Jungheinrich ese 20, Operating Instructions Manual

Page 1: ...Operating instructions 50042902 ESE 20 G 04 99 07 99 ...

Page 2: ...t explanations are indicated by the following graphics f Used before safety instructions which must be observed to avoid danger to personnel m Used before notices which must be observed to avoid material damage A Used before notices and explanations t Used to indicate standard equipment o Used to indicate optional equipment Our trucks are subject to ongoing development Jungheinrich reserves the ri...

Page 3: ...0108 GB ...

Page 4: ...ruck identification plate B 8 C Transportation and commissioning 1 Transportation by crane C 1 2 Commissioning C 1 3 Moving the truck with the drive unit inoperative C 2 D Battery servicing recharging replacement 1 Safety regulations governing the handling of lead acid batteries D 1 2 Battery types D 2 3 Exposing the battery D 2 4 Charging the battery D 3 5 Removing and installing the battery D 4 ...

Page 5: ...uck 1 Operational safety and environmental protection F 1 2 Safety regulations applicable to truck maintenance F 1 3 Servicing and inspection F 3 4 Maintenance checklist ESE 20 F 4 5 Lubrication schedule ESE 20 F 6 5 1 Fuels coolants and lubricants F 7 6 Instructions for the servicing operations F 8 6 1 Preparing the truck for servicing and maintenance operations F 8 6 2 Tightening the wheel screw...

Page 6: ...elf or on whose behalf it is used In special cases e g leasing or renting the user is conside red the person who in accordance with existing contractual agreements between the owner and the user of the fork lift truck is charged with the observance of the opera ting duties The user must ensure that the truck is not abused and only used within its design li mits and that all danger to life and limb...

Page 7: ...A 2 0499 GB ...

Page 8: ...h an electrical steering wheel steering system The ESE is designed for transport and order picking operations on level ground Pal lets with open ground support or pallets fitted with lateral boards provided that the boards are outside the range of the load bearing wheels can be picked up The rated capacity of the truck is shown on the identification plate or on the capacity label Qmax ...

Page 9: ... o Combined instrument Information and service indicator 7 t Lifting device 8 t Drive wheel 9 t Supporting wheel 3 t Steering 10 t Dead man s switch 4 t Key switch 11 t Drive cover 5 t Master switch emerg stop 12 t Sitting aid t Standard equipment o Optional equipment 2 3 4 5 7 8 9 6 10 12 11 1 ...

Page 10: ...data Designation Standard t Rapid drive o Q Rated capacity 2000 2000 kg C Load centre distance 600 600 mm Travelling speed with without rated load 8 5 10 5 9 5 12 5 km h Lifting speed with without rated load 4 0 5 0 4 0 5 0 cm s Lowering speed with without rated load 6 5 4 0 6 5 4 0 cm s h 3 l2 b 1 a _ 2 a _ 2 b 12 l1 l6 Ast3 Wa x l y C Q h 13 b 5 b 3 e b 11 ...

Page 11: ...s outside 510 540 660 510 540 660 b11 Track 340 370 490 340 370 490 b3 Distance between forks inside 170 200 330 170 200 330 e Fork width 170 170 a Safety distance 200 200 Dead weight Refer to truck identification label l l1 y1 x1 l6 Wa 1 Ast3 1000 1874 1509 814 1000 1688 2074 1150 2024 1659 964 1200 1838 2274 1200 2074 1709 1014 1200 1888 2274 1400 2274 1909 1214 1400 2088 2474 1600 2474 2109 141...

Page 12: ... 1000 1946 1581 814 1000 1760 2146 1150 2096 1731 964 1200 1910 2346 1200 2146 1781 1014 1200 1950 2346 1400 2346 1981 1214 1400 2160 2546 1600 2546 2181 1414 1600 2360 2746 1950 2896 2159 1392 2000 2338 3146 2150 3096 2359 1592 2100 2538 3246 2400 3346 2607 1840 2400 2786 3546 h 3 l2 b 1 a _ 2 a _ 2 b 12 l1 l6 Ast3 Wa x l y C Q h 13 b 5 b 3 e b 11 ...

Page 13: ... determined by driving over bumps with a constant speed Electromagnetic compatibility EMC The following limit values are observed according to prEN 12895 Electromagnetic Compatibility of Industrial Trucks interference emission EN 50 081 1 interference immunity EN 50 082 2 electrostatic discharge EN 61 000 4 2 A Electrical or electronic components and their arrangement may only be modified after wr...

Page 14: ...Label CAUTION Low voltage electronics Nächste Prüfung 1 2 1 1 1 0 9 8 7 6 5 4 3 2 1 2000 Regelmäßige Prüfung nach UVV VBG 12 a 12 b 20 durch Sachkundigen Ihr Kundendienst Partner Kundendienst Jungheinrich Aktiengesellschaft Hamburg V kg kg kg kg mm Xxx Xxxx Xxxxxxx Xxxxxxxxx Xxxxxx Xxxxxxxxx Xxxxxxxxxx Xxxxx Xxxx Xxxxxxx Xxxxxx Xxxxxx Xxxxxx Xxxxxx Xxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxx...

Page 15: ... 20 Order No 26 Net weight without battery in kg 21 Rated capacity in kg 27 Year of manufacture 22 Battery Voltage V Ampere hours Ah 28 Type No 23 Manufacturer Jungheinrich Aktiengesellschaft Hamburg V kg kg kg kg mm Xxx Xxxx Xxxxxxx Xxxxxxxxx Xxxxxx Xxxxxxxxx Xxxxxxxxxx Xxxxx Xxxx Xxxxxxx Xxxxxx Xxxxxx Xxxxxx Xxxxxx Xxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxxx Xxxxxxxx...

Page 16: ...be operated on battery current Rectified alternate current will damage the electronics Cables connected to the battery trailing cables must be less than 6 meters in length In order to prepare the truck for work following delivery or transportation the following operations must be performed Check the truck for completeness and satisfactory condition of the equipment If necessary install the battery...

Page 17: ...ve the key Ensure that the truck cannot accidentally move Remove the drive cover 5 and put it aside Slacken the lock nuts 4 and tighten the screws 3 The brake has now been released and the truck can be moved f After arriving at the repair bay ensure that the brake is put back to its initial state The truck must on no account be parked with the brake in the released condition Loosen the screws 3 by...

Page 18: ...s and cable shoes must be clean lightly greased with pole grease and must be securely tightened Batteries with non isolated poles must be covered with a non slip isolation mat Disposal of the battery Batteries must only be disposed of as stipulated in the national environmental protection regulations or waste disposal provisions The manufacturer s specifications for disposal must be heeded m Befor...

Page 19: ...y f Park the truck and render it safe refer to chapter E section 4 5 Press the lock 3 and lift the battery hood 2 slightly up wards Then pull it to the front and remove it Press the lock 5 bend the side panel 4 aside and re move it by pulling it upwards f Open and close the battery hood and side panel carefully Installation is in the reverse order f All covers and connections must be restored to t...

Page 20: ...ops of the battery cells must be exposed to ensure adequate ventilation No metal objects must be placed on the battery Prior to starting the recharging operation check all cable connections and plugged connections for visible damage All safety instructions as provided by the battery supplier and battery charger supplier must be strictly observed Withdraw the battery connector 1 Remove any insulati...

Page 21: ...t points in such a way that the lifting gear when slack cannot collapse on the battery cells Expose the battery refer to chapter D section 3 Withdraw the battery connector 1 Detach the battery cable from the cable guide 7 Remove the red battery lock 9 Pull the battery 8 laterally onto the battery change station f Heed the operating instructions of the manufacturer of the battery exchange trolley I...

Page 22: ...batteries and 50 in the case of maintenance free batteries Battery recharging is now advisable The advance CAUTION symbol 11 will go out and a flashing STOP symbol 12 will appear at a residual battery capacity of 20 in the case of standard batteries and 40 in the case of maintenance free batteries After a period of 5 minutes the STOP symbol 12 will remain permanently lit Battery recharging is now ...

Page 23: ...e dama ged due to a complete discharge Contact the JUNGHEINRICH customer service for setting the instrument If the remaining battery capacity falls below 30 it is required to recharge the battery Battery discharge monitor If the residual capacity falls below the specified mini mum value the lifting function is switched off A corresponding message is displayed in the information and service indicat...

Page 24: ...ruck or on the attachments must immediately be brought to the notice of the person in charge Fork lift trucks that cannot be safely operated e g due to worn tyres or defective brakes must not be used until they have been properly repaired Repairs Without specific training and express authorisation the driver is not allowed to perform any repairs or modifications on the fork lift truck Under no cir...

Page 25: ...pter D section 6 Indicates important driving and lifting para meters warning messages notes on operation faults and service information see chapter E section 5 6 Steering t Steering the truck 7 Key switch t Switches the control current on and off When the key is removed from the key switch the truck cannot be operated by unauthorised persons 8 Master switch emergency stop t The circuit is interrup...

Page 26: ...E 3 0799 GB 2 3 1 5 10 6 7 8 9 4 ...

Page 27: ...t and the cable connections f Do not operate the driving switch while mounting the truck Switching on the truck Step on to the standing platform Pull up the master switch 8 Insert the key in the key switch 7 and turn the key clockwise towards the I position until reaching the stop Check the horn 4 for correct functioning Check whether the deadman key 9 and driving switch 1 are properly functioning...

Page 28: ...E 5 0799 GB 7 8 9 4 1 ...

Page 29: ... always be carried at that end of the truck facing uphill U turns cutting obliquely over slopes or inclines and parking of the fork lift truck on slopes or inclines is not permitted Inclines must only be negotiated at slow speed with the driver ready to brake at any moment Use of lifts and driving on loading platforms Lifts and loading platforms must only be used if they are of adequate load beari...

Page 30: ...ded up backrest Folded down sitting aid m Adjusting the sitting aid to the operator requirements Fold down the sitting aid Use the adjusting screw 10 to incline it in the desired position Turning left down turning right up f The truck may only be operated and driven if the sitting aid is properly adjusted 10 ...

Page 31: ...ces the driving speed of the truck to low speed If such a fault occurs the driving speed is not reset to normal speed by switching the truck off and on again This method prevents the cancellation of a fault without eliminating the fault f As the steering system is a safety relevant component the fault must be eliminated by trained service personnel Emergency stop Depress the master switch 8 This w...

Page 32: ...will move in the selected direction A The travelling speed is controlled by means of the controller Driving on inclines m Loads must always be carried at that end of the truck facing uphill Securing the truck against rolling downhill With the controller 1 set to 0 the service brake is automatically applied after a short jerk the control system detects rolling downhill on an incline The service bra...

Page 33: ...A During normal operation the generator brake and counter current braking should be applied These methods of braking reduce wear and require less energy energy recovery Braking by means of the service brake Release the deadman key 9 The truck is braked at the maximum possible deceleration rate until it stands still Braking by means of the generator brake coasting Release the controller 1 the contr...

Page 34: ...y palletised and that the capacity of the truck is not exceeded Pass the lifting device as far as possible under the load Picking up long loads crosswise is not permitted m Pick up the load ensuring that it does not project excessively from the tips of the lifting device less than 50 mm Lifting and lowering A When operating the keys Lifting or Lowering the lifting or lowering movement will be at a...

Page 35: ... be completely lowered Lower the lifting device Set the drive wheel to the straight ahead position Turn the steering wheel 6 until the drive wheel is set to its straight ahead position o If required check the steering angle indica tion on the information and service indicator 5 Switch the key switch 7 to position OFF 0 and remove the key Depress the master switch emergency cut out 8 to the OFF pos...

Page 36: ...ors Two lit LED indicators show the following states 5 2 o Keyboard assignment Pos Function 15 Driving direction forward direction of the drive green LED 16 Driving direction backwards direction of the load green LED Pos Function 17 Double function increase of the selected parameter in steps Selection of the individual menu items in upward direction 18 Double function decrease of the selected para...

Page 37: ...IVE L SPEED OF FORK L SLOW FORK L BUZZER ON OFF O F F L BASIC SETTING L Issues an audible alarm in case of an operating fault This setting has no function This driving parameter may only be adjusted by the JUNGHEINRICH service This driving parameter has no function This driving parameter may only be adjusted by the JUNGHEINRICH service This driving parameter has no function This driving parameter ...

Page 38: ...g diagram if you want to check or modify any truck parameters Use the following keys to change between the adjustment parameters 17 and 18 Acceleration L1 Setting the time XX XX L1 Buzzer on off OFF L1 Low speed ride Load direction L1 Speed Load direction L1 Low speed ride Direction of the driveL1 Speed Direction of the driveL1 Reverse brake L3 Coasting brake L1 Acceleration S2 Setting the time XX...

Page 39: ...onnected Master switch emergency stop depressed Key switch in position 0 Battery exhausted Platform switch not operated Fuse defective Check the battery connector and connect if necessary Release the master switch Set the key switch to position I Check the charging condition of the battery and recharge if necessary Operate platform switch Check fuses F1 and 1F1 Load cannot be lifted Truck not oper...

Page 40: ...icians trained especially for these assignments We thus recommend signing a maintenance contract with the relevant service location of the manufacturer Lifting and jacking up When a fork lift truck is to be lifted the lifting gear must only be secured to the points specially provided for this purpose When the truck is to be jacked up suitable measures must be taken to prevent the truck from slippi...

Page 41: ... specific settings have to be retained Tyres The quality of the tyres greatly affects the stability and the driving behaviour of the fork lift truck Changes must only be made following consultations with the manufacturer When replacing wheels or tyres it must be ensured that the fork lift truck remains level tyres and wheels must always be replaced in pairs i e left and right together Lift chains ...

Page 42: ... accordingly The following servicing checklist indicates the operations to be performed and the respective intervals to be observed The servicing intervals are defined as follows W1 every 50 operating hours but at least once per week M3 every 500 operating hours but at least every 3 months M6 every 1000 operating hours but at least every 6 months M12 every 2000 operating hours but at least every 1...

Page 43: ...ck l t 5 2 Check the brake linings for wear t 5 3 Check reset function of the deadman key t 5 4 Check the brake linkage adjust if necessary l t Hydraulic system 6 1 Performance check l t 6 2 Check all connections for leakage and damage b l t 6 3 Check hydraulic cylinders for leakage damage and secure attachment l t 6 4 Clean filter t 6 5 Check the oil level l t 6 6 Change hydraulic oil c l t 6 7 C...

Page 44: ... t Lifting device 10 1 Performance and adjustment check t 10 2 Perform sight check of rollers sliding elements and stops l t 10 3 Check fork tines and fork carrier for wear and damage l t Lubrication 11 1 Grease the vehicle in accordance with the lubrication schedule l t General measurements 12 1 Check the electrical system for a grounding fault t 12 2 Check the driving speed and braking distance ...

Page 45: ...nipples Filler plug for hydraulic oil b Filler plug for gear oil a Drain plug for gear oil Cold store usage 1 Compound for cold store usage 1 1 2 1 25l 1 3l depending on the drive type always up to the lower edge of the filler neck B 1 25 1 3 l B C 1 2 E F G 0 7 l A A C 1 ...

Page 46: ...cept if mixing is expressively prescribed in these operating instructions Avoid spilling Spilt liquid must be removed immediately using a suitable binding agent and the mixture of consumption type material and binding agent is to be disposed of according to the regulations Grease data Code Order No Supply Qty Designation Used for A 29 200 670 5 0 l H LP 46 DIN 51524 Hydraulic system B 29 200 680 5...

Page 47: ...formed under the jacked up truck suitable measures must be taken to prevent any dropping tilting or slipping of the truck When lifting the truck the instructions contained in the chapter Transportation and commissioning have to be observed 6 2 Tightening the wheel screws The wheel screws of the drive wheel must be retightened in accordance with the servicing intervals indicated in the servicing ch...

Page 48: ...sitting aid 4 Carefully open the drive cover 6 above the recessed grip 5 then pull it off and store it in a safe location Installation occurs in the reverse order of steps f Do not drive the truck unless the hoods are closed and locked in the stipulated manner 4 5 6 ...

Page 49: ...all fuses for correct rating and damage replace fuses where required Remount the drive cover see chapter F section 6 3 Item Designation Protection of Value 7 1F1 t Drive motor 150 A 8 2F1 t Pump motor 150 A 9 1F10 t Field Driving 40 A 10 6F2 o Battery discharge indicator operating hour meter 10 A 11 F1 t Entire control circuit 10 A 12 3F9 t Steering motor 30 A t Standard equipment o Optional equip...

Page 50: ...e ground Only this measure will ensure that wheels and wheel bearings do not suffer damage If the fork lift truck is to be decommissioned for more than 6 months additional measures must be discussed with the Service Department of the manufacturer 7 1 Operations to be performed prior to decommissioning Thoroughly clean the fork lift truck Check the brakes for correct function Check the hydraulic oi...

Page 51: ...brication chart refer to chapter F section 5 Clean the battery Grease the pole screws using pole grease and reconnect the battery Recharge the battery refer to chapter D section 4 Check if the gear oil contains condensed water and change if required Check if the hydraulic oil contains condensed water and change if required Start up the fork lift truck refer to chapter E section 3 A If switching tr...

Page 52: ...mprise a comprehensive check of the technical condition of the fork lift truck with regard to accident prevention aspects Apart from this the fork lift truck must be thoroughly inspected for damage possibly caused by incorrect use of the fork lift truck The inspection results must be recorded in an inspection report which must be kept available for a period spanning at least the next two inspectio...

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