) and the rubber puck (9) shall fix the toothed securing plate.
! NOTE! The bolster and stakes are relatively heavy, so
when mounting, you need some type of lifting equipment
(crane or equal) to avoid body injuries.
10
OK
3-4mm

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Art nr: AD00234_Eng REV-A © Copyright Exte fabriks AB.
The stakes are delivered from factory pre-mounted with hydraulic
cylinder and brake function.
N.B. Remove tape (1) that holds a transport security device (pin),
that in its turn holds the hydraulic cylinder in place.
Place the stake in the bolster.
Make sure the pin (2) runs through both
the bolster, stake and hydraulic cylinder.
Mounting of complete or only upper stake.
!
When lifting the complete stakes, it’s advantageous to use a strap
(A) that is stopped from sliding by using a clamp as shown in the figure.
When mounting or removing only the upper stake, it can be lifted in
the lashing arm at (B).
When the stake is seated in the bolster, the pin (2) should be mounted by
using it to slide the transport security device away until the pin is all the
way through and in its place. Mount the screws (3) with the washers (4).
Use thread lock.
The locking device (5) shall together with the nut (6) be inserted from below
into the bolster and the screw (7) and washer (8) inserted from the top.
Tighten the screw so the locking device is compressed and therefore
secures the stake in the bolster.
After using the equipment for a while the locking device must be re-tightened
to avoid the stakes vibrating loose.
USE LIFTING DEVISE TO AVOID INJURY!
! NOTE! The bunks and stakes are relatively heavy, so
when mounting, you need some type of lifting equipment
(crane or equal) to avoid body injuries.
1
(A)
(B)
3
4
2
3
4
5
6
7
8
COM 90
Lashing arm with hook shall be mounted on the left side of the vehicle.
Lashing arm with ring shall be mounted on the right side of the vehicle.
See image on pg.4.

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Art nr: AD00234_Eng REV-A © Copyright Exte fabriks AB.
Assembling the stakes and lashing arms.
At delivery of stakes the lashing arm is normally mounted.
Mounting and removing of lashing arm is described in the following images and
describes the order that is proven and works well.
Hook / Ring Rib
Lashing arm
Rack
Slide bearing plate
Pinion
A
fig. 1
1. Place the upper stake horizontally in a vice.
2. Insert the pinion from the top side of the
stake and direct the axle with mounted keyway
from the side and direct it through the pinion.
Be careful not to damage the keyway or
pinion if the fit is not perfect.
Normally hand power should be enough to push
the shaft through the pinion’s hole.
If necessary a rubber mallet can be used to
lightly tap the shaft.
Friction pads
Light greasing of the shaft is suitable before
mounting. Wood tar can also be used.
Lashing link

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Art nr: AD00234_Eng REV-A © Copyright Exte fabriks AB.
3. Mount slide bushings from both sides.
There must be a play of min 0.2 mm. between
the stake's bearing guide and the bushing.
The bushing’s hole against the shaft should
have press-fitting and a light tap with a rubber
mallet might be used for mounting.
4. With the rubber mallet, hit the shaft over to
the rear side as in the image and turn it so the
keyway has a 90° angle to the stake pipe.
This is necessary to get a correct mounting of
the hydraulic cylinder to the rack.
Grease the rack with rack grease before
mounting it in the stake.
5. With the slide bearing plate mounted on the
cylinder rack, slide it into the stake pipe’s
bottom end as in figure.
Grease
Assembling the stakes and lashing arms.
Continued.
90°
0,2

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Art nr: AD00234_Eng REV-A © Copyright Exte fabriks AB.
6. Mount the friction pads on both sides of the
brake housing and hold them in place with the
hand until the brake housing is inserted into the
stake.
Remember the support plate under the friction
pad on the piston side. See drawing.
Insert the cylinder / rack all the way until rack
and pinion grips each other.
7. A support plate can also be mounted
on the brake housing’s “fixed” side to
reduce the stroke of the piston and increasing
the usable depth of the friction pads, but this
has to be decided on a case by case basis
since the measurements of the stake profile
can vary slightly.
8. With the rack in position as shown in the
image, mount a stop screw with a few drops of
Thread locking, M10 x 20 and a thick washer
(10.5 x 22 x 4).
Friction pads
Support plate
Piston
Support plate
Don´t forget the stop screw!
Assembling the stakes and lashing arms.
Continued.
Thread locking

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Art nr: AD00234_Eng REV-A © Copyright Exte fabriks AB.
9. Mounting the lashing link.
This is done by first putting the link on the
protruding part of the shaft at (A).
Then, the lashing link is bent over the shaft’s
other end with a breaking bar at (B).
Lightly beat the shaft with a rubber mallet to
center the shaft on both sides (C).
N.B. Do not use a steel hammer to prevent
damage to the shaft ends!
10. Mount the lashing link drivers on both
sides.
The driver’s contact surface against the lashing
link must be protected against corrosion with
either grease or wood tar.
Be careful when the driver is fitted against the
lashing link to prevent damage to the surfaces.
The driver shall be fitted on the keyway at the
same time as the lashing link’s holes shall be
centered on the driver.
A light tap with the rubber mallet could be
needed to get the parts in place.
Grease / Tar
Assembling the stakes and lashing arms.
Continued.
Chassis grease can also be replaced with
wood tar.
The purpose of the tar or grease is to
protect against corrosion.
A
CB

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Art nr: AD00234_Eng REV-A © Copyright Exte fabriks AB.
11. Mount screw M10 x 170 together with the
nut protection.
12. Mount overload screw with lock nut on
both sides.
The screw should shear off at excess load or
harsh handling before the pinion or rack gets
damaged.
13. Check that the lashing link has the position
shown in the image, when the rack is run to its
top, end position.
14. Mount stake lid with 4 pcs. M10 x 20
Use your fingers to tighten the screws to make
sure the threads are gripping.
Then tighten them with a spanner.
15. Readjustment of the lashing arm position
can be done by choosing one of the three holes
available for the break pin.
Assembling the stakes and lashing arms.
Continued.

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Art nr: AD00234_Eng REV-A © Copyright Exte fabriks AB.
Right stakes
From
pump
To valves.
Truck.
This sketch should be seen
as a general placement
sketch.
Location of parts is free, but
please remember to build so
that the equipment is well
protected and easily
accessible.
½” to trailer valve
Pressure filter
mounts with its
own attachement
Hose dimensions:
Suction line = 2”
Press. line, pump - filter - valve = ½”
-”- valve - dist. block = 3/8”
-”- dist. block - stakes = 1/4”
Return line = 3/4”
Brake line = 1/4”
See desc. of
connection on
pg. 16.
A=
down A=
down
B=up B=up
1/4" 1/4"
1/4"
Distr.block
front and rearside ½” from pump
Return to tank 3/4”
Brake 1/4”
Placement of the distribution
block is free, but watch out
for crossbars and other
equipment in the frame.
Leak oil line 3/8”
between by-pass
valve and tank.
TANK
Distribution block is marked
A in and B in for connection
with 3/8” hose from main valve
Use the connection hole that fit
and plug all the others.
Distribution block is marked
A out and B out for connection
to resp A and B connection on
stake cylinder.
Brake Line
Left stakes
Main pressure valve 150 Bar
Main distribution valve
Mounting of hydraulic components TRUCK
Principle sketch
Hose routing shall be done
so that the hoses are located
in the frame and get a natural
protection.

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Art nr: AD00234_Eng REV-A © Copyright Exte fabriks AB.
The tank shall be mounted on the front
protection wall on the truck.
Lower tank bracket (1) and
Upper tank bracket (5) is delivered in a cut off
length so it can be adjusted to different type of
wallbars.
The upper brackets must be placed under the
tank lid.
Rubber protection (2) to protect the tank from
damage by abrasion
.
Front bar (8) fixes the tank with use of a screw
(7) and a rubber hose (6) as an abration
protection.
The tank is compl. with a suction hose
connection 2” (3) and a 1/2” connection (4) in
the bottom to use for an outlet hose in case of
need to empty the tank.
Oil low level sensor (9)
Connection (10) 3/8” for the hose from the
bypass valve on the pump.
Fillercap incl. air filter (11).
Returnfilter (12) incl. connection for return hose
3/4” from the main hydraulic valves.
A refill connection can be fitted on the filter in
combination with a quick connection and a hose
so the tank can be refilled by pump through the
filter.
3/4” refill hose
Outlet hose 1/2”
34
8
1
2
7
6
5
11
12
10
9
Mounting of hydraulic components TRUCK
Hydraulik tank.

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Art nr: AD00234_Eng REV-A © Copyright Exte fabriks AB.
Single stack block (Truck)
Hydraulic connections are accessible
from the back of the housing.
1. 1/2” 2 pcs. connection inputs for
pressure line, one from
pressurefilter and one for further
hose routing to the trailer valve’s
pressure connection.
2. 3/4” Return line to tank / return filter
3. 1/4” Output for brake line for further
extension to all stakes.
4. 3/8" Left stakes UP
5. 3/8" Left stakes DOWN
6. 3/8" Right stakes UP
7. 3/8" Right stakes DOWN
8. Cable entry.
Location of distribution blocks.
3
5
7
8
1
2
4
6
Preferably locate the the distribution blocks
under, or close to protection banks and
approximately centered between the Com-90
banks.
It is preferred that the hose lengths from the
distribution blocks out to all the stakes are
approximately the same.
Always have serviceability in mind!
Mounting of hydraulic components TRUCK
Hydraulic block.

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Art nr: AD00234_Eng REV-A © Copyright Exte fabriks AB.
Each pump brand has their own manual for how
installation should be done which MUST be
followed.
Make sure that the installation is done correctly.
Regardless of manufacturer the hydraulic pump
must be bled before start-up to avoid damage to
the pump.
The bleeding is done by loosening plug (5), see
below.
We recommend a shut-off valve between the
hydraulic tank and pump, for serviceability and
easier pump replacement in the future.
To avoid overheating the hydraulic pump when the
system is not activated, a leak line must be installed
between bypass block and hydraulic tank to enable
circulation of oil in the pump. See drawing.
1. Bypass block (NOT INCLUDED in Com 90-
system)
2. 2" Connection to suction line from tank
3. 1/2" Pressure line to direction valves
4. 3/8" Leak oil line to tank
5. Plug (for bleeding)
1
2
3
4
5
1
3
4
2
The magnetic spool for the by pass
valve connects to I/O-unit channel 8,
as shown at page 37.
Connecting the hydraulic pump.
!
NOTE!
Pump or by-pass valve
NOT INCLUDED
in the Com 90-system!
!
NOTE!
The system is dimensioned
for MAX flow 50 lit/min!
We recommend 40 lit/min.
Please note that this drawing shows the principle and can
differ somewhat depending on the pump brand.
Always check the pump manufacturer’s recommendations!
Bypass valve is not included in the Com 90-system.

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Art nr: AD00234_Eng REV-A © Copyright Exte fabriks AB.
Right stakes
A=
down
B=up
Left stakes
A=
down B=up
T P
1/4" 1/4"
1/4"
Brake
Trailer.
This sketch should be seen
as a general placement sketch.
Location of parts is free, place
the equipment well protected
and easily accessible.
Distr.blocks
Front and rearside.
Placeing the distribution
block is free, but take care
of crossbars and other
equipment in the frame
See connection
description on
next page.
Distribution block is marked
A out and B out for connection
to resp A and B connection on
stake cylinder.
Hose dimensions:
Pr.hose,pump-filter-valve = 1/2”
-”- valve-distr. block = 3/8”
-”- distr. block-stakes = 1/4”
Return line = 3/4”
Brake line = 1/4”
Hose and pipe routing shall
be done so that they get a
natural protection from frame
and body build.
Mounting of hydraulic components TRAILER
Principle sketch.
Main distribution valve
Trailer (2-stacks)
Place on preferred side.
If sliding table are used for one stack,
it is advantageous to use special
attachement for the distr. blocks for
one of the banks.
Distribution block is marked
A in and B in for connection
with 3/8” hose from main valve.
Use the connection hole that fit
and plug all the others.
Pressurefilter mounts with a
special bracket to the frame.

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Art nr: AD00234_Eng REV-A © Copyright Exte fabriks AB.
Two stack block (Standard trailer).
The connections are accessible
from the backside of the box.
1. 2 pcs. ½” connection inputs for pressure
line, one from pressure filter and one for
further routing if needed.
2. 3/4" Return line to tank / return filter.
3. 1/4” Connection for brake pressure
line for further extension to all stakes.
4. 3/8" Left stakes UP
5. 3/8" Left stakes DOWN
6. 3/8" Right stakes UP
7. 3/8" Right stakes DOWN
8. 3/8" Left stakes UP
9. 3/8" Left stakes DOWN
10. 3/8" Right stakse UP
11. 3/8" Right stakes DOWN
12. Cable entry.
Section (Stack)1
Section (stack) 2
Mounting of hydraulic components TRAILER
The valve block.
4
5
6
7
8
9
10
11
2
1
12
3
Banke par 1
Banke par 2

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Art nr: AD00234_Eng REV-A © Copyright Exte fabriks AB.
P T
To trailer
Hydraulic diagram Com 90 Single stack (Truck)
TANK
Main pressure 150 bar
Brake
High speed
Left
PS 2
PS 1
B4
B2
B3
B6
B5
11
2
2
13
V1
40 bar
Main pressure Brake pressure Reduced brake pressure (high speed)
Brake Brake Brake
Adjustment of lashing arm speeds
Left Right
P1 P2 P3
B3
B2
B4
B6
B5 B7
4B 4A 2B 2A 6A
6B
I/O unit channells
By-pass valve
Right
B7
Pv1
2
2
13
V1
Brake
Oil level sensor
150 bar 150 bar 40 bar
P