BT Cargo Range Forklift CBD 2.5 CBD 3.0 CBD 3.5 CBG 2.5 CBG 3.0 CBG 3.5 Workshop Service Manual

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This workshop service manual covers the BT Cargo Range Forklift Truck models, including CBD 2.5, CBD 3.0, CBD 3.5, CBG 2.5, CBG 3.0, and CBG 3.5. BT, now part of...

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Taper: Forklift

Distributeur:

UGS: 72767

Mots clés: BT CBD 2.5 CBD 3.0 CBD 3.5 CBG 2.5 CBG 3.0 CBG 3.5 CBG Models Forklift Forklifts Kubota Material Handling

Variantes de produits

Description

This workshop service manual covers the BT Cargo Range Forklift Truck models, including CBD 2.5, CBD 3.0, CBD 3.5, CBG 2.5, CBG 3.0, and CBG 3.5. BT, now part of Toyota Material Handling, is recognized for producing robust and reliable material handling equipment. The Cargo Range represents versatile forklifts designed for various logistics and warehouse applications, featuring advanced electronic hydrostatic transmissions and optional Kubota or Continental engines. These trucks are engineered for durability and efficiency, making them a trusted choice for demanding operational environments. This comprehensive 120-page manual in English provides detailed guidance on the operation, maintenance, and repair of your BT Cargo Range forklift. It covers essential systems such as the powertrain, brakes, electrical, and hydraulic systems, along with chassis and running gear. Specific procedures for engine and transmission maintenance, brake system checks, steering adjustments, and mast and fork inspections are included. The manual also offers in-depth troubleshooting, diagnostics for electronic control systems like the TCS, and calibration procedures, ensuring that technicians and owners can effectively maintain the vehicle's performance and safety.

🏷️ Basic Information

Identification

Make:

Model:

Cargo Range Forklift Truck

Codes

Covered Models:

CBD 2.5, CBD 3.0, CBD 3.5, CBG 2.5, CBG 3.0, CBG 3.5

👋 Introduction

Market Position

Classification:

Industrial Forklift Truck

Key Features

Manual Highlights:

Original factory documentation, detailed illustrations, circuit diagrams, comprehensive coverage.

Competitive Analysis

Target User:

Forklift technicians, maintenance personnel, and fleet managers responsible for the upkeep of BT Cargo Range forklifts.

📋 Manual Details

Coverage Areas

Manual Scope:

Operation, maintenance, and repair

Page Count

Pages:

Manual Type

Type:

Workshop Service Manual

Language

Language:

English

Format

Digital Format:

PDF Download

📖 Manual Coverage

Systems Covered

Powertrain:

Endothermic Engine (Kubota/Continental), Electronic Hydrostatic Transmission (Pump, Motor, Maintenance)

Brakes:

Service Brake, Parking Brake, System Diagrams, Checks, Towing Procedures

Electrical System:

Battery, Electric Components, Fuse Panels, Engine Actuators, Potentiometers, Microswitches, Wiring Diagrams

Hydraulic System:

Hydraulic Diagrams, Hydrostatic Pump, Hydraulic Motor, Hydraulic Distributor

Control Systems:

TCS System (Menus, Parameters, Calibration, Fault Detection), Display Information, Customized Settings (Pump, Engine)

Chassis And Running Gear:

Operator's Seat, Dashboard, Wheels/Tyres, Steering Unit (Control, Axle, Bearings), Masts (Cylinder Components, Inspection, Lubrication, Installation, Safety Stops, Chains, Forks)

Operator Interface:

Pedals, Service Brake, Dashboard Indicators, Parking Switch, Lever Sets, Capacity Plates.

Auxiliary Systems:

Wheels, Tyres, Steering Unit, Masts (including hydraulic cylinders, chains, and forks).

Procedures Included

Engine Maintenance:

Oil Change, Oil Filter Replacement, Coolant Topping Up, Air Filter Service, Cyclone Prefilter, Engine Running-in

Transmission Maintenance:

Filter Replacement, Transmission Oil Change

Brake Procedures:

Service Brake Checking, Brake Release for Towing

Calibration And Diagnostics:

Transmission System Calibration and First Start-up, Troubleshooting of System Faults and Failures

Steering System Maintenance:

Bearings Adjustment

Mast And Fork Maintenance:

Cylinder Inspection, Chain Inspection, Fork Inspection

Lifting And Handling:

Truck Lifting Procedures, Hooking Points Identification

Engine Diagnostics:

Kubota engine data and Continental engine data are provided, suggesting diagnostic information for both.

Electrical System Repair:

Includes wiring diagrams, fuse panel information, and troubleshooting for electrical components.

Technical Depth

Depth:

Comprehensive, covering routine maintenance, troubleshooting, diagnostics, and component-level repair.

Diagnostic Capabilities:

Covers electronic system diagnostics including the TCS system, fault detection, and calibration errors.

Complexity Of Repairs:

Covers everything from basic fluid checks and filter changes to component-level diagnostics and potential rebuild guidance for complex systems like the hydrostatic transmission and masts.

📊 Manual Specifications

File Format

PDF Quality:

High quality, with searchable text and navigation bookmarks.

Searchable Text:

Navigation Bookmarks:

Print Quality

Printable:

All pages are printable.

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Options:

Kubota Engine (specific model not detailed, but common in industrial applications), Continental Engine (specific model not detailed).

Engine Maintenance Procedures:

Specific instructions for oil change and engine oil filter replacement, topping up coolant, air filter servicing, and cyclone prefilter cleaning/replacement.

Engine Identification:

Covers both Kubota and Continental engine variants, providing specific data for each where applicable.

Performance

Engine Maintenance:

Detailed procedures for oil changes, filter replacements, coolant checks, and air intake systems.

Fuel System

Fuel Type:

Likely Diesel (common for forklifts of this capacity range, though not explicitly stated in the product info).

🔧 Transmission

Standard

Type:

Electronic Hydrostatic Transmission

Transmission Components:

Details on hydrostatic pump, hydraulic motor, and closed-loop hydrostatic transmission principles.

Features

Transmission Operation:

Explanation of closed-loop hydrostatic transmission, axial piston variable displacement pumps, and electronic control system functions.

Transmission Maintenance:

Procedures for filter replacement and transmission oil changes, including specifications (likely provided within the manual).

Electronic Transmission Control:

Detailed explanation of the electronic hydrostatic system and its main functions, including custom pump and engine settings.

📐 Dimensions

Weights

Capacity Variants:

2.5 Ton (2500 kg), 3.0 Ton (3000 kg), 3.5 Ton (3500 kg) rated operating capacities.

Weight Information:

Service weights are not specified but will vary by specific model configuration and mast type. Capacity plates provide load information.

Exterior

Lift Height:

Not specified, but mast descriptions and cylinder inspection imply various lift height configurations are possible.

Cargo

Load Handling:

Covers set of levers for load handling, capacity plates for identifying load limits.

🛡️ Safety Features

Ratings

Safety Focus:

The manual emphasizes safety through specific procedures for mast installations, fork inspections, and steering unit adjustments.

Active Features

Control Systems:

TCS (Traction Control System) functionality and parameters, contributing to safe operation.

Control System Parameters:

Information on TCS system parameters and custom engine/pump settings that influence safe operation.

Passive Features

Component Safety:

Safety limit stops for fork mounting carriages, mast component inspection procedures.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Industrial forklift, not equipped with typical automotive infotainment).

Driver Assistance

Electronic Controls:

Advanced Electronic Hydrostatic Transmission control, TCS (Traction Control System), and dashboard indicators are key technological features discussed.

Electronic Components Details:

Details on potentiometers, microswitches, engine actuators, and fuse holding panels within the electrical system.

Calibration Procedures:

In-depth procedures for calibrating the transmission system and first start-up, critical for electronic hydrostatic systems.

Connectivity

Connectivity Features:

N/A (Industrial forklift, not equipped with typical automotive connectivity features like Bluetooth or Wi-Fi).

🔧 Maintenance

Service Intervals

Scheduled Maintenance:

A dedicated 'Table for the truck maintenance during the running-in stage' and 'Table for the maintenance schedule' are included, providing specific intervals for various checks and fluid services.

Running In Maintenance:

Specific maintenance tasks and checks recommended during the initial operating period of the truck.

Fluid Specifications

Oil And Grease Specs:

A 'Table for oil and grease specifications' is provided, indicating detailed fluid and lubricant recommendations for engine, transmission, hydraulic systems, and lubrication points.

Lubrication Points:

Mast lubrication procedures are detailed, suggesting specific points and lubricants.

Known Issues

Troubleshooting Coverage:

The manual includes sections on 'System faults and failures' and 'Troubleshooting,' offering guidance on diagnosing and resolving common operational problems.

Troubleshooting Tips:

Sections dedicated to troubleshooting problems occurring during calibration and general system faults and failures.

📚 Vehicle History

Brand Heritage

Manufacturer Profile:

BT is a well-established manufacturer of material handling equipment, now part of Toyota Material Handling. Known for robust and reliable forklift trucks.

Model Evolution

Model Line:

The Cargo Range likely represents a line of versatile forklifts designed for various warehouse and logistics applications, featuring both counterbalanced (CBD) and potentially other configurations (CBG, though less common identifier for counterbalanced).

Production

Production Years:

Specific production years are not provided, but the manual covers models likely produced from the late 1990s to mid-2010s, based on common industrial equipment lifecycles and technology featured (e.g., electronic hydrostatic transmissions).