CESAB S210 Operating instructions

Repair manual 7588857-040
S210, S212, S212S, S212L, S214, S214L, S220D.
https://www.forkliftpdfmanuals.com/

© Cesab T Codes(s): 841, 842, 843
Translation of the original instructions.
Document revisions:
This manual contains information on the following trucks:
Issue date Order
number Changes
2015-09-01 7588857-040 Completely new issue.
2016-12-01 7588857-040
Chapter 4: Operations and connection sequence - Updated
Chapter 7: Maintenance - New value for clearance
Chapter 8: Troubleshooting - New error codes added
Chapter 12: Brake system/wheels - New dust cover and brake
clearance
Chapter 15: Hydraulics - Replacing the hose rupture valve added
2017-09-30 7588857-040
Chapter 8: Troubleshooting - Error codes 3:547 and 3:583 updated
Chapter 12: Brake system/Wheels - Updated
Chapter 13: Steering system - Updated
Chapter 23: Lubricants specification - added lubricants for the food
processing industry
2018-05-01 7588857-040
Chapter 5: Parameter - Parameter 109 updated
Chapter 6: Installation - PIN codes updated
Chapter 8: Troubleshooting - Error code 8:033 added
Chapter 12: Brake system/wheels - New dust cover
Chapter 16: Mast - Added replacing the idler roller and the chain bolt
T-Code Model: Serial number
841 S210 6384351-
841 S212 6384351-
842 S212L 6384351-
841 S214 6384351-
842 S214L 6384351-
842 S220D 6384351-
843 S212S 6384351-
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© Cesab 1 – 1 T Code(s): 841, 842, 843
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................................................................................................... 2–3
3. General safety rules....................................................................................... 3–1
3.1 Work safety.................................................................................................. 3–1
3.2 Electrical system.......................................................................................... 3–3
3.3 Safe lifting.................................................................................................... 3–4
3.4 Truck modifications...................................................................................... 3–5
4. Operation and connection sequences......................................................... 4–1
Symbols on keypad and display 4–2
4.1 Battery is connected.................................................................................... 4–3
4.2 Login via keypad.......................................................................................... 4–3
4.3 Tiller arm lowered for driving ....................................................................... 4–4
4.4 Driving in fork direction................................................................................ 4–4
4.5 Driving in the drive wheel direction.............................................................. 4–5
4.6 Neutral position braking............................................................................... 4–5
4.7 Reverse braking .......................................................................................... 4–6
4.8 Mechanical braking...................................................................................... 4–6
4.9 Emergency reversal..................................................................................... 4–7
4.10 Fork lifting.................................................................................................. 4–7
4.11 Fork lifting (S210) ...................................................................................... 4–8
4.12 Support arm lift (S212L, 214L, S220D) ..................................................... 4–8
4.13 Fork lowering............................................................................................. 4–9
4.14 Support arm lowering (S212L, 214L, S220D)............................................ 4–9
4.15 Click-2-Creep........................................................................................... 4–10
4.16 Turtle function (option)............................................................................. 4–10
5. Parameters...................................................................................................... 5–1
5.1 General........................................................................................................ 5–1
5.1.1 Show/change parameters .............................................................. 5–2
5.1.2 Operator parameters...................................................................... 5–3
5.1.3 Overview ........................................................................................ 5–3
5.1.4 Connection to logged-in operator................................................... 5–4
Description of operator parameters 5–4
Parameters 3 and 4 – Acceleration/Deceleration 5–4
Parameters 6 and 7 – Maximum travel speed 5–5
5.2 General service parameters ........................................................................ 5–6
5.2.1 Overview ........................................................................................ 5–6
5.2.2 Description ..................................................................................... 5–7
Parameter 101/104 – Service/Log-out 5–7
Parameter 102 - Operator access 5–7
Parameter 103 - Start-up display 5–8
Parameter 105/106 - Collision sensor sensitivity for X/Y (Optional) 5–9
Parameter 107 – Battery size 5–10
Table applicable to P214, 216, 218, 220 5–11
Table concerning P225 5–12
Table concerning S208L, 210, 212S, 212L, 212, 214L, 214, 220D 5–13
Verifying parameter settings for freely ventilated batteries
(lead-acid batteries) 5–14
Verifying the parameter setting for valve-regulated batteries
(Exide) 5–14
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© Cesab 1 – 2 T Code(s): 841, 842, 843
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
5.3 Service parameters, travel functions......................................................... 5–17
5.3.1 Overview ...................................................................................... 5–17
5.3.2 Description ................................................................................... 5–18
Parameter 201 – Deceleration when reversing 5–18
Parameter 202 – Maximum speed Turtle mode activated 5–18
Parameter 203 - Maximum speed, forks above 1.8 m 5–19
Parameter 204 - Maximum acceleration, forks above 1.8 m 5–19
Parameter 205 - Maximum reversing, forks above 1.8 m 5–19
Parameter 206 - Automatic speed reduction, forks above 1.8 m 5–20
5.4 Service parameters, hydraulic functions.................................................... 5–21
5.4.1 Description ................................................................................... 5–22
Parameter 301 – Ramping value for lowering stop 5–22
Parameter 302 - Fork, lowering speed 5–22
Parameter 303 - EVP start mode 5–22
Parameter 304 - EVP support arm lowering speed 5–23
Parameter 305 - EVP slow lowering speed 5–23
Parameter 306 - Activation of “Click-2-Creep” lifting/lowering 5–23
Parameter 307 - Automatic support arm lowering (On/Off) 5–24
Parameter 499 - (Not applicable) 5–24
5.5 Factory parameters ................................................................................... 5–25
5.5.1 Overview ...................................................................................... 5–25
5.5.2 Description ................................................................................... 5–26
Parameter 1001 - Type of truck 5–26
Parameter 1002 - Non-configurable options 5–27
Parameters 1003-1042 – Optional functions 5–28
Parameter 1044 - Master maximum speed 5–41
Parameter 1045 - Type of battery in the truck 5–41
Parameter 1046 - Adapting to special trucks 5–42
Parameter 1101 - Built-in battery charger 5–42
Parameter 1102 - Controls for hydraulic function 5–43
Parameter 1110 – Reset voltage for BDI 5–44
Parameter 1118 - Hardware version 5–45
6. Installation and commissioning ................................................................... 6–1
6.1 Transporting the truck.................................................................................. 6–1
6.2 Transporting the mast.................................................................................. 6–1
6.3 Safe lifting.................................................................................................... 6–2
6.4 Installing the battery .................................................................................... 6–3
6.5 Using PIN codes.......................................................................................... 6–4
6.5.1 General........................................................................................... 6–4
6.5.2 PIN code for resetting after a collision............................................ 6–4
6.5.3 Programming PIN codes ................................................................ 6–5
6.5.4 PIN code at delivery ....................................................................... 6–5
6.6 Programming PIN codes ............................................................................. 6–6
6.6.1 PIN code defaults........................................................................... 6–7
6.7 Setting parameters ...................................................................................... 6–8
6.8 Function and safety checks......................................................................... 6–9
7. Maintenance ................................................................................................... 7–1
7.1 Introduction.................................................................................................. 7–1
7.2 Maintenance instructions............................................................................. 7–1
7.2.1 Cleaning and washing.................................................................... 7–1
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© Cesab 1 – 3 T Code(s): 841, 842, 843
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................................................... 7–2
7.2.7 Electric components....................................................................... 7–3
7.3 Maintenance schedule................................................................................. 7–3
8. Troubleshooting............................................................................................. 8–1
8.1 General........................................................................................................ 8–1
Software compatibility 8–1
8.2 Towing a defective truck.............................................................................. 8–1
Tow using a tow truck and tow wagon: 8–2
8.3 Emergency driving mode............................................................................. 8–2
8.4 Troubleshooting methods............................................................................ 8–3
8.4.1 General initial troubleshooting........................................................ 8–3
8.4.2 Concluding troubleshooting............................................................ 8–4
8.5 Error code history........................................................................................ 8–5
8.6 Error code system ....................................................................................... 8–6
8.7 Error codes.................................................................................................. 8–7
8.8 Troubleshooting chart................................................................................ 8–45
8.8.1 The truck cannot be driven........................................................... 8–46
8.8.2 Truck only travels at reduced speed ............................................ 8–47
8.8.3 The truck can be driven but behaves abnormally......................... 8–48
8.8.4 The truck can be driven, but some functions do not work............ 8–49
Software compatibility 8–49
Hardware compatibility matrix 8–49
8.8.5 Defective hydraulic functions........................................................ 8–50
8.9 Built-in test function................................................................................... 8–54
8.10 Digital input/output status ........................................................................ 8–56
8.10.1 Test mode "9" –.......................................................................... 8–56
8.10.2 Test function “10” – Logic card................................................... 8–57
8.10.3 Test mode “12” – Expansion unit SEU (option).......................... 8–58
8.11 Built-in test function for the tiller arm ....................................................... 8–59
8.11.1 Display test................................................................................. 8–59
8.11.2 Speed control............................................................................. 8–59
8.11.3 Safety reversing ......................................................................... 8–59
8.11.4 Controls for lifting/lowering......................................................... 8–59
8.11.5 Sensilift....................................................................................... 8–60
8.11.6 Keypad ....................................................................................... 8–60
8.12 Checking the built-in battery charger....................................................... 8–61
9. Chassis 0000 .................................................................................................. 9–1
9.1 Support arm 0350........................................................................................ 9–1
9.1.1 Support arm lift, lateral adjustment................................................. 9–1
9.1.2 Adjusting the kneeling action.......................................................... 9–2
9.2 Motor mounts 0450...................................................................................... 9–3
9.2.1 Replacing springs (not applicable for S212S) ................................ 9–3
9.3 Removing the platform ................................................................................ 9–5
10. Electric drive motor 1700 .......................................................................... 10–1
10.1 Overview.................................................................................................. 10–1
10.2 Removing the motor from the truck ......................................................... 10–2
10.3 Removing the toothed wheel................................................................... 10–4
10.4 Removing motor bearings ....................................................................... 10–6
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© Cesab 1 – 4 T Code(s): 841, 842, 843
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 ................................................................................................ 10–10
11. Drive gear 2550........................................................................................... 11–1
11.1 General.................................................................................................... 11–1
11.2 Overview.................................................................................................. 11–2
11.3 Removing the gear from the truck (not applicable for S212S)................. 11–3
11.4 Removing the drive gear from the truck (S212S) .................................... 11–5
11.5 Fitting grease nipples, steering bearings (Option)................................... 11–6
11.6 Lubrication the steering bearings (Option) .............................................. 11–7
11.7 Checking and changing the oil ................................................................ 11–8
11.7.1 Draining oil ................................................................................. 11–8
11.7.2 Checking/refilling oil ................................................................... 11–9
11.8 Replacing the wheel hub seal................................................................ 11–10
Removing the seal 11–10
Fitting the seal 11–11
11.8.1 Replacing studs........................................................................ 11–12
12. Brake system/Wheels C3000..................................................................... 12–1
12.1 Brake system - C3100............................................................................ 12–1
12.1.1 Description ................................................................................. 12–1
Travel brake 12–1
Parking brake 12–1
Emergency brake 12–1
12.2 Parking brake 3180 ................................................................................. 12–2
12.2.1 Overview .................................................................................... 12–2
12.2.2 Emergency release of the parking brake.................................... 12–3
12.3 Removing the parking brake.................................................................... 12–4
12.4 Fitting the parking brake.......................................................................... 12–5
12.5 Checking the air gap................................................................................ 12–6
12.6 Drive wheel 3530..................................................................................... 12–7
12.6.1 Replacing the drive wheel .......................................................... 12–7
12.7 Castor wheels 3540................................................................................. 12–8
12.7.1 Overview .................................................................................... 12–8
12.7.2 Castor wheel mounting............................................................... 12–9
12.7.3 Replacing the castor wheel...................................................... 12–10
12.7.4 Disassembling the castor wheel cradle.................................... 12–11
12.8 Spring replacement ............................................................................... 12–11
12.8.1 Removing springs..................................................................... 12–11
12.8.2 Fitting the spring....................................................................... 12–11
12.9 Support arm wheel 3550 ....................................................................... 12–12
12.9.1 Overview .................................................................................. 12–12
12.10 Climber wheels.................................................................................... 12–14
12.10.1 Overview ................................................................................ 12–14
13. Tiller arm 4000............................................................................................ 13–1
13.1 Overview.................................................................................................. 13–1
13.2 Removing the tiller arm............................................................................ 13–3
13.3 Replacing an gas strut............................................................................. 13–3
13.4 Replacing the safety sensor .................................................................... 13–4
13.4.1 Removal ..................................................................................... 13–4
13.4.2 Installation.................................................................................. 13–4
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© Cesab 1 – 5 T Code(s): 841, 842, 843
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.............................................. 13–8
Removing the upper cover 13–8
13.5.5 Replacing the tiller arm handle................................................. 13–10
Removing the tiller arm handle 13–10
Fitting the tiller arm handle 13–10
13.5.6 Replacing the logic card........................................................... 13–11
Removing the logic card 13–11
Installing a logic card 13–12
13.5.7 Checking the handle................................................................. 13–13
13.5.8 Update the software................................................................. 13–13
13.5.9 Replacing the signal button/switch........................................... 13–14
13.5.10 Replacing the lift/lower button ................................................ 13–15
13.5.11 Replacing the sensilift ............................................................ 13–16
13.5.12 Replacing the stomach button................................................ 13–17
13.5.13 Changing the position of the controls - support arm
lift/fork lift ............................................................................................. 13–18
14. Electrical components-5000...................................................................... 14–1
14.1 Li-ion battery (Hoppecke) ........................................................................ 14–1
14.1.1 Resetting/restarting the battery.................................................. 14–1
14.2 Inspecting the battery .............................................................................. 14–1
14.3 Replacing the wiring harness .................................................................. 14–2
14.3.1 Replacing the transistor regulator wiring harness ...................... 14–3
14.4 Replacing the transistor regulator............................................................ 14–4
15. Hydraulic system 6000 .............................................................................. 15–1
15.1 General.................................................................................................... 15–1
15.2 Hydraulic hygiene.................................................................................... 15–2
15.2.1 Washing ..................................................................................... 15–2
15.2.2 Packaging................................................................................... 15–2
15.2.3 Handling..................................................................................... 15–2
15.2.4 Storage....................................................................................... 15–3
15.2.5 Work procedures........................................................................ 15–3
15.3 Hydraulic unit 6100.................................................................................. 15–4
15.3.1 Emptying the hydraulic tank ....................................................... 15–5
15.3.2 Hydraulic system, bleeding ........................................................ 15–5
Cylinders with bleeding valve 15–5
Cylinders without bleeding valve 15–5
15.4 Hydraulic connections 6230 .................................................................... 15–6
15.4.1 Quick change connectors........................................................... 15–6
Connecting the quick change connector 15–6
Disassembly of the quick change connector 15–7
15.5 Hose rupture valve .................................................................................. 15–8
15.5.1 Replacing the hose rupture valve............................................... 15–8
15.6 Hydraulic calibration ................................................................................ 15–9
15.7 Adjusting the pressure limiting valve ..................................................... 15–10
15.8 Disassembling the hydraulic unit........................................................... 15–12
15.9 Hydraulic unit tightening torques ........................................................... 15–14
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© Cesab 1 – 6 T Code(s): 841, 842, 843
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
Lubrication 16–2
16.2 Fork carriage 7420 .................................................................................. 16–3
16.2.1 Maintenance............................................................................... 16–3
16.3 Main lift chain system 7120 ..................................................................... 16–4
16.3.1 General....................................................................................... 16–4
16.3.2 Checking the chain setting......................................................... 16–5
16.3.3 Checking the chain..................................................................... 16–5
Noise 16–5
Surface rust 16–5
Rusty links 16–5
Stiff links 16–5
Bolt rotation 16–6
Loose bolts 16–6
Outline wear 16–7
Stretching 16–8
Damage 16–8
Damaged plates 16–9
Damaged bolts 16–9
Dirty chain 16–9
16.3.4 Cleaning..................................................................................... 16–9
16.3.5 Lubrication................................................................................ 16–10
16.3.6 Adjustment ............................................................................... 16–11
16.4 Replacing the fork carriage.................................................................... 16–12
16.5 Replacement of the mast....................................................................... 16–14
16.6 Replacing the idler roller........................................................................ 16–19
16.7 Adjusting the mast................................................................................. 16–20
17. Peripherals C8000...................................................................................... 17–1
18. Accessories................................................................................................ 18–1
18.1 Spider expansion unit.............................................................................. 18–1
18.2 TLS - Truck log system............................................................................ 18–2
18.3 ID unit ...................................................................................................... 18–2
18.4 DC/DC converter ..................................................................................... 18–3
18.5 Collision sensor ....................................................................................... 18–3
18.6 Built-in battery charger ............................................................................ 18–4
18.6.1 Technical data............................................................................ 18–4
18.6.2 Charging the battery................................................................... 18–5
Main charging 18–5
Equalising charging 18–5
Charging completed 18–5
19. Instructions for disposal........................................................................... 19–1
19.1 General.................................................................................................... 19–1
19.2 Marking of plastics................................................................................... 19–1
19.2.1 General marking of products and packaging.............................. 19–1
19.2.2 Marking according to the manufacturer’s standards .................. 19–2
Abbreviations 19–2
Marking examples 19–2
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© Cesab 1 – 7 T Code(s): 841, 842, 843
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 ................................................................................ 20–1
20.2 Wiring diagram ........................................................................................ 20–5
20.2.1 List of symbols............................................................................ 20–5
20.2.2 General wiring diagram .............................................................. 20–6
20.2.3 Wiring diagram ........................................................................... 20–7
21. Hydraulics chart......................................................................................... 21–1
22. Tools............................................................................................................ 22–1
22.1 MQS contacts.......................................................................................... 22–1
22.2 AMP connectors ...................................................................................... 22–3
22.2.1 AMP connectors, Multilock series 040 ....................................... 22–4
22.3 Molex connectors .................................................................................... 22–4
22.4 Grease guns............................................................................................ 22–5
22.5 Other tools............................................................................................... 22–6
23. Lubricants specification............................................................................ 23–1
23.1 General tightening torques ...................................................................... 23–1
23.2 Lubricants specification ........................................................................... 23–2
24. Technical data ............................................................................................ 24–1
24.1 S210, S212, S214 ................................................................................... 24–1
24.2 S212L, S214L, S220D............................................................................. 24–4
24.3 S212S...................................................................................................... 24–7
24.4 Overflow pressure for mast ................................................................... 24–10
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© Cesab 1 – 8 T Code(s): 841, 842, 843
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 2 – 1 T Code(s): 841, 842, 843
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:
• General safety rules.
•Operation and connection sequences – This chapter provides a basic
description of the main functions of the truck and their interdependencies.
•Parameters – This chapter provides a basic description of the truck
parameters.
•Installation – This chapter describes the preparatory work that is to be
done before the truck is used for the first time.
•Maintenance – This chapter provides an overview of periodic
maintenance.
•Troubleshooting – This chapter describes the action you should take
when the truck is completely or partially malfunctioning. It also describes
the cause of the problem together with suggested remedies.
•C codes – This chapter describes the various truck systems, e.g. the
hydraulic system and includes descriptions of system parts and the
necessary service procedures. These descriptions are divided according
to Cesab's C code system.
•Instructions for disposal – This chapter specifies the proper sorting
categories for the materials used in the various truck components.
•Wiring diagram – This chapter provides information on electrical
components and wiring diagrams.
•Hydraulic diagram – This chapter provides information on hydraulic
components and hydraulic diagrams.
•Tools – This chapter provides a list of the special tools required.
•Service data and grease specifications – This chapter contains
information on general tightening torques and an oil and grease
specification.
•Technical data.
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© Cesab 2 – 2 T Code(s): 841, 842, 843
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 – if not avoided – will cause death or
serious bodily injury.
WARNING
Indicates a dangerous situation that – if not avoided – will cause a slight or
minor bodily injury.
NOTE
Indicates a dangerous situation that – if not avoided – will cause a slight or
minor bodily injury.
Note:
Used in connection with actions that can cause material damage but not
bodily injury.
Note:
Used to attract attention and to give information about various actions.
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© Cesab 2 – 3 T Code(s): 841, 842, 843
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
connections. Component replacement.
Cleaning Measurement
Check of fluid level and
check for leaks. Check that bolts, nuts, etc. are tightened to torque.
Listening for noise. Lubrication, application.
Check of functions. Calibration
Adjustment Welding
Disassembly/removal Assembly/installation
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© Cesab 2 – 4 T Code(s): 841, 842, 843
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-
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.
— Slut på avsnittet —
Open Close
Refilling Emptying
Update
Symbol Measure Symbol Measure
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© Cesab 3 – 1 T Code(s): 841, 842, 843
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.
3.1 Work safety
To make work safer and prevent accidents, always keep the following in
mind:
• Keep the maintenance work site clean. Oil and water on the floor will make
it slippery.
• Use the correct working posture. Service work often involves sitting on
your knees or bending over forwards. Try sitting on a toolbox, for example,
to relieve the strain on your knees and back.
• Loose items and jewellery can get caught in moving parts of the truck. So
never wear loose articles or jewellery while working on the truck.
• Exercise caution and always follow applicable local regulations when
working at high heights.
• Use the correct tools for the work you are carrying out.
• Keep all tools well maintained.
• Make sure that all safety equipment including guards and covers are
properly secured and that they work as intended before starting the repair
work. If a guard or cover must be removed in order to perform the repair
work, extra care must be taken, and when the repair work is finished the
guard or cover must be refitted.
• Relieve the system pressure slowly before starting work on the truck’s
hydraulic system.
• Use paper or a stiff piece of cardboard when checking for possible oil
leaks. Do not use your hands.
• Drive unit oil and the hydraulic system oil may be hot.
DANGER!
Risk of burn injury.
Hot drive unit and hydraulic oil.
Allow the truck to cool down before changing the oil.
• Only fill the hydraulic system with new and clean oil.
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© Cesab 3 – 2 T Code(s): 841, 842, 843
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.
Always use new and clean oil in the hydraulic system.
• Store and transport changed oil according to applicable local directions.
• Do not flush solvents, etc. down the drain unless they are intended to be
disposed of in this way.
Follow local disposal regulations.
• Disconnect the battery prior to performing any welding work on the truck.
Note:
The battery could be damaged.
When welding with an electric welding unit, the current may enter the battery.
The battery must be disconnected.
• Prior to welding or grinding on painted surfaces, be sure to remove the
paint at least 100 mm around the welding/grinding area by using
sandblasting equipment or paint remover.
DANGER!
Harmful gasses.
Heated paint gives off harmful gases.
Remove all paint within 100 mm of the welding/grinding site.
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© Cesab 3 – 3 T Code(s): 841, 842, 843
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.
DANGER!
Short-circuiting/Burn injury.
Short circuits and burn injuries can occur if metal objects come into contact
with live electrical connections when working on the truck's electrical
system.
Remove wristwatches, rings and other metal objects beforehand.
• Always use insulated tools when working on the electrical system.
• Always disconnect the battery before opening any covers to drive units or
the electrical system.
• Always disconnect the battery prior to welding work using an electric
welding unit. The welding current may damage the battery.
• Always disconnect the battery when carrying out maintenance or repair
work on the truck unless otherwise stated in this repair manual.
• Clean electric motors using a rag or a vacuum cleaner.
• Clean electrical panels, electronic cards, contactors, contacts, magnetic
valves, etc. with a dampened cloth and a cleaning agent that will not
damage the part.
Note:
Risk of short-circuiting that may damage electrical components.
Do not break the warranty seal on the logic cards.
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© Cesab 3 – 4 T Code(s): 841, 842, 843
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.
To prevent the truck moving while it is being lifted, it must not be lifted with
anyone on the platform or with the tiller arm in the lowered position.
If the drive wheel, which is braked, is being lifted the other wheels must be
chocked to stop the truck from moving.
Select the lifting point so that the lift is as light as possible, for example one
corner at a time. If the truck has marked lifting points on the lower part of the
chassis, these must be used to ensure balanced lifting.
Make sure the surface where the jack is placed is clean and free of oil and
grease.
Make sure your hands and the jack lever are free of grease and oil.
Only use the lever supplied with the jack. If the lever is too short, more
exertion than is necessary will be required. If the lever is too long, there is a
risk that the jack will be overloaded.
DANGER!
Risk of crushing since a poorly supported truck could fall down.
Never work under a truck that is not supported by trestles and secured by a
lifting device.
Support the truck:
• as close to the lifted part of the chassis as possible in order to reduce the
falling height if the truck should collapse
• so the truck cannot move.
Never support the jack on trestles to achieve a higher lift.
Never work under a raised truck without it being properly supported on
trestles.
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© Cesab 3 – 5 T Code(s): 841, 842, 843
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
oftruck maybeperformed thatmay influence the capacity,stabilityandsafety
of the truck without prior written approval from the manufacturer, its
representative or successor.
In the case of the manufacturer no longer being in business and there being
no successor, the user of the truck may arrange for modifications on the
precondition that the user:
• makes sure that an engineer with expert knowledge of industrial trucks
and their safety designs, tests and implements the modification,
• files all documentation of the designs, tests and implementation of the
modification,
• approves and makes the applicable changes to the capacity plate,
adhesive labels, markings and operator’s manual and
• affixes a permanent and well visible sign to the truck stating how the truck
has been modified, together with the date of the modification and the
name and address of the company that carried out the modification work.
— Slut på avsnittet —
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© Cesab 3 – 6 T Code(s): 841, 842, 843
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-
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