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S210
CESAB S210 User Manual
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© Cesab
20 –
4
T Code(s):
841
, 842, 843
Repair man
ual:
Electrical comp
onents and wiri
ng diagrams
Model(s):
S210, S
212,
S212S, S212L,
S214,
S
214L,
S220D
Publication Nu
mber:
758885
7-040
Date:
2018-05
-01
Applies from s
erial number:
6
384351-
S21
X1
G1
F1
F50, F51
, F52
B90
X40
A30
Q10
Q25
T1
T7/T8
X21
https://www.forkliftpdfmanuals.com/
281
283
Table of Contents
1. Contents
3
2. General introduction
11
2.1 How to use this manual
11
2.2 Warning levels and symbols
12
2.3 Pictograms
13
3. General safety rules
15
3.1 Work safety
15
3.2 Electrical system
17
3.3 Safe lifting
18
3.4 Truck modifications
19
4. Operation and connection sequences
21
Symbols on keypad and display
22
4.1 Battery is connected
23
4.2 Login via keypad
23
4.3 Tiller arm lowered for driving
24
4.4 Driving in fork direction
24
4.5 Driving in the drive wheel direction
25
4.6 Neutral position braking
25
4.7 Reverse braking
26
4.8 Mechanical braking
26
4.9 Emergency reversal
27
4.10 Fork lifting
27
4.11 Fork lifting (S210)
28
4.12 Support arm lift (S212L, 214L, S220D)
28
4.13 Fork lowering
29
4.14 Support arm lowering (S212L, 214L, S220D)
29
4.15 Click-2-Creep
30
4.16 Turtle function (option)
30
5. Parameters
31
5.1 General
31
5.1.1 Show/change parameters
32
5.1.2 Operator parameters
33
5.1.3 Overview
33
5.1.4 Connection to logged-in operator
34
Description of operator parameters
34
Parameters 3 and 4 – Acceleration/Deceleration
34
Parameters 6 and 7 – Maximum travel speed
35
5.2 General service parameters
36
5.2.1 Overview
36
5.2.2 Description
37
Parameter 101/104 – Service/Log-out
37
Parameter 102 - Operator access
37
Parameter 103 - Start-up display
38
Parameter 105/106 - Collision sensor sensitivity for X/Y (Optional)
39
Parameter 107 – Battery size
40
Table applicable to P214, 216, 218, 220
41
Table concerning P225
42
Table concerning S208L, 210, 212S, 212L, 212, 214L, 214, 220D
43
Verifying parameter settings for freely ventilated batteries (lead-acid batteries)
44
Verifying the parameter setting for valve-regulated batteries (Exide)
44
Parameters 109/110 - Built-in charger (option)
45
Parameter 111 - Reset procedure after collision (option)
46
Parameter 112 - Clear application data
46
5.3 Service parameters, travel functions
47
5.3.1 Overview
47
5.3.2 Description
48
Parameter 201 – Deceleration when reversing
48
Parameter 202 – Maximum speed Turtle mode activated
48
Parameter 203 - Maximum speed, forks above 1.8 m
49
Parameter 204 - Maximum acceleration, forks above 1.8 m
49
Parameter 205 - Maximum reversing, forks above 1.8 m
49
Parameter 206 - Automatic speed reduction, forks above 1.8 m
50
5.4 Service parameters, hydraulic functions
51
5.4.1 Description
52
Parameter 301 – Ramping value for lowering stop
52
Parameter 302 - Fork, lowering speed
52
Parameter 303 - EVP start mode
52
Parameter 304 - EVP support arm lowering speed
53
Parameter 305 - EVP slow lowering speed
53
Parameter 306 - Activation of “Click-2-Creep” lifting/lowering
53
Parameter 307 - Automatic support arm lowering (On/Off)
54
Parameter 499 - (Not applicable)
54
5.5 Factory parameters
55
5.5.1 Overview
55
5.5.2 Description
56
Parameter 1001 - Type of truck
56
Parameter 1002 - Non-configurable options
57
Parameters 1003-1042 – Optional functions
58
Parameter 1044 - Master maximum speed
71
Parameter 1045 - Type of battery in the truck
71
Parameter 1046 - Adapting to special trucks
72
Parameter 1101 - Built-in battery charger
72
Parameter 1102 - Controls for hydraulic function
73
Parameter 1110 – Reset voltage for BDI
74
Parameter 1118 - Hardware version
75
6. Installation and commissioning
77
6.1 Transporting the truck
77
6.2 Transporting the mast
77
6.3 Safe lifting
78
6.4 Installing the battery
79
6.5 Using PIN codes
80
6.5.1 General
80
6.5.2 PIN code for resetting after a collision
80
6.5.3 Programming PIN codes
81
6.5.4 PIN code at delivery
81
6.6 Programming PIN codes
82
6.6.1 PIN code defaults
83
6.7 Setting parameters
84
6.8 Function and safety checks
85
7. Maintenance
87
7.1 Introduction
87
7.2 Maintenance instructions
87
7.2.1 Cleaning and washing
87
7.2.2 High-pressure washers
87
7.2.3 Degreasing agents
88
7.2.4 Cleaning the exterior
88
7.2.5 Cleaning the chain
88
7.2.6 Cleaning the motor compartment
88
7.2.7 Electric components
89
7.3 Maintenance schedule
89
8. Troubleshooting
101
8.1 General
101
Software compatibility
101
8.2 Towing a defective truck
101
Tow using a tow truck and tow wagon:
102
8.3 Emergency driving mode
102
8.4 Troubleshooting methods
103
8.4.1 General initial troubleshooting
103
8.4.2 Concluding troubleshooting
104
8.5 Error code history
105
8.6 Error code system
106
8.7 Error codes
107
8.8 Troubleshooting chart
145
8.8.1 The truck cannot be driven.
146
8.8.2 Truck only travels at reduced speed
147
8.8.3 The truck can be driven but behaves abnormally
148
8.8.4 The truck can be driven, but some functions do not work
149
Software compatibility
149
Hardware compatibility matrix
149
8.8.5 Defective hydraulic functions
150
8.9 Built-in test function
154
8.10 Digital input/output status
156
8.10.1 Test mode "9" –
156
8.10.2 Test function “10” – Logic card
157
8.10.3 Test mode “12” – Expansion unit SEU (option).
158
8.11 Built-in test function for the tiller arm
159
8.11.1 Display test
159
8.11.2 Speed control
159
8.11.3 Safety reversing
159
8.11.4 Controls for lifting/lowering
159
8.11.5 Sensilift
160
8.11.6 Keypad
160
8.12 Checking the built-in battery charger
161
9. Chassis 0000
163
9.1 Support arm 0350
163
9.1.1 Support arm lift, lateral adjustment
163
9.1.2 Adjusting the kneeling action
164
9.2 Motor mounts 0450
165
9.2.1 Replacing springs (not applicable for S212S)
165
9.3 Removing the platform
167
10. Electric drive motor 1700
169
10.1 Overview
169
10.2 Removing the motor from the truck
170
10.3 Removing the toothed wheel
172
10.4 Removing motor bearings
174
10.5 Removing the RPM sensor
175
10.6 Installing the temperature sensor
176
10.7 Drive motor tightening torques
177
10.8 Cleaning
178
11. Drive gear 2550
179
11.1 General
179
11.2 Overview
180
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 oil
186
11.7.1 Draining oil
186
11.7.2 Checking/refilling oil
187
11.8 Replacing the wheel hub seal
188
Removing the seal
188
Fitting the seal
189
11.8.1 Replacing studs
190
12. Brake system/Wheels C3000
191
12.1 Brake system - C3100
191
12.1.1 Description
191
Travel brake
191
Parking brake
191
Emergency brake
191
12.2 Parking brake 3180
192
12.2.1 Overview
192
12.2.2 Emergency release of the parking brake
193
12.3 Removing the parking brake
194
12.4 Fitting the parking brake
195
12.5 Checking the air gap
196
12.6 Drive wheel 3530
197
12.6.1 Replacing the drive wheel
197
12.7 Castor wheels 3540
198
12.7.1 Overview
198
12.7.2 Castor wheel mounting
199
12.7.3 Replacing the castor wheel
200
12.7.4 Disassembling the castor wheel cradle
201
12.8 Spring replacement
201
12.8.1 Removing springs
201
12.8.2 Fitting the spring
201
12.9 Support arm wheel 3550
202
12.9.1 Overview
202
12.10 Climber wheels
204
12.10.1 Overview
204
13. Tiller arm 4000
205
13.1 Overview
205
13.2 Removing the tiller arm
207
13.3 Replacing an gas strut
207
13.4 Replacing the safety sensor
208
13.4.1 Removal
208
13.4.2 Installation
208
13.5 Electric steering system – 4000
209
13.5.1 Tiller arm handle C4110
209
13.5.2 Overview
209
13.5.3 Replacing the keypad C9420
211
13.5.4 Replacing the upper cover C4110
212
Removing the upper cover
212
13.5.5 Replacing the tiller arm handle
214
Removing the tiller arm handle
214
Fitting the tiller arm handle
214
13.5.6 Replacing the logic card
215
Removing the logic card
215
Installing a logic card
216
13.5.7 Checking the handle
217
13.5.8 Update the software
217
13.5.9 Replacing the signal button/switch
218
13.5.10 Replacing the lift/lower button
219
13.5.11 Replacing the sensilift
220
13.5.12 Replacing the stomach button
221
13.5.13 Changing the position of the controls - support arm lift/ fork lift
222
14. Electrical components-5000
223
14.1 Li-ion battery (Hoppecke)
223
14.1.1 Resetting/restarting the battery
223
14.2 Inspecting the battery
223
14.3 Replacing the wiring harness
224
14.3.1 Replacing the transistor regulator wiring harness
225
14.4 Replacing the transistor regulator
226
15. Hydraulic system 6000
229
15.1 General
229
15.2 Hydraulic hygiene
230
15.2.1 Washing
230
15.2.2 Packaging
230
15.2.3 Handling
230
15.2.4 Storage
231
15.2.5 Work procedures
231
15.3 Hydraulic unit 6100
232
15.3.1 Emptying the hydraulic tank
233
15.3.2 Hydraulic system, bleeding
233
Cylinders with bleeding valve
233
Cylinders without bleeding valve
233
15.4 Hydraulic connections 6230
234
15.4.1 Quick change connectors
234
Connecting the quick change connector
234
Disassembly of the quick change connector
235
15.5 Hose rupture valve
236
15.5.1 Replacing the hose rupture valve
236
15.6 Hydraulic calibration
237
15.7 Adjusting the pressure limiting valve
238
15.8 Disassembling the hydraulic unit
240
15.9 Hydraulic unit tightening torques
242
16. Mast C7000
243
16.1 Main mast 7100
243
16.1.1 Components
243
16.1.2 Maintenance
244
Fixing point
244
Lubrication
244
16.2 Fork carriage 7420
245
16.2.1 Maintenance
245
16.3 Main lift chain system 7120
246
16.3.1 General
246
16.3.2 Checking the chain setting
247
16.3.3 Checking the chain
247
Noise
247
Surface rust
247
Rusty links
247
Stiff links
247
Bolt rotation
248
Loose bolts
248
Outline wear
249
Stretching
250
Damage
250
Damaged plates
251
Damaged bolts
251
Dirty chain
251
16.3.4 Cleaning
251
16.3.5 Lubrication
252
16.3.6 Adjustment
253
16.4 Replacing the fork carriage
254
16.5 Replacement of the mast
256
16.6 Replacing the idler roller
261
16.7 Adjusting the mast
262
17. Peripherals C8000
265
18. Accessories
267
18.1 Spider expansion unit
267
18.2 TLS - Truck log system
268
18.3 ID unit
268
18.4 DC/DC converter
269
18.5 Collision sensor
269
18.6 Built-in battery charger
270
18.6.1 Technical data
270
18.6.2 Charging the battery
271
Main charging
271
Equalising charging
271
Charging completed
271
19. Instructions for disposal
273
19.1 General
273
19.2 Marking of plastics
273
19.2.1 General marking of products and packaging
273
19.2.2 Marking according to the manufacturer’s standards
274
Abbreviations
274
Marking examples
274
19.3 Pressure vessels
275
19.3.1 Gas struts
275
19.4 Sorting categories
276
20. Electrical components and wiring diagrams
279
20.1 Electric components
279
20.2 Wiring diagram
283
20.2.1 List of symbols
283
20.2.2 General wiring diagram
284
20.2.3 Wiring diagram
285
21. Hydraulics chart
297
22. Tools
299
22.1 MQS contacts
299
22.2 AMP connectors
301
22.2.1 AMP connectors, Multilock series 040
302
22.3 Molex connectors
302
22.4 Grease guns
303
22.5 Other tools
304
23. Lubricants specification
307
23.1 General tightening torques
307
23.2 Lubricants specification
308
24. Technical data
309
24.1 S210, S212, S214
309
24.2 S212L, S214L, S220D
312
24.3 S212S
315
24.4 Overflow pressure for mast
318
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CESAB S210 Specifications
General
Brand
CESAB
Model
S210
Category
Trucks
Language
English
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