Related Manuals for CESAB S212L
Summarization of Contents
General Introduction
How to Use This Manual
Explains how the repair manual is divided into chapters and the information contained within.
Warning Levels and Symbols
Defines the warning levels (Danger, Warning, Note) and associated symbols used in the manual.
Pictograms
Illustrates common symbols used in the manual for various actions like inspection, cleaning, and measurement.
General Safety Rules
Work Safety
Guidelines for safe working practices to prevent accidents and ensure a safe maintenance environment.
Electrical System Safety
Precautions when working on the truck's electrical system, including risks of short-circuiting and burn injuries.
Safe Lifting Procedures
Instructions for safely lifting the truck, emphasizing proper support and risk of crushing.
Truck Modifications Policy
Rules and procedures for modifying the truck, requiring manufacturer approval and specific documentation.
Operation and Connection Sequences
Battery Connection
Details the event, action, influencing elements, and resulting conditions for connecting the truck battery.
Login via Keypad
Describes the process of logging into the truck using a PIN code via the keypad.
Tiller Arm Operation
Covers the sequence for lowering the tiller arm for driving and driving in different directions.
Braking Functions
Explains neutral braking, reverse braking, and mechanical braking functions of the truck.
Fork and Support Arm Lifting/Lowering
Details the sequences for operating the fork lifting and support arm lifting/lowering functions.
Special Functions (Click-2-Creep, Turtle)
Describes the activation and operation of Click-2-Creep and Turtle functions for controlled movement.
Parameters
General Parameter Information
Introduces parameters, their grouping (operator, service, factory), and how they configure truck operations.
Operator Parameters Overview
Lists and describes operator parameters related to acceleration, deceleration, and maximum speed.
Service Parameters Overview
Provides an overview of general service parameters like service intervals, operator access, and collision sensor settings.
Description of Key Parameters
Detailed descriptions for parameters 101-112 covering service intervals, operator access, battery settings, and data clearing.
Factory Parameters Overview
Lists factory parameters related to truck type, optional functions, battery type, and hardware version.
Optional Functions Configuration
Details configurable optional functions, including SEU outputs, reduced travel speed, and activation logic.
Installation and Commissioning
Truck and Mast Transportation
Instructions for safely anchoring and transporting the truck and its mast.
Safe Lifting Procedures
Guidelines for safely lifting the truck, emphasizing correct lifting points and risk of tipping.
Battery Installation
Steps for correctly installing the battery, including safety warnings about polarity and electrolyte level.
Using PIN Codes
Explains the use of PIN codes for operator profiles, collision reset, and delivery procedures.
Setting Parameters
Covers essential parameters to set during commissioning, referring to the Parameters chapter for details.
Function and Safety Checks
A checklist of essential function and safety checks to perform before putting the truck into use.
Maintenance
Introduction and Safety
Highlights the importance of maintenance for safety and minimizing downtime, including warranty considerations.
Cleaning and Washing Procedures
Details on cleaning the truck's exterior, chains, motor compartment, and electric components.
Maintenance Schedule
Specifies service intervals (750 operating hours or 12 months) and refers to oil and grease specifications.
Troubleshooting
General Troubleshooting Approach
Provides a flowchart for initial troubleshooting, error identification, and problem localization.
Error Code System and History
Explains how to display error code history and the structure of error codes (Group, Sequential Number).
Troubleshooting Charts
Categorizes common truck issues (cannot be driven, reduced speed, abnormal behavior, hydraulic faults) with possible causes.
Built-in Test Functions
Details the built-in test functions for various truck systems like display, speed control, and safety reversing.
Checking the Built-in Battery Charger
A checklist for verifying the proper functioning and parameter settings of the built-in battery charger.
Chassis
Support Arm Adjustments
Instructions for adjusting the support arm lift and lateral guides, including gap checks.
Motor Mounts Spring Replacement
Procedure for replacing springs in the motor mounts, including component removal and installation.
Platform Removal
Steps for disassembling and removing the truck platform, with attention to spring tension.
Electric Drive Motor
Overview and Components
Identifies the key components of the electric drive motor, including sensors and connections.
Motor Removal and Installation
Step-by-step guide for removing the drive motor from the truck and its subsequent installation.
Removing Toothed Wheel and Bearings
Procedures for removing the toothed wheel and motor bearings from the drive motor assembly.
Installing Temperature Sensor
Instructions for installing a new temperature sensor, including cleaning and sealing procedures.
Drive Motor Tightening Torques
Specifies the correct tightening torques for the drive motor mounting screws.
Drive Gear
General Description
Provides a general overview of the drive gear, its integration, and service requirements.
Overview and Components
Details the components and specifications of the drive gear unit, including gear ratio and oil quality.
Gear Removal and Installation
Step-by-step instructions for removing and installing the drive gear from the truck.
Fitting Grease Nipples and Lubrication
Procedure for fitting grease nipples and lubricating steering bearings as an option.
Checking and Changing Oil
Instructions for draining and refilling the drive gear oil, including cleaning the oil plug.
Replacing Wheel Hub Seal
Steps for removing and fitting the wheel hub seal.
Replacing Studs
Procedure for replacing damaged or broken studs on the drive wheel hub.
Brake System and Wheels
Brake System Description
Describes the three types of brakes: travel, parking, and emergency brakes.
Parking Brake Maintenance
Information on parking brake maintenance, overview, and emergency release procedures.
Drive Wheel Replacement
Steps for replacing the drive wheel, including lifting the truck and tightening wheel nuts.
Castor Wheel Replacement
Procedure for replacing castor wheels, including disassembly and mounting steps.
Spring Replacement
Instructions for removing and fitting springs, with notes on pre-tensioning.
Support Arm Wheel Overview
Details the components of the support arm wheel assembly.
Climber Wheels Overview
Illustrates the components of the climber wheels assembly.
Tiller Arm
Overview
Provides an overview of the tiller arm components.
Tiller Arm and Gas Strut Replacement
Procedures for removing the tiller arm and replacing the gas strut.
Safety Sensor Replacement
Steps for removing and installing the safety sensor, including cable routing.
Electric Steering System Components
Overview of the electric steering system components within the tiller arm.
Keypad and Upper Cover Replacement
Instructions for replacing the keypad and the upper cover of the tiller arm.
Tiller Arm Handle and Logic Card Replacement
Procedures for replacing the tiller arm handle and the logic card, including ESD precautions.
Control Button and Sensilift Replacement
Steps for replacing signal buttons/switches and the sensilift.
Stomach Button Replacement
Procedure for replacing the stomach button, noting it must be replaced as a unit with the cover.
Electrical Components
Li-ion Battery Handling
Instructions for resetting/restarting the Li-ion battery and inspecting its condition.
Wiring Harness Replacement
Procedure for disconnecting and replacing the wiring harness connectors.
Transistor Regulator Replacement
Steps for replacing the transistor regulator, requiring TruckCom for configuration.
Hydraulic System
General Safety Precautions
Essential safety measures before working on hydraulic systems, including pressure release and hot oil warnings.
Hydraulic Hygiene Standards
Instructions for cleaning, packaging, and handling hydraulic components to prevent contamination.
Hydraulic Unit Overview and Procedures
Details the hydraulic unit components and procedures for tank emptying and system bleeding.
Hydraulic Calibration
Explains the calibration function for proportional valves, affecting lowering speeds and starting positions.
Adjusting Pressure Limiting Valve
Procedure for adjusting the pressure limiting valve to ensure the truck can lift the rated load.
Disassembling and Assembling Hydraulic Unit
Step-by-step guide for disassembling the hydraulic unit, including hose and cable disconnections.
Hydraulic Unit Tightening Torques
Provides specific tightening torques for various components of the hydraulic unit.
Mast C7000
Main Mast Components and Maintenance
Details components of the main mast and maintenance procedures for fixing points and lubrication.
Fork Carriage Maintenance
Instructions for checking fork carriage play and adjusting rollers with shims.
Main Lift Chain System Checks and Cleaning
Guidance on checking and cleaning the main lift chain system, including bolt replacement.
Chain Wear and Damage
Describes types of chain wear (outline, stretching), damage, and when to replace the chain.
Chain Adjustment
Procedure for adjusting lifting chains due to stretching, including torque specifications for lock nuts.
Fork Carriage Replacement
Steps for removing and replacing the fork carriage, including chain bolt removal.
Mast Replacement
Instructions for removing and installing the mast, emphasizing securing it during the process.
Replacing Idler Roller
Procedure for replacing the idler roller, noting shim usage and guide movement checks.
Adjusting the Mast
Guidance on checking and adjusting mast angle after replacement, ensuring the truck is on a level surface.
Accessories
Spider Expansion Unit (SEU)
Describes the SEU's function for expanding inputs/outputs and its connection via CAN bus.
TLS - Truck Log System
Refers to a separate manual for information on the truck log system.
ID Unit
Refers to a separate manual for information on the ID unit software.
DC/DC Converter
Describes the DC/DC converter's function, protection features, and connection.
Collision Sensor
Explains how the collision sensor registers impacts and counts them as collisions based on parameter settings.
Built-in Battery Charger
Information on retrofitting and installing the built-in battery charger, including technical data.
Instructions for Disposal
General Disposal Guidelines
General instructions for environmental protection through recycling and proper sorting of truck components.
Plastic Material Marking
Explains the general marking system for plastics, including resin identification codes.
Sorting Categories for Components
Provides a table categorizing various truck components for proper sorting and disposal.
Gas Struts Handling
Safety warnings and procedures for disassembling gas struts due to high internal pressure.
Electrical Components and Wiring Diagrams
Electric Components Summary
A table listing major electric components, their symbols, functions, and remarks.
Wiring Diagrams
Provides general wiring diagrams and detailed diagrams for various truck systems.
List of Symbols
A key explaining the meaning of symbols used in the wiring diagrams.
Tools
MQS Contacts and Toolkits
Lists MQS contact tools, including basic and refill toolboxes with their uses.
AMP and Molex Connectors
Details AMP connectors (Power Timer, Junior, Micro) and Molex connectors with relevant tools.
Grease Guns and Accessories
Describes various types of grease guns, hoses, and nozzles for lubrication tasks.
Other Tools
Lists other necessary tools, including CAN service keys and programming instruments.
Lubricants Specification
General Tightening Torques
Provides a table of tightening torques for millimetre threads (M3 to M24) based on strength class.
Lubricant Specification Table
Details recommended lubricants based on ambient temperature and viscosity class for various components.
Technical Data
Model-Specific Data (S210, S212, S214)
Technical specifications for drive motor, brake, transmission, and hydraulic system for S210, S212, S214 models.
Model-Specific Data (S212L, S214L, S220D)
Technical specifications for drive motor, brake, transmission, and hydraulic system for S212L, S214L, S220D models.
Model-Specific Data (S212S)
Technical specifications for drive motor, brake, transmission, and hydraulic system for S212S model.
Mast Overflow Pressure
Table showing pressure and pump flow data for various mast types and their recommended overflow pressures.
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