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02 C200-250H Sauer-Carraro 17-09 en
02 C200-250H Sauer-Carraro 17-09 en
02 C200-250H Sauer-Carraro 17-09 en
Technical
Specifications
Dimensions (in)
E
A B C D narrow wide F G I J K L
version version
C200H
6ft 8.7in 9.6in 12.2in 4ft 6.1in 4ft 9.5in 5ft 10in R 9ft 2.2in 8ft 6.4in 4in 1.6in 2ft 13ft 11in
C200HI
C200H x4
6ft 9.9in 10.6in 12.2in 4ft 6.8in 4ft 9.5in 5ft 10in R 14ft 5.2in 9ft 6.2in 4in 1.6in 2ft 13ft 11in
C200HI x4
C250H
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
C250HI
C250H
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
C250H x4
Dimensions (mm)
E
A B C D narrow wide F G I J K L
version version
C200H
2050 245 310 1375 1460 1782 R 2800 2600 100 40 610 4240
C200HI
C200H x4
2080 270 310 1392 1460 1782 R 4400 2900 100 40 610 4240
C200HI x4
C250H
2150 280 390 1375 1510 1810 R 2800 2600 130 45 615 4245
C250HI
C250H
2120 320 390 1392 1510 1810 R 4400 2900 130 45 615 4245
C250H x4
C200H / C200H x4 / C200HI / C200HI x4
C250H / C250H x4 / C250HI / C250HI x4
Technical
Specifications Mast chart (in)
Duplex (Std.) 10ft 10in Narrow / Wide (op.) 4.7in 7ft 10.3in 8ft 0.9in 13ft 7.4in 13ft 10in 4040 4040 4040 5060 5060 5060
Duplex 8ft 6in Narrow / Wide (op.) 4.7in 6ft 8.5in 6ft 11in 11ft 3.9in 11ft 6.4in 4040 4040 4040 5060 5060 5060
Duplex 11ft 10in Narrow / Wide (op.) 4.7in 8ft 4.2in 8ft 6.8in 14ft 7.2in 14ft 9.8in 4040 4040 4040 4650 4850 5060
Duplex 14ft 9in Wide / Narrow (HI) 4.7in 9ft 9.9in 10ft 0.5in 17ft 6.6in 17ft 9.2in - 3640 3640 - 4250 5060
Triplex
12ft 2in Narrow / Wide (op.) 4ft 4in 6ft 8.5in 8ft 11.5in 15ft 0.7in 15ft 3.7in 3640 4040 4040 4450 4650 5060
(free lift)
Triplex
14ft 1in Wide / Narrow (HI) 4ft 4in 7ft 4.5in 7ft 7.5in 17ft 2in 17ft 5in - 3640 3640 - 4250 5060
(free lift)
Triplex
17ft 8in Narrow / Wide (op.) 5ft 6in 8ft 6.8in 8ft 9.7in 20ft 7.8in 20ft 11in - 2220 3440 - 2220 4430
(free lift)
Duplex (Std.) 3300 Narrow / Wide (op.) 120 2395 2460 4150 4215 2000 2000 2000 2500 2500 2500
Duplex 2600 Narrow / Wide (op.) 120 2045 2110 3450 3515 2000 2000 2000 2500 2500 2500
Duplex 3600 Narrow / Wide (op.) 120 2545 2610 4450 4515 2000 2000 2000 2300 2400 2500
Duplex 4500 Wide / Narrow (HI) 120 2995 3060 5350 5415 - 1800 1800 - 2100 2500
Triplex
3700 Narrow / Wide (op.) 1130 2045 2120 4590 4665 1800 2000 2000 2200 2300 2500
(free lift)
Triplex
4300 Wide / Narrow (HI) 1330 2245 2320 5230 5300 - 1800 1800 - 2100 2500
(free lift)
Triplex
5400 Narrow / Wide (op.) 1680 2610 2685 6295 6370 - 1100 1700 - 1100 2200
(free lift)
C200H / C200H x4 / C200HI / C200HI x4
C250H / C250H x4 / C250HI / C250HI x4
Transmission
Hydrostatic system, with variable flow pump and motor and automatic adjustment.
Slow approach function (inching).
Front axle with self-locking differential
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 selected.
Steering
Hydraulic powered with one double acting hydraulic cylinder on the rear axle.
C250H / C250HI:
Working pressure: 870 psi (60 bar)
C200H / C200H x4 / C200HI / C200HI x4
C250H / C250H x4 / C250HI / C250HI x4
Technical Wheels
Rear wheels
Dimensions Speed rating Load index
C200H 7,00 - 12” A4 113
C200HI 7,00 - 12” A4 113
C200H x4 27 x 10,5 – 12” A4 113
C200HI x4 27 x 10,5 – 12” A4 113
C250H 7,00 - 12” A4 117
C250HI 7,00 - 12” A4 117
C250H x4 10,0/75 - 15,3” A4 117
C250HI x4 10,0/75 - 15,3” A4 117
Pressures
Pressures (bar)
Front wheels Rear wheels
C200H 4,5 ± 0,5 8,5 ± 0,7
C200HI 3 ± 0,3 8,5 ± 0,7
C200H x4 4,5 ± 0,5 4,5 ± 0,5
C200HI x4 4,5 ± 0,5 4,5 ± 0,5
C250H 4,5 ± 0,5 8,5 ± 0,7
C250HI 5 ± 0,5 8,5 ± 0,7
C250H x4 5 ± 0,5 3,5 ± 0,4
C250HI x4 5 ± 0,5 6 ± 0,5
Pressures (bar)
Flotation front wheels
Rear wheels
(optional)
C250H x4 2,5 ± 0,3 3,5 ± 0,4
NOTE
Tyres with a combination of different loads index and speed rates than those
indicated, can give equivalent results in terms of load and speed conditions
required for each vehicle according to the specifications of load variation with
speed reduction established by the E.T.R.T.O. technical manual.
C200H / C200H x4 / C200HI / C200HI x4
C250H / C250H x4 / C250HI / C250HI x4
Technical Brakes
Service brake. Multidisc sealed hydraulic brake.
Specifications Parking brake. Multidisc sealed brake spring applied, hydraulically released.
Hydraulic circuit
One double gear pump driven by the hydrostatic pump of the transmission; one body
for the mast operations and one for the hydraulic steering.
Working temperature
From 5ºF to 104ºF (from -15ºC to 40ºC)
Weights
Load Capacity
With the load center of the load at 500 mm. (see LOAD CHARTS In this manual)
C200H / C200H x4 / C200HI / C200HI x4: 4409 lbs. (2.000 Kg)
C250H / C250H x4 / C250HI / C250HI x4: 5511 lbs. (2.500 Kg.)
With the load center at 600 mm (see LOAD CHARTS In this manual)
C200H / C200H x4 / C200HI / C200HI x4: 4078 lbs. (1850 Kg.)
C250H / C250H x4 / C250HI / C250HI x4: 5070 lbs. (2300 Kg.)
Standard mast
Side-shift 47 in. (1200 mm ) width
Lifting height: 10ft. 10in. (330 mm).
Free litf: 6 inches (150 mm).
Forks length: 47 inches (1200 mm).
Fork carriage
Class: FEM III
Lifting speed
Without load: 103 ft/min (0,526 m./sec).
With load: 101 ft/min (0,513 m./sec).
Lowering speed
Without load: 81 ft/min. (0,412 m./sec).
With load: 125 ft/min (0,637 m./sec).
WARNING
This forklift is not designed to travel with elevated load or with the mast tilted
forward.
Do not tilt forward the mast with the forks elevated except to pick up or deposit
the load.
C200H / C200H x4 / C200HI / C200HI x4
C250H / C250H x4 / C250HI / C250HI x4
Lighting (¬)
Work lighting equipment, steering indicators, parking lights and warning.
Overhead guard
Manufactured according with ISO 3449 and ISO 3471 / ASME B56.6.
WARNING
The operator is protected by an overhead 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 the operator may suffer
serious injury or even loss of life as a result of crushing from the forklift or even
the overhead guard itself.
Aisle widths
See graph.
C200H / C200H x4 / C200HI / C200HI x4
C250H / C250H x4 / C250HI / C250HI x4
Electric circuit
CABLE COLOURS
A Light Blue
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:
Electric circuit H1
C200H / C200H x4 / C200HI / C200HI x4
C250H / C250H x4 / C250HI / C250HI x4
Electric circuit H2
C200H / C200H x4 / C200HI / C200HI x4
C250H / C250H x4 / C250HI / C250HI x4
Electric circuit H3
C200H / C200H x4 / C200HI / C200HI x4
C250H / C250H x4 / C250HI / C250HI x4
Electric circuit H4
C200H / C200H x4 / C200HI / C200HI x4
C250H / C250H x4 / C250HI / C250HI x4
Electric circuit H5
C200H / C200H x4 / C200HI / C200HI x4
C250H / C250H x4 / C250HI / C250HI x4
Electric circuit H6
C200H / C200H x4 / C200HI / C200HI x4
C250H / C250H x4 / C250HI / C250HI x4
Electric circuit
A100 Sauer Unit (ECU) 5 H71 Dash panel buzzer (warning lights) 1
E12 Left hand headlight 4 K7 Joystick neutral signal relay (only C150H)** 6
F3 Side lights / brake lights / reverse relay fuse (7'5A) 4 K65 Start permission relay* 1
F7 Seat switch / hand brake / timer relay fuse (10A)* 2 K73 FNR switch disconnection relay (handbrake on)* 2
F7 Seat switch / hand brake / timer relay fuse (10A)** 6 K74 H1 inhibit relay 2
3rd.and 4rth.service solenoids (sideshift or M14 Wiper motor 1
F8 2
attachments) fuse (7'5A)
F9 Dash panel lights / heater motor fuse (10A) 1 M15 Rear wiper motor 4
F10 Flashing / rotating beacon and working lights fuse (25A) 4 M20 Electric fuel pump 3
F11 Permanent live warning lights switch (5A) 4 M25 Starting motor 1
FG1 Permanent live main fuse (50A) 1 M32 Windscreen washer motor 3
FG2 Starter motor relay main fuse (50A) 1 P52 Multifunction instrument 1
FG3 Pre-heat relay main fuse (30A) 1 R1 Diagnosis CAN resistance 120 Ω 5
H2 Brake and tail lights right hand side 4 S23 Coolant temperature warning switch 1
H6 Brake and tail lights left hand side 4 S33 Seat switch** 6
Y4 Front solenoid 5
Y5 Rear solenoid 5
OPTIONALS LIST
Item Description Page
Opcional 1 4x4 Transmission (Full Grip) 3
* Opcional 2 Removed with Optional 2 -
** Opcional 2 Australia security 6
1
Engine Kubota Air Filter .
V2403-M Outer
Inner
2
Hydrostatic pump Hydrostatic motor Hydraulic pump Hydraulic pump Functions
Sauer 420 Bar / Sauer 420 Bar / Steering: 220 Bar / 18 cc
4x4 53 cc 80 cc
160 Bar / 8 cc (2wd)
FullGrip® valve 60 bar / 8 cc (4wd)
3
Charge pressure By-pass valves Speed sensor Displacement Braking valve
relief valve valve
4
Previous style Current style
Speed sensor Speed sensor
5
Hydrostatic
Pump controller
6
Joystick spools
Control valve Locking Hydraulic oil
solenoids filter
p/n 60.20100.00
7
Stop lights Brake master
Service brake Park brake switch cylinder
8
Fuel pre-filter Fuel pump Tilting
cylinders
safety valves
9
K63 Driver seat timer relay
K64 Blinker relay
K65 Start permission relay
K67 Reverse alarm relay
K68 Start relay
K73 FNR switch disconnect relay (park brake on)
K74 steering column buzzer inhibit relay
10
F1 Low beam fuse (10A)
F5 Ignition feed stop solenoid / fuel pump / pre-heating / alternator fuse (7'5A)
Seat sensor
11
C250 ELECTRICAL
In order to check electrical settings on C250 first of all we
have to check Hydrostatic pump is working properly:
Steering pump
160 bar (2wd) Full Grip valve
60 bar (4wd)
GC130716
Check that two solenoids from hydrostatic motor are correctly
placed. In case wrong Y1 and Y2 connectors, Sauer Box does
not shows any error code and machine not works properly:
FRONT MACHINE
MACHINE COUNTERWEIGHT
Y1 connector Y2 connector
SPEED MOTOR SELENOID PARKING BRAKE SELENOID
GC130716
Fuses location number is written on left side on the plastic
support, better to check on the machine than on this
instruction as fuses box can be turned up.
F9
F5
F1
F6 F2
F10
F7
F3
F8 F4
F11
GC130716
GC130716
To check all relays is necessary to screw out plastic covers from
steering column (relays color can be different depending on
the supplier of them)
K63= 12.11047.00
K65 K73 K67 K68
K64= IM.20025.00
K65= IM.20026.00
K67= IM.20026.00
K68= 10.14288.00
K73= IM.20026.00
X66 / X73
GC130716
S55 S59
S56 S61
GC130716
GENERAL SCHEME
1/2 SPEED
GEARBOX FULLGRIP
FullGrip ® system is inside the transfer box and is made by 2 groups of discs, half
of them fixed to the front transmission and the other half to the rear transmission.
When 4WD is not necessary the discs are relaxed without any friction and all
engine
g p
power is only
y given
g to the rear axle.
4WD will be automatically deactivated when you stop the engine (M 350 H) / do
not press button (Forklifts).
DISCONNECTED CONNECTED
2WD 4WD
MAIN ADVANTAGES
Shift on fly. Just connect the FullGrip ® while
driving, you will immediately have a full 4WD
transmission. Connection and disconnection can
b d
be done at any speed d even if you are turning,
i or
your vehicle wheels are slipping.
FORKLIFTS C 200/250/300/350/400/500 H
MANUALE DI RIPARAZIONE
REPAIR MANUAL
ASSALE ANTERIORE
FRONT AXLE
Mod. 28.16M
ASSALE POSTERIORE
REAR AXLE
Mod. 26.09M
a - Locate release plugs (b) (fig. 2, 3) in the front axle. 2 are in the front face and 2
in the rear face.
- With a 24mm. spanner wrench hold the external nut (c) (fig. 4) while slacking
and removing plug (d) with a 8 mm. allen key.
Repeat this operation in all 4 plugs (b)
- Insert a 8 mm. allen key in one of the orifices and bring near the inner release
screws (e) (fig. 5) until abutting inside. DO NOT FORCE. APPROXIMATE ONLY.
Repeat this operation in all 4 orifices (a).
- With a 8 mm. allen key, tighten up the inner screws (e) until abutting inside the
(fig. 1)
brake, first both of the right side (front a rear face) and then both of the left side
(front and rear face) or vice versa.
The intervals of tightening the inner release screws (e) should be HALF TURN
AFTER HALF TURN. DO NOT FULLY TIGHT AND ALWAYS FIRST ONE SIDE OF
a
b a
b THE BRAKE AND AFTER THE OTHER SIDE.
Once the forkfift is fixed, to return the brake to its working position:
- With a 8mm. allen key, lose inner release screws (e) until leaving them free,
first both of the right side (front a rear face) and then both of the left side (front
and rear face) or vice versa. The intervals of loosen the inner release screws
(e) should be HALF TURN AFTER HALF TURN. DO NOT FULLY TIGHT AND
ALWAYS FIRST ONE SIDE OF THE BRAKE AND AFTER THE OTHER SIDE.
(fig. 2)
- Once the inner screws (e) stop straining, loose 2 more turns and leave them in
this position.
- With a 24mm. spanner wrench, hold the external nut (c) (fig. 4) while installing
plug (d) with an 8 mm. allen key. Repeat this operation in all 4 plugs (b).
WARNING
Any repair to the brake system should be carried out by an authorized AUSA
dealer.
a a
(fig. 3)
b b
a
d a
e
a
c
(fig. 4)
(fig. 5)
H1 45/53 Closed
Circuit Axial Piston
Pumps
Service Manual
C200H / C200H x4 / C200HI / C200HI x4
C250H / C250H x4 / C250HI / C250HI x4
CAUTION
It is possible to damage the drive motor by operating in bypass mode without
charge pressure. Move the forklift at a speed not more than 20% of maximum
for a duration not exceeding 3 minutes.
Use this procedure to bypass the pump to allow moving the forklift short distances when
you cannot start the engine.
Service Manual
H1B 060/080/110/160/250
Bent Axis Motors
powersolutions.danfoss.com
C200H / C200H x4 / C200HI / C200HI x4
C250H / C250H x4 / C250HI / C250HI x4
Hydrostatic SAFE-Mode
The machine will stop with error ramp and will not be able to be driven.
Transmission •• Clear the error
Error conditions •• Restart the machine
LIMITED-Mode
The machine will stop with error ramp. If the error can not be cleared, the machine can
run in LIMITED-Mode. The pump current will be reduced by parameter defined in the
System Setup and the motor will be held in vgmax. Functions like swash-plate control,
constant speed, flow limiter and speed limiter are switched off!
•• Engine speed must be lower than the X1 value in the active mode
The Error Flash Codes on the red led are interpreted as follows:
This example shows the error 35: Short circuit selector switch forward / neutral / reverse.
The machine would go to safe mode
Additional Information
•• If the minimum value will be lower than 2,5% of the sensor power (approximately
0,125V) an open circuit will be detected.
•• If the maximum value will be higher than 97,5% of the sensor power (approximately
4,875V) a short circuit will be detected.
The error conditions for this system will cover all important parts of the MC024-21
Automotive System. If any of the errors listed in the table occur the machine will ramp
down the pump current to stop.
C200H / C200H x4 / C200HI / C200HI x4
C250H / C250H x4 / C250HI / C250HI x4
Hydrostatic Error table for models fitting hydrostatic motor with speed sensor (b) (fig. 1)
Transmission Error
Flash Description Action Reference Page
Error conditions Code
Internal Reference Voltage failed Analog Injection
11 SAFE-Mode Internal
Channel Watchdog
12 Analog Injection Channel SAFE-Mode
13 Watchdog SAFE-Mode
The Battery Voltage will be monitored.
14 SAFE-Mode Software
<9 V or > 36V is SAFE-Mode
12V System: < 9V is SAFE-Mode >16V is LIMITED-
Mode
15 LIMITED-Mode
24V System: < 18V or > 32V is
LIMITED-Mode
Sensor Voltage Error. Nominal 5V.
16 SAFE-Mode
<4,875V or >5,125V is out of Range.
19 Pump Coil Wiring crossed SAFE-Mode
Mechanical or
21 Pump Forward and Reverse Control Valve Error SAFE-Mode Valve Output
Overview
Pump Forward Control Valve Error
22 LIMITED-Mode
Feedback Error / Valve Resistance out of Range
Pump Forward Control Valve Error
23 LIMITED-Mode
Feedback Error / Valve Resistance out of Range
Digital Outputs A1 (PSCp03) / A2 (PSC2p04)
25 SAFE-Mode Electrical Outputs
Feedback Error
Digital Outputs B1 (CC2p10) / B2 (CC2p09)
26 SAFE-Mode
Feedback Error
Motor Control Valve Error
28 LIMITED-Mode
Feedback Error / Valve Resistance out of Range
Motor Brake Pressure Defeat Valve
29 LIMITED-Mode
Feedback Error
Engine/pump Speed RPM Error / Input Frequency
31 >10.000 Hz / >8000 rpm / Pump rpm < lowest LIMITED-Mode Electrical Inputs
allowed engine/pump rpm
35 FNR Shortcut Error SAFE-Mode
a
b
(fig. 1)
WORKSHOP MANUAL
DIESEL ENGINE
03-M-E3B SERIES,
03-M-DI-E3B SERIES,
03-M-E3BG SERIES
Transmission Troubleshooting
INSTRUCTIONS FOR THE IDENTIFICATION OF FAILURES IN HYDROSTATIC TRANSMISSIONS
Hydraulic oil cartridge is clogged Depressor marked in vacuum gauge Suction filter < 0,3 bar
Hydraulic oil Suction line is not sealed Sealing for hoses, fittings and Oil connections
overheating cartridge
Recommended max.
Faulty high pressure relief valves Working pressure Working pressure ports in pump
Pressures 345 or 410 bar.
Max. Engine RPM is higher than recommended Max. RPM on the engine Engine
Transmission
over speed Faulty hydrostatic motor. Does not move to max.
flow.
Irregular M4, M5 (SAUER) or Xa, Xb (BOSCH REXROTH)
Hydraulic Chart Oil connections
running Piloting hoses of hydrostatic motor are reversed.