Jungheinrich ESD 220 Operating Instructions Manual
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Jungheinrich ESD 220 Operating Instructions Manual

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

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Summary of Contents for Jungheinrich ESD 220

  • Page 1 ESD 220 06.10 Operating instructions en-GB 51190940 10.19 ESD 220...
  • Page 3 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).
  • Page 5 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.
  • Page 6 Copyright 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...

  • Page 7: Table Of Contents

    Contents Correct Use and Application General Correct application Approved application conditions Proprietor responsibilities Adding attachments and/or optional equipment Truck Description Application Truck models and rated capacity Travel direction definition Assemblies and Functional Description Assembly Overview Functional Description Technical Specifications Performance data Dimensions Weights Tyre type...
  • Page 8 Truck does not start Load cannot be lifted Operating the truck without its own drive system Load handler emergency lowering Optional equipment Brake Pedal in Footwell with ESD 220 Display and control unit Setting the time Keypad (CanCode) (o) ISM access module (o)
  • Page 9 Restoring the truck to service after decommissioning Safety tests to be performed at intervals and after unusual incidents Final de-commissioning, disposal Human vibration measurement Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement Maintenance Contents ESD 220 Owner Customer Service...
  • Page 11 Appendix JH Traction Battery Operating Instructions These operating instructions apply only to Jungheinrich battery models. If using another brand, refer to the manufacturer's operating instructions.

  • Page 13: A Correct Use And Application

    A Correct Use and Application 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. Correct application NOTICE The maximum load and load distance are indicated on the capacity plate and must...

  • Page 14: Approved Application Conditions

    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.

  • Page 15: Proprietor Responsibilities

    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.

  • Page 17: B Truck Description

    B Truck Description 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.

  • Page 18: Travel Direction Definition

    Travel direction definition The following determinations have been made for travel direction specification: Item Travel Direction Left Drive direction Load direction Right...

  • Page 19: Assemblies And Functional Description

    Assemblies and Functional Description Assembly Overview...
  • Page 20 Item Description Item Description t Charge status indicator 14 t Floor-plate height adjuster t Key switch 15 t Battery o Control/display unit 16 t Load wheels o CanCode code lock 17 t Load handler o ISM access module 18 t Seat panel 10 t multiPILOT 19 t Steering wheel 11 t Mast...

  • Page 22: Functional Description

    Functional Description Safety mechanisms An enclosed, smooth truck geometry with rounded edges ensures safe handling of the truck. The wheels are surrounded by a solid skirt. Activating the emergency disconnect switch rapidly cuts out all electrical functions in hazardous situations. The protective screen or grille (o) protects the operator from moving mast parts and the load.
  • Page 23 Operator position The driver's seat and floor plate can be adjusted to suit different sized operators. All travel and lift operations can be performed sensitively without having to reach. The ergonomic steering wheel provides secure control of the truck. Electrical system The truck has electronic traction, lift and steering controllers.
  • Page 24 Hydraulic system Infinitely variable lifting and lowering operations are performed by moving the Multi- Pilot forward and back. When lifting is activated, the pump unit starts to operate, supplying hydraulic oil from the oil reservoir to the lift cylinder. If the truck is fitted with the "z" auxiliary lift, the wheel arms can be raised and lowered via buttons.
  • Page 25 3.2.1 Hourmeter Prepare the truck for operation, see page 65 or see page 99. Service hours are counted while the truck is operational and the deadman button is pressed.

  • Page 26: Technical Specifications

    Technical Specifications The technical specifications comply with the German "Industrial Truck Data Sheet" Guidelines. Technical modifications and additions reserved. Performance data ESD 220 Q Rated capacity 1) 2000 Travel speed 9,1/ 9,1 km/h w / w.o. rated load Lift speed...

  • Page 27: Dimensions

    Dimensions...
  • Page 28 ESD 220 Load centre distance Load distance raised 2) Wheelbase raised 2) 1734 h1 Mast height when retracted 1309 h3 Lift 1660 h4 Mast height when extended 2150 h5 Initial lift h7 Seat height / standing height h13 Lowered height...

  • Page 29: Weights

    Weights ESD 220 Net weight excl. battery Axle load, w. load 1358 / 1984 front/rear + battery Axle load, w.o. load 968 / 371 front/rear + battery Battery weight Tyre type ESD 220 Tyre size, drive 230 x 77 Tyre size, load section...

  • Page 30: Norms

    EN norms Continuous sound pressure level – ESD 220: 69 dB(A) in accordance with EN 12053 as harmonised with ISO 4871. The continuous sound pressure level is calculated according to standard procedures and takes into account the sound pressure level when travelling, lifting and idling.

  • Page 31: Conditions Of Use

    Conditions of use Ambient temperature – operating at 5°C to 40°C Special equipment and authorisation are required if the truck is to be used continually in conditions of extreme temperature or condensing air humidity fluctuations. Electrical Requirements The manufacturer certifies compliance with the requirements for the design and manufacture of electrical equipment, according to EN 1175-1 "Industrial Truck Safety - Electrical Requirements", provided the truck is used according to its purpose.

  • Page 32: Identification Points And Data Plates

    Identification Points and Data Plates...
  • Page 33 Item Description Load handler capacity plate Raise/lower support arms Double-decker mode capacity plate Prohibition plate: "Do not reach through the mast" Prohibition plate: “Do not step under the load handler” Floor plate adjustment Type Serial number MULTI-PILOT Data plate Final inspection Inspection plaque Attachment points for crane lifting...

  • Page 34: Data Plate

    Data plate Item Model Item Model Rated capacity (kg) Load centre distance (mm) Battery voltage (V) Drive output Net weight w.o. battery (kg) Min./max. battery weight (kg) Option Manufacturer Model QR code Serial number Manufacturer's logo Year of manufacture For queries regarding the truck or when ordering spare parts, always quote the truck serial number (40).

  • Page 35: Truck Capacity Plate

    Truck capacity plate Previous capacity plate Current capacity plate The capacity plate (22) indicates the maximum capacity Q (in kg) for a given load centre distance D (in mm) and corresponding lift height H (in mm) for the truck when raising a load.
  • Page 36 Lift height limits The arrow shaped markings on the outer mast (49) and on the inner mast (48) indicate to the operator when the height limits specified on the capacity plate have been exceeded.

  • Page 37: Double Decker Mode Capacity Plate

    Double Decker Mode Capacity Plate The capacity plate (24) indicates the capacity Q kg of the truck while travelling: No transporting with a raised load Max. capacity for horizontal transporting XXX kg with raised wheel arms without mast lift. Double decker mode: Max.

  • Page 39: C Transport And Commissioning

    C Transport and Commissioning Lifting by crane WARNING! Improper loading by crane can result in accidents Improper use or use of unsuitable lifting gear can cause the truck to crash when being loaded by crane. Prevent the truck from hitting other objects during lifting, and avoid uncontrolled movements.
  • Page 40 Lifting the truck by crane Requirements – Park the truck securely, see page 67. – Remove any mast guards. Tools and Material Required – Lifting gear – Crane lifting gear Procedure • Secure the lifting slings to the strap points (34). The truck can now be lifted by crane.

  • Page 41: Transport

    Transport WARNING! Accidental movement during transport Improper fastening of the truck and mast during transport can result in serious accidents. uLoading must only be performed by specialist personnel trained for this purpose. The specialist personnel must be instructed in securing loads on road vehicles and handling load securing devices.
  • Page 42 Securing the truck for transport Requirements – Load the truck. – Truck parked securely, see page 67. Tools and Material Required – Lashing straps – Edge protectors – Wooden beam or pallet Procedure • Position the wooden beam or pallet between the front of the transport vehicle and the load handler to ensure a positive fit between the front of the transport vehicle and the load handler.

  • Page 43: Using The Truck For The First Time

    Using the Truck for the First Time WARNING! The use of unsuitable energy sources can be hazardous Rectified AC current will damage the assemblies (controllers, sensors, motors etc.) of the electronic system. Unsuitable cable connections (too long, insufficient wire cross-section) to the battery (tow cables) can overheat, setting the truck and battery on fire.

  • Page 45: D Battery - Servicing, Recharging, Replacement

    D Battery - Servicing, Recharging, Replacement Safety instructions for handling lead-acid batteries Maintenance personnel Batteries may only be charged, serviced or replaced by trained personnel. These operating instructions and the manufacturer’s instructions concerning batteries and charging stations must be observed when carrying out the work. Fire Protection Do not smoke and avoid naked flames when handling batteries.
  • Page 46 Battery maintenance The battery-cell covers must be kept dry and clean. The terminals and cable lugs must be clean, secure and have a light coating of terminal grease. WARNING! Short circuits can result in fire Damaged cables can cause short circuits, setting the truck and battery on fire. uBefore closing the battery cover make sure that the battery cables are not damaged.
  • Page 47 The use of unsuitable batteries that have not been approved for the truck by Jungheinrich, can lead to a deterioration of the braking characteristics of the truck during energy recovery, causing considerable damage to the electric controller and resulting in serious danger to the health and safety of individuals.

  • Page 48: Battery Types

    Battery types Depending on the model, the truck will be supplied with different battery types. The following table shows which combinations are included as standard: Battery type Capacity Weight 24 volt battery 3 PzS 465 Ah 380 kg 796 x 210 x 782 mm (LXWXH) The battery weights can be taken from the battery data plate.

  • Page 49: Exposing The Battery

    Exposing the battery WARNING! An unsecured truck can cause accidents Parking the truck on an incline or with a raised load handler is dangerous and is strictly prohibited. uPark the truck on a level surface. In special cases the truck may need to be secured with wedges.

  • Page 50: Charging The Battery

    Charging the battery WARNING! The gases produced during charging can cause explosions The battery produces a mixture of nitrogen and hydrogen (electrolytic gas) during charging. Gassing is a chemical process. This gas mixture is highly explosive and must not be ignited. uSwitch the charging station and truck off first before connecting/disconnecting the charging cable of the battery charging station to/from the battery connector.
  • Page 51 Charging the battery Requirements – Expose the battery, see page 47. – Correct charging program set on charger. Procedure • Remove the battery connector (52) from the truck plug (53). • Remove any insulating mats from the battery. • Connect the battery connector (52) to charging cable (54)

  • Page 52: Battery Removal And Installation

    Battery removal and installation WARNING! Accident risk during battery removal and installation Due to the battery weight and acid there is a risk of trapping or scalding when the battery is removed and installed. uNote the "Safety regulations for handling acid batteries" section in this chapter. uWear safety shoes when removing and installing the battery.
  • Page 53 Removing the battery Requirements – Park the truck securely, see page 67. – Expose the battery, see page 47. Tools and Material Required – Battery replacement trolley (o) Procedure • Remove the battery connector (52) from the truck. • Place the battery connector (52) on the battery (55). •...
  • Page 54 Checking the battery acid level Requirements – Park the truck securely, see page 67. – Expose the battery, see page 47. Procedure • Remove the battery connector (52) from the truck. • Place the battery connector (52) on the battery (55). •...
  • Page 55 • Release the battery lock (51). • Keep pushing the battery (55) into the truck until the lock engages on the battery again. The acid level has now been checked.

  • Page 57: E Operation

    E Operation Safety Regulations for the Operation of Forklift Trucks Driver authorisation The truck may only be used by suitably trained personnel, who have demonstrated to the proprietor or his representative that they can drive and handle loads and have been authorised to operate the truck by the proprietor or his representative.
  • Page 58 Repairs The operator must not carry out any repairs or alterations to the truck without authorisation and the necessary training to do so. The operator must never disable or adjust safety mechanisms or switches. Hazardous area WARNING! Risk of accidents/injury in the hazardous area of the truck A hazardous area is defined as the area in which people are at risk due to travel or lifting operations of the truck, its load handler or the load.

  • Page 59: Displays And Controls

    Displays and Controls...
  • Page 60 Item Control/display Function t Shows the battery charge status. Charge/discharge indicator Key switch and key t – Activates the truck by applying the control voltage – Removing the key prevents the truck from being switched on by unauthorised personnel o Replaces the key switch CanCode code lock –...
  • Page 61 Item Control/display Function o – Switches the seat heating on and off "Seat heater" switch – Indicates when the seat heating is switched on t Adjusts the driver's seat horizontally Seat adjustment lever t Sets the ideal seat cushioning for the Seat cushioning adjusting wheel driver's weight...

  • Page 62: Battery Discharge Indicator

    Battery discharge indicator When the truck has been released via the key switch, CanCode or ISM, the battery charge status is displayed. The LED colours (62) represent the following conditions: LED colour Charge status Green 40–100% Orange 30–40% Green/orange 20–30% flashes at 1 Hz 0–20% If the LED is red, the load can no longer be lifted.

  • Page 63: Preparing The Truck For Operation

    Preparing the Truck for Operation Checks and Operations to Be Performed Before Starting Daily Work WARNING! Damage and other truck or attachment (optional equipment) defects can result in accidents. If damage or other truck or attachment (optional equipment) defects are discovered during the following checks, the truck must be taken out of service until it has been repaired.

  • Page 64: Entry And Exit

    Entry and exit Requirements – Load handler fully lowered. Procedure Always enter and exit the truck facing the load direction. To enter and exit, hold onto the handle (63). • Enter or leave the truck. CAUTION! No more than one person may operate the truck at a time.

  • Page 65: Adjusting The Floor-Plate Height

    Adjusting the Floor-Plate Height Procedure • Sit down on the driver’s seat. • Press and hold down on the floor plate height adjustment button (14). The floor plate can now be adjusted. • Set the floor plate (64) to the correct height by standing on it / discharging it. •...

  • Page 66: Adjusting The Driver's Seat

    Adjusting the driver’s seat CAUTION! An unsecured driver's seat can cause injury An unsecured driver's seat can slide out of its guide during travel, resulting in accidents. uThe driver's seat must be locked in position. uDo not adjust the driver’s seat while travelling. Adjusting the driver’s seat Procedure •...

  • Page 67: Preparing The Truck For Operation

    Preparing the truck for operation Switching on the truck Requirements – For checks and operations to be performed before starting daily operation, see page 61. Procedure • Enter the operator position, see page 62. • Pull the Emergency Disconnect switch (12) to unlock it. •...

  • Page 68: Checks And Operations To Be Carried Out When The Truck Is Operational

    Checks and operations to be carried out when the truck is operational WARNING! Risk of accident due to damage to or other defects in the truck and optional features If damage or other truck or attachment (optional equipment) defects are discovered during the following checks, the truck must be taken out of service until it has been repaired.

  • Page 69: Parking The Truck Securely

    Parking the truck securely WARNING! An unsecured truck can cause accidents Parking the truck on an incline, without the brakes applied or with a raised load or load handler is dangerous and is strictly prohibited. uPark the truck on a level surface. In special cases the truck may need to be secured with wedges.
  • Page 70 Parking the truck securely Procedure • Park the truck on a level surface. • Fully lower the load handler (65): • Apply the “wheel arm lower” button (23) . • Press the Multi-Pilot (10) in the arrow direction. • Set the drive wheel to “Straight ahead”. •...

  • Page 71: Industrial Truck Operation

    Industrial Truck Operation Safety regulations for truck operation Travel routes and work areas Only use lanes and routes specifically designated for truck traffic. Unauthorised third parties must stay away from work areas. Loads must only be stored in places specially designated for this purpose. The truck must only be operated in work areas with sufficient lighting to avoid danger to personnel and materials.
  • Page 72 Travel visibility The operator must look in the direction of travel and must always have a clear view of the route ahead. If the truck is carrying loads that affect visibility, the truck must travel against the load direction. If this is not possible, a second person must walk alongside the truck as a lookout to observe the travel route while maintaining eye contact with the operator.
  • Page 73 Negotiating lifts, loading ramps and docks Lifts may only be negotiated if they have sufficient capacity, are suitable for driving on and authorised for truck traffic by the owner. The driver must satisfy himself of the above before entering these areas. The truck must enter lifts with the load in front and must take up a position which does not allow it to come into contact with the walls of the lift shaft.
  • Page 74 WARNING! Wind loads Wind forces can affect the stability of a truck when transporting loads with large surface areas. Light loads must be especially secured when they are subjected to wind forces. Stop the truck in both cases. WARNING! Accident risk due to removing or disabling of safety devices Removal or disabling of safety devices such as the Emergency Disconnect switch, deadman switch, horn, warning lights, gates, protective window, covers, etc.

  • Page 75: Emergency Disconnect

    Emergency Disconnect CAUTION! Applying maximum braking can result in accidents Applying the Emergency Disconnect switch during travel will cause the truck to decelerate to a halt at maximum force. This may cause the load to slide off the load handler. There is a higher risk of accidents and injury. uDo not use the Emergency Disconnect switch as a service brake.
  • Page 76 Pressing the emergency disconnect switch Procedure • Press the emergency disconnect switch (12). All electrical functions are deactivated. The truck brakes to a halt. Press the Emergency Disconnect switch on in emergencies. Releasing the Emergency Disconnect switch Procedure • Pull the Emergency Disconnect switch (12) to unlock it. All electrical functions are enabled and the truck is operational again (provided the truck was operational before the Emergency Disconnect was pressed).

  • Page 78: Deadman Button

    Deadman button The deadman switch (20) must be pressed to lift, lower or travel. If the deadman switch is released during travel, the truck decelerates at the maximum rate until it stops. If the deadman switch is released during lifting or lowering, the respective function cuts out immediately.
  • Page 80 4.4.1 Changing direction during travel CAUTION! Danger when changing direction during travel Changing direction during travel causes the truck to decelerate rapidly. When the truck changes direction, it can start travelling at high speed in the opposite direction unless the Multi-Pilot is released in time. uAfter setting off in the opposite direction, apply the Multi-Pilot gently or not at all.

  • Page 81: Steering

    Steering Requirements – Start up the truck, see page 65. Procedure • Turn the steering wheel (19) to the left or right. The wheel position is indicated on the display (7) (o). The truck is steered in the required direction.

  • Page 82: Brakes

    Brakes WARNING! Accident risk while braking The truck’s braking response depends largely on the floor condition and the type of surface. The truck’s braking distance increases when the ground is wet or dirty. uThe operator must be aware of floor conditions and take them into account when braking.

  • Page 84: Load Handler Raise/Lower

    Load handler raise/lower WARNING! Accident risk when lifting and lowering Other people can be injured in the truck's hazardous area. The hazardous area is defined as the area in which people are at risk from the movement of the truck including the load handler, etc. This also includes areas which can be reached by falling loads, operating equipment, etc.
  • Page 85 4.7.1 Raising the load handler Requirements – Prepare the truck for operation, see page 65. – Deadman switch pressed, see page 76. Procedure • Pull the Multi-Pilot (10) in the arrow direction until you reach the required lift height. The lift and lower speeds can be infinitely controlled by moving the Multi-Pilot.
  • Page 86 4.7.3 Raising the wheel arms Requirements – Prepare the truck for operation, see page 65. – Deadman switch pressed, page 76. Procedure • Press the "wheel arm lift" button (57) on the Multi-Pilot. Press down on the button until the wheel arms have...

  • Page 87: Lifting, Transporting And Depositing Loads

    Lifting, transporting and depositing loads WARNING! Unsecured and incorrectly positioned loads can cause accidents Before lifting a load, the operator must make sure that it has been correctly palletised and does not exceed the truck’s capacity. uInstruct other people to move out of the hazardous area of the truck. Stop working with the truck if people do not leave the hazardous area.
  • Page 88 4.8.1 Raising a load Requirements – Load correctly palletised. – Load weight matches the truck's capacity. – Load handler evenly loaded for heavy loads. Procedure • Drive the truck carefully up to the pallet. • Drive the load handler slowly into the pallet until the pallet is against the back of the load handler (see graphic to the right).
  • Page 89 4.8.2 Transporting a load Requirements – Load raised correctly. – Mast lowered transport (approx. 150 - 200 mm above the ground). – Good ground conditions. Procedure • Accelerate and decelerate with care. • Adapt your travel speed to the conditions of the route and the load you are transporting.
  • Page 90 Requirements – Load correctly palletised. – Capacity of the truck sufficient for load, see see page 33. – Load handler evenly loaded for heavy loads. Procedure • Drive the truck slowly up to the pallet. • Insert the load fork slowly into the pallet until the pallet is resting against the back (see figure).
  • Page 91 4.8.6 Lowering Two Pallets In Turn CAUTION! Loads must not be deposited on traffic lanes or escape routes, or in front of safety equipment or operating equipment that must be accessible at all times. Requirements – Storage location suitable for storing the load. Procedure •...

  • Page 92: Troubleshooting

    Troubleshooting This chapter enables the operator to localize and rectify basic faults or the results of incorrect operation himself. When trying to locate a fault, proceed in the order shown in the remedy table. If, after carrying out the following remedial action, the truck cannot be restored to operation or if a fault in the electronics system is displayed with a corresponding error code, contact the manufacturer’s service department.

  • Page 93: Truck Does Not Start

    Truck does not start Possible Cause Remedy Battery connector not inserted Check the battery connector and insert if necessary Emergency Disconnect switch pressed Release the Emergency Disconnect switch, see page 73 Key switch set to O Set the key switch to “I” Deadman switch not pressed Press deadman switch Battery charge too low...

  • Page 94: Operating The Truck Without Its Own Drive System

    Operating the truck without its own drive system WARNING! Accidental truck movement When the brakes are de-activated the truck must be parked on a level surface, since the brakes are no longer effective. uDo not release the brake on slopes or inclines. uDo not park the truck with the brake released.
  • Page 95 Activating the brake Procedure • Use wedges to prevent the truck from moving. • Unscrew the two M5x45 screws (66) again. CAUTION! Open covers can cause injury and accidents uThe covers (battery cover, side panels, drive compartment cover etc.) must be closed during operation.

  • Page 96: Load Handler Emergency Lowering

    Load handler emergency lowering WARNING! Lowering the load handler can result in injuries The hazardous area is defined as the area in which people are at risk from the mast, the load handler or the load. This also includes areas which can be reached by falling loads or lowering operating equipment.
  • Page 97 Load handler emergency lowering Requirements – Load handler is not in the rack. – 3 mm diameter pin, tool etc. Procedure • Fully lower the floor plate (64), see page 63. • Remove the screws (67) from the seat cover (68). •...

  • Page 98: Optional Equipment

    Optional equipment Brake Pedal in Footwell with ESD 220 Item Control/display Function o Pedal for reducing the travel speed and for Brake pedal (electric) braking the truck to a halt Braking with the brake pedal Procedure • Press down the brake pedal (21) during travel until you reach the required deceleration.

  • Page 99: Display And Control Unit

    Display and control unit Item Description STOP Parking brake applied WARNING Displays the current steer angle (drive wheel direction) Steer mode, displays possible travel directions Time display (hours: minutes) Battery charge status Discharge indicator Set travel speed for current profile (max = 5 bars) Slow travel activated (reduced travel speed) Profile number (travel profile 1, 2 or 3) Deadman button not pressed...

  • Page 100: Setting The Time

    Setting the time Setting the time (75) Procedure • Press the Shift key (86) for 8 secs. until the "Set Clock Time" menu is displayed. • Set the time with the Up (84) and Down (85) keys. • Confirm with the Shift key (86). •...

  • Page 101: Keypad (Cancode) (O)

    Keypad (CanCode) (o) 8.4.1 Code lock The code lock allows a user or group of users to assign an individual user code. Travel programs can also be assigned to the individual user codes. The user code is configured with a master code and is described in the following sections in this chapter.
  • Page 102 The keypad consists of 10 digit keys, a Set key (91) and a o key (93). Digit keys The digit keys are used to enter the user or master code and select the travel program. The green LEDs of the digit keys 1, 2 and 3 (88, 89, 90) show the travel program setting.
  • Page 103 8.4.2 Preparing the truck for operation with the keypad (CanCode) Preparing the truck for operation by entering a valid operator code Procedure • Pull the Emergency Disconnect to unlock it, see page 73. The LED (92) lights up red. • Enter the operator code with the digit keys. When you have entered a valid operator code the LED (92) lights up green, the travel program selected is indicated by the corresponding LEDs (88,89,90) and the truck is switched on.
  • Page 104 8.4.4 Changing the master code To change the length of the master code you must follow the procedure in "Choose length of the new master code (4-6 digit) and add user codes", see page 111. If there are still user codes stored in the code lock, the master code to be changed must be the same length as the saved user codes.
  • Page 105 Error displays changing the master code For the following events the LED (92) flashes red: Cause Remedy – Switch off the truck, see page 101. – Choose a different master code, see page 102. – New master code is already –...
  • Page 106 8.4.5 Add operator code Requirements – To prepare the truck for operation, see page 101. Procedure • Press the O key (93). • Enter the valid master code with the digit keys. When you enter the valid master code the LED (92) flashes green.
  • Page 107 Error displays adding a user code For the following events the LED (92) flashes red: Cause Remedy – The user code entered is – Switch off the truck, see page 101. not the same length as the – Repeat the entry, making sure that the master master code code is the same length as the user code.
  • Page 108 8.4.6 Change operator code Requirements – To prepare the truck for operation, see page 101. Procedure • Press the O key (93). • Enter the valid master code with the digit keys. When you enter the valid master code the LED (92) flashes green.
  • Page 109 Error displays changing a user code For the following events the LED (92) flashes red: Cause Remedy – The user code entered is – Switch off the truck, see page 101. not the same length as the – Repeat the entry, making sure that the master master code code is the same length as the user code.
  • Page 110 8.4.7 Delete individual user codes Requirements – To prepare the truck for operation, see page 101. Procedure • Press the O key (93). • Enter the valid master code with the digit keys. When you enter the valid master code the LED (92) flashes green.
  • Page 111 Error displays deleting individual user codes For the following events the LED (92) flashes red: Cause Remedy – The user code entered is – Switch off the truck, see page 101. not the same length as the – Repeat the entry, making sure that the master master code code is the same length as the user code.
  • Page 112 8.4.8 Delete all user codes, Requirements – To prepare the truck for operation, see page 101. Procedure • Press the O key (93). • Enter the valid master code with the digit keys. When you enter the valid master code the LED (92) flashes green.
  • Page 113 8.4.9 Choose length of the new master code (4-6 digit) and add user codes The master code is factory set to a four-digit entry: If necessary, the four-digit master code can be changed to a five or six-digit entry. Before the master code length can be changed, all user codes must be deleted.
  • Page 114 8.4.10 Setting the automatic truck cutout (timeframe) Requirements – To prepare the truck for operation, see page 101. Procedure • Press the O key (93). • Enter the valid master code with the digit keys. When you enter the correct master code the LED (92) flashes green.
  • Page 115 Error displays setting the automatic cutout period of the truck For the following events the LED (92) flashes red: Cause Remedy – Switch off the truck, see page 101. – Cutout time entered is out of – Enter the time again while making sure it is range within range.
  • Page 116 8.4.11 Assigning the travel program The travel programs are fixed to the user code and can be released or blocked with a configuration code. The configuration code can also be used to assign a starting travel program to each user code. The starting travel program is the travel program that is activated when the truck is switched on and is displayed by the (88,89,90) LEDs.
  • Page 117 Specifying a configuration code: Setting Description – Travel program 1 is blocked for the user code selected 1st digit – Travel program 1 is enabled for the user code selected – Travel program 2 is blocked for the user code selected 2nd digit –...
  • Page 118 Adapting the travel program configuration to the user code Procedure • Press the O key (93). • Enter the valid master code with the digit keys. When you enter the valid master code the green LED (92) flashes green. • Enter the parameters 0-2-4 with the digit keys. •...

  • Page 119: Ism Access Module (O)

    Error displays configuring the travel programs For the following events the LED (92) flashes red: Cause Remedy – Blocked travel program – Switch off the truck, see page 101. defined as start travel – Try again, making sure the configuration code is program entered correctly.

  • Page 120: Floor-Spot

    Floor-Spot The floor spot serves as an auxiliary device and projects a coloured dot onto the ground. CAUTION! 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 the floor spot carefully.
  • Page 121 8.6.1 Additional information on Floor-Spot blue CAUTION! Risk of retinal damage due to blue light The Floor-Spot on the truck is classified in risk group 2 according to the standard IEC 62471: medium risk. In the range of 400 nm to 780 nm, blue light can potentially damage the retina of the human eye.

  • Page 123: F Industrial Truck Maintenance

    The manufacturer cannot be held liable for damage caused by the use of non-original spare parts. product-related electronic spare parts catalogue found (www.jungheinrich.de/spare-parts-search) by entering the serial number. The serial number can be found on the data plate, see page 32.

  • Page 124: Operational Safety And Environmental Protection

    Operational Safety and Environmental Protection The inspections and maintenance tasks listed in chapter "Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement" must be performed according to the defined service intervals (see page 145). The manufacturer recommends the replacement of the maintenance parts also listed in chapter "Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement"...

  • Page 125: Maintenance Safety Regulations

    Maintenance Safety Regulations Maintenance and repair personnel The manufacturer has a customer service department specially trained for these tasks. A maintenance contract with the manufacturer will support trouble-free operation. Truck maintenance, repair work and changing of parts requiring replacement must only be carried out by specialist personnel.

  • Page 126: Working On The Electrical System

    Working on the electrical system WARNING! Electrical current can cause accidents Make sure the electrical system is voltage-free before starting work on it. The capacitors in the controller must be completely discharged. The capacitors are completely discharged after approximately 10 minutes. Before starting maintenance on the electrical system: uOnly suitably trained electricians may operate on the truck's electrical system.

  • Page 127: Hydraulic System

    Hydraulic system WARNING! Leaky hydraulic systems can result in accidents Hydraulic oil can escape from leaky and faulty hydraulic systems. 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.

  • Page 128: Lift Chains

    Lift Chains WARNING! Risk of accident from non-lubricated and incorrectly cleaned lift chains Lift chains are safety-critical parts. Lift chains must not show signs of serious contamination. Lift chains and pivot pins must always be clean and sufficiently lubricated. uThe lift chains are cleaned by wiping or brushing. Significant contamination can be softened by a paraffin derivative such as petroleum.

  • Page 129: Lubricants And Lubrication Schedule

    Lubricants and Lubrication Schedule Handling consumables safely Handling consumables Consumables must always be handled correctly. Follow the manufacturer’s instructions. WARNING! Improper handling is hazardous to health, life and the environment Consumables can be flammable. uKeep consumables away from hot components and naked flames. uAlways keep consumables in prescribed marked containers.
  • Page 130 WARNING! Improper handling of oils can be hazardous Oils (chain spray / hydraulic oil) are flammable and poisonous. uDispose of used oils in accordance with regulations. Store used oil safely until it can be disposed of in accordance with regulations. uDo not spill oil.

  • Page 131: Lubrication Schedule

    Lubrication Schedule A + B 1,05 l g Contact surfaces Cold-store application a Transmission oil drain plug Grease nipple Hydraulic oil drain plug Hydraulic oil filler plug Compound ratio for cold store usage 1:1...

  • Page 132: Consumables

    Grease, DIN 51825 Lubrication *The trucks are delivered ex-works with a special hydraulic oil (the Jungheinrich hydraulic oil with a blue colouration) and the cold-store hydraulic oil (red colouration). The Jungheinrich hydraulic oil is available only from the Jungheinrich service department.

  • Page 133: Maintenance And Repairs

    Maintenance and repairs Preparing the truck for maintenance and repairs Procedure • Park the truck securely, see page 67. • Disconnect the battery to prevent the truck from being switched on accidentally. Lifting and jacking up the truck safely WARNING! Lifting and jacking up the truck safely In order to raise the truck, the lifting gear must only be secured to the points specially provided for this purpose.

  • Page 134: Cleaning

    Cleaning 5.3.1 Cleaning the truck The truck may only be cleaned in the designated locations, which adhere to the stipulations of the country of use. CAUTION! Fire hazard Do not use flammable liquids to clean the industrial truck. uDisconnect the battery before starting cleaning work. uCarry out all necessary safety measures to prevent sparking before cleaning (e.g.
  • Page 135 Requirements – Truck prepared for maintenance and repair work (see page 131). Tools and Material Required – Water-based solvents – Sponge or cloth Procedure • Clean the surface of the truck with water-based solvents and water. Use a sponge or cloth to clean. •...
  • Page 136 5.3.2 Cleaning the electrical system assemblies CAUTION! Risk of electrical system damage Cleaning the assemblies (controllers, sensors, motors etc.) of the electronic system with water can damage the electrical system. uDo not clean the electrical system with water. uClean the electrical system with weak suction or compressed air (use a compressor with a water trap) and not a conductive, anti-static brush.

  • Page 137: Drive Compartment Cover Disassembly/Assembly

    Drive compartment cover disassembly/assembly Remove drive compartment cover Requirements – Prepare the truck for maintenance and repairs (see page 131). Tools and Material Required – Allen key Procedure Hold onto the cover (95) when removing the screws. Remove the four screws (96) with the Allen key.

  • Page 138: Replacing The Drive Wheel

    Replacing the drive wheel The drive wheel must only be replaced by the manufacturer’s authorised customer service department.

  • Page 139: Tightening The Wheel Nuts

    Tightening the wheel nuts The wheel nuts on the drive wheel must be retightened in accordance with the maintenance intervals indicated in the maintenance checklist, see page 145. Tightening the wheels nuts Requirements – Prepare the truck for maintenance and repair work, see page 131. Tools and Material Required –...

  • Page 140: Checking The Hydraulic Oil Level

    Checking the hydraulic oil level Checking hydraulic level replenishing Requirements – Fully lower the load handler. – Prepare the truck for maintenance and repairs, see page 131. Procedure • Remove the drive compartment cover, see page 135. • Check level hydraulic reservoir (102).

  • Page 141: Checking Electrical Fuses

    Checking electrical fuses Check fuses Requirements – Truck prepared for maintenance and repairs. Procedure • Fold up the arm rest. • Check the fuse ratings against the table and replace if necessary. • Close the armrest. The fuses are now checked. F15 F1 6F1 9F22 3F1 F17 Description To protect...

  • Page 142: Restoring The Truck To Service After Maintenance And Repairs

    Restoring the truck to service after maintenance and repairs Procedure • Thoroughly clean the truck, see page 132. • Lubricate the truck according to the lubrication diagram, see page 129. • Clean the battery, grease the terminals and connect the battery. •...

  • Page 143: Decommissioning The Industrial Truck

    Decommissioning the Industrial Truck If the truck is to be out of service for more than a month, it must be stored in a frost- free and dry room. All necessary measures must be taken before, during and after decommissioning 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.

  • Page 144: Restoring The Truck To Service After Decommissioning

    Restoring the truck to service after decommissioning Procedure • Thoroughly clean the truck, see page 132. • Lubricate the truck according to the lubrication schedule, see page 129. • Clean the battery, grease the terminal screws and connect the battery. •...

  • Page 145: Safety Tests To Be Performed At Intervals And After Unusual Incidents

    Safety tests to be performed at intervals and after unusual incidents The truck must be inspected at least annually (refer to national regulations) or after any unusual event by a qualified inspector. The manufacturer offers a safety inspection service which is performed by personnel specifically trained for this purpose.

  • Page 146: Final De-Commissioning, Disposal

    Final de-commissioning, disposal Final de-commissioning or disposal of the truck in must be performed in accordance with the regulations of the country of use. In particular, regulations governing the disposal of batteries, consumables and electronic and electrical systems must be observed.

  • Page 147: G Maintenance, Inspection And Changing Of Maintenance Parts Requiring Replacement

    G Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement WARNING! Lack of maintenance can result in accidents Failure to perform regular maintenance and inspections can lead to truck failure and poses a potential hazard to personnel and equipment. uThorough and expert maintenance and inspections are among the most important requirements for the safe operation of the industrial truck.

  • Page 148: Maintenance Contents Esd

    Maintenance Contents ESD 220 Issued on: 2019-10-09 16:30 Owner To be performed every 50 service hours, but at least once a week. 1.1.1 Maintenance contents 1.1.1.1 Standard equipment Brakes Test the function of the brakes Hydraulic operations Lubricate the load chains.
  • Page 149 1.1.1.2 Optional equipment Lead-acid battery, international Power supply Correct the battery acid level using demineralised water. Lead-acid battery Power supply Correct the battery acid level using demineralised water.
  • Page 150 1.1.2 Inspection contents 1.1.2.1 Standard equipment The following points must be checked: Electrical system Warning and safety devices are in accordance with the operating instructions Function of display and controls The function of the emergency disconnect and for damage Power supply Battery and battery components for damage The function and secure seating of the battery connector and for damage Travel...
  • Page 151 1.1.2.2 Optional equipment The following points must be checked: Lead-acid battery, international Power supply Battery and battery components for damage Battery cable connections are secure Lead-acid battery Power supply Battery cable connections are secure...

  • Page 152: Customer Service

    Customer Service 1.2.1 Maintenance contents In accordance with the ESD 220 service interval, to be performed every 1000 service hours, but at least once a year. 1.2.1.1 Standard equipment Brakes Test the function of the brakes Measure the air gap of the magnetic brake.
  • Page 153 1.2.1.2 Optional equipment Data radio System components Clean the scanner and terminal. Lead-acid battery, international Power supply Clean and grease the battery terminals. Clean the battery. Measure the acid density and battery voltage. Correct the battery acid level using demineralised water. Lead-acid battery Power supply Clean and grease the battery terminals.
  • Page 154 1.2.2 Inspection contents The following points must be checked: 1.2.2.1 Standard equipment Electrical system Cables and engine are secure and for damage Warning and safety devices are in accordance with the operating instructions Function of display and controls The function of the emergency disconnect and for damage Contactors and/or relays for wear and damage The electric wiring for damage (insulation damage, connections) and the fuse ratings Carbon brushes for wear...
  • Page 155 Hydraulic operations Load chain mounting elements and chain pins for wear and damage The mast rollers and their running surfaces for wear and damage The mast stops for damage The function of the hydraulic system The forks or load handler for wear and damage Tie/plunger rods are uniformly adjusted and for wear and damage Steering The function of the electric steering and its components and for wear and damage...
  • Page 156 1.2.2.2 Optional equipment Electrolyte circulation Power supply The function of the hose connections and pump Aquamatik Power supply The function of the Aquamatik plug, hose connections and float and for leaks The function of the flow indicator and for leaks Load backrest Hydraulic operations Proper securing of the attachment to the truck and the load-bearing components for...
  • Page 157 1.2.3 Maintenance parts The manufacturer recommends the replacement of the following maintenance parts at the specified intervals. 1.2.3.1 Standard equipment maintenance part service hours months Hydraulic oil 2000 Hydraulic system - breather filter 2000 Transmission oil 2000 1.2.3.2 Optional equipment Cold-store application maintenance part service hours...
  • Page 159 Foreword Notes to the operating instructions The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide sufficient instruction for the safe operation of the traction battery. The information is presented in a precise and clear manner. The chapters are arranged by letter and the pages are numbered continuously.
  • Page 160 Copyright 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...
  • Page 161 Contents Traction battery ............... Correct Use and Application..............Data plate ....................Safety Instructions, Warning Indications and other Notes ....... Lead acid batteries with armour plated cells and liquid electrolyte..Description....................Operation....................Servicing lead-acid batteries with armour plated cells......PzV and PzV-BS lead-acid batteries with sealed armour plated cells..Description....................

  • Page 163: A Traction Battery

    A Traction battery Correct Use and Application This appendix does not apply to trucks with lithium-ion batteries. Further documentation for lithium-ion batteries can be obtained from the supplied documents. Failure to observe the operating instructions, carrying out repairs with non-original spare parts, tampering with the battery or using electrolyte additives will invalidate the warranty.
  • Page 164 Safety instructions and warning information...

  • Page 165: Safety Instructions, Warning Indications And Other Notes

    Safety Instructions, Warning Indications and other Notes Used batteries must be treated as hazardous waste. These batteries are marked with the recycling symbol and the sign showing a crossed-out rubbish bin, and should not be disposed of with ordinary household waste. Buy-back terms and type of recycling are to be agreed with the manufacturer as described in §...

  • Page 166: Lead Acid Batteries With Armour Plated Cells And Liquid Electrolyte

    Lead acid batteries with armour plated cells and liquid electrolyte Description Jungheinrich traction batteries are lead acid batteries with armour plated cells and liquid electrolyte. The names of the traction batteries are PzS, PzB, PzS Lib and PzM. Name Explanation –...
  • Page 167 4.1.1 Battery nominal data Product Traction battery Nominal voltage 2.0 V x number of cells Rated capacity C5 See data plate Discharge current C5/5h Nominal electrolyte density 1.29 kg/l Nominal temperature 30 °C System rated electrolyte level up to "Max" electrolyte level marking Limit temperature 55 °C 1.

  • Page 168: Operation

    Operation 4.2.1 Commissioning unfilled batteries The operations required must be carried out by the manufacturer's customer service department or a customer service organisation authorised by the manufacturer. 4.2.2 Commissioning filled and charged batteries Battery cell cross section Top view of a battery cell Checks and operations to be performed before starting daily work Procedure •...
  • Page 169 4.2.3 Discharging the battery To achieve an optimum useful life avoid operational discharge of more than 80% of nominal capacity (full discharge). This corresponds to a minimum electrolyte density of 1.13 kg/l at the end of the discharge. Fully or partially discharged batteries must be re-charged immediately and not left unattended.
  • Page 170 The electrolyte temperature rises by approx. 10°C during charging. Charging should therefore only begin when the electrolyte temperature is below 45°C. The electrolyte temperature of batteries must be at least +10°C before charging. Otherwise the battery will not charge correctly. Below 10°C the battery is insufficiently charged with standard charging systems.

  • Page 171: Servicing Lead-Acid Batteries With Armour Plated Cells

    Servicing lead-acid batteries with armour plated cells 4.3.1 Quality of Water for Adding Electrolyte The quality of the water used to add electrolyte must correspond to purified or distilled water. Purified water can be produced through distillation or ion exchangers and is then suitable for the production of electrolyte. 4.3.2 Daily Battery cell cross section Top view of a battery cell...
  • Page 172 4.3.3 Weekly – After re-charging, carry out a visual inspection for dirt and physical damage. – If the battery is charged regularly according to the IU characteristic, carry out a compensation charge. 4.3.4 Monthly – Towards the end of the charging process measure and record the voltages of all the cells with the charger switched on.

  • Page 173: Pzv And Pzv-Bs Lead-Acid Batteries With Sealed Armour Plated Cells

    PzV and PzV-BS lead-acid batteries with sealed armour plated cells Description PzV batteries are sealed batteries with fixed electrolytes, to which no water can be added over the entire lifespan of the battery. Relief valves are used as plugs which are destroyed when opened.

  • Page 174: Operation

    Operation 5.2.1 Commissioning Checks and operations to be performed before starting daily work Procedure • Make sure the battery is in physically good condition. • Make sure the terminals are correct (positive to positive and negative to negative) and check that contacts on the battery terminal conducting system are secure. •...
  • Page 175 NOTE Charging the battery incorrectly can result in material damage. Incorrect battery charging can result in overloading of the electric wires and contacts, hazardous gas formation and electrolyte leakage from the battery cell. Always charge the battery with DC current. All DIN 41773 charging procedures are permitted in the format approved by the manufacturer.
  • Page 176 Charging the battery Requirements – Electrolyte temperature between +15°C and +35°C Procedure • Open or take off the tray lid or covers from the battery compartment. • Connect the battery to the switched off charger, ensuring the terminals are connect (positive to positive and negative to negative).

  • Page 177: Servicing Pzv And Pzv-Bs Lead-Acid Batteries With Sealed Armour Plated Cells

    Servicing PzV and PzV-BS lead-acid batteries with sealed armour plated cells Do not add water! 5.3.1 Daily – Charge the battery after each discharge. 5.3.2 Weekly – Visually inspect for dirt and physical damage. 5.3.3 Every three months – Measure and record the overall voltage. –...

  • Page 178: Aquamatik Water Replenishment System

    Aquamatik water replenishment system Water replenishment system design > 3 m Water container Tap connection with ball cock Flow indicator Shut-off cock Locking coupling Battery lock connector...

  • Page 179: Functional Description

    Functional Description The Aquamatik water replenishment system is used to adjust the rated electrolyte level automatically on traction batteries for industrial trucks. The battery cells are interconnected through hoses and are attached to the water supply (e.g. water container) through a plug connection. When the shut-off cock is opened all the cells are filled with water.

  • Page 180: Filling Time

    Filling time The filling time for a battery depends on the electrolyte level, the ambient temperature and the filling pressure. Filling ends automatically. The water supply line must be disconnected from the battery when the water has been filled. Water quality The quality of the water used to fill up electrolyte must correspond to purified or distilled water.

  • Page 181: Electrolyte Circulation

    Electrolyte circulation Functional Description Electrolyte circulation ensures the supply of air during charging to mix the electrolyte, thereby preventing any acid layer, shortening the charge time (charge factor approx. 1.07) and reducing the formation of gas during charging. The charger must be suitable for the battery and electrolyte circulation.
  • Page 182 NOTE If an installed electrolyte circulation system is seldom used or not used at all, or if the battery is subjected to severe temperature fluctuations, the electrolyte may flow back into the hose system. Attach a separate coupling system to the air inlet line, such as: locking coupling to the battery side and through-coupling to the air supply side.

  • Page 183: Cleaning Batteries

    Cleaning batteries Batteries and trays must be cleaned in order to – Maintain cell insulation and protect cells from ground or external conductive parts. – Avoid damage from corrosion and stray currents. – Avoid excessive and varying automatic discharge of the individual cells or block batteries due to stray currents.
  • Page 184 Cleaning the battery with a high pressure cleaner Requirements – Cell connectors tight, plugged in securely – Cell plugs closed Procedure • Follow the high pressure cleaner's user instructions. • Do not use any cleaning additives. • Observe the permissible cleaning device temperature setting of 140°C. This generally ensures that the temperature does not exceed 60°C at a distance of 30cm behind the outlet nozzle.

  • Page 185: Storing The Battery

    Storing the battery NOTE The battery should not be stored for longer than 3 months without charging as otherwise it will no longer be functional. If the battery is to be taken out of service for a long period, it should be stored fully charged in a dry room protected from frost.

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