AUSA CH 200, Operator'S Manual

Page 1: ...CH 200 CH 200 x4 CH 250 CH 250 x4 OPERATOR S MANUAL ENGLISH ...

Page 2: ...AUSA Forklift CH 200 CH 200 4x4 CH 250 CH 250 4x4 ...

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Page 4: ...this forklift read and understand this Manual When not in use keep it stored on the forklift in the Manual holder box under the arm rest 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 ligh ting must be complied with For further information you may write FAX or E...

Page 5: ...instrument 18 Operating the machine 27 Parking the machine 30 Periodic maintenance operations 35 Capacities 36 Greasing points 50 Maintenance chart Technical characteristics 11 Machine decals USA market 22 Safety 13 Machine decals UK market 28 Transporting the machine 37 Electric circuit CH 200 42 Electric circuit CH 250 47 Hydraulic diagram Side shift 48 Hydraulic diagram Hydromatik CH 200 49 Hyd...

Page 6: ...achine 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 in option 11 Rear view mirror 5 2 8 4 7 6 9 1 1 0 3 1 0 1 1 ...

Page 7: ...rial number Engine serial 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 e...

Page 8: ... joystick When a direction is selected the arrow lamp indicator light on Steering Hydraulic powered with one double acting hydraulic cylinder on the rear axle Working pressure 2320 PSI 160 bar Service Pressures CH 200Compact Front 10 0 75 15 3 96 PSI 6 5 bar Rear 6 50 10 65 PSI 4 5 bar CH 200 Front 11 5 80 15 3 65 PSI 4 5 bar Rear 7 00 12 123 PSI 8 5 bar CH 200x4 Front 11 5 80 15 3 65 PSI 4 5 bar ...

Page 9: ...ter of the load at 500 mm see load charts CH 200 2 000 Kg CH 250 2 500 Kg With the load center at 24 inches 600 mm CH 200 4040 lbs 1835 Kg CH 250 5060 lbs 2294 Kg Fork carriage Class FEM ISO 2 Standard mast Lifting height 10ft 10in 3 30 m Free litf 6 inches 150 mm Forks length 47 inches 1200 mm Lifting speed Without load 103 ft min 0 526 m seg with load 101 ft min 0 513 m seg Lowering speed Withou...

Page 10: ...sed cab front and rear windshield Extra wide tyres Closed cab with heating Lighting equipment Hydraulic shovels 10 5 cu ft and 14 cu ft Other masts and attachments are also available in option Load backrest standard for USA market Electronic equipment anti theft Front laminate windshield with wiper Oxi catalytic exhaust purifier Rear windshield with wiper Filter of gas oil with water separator ...

Page 11: ...11 CH 200 CH 250 Machine decals USA market Information ...

Page 12: ...12 CH 200 CH 250 Machine decals USA market Warning Load charts ...

Page 13: ...13 CH 200 CH 250 Machine decals UK market Information ...

Page 14: ...14 CH 200 CH 250 Load graphs Machine decals UK market ...

Page 15: ...cated on the left of the joystick 5 Speed control fig 3 Only in CH 200 and CH 200 x4 Pushing the joystick switch button 4 the fast speed is connected disconnected When it is connected the fast speed lamp on the instrument panel is lit Emergency control brake In emergency event use the inching pedal Parking brake fig 4 The parking control works electrically by means of the switch 1 Load controls fi...

Page 16: ...e Electrical Diagram at the rear of this Manual to identify the number and function of each fuse 9 Switch lever for turn signal high beam windshield wiper and water pump version with lighting equipment or windshield fig 3 9 1 Turn signal switch Push the lever to the right or to the left according to the side chosen for turning 9 2 High beam switch Push the lever upward to switch on the high beams ...

Page 17: ...ing low oil pressure to the engine The engine should be stopped immediately to pre vent engine damage Add oil to the engine until the proper level is reached H Charge battery lamp This gauge shows the condition of the battery and will tell you if the battery charge is too low or if the alternator is not charging properly Once the engine starts to run this red lamp will go out If it remains lit sto...

Page 18: ...t directional control switch in neutral and the parking brake engaged Insert the key in the ignition switch turn it fully clockwise and depress lightly the accelerator pedal At this moment the pilots of battery charge oil pressure and pre heat in the dashboard panel will illuminate After some seconds the pre heat light will go off and the engine will start When engine is run ning battery charge an...

Page 19: ...ft mudguard With load centre at 20 in or 500mm European and ISO standards the CH 200 has a rated capacity of 4 384lbs or 2000Kg and the CH 250 has a rated capacity of 5 48lbs or 2 500Kg With load centre at 24 in or 600 mm American Standard the CH200 has a rated capacity of 4040lbs 1835 Kg and the CH 250 has a rated capacity of 5060 lbs 2294 Kg If the load is too heavy split it and re stack it Use ...

Page 20: ...urface with the load evenly displaced like a square box with the weight centred and a lift height standard mast of 10ft 10in 3 3 m The horizontal axis T often referred to as the X axis represents the distance in inches mm that the load centre is moved forward from the face of the forks The vertical axis G often referred to as the Y axis shows the load weight in pounds kgs The raising and lowering ...

Page 21: ... and pushing the joystick to the right will move the forks to the right Always center the carriage when in transit or when transporting a load Fourth valve option Additionally it is available a fourth load control for attachments with two hydraulic functions Pushing the joystick switch button 6 and pushing the joystick forwards and backwards this control in working on Speed ranges If the machine h...

Page 22: ...ean any oil or fuel leaks that may exist on the forklift controls or operating area Check tire conditions and pressures Retight wheel nuts if necessary Check that all controls are working correctly Check the operator seat s safety belt and its attachments Check brake pedal travel and effectiveness Check the following fluid levels Fuel Braking fluid Hydraulic fluid Cooling system fluid Engine oil C...

Page 23: ...movements of the forks causes instability and danger of overturning This forklift was designed to lift loads not people Never transport people on any part of the forklift Do not let people ride on the forks Fig 5 Do not drive rapidly Driving too fast is dangerous to the driver and to the load The speed at which the forklift is operated should always be suited to the working conditions and to the s...

Page 24: ... in the low position and with the mast tilted back fig 14 Never transport loads with the forks raised keep them as low as possible to attain maximum stability The risk of overturning increases when the foklift is driven with the load raised Keep it low when in transit fig 15 Only lift the forks to load unload them Do not drive on surfaces that could affect the stability of the machine Only raise t...

Page 25: ...erate the forklift near or close to overhead power lines If the forklift is operated in an enclosed area use ventilation systems to replace the exhaust fumes with fresh air Use ventilation systems to remove any flammable dust or vapours in the working area Do not overload the forklift and do not allow the load centers to move Always manoeuvre slowly and smoothly especially when changing direction ...

Page 26: ...ened together so as to be stable and secure When leaving the forklift fig 16 17 Place the forks in the fully lowered position Set all the controls in the O neutral position Apply the parking brake Do not park the forklift on a slope Stop the engine and cut the ignition circuit Remove the ignition key Lock all mechanisms to prevent any unauthorized person from using the machine ...

Page 27: ...en to leave the materials in public places When changing the engine oil or other fluids use a big collecting trough Make sure not to pollu te the environment with emerging oil and other waste products coolant batteries etc bring them to the corresponding recycling centre In case that substances escape from the machine that are harmful to the environment and or to the people take remedial measures ...

Page 28: ... attached While lifting the forklift do not permit riders on the forklift or by standers within 15ft 5m To llift t the m machine w with a a c crane b bear iin m mind t the f following a advice Front slings must not be shorter than 8ft 2 5 meters Always raise the machine in a balanced position Keep the angle of inclination of the front sling approximately the same as the angle of inclination of the...

Page 29: ...n off highway machine on public roads and highways Before towing the machine Tight the screws of the safety relief valve on the hydrostatic pump to allow the relief of the fluid See arrows on fig 3 To have the machine again on working position loose these screws and tight the nuts again Remove the negative brake group on the reductor gear To carry out it loose the nuts and take out them from the s...

Page 30: ...orklift The alternator should only be run when the battery and the voltage regula tor are connected to the electrical system To run the engine without the battery disconnect the alternator belt The hydraulic system should be checked periodically to avoid poor performance or accidents which might be caused by hydraulic oil leaks or by maladjustment of the pressure relief valves Take precautions to ...

Page 31: ...er users of the road with the hazard warning triangles They could be stored under the cabin raising it CAUTION Never remove the cap of the radiator or of the coolant reservoir tank when the engine is hot as severe burning could from steam or coolant expelled from the radiator or coolant reservoir Always add coolant when necessary through the coolant reservoir tank Engine For information on correct...

Page 32: ...CH200 and 450 hours CH 250 intervals See Maintenance Chart Fuel prefilter fig 2 On the CH 250 there is a fuel prefilter It has to be serviced at 150 hours intervals and repla ced every 300 hours Wheels Check weekly the fastening torque of the wheel nuts Torque 258 lb ft 35 7 mkg 350 Nm Unless it was strictly necessary due to the operation requirements it is not recommended to assemble solid tyres ...

Page 33: ...l and filter fig 5 With the forklift on level ground the engine stopped and the forks at the lowest position check the hydraulic oil level by means of the dipstick 1 The normal level is at the upper mark of the dipstick Top up if necessary through this dipstick filling hole The hydrostatic oil filter is assembled on the hydraulic circuit outside the hydraulic tank and is located under the cab floo...

Page 34: ...ion as tyre inflation can be dangerous if not done with care The following procedure steps should be taken when inflating the tyres with special caution exercised when working on the front axle tyres Park the machine on level ground and turn the engine off Always wear goggles to prevent injury from an unforeseen air jet Always inflate tyres before it has been operated and the tyres are still cold ...

Page 35: ...g 1 11 13 2 50 Hydraulic Oil tank 10 3 12 4 47 Hydraulic brakes reservoir 0 05 0 07 0 25 Negative brakes housing 0 035 0 0423 0 16 Engine coolant reservoir fig 2 1 54 1 85 7 Windshield washer reservoir optional 0 22 0 26 1 See de MANINTENANCE CHART for the type of diesel fuel lubricating and hydraulic oils brake fluid and engine coolant as well as the recommended change ser vice intervals fig 1 fi...

Page 36: ...les 1 on each wheel kingpin 4 WD models 4 nipples 2 on each articulation of the wheel reduction gears Universal drive joints only 4 WD models fig 2 and 3 2 nipples on each joint figs 3 and 4 Mast support fig 4 2 nipples 1 on each articulation mast axle fig 5 Tilting cylinders fig 5 2 nipples 1 on each articulation axle fig 6 fig 3 fig 1 fig 4 fig 5 fig 2 ...

Page 37: ...37 CH 200 CH 250 Electric circuit CH200 1 ...

Page 38: ...Electric circuit CH200 2 38 CH 200 CH 250 ...

Page 39: ...Electric circuit CH200 3 39 CH 200 CH 250 ...

Page 40: ...Electric circuit CH200 4 40 CH 200 CH 250 ...

Page 41: ...59 4x4 switch not used 2 G26 Alternator 1 S60 Front windscreen wiper switch 3 H1 Right hand reverse light 4 S61 Handbrake switch 2 H2 Brake and tail lights right hand side 4 S99 Joystick spool valve lock link connector 3 H3 Rear right hand indicator 4 S100 Forward and Reverse switch joystick 2 H5 Rear left hand indicator 4 S101 Horn switch joystick 2 H6 Brake and tail lights left hand side 4 S102 ...

Page 42: ...Electric circuit CH250 1 42 CH 200 CH 250 ...

Page 43: ...Electric circuit CH250 2 43 CH 200 CH 250 ...

Page 44: ...Electric circuit CH250 3 44 CH 200 CH 250 ...

Page 45: ...Electric circuit CH250 4 45 CH 200 CH 250 ...

Page 46: ... 2 G26 Alternator 1 S60 Front windscreen wiper switch 3 H1 Right hand reverse light 4 S61 Handbrake switch 2 H2 Brake and tail lights right hand side 4 S99 Joystick spool valve lock link connector 3 H3 Rear right hand indicator 4 S100 Forward and Reverse switch joystick 2 H5 Rear left hand indicator 4 S101 Horn switch joystick 2 H6 Brake and tail lights left hand side 4 S102 2 Speed selector switc...

Page 47: ...Hydraulic diagram Side shift 1 47 CH 200 CH 250 ...

Page 48: ...Hydraulic diagram Hydromatik CH200 1 48 CH 200 CH 250 ...

Page 49: ...Hydraulic diagram Hydromatik CH250 1 49 CH 200 CH 250 ...

Page 50: ...C GREASE Grease every 50 h 2 LITIO 2 SPECIAL AM MUTIS 2 LS 2 Consistency NLG12 Without dismantling the chains clean them a clean gas oil mixture by Grease chains every 50h brushing vigorously with a hard nylon brush Dry with compressed air wi t h a brush i m pregnated wi t h SAE 90 oi l SAE 10W or liquid ATF serie A sufix A Change fluid every 1000 h First after 50 h MOBIL DTE 26 Next everty 1000 h...

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