CESAB S210 - Mast Maintenance and Adjustments

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Repair manual: Mast C7000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D

Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351-

16. Mast C7000

16.1 Main mast 7100

16.1.1 Components

Pos

Description Tightening torque

a Upper mast fixing

points.

189 ± 8 Nm

b Lower mast fixing

points.

83±4Nm

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Main Page

1. Contents3
2. General introduction11
- 2.1 How to use this manual11
- 2.2 Warning levels and symbols12
- 2.3 Pictograms13
3. General safety rules15
- 3.1 Work safety15
- 3.2 Electrical system17
- 3.3 Safe lifting18
- 3.4 Truck modifications19
4. Operation and connection sequences21
- Symbols on keypad and display22
- 4.1 Battery is connected23
- 4.2 Login via keypad23
- 4.3 Tiller arm lowered for driving24
- 4.4 Driving in fork direction24
- 4.5 Driving in the drive wheel direction25
- 4.6 Neutral position braking25
- 4.7 Reverse braking26
- 4.8 Mechanical braking26
- 4.9 Emergency reversal27
- 4.10 Fork lifting27
- 4.11 Fork lifting (S210)28
- 4.12 Support arm lift (S212L, 214L, S220D)28
- 4.13 Fork lowering29
- 4.14 Support arm lowering (S212L, 214L, S220D)29
- 4.15 Click-2-Creep30
- 4.16 Turtle function (option)30
5. Parameters31
- 5.1 General31
- 5.2 General service parameters36
  - 5.2.1 Overview36
  - 5.2.2 Description37
- 5.3 Service parameters, travel functions47
  - 5.3.1 Overview47
  - 5.3.2 Description48
- 5.4 Service parameters, hydraulic functions51
  - 5.4.1 Description52
- 5.5 Factory parameters55
  - 5.5.1 Overview55
  - 5.5.2 Description56
6. Installation and commissioning77
- 6.1 Transporting the truck77
- 6.2 Transporting the mast77
- 6.3 Safe lifting78
- 6.4 Installing the battery79
- 6.5 Using PIN codes80
- 6.6 Programming PIN codes82
  - 6.6.1 PIN code defaults83
- 6.7 Setting parameters84
- 6.8 Function and safety checks85
7. Maintenance87
- 7.1 Introduction87
- 7.2 Maintenance instructions87
- 7.3 Maintenance schedule89
8. Troubleshooting101
- 8.1 General101
  - Software compatibility101
- 8.2 Towing a defective truck101
  - Tow using a tow truck and tow wagon:102
- 8.3 Emergency driving mode102
- 8.4 Troubleshooting methods103
  - 8.4.1 General initial troubleshooting103
  - 8.4.2 Concluding troubleshooting104
- 8.5 Error code history105
- 8.6 Error code system106
- 8.7 Error codes107
- 8.8 Troubleshooting chart145
- 8.9 Built-in test function154
- 8.10 Digital input/output status156
- 8.11 Built-in test function for the tiller arm159
- 8.12 Checking the built-in battery charger161
9. Chassis 0000163
- 9.1 Support arm 0350163
  - 9.1.1 Support arm lift, lateral adjustment163
  - 9.1.2 Adjusting the kneeling action164
- 9.2 Motor mounts 0450165
  - 9.2.1 Replacing springs (not applicable for S212S)165
- 9.3 Removing the platform167
10. Electric drive motor 1700169
- 10.1 Overview169
- 10.2 Removing the motor from the truck170
- 10.3 Removing the toothed wheel172
- 10.4 Removing motor bearings174
- 10.5 Removing the RPM sensor175
- 10.6 Installing the temperature sensor176
- 10.7 Drive motor tightening torques177
- 10.8 Cleaning178
11. Drive gear 2550179
- 11.1 General179
- 11.2 Overview180
- 11.3 Removing the gear from the truck (not applicable for S212S)181
- 11.4 Removing the drive gear from the truck (S212S)183
- 11.5 Fitting grease nipples, steering bearings (Option)184
- 11.6 Lubrication the steering bearings (Option)185
- 11.7 Checking and changing the oil186
  - 11.7.1 Draining oil186
  - 11.7.2 Checking/refilling oil187
- 11.8 Replacing the wheel hub seal188
12. Brake system/Wheels C3000191
- 12.1 Brake system - C3100191
  - 12.1.1 Description191
- 12.2 Parking brake 3180192
  - 12.2.1 Overview192
  - 12.2.2 Emergency release of the parking brake193
- 12.3 Removing the parking brake194
- 12.4 Fitting the parking brake195
- 12.5 Checking the air gap196
- 12.6 Drive wheel 3530197
  - 12.6.1 Replacing the drive wheel197
- 12.7 Castor wheels 3540198
- 12.8 Spring replacement201
  - 12.8.1 Removing springs201
  - 12.8.2 Fitting the spring201
- 12.9 Support arm wheel 3550202
  - 12.9.1 Overview202
- 12.10 Climber wheels204
  - 12.10.1 Overview204
13. Tiller arm 4000205
- 13.1 Overview205
- 13.2 Removing the tiller arm207
- 13.3 Replacing an gas strut207
- 13.4 Replacing the safety sensor208
  - 13.4.1 Removal208
  - 13.4.2 Installation208
- 13.5 Electric steering system – 4000209
14. Electrical components-5000223
- 14.1 Li-ion battery (Hoppecke)223
  - 14.1.1 Resetting/restarting the battery223
- 14.2 Inspecting the battery223
- 14.3 Replacing the wiring harness224
  - 14.3.1 Replacing the transistor regulator wiring harness225
- 14.4 Replacing the transistor regulator226
15. Hydraulic system 6000229
- 15.1 General229
- 15.2 Hydraulic hygiene230
- 15.3 Hydraulic unit 6100232
  - 15.3.1 Emptying the hydraulic tank233
  - 15.3.2 Hydraulic system, bleeding233
    - Cylinders with bleeding valve233
    - Cylinders without bleeding valve233
- 15.4 Hydraulic connections 6230234
  - 15.4.1 Quick change connectors234
    - Connecting the quick change connector234
    - Disassembly of the quick change connector235
- 15.5 Hose rupture valve236
  - 15.5.1 Replacing the hose rupture valve236
- 15.6 Hydraulic calibration237
- 15.7 Adjusting the pressure limiting valve238
- 15.8 Disassembling the hydraulic unit240
- 15.9 Hydraulic unit tightening torques242
16. Mast C7000243
- 16.1 Main mast 7100243
  - 16.1.1 Components243
  - 16.1.2 Maintenance244
    - Fixing point244
    - Lubrication244
- 16.2 Fork carriage 7420245
  - 16.2.1 Maintenance245
- 16.3 Main lift chain system 7120246
- 16.4 Replacing the fork carriage254
- 16.5 Replacement of the mast256
- 16.6 Replacing the idler roller261
- 16.7 Adjusting the mast262
17. Peripherals C8000265
18. Accessories267
- 18.1 Spider expansion unit267
- 18.2 TLS - Truck log system268
- 18.3 ID unit268
- 18.4 DC/DC converter269
- 18.5 Collision sensor269
- 18.6 Built-in battery charger270
  - 18.6.1 Technical data270
  - 18.6.2 Charging the battery271
19. Instructions for disposal273
- 19.1 General273
- 19.2 Marking of plastics273
  - 19.2.1 General marking of products and packaging273
  - 19.2.2 Marking according to the manufacturer’s standards274
    - Abbreviations274
    - Marking examples274
- 19.3 Pressure vessels275
  - 19.3.1 Gas struts275
- 19.4 Sorting categories276
20. Electrical components and wiring diagrams279
- 20.1 Electric components279
- 20.2 Wiring diagram283
21. Hydraulics chart297
22. Tools299
- 22.1 MQS contacts299
- 22.2 AMP connectors301
  - 22.2.1 AMP connectors, Multilock series 040302
- 22.3 Molex connectors302
- 22.4 Grease guns303
- 22.5 Other tools304
23. Lubricants specification307
- 23.1 General tightening torques307
- 23.2 Lubricants specification308
24. Technical data309
- 24.1 S210, S212, S214309
- 24.2 S212L, S214L, S220D312
- 24.3 S212S315
- 24.4 Overflow pressure for mast318

CESAB S210 - Mast Maintenance and Adjustments

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