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CESAB S210, Repair Manual

The CESAB S210 Product Manual is your essential guide for operating this powerful equipment. Available for free download at our website, this comprehensive manual provides step-by-step instructions and helpful tips to maximize your experience with the CESAB S210. Get yours now at manualshive.com and unlock the full potential of your product.

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© Cesab

8 – 27

T Code(s): 841, 842, 843

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-

3:540

Hardware in T1 
detects a short 
circuit in the power 
stage and a phase-
to-phase short 
circuit, phase B- 
and phase B+

Everything is 
stopped at once, 
the parking brake 
is activated, and 
the main 
contactor opens

1:

Short circuit in
motor

2:

Short circuit in
motor 

wiring

harness

3:

Short circuit in
power stage

1:

Check the motor

•

Disconnect motor wiring 
including sensor wires.

•

Insulation test. Check that the 
coils are not electrically 
connected to the chassis. 
Replace M1 if the motor is not 
isolated

2:

Check 

the 

motor 

wiring

harness

•

Visual check of the motor wiring 
harness. Check that there is no 
contact between the pole 
connections on the motor/motor 
control. Search for contact and 
damaged insulation on the 
wiring harness.

•

Disconnect the motor wiring 
harness at the motor control and 
the motor and measure the 
ohms of the wiring harness 
between the phases and verify 
that there is no contact.

3:

Replace T1

3:545

Hardware 
protection in T1 
detects a short 
circuit in the output 
to the brake (Q1) 
The current 
through the brake 
exceeds the limit 
values. Maximum 
value = 5.95A, 
continuous value = 
3A

Everything is 
stopped at once, 
the parking brake 
is activated, and 
the main 
contactor opens

High power 
consumption or 
short circuit

1:

 Check for overcurrent or short
circuit:

•

Check the ohms and the 
amperes of the component, 
compare them to the setpoint 
values if they outside the 
accepted range.

•

Check the connections and 
wiring harness for short-circuit.

•

Check that the component does 
not seize or is jammed.

•

If points 1-3 are OK, it indicates 
that the output stage is short 
circuited - Replace the power-
supplying component

Code

Description

Truck 
behaviour

Error cause(s)

Procedure

https://www.forkliftpdfmanuals.com/

Summary of Contents for S210

Page 1: ...Repair manual 7588857 040 S210 S212 S212S S212L S214 S214L S220D https www forkliftpdfmanuals com ...

Page 2: ...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 ...

Page 3: ...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...

Page 4: ...d 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 Pa...

Page 5: ...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 Bu...

Page 6: ...uds 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 Replac...

Page 7: ...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 ...

Page 8: ...maged 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 1...

Page 9: ... 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 2...

Page 10: ...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 ...

Page 11: ...pter 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 syste...

Page 12: ...NGER 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 Use...

Page 13: ...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 https www forkliftpdfmanuals co...

Page 14: ...8857 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 https www forkliftpdfmanuals com ...

Page 15: ...r 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 c...

Page 16: ...nts 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 ...

Page 17: ...ects 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 ot...

Page 18: ... 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 ...

Page 19: ...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 ...

Page 20: ...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 https www forkliftpdfmanuals com ...

Page 21: ...taken place immediately before the current event in order for the latter to be performed correctly Action s An action that the driver must perform in order for an event to happen Influencing elements Conditions that must be fulfilled in order for an event to happen Certain parameter settings may also affect the outcome of the event Resulting conditions Describe the key events that can be checked i...

Page 22: ...ion 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 and confirm entered settings during PIN code management OFF button Error code Battery charge as a percentage Parameter Hour counter https www forkliftpdfmanuals com ...

Page 23: ...lting conditions The status LED for the transistor regulator lights continuously T1 Event Logging in Preceding event The battery is connected Action s Enter a valid PIN code and press the ON button on the keypad S223 Influencing elements The emergency stop S21 has not been activated T1 INP SUPPLY 24V DC high Tiller arm sensor in drive position B60 Resulting conditions The power indicator lamp is l...

Page 24: ... INP TILLER ARM IN DRIVE POS low Event Driving in fork direction Preceding event Tiller arm is lowered to the drive position Action s Turn the speed control in the fork direction Influencing elements Speed control with Hall sensor A5 S310 318 Settings of operator parameters 4 5 and 6 determine truck travel performance Resulting conditions The main contactor output voltage goes low T1 OUT MAIN CONT...

Page 25: ...ain contactor closes Q10 T1 OUT BRAKE RELEASE goes low Brake coil Q1 is activated and the mechanical brake is released The current feed to the drive motor field winding S2 ve and S1 ve Pulsed current feed to drive motor rotor is proportional to speed control actuation Event Neutral braking Preceding event Truck travels in fork or drive wheel direction Action s Allow the speed control to return to ...

Page 26: ...e excess energy in the form of electricity is fed back to the battery G1 helping to recharge it The braking effect increases the more the speed control is turned The mechanical brake Q1 T1 OUT BRAKE RELEASE is applied when the truck stops Event Mechanical braking Preceding event Truck travels in fork or drive wheel direction Action s The tiller arm is folded completely up or down Influencing eleme...

Page 27: ...ing conditions The Hall sensor A5 S317 is immediately activated The card A5 interprets this signal as a command to the transistor regulator T1 to run the drive motor at a reduced speed in the fork direction as long as the button is depressed The normal drive command signal received from L1 is blocked until L1 is released and returns to neutral position Event Fork lifting Preceding event Start the ...

Page 28: ...fork lift button A5 S320 Influencing elements Main contactor Q10 Fuse F1 Lift forks button A5 S320 Battery status OK battery discharge indicator 0 or battery charge 20 Resulting conditions Pump motor M3 starts Event Fork lifting Preceding event Start the truck Action s Press the button for support arm lift A5 S321 Influencing elements Main contactor Q10 Fuse F1 Button for support arm lift A5 S321 ...

Page 29: ... fork lifting Action s Press the fork lowering button A5 S321 Influencing elements Main contactor Q10 Fork lowering button A5 S321 Resulting conditions T1 OUT LOWER VALVE goes low the hydraulic lowering valve Q4 opens Event Fork lowering Preceding event Start the truck or commence fork lifting Action s Press the support arm lowering button A5 S321 Influencing elements Main contactor Q10 Support ar...

Page 30: ...sed Power is fed to the drive motor s field coils S2 ve and S1 ve Pulsed current feed to drive motor rotor is proportional to speed control actuation SLO is displayed flashes Event Turtle function option Preceding event Tiller arm is lowered to the drive position Action s Press S206 to activate this function Turn the speed control in either direction Influencing elements Main contactor Q10 Option ...

Page 31: ...ofiles can be stored Service parameters The service parameters range 101 1000 are used to adapt the truck s performance response and cover all other parameters not covered by the operator parameters Factory parameters range 1001 1250 Truck specific parameters Operator parameters are displayed and changed only for a selected operator but if a CAN service key is connected the parameters for all oper...

Page 32: ... Press and then release the horn button Info is shown on the display 3 Move between menus by turning the speed control several times 4 Par is shown on the display 5 Press the horn button to select The parameter symbol lights up 6 By pressing the speed control repeatedly you can move through the parameter list See section 5 Parameters For setting parameters To show a parameter release the speed con...

Page 33: ...1 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 5 1 3 Overview Par Description 3 Acceleration 4 Deceleration 6 Maximum speed 7 Maximum speed forks above 1 8 m https www forkliftpdfmanuals com ...

Page 34: ...ameters Parameters 3 and 4 Acceleration Deceleration These two parameters can be used to get a smoother acceleration deceleration where the application or operator profile so requires 3 Acceleration The lower the parameter value the more time is needed to accelerate to the maximum speed 4 Deceleration Defines plug braking force when speed control L1 returns to the neutral position The lower the va...

Page 35: ...ed in operator profile The maximum travel speed can also be limited by factory parameter 1044 and it is always the lowest speed for a parameter that is the limiting one 6 Maximum speed Determines the maximum travel speed 7 Maximum speed forks above 1 8m Adjusts the truck maximum speed when the forks are above 1 8 m Is set as a of parameter 203 Par Description Min Defa ult Max Incre ment Unit 6 Max...

Page 36: ...X41 5 2 1 Overview Note Changing specific truck parameters changes the truck s driving properties Do not change any parameter values without the necessary know how Par Description 101 Service intervals 102 Operator access 103 Start up alternative 104 Automatic logout min 105 Collision sensor X level 106 Collision sensor Y level 107 Battery adjustment Ah 109 Battery type built in charger 110 Batter...

Page 37: ...minutes before automatic log out if the truck is inactive If the value is set as 0 logout takes place after 4 hours Parameter 102 Operator access 102 Operator access Specifies which login method should be used and if the operator will have the possibility of changing the operator parameter settings Values 1 and 2 Key Values 3 and 4 Keypad with 100 PIN codes See section 6 6 Programming PIN codes Va...

Page 38: ...at the same time as the battery indicator is lit The truck control system stores five different time values Value 2 Operating time is the default value on the start up display Par Description Min Defa ult Max Incre ment Unit 103 Start up display 1 2 5 1 Hour meter values Display Value 1 A Key time The total time the truck has been in use Value 2 B Operating time Combined time during which the pump...

Page 39: ...d not be set in the truck Collision monitoring is instead administrated via I_Site This parameter must be set during truck installation 106 Collision sensor Y sensitivity degree Indicates the degree of sensitivity for what should be interpreted as a side impact 0 Collision sensor not activated The collision sensor can also be used in combination with DHU In such cases the parameters should not be ...

Page 40: ...ge the battery even more reducing the value if the battery is discharged too much In order to set the meter for battery charge level consideration must be given to the following Acid density when the battery is fully charged to check the quality of the battery This value should be between 1 27 and 1 29 Please note that the acid density may vary between different kinds of battery When the lifting c...

Page 41: ...e Lead acid battery Battery size Hawker Evolution Battery size gel battery Slight discharge Deeper discharge 1 2 3 4 5 6 7 311 330 Ah 261 280 Ah 271 290 Ah 8 291 310 Ah 241 260 Ah 251 270 Ah 9 271 290 Ah 221 240 Ah 231 250 Ah 10 251 270 Ah 201 220 Ah 211 230 Ah 11 231 250 Ah 181 200 Ah 191 210 Ah 12 216 230 Ah 161 180 Ah 171 190 Ah 13 201 215 Ah 141 160 Ah 151 170 Ah 14 186 200 Ah 120 140 Ah 131 1...

Page 42: ...ire a different setting of parameter 107 Check that the parameter setting is the correct one using the instructions below Parameter 107 Battery size Lead acid battery Battery size Hawker Evolution Battery size gel battery Slight discharge Deeper discharge 1 2 3 4 5 6 7 8 9 311 330 Ah 261 280 Ah 271 290 Ah 10 291 310 Ah 241 260 Ah 251 270 Ah 11 271 290 Ah 221 240 Ah 231 250 Ah 12 251 270 Ah 201 220...

Page 43: ...r applications may require a different setting of parameter 107 Check that the parameter setting is the correct one using the instructions below Parameter 107 Battery size Lead acid battery Battery size Hawker Evolution Battery size gel battery Slight discharge Deeper discharge 1 2 3 4 5 6 271 280 Ah 271 290 Ah 7 251 270 Ah 251 270 Ah 8 231 250 Ah 231 250 Ah 9 286 320 Ah 211 230 Ah 211 230 Ah 10 2...

Page 44: ...sired then increase the parameter value by no more than one unit Note Each change should be followed up by a new verification of the parameter setting Verifying the parameter setting for valve regulated batteries Exide 1 Charge the battery 2 Operate the truck in its normal application until the battery indicator indicates a discharged battery 0 in the display 3 Disconnect the battery from the truc...

Page 45: ...n charger 0 No charging 1 Lead acid battery 2 Hawker Evolution battery 3 Exide gel battery 32766 TMHMS Li ion battery 110 Battery type built in charger Optional Sets the battery size used with the built in charger so the correct charging current is chosen For Hawker Evolution only the sizes 134 Ah 174 Ah and 201 Ah are approved This parameter has no use unless there is a built in charger Par Descr...

Page 46: ...eleted at login The histogram data consists of the logged motor temperature motor control and steering motor in the form of a histogram You clear this data by setting parameter 112 1 This is useful when transferring the truck from one client to another The collision log is a log with the 10 latest collisions are stored together with the operator PIN code You clear this data by setting parameter 11...

Page 47: ...1 5 3 Service parameters travel functions 5 3 1 Overview Par Description 201 Braking force when reversing the travel direction 202 Maximum speed Turtle mode activated 203 Maximum speed forks above 1 8 m 204 Acceleration forks above 1 8 m 205 Braking force when reversing the travel direction forks above 1 8 m 206 Automatic deceleration forks above 1 8 m https www forkliftpdfmanuals com ...

Page 48: ...ed control is turned in the opposite direction and used to get a smoother deceleration where the application requires this for all operator profiles Parameter 202 Maximum speed Turtle mode activated 202 Maximum speed Turtle mode activated Sets the maximum speed when Turtle mode is activated Par Description Min Defa ult Max Incre ment Unit 201 Deceleration when reversing 70 100 100 5 Par Descriptio...

Page 49: ...ts the maximum acceleration when the forks are above 1 8 m As a percentage of maximum acceleration for this application Parameter 205 Maximum reversing forks above 1 8 m Applies to S208L 210 212S 212L 212 214L 214 220D 205 Maximum reversing forks above 1 8 m Sets the maximum reversing when the forks are above 1 8 m As a percentage of maximum acceleration for this application Par Description Min De...

Page 50: ...tomatic speed reduction forks above 1 8 m Applies to S208L 210 212S 212L 212 214L 214 220D 206 Automatic speed reduction forks above 1 8 m Sets the maximum speed reduction when the forks are above 1 8 m As a percentage of maximum acceleration for this application Par Description Min Defa ult Max Incre ment Unit 206 Automatic speed reduction forks above 1 8 m 45 60 80 5 https www forkliftpdfmanuals...

Page 51: ...serial number 6384351 5 4 Service parameters hydraulic functions Par Description 301 Lowering stop ramp 302 Fork lowering speed 303 EVP startup mode 304 Support arm lowering speed 305 EVP slow lowering speed 306 Enable two speeds for lifting lowering 307 Automatic support arm lowering 499 Not applicable for field test software only https www forkliftpdfmanuals com ...

Page 52: ...302 Fork lowering speed Determines the maximum lowering speed of the forks This parameter can be adjusted manually or can be set by using the calibration function Parameter 303 EVP start mode Applies to S208L 210 212S 212L 212 214L 214 220D Parameter 303 EVP start mode Determines the start position of the proportional valve This parameter can be adjusted manually or can be set by using the calibra...

Page 53: ... 220D Parameter 305 EVP slow lowering speed Determines the slow lowering speed when using Click 2 Creep This parameter can be adjusted manually or can be set by using the calibration function Parameter 306 Activation of Click 2 Creep lifting lowering Applies to S208L 210 212S 212L 212 214L 214 220D Parameter 306 Activation of Click 2 Creep lifting lowering Activate Click 2 Creep lifting lowering P...

Page 54: ...On Off Applies to S208L 210 212S 212L 212 214L 214 220D 307 Automatic support arm lowering On Off Controls whether the support arms should be lowered automatically when the forks reach the 1 8 m sensor Parameter 499 Not applicable This parameter is only used for field test software Par Description Min Defa ult Max Incre ment Unit 307 Automatic support arm lowering 0 1 1 1 Value Function 0 OFF 1 On...

Page 55: ... not change any parameter values without the necessary know how Only authorised service technicians with personal TruckCom user identities have the rights to change factory settings The parameters should only be changed when a specific need for this arises The user ID and time of changing parameters will be logged in the logic card housed in the tiller arm handle 5 5 1 Overview Par Description 100...

Page 56: ...n Parameter 1001 Type of truck Parameter 1001 Truck type This parameter is used to set which truck type the program is to adapt operational data for Par Description Min Defa ult Max Incre ment Unit 1001 Truck type 0 0 108 1 Value Function 0 Unknown truck type 1 P214 2 P216 3 P218 4 P220 5 P225 101 S210 102 S212 103 S214 104 S212L 105 S214L 106 S220D 107 S208L 108 S212S https www forkliftpdfmanuals...

Page 57: ...02 These functions are either active or inactive The functions do not require any further adjustment and are thus referred to as non configurable options Par Description Min Defa ult Max Incre ment Unit 1002 Non configurable option 0 1 7 1 Value Function 0 No optional function 1 CLICK 2 CREEP 2 TURTLE 3 CLICK 2 CREEP and TURTLE 4 SAFETY REVERSING HORN 5 SAFETY REVERSING HORN and CLICK 2 CREEP 6 SA...

Page 58: ...ptional function 3Arg4 0 0 255 1 1018 Optional function 4 0 0 21 1 1019 Optional function 4Arg1 0 0 255 1 1020 Optional function 4Arg2 0 0 255 1 1021 Optional function 4Arg3 0 0 255 1 1022 Optional function 4Arg4 0 0 255 1 1023 Optional function 5 0 0 21 1 1024 Optional function 5Arg1 0 0 255 1 1025 Optional function 5Arg2 0 0 255 1 1026 Optional function 5Arg3 0 0 255 1 1027 Optional function 5Ar...

Page 59: ...ing that special options function correctly Factory parameter no 1003 1008 1013 1018 1023 1028 1033 and 1038 can be adjusted to allow up to a maximum of 8 pre programmed Basic options to be activated and configured to suit a specific special option or customisation Activation of optional functions The system can use up to eight configurable optional functions simultaneously Each configurable funct...

Page 60: ... 0 activates digital output 1 1 6 A on SEU 16 1 activates digital output 2 1 6 A on SEU 30 2 activates digital output 3 1 6 A on SEU 2 3 activates digital output 4 1 6 A on SEU 3 Argument 3 Selection of option switch Values Meaning 0 activated by option switch 2 or 5 1 activated by option switch 1 2 activated by option switch 2 3 activated by option switch 3 4 activated by option switch 4 5 activa...

Page 61: ... 0 activates digital input 1 1 mA on SEU 5 1 activates digital input 2 1 mA on SEU 19 2 activates digital input 3 1 mA on SEU 33 3 activates digital input 4 1 mA on SEU 6 4 activates digital input 5 7 mA on SEU 20 5 activates digital input 6 7 mA on SEU 34 6 activates digital input 7 7 mA on SEU 7 7 activates digital input 8 7 mA on SEU 21 Argument 3 Speed limitation as a percentage of max speed V...

Page 62: ...U output Argument 1 Selection of SEU unit 1 or 2 Values Meaning 0 option is handled by SEU unit 1 A36 1 option is handled by SEU unit 2 the second SEU unit Argument 2 Selection of SEU digital output Values Meaning Pin no 0 activates digital output 1 1 6 A on SEU 16 1 activates digital output 2 1 6 A on SEU 30 2 activates digital output 3 1 6 A on SEU 2 3 activates digital output 4 1 6 A on SEU 3 h...

Page 63: ...iving drive wheel direction Fork lifting Fork lowering 1 X 2 X 3 X X 4 X 5 X X 6 X X 7 X X X 8 X 9 X X 10 X X 11 X X X 12 X X 13 X X X 14 X X X 15 X X X X 16 17 X 18 X 19 X X 20 X 21 X X 22 X X 23 X X X 24 X 25 X X 26 X X 27 X X X 28 X X 29 X X X 30 X X X 31 X X X X Argument 4 Output switching mode Values Meaning 0 Output continuously on 1 Output switches at 1 Hz 2 Output switches at 2 Hz Basic op...

Page 64: ...election of SEU digital input Values Meaning Pin no 0 activated by digital input 1 1 mA on SEU 5 1 activated by digital input 2 1 mA on SEU 19 2 activated by digital input 3 1 mA on SEU 3 33 3 activated by digital input 4 1 mA on SEU 6 4 activated by digital input 5 7 mA on SEU 20 5 activated by digital input 6 7 mA on SEU 34 6 activated by digital input 7 7 mA on SEU 7 7 activated by digital inpu...

Page 65: ...SEU digital input 3 on SEU Lowering block SEU digital input 4 on SEU 19 33 6 2 Lift SEU digital input 3 on SEU Lower SEU digital input 4 on SEU Lowering block SEU digital input 5 on SEU 33 6 20 3 Lift SEU digital input 4 on SEU Lower SEU digital input 5 on SEU Lowering block SEU digital input 6 on SEU 6 20 34 4 Lift SEU digital input 5 on SEU Lower SEU digital input 6 on SEU Lowering block SEU dig...

Page 66: ...A on SEU 33 3 activates digital input 4 1 mA on SEU 6 4 activates digital input 5 7 mA on SEU 20 5 activates digital input 6 7 mA on SEU 34 6 activates digital input 7 7 mA on SEU 7 7 activates digital input 8 7 mA on SEU 21 Argument 3 Selection of option switch for override function Values Meaning 0 activated by option switch 2 or 5 1 activated by option switch 1 2 activated by option switch 2 3 ...

Page 67: ...n no 0 photocell digital input 1 on SEU lowest position digital input 2 on SEU highest position digital input 3 on SEU external lifting switch digital input 4 on SEU external lowering switch digital input 5 on SEU lamp digital output 1 on SEU 5 19 33 6 20 16 1 photocell digital input 2 on SEU lowest position digital input 3 on SEU highest position digital input 4 on SEU external lifting switch dig...

Page 68: ...ion of SEU unit 1 or 2 Values Meaning 0 option is handled by SEU unit 1 A36 1 option is handled by SEU unit 2 the second SEU unit Argument 2 Selection of SEU digital output Pin no 0 activates digital output 1 1 6 A on SEU 16 1 activates digital output 2 1 6 A on SEU 30 2 activates digital output 3 1 6 A on SEU 2 3 activates digital output 4 1 6 A on SEU 3 Argument 3 Not used Argument 4 SEU output ...

Page 69: ...8 Operator profile 1 8 9 Operator profile 1 9 10 Operator profile 1 10 Argument 3 Connecting restrictions The values in argument 3 can be combined through addition e g value 1 value 8 value 9 Values Meaning 1 Block the lift pressurising of hydraulic function 1 2 Block the lowering depressurising of hydraulic function 1 4 Block the lift pressurising of hydraulic function 2 8 Block the lowering depr...

Page 70: ...ctions The values in argument 3 can be combined through addition e g value 1 value 8 value 9 Values Meaning 1 Block the lift pressurising of hydraulic function 1 2 Block the lowering depressurising of hydraulic function 1 4 Block the lift pressurising of hydraulic function 2 8 Block the lowering depressurising of hydraulic function 2 16 Block the lift pressurising of hydraulic function 3 32 Block ...

Page 71: ...d can never exceed the value of this parameter regardless of the settings of the other parameters Parameter 1045 Type of battery in the truck 1045 Type of battery in the truck Specifies the type of battery found in the application Par Description Min Defa ult Max Incre ment Unit 1044 Master maximum speed 0 5 6 0 6 0 0 5 km h Par Description Min Defa ult Max Incre ment Unit 1045 Type of battery in ...

Page 72: ...ery charger 1101 Built in charger Indicates if there is a battery charger on the application If there is a battery charger parameters 109 and 110 must also be set Par Description Min Defa ult Max Incre ment Unit 1046 Adapting to special trucks 0 0 1 1 Value Function 0 Function not activated 1 The function is activated Par Description Min Defa ult Max Incre ment Unit 1101 Built in battery charger 0...

Page 73: ...unction 1 The rear lifting and lowering control is connected to the second hydraulic function while the front control is connected to the first hydraulic function 2 The rear lifting and lowering control is connected to the first hydraulic function while the front control is connected to the second hydraulic function 3 Both lifting and lowering controls are connected to the first hydraulic function...

Page 74: ...between the battery and the logic card In case of reset problems Charge the battery to full capacity following the instructions in the operator s manual Then drive the truck for at least 25 seconds before logging out BDI is only set to 100 if the battery has been disconnected reconnected Check the voltage across the battery compared to the voltage between wires 20 and 40 on the tiller arm logic ca...

Page 75: ... for the correct setting of factory parameter 1118 The setting depends on which version of motor control is installed on the truck Value 0 1 5 kHz default value Value 1 8 kHz Slut på avsnittet Par Description Min Defa ult Max Incre ment Unit 1118 Hardware version 0 1 1 1 Value Function 0 Before 2010 03 22 1 After 2010 03 22 Motor controller Factory parameter 1118 Value 0 Value 1 243428 001 002 246...

Page 76: ...46 T Code s 841 842 843 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 ...

Page 77: ...ng the truck on a lorry or the like the truck must be properly anchored with stropping A Use inserts and sheets of shock absorbing material to prevent damage to the truck during lashing and transport 6 2 Transporting the mast When transporting the mast alone you must properly anchor all loose parts The guides must be secured so that they cannot glide apart Chains and any hoses must be fastened so ...

Page 78: ...to the forks of the lifting truck Lift it very carefully WARNING Risk of tipping The truck may tip over if it is lifted incorrectly Always lift the truck when it has been fastened to the forks of the lifting truck and its centre of gravity between the forks Only lift the truck at the indicated lifting points using suitable lifting equipment WARNING Risk of tipping The truck may tip over if it is l...

Page 79: ...ce prepare trestles or other suitable supports of the right height to support it Check the height of the supporting material before releasing the lifting hook 2 Check the electrolyte level in the battery Normally the level should be around 10 15 mm above the cell plates 3 Connect the battery cables battery connector DANGER Check that the polarity is correct when connecting the battery cables Compa...

Page 80: ...e truck has three ready to use operator profiles Page 6 7 PIN codes can be activated or changed according to the preferences of the operator An operator profile is activated upon normal log in by all PIN codes whose block number is activated 6 5 2 PIN code for resetting after a collision If the truck has stopped as a result of a collision it needs to be reset by entering a special PIN code This PI...

Page 81: ...e 0 The truck program stores a standard set of PIN codes as indicated in the table in the section PIN code defaults Note The truck program will not accept attempts to program PIN codes that have already been set The previous code will be restored When a PIN code is programmed there is a check to ensure that it is not used elsewhere in the table regardless of whether the block is active or inactive...

Page 82: ...on Blocks 0 9 are deactivated and all PIN codes are reset to 0000 Activate a new PIN code s block Press 2 b ON button b Block 0 9 Upon activation of a PIN code s block the codes already stored become available again Deactivate a PIN code s block Press 3 b ON button b Block 0 9 No codes will be deleted They will be available again when the PIN code s block is reactivated Programming a new PIN code ...

Page 83: ...0 0000 0000 0000 Block 1 1258 2258 3258 0000 0000 0000 0000 0000 9258 0000 Block 2 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 Block 3 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 Block 4 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 Block 5 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 Block 6 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 Block 7 0000 0000 0000 0000 0000 00...

Page 84: ...rameters chapter Check to make sure all parameters are set to the desired values in terms of maximum speed operator parameter Page 5 3 acceleration operator parameters Page 5 3 deceleration operator parameters Page 5 3 collision sensor option Page 5 9 battery Page 5 10 battery charger option Page 5 15Page 5 42 Note When checking or setting parameters be sure to keep written records e g in a truck ...

Page 85: ...Check the function d Control units Check the function e Brake Check the function f Emergency switch off Check the function g Hydraulic system Check all components h Power pack Check for any noise or oil leakage j Wheels Inspect for any damage remove dirt etc k Chassis Inspect for any damage remove dirt etc m Battery cover and lock Check the function n Battery Inspect the battery acid level and cha...

Page 86: ...s 841 842 843 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 ...

Page 87: ...if non approved spare parts are used the truck warranty ceases to be valid 7 2 Maintenance instructions 7 2 1 Cleaning and washing Cleaning and washing the truck is an important factor in maintaining truck reliability Carry out general cleaning and washing each week Note Risk of short circuiting Risk of damage to the electrical system Disconnect the battery before washing by pulling out the batter...

Page 88: ...anical parts Once washed the truck should be lubricated as set out in the maintenance instructions 7 2 5 Cleaning the chain We recommend you to replace a chain that is very dirty Dirty chains should be cleaned before they are lubricated e g by washing with solvent such as diesel or petrol The chain should be blown dry using compressed air and lubricated directly after cleaning Note Exercise care w...

Page 89: ...h a rag moistened with water and a suitable detergent Note Risk of short circuiting Risk of damage to electrical components Do not break the warranty seals on the electronic circuit boards 7 3 Maintenance schedule Service maintenance should be performed in intervals of 750 operating hours or every 12 months whichever occurs first The order in the maintenance schedule is not optimal for the working...

Page 90: ...ruck area Pos Measure 750h 12m Time expendi ture 0000 Chassis a Inspect cover mountings X 5 20 minutes including removal of covers b Check signs and adhesive labels X c Check for cracks and damage X d Check the mast fixing bolts X e Check for cracks and damage to the motor fixing points X f Secure the paper holder strap if necessary X a a b b b b b b b b b c d d e A B C D M PLATE A B C D E E F G Q...

Page 91: ...lay1 1 Only applies to trucks with support arm lift S212L S214L and S220D X c Check for cracks and damage to the push rods X d Check all shafts links and spring pins X Truck area Pos Measure 750h 12m Time expendi ture 0380 Fork carriage e Check for cracks and damage X 1 30 minutes f Check the rollers for looseness X g Check the load support Option X Inspect the fork stop screws S212S X Check that ...

Page 92: ... 7588857 040 Date 2018 05 01 Applies from serial number 6384351 Truck area Pos Measure 750h 12m Time expendi ture 0560 Platform and mountings a Check for cracks and damage X 1 30 minutes b Check the spring and that the platform returns to the upright position from the lowered position X a b https www forkliftpdfmanuals com ...

Page 93: ... grease nipples steering bearings Option X1 1 Option Does not need any lubrication when used normally For trucks that are used intensively or in cold storages we recommend lubrication every 1500 hrs e Inspect the steering bearing for correct mounting and play X f Change the drive gear oil X2 2 Note The oil in the drive gear only needs to be replaced after 750 hrs For trucks that are used intensive...

Page 94: ...s from serial number 6384351 Truck area Pos Measure 750h 12m Time expen diture 3500 Wheels a Inspect the drive wheel for wear X 2 minutes b Check the nuts X c Inspect castor wheel wear 1 1 Not applicable for S212S X d Check for wear on support arm wheels X e Check whether the castor wheels swivel freely X a d e g h i b c f d https www forkliftpdfmanuals com ...

Page 95: ...L S214 S214L S220D Publication Number 7588857 040 Date 2018 05 01 Applies from serial number 6384351 Wheels Standard measurements mm Minimum dimensions mm Drive wheel 30 15 Castor wheels1 1 Not applicable for S212S 10 5 Support arm wheels 11 5 5 a b c d e https www forkliftpdfmanuals com ...

Page 96: ...m a Check for proper attachment X 1 45 minutes b Inspect the operating console for correct mounting X c Check the mounting of the handle X d Check the force and locking of the gas spring The tiller arm should return to the top position both from the bottom position and from the lower position where the brake is applied X Check that the braking function is activated in both upper and lower tiller a...

Page 97: ...ontacts wiring harness including the battery cables cable insulation and that all cables can move freely X 4 30 minutes b Inspect the contactors for correct operation X c Check error code log operating times and all the segments on the display X d Clean and check that there is no play between the steering box and the heat dissipation plate X e Check and tighten the cable connections X f Check all ...

Page 98: ...g to illustration X c Check the mounting of the hydraulic unit X d Inspect the hydraulic system for possible leakage X e Change the oil and clean the oil tank Note Initially after 750 h 12 m then every 4500 h 36 m X f Clean the oil strainer Note Initially after 750 h 12 m then every 4500 h 36 m X 6600 Lift cylinder g Inspect the lifting cylinder for leakage X h Inspect the lifting cylinder for cor...

Page 99: ...tes b Check that there is no looseness in the mast s mounting points X c Check for play between the mast beam and the inner runner s rollers X d Check the inner runner s side play X e Check for wear on the lifting chains and chain rollers See section 16 3 Main lift chain system 7120 500h f Check the adjustment of the lifting chains See section 16 3 Main lift chain system 7120 500h g Lubricate the ...

Page 100: ...4 T Code s 841 842 843 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 f https www forkliftpdfmanuals com ...

Page 101: ...he supplier for more information Note The request Restart the truck means that the battery connector must be disconnected before attempting to start the truck again Software compatibility Ensure that the logic card ICH A5 motor control ACT T1 and battery charger BCU A30 have software from the same software package To ensure full functionality the latest software package must be downloaded 8 2 Towi...

Page 102: ...his mode it is possible to lower and lift the forks 1 Make sure that the truck is switched off Enter your PIN code 2 Press and then release the horn button Info is shown on the display 3 Turn the speed control several times until Ed is shown on the display 4 Press and then release the horn button to select 5 All lamps flash and SLO is shown on the display It is now possible to drive the truck but ...

Page 103: ...he problem Identify all parts that may have caused the problem Use the wiring chart if needed Was an error code displayed What is the problem When the error is localized see the instructions in the section for procedures When did the problem occur Which functions are affected Where at the place of work did the problem occur Follow the instructions in the troubleshooting chart Follow the instructio...

Page 104: ...em we ask you to please get in touch again to tell us how the problem was resolved Sending feedback will add to the common knowledge database This is important for the continued improvement of the support to the service technicians in the field Make sure all wiring and hoses are refitted in the correct manner Make sure that parts that have been emptied of fluids are refilled to the correct level R...

Page 105: ...code Note Do not press the ON switch 2 Press and then release the horn button Info is shown on the display 3 Press and then release the horn button to select the Info menu 4 Turn the speed control several times until E is shown on the display The error code symbol lights up 5 Press and then release the horn button to select 6 The most recent error is then displayed The display alternates between t...

Page 106: ...e system See the tables below for an explanation of the error code system Structure Description X YZZ Example 3 510 X 3 Group Indicates which truck system is affected by the error YZZ 510 Sequential number Group Description 1 Not used 2 Main control unit A5 ICH 3 Drive system 4 Hydraulic system 5 Steering system 6 Not used 7 Not used 8 Option auxiliary system 9 Not used https www forkliftpdfmanual...

Page 107: ...rameter or it has changed the parameter limit values 2 Corrupt memory A5 1 Check parameters Check that factory parameters are set according to the truck configuration Check that other parameters are set correctly 2 Replace A5 2 004 Backup copies do not match Backup copy in secondary unit T1 does not match data in primary unit A5 Not influenced 1 Hardware T1 or A5 has been replaced 2 Software has b...

Page 108: ...ter Check connectors joints and splices for damage or corrosion Check fuses F1 and F50 3 Check the battery 4 Check parameters Check that factory parameters are set according to the truck configuration Check that other parameters are set correctly 2 007 Internal program error A5 Not influenced Internal program error Create a truck report Send a report to the manufacturer Update the truck software t...

Page 109: ...carefully in the branches of the wiring harness to find any loose connections and note when if the error code appears 3 Check the CAN node Deactivate and disconnect the option unit connected to the CAN wiring Activate and then connect them one by one to identify which unit produces the communication error 4 Update the truck software Update the truck software package to the latest available version...

Page 110: ...on 2 285 Incorrect signal combination from the support arm position sensor Creep speed blocked lifting lowering movement 1 High signal from both B62 and B65 2 Constantly high signal at inputs T1 94 and T1 87 1 Check the sensor signal Check that the distance between the sensor and the opposite part is correct Check that there is no dirt or foreign objects on the sensor Inspect cabling Measure the s...

Page 111: ...tly 2 502 Truck type not set Parameter 1001 is incorrectly set Everything is stopped at once the parking brake is activated and the main contactor opens 1 A5 is replaced and or erroneous value for factory parameters 2 Incorrect value for parameter 1001 1 Copy the truck configuration using TruckCom See the separate manual for TruckCom 2 Check parameters Check that factory parameters are set accordi...

Page 112: ...nnect the battery Check that the resistance between X41 3 and X41 4 is 54 66 ohms Check that the CAN wiring harness is not pinched Measure resistance between the chassis and CAN connector Limit value 24 kOhm 2 Check for loose connections Switch on the truck and pull carefully in the branches of the wiring harness to find any loose connections and note when if the error code appears 3 Check the CAN...

Page 113: ...asure resistance between the chassis and CAN connector Limit value 24 kOhm 2 Check parameters Check that factory parameters are set according to the truck configuration Check that other parameters are set correctly 3 Check K110 DHU TWIS Check that the DHU s green LED is lit If the LED is not lit Check the DHU s feed voltage battery voltage Make sure it is possible to connect TruckCom to the DHU If...

Page 114: ...ated and the main contactor opens 1 New software has been loaded in the truck adding a new parameter or it has changed the parameter limit values 2 Corrupt memory circuit 3 Checksum error 1 Check parameters Check that factory parameters are set according to the truck configuration Check that other parameters are set correctly 2 Replace A5 3 Set new checksum If the problem with the check sum occurs...

Page 115: ...ow signal Replace A5 if the Hall sensors have an error function 2 523 Internal memory FRAM or RAM is faulty Reading from or writing to memory failed Everything is stopped at once the parking brake is activated and the main contactor opens Corrupt memory circuit 1 Replace A5 2 580 The Hall element for the speed control gives a signal active low when it should not Plug braking to stop then the main ...

Page 116: ... speed control does not spring back to neutral position 3 A5 defective 1 Let go of the control and wait for four seconds 2 Check the speed control Check the spring function Check that the speed control is not seized Check that the plastic cover where the spring is attached is intact 3 Check the Hall sensors Check with TruckCom or the built in test for the Hall sensors that they work the way they s...

Page 117: ...cause the cooling not to work properly Check that the fans work when the speed control is activated fans behind T1 and motor fan Check that the fan on charger T14 works when the charging starts i e when the mains cable is connected Check the signal from the temperature sensors for T1 and T13 and from B1 using the integrated test or TruckCom Determine if the temperature signals are plausible relati...

Page 118: ...s well as the battery charger and fans and filters for accumulations of dirt and dust Too much dust and dirt cause the cooling not to work properly Check that the fans work when the speed control is activated fans behind T1 and motor fan Check that the fan on charger T14 works when the charging starts i e when the mains cable is connected Check the signal from the temperature sensors for T1 and T1...

Page 119: ...ected Check the signal from the temperature sensors for T1 and T13 and from B1 using the integrated test or TruckCom Determine if the temperature signals are plausible relative to the real temperatures of the components If not replace T1 T13 or replace B1 with a repair kit 3 100 Motor control warning Unknown warning Creep speed blocked lifting lowering movement 1 Internal program error 2 Software ...

Page 120: ...ion in T1 detects a short circuit in the output for the horn The current through the horn is above the valid limit value Maximum value 500mA continuous value 300mA Not influenced High power consumption or short circuit 1 Check for overcurrent or short circuit Check the ohms and the amperes of the component compare them to the setpoint values if they outside the accepted range Check the connections...

Page 121: ...n the chassis and CAN connector Limit value 24 kOhm 2 Check parameters Check that factory parameters are set according to the truck configuration Check that other parameters are set correctly 3 Check wiring after the break Disconnect the battery Using instruments check that there is no break in any wire Measure and check the voltage for the activated functions 4 Replace T1 3 500 Internal error in ...

Page 122: ...he parking brake is activated and the main contactor opens 1 Error on CAN bus wiring or connection 2 CAN module in A5 defective 1 Check the CAN bus Check that CAN bus is intact in terms of wiring harness resistance and connectors Disconnect the battery Check that the resistance between X41 3 and X41 4 is 54 66 ohms Check that the CAN wiring harness is not pinched Measure resistance between the cha...

Page 123: ... A5 3 515 The motor control has detected low motor voltage Everything is stopped at once the parking brake is activated and the main contactor opens 1 Short circuit in motor 2 Short circuit in motor wiring harness 3 Short circuit in power stage 1 Check the motor Disconnect motor wiring including sensor wires Insulation test Check that the coils are not electrically connected to the chassis Replace...

Page 124: ...ntact and damaged insulation on the wiring harness Disconnect the motor wiring harness at the motor control and the motor and measure the ohms of the wiring harness between the phases and verify that there is no contact 3 Replace T1 3 526 Internal error in T1 Everything is stopped at once the parking brake is activated and the main contactor opens 1 Software failure 2 Defective motor control 1 Upd...

Page 125: ...al values Everything is stopped at once the parking brake is activated and the main contactor opens The charging voltage for the motor control capacitor indicates abnormal values 1 Check connections and wiring harness Wire 20 The connection point T1 84 must be 24 V Motor controller Pump contactor 2 If the error persists replace T1 3 535 Incorrectchecksum for the motor control parameters Everything...

Page 126: ...tage using a volt meter Measuring point F50 B and compare with the TruckCom value Battery Voltage Node ACT Analogue I O Limit values TBD Check the voltage using a volt meter Measuring point F1 B and compare with the TruckCom value Battery Voltage Node ACT Analogue I O Limit values If the contactor is open there is several volts of difference normal If the contactor is closed voltage should match t...

Page 127: ...control Search for contact and damaged insulation on the wiring harness Disconnect the motor wiring harness at the motor control and the motor and measure the ohms of the wiring harness between the phases and verify that there is no contact 3 Replace T1 3 545 Hardware protection in T1 detects a short circuit in the output to the brake Q1 The current through the brake exceeds the limit values Maxim...

Page 128: ...ircuited Replace the power supplying component 3 547 Hardware protection in T1 detects a short circuit in the output High Side driver Everything is stopped at once the parking brake is activated and the main contactor opens 1 Components are using too much power or wiring is short circuited 2 No software compatibility 3 Short circuit in power stage 1 Check components that are supplied with power fr...

Page 129: ... that the output stage is short circuited Replace the power supplying component 3 549 The motor control detects missing phases to the motor Everything is stopped at once the parking brake is activated and the main contactor opens 1 Short circuit in motor 2 Low power consumption or break 3 Short circuit in power stage 1 Check the motor Disconnect motor wiring including sensor wires Insulation test ...

Page 130: ...values and replace the unit if they are outside the accepted range Reconnect the battery Measure and check the voltage for the activated functions 3 564 The amperage is below the limit value 100mA on the output to main contactor Q10 Everything is stopped at once the parking brake is activated and the main contactor opens 1 Low power consumption or break 1 Check wiring and component after the break...

Page 131: ...ery Visually check the wiring harness Using instruments check that there is no break in any wire Check the Ohms and the Amperes of the component compare them to the setpoint values and replace the unit if they are outside the accepted range Reconnect the battery Measure and check the voltage for the activated functions 2 Replace T1 3 583 Internal transistor regulator voltage supply has not been sw...

Page 132: ...t the battery Using instruments check that there is no break in any wire Measure and check the voltage with the functions activated 2 Check the rotational speed sensor Disconnect the B11 Check that there are no metal fragments on B11 sensor points Check that the toothed wheel on the motor axle is clean intact and properly mounted 3 Drive carefully if there is a risk of slipping 3 592 Internal elec...

Page 133: ...starts i e when the mains cable is connected Check the signal from the temperature sensors for T1 and T13 and from B1 using the integrated test or TruckCom Determine if the temperature signals are plausible relative to the real temperatures of the components If not replace T1 T13 or replace B1 with a repair kit 4 001 Lifting lowering control is not in neutral position at start up Lifting is preven...

Page 134: ...erates Creep speed blocked lifting lowering movement 1 Defective power supply to the motor control Replace T1 4 126 Excessive pump motor current feedback at start up and in the standby mode Creep speed blocked lifting lowering movement 1 Defective power supply to the motor control Replace T1 4 521 Pump motor voltage too low The main contactor opens 1 Wire break between T1 and the pump motor 2 The ...

Page 135: ...ng valve has short circuited 2 Internal short circuit in the motor control 1 Inspect the connections and wiring harness Disconnect the lowering valve and try restarting the truck 2 If the error remains replace the lowering valve of the T1 4 541 The transistor regulator output to the lowering valve has short circuited with B Everything is stopped at once the parking brake is activated and the main ...

Page 136: ...nfiguration Check that other parameters are set correctly 8 004 One or more option buttons on A5 is activated at start up Not influenced All option buttons are non functional until the option button that is influenced is not influenced any more 1 Option button pressed during start up 1 Check your option buttons Check the function of the option buttons via the built in test mode Service Information...

Page 137: ...luenced 1 Battery not connected to charger 1 Check the battery charger cables Disconnect the battery by disconnecting the connector and power cable from the charger Measure the ohms on red and black wires from T14 to X1 Replace the cables in case of breakage 8 021 T14 detects low battery voltage when charging Voltage below valid level 19 8V Not influenced 1 The battery is defective 1 Check the bat...

Page 138: ...harging starts i e when the mains cable is connected Check the signal from the temperature sensors for T1 and T13 and from B1 using the integrated test or TruckCom Determine if the temperature signals are plausible relative to the real temperatures of the components If not replace T1 T13 or replace B1 with a repair kit 8 027 Internal error in T14 Not influenced 1 No software compatibility 2 Defect...

Page 139: ...y 8 031 Saving parameter in T14 failed Not influenced 1 No software compatibility 1 Update the truck software Update the truck software to the latest version 8 032 Wrong battery type selected via parameters 109 and 110 Not influenced 1 Battery parameters 109 and 110 incorrectly set 1 Check parameters Check that factory parameters are set according to the truck configuration Check that other parame...

Page 140: ...ep speed blocked lifting lowering movement 1 Error on CAN bus wiring or connections 1 Check the CAN bus Check that CAN bus is intact in terms of wiring harness resistance and connectors Disconnect the battery Check that the resistance between X41 3 and X41 4 is 54 66 ohms Check that the CAN wiring harness is not pinched Measure resistance between the chassis and CAN connector Limit value 24 kOhm 8...

Page 141: ...sistance between the chassis and CAN connector Limit value 24 kOhm 8 131 Temperature in the li ion battery is too high Creep speed blocked lifting movement 1 1 Let the battery cool down 8 132 Current in the li ion battery is too high Creep speed blocked lifting movement 1 Regenerative braking with fully charged battery 2 1 No action 2 Check battery voltage Check the voltage using the built in test...

Page 142: ...ow Let the battery rest and then restart the battery 8 138 Low battery voltage in the li ion battery Creep speed blocked lifting movement 1 Battery discharged 2 Voltage drop 1 Charge the battery 2 Check battery voltage Check the voltage using the built in test procedure and comparing with value from external volt meter Check connectors joints and splices for damage or corrosion Check fuses F1 and ...

Page 143: ...the speed control is activated fans behind T1 and motor fan Check that the fan on charger A30 works when the charging starts i e when the mains cable is connected Check the signal from the temperature sensor for T1 and from B1 using the built in test or TruckCom Determine if the temperature signals are plausible relative to the real temperatures of the components If not replace T1 or replace B1 wi...

Page 144: ... acceleration 1 Travel speed reduced because of activated Click 2 Creep turtle or emergency drive mode 1 StOP It is not possible to lift the support arms or the forks because of the interlock Blocked lifting movement 1 The forks cannot be lifted above 1 8 m if the support arms are raised 2 The support arms cannot be raised if the forks are 1 8m Code Description Truck behaviour Error cause s Proced...

Page 145: ...351 8 8 Troubleshooting chart The following section describes the type of errors that can occur together with a description of the cause Troubleshooting is divided into groups according to truck symptoms The truck cannot be driven The truck can be driven but only at reduced speed The truck can be driven but behaves abnormally Defective hydraulic functions https www forkliftpdfmanuals com ...

Page 146: ... supply Motor control input T1 95 Motor control defective Mechanical brake cannot be released Sensor B60 Sensor in wrong position or cannot be normally actuated Defective sensor Break in sensor wiring harness Motor control input T1 95 Motor control output T1 90 Motor control defective Corrosion Brake has seized due to corrosion Truck cannot travel after start up although tiller arm handle was in r...

Page 147: ...ts Possible cause Speed always reduced Click 2 Creep function Click 2 Creep function activated Turtle function Turtle function activated Operator parameter 6 speed Operator parameter 6 has not been set to the maximum value Pulse transducer B11 Defective or disconnected pulse transducer B11 Motor cable connections One of the phases U V W has been disconnected Broken wiring Mechanical brake Partiall...

Page 148: ...ration always reduced Operator parameter 4 Value setting low Reversing braking always reduced Service parameter 201 Value setting low Neutral braking always reduced Operator parameter 5 Value setting low The truck cannot be switched off Parameter 102 The Red off key on the keypad does not work Parameter 102 has been incorrectly set for the log in unit installed in the truck Speed always reduced Pu...

Page 149: ... compatibility matrix Make sure the correct software for the logic card A5 and motor control T1 are installed on the truck by referring to the matrix below Motor control ACT T1 not replaced Motor control ACT T1 replaced ICH logic card A5 not replaced OK Warning 2 004 Use TruckCom to download new backup values Open TruckCom and select Copy configuration to secondary unit ACT ICH logic card A5 repla...

Page 150: ... and voltage through pump contactor Q25 For more information see the table below Pump contactor Q25 does not close Pump contactor Q25 voltage current normal No current or voltage through across the contactor coil Q25 Voltage across contactor coil Q25 but no current through the coil Pump motor M3 does not work Hydraulic unit fuse F1 has blown replace fuse For more information see the following tabl...

Page 151: ...A5 faulty Replace the logic card Defective motor control T1 Replace the motor control Factory parameter 1023 Check the parameter value settings Cont d Pump contactor Q25 does not close Symptom Influencing elements Possible cause Remedy Pump contactor Q25 voltage current normal Defective contact tongues Replace the pump contactor No current or voltage through across the contactor Q25 coil Damaged w...

Page 152: ...er 7588857 040 Date 2018 05 01 Applies from serial number 6384351 Voltage across contactor coil Q25 but no current through the coil Interruption in the pump contactor coil Q25 Replace the pump contactor Cont d Pump contactor Q25 does not close Symptom Influencing elements Possible cause Remedy https www forkliftpdfmanuals com ...

Page 153: ...unit Cont d The solenoid valve Q4 for lowering the forks does not open Symptom Influencing elements Possible cause Remedy Solenoid valve Q4 voltage current normal Mechanical fault in the valve Q4 Replace the hydraulic unit Low or no current voltage through across the solenoid valve coil Q4 Damage to the solenoid valve Q4 wiring harness or connections Check the wiring harness for interruptions or s...

Page 154: ...ting the truck and reading the display at the same time Data Flashing symbol Description Resolution Unit Standard value BDI 10 0 100 1 Battery voltage 0 1 V Depending on battery type Compare with the real battery voltage 2 Battery voltage the value indicated in an approximate value of motor and pump voltages 1 A 0 450A 3 The set speed that is signalled to ACT from ICH Positive value in the drive w...

Page 155: ...description in Test mode 9 on page 56 10 TBD 11 Maximum value for collision sensor X and Y nonE is shown if no sensor exists 0 1 G 0 G 10 G 12 SEU digital I 0 See description in Test mode 12 Expansion unit SEU option on page 58 nonE is shown if no SEU exists 13 Steering angle 1 0 90 14 Drive motor temperature 1 C 15 ACT temperature 1 C Data Flashing symbol Description Resolution Unit Standard valu...

Page 156: ... Segment Description Segment Description 1 Option button 6 1 Rear button up 2 Option button 5 2 Rear button down 3 Option button 4 3 Front button up 4 Option button 1 4 Front button down 5 Option button 2 5 Main contactor 6 Option button 3 6 Horn input 7 ICH address node ID 7 Brake output 8 8 Pump Digit 3 ICH digital in Digit 4 ICH digital in Segment Description Segmen t Description 1 Top position...

Page 157: ...ressed Rear fork lift button A5 S21 F Lit Button depressed Rear fork lowering button A5 S22 G Lit Button depressed Sound signal control S18 H Lit Button depressed Outermost option button right side S116 A Lit Button depressed Centre option button right side S115 B Lit Button depressed Innermost option button right side S114 C Lit Button depressed Outermost option button left side S113 D Lit Button...

Page 158: ... 1 SEU 0 inputs 2 SEU 0 outputs 3 SEU 1 inputs 4 SEU 1 outputs 1 8 Reference to segment Digit 1 SEU 0 digital in Digit 2 SEU 0 digital out Segment Description Segment Description 1 In 1 1 Out 1 2 In 2 2 Out 2 3 In 3 3 Out 3 4 In 4 4 Out 4 5 In 5 5 6 In 6 6 7 In 7 7 8 In 8 8 Digit 3 SEU 1 digital in Digit 4 SEU 1 digital out Segment Description Segment Description 1 In 1 1 Out 1 2 In 2 2 Out 2 3 In...

Page 159: ...h 8 11 1 Display test The digital display A6 can be tested to verify all the segments of the display function correctly A moving 8 tests all the segments of the display 8 11 2 Speed control The Hall elements are tested by moving the speed control all the way back and forth Follow these steps to test the Hall elements Move the rocker from the neutral position to begin the test This is visualised as...

Page 160: ...utral position to begin the test The analogue value from the sensilift potentiometer is shown in mV 8 11 6 Keypad Press a number to start testing the keypad b1 up to b11 is shown in the display depending on which button is pressed The numbers 0 9 are shown as b0 to b9 The red button b10 and the green button b11 9 Switch off the truck by pressing the OFF button or return to the previous menu by pre...

Page 161: ... to all of the questions the charger is functioning properly and does not require replacement If not fill in the rest of the checklist on the next page Check Yes No 1 Are all of the charger s connectors properly connected 2 Does the fan blow air out of the charger it should begin running at start up 3 Does battery voltage increase when the charger is connected to mains voltage Measure across the b...

Page 162: ...improvement work Check Yes No 1 Is there any evidence of moisture on the inside or outside Investigate for interior moisture through the perforated sides 2 Has the truck been used in an environment with a temperature below 0 Celsius 3 Has the truck been used outdoors 4 Are there signs of mechanical damage 5 Has the truck travelled over uneven floors or loading ramps 6 Are there any error codes If ...

Page 163: ...4351 9 Chassis 0000 9 1 Support arm 0350 9 1 1 Support arm lift lateral adjustment 1 Loosen the locking nut 2 Adjust the lateral guides using the adjustment screw b There are four adjustment screws 3 Adjust the lateral guides so that there is no play but so that the lowering does not jam 4 Lock the adjustment screws position with the locking nut b a https www forkliftpdfmanuals com ...

Page 164: ...is pressure plate and the support arm link roller must be between the minimum value of 0 4 and the maximum of 2 0 1 Check the gap A precondition for checking the gap is that the roller is fit ted and that they are in the lowered position 2 Loosen the cylinder a if the gap is incorrect 6 mm Allen 3 Place a suitable number of shims 7501642 under the cylinder a 4 Tighten the cylinder 5 Check that the...

Page 165: ...1 Remove the covers and the battery door The top cover is secured with Velcro tape Be careful when detaching the cover Use of a suitable tool is recommended 2 Lift out the battery 3 Disconnect the cables to the drive motor and the pump motor and also the wiring harness 4 Disconnect the cable duct 5 Unfasten the battery connector and the battery cable bracket 6 Install the threaded M16 bar See sect...

Page 166: ...e upper stop screws for M8 x 120 washers are not needed 9 Remove and discard the screws to the upper bracket 10 Remove the lower screws 11 Compress the spring assembly using the threaded bar until the lips are clear 12 Unload the springs by prying up the bracket using the threaded bar Note Check that the bushings do not get stuck or become damaged during reassembly https www forkliftpdfmanuals com...

Page 167: ...ly a load on the platform and loosen the upper dampening stop to gether with the spring cover plate 2 Disassemble the platform from the truck by loosening the four bolts 3 Put the platform on the floor behind the truck with the spring facing you and placing the other edge under the truck s foot guard 4 Loosen all 8 screws securing the bracket which the spring clamp is push ing against https www fo...

Page 168: ...40 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 6 Pull out the axle and replace the part s that should be replaced 7 Install in reverse order https www forkliftpdfmanuals com ...

Page 169: ...L S220D Publication Number 7588857 040 Date 2018 05 01 Applies from serial number 6384351 10 Electric drive motor 1700 10 1 Overview Pos Description a Speed sensor b Connection motor cables c Motor S212L 214 214L 220D 1 5kW c Motor S210 212 212S 1 0kW e Temperature sensor a b c e https www forkliftpdfmanuals com ...

Page 170: ...ul when detaching the cover Use of a suitable tool is recommended 2 Cut off the cable ties of the cable duct on the transistor regulator side and disconnect cable connections X5 and X65 3 Loosen the operating console s mounting screws a and remove the op erating console and tiller arm 4 Remove the brake s cable connection Q1 5 Remove the speed sensor s cable connector B11 6 Remove the temperature ...

Page 171: ...e drive motor has been removed Install the motor in the reverse order See section 10 7 Drive motor tightening torques Note During installation it is very important for the motor to be adjusted so that the grooves in the motor and motor bracket face each other before the retaining screws are tightened See the illustration below Tighten the 4 drive motor mounting screws a The screws must be tightene...

Page 172: ...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 1 Remove the circlip 2 Remove the brake hub 3 Remove the key https www forkliftpdfmanuals com ...

Page 173: ...l 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 ...

Page 174: ...2L 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 Carefully knock out the stator 8 Remove the circlip inside the motor https www forkliftpdfmanuals com ...

Page 175: ... 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 1 Undo the screw and pull the RPM sensor straight out Disconnect connector B11 2 Install in reverse order https www forkliftpdfmanuals com ...

Page 176: ...urfaces are dry 4 Apply plastic steel by pushing out a string that is half the length of the cur ing agent compared to the putty then carefully mix the two be careful not to mix a larger amount than will be used in 5 minutes 5 Apply a layer of plastic steel at least 4 mm thick and make sure the re paired surface has an overlap of at least 2 cm 6 Secure the steel plastic with masking tape and allow...

Page 177: ... 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 T30 T30 Nm 3 5 10 mm 10 5 4 5 0 5 Nm 1 5 Nm https www forkliftpdfmanuals com ...

Page 178: ...operation Regularly inspect the motor and motor compartment for build up of dust oil and other contaminants Dirty and or greasy components should be cleaned with a rag moistened with solvent Use a rag of lint free cloth material Do not use too much solvent as it could penetrate into the motor parts After cleaning dry the components thoroughly The easiest way is by heating Note Windings and insulat...

Page 179: ...ear that is integrated with the motor and brake assembly in a complete drive unit The drive gear is fitted to the chassis with bolts At the top edge of the gear the steering bearing and a gear ring for the steering motor option are fitted These service instructions cover descriptions of service performed on site at the customer A complete reconditioning of the drive gear must be performed in the w...

Page 180: ...88857 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 Notes a Transmission housing b Motor bearing and packing box c Steering bearings d Seal and cover ring e Stud bolt M12x1 5 a b c d e https www forkliftpdfmanuals com ...

Page 181: ...e cable ties of the cable duct on the transistor regulator side and disconnect cable connections X5 and X65 3 Unscrew the retaining screws of the steering console and remove the steering console and the tiller arm 4 Disassemble the speed sensor and disconnect the cable connections Q1 and B1 5 Disconnect the motor cables and unscrew the motor retaining screws 6 Lift out the motor from the truck 7 I...

Page 182: ...tor bracket using the threaded rod until the drive wheel is lifted approx 4 mm from the floor 11 Unscrew the retaining screws of the gear box 12 Lift carefully approx 125 mm lay the gear down on the floor 13 Lift a further 100 mm a total of 225 mm and pull it out to the rear edge Install in reverse order Please note the risk of crushing when installing the unit Steps 12 13 https www forkliftpdfman...

Page 183: ... transistor regulator side and disconnect cable connections X5 and X60 5 Unscrew the retaining screws of the steering console and remove the steering console and the tiller arm 6 Disassemble the speed sensor and disconnect the cable connections Q1 and B1 7 Disconnect the motor cables and unscrew the motor retaining screws 8 Lift out the motor from the truck 9 Insert a plug in the hole in the gear ...

Page 184: ...588857 040 Date 2018 05 01 Applies from serial number 6384351 11 5 Fitting grease nipples steering bearings Option 1 Clean the surface remove all dirt from the recess for the grease nipples 2 Unscrew the stop screws 3 Screw in the grease nipples using an extension piece 2 each Step 1 Step 2 Step 3 https www forkliftpdfmanuals com ...

Page 185: ...11 6 Lubrication the steering bearings Option 1 Turn the steering wheel to the end position 2 Press in some grease not so much that the seal lifts check the seal at the grease nipple position 3 Turn the wheel about 15 degrees press in some more grease continue to the other end position 4 Do the same with the other grease nipple to lubricate the entire bearing https www forkliftpdfmanuals com ...

Page 186: ...2018 05 01 Applies from serial number 6384351 11 7 Checking and changing the oil 11 7 1 Draining oil 1 Undo and remove the oil plug on the lower part of the gear housing 2 Drain all old oil into a suitable receptacle 3 Clean away dirt and metal shavings from the oil plug before fitting Step 1 Step 2 Step 3 T 20 Nm https www forkliftpdfmanuals com ...

Page 187: ...on Number 7588857 040 Date 2018 05 01 Applies from serial number 6384351 11 7 2 Checking refilling oil 1 Remove the oil filler plug on the upper part of the gear housing 2 Top up with oil up to the lower edge of the hole to reach the correct level 3 Screw in the plug Step 2 Step 3 Step 1 https www forkliftpdfmanuals com ...

Page 188: ...12L 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 1 Remove the cover ring using a screwdriver or similar 2 Remove the seal using a screwdriver or similar https www forkliftpdfmanuals com ...

Page 189: ...212S S212L S214 S214L S220D Publication Number 7588857 040 Date 2018 05 01 Applies from serial number 6384351 Fitting the seal 1 Fit a new seal Tap lightly to get it into the right position 2 Fit a new cover ring Tap it lightly into place Step 1 Step 2 https www forkliftpdfmanuals com ...

Page 190: ...od 1 Drill a hole in the centre of the stud and remove it using a bolt extractor Method 2 If the stud will not come loose with a bolt extractor it will have to be drilled out Drive a centre punch as close to the centre of the stud as possible Drill a pilot hole through the stud using a 5 mm bit Drill out the screw with a drill Try to remove the stud remains using pliers etc If that does not work r...

Page 191: ...ake that is released when the magnetic coil is energised This brake serves as a parking brake and emergency brake The parking brake is activated is active as follows The parking brake is applied automatically when the truck stops during operation The brake is released when the truck moves off The parking brake remains active after the main power has been switched on Emergency brake Emergency braki...

Page 192: ...4351 12 2 Parking brake 3180 In normal work environments the brake should not require any maintenance 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 Only the actions described in this section may be carried out on the parking brake 12 2 1 Overview d f b j h i g e c a https www forkliftpdfmanuals com ...

Page 193: ...should only be performed when the truck needs to be moved in connection with work for service and repairs The brakes on the truck can be manually released by screwing two screws M5 into the holes A The screws should be 30 35 mm long Note Remember to remove the screws before operating the truck again Pos no Description a Dust seal b O ring c Dust seal d Wiring harness e Magnet housing f Dust seal g...

Page 194: ...brake system there is a risk of brake function being partly or completely lost Truck switched off and the battery disconnected Motor compartment open 1 Remove the steering yoke from the truck together with the tiller arm see the repair manual Note the position of the conduit entry so that refitting is done correctly 2 Remove the brake and the cable connector Q1 3 Remove the brake unit from the tru...

Page 195: ...n the brake retaining screws to 5 Nm 2 Fit the connector Q1 3 Install the dust caps 4 Fit the tiller arm and the steering yoke and tighten the mounting bolts to 23Nm Make sure the wire grommet is mounted securely to the brake and placed according to your notes Connect the battery and close the motor compartment cover Start the truck and check that the brake works correctly Steps 1 and 2 T 5Nm Step...

Page 196: ...ressed air Clean from the inside outwards 3 If there are particles that cannot be cleared away with compressed air these may be carefully scraped away Measure the air gap between the magnet housing of the brake unit and the movable pressure disc Measuring must be done around the entire pressure disc both on the inside and the outside Note It is most important to maintain a clearance of 0 2 0 7mm a...

Page 197: ... 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 2 Disassemble the drive wheel A It is simplest to loosen the drive wheel between the forks Angle the wheel to the side in order to work more easily under the truck 3 Put the new wheel in position A and tighten the nuts B 81 19 Nm A B https www forkliftpdfmanuals com ...

Page 198: ...lication 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 A Circlip H Screw B Washer I Spacer C Screw J Spacer D Bracket K Bearings E Nut L Guard F Bearings M Nut G Circlip A B D C E F G H I J K L M https www forkliftpdfmanuals com ...

Page 199: ...er 7588857 040 Date 2018 05 01 Applies from serial number 6384351 12 7 2 Castor wheel mounting Pos Description Pos Description 11 Nut 17 Screw 12 Control units 18 Washer 13 Spring 19 Bracket 14 Control units 20 Bushing 15 Cradle 21 Shims max 1mm gap Add as needed 16 Screw 11 12 13 14 15 16 17 18 19 20 21 https www forkliftpdfmanuals com ...

Page 200: ...from serial number 6384351 12 7 3 Replacing the castor wheel DANGER Risk of crushing since a poorly supported truck could fall down 1 Secure the truck in a safe manner 2 Disconnect the truck battery 3 Unscrew the castor wheel 4 Refit the castor wheel and its four fastening screws and washers 5 Connect the battery 6 Remove the support trestles https www forkliftpdfmanuals com ...

Page 201: ...hat the springs are released from the upper bracket 3 Loosen the lower locking nut on the spring that is to be changed Note The spring is pre tensioned take care when loosening the lower locking nut 12 8 2 Fitting the spring 1 Place a block under the spring bolt so that the spring screw is held in place 2 Fit the spring with the lower locking nut and washer Use a short sleeve in order to screw the...

Page 202: ...L 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 a Screw b Bracket c Bogie wheel d Single wheel e Shaft f Circlip g Nut h Screw i Bracket e g h i d d f e a b c https www forkliftpdfmanuals com ...

Page 203: ...s S210 S212 S212S S212L S214 S214L S220D Publication Number 7588857 040 Date 2018 05 01 Applies from serial number 6384351 Pos Description 13 Shaft 14 Pin 25 Shaft Pos Description 1 P214 216 2 P218 220 225 13 14 25 14 e 156 mm e e 180 mm e 13 14 1 2 https www forkliftpdfmanuals com ...

Page 204: ...ber 7588857 040 Date 2018 05 01 Applies from serial number 6384351 12 10 Climber wheels 12 10 1 Overview Pos Description Pos Description A Screw K6S 8x12 G Wheel assy B Screw MF6S 8x35 H Wheel bracket C Sleeve I Shaft D Climber wheels J Wheels E Slide pad K Spring pin F Lock nut M8 A B C D E F G H I J K https www forkliftpdfmanuals com ...

Page 205: ...er 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 A B C D E F G H I J K L M N O P Q R S T U V w https www forkliftpdfmanuals com ...

Page 206: ...erial number 6384351 O Pos Description Pos Description A Tiller arm M Indicator sleeve B Rubber buffer N Plate C Cylindrical bolt O Yoke D Gas strut P Cable clamp E Circlip Q Screw F Rubber buffer R Yoke G Bushing S Screw H Threaded insert T Cover I Stop screw U Cover J Holder V Cable clamp K Safety sensor B60 W Cable clamp screw L Shaft https www forkliftpdfmanuals com ...

Page 207: ...out through the hole in the steering console Note Do not try to prise away the cable clamp with a screwdriver 5 Cut off the cable ties of the cable duct on the transistor regulator side and disconnect cable connections X5 and X65 Install in reverse order 13 3 Replacing an gas strut 1 Remove the cover T 2 Remove the cable clamp retaining screw W 3 Unscrew the adjusting screw Q 4 Remove the locking ...

Page 208: ...h sides at the same time 5 Tap out the shaft L Note Make sure that the handle does not drop down and damage the cables 6 Remove the cable clamp retaining screw W 7 Remove the sensor retaining screw S 8 Detach contact B60 from the sensor K 9 Remove the sensor 13 4 2 Installation 1 Fit the sensor K 2 Attach connector B60 to the sensor 3 Apply Loctite to the sensor retaining screw S or replace it Fas...

Page 209: ...l 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 a b c d e f g h i j k l m n a https www forkliftpdfmanuals com ...

Page 210: ...ion Number 7588857 040 Date 2018 05 01 Applies from serial number 6384351 Pos Description a Cover b Plug c Wiring harness d Cover e Toggle switch f Horn button g Button lifting lowering h Display i Horn button j Switch horn k Display l Electronic card A5 m Stomach button n Speed control https www forkliftpdfmanuals com ...

Page 211: ...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 Installing a keypad Connect the keypad and screw it in position https www forkliftpdfmanuals com ...

Page 212: ... 01 Applies from serial number 6384351 13 5 4 Replacing the upper cover C4110 Removing the upper cover Remove the keypad Page 13 7 1 Remove the screws holding the upper cover and keep hold of the upper cover to prevent damage to the cable to the logic board 2 Disconnect the CAN connection to the logic card Step 1 Step 2 https www forkliftpdfmanuals com ...

Page 213: ...he left side and then proceed with the right side 3 Turn the screws crosswise as depicted below a further four complete turns a total of nine turns which corresponds to 1 Nm 4 Check that there is no space between the handle and the steering head 5 Make sure that the control can be moved back and forth without difficulty and that the control returns to the neutral position If the control shows sign...

Page 214: ...m serial number 6384351 13 5 5 Replacing the tiller arm handle Removing the tiller arm handle Remove the upper cover Page 13 8 1 Remove the cable bracket handle in the tiller arm Fitting the tiller arm handle 1 Fit the handle cable bracket Note Mount the wiring harness so that it does not get pinched Fit the upper cover Page 13 9 T 12Nm https www forkliftpdfmanuals com ...

Page 215: ...of static discharge that can damage the electronics Make sure you take the necessary steps to prevent static electricity ESD protection before starting work on the steering module 1 Remove the screws holding the cover for the logic card and carefully lift away the cover Hint Hold a finger between the cover and the shaft for the speed control buttons to prevent the speed control assembly from falli...

Page 216: ...l number 6384351 Installing a logic card 1 Fit the new logic card in place and connect it 2 Check the cable connection on the logic card and that the connectors are correctly connected 3 Fit the cover in place and screw it down Make sure the conduit entry is intact and correctly positioned Fit the upper cover Page 13 9 Steps 1 2 Step 3 Step 3 https www forkliftpdfmanuals com ...

Page 217: ...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 See the TruckCom manual https www forkliftpdfmanuals com ...

Page 218: ...51 13 5 9 Replacing the signal button switch Remove the stomach button Page 13 17 1 Remove the screws to the wire fittings 2 Remove the connectors to the logic card 3 Remove the horn button use a screwdriver to carefully prise it off the clip fasteners 4 Remove the switch by pulling it straight up Install in reverse order Step 1 Step 2 Step 3 Step 3 Step 4 https www forkliftpdfmanuals com ...

Page 219: ...the speed control 2 Use a screwdriver and carefully press down the button fitting 3 Pull the button straight out compress the spring when removing it Reassemble in reverse order Lubricate the spring a with Molcate PC 75 Make sure there is no play when operating the rocker adjust the spring legs if necessary In case the control does not spring back Check that the spring is fitted correctly Fit the ...

Page 220: ...Publication Number 7588857 040 Date 2018 05 01 Applies from serial number 6384351 13 5 11 Replacing the sensilift Remove the stomach button Page 13 17 1 Remove the button use a screwdriver to carefully prise it loose 2 Pull it straight up Reassemble in reverse order Step 1 Step 2 https www forkliftpdfmanuals com ...

Page 221: ...move the upper cover Page 13 8 1 Remove the screws holding the cover stomach button over the logic card and carefully lift away the cover Hint Hold a finger between the cover and the shaft for the speed control buttons to prevent the speed control assembly from falling down Note The stomach button must not be replaced by itself the complete cover and button must be replaced as a unit Step 1 Step 1...

Page 222: ...3 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 2 Make sure the lips catch when the new buttons are inserted 3 Connect a PDA or PC and use TruckCom to change parameter 1023 to 2 4 Start the truck and make sure the change is correct https www forkliftpdfmanuals com ...

Page 223: ... be restarted 1 Disconnect the battery yoke Note the yoke must be removed from the battery 2 Disconnect the CAN connector X111 3 Wait until the light goes out 4 Connect the CAN connector 5 Wait until the lamp on the battery shows steady green 6 Reconnect the battery yoke 14 2 Inspecting the battery 1 Check that a green lamp is lit on the battery This indicates that everything is OK 2 Check the att...

Page 224: ...ws when replacing the wiring harness 1 When prying the X connectors apart press in the connector lock A of the female part B and pull upwards 2 Disconnect the female part B of the connector from the male part D 3 Then disconnect the male part D by pulling it downwards The bracket C remains on the connector panel Pos Description A Connector clamp B Connector female part C Bracket D Connector male p...

Page 225: ...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 First press down on the bracket clamp B Then lift up the connector lever C A B C https www forkliftpdfmanuals com ...

Page 226: ...t on the transistor regulator side 3 Disconnect the connectors A from the connector bracket 4 Undo the screws D and move the connector bracket aside 5 Disconnect all cables and connectors from the transistor regulator 6 Loosen the fastening nuts B of the fixing plate 7 Remove the transistor regulator Angle out the top edge of the fixing plate and turn it in the drive wheel di rection in order to r...

Page 227: ... 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 3 Select Copy configuration to secondary unit ACT https www forkliftpdfmanuals com ...

Page 228: ...e s 841 842 843 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 ...

Page 229: ...ety precautions prior to commencing work on the truck s hydraulic systems Slowly depressurise system pressure Use some paper or a stiff piece of cardboard when checking for possible oil leaks Do not use your hand Be careful since the oil in the transmission and hydraulic systems can be scalding hot DANGER Risk of burns if hot transmission oil or hydraulic oil gets onto the skin Allow the truck to ...

Page 230: ... 16 13 in accordance with ISO4406 1999 or 16 13 in accordance with ISO4406 1987 Blowing clean with dry filtered air may be done when this is the only practical method to carry out cleaning 15 2 2 Packaging After cleaning all openings must be sealed with protective plugs Connecting surfaces must be protected against handling damage and dirt penetration Completely dry components can be packed in pla...

Page 231: ...draulic system great cleanliness must be observed so that no impurities can enter the system No work that generates particles may be carried out in the same workplace or close to where work is being carried out on the hydraulic system The service technician must ensure that the components to be used are carefully deburred and cleaned Couplings for pipe ends or other openings must never be removed ...

Page 232: ...mp motor M3 h Hydraulic fork connection b Solenoid valve support arm selection Q23 1 1 Only applies to S212L S214L and S220D i Pressure limiting valve c Solenoid valve fork selection Q22 Superscript 1 k Maximum oil level d Proportional valve lowering Q4 m Filling cap e Tank suitable oil volume 5 l n Pump motor cable connection f Screw o Pump motor cable connection g Hydraulic connection support ar...

Page 233: ...stem bleeding Cylinders with bleeding valve 1 Loosen all bleeding screws 2 revolutions 2 Lift slowly at a constant rate until the forks begin to rise 30 40 cm 3 Close the bleeding screws 4 Lower the forks and continue to press the lowering button for 10 15 s 5 Top up with oil 6 Lift the forks to max 7 Lower and check the oil level Cylinders without bleeding valve 1 Lift slowly at a constant rate u...

Page 234: ... 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 2 Push the male fitting into the female fitting until the assembly stop makes contact with the female fitting 3 The coupling is now made and locked https www forkliftpdfmanuals com ...

Page 235: ...om serial number 6384351 Disassembly of the quick change connector 1 Remove the assembly stop with the aid of a screwdriver or similar tool 2 Push the male fitting all the way into the female fitting 3 Pull the male fitting out of the female fitting 4 Refit the assembly stop on the male fitting 5 Place protective plugs on the valve and hose https www forkliftpdfmanuals com ...

Page 236: ...the hose rupture valve The hose rupture valve is built into the cylinder hydraulic hose bracket Note When fitting these components it is very important that no dirt etc enters the hydraulic system 1 Detach the hydraulic hose from the cylinder and plug the connection 2 Unscrew the hydraulic hose bracket hose rupture valve from the cylinder 3 The new hose rupture valve should be torque tightened to ...

Page 237: ... mode strt is shown on the display waiting for one of the two horn buttons to be pressed The calibration begins when one of the two horn buttons is pressed The lowering valve is then opened slowly As soon as the operator notices the movement of the forks the horn button must be released Wait until the display shows end and then restart the truck Service parameter 108 s re set automatically when th...

Page 238: ... able to handle the rated load on the forks Place a rated load on the forks and verify that the truck is able to lift it If the truck cannot lift the rated load 1 Pry off the sealing cap a attached to the pressure limiting valve using a screwdriver 2 Remove the protective cover b 17 mm by turning it anti clockwise Remove the protective cover and the washer housed inside it 3 Loosen the locking nut...

Page 239: ...load apply an additional 100 kg on the forks Verify that the truck cannot lift the load If the truck is able to lift 100 kg more than its rated load 1 Pry off the sealing cap a attached to the pressure limiting valve using a screwdriver 2 Remove the protective cover b 17 mm by turning it anti clockwise Remove the protective cover and the washer housed inside it 3 Loosen the locking nut c 17 mm by ...

Page 240: ... 6384351 15 8 Disassembling the hydraulic unit Before commencing any work on the hydraulic unit make sure the forks have been fully lowered 1 Disconnect the hydraulic hose See section 15 4 1 Quick change connectors 2 Disconnect the motor cables using a wrench 3 Disconnect the electric connection to the lowering valve n s mm Step 1 Step 2 Step 3 s 13mm n 2ea https www forkliftpdfmanuals com ...

Page 241: ...truck 5 Undo the clamp to be able to detach the tank from the motor and lift the valve unit away from the tank 6 Remove and clean the strainer then reattach it in the correct position 7 Change the oil and clean the tank 8 Reassemble everything in reverse order See section 15 9 Hydraulic unit tightening torques Note Be careful with the hydraulic unit seals when re installing Step 4 Step 5 Step 6 n ...

Page 242: ...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 10 2 Nm 13 mm 8 5 0 5 0 5 Nm 24 mm 45 5 Nm 5 0 8 0 8 Nm 24 mm 45 5 Nm 7 mm 4 0 5 0 5 Nm https www forkliftpdfmanuals com ...

Page 243: ...4 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 Pos Description Tightening torque a Upper mast fixing points 189 8 Nm b Lower mast fixing points 83 4Nm a b a b https www forkliftpdfmanuals com ...

Page 244: ...ng 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 The tightening torque should be according to the torque table Lubrication Lubricating the beam 1 The inside of the beam flanges are lubricated with Q8 Rembrandt EP2 https...

Page 245: ...e 2018 05 01 Applies from serial number 6384351 16 2 Fork carriage 7420 16 2 1 Maintenance Check that the play in the fork carriage is not excessive Adjust with shims a if needed There are rollers with different diameters c to compensate for any wear on the guide rails Pos Description a Shim b Roller a b c https www forkliftpdfmanuals com ...

Page 246: ... 1 General Note Replacing the chain bolt When replacing the chain be sure to also replace the chain bolt When the chain assembly with chain bolt is replaced the counter nuts and the cotter pin safety cotter must be replaced at the same time Pos Description a Cotter pin safety cotter b Wide locking nut c Narrow locking nut d Spherical washer e Complete chain including anchor bolt e d c b a a https ...

Page 247: ...hing Wear to the bolts and plate holes causes the chain to stretch The chains are also affected by the environment in which they are used Noise If there has been insufficient lubrication there will be metallic friction on the chain and this will result in noise Replace the chain Surface rust Surface rust is easy to recognise as the chain will be reddish brown Deep seated rust has generally started...

Page 248: ...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 Replace the chain Loose bolts If a bolt is loose it will protrude from the side of the chain and this is due to a stiff link or bolt rotation Replace the chain https www forkliftpdfmanuals com ...

Page 249: ...s H2 in the figure As the truck is used the lifting chain wears radially on the side that rolls over the chain wheel The minimum plate height defined as H3 in the figure denotes the minimum permitted value of the plate height Maximal permitted outline wear is 5 of the thickness H2 If a lifting chain reaches the maximum level of wear it must be replaced The nominal and minimum Plate heights for res...

Page 250: ...or lift chains are stated in the table below Wear to the bolts and around the holes on the discs is one reason why the chain stretches The chain must be replaced if is stretched more than 2 Damage The chain should be replaced if damaged in any way Type of chain Nominal disc height H2 mm Minimum plate height H3 mm Pitch P mm Nominal chain length for 20 30 50 plates mm Maximum permitted chain length...

Page 251: ... rotation and or that the outer plate is loose Replace the chain Dirty chain If a chain is very dirty replacement is recommended first and foremost It can also be removed and cleaned as set out in the chapter Cleaning 16 3 4 Cleaning We recommend you to replace a chain that is very dirty Dirty chains should be cleaned before they are lubricated e g by washing with solvent such as diesel or petrol ...

Page 252: ...d even the fastening bolts It is particularly important that the part of the chain that runs over the chain wheel is well lubricated The lubricate must comply with the viscosity demands at respective temperatures as set out in the table below The following lubricants are recommended Similar products from other manufacturers may be used Note Do not use any special rustproofing agents to prevent cor...

Page 253: ... to stretching This is to be done when other service work with chains is performed The lock nuts on the lifting chains are to be tightened with 50 Nm 12 5 Nm 5 Nm 1 Make sure that the thinner nut b is placed closest to the chain fitting 2 Use a fixed spanner and a torque wrench set to 50 Nm to ensure the correct torque Using the main lifting chains the mast guides must be adjusted so that the bott...

Page 254: ...220D 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 2 Remove the chain bolt 3 Lower the fork carriage https www forkliftpdfmanuals com ...

Page 255: ...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 ...

Page 256: ...er 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 2 Disconnect all connectors to the lift height switches 3 Remove the spiral hose https www forkliftpdfmanuals com ...

Page 257: ...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 6 Lift out the battery https www forkliftpdfmanuals com ...

Page 258: ...r 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 8 Remove the lower finger protectors and the bracket for the hydraulic hose on the cylinder https www forkliftpdfmanuals com ...

Page 259: ...843 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 ...

Page 260: ...l 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 https www forkliftpdfmanuals com ...

Page 261: ...384351 16 6 Replacing the idler roller Remove the mast and place it on a pallet or similar 1 Use a puller to remove the roller Make a note of the number of shims 2 Install the roller fit the same number of shims as were installed before Make sure the guides can move freely and the there is not too much play before you install the mast in the truck https www forkliftpdfmanuals com ...

Page 262: ...ation 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 Fit shims according to the instructions below if needed https www forkliftpdfmanuals com ...

Page 263: ...del 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 ...

Page 264: ... 22 T Code s 841 842 843 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 ...

Page 265: ...1 842 843 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 ...

Page 266: ...T Code s 841 842 843 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 ...

Page 267: ...ler logic which means that a defective SEU can be replaced without the replacement affecting any truck functions The SEU is used for modification of the truck to meet special customer requirements The picture above shows how the SEU is used to allow a greater number of functions to be controlled via the CAN bus SEU has a 42 pin multi pin contact that manages all inputs outputs CAN and power supply...

Page 268: ...4 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 https www forkliftpdfmanuals com ...

Page 269: ...s a PC scanner etc The converter on the input side is protected against polarity reversal short circuit and thermal overload The chassis is not live and the in outputs are galvanically separated The output sits on the E bar profile 18 5 Collision sensor If a collision sensor is installed on the CAN bus this registers when the truck bumps against something If an impact exceeds a certain level speci...

Page 270: ...n existing charger When installing the charger torque tighten nuts A to max 1 6 Nm If the truck is factory fitted with a battery the battery charger is adjusted to suit the battery If the truck is delivered from the factory without a battery the customer technician must set the right parameters based on battery type and size 18 6 1 Technical data Designation SMCO 24 30 Dimensions mm 240x111x77 Wei...

Page 271: ...ted on the display Main charging During the charging process lines appear sequentially from left to right as the battery is charged The battery symbol and the OFF button flash Equalising charging Four lines at the left in the display light continuously while four lines on the right appear sequentially The battery symbol and the OFF button flash Charging completed The battery capacity value and uni...

Page 272: ... 6 T Code s 841 842 843 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 ...

Page 273: ...indicate the proper sorting category for the materials used in the various truck components To achieve optimum sorting all components should be disassembled to a level corresponding to the sorting categories 19 2 Marking of plastics 19 2 1 General marking of products and packaging Markings on plastics consist of three arrows a number and usually also a designation of the plastic material used This...

Page 274: ...n arrows Example PP Abbreviations ABS acrylonitrile butadiene styrene HDPE High Density Polyethylene LDPE Low Density Polyethylene PA Polyamide PA6 Amide resin 6 PA66 Amide resin 66 PBT Polybutylene terephtalate PC Polycarbonate PET Polyethylene terephtalate PMMA Plexiglas POM Polyoxymethylene Polyformaldehyde PP Polypropylene PUR Polyurethane Marking examples Products made from a single substance...

Page 275: ...and accumulators used in hydraulic systems 19 3 1 Gas struts WARNING Gas struts have extremely high internal pressure To prevent injury always follow the instructions of the manufacturer Wear safety goggles when disassembling springs To allow the gas to escape only open and disassemble gas struts as recommended by the manufacturer An example of how to perform this is given for Stabilus Lift O Mat ...

Page 276: ...rs plastic Plastic Sort according to the material marking Forks and frames Iron steel Operator s platforms Iron steel including any gas struts Mats cushions combustible Be sure to depressurise struts Roofs and overhead guards Iron steel Gates and operator protective devices Iron steel Plastic handles PA Crush protectors PMMA Hydraulic unit Oil Hydraulic hoses Oil polluted material Oil tank PP Moto...

Page 277: ...es Hazardous waste Small batteries Hazardous waste Fluorescent tubes Hazardous waste Because of the chemical content in fluorescent tubes do not break them Obsolete fluorescent tubes must be packaged and transported according to local regulations Mast Mast beams rollers cylinders hydraulic pipes Iron steel Hydraulic hoses Oil polluted Wires Sensors switches Electronic components Plastic components...

Page 278: ...de s 841 842 843 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 ...

Page 279: ...ry charger Option B1 Temperature sen sor Drive motor temperature sensor B11 Pulse transformer Speed sensor B60 Inductive switch Mechanical activation of the brake B62 Inductive switch Support arms lowered position B63 Inductive switch Mast switch 1 B64 Inductive switch Mast switch 2 B65 Inductive switch Support arms uppermost posi tion B90 Collision sensor Option F1 Fuse Main fuse 150 A F50 Fuse O...

Page 280: ... switch off S97 Switch Warning lamp P5 Option S206 Switch Turtle function Option S111 Switch Option button Option S113 Switch Option button Option S114 Switch Option button Option S115 Switch Option button Option S116 Switch Option button Option S223 Keypad Smart card Login with PIN code S224 Controls Sensilift Option T1 Transistor regula tor T7 T8 DC DC converter T7 24V 12V T8 24V 24V Option T20 ...

Page 281: ...ical 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 P6 S223 S113 S206 S111 S18 1 S18 2 S114 S116 S115 X41 B60 https www forkliftpdfmanuals com ...

Page 282: ...ical 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 S21 X1 G1 F1 F50 F51 F52 B90 X40 A30 Q10 Q25 T1 T7 T8 X21 https www forkliftpdfmanuals com ...

Page 283: ...s Table 1 List of symbols Symbol Description Symbol Description Truck battery Emergency switch off NC Fuse Switch pressure weight oper ated Horn Sensor inductive NO Motor AC1 1 AC Alternating Current Sensor inductive NC Contactor Variable resistance potentiome ter Brake coil normally applied Push switch NO Coil for the hydraulic solenoid valve Multi pin connector Pressure sensor analogue NO Normal...

Page 284: ...V W MAIN CONTACTOR 106 OUT PUMP CONTACTOR 107 DRIVE MOTOR PUMP MOTOR FORK VALVE 98 SUPPORT ARM VALVE 110 BRAKE RELEASE 90 PROP LOWER VALVE 108 24V 82 SIGNAL HORN 112 5V SPEED SENSOR 85 CAN HIGH LOW 99 100 0V DC X3 24V DC X3 CAN HIGH X3 CAN LOW X3 X3 24V DC X3 0V DC X3 X3 CAN HIGH LOW X1 1 HORN 2 X4 1 HORN 1 X4 2 X1 2 X2 1 2 TURTLE X2 1 3 TURTLE X8 1 5V DC X8 2 FORK LIFT LOWER X8 3 OUT 0V DC X12 X1...

Page 285: ...l 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 1 11 PROD G 236986 https www forkliftpdfmanuals com ...

Page 286: ...epair 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 2 11 PROD G 236986 https www forkliftpdfmanuals com ...

Page 287: ...epair 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 3 11 PROD G 236986 https www forkliftpdfmanuals com ...

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 4 11 PROD G 236986 https www forkliftpdfmanuals com ...

Page 289: ... 842 843 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 ...

Page 290: ... 842 843 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 ...

Page 291: ... 842 843 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 ...

Page 292: ... 842 843 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 ...

Page 293: ... 842 843 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 ...

Page 294: ... 842 843 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 ...

Page 295: ... 842 843 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 ...

Page 296: ... 842 843 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 ...

Page 297: ...L S214 S214L S220D Publication Number 7588857 040 Date 2018 05 01 Applies from serial number 6384351 21 Hydraulics chart SA 1 5 6 4 3 2 Support arms Duplex Hilo Triplex Hilo Simplex Duplex tele Duplex tele panoramic F Q23 Q22 Q4 Max 230 Bar 7 8 9 10 11 12 14 13 https www forkliftpdfmanuals com ...

Page 298: ...tion Pos Description 1 Lift cylinder support arm1 1 Only applies to S212L S214L and S220D 8 Tank 2 Solenoid valve fork selection Q22 9 Filter 3 Solenoid valve support arm selection Q23 10 Filter 4 Proportional valve lowering Q4 11 Air filter 5 Non return valve 12 Flow regulator valve 6 Pressure limiting valve max 230 Bar 13 Lift cylinder mast 7 Pump 14 Hose rupture valve https www forkliftpdfmanua...

Page 299: ...rom serial number 6384351 22 Tools 22 1 MQS contacts Tools Number Use 257841 MQS Basic toolbox The box contains 1 set pliers with tools 25 x splice sleeves 0 5 1 5 mm2 2x complete 2 3 4 6 8 and 12 pin connectors male and female with pre wired cables and splicing sleeves Please use to replace damaged con nectors on the truck https www forkliftpdfmanuals com ...

Page 300: ... x sleeves 0 2 0 5 mm2 200 x sleeves SWS 0 2 0 5 mm2 400 x sleeves SWS 0 5 0 75 mm2 100 x sleeves S Clean body 0 5 0 75 mm2 200 x pins SWS 0 2 0 5 mm2 400 x pins SWS 0 5 0 75 mm2 1200 x seals 200x blind plugs 257843 MQS Complete toolbox Contains 4 pliers with tools MQS SWS 0 25 0 5 mm2 MQS SWS 0 5 0 75 mm2 MQS Std Clean body 0 25 0 5 mm2 MQS Std Clean body 0 5 0 75 mm2 Puller for 2 3 4 6 8 and 12 ...

Page 301: ...Timer 4 8 5 8 6 3 mm JPT Junior Power Timer 2 8 mm MPT Micro Power Timer 1 5 mm Figure Number Use 151080 PT Removal tool for pins sleeves 213296 JPT Removal tool for pins sleeves 213298 MPT Removal tool for pins sleeves 1 163787 JPT 2 163788 JPT 1 213336 MPT 2 213337 MPT Crimping tool sleeves only 1 213336 JPT 2 213549 JPT Crimping tool for fitting pins For 0 5 2 5 mm2 1 2 1 2 https www forkliftpd...

Page 302: ... 040 Date 2018 05 01 Applies from serial number 6384351 22 2 1 AMP connectors Multilock series 040 22 3 Molex connectors Figure Number Use 213130 Pin removal tool 213129 Crimping tool for pins Figure Number Use 156937 Crimping tool for pins 156936 Crimping tool for fitting sleeves pins 1 8 9 16 https www forkliftpdfmanuals com ...

Page 303: ... gun with straight discharge pipe and nozzle fif 755142 Two handed grease gun with angled discharge pipe and nozzle 755152 Two handed grease gun with hose and nozzle 755145 755146 755147 Lubricating hose 450 mm Lubricating hose 750 mm Lubricating hose 1500 mm 202154PM Pointed nozzle for grease guns used to apply grease in recessed nipples Fits grease guns with hose and dis charge pipe Length 125 m...

Page 304: ... Publication Number 7588857 040 Date 2018 05 01 Applies from serial number 6384351 22 5 Other tools Figure Number Use 7513225 Service key CAN 1 7521083 2 163793 Service instrument CASTOR USB for programming 1 163793 2 163792 Service instrument for program changes 1 2 https www forkliftpdfmanuals com ...

Page 305: ...843 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 08 13022 Drive gear puller Figure Number Use https www forkliftpdfmanuals com ...

Page 306: ... 22 8 T Code s 841 842 843 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 ...

Page 307: ...djusted to the values for untreated screws the correct torque value for galvanised screws will also be obtained Do not tighten more than the values indicated in the table otherwise the screws can be destroyed Galvanised not oiled screws Untreated oiled screws Strength class Dimension Strength class 8 8 10 9 12 9 8 8 10 9 12 9 1 1 1 6 2 0 M3 1 2 1 7 2 1 2 8 3 8 4 7 M4 2 9 4 0 4 9 5 5 7 7 9 3 M5 5 7...

Page 308: ...ease Rembrandt EP2 Rembrandt EP2 Beams flanges G Grease Castrol Spheerol LC2 Castrol Tribol 4020 460 2 Steering bearings H Grease Klüberplex BEM 34 132 Steer axle steering damper Pos Ambient temperature Viscosity class Usage B 0 C 40 C ISO VG 32 ISO 6743 4 category HM DIN 51524 part 2 HLP Hydraulic system B 35 C 40 C ISO VG 27 5 ISO 6743 4 category HV DIN 51524 part 3 HVLP Hydraulic system B 0 C 4...

Page 309: ...pe Iskra AML7108 Iskra AML7109 Power kW 1 0 1 5 Duty cycle S2 60 min Weight kg 9 10 5 Brake Type Warner PK10 Braking force Nm 15 Power W 51 13 Resistance coil Ω 10 5 12 0 Nominal gap in actuated position mm 0 2 0 55 Minimum thickness of brake disc mm 7 9 Thickness of new brake disc mm 8 2 Transmission gear mechanism Type Kordel Genius 5 72 02 1 Gear ratio 30 204 Oil volume litres 0 8 Oil See secti...

Page 310: ...hout load kg 235 285 285 Axle pressure at rated load kg 1185 1445 1640 Castor wheel mm 85 Axle pressure without load kg 230 250 200 Axle pressure at rated load kg 280 290 245 Hydraulic system Power kW 2 2 Duty factor S2 60 min Min carbon brush length mm 8 Min commutator thickness diameter mm Pressure at rated load bar See section 24 4 Overflow pressure for mast Overflow pressure bar Pump flow litr...

Page 311: ...nloaded km h Unloaded m s 6 0 1 7 With rated load km h With rated load m s 6 0 1 7 Lifting lowering speed Lifting without load m s 0 28 0 28 0 25 Lift with rated load m s 0 14 0 12 0 11 Lowering without load m s 0 38 0 38 0 38 Lowering with rated load m s 0 38 0 38 0 37 Gradient capability With rated load 8 8 8 Dimensions Short Medium Long 1831 1888 1938 1906 1956 1901 1951 Lift height 3300 4500 4...

Page 312: ...r Type Iskra AML7109 Power kW 1 5 Duty cycle S2 60 min Weight kg 10 5 Brake Type Warner PK10 Braking force Nm 15 Power W 51 13 Resistance coil Ω 10 5 12 0 Nominal gap in actuated position mm 0 2 0 55 Minimum thickness of brake disc mm 7 9 Thickness of new brake disc mm 8 2 Transmission gear mechanism Type Kordel Genius 5 72 02 1 Gear ratio 30 204 Oil volume litres 0 8 Oil See section 23 2 Lubrican...

Page 313: ...hout load kg 265 265 215 Axle pressure at rated load kg 1345 1525 1155 Castor wheel mm 85 Axle pressure without load kg 220 220 100 Axle pressure at rated load kg 340 360 360 Hydraulic system Power kW 2 2 Duty factor S2 60 min Min carbon brush length mm Min commutator thickness diameter mm Pressure at rated load bar See section 24 4 Overflow pressure for mast Overflow pressure bar Pump flow litres...

Page 314: ...el speeds Unloaded km h Unloaded m s 6 0 1 7 With rated load km h With rated load m s 6 0 1 7 Lifting lowering speed Lifting without load m s 0 25 Lift with rated load m s 0 12 0 11 0 12 Lowering without load m s 0 28 Lowering with rated load m s 0 39 0 38 0 39 Gradient capability With rated load 9 8 9 Dimensions Short Medium Long 1910 1960 Lift height 3300 3255 2100 Weight Truck without battery M...

Page 315: ...ra AML7108 Power kW 1 0 Duty cycle S2 60 min Weight kg 9 Brake Type Warner PK10 Braking force Nm 15 Power W 51 13 Resistance coil Ω 10 5 12 0 Nominal gap in actuated position mm 0 2 0 55 Minimum thickness of brake disc mm 7 9 Thickness of new brake disc mm 8 2 Transmission gear mechanism Type Kordel Genius 5 72 02 1 Gear ratio 30 204 Oil volume litres 0 8 Oil See section 23 2 Lubricants specificat...

Page 316: ...le pressure without load kg 340 Axle pressure at rated load kg 1580 Castor wheel mm Axle pressure without load kg Axle pressure at rated load kg Hydraulic system Power kW 2 2 Duty factor S2 60 min Min carbon brush length mm Min commutator thickness diameter mm Pressure at rated load bar See section 24 4 Overflow pressure for mast Overflow pressure bar Pump flow litres minute Tank volume litres 4 5...

Page 317: ...ght kg 214 Truck travel speeds Unloaded km h Unloaded m s 6 0 1 7 With rated load km h With rated load m s 6 0 1 7 Lifting lowering speed Lifting without load m s 0 21 Lift with rated load m s 0 11 Lowering without load m s 0 24 Lowering with rated load m s 0 33 Gradient capability With rated load 8 Dimensions Short Medium Long 1946 1996 Lift height 4755 Weight Truck without battery Medium 795 Mod...

Page 318: ...ad from graph for hydraulic unit Recommended overflow pressure Simplex 1000kg 140 bar 7 1 165 bar Simplex 1200kg 165 bar 6 5 190 bar Tele 1000kg 145 bar 7 0 170 bar Tele 1200kg 170 bar 6 4 195 bar Tele ClearView 1000kg 150 bar 6 8 175 bar Tele ClearView 1200kg 175 bar 6 3 200 bar Tele ClearView 1400kg 200 bar 5 9 225 bar Duplex HiLo 1200kg 150 bar 6 8 170 bar Duplex HiLo 1400kg 170 bar 6 4 190 bar...

Page 319: ...1 T Code s 841 842 843 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 ...

Page 320: ...https www forkliftpdfmanuals com ...

Page 321: ...https www forkliftpdfmanuals com ...

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Page 324: ...Cesab Carelli Elevatori Spa Bologna Italy https www forkliftpdfmanuals com ...

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