Jungheinrich ESC 316z, ESC 316 Operating Instructions Manual

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51314819
ESC 316/316z
Operating instructions G
ESC 316z
ESC 316
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11.1 4 E N
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11.1 4 E N
Foreword
Notes on the operating instructions
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide sufficient instruction for the safe operation of the industrial truck. The information is provided clearly and concisely. The chapters are arranged by letter and the pages are numbered continuously.
The operator manual details different industrial truck models. When operating and servicing the industrial truck, make sure that the particular section applies to your truck model.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to alter the design, equipment and technical features of the system. No guarantee of particular features of the truck should therefore be assumed from the present operating instructions.
Safety notices and text mark-ups
Safety instructions and important explanations are indicated by the following graphics:
DANGER!
Indicates an extremely hazardous situation. Failure to comply with this instruction will result in severe irreparable injury and even death.
WARNING!
Indicates an extremely hazardous situation. Failure to comply with this instruction may result in severe irreparable injury and even death.
CAUTION!
Indicates a hazardous situation. Failure to comply with this instruction may result in slight to medium injury.
NOTE
Indicates a material hazard. Failure to comply with this instruction may result in material damage.
Z Used before notices and explanations.
t Indicates standard equipment o Indicates optional equipment
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Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Am Stadtrand 35 22047 Hamburg - Germany
Tel: +49 (0) 40/6948-0
www.jungheinrich.com
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11.1 4 E N
Table of contents
A Correct Use and Application ................................................... 9
1 General.................................................................................................... 9
2 Correct application................................................................................... 9
3 Approved application conditions.............................................................. 10
4 Proprietor responsibilities ........................................................................ 11
5 Adding attachments and/or optional equipment ...................................... 11
B Truck Description .................................................................... 13
1 Application ............................................................................................... 13
1.1 Truck models and rated capacity............................................................. 13
2 Travel direction definition......................................................................... 14
3 Assemblies and Functional Description................................................... 15
3.1 Assembly Overview ................................................................................. 15
3.2 Functional Description ............................................................................. 16
4 Technical Specifications .......................................................................... 18
4.1 Performance data .................................................................................... 18
4.2 Dimensions .............................................................................................. 19
4.3 Weights.................................................................................................... 22
4.4 Tyre type.................................................................................................. 22
4.5 Mast versions .......................................................................................... 23
4.6 EN norms................................................................................................. 24
4.7 Conditions of use ..................................................................................... 25
4.8 Electrical requirements ............................................................................ 25
5 Identification points and data plates ........................................................ 26
5.1 Data plate ................................................................................................ 27
5.2 Truck capacity plate................................................................................. 28
C Transport and Commissioning ................................................ 29
1 Lifting by crane ........................................................................................ 29
2 Transport ................................................................................................. 30
3 Using the Truck for the First Time ........................................................... 31
D Battery - Servicing, Recharging, Replacement ....................... 33
1 Safety Regulations Governing the Handling of Lead-Acid Batteries ....... 33
2 Battery types............................................................................................ 35
3 Exposing the battery................................................................................ 36
4 Charging the battery ................................................................................ 37
5 Battery removal and installation .............................................................. 39
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E Operation ................................................................................ 43
1 Safety Regulations for the Operation of the Forklift Truck....................... 43
2 Displays and Controls.............................................................................. 45
2.1 Battery discharge indicator ...................................................................... 48
2.2 Battery discharge monitor........................................................................ 49
3 Preparing the Truck for Operation ........................................................... 50
3.1 Checks and operations to be performed before starting daily operation . 50
3.2 Preparing the truck for operation ............................................................. 51
3.3 Checks and operations to be carried out when the truck is operational .. 52
3.4 Parking the truck securely ....................................................................... 53
3.5 Entry and exit........................................................................................... 55
3.6 Adjusting the floor plate height ................................................................ 56
3.7 Adjusting the driver’s seat ....................................................................... 57
4 Industrial Truck Operation ....................................................................... 58
4.1 Safety regulations for truck operation ...................................................... 58
4.2 Emergency Disconnect............................................................................ 61
4.3 Travel....................................................................................................... 63
4.4 Steering ................................................................................................... 65
4.5 Brakes ..................................................................................................... 66
4.6 Load handler raise/lower ......................................................................... 68
4.7 Lifting, transporting and depositing loads ................................................ 72
5 Troubleshooting....................................................................................... 75
5.1 Truck does not start ................................................................................. 76
5.2 Load cannot be lifted ............................................................................... 76
6 Operating the truck without its own drive system .................................... 77
7 Load handler emergency lowering .......................................................... 79
8 Optional equipment ................................................................................. 81
8.1 Display and control unit ........................................................................... 81
8.2 Setting the time........................................................................................ 82
8.3 Keypad (CanCode) (o) ........................................................................... 83
8.4 ISM access module (o)........................................................................... 101
F Industrial Truck Maintenance .................................................. 103
1 Operational Safety and Environmental Protection................................... 103
2 Maintenance Safety Regulations............................................................. 104
2.1 Working on the electrical system ............................................................. 105
2.2 Consumables and used parts .................................................................. 105
2.3 Wheels..................................................................................................... 105
2.4 Hydraulic system ..................................................................................... 106
2.5 Lift Chains................................................................................................ 107
3 Lubricants and Lubrication Schedule ...................................................... 108
3.1 Handling consumables safely .................................................................. 108
3.2 Lubrication Schedule ............................................................................... 110
3.3 Consumables........................................................................................... 111
4 Maintenance and repairs ......................................................................... 112
4.1 Preparing the truck for maintenance and repairs .................................... 112
4.2 Lifting and jacking up the truck safely...................................................... 112
4.3 Cleaning .................................................................................................. 113
4.4 Drive compartment cover disassembly/assembly ................................... 116
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4.5 Checking the hydraulic oil level ............................................................... 117
4.6 Tightening the wheel nuts........................................................................ 118
4.7 Checking electrical fuses ......................................................................... 119
4.8 Restoring the truck to service after maintenance and repairs ................. 120
5 Decommissioning the industrial truck ...................................................... 121
5.1 Prior to decommissioning ........................................................................ 121
5.2 During decommissioning ......................................................................... 121
5.3 Restoring the truck to service after decommissioning ............................. 122
6 Safety tests to be performed at intervals and after unusual incidents ..... 123
7 Final de-commissioning, disposal............................................................ 123
8 Human vibration measurement ............................................................... 123
9 Servicing and Inspection ......................................................................... 124
10 ESC 316 maintenance checklist.............................................................. 125
10.1 Operating company ................................................................................. 125
10.2 Customer service..................................................................................... 126
11 ESC 316z maintenance checklist ............................................................ 130
11.1 Operating company ................................................................................. 130
11.2 Customer service..................................................................................... 131
G Traction Battery Appendix....................................................... 135
1 Correct Use and Application.................................................................... 135
2 Data plate ................................................................................................ 135
3 Safety Instructions, Warning Indications and other Notes....................... 136
4 Lead acid batteries with armour plated cells and liquid electrolyte.......... 137
4.1 Description............................................................................................... 137
4.2 Operation ................................................................................................. 138
4.3 Servicing lead-acid batteries with armour plated cells............................. 141
5 PzV and PzV-BS lead-acid batteries with sealed armour plated cells..... 142
5.1 Description............................................................................................... 142
5.2 Operation ................................................................................................. 143
5.3 Servicing PzV and PzV-BS lead-acid batteries with sealed armour plated
cells ......................................................................................................... 146
6 Aquamatik water replenishment system.................................................. 147
6.1 Water replenishment system design ....................................................... 147
6.2 Functional Description ............................................................................. 148
6.3 Adding water............................................................................................ 148
6.4 Water pressure ........................................................................................ 148
6.5 Filling time ............................................................................................... 149
6.6 Water quality............................................................................................ 149
6.7 Battery tubing .......................................................................................... 149
6.8 Operating temperature ............................................................................ 149
6.9 Cleaning measures.................................................................................. 150
6.10 Service mobile vehicle ............................................................................. 150
7 Electrolyte circulation............................................................................... 151
7.1 Functional Description ............................................................................. 151
8 Cleaning batteries.................................................................................... 153
9 Storing the battery ................................................................................... 155
10 Troubleshooting....................................................................................... 155
11 Disposal................................................................................................... 155
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A Correct Use and Application
1 General
The truck must be used, operated and serviced in accordance with the present instructions. All other types of use are beyond its scope of application and may result in damage to personnel, the industrial truck or property.
2 Correct application
NOTE
The maximum load and load distance are indicated on the capacity plate and must not be exceeded. The load must rest on the load handler or be lifted by an attachment approved by the manufacturer. The load must be fully raised,see "Lifting, transporting and depositing loads" on page 72.
The following operations are in accordance with regulations and are permitted: – Lifting and lowering loads. – Transporting lowered loads.
The following operations are prohibited: – Travelling with a raised load (>300 mm). – Carrying and lifting passengers. – Pushing or pulling loads.
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3 Approved application conditions
– Operation in industrial and commercial environments. – Permissible temperature range 5°C to 40°C. – Operation only on secure, level surfaces with sufficient capacity. – Do not exceed the permissible surface and spot load limits on the travel routes. – Operation only on routes that are visible and approved by the operating company. – Negotiating inclines up to a maximum of 12 %. – Do not travel across or at an angle on inclines. Travel with the load facing uphill. – Operation in partially public traffic.
WARNING!
Use under extreme conditions
Using the truck under extreme conditions can result in malfunctions and accidents. XSpecial equipment and authorisation are required if the truck is to be constantly
used in extreme conditions, especially in dusty or corrosive atmospheres.
XThe truck cannot be used in areas at risk of explosion. XIn adverse weather conditions (thunder, lightning) the industrial truck must not be
operated outside or in endangered areas.
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4 Proprietor responsibilities
For the purposes of the present operating instructions the “operating company” is defined as any natural or legal person who either uses the industrial truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting) the proprietor is considered the person who, in accordance with existing contractual agreements between the owner and user of the industrial truck, is charged with operational duties. The proprietor must ensure that the industrial truck is used only for the purpose it is intended for and that danger to life and limb of the user and third parties are excluded. Furthermore, accident prevention regulations, safety regulations and operating, servicing and repair guidelines must be followed. The operating company must ensure that all users have read and understood these operating instructions.
NOTE
Failure to comply with the operating instructions invalidates the warranty. The same applies if improper work is carried out on the truck by the customer or third parties without the permission of the manufacturer.
5 Adding attachments and/or optional equipment
The mounting or installation of additional equipment which affects or enhances the performance of the industrial truck requires the written permission of the manufacturer. Local authority approval may also need to be obtained. Local authority approval however does not constitute the manufacturer’s approval.
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B Truck Description
1 Application
The ESC 316/316z is a four-wheel, electric side-seated pallet truck with a driver's seat equipped with an electric steering wheel system. The ESC 316/316z is designed to transport goods on level surfaces. The wheel arm lift, also called initial lift (ESC 316z only), increases the ground clearance when transporting loads on uneven ground. The truck can lift open bottom or diagonal board pallets beyond the area of the load wheels as well as roll cages. Loads can be stacked, unstacked and transported over long distances up to 5,25 m depending on the mast type.
1.1 Truck models and rated capacity
The rated capacity depends on the model. The rated capacity can be derived from the model name.
The rated capacity is not generally the same as the permissible capacity. The capacity can be found on the capacity plate attached to the truck.
ESC316
ESC Model name
3Series
16 Rated capacity x 100 kg
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2 Travel direction definition
The following determinations have been made for travel direction specification:
Item Travel direction
1 Left 2 Drive direction 3 Load direction 4 Right
1
2
3
4
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3 Assemblies and Functional Description
3.1 Assembly Overview
Item Description Item Description
5 t Discharge indicator 14 t Armrest 6 t Key switch 15 t Floor plate height adjuster 7 o Control / display unit 16 t Steering wheel 8 o CanCode code lock 17 t Battery
9 o ISM access module 18 t Load wheels 10 t Overhead guard 19 t Load handler 11 t Mast 20 t Deadman switch 12 t Multi-Pilot 21 t Seat cover 13 t Emergency Disconnect switch
t = Standard equipment o = Optional equipment
56 78 79
10
11
12
14 15
17
16
20
21
18
19
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3.2 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 mast grille (o) protects the operator from moving mast parts and the load. The overhead guard protects the operator from falling objects.
Emergency stop safety feature
The emergency stop is activated by the traction controller. Each time the truck is switched on the system performs a self diagnosis. The steering controller sends a system status signal which is monitored by the traction controller. If the signal fails to appear or a fault is identified the truck automatically brakes to a halt. Control displays on the control and display unit (o) indicate the emergency stop.
Deadman switch
The deadman switch ensures that the driver's feet do not extend outside the truck during travel. The deadman switch in the foot compartment must be depressed to enable the driver to operate the truck. Lifting and travel are inhibited if the operator takes his foot off the deadman switch. Steering and braking remain enabled.
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. The operating voltage of the truck's electrical system is 24 volts.
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11.1 4 E N
Drive system
A fixed AC three-phase motor actuates the drive wheel via a bevel spur gearbox. The electronic traction controller ensures smooth drive-motor-speed control and hence smooth starting, powerful acceleration and electrically controlled braking with energy regeneration. The driver can choose from 3 travel programs depending on the load and the environment: from high-performance to energy-saving.
Controls and displays
Ergonomic controls ensure fatigue-free operation for sensitive application of the travel and hydraulic operations. The charge indicator shows the available battery capacity. The control and display unit (o) shows the key operator information such as battery capacity, service hours and event messages.
Steering
The operator steers with an ergonomically inclined steering wheel. The steering motion is transmitted from the steering controller via a steer motor directly to the ring gear of the pivoted drive system. The steering wheel has a steer angle of 180°. Automatic travel speed reduction as a function of the steer angle (Curve Control o) is optionally available.
Hydraulic system
Infinitely variable lifting and lowering operations are performed by moving the Multi­Pilot 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. When the lift button is pressed the wheel arms are raised at an even speed; when the lower button is pressed the wheel arms are lowered. When the wheel arms are raised (initial lift) the lift height is restricted. When the lift height exceeds 1800 mm the wheel arms lower automatically. The wheel arms can only be lowered below this lift height.
Mast
The high strength steel sections are narrow, enabling excellent visibility of the load handler. The lift rails and the load handler run on permanently-lubricated and hence maintenance-free angled rollers.
3.2.1 Hourmeter
Z Prepare the truck for operation, see "Preparing the truck for operation" on page 51
or see "Keypad (CanCode) (o)" on page 83.
Service hours are counted while the truck is operational and the deadman button is pressed.
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4 Technical Specifications
Z The technical specifications comply with the German "Industrial Truck Data Sheet"
Guidelines. Technical modifications and additions reserved.
4.1 Performance data
ESC316 ESC316z
Q Rated capacity 1600 kg
Travel speed with / without rated load
9.1/ 9.1 km/h
Lift speed with / without rated load
0.13 / 0.24 0.14 / 0.23 m/s
Lower speed with / without rated load
0.42 / 0.42 0.42 / 0.38 m/s
Max. gradeability with / without rated load
7 / 12 %
Drive motor, Output S2 60 min
2.8 kW
Lift motor, Output S3 15%
3.0 (8 %) kW
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4.2 Dimensions
b11
b5
b2
x
Wa
e
a/2
Ast
a/2
h13
h2
h3
h1
h4
l2
y
l1
l
c
m2
s
187
1278
h6
Q
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ESC316 ESC316z
c Load centre distance 600 mm
x
Load distance lowered / raised
860 874 / 796 mm
y
Wheelbase lowered / raised
1648 1692 / 1514 mm
h1 Mast height retracted 1995 mm
h2 Free lift 100 mm
h3 Lift 2800 mm
h4 Mast height extended 3422 mm
h5 Wheel arm lift (initial lift) - 125 mm
h6
Height above overhead guard
2095 mm
h7 Seat height / standing height 950 mm
h13 Lowered height 90 mm
l1 Length 2125 2155 mm
l2 Headlength 975 1005 mm
b2 Overall width (drive) 930 mm
b5
Overall width of the load handler
570
mm
s/e/l Load handler dimensions 60 / 185 / 1150 mm
b10 Track width, drive direction 645 mm
b11 Track width, load direction 385 mm
m1 Ground clearance, laden,
below mast
30 -
m2
Ground clearance, centre wheelbase
30 25
mm
Ast
Working aisle width @ pallet 1000x1200 transv.
2310 / 2643 2383 / 2720 mm
Ast
Working aisle width @ pallet 800x1200 length
2360 / 2549 2433 / 2623 mm
Wa
Turning radius lowered / raised
1863 1907 / 1830
mm
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11.1 4 E N
b11
b5
b2
x
Wa
e
a/2
Ast
a/2
h13
h2
h3
h1
h4
l2
y
l1
l
c
m2
s
187
1278
h6
Q
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4.3 Weights
4.4 Tyre type
ESC316 ESC316z
Net weight excl. battery 1366 1305 kg
Axle loading, laden Drive direction / load direction + battery
1459 / 1228 1432 / 1857 kg
Axle loading, unladen Drive direction / load direction + battery
1891 / 518 1190 / 495 kg
Battery weight 380 kg
ESC316 ESC316z
Tyres Vulkollan
Wheel size, drive direction 230 x 77 mm
Wheel size, load direction 85 x 85 mm
Caster wheel (twin roller) 140 x 54 mm
Wheels, no. Drive direction (x = driven)
2 + 1x
Wheels, no. Load direction
4
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4.5 Mast versions
*) With these masts the view of the load handler is restricted by the top cross member.
h1 h2 h3 h4 h6
ZT
1995 100 2800* 3372 2093 mm 2145 100 3100 3672 2243 mm 2345 100 3500 4072 2288 mm 2595 100 4000 4572 2288 mm 2695 100 4200 4772 2288 mm
ZZ
1945 1373 2800* 3372 2093 mm 2095 1523 3100 3672 2243 mm 2295 1723 3500 4072 2288 mm 2545 1973 4000 4572 2288 mm 2645 2073 4200 4772 2288 mm
DZ
1945 1376 4200* 4770 2093 mm 2295 1726 5250 5820 2288 mm
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4.6 EN norms
Noise emission level
– ESC 316/316z: 61 dB(A)
in accordance with 12053 as harmonised with ISO 4871.
Z The noise emission level is calculated in accordance with standard procedures and
takes into account the noise level when travelling, lifting and when idle. The noise level is measured at the level of the driver's ear.
Vibration
– ESC 316/316z: 0,73 m/s²
in accordance with EN 13059
Z The vibration acceleration acting on the body in the operating position is, in
accordance with standard procedures, the linearly integrated, weighted acceleration in the vertical direction. It is calculated when travelling over thresholds at constant speed. These recordings were taken on a single occasion for the industrial truck and must not be confused with the human vibrations of the "2002/ 44/EC/Vibrations" operator directive. The manufacturer offers a special service to measure these human vibrations, see "Human vibration measurement" on page 123.
Electromagnetic compatibility (EMC)
The manufacturer confirms that the truck adheres to the limits for electromagnetic emissions and resistance as well as the static electricity discharge test in accordance with EN 12895 as well as the standardised instructions contained therein.
Z No changes to electric or electronic components or their arrangement may be
made without the written agreement of the manufacturer.
WARNING!
Medical equipment can be damaged by non-ionised radiation
Electrical equipment on the truck emitting non-ionised radiation (e.g. wireless data transmission) can affect operators' medical equipment (pacemakers, hearing aids etc.) and result in malfunctions. Consult with a doctor or the medical equipment manufacturer to clarify whether it can be used near the industrial truck.
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11.1 4 E N
4.7 Conditions of use
Ambient temperature
– operating at 5°C to 40°C
Z Special equipment and authorisation are required if the truck is to be used
continually in conditions of extreme temperature or condensing air humidity fluctuations.
4.8 Electrical requirements
The manufacturer certifies compliance with the requirements for the design and manufacture of electrical equipment, according to EN 1175 "Industrial Truck Safety ­Electrical Requirements", provided the truck is used according to its purpose.
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5 Identification points and data plates
Item Description
22 Warning: “Do not step under the load handler” 23 Warning: "Do not reach through the mast" 24 Raise / lower wheel arms 25 Capacity plate 26 Multi-Pilot 27 Floor plate adjustment 28 Data plate 29 Test plaque 30 Attachment points for lifting by crane 31 Serial number 32 Model description
X.XXXX.XX.XX
22
23
24
25
26
27
28
30 31
29
32
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5.1 Data plate
Z For queries regarding the truck or ordering spare parts always quote the truck serial
number (34).
33 34 3635 37
44
40
43
42
41
3938
Item Description Item Description
33 Type 39 Year of manufacture 34 Serial number 40 Load centre (mm) 35 Rated capacity (kg) 41 Output 36 Battery voltage (V) 42 Min./max. battery weight (kg) 37 Net weight w.o. battery (kg) 43 Manufacturer 38 Option 44 Manufacturer’s logo
11.1 4 E N
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5.2 Truck capacity plate
The rating plate (45) indicates the maximum capacity Q (in kg) for a given load centre C (in mm) and corresponding lift height H (in mm) for the truck with a horizontal load.
Example of how to calculate the maximum capacity: With a load centre distance C of 600 mm and a maximum lift height H of 3600 mm. the max. capacity Q is 1105 kg.
600
X.XXXX.XX.XX
11053600
45
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C Transport and Commissioning
1 Lifting by crane
WARNING!
Incorrect lifting by crane can result in accidents
Improper use or use of unsuitable lifting gear and can cause the truck to fall when being lifted by crane.
Prevent the truck from hitting other objects during lifting, and avoid uncontrolled movements. If necessary, secure the truck with guide ropes.
XThe truck should only be loaded by personnel trained in the use of lifting slings and
tools.
XWear personal protective equipment (e. g. safety shoes, safety helmet, hi-vis
jacket, protective gloves, etc.) when loading by crane.
XDo not stand under suspended loads. XDo not enter or stand in a hazardous area. XAlways use lifting gear with sufficient capacity (for truck weight see truck rating
plate).
XAlways attach the crane lifting gear to the prescribed strap points and prevent them
from slipping.
XUse the lifting slings only in the prescribed loading direction. XCrane slings should be fastened in such a way that they do not come into contact
with any attachments when lifting.
Lifting the truck by crane
Requirements
– Park the truck securely, see "Parking the
truck securely" on page 53.
– Remove any mast guards.
Tools and Material Required
– Lifting gear – Crane lifting gear
Procedure
• Secure the lifting slings to the strap points (30).
The truck can now be lifted by crane.
30
30
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