Professional Documents
Culture Documents
CBD/G
2.5
3.0
3.5
Cargo Range
CARGO 2.5
BT Svenska AB
Per Wrmlund
INTERNAL
COMBUSTION
SERVICE MANUAL
page 3
Copyright by
CESAB S. p. A.
SERVICE MANUAL
page 4
INTERNAL
COMBUSTION
INDEX
TECHNICAL DATA ............................................................................................. 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
p.
p.
p.
p.
p.
p.
p.
p.
p.
13
13
14
15
16
16
17
17
17
p.
p.
p.
p.
p.
18
19
20
21
22
24
26
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
p.
p.
p.
p.
33
33
34
34
INTERNAL
COMBUSTION
SERVICE MANUAL
page 5
p.
p.
p.
p.
35
35
36
37
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
59
59
p.
p.
p.
p.
60
60
61
62
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
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.
SERVICE MANUAL
TECHNICAL DATA
INTERNAL
COMBUSTION
INTERNAL
COMBUSTION
SERVICE MANUAL
SERVICE MANUAL
page 8
INTERNAL
COMBUSTION
1
o
1 forward speed
o 0 neutral
2 reverse speed
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
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.
SERVICE MANUAL
page 10
6
7
INTERNAL
COMBUSTION
10
11
12
13
14
15
SERVICE MANUAL
INTERNAL
COMBUSTION
A:
B:
1
PARKING SWITCH
ELECTRONIC FAILURE WARNING LIGHT
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
-
If the start up procedure has not been correctly performed, the truck
will not start up. If so, repeat the procedure above.
2
SERVICE MANUAL
INTERNAL
COMBUSTION
page 12
L
K
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
LIFT HEIGHT
mm
MOTOR
SERIAL N
RATED CAPACITY
kW
SERIAL N
kg
BATTERY MASS
kg
min.
MANUFACT. YEAR
SERVICE MASS
Without
Battery kg
kg
max.
TENSION
Cod. 0312004
Cod. 0312005
DERATED CAPACITY Kg
CAPACITY PLATE
CESAB LDT
Bevan Way
Smethwick - Warley
West Midla 1ds B66 1BZ
INTERNAL
COMBUSTION
SERVICE MANUAL
page 13
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
10
11
12
13
14
15
16
17
18
SERVICE MANUAL
page 14
4 in line
Bore
98 mm
Travel
110 mm
Swept volume
3318 cm
Compression ratio
22,6:1
46 kW
Maximum torque
230 Nm
at 1600 rpm
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
CONTINENTAL TM 27 ENGINE
No. cylinders
Bore
4 in line
91 mm
Travel
103,5 mm
Swept volume
2700 cm
Compression ratio
8:1
43 kW
Maximum torque
200 Nm
at 1500 rpm
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
SERVICE MANUAL
INTERNAL
COMBUSTION
page 16
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.
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
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.
CYLONE PREFILTER
A
Every 8 hours
- clean the cyclone prefilter.
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.
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.
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)
actuator on the thermal engine (adjustment of the fuel pump or the carburettor)
Travel pedal
Brake/inching
pedal
Running direction
selector
Thermal engine
speed sensor
Hydrostatic
pump
Failure warning
light
INTERNAL
COMBUSTION
SERVICE MANUAL
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.
SERVICE MANUAL
INTERNAL
COMBUSTION
On tilt 0, it corresponds to 0 mm
of stroke, therefore 0 capacity.
(machine stopped)
INTERNAL
COMBUSTION
SERVICE MANUAL
page 21
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)
SERVICE MANUAL
page 22
INTERNAL
COMBUSTION
INTERNAL
COMBUSTION
SERVICE MANUAL
Oljefilter
Fram&Back
Orbitrol
Styrning
Gaspedal
A=Bypasskruv fr bogsering
Broms
Prioriteringsventil
HYDRAULIC DIAGRAM
Magnetventil
Broms
SERVICE MANUAL
INTERNAL
COMBUSTION
page 25
HIGH PRESSURE CHECK POINT
EXCHANGE VALVE
OIL RETURN TO
TANK
NEGATIVE BRAKE
ELECTROVALVE
TRANSMISSION
SUCTION
RETURN
LIFTING
OIL
TEMP
LIFTING
SUCTION
AUXILIARY SERVICE
CHECKING POINT
RETURN
TRANSMISSION
OIL
DRAINAGE
MOTEURS
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.
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
A
HIGH PRESSURE
(to motors)
INTERNAL
COMBUSTION
DRAIN INLET
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
7/8 - 14 UN - 2B
A
V
O
V
9/16 - 18 UNF - 2B
V
R
E
7/16 - 20 UNF - 2B
S
7/16 - 20 UNF - 2B
page 27
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
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).
SERVICE MANUAL
page 30
INTERNAL
COMBUSTION
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
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
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
SERVICE MANUAL
page 32
L
N
INTERNAL
COMBUSTION
SERVICE MANUAL
INTERNAL
COMBUSTION
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.
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
CODE
E1-E2
RELAIS TYPE
CODE
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.
A
C
C
C
BRAKE PEDAL
TRAVEL PEDAL
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
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.
SERVICE MANUAL
page 40
INTERNAL
COMBUSTION
N. Menu
1
2
3
4
5
6
7
8
Functions
CALIBRATION
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
CALIBRATION MENU
N. SUBMENU
A travel pedal
CALIBRATION MODE
calibration of the travel pedal
B brake/inching
pedal
C mast lever
D engine calibration
E
F
G
H
I
L
M
(*)
N
pump neutral
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
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.
SERVICE MANUAL
page 42
INTERNAL
COMBUSTION
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:
SERVICE MANUAL
INTERNAL
COMBUSTION
0,35 - 2,3volts
2,4 - 4,65 volts
SERVICE MANUAL
page 44
INTERNAL
COMBUSTION
INTERNAL
COMBUSTION
SERVICE MANUAL
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
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.
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
INTERNAL
COMBUSTION
SERVICE MANUAL
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.
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
Power Supply
The supply voltage of TCS control unit is < 9.5V or > 32V for more than
2 sec. long.
The signal (voltage) of the travel pedal potentiometer has exceeded the
limits set while calibrating.
The signal (voltage) of the brake pedal potentiometer has exceeded the
limits set while calibrating.
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.
During the calibration the pump neutral is out the limits fixed.
The difference between the pump in neutral calibration function and the
pump in neutral while the values are not fed is >341 mV
The pump feedback changes too fast in comparison with the real change of
the pump displacement.
INTERNAL
COMBUSTION
SERVICE MANUAL
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.
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.
travel pedal
brake pedal
mast lever
thermal engine actuator
hydrostatic pump potentiometer
SERVICE MANUAL
INTERNAL
COMBUSTION
page 51
1) TRAVEL PEDAL
(error message)
select the
TRAVEL PEDAL submenu
yes
voltage = 0 volt?
no
check the
potentiometer wiring
no
SERVICE MANUAL
INTERNAL
COMBUSTION
page 52
2) BRAKE/INCHING PEDAL
(error message)
yes
voltage = 0 volt?
no
check the
potentiometer wiring
no
SERVICE MANUAL
INTERNAL
COMBUSTION
page 53
3) MAST LEVER
(error message)
select the
MAST LEVER submenu
yes
voltage = 0 volt ?
no
no
SERVICE MANUAL
INTERNAL
COMBUSTION
page 54
(error message)
yes
voltage = 0 volts?
no
INTERNAL
COMBUSTION
SERVICE MANUAL
page 55
feed-back error
(error message)
select the
PUMP NEUTRAL submenu
yes
yes
no
SERVICE MANUAL
page 56
INTERNAL
COMBUSTION
Cause
Cure
brake/inching pedal
sensor
actuator sensor
error on actuator
control loop
This message may be
displayed if the
accelerator is pressed
(green light on) when
the engine is off and the
brake is unlocked
power supply out of
range
- the supply voltage of TCS control unit - check the supply voltage value
is not included in the 9.5 - 48 volts range
INTERNAL
COMBUSTION
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
SERVICE MANUAL
page 58
INTERNAL
COMBUSTION
TROUBLESHOOTING
Fault
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
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.
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
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.
PRIORITY VALVE
(C)
POWER STEERING
CIRCUIT DRAWING
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
END STROKE
SETTING SCREW
G
STEERING AXLE
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
HYDRAULIC DISTRIBUTOR
Nominal capacity 80 l/min
3 - 4 - 5 section
Microswitch
Restrictor 2 mm
Lifting potentiometer
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
Fork carriage
Internal
section bar
Intermediate
section bar
External
section bar
SERVICE MANUAL
page 66
6
5
4
7
DIAMETRO
DI
SPINTA
2
5
1
Fig. A
Fig. B
INTERNAL
COMBUSTION
INTERNAL
COMBUSTION
SERVICE MANUAL
page 67
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.
F
E
SERVICE MANUAL
INTERNAL
COMBUSTION
C) Sideshift
(upper part) 2 grease nipples
(lower part) no grease nipple
INSTALLATION CHECKS
SAFETY SPECIFICATIONS
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
Rate
X = 152 mm (2,5T)
203 mm (3,0 - 3,5T)
"X" ( 5)
IB
999
114 mm
II B
1 000
2 500
152 mm
III B
2 501
4 999
203 mm
IV B
5 000
8 000
254 mm
VB
8 001
10 999
257 mm
SERVICE MANUAL
INTERNAL
COMBUSTION
page 71
TRUCK WEIGHT
2.5 t
4050 kg
2070 / 1980
kg
3.0 t
4600 kg
2100 / 2500
kg
3.5 t
5160 kg
2260 / 2900
kg
SERVICE MANUAL
page 72
INTERNAL
COMBUSTION
SPECIFICATIONS
QTY.
AGIP ARNICA 46
ISO - L - HV
FZG tests to stage 11
39 L
MOBIL ANTICONGELANTE
Cooling liquid
DIESEL engine
20 40 SAE
MOBILGREASE SPECIAL
Lithium base
ASTM 275 305 NLGI N.2
dropping point 180
ISO - L - HV
FZG tests to stage 10
39 L
Thickening Infusible
ASTM 265 295 NLGI N.2
Dropping point >260
FRONT tyres
REAR tyres
WHEEL TORQUE
37 daNm
steered wheels
50 daNm
driven wheels
DRIVE UNIT TORQUE
27 daNm
40 daNm
0,8 1,2 daNm
77 daNm
SERVICE MANUAL
INTERNAL
COMBUSTION
RUNNING IN MAINTENANCE
50
500
7/-
-/3
at # days/months FOR
OCCASIONAL USE
ENGINES
oil filter
HYDROSTATIC TRANSMISSION
transmission oil
LEGEND
SERVICE MANUAL
page 74
INTERNAL
COMBUSTION
MAINTENANCE TIMES
50
250
500
1 000
2
000
4
000
10
000
1/-
7/-
-/1
-/3
-/6
-/12
-/24
-/60
at # days/months
FOR OCCASIONAL USE
forks
mast tilting
lifting chains
SERVICE MANUAL
INTERNAL
COMBUSTION
MAINTENANCE TIMES
8
50
250
500
1000
2000
4000 10 000
1/-
7/-
-/1
-/3
-/6
-/12
-/24
-/60
chassis - cleaning
bolts in general
drivers seat
tyre pressures
steering lock
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
air filter
cyclone prefilter
engine supports
SERVICE MANUAL
INTERNAL
COMBUSTION
MAINTENANCE TIMES
50
250
500
1000
1/-
7/-
-/1
-/3
-/6
-/24
-/60
HYDROSTATIC TRANSMISSION
system seal
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
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
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
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
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
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
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
GB
Issue 11/2000
CONSOLE MAP
CBD/G 2,5-3,0-3,5
CALIBRATION SECTION
"CALIBRATION"
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
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
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
Calibration
Travel Pedal
IfForwardswitch
select it ('ENT')
Calibration
Travel Pedal
Pushslowlytravel
pedal
Calibration
Travel Pedal
Full depression in
Forward (press a key)
Calibration
Travel Pedal
Forwardcompleted
(press a key)
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)
press+
Calibration
Engine Calibration
press+
press+
Calibration
Max. forward speed
press+
press+
press+
acquisition of the
min. and max.
RPM of the
engine, ENTER
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
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
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
DISPLAY
CONSOLE
Display
Engine speed
PRESS
ENTER
ENTER
ESC
press+
Display
Pumpdisplacement
Calibration
ENTER
ESC
press+
Display
Display
Enginecommand
PRESS+
ENTER
ESC
press+
Display
Antistall
press ENTER,,
to display the information of
the engine / hydrostatic pump
ENTER
ESC
press+
Display
Parkingbrake
ENTER
ESC
press+
ENTER
ESC
press+
Display
MastengineCmd
ENTER
ESC
press+
Display
Pump feed-back
ENTER
ESC
press+
Display
Directionswitch
ENTER
ESC
press+
Display
Mastswitch
ENTER
ESC
press+
Display
Constantspeed
ENTER
ESC
press+
Display
Actuator feedback
ENTER
ESC
press+
Display
Power supply
ENTER
ESC
press+
Display
Sensorexitation
ENTER
ESC
press+
Display
Neutraldrift
Display
Brakeswitch
ENTER
ESC
CBD/G 2,5-3,0-3,5
Calibration
Calibration Status
first operation
to be carried
PRESS
ENTER
ENTER
Calibration
Calibration
Travel Pedal
ENTER
Calibration
Calibration Status
Locked
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
Engine Customized
Mast fixed Cmd 1
45 Percent
Engine Customized
Mast fixed Cmd 2
45 Percent
Engine Customized
Mast fixed Cmd 2
45 Percent
JULY 2000
CBD/G 2,5-3,0-3,5
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
press+
press+
ESC
Fault detected
Fault occuring now
No default
no alarms
ESC
Fault detected
Fault occuring now
Actuator sensor
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
DISPLAY
CONSOLE
Press ENTER to
select the main menu
Calibration
Press +
Display
Press +
Pump Customized
Press +
Engine Customized
Press +
Fault Detected
Press +
Information
SOFTWARE version
Press +
Ph Parameters
Press +
EEprom reset
JULY 2000
CBD/G 2,5-3,0-3,5
"PUMP CUSTOMIZED"
SECTION
DISPLAY
CONSOLE
Calibration
Calibration Status
first operation
to be carried
PRESS
ENTER
ENTER
Calibration
Calibration
Travel Pedal
Calibration
Calibration Status
Locked
ENTER
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,=('
67$1'$5'9$/8(
YES/NO
10% - 100%
10% - 100%
YES
100%
100%
850
2200
PRESENT
95%
ENABLE
3803&86720,=('
$&&(77$%/(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%
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
(1*,1(&86720,=('
#
#
$&&(77$%/(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%
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
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
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
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
+
Display information on the transmission (engine RPM, transmission
displacement, micro switches status, etc.)
Display
+
Pump
Customised
+
Engine
Customised
+
Fault
Detected
+
Information
Software version
+
Ph Parameters
+
Eeprom reset
Motor Shifting
+
Actuator Pid
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)
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)
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
Press a key
Calibration
Brake inching pedal
Full depression
(press a key)
Calibration Travel
Ful depression in
reverse (Press a key)
Completely press
the pedal,
keep it pressed
Calibration
ENTER
Brake / inching
pedal completed
ESC
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
ESCAPE
Ended configuration of the
lifting potentiometer
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
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
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.......
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
List for
2.5 - 3.5t
Display
Actuator feed back
+
Display
Power supply
Display
Sensor excitation
ESCAPE
ESC
ESC
ENTER
ESC
+
List for
4.0 - 5.0t
ESC
ESC
+
ENTER
ENTER
ENTER
Display
Antistall
Display
+
Display
Neutral drift
ENTER
ESC
ENTER
ESC
ENTER
ESC
ENTER
ESC
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
- +
ENTER
ESC
Programmering av TCS-systemet
BT Cargo CBD/CBG 2.5-5.0
ESC
Pump
Customised
ENTER
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)
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
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.
+
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
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
+
+
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
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
DISPLAY
PUMP CUSTOMIZED
ENGINE CUSTOMIZED
FAULT DETECTED
INFORMATION
software versions
PH PARAMETERS (password)
MOTOR SHIFTING(password)
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
mast lever
engine calibration
pump neutral
calibration status
reduced speed
number of teeth
power supply
sensor excitation
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
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
Sida 11
BT Cargo Teknikutbildning
Programmering av TCS-systemet
Sida 12
BT Cargo Teknikutbildning
Programmering av TCS-systemet
2) DISPLAY
This menu displays the transmission data.
Press ENTER to display data (e.g. Thermal engine speed).
(Hold down the key to display data in sequence)
ENGINE SPEED
Real speed of the thermal engine (expressed in RPM)
PUMP DISPLACEMENT
Pump displacement required by TCS (expressed in cc). Warning: this is the displacement control sent
by the control unit to the pump, so the value displayed may be different from the real displacement.
ENGINE COMMAND
Speed of the thermal engine required by TCS (in RPM).
ANTISTALL
Indicates whether the anitstall function is enabled or not (enable / disable).
PARKING BRAKE
Displays whether the negative brakes are set or not (set / not set).
BRAKE SWITCH
Displays whether the parking brake switch is set or not (set / not set)
MAST ENGINE COMMAND
Speed of the thermal engine required by TCS (in RPM) when the mast is actuated.
PUMP FEED-BACK
Actual displacement of the pump (expressed in cc). This is the displacement measured by the
potentiometer located on the pump.
DIRECTION SWITCH
Displays the running direction controlled by the pedal micro-switches or the steering-wheel operated
reverse gear (neutral / forward / reverse).
MAST SWITCH
Displays the state of the valve bank microswitches 1 = tilt / sideshift (set / not set)
CONSTANT SPEED.
Displays the constant speed function enabling when the mast is actuated while the truck is running
(set / not set).
REDUCED SPEED
Displays if the reduced speed function is enabled (the trvel speed is limited to a preset percentage
value of the max. speed). optional
ACTUATOR FEED BACK
Displays the engine actuator signal in Volts. Increases during acceleration and vice versa.
POWER SUPPLY
Displays the voltage supply to the control unit: battery voltage (12V)
Must be between 9,5 and 48,5 Volt.
SENSOR EXCITATION
Displays the voltage supply to the sensors. Correct value 5 Volt.
NEUTRAL DRIFT
Displays the difference in value between the theoretical and real pump potentiometer value (in mV)
This parameter is present with the Hall potentiometer software only.
Sida 13
BT Cargo Teknikutbildning
Programmering av TCS-systemet
3) PUMP CUSTOMIZED
Sets the parameters for the control of the hydrostatic pump.
This parameter is used to modify the acceleration and deceleration of the truck.
Enable the program to modify such values (calibration status - not locked).
TRAVEL PEDAL INC.
This parameter defines how long the pump takes to reach its max displacement when the travel pedal
is fully pressed (the higher the value of this parameter, the less the acceleration of the truck).
TRAVEL PEDAL DEC.
This paramter defines how long the pump takes to reach its neutral displacement mode when the
travel pedal is released (the higher the value of this parameter, the less the deceleration of the truck
during the hydrostatic braking).
HARD BRAKING RATIO
This parameter (%) changes the release braking value (travel pedal dec) as the following table:
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
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
BT Cargo Teknikutbildning
Programmering av TCS-systemet
4) ENGINE CUSTOMIZED
Sets the parameters for the thermal engine control. Do not modify the standard values.
TRAVEL PEDAL INC.
This parameter defines how long the actuator takes to achieve its stroke when the travel pedal is fully
pressed (the higher the value of this parameter, the longer the time the thermal engine takes to range
from its min RPM to its max RPM.)
TRAVEL PEDAL DEC.
This is the same as the previous parameter (the time the thermal engine takes to range from its min
speed to its max. Speed.)
MAST INC.
This parameter defines the time the actuator takes to achieve its stroke when the mast lever is fully
pulled back. (The higher the value of this parameter, the longer the time the thermal engine takes to
range from its min RPM to its max RPM)
MAST DEC.
This parameter is similar to the previous one (time the engine takes to range from its max RPM to its
min. RPM when the mast lever is released).
MAST FIXED CMD 1
MAST FIXED CMD 2
Parameters that define the thermal engine speed rate when one of the auxiliary devices of the hoisting
unit is actuated (tilt unit, sideshift, 4th way, 5th way).
When one of the value levers is actuated (except for the mast lever) the engine speed increases by a
quantity proportional to the parameter setting. Standard value is 30 - 40 %
Ex: Engine min speed: 700 rpm; engine max.speed: 2,500rpm
usable range: 2,500 - 700 = 1,800rpm
parameter (mast fixed cmd): 25%
If the engine operates at a speed higher than 1,100rpm and the distributor is actuated, the
actuator will bring the engine rpm to: 1,100 + (2,500 - 700) x 0.25 = 1,500rpm
Do not increase the speeds set to avoid dangerous manoeuvres.
Stroke of the sideshift: 2 - 2.5secs
Tilting:
4.5 - 5 secs
MAST MAXIMUM CMD (Available from 2001)
Parameter which defines the max thermal motor rpm when the lifting is started. By activating the lever,
the motor speed increases step by step until the max value set.
Sida 15
BT Cargo Teknikutbildning
Programmering av TCS-systemet
5) FAULT DETECTED
Displays the system faults.
Power Supply
The supply voltage of TCS control unit is <9.5V or >32V for more
than 2 secs long
The signal (voltage) of the mast lever has exceeded the limits
set while calibrating
Actuator Sensor
>20% error, for more than 0.5secs, between the actuator setpoint
and the potentiometer feedback
>20% error, for more than 0.5 secs, between the pump control
signal and the potentiometer feedback signal in the pump.
The pump feedback changes too fast in comparison with the real
change of the pump displacement.
The TCS control unit takes contemporarily the forward and reverse gear
(running mode) started
Other default
Other faults
6) INFORMATION
Displays the SOFTWARE version
Sida 16
BT Cargo Teknikutbildning
Programmering av TCS-systemet
7) PH PARAMETERS
- PASSWORD
Enter the password (4 numbers) with the digital key and then valid (enter).
Press the key / esc then (+) or (-) in order to have access to the rest of the menu
- PUMP NEUTRAL OFFSET
This parameter is used to offset pump feedback
- 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
- 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
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.
Sida 17
BT Cargo Teknikutbildning
Programmering av TCS-systemet
8) EPROM RESET
This menu is used to reset the data of the EEPROM
- PASSWORD
Enter the password (4 numbers) with the digital key and then press enter.
Press the key / esc then (+) or (-) in order to have access to the rest of the menu
Sida 18
BT Cargo Teknikutbildning
Programmering av TCS-systemet
Travel pedal
Brake pedal
Mast lever
Thermal engine actuator
Hydrostatic pump potentiometer
1) TRAVEL PEDAL
Yes
(Error message)
Select the
TRAVEL PEDAL submenu
Voltage = 0 volts?
No
Yes
Sida 19
BT Cargo Teknikutbildning
Programmering av TCS-systemet
(Error message)
Select the
BRAKE/INCHING PEDAL submenu
Yes
Voltage = 0 volts?
No
Yes
Sida 20
BT Cargo Teknikutbildning
Programmering av TCS-systemet
(Error message)
Select the
MAST LEVER submenu
Yes
Voltage = 0 volts?
No
Yes
Sida 21
BT Cargo Teknikutbildning
Programmering av TCS-systemet
(Error message)
Select the
ENGINE CALIBRATION submenu
Yes
Voltage = 0 volts?
Engage the
parking brake
No and press the
accelerator
pedal
Hold down the [ENTER] key and
check if voltage changes while the
actuator rotates
Yes
Sida 22
BT Cargo Teknikutbildning
Programmering av TCS-systemet
(Error message)
Select the
PUMP NEUTRAL submenu
Yes
No
Sida 23
BT Cargo Teknikutbildning
Programmering av TCS-systemet
Error message
Cause
Cure
Actuator sensor
Sida 24
BT Cargo Teknikutbildning
Programmering av TCS-systemet
FELMEDDELANDE
ORSAK
KONTROLLERA
- Att spnningen frn feedbackpotentiometern ligger p 2.5 +/0.15 volt nr pumpen str i
neutrallge.
- Att spnningen frn feedbackpotentiometern ligger p 2.5 +/0.15 volt nr pumpen str i
neutrallge.
Excitation voltage
Feedback error
Sida 25
BT Cargo Teknikutbildning
Programmering av TCS-systemet
FELSKNING
Typ av fel
Mjlig orsak
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