Cesab B300 B400 Series II Forklift Repair Manual 036-0447-00

Description

Cesab B300 B400 Series II Forklift Repair Manual

This is the full workshop repair manual for the Cesab B300 and B400 Series II counterbalance forklift trucks, published under document number 036-0447-00. It is a complete service and repair reference covering the B315II, B316II, B316LII, B318II, B318LII, B320II, B415II, B416II, B416LII, B418II, B418LII, B420II and B420LII models. Whether you are servicing a single truck or running a fleet, the Cesab B300 B400 Series II Forklift Repair Manual gives you the procedures, torque figures and diagnostic paths needed to work on these machines from bumper to counterweight.

File Details

• Manual type: Repair / workshop manual
• Brand: Cesab
• Series: B300 II / B400 II
• Document number: 036-0447-00
• Language: English (translation of the original instruction)
• Page count: 786
• File format: PDF
• Models covered: B315II, B316II, B316LII, B318II, B318LII, B320II, B415II, B416II, B416LII, B418II, B418LII, B420II, B420LII

Chapters Covered

This Cesab B300 B400 Series II forklift repair manual is organised into numbered chapter groups. The main topics are listed below with their major sub-sections.

• General – vehicle exterior view, vehicle models, chassis number location, how to use the manual, operating tips, jack-up points, lifting the vehicle, suspension rope angles, safety load for each suspension rope angle, component weights, towing the truck, electrical components inspection, stability system notes, tightening torque tables (ISO metric coarse and fine thread), lubricants and fluids table, periodic maintenance schedules and lubrication chart.
• Battery – lead battery and lithium battery sections, battery compartment dimensions, required battery weights, standard service values, multi-display battery charge indicator functions, battery management parameters, battery voltage reading procedures, BDI parameter tables, battery indicator troubleshooting, battery unit disassembly and assembly, PMU board, BMS card, energy saving activation and deactivation, charging procedures.
• Control System – general layout, rear compartment fuses, fuses under the dashboard, contactors, DC/DC converters, traction and lifting logic units, steering logic unit (EPS), MCB card, multi-display functions, armrest card standard and multifunction joystick versions, armrest potentiometers, accelerator and brake potentiometers, steering sensors (3-wheel and 4-wheel), tilt angle potentiometer, mast pressure sensor, mast height switch, and calibration procedures.
• Multi-Function Display – general display and button layout, menu map, operator menu, administrator menu (password entry, power control, traction setting, material handling, truck management, shock sensor), mask menu (analyzer, tuning, option set, matching, others menu), and forced ignition.
• Troubleshooting – connector check, wire harness and connectors inspection procedure, insulation check procedure, motor winding check procedure, temperature sensor check procedure, CAN-bus check procedure, full diagnostic codes list with causes and remedies, and procedures for when an error code is displayed.
• Motors – traction motor and pump motor general information, disassembly, inspection and reassembly, temperature sensor replacement.
• Drive Unit & Front Axle – front axle assembly, disassembly and assembly with point operations, drive unit removal, oil draining and refilling.
• Rear Axle – rear axle unit for 3-wheel and 4-wheel versions, rear axle hub with cast articulated joint, rear axle cylinder, wheels and tyre specifications.
• Hydraulic Steering – steering column, TFD sensor (3-wheel version), orbitrol (4-wheel version), inspection and adjustment of maximum pressure, and priority valve (4-wheel version).
• Brake – general brake system, service brake pedal, parking brake, emergency release procedure and service brake bleeding.
• Chassis – components for 3-wheel and 4-wheel versions, operator’s seat, battery cover unit, overhead guard, counterweight removal and installation.
• Material Handling System – hydraulic circuit for 3-wheel and 4-wheel versions, oil filter, lifting load down test, natural forward tilting test, oil leak test.
• Masts – mast general, fork carriage assembly and mast removal, mast group (V, FV, FSV, FW, FSW), fork carriage, guide shoes, mast adjustment, standard for selecting oversize rollers, mast roller, chains, forks, and adjusting rings on the lift cylinder rod.
• Cylinders – lifting cylinders (central and side cylinders for all mast types) and tilting cylinders, with general information, specifications, disassembly, inspection and assembly.
• Oil Pump – specifications, adjusting the oil flow rate, disassembly and assembly, test method.
• Oil Control Valve – hydraulic diagram, components, specifications, disassembly and assembly, maximum pressure adjustment, manual lowering valve.
• Stability System – general I.S.D. (Intelligent Stability Design) system, repair work procedures, hand grip position correction valve, oscillation lock cylinder.
• Main Options – rear compartment fuses, fuses under dashboard, height selector (maximum height limiter, height limiter, automatic height control), flash and rotating lamp, work spotlights, combined lights, rear blue light, front blue light, heater, heated rear window, radio, windscreen wiper, courtesy light, and multifunction joystick.
• Appendix – wiring harness, wiring diagram (multifunction joystick version, 3-wheel and 4-wheel versions, low and full options versions), and wiring diagram for lithium battery.

Across all these sections, the manual provides the full workshop-level information required to maintain and repair these trucks. Hydraulic circuit diagrams, wiring schematics, exploded component views, torque tables and step-by-step point operations are included so that jobs can be carried out correctly rather than by guesswork.

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What This Manual Enables You to Do

The Cesab B300 B400 Series II Forklift Repair Manual covers the complete machine, from the traction motor and drive axle through the hydraulic pump and control valve to the mast, chains and cylinders. It also includes the electrical architecture: the traction and lift logic units, EPS steering unit, MCB card, armrest cards, displays, sensors and the full CAN-bus network. When a fault code appears, the troubleshooting section explains what the code means, what conditions trigger it, and which components, connectors or wiring to check.

Routine maintenance schedules, lubricant specifications, tightening torques and component weights are provided so that periodic servicing can be carried out to the correct standard. For major repairs such as mast removal, cylinder resealing, axle overhaul or brake work, the point operations and exploded illustrations guide the sequence and identify special tools where required.

Why This Manual Matters

Counterbalance forklifts are safety-critical machines. Incorrect assembly of a mast, brake or steering component can lead to load loss, tipping or loss of control. The Cesab B300 B400 Series II Forklift Repair Manual provides the correct procedures, component identification, wear limits and adjustment values so that repairs are completed to specification. Having the diagnostic code list and electrical schematics on hand also reduces downtime by directing fault-finding to the right circuit or component rather than replacing parts by trial and error.

Delivery

The manual is delivered as an instant PDF download after payment. There is no shipping and no waiting. The file can be viewed on any device, searched for the section you need, and printed if a paper copy is preferred for the workshop. Keep it on a laptop, tablet or phone and have the complete Cesab B300 B400 Series II forklift repair information available whenever a job comes in.