CESAB B 200 Operating instructions

REPAIR MANUAL
B 200
Code 036-0436-00 03/2012
210- 213- 215
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Document changes history:
This manual covers the following truck models:
Edition Changes
036-0436-00 New version
Model Starting serial number Ending serial number
B 210 CE365070
B 213 CE365283
B 215 CE364785
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INDEX
GENERAL 0
BATTERY 1
CONTROLLERS 2
DISPLAY 3
TROUBLESHOOTING 4
MOTOR 5
DRIVE UNIT & REAR AXLE 6
STEERING SYSTEM 7
BRAKE 8
BODY & FRAME 9
MATERIAL HANDLING SYSTEM 10
MAST 11
CYLINDER 12
OIL PUMP 13
OIL CONTROL VALVE 14
MAIN OPTIONS 15
PROGRAMMER 16
APPENDIX 17
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E
GENERAL
Page
VEHICLE EXTERIOR VIEW.........................................0-2
VEHICLE MODELS......................................................0-3
CHASSIS NUMBER.....................................................0-3
TRUCK CAPACITY AND IDENTIFICATION
PLATES.....................................................................0-4
HOW TO USE THIS MANUAL.....................................0-8
EXPLANATION METHOD ......................................................0-8
TERMINOLOGY......................................................................0-9
ABBREVIATIONS...................................................................0-9
ILLUSTRATIONS....................................................................0-9
SI UNITS ...............................................................................0-10
OPERATING TIPS......................................................0-11
GENERAL INSTRUCTIONS................................................. 0-11
BATTERY RECYCLING/DISCARDING................................0-12
JACK-UP POINT........................................................0-13
MEMBER WEIGHTS..................................................0-14
TOWING THE TRUCK..........................................................0-15
ELECTRICAL PARTS INSPECTION.........................0-16
TIGHTENING TORQUE TABLE.................................0-17
LUBRICANTS CAPACITY AND TYPE TABLE .........0-18
PERIODIC MAINTENANCE.......................................0-19
PERIODIC REPLACEMENT TABLE....................................0-19
PERIODIC MAINTENANCE TABLE..........................0-20
LUBRICATION CHART..............................................0-26
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VEHICLE EXTERIOR VIEW
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VEHICLE MODELS
CHASSIS NUMBER
Load capacity Control method Supply voltage (V)
1.0 ton AC microcomputer controller 24
1.3 ton ↑↑
1.5 ton ↑↑
Vehicle type Serial number
format Serial number position
100 CE000000
130 CE000000
150 CE000000
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TRUCK CAPACITY AND IDENTIFICATION PLATES
A) IDENTIFICATION PLATE
B) LOAD CAPACITY PLATE
The position of the plates, like shown in the image, refers to standard truck: this position could vary in case
of special trucks
How to Read the Plates
A: Identification plate
It identifies the lift truck technical data
1. Vehicle model
2. Motor power
3. Nominal rated capacity
4. Truck serial number
5. Draw-bar pull
6. Battery weight (min/max)
7. Truck weight (without battery)
8. Year of manufacture
9. Battery voltage
10.Notes
B: Load capacity plate
It identifies the load capacity with a load center of
600 mm (except for different indications)
11. Special model, Attachment model
12.Truck tyres
13.Attachment serial number
14.Load center
15.Lift height Rated capacity
AB
RATED CAPACITYMOTOR
MODELL Type
DRAW-BAR PULL (1 h)
SERIAL N°
SEVICE MASS
Without
Battery kg
BATTERY MASS
MANUFACT. YEAR BATTERY V
kg
max.
kg
min.
N
kW kg
V
Cod.0311014
CESAB Carrelli Elevatori S. p. A.
Via Persicetana Vecchia 10
40132 - Bologna - Italia
123
4
5
67
89
10
SERIAL N°
TYRES
CENTER OF LOAD DISTANCE mm
LIFT HEIGHT
mm
DERATED CAPACITY Kg
ATTACHMENT OR SPECIAL CONDITION OF USE
Cod 0311013
CESAB Carrelli Elevatori S. p. A.
Via Persicetana Vecchia 10
40132 - Bologna - Italia
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TECHNICAL AND WORKING SPECIFICATIONS FORKLIFT MODEL (Standard Version)
CHARACTERISTICS
1.1 Manufacturer CESAB CESAB CESAB 1.2 Model X243 1000 X243 1250 X243 1500 1.3 Power: electric (battery), diesel, petrol, LPG Electric Electric Electric 1.4 Operation: manual, pedestrian, stand-on, driver seated driver seated driver seated driver seated 1.5 Load capacity Q [Kg] 1000 1250 1500 1.6 Load centre c [mm] 500 500 500 1.8 Axle centre to fork face x [mm] 330 a 330 a 330 a 1.9 Wheel-base y [mm] 984 1146 1200
WEIGHTS 2.1 Weight kg 2550 2820 2930 2.2 Axle load with load, front/rear kg 2950 / 600 3390 / 680 3820 / 610 2.3 Axle load without load, front/rear kg 1100 / 1450 1230 / 1590 1280 / 1650 WHEELS - CHASSIS 3.1 Tyres: C=Cushion, PN=Pneumatic, SE=Superelastic, G=Twin C / SE / PN C / SE / PN C / SE / PN 3.2 Tyre size, front 457x152 / 18x7-8 / 18x7-8 457x152 / 18x7-8 / 18x7-8 457x152 / 18x7-8 / 18x7-8
3.3 Tyre size, rear 457x152 / 18x7-8 / 18x7-8 457x152 / 18x7-8 / 18x7-8 457x152 / 18x7-8 / 18x7-8
3.5 Wheels: number front/rear (x = driven) 2 / 1x 2 / 1x 2 / 1x 3.6 Track width, front b10 [mm] 837 / 837 / 847 b 837 / 837 / 847 b 881 / 837 / 847 c 3.7 Track width, rear b11 [mm] 0 0 0
DIMENSIONS 4.1 Mast tilt: forward / backward α /
β
[°] 3° / 6° 3° / 6° 3° / 6°
4.2 Height of mast, lowered h1 [mm] 2140 2140 2140 4.3 Free lift h2 [mm] 80 80 80
4.4 Lift height h3 [mm] 3270 3270 3270
4.5 Height of mast, extended h4 [mm] 3820 3820 3820 4.7 Height of overhead guard h6 [mm] 1980 d 1980 d 1980 d 4.8 Height of driver’s seat h7 [mm] 941 941 941 4.12 Towing coupling height h10 [mm] 615 615 615 4.19 Overall lenght I1 [mm] 2564 a 2726 a 2780 a 4.20 Lenght to fork face I2 [mm] 1564 a 1726 a 1780 a 4.21 Overall width b1\b2 [mm] 990 / 990 / 1030 e 990 / 990 / 1030 e 1062 / 990 / 1030 e
TECHNICAL DATA
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4.22 Fork dimensions s/e/l [mm] 35x100x1000 35x100x1000 35x100x1000 4.23 Fork carriage to DIN 15173, class/form A, B II A II A II A 4.24 Width of fork carriage b3 [mm] 900 900 900 4.31 Floor clearance, mast (with load) m1 [mm] 90 90 90 4.32 Floor clearance, centre of wheel-base (with load) m2 [mm] 90 90 90 4.33 Aisle width with pallets 1000x1200 across forks Ast [mm] 2893 3055 3109 4.34 Aisle width with pallets 800x1200 along forks Ast [mm] 3015 3177 3231 4.35 Turning radius Wa [mm] 1234 1396 1450 4.36 Minimum distance between the centres of rotation b13 [mm] --- --- --- PERFORMANCE 5.1 Travel speed, with/without load km/h 12 / 12,5 12 / 12,5 12 / 12,5 5.2 Lifting speed, with/without load m/s 0,32 / 0,52 0,31 / 0,52 0,30 / 0,52 5.3 Lowering speed, with/without load m/s 0,59 / 0,52 0,59 / 0,52 0,59 / 0,52 5.5 Tractive force, with/without load N 1470 / 1670 1420 / 1670 1370 / 1670 5.6 Maximum tractive force, with/without load (S2 5 minute rating) N 7300 / 7500 f 7250 / 7500 f 7200 / 7500 f 5.7 Climbing ability, with/without load (S2 30 minute rating) % 8 / 12,5 7 / 11,5 6,5 / 11 5.8 Maximum climbing ability, with/without load (S2 5 minute rating) % 19 / 25 f 17 / 25 f 16 / 25 f 5.9 Acceleration time, with/without load s --- --- --- 5.10 Service brake: mechanical / hydraulic / electric / pneumatic hydraulic hydraulic hydraulic MOTORE ELETTRICO 6.1 Drive motor, power (S2 60 minute rating) kW 5,1 5,1 5,1 6.2 Lift motor, power (S3 15% rating) kW 7,5 7,5 7,5 6.3 Battery according to DIN 43531/35/36 A, B, C, NO DIN 43535 A DIN 43535 A DIN 43535 A 6.4 Battery voltage / rated capacity (K5) V/Ah 24 / 400-500 24 / 700-875 24 / 800-1000 6.5 Battery weight kg 372 600 676 OTHERS 8.1 Type of drive control Inverter MOSFET Inverter MOSFET Inverter MOSFET 8.2 Working pressure for attachments bar 140 140 140 8.3 Oil flow for attachments l/min --- --- --- 8.4 Noise level at driver’s ear dB (A) --- --- --- 8.5 Towing coupling design / type DIN --- --- --- a) With side shift = +34 mm b) 909 / 909 / 909 with 2M h3>4000 - 3M h3 > 4350 c) 881 / 909 / 909 with 2M h3>4000 - 3M h3 > 4350 d) + 150 mm raised version available e) 1062 / 1062 / 1092 with 2M h3>4000 - 3M h3 > 4350 f) The shown values point out the electric motors capacity
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CAPACITY DIAGRAMS (with SE tyres)
Barycentre [mm] Capacity [Kg] 1.0 t
500 1000
600 890
700 810
800 730
900 670
1000 620
Barycentre [mm] Capacity [Kg] 1.25 t
500 1250
600 1120
700 1010
800 920
900 840
1000 780
Barycentre [mm] Capacity [Kg] 1.5 t
500 1500
600 1340
700 1210
800 1100
900 1010
1000 940
a [mm] = 200
CAPACITY [kg]
BARYCENTRE [mm]
CAPACITY [kg]
BARYCENTRE [mm]
CAPACITY [kg]
BARYCENTRE [mm]
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HOW TO USE THIS MANUAL
EXPLANATION METHOD
1 Operating procedure
(1) Operating procedures are described using either pattern A or pattern B
(a) Pattern A: Each step of the operation is explained with its own illustration
(b) Pattern B: The entire operation is indicated by step numbers in one illustration, followed by
cautions, notes, and point operations
Example of pattern B
DISASSEMBLY · INSPECTION · REASSEMBLY Tightening torque unit T=Nm
Disassembly Procedure
1 Remove the cover [POINT 1]
2 Remove the bushing [POINT 2]
3 Remove the gear
Point Operations
[POINT 1]
Disassembly:
Make match marks before removing the pump cover
[POINT 2]
Inspection:
Measure the bushing inside diameter.
Limit 19.12 mm
• Some step numbers may be
omitted in some illustrations.
• When a part requiring
tightening torque instruction is
not indicatedin the illustration,
the part name is described in
the illustration frame.
T = 46.1 to 48.1
(470 to 490)
[34.0 to 35.5]
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8
591
Operation to be explained
Explanation of operation point with illustration
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Matters omitted from this manual
This manual omits descriptions of the following jobs, but perform them in actual operation:
(a) Cleaning and washing of removed parts as required
(b) Visual inspection (partially described)
TERMINOLOGY
Caution:
Important matters, whose negligence may cause accidents. Be sure to observe them.
Note:
Important items, whose negligence may cause accidents or matters during operating so it is
required special attention.
Standard:
Value showing the allowable range in inspection or adjustment.
Limit:
The maximum or minimum value allowed in inspection or adjustment.
ABBREVIATIONS
ILLUSTRATIONS
Illustrations are supposed to point out the correct methods to work on the machine and its components,
therefore they could not display exactly the same elements.
Abbreviation Meaning Abbreviation Meaning
-- -- RH Right hand
ATT Attachment SAE Society of Automotive Engineers
(USA)
EHPS Electronically controlled fully
hydraulic power steering SAS System of active stability
FHPS Fully hydraulic power steering SST Special service tool
LH Left hand STD Standard
L/ Less T= Tightening torque
OPT Option   T Number of teeth (  T)
O/S Oversize U/S Undersize
PS Power steering W/ With
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SI UNITS
Meaning of SI
This manual uses SI units. SI represents the International System of Units, which was established to unify
the various systems of units used in the past for smoother international technical communication.
New Units Adopted in SI
<Reference>
(*): X represents the value in SI units as converted from 1 [in conventional units], which can be
used as the rate for conversion between conventional and SI units
(**): In the past, kilogram [kg] representing mass was often used in place of weight kilogram [kgf],
which should be used as the unit of force.
Conversion between Conventional and SI Units
Equation for conversion
When converting, change the unit of the value in conventional or SI units to the one in the
conversion rate column in the table above before calculation. For example, when converting 100 W
to the value in conventional unit PS, first change it to 0.1 kW and divide by the conversion rate
0.735499.
Item New unit Conventional
unit Conversion rate
(*)
)
(1 [conventional unit] = X [SI unit])
Force
(**)
N (newton) kgf 1 kgf = 9.80665 N
Torque
(**)
(Moment) N·m kgf·cm 1 kgf·cm = 9.80665 N·m
Pressure
(**)
Bar kgf/cm
2
1 Bar = 1 kgf / cm
2
Pressure
(**)
Pa (pascal) kgf/cm
2
1 kgf/cm
2
= 98.0665 kPa = 0.0980665 MPa
↑↑mmHg 1 mmHg = 0.133322 kPa
Revolving speed rpm rpm 1 rpm = 1 r/min
Spring constant
(**)
N/mm kgf/mm 1 kgf/mm = 9.80665 N/mm
Volume l cc 1 cc = 1 ml
Power W PS system 1 PS = 0.735499 kW
Heat quantity W·h cal 1 kcal = 1.16279 W·h
Specific fuel consumption g/W·h g/PS·h 1 g/PS·h = 1.3596 g/kW·h
Value in SI unit = Conversion rate ×Value in conventional unit Conversion rate: Figure corresponding
to X in the conversion rate column in
the table above
Value in conventional unit = Value in SI unit ÷Conversion rate
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OPERATING TIPS
GENERAL INSTRUCTIONS
1. Safe operation
(1) After jacking up, always support with wooden blocks or rigid stands
(2) When hoisting the vehicle or its heavy component, use wire rope(s) with a sufficient reserve in load
capacity
(3) Always disconnect the battery plug before the inspection or servicing of electrical parts
2. Skillful operation
(1) Prepare the tools, necessary measuring instruments (circuit tester, megohmmeter, oil pressure
gauge, etc.) and SSTs before starting operation
(2) Check the cable color and wiring state before disconnecting any wiring
(3) When overhauling functional parts, complicated sections or related mechanisms, arrange the parts
neatly to prevent confusion
(4) When disassembling and inspecting a specific part such as the control valve, use clean tools and
operate in a clean location
(5) Follow the specified procedures for disassembly, inspection and reassembly
(6) Always replace gaskets, packing, O-rings, self-locking nuts and cotter pins with new ones each
time they are disassembled
(7) Use genuine Cesab parts for replacement
(8) Use specified bolts and nuts and observe the specified tightening torque when reassembling
(tighten to the medium value of the specified tightening torque range). If no tightening torque is
specified, use the value given in the “standard tightening torque table”
3. Protection of functional parts (battery operated vehicles)
Before connecting the battery plug after vehicle inspection or maintenance, thoroughly check each
connector for any connection failure or imperfect connection.
Failure or imperfect connection of connectors related to controllers, especially, may damage
elements inside the controllers
4. Defect status check
Do not start disassembly and/or replacement immediately, but first check that disassembly and/or
replacement is necessary for the defect
5. Waste fluids and solid refuses disposal
Always use a proper container when draining waste fluids from the vehicle. Careless discharge of oil,
fuel, coolant, oil filter, battery, solid refuses or other harmful substance may adversely affect human
health and destroy the environment. Always collect and sort well this kind of materials, and treat them
properly requesting disposal by specialized companies and according to current laws
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BATTERY RECYCLING/DISCARDING
This forklift truck uses a lead accumulator and, in case of
some battery-powered trucks, a lithium battery.
Materials contained in batteries (also accumulators) are
hazardous to the environment and humans and therefore
discarded batteries should be returned to the manufacturer
for recycling.
DISCARDING THE BATTERY
When the working life of the battery ends up (change for a new battery) or the truck has to be scrapped, it
is required a special attention to environmental risks when disposing/recycling batteries. Contact the
manufacturer for changing or discarding batteries.
RECYCLING
2
3
4
5
1
6
1BODYWORK steel, brass, bronze, ABS, plastic-reinforced fibre-glass,
polymers
2 DRIVE UNIT steel, copper, nylon, graphite,
polymers
3 BRAKING UNIT steel, polymers, nylon
4 ELECTRIC UNIT steel, copper, silicon, brass, aluminium, lead, zinc, graphite,
nylon, polymers
5 STEERING UNIT steel, bronze, polymers
6HYDRAULIC
UNIT steel, copper, bronze, brass, aluminium, graphite, polymers
VARIOUS
COMPONENTS steel, copper, brass, aluminium, cast-iron, ABS, nylon, polymers
DISPOSAL OF
MINERAL OILS,
GREASE AND
BATTERY
In compliance with local
directives.
Please dispose of in an
environmentally friendly way!
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JACK-UP POINT
Always observe the following instructions when jacking up the vehicle:
• When the fork is loaded, unload it and park the vehicle on a flat surface. Be sure to avoid an
inclined or rough surface.
• Use a jack with ample capacity and jack up the vehicle at the specified jack-up point. Jacking up
at any other point is dangerous.
• Always support the load of jacked-up vehicle with wooden blocks at specified points.
Supporting the vehicle with the jack only is very dangerous.
• Never, under any circumstances, put any part of the body (including hands and feet) under the
jacked-up vehicle.
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MEMBER WEIGHTS
Member Vehicle model Weight (Kg)
Battery 100 372 ÷ 420
125 600 ÷ 690
150 676 ÷ 780
Drive motor 100 - 150 ~ 34
Pump motor (Hydraulic pump + electric motor) 100 - 150 ~ 40
Rear axle (without wheels and dry) 100 - 150 ~ 53
Counterweight 100 - 150 ~ 900
Mast with lift brackets (with lift cylinder, without forks, lifting
height 4350 mm, 2M T.V.) 100 - 150 ~ 450
Vehicle weight (w/battery) 100 ~ 2550
125 ~ 2820
150 ~ 2930
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TOWING THE TRUCK
The standard fork lift trucks are not suited for towing.
In special case, the rear draw bar can be used to tow a faulty
lift truck.
In this case it is obligatory to use a stiff towing bar, fastened
between the rear draw bar of the truck and the towing
vehicle. You must proceed carefully and slowly, if possible on
a level surface.
• while towing, do not carry any other loads on the forks;
• as far as possible, avoid driving on gradients. In any case,
do not go over the figure for driving on gradients with a
load.
Note the cautions below when towing the vehicle with
back wheels lifted.
• Lift the rear wheels for towing
• The traveling speed when towing must not exceed the
maximum traveling speed of the forklift
• Before starting towing, always set the key switch to OFF,
the direction switch to the neutral position and parking
brake of released
• Before towing, either remove the fork or take action to
prevent the fork from coming into contact with the ground
due to bouncing
When making a curve, towed loads tend to reduce the
curving radius; therefore it is important to widen the entrance
radius in order to avoid striking against any obstacle.
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ELECTRICAL PARTS INSPECTION
1. Always disconnect the battery plug before inspecting or servicing electrical parts.
2. Pay sufficient attention when handling electronic parts.
(1) Never subject electronic parts, such as computers
and relays, to impact
(2) Never expose electronic parts to high temperature or
moisture
(3) Do not touch connector terminals, as they may be
deformed or damaged due to static electricity
3. Use a circuit multimeter that matches the object and purpose of measurement.
Analogtype:Thistypeisconvenientforobservingmovementduringoperationandtheoperating
condition. Measured value is only a reference
Digital type:Afairlyaccuratereadingispossible.However,itis difficult to observe operation or
movement.
(1) Difference between results of measurement with analog and digital types
∗The results of measurements using the analog type and the digital type may be different.
Differences between the polarities of the analog type and the digital type are described below.
1) Analog circuit multimeter
Example of measurement result
Multimeter range: 1 kΩ
2) Digital circuit multimeter
Example of measurement result
Multimeter range: 2MΩ
Forward Reverse
Analog type
Forward Continuity
11 kΩ
Reverse No continuity
∞
Forward Reverse
Digital type
Forward No continuity
1
Reverse Continuity
2 MΩ
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