Jungheinrich ESE 533 User manual

ESE 533 03.10
Operating instructions
51157401
02.21
en-GB
ESE 533

2

Declaration of Conformity
Manufacturer
Jungheinrich AG, 22039 Hamburg, Germany
Description
Industrial truck
Type Option Serial no. Year of
manufacture
ESE 533
On behalf of
Date
EU DECLARATION OF CONFORMITY
The undersigned hereby declare that the powered truck described in detail complies
with the current versions of European Directives 2006/42/EG (Machinery Directive)
and 2014/30/EU (Electromagnetic Compatibility - EMC). The manufacturer is
authorised to compile the technical file.
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Foreword
Notes on the operating instructions
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide
sufficient instruction for the safe operation of the industrial truck. The information is
provided clearly and concisely. The chapters are arranged by letter and the pages
are numbered continuously.
The operator manual details different industrial truck models. When operating and
servicing the industrial truck, make sure that the particular section applies to your
truck model.
Our trucks are subject to ongoing development. We reserve the right to alter the
design, equipment and technical features of the system. No guarantee of particular
features of the truck should therefore be assumed from the present operating
instructions.
Safety notices and text mark-ups
Safety instructions and important explanations are indicated by the following
graphics:
DANGER!
Indicates an extremely hazardous situation. Failure to comply with this instruction will
result in severe irreparable injury and even death.
WARNING!
Indicates an extremely hazardous situation. Failure to comply with this instruction
may result in severe irreparable injury and even death.
CAUTION!
Indicates a hazardous situation. Failure to comply with this instruction may result in
slight to medium injury.
NOTICE
Indicates a material hazard. Failure to comply with this instruction may result in
material damage.
ZUsed before notices and explanations.
tIndicates standard equipment
oIndicates optional equipment
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Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Friedrich-Ebert-Damm 129
22047 Hamburg - Germany
Tel: [phone]
www.jungheinrich.com
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Contents
.
A Correct Use and Application 9
.
1 General 9
2 Correct application 9
3 Approved application conditions 9
4 Proprietor responsibilities 10
5 Adding attachments and/or accessories 10
.
B Truck Description 11
.
1 Application 11
2 Travel direction definition 12
3 Assemblies and Functional Description 13
3.1 Assembly Overview 13
3.2 Functional Description 14
4 Technical Specifications 17
4.1 Performance data 17
4.2 Dimensions 18
4.3 Weights 20
4.4 Tyre type 20
4.5 EN norms 21
4.6 Conditions of use 22
4.7 Electrical Requirements 22
5 Identification points and data plates 23
5.1 Indication Points 23
5.2 Data plate 25
5.3 Stability 26
.
C Transport and Commissioning 27
.
1 Lifting by crane 27
2 Securing the truck during transport 29
3 Using the Truck for the First Time 31
.
D Battery - Servicing, Recharging, Replacement 33
.
1 Safety instructions for handling lead-acid batteries 33
1.1 General notes on handling batteries 34
2 Battery types 35
3 Battery removal and installation 36
4 Charging the battery 40
.
E Operation 41
.
1 Safety Regulations for the Operation of Forklift Trucks 41
2 Displays and Controls 43
2.1 Display unit 45
3 Preparing the Truck for Operation 49
3.1 Checks and operations to be performed before starting daily operation 49
3.2 Entry and exit 50
3.3 Setting up the operator position 51
3.4 Preparing the truck for operation 56
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3.5 Checks and operations to be carried out when the truck is operational 57
3.6 Parking the truck securely 58
4 Industrial Truck Operation 59
4.1 Safety regulations for truck operation 59
4.2 Emergency Disconnect 61
4.3 Travel 63
4.4 Brakes 65
4.5 Steering 67
4.6 Lifting, transporting and depositing loads 68
5 Operating the truck without its own drive system 70
6 Troubleshooting 74
6.1 Truck does not start 75
6.2 Load cannot be lifted 75
7 Optional equipment 76
7.1 Keypad (CanCode) (o) 76
7.2 Floor-Spot 95
.
F Industrial Truck Maintenance 97
.
1 Spare Parts 97
2 Operational Safety and Environmental Protection 98
3 Maintenance Safety Regulations 99
3.1 Consumables and used parts 99
3.2 Wheels 100
3.3 Hydraulic system 101
4 Lubricants and Lubrication Schedule 102
4.1 Handling consumables safely 102
4.2 Lubrication Schedule 104
4.3 Consumables 106
5 Maintenance and repairs 107
5.1 Preparing the truck for maintenance and repairs 107
5.2 Lifting and jacking up the truck safely 107
5.3 Cleaning 108
5.4 Drive compartment cover disassembly/assembly 111
5.5 Checking the hydraulic oil level 112
5.6 Checking electrical fuses 114
5.7 Checking the wheel attachments. 116
5.8 Restoring the truck to service after maintenance and repairs 118
6 Decommissioning the industrial truck 119
6.1 Prior to decommissioning 120
6.2 During decommissioning 120
6.3 Restoring the truck to service after decommissioning 121
7 Safety tests to be performed at intervals and after unusual incidents 122
8 Final de-commissioning, disposal 123
9 Human vibration measurement 123
.
G Maintenance, Inspection and Changing of Maintenance
Parts Requiring Replacement 125
.
1 Maintenance Contents ESE 533 126
1.1 Owner 126
1.2 Customer Service 128
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A Correct Use and Application
1 General
The truck must be used, operated and serviced in accordance with the present
instructions. All other types of use are beyond its scope of application and may result
in damage to personnel, the industrial truck or property.
2 Correct application
NOTICE
The maximum load and load distance are indicated on the capacity plate and must
not be exceeded.
The load must rest on the load handler or be lifted by an attachment approved by the
manufacturer.
The load must be fully raised, see page 68.
– Lifting and lowering of loads.
– Transporting lowered loads.
– Do not carry or lift passengers.
– Do push or pull load units.
3 Approved application conditions
– Operation in industrial and commercial environments.
– Permissible temperature range 5°C to 40°C.
– Operation only on secure, level surfaces with sufficient capacity.
– Operation only on routes that are visible and approved by the operating company.
– Negotiating inclines up to a maximum of 10% ohne Last, 5% mit Last.
– Do not travel across or at an angle on inclines. Travel with the load facing uphill.
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4 Proprietor responsibilities
For the purposes of the present operating instructions the “operating company” is
defined as any natural or legal person who either uses the industrial truck himself, or
on whose behalf it is used. In special cases (e.g. leasing or renting) the proprietor is
considered the person who, in accordance with existing contractual agreements
between the owner and user of the industrial truck, is charged with operational
duties.
The proprietor must ensure that the industrial truck is used only for the purpose it is
intended for and that danger to life and limb of the user and third parties are
excluded. Furthermore, accident prevention regulations, safety regulations and
operating, servicing and repair guidelines must be followed. The operating company
must ensure that all users have read and understood these operating instructions.
NOTICE
Failure to comply with the operating instructions invalidates the warranty. The same
applies if improper work is carried out on the truck by the customer or third parties
without the permission of the manufacturer.
5 Adding attachments and/or accessories
The mounting or installation of additional equipment which affects or enhances the
performance of the industrial truck requires the written permission of the
manufacturer. Local authority approval may also need to be obtained.
Local authority approval however does not constitute the manufacturer’s approval.
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B Truck Description
1 Application
The ESE 533 is a four-wheel, electric side-seated pallet truck with two drive units
and electrical steering with two steer motors.
The truck is designed for transporting goods on level surfaces. It can lift open bottom
or diagonal board pallets as well as roll
cages beyond the area of the load wheels or roll cages.
The capacity is shown on the data plate or the data capacity plate.
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2 Travel direction definition
The following determinations have been made for travel direction specification:
1
2
3
4
Item Travel Direction
1 Left
2 Drive direction
3 Load direction
4 Right
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3 Assemblies and Functional Description
3.1 Assembly Overview
14
9
8
7
6
5
10
12
13
15
15
11
Item Component Item Component
5tSteering wheel 11 tOption bar
6tDisplay unit 12 tAccelerator pedal
7tKey switch 13 tBrake pedal
8tEmergency Disconnect
switch
14 tDriver's seat
9tSolopilot 15 tDrive wheel
10 tFork
tStandard equipment oOptional equipment
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3.2 Functional Description
Safety Mechanisms
Enclosed, smooth truck geometry. The wheels are surrounded by a solid skirt. The
key switch (7) or Emergency Disconnect switch (8) disconnects all electrical function
in hazardous situations. Travelling is inhibited if the driver door is not closed.
Truck design
The pallet truck has four wheels including two steered drive wheels (15). Easy to
open drive compartment covers and panels provide easy access to all the units for
the service engineers. The controls are ergonomically arranged.
Drive system
The entire drive unit is bolted onto the chassis of the truck. Two fixed 6.9 kW
threephase motors control the drive wheels (15) each via separate toothed gearing.
The electronic traction current controllers ensures smooth drive motor speed and
hence smooth start-up, powerful acceleration and electronically controlled braking
with energy recovery.
Steering
Bevel gear steering with one steering drive per traction drive and fully electronic
controller as standard. The pivoting gear unit can move 360°.
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Controls and displays
Controls and displays are clearly arranged in the operator position. The controls on
soloPILOT (9) enable the travel direction, lifting/lowering and the horn to be
controlled with one hand. Display unit (6) with large LC display as well as integrated
hour meter, battery discharge indicator with lift cut-off function and speed display.
Hydraulic System
Lifting and lowering are activated via the hydraulic control lever. When lifting is
activated, the pump unit starts to operate, supplying hydraulic oil from the oil
reservoir to the lift cylinder.
The lift mechanism with the load forks (10) is connected to the chassis via the lift
cylinder and the lift linkage. The forks are raised when the lift cylinder is extended
while simultaneously moving the load wheel support through the lift linkage.
Electrical system
48 volt system acting as a two wire network. An infinitely variable electronic traction
current controller and an electric steering controller are standard.
Brake system
The electric brake system consists of independent brake systems. Braking occurs in
two stages. When the brake pedal is applied both drive motors brake (first stage of
2-stage braking). When the truck has come to a halt the parking brake applies
(second stage of 2-stage braking).
The parking brake is electrically actuated and acts mechanically (compression
spring) through a brake disk on the drive shafts. A warning indicator appears when
the parking brake is applied. Steering and brake system faults are shown on the
driver’s display.
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Emergency Stop safety feature
The emergency stop is controlled by the traction controllers. The steering controllers
send a system status signal which is monitored by the traction controllers. If the
signal fails to appear or a fault is identified the truck automatically brakes to a halt.
Control displays on the driver’s display indicate the emergency stop. Each time the
truck is switched on the system performed a self diagnosis. The parking brake is
only released once the functional test has been passed. The parking brake must
then be released by pressing a button.
Emergency stop reset
The Emergency Stop is reset by switching the key switch and the Emergency
Disconnect off and on.
3.2.1 Hourmeter
ZPrepare the truck for operation, see page 56 or see page 78.
The service hours are counted when the truck is switched on and the seat switch is
closed.
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4 Technical Specifications
ZThe technical specification is given according to the German guideline "Type sheets
for industrial trucks". Technical modifications and additions reserved.
4.1 Performance data
Description ESE 533
Q Rated capacity 3300 kg
Travel speed
w / w.o. rated load1
19 / 20 km/h
Lift speed
with / without rated load1
5.6 / 6.0 cm/sec
Lower speed
with / without rated load1
5.2 / 5.0 cm/sec
Gradeability w / w.o. load 5 / 10 %
Traction motor, output (S2 = 60 min) 2 x 6.9 kW
Lift motor, output at S3 15% 3.0 DC kW
1 Load evenly distributed over the entire fork length.
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4.2 Dimensions
Description ESE 533
C Load centre distance with standard
fork length (3600 mm) 1
1800 mm
x Load distance (lowered / raised) 2680 / 2630 mm
y Wheel base (lowered / raised) 3770 / 3720 mm
h3 Lift 115 mm
h7 Seat height / standing height 1470 mm
h13 Lowered fork height 95 mm
l1 Overall length 4895 mm
l2 Headlength 1295 mm
b2 Truck width 1000 mm
s/e/l Fork dimensions 70 / 200 / 3600 mm
b5 Outside straddle 580 mm
m2 Ground clearance centre wheelbase 20 mm
b10 Track width, drive 592 mm
b11 Track width, load section 380 mm
Wa Turning radius (lowered / raised) 3982 / 3922 mm
Ast Aisle width for pallets
800 x 1200 length
5196 mm
a Safety distance 200 mm
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4.3 Weights
Component ESE 533
Net weight (including battery) 3480 kg
Axle load, w. load front/rear
(incl. battery)
3460 / 3320 kg
Axle load, w.o. load front/rear
(incl. battery)
2750 / 730 kg
Battery weight 1450 kg
4.4 Tyre type
Description ESE 533
Tyres (full rubber, super elastic,
pneumatic, polyurethane)
Vulkollan
Tyre size, front 343x140 Ø in mm
Tyre size, rear 90x100 Ø in mm
Wheels, number front / rear (x = driven) 2x / 4
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