CBD&CBG 25-35 PDF

Service Manual
CBD/G
2.5
3.0
3.5
Cargo Range
CARGO 2.5
BT Svenska AB < Tillbaka till Index

Per Wärmlund
2,5 - 3,0 - 3,5 t
INTERNAL
COMBUSTION
SERVICE MANUAL
page 3
CESAB S.p.a. reserves all rights of

reproduction of this handbook
The text and the numbering system

may not be used in other printed matter,
reprinted or translated, whether entirely
or in part, without written authorization
from
CESAB reserves the right to make any

necessary modifications without obligation
to promptly update this handbook.
Copyright by
CESAB S. p. A.
BOLOGNA’S FACTORY, AFTER SALES SERVICE

2,5 - 3,0 - 3,5 t
SERVICE MANUAL INTERNAL
COMBUSTION
page 4
INDEX
TECHNICAL DATA ............................................................................................. p. 6
OPERATOR’S SEAT .......................................................................................... p. 8

Pedals version ................................................................................................... p. 8
Service brake .................................................................................................... p. 8
DASHBOARD ..................................................................................................... p. 9
Dashboard indicator .......................................................................................... p. 9
Parking switch ................................................................................................... p. 11
Truck start up ..................................................................................................... p. 11
Set of levers - Load handling .............................................................................. p. 12
Capacity plates ................................................................................................. p. 12
ENDOTHERMIC ENGINE .................................................................................. p. 13

KUBOTA ENGINE ............................................................................................. p. 13
Kubota engine data ........................................................................................... p. 14
Continental engine data ..................................................................................... p. 15
Oil change and engine oil filter replacement ....................................................... p. 16
Topping up with coolant...................................................................................... p. 16
Air filter .............................................................................................................. p. 17
Cyclone prefilter ................................................................................................. p. 17
Engine running-in ............................................................................................... p. 17
ELECTRONIC HYDROSTATIC TRANSMISSION .............................................. p. 18

Example of a closed loop hydrostatic transmission ............................................ p. 19
Operation of the variable displacement pump with axial pistons ......................... p. 20
Operation of the electronic hydrostatic system ................................................... p. 21
Description of the main functions ....................................................................... p. 22
HYDRAULIC DIAGRAM ...................................................................................... p. 24
HYDROSTATIC PUMP ......................................................................................... p. 26
HYDRAULIC MOTOR ........................................................................................... p. 28

HYDROSTATIC TRANSMISSION MAINTENANCE............................................... p. 30
Replacing the filter and changing the transmission oil ......................................... p. 30
BRAKES ............................................................................................................. p. 31
Diagram of the service brake and the parking brake systems ............................ p. 31
Checking the service brake ............................................................................... p. 32
Releasing the brakes for towing of the truck....................................................... p. 32
ELECTRIC SYSTEM ............................................................................................ p. 33

Battery ............................................................................................................... p. 33
Electric components .......................................................................................... p. 34
Fuse holding panel ............................................................................................ p. 34
2,5 - 3,0 - 3,5 t
INTERNAL
COMBUSTION
SERVICE MANUAL
page 5
Engine actuator ................................................................................................. p. 35

Potentiometer and microswitches ...................................................................... p. 35
Rotary / Linear potentiometer ............................................................................. p. 36
Wiring diagrams ................................................................................................ p. 37
MENUS AND PARAMETERS FOR THE TCS SYSTEM ..................................... p. 39
CALIBRATION ..................................................................................................... p. 40
Calibration and first start up of the transmission system ..................................... p. 42
DISPLAY .............................................................................................................. p. 45
PUMP CUSTOMIZED .......................................................................................... p. 46
ENGINE CUSTOMIZED ....................................................................................... p. 47
FAULT DETECTED ............................................................................................. p. 48
INFORMATION / PH PARAMETERS .................................................................... p. 49
EPROM RESET .................................................................................................. P. 50
Troubles occuring while calibrating ..................................................................... p. 50
System faults and failures .................................................................................. p. 56
Troubleshooting ................................................................................................. p. 58
WHEELS / TYRES .............................................................................................. p. 59

Safety of wheels and rims while using the truck .................................................. p. 59
STEERING UNIT ................................................................................................ p. 60

Steering control ................................................................................................. p. 60
Steering axle ..................................................................................................... p. 61
Bearings adjustment .......................................................................................... p. 62
HYDRAULIC DISTRIBUTOR ............................................................................. p. 63
MASTS ................................................................................................................ p. 64
Description of the cylinder components .............................................................. p. 66
Cylinder inspection procedures.......................................................................... p. 67
Lubrication ........................................................................................................ p. 68
Installation checks safety specifications ............................................................. p. 69
Safety limit stops of the fork mounting carriages ................................................ p. 69
Chains inspection .............................................................................................. p. 70
Fork inspection ................................................................................................. p. 70
LIFTING THE TRUCK ........................................................................................ p. 71

Hooking points .................................................................................................. p. 71
TABLES .............................................................................................................. p. 72
Table for oil and grease specifications ................................................................ p. 72
Table for the truck maintenance during the running-in stage ................................ p. 73
Table for the maintenance schedule ................................................................... p. 74
2,5 - 3,0 - 3,5 t
COMBUSTION
page 6
TECHNICAL DATA
2,5 - 3,0 - 3,5 t
INTERNAL
COMBUSTION
SERVICE MANUAL
page 7
2,5 - 3,0 - 3,5 t
COMBUSTION
page 8
FOOT PEDALS VERSION
B Pedals consist of:

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

D
Lever of direction selector (D)
1
o é 1 forward speed
2
o 0 neutral
ê 2 reverse speed
One travel pedal (E)
E
C
BALANCED PEDAL VERSION

Forward pedal (F)
G
Reverse pedal (G)
Brake pedal (C)
C F
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).
2,5 - 3,0 - 3,5 t
INTERNAL
COMBUSTION
SERVICE MANUAL
page 9
DASHBOARD
During ordinary operation, all warning lights in the dashboard are to be off.
1) Fuel gauge
2) Water temperature indicator
1 2 3 4 5 6 7 8 3) Fuel level warning light
4) Generator warning light
5) Glow plug warning light (Diesel engine)
15 6) Parking brake-on warning light
7) Oil pressure warning light
8) Indicator light (optional)
9 10 11 12 13 14 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
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
D operation.
DASHBOARD INDICATORS
1) Fuel gauge
2) Coolant temperature level

Indicates the coolant temperature.
The pointer must never reach the red sector; the working temperature
corresponds to 95 °C.
3) Fuel level warning light

The fuel level warning light turns on when approx. 5.5 l of fuel
1 2 are left in the tank.
4) Generator warning light

3 That warning light is to be off when the engine is running. If not,
it indicates that the alternator does not supply any current for the
battery or the electric system charge. This may be caused by the
breaking of the belt that drives the alternator pulley, or by a failure
4 of the alternator.
2,5 - 3,0 - 3,5 t
COMBUSTION
page 10
5
5) Glow plug warning light (Diesel engine).
This warning light turns on when the ignition key is in position (2);
6 6) Parking brake on warning light
7) Engine oil pressure warning light

7 During ordinary operation, this warning light is to be off.
If it turns on, immediately check the oil level in the engine. That warning
light could turn on when the engine is idling and hot, due to a lesser
lubricant viscosity, even if no failure has occurred.
8 8) Direction indicator on warning light (optional)
9 9) Electronic hour counter

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

It indicates the engine overheating. Should it turn on, stop the vehicle
immediately.
Check the correct operation of the radiator fan, the water pump and the
coolant level in the radiator.
11 11)Transmission oil temperature warning light

It indicates that the temperature limits required for the correct operation
of the pump and the hydrostatic engine have been exceeded.
Should it turn on, stop working and determine the reasons for the overtemperature
transmission oil.
Check the oil level and that the radiator is clean and in good operating
conditions.
12 12)Transmission oil filter clogged warning light (replace filter)
13 13)Warning light (not used)
14 14)Warning light (not used)
15 15)Air filter clogged warning light (replace filter)

2,5 - 3,0 - 3,5 t
INTERNAL
COMBUSTION
SERVICE MANUAL
page 11
A: PARKING SWITCH
B: ELECTRONIC FAILURE WARNING LIGHT
1
A position 1 - Travel enabled
Switch A in position 1 enables the truck to travel (green
warning light B and warning light 6 on the dashboard are on);
brakes are engaged, but will automatically be released if the control
pedal is pressed (warning lights B and 6 turn off).
B
position 2 - Parking - start up
Switch A in position 2 (green warning light B off) starting of
the engine is possible. Travel blocked to prevent any accidents.
2
Brakes are engaged (parking condition).
A
HYDROSTATIC BRAKING
Lift the travel pedals or the accelerator to enable the hydrostatic braking
B (adjustable) until the truck stops.
The brakes are engaged if the control pedals are not actuated within
a short period of time. When reoperating the control pedal, brakes
will be automatically be released.
TRUCK START UP
- the operator must be seated

- parking switch A in position 2 (parking)
- turn the key to position 1 (ignition on)
- turn the key to position 2 (glow plugs on)
- turn the key to position 3 (starter contact) to start the engine
- once the engine has started up, turn the parking switch
A to position 1.
- select the foward or reverse direction. The truck is ready to travel.
If the start up procedure has not been correctly performed, the truck
will not start up. If so, repeat the procedure above.
1 2
2,5 - 3,0 - 3,5 t
COMBUSTION
page 12
L N SET OF LEVERS - LOAD HANDLING
K K) Lifting control (yellow).

M
L) Tilt control lever (green).
M)Control lever of the sideshift or other devices (red).
N) Available (if existing; black)
I
OPENING ENGINE COMPARTMENT COVER
L Before lifting the engine compartment cover, turn the ignition key to
pos.0.
C 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
IDENTIFICATION PLATE
of 500 mm (except for different indications)
It identifies the lift truck technical data
ATTACHMENT OR SPECIAL CONDITION OF USE
MODEL Type MOTOR RATED CAPACITY
TYRES SERIAL N° kW kg
SERIAL N° DRAW-BAR PULL (1h)

CENTER OF LOAD DISTANCE mm
LIFT HEIGHT N
mm
BATTERY MASS SERVICE MASS

kg kg Without
A B min. max. Battery kg
MANUFACT. YEAR TENSION
V
Cod. 0312005
Cod. 0312004
DERATED CAPACITY Kg
CARRELLI ELEVATORI S.p.A. CESAB LDT

via Persicetana vecchia, 10 Bevan Way
CAPACITY PLATE 40132 - Bologna - Italia Smethwick - Warley
West Midla 1ds B66 1BZ
2,5 - 3,0 - 3,5 t
INTERNAL
COMBUSTION
SERVICE MANUAL
page 13
ENGINE KUBOTA 3300 - E
1 - Intake manifold 10 - Oil filler plug

2 - Speed control lever 11 - Exhaust manifold
3 - Engine stop lever 12 - Alternator
4 - Shut off solenoid 13 - Starter
5 - Fuel feed pump 14 - Fan belt
6 - Cooling fan 15 - Oil pressure switch
7 - Engine hook 16 - Flywheel
8 - Oil filter cartridge 17 - Oil drain plug
9 - Fuel filter plug 18 - Oil pan
2,5 - 3,0 - 3,5 t
COMBUSTION
page 14
KUBOTA V 3300 ENGINE

No. cylinders 4 in line
Bore 98 mm
Travel 110 mm
Swept volume 3318 cm‡
Compression ratio 22,6:1
SAE J1349 power 46 kW

230 Nm
Maximum torque
at 1600 rpm
Maximum speed (with
2200 rpm
load)
Cooling water
Injection indirect
Injection pump in line
Induction atmospheric
Electrical system 12 V
Lubrication forced
13,2 L
Oil sump (capacity)
including filter
Alternator 540 W - 45 A
Starter motor 2.5 kW
2,5 - 3,0 - 3,5 t
INTERNAL
COMBUSTION
SERVICE MANUAL
page 15
CONTINENTAL TM 27 ENGINE
No. cylinders 4 in line
Bore 91 mm
Travel 103,5 mm
Swept volume 2700 cm‡
Compression ratio 8:1
SAE J1349 power 43 kW

200 Nm
Maximum torque
at 1500 rpm
Maximum speed (with 2400 rpm
load) 2200 rpm
Cooling water
Feeding LPG
Induction atmospheric
Electrical system 12 V
Lubrication forced
Oil sump (capacity) 4 L
Alternator 12 V - 65 A
Starter motor 1.4 kW
2,5 - 3,0 - 3,5 t
COMBUSTION
page 16
OIL CHANGE AND ENGINE OIL FILTER REPLACEMENT
The oil level in the sump is checked with the dip-stick, making sure that the level is
between the MIN and MAX notches.
If it is necessary to top up, use the same oil as that used for filling.
CHANGING OIL AND FILTER

After the first 50 hours: change oil and filter of the engine
and then
every 50 hours: check oil engine level
every 250 hours: change oil and filter of the engine
To replace the oil and the filter, proceed as follows:

-with the engine hot, remove filling cap, then unscrew the drain plug and allow the oil
to drain out.
-Unscrew the engine filter cartridge.
-Fit the new filter and tighten it, paying particular attention to the position of the seal that
should be previously oiled.
-Tighten the drain plug and fill the oil sump up to the Max level on the dip-stick.
TOPPING UP WITH COOLANT
Every 50 hours
- Make sure the coolant level is up to the radiator cap (B).
B
The caps of the tank and radiator must be removed only when
the engine is cold.
Every 250 hours

- clean the radiator outside.
Every 2000 hours

- replace the coolant mixture;
check the freezing point of the coolant mixture, especially when
driving areas with cold weather.
The truck is supplied with a 50% mixture of coolant. If you want to vary
the mixture, refer to the values stated in the table below.
ANTIFREEZE APPLICATION RANGE
10% 20% 30% 40% 50% % VOLUME OF ANTIFREEZE
-4 C -10 C -17 C -24 C -40 C FREEZING TEMPERATURE
101 C 102 C 104 C 106 C 109 C BOILING TEMPERATURE

2,5 - 3,0 - 3,5 t
INTERNAL
COMBUSTION
SERVICE MANUAL
page 17
AIR FILTER
The air suction filter for the fuel supply is composed of two filtering
elements.
Every 250 hours
- Clean the element outside the filter (the element inside is not to be
cleaned).
The filter is to be cleaned also when relevant warning light (15) on
A 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 B
Every 8 hours
- clean the cyclone prefilter.
Cleaning the cyclone prefilter

C - loosen wing-nut (A);
- remove cover (B);
- remove tank (C);
- empty the tank and reassemble.
ENGINE RUNNING-IN
During the running-in period, the engine may consume more oil than
usual. It is recommended that the oil level be checked every 8 working
hours, with engine at stand still for at least 10 minutes.
Do not use the engine at its peak RPM until it has reached its working
temperature.
2,5 - 3,0 - 3,5 t
COMBUSTION
page 18
HYDROSTATIC TRANSMISSION
Hydrostatic transmission consists of a variable displacement pump, which is
controlled by the thermal engine and which delivers oil towards two hydraulic
motors that drive the front wheels.
The hydraulic connections of both motors allow a proportional division of the
oil flow generated by the hydrostatic transmission, so as to support the outer
wheel while turning; that kind of transmission acts as the differential transmission.
The control and adjustment of the electronic transmission are made by

a control unit (Total Control System) that drives the following:
· thermal engine
· hydrostratic pump
· hydraulic motors
· parking brakes
by means of sensors:
· potentiometers (on the accelerator pedal, the brake/inching pedal and the mast lever)
· switches (on the tilt levers and sideshift, the forward/reverse gearshift lever and to engage the parking
brake)
· potentiometer detecting the pump displacement
· sensor of the thermal engine speed of rotation
and by means of actuators:
· proportional solenoid valves of the hydrostatic pump (displacement adjustment)
· actuator on the thermal engine (adjustment of the fuel pump or the carburettor)
· solenoid valve for the displacement shifting of the hydraulic motors
· solenoid valve for the parking brakes release
Control unit
Portable
Terminal
Travel pedal
Parking brake switch Brake/inching

pedal
Potentiometer on
mast lever
Running direction
selector
Thermal engine
speed sensor
Failure warning
light
Solenoid valve for parking
Hydrostatic brake release
pump Thermal engine actuator
2,5 - 3,0 - 3,5 t
INTERNAL
COMBUSTION
SERVICE MANUAL
page 19
EXAMPLE OF A CLOSED LOOP HYDROSTATIC TRANSMISSION
Basic system - pump / motor
The system is equipped with two max. pressure valves, one on each side of the high pressure circuit.
There function is to protect the hydrostatic transmission (pump and motor) from overloads.
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.
circuit.tif
An integrated auxiliary pump is used for restoring of the lost oil. The system is completed
by an pressure reducing valve, to control the charge pressure.
2,5 - 3,0 - 3,5 t
COMBUSTION
page 20
OPERATION OF THE VARIABLE DISPLACEMENT PUMP WITH AXIAL

PISTONS
The capacity of the pump is depending of the rpm, and of

the displacement, which can be changed in continuity.
By increasing the tilting of the plate, the capacity
increases from 0, to the max. value.
On tilt 0°, it corresponds to 0 mm

of stroke, therefore 0 capacity.
(machine stopped)
If the tilting plate of the pump is positioned

beyond the neutral point, the oil flow direction
will be inverted.
2,5 - 3,0 - 3,5 t
INTERNAL
COMBUSTION
SERVICE MANUAL
page 21
OPERATION OF THE ELECTRONIC HYDROSTATIC SYSTEM
ê
17 1 3
ê
5 ê 13
2 16
14 10
15
9
8
11
3
12
6
7
le
1 Thermal engine
2 Hydrostatic pump
3 Hydraulic motors with built-in parking brake
4 Boost pump (charge pump)
5 Solenoid valves adjusting the pump displacement (proportionella > 0-5V)
6 TCS control unit
7 Accelerator pedal (0-5V)
8 Direction selector (steering-wheel operated reverse gear with single pedal or acting directly on the
double/swaying pedal system)
9 Actuator of the thermal engine
10 Sensor for the motor speed of rotation
11 Sensor for the hydrostatic pump displacement (magnet potentiometer)
12 Brake pedal (0-5V, 0-95% av rörelsen=hydrostatbroms. 95-100% = parkeringsbroms)
13 Solenoid valve to release the brakes on the motors
14 Parking brake switch
15 Fault warning light
16 Service pump
17 potentiometer/microswitches on the mast lever, the tilt system, the sideshift and any auxiliary
devices. (lyftpotentiometer > 0-5V)
2,5 - 3,0 - 3,5 t
COMBUSTION
page 22
DESCRIPTION OF THE MAIN FUNCTIONS
TRUCK TRAVEL The thermal engine may only be started if the parking brake is on.
The system allows the pump to increase the displacement (truck motion) only if:
- the motor is running
- the parking brake is off
- the running selector is not in neutral position.
Should one of those conditions not be true, the actuation of the accelerator pedal will only
result in thermal engine speeding up.
The position of the accelerator pedal - through the thermal engine and the hydrostatic pump -
affects the truck speed, i.e. each position of the pedal potentiometer corresponds to the
following preset values, according to the setting values programmed in the control unit:
- speed of the thermal engine
- pump displacement.
ACCELERATION / DECELERATION The truck acceleration depends on the speed

with which the accelerator pedal is pressed and on the parameters set in the control unit.
BRAKING / INCHING The brake pedal has two functions: 1) hydrostatic braking (the
pump displacement cancels itself out) with a strength depending on the pedal stroke; 2) “inching”
function, that can be obtained by simultaneously pressing the brake pedal and the accelerator
pedal.
PUMP DISPLACEMENT The displacement of the hydrostatic pump depends on the stroke
of the accelerator pedal (and on the stroke of the brake pedal in the “inching” function). The
accelerator pedal also determines the rate of rotation of the thermal engine (by means of the
actuator).
ANTISTALL FUNCTION During the truck ordinary operation, if the power required by
the hydrostatic transmission exceeds the power that may be supplied to the thermal engine,
the pump displacement will be automatically reduced to avoid the engine to stall.
PARKING BRAKE The parking brake is engaged by pressing a switch located next to the
distributor levers. When the parking brake is on, the accelerator pedal is disabled (the thermal
engine accelerates, but the truck cannot run). If the parking brake is engaged while the truck
is running, the driving wheels will be automatically locked. Therefore, avoid engaging the
parking brake while the truck is running, unless you are in an emergency condition.
CONSTANT SPEED When using the mast levers, tilt system and sideshift, the thermal
engine automatically accelerates to meet the request for additional power; the pump
displacement will be simultaneously reduced to ensure that the truck speed is kept constant.
2,5 - 3,0 - 3,5 t
INTERNAL
COMBUSTION
SERVICE MANUAL
page 23
RUNNING DIRECTION May be selected through the steering-wheel operated reverse

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

is optimized according to the truck speed the operator needs.
SPEED DECREASE (OPTIONAL) The truck speed may be decreased for example in
case of transmission oil overtemperature.
Oljefilter
HYDRAULIC DIAGRAM
Magnetventil
Broms
Fram&Back
Orbitrol Gaspedal
Styrning
A A=Bypasskruv för bogsering
Broms
Prioriterings-
ventil
Exchange valve, 19bar
(återfyllnad av systemet, kompensation för läckolja)
2,5 - 3,0 - 3,5 t
INTERNAL
COMBUSTION
SERVICE MANUAL
page 25
HIGH PRESSURE CHECK POINT

HIGH PRESSURE CIRCUIT
BOOST PRESSURE CHECK POINT
HIGH PRESSURE CHECK POINT
å
å
å
å å
EXCHANGE VALVE
OIL RETURN TO
TANK
NEGATIVE BRAKE
ELECTROVALVE
LOW PRESSURE CIRCUIT
BY-PASS VALVE
2 BAR
TRANSMISSION
SUCTION RETURN
â LIFTING
OIL
á
å
à
TEMP
DRAINAGE
LIFTING
MOTEURS SUCTION
å
à
à
RETURN
TRANSMISSION
OIL
AUXILIARY SERVICE
CHECKING POINT
2,5 - 3,0 - 3,5 t
COMBUSTION
page 26
HYDROSTATIC PUMP
PUMP Mod. POCLAIN PV75 SA (Eaton, USA)
Displacement 75.5 cc/rev
Boost pump displacement 13.9 cc/rev
Max. pressure measured in M1 or M2 (stall) 450 Bar
Boost pressure measured in M3 24-30 Bar
Drain pressure measured in T1 or T2 max. 5 Bar
(cold pump) or after temperature stabilization max. 2.8 Bar
Vacuum pressure (absolute pr., measured in S) 0.8 Bar
EXCHANGE UNIT
Valve setting 19 Bar
Boost pump
Solenoid valves
Displacement adjusting
plate
Actuator
To motors
Pump displacement
potentiometer
Hydrostatic
pump
The pump displacement is controlled by two proportional solenoid valves which are fed by
the boost pressure and controlled by the control unit through an electric signal. The spool shift
of the solenoid valves controls the pressure over the two chambers of a piston servocontrol
that is mechanically coupled to the pump plate; the difference in pressure between the two
chambers determines the piston shift, i.e. the displacement shifting.
The pump displacement is then detected by a rotary potentiometer sending a signal proportional
to the plate shift.
The electric control through the solenoid valves and the potentiometer represents a feedbacked
circuit for the adjustment of the pump displacement.
A sensor detecting the speed of rotation is to be found as well.
(from the exchange unit)
2
< 0-5V (2,5V i mittläget)
COMBUSTION
DRAIN INLET POTENTIOMETER
E MECHANICAL ZERO
INTERNAL
T1 MEASURING THE PUMP ADJUSTMENT
M
1 1/16 - 12 UN - 2B DISPLACEMENT POTENTIOMETER
V CONNECTOR
L
A
A HIGH PRESSURE
B (to motors)
HIGH PRESSURE
TION MOTOR
SIDE
A
SERVICE MANUAL
PROPORTIONAL
(to the radiator) SERVOVALVES FOR
T
THE DISPLACEMENT
ADJUSTMENT S
O CHARGE PUMP INLET PORT
(FROM THE OIL FIL
SENSOR FOR THE SPEED OF
DRAIN OUTLET R SERVOVALVE CONNECTOR
T2
1 1/16 - 12 UN - 2B
VE PRESSURE
BOOST V SOCKET 2
HIGH PRESSURE DETECTIONMSOCKET
5
M2 9/16 - 18 UNF - 2B L
VE PRESSURE SOCKET 1
M4
BOOST PRESSURE SOCKET A L
M3 7/8 - 14 UN - 2B
V A
O V
V O
HIGH PRESSURE DETECTION SOCKET
M1 9/16 - 18 UNF - 2B
R V
E R
2,5 - 3,0 - 3,5 t

page 27
S E
7/16 - 20 UNF - 2B
S
7/16 - 20 UNF - 2B
2,5 - 3,0 - 3,5 t
COMBUSTION
page 28
HYDRAULIC MOTOR
Motors Poclain MS 05 (radial pistons)
Maximum displacement 468 cc/rev

Maximum pressure 450 Bar
Theoretical torque 740 Nm
Maximum speed 240 RPM
Brake multidisc type
Braking torque max. 3060 Nm
Number of pistons 8
Brake driving pressure (measured in x) 12-30 Bar
Displacement shifting driving pressure (measured in y) 10-30 Bar
Drain pressure (measured in 1) with cold motor max. 3 Bar
after temperature stabilization max. 1.5 Bar
wheel cylinder distributor brake

hub unit
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COMBUSTION
SERVICE MANUAL
page 29
The hydraulic motor is of “slow” type. Due to its radial

pistons, it is characterized by a high displacement/rev (if
compared to engines with axial pistons) so it produces a
high torque at a low speed rate, with no reduction gear
between the engine and the wheel hub.
The engine is also equipped with an oil-bath multidisc brake that is normally engaged
(wheel locked) by the pre-load of a Belleville washer (negative brake); the brake is
hydraulically released by means of a solenoid valve controlled by the control unit: when
the solenoid is fed, the valve opens and the fuel boost pressure on the brake piston
releases the brake.
The multidisc brake on the motor is used only for the truck parking and emergency
braking; on the other hand, service breaking is a hydrostatic one.
The motor-brake unit is fully lubricated by the transmission oil (oil dripping from the
hydraulic motor).
R, L High pression inlet - 3/4 GAS

1 Drain hole 3/8 GAS
X Negative brake pilote 1/4 GAS
Braking release hole- M12 x 1,75

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COMBUSTION
page 30
HYDROSTATIC TRANSMISSION MAINTENANCE

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

order to keep the circuit clean.
B A D C
REPLACING THE FILTER AND CHANGING THE

TRANSMISSION OIL
After 50 hours
- First transmission filter replacement.
After 500 hours
- Second transmission filter replacement;
- First oil change for the transmission/hoisting systems.
Then, every 2,000 hours
- transmission filter replacement;
á
- oil change for the transmission/hoisting systems.
T
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.
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page 31
BRAKES
The brake pedal has two different functions:
- braking (if it is used alone)
- “inching” function if it is used simultaneously with the accelerator pedal.
The brake pedal stroke is divided into two configurable intervals:

0 to 95 % of the whole stroke: hydrostatic braking. The control unit reduces the pump
displacement according to a programmed ramp. The braking effect is proportional to the
pedal stroke.
95 to 100 % of the whole stroke: mechanical braking. The pump displacement cancels
itself out in about 1.5 secs and the negative brakes get engaged.
During ordinary operation, if the truck is slowed down and stopped, the mechanical brakes
act automatically (after approx. 0.5 secs) on motors. Press the accelerator pedal again to
release the brake and to speed up.
When the mechanical brake is engaged, the relevant warning light on the dashboard turns on.
The braking effect may also be obtained by releasing the accelerator pedal (hydrostatic braking)
or by reversing the running direction (hydrostatic reverse braking, more efficient than the mere
hydrostatic braking).
B A DIAGRAM OF THE SERVICE BRAKE

S S AND PARKING BRAKE SYSTEMS
A) Hydraulic motor
B) Brake unit
S C) Solenoid valve
C
D) Tank
D E) Electronic control unit
F) Hydrostatic transmission
E
G) Service brake pedal
F
H) Parking switch
G
I) Potentiometer
I
H
Every 4,000 hours

- replace solenoid valve (C) for the brake control.
H
Every 10,000 hours
- replace brake hoses (S).
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COMBUSTION
page 32
CHECKING THE SERVICE BRAKE
The disc brakes are in oil-bath; they make use of the same oil as the traction hydraulic
motors.
The disc brake unit is composed of 11 discs and 11 counterdiscs. The total disc
thickness is: min. 27 mm, max. 34 mm.
Every 250 hours

- check the pedal operation; the pedal has to be free from any obstacle;
- check the brake wear;
RELEASING THE BRAKES FOR THE TRUCK TOWING
In case of breakdown, previously release the brake discs inside the two traction units
to tow the truck.
Brake release
Position appropriate tool (M), code 1996086 (M12 x 1,75), one for each brake unit;
tighten screw (N) into hole (L) on the brake unit; keep tool (M) locked and tighten
nut (O) until the brakes unlock.
L
N O
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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).
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.
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COMBUSTION
page 34
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.
B C
Fuse specifications
1 F1 alternator, starter 40A
2 F2 horn 5 A
5 F5 system protection 7.5 A
7 F7 alternator 7.5 A
8 F8 engine stop 5 A
11 F11 glow plug 5 A
15 F15 rear lights - reverse light 5 A
16- F16-rear lights - brake/stop light 5 A
the other fuses are intended for optional systems
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
E3-E4-E5-E6-E8-E9 E1-E2
E5 - forward speed validation
E6 - brake/stop rear light RELAIS TYPE RELAIS TYPE
E8 - reverse rear light CODE CODE
the other fuses are intended for optional systems

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COMBUSTION
SERVICE MANUAL
page 35
C D
YELLOW
BROWN
BLACK
BLUE
RED
ENGINE ACTUATOR
The engine actuator is controlled by TCS control unit; it adjusts the Diesel engine injection pump.
The engine actuator is composed of an electric motor controlling the control shaft of the pump tie
rod and of a potentiometer detecting the shaft rotation and generating a feedback electric signal
(voltage).
When calibrating, the control unit correlates the actuator stroke (rotation) measured by the
potentiometer with the thermal engine speed of rotation, measured by the sensor located on the
hydrostatic pump. The unit composed of the actuator and the rev sensor is a feedback system
intended for adjusting the engine speed.
WARNING - POTENTIOMETERS AND MICROSWITCHES
To avoid compromising the functional characters of the truck, fixing or adjusting of the potentiometers
(D), the micrositches (B), the mechanical stops (C) and the accelerator control tie-rod (D), is
forbidden.
A A B
C
C
C
C B
BRAKE PEDAL
TRAVEL PEDAL
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COMBUSTION
page 36
ROTARY POTENTIOMETER
(on the accelerator and brake pedals) resistance: 2.5 kohm
electric stroke: 54°
mechanical stroke: 60°
LINEAR POTENTIOMETER
(on the mast lever) resistance: 5 kohm
electric stroke: 10 mm
mechanical stroke: 12.5 mm
yellow
red red
green
yellow
green
AMP CONNECTOR type: 144-796-1

(on control unit) 55-pin
Page 37
Page 38
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COMBUSTION
SERVICE MANUAL
page 39
MENUS AND PARAMETERS FOR THE TCS

SYSTEM
The parameters for the transmission control are composed of submenus and may be viewed
and modified through the portable terminal (code 0058039), that may be connected to the
control unit .
För att programmera en lös TCS-box:

Anslut Pin 18 och 55 till B-
Anslut Pin 19 och 37 till B+
The [ENTER] key is used for selecting a menu or submenu and for the confirmation of a
parameter numeric value.
The [ESC] key is used for quitting a menu or submenu or for deleting the last character
entered.
The [+] and [-] keys are used for moving through the menu list or increasing and decreasing
the numeric value of a parameter.
Use the numeric keypad to enter the parameter values; use the [.] key for decimal places.
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page 40
The main menus are listed below:
N. Menu Functions
1 CALIBRATION to calibrate potentiometers and transmission actuators (pedals,

distributor, engine actuator, ...)
2 DISPLAY to display the information on the transmission (thermal engine speed,
pump displacement, antistall function, ...)
3 PUMP CUSTOMIZED to customize the transmission (more or less prompt breaking and
acceleration)
4 ENGINE CUSTOMIZED to customatize the thermal engine control (higher or lower acceleration
of the thermal engine, engine speed when the tilt system and the
sideshift are on, ...)
5 FAULT DETECTED to display the system faults
6 INFORMATION software versions
7 PH PARAMETERS (password) configuration of the system operation parameters
8 EEPROM RESET (password) to reset the control unit memory
1) CALIBRATION
The CALIBRATION menu is used. That menu has two functions:
· when the parking brake is locked and the “calibration status” parameter is “not locked” , it allows the
calibration and configuration of the system elements (calibrating mode);
· when the parking brake is not locked or the “calibration status” parameter is “locked”, that menu
allows to view the output voltages of the system sensors and the state of some components (display mode).
After any calibration, release and engage the parking brake again to exit from the “calibration status” mode and
return to the standard operating mode.
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CALIBRATION MENU
N. SUBMENU CALIBRATION MODE DISPLAY MODE

A travel pedal calibration of the travel pedal display of the voltage supplied by the
potentiometer for the travel pedal
B brake/inching calibration of the brake pedal display of the voltage supplied by the
pedal potentiometer for the brake pedal
C mast lever calibration of the mast lever display of the voltage supplied by the
potentiometer for the mast lever
D engine calibration calibration of the actuator-thermal display of the voltage supplied by the
engine potentiometer for the actuator
E pump neutral calibration of the pump in neutral display of the voltage supplied by the
position potentiometer for the hydrostatic pump
F max. forward limiting of the truck max. display of the truck forward speed
speed forward speed (as a percentage of the max. speed)
G max. reverse limiting of the truck max. display of the truck reverse speed
speed reverse speed (as a percentage of the max. speed)
H parking brake set definition of the brake pedal displays the brake pedal position in which
position in which the mechanical the mechanical brake is locked
pedal is engaged
I min engine speed definition of the minimum engine displays the minimun engine RPM
RPM (tomgång)
L max engine speed definition of the maximum engine displays the maximum engine RPM
RPM (fullvarv)
M pump pot. inverted definition of the connections type displays the connections type
(*) of the pump potentiometer of the pump potentiometer
N calibration status lock or unlock the calibration status of the calibration menu
menu
(*) With Hall potentiometer software only
For the TCS correct operation, the voltage values read by the potentiometers in the pedals, the mast
system and the motor actuator must not exceed the limits set. If the mechanical limit stops of the
potentiometer are not properly adjusted, the voltage supplied by the potentiometers and exceeding
the range of values allowed by the control unit disables the calibration procedure.
That trouble may also occur after a correct calibration if, for whatever reason, the limit stop is
modified.
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page 42
CALIBRATION AND FIRST START UP OF THE TRANSMISSION SYSTEM
The system calibration is to be performed when the thermal engine is stopped. The following are to be calibrated:
· Potentiometer for the travel pedal (TRAVEL PEDAL)

· Potentiometer for the brake pedal (BRAKE/INCHING PEDAL)
· Potentiometer for the mast lever (MAST LEVER)
· Feedback potentiometer for the hydrostatic pump (PUMP NEUTRAL)
While calibrating, check the parameters below:

· Max. forward speed (truck max. speed) 100 %
· Max. reverse speed (truck max. speed) 100 %
· Parking brake set (brake setting) 95 %
· Min engine speed (minimum engine RPM) 850
· Max engine speed (maximum engine RPM) 2250
· Pump pot. inverted (with potentiometer Hall effect only) Enable
Calibration also includes the actuator setting while the thermal engine is running (ENGINE CALIBRATION). For
the engine calibration, do the following:
· Lift the truck onto the shim blocks

· Fill the hydraulic circuit and bleed the air
· Engage the parking brake
· Select the neutral position (through the steering-wheel operated reverse gear)
· Start up the engine and wait for the stabilization of the fuel boost pressure
· Adjust the engine min. and max. RPM through the actuator limit stop screws (the limit stops are to be obtained
on the actuator support, not on the injection pump). The engine RPM is to be measured through the “engine
speed” parameter in the “DISPLAY” menu.
· Calibrate the actuator (ENGINE CALIBRATION)
· Press the accelerator pedal; the actuator has to rotate clockwise and the voltage of the feedback potentiometer
in the actuator has to increase (such voltage may be measured in the “engine calibration” parameter in the
“calibration” menu after engaging the parking brake).
Once the calibration procedure is over, check the transmission operation (wheels must be up):
· Release the parking brake
· Position the steering-wheel operated reverse gear to forward gear
· Gradually press the forward pedal: wheels should slowly rotate forwards.
CAUTION: the hydraulic motors must not rotate quickly when wheels are up.
When wheels rotate forwards, check that the voltage of the pump feedback potentiometer increases from 2.5 to
5 volts (for the voltage detection, use “pump neutral” parameter in the “calibration” menu).
Check the correct operation under the following conditions:
- mast lifting, sideshift and tilt operation, etc.: if the relevant levers are adjusted, the thermal engine
will accelerate.
- forward/reverse speed and braking
- parking brake: if engaged, the travel pedal will be disabled (the engine RPM will increase, but the truck
wheels will be locked)
- emergency button.
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page 43
A) TRAVEL PEDAL CALIBRATION
For calibrating, voltages are not to exceed the following ranges (voltages may be detected in display mode):
pedal in its min. position 0,35 - 2,4 volts (7 - 48 % of the supply voltage)
pedal in its max. position 2,6 - 4,65 volts (52 - 93 % of the supply voltage)
(the supply voltage of all sensors is of 5 Volts)
Vid 2-pedal system:
SEE THE “DIAGRAM FOR USING CONSOLE” Se till att max positionerna är
SECTION “CALIBRATION” lika för fram och back!
B) BRAKE / INCHING CALIBRATION
Allows to define the voltage values corresponding to the min. and max. positions of the brake pedal (and the
“inching” function).
For calibrating, voltages are not to exceed the following ranges:
pedal in its min. position 0,35 - 2,4 volts (7 - 48 % of the supply voltage)
pedal in its max. position 2,6 - 4,65 volts (52 - 93 % of the supply voltage)
SEE THE “DIAGRAM FOR USING CONSOLE”

SECTION “CALIBRATION”
C) MAST LEVER CALIBRATION
Allows to define the voltage values corresponding to the maximum and minimum positions of the mast lever.
lever in neutral position 0,35 - 2,3volts (7 - 46 % of the supply voltage)

lever fully pulled 2,4 - 4,65 volts (48 - 93 % of the supply voltage)

D) ENGINE CALIBRATION
Allows to match the actuator angular position (voltage of the actuator feedback potentiometer) with the engine
speed of rotation values.
For calibration, voltages are not to exceed the following ranges:
actuator in its min. position 0,35 - 2,4 volts (7 - 48 % of the supply voltage)
actuator in its max. position 2,6 - 4,65 volts (52 - 93 % of the supply voltage)
Such values may be viewed if the parking brake is engaged.
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COMBUSTION
page 44

The control unit automatically controls the actuator by bringing it to its minimum and maximum positions (that are
determined by the mechanical limit stops located on the actuator support). With respect to the min. and max.
positions, TCS reads the min. and max. RPM as well as some intermediate values.
The limit stops are to be obtained on the actuator, not on the injection pump.
E) PUMP NEUTRAL CALIBRATION
Allows to define the voltage corresponding to the neutral displacement position of the hydrostatic pump (feedback
potentiometer).
The voltage value must not exceed the following range: 2.49 to 2.51 volts.
(In display mode and when the truck is running, the voltage value must vary. When the wheels rotate forwards, the
potentiometer voltage must tend to 5 Volts and remain constant).

F) MAX FORWARD SPEED

This parameter (expressed as a percentage of the truck forward max. speed) limits the travel speed. This parameter
may be modified (in calibration mode).
G) MAX REVERSE SPEED

This parameter (expressed as a percentage of the truck reverse max. speed) limits the travel speed. This parameter
may be modified (in calibration mode).
H) PARKING BRAKE SET

This parameter defines the stroke of the brake pedal necesary to engage the mechanical brake. The standard
value is 95%. It is suggested that this value be not changed. Limit values: 90 to 95%.
I) MIN ENGINE SPEED

This parameter defines the minimum engine RPM (standard value 850).
L) MAX ENGINE SPEED

This parameter defines the maximum engine RPM (standard value 2250).
M) PUMP POT. INVERTED

This parameter defines the connections type of the pump potentiometer.
This parameter is present with the Hall potentiometer software only.
N) CALIBRATION STATUS
This parameter enables or disables the calibration mode.
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page 45
2) DISPLAY
This menu displays the transmission data.
Press [ENTER] to display a data (e.g. thermal engine speed). Hold down the key to display data in sequence.
ENGINE SPEED
Real speed of the thermal engine (expressed in RPM). (9 pulser/varv)
PUMP DISPLACEMENT
Pump displacement required by TCS (expressed in cc). Warning: this is the displacement control sent by the
control unit to the pump, so the value displayed may be different from the real displacement.
ENGINE COMMAND
Speed of the thermal engine required by TCS (in RPM).
ANTISTALL
Indicates whether the antistall function is enabled or not (enable/disable).
PARKING BRAKE
Displays whether the negative brakes are set or not (set/not set).
BRAKE SWITCH
Displays whether the parking brake switch is set or not (set/not set).
MAST ENGINE COMMAND

Speed of the thermal engine required by TCS (in RPM) when the mast is actuated.
PUMP FEED-BACK
Actual displacement of the pump (expressed in cc). This is the displacement measured by the potentiometer
located on the pump.
DIRECTION SWITCH
Displays the running direction controlled by the pedal microswitches or the steering-wheel operated reverse
gear (neutral/forward/reverse).
MAST SWITCH
Displays the state of the distributor microswitches 1 = tilt/sideshift (set/not set).
CONSTANT SPEED
Displays the constant speed function enabling when the mast is actuated while the truck is running (set/not set).
ACTUATOR FEED BACK

Displays the engine actuator signal in Volt. Increase during the acceleration and vice versa.
POWER SUPPLY
Displays the voltage supply of the contol unit: battey voltage (12 V). Must be between 9,5 and 48,5 Volt.
SENSOR EXCITATION
Displays the voltage supply of the sensor. Correct value 5 Volt.
NEUTRAL DRIFT
Displays the value difference between the theorical and real pump potentiometer value (in mV).
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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 från 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 från 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) 2 5 7 10 Låg hastighet
Hard braking ratio (%)

0 2 5 7 10
17 1.7 3.8 5 6.5
50 - 2.8 - - Hög hastighet
67 1.6 2.5 3.1 3.6
83 - 2.3 - -
100 1.3 2.1 2.5 2.9
0=Samma bromskraft vid alla hastigheter. 100=Hårdare broms vid hög hastighet.
SENSITIVITY
This parameter defines the sensitivity of the pump control when changing the pedal position (this value is
expressed as a percentage of the pump max. displacement control).
INCHING PEDAL INC.

This parameter defines how long time it takes for the pump to reach its max. displacement when the inching
pedal is instantaneously released after it has been fully pressed in conjunction with the travel pedal.
INCHING PEDAL DEC.

This parameter defines how long time it takes for the pump to range from the max. displacement to the neutral
position when the inching pedal is instantaneously pressed after fully pressing the travel pedal.
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4) ENGINE CUSTOMIZED
Allows setting of the parameters who controls the thermal engine . Do not modify the standard values.
TRAVEL PEDAL INC. (sekunder från tomgång 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 från fullgas till tomgång)

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.
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COMBUSTION
page 48
5) FAULT DETECTED
Displays the system faults.
- FAULT OCCURRING NOW

Press [ENTER] to display the current fault.
- FAULT SINCE START UP

Press [+] and [-] to display the last five faults occurred.
FAULTS MESSAGES SHOW ON THE CONSOLE
“Excitation Sensor” The exitation voltage of the sensor is < 2V or > 5.5V.
“Power Supply” The supply voltage of TCS control unit is < 9.5V or > 32V for more than
2 sec. long.
“Travel Pedal Sensor” The signal (voltage) of the travel pedal potentiometer has exceeded the
limits set while calibrating.
“Break/Inching Pedal Sensor” The signal (voltage) of the brake pedal potentiometer has exceeded the
limits set while calibrating.
“Mast Lever Sensor” The signal (voltage) of the mast lever has exceeded the limits set while
calibrating.
“Actuator Sensor” The signal (voltage) of the feedback potentiometer has exceeded the limits
set while calibrating.
“Error on Actuator control loop” >20% error, for more than 0.5 secs, between the actuator setpoint and the
potentiometer feedback
“Error on pump control loop” >20% error, for more than 0.5 secs, between the pump control signal and
the potentiometer feedback signal in the pump.
“Feed bak error” Pump feed back is < 0.25V or > 4.75V.
“Neutral out of range” During the calibration the pump neutral is out the limits fixed.
“Pump neutral drift too high” The difference between the pump in neutral calibration function and the
pump in neutral while the values are not fed is >341 mV
“Feedback moves too fast” The pump feedback changes too fast in comparison with the real change of
the pump displacement.
“Eeprom error at address” One parameter at least is outside the field of acceptable values.
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“Direction switches error” The TCS control unit takes contemporarily the forward and reverse gear
(running mode) started..
“Other Default” Other faults.
6) INFORMATION
Displays the SOFTWARE version
7) PH PARAMETERS
- PASSWORD (4567 or 4321)

Enter the password (4 numbers) with the digital key and then valid (enter).
Press the key / esc then [+] and [-] in order to haves access to the rest of the menu.
- PUMP NEUTRAL OFFSET

This parameter is made to offset pump feedback
- ENABLE LIMIT CHANGE

During the calibration of the pedals, the auxilary’s levers and the actuator, it is possible that the minimal values and
maximal values abtained on the potentiometer are not conform to the limit fixed by the programm. It is possible to
modify theses limits.
In the menu calibration, authorise the mode calibration. Go into the menu “PH PARAMETERS” and into the
under menu “ENABLE LIMIT CHANGE”.
It is necessary to be in “NOT LOCKED”.
- INVERSION BRAKING
This function is made to have a braking action if direction switch is set in the reverse position during the translation
of the machine.
The brake action will be proportionnal to the position of the travel pedal.
- INVERSION DESPLACEMENT
This parameter set the inversion time range from: 0 - 10 cc
- DISABLE PUMP DELAY

Parameter which defines the time of delay of the negative brakes starting up (standard values 30 cycles). It is the
delay for the brakes starting up after the pump has reset its displacement. In order to have the brakes started up
in a shortime, for example in ramp, reduce the value (min 5 max 45 cycles)
- REGULATOR OFFSET
This is the acceptable difference between the ordered engine speed and the measured engine speed.
If this value is exceeded, the antistall function is active.
2,5 - 3,0 - 3,5 t
COMBUSTION
page 50
- 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
Press the key / esc then [+] and [-] in order to haves access to the rest of the menu.
- ALL EEPROM RESET

A press on the key (ENT) cancel the list of the statistics.
- FAULT LIST RESET

A press on the key (ENT) cancel the list of the detected defaults.
TROUBLES OCCURRING WHILE CALIBRATING
The voltage values read by the transmission potentiometers (pedals, hoisting, etc.) must not exceed the limits set.
If there is some wiring failure or the mechanical limit stops of the potentiometers are not properly adjusted, the
voltage they supply will exceed the allowable range for the control unit, thus preventing the calibration procedure.
In that case, the terminal will display one of the following messages (while calibrating or in the “fault detected”
alarm menu):
travel pedal position out of range travel pedal

brake/inching pedal sensor brake pedal
mast lever sensor mast lever
actuator position out of range thermal engine actuator
feed-back error hydrostatic pump potentiometer
2,5 - 3,0 - 3,5 t
INTERNAL
COMBUSTION
SERVICE MANUAL
page 51
1) TRAVEL PEDAL
travel pedal position out of range (error message)
ê
release the parking brake (the terminal will range from
the CALIBRATION MODE to the
DISPLAY MODE)
ê
select the (the terminal will display the
TRAVEL PEDAL submenu voltage - expressed in volts - that
is supplied from the otentiometer
in the travel pedal)
ê
yes voltage = 0 volt? no
ê ê
check the hold down the [ENTER] key and
potentiometer wiring check if voltage changes when
the pedal is pressed
ê
does voltage change?
yes no
ê ê
press the [ENTER] key to check the potentiometer wiring
measure the min. and max. voltage
supplied by the potentiometer
ê
adjust the mechanical limit stop of
the pedal so that the voltage does
not exceed the ranges set
(see “travel calibration”)
Calibrate the travel pedal.

2,5 - 3,0 - 3,5 t
COMBUSTION
page 52
2) BRAKE/INCHING PEDAL
brake/inching position out of range (error message)
ê
DISPLAY MODE)
ê
select the BRAKE/ (the terminal will display the voltage in
INCHING PEDAL submenu volts, that is supplied by the brake
pedal potentiometer)
ê
yes voltage = 0 volt? no
ê ê
check the hold down the [ENTER] key and
potentiometer wiring check if voltage changes when
ê
yes no
ê ê
press the [ENTER] key to check the potentiometer wiring
measure the min. and max. voltage
supplied by the potentiometer
ê
adjust the mechanical limit stops of
Calibrate the brake pedal.

2,5 - 3,0 - 3,5 t
INTERNAL
COMBUSTION
SERVICE MANUAL
page 53
3) MAST LEVER
mast lever sensor out of range (error message)
ê
DISPLAY MODE)
ê
select the (the terminal will display the
MAST LEVER submenu voltage in volts, that is supplied
by the mast lever)
ê
yes voltage = 0 volt ? no
ê ê
check the potentiometer Hold down the [ENTER] key and
wiring check whether voltage changes
when the lever is pulled
ê
yes no
ê ê
press [ENTER] to measure the check the electrical connections
min. and max. voltage supplied by of the potentiometer
the potentiometer
ê
Adjust the shims of the
potentiometer support bracket so
that the voltage does not exceed
the ranges set (see “mast lever
calibration”).
If the lever is shifted
forward from its middle position
(for the forks lowering) voltage is
not to decrease.
Calibrate the mast lever.

2,5 - 3,0 - 3,5 t
COMBUSTION
page 54
4) THERMAL ENGINE ACTUATOR
actuator position out of range (error message)
ê
release the parking brake (the terminal will switch from the
CALIBRATION MODE to the DISPLAY
MODE)
ê
select the ENGINE (the terminal will display the voltage,
CALIBRATION submenu in volts, supplied by the potentiometer of
of the actuator)
ê (engage the
yes voltage = 0 volts? no parking brake and
press the
accelerator pedal)
ê ê
check the electrical con- hold down the [ENTER] key and
nections of the actuator check if voltage changes while the
actuator rotates
ê
yes no
ê ê
press the [ENTER] key to measure check the actuator electrical connections
the min. and max. voltage supplied
by the actuator potentiometer
ê
adjust the length of the tie rod so
that voltage does not exceed
the ranges set
(see “engine calibration”)
Calibrate the actuator.

2,5 - 3,0 - 3,5 t
INTERNAL
COMBUSTION
SERVICE MANUAL
page 55
5) POTENTIOMETER IN THE HYDROSTATIC PUMP
feed-back error (error message)
ê
release the parking brake (the terminal will range from the
CALIBRATION MODE to the
DISPLAY MODE)
ê
select the
PUMP NEUTRAL submenu (the terminal will display the
voltage, in volts, that is supplied
by the potentiometer in the
ê hydrostatic pump)
yes voltage = 0 volts or 5 volts ? no
ê ê
check the potentiometer voltage = 2.48 ¸ 2.52 volts ?
electrical connections
yes no
ê ê
engage the parking brake, - check the potentiometer wiring
switch to CALIBRATION mode - lift the truck on the shim blocks,
and calibrate the pump electrically disconnect the pump
potentiometer to zero solenoid valves and start up the
engine: if the pump supplies some
oil, the trouble is a hydraulic or
mechanical type (mechanical
maladjustment of the pump plate
positioning in neutral
displacement)
- after disconnecting the valves, if the
pump supplies some oil, switch off
the engine and hold down the
[ENTER] key in order to read the
voltage, until a 2.5 volt value is
obtained.
ê
engage the parking brake, switch
to CALIBRATION mode and
calibrate the pump potentiometer
zero.
2,5 - 3,0 - 3,5 t
COMBUSTION
page 56
SYSTEM FAULTS AND FAILURES
Any system failure is signalled by the blinking warning light located beside the distributor levers.
The blinking intermittence indicates the failure importance.
The kind of fault is displayed in the FAULT DETECTED menu (“FAULT OCCURRING NOW”
submenu).
If the warning light blinks slowly (0.5 Hz) the fault is not very important; the machine is able
to work.
Error message Cause Cure

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

brake/inching pedal potentiometer has exceeded the limits set
sensor while calibrating - as above (see page 52)
- connector disconnected or wrong wiring
- the signal (voltage) of the mast lever has

mast lever sensor exceeded the limits set while calibrating - as above (see page 53)
- connector disconnected or wrong wiring
- the signal (voltage) of the feedback

potentiometer has exceeded the limits set
actuator sensor - as above (see page 54)
while calibrating
- connector disconnected or wrong wiring.
- >20% error, for more than 0.5 secs, - check the actuator wiring
error on actuator
between the actuator setpoint and the - check theactuator potentiometer
control loop
potentiometer feedback output signal (if you press the
- connector disconnected or wrong wiring. accelerator pedal, the actuator
This message may be
shall rotate forward and the
displayed if the
voltage - measured in “engine
accelerator is pressed
calibration” when the brake is
(green light on) when
released - shall increase)
the engine is off and the
brake is unlocked
power supply out of - the supply voltage of TCS control unit - check the supply voltage value
range is not included in the 9.5 - 48 volts range
2,5 - 3,0 - 3,5 t
INTERNAL
COMBUSTION
SERVICE MANUAL
page 57
If the warning light blinks quickly (1 Hz) the fault is serious; the machine stops.

- wrong value of the supply - check that the voltage is equal to 5 volts
excitation voltage voltage of the potentiometers and ± 5%
microswitches
- wrong signal of the feedbackk - check that the feedback potentiometer

potentiometer in the hydrostatic voltage is equal to 2.5 ± 0.15 volts
feedback error pump when the pump is in neutral
displacement mode (see page 55)
- wrong signal of the feedback - check the potentiometer calibration
potentiometer in the hydrostatic (PUMP NEUTRAL)
pump when the latter is in - check that the feedback potentiometer
neutral out of neutral displacement mode voltage is equal to 2.5 ± 0.15 volts
range when the pump is in neutral displacement
mode (see page 55)
- >20% error, for more than 0.5 - check the pump wiring
secs, between the pump control (potentiometer and solenoid valves)
signal and the potentiometer - check that the feedback potentiometer
error on pump feedback signal in the pump voltage properly changes while
control loop controlling the solenoid valves
- measure the min. and max. voltage of
the pump potentiometer and check that
the control max. value is kept constant
during the forward and reverse running
mode (when the wheels turn forwards,
the potentiometer voltage has to tend
to 5 volts) (when the machine is running
in the pump neutral calibration function)
2,5 - 3,0 - 3,5 t
COMBUSTION
page 58
TROUBLESHOOTING
Fault Possible cure
- check the parking brake operation (DISPLAY-BRAKE SWITCH

(set-not set) menu)
The thermal engine works correctly - check the operation of the speed selector (pedals with steering-
but the pump is faulty wheel 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
The pump works correctly but the
pump)
thermal engine is faulty
(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) -
The pump and engine work correctly, (CALIBRATION (display mode)-MAST
but the engine does not accelerate LEVER CALIBRATION menu)
when the distributor levers are - check if the potentiometer is fitted (TCS parameter)
actuated (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:
The pump and thermal engine do not - check the signal of the travel pedal
work (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
NEUTRAL)
- wiring of the pump potentiometer
NEUTRAL )
- wiring of the pump displacement control solenoid valves
(VISUAL INSPECTION)
2,5 - 3,0 - 3,5 t
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.
WHEEL TIGHTENING TORQUE

Driving wheels 17 daNm
Steering wheels 24 daNm
SUPERELASTIC (SE)
PNEUMATIC (PN)
AI R
T YRE T YPE S I ZE T YPE
PRESSIO N
7.00 -12 2.5
F R O NT
S U P E R E L AS T I C 27X10 -12 3.0 - 3.5
(SE) 2.5-3.0-3.-
REAR 6.50 - 10
5
7.00 -12
27X10 -12 (16 9 bar
2.5
F R O NT PR) 8 bar
P N E U M AT I C 3.0 - 3.5
27X10 -12 (20 10 bar
(PN) PR)
2.5-3.0-3.-
REAR 6.50 - 10 7,75 bar
5
T WIN
2.5
S U P E R E L AS T I C F R O NT 7.00-12
3.0 - 3.5
(SEG )
T WIN
2.5
P N E U M AT I C REAR 7.00-12 9 bar
3.0 - 3.5
(PNG )
2,5 - 3,0 - 3,5 t
COMBUSTION
page 60
STEERING CONTROL
The steering uses the same oil as the lifting by means a priority valve, so that a sufficient
oil flow to the power steering is always assured.
The oil capacity is checked by the Ls signal (load - sersing) coming from the steering
unit and it occurrs so that the oil capacity sent to the power steering is equal to its
actual request.
The exceeding oil is sent to the control valve for other functions.
When the steering wheel is turned the steering unit “measures” a volume of oil proportional
to the above rotation and sends it into the steering cylinder.
CHECKING THE SYSTEM SEALING AND CLEANING

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

1 - Install a pressure gauge in (C) the power steering;
2 - With a socket head spanner, remove the cap located in the Orbitrol upper part to reach the
adjusting screw (B) (power steering unit);
- screw in to increase pressure
- screw out decrease pressure
PRIORITY VALVE
(C)
POWER STEERING
CIRCUIT DRAWING
2,5 - 3,0 - 3,5 t
INTERNAL
COMBUSTION
SERVICE MANUAL
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

C 80° MAX VALUE WITH PN
C
85° MAX VALUE WITH SE
C ANGLE MEASURED BY THE AXLE FRAME TO THE INTERNAL
WHEEL THROUGH A SPECIAL DEVICE
END STROKE
SETTING SCREW
STEERING AXLE
2,5 - 3,0 - 3,5 t
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.
4
1
2,5 - 3,0 - 3,5 t
INTERNAL
COMBUSTION
SERVICE MANUAL
page 63
HYDRAULIC DISTRIBUTOR
Nominal capacity 80 l/min

3 - 4 - 5 section
Relief valve pression

Tilting 180 Bar
Side shift 150 Bar
Max lifting pression 235 ± 5 Bar

Nipple 1/2 Gas
Microswitch
Lifting potentiometer
Restrictor Ø 2 mm
2,5 - 3,0 - 3,5 t
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

2,5 - 3,0 - 3,5 t
INTERNAL
COMBUSTION
SERVICE MANUAL
page 65
TRIPLE MAST SECTION
Fork carriage
Internal
section bar
Intermediate
section bar
External
section bar
2,5 - 3,0 - 3,5 t
COMBUSTION
page 66
DESCRIPTION OF THE CYLINDER COMPONENTS

The cylinder pistons are single-acting types (fig. A).
6 In these cylinders a seal (1) has been fitted on the

piston (2) that works on the inner surface of the
5 cylinder liner (3).
4 The rod guide is made by the plug (4) and by the

piston through anti-friction rings (5).
7 The dust control ring (6) prevents any dirt and water
from penetrating the cylinder.
Slight leakages that may occur are directed to the

tank through the drain pipe connected to the pipe
DIAMETRO coupling (7).
DI
SPINTA
3 The drain pipe shall reach the oil tank (fig. B)
A small quantity of oil will always remain in the loop

formed by the pipe before connecting to the tank. It
acts as a trap and constantly moisturizes the cylinder
liner, when it is completely closed (fig. B).
2
5
Fig. A Fig. B
2,5 - 3,0 - 3,5 t
INTERNAL
COMBUSTION
SERVICE MANUAL
page 67
CYLINDER CHECKING METHODS
1ST CHECK
Remove the drain pipe from the cylinder (fig. C)
Lift the cylinder some times to end stroke, so as to

discharge any oil residual.
Put a load on the forks and lift it by at least 200 mm.
After 10 minutes, measure the amount by which the

load has lowered. A drop of a few millimetres is quite
normal, as in the distributor there are always some
leakages.
Now, lift the cylinder to its end stroke, if no oil leaks
from the drain pipe coupling, it means that the load
lowering is only due to the leakages on the distributor.
Fig. C In the presence of leakages, it will be necessary to

replace the seal. Should this be the case, inspect the
cylinder liner.
2nd CHECK
(To be carried out if the 1st inspection has been
successful and after seal replacement).
Remove the drain pipe from the cylinder.
Lift the cylinder some times to end stroke, so that all

the possible remaining oil is discharged.
Put a load on the forks. Lift and lower it for 10 minutes,

making sure that the limit stop is never reached.
Lift the cylinder to end stroke.
If any leakages should be still present, the cylinder is

damaged and then it must be replaced.
2,5 - 3,0 - 3,5 t
COMBUSTION
page 68
LUBRICATION
Masts
After the first 50 hours

D - 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.
E
Every 50-100 hours
- Grease the mast sliding guides
- through the grease nipples, lubricate the articulations of the tilt cylinders
and of frame coupling.
Every 250 hours

A
- adjust the guide shoes;
- grease mast guide rollers (E).
Every 2000 hours

- inspect mast guide rollers (E); they have to rotate freely and not
to be too worn out.
A) tilt cylinders
2+2 grease nipples
B) mast coupling
B 1+1 grease nipples
Fork mounting carriage and sideshift
After the first 50 hours

- adjust the guide shoes through socket hallen screw (D).
Use a 0.2 - 0.5 mm thickness gauge, fit it from the bottom upwards
up to socket hallen screw (D), going behind roller (E).
Every 50 hours
- lubricate the sideshift guides through the grease nipples.
D
Every 250 hours
- grease the pins and the fork positioning slots;
- adjust the guide shoes;
- grease the guide rollers of carriage (F).
F
E
2,5 - 3,0 - 3,5 t
INTERNAL
COMBUSTION
SERVICE MANUAL
page 69
Every 2,000 hours

- check the conditions of the guide rollers; they
have to rotate freely and not to be too worn
out.
C
C) Sideshift
(upper part) 2 grease nipples
(lower part) no grease nipple
INSTALLATION CHECKS
D SAFETY SPECIFICATIONS
Make sure that:

- the hoisting chain stretchers are not faulty and
B
the adjusting nuts are locked by counternuts and
check pins (F);
- safety limit stops (A) of the fork mounting carriage
are fitted and tightened up;
- stop collars (D) are fitted and tightened up;
Every 500 hours

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

MOUNTING CARRIAGES
The mast unit is equipped with a mechanical safety
limit stop to prevent the accidental removal of the
F fork mounting carriage from the mast downwards.
Limit stops (A) consist of two socket head screws
with counternut. Loosen limit stops (A) before
disassembling the fork mounting carriage.
A
2,5 - 3,0 - 3,5 t
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)
- Surface cracks particularly in D/E/F

G G
- Height difference of the tips (is to be < 3% than the fork
length)
E E - Positioning latch (G)
- Punching is to be clear
- Fork measure (maximum wear = 10% of the original thickness)
F
particularly in point D
F
- Wear of the fork fastening devices on the carriage (E-
D D
F)
TABLE ISO 2328 - 1993
Rate lifting load (kg) "X" (– 5)

IB 0 999 114 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
X = 152 mm (2,5T)
203 mm (3,0 - 3,5T)
2,5 - 3,0 - 3,5 t
INTERNAL
COMBUSTION
SERVICE MANUAL
page 71
LIFTING OF THE TRUCK
HOOKS ATTACHMENT POINTS FOR

LIFTING THE TRUCK
To lift the truck the following equipment must be

used:
A
A- CHAINS: dia. 13 mm - Degree T (8) - UNI
9425
B B- HOOKS: for 5.4 t - UNI/ISO 7597
C C LIFTING OF THE FORKLIFT TRUCK

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

A A
9425
B B- HOOKS: for 5.4 t - UNI/ISO 7597
C- N° 2 upper brackets to hold the chains.
ON THE AXLE WITH OUT

TRUCK WEIGHT LOAD
(FRONT / REAR)
2.5 t 4050 kg 2070 / 1980 kg
3.0 t 4600 kg 2100 / 2500 kg
3.5 t 5160 kg 2260 / 2900 kg

2,5 - 3,0 - 3,5 t
COMBUSTION
page 72
OIL AND GREASE SPECIFICATIONS

FOR NORMAL ENVIRONMENTS
PARTS INVOLVED
USED TYPE SPECIFICATIONS QTY.
ISO - L - HV Hydraulic system, lifting, power steering and

AGIP ARNICA 46 FZG tests to stage 11
39 L
hydrostatic transmission
MOBIL ANTICONGELANTE - - Cooling liquid

API CD-SF CCMC-D3
MOBIL DELVAC 1300
(SHPDO)-PD1 MIL-L-2104D - DIESEL engine
SUPER SAE 15W-40 MIL-L-46152B
20 ÷ 40 SAE - - Mast chain lubrication

Lithium base
Mast securing joints - sideshift unit - steering
MOBILGREASE SPECIAL ASTM 275 305 NLGI N.2 -
dropping point 180 joint - general lubrication with grease nipples
FOR COLD CLIMATES AND COLD-
STORAGE CELLS
PARTS INVOLVED
ISO - L - HV Hydraulic system, lifting and power steering

AGIP ARNICA 22 FZG tests to stage 10
39 L
units
Thickening Infusible Mast securing joints - sideshift unit - steering
MOBILTEMP SHC 100 ASTM 265 295 NLGI N.2 - joint - general lubrication with grease nipples -
Dropping point >260
mast guides
TYRE PRESSURES TIGHTENING TORQUES
TYRE PRESSURES
9,5 bar 400-450

FRONT tyres
7,5 bar 500
9,25
REAR tyres
bar
WHEEL TORQUE
37 daNm steered wheels
50 daNm driven wheels
DRIVE UNIT TORQUE
27 daNm engine fixing to chassis
VARIOUS TORQUES
40 daNm bolts securing mast
0,8 1,2 daNm jack collar self-locking nuts
77 daNm counterweight blocking screws

2,5 - 3,0 - 3,5 t
INTERNAL
COMBUSTION
SERVICE MANUAL
page 73
RUNNING IN MAINTENANCE
at # hours for MEDIUM/INTENSE
50 500 #
USE
at # days/months FOR
7/- -/3 #
OCCASIONAL USE
ENGINES
engine oil and cartridge
clearances engine values
fan belt and alternator belt
CHASSIS AND CONTROLS
general bolt and nuts
wheel torque (1)
(1) During the first 500 worning hours, check

the torque every 50 hours
LIFTING UNIT - MASTS
mast guide pads
oil filter
transmission oil filter
transmission oil
LEGEND
In the maintenance table showing a visual

control and cleaning of the parts indicated .
The servicing periods are divided into hours, considering
an average working day of 8 hours of effective operation.
If the truck is used on average for less than 8 hours per
I n the maintenance table showing the day, refer to the schedules expressed in days/months
replacement of the parts indicated.
In the maintenance table showing lubrification

of the parts indicated.
In the maintenance table showing tightening

or adjustment of the parts indicated.
2,5 - 3,0 - 3,5 t
COMBUSTION
page 74
MAINTENANCE TIMES
2 4 10 at # hours for MEDIUM/INTENSE

8 50 250 500 1 000
000 000 000 #
USE
at # days/months
1/- 7/- -/1 -/3 -/6 -/12 -/24 -/60 #
FOR OCCASIONAL USE
mast guide pads
carriage - sideshift unit slides
mast rollers and chain rollers
tilting jacks supply tubes
fork positioning pins
mast guides, mast and jack fixing
lifting jack collars
fork carriage position
forks
mast tilting
mast secured to chassis
lifting chains
chain securing bolts
high pressure hydraulic hoses
system seal and connections

2,5 - 3,0 - 3,5 t
INTERNAL
COMBUSTION
SERVICE MANUAL
page 75
MAINTENANCE TIMES
afteri # hours FOR

8 50 250 500 1000 2000 4000 10 000 #
MEDIUM/INTENSE USE
after # days/months FOR
1/- 7/- -/1 -/3 -/6 -/12 -/24 -/60 #
OCCASIONAL USE
CHASSIS AND COMMANDS
chassis - cleaning
bolts in general
fuel tank cleaning
fuel tank control
driver’s seat
wheels - hub bearings
tyre inspection and wheel tightness
tyre pressures
steering system and tubing seal
hoses from orbitrol to steering jack
rear axle and weheel hub bearings
steering lock
pedals in general - linkage
brake commands solenoid valve

2,5 - 3,0 - 3,5 t
COMBUSTION
page 76
MAINTENANCE TIMES
10 at # hours for M EDIUM/INT ENSE

8 50 250 500 1 000 2 000 4 000 #
000 USE
at # days/months FOR OCCASION
1/- 7/- -/1 -/3 -/6 -/12 -/24 -/60 #
USE
ENGINE
cooling liquid
fuel filter cartridge
air filter
dusty environment air filter
cyclone prefilter
water and oil radiator (external cleaning)
water and oil radiator in dusty

environments
fan belt and alternator belt
engine oil and filter cartridge
engine supports
engine linkage and fuel connections
fexible fuel and water hosing
DIESEL engine injection pressure control
DIESEL engine valve clearance
PETROL and LPG engine valve

clearance
PETROL and LPG engine spark plugs
LPG system control
LPG bottle hose and safety valve
LPG pressure reducer

2,5 - 3,0 - 3,5 t
INTERNAL
COMBUSTION
SERVICE MANUAL
page 77
MAINTENANCE TIMES
at # hours for MEDIUM/INTENSE

8 50 250 500 1000 2000 4000 10000 #
USE
ati # days/months for
1/- 7/- -/1 -/3 -/6 -/12 -/24 -/60 #
OCCASIONAL USE
ELECTRIC SYSTEM
pushbuttons - pedal microswitches
cable terminals - cable sheaths
battery electrolyte level and density -

replacement
battery terminals and poles
system seal
transmissin oil filter
transmissin oil
complete unit
Totaldokument
BT Cargo CBD 2.5-3.5
Var 250:e timme
Pos Kontroll av: Pos Kontroll av: Pos Kontroll av:
0:0 Grupp 0 Hel maskin 2:0 Grupp 2 Hydrostatik 5:6 Batteri, fastsättning
0:1 Dörrar/luckor 2:1 Läckage 5:7 Säkringar
0:2 Motviktsinfästning 2:2 Funktion 5:8 Batterivätskenivå
0:3 Förarskydd/hytt
0:4 Skyltar/dekaler 3:0 Grupp 3 Bromsar/hjul 6:0 Grupp 6 Hydraulik
0:5 Förarmiljö 3:1 Däck/hjul 6:1 Slangar/rör
0:6 Stol/mattor 3:2 Lufttryck däck 6:2 Ventilreglage/länkage
0:7 Pedalgummin 3:3 Hjulbultar/hjullager 6:3 Oljenivå
0:8 Torkare/spolare 3:4 Färdbroms, funktion/läckage
0:9 Provkörning test av 3:5 Parkeringsbroms, funktion 7:0 Grupp 7 Arbetsfunktion
samtliga funktioner 3:6 Pedallänkage 7:1 Lyftstativ, infästning
0:10 Smörjning enligt schema 7:2 Gafflar
0:11 Tvätt/rengöring 4:0 Grupp 4 Styrning 7:3 Lyftkedjor
4:1 Styrleder/Styrspindlar 7:4 Laststöd
1:0 Grupp 1 Motor 4:2 Styrcylinder, fastsättning 7:5 Lyft-/tiltcylindrar
1:1 Missljud/läckage 4:3 Styrlagring/upphängning
1:2 Gaspedal/reglage
1:3 Luftfilter, kontroll 5:0 Grupp 5 Elsystem
1:4 Kylvätska, nivå/fryspunkt 5:1 Belysning/körriktningsvisare
1:5 Remmar, kontroll 5:2 Instrument/kontrollampor
1:6 Motorolja, byte 5:3 Signalhorn
1:7 Motoroljefilter, byte 5:4 P-broms-/Backalarm
1:8 Bränslesystem, läckage 5:5 Timmätare, avläsning
1:9 Glödning
Var 500:e timme tillkommer: Var 1000:e timme tillkommer: Var 2000:e timme tillkommer:
0:0 Grupp 0 Hel maskin 0:0 Grupp 0 Hel maskin 0:0 Grupp 0 Hel maskin
0:12 Bultar/Muttrar, fastsättning 0:13 Bränsletank, rengöring 0:14 Ram, kontroll av sprickor
1:0 Grupp 1 Motorer 1:0 Grupp 1 Motor 1:0 Grupp 1 Motorer

1:10 Bränslefilter, byte 1:13 Remmar, byte 1:15 Kylvätska, byte
1:11 Luftfilter, byte 1:14 Ventilspel, kontroll
1:12 Motorfästen 4:0 Grupp 4 Styrning
2:0 Grupp 2 Hydrostatik 4:4 Slangar, kontroll
5:0 Grupp 5 Elsystem 2:3 Bultar, kontroll/fastsättning 4:5 Styrtryck, kontroll
5:9 Batteripoler reng./infettning
5:10 Färdväljare/länkage 3:0 Grupp 3 Bromsar/hjul 5:0 Grupp 5 Elsystem
5:11 Microbrytare 3:7 Hjullager infettning 5:13 Laddning, kontroll
5:0 Grupp 5 Elsystem 6:0 Grupp 6 Hydraulik

5:12 Kablage/anslutningar 6:5 Hydraultryck, kontroll
6:6 Hydraulolja, byte
6:0 Grupp 6 Hydraulik 6:7 Returfilter, byte
6:4 Andningsfilter, reng./byte 6:8 Sugfilter, rengöring/byte
7:0 Grupp 7 Arbetsfunktion

7:6 Gafflar, gaffeltest
Totaldokument
BT Cargo CBG 2.5-3.5
Var 250:e timme
Pos Kontroll av:

Pos Kontroll av: Pos Kontroll av:
0:0 Grupp 0 Hel maskin
0:1 Dörrar/luckor 1:9 Gasolsystem, läckage 5:2 Instrument/kontrollampor
0:2 Motviktsinfästning 1:10 Tändsystem, kondition 5:3 Signalhorn
0:3 Förarskydd/hytt 5:4 P-broms-/Backalarm
0:4 Skyltar/dekaler 2:0 Grupp 2 Hydrostatik 5:5 Timmätare, avläsning
0:5 Förarmiljö 2:1 Läckage 5:6 Batteri, fastsättning
0:6 Stol/mattor 2:2 Funktion 5:7 Säkringar
0:7 Pedalgummin 5:8 Batterivätskenivå
0:8 Torkare/spolare 3:0 Grupp 3 Bromsar/hjul
0:9 Provkörning test av 3:1 Däck/hjul 6:0 Grupp 6 Hydraulik
samtliga funktioner 3:2 Lufttryck däck 6:1 Slangar/rör
0:10 Smörjning enligt schema 3:3 Hjulbultar/hjullager 6:2 Ventilreglage/länkage
0:11 Tvätt/rengöring 3:4 Färdbroms, funktion/läckage 6:3 Oljenivå
3:5 Parkeringsbroms, funktion
1:0 Grupp 1 Motor 3:6 Pedallänkage 7:0 Grupp 7 Arbetsfunktion
1:1 Missljud/läckage 7:1 Lyftstativ, infästning
1:2 Gaspedal/reglage 4:0 Grupp 4 Styrning 7:2 Gafflar
1:3 Luftfilter, kontroll 4:1 Styrleder/Styrspindlar 7:3 Lyftkedjor
1:4 Kylvätska, nivå/fryspunkt 4:2 Styrcylinder, fastsättning 7:4 Laststöd
1:5 Remmar, kontroll 4:3 Styrlagring/upphängning 7:5 Lyft-/tiltcylindrar
1:6 Motorolja, byte
1:7 Motoroljefilter, byte 5:0 Grupp 5 Elsystem
1:8 Gasolsystem, funktion 5:1 Belysning/körriktningsvisare
Var 500:e timme tillkommer: Var 1000:e timme tillkommer: Var 2000:e timme tillkommer:
0:0 Grupp 0 Hel maskin 1:0 Grupp 1 Motor 0:0 Grupp 0 Hel maskin
0:12 Bultar/Muttrar, fastsättning 1:14 Remmar, byte 0:13 Ram, kontroll av sprickor
1:15 Tändinställning
1:0 Grupp 1 Motorer 1:16 Tändstift, byte 1:0 Grupp 1 Motorer
1:11 Luftfilter, byte 1:17 Kylvätska, byte
1:12 Motorfästen 2:0 Grupp 2 Hydrostatik
1:13 Ventilspel, kontroll 2:3 Bultar, kontroll/fastsättning 4:0 Grupp 4 Styrning
4:4 Slangar, kontroll
5:0 Grupp 5 Elsystem 3:0 Grupp 3 Bromsar/hjul 4:5 Styrtryck, kontroll
5:9 Batteripoler reng./infettning 3:7 Hjullager infettning
5:10 Färdväljare/länkage 5:0 Grupp 5 Elsystem
5:11 Microbrytare 5:0 Grupp 5 Elsystem 5:13 Laddning, kontroll
5:12 Kablage/anslutningar
6:0 Grupp 6 Hydraulik
6:0 Grupp 6 Hydraulik 6:5 Hydraultryck, kontroll
6:4 Andningsfilter, reng./byte 6:6 Hydraulolja, byte
6:7 Returfilter, byte
6:8 Sugfilter, rengöring/byte
7:0 Grupp 7 Arbetsfunktion

7:6 Gafflar, gaffeltest
Cargo Range
CESAB S.p.A
via Persicetana Vecchia, 10 40132 Bologna - Italy
Tel. (0039) 051.20 54 11
Fax (0039) 051.72 80 07
E-mail: cesab@cesab.it
Code 036 2005-1 GB Issue 11/2000

CONSOLE MAP
CBD/G 2,5-3,0-3,5 CALIBRATION SECTION
"CALIBRATION"
DIAGRAM FOR USING CONSOLE (ANALYSER)
-Connect the console and turn the key without starting TO BE CARRIED OUT WHENEVER A CONTROL
DISPLAY
CONSOLLE COMPONENT IS REPLACED
select the parking
Calibration ENTER Calibration brake switch and Calibration
Calibration Status Calibration Status press+ Calibration Status
first operation è Locked Not Locked
PRESS to be carried
ENTER out to release é é
ESC
the program press - press+
press ê configuration operate the forward

Calibration without pressing switch (only for hand
Calibration ENTER accelerator pedal Calibration
any pedal,
Calibration Calibration
Travel Pedal potentiometer, ENTER Travel Pedal Travel Pedal direction version) Travel Pedal
ENTER
è Don't touch teh IfForwardswitch press ENTER Pushslowlytravel
ê travel pedal ('ENT') select it ('ENT')
é pedal
HAND VERSION PEDAL VERSION
press the accel. press the forward
pedal, ENTER pedal, ENTER
completely press
Calibration the accel. pedal, Calibration Calibration
Travel Pedal keep it pressed, Travel Pedal Travel Pedal
Forwardcompleted ENTER Full depression in ENTER Forwardcompleted
press+ (ENT) Forward (press a key) (press a key)
ended acquisition of
the forward pedal operate the reverse
signal,ENTER without pressing switch (only for hand
Calibration any pedal, Calibration Calibration
Travel Pedal Travel Pedal direction version) Travel Pedal
ENTER press ENTER
N.B. WITH THE PROGRAM Don't touch the If Reverse switch
select it ('ENT')
Pushslowlytravel
ended travel pedal ('ENT') pedal
LOCKED IT IS POSSIBLE TO configuration of HAND VERSION PEDAL VERSION
the accelerator,
READ THE SENSORS VALUE ESC completely press
press the accel. press the forward
pedal, ENTER pedal, ENTER
the accel. pedal,
Calibration Calibration keep it pressed, Calibration Calibration
ENTER Travel Pedal ENTER Travel Pedal
Travel Pedal Travel Pedal ENTER
Completed Reverse completed Full depression in Reverse completed
(ENT) Reverse (press a key) (press a key)
Calibration configuration brake Calibration Calibration completely press Calibration

Brake/inching pedal pedal potentiometer, Brake/inching pedal min. value stored, Brake/inching pedal the pedal, keep it Brake/inching pedal
ENTER Rest reading ENTER Full depression pressed, ENTER Completed
è (Press a key) (Press a key)
ê é
ended configuration of
the brake pedal, ESC
press+
configuration of the Calibration Calibration Calibration

Calibration lifting potentiometer, min. value stored,
Mast lever Mast lever Press 1 Mast lever Mast lever
ENTER Mast sensor presence Rest reading ENTER Full depression
è YES (1) NO (0) (Press a key) (Press a key)
é pull the lifting lever to
ended configuration of the the end stroke, keep it
press+ Calibration
lifting potentiometer, ESC pulled, ENTER
Mast lever
Completed
ê
Calibration ACQUISITION TO BE CARRIED OUT IN A SECOND
Engine Calibration TIME WITH THE ENGINE ON
press+
acquisition of the
ê neutral pump Calibration
Calibration position, ENTER Pump Neutral
Pump neutral è Completed ended acquisition of
the neutral pump
press+ é position, ESC
ê
Calibration
Max. forward speed NOT MODIFY
press+
ê FUNCTION TO BE CARRIED OUT WITH THE ENGINE ON
Calibration NOT MODIFY
Max. reverse speed acquisition of the
Calibration min. and max.
RPM of the Engine Calibration Engine Calibration
press+ Engine Calibration engine, ENTER Slowest engine speed Highest engine speed
ê è Reading...... Reading.........
Calibration é then the engine
Parking brake set NOT MODIFY starts to
accelerate by
press+ itself
ê
Calibration
Mini engine speed NOT MODIFY
Engine Calibration Calibration
press+ End of engine Engine Calibration
ê calibration Reading...(8 mesures)
Calibration NOT MODIFY
Maxi engine speed ended acquisition
of the min. and
press+ max. RPM of the
engine, ENTER
ê
Calibration
Pump pot. inverted NOT MODIFY
JULY 2000
CBD/G 2,5-3,0-3,5
-Connect the console and turn the key DISPLAY SECTION
"DISPLAY"
DISPLAY
CONSOLE
ê
Display ENTER
PRESS Display the real engine RPM
ENTER Engine speed
ê
ESC
press+
Calibration
ê
Display ENTER
Display the pump displacement
Pumpdisplacement requested by the Logic Unit (cc)
ê
ESC
PRESS+ press+
Display the engine RPM
ê
Display ENTER
requested by the Logic Unit
Display Enginecommand
ê
ESC
press+
press ENTER,,
ê
Display ENTER Display the status of the
to display the information of
Antistall function (enable / disable)
ê
the engine / hydrostatic pump ESC
press+
Dispaly the status of the negative

ê
Display ENTER
Parkingbrake brakes (enable / disable)
ê
ESC
press+
ê
Display ENTER Display the status of the parking

Brakeswitch brake switch (set / not set)
ê
ESC
N.B.: TO READ THE press+
VALUES ON SEQUENCE
ê
Display ENTER Display the engine RPM

KEEP ENTER PUSH MastengineCmd with the lifting lever pulled
ê
ESC
BUTTON PRESSED press+
ê
Display ENTER Display the real pump displacement

Pump feed-back (cc) by the potentiometer
ê
ESC
press+
ê
Display ENTER Display the status of the direction switches

Directionswitch (neutral / forward / backward)
ê
ESC
press+
ê
Display ENTER Display the status of the control valve switches

Mastswitch 1=tilting/sideshift (set / not set)
ê
ESC
press+
ê
Display ENTER Display the constant driving speed function

Constantspeed status with the lifting activated (set / not set)
ê
ESC
press+
ê
Display ENTER Display the signal of the engine

Actuator feedback actuator in Volt
ê
ESC
press+
Display the tension of the unit
ê
Display ENTER
logic (enable / disable)
Power supply
ê
ESC
press+
ê
Display ENTER Display the sensor tension supplyed by the unit

Sensorexitation logic
ê
ESC
press+
Display the different of the pump potentiometer
ê
Display ENTER
signal from the theoretic value (in mV)
Neutraldrift
ê
ESC
JULY 2000
CBD/G 2,5-3,0-3,5
-Connect the console and turn the key "ENGINE CUSTOMIZED"
SECTION
DISPLAY
CONSOLE
Calibration select the parking Calibration

Calibration ENTER switch and press +
Calibration Status Calibration Status Calibration Status
PRESS first operation è Locked Not Locked
ENTER to be carried é é ESC
out to relaese press -
the program press+
ENTER
ê
Calibration
è è Calibration
Travel Pedal
ESC
press +
Display
press +
Engine Customized not modified
Pump Customized Travel pedal Inc.
press+
press +
Engine Customized
press ENTER,, Travel pedal Dec. not modified
Engine Customized engine setting
è press+
é Engine Customized not modified

Mast Dec.
press+
Engine Customized not modified

Mast Inc.
press+ engine RPM
with tilting set the requested value
Engine Customized ENTER, Engine Customized typing it directly by the
Mast fixed Cmd 1 è Mast fixed Cmd 1 keybord numbers or
45 Percent pressing + o -, ENTER
ê é (N.B. more RPM,
higher value
less RPM,
lower value)
press+ ESC Engine Customized
Mast fixed Cmd 1
45 Percent
engine RPM
with sideshift set the requested value
ESC Engine Customized Engine Customized
ENTER, typing it directly by the
Mast fixed Cmd 2 è Mast fixed Cmd 2 keybord numbers or
é 45 Percent pressing + o -, ENTER
(N.B. more RPM,
higher value
less RPM,
lower value)
ESC Engine Customized
Mast fixed Cmd 2
45 Percent
JULY 2000
CBD/G 2,5-3,0-3,5
-Connect the console and turn the key
ALARMS SECTION
DISPLAY "FAULT DETECTED"
CONSOLLE
PRESS
ENTER
Calibration
press+
Dispaly
press+
Pump Customized
press+
Engine Customized
ê ENTER, to display the
ESC
Fault detected faults in real time Fault detected
press+
Fault occuring now è Fault occuring now è
press ENTER,
to display the faults ê No default
Fault detected
è press+
no alarms
press+
é
Fault detected ESC
Fault occuring now è
Actuator sensor
alarm present
ENTER, to display the
stored alarms (faults)
Fault detected (max 5) Fault detected
Fault since startup è Fault since startup
é Start of the list
press+
to read the
alarms Fault detected
Fault since startup
Neutral out of range
press+
Fault detected
ESC
Fault since startup
End of the list
JULY 2000
CBD/G 2,5-3,0-3,5
MAIN MENU
-Connect the console and turn the key without starting
DISPLAY
CONSOLE
Press ENTER to
select the main menu
Calibration Calibration of the potentiometers and the transmission actuators (pedals, control
valve, engine actuator, etc.)
Press +
Display Display information on the transmission (engine RPM, transmission

displacement, microswitches status, ecc.)
Press +
Pump Customized
Personalization of the transmission behavior
Press +
Engine Customized Personalization of the engine setting
Press +
Fault Detected System faults display
Press +
Information SOFTWARE version
Press +
Ph Parameters Not accessible (PASSWORD)
Press +
EEprom reset Not accessible (PASSWORD)
JULY 2000
CBD/G 2,5-3,0-3,5
-Connect the console and turn the key
"PUMP CUSTOMIZED"
DISPLAY SECTION
CONSOLE
Calibration select the parking Calibration

Calibration ENTER switch and press +
Calibration Status Calibration Status Calibration Status
PRESS first operation è Locked Not Locked
ENTER to be carried é é ESC
out to relaese press -
the program press+
ENTER
ê
Calibration
è è Calibration
Travel Pedal
ESC
press +
Display
press +
press ENTER, pump acceleration
pump setting time, ENTER,
Pump Customized Pump Customized Pump Customized
è Travel pedal Inc. è Travel pedal Inc.
é ê é 5.0 Seconds
set the requested value typing it directly by the
press+ keybord numbers or pressing + o -, ENTER
(N.B. quicker acceleration,lower value
slower acceleration,higher value)
ESC
Pump Customized
Travel pedal Inc.
5.0 Seconds
pump deceleration
time, ENTER
Pump Customized (braking) Pump Customized
Travel pedal Dec. è Travel pedal Dec.
ê é 5.0 Seconds
set the requested value typing it directly by the
keybord numbers or pressing + o -, ENTER
press+ (N.B. stronger brake ,lower value
softer brake, higher value)
Pump Customized
ESC Travel pedal Dec.
5.0 Seconds
Pump Customized not modified

Sensitivity
press+
Pump Customized not modified

Inching pedal Inc.
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 $&&(77$%/(9$/8( 67$1'$5'9$/8(
MAST PRESENCE YES/NO YES

MAX FORWARD SPEED 10% - 100% 100%
MAX REVERSE SPEED 10% - 100% 100%
MIN ENGINE SPEED 850
MAX ENGINE SPEED 2200
MULTI DISK BRAKE PRESENT / NOT PRESENT PRESENT
PARKING BRAKE SET 80% - 95% 95%
PUMP POT. INVERTED ENABLE
3803&86720,=(' $&&(77$%/(9$/8( 67$1'$5'9$/8(
TRAVEL PEDAL INC # 2,5 - 4 SEC 3

TRAVEL PEDAL DEC. # 3 - 4 SEC 3,5
SENSITIVITY 10% - 70% 50%
INCHING PEDAL INC. 4 - 6 SEC 4
INCHING PEDAL DEC. 1,5 - 2,5 SEC 2
(1*,1(&86720,=(' $&&(77$%/(9$/8( 67$1'$5'9$/8(
TRAVEL PEDAL INC 0,5 - 3 SEC 1,8

TRAVEL PEDAL DEC. 0,3 - 2 SEC 1,3
MAST INC. 0,5 - 2 SEC 1
MAST DEC. 0,8 - 2 SEC 1
MAST FIXED CDM 1 0% - 100% 30%
# ONLY THESE VALUES CAN BE MODIFIED

CBD 2.5-3.0-3.5
KUBOTA ENGINE
SETTING VALUE
&$/,%5$7,216(&7,21 $&&(77$%/(9$/8( 67$1'$5'9$/8(
MAST PRESENCE YES/NO YES

MAX FORWARD SPEED 0% - 100% 100%
MAX REVERSE SPEED 0% - 100% 100%
NUMBER OF TEETH 1 - 200 9
MULTI DISK BRAKE PRESENT / NOT PRESENT PRESENT
PARKING BRAKE SET 80% - 95% 95%
PUMP POT. INVERTED ENABLE / DISABLE ENABLE
3803&86720,=(' $&&(77$%/(9$/8( 67$1'$5'9$/8(
TRAVEL PEDAL INC # 2.5 - 4 SEC 3

TRAVEL PEDAL DEC. # 3 - 4 SEC 3,5
SENSITIVITY 10% - 70% 50%
INCHING PEDAL INC. 4 - 6 SEC 4
INCHING PEDAL DEC. 1.5 - 2.5 SEC 2
(1*,1(&86720,=(' $&&(77$%/(9$/8( 67$1'$5'9$/8(
TRAVEL PEDAL INC 0,5 - 2 SEC 1,2

TRAVEL PEDAL DEC. 0,3 - 2 SEC 1
MAST INC. 0,3 - 2 SEC 1
MAST DEC. 0,3 - 2 SEC 1
# ONLY THESE VALUES CAN BE MODIFIED

LEGEND
DESCRIPTION ENGLISH DEUTSCH FRANCAIS ESPAÑOL
4' via 4th valve 4.Steuerkreis 4.ème levier 4a.leva

5' via 5th valve 5.Steuerkreis 5.ème levier 5a.leva
abilitazione attiva enable on Freigabe ein abilitation activée habilitación activada
abilitazione freni brakes enable Bremsenfreigabe abilitation des freins habilitación de los frenos
abilitazione parcheggio parking enable Festellfreigabe abilitation de stationnement habilitación de aparcamiento
acceleratore accelerator pedal Fahrpedal pédale accélérateur pedal acelerador
alternatore alternator Lichtmaschine alternateur alternador
anomalia centralina logic unit defect Logikeinheitsdefekt anomalie d’unité logique anomalía unidad lógica
attuatore actuator Aktuator actionneur actuador
arresto motore motor stop Motorstop arrêt du moteur parada del motor
batteria battery Batterie batterie batería
bobina coil Spule bobine bobina
brandeggio tilting Neigung inclinaison inclinación
candele spark plugs Zundkerzen bougies d’allumage bujías
candelette glow plugs Glühkerzen bougies de chauffage bu jías incandescente
chiave key Schlüssel clé llave
chiave avviamento start key Anlaßschlüssel clé de démarrage llave de arranque
clacson horn Hupe klaxon claxon
comandi luci supplem. additional lights controls Zusatzbeleuchtungssteuerung commandes lumières suppl. mandos luces adicionales
comando elettroventola electric fan control Elektroflügelsteuerung commande électro-ventilateur mando electroventilador
comando fanali stop stop lights control Stoplichtesteuerung commande feus de stop mando faroles de stop
conn.batteria battery connector Batteriestecker connecteur batterie enchufe batería
cruscotto dashboard Armaturenbrett panneau de commande salpicadero
dispositivo candelette glow plugs device Glühkerzevorrichtung dispositif bougie de chauffage dispositivo bujia incandescente
elettrovalvole marcia speed electrovalves Gangelektroventile electrovannes de marche electroválvulas de marcha
elettroventola electric fan Elektroflügelrad électro-ventilateur electroventilador
emergenza emergency Notstand urgence emergencia
fanali retromarcia reversing lights Rückfahrscheinwerfer feus de marche arrière faroles de marcha atras
fanali stop stop lights Stoplichte feus de stop faroles de stop
freno brake Bremse frein freno
freno pedale pedal brake Bremspedal frein pédale freno pedal
freno stazionamento parking brake Festellbremse frein de stationnement freno de aparcamiento
indicatore riserva gas LPG reserve indicator GPL Reserveanzeiger indicateur réserve GPL indicador reserva GPL
LEGEND
indicatore temperatura ac water temperature indicator Wassertemperaturanzeiger indicateur temperature de l’ea indicador temperatura del agua
intas.filtro aria air filter clogging Luftfilterverstopfung encrassement filtre à air obstrucción filtro aire
intas.filtro olio oil filter clogging Ölfilterverstopfung encrassement filtre huile obstrucció filtro aceite
intas.filtro olio idraul. hydraulic oil filter clogging Hydraulikölfilterverstopfung encrassement filtre huile hydr. obstrucción filtro aceite hidr.
inversore inversor lever Umschaltung inverseur de direction palanca de inversión
inversore manuale drive direction lever Handumschaltung inverseur de direction palanca de inversión
livello carburante fuel level Treibstoffstand niveau carburant nivel carburante
liv.liquido freni brake fluid level Bremsflüssigkeitsstand jauge d’huile de freins nivel aceite frenos
luci posteriori back lights Rücklichte lumières arrières luces traseras
luci retromarcia reversing lamps Rückfahrlampen ampoule marche arrière lampara de marcha atrás
marcia avanti forward speed Vorwärtsgang marche avant marcha adelante
marcia indietro backward speed Rückwärtsgang marche arrière marcha atrás
marcia lenta slow speed langsamer Gang marche lente marcha lenta
mot.trazione traction motor Fahrmotor moteur de traction motor de tracción
motore avviamento starter motor Anlaßmotor démarreur motor de arranque
motore idroguida power steering motor Hydrolenkungsmotor moteur direction assistée motor servodirección
motore pompa pump motor Pumpenmotor moteur pompe motor bomba
pedale freno brake pedal Bremsepedal pédale du frein pedal del freno
pedaliera pedals Pedale jeu de pédales juego de pedales
pedaliera doppia double pedals Doppelpedal pédales double pedales doble
pompa pump Pumpe pompe bomba
pompa iniezione injection pump Einspritzungspumpe pompe d’injection bomba inyección
post combustione afterburning Nachverbrennung postcombustion postcombustión
potenziometro sollev. lifting potentiometer Hubpotentiometer potentiomètre d’élévation potenciómetro levantamiento
pressione olio motore motor oil pressure Ölmotordruck pression d’huile moteur presión aceite motor
pressostato freni brakes press.switch Bremsdruckschalter pressostat freins presóstato frenos
pulsante clacson horn push button Hupeknopf poussoir klaxon pulsador de claxon
pulsante emergenza emergency.pushbutton Notdruckknopf poussoir d’urgence pulsador de emergencia
relè avviamento starter relay Anlaßrelais relais démarreur relé arranque
riserva gas LPG reserve GPL Reserve réserve GPL reserva GPL
scatola acc. speed box Fahrschalter boitier du vitesse caja aceleradores
sensore velocita’ speed sensor Geschwindigkeitsensor senseur de vitesse sensor de velocidad
sollevamento lifting Hub élévation levantamiento
spia candelette glow plugs warning light Glühkerzenwarnlampe voyant bougies de chauffage luz testigo bujías incandescen.
LEGEND
SW cofano bonnet switch Schutzhaubeschalter interrupteur coffre interruptor cofre

temp.olio trasmis. oil temperature transmission Öltemperaturgetriebe temperature d’huile transmis. temperatura aceite transmisión
temperatura acqua water temperature Wassertemperatur temperature d’eau temperatura agua
termico thermal sensor Wärmesensor senseur thermique sensor térmico
traslatore sideshift Seitenschieber déplacement lateral desplazador lateral
uomo presente deadman device Totmann-schalter Homme mort conductor presente
ventola motore motor fan Motorflügel ventilateur moteur motor ventilador
ventole fan Flügelräder ventilateur ventilador
vista posteriore rear view Rücksicht vue arrière vista rasera
COLORI COLOURS FARBEN COULEURS COLORES

arancio orange Orange orange anaranjado
azzurro blue Hellblau bleu azul
bianco white Weiß blanc blanco
blu dark blue Blau bleu azul
giallo yellow Gelb jaune amarillo
grigio grey Grau gris gris
marrone brown Braun marron marron
nero black Schwarz noir negro
rosa pink Rose rose rosa
rosso red Rot rouge rojo
verde green Grun vert verde
viola purple Violett violet violeta
BT Cargo Teknikutbildning
Programmering av TCS-systemet
BT Cargo CBD/CBG 2.5-5.0
F1 F2 F3 F4
A B C D E
/ ( 1 2 3
F G H I J
* ) 4 5 6
K L M N O
- # 7 8 9
P Q R S T
, .
+ = 0
U V W X Y
CTRL ESC
SHIFT SPACE ENTER
Z BKSP
Per Wärmlund / Avd. service

BT Cargo Teknikutbildning Programmering av TCS-systemet
Main Menu
Connect the
console and turn the
key without starting
Press ENTER
to select the
main menu
ENTER
Calibration of the potentiometers and the transmission actuators (pedals,

Calibration control valve, engine actuator, etc.)
+
Display Display information on the transmission (engine RPM, transmission
displacement, micro switches status, etc.)
+
Pump Personalization of the transmission behavior
Customised
+
Engine Personalization of the engine setting
Customised
+
Fault
Detected System fault display
+
Information Software version
+
Ph Parameters Not accessible (Password only)
+
Eeprom reset Not accessible (Password only)
+ End of list 2.5 - 3.5t
Motor Shifting Not accessible (Password only)
+
Actuator Pid Not accessible (Password only)
+ End of list 4.0 - 5.0t

Sida 1
Calibration
First operation Select the

Calibration ENTER Calibration parking brake Calibration
to be carried
Calibration Status calibration Status Calibration Status
out to release locked switch and not locked
ENTER
the program
- +
press
+ ESC
Configuration
accelerator pedal Calibration
ENTER potentiometer Calibration
Calibration Travel pedal Travel Pedal
Calibration Travel Pedal If Forward switch
ENTER Don’t touch the ENTER
travel pedal (’ENT’) select it (’ENT’)
ENTER
Operate the forward
switch lever or depress
the twin forward. Pedal
N.B. With the program to close switch
locked it is possible to Calibration Calibration Travel Calibration
read the sensor Travel Pedal Press a key Pedal ENTER Travel Pedal
Forward complete Full depression in Forward complete
values.. (ENT) Forward (Press a key) (ENT)
ENTER
Calibration Travel Calibration Calibration

pedal. Don’t touch ENTER Travel Pedal ENTER Travel Pedal
the travel pedal If Reverse switch Reverse complete
(’ENT’) select it (’ENT’) (ENT)
ENTER
Operate the reverse
switch lever or depress
the twin reverse. Pedal
to close switch
Calibration Calibration Travel

Calibration ENTER Travel Pedal Press a key Pedal
Travel Pedal Reverse complete Ful depression in
ESCAPE Completed (ENT) reverse (Press a key)
Configuration Completely press

brake pedal the pedal,
potentiometer Calibration Min value stored, Calibration keep it pressed
Calibration Press a key Calibration
Brake / inching ENTER Brake / inching pedal Brake inching pedal ENTER Brake / inching
pedal Rest reading Full depression pedal completed
(press a key) (press a key)
+ Ended configuration of the brake pedal,

ESC
To page 3
Calibration Mast Lever
Sida 2
Calibration
From page 2
Calibration Mast Lever
Configuration of the Min. Value

lifting potentiometer, stored
Calibration Calibration Calibration
ENTER Press 1 Mast lever
Calibration Mast lever Mast lever
Mast lever Mast sensor presence Rest reading Press Full depression
YES (1) NO (0) (Press a key) a key (press a key)
+ Pull the lifting lever to

the end stroke, keep it
pulled, ENTER
Calibration
ESCAPE Mast lever
Ended configuration of the completed
ACQUISITION TO BE CARRIED OUT lifting potentiometer
Calibration WITH THE ENGINE ON
Engine Calibration
+
Acquisition of
the neutral Calibration
pump position Pump neutral Ended acquisition
Calibration Completed of the neutral
Pump Neutral ENTER pump position
+
Calibration May be Modified
max.forward speed
+
Calibration
Max.reverse speed May be Modified FUNCTION TO BE CARRIED
OUT WITH THE ENGINE ON
+ LIST FOR 2.5-3.5t

NOT MODIFY
LIST FOR 4.0-5.0t
May be Modified ESCAPE
Acquisition of the
min.and max.
RPM of the engine
Parking brake set Calibration Engine Calibration
Reduce speed ENTER Lowest engine speed
Engine calibration
+ Standard
value
850 RPM
+ NOT
MODIFY
Ended acquisition
of the min. and max
Reading.......
Then the engine

Calibration Calibration RPM of the engine, starts to accelerate
Mini engine set by itself
Number of teeth Engine Calibration
End of engine
+ Standard
value
2250 RPM
+ NOT
calibration ESCAPE
MODIFY
Maxi engine speed Power supply
Calibration
+ NOT
+ NOT
Engine Calibration
Reading...
Engine Calibration
Highest engine speed
Reading.....
MODIFY MODIFY (8 values)
Pump pot.inverted Sensor excitation
+ + NOT
NOT MODIFY
Back to calibration
Calibration
MODIFY
+ Calibration +
NOT MODIFY
Calibration
Pump pot.inverted
+ Back to calibration
Multi disc brake Parking brake set
Sida 3
Display BT Cargo CBD/CBG 2.5-5.0
Menu Display ENTER
Engine Speed Display the real engine RPM
ESC
+ Display
ENTER Display the pump displacement
pump displacement requested by the logic unit (cc)
ESC
ENTER + ENTER
Display Display the engine RPM
Engine command requested by the logic unit
Calibration ESC
+ ENTER
+ Display
Antistall
ESC
Display the status of the
function (enable / disable)
Display + Display ENTER

Display the status of the negative
ENTER
Parking brake brakes (enable / disable)
Displays information ESC
of the engine and
hydrostat pump
+ Display
ENTER Display the status of the parking
HOLD DOWN THE ENTER Brake switch brake switch (set / not set)
ESC
KEY TO DISPLAY DATA IN
SEQUENCE + Display
ENTER
Display the engine RPM
Mast engine Cmd
ESC with the lifting lever pulled
+ Display
ENTER Display the real pump displacement
Pump feed-back (cc) by the potentiometer
ESC
+ Display ENTER Display the status of the direction switches
Direction switch (neutral / forward / backward)
ESC
+ Display
ENTER Display the status of the control valve switches
Mast switch 1=tilting / sideshift (set / not set)
ESC
List for
4.0 - 5.0t
+ Display ENTER Display the constant driving speed function
Constant speed status with the lifting activated (set / not set)
ESC
Display
Reduced speed
ENTER
+ Display the reduced speed function
ESC status (enable / disable)
+ ENTER Display the difference of the pump potentiometer
Display List for
Neutral drift signal from the theoretical value (in mV)
ESC 2.5 - 3.5t
ESCAPE ENTER Display the signal of the engine
Display
Actuator feed back actuator in volts
ESC
+ Display
ENTER
Display the voltage of the logic
Power supply unit (enable / disable)
ESC
+ Display
ENTER
Display the sensor voltage supplied by the
Sensor excitation logic unit
ESC
ESCAPE
+ Display
ENTER Display the difference of the pump potentiometer
Neutral drift signal from the theoretic value (in mV)
ESC
Sida 4
Pump Customised BT Cargo CBD/CBG 2.5-5.0
Section
Calibration status Select the Parking brake

has to be un locked switch and press
to release the
parameters for Calibration ENTER Calibration + Calibration
modification Calibration status Calibration status
Calibration status Not Locked
Locked
ENTER
ESC
- + ESC
ENTER
travel Pedal
ESCAPE
+ ESC
Pump acceleration
Display time
Pump Customised ENTER Pump Customised
+ Travel pedal Inc. Travel pedal Inc.
5.0 Seconds
Pump
ESC
ENTER + Set the requested value by typing it directly
Customised with the keyboard numbers or pressing + 0 -
ENTER ( N.B. Quicker acceleration, lower
value, slower acceleration, higher value)
ESCAPE Pump Customised
Travel pedal Inc.
5.0 Seconds
Pump deceleration
time (Braking) Pump Customised
Pump Customised Travel pedal Dec.
Travel pedal Dec. ENTER 5.0 Seconds
+ Set the requested value by

typing it directly
with the keyboard numbers
or pressing + 0 -
Hard braking ratio ENTER ( N.B. Stronger brake,
ENTER lower value
softer brake, higher value)

Travel pedal Dec.
5.0 Seconds
Pump Customised
Sensitivity Not Modified
+Pump Customised Pump Customised

Inching pedal Inc. Not Modified Hard braking
ratio 00%
+
ENTER
See page 14
Inching pedal Dec. Not Modified

Hard braking
ratio 00%
Sida 5
Engine Customised BT Cargo CBD/CBG 2.5-5.0
Section
Calibration status Select the Parking brake

has to be un locked switch and press
to release the
parameters for Calibration ENTER Calibration + Calibration
modification Calibration status Calibration status
Calibration status Not Locked
Locked
ENTER - + ESC
ENTER
travel Pedal
ESCAPE
+
Display
+ Engine Customised
Travel pedal Inc.
Pump
Customised +
+ Engine Customised
Travel pedal Dec.
Engine
Customised
ENTER +
Engine Customised Set the requested value by typing it
Mast Inc. directly, or by the +0- ENTER
+ (N.B. More RPM higher value less RPM

lower value)
Engine Customised Engine Customised
Mast Dec. Mast fixed Cmd. 1
45%
+
Engine Customised ENTER ENTER
Mast fixed Cmd. 1 Engine RPM
Tilting 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

Engine Customised ENTER
Mast fixed Cmd. 2
Mast fixed Cmd. 2 Engine RPM
45%
Sideshift
ENTER
Engine Customised
ESCAPE Mast fixed Cmd. 2
45%
Sida 6
Alarms Section BT Cargo CBD/CBG 2.5-5.0
“Fault Detected”
DISPLAY CONSOLE
ENTER
Calibration
+
Display
+
Pump
Customised
ESC
ENTER To display the
Engine faults in real time Fault detected
Fault Detected Fault occuring now
Customised Fault occuring now No default
+ Press ENTER
+ No alarms
Fault to display the faults +

Detected
Fault detected
Fault occuring now
Actuator sensor
Alarm present
ENTER To display the

stored alarms (faults)
(max 5) Fault detected
Fault Detected Fault since startup
ESC Fault since startup Start of the list
+
To read
the alarms
Fault detected
Example:- Fault since startup
Neutral out of range
+
ESC Fault detected
Fault since startup
End of the list
Sida 7
Här är huvudmenyerna:
N Meny Funktion
1 CALIBRATION Kalibrering av sensorer och potentiometrar. Visning av aktuella

spänningar (Calibration Status = Locked)
2 DISPLAY to display the information on the transmission (thermal engine speed,

pump displacement, anitstall function,....)
3 PUMP CUSTOMIZED to customize the transmission (more or less prompt braking and
acceleration)
4 ENGINE CUSTOMIZED to customize the thermal engine control (higher or lower acceleration
of the thermal engine, engine speed when the tilt system and the
sideshift are on,...)
5 FAULT DETECTED to display the system faults
6 INFORMATION software versions
7 PH PARAMETERS (password) configuration of the system operation parameters
8 EEPROM RESET (password) to reset the control unit memory
9 MOTOR SHIFTING(password) configuration of the parameters controlling the displacement

Shifting of the hydraulic motors
10 ACTUATOR PID (password) configuration of the actuator feedback parameter
1 CALIBRATION
The CALIBRATION menu has two functions:
Calibrating mode
when the parking brake is locked and the “calibration status” parameter is “not locked”, it allows the
calibration and configuration of the system.
Display mode
when the parking brake is not locked or the “calibration status” parameter is “locked” this menu
views the output voltages of the system sensors and the state of some components.
After calibration, release and engage the parking brake again to exit from the “calibration status” mode and
return to the standard operating mode.
Sida 8
CALIBRATION MENU
N SUBMENU CALIBRATION MODE DISPLAY MODE
A Travel pedal calibration of the travel pedal display of the voltage supplied by the
potentiometer for the travel pedal
B brake / inching pedal calibration of the brake pedal display of the voltage supplied by the
potentiometer for the brake pedal
C mast lever calibration of the mast lever display of the voltage supplied by the
potentiometer for the mast lever
D engine calibration calibration of the actuator-thermal display of the voltage supplied by the
potentiometer for the actuator
E pump neutral calibration of the pump in neutral display of the voltage supplied by the
position potentiometer for the hydrostatic pump
F max forward speed limiting of the truck max display of truck forward speed
forward speed (as a percentage of the max speed)
G max reverse speed limiting of the truck max display of the truck reverse speed
reverse speed (as a percentage of the max speed)
H parking brake set definition of the brake pedal displays the brake pedal position in
position in which the mechanical which the mechanical brake is locked
pedal is engaged
I min engine speed definition of the minimum engine displays the minimum engine RPM
RPM
L max engine speed definition of the maximum engine displays the maximum engine RPM
RPM
M pump pot. Inverted definition of the connections type displays the connections type
of the pump potentiometer of the pump potentiometer
N calibration status validations and invalidation of the status of the calibration menu
calibration menu
O reduced speed limiting of the truck max. Speed displays if the truck reduced speed is
(Enable / disable)
P number of teeth definition of the number of teeth display of the number of teeth/rev
Per engine rev (speed sensor in
The thermal engine
R power supply measures the supply voltage of measures the supply voltage of
Control unit the control unit
S sensor excitation measures the supply voltage of measures the supply voltage of the
Sensors sensors
T multi disc brake definition of the type of brake type of brake used
Used
For the TCS to operate correctly, the voltage values read by the potentiometers in the pedals, the mast
system and the motor actuator must not exceed the limits set. If the mechanical limit stops of the
potentiometer are not properly adjusted, the voltage supplied by the potentiometer is exceeded. The range
of values allowed by the control unit disables the calibration procedure.
Trouble may also occur after a correct calibration if, for whatever reason, the limit stop is modified.
Sida 9
CALIBRATION AND FIRST START UP OF THE TRANSMISSION SYSTEM
The system calibration is to be performed when the thermal engine is stopped.

The following are to be calibrated:
Potentiometer for the travel pedal (TRAVEL PEDAL)

Potentiometer for the brake pedal (BRAKE / INCHING PEDAL)
Potentiometer for the mast lever (MAST LEVER)
Potentiometer for the hydrostatic pump (PUMP NEUTRAL)
While calibrating, check the parameters below:
Max. forward speed (truck max speed) 100%

Max reverse speed (truck max speed) 100%
Parking brake set (brake setting) 95%
Min engine speed(minimum engine RPM) 850
Max engine speed (maximum engine RPM) 2250
Pump pot. Inverted (with Potentiometer Hall effect only) 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 speed”parameter in the “DISPLAY” menu.
Calibrate the actuator (ENGINE CALIBRATION)
Press the accelerator pedal; the actuator has to rotate clockwise and the voltage of the
feedback potentiometer in the actuator has to increase (such voltage may be measured in the
“engine calibration” parameter in the “calibration” menu after engaging the parking brake).
Once the calibration procedure is over, check the transmission operation (wheels must be 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
SEE THE DIAGRAM FOR USING CONSOLE

A) TRAVEL PEDAL CALIBRATION
For calibrating, voltages are not to exceed the following ranges (voltages may be read in display mode).
Pedal in its min. position 0,35 - 2,4 volts (7 - 48% of the supply voltage)
Pedal in its max.position 2,6 - 4,65 volts (52 - 93% of the supply voltage)
(the supply voltage of all sensors is of 5 volts)
B) BRAKE / INCHING CALIBRATION
Defines the voltage values corresponding to the min. and max. positions of the brake pedal ( and the
“ inching” function.
Pedal in its min. position 0,35 - 2,4 volts (7 - 48 % of the supply voltage)
Pedal in its max. position 2,6 - 4,65 volts (52 - 93% of the supply voltage)
C) MAST LEVER CALIBRATION
Defines the voltage values corresponding to the maximum and minimum positions of the mast lever.

Lever in neutral position 0,35 - 2,3 volts (7 - 46 % of the supply voltage)
Lever fully pulled 2,4 - 4,65 volts (48 - 93% of the supply voltage)
D) ENGINE CALIBRATION
Matches the actuator position angle (voltage of the actuator feedback potentiometer) with the engine
speed value.
For calibration, voltages are not to exceed the following ranges:
Actuator in its min. position 0,35 - 2,4 volts (7 - 48 % of the supply voltage)
Actuator in its max. position 2,6 - 4,65 volts (52 - 93% of the supply voltage)
Such values may be viewed if the parking brake is engaged.
The control unit automatically controls the actuator by bringing it to its minimum and maximum positions
(that are determined by the mechanical limit stops located on the actuator support). With respect to the
min.and max. Positions, TCS reads the min.and max RPM as well as some intermediate values.
The limit stops are to be obtained on the actuator, not on the injection pump.
E) PUMP NEUTRAL CALIBRATION

Defines the voltage corresponding to the neutral displacement position of the hydrostatic pump (feedback
potentiometer).
The voltage value must not exceed the following range 2.48 to 2.52 volts.
(In display mode and when the truck is running, the voltage value must vary. When the wheels rotate
forward, the potentiometer voltage must rise to 5 volts and remain constant).
Sida 11
SEE THE DIAGRAM FOR USING CONSOLE

F) MAX FORWARD SPEED

This parameter (expressed as a percentage of the truck’s forward max. speed) limits the travel speed.
This parameter may be modified (in calibration mode).
G) MAX REVERSE SPEED

This parameter (expressed as a percentage of the truck’s reverse max speed) limits the travel speed.
This parameter may be modified (in calibration mode).
H) PARKING BRAKE SET

This parameter defines the stroke of the brake pedal necessary to engage the mechanical brake. The
standard value is 95%. It is suggested that this value is not changed. Limit values: 90 to 95%.
I) MIN ENGINE SPEED

This parameter defines the minimum engine RPM (standard value 850).
L) MAX ENGINE SPEED

This parameter defines the maximum engine RPM (standard value 2250)
M) PUMP POT. INVERTED

This parameter defines the type of connections at the pump potentiometer. This parameter is present with
the Hall potentiometer software only.
N) CALIBRATION STATUS
This parameter enables or disables the calibration mode.
O) REDUCED SPEED
This parameter expressed if the truck reduced speed is activated (enable / disable). This parameter may
be modified (in calibration mode).
P) NUMBER OF TEETH
This parameter defines the number of pulse per revolution of the thermal engine sent by the speed sensor
to the control unit.
R) POWER SUPPLY
Displays the supply voltage of the control unit: battery voltage (12 volts)
S) SENSOR EXCITATION
This parameter displays the voltage supplied by the control unit to the sensors. Correct value: 5 volts.
T) MULTI DISC BRAKE

this parameter defines whether the multidisc brake is fitted or not (the multidisc brake is an on/off brake,
i.e. It is not gradual.
Sida 12
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)
Sida 13
3) PUMP CUSTOMIZED
Sets the parameters for the control of the hydrostatic pump.

This parameter is used to modify the acceleration and deceleration of the truck.
Enable the program to modify such values (calibration status - not locked).
TRAVEL PEDAL INC.

This parameter defines how long the pump takes to reach its max displacement when the travel pedal
is fully pressed (the higher the value of this parameter, the less the acceleration of the truck).
TRAVEL PEDAL DEC.

This paramter defines how long the pump takes to reach its neutral displacement mode when the
travel pedal is released (the higher the value of this parameter, the less the deceleration of the truck
during the hydrostatic braking).
HARD BRAKING RATIO

This parameter (%) changes the release braking value (travel pedal dec) as the following table:
Braking times of the truck function of the two parameters

“Travel pedal dec” (s) and Hard braking ratio”(%)
Travel pedal dec (s) 2 5 7 10 Bromskraft vid låg

hastighet
Hard braking ratio (%)
0 2 5 7 10
17 1.7 3.8 5 6.5
50 - 2.8 - - Bromskraft vid hög

hastighet
67 1.6 2.5 3.1 3.6
83 - 2.3 - -
100 1.3 2.1 2.5 2.9
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 it’s 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
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
5) FAULT DETECTED
Displays the system faults.
- FAULT OCCURRING NOW

Press enter to display the current fault
- FAULT SINCE START UP

Press (+) and (-) to display the last five faults occurred
- FAULT MESSAGES SHOWN ON THE CONSOLE
“Excitation Sensor” The excitation voltage of the sensor is <2V or >5.5V
“Power Supply” The supply voltage of TCS control unit is <9.5V or >32V for more
than 2 secs long
“Travel Pedal Sensor” The signal (voltage) of the travel pedal potentiometer has
exceeded the limits set while calibrating
“Brake / Inching pedal Sensor“ The signal (voltage) of the brake pedal potentiometer has
exceeded the limits set while calibrating
“Mast lever Sensor” The signal (voltage) of the mast lever has exceeded the limits
set while calibrating
“Actuator Sensor” The signal (voltage) of the feedback potentiometer has exceed
the limits set while calibrating
“Error on Actuator control loop” >20% error, for more than 0.5secs, between the actuator setpoint
and the potentiometer feedback
“Error on pump control loop” >20% error, for more than 0.5 secs, between the pump control
signal and the potentiometer feedback signal in the pump.
“Feed back error“ Pump feed back is <0.25V or >4.75V
“Neutral out of range” During calibration the pump neutral is outside of the fixed limits
“Pump neutral drift too high” The difference between the pump in neutral calibration function
and the pump in neutral while the values are fed is >341 mV
“Feedback moves too fast” The pump feedback changes too fast in comparison with the real
change of the pump displacement.
“Eeprom error at address” One parameter at least is outside of the field of acceptable values
“Direction switches error” The TCS control unit takes contemporarily the forward and reverse gear
(running mode) started
“Other default” Other faults
6) INFORMATION
Displays the SOFTWARE version
Sida 16
7) PH PARAMETERS
- PASSWORD
Press the key / esc then (+) or (-) in order to have access to the rest of the menu
- PUMP NEUTRAL OFFSET

This parameter is used to offset pump feedback
- ENABLE LIMIT CHANGE

During the calibration of the pedals, the auxiliary levers and the actuator, it is possible that the minimum
and maximum values obtained on the potentiometer do not conform to the limits fixed by the programme.
It is possible to modify these limits.
In the menu calibration, authorise the mode calibration. Go into the menu “PH PARAMETERS”and into
the menu “ENABLE LIMIT CHANGE”.
It is necessary to be in “NOT LOCKED”
- INVERSION BRAKING
This function is used to have a braking action if the direction switch is set to the reverse position during the
operation of the machine (plug braking)
The braking action will be proportional to the position of the travel pedal.
- INVERSION DISPLACEMENT
This parameter sets the inversion time range from 0 - 10 seconds
- DISABLE PUMP DELAY

Parameter which defines the time delay of the negative brakes releasing (standard values 30 cycles). It is
the delay for the brakes releasing after the pump has reset its displacement. In order to have the brakes
release in a short time, for example on a ramp, reduce the value (min 5 max 45 cycles).
- REGULATOR OFFSET
This is the acceptable difference between the requested engine speed and the measured engine speed.
If this value is exceeded, the antistall function is active
- ANTISTALL COEF
coefficient applied to the action of the anitstall function.
The parameter change from 3 to 8
The higher the value the more the displacement will decrease
- DERIVE ANTISTALL
Definition of the derived gain for the antistall action. The parameter is a variable number from 10 - 30
The higher the number the more sensitive antistall is to RPM variations
- FULL STROKE CMD

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

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

This value is the complementary value of engine delay dec. It is to take into account during the engine deceleration
This paramter is the time taken for engine deceleration.
Sida 17
8) EPROM RESET
This menu is used to reset the data of the EEPROM
- PASSWORD
Enter the password (4 numbers) with the digital key and then press enter.
Press the key / esc then (+) or (-) in order to have access to the rest of the menu
- ALL EEPROM RESET

Press the enter key to cancel the list of statistics
- FAULT LIST RESET

Press the enter key to cancel the list of the detected faults.
Sida 18

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

Brake/inching pedal sensor Brake pedal
Mast lever sensor Mast lever
Actuator position out of range Thermal engine actuator
Feed back error Hydrostatic pump potentiometer
1) TRAVEL PEDAL
Travel pedal position out of range (Error message)
The terminal will switch from the

Release the parking brake CALIBRATION MODE to the
DISPLAY MODE
The terminal will display the

Select the voltage that is supplied
TRAVEL PEDAL submenu from the potentiometer in
the travel pedal
Yes Voltage = 0 volts? No
Hold down the [ENTER] key and

Check the potentiometer wiring check if voltage changes when
Yes Does voltage change?
No
Press the [ENTER] key to Check the potentiometer wiring

measure the min. and max.
Voltage supplied by the
potentiometer
Adjust the mechanical limit stop of

Calibrate the travel pedal
Sida 19

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

DISPLAY MODE

BRAKE/INCHING PEDAL submenu from the brake pedal
potentiometer

No

potentiometer
Adjust the mechanical limit stop of

Calibrate the brake pedal
Sida 20

3) MAST LEVER
Mast lever sensor out of range (Error message)

DISPLAY MODE

MAST LEVER submenu from the mast lever
potentiometer

No

potentiometer
Adjust the shims of the

potentiometer support bracket so
the ranges set (see “mast lever
calibration”) If the lever is moved
forward from its middle position
(for forks lowering) voltage is not
to decrease.
Calibrate the mast lever
Sida 21

4) THERMAL ENGINE ACTUATOR
Actuator position out of range (Error message)

DISPLAY MODE

ENGINE CALIBRATION submenu by the potentiometer of
the actuator
Engage the
parking brake
Yes Voltage = 0 volts? No and press the
accelerator
pedal
Check the electrical connections check if voltage changes while the
of the actuator actuator rotates
No
Press the [ENTER] key to Check the actuator electrical

measure the min. and max. connections
actuator potentiometer
Adjust the length of the tie rod so

the ranges set (see “engine
calibration”)
Calibrate the actuator
Sida 22

5) POTENTIOMETER IN THE HYDROSTATIC PUMP
Feed back error (Error message)

DISPLAY MODE

PUMP NEUTRAL submenu by the potentiometer in the
hydrostatic pump
Yes Voltage = 0 volts or 5 volts No
Check the potentiometer Voltage = 2.48 - 2.52 volts

electrical connections Yes
No
Engage the parking brake, Check the potentiometer wiring, lift

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

CALIBRATION mode and clibrate
the pump potentiometer zero.
Sida 23
SYSTEM FAULTS AND FAILURES
Any system failure is signalled by the flashing warning light located beside the valve bank levers.
The frequency indicated the failure importance.
The kind of fault is displayed in the FAULT DETECTED menu (FAULT OCCURRING NOW SUBMENU).
If the warning light blinks slowly (0.5Hz) the fault is not very important; the machine is able to drive.
The signal voltage of the travel pedal Check the potentiometer

potentiometer has exceeded the limits set wiring.
while calibrating. Check if the voltage values at
Travel pedal sensor Connector disconnected or wrong wiring. the pedal stop do not exceed
the preset limits.
Adjust the pedal limit stop.
Calibrate the pedal again.
The signal voltage of the brake pedal Check the potentiometer

Brake/inching pedal sensor Connector disconnected or wrong wiring. the pedal stop do not exceed
the preset limits.
Adjust the pedal limit stop.
Calibrate the pedal again.
The signal voltage of the mast lever Check the potentiometer

Mast lever sensor Connector disconnected or wrong wiring. the lever stop do not exceed
the preset limits.
Adjust the lever limit stop.
Calibrate the lever again.
The signal voltage of the feedback Check the potentiometer

Actuator sensor while calibrating. Check if the voltage values at
Connector disconnected or wrong wiring. the actuator stop do not
exceed the preset limits.
Adjust the actuator limit stop.
Calibrate the actuator again.
Error on actuator control .20% error, for more than 0.5 secretary.. Check the actuator wiring.
loop Between the actuator set point and the Check the actuator
This message may be potentiometer feed back. potentiometer output signal. If
displayed if the accelerator Connector disconnected or wrong wiring. you press the accelerator
is pressed(green light on) pedal, the actuator will rotate
when the engine is off and forward and the voltage -
the brake is unlocked. measured in engine calibration
when the brake is released -
will increase.
Power supply out of range The supply voltage of TCS control unit is Check the supply voltage value.
not within the 9.5 - 48 volt range.
Sida 24
SYSTEMFEL OCH FELMEDDELANDEN

Om varningslampan blinkar snabbt (1hz) är felet allvarligt, och maskinen går ej att köra!
FELMEDDELANDE ORSAK KONTROLLERA
Felaktig matningsspänning till sensorer - Att spänningen ligger på 5 volt

och microbrytare. +/- 5%
Excitation voltage
Fel signal från feedback-potentiometern - Att spänningen från feedback-

på pumpen. potentiometern ligger på 2.5 +/-
0.15 volt när pumpen står i
Feedback error neutralläge.
Fel signal från feedback-potentiometern - Att spänningen från feedback-

på pumpen, med pumpen i neutralläge. potentiometern ligger på 2.5 +/-
0.15 volt när pumpen står i
Neutral out of range neutralläge.
Fel signal från feedback-potentiometern - Kablaget till feedback-

på pumpen. Avvikelsen mellan feedback potentiometern och EDC
Error on pump control loop signalen och det förväntade värdet kontrollen.
tillbaka till TCS kontrollen är >20%, i mer
än 0.5 sec. - Att feedback signalen ändrar
sig när man ökar körhastigheten.
- Att Min och Max spänningen

från feedback potentiometern är
konstant, och att värdet är lika
varje gång. Spänningen skall
stiga till upp emot 5 volt.
Sida 25
FELSÖKNING
Typ av fel Möjlig orsak
Motorn går men ingen drivning. Kontrollera p-broms brytarens funktion i menyn: "DISPLAY /
Pumpen vinklar inte ut, varken BRAKE SWITCH" (set / not set).
framåt eller bakåt.
Kontrollera fram&back brytarnas funktion i menyn: "DISPLAY /
DIRECTION SWITCH" (neutral / forward / reverse).
Drivningen fungerar och pumpen Kontrollera varvtalssensorns funktion i menyn: "DISPLAY/ENGINE

vinklar ut, men motorn varvar SPEED" - värdet skall vara relevant till det verkliga motorvarvet.
inte upp.
Kontrollera feedback signalen från pump-potentiometern i menyn:
"CALIBRATION / PUMP NEUTRAL" (calibration status = locked)
Kontrollera gasmotorn funktion i menyn: "CALIBRATION / ENGINE

CALIBRATION" (calibration status = locked)
Drivningen fungerar och motorn Kontrollera lyftpotentiometerns funktion i menyn:

varvar upp vid körning. "CALIBRATION / MAST LEVER / MAST SENSOR PRESENCE"
Inget gaspådrag när man (Yes=1/ No=0)
använder hydraulfunktionerna.
Kontrollera lyftpotentiometerns funktion i menyn:
"CALIBRATION/MAST LEVER" (calibration status = locked)
Kontrollera Tilt/Aux brytarnas funktion i menyn: "DISPLAY / MAST

SWITCH" (set / not set).
Varken drivning eller gaspådrag Om varningslampan är släckt:

fungerar. Kontrollera varvtalssensorns funktion i menyn: "DISPLAY/ENGINE
SPEED" - värdet skall vara relevant till det verkliga motorvarvet.
Om varningslampan blinkar sakta:

Kontrollera signalen från gaspedalen i menyn: "CALIBRATION/
TRAVEL PEDAL CALIBRATION" (calibration status = locked).
Om varningslampan blinkar snabbt:

Kontrollera spänningsmatningen till sensorerna i menyn:
"DISPLAY / SENSOR EXCITATION" (5 volt).
Kontrollera spänningsmatningen till TCS enheten i menyn:

"DISPLAY / POWER SUPPLY"
Kontrollera feedback signalen från pump-potentiometern i menyn:

"CALIBRATION / PUMP NEUTRAL" (calibration status = locked)
Kontrollera kablaget till EDC-kontrollen.
Sida 26

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Service Manual

BT Svenska AB < Tillbaka till Index

CESAB S.p.a. reserves all rights of

The text and the numbering system

CESAB reserves the right to make any

BOLOGNA’S FACTORY, AFTER SALES SERVICE

TECHNICAL DATA ............................................................................................. p. 6

OPERATOR’S SEAT .......................................................................................... p. 8

ENDOTHERMIC ENGINE .................................................................................. p. 13

ELECTRONIC HYDROSTATIC TRANSMISSION .............................................. p. 18

HYDRAULIC DIAGRAM ...................................................................................... p. 24

HYDROSTATIC PUMP ......................................................................................... p. 26

HYDRAULIC MOTOR ........................................................................................... p. 28

ELECTRIC SYSTEM ............................................................................................ p. 33

Engine actuator ................................................................................................. p. 35

MENUS AND PARAMETERS FOR THE TCS SYSTEM ..................................... p. 39

WHEELS / TYRES .............................................................................................. p. 59

STEERING UNIT ................................................................................................ p. 60

HYDRAULIC DISTRIBUTOR ............................................................................. p. 63

LIFTING THE TRUCK ........................................................................................ p. 71

FOOT PEDALS VERSION

B Pedals consist of:

HAND DIRECTION LEVER VERSION

One travel pedal (E)

BALANCED PEDAL VERSION

2) Coolant temperature level

3) Fuel level warning light

4) Generator warning light

6 6) Parking brake on warning light

7) Engine oil pressure warning light

8 8) Direction indicator on warning light (optional)

9 9) Electronic hour counter

10 10)Coolant temperature warning light

11 11)Transmission oil temperature warning light

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

13 13)Warning light (not used)

14 14)Warning light (not used)

15 15)Air filter clogged warning light (replace filter)

- the operator must be seated

L N SET OF LEVERS - LOAD HANDLING

K K) Lifting control (yellow).

SERIAL N° DRAW-BAR PULL (1h)

BATTERY MASS SERVICE MASS

CARRELLI ELEVATORI S.p.A. CESAB LDT

ENGINE KUBOTA 3300 - E

1 - Intake manifold 10 - Oil filler plug

KUBOTA V 3300 ENGINE

Compression ratio 22,6:1

SAE J1349 power 46 kW

Compression ratio 8:1

SAE J1349 power 43 kW

Oil sump (capacity) 4 L

OIL CHANGE AND ENGINE OIL FILTER REPLACEMENT

CHANGING OIL AND FILTER

To replace the oil and the filter, proceed as follows:

TOPPING UP WITH COOLANT

Every 250 hours

Every 2000 hours

ANTIFREEZE APPLICATION RANGE

10% 20% 30% 40% 50% % VOLUME OF ANTIFREEZE

-4 C -10 C -17 C -24 C -40 C FREEZING TEMPERATURE

101 C 102 C 104 C 106 C 109 C BOILING TEMPERATURE

Disassembling and cleaning the filter