Jungheinrich ESD 220 User manual

ESD 220 06.10
Operating instructions
51190940
10.19
en-GB
ESD 220

2

Declaration of Conformity
Manufacturer
Jungheinrich AG, 22039 Hamburg, Germany
Description
Industrial truck
Type Option Serial no. Year of
manufacture
ESD 220
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 documentation.
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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 11
.
1 General 11
2 Correct application 11
3 Approved application conditions 12
4 Proprietor responsibilities 13
5 Adding attachments and/or optional equipment 13
.
B Truck Description 15
.
1 Application 15
1.1 Truck models and rated capacity 15
2 Travel direction definition 16
3 Assemblies and Functional Description 17
3.1 Assembly Overview 17
3.2 Functional Description 20
4 Technical Specifications 24
4.1 Performance data 24
4.2 Dimensions 25
4.3 Weights 27
4.4 Tyre type 27
4.5 EN norms 28
4.6 Conditions of use 29
4.7 Electrical Requirements 29
5 Identification Points and Data Plates 30
5.1 Data plate 32
5.2 Truck capacity plate 33
5.3 Double Decker Mode Capacity Plate 35
.
C Transport and Commissioning 37
.
1 Lifting by crane 37
2 Transport 39
3 Using the Truck for the First Time 41
.
D Battery - Servicing, Recharging, Replacement 43
.
1 Safety instructions for handling lead-acid batteries 43
2 Battery types 46
3 Exposing the battery 47
4 Charging the battery 48
5 Battery removal and installation 50
.
E Operation 55
.
1 Safety Regulations for the Operation of Forklift Trucks 55
2 Displays and Controls 57
2.1 Battery discharge indicator 60
2.2 Battery discharge monitor 60
3 Preparing the Truck for Operation 61
3.1 Checks and Operations to Be Performed Before Starting Daily Work 61
3.2 Entry and exit 62
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3.3 Adjusting the Floor-Plate Height 63
3.4 Adjusting the driver’s seat 64
3.5 Preparing the truck for operation 65
3.6 Checks and operations to be carried out when the truck is operational 66
3.7 Parking the truck securely 67
4 Industrial Truck Operation 69
4.1 Safety regulations for truck operation 69
4.2 Emergency Disconnect 73
4.3 Deadman button 76
4.4 Travel 76
4.5 Steering 79
4.6 Brakes 80
4.7 Load handler raise/lower 82
4.8 Lifting, transporting and depositing loads 85
5 Troubleshooting 90
5.1 Truck does not start 91
5.2 Load cannot be lifted 91
6 Operating the truck without its own drive system 92
7 Load handler emergency lowering 94
8 Optional equipment 96
8.1 Brake Pedal in Footwell with ESD 220 96
8.2 Display and control unit 97
8.3 Setting the time 98
8.4 Keypad (CanCode) (o) 99
8.5 ISM access module (o) 117
8.6 Floor-Spot 118
.
F Industrial Truck Maintenance 121
.
1 Spare Parts 121
2 Operational Safety and Environmental Protection 122
3 Maintenance Safety Regulations 123
3.1 Working on the electrical system 124
3.2 Consumables and used parts 124
3.3 Wheels 124
3.4 Hydraulic system 125
3.5 Lift Chains 126
4 Lubricants and Lubrication Schedule 127
4.1 Handling consumables safely 127
4.2 Lubrication Schedule 129
4.3 Consumables 130
5 Maintenance and repairs 131
5.1 Preparing the truck for maintenance and repairs 131
5.2 Lifting and jacking up the truck safely 131
5.3 Cleaning 132
5.4 Drive compartment cover disassembly/assembly 135
5.5 Replacing the drive wheel 136
5.6 Tightening the wheel nuts 137
5.7 Checking the hydraulic oil level 138
5.8 Checking electrical fuses 139
5.9 Restoring the truck to service after maintenance and repairs 140
6 Decommissioning the Industrial Truck 141
6.1 Prior to decommissioning 141
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6.2 Action to be taken during decommissioning 141
6.3 Restoring the truck to service after decommissioning 142
7 Safety tests to be performed at intervals and after unusual incidents 143
8 Final de-commissioning, disposal 144
9 Human vibration measurement 144
.
G Maintenance, Inspection and Changing of Maintenance
Parts Requiring Replacement 145
.
1 Maintenance Contents ESD 220 146
1.1 Owner 146
1.2 Customer Service 150
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1
0506.GB
Appendix
JH Traction Battery Operating Instructions
ZThese operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.
1
0506.GB
Appendix
JH Traction Battery Operating Instructions
ZThese operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.

0506.GB
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0506.GB
2

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 85.
The following operations are in accordance with regulations and are permitted:
– Lifting and lowering of loads.
– Stacking and retrieving loads.
– Transporting lowered loads.
The following operations are prohibited:
– Travelling with a raised load (>300 mm).
– Carrying and lifting passengers.
– Pushing or pulling loads.
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3 Approved application conditions
WARNING!
Use under extreme conditions
Using the truck under extreme conditions can result in malfunctions and accidents.
uSpecial equipment and authorisation are required if the truck is to be constantly
used in extreme conditions, especially in dusty or corrosive atmospheres.
uThe truck cannot be used in areas at risk of explosion.
uIn adverse weather conditions (thunder, lightning) the industrial truck must not be
operated outside or in endangered areas.
– Operation in industrial and commercial environments.
– Permissible temperature range 5°C to 40°C.
– Operation only on secure, level surfaces with sufficient capacity.
– Do not exceed the permissible surface and point load limits on the travel routes.
– Operation only on travel paths that are visible and approved by the operating
company.
– Negotiating inclines up to a maximum of 14 %.
– 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 optional equipment
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 ESD 220 is a four-wheel, sideways-seated pallet truck with a driver's seat. The
ESD 220 is equipped with an electric steering wheel system.
As a double-deck truck it can lift two Euro pallets lying on top of each other
simultaneously via mast and support arm lift. Open-bottom pallets, pallets with
transverse boards or roll cages can be lifted outside the area of the load wheels.
1.1 Truck models and rated capacity
The rated capacity depends on the model. The rated capacity can be derived from
the model name.
ESD220
ESD Model name
2 Series
20 Rated capacity x 100 kg
The rated capacity is not generally the same as the permissible capacity. The
capacity can be found on the capacity plate attached to the truck.
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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
7
8
6
5
7
9
11
10
12
14
16
20
17
15
19
18
13
21
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Item Description Item Description
5tCharge status indicator 14 tFloor-plate height adjuster
6tKey switch 15 tBattery
7oControl/display unit 16 tLoad wheels
8oCanCode code lock 17 tLoad handler
9oISM access module 18 tSeat panel
10 tmultiPILOT 19 tSteering wheel
11 tMast 20 tDeadman switch
12 tEmergency disconnect switch 21 oBrake pedal (electric)
13 tArmrest
t = Standard equipment o = Optional equipment
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