BT FORKLIFT C3E150 C4E150 C3E160 C4E160 C3E160L C4E160L C3E180 C4E180 C3E180L C4E180L C3E200 C4E200 REPAIR MANUAL 036-0437-00 – PDF DOWNLOAD

Repair Manual C3/4E150-200..................  1
	Index...................................  3
	Chapter 0: General......................  5
	Chapter 1: Battery...................... 33
	Chapter 2: Controllers.................. 57
	Chapter 3: Display......................103
	Chapter 4: Troubleshooting..............189
	Chapter 5: Motor........................275
	Chapter 6: Drive unit & Front axle......293
	Chapter 7: Rear axle....................297
	Chapter 8: Steering system..............311
	Chapter 9: Brakes.......................325
	Chapter 10: Body & Frame................353
	Chapter 11: Material handling system....361
	Chapter 12: Mast........................375
	Chapter 13: Cylinder....................399
	Chapter 14: Oil pump....................421
	Chapter 15: Oil control valve...........427
	Chapter 16: Main options................443
	Chapter 17: Programmer..................479
	Chapter 18: Appendix....................499

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