CBD/G
2.5
3.0
3.5
Service Manual
Cargo Range
CARGO 2.5
< Tillbaka till Index
SERVICE MANUAL
page 3
INTERNAL
COMBUSTION
2,5 - 3,0 - 3,5 t
BOLOGNA’S FACTORY, AFTER SALES SERVICE
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.
SERVICE MANUAL
page 4
2,5 - 3,0 - 3,5 t
INTERNAL
COMBUSTION
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
SERVICE MANUAL
page 5
INTERNAL
COMBUSTION
2,5 - 3,0 - 3,5 t
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
SERVICE MANUAL
page 6
2,5 - 3,0 - 3,5 t
INTERNAL
COMBUSTION
TECHNICAL DATA
SERVICE MANUAL
page 7
INTERNAL
COMBUSTION
2,5 - 3,0 - 3,5 t
SERVICE MANUAL
page 8
2,5 - 3,0 - 3,5 t
INTERNAL
COMBUSTION
FOOT PEDALS VERSION
Pedals consist of:
- two travel pedals, one forward pedal (A)
and one reverse pedal (B)
- a service brake pedal (C)
One travel pedal (E)
HAND DIRECTION LEVER VERSION
Lever of direction selector (D)
1 forward speed
0 neutral
2 reverse speed
1
o
2
ê
é
o
D
C
B
A
E
C
G
C F
BALANCED PEDAL VERSION
Forward pedal (F)
Reverse pedal (G)
Brake pedal (C)
SERVICE BRAKE
Foot service brake (C) controls a hydrostatic braking
in the first part of the stroke by means of the electronic
control unit; if fully pressed, it engages the oil-bath disc
brakes (over the front driving wheels).
SERVICE MANUAL
page 9
INTERNAL
COMBUSTION
2,5 - 3,0 - 3,5 t
DASHBOARD
During ordinary operation, all warning lights in the dashboard are to be off.
9 13 12 11 10
15
14
8 6 5 7 4 3 2 1
1 2
4
3
1) Fuel gauge
2) Water temperature indicator
3) Fuel level warning light
4) Generator warning light
5) Glow plug warning light (Diesel engine)
6) Parking brake-on warning light
7) Oil pressure warning light
8) Indicator light (optional)
9) Electronic hour counter
10) Water temperature warning light
11) Transmission oil temperature warning light
12) Hydraulic oil filter clogged warning light
13)Warning light (not used)
14) Warning light (not used)
15) Warning light indicating air filter clogged
A) Parking switch;
B) Electronic failure warning light
If the warning light blinks during ordinary operation, this indicates
a failure in the electronic control unit; the vehicle will stop.
C) Ignition key
D) Emergency push-button; it acts as an emergency brake.
CAUTION
The vehicle could instantaneously stop if buttons (A) and (D)
are pressed; never press those buttons during the truck ordinary
operation.
DASHBOARD INDICATORS
1) Fuel gauge
2) Coolant temperature level
Indicates the coolant temperature.
The pointer must never reach the red sector; the working temperature
corresponds to 95 °C.
3) Fuel level warning light
The fuel level warning light turns on when approx. 5.5 l of fuel
are left in the tank.
4) Generator warning light
That warning light is to be off when the engine is running. If not,
it indicates that the alternator does not supply any current for the
battery or the electric system charge. This may be caused by the
breaking of the belt that drives the alternator pulley, or by a failure
of the alternator.
D
B
C
A
SERVICE MANUAL
page 10
2,5 - 3,0 - 3,5 t
INTERNAL
COMBUSTION
5) Glow plug warning light (Diesel engine).
This warning light turns on when the ignition key is in position (2);
6) Parking brake on warning light
7) Engine oil pressure warning light
During ordinary operation, this warning light is to be off.
If it turns on, immediately check the oil level in the engine. That warning
light could turn on when the engine is idling and hot, due to a lesser
lubricant viscosity, even if no failure has occurred.
8) Direction indicator on warning light (optional)
9) Electronic hour counter
It indicates the working hours and hour fractions of your truck; it is controlled
by the contact key and has the function to simplify scheduled maintenance
programming.
10)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)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)Transmission oil filter clogged warning light (replace filter)
13)Warning light (not used)
14)Warning light (not used)
15)Air filter clogged warning light (replace filter)
8
7
9
10
11
5
6
12
13
14
15
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BT CBD / CBG 2.5 3.0 3.5 Forklift Cargo Range Service Repair Workshop Manual
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Description
This is a comprehensive service repair workshop manual for the BT CBD / CBG 2.5 3.0 3.5 Forklift Cargo Range. The manual features easy-to-read text sections with high-quality diagrams and instructions, making it suitable for both DIY enthusiasts and experienced mechanics. It includes step-by-step instructions and detailed exploded pictures and diagrams to effectively complete the required job.
Models Covered:
- BT Forklift CBD 2.5 25 Cargo Range
- BT Forklift CBD 3.0 30 Cargo Range
- BT Forklift CBD 3.5 35 Cargo Range
- BT Forklift CBG 2.5 25 Cargo Range
- BT Forklift CBG 3.0 30 Cargo Range
- BT Forklift CBG 3.5 35 Cargo Range
Service Repair Manual Covers:
- Data Sheet
- Operators Seat
- Lifting Accelerator Device
- Engine Features
- Hydrostatic Transmission
- Adjustments Value
- Traction, Brake/Inching And Lifting Device
- Radial Hydraulic Motors
- Hydrostatic Transmission Oil/Filters
- Hydrostatic Transmission Trouble Shooting
- Brakes
- Electric System
- Steering Control
- Control Valve
- Mast Group
- Lifting Of The Truck
- L.p.g. System
- Initial Timing Adjustment
- Oil- Grease - Coolant
- Maintenance Times Table
- And More......
File Format: .PDF
Compatibility: All Versions of Windows & Mac
Language: English
Requirements: Adobe Reader & Win
No waiting, all pages are printable. The BT CBD / CBG 2.5 3.0 3.5 Forklift Cargo Range Service Repair Workshop Manual is a cost-effective solution that saves money on postage and packaging. It is an essential resource for maintaining your vehicle.
