Page 1 Repair manual 7588857-040 S210, S212, S212S, S212L, S214, S214L, S220D. https://www.forkliftpdfmanuals.com/...
Page 2 Chapter 12: Brake system/wheels - New dust cover Chapter 16: Mast - Added replacing the idler roller and the chain bolt This manual contains information on the following trucks: T-Code Model: Serial number S210 6384351- S212 6384351- S212L 6384351- S214...
Page 3: Table Of Contents
Repair manual: Contents Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 1. Contents 2. General introduction..................2–1 2.1 How to use this manual ................2–1 2.2 Warning levels and symbols ................ 2–2 2.3 Pictograms....................
Page 4 Repair manual: Contents Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Parameters 109/110 - Built-in charger (option) 5–15 Parameter 111 - Reset procedure after collision (option) 5–16 Parameter 112 - Clear application data 5–16...
Page 5 Repair manual: Contents Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 7.2.2 High-pressure washers ..............7–1 7.2.3 Degreasing agents ................. 7–2 7.2.4 Cleaning the exterior ..............7–2 7.2.5 Cleaning the chain................7–2 7.2.6 Cleaning the motor compartment ...........
Page 6 Repair manual: Contents Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 10.5 Removing the RPM sensor..............10–7 10.6 Installing the temperature sensor ............10–8 10.7 Drive motor tightening torques ..............10–9 10.8 Cleaning ....................
Page 7 Repair manual: Contents Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 13.5 Electric steering system – 4000............... 13–5 13.5.1 Tiller arm handle C4110 ............. 13–5 13.5.2 Overview ..................13–5 13.5.3 Replacing the keypad C9420 ............. 13–7 13.5.4 Replacing the upper cover C4110..........
Page 8 Repair manual: Contents 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 16.1 Main mast 7100 ..................16–1 16.1.1 Components ................16–1 16.1.2 Maintenance................16–2 Fixing point 16–2...
Page 9 Repair manual: Contents Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 19.3 Pressure vessels ..................19–3 19.3.1 Gas struts ................... 19–3 19.4 Sorting categories..................19–4 20. Electrical components and wiring diagrams........... 20–1 20.1 Electric components ................
Page 10 Repair manual: Contents Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- https://www.forkliftpdfmanuals.com/ © Cesab 1 – 8 T Code(s): 841, 842, 843...
Page 11: General Introduction
Repair manual: General introduction Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 2. General introduction 2.1 How to use this manual The repair manual is divided into chapters containing the following information: •...
Page 12: Warning Levels And Symbols
Repair manual: General introduction Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 2.2 Warning levels and symbols The following warning levels and symbols are used in the repair manual: DANGER Indicates a dangerous situation that –...
Page 13: Pictograms
Repair manual: General introduction Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 2.3 Pictograms Symbol Measure Symbol Measure Visual inspection of condition, wear and loose Component replacement. connections. Cleaning Measurement Check of fluid level and Check that bolts, nuts, etc.
Page 14 Repair manual: General introduction Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Symbol Measure Symbol Measure Open Close Refilling Emptying Update An example of another type of pictogram is “Cut cable ties”: Additional information under the pictogram can, for example, indicate the number of cable ties to be cut.
Page 15: General Safety Rules
Repair manual: General safety rules Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 3. General safety rules Only personnel trained in servicing and repair of this type of truck are authorised to carry out service and repair activities.
Page 16 Repair manual: General safety rules Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- DANGER! The hydraulic system can be damaged. If the oil is contaminated, the hydraulic components will suffer damage.
Page 17: Electrical System
Repair manual: General safety rules Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 3.2 Electrical system When working on the electrical system of the truck, remember the following: • Never wear loose items or jewellery when working with the truck.
Page 18: Safe Lifting
Repair manual: General safety rules Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 3.3 Safe lifting All lifting must be carried out on a level, non-slip and stable surface. Asphalt surfaces should be avoided if possible.
Page 19: Truck Modifications
Repair manual: General safety rules Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 3.4 Truck modifications Any modification of the truck must be approved beforehand. No modification of truck may be performed that may influence the capacity, stability and safety of the truck without prior written approval from the manufacturer, its representative or successor.
Page 20 Repair manual: General safety rules Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- https://www.forkliftpdfmanuals.com/ © Cesab 3 – 6 T Code(s): 841, 842, 843...
Page 21: Operation And Connection Sequences
Repair manual: Operation and connection sequencesModel(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 4. Operation and connection sequences This section provides a basic description of the main functions of the truck.
Page 22: Symbols On Keypad And Display
Repair manual: Operation and connection sequencesModel(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Symbols on keypad and display Symbol Description ON button This button is used to start the truck...
Page 23: Battery Is Connected
Repair manual: Operation and connection sequencesModel(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 4.1 Battery is connected Event Connection of battery Preceding event Connect the truck battery [G1] Action(s) Main power fuses OK [F1]...
Page 24: Tiller Arm Lowered For Driving
Repair manual: Operation and connection sequencesModel(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 4.3 Tiller arm lowered for driving Event Tiller arm lowered for driving Start the truck. Preceding event Lower the tiller arm.
Page 25: Driving In The Drive Wheel Direction
Repair manual: Operation and connection sequencesModel(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 4.5 Driving in the drive wheel direction Event Driving in the drive wheel direction Tiller arm is lowered to the drive position.
Page 26: Reverse Braking
Repair manual: Operation and connection sequencesModel(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 4.7 Reverse braking Event Reverse braking Truck travels in fork or drive wheel direction. Preceding event Speed control turned to opposite travel direction.
Page 27: Emergency Reversal
Repair manual: Operation and connection sequencesModel(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 4.9 Emergency reversal Event Emergency reversal Preceding event Driving in the drive wheel direction When driving in the drive wheel direction, the emergency...
Page 28: Fork Lifting (S210)
Repair manual: Operation and connection sequencesModel(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 4.11 Fork lifting (S210) Event Fork lifting Start the truck. Preceding event Press the fork lift button [A5:S320].
Page 29: Fork Lowering
Repair manual: Operation and connection sequencesModel(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 4.13 Fork lowering Event Fork lowering Start the truck or commence fork lifting. Preceding event Press the fork lowering button [A5:S321].
Page 30: Click-2-Creep
Repair manual: Operation and connection sequencesModel(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 4.15 Click-2-Creep Event Click-2-Creep Start the truck. Preceding event Quick double-actuation of the speed control to activate the function.
Page 31: Parameters
Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 5. Parameters 5.1 General The truck's control system can store a number of different parameters. These are used to configure the truck according to the task to be performed. The parameters are divided into groups: –...
Page 32: Show/Change Parameters
Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 5.1.1 Show/change parameters Make sure that the truck is switched off. Connect the CAN key or enter the PIN code. Note: Do not press the ON switch.
Page 33: Operator Parameters
Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 5.1.2 Operator parameters Note: Changing specific truck parameters changes the truck's driving properties. Do not change any parameter values without the necessary know-how.
Page 34: Connection To Logged-In Operator
Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 5.1.4 Connection to logged-in operator The operator parameters can be adjusted individually to the available log-in profiles. The parameter’s connection to the operator is done by a combination of operator and parameter numbers where the single digit always corresponds to the parameter.
Page 35: Parameters 6 And 7 - Maximum Travel Speed
Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Parameters 6 and 7 – Maximum travel speed These two parameters are used to limit the maximum travel speed for the logged-in operator profile.
Page 36: General Service Parameters
Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 5.2 General service parameters Before any service parameter can be changed, the CAN service key must be connected to the contact [X41].
Page 37 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 5.2.2 Description Parameter 101/104 – Service/Log-out Defa Incre Par. Description Min. Max. Unit ment Service intervals 2000 Time to automatic logout min.
Page 38 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Parameter 103 - Start-up display Defa Incre Par. Description Min. Max. Unit ment Start-up display #103 - Start-up display Sets which value is shown on the display when the truck is started.
Page 39 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Parameter 105/106 - Collision sensor sensitivity for X/Y (Optional) Defa Incre Par. Description Min. Max. Unit ment Collision sensor X-degree of...
Page 40 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Parameter 107 – Battery size Defa Incre Par. Description Min. Max. Unit ment Battery size # 107 - Battery size Specifies what type of battery the truck is equipped with.
Page 41 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Table applicable to P214, 216, 218, 220 Refer to the table below for recommended parameter settings. Parameter 107 Battery size...
Page 42 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Table concerning P225 Refer to the table below for recommended parameter settings. Parameter 107 Battery size Battery size Battery size...
Page 43 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Table concerning S208L, 210, 212S, 212L, 212, 214L, 214, 220D Refer to the table below for recommended parameter settings.
Page 44 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Verifying parameter settings for freely ventilated batteries (lead-acid batteries) 1. Charge the battery. 2. Use the truck in its normal application until the battery indicator shows a discharged battery (0% on the display).
Page 45 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Parameters 109/110 - Built-in charger (option) Defa Incre Par. Description Min. Max. Unit ment Battery type, built-in charger 32766...
Page 46 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Parameter 111 - Reset procedure after collision (option) Defa Incre Par. Description Min. Max. Unit ment Resetting procedure after...
Page 47 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 5.3 Service parameters, travel functions 5.3.1 Overview Par. Description Braking force when reversing the travel direction Maximum speed Turtle mode activated Maximum speed, forks above 1.8 m...
Page 48 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 5.3.2 Description Parameter 201 – Deceleration when reversing Defa Incre Par. Description Min. Max. Unit ment Deceleration when reversing...
Page 49 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Parameter 203 - Maximum speed, forks above 1.8 m Applies to S208L, 210, 212S, 212L, 212, 214L, 214, 220D...
Page 50 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Parameter 206 - Automatic speed reduction, forks above 1.8 m Applies to S208L, 210, 212S, 212L, 212, 214L, 214, 220D...
Page 51 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 5.4 Service parameters, hydraulic functions Par. Description Lowering stop ramp Fork lowering speed EVP startup mode Support arm, lowering speed...
Page 52 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 5.4.1 Description Parameter 301 – Ramping value for lowering stop Applies to S208L, 210, 212S, 212L, 212, 214L, 214, 220D...
Page 53 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Parameter 304 - EVP support arm lowering speed Applies to S208L, 210, 212S, 212L, 212, 214L, 214, 220D Defa Incre Par.
Page 54 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Parameter 307 - Automatic support arm lowering (On/Off) Applies to S208L, 210, 212S, 212L, 212, 214L, 214, 220D Defa Incre Par.
Page 55 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 5.5 Factory parameters The truck's factory parameters are preset in the truck during production at the factory. Factory parameters can only be changed using the TruckCom software application.
Page 56 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 5.5.2 Description Parameter 1001 - Type of truck Defa Incre Par. Description Min. Max. Unit ment 1001 Truck type...
Page 57 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Parameter 1002 - Non-configurable options Defa Incre Par. Description Min. Max. Unit ment 1002 Non-configurable option #1002 - Non-configurable options 3 different functions are accessible via parameter 1002.
Page 58 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Parameters 1003-1042 – Optional functions Defa Incre Par. Description Min. Max. Unit ment 1003 Optional function 1 1004 Optional function 1Arg1...
Page 59 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Parameters #1003-1042 Factory parameters # 1003 to 1042 - configurable optional functions Parameters #1003 to #1042 are reserved in the truck’s control system for extra truck options and/or special product modifications.
Page 60 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Basic option 1 - Option switch controls SEU output Argument #1 Selection of SEU unit 1 or 2 Values...
Page 61 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Basic option 2 - Reduced travel speed via SEU inputs Argument #1 Selection of SEU unit 1 or 2...
Page 62 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Basic option 3 - Truck movement activates SEU output Argument #1 Selection of SEU unit 1 or 2 Values...
Page 63 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Basic option 3 - Truck movement activates SEU output Argument #3 Selection of activation movement When driving When driving...
Page 64 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Basic option 4 - Activate main contactor by SEU input Argument #1 Selection of SEU unit 1 or 2...
Page 65 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Basic option 5 - Activate lifting/lowering by SEU input Argument #1 Selection of SEU unit 1 or 2 Values...
Page 66 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Basic option 6 - Lift height limitation by SEU input and override Argument #1 Selection of SEU unit 1 or 2...
Page 67 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Basic option 11 - Automatic height preselector Argument #1 Selection of SEU unit 1 or 2 Values Meaning option is handled by SEU unit 1 (A36)
Page 68 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Basic option 11 - Automatic height preselector Argument #1 Selection of SEU unit 1 or 2 Argument #4 Activation/deactivation external lifting/lowering switch...
Page 69 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Basic option 14 – Activate restrictions on hydraulics via operator profiles Argument #1 Not used. SEU unit not required...
Page 70 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Basic option 15 – Activate restrictions on hydraulics via SEU inputs Argument #1 Selection of SEU unit 1 or 2...
Page 71 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Parameter 1044 - Master maximum speed Defa Incre Par. Description Min. Max. Unit ment 1044 Master maximum speed km/h #1044 - Master maximum speed Sets the maximum speed for the application.
Page 72 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Parameter 1046 - Adapting to special trucks Defa Incre Par. Description Min. Max. Unit ment 1046 Adapting to special trucks...
Page 73 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Parameter 1102 - Controls for hydraulic function Defa Incre Par. Description Min. Max. Unit ment 1102 Controls for hydraulic function...
Page 74 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Parameter 1110 – Reset voltage for BDI Defa Incre Par. Description Min. Max. Unit ment 1110 24.8 25.2 27.0 #1110 –...
Page 75 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Parameter 1118 - Hardware version Defa Incre Par. Description Min. Max. Unit ment 1118 Hardware version #1118 - Hardware version...
Page 76 Repair manual: Parameters Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- https://www.forkliftpdfmanuals.com/ © Cesab 5 – 46 T Code(s): 841, 842, 843...
Page 77 Repair manual: Installation and commissioning Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 6. Installation and commissioning This chapter describes the work that is necessary before the truck can be put into use.
Page 78 Repair manual: Installation and commissioning Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 6.3 Safe lifting • Lift the truck at its centre of gravity using another fork lift truck.
Page 79 Repair manual: Installation and commissioning Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 6.4 Installing the battery The battery to be installed in the truck must be of the right size. If the battery is too small in terms of size and weight, it can seriously affect the truck's braking ability and truck stability when lifting goods.
Page 80 Repair manual: Installation and commissioning Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 6.5 Using PIN codes 6.5.1 General PIN codes can be used e.g. to link different operator experience levels to specific truck characteristics –...
Page 81 Repair manual: Installation and commissioning Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 6.5.3 Programming PIN codes Note: There are two possible methods for programming PIN codes. The first and the simplest is to use TruckCom, which provides clear instructions.
Page 82 Repair manual: Installation and commissioning Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 6.6 Programming PIN codes Make sure that the truck is switched off. Connect the CAN service key to connector [X41].
Page 83 Repair manual: Installation and commissioning Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 6.6.1 PIN code defaults The PIN codes are factory set so that only block 1/operator profiles 1-10 are activated.
Page 84 Repair manual: Installation and commissioning Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 6.7 Setting parameters This chapter covers only those parameters that need to be set upon commissioning of the truck and which require detailed descriptions. Fore more information on the parameters, please refer to the Parameters chapter.
Page 85 Repair manual: Installation and commissioning Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 6.8 Function and safety checks Prior to putting the truck into use, check the following items: Pos.
Page 86 Repair manual: Installation and commissioning Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- https://www.forkliftpdfmanuals.com/ © Cesab 6 – 10 T Code(s): 841, 842, 843...
Page 87 Repair manual: Maintenance Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 7. Maintenance 7.1 Introduction To maintain a high level of truck safety and to minimise downtime, all the points specified in the service programme must be carried out.
Page 88 Repair manual: Maintenance Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 7.2.3 Degreasing agents When using degreasing agents, only environmentally-friendly cold degreasing agents may be used, such as those that are designed for general vehicle cleaning and do not damage paintwork, plastic components, cables, hydraulic hoses or decals.
Page 89 Repair manual: Maintenance Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 7.2.7 Electric components • Clean electric motors using vacuum cleaner or a rag. • Clean electric panels, logic cards, contactors, connectors, magnetic valves, etc.
Page 90 Repair manual: Maintenance Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck area Pos. Measure 750h/12m Time expendi ture 0000 Chassis Inspect cover mountings. 5:20 minutes Check signs and adhesive including labels.
Page 91 Repair manual: Maintenance Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck area Pos. Measure 750h/12m Time expendi ture Support arms – Check for cracks and damage. 1:30 minutes. 0350...
Page 92 Repair manual: Maintenance Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck area Pos. Measure 750h/12m Time expendi ture 0560 Platform Check for cracks and damage 1:30 minutes. and mountings...
Page 93 Repair manual: Maintenance Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck area Pos. Measure 750h Time /12m expenditure 1700 Drive Check the drive motor's attachment. 4:30 minutes (excluding oil motor Clean the drive motor.
Page 94 Repair manual: Maintenance Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- g,h,i Truck area Pos. Measure 750h/12m Time expen diture 3500 Wheels Inspect the drive wheel for wear. minutes Check the nuts.
Page 95 Repair manual: Maintenance Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Wheels Standard Minimum measurements, mm dimensions, mm Drive wheel Castor wheels Support arm wheels 1. Not applicable for S212S https://www.forkliftpdfmanuals.com/...
Page 96 Repair manual: Maintenance Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck area Pos. Measure 750h/12m Time expen diture 4110 Tiller arm Check for proper attachment. 1:45 minutes Inspect the operating console for correct mounting.
Page 97 Repair manual: Maintenance Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck area Pos. Measure 750h/12m Time expendi ture 5000 Electrical Inspect the contacts, wiring harness 4:30 (including the battery cables), cable...
Page 98 Repair manual: Maintenance Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck area Pos. Measure 750h/12m Time expen diture 6000 Hydraulic Check wear on hoses and pipes. minutes Check the oil level.
Page 99 Repair manual: Maintenance Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck area Pos. Measure 750h/12m Time expen diture 7100 Mast Check for any cracks or damage. minutes Check that there is no looseness in the mast's mounting points.
Page 100 Repair manual: Maintenance Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- https://www.forkliftpdfmanuals.com/ © Cesab 7 – 14 T Code(s): 841, 842, 843...
Page 101 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 8. Troubleshooting 8.1 General The troubleshooting section describes the error codes that are displayed when the truck is partially or completely disabled. It also describes the cause of the problem together with corrective remedies.
Page 102 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Tow using a tow truck and tow wagon: 1. Lift the truck onto the tow wagon. See the instructions under Lifting a truck.
Page 103 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 8.4 Troubleshooting methods 8.4.1 General initial troubleshooting Begin troubleshooting error code Follow the instructions in Eliminate improbable displayed? chapter...
Page 104 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 8.4.2 Concluding troubleshooting End the troubleshooting Drive the truck in the same way it was driven when the problem occurred. Verify that the problem does not occur again.
Page 105 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 8.5 Error code history Up to 50 of the most recent error code events can be stored in a log along with the hour meter reading when the error occurred.
Page 106 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 8.6 Error code system See the tables below for an explanation of the error code system. Structure Description X.YZZ Example: 3.510...
Page 107 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 8.7 Error codes Please note that some error codes are saved in the log and disappear from the display, while other error codes remain on the display and require that the truck be switched off and then on again for the error code to disappear.
Page 108 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour Battery Connect the battery connector. connector Check battery voltage disconnected • Check the voltage using the...
Page 109 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour Error on CAN Check the CAN bus bus wiring or • Check that CAN bus is intact in...
Page 110 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour Check parameters • Check that factory parameters Configuration error. Creep speed, are set according to the truck...
Page 111 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour The battery is Charge the battery. discharged Check battery voltage Voltage loss •...
Page 112 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour Error on CAN Check the CAN bus bus wiring or • Check that CAN bus is intact in...
Page 113 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour Error on CAN Check the CAN bus bus wiring or • Check that CAN bus is intact in...
Page 114 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour A5 has an incorrect Check whether contact X203 box address. Everything is is short circuited.
Page 115 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour Check the Hall sensors • Check with TruckCom or the Incorrect power...
Page 116 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour Control Let go of the control, and wait manipulated. for four seconds...
Page 117 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour Cooling Check the cooling reduced or the • Check the cooling flanges of the...
Page 118 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour Cooling Check the cooling reduced or the • Check the cooling flanges of the...
Page 119 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour Cooling Check the cooling reduced or the • Check the cooling flanges of the...
Page 120 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour Restart the truck. Update the truck software Creep speed, The motor control blocked lifting/ •...
Page 121 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour Error on CAN Check the CAN bus bus wiring or • Check that CAN bus is intact in...
Page 122 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour Everything is Replace T1 stopped at once, Error in T1 when the parking brake...
Page 123 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour Error on CAN Check the CAN bus bus wiring or • Check that CAN bus is intact in...
Page 124 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour Short circuit in Check the motor motor • Disconnect motor wiring Short circuit in including sensor wires.
Page 125 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour Everything is Software Update the truck software to stopped at once, failure the latest version.
Page 126 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour The battery is Charge the battery. discharged Check the voltages in T1...
Page 127 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour Short circuit in Check the motor motor • Disconnect motor wiring Short circuit in including sensor wires.
Page 128 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour Check for overcurrent or short circuit: • Check the ohms and the...
Page 129 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour Check for overcurrent or short circuit: • Check the ohms and the...
Page 130 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour power Check wiring and component consumption after the break or break • Disconnect the battery •...
Page 131 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour Low power Check wiring and component consumption after a break (main contactor,...
Page 132 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour Broken wiring Check wiring after the break. Defective • Disconnect the battery component •...
Page 133 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour Intensive use Intensive use of the truck. Let of the truck the truck cool down.
Page 134 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour Incorrect value Check parameters for parameter • Check that factory parameters Signal from the...
Page 135 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour Wire break Check wiring after the break. between • Disconnect the battery and the pump •...
Page 136 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour Collision Resetting truck after collision Collision sensor Parameters Check parameters has registered...
Page 137 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour Error on CAN Check the CAN bus bus wiring or • Check that CAN bus is intact in...
Page 138 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour Cooling Check the cooling reduced or the • Check the cooling flanges of the...
Page 139 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour Battery Check parameters parameters • Check that factory parameters 109 and 110...
Page 140 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour Error on CAN Check the CAN bus bus wiring or • Check that CAN bus is intact in...
Page 141 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour Argument Check parameters error option • Check that factory parameters Argument error in...
Page 142 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour A module in Restart the battery. the battery has Creep speed, been switched...
Page 143 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour Intensive use Intensive use of the truck. Let of the truck the truck cool down.
Page 144 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Truck Code Description Error cause(s) Procedure behaviour Travel speed reduced because of activated Reduced travel Reduced speed Click-2-Creep, speed...
Page 145 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 8.8 Troubleshooting chart The following section describes the type of errors that can occur together with a description of the cause.
Page 146 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 8.8.1 The truck cannot be driven. Symptom Influencing elements Possible cause Mechanical brake cannot Sensor [B60] • Sensor in wrong position or be applied.
Page 147 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 8.8.2 Truck only travels at reduced speed Symptom Influencing elements Possible cause Speed always reduced Click-2-Creep function Click-2-Creep function activated...
Page 148 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 8.8.3 The truck can be driven but behaves abnormally Symptom Influencing elements Possible cause Truck travels in wrong Motor cable connections Incorrect U, V, W connections direction.
Page 149 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 8.8.4 The truck can be driven, but some functions do not work Software compatibility Ensure that the correct software for logic card [A5], motor control [T1] and battery charger [A30] is installed on the truck.
Page 150 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 8.8.5 Defective hydraulic functions Symptom Influencing elements Possible cause/Remedy The forks can be lowered but Low or no hydraulic pressure •...
Page 151 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Symptom Influencing elements Possible cause/Remedy Forks can be raised but not The proportional valve [Q4] for • Measure current and voltage lowered.
Page 152 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Cont'd. Pump contactor [Q25] does not close Symptom Influencing elements Possible cause/Remedy Voltage across contactor coil Interruption in the pump...
Page 153 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Cont'd. Pump motor [M3] does not operate: Symptom Influencing elements Possible cause/Remedy Pump motor [M3] voltage/ Mechanical fault in the pump...
Page 154 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 8.9 Built-in test function The truck has a service information mode that is a useful aid for troubleshooting. To activate: 1.
Page 155 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Data Flashing symbol Description Resolution Unit Standard value Digital I/0 for ICH and ACT. See description in “Test mode "9" –” on...
Page 156 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 8.10 Digital input/output status 8.10.1 Test mode "9" – In this mode, the digital inputs and outputs are tested by checking specific segments on the display according to the following tables.
Page 157 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 8.10.2 Test function “10” – Logic card Function Pos 1 Pos 2 Pos 3 Pos 4 Not assigned Not assigned...
Page 158 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 8.10.3 Test mode “12” – Expansion unit SEU (option). In this mode, the digital inputs and outputs are tested by checking specific segments on the display according to the following tables.
Page 159 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 8.11 Built-in test function for the tiller arm Make sure the battery is connected. Check that the truck is switched off. Press the OFF switch.
Page 160 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 8.11.5 Sensilift Move the sensilift rocker switch from the neutral position to begin the test. The analogue value from the sensilift potentiometer is shown in mV.
Page 161 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 8.12 Checking the built-in battery charger This checklist must be filled in and sent in together with the replaced charger.
Page 162 Repair manual: Troubleshooting Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- This part of the checklist is intended to help us in our improvement work. Check Is there any evidence of moisture on the inside...
Page 163 Repair manual: Chassis 0000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 9. Chassis 0000 9.1 Support arm 0350 9.1.1 Support arm lift, lateral adjustment 1. Loosen the locking nut 2.
Page 164 Repair manual: Chassis 0000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 9.1.2 Adjusting the kneeling action The gap between the chassis pressure plate and the support arm link roller must be between the minimum value of 0.4 and the maximum of 2.0.
Page 165 Repair manual: Chassis 0000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 9.2 Motor mounts 0450 9.2.1 Replacing springs (not applicable for S212S) Proceed as follows to replace the springs that press the drive unit against the ground: 1.
Page 166 Repair manual: Chassis 0000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 8. Change the upper stop screws for M8 x 120, washers are not needed. 9. Remove and discard the screws to the upper bracket.
Page 167 Repair manual: Chassis 0000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 9.3 Removing the platform 1. Apply a load on the platform and loosen the upper dampening stop to- gether with the spring cover plate.
Page 168 Repair manual: Chassis 0000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Note: Pay utmost attention when working with tensioned springs. 5. Relieve the spring using a crowbar or a large screwdriver and carefully remove the bracket.
Page 169 Repair manual: Electric drive motor 1700 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 10. Electric drive motor 1700 10.1 Overview Pos. Description Speed sensor Connection, motor cables Motor: S212L/214/214L/220D 1.5kW Motor: S210/212/212S 1.0kW...
Page 170 Repair manual: Electric drive motor 1700 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 10.2 Removing the motor from the truck 1. Remove the covers. The top cover is secured with Velcro tape. Be careful when detaching the cover.
Page 171 Repair manual: Electric drive motor 1700 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 8. Lift out the motor from the truck. 9. If needed, remove the brake and the speed sensor.
Page 172 Repair manual: Electric drive motor 1700 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 10.3 Removing the toothed wheel • Remove the motor from the truck. Page 10–2 Note: Place the motor on a working surface and make sure that it is secured and cannot fall over.
Page 173 Repair manual: Electric drive motor 1700 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 4. Remove the toothed wheel 5. Reassemble in reverse order https://www.forkliftpdfmanuals.com/ © Cesab 10 – 5...
Page 174 Repair manual: Electric drive motor 1700 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 10.4 Removing motor bearings • Remove the toothed wheel Page 10–4 6. Remove the circlip from above 7.
Page 175 Repair manual: Electric drive motor 1700 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 9. Knock out the bearing 10. Reassemble in reverse order 10.5 Removing the RPM sensor • Remove the hood Undo the screw and pull the RPM sensor straight out.
Page 176 Repair manual: Electric drive motor 1700 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 10.6 Installing the temperature sensor 1. Cut off the wiring to the broken temperature sensor, and splice on the new one 2.
Page 177 Repair manual: Electric drive motor 1700 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 10.7 Drive motor tightening torques The drive motor tightening torques are depicted in the figure below:...
Page 178 Repair manual: Electric drive motor 1700 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 10.8 Cleaning Keep the motor as clean as possible since this is a decisive factor for correct operation.
Page 179 Repair manual: Drive gear 2550 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 11. Drive gear 2550 11.1 General The drive gear is a two-stage angle gear that is integrated with the motor and brake assembly in a complete drive unit.
Page 180 Repair manual: Drive gear 2550 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 11.2 Overview Description Value Gear ratio 29.85 Oil quality 0.8 litres Drive wheel Ø 230 Pos. Description...
Page 181 Repair manual: Drive gear 2550 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 11.3 Removing the gear from the truck (not applicable for S212S) 1. Remove the covers. The top cover is secured with Velcro tape. Be careful when detaching the cover.
Page 182 Repair manual: Drive gear 2550 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 10. Lift the motor bracket using the threaded rod until the drive wheel is lifted approx. 4 mm from the floor.
Page 183 Repair manual: Drive gear 2550 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 11.4 Removing the drive gear from the truck (S212S) 1. Elevate the drive unit approx 190 mm.
Page 184 Repair manual: Drive gear 2550 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 11.5 Fitting grease nipples, steering bearings (Option) Step 1 Step 2 Step 3 Clean the surface, remove all dirt from the recess for the grease nipples.
Page 185 Repair manual: Drive gear 2550 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 11.6 Lubrication the steering bearings (Option) Turn the steering wheel to the end position. Press in some grease, not so much that the seal lifts, check the seal at the grease nipple position.
Page 186 Repair manual: Drive gear 2550 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 11.7 Checking and changing the oil 11.7.1 Draining oil Step 3 T=20 Nm Step 1 Step 2 Undo and remove the oil plug on the lower part of the gear housing.
Page 187 Repair manual: Drive gear 2550 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 11.7.2 Checking/refilling oil Step 1 Step 3 Step 2 Remove the oil filler plug on the upper part of the gear housing.
Page 188 Repair manual: Drive gear 2550 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 11.8 Replacing the wheel hub seal Removing the seal Remove the cover ring using a screwdriver or similar.
Page 189 Repair manual: Drive gear 2550 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Fitting the seal Step 1 Step 2 Fit a new seal. Tap lightly to get it into the right position.
Page 190 Repair manual: Drive gear 2550 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 11.8.1 Replacing studs The drive wheel is fixed to the hub with five studs, conical washers and nuts.
Page 191 Repair manual: Brake system/Wheels C3000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 12. Brake system/Wheels C3000 12.1 Brake system - C3100 12.1.1 Description The truck has three different types of brake: •...
Page 192 Repair manual: Brake system/Wheels C3000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 12.2 Parking brake 3180 In normal work environments, the brake should not require any maintenance. DANGER! Risk of brake function being lost.
Page 193 Repair manual: Brake system/Wheels C3000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Pos. no. Description Dust seal O-ring Dust seal Wiring harness Magnet housing Dust seal Friction disc Pressure disc Mounting plate 12.2.2 Emergency release of the parking brake...
Page 194 Repair manual: Brake system/Wheels C3000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 12.3 Removing the parking brake DANGER! Risk of brake function being lost. When work is done in the brake system, there is a risk of brake function being partly or completely lost.
Page 195 Repair manual: Brake system/Wheels C3000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 12.4 Fitting the parking brake Steps 1 and 2 Step 3 T=5Nm 1. Torque tighten the brake retaining screws to 5 Nm.
Page 196 Repair manual: Brake system/Wheels C3000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 12.5 Checking the air gap • Remove the parking brake Steps 1, 2 and 3 Spacing=0.2 - 0.7mm Place the parking brake on a workbench with the magnet housing facing downwards.
Page 197 Repair manual: Brake system/Wheels C3000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 12.6 Drive wheel 3530 12.6.1 Replacing the drive wheel 1. Raise the forks and lift the truck (approx. 100 mm).
Page 198 Repair manual: Brake system/Wheels C3000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 12.7 Castor wheels 3540 12.7.1 Overview Pos. Description Pos. Description Circlip Screw Washer Spacer Screw Spacer Bracket...
Page 199 Repair manual: Brake system/Wheels C3000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 12.7.2 Castor wheel mounting Pos. Description Pos. Description Screw Control units Washer Spring Bracket Control units Bushing Cradle Shims, max 1mm gap.
Page 200 Repair manual: Brake system/Wheels C3000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 12.7.3 Replacing the castor wheel DANGER! Risk of crushing since a poorly supported truck could fall down.
Page 201 Repair manual: Brake system/Wheels C3000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 12.7.4 Disassembling the castor wheel cradle 1. Raise the forks. 2. Remove the inspection cover. 3. Loosen the spring fasteners.
Page 202 Repair manual: Brake system/Wheels C3000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 12.9 Support arm wheel 3550 12.9.1 Overview Pos. Description Screw Bracket Bogie wheel Single wheel Shaft Circlip...
Page 203 Repair manual: Brake system/Wheels C3000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- e=156 mm e=180 mm Pos. Description Shaft Shaft Pos. Description P214/216 P218/220/225 https://www.forkliftpdfmanuals.com/ © Cesab 12 – 13...
Page 204 Repair manual: Brake system/Wheels C3000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 12.10 Climber wheels 12.10.1 Overview Pos. Description Pos. Description Screw, K6S 8x12 Wheel, assy Screw, MF6S 8x35...
Page 205 Repair manual: Tiller arm 4000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 13. Tiller arm 4000 13.1 Overview https://www.forkliftpdfmanuals.com/ © Cesab 13 – 1 T Code(s): 841, 842, 843...
Page 206: Description
Repair manual: Tiller arm 4000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Pos. Description Pos. Description Tiller arm Indicator sleeve Rubber buffer Plate Cylindrical bolt Yoke Gas strut Cable clamp...
Page 207 Repair manual: Tiller arm 4000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 13.2 Removing the tiller arm 1. Remove the inspection cover. 2. Remove the cover (T). 3. Unscrew the retaining screws of the yoke (R).
Page 208 Repair manual: Tiller arm 4000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 13.4 Replacing the safety sensor 13.4.1 Removal 1. Remove the gas strut. See section “13.3 Replacing an gas strut”.
Page 209 Repair manual: Tiller arm 4000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 13.5 Electric steering system – 4000 13.5.1 Tiller arm handle C4110 13.5.2 Overview https://www.forkliftpdfmanuals.com/ © Cesab 13 – 5...
Page 210 Repair manual: Tiller arm 4000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Pos. Description Cover Plug Wiring harness Cover Toggle switch Horn button Button "lifting/lowering" Display Horn button Switch "horn"...
Page 211 Repair manual: Tiller arm 4000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 13.5.3 Replacing the keypad C9420 Removing the keypad Detach the keypad and disconnect it from the logic card...
Page 212 Repair manual: Tiller arm 4000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 13.5.4 Replacing the upper cover C4110 Removing the upper cover Step 2 Step 1 • Remove the keypad. Page 13–7...
Page 213 Repair manual: Tiller arm 4000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Installing the upper cover Step 2 Step 1 Step 4 Step 3 Connect the CAN bus connection to the logic card Press together the upper and the lower parts, and turn the screws five complete turns.
Page 214 Repair manual: Tiller arm 4000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 13.5.5 Replacing the tiller arm handle Removing the tiller arm handle • Remove the upper cover. Page 13–8 Remove the cable bracket/handle in the tiller arm.
Page 215 Repair manual: Tiller arm 4000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 13.5.6 Replacing the logic card Removing the logic card Step 2 Step 1 Step 1 • Remove the upper cover. Page 13–8...
Page 216 Repair manual: Tiller arm 4000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Installing a logic card Step 3 Step 3 Steps 1, 2 Fit the new logic card in place and connect it.
Page 217 Repair manual: Tiller arm 4000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 13.5.7 Checking the handle Test drive the truck and check the functions of the handle 13.5.8 Update the software If a new logic card without software has been installed, use TruckCom to download software and reset the parameters.
Page 218 Repair manual: Tiller arm 4000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 13.5.9 Replacing the signal button/switch Step 1 Step 2 Step 3 Step 3 Step 4 • Remove the stomach button Page 13–17 Remove the screws to the wire fittings.
Page 219 Repair manual: Tiller arm 4000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 13.5.10 Replacing the lift/lower button Step 3 Step 1 Step 2 • Remove the stomach button Page 13–17...
Page 220 Repair manual: Tiller arm 4000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 13.5.11 Replacing the sensilift Step 1 Step 2 • Remove the stomach button Page 13–17 Remove the button, use a screwdriver to carefully prise it loose Pull it straight up •...
Page 221 Repair manual: Tiller arm 4000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 13.5.12 Replacing the stomach button Step 1 Step 1 • Remove the upper cover Page 13–8 Remove the screws holding the cover/stomach button over the logic card and carefully lift away the cover.
Page 222 Repair manual: Tiller arm 4000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 13.5.13 Changing the position of the controls - support arm lift/ fork lift 1. Pry off the lift control buttons using a thin screwdriver and switch the positions with the rear buttons.
Page 223 Repair manual: Electrical components-5000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 14. Electrical components-5000 14.1 Li-ion battery (Hoppecke) 14.1.1 Resetting/restarting the battery If error codes are generated or the battery lamp does not light with a steady green glow, the battery can be restarted.
Page 224 Repair manual: Electrical components-5000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 14.3 Replacing the wiring harness Pos. Description Connector clamp Connector, female part Bracket Connector, male part Proceed as follows when replacing the wiring harness: 1.
Page 225 Repair manual: Electrical components-5000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 14.3.1 Replacing the transistor regulator wiring harness Keep the following in mind if it becomes necessary to disconnect the connector (A) of the transistor regulator: •...
Page 226 Repair manual: Electrical components-5000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 14.4 Replacing the transistor regulator Note: This action requires access to TruckCom! ±1,4 Nm 1. Remove the inspection cover.
Page 227 Repair manual: Electrical components-5000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- After installation of the new transistor regulator, the truck will display error code 2.004. 1. Connect TruckCom. 2. Select “Copy truck configuration”.
Page 228 Repair manual: Electrical components-5000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- https://www.forkliftpdfmanuals.com/ © Cesab 14 – 6 T Code(s): 841, 842, 843...
Page 229 Repair manual: Hydraulic system 6000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 15. Hydraulic system 6000 15.1 General Always take the following safety precautions prior to commencing work on the truck's hydraulic systems: •...
Page 230 Repair manual: Hydraulic system 6000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 15.2 Hydraulic hygiene Note: Risk of malfunction. If impurities get into the hydraulic system, there is a risk of malfunctions in part or all of the hydraulic system.
Page 231 Repair manual: Hydraulic system 6000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 15.2.4 Storage Hydraulic components must be handled and stored so that: • no rusting can occur • dust and dirt particles are shielded out •...
Page 232 Repair manual: Hydraulic system 6000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 15.3 Hydraulic unit 6100 Pos. Description Pos. Description Pump motor [M3] Hydraulic fork connection Solenoid valve, support arm selection...
Page 233 Repair manual: Hydraulic system 6000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 15.3.1 Emptying the hydraulic tank 1. Loosen all cables and tubes to the hydraulic unit. 2. Loosen the hydraulic unit from the truck by releasing the clamps that surround the pump motor.
Page 234 Repair manual: Hydraulic system 6000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 15.4 Hydraulic connections 6230 15.4.1 Quick change connectors Connecting the quick change connector 1. Place the assembly stop (1) on the male fitting and make sure that the dismantling ring (2) runs freely in the groove.
Page 235 Repair manual: Hydraulic system 6000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Disassembly of the quick change connector 1. Remove the assembly stop (with the aid of a screwdriver or similar tool).
Page 236 Repair manual: Hydraulic system 6000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 15.5 Hose rupture valve 15.5.1 Replacing the hose rupture valve The hose rupture valve is built into the cylinder/hydraulic hose bracket.
Page 237 Repair manual: Hydraulic system 6000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 15.6 Hydraulic calibration A calibration function can be used to handle the proportional valve's [Q4] tolerance. Service mode “cal” must have the setting “1” and the truck must be restarted in order to activate the calibration mode.
Page 238 Repair manual: Hydraulic system 6000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 15.7 Adjusting the pressure limiting valve Valve location The truck must be able to handle the rated load on the forks.
Page 239 Repair manual: Hydraulic system 6000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 4. Turn the adjusting screw clockwise until the truck is able to lift the load without any problem.
Page 240 Repair manual: Hydraulic system 6000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 15.8 Disassembling the hydraulic unit Before commencing any work on the hydraulic unit, make sure the forks have been fully lowered.
Page 241 Repair manual: Hydraulic system 6000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Step 5. × n s mm Step 4. s: 7mm, n: 1ea × n s mm s: 6mm, n: 1ea Step 6.
Page 242 Repair manual: Hydraulic system 6000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 15.9 Hydraulic unit tightening torques The hydraulic unit tightening torques are depicted in the picture below: 10 mm...
Page 243 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 Description Tightening torque Upper mast fixing 189 ± 8 Nm points.
Page 244 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- 16.1.2 Maintenance Fixing point According to the maintenance chart, the mast mounting bolts (a) should only be visually inspected and not re-tightened on inspection. If the mast needs to be replaced or if the bolts have come loose, then be sure to use new bolts and washers.
Page 245 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- 16.2 Fork carriage 7420 Pos. Description Shim Roller 16.2.1 Maintenance • Check that the play in the fork carriage is not excessive.
Page 246 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- 16.3 Main lift chain system 7120 16.3.1 General Note: Replacing the chain bolt • When replacing the chain, be sure to also replace the chain bolt •...
Page 247 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- 16.3.2 Checking the chain setting The lifting chains must be adjusted at regular periods due to stretching; see below.
Page 248 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- Bolt rotation Bolt rotation can be a phenomenon of stiff links. The fault is easy to see when comparing with a new chain.
Page 249 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- Outline wear P = Pitch. H2 = Nominal disc height. H3 = Minimum disc height A new lifting chain has a specific nominal plate thickness (H2 in the figure). As the truck is used, the lifting chain wears radially on the side that rolls over the chain wheel.
Page 250 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- Stretching The amount of stretch on a lifting chain is measured on the part of the chain that runs over the chain roller. The amount of stretch may, at the most, be 2% on the most worn section of the chain.
Page 251 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- Damaged plates If a plate has broken on the chain, this may be due to overloading or corrosion.
Page 252 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- 16.3.5 Lubrication Both mineral and synthetic oils can be used to lubricate Rexnord chains. Note: Lubricants must not contain substances such as molybdenum disulphide, PTFE or such.
Page 253 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- 16.3.6 Adjustment The lifting chains must be adjusted at regular periods due to stretching. This is to be done when other service work with chains is performed.
Page 254 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.
Page 255 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- 4. Lift the inner guides. 5. Remove the fork carriage. 6. Install in reverse order. https://www.forkliftpdfmanuals.com/ © Cesab 16 –...
Page 256 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- 16.5 Replacement of the mast We use a Duplex Hilo mast in this example. 1. Start by disconnecting the fork carriage according to the example above.
Page 257 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- 4. Disconnect the main hydraulic hose from the T-connector. 5. Connect a hose plug in the hose to stop the oil flow.
Page 258 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- 7. Lower the mast and secure it in both lifting points with the help of an overhead crane or another truck.See section “22.5 Other tools”.
Page 259 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- 9. Remove the four bolts holding the mast. https://www.forkliftpdfmanuals.com/ © Cesab 16 – 17 T Code(s): 841, 842, 843...
Page 260 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- 10. Make sure that the mast is freed, and lift it past the guide lugs. 11. Attach the new mast in reverse order.
Page 261 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- 16.6 Replacing the idler roller Remove the mast, and place it on a pallet or similar Use a puller to remove the roller.
Page 262 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- 16.7 Adjusting the mast The angle of the mast must be checked after replacement. Make sure that the truck is standing on a level surface when checking.
Page 263 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- Tighten the screws that hold the mast See section “16.1.1 Components”.with the correct tightening torque. https://www.forkliftpdfmanuals.com/ © Cesab 16 –...
Page 264 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- https://www.forkliftpdfmanuals.com/ © Cesab 16 – 22 T Code(s): 841, 842, 843...
Page 265 Repair manual: Peripherals C8000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 17. Peripherals C8000 https://www.forkliftpdfmanuals.com/ © Cesab 17 – 1 T Code(s): 841, 842, 843...
Page 266 Repair manual: Peripherals C8000 Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- https://www.forkliftpdfmanuals.com/ © Cesab 17 – 2 T Code(s): 841, 842, 843...
Page 267 Repair manual: Accessories Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 18. Accessories 18.1 Spider expansion unit The spider expansion unit, called SEU, allows the main logic card to handle a greater number of inputs and outputs.
Page 268 Repair manual: Accessories Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 18.2 TLS - Truck log system See the separate manual that is included with the truck log system. 18.3 ID unit See the separate manual that is included with the software.
Page 269 Repair manual: Accessories Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 18.4 DC/DC converter The truck can be equipped with a DC/DC converter to supply power to equipment such as a PC, scanner, etc. The converter on the input side is protected against polarity reversal, short circuit and thermal overload.
Page 270 Repair manual: Accessories Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 18.6 Built-in battery charger Note: If retrofitting the built-in battery charger, TruckCom is required to be able to set all necessary parameters. TruckCom is not needed if replacing an existing charger.
Page 271 Repair manual: Accessories Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 18.6.2 Charging the battery To start charging, open the battery compartment cover and connect the charger connector to a wall outlet.
Page 272 Repair manual: Accessories Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- https://www.forkliftpdfmanuals.com/ © Cesab 18 – 6 T Code(s): 841, 842, 843...
Page 273 Repair manual: Instructions for disposal Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 19. Instructions for disposal 19.1 General The disposal instructions were developed to support our company's objective of protecting the environment. By recycling materials, resources can be utilised more efficiently, while reducing emissions.
Page 274 Repair manual: Instructions for disposal Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 19.2.2 Marking according to the manufacturer’s standards Standards: 58-02-001 58-02-003 and 58-02-004. A few examples of markings are given here. For more information, please refer to the standards above.
Page 275 Repair manual: Instructions for disposal Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 19.3 Pressure vessels Pressure vessels sent for recycling/destruction must have been depressurised beforehand and, if possible, opened.
Page 276 Repair manual: Instructions for disposal Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 19.4 Sorting categories • Plastic and rubber material • Iron/steel (including bolts, washers and nuts) • Oils •...
Page 277 Repair manual: Instructions for disposal Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Component Category Comments Electronic components Tiller arms Wires Be sure to depressurise struts Iron/steel, also gas struts...
Page 278 Repair manual: Instructions for disposal Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- https://www.forkliftpdfmanuals.com/ © Cesab 19 – 6 T Code(s): 841, 842, 843...
Page 279 Repair manual: Electrical components and wiring diagrams Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 20. Electrical components and wiring diagrams 20.1 Electric components The table below shows a summary of the major electric components of this truck.
Page 280 Repair manual: Electrical components and wiring diagrams Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Display Truck function display Electromechanical Mechanical brake brake Solenoid valve Fork lowering Contactor Main contactor...
Page 281 Repair manual: Electrical components and wiring diagrams Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- S113 S116 S206 S115 S111 S114 S18:2 S18:1 S223 https://www.forkliftpdfmanuals.com/ © Cesab 20 – 3...
Page 282 Repair manual: Electrical components and wiring diagrams Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- T7/T8 F50, F51, F52 https://www.forkliftpdfmanuals.com/ © Cesab 20 – 4 T Code(s): 841, 842, 843...
Page 283 Repair manual: Electrical components and wiring diagrams Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 20.2 Wiring diagram 20.2.1 List of symbols Table 1: List of symbols Symbol Description Symbol Description Truck battery.
Page 284 Repair manual: Electrical components and wiring diagrams Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 20.2.2 General wiring diagram (+) B+ (83) +24V (-) B- DRIVE MOTOR (95) TILLER ARM IN DRIVE POS.
Page 285 Repair manual: Electrical components and wiring diagrams Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 20.2.3 Wiring diagram https://www.forkliftpdfmanuals.com/ © Cesab 20 – 7 T Code(s): 841, 842, 843...
Page 286 Repair manual: Electrical components and wiring diagrams Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- https://www.forkliftpdfmanuals.com/ © Cesab 20 – 8 T Code(s): 841, 842, 843...
Page 287 Repair manual: Electrical components and wiring diagrams Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- https://www.forkliftpdfmanuals.com/ © Cesab 20 – 9 T Code(s): 841, 842, 843...
Page 288 Repair manual: Electrical components and wiring diagrams Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- https://www.forkliftpdfmanuals.com/ © Cesab 20 – 10 T Code(s): 841, 842, 843...
Page 289 Repair manual: Electrical components and wiring diagrams Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- https://www.forkliftpdfmanuals.com/ © Cesab 20 – 11 T Code(s): 841, 842, 843...
Page 290 Repair manual: Electrical components and wiring diagrams Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- https://www.forkliftpdfmanuals.com/ © Cesab 20 – 12 T Code(s): 841, 842, 843...
Page 291 Repair manual: Electrical components and wiring diagrams Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- https://www.forkliftpdfmanuals.com/ © Cesab 20 – 13 T Code(s): 841, 842, 843...
Page 292 Repair manual: Electrical components and wiring diagrams Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- https://www.forkliftpdfmanuals.com/ © Cesab 20 – 14 T Code(s): 841, 842, 843...
Page 293 Repair manual: Electrical components and wiring diagrams Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- https://www.forkliftpdfmanuals.com/ © Cesab 20 – 15 T Code(s): 841, 842, 843...
Page 294 Repair manual: Electrical components and wiring diagrams Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- https://www.forkliftpdfmanuals.com/ © Cesab 20 – 16 T Code(s): 841, 842, 843...
Page 295 Repair manual: Electrical components and wiring diagrams Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- https://www.forkliftpdfmanuals.com/ © Cesab 20 – 17 T Code(s): 841, 842, 843...
Page 296 Repair manual: Electrical components and wiring diagrams Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- https://www.forkliftpdfmanuals.com/ © Cesab 20 – 18 T Code(s): 841, 842, 843...
Page 297 Repair manual: Hydraulics chart Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 21. Hydraulics chart Simplex/ Duplex tele Duplex Hilo Triplex Hilo Duplex tele panoramic Support arms Max 230 Bar https://www.forkliftpdfmanuals.com/...
Page 298 Repair manual: Hydraulics chart Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Pos. Description Pos. Description Tank Lift cylinder, support arm Solenoid valve, fork selection [Q22] Filter Solenoid valve, support arm selection...
Page 299 Repair manual: Tools Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 22. Tools 22.1 MQS contacts Tools Number 257841 MQS Basic toolbox. The box contains: 1 set pliers with tools 25 x splice sleeves 0.5-1.5 mm...
Page 300 Repair manual: Tools Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Tools Number 257842 MQS refill box. Use to refill the “MQS 257843 Com- plete toolbox”. The refill box contains: 200 x sleeves 0.2-0.5 mm...
Page 301 Repair manual: Tools Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 22.2 AMP connectors PT = Power Timer (4.8. 5.8. 6.3 mm) JPT = Junior Power Timer (2.8 mm) MPT = Micro Power Timer (1.5 mm)
Page 302 Repair manual: Tools Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 22.2.1 AMP connectors, Multilock series 040 Figure Number 213130 Pin removal tool 213129 Crimping tool for pins 22.3 Molex connectors...
Page 303 Repair manual: Tools Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 22.4 Grease guns Figure Number 24981 A tool with a pointed nozzle used to apply grease. Length 170 mm.
Page 304 Repair manual: Tools Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 22.5 Other tools Figure Number 7513225 Service key (CAN) 1=7521083 2=163793 Service instrument (CASTOR USB) for programming 1=163793 Service instrument for...
Page 305 Repair manual: Tools Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Figure Number 08-13022 Drive gear puller https://www.forkliftpdfmanuals.com/ © Cesab 22 – 7 T Code(s): 841, 842, 843...
Page 306 Repair manual: Tools Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- https://www.forkliftpdfmanuals.com/ © Cesab 22 – 8 T Code(s): 841, 842, 843...
Page 307 Repair manual: Lubricants specification Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 23. Lubricants specification 23.1 General tightening torques Millimetre threads M3 to M24. The following applies in the case of good conditions, e.g.
Page 308 Repair manual: Lubricants specification Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 23.2 Lubricants specification Specification Lubricant type Usage > -15°C < -15° C S213366 S213366 Grease Bearings and bushes...
Page 309 Repair manual: Technical data Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 24. Technical data 24.1 S210, S212, S214 Model S210 S212 S214 Drive motor Type Iskra AML7108 Iskra AML7109 Power, kW 1.0,...
Page 310 Repair manual: Technical data Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Model S210 S212 S214 Wheels Drive wheel, mm Wheel pressure (kg/mm²) 0.22 0.24 Axle pressure without load, kg...
Page 311 Repair manual: Technical data Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Model S210 S212 S214 Battery compartment, Batteries Capacity, Ah Weight, kg min/max 189/280 189/280 189/280 Truck travel speeds...
Page 312 Repair manual: Technical data Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 24.2 S212L, S214L, S220D Model S212L S214L S220D Drive motor Type Iskra AML7109 Power, kW Duty cycle S2-60 min Weight, kg 10.5...
Page 313 Repair manual: Technical data Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Model S212L S214L S220D Wheels Drive wheel, mm Wheel pressure (kg/mm²) 0.24 0.24 0.27 Axle pressure without load, kg...
Page 314 Repair manual: Technical data Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Model S212L S214L S220D Battery compartment, Batteries Capacity, Ah Weight, kg min/max 189/280 Truck travel speeds Unloaded, km/h...
Page 315 Repair manual: Technical data Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 24.3 S212S Model S212S Drive motor Type Iskra AML7108 Power, kW Duty cycle S2-60 min Weight, kg Brake...
Page 316 Repair manual: Technical data Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Model S212S Wheels Drive wheel, mm Wheel pressure (kg/mm²) 0.32 Axle pressure without load, kg Axle pressure at rated load, kg Wheel bolts tightening torque, Nm 81±19...
Page 317 Repair manual: Technical data Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- Model S212S Battery compartment, Batteries Capacity, Ah Weight, kg Truck travel speeds Unloaded, km/h Unloaded, m/s With rated load, km/h...
Page 318 Repair manual: Technical data Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- 24.4 Overflow pressure for mast Mast (rated load) Pressure at Pump flow at Recommended rated load rated load...
Page 319 Repair manual: Technical data Model(s): S210, S212, S212S, S212L, S214, S214L, S220D Publication Number: 7588857-040 Date: 2018-05-01 Applies from serial number: 6384351- https://www.forkliftpdfmanuals.com/ © Cesab 24 – 11 T Code(s): 841, 842, 843...
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This manual is also suitable for:

S212 S212s S212l S214 S214l S220d

CESAB S210 Repair Manual

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Summary of Contents for CESAB S210

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