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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