Jungheinrich ESE 533 Operating Instructions Manual Download Page 118

Page: 118 / 133

5.8

Restoring the truck to service after maintenance and repairs

147

Procedure

• Attach the battery connector (147) to the industrial truck.
• Preparing the truck for operation, see page 49.
• Prepare the truck for operation, see page 56.
• Test the safety mechanisms, see page 57.

118

02.21 en-GB

Summary of Contents for ESE 533

Page 1: ...ESE 533 03 10 Operating instructions 51157401 02 21 en GB ESE 533...

Page 2: ...2...

Page 3: ...re 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...

Page 4: ...4 02 21 en GB...

Page 5: ...lar 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 follo...

Page 6: ...ht Copyright of these operating instructions remains with JUNGHEINRICH AG Jungheinrich Aktiengesellschaft Friedrich Ebert Damm 129 22047 Hamburg Germany Tel 49 0 40 6948 0 www jungheinrich com 6 02 21...

Page 7: ...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 Bat...

Page 8: ...2 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...

Page 9: ...y 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 uni...

Page 10: ...luded 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 under...

Page 11: ...ts 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...

Page 12: ...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 12 02 21 en G...

Page 13: ...11 Item Component Item Component 5 t Steering wheel 11 t Option bar 6 t Display unit 12 t Accelerator pedal 7 t Key switch 13 t Brake pedal 8 t Emergency Disconnect switch 14 t Driver s seat 9 t Solo...

Page 14: ...vide 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 threepha...

Page 15: ...inkage 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...

Page 16: ...cate 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...

Page 17: ...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...

Page 18: ...eight 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 c...

Page 19: ...19 02 21 en GB...

Page 20: ...ry 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 si...

Page 21: ...with the human vibrations of the operator directive The manufacturer offers a special service to measure these human vibrations see page 123 Electromagnetic compatibility EMC The manufacturer confirm...

Page 22: ...in conditions of extreme temperature or condensing air humidity fluctuations 4 7 Electrical Requirements The manufacturer certifies compliance with the requirements for the design and manufacture of...

Page 23: ...26 24 23 21 22 19 19 17 17 16 20 25 18 18 Item Component 16 Floor plate adjustment 17 Strap point for crane lifting 18 Cold store plate cold store trucks only o 19 Risk of trapping label 20 Seat belt...

Page 24: ...Item Component 23 Truck data plate 24 Final inspection 25 Company name 26 Test plaque 24 02 21 en GB...

Page 25: ...oad centre distance mm 28 Battery voltage V 35 Drive output 29 Net weight w o battery kg 36 Min max battery weight kg 30 Option 37 Manufacturer 31 Model 38 QR code 32 Serial number 39 Manufacturer s l...

Page 26: ...nt Transported load size weight and centre of gravity Changing the components can alter the stability 5 3 1 Wind loads Wind forces can affect the stability of a truck when lifting lowering and transpo...

Page 27: ...cessories and lifting gear uWear personal protective equipment e g safety shoes safety helmet hi vis jacket protective gloves when loading by crane uDo not stand under suspended loads uDo not walk int...

Page 28: ...ta plate Procedure Remove the dummy plugs from the load section and screw in the two ring screws 40 Insert load hooks on either side of the ring screws Secure the load hooks to the strap points 41 Rai...

Page 29: ...rrect measurements must be taken and appropriate safety measures applied uThe truck must be securely fastened when transported on a lorry or a trailer uThe lorry or trailer must have fastening rings u...

Page 30: ...ler to ensure a positive fit between the front of the transport vehicle and the load handler Lay the lashing straps 43 over the truck attach to the transport vehicle and tension sufficiently Z Use edg...

Page 31: ...e truck and battery on fire uThe truck must only be operated with battery current uCable connections to the battery tow leads must be less than 6 m long and have a minimum cross section of 50 mm If th...

Page 32: ...32 02 21 en GB...

Page 33: ...of fire a reaction with the battery acid can occur if water is used to extinguish the fire This can lead to acid burns uUse powder extinguishers uNever extinguish burning batteries with water Do not...

Page 34: ...ries that have not been approved by Jungheinrich for the truck can be hazardous The design weight and dimensions of the battery have a considerable effect on the operational safety of the truck in par...

Page 35: ...included as standard Component Capacity 10 PzB1000 48 V 1000 Ah The battery weight can be taken from the battery data plate Batteries with non insulated terminals must be covered with a non slip insul...

Page 36: ...pacity to replace the battery uUse only approved battery replacement devices battery roller stand replacement trolley etc uMake sure the battery is securely located in the truck s battery compartment...

Page 37: ...up to the side of the battery tray 50 Drive the cantilevered truck into the fork pockets on the battery Raise the battery slightly and drive out The battery has been removed Assembly is carried out i...

Page 38: ...l 45 Undo the battery latch 49 To do this pull the battery latch 49 upwards and remove the locking plate 46 attached to the clamping yoke 48 from the battery tray Set the locking plate 46 down on the...

Page 39: ...backwards Tighten the counternuts 52 on the four feet 54 Pull the battery onto the battery roller stand 53 Tighten the battery retainer 55 to prevent the battery from rolling backwards The battery has...

Page 40: ...battery cover must be open and the battery cell surfaces must be exposed during charging to ensure adequate ventilation uDo not smoke and avoid naked flames when handling batteries uWherever an indus...

Page 41: ...structions Safety shoes must be worn on pedestrian operated trucks Unauthorised use of truck The operator is responsible for the truck during the time it is in use The operator must prevent unauthoris...

Page 42: ...falling loads or lowering falling operating equipment uInstruct unauthorised persons to leave the hazardous area uIn case of danger to third parties give a warning signal in good time uIf unauthorise...

Page 43: ...2 Displays and Controls 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 43 02 21 en GB...

Page 44: ...Issues a warning signal 58 Shunt mode button t Lifting lowering and slow travel when seat switch is not applied 59 Armrest adjusting lever Changes the armrest position longitudinally 60 Hydraulic cont...

Page 45: ...ments to the truck can be made by pressing the four short stroke keys 83 84 85 86 The LEDs of the 7 luminous buttons 68 70 77 79 81 82 can show 3 conditions on flashing or off The display unit gives i...

Page 46: ...urrent profile in bars from 1 to 5 77 Slow travel The green icon lights up when slow travel is set 78 Performance setting number Performance setting number 1 2 or 3 79 Deadman switch Gelbes Grafiksymb...

Page 47: ...the Set time menu is displayed Set the hours with the Up 83 and Down 84 buttons Confirm with the Shift button 85 Set the minutes with the Up 83 and Down 84 buttons Confirm with the Shift 85 or Profil...

Page 48: ...fting is inhibited A corresponding message appears on the display 6 Lifting is not enabled until the connected battery is at least 70 charged 2 1 3 Energy recovery during regenerative braking When the...

Page 49: ...r supervisor uMark defective truck and take out of service uDo not return the industrial truck to service until you have identified and rectified the fault Pre start inspections Procedure Check the wh...

Page 50: ...tside Pull the door handle 89 From the inside Apply the door lock lever 87 and open the door To enter and exit the cab hold onto the handles 88 Enter or leave the truck via the step 88 90 89 87 88 CAU...

Page 51: ...et the driver s weight when the seat is occupied uHold the weight adjustment lever only by the recess do not reach through underneath the weight adjustment lever Procedure Fold out the weight adjustme...

Page 52: ...ds or backwards to the desired position Engage the driver s seat locking lever 66 in position The seat position is now correctly set Switching the seat heating on and off o Procedure Press the seat he...

Page 53: ...r pulleys must be thawed out and dried to prevent them from freezing up again The temperature of the warm air should not exceed 60 C Putting on the seat belt Procedure Sit on the driver s seat so that...

Page 54: ...The steering column is now positioned 3 3 4 Adjusting the armrest with soloPILOT Z The armrest control unit with soloPILOT can be lengthways adjusted incrementally Procedure Pull the unlocking lever 9...

Page 55: ...ootplate Procedure Press and hold down on the footplate unlocking button 100 Apply pressure to the footplate 101 to tilt it down Relieve the pressure from the footplate to tilt it up Release the footp...

Page 56: ...k can only be operated when the seat is occupied and the door closed Turn the Emergency Disconnect switch 8 to unlock it Switch on the truck to do this Insert the key in the key switch 7 and turn it a...

Page 57: ...until you have identified and rectified the fault Procedure Test warning indicators and safety devices Test the Emergency Disconnect function by pressing the Emergency Disconnect switch The main circu...

Page 58: ...s the truck may need to be secured with wedges uFully lower the load handler uSelect a place to park where no other people are at risk of injury from the lowered load handler uIf the brakes are not wo...

Page 59: ...n front and must be in control of the truck at all times Abrupt stopping except in emergencies rapid U turns and overtaking at dangerous or blind spots are not permitted Do not lean out or reach beyon...

Page 60: ...unloading Type of loads to be carried The operator must make sure that the load is in a satisfactory condition Loads must always be positioned safely and carefully Use suitable precautions to prevent...

Page 61: ...es CAUTION Faulty or non accessible Emergency Disconnect switches can cause accidents A faulty or non accessible Emergency Disconnect switch can cause accidents In dangerous situations the operator ca...

Page 62: ...witch on in emergencies Releasing the emergency disconnect switch Procedure Turn the emergency disconnect switch 106 to unlock it All electrical functions are enabled and the truck is operational agai...

Page 63: ...l WARNING Improper travel can result in accidents uDo not get up from the driver s seat during travel uDo not drive the truck unless the panels are closed and properly locked 61 6 5 83 84 12 13 63 02...

Page 64: ...Choose the travel direction with the travel direction switch 61 Select slow travel if necessary to do this press the slow travel button 83 Note the steer angle in the display 6 Apply the accelerator p...

Page 65: ...ersion brake Coasting brake 61 12 13 WARNING Accident risk The brake pattern of the truck depends largely on the ground conditions uThe driver must be aware of travel route conditions and them into ac...

Page 66: ...le travelling The truck decelerates until it starts to travel in the opposite direction Braking with the coasting brake Procedure Take your foot off the accelerator pedal 12 The truck decelerates Brak...

Page 67: ...ys negotiate bends at slow speed Steers the truck Procedure Turn the steering wheel 5 to the left or right Z The steering direction depends on the steer angle and the direction selected When travellin...

Page 68: ...he truck s capacity Distribute loads evenly on the fork arms Procedure Drive the truck slowly up to the pallet Carefully insert the fork arms into the pallet Z The load unit must not extend by more th...

Page 69: ...the ground clearance Setting down the load Requirements Storage location suitable for storing the load Procedure Drive carefully up to the storage location Press the soloPILOT lever 60 Z The lowering...

Page 70: ...revent the truck from rolling away Remove the drive panel To do this undo the mounting screws carefully remove the drive panel and pull off the fan connector contained in the panel 108 Truck prepared...

Page 71: ...Operating the truck without its own drive system 109 109 Requirements Truck prepared to be moved without its own drive system 71 02 21 en GB...

Page 72: ...110 in accordance with the tool kit table CAUTION Tensioned tyres can cause accidents When steering stationary the drive wheel tyres are under tension Releasing the crank can create a correcting momen...

Page 73: ...nect both magnetic brakes to four pin connectors Fit the drive panel To do this re connect the plug connectors with the fans position the drive panel correctly and bolt it in place 5 mounting screws T...

Page 74: ...ult the following information is essential Truck serial number Error number on the display unit if applicable Error description Current location of truck Warning messages Display Meaning LED 31 Batter...

Page 75: ...tery charge too low Check the battery charge and charge battery if necessary Faulty fuse Check fuses 6 2 Load cannot be lifted Possible Cause Remedy Truck not operational Carry out all measures listed...

Page 76: ...hydraulic operations The code lock is in programming mode When you enter one of the following parameters the settings in the code lock can be changed Parameter Description 0 0 0 Change master code se...

Page 77: ...Pressing the o key switches the truck off and sets it to non operational status The o key indicates the follow operating conditions via a red green LED 115 Code lock function commissioning the truck...

Page 78: ...on Z If the LED 115 flashes red this means the wrong code has been entered Enter the code again The Set key 114 has no function in operating mode 7 1 3 Switching off the truck with the keypad CanCode...

Page 79: ...y 114 The LEDs 111 115 flash green Enter the valid master code again with the digit keys Confirm with the SET key 114 The LEDs 112 115 flash green Enter the valid master code with the digit keys Z The...

Page 80: ...hat the required master code can be used see page 83 Delete the user code so that the required master code can be used see page 85 The master codes to be changed do not match Switch off the truck see...

Page 81: ...must also be different from the existing master code Confirm with the SET key 114 The LEDs 113 115 flash green Enter the new user code again with the digit keys Confirm with the SET key 114 Wait unti...

Page 82: ...the master code is the same length as the user code New user code is already occupied by a master code Switch off the truck see page 78 Choose a different user code see page 81 The newly entered user...

Page 83: ...t of the previously entered master code The new user code must also be different from the existing master code Confirm with the SET key 114 The LEDs 113 115 flash green Enter the new user code again w...

Page 84: ...e master code is the same length as the user code Operator code to be changed does not exist Switch off the truck see page 78 Check the user code entered The user codes to be changed do not match Swit...

Page 85: ...onfirm with the SET key 114 The LEDs 113 115 flash green Enter the user code to be deleted again with the digit keys Confirm with the SET key 114 Wait until the LED 115 flashes green The user code is...

Page 86: ...code Switch off the truck see page 78 Repeat the entry making sure that the master code is the same length as the user code Tried to delete an operator code that does not exist Switch off the truck se...

Page 87: ...sh green Enter the code 3 2 6 5 with the digit keys Confirm with the SET key 114 Wait until the LED 115 flashes green All user codes are deleted Press the O key 116 The truck is switched off and the L...

Page 88: ...can be changed all user codes must be deleted The length of the user code 4 6 digit is always determined by the length of the master code Requirements To prepare the truck for operation see page 78 Pr...

Page 89: ...inute maximum cutout time is 30 minutes 31 After 10 seconds the truck cuts out automatically Confirm with the SET key 114 Wait until the LED 115 flashes green The setting is saved Press the O key 116...

Page 90: ...ic cutout period of the truck For the following events the LED 115 flashes red Cause Remedy Cutout time entered is out of range Switch off the truck see page 78 Enter the time again while making sure...

Page 91: ...he 111 112 113 LEDs LED 111 lit travel program 1 activated LED 112 lit travel program 2 activated LED 113 lit travel program 3 activated The configuration code is four digit and is comprised as follow...

Page 92: ...4th digit 0 When the truck has been switched on with the selected user code no travel program is activated 1 When the truck has been switched on with the selected user code travel program 1 is activat...

Page 93: ...configuration code 4 digit for the travel programs again using the digit keys Confirm with the SET key 114 Wait until the LED 115 flashes green The travel programs are now assigned to the user code Pr...

Page 94: ...rograms For the following events the LED 115 flashes red Cause Remedy Blocked travel program defined as start travel program Switch off the truck see page 78 Try again making sure the configuration co...

Page 95: ...ION Risk of accident due to restricted view Looking directly at the LED light can dazzle and temporarily impair eyesight uDo not look directly at the LED light uPractise travelling and working with th...

Page 96: ...80 nm blue light can potentially damage the retina of the human eye uCheck that the warning notice Caution Potentially dangerous optical radiation is present and legible and replace if necessary uDo n...

Page 97: ...ety size accuracy and material The installation or use of non original spare parts can negatively affect the specified properties of the product and impair safety The manufacturer cannot be held liabl...

Page 98: ...eption Operating companies should only make changes or have changes made to powered industrial trucks if the manufacturer is no longer operating in the field and there is no successor to the business...

Page 99: ...d by the operating company are also written down see page 97 Customer Services Customer Services are specially trained in the use of the truck and are able to carry out maintenance and repairs indepen...

Page 100: ...ewed uAlways replace wheels in pairs i e left and right at the same time Z When replacing wheels fitted at the factory only use the manufacturer s original spare parts Otherwise the truck s rated perf...

Page 101: ...tems uReport any defects immediately to your supervisor uMark defective truck and take out of service uDo not return the industrial truck to service until you have identified and rectified the fault u...

Page 102: ...ure must be disposed of in accordance with regulations WARNING Improper handling of oils can be hazardous Oils chain spray hydraulic oil are flammable and poisonous uDispose of used oils in accordance...

Page 103: ...be disposed of in accordance with the applicable environmental protection regulations Oil changes should be carried out by the manufacturer s customer service department whose staff are specially tra...

Page 104: ...2015 s s s E g kF B k B C 1 2 9 l A C k A 0 7 l 1 E kF g Contact surfaces k Cold Store Application s Grease nipple b Transmission oil filler neck Hydraulic oil filler neck a Transmission oil drain plu...

Page 105: ...g kF B k B C 1 2 9 l A C k A 0 7 l 1 E kF g Contact surfaces k Cold Store Application s Grease nipple b Transmission oil filler neck Hydraulic oil filler neck a Transmission oil drain plug 1 Compound...

Page 106: ...actory equipped with a special hydraulic oil the Jungheinrich hydraulic oil with a blue colouration The Jungheinrich hydraulic oil is available only from the Jungheinrich service department The use of...

Page 107: ...st only be secured to the points specially provided for this purpose In order to raise and jack up the truck safely proceed as follows uJack up the truck only on a level surface and prevent it from mo...

Page 108: ...necessary safety measures to prevent sparking before cleaning e g by short circuiting NOTICE Risk of component damage when cleaning the truck Cleaning with a high pressure cleaner can result in malfun...

Page 109: ...d solvents and water Use a sponge or cloth to clean In particular clean the following areas Window s Oil filler ports and their surroundings Grease nipples before lubrication Dry the truck after clean...

Page 110: ...trical system assemblies Requirements Truck prepared for maintenance and repair work see page 107 Tools and Material Required Compressor with water separator Non conductive antistatic brush Procedure...

Page 111: ...Allen key The drive compartment cover is now disassembled 119 118 Fitting the drive compartment panel Tools and Material Required Allen key Procedure CAUTION Arm trapping hazard There is a risk of tra...

Page 112: ...5 5 Checking the hydraulic oil level NOTICE There are markings on the hydraulic reservoir Always check the hydraulic oil level when the load handler is lowered 120 121 123 124 125 122 112 02 21 en GB...

Page 113: ...c oil if necessary Loosen M12 screws 122 Lift out the hydraulic unit and place on the load handler Turn the lid 123 anti clockwise from the hydraulic reservoir 125 Add hydraulic oil of the correct gra...

Page 114: ...protect Value 126 F8 Main fuse 425 A 127 F1 Power up contactor 30 A 128 3F1 3F2 Steering controller 1 2 30 A 129 1F1 1F2 Traction controller 1 2 250 A 130 2F1 Pump motor 150 A 131 F17 Radio data 7 5 A...

Page 115: ...126 129 128 127 130 144 142 143 140 141 138 139 136 134 133 135 132 131 137 115 02 21 en GB...

Page 116: ...bolt per load wheel 84 Nm Drive wheel 195 10 Nm Checking the wheel attachment Requirements Truck prepared for maintenance and repairs see page 107 Tools and Material Required Torque wrench for M14 hex...

Page 117: ...es Alternatively the wheel bolts can also be reached after removing the skirt 145 and the service panel 146 To do this undo the 4 screws from the service panel and the 5 screws from the skirt M10 hex...

Page 118: ...maintenance and repairs 147 Procedure Attach the battery connector 147 to the industrial truck Preparing the truck for operation see page 49 Prepare the truck for operation see page 56 Test the safet...

Page 119: ...ecommissioning as described hereafter When the truck is out of service it must be jacked up so that all the wheels are clear of the ground This is the only way of ensuring that the wheels and wheel be...

Page 120: ...page 40 Charge the battery see page 40 Disconnect and clean the battery Clean the terminal screws grease them with terminal grease and screw them into the connection thread to prevent short circuits Z...

Page 121: ...er on the battery Insert the truck side control line into the connection on the battery trough Equipped with lithium ion battery o with interface converter on the battery Pull the battery forward Inse...

Page 122: ...inspector The manufacturer offers a safety inspection service which is performed by personnel specifically trained for this purpose A complete test must be carried out on the technical condition of t...

Page 123: ...rained personnel in accordance with the procedures as specified by the manufacturer 9 Human vibration measurement Z Vibrations that affect the operator over the course of the day are known as human vi...

Page 124: ...124 02 21 en GB...

Page 125: ...uck have a considerable impact on component wear The following service inspection and replacement intervals are based on single shift operation under normal operating conditions The intervals must be...

Page 126: ...using demineralised water Lead acid battery Power supply Correct the battery acid level using demineralised water 1 1 2 Inspection contents 1 1 2 1 Standard equipment The following points must be chec...

Page 127: ...following points must be checked Cold store cabin Chassis structure Roof hatch for functionality and damage Windscreens for damage Test doors and check for damage Electrical heating Chassis structure...

Page 128: ...ect the transmission oil level or grease filling of the transmission Chassis structure Text cut outs triggered by the seat switch gates etc Check that the panels and covers as well as the floor plate...

Page 129: ...ure acid density and battery voltage Correct the battery acid level using demineralised water 1 2 2 Inspection contents The following points must be checked 1 2 2 1 Standard equipment Brakes Connectio...

Page 130: ...tment mechanism Check operator mat and steps are non slip and free of damage Hydraulic operations Test hydraulic controls and check their labels for legibility completeness and plausibility Lift limit...

Page 131: ...r for functionality and sealing Battery refill system Power supply Refill system for functionality and leaks Intercom system Electrical system Intercom system for functionality and damage Seat heating...

Page 132: ...rap or chain and check for damage Lead acid battery international Power supply Check battery battery cables and cell connectors are securely attached and check for damage Ensure safety labels are pres...

Page 133: ...2 Optional equipment Cold store application maintenance part service hours months Transmission oil in cold store application Transmission oil additive Hydraulic oil Hydraulic oil additive 133 02 21 e...

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Summary of Contents for ESE 533

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Jungheinrich ESE 533, Operating Instructions Manual, Page: 118 / 133

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Summary of Contents for ESE 533

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