Jungheinrich ESE 220 Operating Instructions Manual
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Jungheinrich ESE 220 Operating Instructions Manual

Pallet truck
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ESE 220/320
Operating instructions
51163703
04.19
03.10
en-GB
ESE 220
ESE 320

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Summary of Contents for Jungheinrich ESE 220

  • Page 1 ESE 220/320 03.10 Operating instructions en-GB 51163703 04.19 ESE 220 ESE 320...
  • Page 3 Declaration of Conformity Manufacturer Jungheinrich AG, 22039 Hamburg, Germany Description Industrial truck Type Option Serial no. Year of manufacture ESE 220 ESE 320 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 Troubleshooting Truck does not start Load cannot be lifted Operating the truck without its own drive system Optional equipment Brake Pedal in Footwell with ESE 220 Display and control unit Setting the time Keypad (CanCode) (o) ISM access module (o)
  • Page 9 Final de-commissioning, disposal Human vibration measurement Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement Maintenance Contents ESE 220 Owner Customer Service Maintenance Contents ESE 320 Owner Customer Service Traction Battery Appendix Correct Use and Application Data plate Safety Instructions, Warning Indications and other Notes...

  • Page 11: 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 12: Approved Application Conditions

    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 point loading on the travel paths. –...

  • Page 13: 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 15: B Truck Description

    The ESE 220/320 is a four-wheel, electric side-seated pallet truck with a driver's seat equipped with an electric steering wheel system. The ESE 220/320 is designed to transport goods on level surfaces. The truck can lift open bottom or diagonal board pallets beyond the area of the load wheels as well as roll cages.

  • Page 16: 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 17: Assemblies And Functional Description

    Assemblies and Functional Description Assembly Overview Item Description Item Description t Charge status indicator 12 t Armrest t Key switch 13 t Floor-plate height adjuster o Control/display unit 14 t Steering wheel o CanCode code lock 15 t Load rollers o ISM access module 16 t Battery 10 t multiPILOT...

  • Page 18: Functional Description

    Functional Description Safety equipment An enclosed, smooth truck geometry with rounded edges ensures safe handling of the truck. The wheels are surrounded by a solid skirt offering collision protection. Activating the emergency disconnect switch rapidly cuts out all electrical functions in hazardous situations.
  • Page 19 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.

  • Page 20: Technical Specifications

    Technical Specifications The technical specification is given according to the German guideline "Type sheets for industrial trucks". Technical modifications and additions reserved. Performance data ESE 220 ESE 320 Q Rated capacity 2000 Travel speed 10/12.5 km/h with/without load Lift speed 0.06/0.07...

  • Page 21: Dimensions

    Dimensions ESE 220 ESE 320 Load centre distance Load distance Wheelbase 1535 1541 Lift Seat height 1020 h13 Lowered height...
  • Page 22 ESE 220 ESE 320 Overall length 2009 Length including fork shank b2/b1 Overall width Overall width of the load handler b10 Track Track s / e / Load-handler dimensions 60 / 185 / 1150 Ground clearance, centre of wheelbase Aisle width for...

  • Page 23: Weights

    Weights ESE 220 ESE 320 Net weight including battery 1062 1074 Axle load with load 1896 / 1142 1902 / 1182 front / rear Axle load without load 258 / 808 264 / 816 front / rear Battery weight Tyre type...

  • Page 24: En Norms

    EN norms Continuous sound pressure level – ESE 220/320: 73 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 25: Specifications According To Red Guideline (Radio Equipment Directive) For Radio Units

    Specifications according to RED guideline (Radio Equipment Directive) for radio units The table contains any components installed according to the European Directive 2014/53/EU. The table shows the affected frequency range and the emitted transmission power for each component. Component Frequency range Transmission power Radio module (ISM Online) 433,05 - 434,79 MHz...

  • Page 26: Identification Points And Data Plates

    Identification Points and Data Plates Item Description Load handler lift/lower Truck capacity plate multiPILOT Floor-plate adjustment Data plate Inspection plaque Attachment points for loading by crane Model description Serial number...

  • Page 27: Data Plate

    Data plate Item Description Item Description Type Year of manufacture Serial number Load centre distance (mm) Rated capacity (kg) Nominal power Battery voltage (V) Min./max. battery weight (kg) Net weight without battery (kg) Manufacturer Option Manufacturer's logo For queries regarding the truck or when ordering spare parts, always quote the truck serial number (29).

  • Page 28: Truck Capacity Plate

    Truck capacity plate The capacity plate (40) gives the maximum load-bearing capacity (Q) of the truck in kg assuming the load on the load handler is evenly distributed.

  • Page 29: 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 30: Transport

    Transport WARNING! Uncontrolled movement during transport Improper fastening of the truck and mast during transport can result in serious accidents. uLoading is only to be carried out by specially trained staff. The specialist personnel must be instructed in the securing of loads on road vehicles and in the use of load- securing equipment.
  • Page 31 Securing the truck for transport Requirements – Load the truck. – Truck parked securely, see page 60. 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 32: Using The Truck For The First Time

    Using the Truck for the First Time If the truck is delivered in multiple parts, setup and commissioning must only be performed by trained, authorised personnel. NOTICE Cold store trucks uTrucks designed for use in cold stores have a cold store hydraulic oil. uIf a truck with cold store oil is used outside the cold store, the lowering speeds may increase.

  • Page 33: D Battery - Servicing, Recharging, Replacement

    D Battery - Servicing, Recharging, Replacement Safety Regulations Governing the Handling of 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 34 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 35: 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 36: Exposing The Battery

    Exposing the battery CAUTION! Trapping hazard uMake sure there is nothing between the battery cover and the truck when you fit the battery cover. 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.
  • Page 37 • Fold up the arm rest (12). The battery connector (43) can be accessed. The battery retainer (42) is accessible on the ESE 220. On the ESE 320 the battery latch (44) is on the right-hand side of the truck.

  • Page 38: 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 39 Procedure • Complete charging in accordance with the charger operating instructions. • Disconnect the battery connector (43) from the charging cable (46) of the stationary charger. • Attach the battery connector (43) to the industrial truck. The truck is now ready for operation.

  • Page 40: 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 41 ESE 220 Removing the battery Requirements – Park the truck securely, see page 60. – Expose the battery, see page 36. Tools and Material Required – Battery replacement trolley (o) Procedure • Remove the battery connector (43) from the truck.
  • Page 42 ESE 320 Removing the battery Requirements – Park the truck on a horizontal surface. – Park the truck securely, see page 60. – Expose the battery, see page 36. Tools and Material Required – Battery replacement trolley (o) Procedure • Remove the battery connector (43) from the truck. •...
  • Page 43 Installing the battery Requirements – Park the truck securely, see page 60. Tools and Material Required – Battery replacement station (o) Procedure • Insert the battery (48) in the truck. Place the battery cable on the battery tray so that it cannot be damaged when the battery is installed.

  • Page 44: Checking The Battery Acid Level

    Checking the battery acid level ESE 220 Checking the battery acid level Requirements – Park the truck securely, see page 60. – Expose the battery, see page 36. Procedure • Remove the battery connector (43) from the truck. • Place the battery connector (43) on the battery (48).
  • Page 45 • Check the acid level of the battery (48). All indicators should show sufficient acid level, if necessary add battery water, see page 149. • Pull the battery lock (47) up. CAUTION! Unsecured battery An unsecured battery can result in trapping and injury uWear safety shoes when removing and installing the battery.
  • Page 46 Checking the battery acid level on the ESE 320 Requirements – Park the truck on a horizontal surface. – Park the truck securely, see page 60. – Expose the battery, see page 36. Procedure • Remove the battery connector (43) from the truck. •...

  • Page 47: 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 48 WARNING! Removing or disabling safety devices can cause accidents Removing or disabling safety devices such as the emergency disconnect switch, key switch, buttons, horn, strobe lights, sensors, panels, etc. can result in accidents and injury. uReport any defects immediately to your supervisor. uMark defective truck and take it out of service.

  • Page 49: Displays And Controls

    Displays and Controls 5, 7...
  • Page 50 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 51 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 52: 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 (57) 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 53: Battery Discharge Monitor

    Battery discharge monitor The standard setting for the battery discharge indicator / discharge monitor is based on standard batteries. When using maintenance-free or special batteries, the display and cut-out points of the battery discharge monitor must be set by manufacturer's service department.

  • Page 54: Preparing The Truck For Operation

    Preparing the Truck for Operation Checks and Operations to Be Performed Before Starting Daily Work 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 55: 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 (58). • Enter or leave the truck. CAUTION! No more than one person may operate the truck at a time.

  • Page 56: 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 57 • Set the floor plate (59) to the correct height by standing on it / discharging it. • Release the floor plate height adjustment button (13). The floor plate is now adjusted and locked at the required height...

  • Page 58: Preparing The Truck For Operation

    Preparing the truck for operation Switching on the truck Requirements – Checks and operations to be performed before starting daily work, see page 54. Procedure • Enter the operator position, see page 55. • Sit down on the driver's seat. •...

  • Page 59: 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 60: 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 61: 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 62 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 63 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 64: 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 65 Press the Emergency Disconnect switch Procedure • Press the Emergency Disconnect (11). 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 (11) 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 66: Deadman Button

    Deadman button The deadman button must be pressed to lift, lower or travel. If the deadman button is released during travel, the truck decelerates at the maximum rate until it stops. If the deadman button is released during lifting or lowering, the respective function cuts out immediately.
  • Page 67 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 68: Steering

    Steering Requirements – Start up the truck, see page 58. Procedure • Turn the steering wheel (14) to the left or right. The wheel position is indicated on the display (7) (o). The truck is steered in the required direction.

  • Page 69: 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 71: 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 72 4.7.1 Raising the load handler Requirements – Prepare the truck for operation, see page 58. – Deadman switch actuated, see page 66. Procedure • Press the "raise load handler" button (50) on the multiPILOT. Hold down the button until the load handler has reached the maximum height.

  • Page 73: Lifting, Transporting And Depositing Loads

    Lifting, transporting and depositing loads WARNING! Unsecured and incorrectly positioned loads can cause accidents. Before lifting a load unit, the driver 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 74 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...
  • Page 75 4.8.2 Transporting a load Requirements – Load raised correctly. – Load is not on the ground. – Perfect 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 76: 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 77: 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 64 Key switch set to O Set the key switch to “I” Deadman switch not pressed Press deadman switch Battery charge too low...

  • Page 78: 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.
  • Page 79 The brake is now released. The truck can be moved.
  • Page 80 Activating the brake Procedure • Use wedges to prevent the truck from moving. • Unscrew the two M5x45 screws (61) 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 81: Optional Equipment

    Optional equipment Brake Pedal in Footwell with ESE 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 (62) during travel until you reach the required deceleration.

  • Page 82: 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 83: Setting The Time

    Setting the time Setting the time (68) Procedure • Press the Shift key (79) for 8 secs. until the "Set Clock Time" menu is displayed. • Set the time with the Up (77) and Down (81) keys. • Confirm with the Shift key (79). •...

  • Page 84: Keypad (Cancode) (O)

    Keypad (CanCode) (o) 7.4.1 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 85 The keypad consists of 10 digit keys, a Set key (85) and a o key (87). 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 (82, 83, 84) show the travel program setting.
  • Page 86 7.4.2 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 64. The LED (86) lights up red. • Enter the operator code with the digit keys. When you have entered a valid operator code the LED (86) lights up green, the travel program selected is indicated by the corresponding LEDs (82,83,84) and the truck is switched on.
  • Page 87 7.4.4 Changing the Set-up 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 96. 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 88 Error displays changing the master code For the following events the LED (86) flashes red: Cause Remedy – Switch off the truck, see page 86. – Choose a different master code, see page 87. – New master code is already –...
  • Page 89 7.4.5 Add operator code Requirements – To prepare the truck for operation, see page 86. Procedure • Press the O key (87). • Enter the valid master code with the digit keys. When you enter the valid master code the LED (86) flashes green.
  • Page 90 Error displays adding a user code For the following events the LED (86) flashes red: Cause Remedy – The user code entered is – Switch off the truck, see page 86. 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 91 7.4.6 Change operator code Requirements – To prepare the truck for operation, see page 86. Procedure • Press the O key (87). • Enter the valid master code with the digit keys. When you enter the valid master code the LED (86) flashes green.
  • Page 92 Error displays changing a user code For the following events the LED (86) flashes red: Cause Remedy – The user code entered is – Switch off the truck, see page 86. 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 93 7.4.7 Delete individual user codes Requirements – To prepare the truck for operation, see page 86. Procedure • Press the O key (87). • Enter the valid master code with the digit keys. When you enter the valid master code the LED (86) flashes green.
  • Page 94 Error displays deleting individual user codes For the following events the LED (86) flashes red: Cause Remedy – The user code entered is – Switch off the truck, see page 86. 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 95 7.4.8 Delete all user codes, Requirements – To prepare the truck for operation, see page 86. Procedure • Press the O key (87). • Enter the valid master code with the digit keys. When you enter the valid master code the LED (86) flashes green.
  • Page 96 7.4.9 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 97 7.4.10 Setting the automatic truck cutout (timeframe) Requirements – To prepare the truck for operation, see page 86. Procedure • Press the O key (87). • Enter the valid master code with the digit keys. When you enter the correct master code the LED (86) flashes green.
  • Page 98 Error displays setting the automatic cutout period of the truck For the following events the LED (86) flashes red: Cause Remedy – Switch off the truck, see page 86. – Cutout time entered is out of – Enter the time again while making sure it is range within range.
  • Page 99 7.4.11 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 (82,83,84) LEDs.
  • Page 100 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 101 Adapting the travel program configuration to the user code Procedure • Press the O key (87). • Enter the valid master code with the digit keys. When you enter the valid master code the green LED (86) flashes green. • Enter the parameters 0-2-4 with the digit keys. •...

  • Page 102: Ism Access Module (O)

    Error displays configuring the travel programs For the following events the LED (86) flashes red: Cause Remedy – Blocked travel program – Switch off the truck, see page 86. defined as start travel – Try again, making sure the configuration code is program entered correctly.

  • Page 103: 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 104 7.6.1 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 105: F Industrial Truck Maintenance

    F Industrial Truck Maintenance 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 125). The manufacturer recommends the replacement of the maintenance parts also listed in chapter "Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement"...

  • Page 106: 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 107: 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 108: 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 109: 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 containers.
  • Page 110 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 111: Lubrication Schedule

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

  • Page 112: Consumables

    The Jungheinrich hydraulic oil may be mixed with one of the named alternative hydraulic oils. For cold store operations the Jungheinrich hydraulic oil and the cold store hydraulic oil must be mixed in a 1:1 ratio.

  • Page 113: Maintenance And Repairs

    Maintenance and repairs Preparing the truck for maintenance and repairs Procedure • Park the truck securely, see page 60. • 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 114: Cleaning

    Cleaning 4.3.1 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 115 Cleaning the truck Requirements – Prepare the truck for maintenance and repairs (see page 113). 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 116 4.3.2 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 117 4.3.3 Drive compartment cover disassembly/assembly Remove drive compartment cover Requirements – Prepare the truck for maintenance and repairs (see page 113). Tools and Material Required – Allen key Procedure Hold onto the cover (89) when removing the screws. Remove the four screws (90) with the Allen key.

  • Page 118: 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 113. Procedure • Remove the front panel, see page 117. • Check level hydraulic reservoir (93).

  • Page 119: 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 125. Tightening the wheel nuts Requirements – Prepare the truck for maintenance and repairs, see page 113. Tools and Material Required –...

  • Page 120: 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 121: 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 114. • Lubricate the truck according to the lubrication diagram, see page 111. • Clean the battery, grease the terminals and connect the battery. •...

  • Page 122: 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 123: Restoring The Truck To Service After Decommissioning

    Restoring the truck to service after decommissioning Procedure • Thoroughly clean the truck, see page 114. • Lubricate the truck according to the lubrication schedule, see page 111. • Clean the battery, grease the terminal screws and connect the battery. •...

  • Page 124: 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 125: 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 126: Maintenance Contents Ese

    Maintenance Contents ESE 220 Issued on: 2019-04-24 12:00 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 Correct the hydraulic oil level.
  • Page 127 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 128 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 129 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 130: Customer Service

    Customer Service 1.2.1 Maintenance contents In accordance with the ESE 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 131 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 132 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 133 Hydraulic operations Mast rollers and their running surfaces for wear and damage The function of the hydraulic system The secure seating of the hydraulic connections, hoses and pipes and for leaks and damage The forks or load handler for wear and damage Tie/plunger rods are uniformly adjusted and for wear and damage The secure seating of the hoses, pipes and connections and for wear, leaks, damage, blisters and kinks...
  • Page 134 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 135 Lead-acid battery Power supply The secure seating of the battery, battery cables and cell connectors and for damage...
  • Page 136 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 Hydraulic oil filter 2000 Hydraulic system - venting plug 2000 Transmission oil 10000...

  • Page 137: Maintenance Contents Ese

    Maintenance Contents ESE 320 Issued on: 2019-04-24 12:00 Owner To be performed every 50 service hours, but at least once a week. 2.1.1 Maintenance contents 2.1.1.1 Standard equipment Brakes Test the function of the brakes Hydraulic operations Correct the hydraulic oil level.
  • Page 138 2.1.1.2 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 139 2.1.2 Inspection contents 2.1.2.1 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 140 2.1.2.2 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 141: Customer Service

    Customer Service 2.2.1 Maintenance contents In accordance with the ESE 320 service interval, to be performed every 1000 service hours, but at least once a year. 2.2.1.1 Standard equipment Brakes Test the function of the brakes Measure the air gap of the magnetic brake. Electrical system Test the contactors and/or relays.
  • Page 142 2.2.1.2 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 143 2.2.2 Inspection contents The following points must be checked: 2.2.2.1 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 144 Hydraulic operations Mast rollers and their running surfaces for wear and damage The function of the hydraulic system The secure seating of the hydraulic connections, hoses and pipes and for leaks and damage The forks or load handler for wear and damage Tie/plunger rods are uniformly adjusted and for wear and damage The secure seating of the hoses, pipes and connections and for wear, leaks, damage, blisters and kinks...
  • Page 145 2.2.2.2 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 146 Lead-acid battery Power supply The secure seating of the battery, battery cables and cell connectors and for damage...
  • Page 147 2.2.3 Maintenance parts The manufacturer recommends the replacement of the following maintenance parts at the specified intervals. 2.2.3.1 Standard equipment maintenance part service hours months Hydraulic oil 2000 Hydraulic system - breather filter 2000 Hydraulic oil filter 2000 Hydraulic system - venting plug 2000 Transmission oil 10000...

  • Page 149: H Traction Battery Appendix

    H Traction Battery Appendix Correct Use and Application 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. Observe the instructions for maintaining the safety rating during operation for batteries in accordance with Ex I and Ex II (see relevant certification).

  • Page 150: 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 151: 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 152 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 1.29 kg/l Nominal electrolyte density 30 °C Nominal temperature System rated electrolyte level up to "Max" electrolyte level marking 55 °C Limit temperature 1) Reached within the first 10 cycles.

  • Page 153: 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 154 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 155 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 156: 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.
  • Page 157 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 158: 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 159: 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 160 NOTICE 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. uAlways charge the battery with DC current. uAll DIN 41773 charging procedures are permitted in the format approved by the manufacturer.
  • Page 161 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 162: 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 163: 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 164: 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 165: 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 166: 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 167 NOTICE 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. uAttach 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 168: 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 169 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 170: Storing The Battery

    Storing the battery NOTICE 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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Ese 320

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