AUSA C 200 H, Operator'S Manual

Page 1: ...C 200 H C 200 HI C 200 H x4 C 250 H C 250 HI C 250 HI LE C 250 H x4 C 250 H x4 LE OPERATOR S MANUAL ENGLISH Original Manual ...

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Page 3: ...AUSA Forklift Truck C 200 H C 200 HI C 200 H x4 C 250 H C 250 HI C 250 HI LE C 250 H x4 C 250 HI x4 LE Above chassis number 206 62866 ORIGINAL MANUAL ...

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Page 5: ... an order for spares please contact your Official AUSA Dealer This forklift is designed and intended for off highway use If it is temporarily operated on any public street or highway the state and local laws governing speed size weight brakes and lighting must be complied with For further information you may write FAX or E mail to AUSA Center S L U Apartado P O B 194 08243 MANRESA Barcelona SPAIN ...

Page 6: ... Parking the machine 72 Transporting the machine 73 Recommended fluids and lubricants 76 Maintenance Chart 78 Periodic Maintenance Operations 80 Hydrostatic transmission error conditions 100 Electric circuit 102 Electric circuit C200H C200HI C200H x4 C250HI LE C250H x4 LE 103 Electric wiring C200H C200HI C200H x4 C250HI LE C250H x4 LE 107 Electric circuit C250H C250HI C250H x4 108 Electric wiring ...

Page 7: ... relative to the forklift When handling loads or carrying out maintenance and or repair work the occupational health and safety regulations together with those relative to accident prevention should be observed When driving with the forklift on public highways special care should be taken to ensure compliance with the current legislation for this type of vehicle Highway Code AUSA does not assume r...

Page 8: ...the front and back of the machine as viewed from the operators seat looking forward Identification components 1 Overhead guard 2 Driving and load control Joystick 3 Parking brake switch 4 Driver seat with seat belt 5 Diesel tank 6 Hydraulic tank 7 Forks 8 Lifting mast 9 Rotating beacon 10 Lighting equipment 11 Rear view mirror Identification of the forklift components 1 3 2 4 10 8 6 5 11 9 10 7 ...

Page 9: ...rial number The Vehicle Identification Plate is located at the left of the operators seat fig 1 The Engine Serial Number is located on the left side of the engine fig 3 4 The Chassis Serial Number is located on the right side of the chassis fig 2 Principals components of identification plates The plates of every components not built directly by AUSA for example engines pumps etc are directly appli...

Page 10: ...0 HI 7ft 0 6in 11in 15 3in 4ft 6 1in 4ft 11 5in 5ft 11 2in R 9ft 2 2in 8ft 6 4in 5 1in 1 8in 2 01ft 13ft 11 1in C 250 H x4 6ft 11 5in 12 6in 15 3in 4ft 6 8in 4ft 11 5in 5ft 11 2in R 14ft 5 2in 9ft 6 2in 5 1in 1 8in 2 01ft 13ft 11 1in Dimensions mm A B C D E F G I J K L narrow version wide version C 200 H COMPACT 2010 205 295 1360 1375 R 2800 2600 100 40 610 4240 C 200 H C 200 HI C 250 HI LE 2050 2...

Page 11: ...40 4040 4040 4450 4650 5060 Triplex free lift 14ft 1in Wide Narrow HI 4ft 4in 7ft 4 5in 7ft 7 5in 17ft 2in 17ft 5in 3640 3640 4250 5060 Triplex free lift 17ft 8in Narrow Wide op 5ft 6in 8ft 6 8in 8ft 9 7in 20ft 7 8in 20ft 11in 2220 3440 2220 4430 Mast chart mm Type of mast Max lifting height mm Front axle Free lift mm Machine height with mast retracted mm Machine height with mast extended mm Pay L...

Page 12: ...091 PSI 420 bar Both models with 2 wheel drive version 2WD and 4 wheel drive version 4WD Permanent 4WD with COMPEN System in Standard Machine 4x4 connectable on demand with Full grip system Directional control The selection of the drive forwards backwards is made using a switch on the lower part of the joystick A lamp in the shape of an arrow lights up on the top of it when a movement mode is sele...

Page 13: ...rpm Monoblock control valve with two spools and selectable solenoid for side shift Restrictor valve to control the speed of the mast lowering with load Oil tank capacity 12 US Gal 45 l Service pressure C 200 H C200HI C 200 H x4 2610 PSI 180 bar C 250 H C250HI C 250 H x4 C 250 HI LE C 250 HI x4 LE 3190 PSI 220 bar Working temperature From 15ºC to 40ºC Vibration and noise levels Sound power level Wa...

Page 14: ...I x4 LE 6900 kg 15 211 lbs The Compact machine has the same weight than the C 200 H HI Load Capacity With the load center of the load at 500 mm see LOAD CHARTS In this manual C 200 H HI C 200 H x4 2 000 Kg C 250 H HI C 250 H x4 C 250 H x4 LE C 250 HI x4 LE 2 500 Kg With the load center at 24 inches 600 mm see LOAD CHARTS In this manual C 200 H HI C 200 H x4 4040 lbs 1835 Kg C 250 H HI C 250 H x4 C...

Page 15: ...d guard which complies with the ISO 3449 and ISO 3471 ASME B56 6 standards It provides protection against falling objects and together with the mast provides protection should the forklift overturn The seat belt is an important part of the safety system and should always be fastened before starting to operate the forklift In the event of the forklift overturning if the seat belt is not fastened th...

Page 16: ...er extension from face of forks D inches 24 28 32 36 40 44 48 D G G LBS MAXIMUM FORKLIFT LOAD ON LEVEL SURFACE MODEL C200H C200H x4 4040 3740 3470 3240 3040 2861 2700 8ft 6in 10ft 10in 11ft 10in 12ft 2in 08243 MANRESA SPAIN 43 01350 28 AUSA Center S L U D Load center extension from face of forks D inches 24 28 32 36 40 44 48 D G G LBS MAXIMUM FORKLIFT LOAD ON LEVEL SURFACE MODEL C200H C200H x4 364...

Page 17: ...U D Load center extension from face of forks D inches 24 28 32 36 40 44 48 D G G LBS MAXIMUM FORKLIFT LOAD ON LEVEL SURFACE MODEL C200H C200H x4 4040 3740 3470 3240 3040 2861 2700 8ft 6in 10ft 10in 11ft 10in 08243 MANRESA SPAIN 43 01350 28 AUSA Center S L U D Load center extension from face of forks D inches 24 28 32 36 40 44 48 D G G LBS MAXIMUM FORKLIFT LOAD ON LEVEL SURFACE MODEL C200H C200H x4...

Page 18: ...AD ON LEVEL SURFACE MODEL C250H C250H x4 5060 4670 4340 4060 3800 3580 3390 8ft 6in 10ft 10in 08243 MANRESA SPAIN 43 01350 28 AUSA Center S L U D Load center extension from face of forks D inches 24 28 32 36 40 44 48 D G G LBS MAXIMUM FORKLIFT LOAD ON LEVEL SURFACE MODEL C250H C250H x4 4850 4400 4170 3890 3650 3440 3250 11ft 10in 08243 MANRESA SPAIN 43 01350 28 AUSA Center S L U D Load center exte...

Page 19: ...USA Center S L U D Load center extension from face of forks D inches 24 28 32 36 40 44 48 D G G LBS MAXIMUM FORKLIFT LOAD ON LEVEL SURFACE MODEL C250H C250H x4 14ft 1in 14ft 9in 4250 3930 3650 3410 3200 3000 2840 08243 MANRESA SPAIN 43 01350 28 AUSA Center S L U D Load center extension from face of forks D inches 24 28 32 36 40 44 48 D G G LBS MAXIMUM FORKLIFT LOAD ON LEVEL SURFACE MODEL C250H C25...

Page 20: ... HI C200H x4 C250H HI C250HI LE C250H x4 C250H x4 LE Load charts for C250H C250H x4 C250H x4 LE with narrow axle 500 mm load centre Load charts for C250H C250H x4 C250H x4 LE with narrow axle 24 in load centre ...

Page 21: ...of forks D inches 24 28 32 36 40 44 48 D G G LBS MAXIMUM FORKLIFT LOAD ON LEVEL SURFACE MODEL C200HI 8ft 6in 10ft 10in 11ft 10in 12ft 2in 4040 3740 3470 3240 3040 2861 2700 08243 MANRESA SPAIN 43 01350 28 AUSA Center S L U D Load center extension from face of forks D inches 24 28 32 36 40 44 48 D G G LBS MAXIMUM FORKLIFT LOAD ON LEVEL SURFACE MODEL C200HI 14ft 1in 14ft 9in 3640 3350 3110 2910 2735...

Page 22: ...20 C200H HI C200H x4 C250H HI C250HI LE C250H x4 C250H x4 LE Load charts for C250HI C250HI LE 500 mm load centre Load charts for C250HI C250HI LE 24 in load centre ...

Page 23: ...ctronic equipment anti theft Oxi catalytic exhaust purifier Exhaust Spark arrestor Filter of gas oil with water separator Side shift fork carriage 63 in 1600 mm width Super elastic solid tyres Extra wide tyres Industrial use tyres Lighting equipment standard for USA market 4th hydraulic control for attachments Where the forklift comes equipped with accessories mounted at factory please read the re...

Page 24: ... 10 15005 01 at 0 1969 in STICKER JOYSTICK FUNCTION BUTTONS REFERENCE 10 15005 01 DESCRIPTION INDICATIVE STICKER MAST SIDE SHIFT QUANTITY 1 POSITION Stuck on the inside of the right front fender in the top center position Just above sticker ref 10 15003 01 at 0 1969 in STICKER JOYSTICK FUNCTION BUTTONS REFERENCE 10 15009 00 DESCRIPTION INDICATIVE STICKER AUXILIAR HYDRAULIC LINE QUANTITY 1 POSITION...

Page 25: ...69 in STICKER DANGEROUS AREA REFERENCE 45 01352 00 DESCRIPTION INDICATIVE STICKER QUANTITY 2 POSITION On both sides of the mast above the beam with its upper side aligned at 4ft 92 in from the ground below the sticker ref 13 12136 00 AUSA Make and 0 3937 in away from it STICKER TO HOIST MACHINE REFERENCE 58 01353 01 DESCRIPTION INDICATIVE STICKER 105X100 QUANTITY 1 POSITION On the left side of the...

Page 26: ...E Only on C200H compact REFERENCE 01 12107 00 DESCRIPTION INDICATIVE STICKER 6 5 BAR 96 PSI QUANTITY 2 POSITION On both sides of the machine above the fenders of the front wheels at the front outer end of the fenders aligned with the outer edge STICKER FRONT AXLE WHEELS INFLATED PRESSURE ALL MODELS EXCEPT C200H compact REFERENCE 01 12105 01 DESCRIPTION INDICATIVE STICKER 4 5 BAR 66 PSI QUANTITY 2 ...

Page 27: ...HEELS INFLATED PRESSURE Only C250H x4 REFERENCE 01 12103 01 DESCRIPTION INDICATIVE STICKER 3 5 BAR 51 PSI QUANTITY 2 POSITION On both sides of the machine on top of the vertical face in the upper rear position of each tank aligned with the bottom of the tank STICKER REAR AXLE WHEELS INFLATED PRESSURE All models except C200H compact and C250H x4 REFERENCE 01 12108 01 DESCRIPTION INDICATIVE STICKER ...

Page 28: ...TICKER EC INDICATION REFERENCE DESCRIPTION QUANTITY 45 19101 00 INDICATIVE STICKER 70x70 1 POSITION On the left side of the machine at the bottom inner side of the front fenders aligned on its upper side with mark id 58 01353 01 To hoist machine STICKER HYDRAULIC OIL TYPE REFERENCE DESCRIPTION QUANTITY 43 01352 20 INDICATIVE STICKER 70x32 HYDRAULIC OIL 1 POSITION On the left hand side tank below t...

Page 29: ...010 01 INDICATIVE STICKER 68x267 MODEL C200H 2 POSITION On both sides of the machine at a distance of 0 984 in and a height of 5 906 in from the lower rear corner of each tank aligned with the bottom of the tank STICKER MACHINE MODEL INDICATION C250H HI C250H x4 REFERENCE DESCRIPTION QUANTITY 20 12011 01 INDICATIVE STICKER 68x267 MODEL C250H 2 POSITION On both sides of the machine at a distance of...

Page 30: ...tank aligned with the bottom of the tank STICKER CHARACTERISTICS PLATE REFERENCE DESCRIPTION QUANTITY 01 00779 26 PLATE CHARACTERISTICS 100x130 1 POSITION Riveted on top of the engine bulkhead on its rear upper left hand side in forward direction of machine in the holes prepared Etched according to as sembly instruction STICKER AUSA ANAGRAM REFERENCE DESCRIPTION QUANTITY 46 08099 00 AUSA ANAGRAM 1...

Page 31: ...on its left side STICKER ACOUSTIC OPERATOR PROTECTION REFERENCE DESCRIPTION QUANTITY 01 00757 00 INDICATIVE STICKER D40 1 POSITION Top left hand corner of the instrument panel under sticker 02 00774 00 Do not use aligned with this on its right side and centered with sticker ref 12 12010 00 STICKER POINT HOISTED MACHINE REFERENCE DESCRIPTION QUANTITY 09 15720 00 INDICATIVE STICKER 35x35 4 POSITION ...

Page 32: ...oor STICKER MAXIMUM SOUND LEVEL C200H HI C200H x4 C250HI LE C250Hi LE x4 REFERENCE DESCRIPTION QUANTITY 09 12013 00 STICKER NOISE 103 DB 1 POSITION On the inside of the right front wheel arch aligned with the cab floor STICKER COMPEN SYSTEM C200H x4 C250H x4 C250H x4 LE REFERENCE DESCRIPTION QUANTITY 43 00395 00 INDICATIVE STICKER 110X110 2 POSITION On both sides of the machine next to the AUSA st...

Page 33: ...ON QUANTITY 57 12010 00 INDICATIVE STICKER LOWERING MAST 1 POSITION Into the cabin on the left side of the engine s cover next to the handle that releases the cabin latch STICKER ON MOVEMENTS WITH LOAD OFFCENTERED MASTS OF MORE THAN 3 7M 12ft 2 in REFERENCE DESCRIPTION QUANTITY 43 02187 02 INDICATIVE STICKER 70x210 ENGLISH 1 POSITION In the upper part of the dashboard next to the sticker ref 02 00...

Page 34: ...way from it STICKER INDICATION TRANSFER BOX OIL C200H x4 C250H x4 C250H x4 LE REFERENCE DESCRIPTION QUANTITY 43 00396 02 INDICATIVE STICKER 60x95 1 POSITION Into the engine compartment on the external face of the joystick control valve support above Brake fluid indication sticker STICKER NOT USE WITHOUT AUTHORIZATION REFERENCE DESCRIPTION QUANTITY 02 00777 00 INDICATIVE STICKER 50x120 ENGLISH 1 PO...

Page 35: ...N REFERENCE DESCRIPTION QUANTITY 02 00765 00 INDICATIVE STICKER 40x80 ENGLISH 1 POSITION Inside the counterweight near the exhaust manifold easily readable when trying to work on the engine STICKER LOAD CHART PLATE REFERENCE DESCRIPTION QUANTITY 43 01350 28 30 12004 00 INDICATIVE PLATE 91x156 LOAD CHARTS 1 POSITION Riveting in 4 holes provided in the central outer part the left hand front fender E...

Page 36: ...15008 01 at 0 1969 in STICKER JOYSTICK FUNCTION SUBSTITUTE REF 10 15005 01 REFERENCE DESCRIPTION QUANTITY 10 15008 01 INDICATIVE STICKER MAST SIDE SHIFT USA 1 POSITION Stuck on the inside of the right front fender in the top center position Just above sticker ref 10 15006 01 at 0 1969 in STICKER JOYSTICK FUNCTION BUTTONS REFERENCE DESCRIPTION QUANTITY 10 15009 00 INDICATIVE STICKER AUXILIAR HYDRAU...

Page 37: ... 15009 00 at 0 1969 in STICKER DANGEROUS AREA SUBSTITUTE REF 45 01352 00 REFERENCE DESCRIPTION QUANTITY 45 01352 01 INDICATIVE STICKER 2 POSITION On both sides of the mast above the beam with its upper side aligned at 4ft 92 in from the ground below the sticker ref 13 12136 00 AUSA Make and 0 3937 in away from it STICKER TO HOIST MACHINE REFERENCE DESCRIPTION QUANTITY 58 01353 01 INDICATIVE STICKE...

Page 38: ...E Only on C200H compact REFERENCE DESCRIPTION QUANTITY 01 12107 00 INDICATIVE STICKER 6 5 BAR 96 PSI 2 POSITION On both sides of the machine above the fenders of the front wheels at the front outer end of the fenders aligned with the outer edge STICKER FRONT AXLE WHEELS INFLATED PRESSURE ALL MODELS EXCEPT C200H compact REFERENCE DESCRIPTION QUANTITY 01 12105 01 INDICATIVE STICKER 4 5 BAR 66 PSI 2 ...

Page 39: ...HEELS INFLATED PRESSURE Only C250H x4 REFERENCE DESCRIPTION QUANTITY 01 12103 01 INDICATIVE STICKER 3 5 BAR 51 PSI 2 POSITION On both sides of the machine on top of the vertical face in the upper rear position of each tank aligned with the bottom of the tank STICKER REAR AXLE WHEELS INFLATED PRESSURE All models except C200H compact and C250H x4 REFERENCE DESCRIPTION QUANTITY 01 12108 01 INDICATIVE...

Page 40: ...l of the tank STICKER HYDRAULIC OIL TYPE USA SUBSTITUTE REF 43 01352 20 REFERENCE DESCRIPTION QUANTITY 60 01352 01 INDICATIVE STICKER 70x32 HYDRAULIC OIL 1 POSITION On the left hand side tank below the filler cap aligned with the inner edge of the tank and centered with the cap STICKER ENGINE OIL TYPE SUBSTITUTE REF 43 01170 02 REFERENCE DESCRIPTION QUANTITY 43 01170 03 INDICATIVE STICKER 90x45 1 ...

Page 41: ...ODEL INDICATION C250H HI C250H x4 REFERENCE DESCRIPTION QUANTITY 20 12011 01 INDICATIVE STICKER 68x267 MODEL C250H 2 POSITION On both sides of the machine at a distance of 1 969 in and a height of 5 906 in from the lower rear corner of each tank aligned with the bottom of the tank STICKER MACHINE MODEL INDICATION C250 H HI LE REFERENCE DESCRIPTION QUANTITY 20 12017 00 INDICATIVE STICKER 68x267 MOD...

Page 42: ...chine in the holes prepared Etched according to as sembly instruction STICKER AUSA ANAGRAM REFERENCE DESCRIPTION QUANTITY 46 08099 00 AUSA ANAGRAM 1 POSITION Embedded in the cab front panel on its outer side in the upper left hand part in forward direction of machine STICKER WARNING IN CASE OF OVERTURNING THE MACHINE REFERENCE DESCRIPTION QUANTITY 12 12010 00 SAFETY STICKER 1 POSITION Top left han...

Page 43: ...igned with this on its right side and centered with sticker ref 12 12010 00 STICKER POINT HOISTED MACHINE REFERENCE DESCRIPTION QUANTITY 09 15720 00 INDICATIVE STICKER 35x35 4 POSITION Above each of the four eyebolts at the bottom of the frame for lifting the ma chine STICKER MAXIMUM SOUND LEVEL C250H HI C250H x4 REFERENCE DESCRIPTION QUANTITY 09 12014 00 STICKER NOISE 104 DB 1 POSITION On the ins...

Page 44: ...b floor STICKER COMPEN SYSTEM C200H x4 C250H x4 C250H x4 LE REFERENCE DESCRIPTION QUANTITY 43 00395 00 INDICATIVE STICKER 110X110 2 POSITION On both sides of the machine next to the AUSA sticker ref 13 12136 00 and aligned on the right side STICKER FULL GRIP C200H x4 C250H x4 C250H x4 LE REFERENCE DESCRIPTION QUANTITY 43 00397 00 INDICATIVE STICKER 110x110 2 POSITION On both sides of the machine n...

Page 45: ...3 02187 02 REFERENCE DESCRIPTION QUANTITY 43 02187 02 INDICATIVE STICKER 70x210 ENGLISH 1 POSITION In the upper part of the dashboard next to the sticker ref 10 01414 01 Indica tion structure aligned with this on its upper side In heated enclosed cab position at the bottom left hand side of the window 0 3937 in away from the edge bottom left side Heated cab STICKER AUSA STICKER REFERENCE DESCRIPTI...

Page 46: ...on sticker STICKER OT USE WITHOUT AUTHORIZATION SUBSTITUTE REF 02 00777 00 REFERENCE DESCRIPTION QUANTITY 02 00777 04 INDICATIVE STICKER 216x250 ENGLISH 1 POSITION On top of the vertical face of the engine cover easily readable before access ing the forklift aligned with the cab floor STICKER BRAKE FLUID INDICATION REFERENCE DESCRIPTION QUANTITY 43 70780 01 INDICATIVE STICKER 60x100 BRAKE 1 POSITI...

Page 47: ...01350 28 30 12004 00 INDICATIVE PLATE 91x156 LOAD CHARTS 1 POSITION Riveting in 4 holes provided in the central outer part the left hand front fender Etched according to assembly instruction Add another unit at the top in the event of installing a mast higher than 12ft 14 in STICKER REFLECTIVE TRIANGLE WITH PLATE MACHINE WITH OPEN CAB USA REFERENCE DESCRIPTION QUANTITY 10 15120 00 INDICATIVE STICK...

Page 48: ... on the glass aligned with the lower edge 0 3937 in away from it STICKER NOT TO TOUCH INDICATION REFERENCE DESCRIPTION QUANTITY 02 00766 00 INDICATIVE STICKER 40x80 USA 1 POSITION On the top of the radiator fan guard STICKER PROTECTION STRUCTURE INDICATION REFERENCE DESCRIPTION QUANTITY 10 01414 01 INDICATIVE STICKER 60x125 USA 1 POSITION In the upper left hand corner of the dashboard aligned at t...

Page 49: ...I LE C250H x4 C250H x4 LE STICKER CALIFORNIA INDICATION USA REFERENCE DESCRIPTION QUANTITY 43 01171 00 INDICATIVE STICKER 42x77 1 POSITION In the upper right hand corner of the dashboard aligned at the top with the bend in the dashboard ...

Page 50: ...d backward directional travel control FNR control The direction of travel is changed using the electric switch e located on the lower part of the joystick In each case the corresponding arrow showing the direction of travel lights up When the direction arrows are not lit the direction of travel control is at the stop position neutral By pressing the front of the switch the machine travels forwards...

Page 51: ...ton h the fast speed is connected disconnected When it is connected the fast speed lamp on the instrument panel is lit 4x4 connection Full Grip System fig 4 Connecting the 4x4 The 4x4 connects by pressing yellow switch i located underneath the joystick at the right side Disconnecting the 4x4 The 4x4 disconnects just leaving yellow switch i on its rest position CAUTION Do not connect the 4x4 tracti...

Page 52: ...ick to the right the forks move to the right Always centre the carriage when in transit or when transporting a load Additional hydraulic control for attachments fig 3 By holding down button 6 of the joystick and pulling it to the left towards the operator or pushing it to the right pressure is supplied to the quick hydraulic WARNING The fork positioner allows the operator to set the forks with a v...

Page 53: ... control panel are activated for a few seconds c Starter Turning the key to position c starts the engine Before re starting the engine the key should first be switched to position a Fuse box fig 2 This is located at the right of the steering column next to the starter switch See the section Electric circuit in this Operator s and Safety Manual to identify the number and function of each fuse Instr...

Page 54: ...ing light switch To connect the front lights switch turn on the switch 5 Parking brake To activate the forklift parking brake press the switch 6 Windscreen wiper switch To switch on the windscreen wiper press the switch To activate the windscreen wiper washer pump press the same switch again 7 Rotating beacon switch To switch on press the button and it will light up To switch off press the button ...

Page 55: ...ke To activate the forklift parking brake press the switch 6 Windscreen wiper switch To switch on the windscreen wiper press the switch To activate the windscreen wiper washer pump press the same switch again 7 Rotating beacon switch To switch on press the button and it will light up To switch off press the button again 8 Indicators switch The turning indicators are switched on by pressing the swi...

Page 56: ... filter should be immediately cleaned or serviced E Engine pre heat indicator lamp When this lamp glows it indicates that the engine pre heat plugs are in operation and heating the combustion chamber the temperature required to start the engine F Hydraulic oil level warning lamp This lights up and emits an audible warning when the hydraulic oil level is at the minimum level Oil should be added to ...

Page 57: ...rn signal indicator lamp with lighting equipment This lamp will blink indicating turn signals are operating Fuel The current regulations of exhaust emissions require that for the whole life of the machine the level on the different components of these emissions are under the maximum figures stated on the regulations As a consequence of that the maintenance plan of the engine has to be followed up ...

Page 58: ...ains of the fuel have been completely removed Refuelling WARNING Smoking naked flames or sparks are not permitted in the refuelling area Fuel vapours can be explosive Refuel in a well ventilated area Position the forklift as close as possible to the fuel pump so that the filler hose reaches the opening of the tank comfortably Apply the parking brake switch off the engine and lights including the r...

Page 59: ... you come in or come out Adjusting the seat and the steering wheel figs 2 3 4 5 Before using the forklift adjust the seat and the steering wheel to a comfortable driving position On all machines the operator is able to adjust the seat in the fore aft direction by lifting knob a and sliding seat to the desired position then releasing the knob to lock the seat into position The seat suspension may b...

Page 60: ...n the ignition switch and turn to position b ignition Wait a few moments until the engine preheating light goes out Press the accelerator pedal 1 4 of the way and turn the key to position c to start the engine Do not hold the key in this position for more than 15 seconds If the engine does not start repeat the above steps and wait 30 seconds between each attempt Before re starting the engine the k...

Page 61: ...ing capacity of the forklift decreases Load Capacity With the load center of the load at 20 in 500 mm from vertical face of the forks the C 200 H HI and C 200 H x4 has a rated capacity of 2000 Kg With the load center of the load at 24 in 600 mm from vertical face of the forks the C 200 H HI and C 200 H x4 has a rated capacity of 4040 lbs 2000 Kg With the load center of the load at 20 in 500 mm fro...

Page 62: ...makes the forklift unstable hard to handle and will present the danger of tipping over Load charts fig 1 2 The charts you can see in the section TECHNICAL SPECIFICATIONS on this Operator s and Safety Manual shows how much your forklift can lift as the load centre increases out to 4in Note how the lift capacity decreases as the load centre increases This chart is reproduced as a machine decal and i...

Page 63: ...contact to an authorized AUSA dealer as soon as possible After use care When the forklift is used in salt water areas beach areas etc rinse the machine with fresh water to protect the forklift and its components from rust We recommend lubricating the metal components This should be carried out at the end of every day after using the forklift When the forklift has been working in muddy areas it sho...

Page 64: ...starting the engine stop immediately to prevent internal damages and refer contact to an authorized AUSA dealer as soon as possible Immersion of the forklift If the forklift becomes submerged under water it will be necessary to take it to an authorized AUSA dealer as soon as possible CAUTION DO NOT START THE ENGINE Immersion of the forklift may cause serious damage to the engine if the start up pr...

Page 65: ...ment connector under the dash panel next to the steering column fig 1 Remove the protective cover from the connector by lifting the locking tab and moving it forwards With the help of an external battery supply the connector with 12V DC and earth as follows Connector contact 1 12V DC Connector contact 2 earth Push the joystick to the right in order to tilt the mast NOTE To help this movement we re...

Page 66: ...A enforces federal laws that apply to safety of operation application and maintenance of equipment on a worksite Because it is an employer s responsibility to apply these laws an OSHA representative may periodically inspect a worksite to see that these laws are being followed There may also be local or state provincial laws that apply to this equipment and its use along with specific worksite or e...

Page 67: ...ove dangerous If working in an enclosed area make certain there is sufficient ventilation to prevent excessive build up of exhaust fumes Under this conditions always stop this engine when not in use Before starting the forklift be certain to check or test the following items Check for any leaks in the fuel hydraulic or cooling system Clean any oil or fuel leaks that may exist on the forklift contr...

Page 68: ... to be towed to or from work location see the section Towing the forklift on this Operator s and Safety Manual Work circuit The movement of loads within an installation or enclosure must be carried out following certain instructions concerning the circulation of forklifts and pedestrians If you are not aware of these regulations please check with your supervisor Study the movements of the forklift...

Page 69: ...he section Operating the Machine on this Operator s and Safety Manual Rudiments of dynamic equilibrium While the forklift is moving and as it gains speed the equilibrium conditions of the load forklift unit are modified as the centre of gravity shifts This is accentuated on lifting loads turning braking etc In these conditions it is necessary to take the utmost care to ensure that the centre of gr...

Page 70: ...t handle loads that are unstable loose or disproportionate to the size of the forks and the forklift machine itself Make certain that long or wide loads are fastened together so as to be stable and secure The load and counterweight The load should be lifted and lowered with the mast in vertical position or slightly tilted backwards The raised load should only be tilted forwards when it is about to...

Page 71: ...to maintain maximum load stability Always travels directly up or down the slope Do not travel across an incline Never position the forklift sideways on a slope Forks should only be raised on level stable ground You must be the judge whether ground conditions will permit the safe operation of the forklift Operation on an incline can be very dangerous Rain snow loose gravel or soft ground can be fac...

Page 72: ...adequately lit If this is not possible do not continue working with the forklift this may result in an accident Loading bay Communication Shelving and installations The load The loading bay or area where the loads are handled should be correctly equipped and signposted The operating area of the forklift should be free of obstacles and pedestrians however if their presence is necessary the pedestri...

Page 73: ...uld result serious injury or death as you could be crushed by the machine or by the overhead guard The above decal is located on the side of the machine Overhead Guard must be weekly inspected for excessive damage cracks permanent deformation or signs of potential cracks If these incidents appear structure must not be repaired but replaced for a new one When leaving parking the forklift fig 1 2 3 ...

Page 74: ...machine Be careful with the environment At the end of the operating life of the machine bring it to a recycling center or an scrap dealer It is absolutely forbidden to leave the materials in public places When changing the engine oil or other fluids use a big collecting trough Make sure not to pollute the environment with emerging oil and other waste products coolant batteries etc bring them to th...

Page 75: ...o not transport the forklift with a full diesel fuel tank Make certain your seat belt is properly fastened Move the forklift slowly and carefully up the ramp onto the trailer Shift the directional control lever to neutral Apply the parking brake In transit position lower the forks to their lowest level Stop the engine and remove the key Put blocks under the tips of each fork and tilt the mast slig...

Page 76: ...eed as follows to release it Remove the bleeder a from the brake Screw on the nipple b supplied in the forklift tool box Using a hand pump lubricator d insert grease until the internal pressure manages to release the parking brake Remove handbrake release pressure hose and plug in the fitting with a M12 x 1 5 mm thread plug c To finally release the parking brake unscrew the nipple b The grease wil...

Page 77: ...uration not exceeding 3 minutes Use this procedure to bypass the pump to allow moving the forklift short distances when you cannot start the engine C200H fig 1 To open the by pass valves screw in but not over tight them the centre screws of the hydrostatic pump safety relief valves To do so loose the counter nuts Once the machine is fixed screw out again the hydrostatic pump safety relief valves t...

Page 78: ...ngines with internal combustion 50 glycol 50 distilled water in Standard machine See section ENGINE COOLANT in this section 45 00075 01 7 1 8 HYDRAULIC CIRCUIT Hydraulic oil ISO Grade VG 46 in accordance with ISO 6743 4 HV DIN 51524 Part 3 class HVLP 461 00099 06 45 11 9 FRONT AXLE DIFF Transmission oil SAE 90 in accordance with API GL5 MIL L 2105D with additive LIMITED SLIP See section OIL FOR CO...

Page 79: ...eeze containing corrosion inhibitors especially for internal combustion aluminium engines The cooling systems must be filled with distilled water and antifreeze solution 70 water 30 antifreeze in a standard machine for temperatures ranging from 17 C to 127 C 50 water 50 antifreeze for temperatures ranging from 35 C to 145 C Oil for COMPEN FULL GRIP and front axle Oil AUSA COMPEN EFFICIENT p n 461 ...

Page 80: ...e R CUSTOMER Fuel prefilter KUBOTA Engine 1 R R CUSTOMER Fuel tank C CUSTOMER Fuel injection nozzle injection pressure 2 I DEALER Injection pump timing 2 I I DEALER Fuel injection timer KUBOTA Engine 2 I DEALER COOLING SYSTEM Radiator hoses and clamp bands KUBOTA Engine I R CUSTOMER Radiator hoses and clamp bands ISUZU Engine I R CUSTOMER Cooling system pressure test I CUSTOMER Water jacket radiat...

Page 81: ...il leaks I CUSTOMER Fixation wheel nuts torque I CUSTOMER Chassis fixation screws torque I DEALER Cardan joint fixation screws torque I DEALER Flange fixation nut torque I DEALER Condition of tires and pressures I CUSTOMER BRAKES Brake fluid 3 R I R CUSTOMER Foot brake adjustment 3 I I DEALER Handbrake adjustment I I DEALER BODY FRAME Cabin I CUSTOMER Seat belt 3 I CUSTOMER Foot plate access steps...

Page 82: ...he environment When changing oil or other fluids use a suitable container to collect the old fluid Take care not to cause damage to the environment and take all the replaced materials batteries coolant etc to the appropriate recycling centres In the event of leaks of substances which may be harmful to persons or to the environment immediately take the necessary measures to reduce their impact for ...

Page 83: ...stening of all the guards caps and safety stops Absence of cracks or other structural defects visible at first glance Check that all the controls are operating correctly Check fluid levels fuel brake fluid hydraulic circuit fluid coolant circuit fluid Check that alarm and signalling devices are operating correctly for example acoustic warning air intake filter blocked warning etc Check that inform...

Page 84: ...age Refer to an authorized AUSA dealer for the replacement of the alternator belt Engine oil Oil level Checking With the forklift on a level surface while the engine is cold and switched off check the oil level as follows Pull out the dipstick and clean on a clean cloth Replace the dipstick in its casing Remove again and check the oil level This should be at the upper level fig 2 a Full b Add oil ...

Page 85: ...rew the oil drain plug fig 1 Allow all the oil to drain from the engine Clean the oil sump drain plug and replace the plug with a new plug Screw on the plug by hand and tighten it Oil filter cartridge Replacing The oil filter cartridge a is located on the left hand side of the engine Unscrew the oil filter cartridge by turning to the left Clean the base of the filter and oil the seal of the new fi...

Page 86: ...ck the level Top up if necessary CAUTION Do not exceed the maximum level mark Starting the engine with incorrect oil levels may cause serious damage Clean up any spillage Check the oil level often and top up where necessary Dispose of used oil in authorized centres Coolant system Level of coolant Checking WARNING Never remove the coolant reservoir cap while the engine is hot Wait until the engine ...

Page 87: ...TE Although the cooling system is equipped with a self bleeding system refer to an authorized AUSA dealer for the replenishment of the coolant after draining it Dispose of used coolant in authorized centres Air filter Replacing The air intake in the engine is through a dry filter fig 2 3 with double element The life of the engine and its performance largely depend on the correct maintenance of thi...

Page 88: ...on the inside of the chassis CAUTION Always replace this component Never try to clean it a Brackets b Fuel pre filter Remove the fastening brackets and the filter Make sure that the new filter is fitted in the correct direction as shown by the arrow on the body of the filter Dispose of remains of fuel in authorized centres Fuel filter Unscrew by turning to the left the cartridge c of the fuel filt...

Page 89: ...o 1 5 mm 0 04 and 0 06 in making sure that the pump is free of internal pressure If on applying the service brake the pedal lowers too much it should be adjusted To do so contact an AUSA authorized dealer Brake and inching fluid Checking the level With the forklift parked on a level surface the level of the brake fluid in the tank should lie between the marks MIN and MAX fig 2 If necessary top up ...

Page 90: ...city Dispose of used oil in authorized centres Oil level in the rear axles differential 4x4 models fig 3 Checking To check the oil level unscrew the cap b The oil should be at the level of the casing Draining To drain the oil unscrew the plug c located on the lower part Topping up To fill or top up the rear axle with oil use opening b of the level Fill with the specified oil through the opening of...

Page 91: ...ing the level To check the oil level in the differentials use the cap b Differential Draining To drain the oil unscrew the plug c located on the lower part Dispose of used oil in authorized centres Differential Topping up Fill with the specified oil through the opening of the plug b See the FLUIDS AND LUBRICANTS CHART references and capacities in this Operator s manual for oil specs and capacity f...

Page 92: ...emove the wheel WARNING If is necessary to remove the drain plug while the oil is still hot place it on the upper part of the wheel hub and remove the plug carefully covering it with a cloth or similar To drain the oil turn the wheel hub until plug a fig 2 is located on the lower part of it Dispose of used oil in authorized centres Final drives Topping up fig 2 Turn the wheel until the mark Oil St...

Page 93: ...ning The tank is drained through plug b fig 2 on the lower part of the tank Dispose of used oil in authorized centres Topping up Fill with the specified oil through the plug hole a fig 1 See FLUIDS AND LUBRICANTS CHART references and capacities in this Operator s and Safety Manual for oil specs and capacity Clean the hydraulic oil strainer fig 4 There is an oil strainer filter located on the inter...

Page 94: ...seal Remove the plastic cover Unscrew the metal cap b and loosen the locknut To increase the hydraulic pressure turn the screw clockwise using an allen key To reduce the pressure turn the interior screw in the opposite direction Hydrostatic transmission filter Replacing The hydrostatic circuit has a cartridge filter fig 3 which should be replaced regularly See MAINTENANCE CHART Undo the cartridge ...

Page 95: ...ction TECHNICAL SPECIFICATIONS in this Operator s and Safety Manual Checking tyre pressures and inflation should be carried out with a manometer in good condition fitted with a nozzle with safety clip The safety clip is essential for preventing the manometer nozzle from coming off the tyre valve during inflation which could cause serious injury to the operator Use gloves to protect hands Wheel mou...

Page 96: ... 37 184 22 C 200 H 258 37 184 22 C 200 HI 258 37 184 22 C 200 H x4 258 37 258 37 C 250 H 258 37 184 22 C 250 HI 258 37 184 22 C 250 H x4 258 37 258 37 C 250 HI LE 258 37 184 22 C 250 H x4 LE 258 37 258 37 Mast tension and length of mast chains The tension and length of the mast chains should be checked regularly They stretch gradually due to the strain applied to them The mast chains should be rep...

Page 97: ...h wheel pivot fig 2 2 nipples one on hydraulic cylinder pin fig 3 C200H x4 C250H x4 C250H x4 LE 1 nipples on the central articulation of the axle fig 4 4 nipples two on each wheel reduction joint fig 5 Rear Axle cardan shafts C200H x4 C250H x4 C250H x4 LE 2 nipples one on each cross fig 6 1 nipple on the grooving fig 6 fig 1 fig 2 fig 5 fig 6 fig 4 fig 3 Periodic Maintenance Operations ...

Page 98: ... the mast articulation Mast articulation tilting cylinder fig 2 2 nipples one on each support of the articulation Tilting cylinder articulation with the chassis fig 2 2 nipples one on each support Articulations of the controls fig 3 Inching pedal Brake pedal Mast inner profiles fig 4 Fork carriage side shift fig 5 fig 1 fig 2 fig 3 fig 4 fig 5 Periodic Maintenance Operations ...

Page 99: ...acon Operating beacon bulb Remove the connector from the bulb Undo the clip fastening the bulb by pressing it inwards and to the right at the same time Replace the bulb with a new bulb of the same type and power CAUTION Do not touch the surface of the glass of the bulb If it is dirty wipe gently using a clean dry cloth Secure the clip again by pressing it inwards and to the left at the same time I...

Page 100: ...h off the ignition Remove the protective cover from the fuses by pulling it outwards The burnt fuse can be recognised as the metal strip which is visible in the centre of each fuse will have melted viewing window Remove the burnt fuse and replace with a new fuse of the same type CAUTION Do not use fuses of a higher value this could cause major damage Battery fuses checking fig 4 Switch off the ign...

Page 101: ...H x4 C250H x4 LE 99 Windscreen wiper blade replacing fig 1 Loosen screws a to remove the blade from the windscreen wiper arm Replace blade Check that the screws a hold the blade tightly to the wiper arm fig 1 a Periodic Maintenance Operations ...

Page 102: ... MODE SAFE Mode Software 16 Sensor Voltage Error Nominal 5V 4 875V or 5 125V is out of Range SAFE Mode 21 Pump Current Forward Error LIMITED Mode Mechanical 22 Pump Current Reverse Error LIMITED Mode 21 and 22 Pump Current Forward and Reverse Error SAFE Mode 25 COR Error SAFE Mode 26 Buzzer Brake Error LIMITED Mode Electrical Outputs 28 Motor Current Error LIMITED Mode Input Output Overview 30 Bra...

Page 103: ...e red led are interpreted as follows Code numbers interpretation The LED lights for a short space of time is interpreted as POINT If time is longer interpreted as LINE Introduction Space Tens Space Units This example shows the error 35 Short circuit selector switch forward neutral reverse The machine would go to safe mode Additional Information Sensor calibration Driving Rocker and Inching If the ...

Page 104: ...B White C Orange G Yellow H Grey L Blue M Brown N Black R Red S Pink V Green Z Violet Remark In the bicolor cables the longitudinal or traverse shape of the marks on the protective coating are to indicate the color For example G V Yellow and Green with traverse marks G V Yellow Green with longitudinal marks ...

Page 105: ...103 C200H HI C200H x4 C250H HI C250HI LE C250H x4 C250H x4 LE Electric circuit 1 C200H C200HI C200H x4 C250HI LE C250H x4 LE ...

Page 106: ...104 C200H HI C200H x4 C250H HI C250HI LE C250H x4 C250H x4 LE Electric circuit 2 C200H C200HI C200H x4 C250HI LE C250H x4 LE ...

Page 107: ...105 C200H HI C200H x4 C250H HI C250HI LE C250H x4 C250H x4 LE Electric circuit 3 C200H C200HI C200H x4 C250HI LE C250H x4 LE ...

Page 108: ...106 C200H HI C200H x4 C250H HI C250HI LE C250H x4 C250H x4 LE Electric circuit 4 C200H C200HI C200H x4 C250HI LE C250H x4 LE ...

Page 109: ...main fuse 50A 1 S56 Rotating Flashing beacon switch 4 FG2 Starter motor relay main fuse 50A 1 S57 Worklight switch 4 FG3 Pre heat relay main fuse 30A 1 S58 Heater motor switch 3 FG4 Battery main fuse 200A 1 S59 Optional switch 2 G19 Battery 1 S60 Front windscreen wiper switch 3 G26 Alternator 1 S61 Handbrake switch 2 H1 Right hand reverse light 4 S99 Joystick spool valve lock link connector 3 H2 B...

Page 110: ...108 C200H HI C200H x4 C250H HI C250HI LE C250H x4 C250H x4 LE Electric circuit 1 C250H C250HI C250H x4 ...

Page 111: ...109 C200H HI C200H x4 C250H HI C250HI LE C250H x4 C250H x4 LE Electric circuit 2 C250H C250HI C250H x4 ...

Page 112: ...110 C200H HI C200H x4 C250H HI C250HI LE C250H x4 C250H x4 LE Electric circuit 3 C250H C250HI C250H x4 ...

Page 113: ...111 C200H HI C200H x4 C250H HI C250HI LE C250H x4 C250H x4 LE Electric circuit 4 C250H C250HI C250H x4 ...

Page 114: ...112 C200H HI C200H x4 C250H HI C250HI LE C250H x4 C250H x4 LE Electric circuit 5 C250H C250HI C250H x4 ...

Page 115: ... S56 Rotating Flashing beacon switch 4 FG2 Starter motor relay main fuse 50A 1 S57 Worklight switch 4 FG3 Pre heat relay main fuse 30A 1 S58 Heater motor switch 3 FG4 Battery main fuse 200A 1 S59 Optional switch 2 G19 Battery 1 S60 Front windscreen wiper switch 3 G26 Alternator 1 S61 Handbrake switch 2 H1 Right hand reverse light 4 S99 Joystick spool valve lock link connector 3 H2 Brake and tail l...

Page 116: ...114 C200H HI C200H x4 C250H HI C250HI LE C250H x4 C250H x4 LE Hydraulic diagram Hydraulic appliances ...

Page 117: ...115 C200H HI C200H x4 C250H HI C250HI LE C250H x4 C250H x4 LE Hydraulic diagram Transmission C200H C200HI C200H x4 C250HI LE C250H x4 LE ...

Page 118: ...116 C200H HI C200H x4 C250H HI C250HI LE C250H x4 C250H x4 LE Hydraulic diagram Transmission C250H C250HI C250H x4 ...

Page 119: ...wer or faulty engine Engine does not accelerate at max Load Engine 85 95 max rpm of engine High pressure limit is set too low Working pressure Working pressure ports in pump Recommended max Pressure 345 or 410 bar Inching is seized SAUER Potentiometer linkage Pedal 0 3 bar Low traction power Engine does not work at nominal level or it s over Haul of accelerator lever Engine 85 95 max rpm of engine...

Page 120: ...ompatibility Directive 2004 108 EC Sound level Directives of machinery used outdoors 2000 14 EC and 2005 88 EC Exhaust emissions Directives 97 68 and 2004 26 and also it conforms with the following harmonized European Standards EN 1726 1 Safety of industrial trucks Self propelled trucks up to and including 10 000 kg capacity and industrial tractors with a drawbar pull up to and including 20 000 N ...

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