CESAB R200 Series User manual

CESAB R200 1.2 - 1.6 tonne
Reach trucks
PRODUCT GUIDE

This product guide applies to:
Model
R212
R214
R216
Document revision history:
Edition date Changes
January 2011 New generation Reach trucks
Copyright CESAB Material Handling Europe
Edition: January, 2011

Product Guide – R200 3
Contents
Product range information 5
General ……………………………………………………………… 5
Applications 6
Sales arguments 7
Features and benets…………………………………………………… 7
Important sales arguments for R200 ………………………………………15
Product details 17
Main components and controls ……………………………………………17
Emergency switch ………………………………………………………18
Keypad ………………………………………………………………18
Display ………………………………………………………………19
Operating console ………………………………………………………21
Overhead guard panel …………………………………………………23
Operator’s seat …………………………………………………………24
Pedals…………………………………………………………………25
Accessories bar ………………………………………………………26
Storage compartments …………………………………………………26
Technical information 27
Capacity information ……………………………………………………27
Aisle width requirements …………………………………………………28

Product Guide – R200
4
Calculation of aisle width requirements ……………………………………28
Floor requirements………………………………………………………29
Batteries and chargers …………………………………………………29
Options 31
Load support …………………………………………………………31
Extension forks …………………………………………………………31
Lift height limiter ………………………………………………………31
Height indicator and height pre-selection …………………………………32
Side shifting ……………………………………………………………32
Fork tilt angle +4°/-0,5° …………………………………………………33
Warning light …………………………………………………………33
Writing table ……………………………………………………………33
Rear-view mirror ………………………………………………………34
Foot-operated travel direction switch ………………………………………34
Operator’s seat …………………………………………………………35
Operator protection ……………………………………………………35
Overhead guard for drive-in racking ………………………………………36
Battery replacement equipment – Roller bed ………………………………36
Battery change table/trolley ………………………………………………36
Appendix 37
Parameter setting ………………………………………………………37
Programming/deletion of height preselection ………………………………38
Using height preselection ………………………………………………39

Product range information
Product Guide – R200 5
Product range information
General
The R200 series completes the lower capacity
range with capacity segments made up by the
R212 (1200 kg), R214 (1400 kg) and R216 (1600
kg). In the right application, combining AC tech-
nology for driving with DC technology for lifting
results in optimum machine performance.
These are the main characteristics of the R200
Series:
– 360° progressive, electronic steering
– electronic control of hydraulic movement
– possibility to both accelerate and retard (brake)
with the same pedal
– perfect vision in all directions
– electronic, regenerative brake system
– Automatic parking brake

Applications
Product Guide – R200
6
Applications
Typical application involves universal material handling at smaller sites. The truck
can be used for cargo handling in large warehouses and racking, oor stacking and
transport.
Typical customers are made up by small and medium size companies with a vary-
ing number of pallets handled each day. These customers can be found in most
industries, from wholesalers and retailers to small manufacturers and haulage cont-
ractors.

Sales arguments
Product Guide – R200 7
Sales arguments
Features and benets
Operator compartment
The operator compartment should be ergonomi-
cally designed since this is where the operator
spends most of the day. A tired operator is less
productive.
• Low in-step height of only 270 mm
• The black upright has an easy-to-grip surface
for fast, safe entry to the truck.
• Seat with ergonomic design
• Adjustable forward/backward and backrest angle
• Storage compartments for documents, pens, knives, cans, gloves, etc.
• Armrest positioned and designed to provide comfortable support
• Insulated battery wall to reduce the effects of variations in temperature during
work
• Protected operator environment. The operator is
always inside the truck prole
• Large overhead guard that protects the entire
operator compartment
• Excellent view through the overhead guard
• Headrest on the rear up-right protects the
operator’s head and neck against shocks and
bumps
• Plexiglas protection prevents touching of mast

Sales arguments
Product Guide – R200
8
Free-view mast
• The mast width allows excellent visibility from
the operator’s position
• High lifting and lowering speeds
• Dampened movement of fork carrier when
switching from free lift to main lift, and vice
versa
• Soft stopping for all lifts
• Fast reach operation that can be adjusted to suit
any handling situation
• Crawl speed when the reach carriage approaches the end positions
• All hydraulic functions have automatic cushio-
ning:
– Lifting/lowering: Gentle stopping when the
lever is released. This minimises jerking move-
ment in the fork carriage as a result of the high
speed
– Reach extension: Gentle stopping to reduce
the risk of mast sway
– Side shifting: Gentle starting and stopping
• Mast chains with vefold safety implementation
assure the highest level of safety both for the
operator and the handled load.

Sales arguments
Product Guide – R200 9
Fork tilting
• Available on R214 and R216
• No mast sway just like mast tilting
• Minimum transfer of the centre of gravity
• Reduced capacity because of the lifting height
can be minimised
• Quick tilting speed independent of the lifting
height
• Maintained tilting angle no matter what the lifting height
Extra hydraulic functions
• Available on R214 and R216
– The oil ow can be easily adjusted using the 4th and 5th function
– 4th and 5th functions operated via separate levers
• Integrated side shifting as option
– More narrow aisle width
– Improved capacity
– Improved visibility when side shifting
• Integrated hoses as option
Three hoses are integrated in the mast: Two for the oil supply and one for electric
cables. Designed and placed for maximum visibility.

Sales arguments
Product Guide – R200
10
Driving
• Fully electronic steering simplies manoeuvrability.
• Small steering wheel requiring only small hand and arm movements and mini-
mum effort.
• 360° progressive steering for fast and safe operation
• Progressive steering requires less turning at low speed and more turning at high
speed to assure safe, comfortable driving.
• Wrist support next to steering wheel
• Travel direction selector with ergonomic design and optimum position close to
the hydraulic levers.
• Possibility to travel at creep speed without depressing the accelerator pedal for
smooth, precise positioning.
• Pedal arrangement similar to a passenger car for short reaction times.
• The safety pedal prevents the operator from keeping his foot outside the truck
while driving. An audible buzzer or audible buzzer together with braking of the
truck (standard setting) if the pedal is not kept depressed while driving.
Braking
• Progressive automatic braking by releasing the accelerator pedal
• Braking when changing the travel direction
• Programmable power
• Regenerating
– Up to 7–8% of total power consumption (12–15% of the energy when travel-
ling) is recovered to the battery
• Parking brake integrated in brake pedal
• The parking brake is released using the accelerator pedal
• Electrical pedal brake system
– No brake shoes
– No adjustment necessary
– No hydraulic connections
– No wear results in lower maintenance costs
• Automatic braking if
– Truck is switched off
– The operator leaves the operator’s seat, with 2-3 seconds delay
• Automatic safety braking if an error should occur

Sales arguments
Product Guide – R200 11
Parameter settings
Steering response can be set to one of six levels for smooth, safe handling. The
progressive steering can be switched on or off to suit individual needs.
Programmable acceleration, top speed and braking power as a percentage of maxi-
mum. Ideal when training new operators and for handling unstable and fragile
loads. Choice of hour meter displays to suit individual needs.
Controls and functions
Display with indicator lamps shows truck status.
Important to reach full utilisation of the truck.
When the truck is switched on, it performs a diag-
nostic test and quickly reports whether everything
is in order.
Multitasking ability allows several tasks to be performed simultaneously in order
to increase productivity.
All controls are fully electronic for greater freedom in parameter setting. This redu-
ces the noise level, wear, and service and maintenance needs and promotes quick,
precise load handling.
Support arms
Support arm dimensions: 880 mm inside/1120 mm
outside.
Wear stripes
The support arms are tted with replaceable wear
stripes.
Support arm wheels
Protection around the wheels results in lower
maintenance cost.
Reach carriage
Four rollers, protected against dirt and impacts, are
placed inside the support arms.
The reach function is protected by a pressure relief valve
Operates as a shock absorber to prevent damage to the reach cylinder, its xings or
the reach carriage if the forks suddenly collide with something.

Sales arguments
Product Guide – R200
12
Battery
Select between three different battery sizes. This allows adapting the truck to the
work tasks depending on whether it is used for short or long shifts.
Wide battery
Uses the full width of the truck for improved stability and reduced aisle width re-
quirement.
Location on the support arms
To achieve maximum stability, the battery is always in a xed position during
operation.
Battery inspection and maintenance
Easy access to the battery by using the reach carriage.
Battery charging
An easy to reach DIN connector is placed on top of the battery.
Battery replacement, roller bed (option)
Using an optional roller bed, battery replacement is quick and easy. The roller bed
can be pulled out by the reach carrier.
NOTE! Not standard battery container.
Service, maintenance and technical features
2-year factory warranty or 3000 operating hours
2-year warranty on the drive and lift motors, gear box, logic cards and pump con-
troller. For more information, please refer to the warranty conditions.
Easy checking
All operating functions can be checked whilst seated in the cab.
Logic card
Features indicator LEDs for simplied verication. Fast and accurate information
to the service technician.
Error codes with interruption function
If a fault occurs on a component that is vital to truck operation, the truck will be
partly or entirely switched off.
Example: Defective connections in the hydraulics will switch off the hydraulic
function, while a fault in the steering system will cause the complete truck to be
switched off. Error codes immediate displays the fault. Fast and accurate informa-
tion to the service technician.

Sales arguments
Product Guide – R200 13
Caution codes with warning function
Cautions codes warn the operator that something abnormal has occurred. The code
shows what is wrong, however, it is still possible to operate the truck.
Example: No connection with hydraulic levers. Immediate information about what
has occurred. Fast and accurate information to the service technician.
The last 50 error codes are recorded and time stamped
The codes can be shown on the display without any need for a separate monitor.
Availability
Motor cover can be fully opened: Quick and full ac-
cess to the motor and oil tank. No tools required.
Large components, such as the drive and lift motors,
can be easily lifted out. All electronic modules are
housed in a separate compartment, located under
the armrest panel.
Environment protected against oil, dirt and battery
fumes.
Removable panels. Quick and full access to the pe-
dals, brake cylinder, electronics, etc.
Drive wheel easy to reach behind a removable co-
ver. Bolted and easy to replace.
Drive motor without commutator and brushes
Simplied design with improved reliability of motor. No wear. Fewer consumable
parts.
Temperature warning in both motors and their controllers
No overheating.
Only one contactor
No contactor for forwards/backwards travel. No contactor for lifting. Fewer con-
sumable parts.
Service timer
Tells when it is time for next service.
Emergency driving when steering not working
Release the parking brake using the switch under the arm rest panel. The truck can
be steered mechanically via a column that is inserted through a hole in the motor
hood and engaged with the steering motor.

Sales arguments
Product Guide – R200
14
Emergency moving of the truck when driving is not working
Release the parking brake using the switch under
the arm rest panel. The truck can then be towed
without lifting it.
Emergency lowering of the forks
Via a switch under the armrest panel.
Emergency retraction of the mast
Via a switch under the armrest panel.
Digital CAN (Controller Area Network) com-
munication between the logic card and the con-
trollers
More information is transferred in shorter time. Accurate information transfer. Ea-
sier and faster check of the various truck functions. Immunity against radio signal
interference, etc. Reduced cabling. Future development possibilities.
MOSFET components
Higher quality. Lower losses. Higher reliability. Lower cost.

Sales arguments
Product Guide – R200 15
Important sales arguments for R200
Operator environment
•Space
•Low entry
•Ergonomic design with, among others, adjust-
ment of the operator’s seat, operating console,
levers and pedals
•Pedals arranged similarly to a passenger car
• Small steering wheel and lever movements that
require minimum effort reduce the strain on the
operator.
Controls
•Fingertip operation
•From left to right
1: Lift/lowering of forks, quick and smooth
2: Mast extension
3: Tilting
4 and 5: Extra hydraulic functions
•Travel direction selector
•Horn button
•Progressive electronic steering, 360°
•Digital display
•Keypad for programming of parameters and entry of PIN codes
•Emergency switch
View and safety
The operator is always inside the truck prole
•Strong overhead guard
•Plexiglas protection between the hydraulic levers and the mast
•Free view around the truck and upwards
– through and next to the mast
– through the overhead guard
– to the rear through the opening in the side post

Sales arguments
Product Guide – R200
16
Mast
•Fork tilting (R214, R216 )
•Protected lifting rams
Battery
•Easy access
Easy to service
(Open the hood under the operator’s seat
•Steering motor
•Travel drive motor
•Lift motor
•Hydraulic oil tank
Battery connector and charging
•Battery connector position
•DIN-type battery connector
Miscellaneous
•Programmable parameters
•CAN bus technology (CAN = Controller Area Network)
•Microcomputer control
•Drive motor with AC operation
Operation
•360° steering

Product details
Product Guide – R200 17
Product details
Main components and controls
1. Emergency switch
2. Keypad
3. Display
4. Switches and indicators
5. Operating console
6. Knob for adjusting the operating console position
7. Overhead guard panel with height indicator, radio and speakers.
8. Operator’s seat
9. Pedals
10. Accessories bar
1 2 3 4 5 10 7
6
8
9

Product details
Product Guide – R200
18
Emergency switch
The emergency switch is placed on the instrument
panel where it can be reached from both outside
and inside the truck cab. If activated, the truck can
still be steered. Following activation of the emer-
gency switch, the truck must be restarted to reset
the switch.
Keypad
The truck is started by using the keypad on the
instrument panel. Select code 1, 2 or 3 and then
depress the green key (I).
Upon request, a service technician can program
the truck to enable a 4-digit PIN code.
Up to 100 different 4-digit codes can be program-
med. These control access to the truck. Additionally, it is possible to associate a
maximum of 10 different operator proles to the PIN codes.
Upon delivery, all operator proles are the same.
The truck can be switched off by pressing the red key on the keypad. If the
truck is left switched on and is not operated, it can be automatically switched off
after a desired time interval. This feature is preset to approx. 20 minutes
Operator identication and operator parameters
The operator must log in to start the truck. This way, unauthorised persons can be
prevented from starting the truck. Additionally, the truck can be adapted to dif-
ferent operator preferences, such as max. travel speed, max. acceleration, steering
response, etc.
The parameter settings can be locked and access permitted only via a special ser-
vice key. In this case, the management at the work place must decide whether the
parameter settings should be accessible. This way, damage to the truck by unaut-
horised persons can be avoided.
The following parameters can be changed by the operator: Steering response, max-
imum speed, acceleration, motor braking, braking force when changing the direc-
tion of travel.

Product details
Product Guide – R200 19
Display
The truck has an easy-to-read display
with red and green truck status LEDs.
Parking brake indicator (A)
The brake is automatically applied when
the operator leaves the seat. The symbol
“P” lights up in the display window (A).
Direction indicator (B)
The arrows indicate the selected travel direction.
Time display (C)
Shows current time. The clock also records and stores the time together with an
error code if a fault should occur.
Hour meter/error code display (D)
This display window shows the time, the weight of the load and any error codes.
The display symbol (J) lights as long as the hour meter is displayed.
The display symbol (G) lights when a warning or error code is displayed. An E (Er-
ror) or C (Caution) is displayed in the left part of the display together with the error
code on the right. Error codes are described in the operating instructions.
Operator identication (E)
When an operator’s prole is selected, the corresponding number is displayed here.
See the previous page.
Drive wheel indicator (F)
Shows the drive wheel position
Warning/error code indication (G)
This symbol lights in connection with warning/error codes.
A B C D E
F G I J K

Product details
Product Guide – R200
20
Parameter indicator (I)
This display symbol lights when verifying the set parameters.
Hour meter indicator (J)
This display symbol lights when the hour meter is shown. Operating hours can be
displayed in several different ways:
Key time: Measures the total time the truck has remained switched on using the
keypad.
Total operating hours: measures the total hours the truck has remained switched
on, i.e. when a drive or lift function has been active.
Drive motor time: measures the total time the drive motor has been operating.
Lift motor time: measures the total time the lift motor has been operating.
Service time: calculates the time remaining until next service and signals when the
truck should be serviced.
Battery indicator (K)
The battery indicator checks both voltage and current. The battery indicator uses
a 10-segment scale to show the battery charge. As the battery is discharged, the
segments change colour from green to yellow, and nally red.
A red LED starts blinking when only 30% of the battery capacity remains.
When 20% battery capacity remains, the lift function is disabled. However the
truck can still lower the forks and drive.