CESAB S210 - Fork Carriage Replacement Procedure

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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-

16.4 Replacing the fork carriage

1. Lift the fork carriage with an overhead crane or with another truck to take

the load off the chain.

2. Remove the chain bolt.

3. Lower the fork carriage.

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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 - Fork Carriage Replacement Procedure

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