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Service Manual

CBD/G
2.5
3.0
3.5

Cargo Range

CARGO 2.5

BT Svenska AB
Per Wrmlund

< Tillbaka till Index

INTERNAL
COMBUSTION

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

SERVICE MANUAL

page 3

CESAB S.p.a. reserves all rights of


reproduction of this handbook

The text and the numbering system


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

CESAB reserves the right to make any


necessary modifications without obligation
to promptly update this handbook.

Copyright by
CESAB S. p. A.

BOLOGNAS FACTORY, AFTER SALES SERVICE

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

SERVICE MANUAL

page 4

INTERNAL
COMBUSTION

INDEX
TECHNICAL DATA ............................................................................................. p.

OPERATORS SEAT .......................................................................................... p.


Pedals version ................................................................................................... p.
Service brake .................................................................................................... p.

8
8
8

DASHBOARD .....................................................................................................
Dashboard indicator ..........................................................................................
Parking switch ...................................................................................................
Truck start up .....................................................................................................
Set of levers - Load handling ..............................................................................
Capacity plates .................................................................................................

p.
p.
p.
p.
p.
p.

9
9
11
11
12
12

ENDOTHERMIC ENGINE ..................................................................................


KUBOTA ENGINE .............................................................................................
Kubota engine data ...........................................................................................
Continental engine data .....................................................................................
Oil change and engine oil filter replacement .......................................................
Topping up with coolant......................................................................................
Air filter ..............................................................................................................
Cyclone prefilter .................................................................................................
Engine running-in ...............................................................................................

p.
p.
p.
p.
p.
p.
p.
p.
p.

13
13
14
15
16
16
17
17
17

ELECTRONIC HYDROSTATIC TRANSMISSION ..............................................


Example of a closed loop hydrostatic transmission ............................................
Operation of the variable displacement pump with axial pistons .........................
Operation of the electronic hydrostatic system ...................................................
Description of the main functions .......................................................................

p.
p.
p.
p.
p.

18
19
20
21
22

HYDRAULIC DIAGRAM ...................................................................................... p.

24

HYDROSTATIC PUMP ......................................................................................... p.

26

HYDRAULIC MOTOR ........................................................................................... p.


HYDROSTATIC TRANSMISSION MAINTENANCE............................................... p.
Replacing the filter and changing the transmission oil ......................................... p.

28
30
30

BRAKES .............................................................................................................
Diagram of the service brake and the parking brake systems ............................
Checking the service brake ...............................................................................
Releasing the brakes for towing of the truck.......................................................

p.
p.
p.
p.

31
31
32
32

ELECTRIC SYSTEM ............................................................................................


Battery ...............................................................................................................
Electric components ..........................................................................................
Fuse holding panel ............................................................................................

p.
p.
p.
p.

33
33
34
34

INTERNAL
COMBUSTION

SERVICE MANUAL

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

Engine actuator .................................................................................................


Potentiometer and microswitches ......................................................................
Rotary / Linear potentiometer .............................................................................
Wiring diagrams ................................................................................................

page 5

p.
p.
p.
p.

35
35
36
37

MENUS AND PARAMETERS FOR THE TCS SYSTEM ..................................... p.

39

CALIBRATION .....................................................................................................
Calibration and first start up of the transmission system .....................................
DISPLAY ..............................................................................................................
PUMP CUSTOMIZED ..........................................................................................
ENGINE CUSTOMIZED .......................................................................................
FAULT DETECTED .............................................................................................
INFORMATION / PH PARAMETERS ....................................................................
EPROM RESET ..................................................................................................
Troubles occuring while calibrating .....................................................................
System faults and failures ..................................................................................
Troubleshooting .................................................................................................

p.
p.
p.
p.
p.
p.
p.
P.
p.
p.
p.

40
42
45
46
47
48
49
50
50
56
58

WHEELS / TYRES .............................................................................................. p.


Safety of wheels and rims while using the truck .................................................. p.

59
59

STEERING UNIT ................................................................................................


Steering control .................................................................................................
Steering axle .....................................................................................................
Bearings adjustment ..........................................................................................

p.
p.
p.
p.

60
60
61
62

HYDRAULIC DISTRIBUTOR ............................................................................. p.

63

MASTS ................................................................................................................
Description of the cylinder components ..............................................................
Cylinder inspection procedures..........................................................................
Lubrication ........................................................................................................
Installation checks safety specifications .............................................................
Safety limit stops of the fork mounting carriages ................................................
Chains inspection ..............................................................................................
Fork inspection .................................................................................................

p.
p.
p.
p.
p.
p.
p.
p.

64
66
67
68
69
69
70
70

LIFTING THE TRUCK ........................................................................................ p.


Hooking points .................................................................................................. p.

71
71

TABLES ..............................................................................................................
Table for oil and grease specifications ................................................................
Table for the truck maintenance during the running-in stage ................................
Table for the maintenance schedule ...................................................................

72
72
73
74

p.
p.
p.
p.

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page 6

SERVICE MANUAL
TECHNICAL DATA

INTERNAL
COMBUSTION

INTERNAL
COMBUSTION

SERVICE MANUAL

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


page 7

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

SERVICE MANUAL

page 8

INTERNAL
COMBUSTION

FOOT PEDALS VERSION


B
C

Pedals consist of:


- two travel pedals, one forward pedal (A)
and one reverse pedal (B)
- a service brake pedal (C)

HAND DIRECTION LEVER VERSION


D

Lever of direction selector (D)

1
o

1 forward speed
o 0 neutral
2 reverse speed

One travel pedal (E)


E
C

BALANCED PEDAL VERSION


Forward pedal (F)
Reverse pedal (G)
Brake pedal (C)

SERVICE BRAKE
Foot service brake (C) controls a hydrostatic braking
in the first part of the stroke by means of the electronic
control unit; if fully pressed, it engages the oil-bath disc
brakes (over the front driving wheels).

SERVICE MANUAL

INTERNAL
COMBUSTION

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


page 9

DASHBOARD
During ordinary operation, all warning lights in the dashboard are to be off.

3 4 5

6 7

15

10 11

12 13

14

1) Fuel gauge
2) Water temperature indicator
3) Fuel level warning light
4) Generator warning light
5) Glow plug warning light (Diesel engine)
6) Parking brake-on warning light
7) Oil pressure warning light
8) Indicator light (optional)
9) Electronic hour counter
10)Water temperature warning light
11)Transmission oil temperature warning light
12)Hydraulic oil filter clogged warning light
13)Warning light (not used)
14)Warning light (not used)
15)Warning light indicating air filter clogged
A) Parking switch;
B) Electronic failure warning light
If the warning light blinks during ordinary operation, this indicates
a failure in the electronic control unit; the vehicle will stop.
C) Ignition key
D) Emergency push-button; it acts as an emergency brake.

C
B

CAUTION
The vehicle could instantaneously stop if buttons (A) and (D)
are pressed; never press those buttons during the truck ordinary
operation.

DASHBOARD INDICATORS
1) Fuel gauge
2) Coolant temperature level
Indicates the coolant temperature.
The pointer must never reach the red sector; the working temperature
corresponds to 95 C.

3) Fuel level warning light


The fuel level warning light turns on when approx. 5.5 l of fuel
are left in the tank.

4) Generator warning light


That warning light is to be off when the engine is running. If not,
it indicates that the alternator does not supply any current for the
battery or the electric system charge. This may be caused by the
breaking of the belt that drives the alternator pulley, or by a failure
of the alternator.

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

SERVICE MANUAL

page 10

6
7

INTERNAL
COMBUSTION

5) Glow plug warning light (Diesel engine).


This warning light turns on when the ignition key is in position (2);

6) Parking brake on warning light


7) Engine oil pressure warning light
During ordinary operation, this warning light is to be off.
If it turns on, immediately check the oil level in the engine. That warning
light could turn on when the engine is idling and hot, due to a lesser
lubricant viscosity, even if no failure has occurred.

8) Direction indicator on warning light (optional)

9) Electronic hour counter


It indicates the working hours and hour fractions of your truck; it is controlled
by the contact key and has the function to simplify scheduled maintenance
programming.

10

10)Coolant temperature warning light


It indicates the engine overheating. Should it turn on, stop the vehicle
immediately.
Check the correct operation of the radiator fan, the water pump and the
coolant level in the radiator.

11

11)Transmission oil temperature warning light


It indicates that the temperature limits required for the correct operation
of the pump and the hydrostatic engine have been exceeded.
Should it turn on, stop working and determine the reasons for the overtemperature
transmission oil.
Check the oil level and that the radiator is clean and in good operating
conditions.

12

12)Transmission oil filter clogged warning light (replace filter)

13

13)Warning light (not used)

14

14)Warning light (not used)

15

15)Air filter clogged warning light (replace filter)

SERVICE MANUAL

INTERNAL
COMBUSTION

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


page 11

A:
B:
1

PARKING SWITCH
ELECTRONIC FAILURE WARNING LIGHT

position 1 - Travel enabled


Switch A in position 1 enables the truck to travel (green
warning light B and warning light 6 on the dashboard are on);
brakes are engaged, but will automatically be released if the control
pedal is pressed (warning lights B and 6 turn off).

position 2 - Parking - start up


Switch A in position 2 (green warning light B off) starting of
the engine is possible. Travel blocked to prevent any accidents.
Brakes are engaged (parking condition).

2
A

HYDROSTATIC BRAKING
Lift the travel pedals or the accelerator to enable the hydrostatic braking
(adjustable) until the truck stops.
The brakes are engaged if the control pedals are not actuated within
a short period of time. When reoperating the control pedal, brakes
will be automatically be released.

TRUCK START UP
-

the operator must be seated


parking switch A in position 2 (parking)
turn the key to position 1 (ignition on)
turn the key to position 2 (glow plugs on)
turn the key to position 3 (starter contact) to start the engine
once the engine has started up, turn the parking switch
A to position 1.
- select the foward or reverse direction. The truck is ready to travel.

If the start up procedure has not been correctly performed, the truck
will not start up. If so, repeat the procedure above.
2

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SERVICE MANUAL

INTERNAL
COMBUSTION

page 12

SET OF LEVERS - LOAD HANDLING

L
K

K) Lifting control (yellow).


L) Tilt control lever (green).
M)Control lever of the sideshift or other devices (red).
N) Available (if existing; black)

OPENING ENGINE COMPARTMENT COVER

I
L

Before lifting the engine compartment cover, turn the ignition key to
pos.0.
Unlock with the key (I) and turn the handle (C).
Lift the cover by using the special handle (L)
An air spring (J) facilitates the complete lifting of the cowling.

LOAD PLATE
It identifies the load capacity with a load center
of 500 mm (except for different indications)

IDENTIFICATION PLATE
It identifies the lift truck technical data

ATTACHMENT OR SPECIAL CONDITION OF USE


MODEL Type
TYRES

LIFT HEIGHT
mm

MOTOR

SERIAL N

RATED CAPACITY
kW

SERIAL N

CENTER OF LOAD DISTANCE mm

kg

DRAW-BAR PULL (1h)


N

BATTERY MASS
kg
min.

MANUFACT. YEAR

SERVICE MASS
Without
Battery kg

kg
max.
TENSION

Cod. 0312004

Cod. 0312005

DERATED CAPACITY Kg

CAPACITY PLATE

CARRELLI ELEVATORI S.p.A.


via Persicetana vecchia, 10
40132 - Bologna - Italia

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

INTERNAL
COMBUSTION

SERVICE MANUAL

page 13

ENGINE KUBOTA 3300 - E

1
2
3
4
5
6
7
8
9

Intake manifold
Speed control lever
Engine stop lever
Shut off solenoid
Fuel feed pump
Cooling fan
Engine hook
Oil filter cartridge
Fuel filter plug

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10
11
12
13
14
15
16
17
18

Oil filler plug


Exhaust manifold
Alternator
Starter
Fan belt
Oil pressure switch
Flywheel
Oil drain plug
Oil pan

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

SERVICE MANUAL

page 14

KUBOTA V 3300 ENGINE


No. cylinders

4 in line

Bore

98 mm

Travel

110 mm

Swept volume

3318 cm

Compression ratio

22,6:1

SAE J1349 power

46 kW

Maximum torque

230 Nm
at 1600 rpm

Maximum speed (with


load)

2200 rpm

Cooling

water

Injection

indirect

Injection pump
Induction
Electrical system
Lubrication
Oil sump (capacity)
Alternator
Starter motor

in line
atmospheric
12 V
forced
13,2 L
including filter
540 W - 45 A
2.5 kW

INTERNAL
COMBUSTION

SERVICE MANUAL

INTERNAL
COMBUSTION

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


page 15

CONTINENTAL TM 27 ENGINE
No. cylinders
Bore

4 in line
91 mm

Travel

103,5 mm

Swept volume

2700 cm

Compression ratio

8:1

SAE J1349 power

43 kW

Maximum torque

200 Nm
at 1500 rpm

Maximum speed (with


load)

2400 rpm
2200 rpm

Cooling

water

Feeding

LPG

Induction
Electrical system
Lubrication
Oil sump (capacity)
Alternator
Starter motor

atmospheric
12 V
forced
4 L
12 V - 65 A
1.4 kW

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

SERVICE MANUAL

INTERNAL
COMBUSTION

page 16

OIL CHANGE AND ENGINE OIL FILTER REPLACEMENT


The oil level in the sump is checked with the dip-stick, making sure that the level is
between the MIN and MAX notches.
If it is necessary to top up, use the same oil as that used for filling.

CHANGING OIL AND FILTER


After the first 50 hours: change oil and filter of the engine
and then
every 50 hours: check oil engine level
every 250 hours: change oil and filter of the engine
To replace the oil and the filter, proceed as follows:
-with the engine hot, remove filling cap, then unscrew the drain plug and allow the oil
to drain out.
-Unscrew the engine filter cartridge.
-Fit the new filter and tighten it, paying particular attention to the position of the seal that
should be previously oiled.
-Tighten the drain plug and fill the oil sump up to the Max level on the dip-stick.

TOPPING UP WITH COOLANT


Every 50 hours
- Make sure the coolant level is up to the radiator cap (B).

The caps of the tank and radiator must be removed only when
the engine is cold.
Every 250 hours
- clean the radiator outside.
Every 2000 hours
- replace the coolant mixture;
check the freezing point of the coolant mixture, especially when
driving areas with cold weather.
The truck is supplied with a 50% mixture of coolant. If you want to vary
the mixture, refer to the values stated in the table below.

ANTIFREEZE APPLICATION RANGE


10%

20%

30%

40%

50%

% VOLUME OF ANTIFREEZE

-4 C

-10 C

-17 C

-24 C

-40 C

FREEZING TEMPERATURE

101 C

102 C

104 C

106 C

109 C

BOILING TEMPERATURE

SERVICE MANUAL

INTERNAL
COMBUSTION

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


page 17

AIR FILTER
The air suction filter for the fuel supply is composed of two filtering
elements.
Every 250 hours
- Clean the element outside the filter (the element inside is not to be
cleaned).
The filter is to be cleaned also when relevant warning light (15) on
the dashboard turns on.
Every 3 cleaning cycles
- replace the element inside the filter
Every 6 cleaning cycles, or once a year
- replace the element outside the filter.

Disassembling and cleaning the filter


- release the cover fastening screws and remove the filter cartridge;
- clean with compressed air (MAX. 5 bar pressure) from the inside
towards the outside;
- check that no tear is to be found.
Never hit the cartridge on hard surfaces.
Never use any mixture of water and detergent to clean the
filter.
When reassembling the filter cover, make sure that the dust
emptying opening is turned downwards.

CYLONE PREFILTER
A

Every 8 hours
- clean the cyclone prefilter.

Cleaning the cyclone prefilter


- loosen wing-nut (A);
- remove cover (B);
- remove tank (C);
- empty the tank and reassemble.

ENGINE RUNNING-IN
During the running-in period, the engine may consume more oil than
usual. It is recommended that the oil level be checked every 8 working
hours, with engine at stand still for at least 10 minutes.
Do not use the engine at its peak RPM until it has reached its working
temperature.

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

SERVICE MANUAL

INTERNAL
COMBUSTION

page 18

HYDROSTATIC TRANSMISSION
Hydrostatic transmission consists of a variable displacement pump, which is
controlled by the thermal engine and which delivers oil towards two hydraulic
motors that drive the front wheels.
The hydraulic connections of both motors allow a proportional division of the
oil flow generated by the hydrostatic transmission, so as to support the outer
wheel while turning; that kind of transmission acts as the differential transmission.

The control and adjustment of the electronic transmission are made by


a control unit (Total Control System) that drives the following:

thermal engine

hydrostratic pump

hydraulic motors

parking brakes
by means of sensors:

potentiometers (on the accelerator pedal, the brake/inching pedal and the mast lever)

switches (on the tilt levers and sideshift, the forward/reverse gearshift lever and to engage the parking
brake)

potentiometer detecting the pump displacement

sensor of the thermal engine speed of rotation


and by means of actuators:

proportional solenoid valves of the hydrostatic pump (displacement adjustment)

actuator on the thermal engine (adjustment of the fuel pump or the carburettor)

solenoid valve for the displacement shifting of the hydraulic motors

solenoid valve for the parking brakes release


Control unit
Portable
Terminal

Travel pedal

Brake/inching
pedal

Parking brake switch


Potentiometer on
mast lever

Running direction
selector
Thermal engine
speed sensor

Hydrostatic
pump

Solenoid valve for parking


brake release
Thermal engine actuator

Failure warning
light

INTERNAL
COMBUSTION

SERVICE MANUAL

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


page 19

EXAMPLE OF A CLOSED LOOP HYDROSTATIC TRANSMISSION

Basic system - pump / motor

The system is equipped with two max. pressure valves, one on each side of the high pressure circuit.
There function is to protect the hydrostatic transmission (pump and motor) from overloads.

circuit.tif

On the hydraulic motor, and on the pump there are some internal oil leakage (for lubrication and cooling).
This oil is brought back to the tank.

An integrated auxiliary pump is used for restoring of the lost oil. The system is completed
by an pressure reducing valve, to control the charge pressure.

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


page 20

SERVICE MANUAL

INTERNAL
COMBUSTION

OPERATION OF THE VARIABLE DISPLACEMENT PUMP WITH AXIAL


PISTONS
The capacity of the pump is depending of the rpm, and of
the displacement, which can be changed in continuity.
By increasing the tilting of the plate, the capacity
increases from 0, to the max. value.

On tilt 0, it corresponds to 0 mm
of stroke, therefore 0 capacity.
(machine stopped)

If the tilting plate of the pump is positioned


beyond the neutral point, the oil flow direction
will be inverted.

INTERNAL
COMBUSTION

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

SERVICE MANUAL

page 21

OPERATION OF THE ELECTRONIC HYDROSTATIC SYSTEM

4
3

14

17

16

13

10

15

8
11

12
6
7

le
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

Thermal engine
Hydrostatic pump
Hydraulic motors with built-in parking brake
Boost pump (charge pump)
Solenoid valves adjusting the pump displacement (proportionella > 0-5V)
TCS control unit
Accelerator pedal (0-5V)
Direction selector (steering-wheel operated reverse gear with single pedal or acting directly on the
double/swaying pedal system)
Actuator of the thermal engine
Sensor for the motor speed of rotation
Sensor for the hydrostatic pump displacement (magnet potentiometer)
Brake pedal (0-5V, 0-95% av rrelsen=hydrostatbroms. 95-100% = parkeringsbroms)
Solenoid valve to release the brakes on the motors
Parking brake switch
Fault warning light
Service pump
potentiometer/microswitches on the mast lever, the tilt system, the sideshift and any auxiliary
devices. (lyftpotentiometer > 0-5V)

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

SERVICE MANUAL

page 22

INTERNAL
COMBUSTION

DESCRIPTION OF THE MAIN FUNCTIONS


TRUCK TRAVEL The thermal engine may only be started if the parking brake is on.
The system allows the pump to increase the displacement (truck motion) only if:
- the motor is running
- the parking brake is off
- the running selector is not in neutral position.
Should one of those conditions not be true, the actuation of the accelerator pedal will only
result in thermal engine speeding up.
The position of the accelerator pedal - through the thermal engine and the hydrostatic pump affects the truck speed, i.e. each position of the pedal potentiometer corresponds to the
following preset values, according to the setting values programmed in the control unit:
- speed of the thermal engine
- pump displacement.
ACCELERATION / DECELERATION The truck acceleration depends on the speed
with which the accelerator pedal is pressed and on the parameters set in the control unit.
BRAKING / INCHING The brake pedal has two functions: 1) hydrostatic braking (the
pump displacement cancels itself out) with a strength depending on the pedal stroke; 2) inching
function, that can be obtained by simultaneously pressing the brake pedal and the accelerator
pedal.
PUMP DISPLACEMENT The displacement of the hydrostatic pump depends on the stroke
of the accelerator pedal (and on the stroke of the brake pedal in the inching function). The
accelerator pedal also determines the rate of rotation of the thermal engine (by means of the
actuator).
ANTISTALL FUNCTION During the truck ordinary operation, if the power required by
the hydrostatic transmission exceeds the power that may be supplied to the thermal engine,
the pump displacement will be automatically reduced to avoid the engine to stall.
PARKING BRAKE The parking brake is engaged by pressing a switch located next to the
distributor levers. When the parking brake is on, the accelerator pedal is disabled (the thermal
engine accelerates, but the truck cannot run). If the parking brake is engaged while the truck
is running, the driving wheels will be automatically locked. Therefore, avoid engaging the
parking brake while the truck is running, unless you are in an emergency condition.
CONSTANT SPEED When using the mast levers, tilt system and sideshift, the thermal
engine automatically accelerates to meet the request for additional power; the pump
displacement will be simultaneously reduced to ensure that the truck speed is kept constant.

INTERNAL
COMBUSTION

SERVICE MANUAL

RUNNING DIRECTION May be selected through the steering-wheel operated reverse


gear (for simple pedals) or the forward/reverse pedals (for the double and swaying pedal
system). If the lever of the steering-wheel operated reverse gear is shifted to the neutral
position while the truck is running (or the accelerator pedal is released in case of double pedal
system), the truck will hydrostatically brake. If the running direction is reversed while the
truck is running, a hydrostatic braking will occur, which will be immediately followed by the
acceleration in the opposite running direction.
PARAMETER SETTING Most part of the transmission operation parameters may be set
via portable terminal.
CALIBRATION The system sensors and actuators (pedals, motor actuator, etc.) are to be
calibrated using the portable terminal.
FAULT DETECTION A warning light located beside the distributor lever indicates the
system faults (the warning light starts blinking). If the failure concerns the hydrostatic pump,
the truck will immediately stop.
DIAGNOSTICS The portable terminal, which is connected to the control unit, allows to
detect and to store any system fault.
DISPLAY The display of the portable terminal allows to view the information about the
transmission operation (thermal engine speed, pump displacement, and so on).
THERMAL ENGINE OPTIMIZATION The thermal engine operation (rate of rotation)
is optimized according to the truck speed the operator needs.
SPEED DECREASE (OPTIONAL) The truck speed may be decreased for example in
case of transmission oil overtemperature.

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page 23

Oljefilter

Fram&Back

Orbitrol
Styrning

Gaspedal

A=Bypasskruv fr bogsering

Broms
Prioriteringsventil

Exchange valve, 19bar


(terfyllnad av systemet, kompensation fr lckolja)

HYDRAULIC DIAGRAM

Magnetventil
Broms

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SERVICE MANUAL

INTERNAL
COMBUSTION

page 25
HIGH PRESSURE CHECK POINT

HIGH PRESSURE CIRCUIT

BOOST PRESSURE CHECK POINT


HIGH PRESSURE CHECK POINT

EXCHANGE VALVE

OIL RETURN TO
TANK
NEGATIVE BRAKE
ELECTROVALVE

LOW PRESSURE CIRCUIT


BY-PASS VALVE
2 BAR

TRANSMISSION
SUCTION

RETURN

LIFTING
OIL

TEMP

LIFTING
SUCTION

AUXILIARY SERVICE
CHECKING POINT

RETURN
TRANSMISSION
OIL

DRAINAGE
MOTEURS

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

SERVICE MANUAL

INTERNAL
COMBUSTION

page 26

HYDROSTATIC PUMP
PUMP Mod. POCLAIN PV75 SA (Eaton, USA)
Displacement
Boost pump displacement
Max. pressure measured in M1 or M2 (stall)
Boost pressure measured in M3
Drain pressure measured in T1 or T2
(cold pump) or after temperature stabilization
Vacuum pressure (absolute pr., measured in S)

75.5 cc/rev
13.9 cc/rev
450 Bar
24-30 Bar
max. 5 Bar
max. 2.8 Bar
0.8 Bar

EXCHANGE UNIT
Valve setting

19 Bar

Boost pump

Solenoid valves

Displacement adjusting
plate
Actuator
To motors
Pump displacement
potentiometer
Hydrostatic
pump

The pump displacement is controlled by two proportional solenoid valves which are fed by
the boost pressure and controlled by the control unit through an electric signal. The spool shift
of the solenoid valves controls the pressure over the two chambers of a piston servocontrol
that is mechanically coupled to the pump plate; the difference in pressure between the two
chambers determines the piston shift, i.e. the displacement shifting.
The pump displacement is then detected by a rotary potentiometer sending a signal proportional
to the plate shift.
The electric control through the solenoid valves and the potentiometer represents a feedbacked
circuit for the adjustment of the pump displacement.
A sensor detecting the speed of rotation is to be found as well.

(from the exchange unit)


M
2
POTENTIOMETER
E
MEASURING THE PUMP
DISPLACEMENT
V

T1
1 1/16 - 12 UN - 2B

MECHANICAL ZERO
ADJUSTMENT

POTENTIOMETER
CONNECTOR

L
A

B
HIGH PRESSURE

MOTOR
SIDE

TION

PROPORTIONAL
SERVOVALVES FOR
THE DISPLACEMENT
ADJUSTMENT
S
CHARGE PUMP INLET PORT
(FROM THE OIL FIL

T
O
SENSOR FOR THE SPEED OF
R

DRAIN OUTLET

SERVICE MANUAL

(to the radiator)

A
HIGH PRESSURE
(to motors)

INTERNAL
COMBUSTION

DRAIN INLET

< 0-5V (2,5V i mittlget)

SERVOVALVE CONNECTOR

T2
1 1/16 - 12 UN - 2B

VE PRESSURE
BOOST V SOCKET 2

5
HIGH PRESSURE DETECTIONMSOCKET
M2

9/16 - 18 UNF - 2B

VE PRESSURE SOCKET 1
M4

BOOST PRESSURE SOCKET


M3

7/8 - 14 UN - 2B

A
V

O
V

HIGH PRESSURE DETECTION SOCKET


M1

9/16 - 18 UNF - 2B

V
R
E

7/16 - 20 UNF - 2B

S
7/16 - 20 UNF - 2B

page 27

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

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

SERVICE MANUAL

page 28

INTERNAL
COMBUSTION

HYDRAULIC MOTOR
Motors Poclain MS 05 (radial pistons)
Maximum displacement
Maximum pressure
Theoretical torque
Maximum speed
Brake
Braking torque
Number of pistons
Brake driving pressure (measured in x)
Displacement shifting driving pressure (measured in y)
Drain pressure (measured in 1) with cold motor
after temperature stabilization

wheel
hub

cylinder
unit

distributor

468 cc/rev
450 Bar
740 Nm
240 RPM
multidisc type
max. 3060 Nm
8
12-30 Bar
10-30 Bar
max. 3 Bar
max. 1.5 Bar

brake

INTERNAL
COMBUSTION

SERVICE MANUAL

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


page 29

The hydraulic motor is of slow type. Due to its radial


pistons, it is characterized by a high displacement/rev (if
compared to engines with axial pistons) so it produces a
high torque at a low speed rate, with no reduction gear
between the engine and the wheel hub.

The engine is also equipped with an oil-bath multidisc brake that is normally engaged
(wheel locked) by the pre-load of a Belleville washer (negative brake); the brake is
hydraulically released by means of a solenoid valve controlled by the control unit: when
the solenoid is fed, the valve opens and the fuel boost pressure on the brake piston
releases the brake.
The multidisc brake on the motor is used only for the truck parking and emergency
braking; on the other hand, service breaking is a hydrostatic one.
The motor-brake unit is fully lubricated by the transmission oil (oil dripping from the
hydraulic motor).

R, L High pression inlet - 3/4 GAS


1
Drain hole 3/8 GAS
X
Negative brake pilote 1/4 GAS

Braking release hole- M12 x 1,75

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SERVICE MANUAL

page 30

INTERNAL
COMBUSTION

HYDROSTATIC TRANSMISSION MAINTENANCE


The transmission system and hoisting system have the same oil tank, which is provided with one
filter.
Components of the transmission system:
A) Oil level dipstick
B) Oil bleeding hole
C) Hydraulic oil filter unit
D) Oil filling hole
Maintenance consists of the oil change and filter replacement in
order to keep the circuit clean.
B

REPLACING THE FILTER AND CHANGING THE


TRANSMISSION OIL

After 50 hours
- First transmission filter replacement.
After 500 hours
- Second transmission filter replacement;
- First oil change for the transmission/hoisting systems.
Then, every 2,000 hours
- transmission filter replacement;
- oil change for the transmission/hoisting systems.

The oil change is to be performed once a year. The filter is to be changed also when it gets
clogged - warning light (12) on the dashboard on; in that case, replace the filter cartridge
immediately.
To replace the filter, do the following:
- re move plug (C) and extract the filter
- insert the new cartridge and close.
To change the oil in the tank for the transmission and hoisting systems, do the following:
- change the oil while the engine is still hot;
- remove plugs (A) (C) and (T) and let the fluid flow out;
- carefully clean the oil tank;
- fill the tank with clean oil up to the max. level marked on dipstick (A) after fastening drain plug (T).
- only use the oil types mentioned in the specifications section in this manual;
- do not use oil that deteriorated due to a long storage.
After replacing the filter and changing the transmission oil:
- start up the engine, let it idle for about 5-10 minutes while the vehicle is standstill;
- check the oil level; top up, when required.

SERVICE MANUAL

INTERNAL
COMBUSTION

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


page 31

BRAKES
The brake pedal has two different functions:
- braking (if it is used alone)
- inching function if it is used simultaneously with the accelerator pedal.
The brake pedal stroke is divided into two configurable intervals:
0 to 95 % of the whole stroke: hydrostatic braking. The control unit reduces the pump
displacement according to a programmed ramp. The braking effect is proportional to the
pedal stroke.
95 to 100 % of the whole stroke: mechanical braking. The pump displacement cancels
itself out in about 1.5 secs and the negative brakes get engaged.
During ordinary operation, if the truck is slowed down and stopped, the mechanical brakes
act automatically (after approx. 0.5 secs) on motors. Press the accelerator pedal again to
release the brake and to speed up.
When the mechanical brake is engaged, the relevant warning light on the dashboard turns on.
The braking effect may also be obtained by releasing the accelerator pedal (hydrostatic braking)
or by reversing the running direction (hydrostatic reverse braking, more efficient than the mere
hydrostatic braking).

B
S

DIAGRAM OF THE SERVICE BRAKE


AND PARKING BRAKE SYSTEMS

C
D
E
F

A) Hydraulic motor
B) Brake unit
C) Solenoid valve
D) Tank
E) Electronic control unit
F) Hydrostatic transmission
G) Service brake pedal
H) Parking switch
I) Potentiometer

I
H

Every 4,000 hours


- replace solenoid valve (C) for the brake control.
H

Every 10,000 hours


- replace brake hoses (S).

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

SERVICE MANUAL

page 32

CHECKING THE SERVICE BRAKE


The disc brakes are in oil-bath; they make use of the same oil as the traction hydraulic
motors.
The disc brake unit is composed of 11 discs and 11 counterdiscs. The total disc
thickness is: min. 27 mm, max. 34 mm.
Every 250 hours
- check the pedal operation; the pedal has to be free from any obstacle;
- check the brake wear;

RELEASING THE BRAKES FOR THE TRUCK TOWING


In case of breakdown, previously release the brake discs inside the two traction units
to tow the truck.
Brake release
Position appropriate tool (M), code 1996086 (M12 x 1,75), one for each brake unit;
tighten screw (N) into hole (L) on the brake unit; keep tool (M) locked and tighten
nut (O) until the brakes unlock.

L
N

INTERNAL
COMBUSTION

SERVICE MANUAL

INTERNAL
COMBUSTION

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


page 33

ELECTRIC SYSTEM
Every 500 hours
- check the push-buttons wiring and operation;
- check the operation of the microswitches located on the pedals;
Every 1000 hours
- inspect wiring and connections; check if the cable terminals are properly tightened
and the cable insulation is intact.
WARNING:
DISCONNECT THE TRUCK BATTERY BEFORE SERVICING
THE ELECTRIC SYSTEM AND THE ELECTRONIC EQUIPMENT.
P

BATTERY

Battery (P) is located under the engine bonnet; before servicing, always
disconnect safety connector (Q).
Every 500 hours
- clean the battery poles and terminals;
- grease and tighten the terminals;
Every 1,000 hours
- check the earth connections.
Every 4,000 hours
- replace the battery.
The battery supplied has a min. 100 Ah capacitance.
If the battery is a maintenance-free one, inspect as follows:
Every 50 hours
- check the electrolyte level and density; top up with distilled water,
if necessary.
The battery is to be recharged when its voltage has decreased by
1.7V or the electrolyte thickness is under 1.16 kg/dm3.
When the truck is running, never disconnect the battery cables,
so as to avoid dangerous voltage peaks to the alternator diodes.

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

SERVICE MANUAL

page 34

INTERNAL
COMBUSTION

ELECTRIC COMPONENTS
FUSE HOLDING PANEL
Lift the engine bonnet to reach to the fuse panel, which is located below the support of the distributor
controls.
The panel is composed of a fuse block (A), of some relays (B) and optional intermittance (C).
Disassemble the protecting panel to replace the component.

Fuse specifications
1
F1 alternator, starter
2
F2 horn
5
F5 system protection
7
F7 alternator
8
F8 engine stop
11 F11 glow plug
15 F15 rear lights - reverse light
16- F16-rear lights - brake/stop light
the other fuses are intended for optional systems

40A
5 A
7.5 A
7.5 A
5 A
5 A
5 A
5 A

Before replacing a fuse, make sure that the problem generating fuse burning has been solved.
Relays
E1 - start up
E2 - brake validation
E3 - glow plug warning light (diesel engine)
E4 - reverse speed validation
E5 - forward speed validation
E6 - brake/stop rear light
E8 - reverse rear light

E3-E4-E5-E6-E8-E9
RELAIS TYPE

the other fuses are intended for optional systems

CODE

E1-E2
RELAIS TYPE
CODE

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

SERVICE MANUAL

INTERNAL
COMBUSTION

page 35

RED

YELLOW

BROWN

BLUE

BLACK

ENGINE ACTUATOR
The engine actuator is controlled by TCS control unit; it adjusts the Diesel engine injection pump.
The engine actuator is composed of an electric motor controlling the control shaft of the pump tie
rod and of a potentiometer detecting the shaft rotation and generating a feedback electric signal
(voltage).
When calibrating, the control unit correlates the actuator stroke (rotation) measured by the
potentiometer with the thermal engine speed of rotation, measured by the sensor located on the
hydrostatic pump. The unit composed of the actuator and the rev sensor is a feedback system
intended for adjusting the engine speed.

WARNING - POTENTIOMETERS AND MICROSWITCHES


To avoid compromising the functional characters of the truck, fixing or adjusting of the potentiometers
(D), the micrositches (B), the mechanical stops (C) and the accelerator control tie-rod (D), is
forbidden.
B

A
C

C
C

BRAKE PEDAL
TRAVEL PEDAL

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

SERVICE MANUAL

INTERNAL
COMBUSTION

page 36

ROTARY POTENTIOMETER
(on the accelerator and brake pedals)

LINEAR POTENTIOMETER
(on the mast lever)

resistance:
2.5 kohm
electric stroke:
54
mechanical stroke: 60

resistance:
5 kohm
electric stroke:
10 mm
mechanical stroke: 12.5 mm
yellow

red
green

red

yellow
green

AMP CONNECTOR
(on control unit)

type: 144-796-1
55-pin

Page 37

Page 38

INTERNAL
COMBUSTION

SERVICE MANUAL

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


page 39

MENUS AND PARAMETERS FOR THE TCS


SYSTEM
The parameters for the transmission control are composed of submenus and may be viewed
and modified through the portable terminal (code 0058039), that may be connected to the
control unit .

Fr att programmera en ls TCS-box:


Anslut Pin 18 och 55 till BAnslut Pin 19 och 37 till B+

The [ENTER] key is used for selecting a menu or submenu and for the confirmation of a
parameter numeric value.
The [ESC] key is used for quitting a menu or submenu or for deleting the last character
entered.
The [+] and [-] keys are used for moving through the menu list or increasing and decreasing
the numeric value of a parameter.
Use the numeric keypad to enter the parameter values; use the [.] key for decimal places.

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

SERVICE MANUAL

page 40

INTERNAL
COMBUSTION

The main menus are listed below:

N. Menu
1
2
3
4

5
6
7
8

Functions

CALIBRATION

to calibrate potentiometers and transmission actuators (pedals,


distributor, engine actuator, ...)
DISPLAY
to display the information on the transmission (thermal engine speed,
pump displacement, antistall function, ...)
PUMP CUSTOMIZED
to customize the transmission (more or less prompt breaking and
acceleration)
ENGINE CUSTOMIZED
to customatize the thermal engine control (higher or lower acceleration
of the thermal engine, engine speed when the tilt system and the
sideshift are on, ...)
FAULT DETECTED
to display the system faults
INFORMATION
software versions
PH PARAMETERS (password) configuration of the system operation parameters
EEPROM RESET (password) to reset the control unit memory

1) CALIBRATION
The CALIBRATION menu is used. That menu has two functions:
when the parking brake is locked and the calibration status parameter is not locked , it allows the
calibration and configuration of the system elements (calibrating mode);
when the parking brake is not locked or the calibration status parameter is locked, that menu
allows to view the output voltages of the system sensors and the state of some components (display mode).
After any calibration, release and engage the parking brake again to exit from the calibration status mode and
return to the standard operating mode.

INTERNAL
COMBUSTION

SERVICE MANUAL

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


page 41

CALIBRATION MENU
N. SUBMENU
A travel pedal

CALIBRATION MODE
calibration of the travel pedal

B brake/inching
pedal
C mast lever

calibration of the brake pedal

D engine calibration

calibration of the actuator-thermal

E
F
G
H

I
L
M
(*)
N

calibration of the mast lever

pump neutral

calibration of the pump in neutral


position
max. forward
limiting of the truck max.
speed
forward speed
max. reverse
limiting of the truck max.
speed
reverse speed
parking brake set definition of the brake pedal
position in which the mechanical
pedal is engaged
min engine speed definition of the minimum engine
RPM (tomgng)
max engine speed definition of the maximum engine
RPM (fullvarv)
pump pot. inverted definition of the connections type
of the pump potentiometer
calibration status
lock or unlock the calibration
menu

DISPLAY MODE
display of the voltage supplied by the
potentiometer for the travel pedal
display of the voltage supplied by the
potentiometer for the brake pedal
display of the voltage supplied by the
potentiometer for the mast lever
display of the voltage supplied by the
engine potentiometer for the actuator
display of the voltage supplied by the
potentiometer for the hydrostatic pump
display of the truck forward speed
(as a percentage of the max. speed)
display of the truck reverse speed
(as a percentage of the max. speed)
displays the brake pedal position in which
the mechanical brake is locked
displays the minimun engine RPM
displays the maximum engine RPM
displays the connections type
of the pump potentiometer
status of the calibration menu

(*) With Hall potentiometer software only

For the TCS correct operation, the voltage values read by the potentiometers in the pedals, the mast
system and the motor actuator must not exceed the limits set. If the mechanical limit stops of the
potentiometer are not properly adjusted, the voltage supplied by the potentiometers and exceeding
the range of values allowed by the control unit disables the calibration procedure.
That trouble may also occur after a correct calibration if, for whatever reason, the limit stop is
modified.

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

SERVICE MANUAL

page 42

INTERNAL
COMBUSTION

CALIBRATION AND FIRST START UP OF THE TRANSMISSION SYSTEM


The system calibration is to be performed when the thermal engine is stopped. The following are to be calibrated:

Potentiometer for the travel pedal (TRAVEL PEDAL)


Potentiometer for the brake pedal (BRAKE/INCHING PEDAL)
Potentiometer for the mast lever (MAST LEVER)
Feedback potentiometer for the hydrostatic pump (PUMP NEUTRAL)

While calibrating, check the parameters below:


Max. forward speed (truck max. speed)
Max. reverse speed (truck max. speed)
Parking brake set (brake setting)
Min engine speed (minimum engine RPM)
Max engine speed (maximum engine RPM)
Pump pot. inverted (with potentiometer Hall effect only)

100 %
100 %
95 %
850
2250
Enable

Calibration also includes the actuator setting while the thermal engine is running (ENGINE CALIBRATION). For
the engine calibration, do the following:

Lift the truck onto the shim blocks


Fill the hydraulic circuit and bleed the air
Engage the parking brake
Select the neutral position (through the steering-wheel operated reverse gear)
Start up the engine and wait for the stabilization of the fuel boost pressure
Adjust the engine min. and max. RPM through the actuator limit stop screws (the limit stops are to be obtained
on the actuator support, not on the injection pump). The engine RPM is to be measured through the engine
speed parameter in the DISPLAY menu.
Calibrate the actuator (ENGINE CALIBRATION)
Press the accelerator pedal; the actuator has to rotate clockwise and the voltage of the feedback potentiometer
in the actuator has to increase (such voltage may be measured in the engine calibration parameter in the
calibration menu after engaging the parking brake).
Once the calibration procedure is over, check the transmission operation (wheels must be up):
Release the parking brake
Position the steering-wheel operated reverse gear to forward gear
Gradually press the forward pedal: wheels should slowly rotate forwards.
CAUTION: the hydraulic motors must not rotate quickly when wheels are up.
When wheels rotate forwards, check that the voltage of the pump feedback potentiometer increases from 2.5 to
5 volts (for the voltage detection, use pump neutral parameter in the calibration menu).
Check the correct operation under the following conditions:
- mast lifting, sideshift and tilt operation, etc.: if the relevant levers are adjusted, the thermal engine
will accelerate.
- forward/reverse speed and braking
- parking brake: if engaged, the travel pedal will be disabled (the engine RPM will increase, but the truck
wheels will be locked)
- emergency button.

SERVICE MANUAL

INTERNAL
COMBUSTION

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


page 43

A) TRAVEL PEDAL CALIBRATION


For calibrating, voltages are not to exceed the following ranges (voltages may be detected in display mode):
pedal in its min. position 0,35 - 2,4 volts
pedal in its max. position 2,6 - 4,65 volts
(the supply voltage of all sensors is of 5 Volts)

(7 - 48 % of the supply voltage)


(52 - 93 % of the supply voltage)

SEE THE DIAGRAM FOR USING CONSOLE


SECTION CALIBRATION

Vid 2-pedal system:


Se till att max positionerna r
lika fr fram och back!

B) BRAKE / INCHING CALIBRATION


Allows to define the voltage values corresponding to the min. and max. positions of the brake pedal (and the
inching function).
For calibrating, voltages are not to exceed the following ranges:
pedal in its min. position 0,35 - 2,4 volts
pedal in its max. position 2,6 - 4,65 volts

(7 - 48 % of the supply voltage)


(52 - 93 % of the supply voltage)

SEE THE DIAGRAM FOR USING CONSOLE


SECTION CALIBRATION
C) MAST LEVER CALIBRATION
Allows to define the voltage values corresponding to the maximum and minimum positions of the mast lever.
For calibrating, voltages are not to exceed the following ranges:
lever in neutral position
lever fully pulled

0,35 - 2,3volts
2,4 - 4,65 volts

(7 - 46 % of the supply voltage)


(48 - 93 % of the supply voltage)

SEE THE DIAGRAM FOR USING CONSOLE


SECTION CALIBRATION
D) ENGINE CALIBRATION
Allows to match the actuator angular position (voltage of the actuator feedback potentiometer) with the engine
speed of rotation values.
For calibration, voltages are not to exceed the following ranges:
actuator in its min. position
0,35 - 2,4 volts
(7 - 48 % of the supply voltage)
actuator in its max. position
2,6 - 4,65 volts
(52 - 93 % of the supply voltage)
Such values may be viewed if the parking brake is engaged.

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

SERVICE MANUAL

page 44

INTERNAL
COMBUSTION

SEE THE DIAGRAM FOR USING CONSOLE


SECTION CALIBRATION
The control unit automatically controls the actuator by bringing it to its minimum and maximum positions (that are
determined by the mechanical limit stops located on the actuator support). With respect to the min. and max.
positions, TCS reads the min. and max. RPM as well as some intermediate values.
The limit stops are to be obtained on the actuator, not on the injection pump.
E) PUMP NEUTRAL CALIBRATION
Allows to define the voltage corresponding to the neutral displacement position of the hydrostatic pump (feedback
potentiometer).
The voltage value must not exceed the following range: 2.49 to 2.51 volts.
(In display mode and when the truck is running, the voltage value must vary. When the wheels rotate forwards, the
potentiometer voltage must tend to 5 Volts and remain constant).
SEE THE DIAGRAM FOR USING CONSOLE
SECTION CALIBRATION
F) MAX FORWARD SPEED
This parameter (expressed as a percentage of the truck forward max. speed) limits the travel speed. This parameter
may be modified (in calibration mode).
G) MAX REVERSE SPEED
This parameter (expressed as a percentage of the truck reverse max. speed) limits the travel speed. This parameter
may be modified (in calibration mode).
H) PARKING BRAKE SET
This parameter defines the stroke of the brake pedal necesary to engage the mechanical brake. The standard
value is 95%. It is suggested that this value be not changed. Limit values: 90 to 95%.
I) MIN ENGINE SPEED
This parameter defines the minimum engine RPM (standard value 850).
L) MAX ENGINE SPEED
This parameter defines the maximum engine RPM (standard value 2250).
M) PUMP POT. INVERTED
This parameter defines the connections type of the pump potentiometer.
This parameter is present with the Hall potentiometer software only.
N) CALIBRATION STATUS
This parameter enables or disables the calibration mode.

INTERNAL
COMBUSTION

SERVICE MANUAL

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


page 45

2) DISPLAY
This menu displays the transmission data.
Press [ENTER] to display a data (e.g. thermal engine speed). Hold down the key to display data in sequence.
ENGINE SPEED
Real speed of the thermal engine (expressed in RPM).

(9 pulser/varv)

PUMP DISPLACEMENT
Pump displacement required by TCS (expressed in cc). Warning: this is the displacement control sent by the
control unit to the pump, so the value displayed may be different from the real displacement.
ENGINE COMMAND
Speed of the thermal engine required by TCS (in RPM).
ANTISTALL
Indicates whether the antistall function is enabled or not (enable/disable).
PARKING BRAKE
Displays whether the negative brakes are set or not (set/not set).
BRAKE SWITCH
Displays whether the parking brake switch is set or not (set/not set).
MAST ENGINE COMMAND
Speed of the thermal engine required by TCS (in RPM) when the mast is actuated.
PUMP FEED-BACK
Actual displacement of the pump (expressed in cc). This is the displacement measured by the potentiometer
located on the pump.
DIRECTION SWITCH
Displays the running direction controlled by the pedal microswitches or the steering-wheel operated reverse
gear (neutral/forward/reverse).
MAST SWITCH
Displays the state of the distributor microswitches

1 = tilt/sideshift (set/not set).

CONSTANT SPEED
Displays the constant speed function enabling when the mast is actuated while the truck is running (set/not set).
ACTUATOR FEED BACK
Displays the engine actuator signal in Volt. Increase during the acceleration and vice versa.
POWER SUPPLY
Displays the voltage supply of the contol unit: battey voltage (12 V). Must be between 9,5 and 48,5 Volt.
SENSOR EXCITATION
Displays the voltage supply of the sensor. Correct value 5 Volt.
NEUTRAL DRIFT
Displays the value difference between the theorical and real pump potentiometer value (in mV).
This parameter is present with the Hall potentiometer software only.

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

SERVICE MANUAL

INTERNAL
COMBUSTION

page 46

3) PUMP CUSTOMIZED
Allows setting of the parameters who controls the hydrostatic pump.
These parameters is used to modify the acceleration and deceleration of the truck.
First the modification of these parameters must enabled (calibration status - not locked).
TRAVEL PEDAL INC. (sekunder frn neutral till full utvinkling)
This parameter defines how long time it takes for the pump to reach its max. displacement when the travel
pedal is fully pressed ( higher value of this parameter = softer acceleration of the truck).
TRAVEL PEDAL DEC. (sekunder frn full utvinkling till neutral)
This parameter defines how long time it takes for the pump to reach its neutral displacement mode when the
travel pedal is released (higher value of this parameter = softer decceleration of the truck during the
hydrostatic braking).
HARD BRAKING RATIO
This parameter (%) change the release braking value (travel pedal dec.) according to the following table:
Braking times of the truck function of the two parameters
Travel pedal dec (s) and Hard braking ratio (%)
Travel pedal dec. (s)
Hard braking ratio (%)
0
17
50
67
83
100

10

Lg hastighet

2
1.7
1.6
1.3

5
3.8
2.8
2.5
2.3
2.1

7
5
3.1
2.5

10
6.5
3.6
2.9

Hg hastighet

0=Samma bromskraft vid alla hastigheter. 100=Hrdare broms vid hg hastighet.


SENSITIVITY
This parameter defines the sensitivity of the pump control when changing the pedal position (this value is
expressed as a percentage of the pump max. displacement control).
INCHING PEDAL INC.
This parameter defines how long time it takes for the pump to reach its max. displacement when the inching
pedal is instantaneously released after it has been fully pressed in conjunction with the travel pedal.
INCHING PEDAL DEC.
This parameter defines how long time it takes for the pump to range from the max. displacement to the neutral
position when the inching pedal is instantaneously pressed after fully pressing the travel pedal.

INTERNAL
COMBUSTION

SERVICE MANUAL

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page 47

4) ENGINE CUSTOMIZED
Allows setting of the parameters who controls the thermal engine . Do not modify the standard values.
TRAVEL PEDAL INC. (sekunder frn tomgng till fullgas)
This parameter defines how long time it takes for the actuator to achieve its stroke when the travel pedal is
fully pressed (the higher the value of this parameter, the longer the time the thermal engine takes to range from
its min. RPM to its max. RPM).
TRAVEL PEDAL DEC. (sekunder frn fullgas till tomgng)
This is the same as the previous parameter (the time it takes for the thermal engine to range from its min.
speed to its max. speed).
MAST INC.
This parameter defines the time it takes for the actuator to achieve its stroke when the lifting lever is pulled
(higher value of this parameter = longer time for the thermal engine to range from its min. RPM to its
max. RPM).
MAST DEC.
This parameter is similar to the previous one (time it takes for the engine to range from its max. RPM to its
min. RPM when the lifting lever is released).
MAST FIXED CMD 1
MAST FIXED CMD 2
Parameter that defines the thermal engine speed rate when one of the auxiliary devices of the hydraulic
valve unit is activated (tilt , sideshift, 4th way, 5th way).
The engine RPM is increased to a value, according to the parameter set. Standard value is 30 - 40%.
Ex:

engine min. speed: 700 rpm; engine max. speed: 2500 rpm
usable range: 700 - 2500 = 1800 rpm
parameter (mast fixed cmd): 25 %
If the engine operates at a speed higher than 1100 rpm and the hydraulic lever is activated, the actuator will
bring the engine rpm to: 1100 + (2500 - 700)x0.25 = 1550 rpm.
Do not increase the speeds set to avoid dangerous manoeuvres.
Stroke of the sideshift: 2 -2.5 secs
Tilting:
4.5 - 5 secs
MAST MAXIMUM CMD (Available from 2001)
Parameter which defines the max thermal motor rpm when the lifting is started. By activating the lever, the
motor speed increases step by step until the max value set.

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

SERVICE MANUAL

page 48

INTERNAL
COMBUSTION

5) FAULT DETECTED
Displays the system faults.
- FAULT OCCURRING NOW
Press [ENTER] to display the current fault.
- FAULT SINCE START UP
Press [+] and [-] to display the last five faults occurred.
FAULTS MESSAGES SHOW ON THE CONSOLE
Excitation Sensor

The exitation voltage of the sensor is < 2V or > 5.5V.

Power Supply

The supply voltage of TCS control unit is < 9.5V or > 32V for more than
2 sec. long.

Travel Pedal Sensor

The signal (voltage) of the travel pedal potentiometer has exceeded the
limits set while calibrating.

Break/Inching Pedal Sensor

The signal (voltage) of the brake pedal potentiometer has exceeded the
limits set while calibrating.

Mast Lever Sensor

The signal (voltage) of the mast lever has exceeded the limits set while
calibrating.

Actuator Sensor

The signal (voltage) of the feedback potentiometer has exceeded the limits
set while calibrating.

Error on Actuator control loop >20% error, for more than 0.5 secs, between the actuator setpoint and the
potentiometer feedback
Error on pump control loop

>20% error, for more than 0.5 secs, between the pump control signal and
the potentiometer feedback signal in the pump.

Feed bak error

Pump feed back is < 0.25V or > 4.75V.

Neutral out of range

During the calibration the pump neutral is out the limits fixed.

Pump neutral drift too high

The difference between the pump in neutral calibration function and the
pump in neutral while the values are not fed is >341 mV

Feedback moves too fast

The pump feedback changes too fast in comparison with the real change of
the pump displacement.

Eeprom error at address

One parameter at least is outside the field of acceptable values.

INTERNAL
COMBUSTION

SERVICE MANUAL

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


page 49

Direction switches error

The TCS control unit takes contemporarily the forward and reverse gear
(running mode) started..

Other Default

Other faults.

6) INFORMATION
Displays the SOFTWARE version

7) PH PARAMETERS
- PASSWORD (4567 or 4321)
Enter the password (4 numbers) with the digital key and then valid (enter).
Press the key / esc then [+] and [-] in order to haves access to the rest of the menu.
- PUMP NEUTRAL OFFSET
This parameter is made to offset pump feedback
- ENABLE LIMIT CHANGE
During the calibration of the pedals, the auxilarys levers and the actuator, it is possible that the minimal values and
maximal values abtained on the potentiometer are not conform to the limit fixed by the programm. It is possible to
modify theses limits.
In the menu calibration, authorise the mode calibration. Go into the menu PH PARAMETERS and into the
under menu ENABLE LIMIT CHANGE.
It is necessary to be in NOT LOCKED.
- INVERSION BRAKING
This function is made to have a braking action if direction switch is set in the reverse position during the translation
of the machine.
The brake action will be proportionnal to the position of the travel pedal.
- INVERSION DESPLACEMENT
This parameter set the inversion time range from: 0 - 10 cc
- DISABLE PUMP DELAY
Parameter which defines the time of delay of the negative brakes starting up (standard values 30 cycles). It is the
delay for the brakes starting up after the pump has reset its displacement. In order to have the brakes started up
in a shortime, for example in ramp, reduce the value (min 5 max 45 cycles)
- REGULATOR OFFSET
This is the acceptable difference between the ordered engine speed and the measured engine speed.
If this value is exceeded, the antistall function is active.

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

SERVICE MANUAL

page 50

INTERNAL
COMBUSTION

- ANTISTALL COEF
Coefficient apply to the action of antistall function.
The parameter change from 3 to 8.
Bigger is the values more is the desplacement decrease.
- DERIVEE ANTISTALL
Definition of the derived gain for the antistall action. The parameter is a variable number from 10 to 30.
Bigger is the number, bigger is the sensibility at the RPM variation on antistall.
- FULL STROKE CMD
Compensation of the electric stroke used on the recopy potentiometer of the pump.
The parameter is a number (never vary it) 1488
- ENGINE DELAI INC
This parameter is made to take into account the reaction time of the couple actuator/engine in order to activate the
antistall at the right moment. It avoids to put the antistall function all the time.
- ENGINE DELAI DEC
This value is the complementary value of engine delay dec. It is take into account during the engine deceleration.

8) EPROM RESET
This menu is made to reset the data of the EEPROM
- PASSWORD
Enter the password (4 numbers) with the digital key and then valid (enter).
Press the key / esc then [+] and [-] in order to haves access to the rest of the menu.
- ALL EEPROM RESET
A press on the key (ENT) cancel the list of the statistics.
- FAULT LIST RESET
A press on the key (ENT) cancel the list of the detected defaults.

TROUBLES OCCURRING WHILE CALIBRATING


The voltage values read by the transmission potentiometers (pedals, hoisting, etc.) must not exceed the limits set.
If there is some wiring failure or the mechanical limit stops of the potentiometers are not properly adjusted, the
voltage they supply will exceed the allowable range for the control unit, thus preventing the calibration procedure.
In that case, the terminal will display one of the following messages (while calibrating or in the fault detected
alarm menu):
travel pedal position out of range
brake/inching pedal sensor
mast lever sensor
actuator position out of range
feed-back error

travel pedal
brake pedal
mast lever
thermal engine actuator
hydrostatic pump potentiometer

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

SERVICE MANUAL

INTERNAL
COMBUSTION

page 51

1) TRAVEL PEDAL

travel pedal position out of range

(error message)

release the parking brake

select the
TRAVEL PEDAL submenu

(the terminal will range from


the CALIBRATION MODE to the
DISPLAY MODE)

(the terminal will display the


voltage - expressed in volts - that
is supplied from the otentiometer
in the travel pedal)

yes

voltage = 0 volt?

no

check the
potentiometer wiring

hold down the [ENTER] key and


check if voltage changes when
the pedal is pressed

does voltage change?


yes

press the [ENTER] key to


measure the min. and max. voltage
supplied by the potentiometer

adjust the mechanical limit stop of


the pedal so that the voltage does
not exceed the ranges set
(see travel calibration)

Calibrate the travel pedal.

no

check the potentiometer wiring

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

SERVICE MANUAL

INTERNAL
COMBUSTION

page 52

2) BRAKE/INCHING PEDAL

brake/inching position out of range

(error message)

release the parking brake

(the terminal will range from


the CALIBRATION MODE to the
DISPLAY MODE)

select the BRAKE/


INCHING PEDAL submenu

(the terminal will display the voltage in


volts, that is supplied by the brake
pedal potentiometer)

yes

voltage = 0 volt?

no

check the
potentiometer wiring

hold down the [ENTER] key and


check if voltage changes when
the pedal is pressed

does voltage change?


yes

press the [ENTER] key to


measure the min. and max. voltage
supplied by the potentiometer

adjust the mechanical limit stops of


the pedal so that the voltage does
not exceed the ranges set
(see travel calibration)

Calibrate the brake pedal.

no

check the potentiometer wiring

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

SERVICE MANUAL

INTERNAL
COMBUSTION

page 53

3) MAST LEVER

mast lever sensor out of range

(error message)

release the parking brake

select the
MAST LEVER submenu

(the terminal will range from


the CALIBRATION MODE to the
DISPLAY MODE)

(the terminal will display the


voltage in volts, that is supplied
by the mast lever)

yes

voltage = 0 volt ?

no

check the potentiometer


wiring

Hold down the [ENTER] key and


check whether voltage changes
when the lever is pulled

does voltage change?


yes

press [ENTER] to measure the


min. and max. voltage supplied
the potentiometer

Adjust the shims of the


potentiometer support bracket so
that the voltage does not exceed
the ranges set (see mast lever
calibration).
If the lever is shifted
forward from its middle position
(for the forks lowering) voltage is
not to decrease.
Calibrate the mast lever.

no

check the electrical connections


by of the potentiometer

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

SERVICE MANUAL

INTERNAL
COMBUSTION

page 54

4) THERMAL ENGINE ACTUATOR

actuator position out of range

(error message)

release the parking brake

(the terminal will switch from the


CALIBRATION MODE to the DISPLAY
MODE)

select the ENGINE


CALIBRATION submenu

yes

voltage = 0 volts?

(the terminal will display the voltage,


in volts, supplied by the potentiometer of
of the actuator)
(engage
the
no parking brake and
press
the
accelerator pedal)

check the electrical connections of the actuator

hold down the [ENTER] key and


check if voltage changes while the
actuator rotates

does voltage change?


yes

press the [ENTER] key to measure


the min. and max. voltage supplied
by the actuator potentiometer

check the actuator electrical connections

adjust the length of the tie rod so


that voltage does not exceed
the ranges set
(see engine calibration)

Calibrate the actuator.

no

INTERNAL
COMBUSTION

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

SERVICE MANUAL

page 55

5) POTENTIOMETER IN THE HYDROSTATIC PUMP

feed-back error

(error message)

release the parking brake

(the terminal will range from the


CALIBRATION MODE to the
DISPLAY MODE)

select the
PUMP NEUTRAL submenu

yes

voltage = 0 volts or 5 volts ?

(the terminal will display the


voltage, in volts, that is supplied
by the potentiometer in the
hydrostatic pump)
no

check the potentiometer


electrical connections

voltage = 2.48 2.52 volts ?

yes

no

engage the parking brake,


switch to CALIBRATION mode
and calibrate the pump
potentiometer to zero

- check the potentiometer wiring


- lift the truck on the shim blocks,
electrically disconnect the pump
solenoid valves and start up the
engine: if the pump supplies some
oil, the trouble is a hydraulic or
mechanical type (mechanical
maladjustment of the pump plate
positioning in neutral
displacement)
- after disconnecting the valves, if the
pump supplies some oil, switch off
the engine and hold down the
[ENTER] key in order to read the
voltage, until a 2.5 volt value is
obtained.

engage the parking brake, switch


to CALIBRATION mode and
calibrate the pump potentiometer
zero.

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

SERVICE MANUAL

page 56

INTERNAL
COMBUSTION

SYSTEM FAULTS AND FAILURES


Any system failure is signalled by the blinking warning light located beside the distributor levers.
The blinking intermittence indicates the failure importance.
The kind of fault is displayed in the FAULT DETECTED menu (FAULT OCCURRING NOW
submenu).
If the warning light blinks slowly (0.5 Hz) the fault is not very important; the machine is able
to work.
Error message

travel pedal sensor

Cause

Cure

- check the potentiometer wiring


- the signal (voltage) of the travel pedal
- check if the voltage values at the
potentiometer has exceeded the limits
pedal limit stop do not exceed
set while calibrating
the limits preset
- connector disconnected or wrong wiring
- adjust the pedal limit stops
- calibrate the pedal again
- (see page 51)

brake/inching pedal
sensor

- the signal (voltage) of the brake pedal


potentiometer has exceeded the limits set
- as above (see page 52)
while calibrating
- connector disconnected or wrong wiring

mast lever sensor

- the signal (voltage) of the mast lever has


exceeded the limits set while calibrating - as above (see page 53)
- connector disconnected or wrong wiring

actuator sensor

error on actuator
control loop
This message may be
displayed if the
accelerator is pressed
(green light on) when
the engine is off and the
brake is unlocked
power supply out of
range

- the signal (voltage) of the feedback


potentiometer has exceeded the limits set
- as above (see page 54)
while calibrating
- connector disconnected or wrong wiring.
- >20% error, for more than 0.5 secs,
- check the actuator wiring
between the actuator setpoint and the
- check theactuator potentiometer
output signal (if you press the
potentiometer feedback
accelerator pedal, the actuator
- connector disconnected or wrong wiring.
shall rotate forward and the
voltage - measured in engine
calibration when the brake is
released - shall increase)

- the supply voltage of TCS control unit - check the supply voltage value
is not included in the 9.5 - 48 volts range

INTERNAL
COMBUSTION

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

SERVICE MANUAL

page 57

If the warning light blinks quickly (1 Hz) the fault is serious; the machine stops.

Error message
excitation voltage

feedback error

neutral out of
range

error on pump
control loop

Cause

Cure

- wrong value of the supply


voltage of the potentiometers and
microswitches

- check that the voltage is equal to 5 volts


5%

- wrong signal of the feedbackk


potentiometer in the hydrostatic
pump

- check that the feedback potentiometer


voltage is equal to 2.5 0.15 volts
when the pump is in neutral
displacement mode (see page 55)

- wrong signal of the feedback


potentiometer in the hydrostatic
pump when the latter is in
neutral displacement mode

- check the potentiometer calibration


(PUMP NEUTRAL)
- check that the feedback potentiometer
voltage is equal to 2.5 0.15 volts
when the pump is in neutral displacement
mode (see page 55)

- >20% error, for more than 0.5


secs, between the pump control
signal and the potentiometer
feedback signal in the pump

- check the pump wiring


(potentiometer and solenoid valves)
- check that the feedback potentiometer
voltage properly changes while
controlling the solenoid valves
- measure the min. and max. voltage of
the pump potentiometer and check that
the control max. value is kept constant
during the forward and reverse running
mode (when the wheels turn forwards,
the potentiometer voltage has to tend
to 5 volts) (when the machine is running
in the pump neutral calibration function)

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

SERVICE MANUAL

page 58

INTERNAL
COMBUSTION

TROUBLESHOOTING
Fault

The thermal engine works correctly


but the pump is faulty

The pump works correctly but the


thermal engine is faulty

The pump and engine work correctly,


but the engine does not accelerate
when the distributor levers are
actuated

The pump and thermal engine do not


work

Possible cure
- check the parking brake operation (DISPLAY-BRAKE SWITCH
(set-not set) menu)
- check the operation of the speed selector (pedals with steeringwheel operated reverse gear) or the microswitches on the other
pedals DISPLAY-DIRECTION SWITCH (neutral forward
reverse menu)
- check the signal on the speed sensor (on the pump)
(DISPLAY-ENGINE SPEED menu - check if the value
displayed is acceptable)
- check the signal of the feedback potentiometer (on the
pump)
(CALIBRATION menu (display mode)-PUMP
NEUTRAL)
- check the actuator operation
(CALIBRATION (display mode) - ENGINE
CALIBRATION menu)
- check the mast potentiometer signal and wiring (of the
potentiometer and microswitches) (CALIBRATION (display mode)-MAST
LEVER CALIBRATION menu)
- check if the potentiometer is fitted (TCS parameter)
(CALIBRATION menu, MAST LEVER, mast sensor presence
(1) menu)
if the fault warning light is off:
- check the signal of the speed sensor
(DISPLAY-ENGINE SPEED menu (check if the value
displayed is acceptable)
if the warning light blinks slowly:
- check the signal of the travel pedal
(CALIBRATION - TRAVEL PEDAL CALIBRATION menu)
if the warning light blinks quickly:
- check the supply voltage of the sensors (5 volts)
(CALIBRATION - SENSOR EXCITATION menu)
- control unit supply voltage
(CALIBRATION - POWER SUPPLY menu)
- signal of the pump potentiometer
(CALIBRATION menu (display mode)-PUMP
NEUTRAL)
- wiring of the pump potentiometer
(CALIBRATION menu (display mode)-PUMP
NEUTRAL )
- wiring of the pump displacement control solenoid valves
(VISUAL INSPECTION)

INTERNAL
COMBUSTION

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

SERVICE MANUAL

page 59

WHEELS / TYRES
SAFETY OF WHEELS AND RIMS WHILE USING THE TRUCK
TYRES are to be replaced when the tyre tread is under 1.6 mm.
SUPERELASTIC tyres are to be replaced when the tyre tread reaches the
60 J mark, which is printed on the tyre side.

WHEEL TIGHTENING TORQUE


Driving wheels 17 daNm
Steering wheels 24 daNm

SUPERELASTIC (SE)

PNEUMATIC (PN)

T YRE T YPE

S I ZE

AI R
PRESSIO N

T YPE

F R O NT

7.00 -12
27X10 -12

2.5
3.0 - 3.5

REAR

6.50 - 10

2.5-3.0-3.5

F R O NT

7.00 -12
27X10 -12 (16
PR)
27X10 -12 (20
PR)

9 bar
8 bar
10 bar

2.5
3.0 - 3.5

REAR

6.50 - 10

7,75 bar

2.5-3.0-3.5

T WIN
S U P E R E L AS T I C
(SEG )

F R O NT

7.00-12

T WIN
P N E U M AT I C
(PNG )

REAR

7.00-12

S U P E R E L AS T I C
(SE)

P N E U M AT I C
(PN)

2.5
3.0 - 3.5

9 bar

2.5
3.0 - 3.5

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

SERVICE MANUAL

page 60

INTERNAL
COMBUSTION

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.

CHECKING THE SYSTEM SEALING AND CLEANING


THE POWER STEERING SYSTEM
Every 250 hours
- Check the whole system for any possible leakage; before servicing,
release the system pressure.
Every 4,000 working hours
- replace hoses (D) connecting Orbitrol to the steering cylinder.
Every 10,000 working hours
- replace the system pipes.
Adjusting the power steering pressure
The max. pressure of the power steering is to be equal to 100 Bar

Do the following to adjust the power steering pressure:


1 - Install a pressure gauge in (C) the power steering;
2 - With a socket head spanner, remove the cap located in the Orbitrol upper part to reach the
adjusting screw (B) (power steering unit);
- screw in to increase pressure
- screw out decrease pressure

PRIORITY VALVE
(C)

POWER STEERING
CIRCUIT DRAWING

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

SERVICE MANUAL

INTERNAL
COMBUSTION

page 61

STEERING AXLE
Every 500 hours
- lubricate the steering gear joints using the appropriate grease nipples (C);
- 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 75)
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 = 75 STANDARD VALUE
80 MAX VALUE WITH PN
85 MAX VALUE WITH SE

C
C
C

ANGLE MEASURED BY THE AXLE FRAME TO THE INTERNAL


WHEEL THROUGH A SPECIAL DEVICE

END STROKE
SETTING SCREW

G
STEERING AXLE

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

SERVICE MANUAL

INTERNAL
COMBUSTION

page 62

BEARING ADJUSTMENT
Steering wheel bearings require an adjustment once a year.
Steering wheels
lift the steering wheels
remove cap (1);
remove toothed washer(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 toothed washer;
reassemble the cap (1);
lower the wheels again and check that all nuts fixing the rim are well tightened.

2
5

4
1

SERVICE MANUAL

INTERNAL
COMBUSTION

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


page 63

HYDRAULIC DISTRIBUTOR
Nominal capacity 80 l/min
3 - 4 - 5 section

Relief valve pression


Tilting
180 Bar
Side shift
150 Bar

Max lifting pression 235 5 Bar


Nipple 1/2 Gas

Microswitch

Restrictor 2 mm

Lifting potentiometer

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

SERVICE MANUAL

INTERNAL
COMBUSTION

page 64

MAST GROUPS
The mast profile - CESAB design - with double stiffening flange is characterised by a high
flexural and torsional strength.
It allows wide visibility thanks to the reduced dimensions of the profile itself.
Cylinders are single-acting type.
The sideshift system has been housed inside the profiles.
The mast group is a roller type with a variable centre distance (i.e. a fixed roller is fitted on the
outer mast and a mobile one on the inner mast, instead of a number of mobile rollers only on
the inner mast). This solution ensures better grip and stability on operation.
Other features: side plays adjustable from outside. Plastic guide shoes. Roller bearings with
grease nipples, ball joints on axle couplings and tilt cylinders.
Lifting cylinders:
Duplex mast:
VT 2 side cylinders
FFL 2 central cylinders
1 central cylinders for the FFL
Triplex mast

VT 2 side cylinders
FFL 2 side cylinders
1 central cylinders for the FFL

Grease nipple

Adjusting screw

Shoe

Roller

INTERNAL
COMBUSTION

SERVICE MANUAL

page 65

TRIPLE MAST SECTION

Fork carriage

Internal
section bar

Intermediate
section bar

External
section bar

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

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

SERVICE MANUAL

page 66

DESCRIPTION OF THE CYLINDER COMPONENTS


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

6
5
4
7

DIAMETRO
DI
SPINTA

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

INTERNAL
COMBUSTION

INTERNAL
COMBUSTION

SERVICE MANUAL

page 67

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

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

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.

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

SERVICE MANUAL

page 68

INTERNAL
COMBUSTION

LUBRICATION
Masts
After the first 50 hours
- adjust the guide shoes through socket head screw (D).
Use a 0.2 - 0.5 mm thickness gauge; fit it from the bottom upwards
to socket head screw (D) centre, passing behind roller (E) and
creeping on the outer mast.

Every 50-100 hours


- Grease the mast sliding guides
- through the grease nipples, lubricate the articulations of the tilt cylinders
and of frame coupling.
Every 250 hours
- adjust the guide shoes;
- grease mast guide rollers (E).

Every 2000 hours


- inspect mast guide rollers (E); they have to rotate freely and not
to be too worn out.
A) tilt cylinders
2+2 grease nipples
B) mast coupling
1+1 grease nipples

Fork mounting carriage and sideshift


After the first 50 hours
- adjust the guide shoes through socket hallen screw (D).
Use a 0.2 - 0.5 mm thickness gauge, fit it from the bottom upwards
up to socket hallen screw (D), going behind roller (E).
Every 50 hours
- lubricate the sideshift guides through the grease nipples.
D

F
E

Every 250 hours


- grease the pins and the fork positioning slots;
- adjust the guide shoes;
- grease the guide rollers of carriage (F).

SERVICE MANUAL

INTERNAL
COMBUSTION

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


page 69

Every 2,000 hours


- check the conditions of the guide rollers; they
have to rotate freely and not to be too worn
out.
C

C) Sideshift
(upper part) 2 grease nipples
(lower part) no grease nipple

INSTALLATION CHECKS
SAFETY SPECIFICATIONS

Make sure that:


- the hoisting chain stretchers are not faulty and
the adjusting nuts are locked by counternuts and
check pins (F);
- safety limit stops (A) of the fork mounting carriage
are fitted and tightened up;
- stop collars (D) are fitted and tightened up;

Every 500 hours


- check that distance (D) between the collar and
the mast outer cylinder ranges from 0.5 mm to
3 mm;
- check if self-locking nuts (B) are tightened up.
Tightening torques
- Nuts of the stop collars: 0.8 to 1.2 daNm

SAFETY LIMIT STOPS OF THE FORK


MOUNTING CARRIAGES
The mast unit is equipped with a mechanical safety
limit stop to prevent the accidental removal of the
fork mounting carriage from the mast downwards.
Limit stops (A) consist of two socket head screws
with counternut. Loosen limit stops (A) before
disassembling the fork mounting carriage.

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

SERVICE MANUAL

INTERNAL
COMBUSTION

page 70

CHAIN INSPECTION
Every 500 hours (anyway, chains are to be checked every 3 months)
- chains are not to be faulty or worn out.
To check if the chain links are worn out, use the appropriate ruler; remember that
chains must be replaced when, in a portion corresponding to 34 pitches, only
33 pitches are found.
Every 1,000 hours
- disassemble the chains, carefully clean them, reassemble reversing their original
work position, and grease.
Every 10,000 hours
- replace the chains and the fastening tie rods.
Use of original CESAB chains will guarantee that the safety requirements
stated by the regulations in force are complied with.

FORK INSPECTION
(to be performed every 1000 hours)
G
E

F
D

Surface cracks particularly in D/E/F


Height difference of the tips (is to be < 3% than the fork
length)
Positioning latch (G)
Punching is to be clear
Fork measure (maximum wear = 10% of the original thickness)
particularly in point D
Wear of the fork fastening devices on the carriage (EF)

TABLE ISO 2328 - 1993

Rate

X = 152 mm (2,5T)
203 mm (3,0 - 3,5T)

lifting load (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

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

SERVICE MANUAL

INTERNAL
COMBUSTION

page 71

LIFTING OF THE TRUCK

HOOKS ATTACHMENT POINTS FOR


LIFTING THE TRUCK
To lift the truck the following equipment must be
used:
A

A- CHAINS: dia. 13 mm - Degree T (8) - UNI


9425
B

LIFTING OF THE FORKLIFT TRUCK


WITH CABIN

B- HOOKS: for 5.4 t - UNI/ISO 7597

A- CHAINS: dia. 13 mm - Degree T (8) - UNI


9425
B- HOOKS: for 5.4 t - UNI/ISO 7597
C- N 2 upper brackets to hold the chains.

TRUCK WEIGHT

ON THE AXLE WITH OUT


LOAD
(FRONT / REAR)

2.5 t

4050 kg

2070 / 1980

kg

3.0 t

4600 kg

2100 / 2500

kg

3.5 t

5160 kg

2260 / 2900

kg

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

SERVICE MANUAL

page 72

INTERNAL
COMBUSTION

OIL AND GREASE SPECIFICATIONS


FOR NORMAL ENVIRONMENTS
PARTS INVOLVED
USED TYPE

SPECIFICATIONS

QTY.

AGIP ARNICA 46

ISO - L - HV
FZG tests to stage 11

39 L

MOBIL ANTICONGELANTE

Cooling liquid

MOBIL DELVAC 1300


SUPER SAE 15W-40

API CD-SF CCMC-D3


(SHPDO)-PD1 MIL-L-2104D
MIL-L-46152B

DIESEL engine

20 40 SAE

Mast chain lubrication

MOBILGREASE SPECIAL

Lithium base
ASTM 275 305 NLGI N.2
dropping point 180

Mast securing joints - sideshift unit - steering


joint - general lubrication with grease nipples

Hydraulic system, lifting, power steering and


hydrostatic transmission

FOR COLD CLIMATES AND COLDSTORAGE CELLS


PARTS INVOLVED
AGIP ARNICA 22

ISO - L - HV
FZG tests to stage 10

39 L

MOBILTEMP SHC 100

Thickening Infusible
ASTM 265 295 NLGI N.2
Dropping point >260

Hydraulic system, lifting and power steering


units
Mast securing joints - sideshift unit - steering
joint - general lubrication with grease nipples mast guides

TYRE PRESSURES TIGHTENING TORQUES


TYRE PRESSURES
9,5 bar 400-450
7,5 bar 500
9,25
bar

FRONT tyres
REAR tyres
WHEEL TORQUE

37 daNm

steered wheels

50 daNm

driven wheels
DRIVE UNIT TORQUE

27 daNm

engine fixing to chassis


VARIOUS TORQUES

40 daNm
0,8 1,2 daNm
77 daNm

bolts securing mast


jack collar self-locking nuts
counterweight blocking screws

SERVICE MANUAL

INTERNAL
COMBUSTION

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


page 73

RUNNING IN MAINTENANCE
50

500

at # hours for MEDIUM/INTENSE


USE

7/-

-/3

at # days/months FOR
OCCASIONAL USE
ENGINES

engine oil and cartridge

clearances engine values

fan belt and alternator belt

CHASSIS AND CONTROLS

general bolt and nuts

wheel torque (1)


(1) During the first 500 worning hours, check
the torque every 50 hours

LIFTING UNIT - MASTS




mast guide pads

oil filter

HYDROSTATIC TRANSMISSION

transmission oil filter

transmission oil

LEGEND






In the maintenance table showing a visual


control and cleaning of the parts indicated .
I n the maintenance table showing the
replacement of the parts indicated.
In the maintenance table showing lubrification
of the parts indicated.
In the maintenance table showing tightening

or adjustment of the parts indicated.

The servicing periods are divided into hours, considering


an average working day of 8 hours of effective operation.
If the truck is used on average for less than 8 hours per
day, refer to the schedules expressed in days/months

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

SERVICE MANUAL

page 74

INTERNAL
COMBUSTION

MAINTENANCE TIMES

50

250

500

1 000

2
000

4
000

10
000

at # hours for MEDIUM/INTENSE


USE

1/-

7/-

-/1

-/3

-/6

-/12

-/24

-/60

at # days/months
FOR OCCASIONAL USE

mast guide pads

carriage - sideshift unit slides

mast rollers and chain rollers

tilting jacks supply tubes

fork positioning pins

mast guides, mast and jack fixing

lifting jack collars

fork carriage position

forks

mast tilting

mast secured to chassis

lifting chains

chain securing bolts

high pressure hydraulic hoses

system seal and connections

SERVICE MANUAL

INTERNAL
COMBUSTION

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


page 75

MAINTENANCE TIMES
8

50

250

500

1000

2000

4000 10 000

1/-

7/-

-/1

-/3

-/6

-/12

-/24

-/60

afteri # hours FOR


MEDIUM/INTENSE USE
after # days/months FOR
#
OCCASIONAL USE
#

CHASSIS AND COMMANDS

chassis - cleaning

bolts in general

fuel tank cleaning

fuel tank control

drivers seat

wheels - hub bearings

tyre inspection and wheel tightness

tyre pressures




steering system and tubing seal


hoses from orbitrol to steering jack
rear axle and weheel hub bearings

steering lock

pedals in general - linkage

brake commands solenoid valve

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

SERVICE MANUAL

page 76

INTERNAL
COMBUSTION

MAINTENANCE TIMES
8

50

250

500

1/-

7/-

-/1

-/3

1 000 2 000
-/6

-/12

4 000

10
000

-/24

-/60

cooling liquid

fuel filter cartridge

at # hours for M EDIUM/INT ENSE


USE
at # days/months FOR OCCASION
USE
ENGINE

air filter

dusty environment air filter

cyclone prefilter

water and oil radiator (external cleaning)

water and oil radiator in dusty


environments

fan belt and alternator belt

engine oil and filter cartridge

engine supports

engine linkage and fuel connections




fexible fuel and water hosing


DIESEL engine injection pressure control

DIESEL engine valve clearance

PETROL and LPG engine valve


clearance

PETROL and LPG engine spark plugs

LPG system control




LPG bottle hose and safety valve


LPG pressure reducer

SERVICE MANUAL

INTERNAL
COMBUSTION

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


page 77

MAINTENANCE TIMES

50

250

500

1000

1/-

7/-

-/1

-/3

-/6

2000 4000 10000 #


-/12

-/24

-/60

at # hours for MEDIUM/INTENSE


USE
ati # days/months for
OCCASIONAL USE
ELECTRIC SYSTEM

pushbuttons - pedal microswitches

cable terminals - cable sheaths

battery electrolyte level and density replacement

battery terminals and poles

HYDROSTATIC TRANSMISSION

system seal

transmissin oil filter

transmissin oil

complete unit

Totaldokument
BT Cargo CBD 2.5-3.5
Var 250:e timme
Pos

Kontroll av:

Pos

Kontroll av:

Pos

Kontroll av:

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

2:0
2:1
2:2

Grupp 2 Hydrostatik
Lckage
Funktion

5:6
5:7
5:8

Batteri, faststtning
Skringar
Batterivtskeniv

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

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

6:0
6:1
6:2
6:3

Grupp 6 Hydraulik
Slangar/rr
Ventilreglage/lnkage
Oljeniv

0:10
0:11

Grupp 0 Hel maskin


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

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

Grupp 1 Motor
Missljud/lckage
Gaspedal/reglage
Luftfilter, kontroll
Kylvtska, niv/fryspunkt
Remmar, kontroll
Motorolja, byte
Motoroljefilter, byte
Brnslesystem, lckage
Gldning

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

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

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

Grupp 7 Arbetsfunktion
Lyftstativ, infstning
Gafflar
Lyftkedjor
Laststd
Lyft-/tiltcylindrar

5:0
5:1
5:2
5:3
5:4
5:5

Grupp 5 Elsystem
Belysning/krriktningsvisare
Instrument/kontrollampor
Signalhorn
P-broms-/Backalarm
Timmtare, avlsning

Var 500:e timme tillkommer:


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

Var 1000:e timme tillkommer:


0:0
Grupp 0 Hel maskin
0:13 Brnsletank, rengring

Var 2000:e timme tillkommer:


0:0
Grupp 0 Hel maskin
0:14 Ram, kontroll av sprickor

1:0
1:10
1:11
1:12

1:0
1:13
1:14

Grupp 1 Motor
Remmar, byte
Ventilspel, kontroll

1:0
1:15

Grupp 1 Motorer
Kylvtska, byte

2:0
2:3

Grupp 2 Hydrostatik
Bultar, kontroll/faststtning

4:0
4:4
4:5

Grupp 4 Styrning
Slangar, kontroll
Styrtryck, kontroll

3:0
3:7

Grupp 3 Bromsar/hjul
Hjullager infettning

5:0
5:13

Grupp 5 Elsystem
Laddning, kontroll

5:0
5:12

Grupp 5 Elsystem
Kablage/anslutningar

6:0
6:4

Grupp 6 Hydraulik
Andningsfilter, reng./byte

6:0
6:5
6:6
6:7
6:8

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

7:0
7:6

Grupp 7 Arbetsfunktion
Gafflar, gaffeltest

5:0
5:9
5:10
5:11

Grupp 1 Motorer
Brnslefilter, byte
Luftfilter, byte
Motorfsten
Grupp 5 Elsystem
Batteripoler reng./infettning
Frdvljare/lnkage
Microbrytare

Totaldokument
BT Cargo CBG 2.5-3.5
Var 250:e timme
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
0:11

Grupp 0 Hel maskin


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

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

Grupp 1 Motor
Missljud/lckage
Gaspedal/reglage
Luftfilter, kontroll
Kylvtska, niv/fryspunkt
Remmar, kontroll
Motorolja, byte
Motoroljefilter, byte
Gasolsystem, funktion

Var 500:e timme tillkommer:


0:0
Grupp 0 Hel maskin
0:12 Bultar/Muttrar, faststtning
1:0
1:11
1:12
1:13

Grupp 1 Motorer
Luftfilter, byte
Motorfsten
Ventilspel, kontroll

5:0
5:9
5:10
5:11

Grupp 5 Elsystem
Batteripoler reng./infettning
Frdvljare/lnkage
Microbrytare

Pos

Kontroll av:

Pos

Kontroll av:

1:9
1:10

Gasolsystem, lckage
Tndsystem, kondition

2:0
2:1
2:2

Grupp 2 Hydrostatik
Lckage
Funktion

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

Instrument/kontrollampor
Signalhorn
P-broms-/Backalarm
Timmtare, avlsning
Batteri, faststtning
Skringar
Batterivtskeniv

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

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

6:0
6:1
6:2
6:3

Grupp 6 Hydraulik
Slangar/rr
Ventilreglage/lnkage
Oljeniv

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

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

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

Grupp 7 Arbetsfunktion
Lyftstativ, infstning
Gafflar
Lyftkedjor
Laststd
Lyft-/tiltcylindrar

5:0
5:1

Grupp 5 Elsystem
Belysning/krriktningsvisare

Var 1000:e timme tillkommer:


1:0
Grupp 1 Motor
1:14 Remmar, byte
1:15 Tndinstllning
1:16 Tndstift, byte
2:0
2:3

Grupp 2 Hydrostatik
Bultar, kontroll/faststtning

3:0
3:7

Grupp 3 Bromsar/hjul
Hjullager infettning

5:0
5:12

Grupp 5 Elsystem
Kablage/anslutningar

6:0
6:4

Grupp 6 Hydraulik
Andningsfilter, reng./byte

Var 2000:e timme tillkommer:


0:0
Grupp 0 Hel maskin
0:13 Ram, kontroll av sprickor
1:0
1:17

Grupp 1 Motorer
Kylvtska, byte

4:0
4:4
4:5

Grupp 4 Styrning
Slangar, kontroll
Styrtryck, kontroll

5:0
5:13

Grupp 5 Elsystem
Laddning, kontroll

6:0
6:5
6:6
6:7
6:8

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

7:0
7:6

Grupp 7 Arbetsfunktion
Gafflar, gaffeltest

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 2005-1

GB

Issue 11/2000

CONSOLE MAP

CBD/G 2,5-3,0-3,5

CALIBRATION SECTION
"CALIBRATION"

DIAGRAM FOR USING CONSOLE (ANALYSER)

-Connect the console and turn the key without starting

TO BE CARRIED OUT WHENEVER A CONTROL


COMPONENT IS REPLACED

DISPLAY
CONSOLLE

Calibration
Calibration Status

first operation
to be carried

out to release
the program press -

PRESS
ENTER

Calibration

press
ENTER

ENTER

Calibration
Calibration Status
Locked

select the parking


brake switch and
press+

Calibration
Calibration Status
Not Locked
ESC

press+

Calibration
Travel Pedal

configuration
accelerator pedal
potentiometer, ENTER

Calibration
Travel Pedal
Don't touch teh
travel pedal ('ENT')

Calibration
Travel Pedal
Forwardcompleted
(ENT)

press+
ended acquisition of
the forward pedal
signal,ENTER

N.B. WITH THE PROGRAM


LOCKED IT IS POSSIBLE TO
READ THE SENSORS VALUE

Calibration
Travel Pedal
Don't touch the
travel pedal ('ENT')

ended
configuration of
the accelerator,
ESC

Calibration
Travel Pedal
Completed

ENTER

configuration brake
pedal potentiometer,
ENTER

Calibration
Brake/inching pedal

Calibration
Travel Pedal
Reverse completed
(ENT)
Calibration
Brake/inching pedal
Rest reading
(Press a key)

without pressing
any pedal,
ENTER

completely press
the accel. pedal,
keep it pressed,
ENTER

without pressing
any pedal,
ENTER

completely press
the accel. pedal,
keep it pressed,
ENTER

min. value stored,


ENTER

operate the forward


switch (only for hand
direction version)
press ENTER

Calibration
Travel Pedal
IfForwardswitch
select it ('ENT')

Calibration
Travel Pedal
Pushslowlytravel
pedal

HAND VERSION PEDAL VERSION


press the accel. press the forward
pedal, ENTER pedal, ENTER

Calibration
Travel Pedal
Full depression in
Forward (press a key)

Calibration
Travel Pedal
Forwardcompleted
(press a key)

ENTER

operate the reverse


switch (only for hand
direction version)
press ENTER

Calibration
Travel Pedal
If Reverse switch
select it ('ENT')

Calibration
Travel Pedal
Pushslowlytravel
pedal

HAND VERSION
press the accel.
pedal, ENTER

Calibration
Travel Pedal
Full depression in
Reverse (press a key)

Calibration
Brake/inching pedal
Full depression
(Press a key)

PEDAL VERSION
press the forward
pedal, ENTER

Calibration
Travel Pedal
Reverse completed
(press a key)

ENTER

completely press
the pedal, keep it
pressed, ENTER

Calibration
Brake/inching pedal
Completed

ended configuration of
the brake pedal,
ESC
press+

configuration of the
lifting potentiometer,
ENTER

Calibration
Mast lever

Calibration
Mast lever
Mast sensor presence
YES (1) NO (0)

ended configuration of the


lifting potentiometer,
ESC

press+

Calibration
Engine Calibration
press+

press+

Calibration
Max. forward speed
press+

press+

press+

FUNCTION TO BE CARRIED OUT WITH THE ENGINE ON


Calibration
Engine Calibration
NOT MODIFY

acquisition of the
min. and max.
RPM of the
engine, ENTER

then the engine


starts to
accelerate by
itself

Engine Calibration
Slowest engine speed
Reading......

Engine Calibration
Highest engine speed
Reading.........

Engine Calibration
End of engine
calibration

Calibration
Engine Calibration
Reading...(8 mesures)

NOT MODIFY

NOT MODIFY

Calibration
Pump pot. inverted

pull the lifting lever to


the end stroke, keep it
pulled, ENTER

ended acquisition of
the neutral pump
position, ESC

Calibration
Maxi engine speed
press+

Calibration
Pump Neutral
Completed

NOT MODIFY

Calibration
Mini engine speed

Calibration
Mast lever
Completed

Calibration
Mast lever
Full depression
(Press a key)

NOT MODIFY

Calibration
Parking brake set
press+

Calibration
Max. reverse speed

min. value stored,


ENTER

ACQUISITION TO BE CARRIED OUT IN A SECOND


TIME WITH THE ENGINE ON
acquisition of the
neutral pump
position, ENTER

Calibration
Pump neutral

Calibration
Mast lever
Rest reading
(Press a key)

Press 1

ended acquisition
of the min. and
max. RPM of the
engine, ENTER

NOT MODIFY

JULY 2000

CBD/G 2,5-3,0-3,5

DIAGRAM FOR USING CONSOLE (ANALYSER)


DISPLAY SECTION
"DISPLAY"

-Connect the console and turn the key

DISPLAY
CONSOLE

Display
Engine speed

PRESS
ENTER

ENTER

Display the real engine RPM

ESC

press+

Display
Pumpdisplacement

Calibration

ENTER
ESC

Display the pump displacement


requested by the Logic Unit (cc)

press+

Display

Display
Enginecommand

PRESS+

ENTER
ESC

Display the engine RPM


requested by the Logic Unit

press+

Display
Antistall

press ENTER,,
to display the information of
the engine / hydrostatic pump

ENTER
ESC

Display the status of the


function (enable / disable)

press+

Display
Parkingbrake

ENTER
ESC

Dispaly the status of the negative


brakes (enable / disable)

press+

ENTER
ESC

Display the status of the parking


brake switch (set / not set)

press+

Display
MastengineCmd

ENTER
ESC

Display the engine RPM


with the lifting lever pulled

press+

Display
Pump feed-back

ENTER
ESC

Display the real pump displacement


(cc) by the potentiometer

press+

Display
Directionswitch

ENTER
ESC

Display the status of the direction switches


(neutral / forward / backward)

press+

Display
Mastswitch

ENTER
ESC

Display the status of the control valve switches


1=tilting/sideshift (set / not set)

press+

Display
Constantspeed

ENTER
ESC

Display the constant driving speed function


status with the lifting activated (set / not set)

press+

Display
Actuator feedback

ENTER
ESC

Display the signal of the engine


actuator in Volt

press+

Display
Power supply

ENTER
ESC

Display the tension of the unit


logic (enable / disable)

press+

Display
Sensorexitation

ENTER
ESC

Display the sensor tension supplyed by the unit


logic

press+

Display
Neutraldrift

N.B.: TO READ THE


VALUES ON SEQUENCE
KEEP ENTER PUSH
BUTTON PRESSED

Display
Brakeswitch

ENTER
ESC

Display the different of the pump potentiometer


signal from the theoretic value (in mV)
JULY 2000

CBD/G 2,5-3,0-3,5

DIAGRAM FOR USING CONSOLE (ANALYSER)


"ENGINE CUSTOMIZED"
SECTION

-Connect the console and turn the key


DISPLAY
CONSOLE

Calibration
Calibration Status

first operation
to be carried

out to relaese press the program


press+

PRESS
ENTER

ENTER

Calibration

Calibration
Travel Pedal

ENTER

Calibration
Calibration Status
Locked

select the parking


switch and press +

Calibration
Calibration Status
Not Locked
ESC

ESC

press +

Display

press +

Engine Customized
Travel pedal Inc.

Pump Customized

not modified

press+
press +

Engine Customized

press ENTER,,
engine setting

Engine Customized
Travel pedal Dec.

not modified

press+

Engine Customized
Mast Dec.

not modified

press+

Engine Customized
Mast Inc.
press+

Engine Customized
Mast fixed Cmd 1

engine RPM
with tilting
ENTER,

press+

ESC

not modified

ESC

Engine Customized
Mast fixed Cmd 2

engine RPM
with sideshift
ENTER,

ESC

Engine Customized
Mast fixed Cmd 1
45 Percent

set the requested value


typing it directly by the
keybord numbers or
pressing + o -, ENTER
(N.B. more RPM,
higher value
less RPM,
lower value)

Engine Customized
Mast fixed Cmd 1
45 Percent

Engine Customized
Mast fixed Cmd 2
45 Percent

Engine Customized
Mast fixed Cmd 2
45 Percent

set the requested value


typing it directly by the
keybord numbers or
pressing + o -, ENTER
(N.B. more RPM,
higher value
less RPM,
lower value)

JULY 2000

CBD/G 2,5-3,0-3,5

DIAGRAM FOR USING CONSOLE (ANALYSER)


-Connect the console and turn the key

ALARMS SECTION
"FAULT DETECTED"

DISPLAY
CONSOLLE
PRESS
ENTER

Calibration

press+
Dispaly

press+

Pump Customized
press+

Engine Customized

press+
press ENTER,
to display the faults

Fault detected

ENTER, to display the

faults in real time


Fault detected

Fault occuring now

press+

press+

ESC

Fault detected
Fault occuring now
No default

no alarms
ESC
Fault detected
Fault occuring now
Actuator sensor

ENTER, to display the


stored alarms (faults)
(max 5)

Fault detected
Fault since startup

press+
to read the
alarms

alarm present

Fault detected
Fault since startup
Start of the list
Fault detected
Fault since startup
Neutral out of range

press+
ESC

Fault detected
Fault since startup
End of the list

JULY 2000

CBD/G 2,5-3,0-3,5

DIAGRAM FOR USING CONSOLE (ANALYSER)


MAIN MENU
-Connect the console and turn the key without starting

DISPLAY
CONSOLE
Press ENTER to
select the main menu

Calibration

Calibration of the potentiometers and the transmission actuators (pedals, control


valve, engine actuator, etc.)

Press +

Display

Display information on the transmission (engine RPM, transmission


displacement, microswitches status, ecc.)

Press +

Pump Customized

Personalization of the transmission behavior

Press +

Engine Customized

Personalization of the engine setting

Press +

Fault Detected

System faults display

Press +

Information

SOFTWARE version

Press +

Ph Parameters

Not accessible (PASSWORD)

Press +

EEprom reset

Not accessible (PASSWORD)

JULY 2000

CBD/G 2,5-3,0-3,5

DIAGRAM FOR USING CONSOLE (ANALYSER)


-Connect the console and turn the key

"PUMP CUSTOMIZED"
SECTION

DISPLAY
CONSOLE

Calibration
Calibration Status

first operation
to be carried

out to relaese press the program


press+

PRESS
ENTER

ENTER

Calibration

Calibration
Travel Pedal

Calibration
Calibration Status
Locked

ENTER

select the parking


switch and press +

Calibration
Calibration Status
Not Locked
ESC

ESC

press +

Display

press +

Pump Customized

press ENTER,
pump setting

Pump Customized
Travel pedal Inc.

pump acceleration
time, ENTER,

Pump Customized
Travel pedal Inc.
5.0 Seconds
set the requested value typing it directly by the
keybord numbers or pressing + o -, ENTER
(N.B. quicker acceleration,lower value
slower acceleration,higher value)

press+

ESC

Pump Customized
Travel pedal Dec.

pump deceleration
time, ENTER
(braking)

Pump Customized
Travel pedal Dec.
5.0 Seconds
set the requested value typing it directly by the
keybord numbers or pressing + o -, ENTER
(N.B. stronger brake ,lower value
softer brake, higher value)

press+

ESC

Pump Customized
Sensitivity

Pump Customized
Travel pedal Inc.
5.0 Seconds

Pump Customized
Travel pedal Dec.
5.0 Seconds

not modified

press+

Pump Customized
Inching pedal Inc.

not modified

press+
ESC

Pump Customized
Inching pedal Dec.

not modified
JULY 2000

PARAMETER

CBG 2.5-3.0-3.5
CONTINENTAL ENGINE
SETTING VALUE
&$/,%5$7,216(&7,21

MAST PRESENCE
MAX FORWARD SPEED
MAX REVERSE SPEED
MIN ENGINE SPEED
MAX ENGINE SPEED
MULTI DISK BRAKE
PARKING BRAKE SET
PUMP POT. INVERTED

(1*,1(&86720,=('

TRAVEL PEDAL INC


TRAVEL PEDAL DEC.
MAST INC.
MAST DEC.
MAST FIXED CDM 1
MAST FIXED CDM 2

67$1'$5'9$/8(

YES/NO
10% - 100%
10% - 100%

YES
100%
100%
850
2200

PRESENT / NOT PRESENT


80% - 95%

PRESENT
95%
ENABLE

3803&86720,=('

TRAVEL PEDAL INC


TRAVEL PEDAL DEC.
SENSITIVITY
INCHING PEDAL INC.
INCHING PEDAL DEC.

$&&(77$%/(9$/8(

#
#

$&&(77$%/(9$/8(

67$1'$5'9$/8(

2,5 - 4 SEC
3 - 4 SEC
10% - 70%
4 - 6 SEC
1,5 - 2,5 SEC

3
3,5
50%
4
2

$&&(77$%/(9$/8(

67$1'$5'9$/8(

0,5 - 3 SEC
0,3 - 2 SEC
0,5 - 2 SEC
0,8 - 2 SEC
0% - 100%
0% - 100%

1,8
1,3
1
1
30%
30%

# ONLY THESE VALUES CAN BE MODIFIED

CBD 2.5-3.0-3.5
KUBOTA ENGINE
SETTING VALUE
&$/,%5$7,216(&7,21

$&&(77$%/(9$/8(

67$1'$5'9$/8(

MAST PRESENCE
MAX FORWARD SPEED
MAX REVERSE SPEED
NUMBER OF TEETH
MULTI DISK BRAKE
PARKING BRAKE SET
PUMP POT. INVERTED

YES/NO
0% - 100%
0% - 100%
1 - 200
PRESENT / NOT PRESENT
80% - 95%
ENABLE / DISABLE

YES
100%
100%
9
PRESENT
95%
ENABLE

3803&86720,=('

$&&(77$%/(9$/8(

67$1'$5'9$/8(

2.5 - 4 SEC
3 - 4 SEC
10% - 70%
4 - 6 SEC
1.5 - 2.5 SEC

3
3,5
50%
4
2

TRAVEL PEDAL INC


TRAVEL PEDAL DEC.
SENSITIVITY
INCHING PEDAL INC.
INCHING PEDAL DEC.

(1*,1(&86720,=('

TRAVEL PEDAL INC


TRAVEL PEDAL DEC.
MAST INC.
MAST DEC.
MAST FIXED CDM 1
MAST FIXED CDM 2

#
#

$&&(77$%/(9$/8(

67$1'$5'9$/8(

0,5 - 2 SEC
0,3 - 2 SEC
0,3 - 2 SEC
0,3 - 2 SEC
0% - 100%
0% - 100%

1,2
1
1
1
30%
30%

# ONLY THESE VALUES CAN BE MODIFIED

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
5.me levier
abilitation active
abilitation des freins
abilitation de stationnement
pdale acclrateur
alternateur
anomalie dunit logique
actionneur
arrt du moteur
batterie
bobine
inclinaison
bougies dallumage
bougies de chauffage
cl
cl de dmarrage
klaxon
commandes lumires suppl.
commande lectro-ventilateur
commande feus de stop
connecteur batterie
panneau de commande
dispositif bougie de chauffage
electrovannes de marche
lectro-ventilateur
urgence
feus de marche arrire
feus de stop
frein
frein pdale
frein de stationnement
indicateur rserve GPL

4a.leva
5a.leva
habilitacin activada
habilitacin de los frenos
habilitacin de aparcamiento
pedal acelerador
alternador
anomala unidad lgica
actuador
parada del motor
batera
bobina
inclinacin
bujas
bu jas incandescente
llave
llave de arranque
claxon
mandos luces adicionales
mando electroventilador
mando faroles de stop
enchufe batera
salpicadero
dispositivo bujia incandescente
electrovlvulas de marcha
electroventilador
emergencia
faroles de marcha atras
faroles de stop
freno
freno pedal
freno de aparcamiento
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


encrassement filtre air
encrassement filtre huile
encrassement filtre huile hydr.
inverseur de direction
inverseur de direction
niveau carburant
jauge dhuile de freins
lumires arrires
ampoule marche arrire
marche avant
marche arrire
marche lente
moteur de traction
dmarreur
moteur direction assiste
moteur pompe
pdale du frein
jeu de pdales
pdales double
pompe
pompe dinjection
postcombustion
potentiomtre dlvation
pression dhuile moteur
pressostat freins
poussoir klaxon
poussoir durgence
relais dmarreur
rserve GPL
boitier du vitesse
senseur de vitesse
lvation
voyant bougies de chauffage

indicador temperatura del agua


obstruccin filtro aire
obstrucci filtro aceite
obstruccin filtro aceite hidr.
palanca de inversin
palanca de inversin
nivel carburante
nivel aceite frenos
luces traseras
lampara de marcha atrs
marcha adelante
marcha atrs
marcha lenta
motor de traccin
motor de arranque
motor servodireccin
motor bomba
pedal del freno
juego de pedales
pedales doble
bomba
bomba inyeccin
postcombustin
potencimetro levantamiento
presin aceite motor
presstato frenos
pulsador de claxon
pulsador de emergencia
rel arranque
reserva GPL
caja aceleradores
sensor de velocidad
levantamiento
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

BT Cargo Teknikutbildning

Programmering av TCS-systemet
BT Cargo CBD/CBG 2.5-5.0

F1

F2

F3

CTRL

Per Wrmlund / Avd. service

F4

ESC
SHIFT

BKSP

SPACE ENTER

BT Cargo Teknikutbildning
Main Menu

Programmering av TCS-systemet
BT Cargo CBD/CBG 2.5-5.0

Connect the
console and turn the
key without starting
Press ENTER
to select the
main menu
ENTER

Calibration

Calibration of the potentiometers and the transmission actuators (pedals,


control valve, engine actuator, etc.)

+
Display information on the transmission (engine RPM, transmission
displacement, micro switches status, etc.)

Display

+
Pump
Customised

Personalization of the transmission behavior

+
Engine
Customised

Personalization of the engine setting

+
Fault
Detected

System fault display

+
Information

Software version

+
Ph Parameters

Not accessible (Password only)

+
Eeprom reset

Not accessible (Password only)

End of list 2.5 - 3.5t

Motor Shifting

Not accessible (Password only)

+
Actuator Pid

Not accessible (Password only)

End of list 4.0 - 5.0t

Sida 1

BT Cargo Teknikutbildning

Programmering av TCS-systemet
BT Cargo CBD/CBG 2.5-5.0

Calibration

ENTER

Calibration

ENTER

Calibration
Calibration Status

- +
Calibration
Travel Pedal

ENTER

Calibration
calibration Status
locked

Configuration
accelerator pedal
potentiometer

ENTER

Calibration
Travel pedal
Dont touch the
travel pedal (ENT)

Select the
parking brake
switch and
press

ENTER

+
N.B. With the program
locked it is possible to
read the sensor
values..

Calibration
Calibration Status
not locked

ESC
Calibration
Travel Pedal
If Forward switch
select it (ENT)

Operate the forward


switch lever or depress
the twin forward. Pedal
to close switch

Calibration
Travel Pedal
Forward complete
(ENT)

Press a key

Calibration Travel
Pedal
Full depression in
Forward (Press a key)

ENTER

ENTER

First operation
to be carried
out to release
the program

Calibration
Travel Pedal
Forward complete
(ENT)

ENTER

Calibration
Travel Pedal
If Reverse switch
select it (ENT)

ENTER

ENTER

Calibration
Travel Pedal
Reverse complete
(ENT)

ENTER

Calibration Travel
pedal. Dont touch
the travel pedal
(ENT)

Operate the reverse


switch lever or depress
the twin reverse. Pedal
to close switch

ESCAPE

Calibration
Brake / inching
pedal

Configuration
brake pedal
potentiometer

ENTER

Calibration
Travel Pedal
Completed

Calibration
Brake / inching pedal
Rest reading
(press a key)

Calibration
Travel Pedal
Reverse complete
(ENT)

ENTER

Min value stored,

Press a key

Calibration
Brake inching pedal
Full depression
(press a key)

Calibration Travel

Press a key Pedal

Ful depression in
reverse (Press a key)

Completely press
the pedal,
keep it pressed
Calibration
ENTER
Brake / inching
pedal completed

ESC

Ended configuration of the brake pedal,

To page 3
Calibration Mast Lever
Sida 2

Programmering av TCS-systemet
BT Cargo CBD/CBG 2.5-5.0

BT Cargo Teknikutbildning
Calibration
From page 2
Calibration Mast Lever
Configuration of the
lifting potentiometer,

ENTER

Calibration
Mast lever

Calibration
Mast lever
Mast sensor presence
YES (1) NO (0)

Calibration
Mast lever
Rest reading
(Press a key)

Press 1

Min. Value
stored

Calibration
Mast lever
Full depression
(press a key)

Press
a key

Pull the lifting lever to


the end stroke, keep it
pulled,
ENTER

ESCAPE
Ended configuration of the
lifting potentiometer

ACQUISITION TO BE CARRIED OUT


WITH THE ENGINE ON

Calibration
Engine Calibration

Calibration
Mast lever
completed

+
Acquisition of
the neutral
pump position

Calibration
Pump Neutral

Calibration
Pump neutral
Completed

ENTER

Ended acquisition
of the neutral
pump position

+
Calibration
max.forward speed

May be Modified

+
Calibration
Max.reverse speed

+ LIST FOR 2.5-3.5t


NOT MODIFY

Calibration
Parking brake set

Standard
value
850 RPM

Calibration
Mini engine set

Standard
value
2250 RPM

Calibration
Maxi engine speed

FUNCTION TO BE CARRIED
OUT WITH THE ENGINE ON

May be Modified

NOT
MODIFY

Calibration
Pump pot.inverted

+
Back to calibration

LIST FOR 4.0-5.0t


ESCAPE

May be Modified

Calibration
Reduce speed

Calibration
Engine calibration

NOT
MODIFY

Ended acquisition
of the min. and max
RPM of the engine,

Calibration
Number of teeth

Engine Calibration
End of engine
calibration

NOT
MODIFY

Acquisition of the
min.and max.
RPM of the engine

ENTER

Engine Calibration
Lowest engine speed
Reading.......

Then the engine


starts to accelerate
by itself

ESCAPE

Calibration
Power supply

Calibration
Engine Calibration
Reading...
(8 values)

NOT
MODIFY

Engine Calibration
Highest engine speed
Reading.....

Calibration
Sensor excitation

NOT
MODIFY

Calibration
Multi disc brake

NOT MODIFY

Calibration
Parking brake set

NOT MODIFY
Calibration
Pump pot.inverted

Back to calibration

Sida 3

BT Cargo Teknikutbildning
Display
Menu

Programmering av TCS-systemet
BT Cargo CBD/CBG 2.5-5.0
ENTER

Display
Engine Speed

+
Display
pump displacement

ENTER

Display
Engine command

Calibration

Display
Parking brake

Displays information
of the engine and
hydrostat pump
HOLD DOWN THE ENTER
KEY TO DISPLAY DATA IN
SEQUENCE

+
Display
Brake switch

Display
Mast engine Cmd

+
Display
Pump feed-back

Display
Direction switch

Display
Mast switch

Display
Reduced speed

+
Display
Neutral drift

Display
Constant speed
ENTER

ENTER
ESC

ENTER
ESC
ENTER
ESC
ENTER
ESC
ENTER
ESC
ENTER

ENTER

ESC

ESCAPE

ENTER
ESC

Display the status of the


function (enable / disable)
Display the status of the negative
brakes (enable / disable)
Display the status of the parking
brake switch (set / not set)
Display the engine RPM
with the lifting lever pulled
Display the real pump displacement
(cc) by the potentiometer
Display the status of the direction switches
(neutral / forward / backward)
Display the status of the control valve switches
1=tilting / sideshift (set / not set)

Display the constant driving speed function


status with the lifting activated (set / not set)
Display the reduced speed function
status (enable / disable)
Display the difference of the pump potentiometer
signal from the theoretical value (in mV)

List for
2.5 - 3.5t

Display
Actuator feed back

+
Display
Power supply

Display
Sensor excitation

ESCAPE

Display the engine RPM


requested by the logic unit

ESC

ESC

ENTER

Display the pump displacement


requested by the logic unit (cc)

ESC

+
List for
4.0 - 5.0t

ESC

ESC

+
ENTER

ENTER

ENTER

Display
Antistall

Display

Display the real engine RPM


ESC

+
Display
Neutral drift

ENTER
ESC
ENTER
ESC
ENTER
ESC
ENTER
ESC

Display the signal of the engine


actuator in volts
Display the voltage of the logic
unit (enable / disable)
Display the sensor voltage supplied by the
logic unit
Display the difference of the pump potentiometer
signal from the theoretic value (in mV)

Sida 4

BT Cargo Teknikutbildning
Pump Customised
Section

Calibration status
has to be un locked
to release the
parameters for
Calibration
modification
Calibration status

Calibration
Calibration status
Locked

Calibration
Calibration status
Not Locked
ESC

Calibration
travel Pedal
ESCAPE

ESC

Pump acceleration
time
Pump Customised ENTER
Pump Customised
Travel pedal Inc.
Travel pedal Inc.
5.0 Seconds

Display

ENTER

ENTER

Calibration

Select the Parking brake


switch and press

- +

ENTER
ESC

Programmering av TCS-systemet
BT Cargo CBD/CBG 2.5-5.0

ESC

Pump
Customised

ENTER

Set the requested value by typing it directly


with the keyboard numbers or pressing + 0 ENTER ( N.B. Quicker acceleration, lower
value, slower acceleration, higher value)
ESCAPE Pump Customised
Travel pedal Inc.
5.0 Seconds

Pump deceleration
time (Braking)
Pump Customised
Travel pedal Dec. ENTER

+
Hard braking ratio

Pump Customised
Sensitivity

+Pump Customised
Inching pedal Inc.

ENTER

Pump Customised
Travel pedal Dec.
5.0 Seconds
Set the requested value by
typing it directly
with the keyboard numbers
or pressing + 0 ENTER ( N.B. Stronger brake,
lower value
softer brake, higher value)

ESCAPE Pump Customised


Travel pedal Dec.
5.0 Seconds
Not Modified

Not Modified

ESCAPE Pump Customised


Inching pedal Dec. Not Modified

Pump Customised
Hard braking
ratio 00%
ENTER
See page 14
ESCAPE Pump Customised
Hard braking
ratio 00%

Sida 5

BT Cargo Teknikutbildning
Engine Customised
Section

Programmering av TCS-systemet
BT Cargo CBD/CBG 2.5-5.0

Calibration status
has to be un locked
to release the
parameters for
Calibration
modification
Calibration status

Select the Parking brake


switch and press
ENTER

Calibration
Calibration status
Locked

- +

ENTER

Calibration
Calibration status
Not Locked
ESC

ENTER
Calibration
travel Pedal

Calibration

ESCAPE

Display

Engine Customised
Travel pedal Inc.

Pump
Customised

+
Engine
Customised

Engine Customised
Travel pedal Dec.
ENTER

+
Engine Customised
Mast Inc.

Set the requested value by typing it


directly, or by the +0- ENTER
(N.B. More RPM higher value less RPM
lower value)

+
Engine Customised
Mast Dec.

Engine Customised
Mast fixed Cmd. 1
45%

+
Engine Customised ENTER
Mast fixed Cmd. 1 Engine RPM
Tilting

ENTER

Engine Customised
Mast fixed Cmd. 1
ESCAPE 45%
Set the requested value by typing it
directly, or by the +0- ENTER
(N.B. More RPM higher value less RPM
lower value)

ESCAPE

Engine Customised ENTER


Mast fixed Cmd. 2 Engine RPM
Sideshift

Engine Customised
Mast fixed Cmd. 2
45%
ENTER

Engine Customised
ESCAPE Mast fixed Cmd. 2
45%

Sida 6

BT Cargo Teknikutbildning
Alarms Section
Fault Detected

Programmering av TCS-systemet
BT Cargo CBD/CBG 2.5-5.0

DISPLAY CONSOLE

ENTER

Calibration

+
Display

+
+

ENTER To display the


faults in real time Fault detected
Fault Detected
Fault occuring now
Fault occuring now
No default

Engine
Customised

+
Fault
Detected

Press ENTER
to display the faults

ESC

Pump
Customised

No alarms

Fault detected
Fault occuring now
Actuator sensor
Alarm present

ESC

ENTER To display the


stored alarms (faults)
Fault detected
(max 5)
Fault Detected
Fault since startup
Fault since startup
Start of the list

To read
the alarms

Fault detected
Example:- Fault since startup
Neutral out of range

+
ESC Fault detected
Fault since startup
End of the list

Sida 7

BT Cargo Teknikutbildning

Programmering av TCS-systemet

Hr r huvudmenyerna:

Meny

Funktion

CALIBRATION

Kalibrering av sensorer och potentiometrar. Visning av aktuella


spnningar (Calibration Status = Locked)

DISPLAY

to display the information on the transmission (thermal engine speed,


pump displacement, anitstall function,....)

PUMP CUSTOMIZED

to customize the transmission (more or less prompt braking and


acceleration)

ENGINE CUSTOMIZED

to customize the thermal engine control (higher or lower acceleration


of the thermal engine, engine speed when the tilt system and the
sideshift are on,...)

FAULT DETECTED

to display the system faults

INFORMATION

software versions

PH PARAMETERS (password)

configuration of the system operation parameters

EEPROM RESET (password)

to reset the control unit memory

MOTOR SHIFTING(password)

configuration of the parameters controlling the displacement


Shifting of the hydraulic motors

10 ACTUATOR PID (password)

configuration of the actuator feedback parameter

1 CALIBRATION
The CALIBRATION menu has two functions:
Calibrating mode
when the parking brake is locked and the calibration status parameter is not locked, it allows the
calibration and configuration of the system.
Display mode
when the parking brake is not locked or the calibration status parameter is locked this menu
views the output voltages of the system sensors and the state of some components.
After calibration, release and engage the parking brake again to exit from the calibration status mode and
return to the standard operating mode.

Sida 8

BT Cargo Teknikutbildning

Programmering av TCS-systemet

CALIBRATION MENU
N

SUBMENU

CALIBRATION MODE

DISPLAY MODE

Travel pedal

calibration of the travel pedal

display of the voltage supplied by the


potentiometer for the travel pedal

brake / inching pedal calibration of the brake pedal

display of the voltage supplied by the


potentiometer for the brake pedal

mast lever

calibration of the mast lever

display of the voltage supplied by the


potentiometer for the mast lever

engine calibration

calibration of the actuator-thermal display of the voltage supplied by the


potentiometer for the actuator

pump neutral

calibration of the pump in neutral


position

display of the voltage supplied by the


potentiometer for the hydrostatic pump

max forward speed

limiting of the truck max


forward speed

display of truck forward speed


(as a percentage of the max speed)

max reverse speed

limiting of the truck max


reverse speed

display of the truck reverse speed


(as a percentage of the max speed)

parking brake set

definition of the brake pedal


position in which the mechanical
pedal is engaged

displays the brake pedal position in


which the mechanical brake is locked

min engine speed

definition of the minimum engine


RPM

displays the minimum engine RPM

max engine speed

definition of the maximum engine


RPM

displays the maximum engine RPM

pump pot. Inverted

definition of the connections type


of the pump potentiometer

displays the connections type


of the pump potentiometer

calibration status

validations and invalidation of the


calibration menu

status of the calibration menu

reduced speed

limiting of the truck max. Speed

number of teeth

power supply

sensor excitation

multi disc brake

definition of the number of teeth


Per engine rev (speed sensor in
The thermal engine
measures the supply voltage of
Control unit
measures the supply voltage of
Sensors
definition of the type of brake
Used

displays if the truck reduced speed is


(Enable / disable)
display of the number of teeth/rev
measures the supply voltage of
the control unit
measures the supply voltage of the
sensors
type of brake used

For the TCS to operate correctly, the voltage values read by the potentiometers in the pedals, the mast
system and the motor actuator must not exceed the limits set. If the mechanical limit stops of the
potentiometer are not properly adjusted, the voltage supplied by the potentiometer is exceeded. The range
of values allowed by the control unit disables the calibration procedure.
Trouble may also occur after a correct calibration if, for whatever reason, the limit stop is modified.

Sida 9

BT Cargo Teknikutbildning

Programmering av TCS-systemet

CALIBRATION AND FIRST START UP OF THE TRANSMISSION SYSTEM


The system calibration is to be performed when the thermal engine is stopped.
The following are to be calibrated:
Potentiometer for the travel pedal (TRAVEL PEDAL)
Potentiometer for the brake pedal (BRAKE / INCHING PEDAL)
Potentiometer for the mast lever (MAST LEVER)
Potentiometer for the hydrostatic pump (PUMP NEUTRAL)
While calibrating, check the parameters below:
Max. forward speed (truck max speed)
Max reverse speed (truck max speed)
Parking brake set (brake setting)
Min engine speed(minimum engine RPM)
Max engine speed (maximum engine RPM)
Pump pot. Inverted (with Potentiometer Hall effect only)

100%
100%
95%
850
2250
Enable

Calibration also includes the actuator setting while the thermal engine is running (ENGINE CALIBRATION).
For the engine calibration do the following:
Lift the truck onto the blocks
fill the hydraulic circuit and bleed the air from the system
engage the parking brake
select the neutral position (through the steering-wheel operated reverse gear)
start up the engine and wait for the stabilization of the boost pressure
adjust the engine min and max RPM through the actuator limit stop screws (the limit stops are to be
obtained on the actuator support, not on the injection pump). The engine RPM is to be measured
through the engine speedparameter in the DISPLAY menu.
Calibrate the actuator (ENGINE CALIBRATION)
Press the accelerator pedal; the actuator has to rotate clockwise and the voltage of the
feedback potentiometer in the actuator has to increase (such voltage may be measured in the
engine calibration parameter in the calibration menu after engaging the parking brake).
Once the calibration procedure is over, check the transmission operation (wheels must be jacked up):
Release the parking brake
position the steering column switch to forward gear
gradually press the forward pedal: wheels should slowly rotate forward
CAUTION: the hydraulic motors must not rotate quickly when wheels are jacked up
When wheels rotate forward, check that the voltage of the pump feedback potentiometer increases from
2.5 to 5 volts (for the voltage reading use pump neutral parameter in the calibration menu).
Check the correct operation under the following conditions:
- mast lifting, sideshift and tilt operation, etc., : if the relevant levers are adjusted, the thermal engine
will accelerate
- forward / reverse speed and braking
- parking brake: if engaged, the travel pedal will be disabled (the engine RPM will increase, but the
truck wheels will be locked)
- emergency button.

Sida 10

BT Cargo Teknikutbildning

Programmering av TCS-systemet

SEE THE DIAGRAM FOR USING CONSOLE


SECTION CALIBRATION
A) TRAVEL PEDAL CALIBRATION
For calibrating, voltages are not to exceed the following ranges (voltages may be read in display mode).
Pedal in its min. position 0,35 - 2,4 volts
Pedal in its max.position 2,6 - 4,65 volts
(the supply voltage of all sensors is of 5 volts)

(7 - 48% of the supply voltage)


(52 - 93% of the supply voltage)

B) BRAKE / INCHING CALIBRATION


Defines the voltage values corresponding to the min. and max. positions of the brake pedal ( and the
inching function.
For calibrating, voltages are not to exceed the following ranges:
Pedal in its min. position 0,35 - 2,4 volts
Pedal in its max. position 2,6 - 4,65 volts

(7 - 48 % of the supply voltage)


(52 - 93% of the supply voltage)

C) MAST LEVER CALIBRATION


Defines the voltage values corresponding to the maximum and minimum positions of the mast lever.
For calibrating, voltages are not to exceed the following ranges:
Lever in neutral position 0,35 - 2,3 volts
(7 - 46 % of the supply voltage)
Lever fully pulled
2,4 - 4,65 volts
(48 - 93% of the supply voltage)
D) ENGINE CALIBRATION
Matches the actuator position angle (voltage of the actuator feedback potentiometer) with the engine
speed value.
For calibration, voltages are not to exceed the following ranges:
Actuator in its min. position 0,35 - 2,4 volts
(7 - 48 % of the supply voltage)
Actuator in its max. position 2,6 - 4,65 volts
(52 - 93% of the supply voltage)
Such values may be viewed if the parking brake is engaged.
The control unit automatically controls the actuator by bringing it to its minimum and maximum positions
(that are determined by the mechanical limit stops located on the actuator support). With respect to the
min.and max. Positions, TCS reads the min.and max RPM as well as some intermediate values.
The limit stops are to be obtained on the actuator, not on the injection pump.
E) PUMP NEUTRAL CALIBRATION
Defines the voltage corresponding to the neutral displacement position of the hydrostatic pump (feedback
potentiometer).
The voltage value must not exceed the following range 2.48 to 2.52 volts.
(In display mode and when the truck is running, the voltage value must vary. When the wheels rotate
forward, the potentiometer voltage must rise to 5 volts and remain constant).

Sida 11

BT Cargo Teknikutbildning

Programmering av TCS-systemet

SEE THE DIAGRAM FOR USING CONSOLE


SECTION CALIBRATION
F) MAX FORWARD SPEED
This parameter (expressed as a percentage of the trucks forward max. speed) limits the travel speed.
This parameter may be modified (in calibration mode).
G) MAX REVERSE SPEED
This parameter (expressed as a percentage of the trucks reverse max speed) limits the travel speed.
This parameter may be modified (in calibration mode).
H) PARKING BRAKE SET
This parameter defines the stroke of the brake pedal necessary to engage the mechanical brake. The
standard value is 95%. It is suggested that this value is not changed. Limit values: 90 to 95%.
I) MIN ENGINE SPEED
This parameter defines the minimum engine RPM (standard value 850).
L) MAX ENGINE SPEED
This parameter defines the maximum engine RPM (standard value 2250)
M) PUMP POT. INVERTED
This parameter defines the type of connections at the pump potentiometer. This parameter is present with
the Hall potentiometer software only.
N) CALIBRATION STATUS
This parameter enables or disables the calibration mode.
O) REDUCED SPEED
This parameter expressed if the truck reduced speed is activated (enable / disable). This parameter may
be modified (in calibration mode).
P) NUMBER OF TEETH
This parameter defines the number of pulse per revolution of the thermal engine sent by the speed sensor
to the control unit.
R) POWER SUPPLY
Displays the supply voltage of the control unit: battery voltage (12 volts)
S) SENSOR EXCITATION
This parameter displays the voltage supplied by the control unit to the sensors. Correct value: 5 volts.
T) MULTI DISC BRAKE
this parameter defines whether the multidisc brake is fitted or not (the multidisc brake is an on/off brake,
i.e. It is not gradual.

Sida 12

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Programmering av TCS-systemet

2) DISPLAY
This menu displays the transmission data.
Press ENTER to display data (e.g. Thermal engine speed).
(Hold down the key to display data in sequence)
ENGINE SPEED
Real speed of the thermal engine (expressed in RPM)
PUMP DISPLACEMENT
Pump displacement required by TCS (expressed in cc). Warning: this is the displacement control sent
by the control unit to the pump, so the value displayed may be different from the real displacement.
ENGINE COMMAND
Speed of the thermal engine required by TCS (in RPM).
ANTISTALL
Indicates whether the anitstall function is enabled or not (enable / disable).
PARKING BRAKE
Displays whether the negative brakes are set or not (set / not set).
BRAKE SWITCH
Displays whether the parking brake switch is set or not (set / not set)
MAST ENGINE COMMAND
Speed of the thermal engine required by TCS (in RPM) when the mast is actuated.
PUMP FEED-BACK
Actual displacement of the pump (expressed in cc). This is the displacement measured by the
potentiometer located on the pump.
DIRECTION SWITCH
Displays the running direction controlled by the pedal micro-switches or the steering-wheel operated
reverse gear (neutral / forward / reverse).
MAST SWITCH
Displays the state of the valve bank microswitches 1 = tilt / sideshift (set / not set)
CONSTANT SPEED.
Displays the constant speed function enabling when the mast is actuated while the truck is running
(set / not set).
REDUCED SPEED
Displays if the reduced speed function is enabled (the trvel speed is limited to a preset percentage
value of the max. speed). optional
ACTUATOR FEED BACK
Displays the engine actuator signal in Volts. Increases during acceleration and vice versa.
POWER SUPPLY
Displays the voltage supply to the control unit: battery voltage (12V)
Must be between 9,5 and 48,5 Volt.
SENSOR EXCITATION
Displays the voltage supply to the sensors. Correct value 5 Volt.
NEUTRAL DRIFT
Displays the difference in value between the theoretical and real pump potentiometer value (in mV)
This parameter is present with the Hall potentiometer software only.

Sida 13

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Programmering av TCS-systemet

3) PUMP CUSTOMIZED
Sets the parameters for the control of the hydrostatic pump.
This parameter is used to modify the acceleration and deceleration of the truck.
Enable the program to modify such values (calibration status - not locked).
TRAVEL PEDAL INC.
This parameter defines how long the pump takes to reach its max displacement when the travel pedal
is fully pressed (the higher the value of this parameter, the less the acceleration of the truck).
TRAVEL PEDAL DEC.
This paramter defines how long the pump takes to reach its neutral displacement mode when the
travel pedal is released (the higher the value of this parameter, the less the deceleration of the truck
during the hydrostatic braking).
HARD BRAKING RATIO
This parameter (%) changes the release braking value (travel pedal dec) as the following table:

Braking times of the truck function of the two parameters


Travel pedal dec (s) and Hard braking ratio(%)
Travel pedal dec (s)

10

10

17

1.7

3.8

6.5

50

2.8

67

1.6

2.5

3.1

3.6

83

2.3

100

1.3

2.1

2.5

2.9

Bromskraft vid lg
hastighet

Hard braking ratio (%)

Bromskraft vid hg
hastighet

SENSITIVITY
This parameter defines the sensitivity of the pump control when varying the pedal stroke (this value is
expressed as a percentage of the pump max. displacement control).
INCHING PEDAL INC
This parameter defines how long the pump takes to reach its max. displacement when the inching pedal
is instantaneously released after it has been fully pressed in conjunction with the travel pedal.
INCHING PEDAL DEC.
This parameter defines how long the pump takes to range from the max. Displacement to the neutral
displacement when the inching pedal is instantaneously pressed after fully pressing the travel pedal.

Sida 14

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Programmering av TCS-systemet

4) ENGINE CUSTOMIZED
Sets the parameters for the thermal engine control. Do not modify the standard values.
TRAVEL PEDAL INC.
This parameter defines how long the actuator takes to achieve its stroke when the travel pedal is fully
pressed (the higher the value of this parameter, the longer the time the thermal engine takes to range
from its min RPM to its max RPM.)
TRAVEL PEDAL DEC.
This is the same as the previous parameter (the time the thermal engine takes to range from its min
speed to its max. Speed.)
MAST INC.
This parameter defines the time the actuator takes to achieve its stroke when the mast lever is fully
pulled back. (The higher the value of this parameter, the longer the time the thermal engine takes to
range from its min RPM to its max RPM)
MAST DEC.
This parameter is similar to the previous one (time the engine takes to range from its max RPM to its
min. RPM when the mast lever is released).
MAST FIXED CMD 1
MAST FIXED CMD 2
Parameters that define the thermal engine speed rate when one of the auxiliary devices of the hoisting
unit is actuated (tilt unit, sideshift, 4th way, 5th way).
When one of the value levers is actuated (except for the mast lever) the engine speed increases by a
quantity proportional to the parameter setting. Standard value is 30 - 40 %
Ex: Engine min speed: 700 rpm; engine max.speed: 2,500rpm
usable range: 2,500 - 700 = 1,800rpm
parameter (mast fixed cmd): 25%
If the engine operates at a speed higher than 1,100rpm and the distributor is actuated, the
actuator will bring the engine rpm to: 1,100 + (2,500 - 700) x 0.25 = 1,500rpm
Do not increase the speeds set to avoid dangerous manoeuvres.
Stroke of the sideshift: 2 - 2.5secs
Tilting:
4.5 - 5 secs
MAST MAXIMUM CMD (Available from 2001)
Parameter which defines the max thermal motor rpm when the lifting is started. By activating the lever,
the motor speed increases step by step until the max value set.

Sida 15

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Programmering av TCS-systemet

5) FAULT DETECTED
Displays the system faults.

- FAULT OCCURRING NOW


Press enter to display the current fault

- FAULT SINCE START UP


Press (+) and (-) to display the last five faults occurred

- FAULT MESSAGES SHOWN ON THE CONSOLE


Excitation Sensor

The excitation voltage of the sensor is <2V or >5.5V

Power Supply

The supply voltage of TCS control unit is <9.5V or >32V for more
than 2 secs long

Travel Pedal Sensor

The signal (voltage) of the travel pedal potentiometer has


exceeded the limits set while calibrating

Brake / Inching pedal Sensor

The signal (voltage) of the brake pedal potentiometer has


exceeded the limits set while calibrating

Mast lever Sensor

The signal (voltage) of the mast lever has exceeded the limits
set while calibrating

Actuator Sensor

The signal (voltage) of the feedback potentiometer has exceed


the limits set while calibrating

Error on Actuator control loop

>20% error, for more than 0.5secs, between the actuator setpoint
and the potentiometer feedback

Error on pump control loop

>20% error, for more than 0.5 secs, between the pump control
signal and the potentiometer feedback signal in the pump.

Feed back error

Pump feed back is <0.25V or >4.75V

Neutral out of range

During calibration the pump neutral is outside of the fixed limits

Pump neutral drift too high

The difference between the pump in neutral calibration function


and the pump in neutral while the values are fed is >341 mV

Feedback moves too fast

The pump feedback changes too fast in comparison with the real
change of the pump displacement.

Eeprom error at address

One parameter at least is outside of the field of acceptable values

Direction switches error

The TCS control unit takes contemporarily the forward and reverse gear
(running mode) started

Other default

Other faults

6) INFORMATION
Displays the SOFTWARE version

Sida 16

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Programmering av TCS-systemet

7) PH PARAMETERS
- PASSWORD
Enter the password (4 numbers) with the digital key and then valid (enter).
Press the key / esc then (+) or (-) in order to have access to the rest of the menu
- PUMP NEUTRAL OFFSET
This parameter is used to offset pump feedback

- ENABLE LIMIT CHANGE


During the calibration of the pedals, the auxiliary levers and the actuator, it is possible that the minimum
and maximum values obtained on the potentiometer do not conform to the limits fixed by the programme.
It is possible to modify these limits.
In the menu calibration, authorise the mode calibration. Go into the menu PH PARAMETERSand into
the menu ENABLE LIMIT CHANGE.
It is necessary to be in NOT LOCKED

- INVERSION BRAKING
This function is used to have a braking action if the direction switch is set to the reverse position during the
operation of the machine (plug braking)
The braking action will be proportional to the position of the travel pedal.

- INVERSION DISPLACEMENT
This parameter sets the inversion time range from 0 - 10 seconds

- DISABLE PUMP DELAY


Parameter which defines the time delay of the negative brakes releasing (standard values 30 cycles). It is
the delay for the brakes releasing after the pump has reset its displacement. In order to have the brakes
release in a short time, for example on a ramp, reduce the value (min 5 max 45 cycles).

- REGULATOR OFFSET
This is the acceptable difference between the requested engine speed and the measured engine speed.
If this value is exceeded, the antistall function is active

- ANTISTALL COEF
coefficient applied to the action of the anitstall function.
The parameter change from 3 to 8
The higher the value the more the displacement will decrease

- DERIVE ANTISTALL
Definition of the derived gain for the antistall action. The parameter is a variable number from 10 - 30
The higher the number the more sensitive antistall is to RPM variations

- FULL STROKE CMD


Compensation of the electric stroke used on the position potentiometer of the pump swashplate
The parameter is a number (never vary it) 1488

- ENGINE DELAY INC

This parameter is used to take into account the reaction time of the engine actuator in order to activate the
anitistall at the right moment. It avoids unnecessary operations of the antistall functions.

- ENGINE DELAY DEC


This value is the complementary value of engine delay dec. It is to take into account during the engine deceleration
This paramter is the time taken for engine deceleration.

Sida 17

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Programmering av TCS-systemet

8) EPROM RESET
This menu is used to reset the data of the EEPROM

- PASSWORD
Enter the password (4 numbers) with the digital key and then press enter.
Press the key / esc then (+) or (-) in order to have access to the rest of the menu

- ALL EEPROM RESET


Press the enter key to cancel the list of statistics

- FAULT LIST RESET


Press the enter key to cancel the list of the detected faults.

Sida 18

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Programmering av TCS-systemet

TROUBLES OCCURRING WHILE CALIBRATING


The voltage values read by the transmission potentiometer (pedals, hoisting, etc.) Must not exceed the limits set. If
there is some wiring failure or the mechanical limit stops of the potentiometers are not properly adjusted, the voltage
they supply will exceed the allowed range for the control unit, thus preventing the calibration procedure. In that
case, the terminal will display one of the following messages (while calibrating or in the fault detected alarm
menu).
Travel pedal position out of range
Brake/inching pedal sensor
Mast lever sensor
Actuator position out of range
Feed back error

Travel pedal
Brake pedal
Mast lever
Thermal engine actuator
Hydrostatic pump potentiometer

1) TRAVEL PEDAL

Yes

Travel pedal position out of range

(Error message)

Release the parking brake

The terminal will switch from the


CALIBRATION MODE to the
DISPLAY MODE

Select the
TRAVEL PEDAL submenu

The terminal will display the


voltage that is supplied
from the potentiometer in
the travel pedal

Voltage = 0 volts?

No

Hold down the [ENTER] key and


check if voltage changes when
the pedal is pressed

Check the potentiometer wiring

Yes

Does voltage change?


No

Press the [ENTER] key to


measure the min. and max.
Voltage supplied by the
potentiometer

Check the potentiometer wiring

Adjust the mechanical limit stop of


the pedal so that the voltage does
not exceed the ranges set
(see travel calibration)

Calibrate the travel pedal

Sida 19

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Programmering av TCS-systemet

TROUBLES OCCURRING WHILE CALIBRATING


2) BRAKE/INCHING PEDAL
Brake/inching position out of range

(Error message)

Release the parking brake

The terminal will switch from the


CALIBRATION MODE to the
DISPLAY MODE

Select the
BRAKE/INCHING PEDAL submenu

Yes

Voltage = 0 volts?

The terminal will display the


voltage that is supplied
from the brake pedal
potentiometer

No

Hold down the [ENTER] key and


check if voltage changes when
the pedal is pressed

Check the potentiometer wiring

Yes

Does voltage change?


No

Press the [ENTER] key to


measure the min. and max.
Voltage supplied by the
potentiometer

Check the potentiometer wiring

Adjust the mechanical limit stop of


the pedal so that the voltage does
not exceed the ranges set
(see travel calibration)

Calibrate the brake pedal

Sida 20

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Programmering av TCS-systemet

TROUBLES OCCURRING WHILE CALIBRATING


3) MAST LEVER
Mast lever sensor out of range

(Error message)

Release the parking brake

The terminal will switch from the


CALIBRATION MODE to the
DISPLAY MODE

Select the
MAST LEVER submenu

Yes

Voltage = 0 volts?

The terminal will display the


voltage that is supplied
from the mast lever
potentiometer

No

Hold down the [ENTER] key and


check if voltage changes when
the pedal is pressed

Check the potentiometer wiring

Yes

Does voltage change?


No

Press the [ENTER] key to


measure the min. and max.
Voltage supplied by the
potentiometer

Check the potentiometer wiring

Adjust the shims of the


potentiometer support bracket so
that the voltage does not exceed
the ranges set (see mast lever
calibration) If the lever is moved
forward from its middle position
(for forks lowering) voltage is not
to decrease.
Calibrate the mast lever

Sida 21

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Programmering av TCS-systemet

TROUBLES OCCURRING WHILE CALIBRATING


4) THERMAL ENGINE ACTUATOR
Actuator position out of range

(Error message)

Release the parking brake

The terminal will switch from the


CALIBRATION MODE to the
DISPLAY MODE

Select the
ENGINE CALIBRATION submenu

Yes

Voltage = 0 volts?

The terminal will display the


voltage that is supplied
by the potentiometer of
the actuator

Engage the
parking brake
No and press the
accelerator
pedal
Hold down the [ENTER] key and
check if voltage changes while the
actuator rotates

Check the electrical connections


of the actuator

Yes

Does voltage change?


No

Press the [ENTER] key to


measure the min. and max.
Voltage supplied by the
actuator potentiometer

Check the actuator electrical


connections

Adjust the length of the tie rod so


that the voltage does not exceed
the ranges set (see engine
calibration)
Calibrate the actuator

Sida 22

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Programmering av TCS-systemet

TROUBLES OCCURRING WHILE CALIBRATING


5) POTENTIOMETER IN THE HYDROSTATIC PUMP
Feed back error

(Error message)

Release the parking brake

The terminal will switch from the


CALIBRATION MODE to the
DISPLAY MODE

Select the
PUMP NEUTRAL submenu

Yes

Check the potentiometer


electrical connections

Voltage = 0 volts or 5 volts

The terminal will display the


voltage that is supplied
by the potentiometer in the
hydrostatic pump

No

Voltage = 2.48 - 2.52 volts


Yes
No

Engage the parking brake,


switch to CALIBRATION
mode and clibrate the
pump potentiometer to
zero.

Check the potentiometer wiring, lift


the truck onto blocks, electrically
disconnect the pump solenoid
valves and start up the engine: If
the pump supplies some oil, the
trouble is hydraulic or mechanical
(mechanical maladjustment of the
pump plate positioning in neutral)
After disconnecting the valves, if the
pump supplies some oil, switch off
the engine and hold down the
[ENTER] key in order to read the
voltage, until a 2.5 volt value is
obtained

Engage the parking brake, swich to


CALIBRATION mode and clibrate
the pump potentiometer zero.

Sida 23

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Programmering av TCS-systemet

SYSTEM FAULTS AND FAILURES


Any system failure is signalled by the flashing warning light located beside the valve bank levers.
The frequency indicated the failure importance.
The kind of fault is displayed in the FAULT DETECTED menu (FAULT OCCURRING NOW SUBMENU).
If the warning light blinks slowly (0.5Hz) the fault is not very important; the machine is able to drive.

Error message

Cause

Cure

Travel pedal sensor

The signal voltage of the travel pedal


potentiometer has exceeded the limits set
while calibrating.
Connector disconnected or wrong wiring.

Check the potentiometer


wiring.
Check if the voltage values at
the pedal stop do not exceed
the preset limits.
Adjust the pedal limit stop.
Calibrate the pedal again.

Brake/inching pedal sensor

The signal voltage of the brake pedal


potentiometer has exceeded the limits set
while calibrating.
Connector disconnected or wrong wiring.

Check the potentiometer


wiring.
Check if the voltage values at
the pedal stop do not exceed
the preset limits.
Adjust the pedal limit stop.
Calibrate the pedal again.

Mast lever sensor

The signal voltage of the mast lever


potentiometer has exceeded the limits set
while calibrating.
Connector disconnected or wrong wiring.

Check the potentiometer


wiring.
Check if the voltage values at
the lever stop do not exceed
the preset limits.
Adjust the lever limit stop.
Calibrate the lever again.

The signal voltage of the feedback


potentiometer has exceeded the limits set
while calibrating.
Connector disconnected or wrong wiring.

Check the potentiometer


wiring.
Check if the voltage values at
the actuator stop do not
exceed the preset limits.
Adjust the actuator limit stop.
Calibrate the actuator again.

Error on actuator control


loop
This message may be
displayed if the accelerator
is pressed(green light on)
when the engine is off and
the brake is unlocked.

.20% error, for more than 0.5 secretary..


Between the actuator set point and the
potentiometer feed back.
Connector disconnected or wrong wiring.

Check the actuator wiring.


Check the actuator
potentiometer output signal. If
you press the accelerator
pedal, the actuator will rotate
forward and the voltage measured in engine calibration
when the brake is released will increase.

Power supply out of range

The supply voltage of TCS control unit is


not within the 9.5 - 48 volt range.

Check the supply voltage value.

Actuator sensor

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BT Cargo Teknikutbildning

Programmering av TCS-systemet

SYSTEMFEL OCH FELMEDDELANDEN


Om varningslampan blinkar snabbt (1hz) r felet allvarligt, och maskinen gr ej att kra!

FELMEDDELANDE

ORSAK

KONTROLLERA

Felaktig matningsspnning till sensorer


och microbrytare.

- Att spnningen ligger p 5 volt


+/- 5%

Fel signal frn feedback-potentiometern


p pumpen.

- Att spnningen frn feedbackpotentiometern ligger p 2.5 +/0.15 volt nr pumpen str i
neutrallge.

Fel signal frn feedback-potentiometern


p pumpen, med pumpen i neutrallge.

- Att spnningen frn feedbackpotentiometern ligger p 2.5 +/0.15 volt nr pumpen str i
neutrallge.

Fel signal frn feedback-potentiometern


p pumpen. Avvikelsen mellan feedback
signalen och det frvntade vrdet
tillbaka till TCS kontrollen r >20%, i mer
n 0.5 sec.

- Kablaget till feedbackpotentiometern och EDC


kontrollen.

Excitation voltage

Feedback error

Neutral out of range

Error on pump control loop

- Att feedback signalen ndrar


sig nr man kar krhastigheten.
- Att Min och Max spnningen
frn feedback potentiometern r
konstant, och att vrdet r lika
varje gng. Spnningen skall
stiga till upp emot 5 volt.

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BT Cargo Teknikutbildning

Programmering av TCS-systemet

FELSKNING

Typ av fel

Motorn gr men ingen drivning.


Pumpen vinklar inte ut, varken
framt eller bakt.

Mjlig orsak

Kontrollera p-broms brytarens funktion i menyn: "DISPLAY /


BRAKE SWITCH" (set / not set).
Kontrollera fram&back brytarnas funktion i menyn: "DISPLAY /
DIRECTION SWITCH" (neutral / forward / reverse).

Drivningen fungerar och pumpen


vinklar ut, men motorn varvar
inte upp.

Kontrollera varvtalssensorns funktion i menyn: "DISPLAY/ENGINE


SPEED" - vrdet skall vara relevant till det verkliga motorvarvet.
Kontrollera feedback signalen frn pump-potentiometern i menyn:
"CALIBRATION / PUMP NEUTRAL" (calibration status = locked)
Kontrollera gasmotorn funktion i menyn: "CALIBRATION / ENGINE
CALIBRATION" (calibration status = locked)

Drivningen fungerar och motorn


varvar upp vid krning.
Inget gaspdrag nr man
anvnder hydraulfunktionerna.

Kontrollera lyftpotentiometerns funktion i menyn:


"CALIBRATION / MAST LEVER / MAST SENSOR PRESENCE"
(Yes=1/ No=0)
Kontrollera lyftpotentiometerns funktion i menyn:
"CALIBRATION/MAST LEVER" (calibration status = locked)
Kontrollera Tilt/Aux brytarnas funktion i menyn: "DISPLAY / MAST
SWITCH" (set / not set).

Varken drivning eller gaspdrag


fungerar.

Om varningslampan r slckt:
Kontrollera varvtalssensorns funktion i menyn: "DISPLAY/ENGINE
SPEED" - vrdet skall vara relevant till det verkliga motorvarvet.
Om varningslampan blinkar sakta:
Kontrollera signalen frn gaspedalen i menyn: "CALIBRATION/
TRAVEL PEDAL CALIBRATION" (calibration status = locked).
Om varningslampan blinkar snabbt:
Kontrollera spnningsmatningen till sensorerna i menyn:
"DISPLAY / SENSOR EXCITATION" (5 volt).
Kontrollera spnningsmatningen till TCS enheten i menyn:
"DISPLAY / POWER SUPPLY"
Kontrollera feedback signalen frn pump-potentiometern i menyn:
"CALIBRATION / PUMP NEUTRAL" (calibration status = locked)
Kontrollera kablaget till EDC-kontrollen.

Sida 26