Professional Documents
Culture Documents
CBD/G
1.5
1.8
2.0
Cargo Range
CARGO 1.5
BT Svenska AB
Per Wrmlund
INTERNAL
COMBUSTION
SERVICE MANUAL
page. 3
Copyright by
CESAB S. p. A.
SERVICE MANUAL
INTERNAL
COMBUSTION
INDEX
DATA SHEET ...................................................................................................... p.
p.
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8
8
8
8
9
10
11
12
12
12
13
14
15
16
16
16
17
18
19
20
21
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24
25
26
27
28
29
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30
31
32
33
34
35
36
38
39
40
INTERNAL
COMBUSTION
SERVICE MANUAL
BRAKES .........................................................................................................................
Diagram of the brake system .....................................................................................
Brake control ................................................................................................................
Brake unlocking ...........................................................................................................
page. 5
p.
p.
p.
p.
41
41
42
42
43
43
44
45
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47
48
49
50
51
51
p.
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53
54
55
56
57
58
60
61
62
63
66
67
68
69
SERVICE MANUAL
TECHNICAL DATA
INTERNAL
COMBUSTION
INTERNAL
COMBUSTION
SERVICE MANUAL
page. 7
SERVICE MANUAL
page. 8
INTERNAL
COMBUSTION
OPERATOR'S SEAT
PEDALS
1
o
2
SERVICE BRAKE
Foot service brake (C) controls a hydrostatic braking in the first part of the stroke by means of the proportional
valve; if fully pressed, it engages the oil-bath disc brakes (over the front driving wheels).
INTERNAL
COMBUSTION
SERVICE MANUAL
page. 9
DASHBOARD
During ordinary operation, all warning lights in the dashboard are to be off.
1
10 11
1) Fuel gauge
2) Water temperature indicator
3) Fuel level warning light
4) Generator warning light
15
5) Glow plug warning light (Diesel engine)
6) Parking brake-on warning light
7) Engine oil pressure warning light
12 13
14
8) Indicator light (optional)
9) Electronic hour counter
10)Water temperature warning light
11)Transmission oil temperature warning light
12)Transmission oil filter clogged warning light
13)Low brake fluid level warning light (not used)
14)Hydraulic oil filter clogged warning light
A
15)Warning light indicating air filter clogged
3 4 5
6 7
A) Parking switch
B) Ignition key
C) Emergency pushbutton
CAUTION
These pushbuttons(A-C) cause the instant engagement of the
brakes;they must therefore never be used during normal
working operations.
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.
1
SERVICE MANUAL
page. 10
INTERNAL
COMBUSTION
8
9
10
11
12
13
14
15
INTERNAL
COMBUSTION
SERVICE MANUAL
page. 11
A: PARKING SWITCH
position 1 - Travel enabled
Switch A in position 1 enables the truck to travel (the green light
B is on and brake light (6) on the dashboard is off);
1
A
HYDROSTATIC BRAKING
Lift the travel pedals or the accelerator to enable the hydrostatic braking
until the truck stops.
2
A
IGNITION KEY
0
1
2
3
off
ignition on
glow plugs on
starter contact (automatic return to position 1)
TRUCK START UP
- the operator must be seated
- turn the parking switch A in position 2 (parking)
- turn the key in pos. 1 (ignition on)
- turn the key in pos. 2 (glow plugs on)
- turn the key in pos. 3 to start the engine (the key returns
automatically to pos. 1)
- once the engine has started up, turn the parking switch A
to position 1 (green light on)
- select forward 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.
INTERNAL
COMBUSTION
SERVICE MANUAL
page. 12
LEVER UNIT
L
N
I
L
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
RATED CAPACITY
MOTOR
SERIAL N
kW
SERIAL N
kg
LIFT HEIGHT
mm
BATTERY MASS
kg
min.
Cod. 0312005
Cod. 0312004
MANUFACT. YEAR
SERVICE MASS
Without
Battery kg
kg
max.
TENSION
V
DERATED CAPACITY Kg
INTERNAL
COMBUSTION
SERVICE MANUAL
page. 13
ENGINE TYPE
KUBOTA V2203
CONTROL
PEDAL
-DOUBLE FOOT
PEDALS
- HAND
DIRECTION
-DOUBLE FOOT
PEDALS
- HAND
DIRECTION
-FOOT BALANCE
PEDALS
-DOUBLE FOOT
PEDALS
- HAND
DIRECTION
CONTINENTAL
TM 27
(from s/no 169629)
FOOT BALANCE
PEDALS
ACCELERATION
CONTROL TYPE
MECHANIC
WITH CABLE
ACCELERATION DEVICE
NONE
HYDRAULIC
CONTROL
HYDRAULIC
CONTROL
HYDRAULIC
CONTROL
HYDRAULIC
CONTROL
MECHANIC
WITH CABLE
MECHANIC
WITH CABLE
SERVICE MANUAL
page. 14
INTERNAL
COMBUSTION
ENGINE DATA
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SERVICE MANUAL
INTERNAL
COMBUSTION
$17,)5((=($33/,&$7,215$1*(
10%
20%
30%
40%
50%
92/80(2)$17,)5((=(
-4C
-10C
-17C
-24C
-40C
FREEZING TEMPERATURE
101C
102C
104C
106C
109C
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.
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.
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 standstill for at least 10 minutes.
Do not use the engine at its peak RPM until it has reached its working
temperature.
INTERNAL
COMBUSTION
SERVICE MANUAL
HYDROSTATIC TRANSMISSION
An exact awareness of control possibilities is fundamental to the correct use of the truck with
optimum exploitation of the installed power.
The hydrostatic transmission is of prime importance. It transmits power from the internal
combustion engine to the drive wheels.
This kind of transmission allows the transfer of powerful torques to the wheels, with automatic
system feedback. That is to say, when the drive wheels require an increased torque, for example
when a level surface leads onto a ramp, the speed is automatically reduced and the torque
increased, without the intervention of the operator.
The hydrostatic transmission consists of a pump with variable capacity, driven by an internal
combustion engine.
The pump supplies oil to two fixed capacity hydraulic motors.
The hydraulic connection between the two drive motors allows proportional division of the flow
supplied by the hydrostatic transmission, so that on a curve the outer wheel is favoured; this kind
of transmission behaves in the same way as a differential transmission.
An auxiliary pump deals with any leakage from the circuit.
page. 17
SERVICE MANUAL
INTERNAL
COMBUSTION
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.
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.
Laddningstryck: 30bar
60bar p hgtryckssidan vid start
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.
INTERNAL
COMBUSTION
SERVICE MANUAL
page. 19
On tilt 0, it corresponds to 0
stroke, therefore 0 capacity.
(machine stopped)
SERVICE MANUAL
INTERNAL
COMBUSTION
INTERNAL
COMBUSTION
Kylare
2 bar
Chockventiler
130 bar
C
D
Broms
Gas
Prioriteringsventil
D=Hydraulfilter, 90 micron
E= Hydrostatfilter, 10 micron
page. 21
SERVICE MANUAL
P-bromsventil
HYDRAULIC DIAGRAM
STANDARD
A= Vljarventil Fram&Back
B= DA ventil (ger pilottrycket)
C= Pressure cut-off valve
SERVICE MANUAL
CONTINENTAL ENGINE
LIFTING ACCELERATION VERSION
Gas
B
page. 22
Se beskrivning p sid. 31
INTERNAL
COMBUSTION
Se beskrivning p sid. 32
INTERNAL
COMBUSTION
Gascylinder
(inspr. pump)
SERVICE MANUAL
KUBOTA ENGINE
page. 23
SERVICE MANUAL
page. 24
ADJUSTMENT VALUES
ENGINE
RPM min.
RPM max.
KUBOTA
V 2203
900
2400
CONTINENTAL
TM 27
900
2400
HYDROSTATIC
PUMP A10 VG 45 DA
Boost pressure
X1 X2
High pressure
MA MB
Standard restrictor
Valve DA = 3,9
X1+X2
= 0,9
T
= 0,8
New spool on electrovalve
INTERNAL
COMBUSTION
INTERNAL
COMBUSTION
SERVICE MANUAL
page. 25
HYDROSTATIC TRANSMISSION
PRESSURE CHECKING
POINTS
R
X1
X2
PS
MA
G
MB
HYDRAULIC DIAGRAM
INTERNAL
COMBUSTION
SERVICE MANUAL
ADJUSTMENTS TO BE CARRIED OUT ON THE
HYDROSTATIC TRANSMISSION
1
SCREW IN
SETTING SCREW
SCREW
OUT
INTERNAL
COMBUSTION
SERVICE MANUAL
page. 27
ADJUSTING
SCREW
DA
VALVE
ENGINE
2a
+
LOAD
2b
CHANGE THE
DIAPHRAGM
1b
ENGINE
1a
LOAD
N.B.: By the truck on stall the engine R.p.m. has to settle between 200 - 500 revolutions less
than the max. R.p.m.
SERVICE MANUAL
page. 28
INTERNAL
COMBUSTION
ELECTROVALVES
X1
X2
To achieve:
Better acceleration and braking at release:
widen throttle valves A, B or T or replace with larger diameter valves.
INTERNAL
COMBUSTION
SERVICE MANUAL
C
HIGH PRESSURE VALVE B
MB
MA
VALVE ADJUSTMENT
- Screw in completely the cut-off pressure valve and verify that the max pressure MA - MB
is 370 bar at least.
- Screw out the cut-off pressure valve until you obtain (MA - MB) 350 bar.
page. 29
INTERNAL
COMBUSTION
SERVICE MANUAL
page. 30
VALVE
TANK
T
P
OUT
HYDRAULIC
DIAGRAM
IN
INTERNAL
COMBUSTION
SERVICE MANUAL
page. 31
HYDRAULIC
PISTON FOR
2ND 3RD WAY
INTERNAL
COMBUSTION
SERVICE MANUAL
ACCELERATOR CYLINDER
VALVE
LIFTING
BRAKE
PEDAL
TRAVEL
PEDAL
INTERNAL
COMBUSTION
SERVICE MANUAL
page. 33
ACCELERATOR CYLINDER
E
A
Adjusting the X3 driving pressure
- By means of screw F, adjust the PS driving pressure at minimum rpm to achieve a
pressure above 4/5 Bar at the value defined for P2 accelerator cylinder starting
pressure: PS = 12 - 16 bar. (P2 + 4/5 bar)
SERVICE MANUAL
INTERNAL
COMBUSTION
Note that the truck starts with a driving pressure of about 6 bar while the cylinder starts accelerating
the Diesel engine with pressures of 8-12 bar. Consequently, the truck moves at slow speed without
increasing the engine rpm.
SET SCREW
STANDARD PEDALS
SET SCREW
INTERNAL
COMBUSTION
SERVICE MANUAL
page. 35
C
A
The small accelerator cylinder A, driven by the pressure of the distributor, presses, by means of lever B,
the handling device valve C, which in turn provides pressure to the accelerator cylinder.
The small cylinder (A) is threaded to permit adjustment.
By operating the levers, swing and sideshift of the distributor, at most 1200-1250 rpm must be achieved.
By means of screw D, maximum hoisting rpm can be set: this must be 1800-1900 rpm.
INTERNAL
COMBUSTION
SERVICE MANUAL
RADIAL HYDRAULIC MOTOR
(LOW MOTOR)
Rexroth Motor MCR 03F 325 with negative brake (radial pistons )
Displacement
Max. pressure
Output torque at AP = 100 Bar
Peak torque
Oil flow at n.= 100 RPM/100 Bar
Pistons n.
325 cc/tour
350 Bars
NM 517
NM 1875
L/Min 32,5
8
Brake
Holding tourque
Release pressure
multi-disc brake
max. NM 2200
Min. 15 Max 30 Bar
cylinder block
distributor
brake
spring
INTERNAL
COMBUSTION
SERVICE MANUAL
page. 37
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. 38
INTERNAL
COMBUSTION
B
C
D
After 50 hours
-the first filters change
Every 500 hours
-second filters change
-first oil change
Subsequently, every 2000 hurs
-filters change
-oil change
The oil should be changed at least once a year:
The filter should also be changed if it becomes clogged, as indicated
by the warning light (12) on the dashboard.
To change the filters it is necessary to:
- loosen the screws that secure the filter support placed to the
tank
- extract the unit from the tank tank and release the cartridge,
unscreing it in an anticlockwise direction
- tighten the new cartridge and restore the original position.
INTERNAL
COMBUSTION
SERVICE MANUAL
page. 39
INTERNAL
COMBUSTION
SERVICE MANUAL
page. 40
OPERATIONS TO BE
CARRIED OUT
No feeding pressure
VALUE TO CHECK
12 Volt
28-30 BAR
G (Hydromatik)
Check maximum
pressure
The release braking restrictor T
is clogged
Hydromatik
Hydromatic
350 Bar
X1,X2=4-30 Bar
28-30 Bar
Clean restrictors
12 Volt
INTERNAL
COMBUSTION
SERVICE MANUAL
page. 41
BRAKES
The brake pedal has two different functions :
- mechanical braking ( if you push down completely the brake pedal only )
- " inching " function if it is used simultaneously with the accelerator pedal.
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 hydrostatic braking ).
B
S
D
F
E
SERVICE MANUAL
BRAKE CONTROL
BRAKE CONTROL
The brakes are in an oil-bath; they use the same
oil as the drive hydraulic motors
Every 250 hours
- control the pedal functioning, that must be smooth
and with no jamming.
INTERNAL
COMBUSTION
INTERNAL
COMBUSTION
SERVICE MANUAL
page. 43
ELECTRIC SYSTEM
WARNING:
DISCONNECT THE TRUCK BATTERY BEFORE SERVICING
THE ELECTRIC SYSTEM AND THE ELECTRONIC EQUIPMENT.
Q
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. 80 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.
INTERNAL
COMBUSTION
SERVICE MANUAL
ELECTRIC COMPONENTS
ELECTRICAL CONTROL PANEL
This is situated under the driver's platform
The panel consists of a group of fuses (A), relays (B) and optional intermittent circuit (C).
To replace the components, remove the protective panel.
A
B
C
Fuse characteristics
KUBOTA Engine
F1 -system protection
F2 -horn
F5 -dashboard, brakes
F7 -alternator
F8 -timer stop
F11-glow plug
F13-electric fan
F15-lights-reverse direction
F16-backup lights-stop
40A
5 A
7,5 A
7,5 A
5 A
5 A
20 A (opt)
5 A
5 A
CONTINENTAL Engine
F1 -system protection
F2 -horn
F5 -dashboard, brakes
F7 -distributor
F13-electric fan
F15-lights-reverse direction
F16-backup lights-stop
40A
5 A
7,5 A
7,5 A
20 A (opt)
5 A
5 A
E2-E3-E4-E5-E6-E8
RELAIS TYPE
CODE
E1-E7
RELAIS TYPE
CODE
Page 45
Page 46
INTERNAL
COMBUSTION
SERVICE MANUAL
STEERING CONTROL
The steering uses the same oil as the lifting by means a priority valve, so that a sufficient
oil flow to the power steering is always assured.
The oil capacity is checked by the Ls signal (load - sersing) coming from the steering
unit and it occurrs so that the oil capacity sent to the power steering is equal to its
actual request.
The exceeding oil is sent to the control valve for other functions.
When the steering wheel is turned the steering unit measures a volume of oil proportional
to the above rotation and sends it into the steering cylinder.
The steering unit returns automatically in it neutral position when the manoeuvre is finished.
In order to set the power steering pressure, the following operation are necessary:
1 - Fit a manometer on the priority valve(A);
2 - In order reach the adjusting screw (B) remove the cap (by allen wrench) positioned
in the upper side of the orbitrol (power steering unit);
- screw in to incroase the pressure
- screw out to decrease the pressure
page. 47
SERVICE MANUAL
page. 48
INTERNAL
COMBUSTION
STEERING CYLINDER
ORBITROL
PRIORITY
VALVE
A
PUMP
FILTER
INTERNAL
COMBUSTION
SERVICE MANUAL
page. 49
STEERING AXLE
Steering axle check
Every 500 hours
- lubricate the steering gear joints using the appropriate grease nipples (D), (E) and (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 80)
End stroke setting (adjustment):
take the cylinder to the internal end stroke, then operate on the special screws putting
them on the spindles. Then screw in the adjusting screws till when you obtain the desired steering angle
B = 80
SKD090
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.
C
END STROKE
SETTING SCREW
B = 80 Standard
ANGLE MEASURED BY THE AXLE FRAME TO
THE INTERNAL WHEEL THROUGH A SPECIAL
DEVICE
RUBBER BUSHING
STEERING AXLE
SERVICE MANUAL
page. 50
BEARING ADJUSTMENT
Steering wheel bearings require an adjustment once a year.
Steering wheels
lift the steering wheels
remove cap (1);
remove check pin (4);
fasten the nut with a torque setting of 6 dNm;
turn the hub of 2-3 turns in both senses;
unfasten nut (3) and retighten with a 2-1 daNm torque;
check that the wheels slide correctly (max. rolling final torque: 0.2 dNm)
and that there is no side play (maximum axial play of 0.05 mm);
reassemble the check pin;
reassemble the cap (1);
lower the wheels again and check that all nuts fixing the wheel disk (5) to
hub (2) are well tightened.
5
2
1
4
3
INTERNAL
COMBUSTION
INTERNAL
COMBUSTION
SERVICE MANUAL
page. 51
CONTROL VALVES
B
D
A
I
L
DRAGO13.TIF
G
M
E
C
VALVE A
VALVES B-C
tilting pressure
screw in
=
screw out =
A
H
LIFTING
F
B
VALVES D-E
side-shift pressure
screw in
=
increasing
screw out =
decreasing
VALVE R
VALVES F-G
VALVES H
no return valves
TILTING
C
D
x
x
OUTLET
increasing
decreasing
SIDE-SHIFT
SERVICE MANUAL
page. 52
D
A
B
C
D
E
H
R
INTERNAL
COMBUSTION
B
A
Description
page 52
HYDRAULIC DIAGRAM
Lifting
CONTROL VALVE
Tilting
N
M
Lifting
L
Tilting
VALVE I
VALVE L
security valve. The tilting movement (from backward to forward) is locked when the engine is
switch off
VALVE M
security valve. The tilting movement (from forward to backward) is locked when the lifting
speed is to high (Ej CE-mrkt! Gr att ta bort.)
VALVE N
VALVES O
INTERNAL
COMBUSTION
SERVICE MANUAL
page. 53
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
VT
2 side cylinders
Grease nipple
Adjusting screw
Shoe
Roller
SERVICE MANUAL
INTERNAL
COMBUSTION
Adjusting screw
Grease nipple
Shoe
Roller
INTERNAL
COMBUSTION
SERVICE MANUAL
TRIPLEX MAST GROUP
page. 55
SERVICE MANUAL
INTERNAL
COMBUSTION
6
5
4
7
THRUST
DIAMETER
2
5
1
Fig. A
Fig. B
INTERNAL
COMBUSTION
SERVICE MANUAL
CYLINDER CHECKING METHODS
1ST CHECK
Remove the drain pipe from the cylinder (fig. C)
Lift the cylinder some times to end stroke, so as to
discharge any oil residual.
Put a load on the forks and lift it by at least 200 mm.
After 10 minutes, measure the amount by which the
load has lowered. A drop of a few millimetres is quite
normal, as in the distributor there are always some
leakages.
Now, lift the cylinder to its end stroke, if no oil leaks
from the drain pipe coupling, it means that the load
lowering is only due to the leakages on the distributor.
Fig. C
page. 57
SERVICE MANUAL
page. 58
INTERNAL
COMBUSTION
Masts
After the first 50 hours
- adjust the guide shoes adjusting the Allen screw (D)
For the adjustment use a 0.2-0.5 mm thickness gauge,
inserted from below and up to the centre of the Allen
screw (D) passing behind the roller (E).
F
G
INTERNAL
COMBUSTION
SERVICE MANUAL
C) Sideshift unit
(upper part)
3 grease nipples
(lower part)
without grease nipplesexcessive wear.
SKD051
Locking torques:
- collar self-locking nuts 0.8-1.2 daNm
page. 59
INTERNAL
COMBUSTION
SERVICE MANUAL
MAST CHAINS
7$%/(,62
5DWH
X = 152 mm
/LIWLQJSRZHUNJ ;
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
INTERNAL
COMBUSTION
SERVICE MANUAL
page. 61
FORKS
G
E
F
D
FORK INSPECTIONS
General criteria
Fork arms in use must be inspected at intervals of not
more than 1 000 hours and whenever a defect or permanent
deformation is detected. If the truck is subject to intensive
use, more frequent inspections may be required.
Inspection
Fork arm inspection must be carefully carried out by
trained personnel to detect any damage, failure, deformation,
etc., which may impair safety use.
Surface cracks
The fork arm must be thoroughly examined visually for cracks
giving special attention to the heel (D) and top (E) and bottom
(F) hooks.
If necessary, the forks may be subjected to a non-destructive
crack detection process
Difference in height of fork tips
Check the difference in height between the blade tips on each
pair of forks, this must not be more than 3% of blade length
with the forks fitted on the fork plate.
Positioning lock
Check that the fork positioning lock (G) is in good working
order.
SERVICE MANUAL
page. 62
INTERNAL
COMBUSTION
INTERNAL
COMBUSTION
SERVICE MANUAL
page. 63
LPG SYSTEM
B
A=
B=
C=
D=
E=
F=
G=
H=
I=
L=
C
F
D
E
H
L
7
6
Pro
pan
o
GPL
4
3
Bu
ta
no
2
1
0
-30
-20
-10
SERVICE MANUAL
page. 64
A
B
AT VAPORISER
udt2
VACUUM
ATMOSPHERIC
PRESSURE
FILTER VALVE
The liquid gas flows in through filter A which traps all impurities (replace every 1000 hours).
Liquid gas flow is interrupted by valve B (the pressure of the liquid gas keeps this valve
closed: active safety)
The vacuum of the carburetor, connected through hole C, acts on diaphragm D and causes
valve B to open.
L
I
H
AT THE
CARBURETOR
ATMOSPHERIC PRESSURE
INTERNAL
COMBUSTION
INTERNAL
COMBUSTION
SERVICE MANUAL
page. 65
Butano
B
udt4
udt3
D
F
D = CO adjustment at minimum rpm (completely screw up and then unscrew by 3 full turns)
E = CO adjustment at peak rpm. Switching from R (open)to C (closed), the percentage of
gas is reduced.
F = adjustment of minimum rpm
INTERNAL
COMBUSTION
SERVICE MANUAL
LPG BOTTLE
The LPG bottle is not supplied with the truck. For correct truck operation, you should request and use
only bottles designed for VEHICLES, with an INTERNAL FEED PIPE. These bottles are available from
authorized suppliers, whose fitting and maintenance instructions must be scrupulously followed. Secure the
bottle to the support on the truck. Position the bottle so that the internal feed tube points downwards
(ask the bottle supplier for advice).
TAP
INTERNAL
FEED PIPE
FILTER
FLEXIBLE GAS
HOSE FITTING
BOTTLE TYPE B
TAP
INTERNAL
FEED PIPE
FLEXIBLE GAS
HOSE FITTING
FILTER
BOTTLE TYPE A
INTERNAL
COMBUSTION
SERVICE MANUAL
page. 67
REFERENCE
NOTCH ON
PULLEY
-25
-20
-15
-10
-5
-0
FIXED INDEX
FIXED NEEDLE
CD
5 (ADVANCE 5)
0 (UPPER DEAD
POINT)
FLYWHEEL
Fig. 2
Fig. 1
SERVICE MANUAL
page. 68
INTERNAL
COMBUSTION
PARTIS CONCERNED
Hydraulic system
Hydraulic transmission
Lifting unit, power steering
Diesel and Petrol
TYPE
SPECIFICATIONS
Q.TY
ISO-L-HV
CETOP RP 91
H, HV
as required
MOBIL
DELVAC
1300 SUPER
SAE 15W-40
API CD-SF
CCMC-D3
(SHPDO)-PD1
MIL-L-2104D
MIL-L-46152B
as required
MOBILGREASE
SPECIAL
NLGI N.2
as required
AGIP
ARNICA
46
ATF
DEXTRON
II
MOBIL
ANTIFREEZE
Coolant
as required
AGIP
ARNICA
22
ISO-L-HV
CETOP RP 91
H, HV
as required
MOBILTEMP
SHC 100
NLGI N.2
as required
SERVICE MANUAL
INTERNAL
COMBUSTION
DIWHUKRXUV)25
0(',80,17(16(86(
DIWHUGD\VPRQWKV)25
2&&$6,21$/86(
(1*,1(6
&+$66,6$1'&200$1'6
bolts in general
/,)7,1*81,70$676
+<'5267$7,&75$160,66,21
LEGEND
'
&
"
SERVICE MANUAL
page. 70
INTERNAL
COMBUSTION
DIWHUKRXUV)25
0(',80,17(16(86(
DIWHUGD\VPRQWKV)25
2&&$6,21$/86(
(/(&75,&6<67(0
+<'5267$7,&75$160,66,21
system seal
complete unit
SERVICE MANUAL
INTERNAL
COMBUSTION
50
250
500
1 000
2 000
4 000
10 000
DWKRXUVIRU0(',80,17(16(
86(
1/-
7/-
-/1
-/3
-/6
-/12
-/24
-/60
DWGD\VPRQWKV
)252&&$6,21$/86(
/,)7,1*81,70$676
forks
mast tilting
lifting chains
SERVICE MANUAL
page. 72
50
250
500
1000
2000
4000 10 000
1/-
7/-
-/1
-/3
-/6
-/12
-/24
-/60
INTERNAL
COMBUSTION
DIWHUKRXUV)25
0(',80,17(16(86(
DIWHUGD\VPRQWKV)25
2&&$6,21$/86(
&+$66,6$1'&200$1'6
chassis - cleaning
bolts in general
drivers seat
tyre pressures
steering lock
hoses of brake
brake liquid
SERVICE MANUAL
INTERNAL
COMBUSTION
50
250
500
1 000
2 000
4 000
10 000
1/-
7/-
-/1
-/3
-/6
-/12
-/24
-/60
DWKRXUVIRU0(',80,17(16(
86(
DWGD\VPRQWKV)25
2&&$6,21$/86(
(1*,1(6
cooling liquid
air filter
cyclone prefilter
engine supports
Totaldokument
BT Cargo CBD 15-20
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/pedalspel
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
CBD/CBG 15-50
Chassie/hel maskin
BT Svenska AB 01/06
Sida 1
Totaldokument
BT Cargo CBG 15-20
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
1:9
1:10
Gasolsystem, lckage
Tndsystem, kondition
2:0
2:1
2:2
Grupp 2 Hydrostatik
Lckage
Funktion
5:3
5:4
5:5
5:6
5:7
5:8
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/pedalspel
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
Grupp 1 Motor
Missljud/lckage
Gaspedal/reglage
Luftfilter, kontroll
Kylvtska, niv/fryspunkt
Remmar, kontroll
Motorolja, byte
Motoroljefilter, byte
Gasolsystem, funktion
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
Grupp 5 Elsystem
Belysning/krriktningsvisare
Instrument/kontrollampor
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
Sida 2
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
CBD/CBG 15-50
Chassie/hel maskin
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
LEGEND
DESCRIPTION
ENGLISH
4' via
4th valve
5' via
5th valve
abilitazione attiva
enable on
abilitazione freni
brakes enable
abilitazione parcheggio parking enable
acceleratore
accelerator pedal
alternatore
alternator
anomalia centralina
logic unit defect
attuatore
actuator
arresto motore
motor stop
batteria
battery
bobina
coil
brandeggio
tilting
candele
spark plugs
candelette
glow plugs
chiave
key
chiave avviamento
start key
clacson
horn
comandi luci supplem.
additional lights controls
comando elettroventola electric fan control
comando fanali stop
stop lights control
conn.batteria
battery connector
cruscotto
dashboard
dispositivo candelette
glow plugs device
elettrovalvole marcia
speed electrovalves
elettroventola
electric fan
emergenza
emergency
fanali retromarcia
reversing lights
fanali stop
stop lights
freno
brake
freno pedale
pedal brake
freno stazionamento
parking brake
indicatore riserva gas
LPG reserve indicator
DEUTSCH
FRANCAIS
ESPAOL
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
comm.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