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

Jungheinrich ESE 220 Operating Instructions Manual

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ESE 220/320
Operating instructions
52312865
11.22
11.22
en-GB
ESE 220
ESE 320

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Summary of Contents for Jungheinrich ESE 220

  • Page 1 ESE 220/320 11.22 Operating instructions en-GB 52312865 11.22 ESE 220 ESE 320...

  • Page 3: Declaration Of Conformity

    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 4 Declaration of Conformity (o) Product: ESE 220/320 Serial number/type number Manufacturer: Jungheinrich Aktiengesellschaft 22039 Hamburg, Germany UK representative: Jungheinrich UK Ltd Sherbourne House Sherbourne Drive Tilbrook Milton Keynes MK7 8HX Authorised to compile documentation: The manufacturer is authorised to compile the technical documentation and its...
  • 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

    Truck models and rated capacity Travel direction definition Assemblies and Functional Description Assembly Overview Functional Description Technical Specifications ESE 220 ESE 320 EN norms Specifications according to RED guideline (Radio Equipment Directive) for radio units Electrical Requirements Identification Points and Data Plates...
  • Page 8 Safety regulations for handling lithium-ion batteries Lithium-ion battery data plate Battery types Battery charge status Exposing the battery Removing or installing the battery Charging the battery Operation Safety Regulations for the Operation of Forklift Trucks Displays and Controls Access systems Pilots Display unit with 4-inch display Preparing the Truck for Operation...
  • Page 9 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 ESE 220 Owner Customer Service Maintenance Contents ESE 320 Owner Customer Service...

  • 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 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 13 Special equipment and authorisation are required if the truck is to be used continually in conditions of extreme temperature fluctuations or condensing air humidity.

  • Page 14: Instructions For Trucks With Lithium-Ion Batteries

    Instructions for trucks with lithium-ion batteries WARNING! Danger of accidents due to regenerative braking fault Regenerative braking faults can result in extended stopping distances and accidents, particularly when travelling on inclines. Other persons can be injured in the truck's hazardous area. uKeep all persons out of the hazardous area during travel operations.

  • Page 15: Internal Operation Combined With Brief External Or Cold Store Operation (T)

    Internal Operation Combined with Brief External or Cold Store Operation (t) In addition to the permissible operating conditions in industrial and commercial environments, the truck can also be used in outdoor environments, cool stores and fresh food areas. Secure parking is only permissible indoors or in a cold store environment.

  • Page 16: Internal Operation In Cold Stores With Cold Store Equipment (O)

    Internal Operation in Cold Stores with Cold Store Equipment (o) NOTICE Cold store trucks uTrucks designed for use in cold stores have a cold store hydraulic oil and a protective frame instead of a mast guard on the mast. uIf a truck with cold store oil is used outside the cold store, the lowering speeds may increase.

  • Page 17: Wind Loads

    3.3.1 Truck in General Operating and ambient conditions Permissible temperature range -28 °C to +25 °C Temperature range for secure parking +5 °C to +40 °C Maximum relative air humidity 95% non-condensing 3.3.2 Trucks with Lead-Acid Battery Operating and ambient conditions Permissible temperature range -28 °C to +25 °C Minimum temperature for charging...

  • Page 18: Adding Attachments And/Or Optional Equipment

    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. Removal of components It is forbidden to modify or remove truck components, particularly protective and safety equipment.

  • Page 19: 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 20: Travel Direction Definition

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

  • Page 21: Assemblies And Functional Description

    Assemblies and Functional Description Assembly Overview Item Description t multiPILOT t Access systems o Seat heating switch t Emergency disconnect switch t Load fork t Display unit (4-inch display) t Floor-plate height adjuster t Driver's seat t Steering wheel t Seat adjustment lever t Seat cushioning adjusting wheel t Deadman button t Support wheel...
  • Page 22 3.1.1 Access systems Item Description Display unit with 4-inch display Keypad Panel Key switch Transponder reader Plus...
  • Page 23 3.1.2 Comfort Charging Socket for the Lithium-Ion Battery Item Description t Comfort charging socket...
  • Page 24 3.1.3 Options Item Description Red or blue LED light (Floor-Spot) Cup holder Writing board A4 storage facility...

  • Page 25: 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 26 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 27 The same radio anchor can also be connected to the control unit of a hall gate so that it opens when an authorised truck approaches and remains closed to unauthorised trucks. Further information: see page 137. curveCONTROL The curveCONTROL assistance system helps the operator to operate the truck safely.

  • Page 28: Technical Specifications

    Technical Specifications The technical specification is given according to the German guideline "Type sheets for industrial trucks". Technical modifications and additions reserved. ESE 220 4.1.1 Characteristics ESE 220 Manufacturer (short designation) Jungheinrich Manufacturer's type designation ESE 220 Drive system Electric...
  • Page 29 4.1.2 Weights ESE 220 Net weight (incl. battery) 1062 Axle load with load front/rear 1896 / 1142 Axle load without load front/rear 258 / 808 4.1.3 Wheels/Chassis ESE 220 Tyres Polyurethane (PU) Tyre size, front Ø 230 x 78 Tyre size, rear Ø...
  • Page 30 4.1.4 Basic Dimensions ESE 220 Lift (h3) Seat height / standing height 1020 Lowered height Overall length 2009 Length to fork shank Overall width Fork-arm dimensions s/e/l 60 x 172 x 1150 Width across forks Ground clearance, centre of wheelbase...
  • Page 31 4.1.5 Performance data ESE 220 Travel speed with/without load km/h 10 / 12.5 Lift speed with/without load 0.06 / 0.07 Lowering speed with/without load 0.06 / 0.05 Max. gradeability with/without 8 / 13 load Service brake Electric 4.1.6 Electric Motor...
  • Page 32 ESE 320 4.2.1 Characteristics ESE 320 Manufacturer (short designation) Jungheinrich Manufacturer's type designation ESE 320 Drive system Electric Operation Seat Capacity/load 2000 Rated capacity/load for mast lift Load distance Wheelbase 1548...
  • Page 33 4.2.2 Weights ESE 320 Net weight (incl. battery) 1074 Axle load with load front/rear 1902 / 1182 Axle load without load front/rear 264 / 816 4.2.3 Wheels/Chassis ESE 320 Tyres Polyurethane (PU) Tyre size, front Ø 230 x 78 Tyre size, rear Ø...
  • Page 34 4.2.4 Basic Dimensions ESE 320 Lift (h3) Seat height / standing height 1020 Lowered height Overall length 2009 Length to fork shank Overall width Fork-arm dimensions s/e/l 60 x 172 x 1150 Width across forks Ground clearance, centre of wheelbase Aisle width (pallet 800x1200 2259 lengthways)
  • Page 35 4.2.5 Performance data ESE 320 Travel speed with/without load km/h 10 / 12.5 Lift speed with/without load 0.06 / 0.07 Lowering speed with/without load 0.06 / 0.05 Max. gradeability with/without 8 / 13 load Service brake Electric 4.2.6 Electric Motor ESE 320 Drive motor, output S2 60 min Lift motor, output at S3...

  • Page 36: 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 37: 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 WMT 110 13.56 MHz...

  • Page 38: Electrical Requirements

    Component Frequency range Transmission power Telematics box Plus 3G/2G INT 2.4 GHz (Bluetooth) < 10 mW 2.4 GHz (WLAN) < 100 mW 5 GHz (WLAN) < 100 mW 850/ 900 MHz (2G) < 2 W 1800/ 1900 MHz (2G) < 1 W 800/ 850/ 900/ 1900/ <...

  • Page 39: Identification Points And Data Plates

    Identification Points and Data Plates XXXX kg Item Description "multiPILOT operation" plate "Lithium-ion battery" plate Data plate Attachment point for loading by crane "Cold-store equipment" plate Truck capacity plate...

  • Page 40: Data Plate

    Data plate Item Description Item Description Rated capacity (kg) Load centre distance (mm) Battery voltage (V) Output (kW) Net weight without battery (kg) Min./max. battery weight (kg) Option Manufacturer Type 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 (41).

  • Page 41: Truck Capacity Plate

    Truck capacity plate The capacity plate (49) gives the maximum load-bearing capacity (Q) of the truck in kg assuming the load on the load handler is evenly distributed.

  • Page 42: Equipment-Dependent Marking Points

    Equipment-dependent marking points Item Description Revised Floor-Spot version from 2022 Warning notice: "Danger! Optical radiation" (on trucks with blue Floor-Spot)

  • Page 43: 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 fall when being loaded by crane. uPrevent the truck from hitting other objects during lifting, and avoid uncontrolled movements.
  • Page 44 Lifting the truck by crane Requirements – Truck parked securely, see page 97. Tools and Material Required – Two ring screws, for capacity details refer to the truck data plate. – Crane slings, for capacity details refer to the truck data plate. Procedure •...

  • Page 45: 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 46 Securing the truck for transport Requirements – Load the truck. – Truck parked securely, see page 97. 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 47: 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 49: D Battery - Servicing, Recharging, Replacement

    D Battery - Servicing, Recharging, Replacement Notes on types of battery technology Lead-acid battery The truck is fitted with a lead-acid battery as standard. Integrated modular lithium-ion battery (o) The truck is optionally fitted with an integrated modular lithium-ion battery. All notes and information concerning lithium-ion batteries can be found in these operating instructions.

  • Page 50: General Safety Regulations For Batteries

    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 51: Lead-Acid Battery

    Lead-acid battery Safety instructions for handling lead-acid batteries WARNING! Risk of accidents and injuries when handling acid batteries Batteries contain dissolved acid, which is toxic and caustic. Above all, avoid any contact with battery acid. uDispose of used battery acid in accordance with regulations. uWear protective clothing and eye protection when working with acid batteries.

  • Page 52: Battery Types

    Battery types NOTICE The batteries of this truck are equipped with special battery trays to use with the battery retainer used in the truck. The truck will be equipped with different battery models, depending on the application. The following table shows which combinations are included as standard: Designation Voltage/capacity Dimensions...

  • Page 53: Exposing The Battery

    Exposing the battery WARNING! An unsecured truck can cause accidents It is hazardous and prohibited to park the truck on inclines, with a raised operator's position or load handler. uPark the truck on a level surface. In special cases the truck may need to be secured with wedges.
  • Page 54 Requirements – Truck parked securely – see page 97. Procedure The armrest also serves as a battery panel. Fold up the arm rest (55). The battery connector (57) and battery latch (56) can be accessed.

  • Page 55: Charging The Battery

    Charging the battery WARNING! Risk of electric shock and fire due to insufficient or inappropriate residual current devices A lack of residual current devices or the use of inappropriate residual current devices can result in fatal injury due to electric shocks or electrical fires in the event of a fault. uThe owner must conduct an operational risk assessment of the usage location.
  • Page 56 Charging the battery Requirements – Expose the battery, see page 53. – Correct charging program set on charger. Procedure • Remove the battery connector (57) from the truck plug (58). • Remove any insulating mats from the battery. • Connect the battery connector (57) to the charging cable (59) of the stationary charger.
  • Page 57 Checking the battery acid level Requirements – Park the truck securely, see page 97. – Expose the battery, see page 53. Procedure • Remove the battery connector (57) from the truck. • Place the battery connector (57) on the battery (61). •...
  • Page 58 NOTICE If charging has been interrupted, the full battery capacity will not be available. Completing the battery charge Requirements – The battery is fully charged. Procedure • Complete charging in accordance with the battery charger operating instructions. • Remove the battery connector (57) from the charger cable (59) of the stationary battery charger.

  • Page 59: Removing Or Installing The Battery

    Removing or installing the battery 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 60 CAUTION! Trapping hazard Trapping hazard when removing and installing the battery. uWhen removing and installing the battery do not put your hands between the battery and the chassis. Removing the battery Requirements – Park the truck securely, see page 97. –...
  • Page 61 CAUTION! Trapping hazard Trapping hazard when removing and installing the battery. uWhen removing and installing the battery do not put your hands between the battery and the chassis.

  • Page 62: Integrated Modular Lithium-Ion Battery

    The truck is optionally fitted with an integrated modular lithium-ion battery. All notes and information concerning lithium-ion batteries can be found in these operating instructions. The Jungheinrich lithium-ion batteries are maintenance-free batteries with rechargeable high-performance energy cells. The batteries' daily operating time can be extended through intermediate charges.

  • Page 63: Safety Regulations For Handling Lithium-Ion Batteries

    Safety regulations for handling lithium-ion batteries 4.1.1 Correct application WARNING! Do not open the battery! If external influences (e.g. force, fire, flooding) cause unusual conditions or situations, the following instructions must be observed: – The battery cells inside the lithium-ion battery contain substances that can be flammable if they come into contact with oxygen or water.
  • Page 64 4.1.3 Shipping information The Jungheinrich lithium-ion battery is a hazardous material. The applicable ADR regulations must be observed during transport. ADR = Accord européen relatif au transport international des marchandises Dangereuses par Route. If in doubt, contact the manufacturer's customer service department.
  • Page 65 4.1.6 Touch voltage hazard WARNING! Touch voltage hazard Hazardous touch voltages may occur in the event of a technical or mechanical defect on the battery. Touch voltages also occur on seemingly discharged batteries. Touching the battery terminals or live attachments (battery cable, battery connector etc.) can result in dangerous current flows through the body.

  • Page 66: Lithium-Ion Battery Data Plate

    Lithium-ion battery data plate Item Designation Lithium-ion secondary battery Battery type Year of manufacture Serial number Supplier number Rated capacity in ampere-hours (Ah) Rated voltage in volts (V) Rated energy in watt-hours (Wh) Battery number Battery weight (± 5 %) in kg Designation QR code Manufacturer...
  • Page 67 4.2.1 Safety and warning information Used batteries are recyclable commodities. These batteries must be treated as hazardous waste. As indicated by the marking showing the recycling symbol and a crossed-out waste bin, batteries must not be disposed of as domestic waste. Return or recycling of batteries must be ensured, for example, in accordance with the Battery Directive 2006/66/EG.

  • Page 68: Battery Types

    Battery types Depending on the version, the truck is equipped with different battery types. The following table shows the different battery types. Nominal battery data Lithium-ion battery Product 130/260/390 Ah 25.6 V Nominal voltage (3.2 V x 8 cells) 130 Ah 8 (1 unit with 8 cells) Number of cells 260 Ah...

  • Page 69: Battery Charge Status

    Battery charge status The charge status of the lithium ion battery is shown on the display of the display unit (98). The display of the display unit also indicates important information on the operating condition of the lithium-ion battery as required (e.g. low charge status, excessively high or low temperature) –...

  • Page 70: Charging The Battery

    Charging the battery WARNING! Risk of electric shock and fire due to insufficient or inappropriate residual current devices A lack of residual current devices or the use of inappropriate residual current devices can result in fatal injury due to electric shocks or electrical fires in the event of a fault. uThe owner must conduct an operational risk assessment of the usage location.
  • Page 71 Intermediate charging NOTICE Intermediate charging A lithium-ion battery that is not fully discharged can be recharged at any time either in part of in full. In order to ensure the reliable operation of the lithium-ion battery, the following must be borne in mind: uIn the event of frequent intermediate charging, charge the lithium-ion battery fully every 4 weeks.
  • Page 72 4.7.1 Charging the battery with a stationary battery charger NOTICE Damage to the lithium-ion battery due to incorrect charging If a lithium-ion battery is charged directly via the battery connector (57) rather than via the comfort charging socket (25), the battery may be damaged. uNever connect an external battery charger directly to the battery connector (57) of the lithium-ion battery.
  • Page 73 The battery is charging. Trucks with a lithium-ion battery have a display unit with display as standard – see page 69. While the charge connector of the stationary charger is connected to the truck, the electrical functions of the truck are disabled (electric immobiliser). The truck cannot be operated in this case.

  • Page 75: 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 76 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. This also includes the area within reach of falling loads or lowering/falling operating equipment.

  • Page 77: Displays And Controls

    Displays and Controls Item Control/display Function Keyless access systems o Keyless access systems to release the truck t The display unit with 4-inch display provides Display unit with 4-inch display the operator with all important information and enables control of the truck functions. –...
  • Page 78 Item Control/display Function "Floor plate adjustment" t Adjusting the floor-plate height button t Steers the truck Steering wheel t Releasing and locking the backrest Backrest lock t Deadman switch pressed: Deadman switch – Travel and lifting enabled. Deadman switch not pressed: –...

  • Page 80: Access Systems

    Access systems Item Description Display unit with 4-inch display Keypad Panel Key switch Transponder reader Plus...

  • Page 81: Pilots

    Pilots Item Description Function t Lever for operating the basic "Basic functions" lever functions – Travel/braking – Load handler lift/lower t Triggers an audible warning signal Transmitter ("horn")

  • Page 82: Display Unit With 4-Inch Display

    Display unit with 4-inch display - - - - kg R 7 : 30 A - - - - - - - - km/h 08:37 Item Display or control element Function Information line Displays event messages and optional information such as speed.
  • Page 83 Item Display or control element Function Battery charge status The higher the fill level on the charge status indicator, the higher the residual capacity of the battery. Steer mode 180° Steer mode 360° Function keys Selection buttons for the corresponding functions.
  • Page 84 2.3.1 Function Symbols Functions and operator menus that can be operated via the icons and keys of the display unit depend on the operating situation as well as the scope and settings of the truck. General Symbol Meaning Function Function selection Switches through the various functions and displays of the display unit.
  • Page 85 Settings menu Symbol Meaning Function Back Cancels the current operation and returns to the previous menu. Edit access code/ To add or delete access codes or transponder transponders. Changing the Set-up To change the set-up code and to activate the Code keypad or the transponder reader.
  • Page 86 2.3.2 Display symbols Any number of symbols can be shown in the display area. The symbols shown during operation depend on the operating and truck status. Symbol Meaning Colour Function Truck disabled Yellow Lights up when the truck has been disabled due to a serious event.
  • Page 87 Symbol Meaning Colour Function Lift end, load fork yellow Illuminates if the “Raise load fork” button is pressed when the lift limit in green the mast lift has been reached. Manual parking Illuminates when the manual parking brake brake is activated. Slow travel Yellow Lights up when the travel speed is...
  • Page 88 Symbol Meaning Colour Function Lowering limit, Yellow Illuminates if the “Lower support arm support arm lift lift” button is pressed when the lowering limit in the support arm lift has been reached. “Automatic support Green Lights up green when the function for arm lift lowering”...
  • Page 89 2.3.3 Setting the time Setting the time Symbol Procedure Press the button under the settings symbol. Press the button under the clock symbol. Use the arrow up key to change the time digit selected. Use the arrow down key to change the time digit selected. Press the confirm key to move to the next digit or to confirm the time.
  • Page 90 2.3.4 Battery discharge indicator The battery charge status is shown on the truck display unit via a battery symbol (98). When a battery is discharged to the permissible discharge level, the battery symbol (98) is displayed empty. (see page 82) The standard setting for the charge status indicator (98) is based on trucks delivered with a standard battery.

  • Page 91: 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 92: Entering Or Exiting

    Entering or exiting CAUTION! No more than one person may operate the truck at a time. Requirements – Load handler fully lowered. Procedure Always enter and exit the truck facing the load direction. To enter and exit, hold onto the handle (101). •...

  • Page 93: 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 94: Adjusting The Floor-Plate Height

    Adjusting the Floor-Plate Height Procedure • Sit down on the driver's seat. • Press and hold down the "floor-plate adjustment" button (11). The floor plate can now be adjusted. • Set the floor plate (102) to the correct height by standing on it or discharging it. •...

  • Page 95: Preparing The Truck For Operation

    Preparing the truck for operation Switching on the truck Requirements – Checks and operations before starting daily work completed – see page 91. Procedure • Enter the operator position – see page 92. • Sit down on the driver's seat (12). •...

  • Page 96: Visual Inspections And Activities To Be Performed After Establishing Operational Readiness

    Visual inspections and activities to be performed after establishing operational readiness 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 97: 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 98: Working With The Truck

    Working with the truck Safety regulations for travel mode 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.
  • Page 99 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 100: Negotiate Slopes And Inclines

    Negotiate slopes and inclines When negotiating slopes and inclines, observe the following: – It is only permitted to negotiate slopes and inclines that are designated traffic lanes. – Slopes and inclines must be clean and non-slip; it must be possible to negotiate them safely in accordance with the truck’s technical specifications.

  • Page 101: How To Act In Hazardous Situations

    How to act in hazardous situations DANGER! Tipovers can result in fatal accidents If the truck is in danger of tipping over, incorrect operator action can result in serious injury and death. uDo not jump off the truck if it tips over. uIf the truck tips over on the right side of the load direction, hold onto the option bar with both hands.

  • Page 102: 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 103 Pressing the emergency disconnect switch Procedure • Press the emergency disconnect switch (83). The industrial truck brakes to a halt and all electrical functions are deactivated. Press the Emergency Disconnect switch on in emergencies. Unlocking the emergency disconnect switch Procedure •...

  • Page 104: 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 105: Travel

    Travel WARNING! Collision hazard when operating the truck Collisions with personnel and equipment can result if the truck is operated with open panels. uDo not operate the truck unless the panels and covers are closed and properly locked. Requirements – Start up the truck – see page 95. Procedure •...
  • Page 106 4.6.1 Changing the direction of travel CAUTION! Danger when changing travel direction during travel Changing the travel direction causes the truck to decelerate sharply. When the travel direction is changed, this can result in a high speed in the opposite travel direction unless the multiPILOT is released in time.

  • Page 107: Steering

    Steering Steering the truck Procedure • Turn the steering wheel (105) to the left or right. The steer direction is dependent on the steer angle and selected travel direction. When travelling forward (travel in direction of entry = drive direction) steer to the left to turn into a left-hand bend and to the right into a right-hand bend.

  • Page 108: 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 109 Braking with the service brake Procedure • During travel, take your foot off the deadman switch (87). The truck decelerates regeneratively at the maximum rate until it comes to a halt. The parking brake then applies. Regenerative braking Procedure • Release the multiPILOT (5) while travelling. The multiPILOT (5) returns to the neutral position.

  • Page 110: 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 111 4.9.1 Raising the load handler Requirements – Truck has been prepared for operation, see page 95. – Deadman switch actuated – see page 104. Procedure • Pull the multiPILOT (5) in the direction of the arrow until you reach the required lift height.
  • Page 112 4.9.2 Lowering the load handler Requirements – Truck has been prepared for operation, see page 95. – Deadman switch actuated – see page 104. Procedure • Pull the multiPILOT (5) in the direction of the arrow until you reach the required lift height.

  • Page 113: Lifting, Transporting And Depositing Loads

    4.10 Lifting, transporting and depositing loads WARNING! Risk of accident when the centre of gravity of the load is outside of the load centre distance If the centre of gravity G of a raised load lies outside the load centre distance D specified for the load handler in the horizontal or vertical planes, under unfavourable conditions the raised load and also the truck can tip over while working.
  • Page 114 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 115 4.10.1 Raising a load NOTICE Risk of material damage to the hydraulic unit Once have reached the mechanical limit position, release the button for raising the load handler. Otherwise, the hydraulic unit may suffer material damage. Requirements – Load correctly palletised. –...
  • Page 116 4.10.2 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 117: Troubleshooting

    Troubleshooting This chapter allows the user to identify and rectify basic faults or the effects of incorrect operation. When trying to locate a fault, proceed in the order shown in the table. If the fault cannot be rectified after carrying out the above procedures, notify the manufacturer’s service department, as further troubleshooting can only be performed by specially trained and qualified service personnel.
  • Page 118 Event message Possible cause Action Truck not operational – Carry out all measures listed under “Truck does not start” Hydraulic oil level too low – Check the hydraulic oil level, see page 155 Battery charge too low – Check the battery charge and charge battery, if necessary, see page 55...

  • Page 119: Battery

    Battery If any faults are found in the battery or the Jungheinrich battery charger, contact the manufacturer's customer service department immediately. The operating company must not carry out any actions on its own. Independent attempts to tamper with or repair the battery may invalidate the warranty. A service agreement with Jungheinrich will help identify faults before they lead to problems.
  • Page 120 5.2.2 Truck can no longer be switched on Event message Possible cause Actions The lithium-ion battery – Charge the battery, has switched to energy- see page 70 saving mode to protect – If the problem against deep discharge persists, contact the manufacturer's customer service department...

  • Page 121: Moving A Truck Without Its Own Drive System

    Moving a truck without its own drive system WARNING! Accidental truck movement When the brakes are deactivated, the truck must be parked on a level surface, as the brakes are no longer effective. uDo not install or remove the brake on slopes or inclines. uThe brake may only be installed or removed by the manufacturer's customer service department.

  • Page 122: Optional Equipment

    Optional Equipment Keyless Access System The keyless access systems serve as a replacement for the key switch to release the truck. The keyless access system allows an individual code to be allocated to each operator or group of operators. Item Description Keypad (EasyAccess PinCode): –...
  • Page 123 7.1.1 General Information about the Use of Keyless Access Systems The default code is to be found on a sticker. When using for the first time, change the set-up code and remove the sticker! – Default code: 1-2-3-4 – Factory set-up code: 2-4-1-2 When allocating the codes, ensure the rider trucks are given a different code than pedestrian trucks.
  • Page 124 7.1.2.1 Activating the keypad Procedure • Release emergency disconnect switch, see page 102. • Enter the default code 1-2-3-4 using the keys below the display unit (106). The truck is switched on. • Press the key below the "Settings" symbol (107). •...
  • Page 125 7.1.2.2 Activating the transponder reader Procedure • Release emergency disconnect switch, see page 102. • Enter the default code 1-2-3-4 using the keys below the display unit (106). The truck is switched on. • Press the key below the "Settings" symbol (107).
  • Page 126 7.1.3 Using the Keypad 7.1.3.1 Switching on the truck with an access code Procedure • Release the emergency disconnect switch, see page 102. • Enter the access code with the keypad (21). The truck is switched on. Procedure • Press the key under the "Switch off" symbol (113) in the display unit. •...
  • Page 127 7.1.3.3 Changing the set-up code Requirements – The truck is switched on, see page 126. Procedure • Press the key below the "Settings" symbol (107). • Press the key below the "Change set- up code" symbol (108). • Enter the set-up code using the keypad (21).
  • Page 128 7.1.3.4 Adding a new access code Requirements – The truck is switched on, see page 126. Procedure • Press the key below the "Settings" symbol (107). • Press the key below the "Edit access code" symbol (114). The set-up code is requested. •...
  • Page 129 7.1.3.5 Deleting an access code Requirements – The truck is switched on, see page 126. Procedure • Press the key below the "Settings" symbol (107). • Press the key below the "Edit access code" symbol (114). The set-up code is requested. •...
  • Page 130 7.1.3.6 Displaying the log-in history The use of the last different access codes is displayed during the log-in process. The last log-in is displayed first. If multiple access codes are logged as being displayable simultaneously, the display area can be moved by scrolling forward or back. Requirements –...
  • Page 131 7.1.4 Operating the transponder reader NOTICE Take care not to damage the transponder. If the transponder is damaged, the truck cannot be switched on. 7.1.4.1 Switching on the truck with a transponder Procedure • Release the Emergency Disconnect switch, see page 102. •...
  • Page 132 7.1.4.3 Changing the set-up transponder Requirements – The truck is switched on, see page 131. Procedure • Press the key below the "Settings" symbol (107). • Press the key below the "Change set-up code" symbol (108). • Place the set-up transponder on the transponder reader (112).
  • Page 133 7.1.4.4 Adding a new transponder Requirements – The truck is switched on, see page 131. Procedure • Press the key below the "Settings" symbol (107). • Press below "Edit transponder" symbol (114). The set-up transponder is requested. • Place the set-up transponder on the transponder reader (112).
  • Page 134 7.1.4.5 Deleting a transponder Requirements – The truck is switched on, see page 131. Procedure • Press the key below the "Settings" symbol (107). • Press the key below the "Edit transponder" symbol (114). set-up transponder requested. • Place the set-up transponder on the transponder reader (112).
  • Page 135 7.1.4.6 Displaying the log-in history The use of the last different transponders is displayed during the log-in process. The last log-in is displayed first. If multiple transponders are logged as being displayable simultaneously, the display area can be moved by scrolling forward or back. Requirements –...

  • Page 136: Floor-Spot (O)

    Floor-Spot (o) 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 137: Zonecontrol

    They contain comprehensive information about operation as well as important safety instructions and warning information. Fleet Management System *If equipped with a Jungheinrich fleet management component, see the “Jungheinrich fleet management system” operating instructions. Parameters The default settings can be changed by the manufacturer's customer service department.

  • Page 139: 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 40.

  • Page 140: 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 161. The manufacturer recommends the replacement of the maintenance parts also listed in chapter "Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement"...

  • Page 141: 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 142: 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 143: 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 144: 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 145 CAUTION! Consumables and used parts are an environmental hazard Used parts and consumables must be disposed of in accordance with the applicable environmental-protection regulations. Oil changes should be carried out by the manufacturer's customer service department, whose staff are specially trained for this task.

  • Page 146: Lubrication Schedule

    Lubrication Schedule A + B Contact surfaces Cold store application Grease nipple Transmission oil drain plug Hydraulic oil drain plug Hydraulic oil filler plug 1) Mixing ratio for cold store application: 1:1...

  • Page 147: Consumables

    The Jungheinrich hydraulic oil is available only from the Jungheinrich service department. The use of named alternative hydraulic oils is not prohibited, but may lead to a decline in functionality. The Jungheinrich hydraulic oil may be mixed with one of the named alternative hydraulic oils.

  • Page 148: Maintenance And Repairs

    Maintenance and repairs Preparing the truck for maintenance and repair work Procedure • Park the truck securely, see page 97. • 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...

  • Page 149: Cleaning

    Cleaning 5.3.1 Cleaning the truck Cleaning tasks may only take place in the designated locations, which adhere to the stipulations of the country of use. CAUTION! Risk of fire due to use of flammable cleaning agents Using flammable cleaning agents increases the risk of fire. uDo not use any flammable cleaning agents when cleaning.
  • Page 150 Requirements – Truck prepared for maintenance and repair work – see page 148. Tools and Material Required – Water-based cleaning agents – Sponge or cloth Procedure • Clean the surface of the truck with water-based solvents and water. Use a sponge or cloth to clean.
  • Page 151 5.3.2 Cleaning the electrical system assemblies NOTICE Risk of electrical-system damage Cleaning the electronic system assemblies (controllers, sensors, motors etc.) 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 a non-conductive, anti-static brush.

  • Page 152: Removing Or Fitting The Service Flap

    Removing or Fitting the Service Flap Removing the drive compartment cover Requirements – Truck prepared for maintenance and repair work – see page 148. Tools and Material Required – Allen key Procedure Hold onto the cover (120) when removing the screws. Remove 4 screws (121) with the Allen key.

  • Page 153: Demontieren Oder Montieren Der Sitzhaube

    Demontieren oder Montieren der Sitzhaube Procedure • Switch off the truck. • Press the emergency disconnect switch – see page 102. • Fully lower the floor plate (102) – see page 94. • Remove the screws (122) from the seat cover (123). •...

  • Page 154: Replacing The Drive Wheel

    Replacing the drive wheel The drive wheel must only be replaced by the manufacturer’s authorised customer service department. 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 161. Tightening the wheels nuts Requirements –...

  • Page 155: Checking The Hydraulic Oil Level

    Checking the hydraulic oil level Checking the oil level Requirements – Load handler fully lowered – see page 112. – Truck prepared for maintenance and repair work – see page 148. – Seat cover removed – see page 153. Procedure •...

  • Page 156: Checking The Electrical Fuses

    Checking the electrical fuses Checking fuses Requirements – Truck prepared for maintenance and repair work. – Service flap removed – see page 152. Procedure • Check the fuse ratings against the table and replace if necessary. • Fit the service flap. The fuses are now checked.

  • Page 157: Restoring The Truck To Service After Maintenance And Repairs

    5.10 Restoring the truck to service after maintenance and repairs Procedure • Thoroughly clean the truck, see page 149. • Lubricate the truck according to the lubrication diagram, see page 146. • Clean the battery, grease the terminals and connect the battery. •...

  • Page 158: 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 159: Restoring The Truck To Service After Decommissioning

    Restoring the truck to service after decommissioning Procedure • Thoroughly clean the truck, see page 149. • Lubricate the truck according to the lubrication schedule, see page 146. • Clean the battery, grease the terminal screws and connect the battery. •...

  • Page 160: 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 161: Maintenance, Inspection And Changing Of Maintenance Parts Requiring Replacement

    The following chapter defines the tasks to be performed, the respective intervals to be observed and the maintenance parts for which replacement is recommended. Maintenance Contents ESE 220 Issued on: 2022-08-29 15:00 Owner To be performed every 50 service hours, but at least once a week.
  • Page 162 Lead-acid battery Power supply Correct the battery-acid level using demineralised water.
  • Page 163 1.1.2 Inspection contents 1.1.2.1 Standard equipment The following points must be checked: Electrical system Warning and safety equipment in accordance with the operating instructions Functionality of display and controls Test emergency disconnect switch and check for damage Power supply Check battery and battery components for damage Battery connector for secure fit, functionality and damage Travel Check wheels for wear and damage...

  • Page 164: Customer Service

    Customer Service In accordance with the ESE 220 service interval, to be performed every 1000 service hours, but at least once a year. 1.2.1 Maintenance contents 1.2.1.1 Standard equipment Brakes Test the brake. Measure the air gap of the magnetic brake.
  • Page 165 Power supply Clean the battery. Clean and grease the battery terminals. Measure acid density and battery voltage. Correct the battery-acid level using demineralised water. Lead-acid battery Electrical system Carry out a frame leakage test. Power supply Clean the battery. Clean and grease the battery terminals. Measure acid density and battery voltage.
  • Page 166 1.2.2 Inspection contents The following points must be checked: 1.2.2.1 Standard equipment Electrical system Cables and motor for secure fit and damage Warning and safety equipment in accordance with the operating instructions Functionality of display and controls Test emergency disconnect switch and check for damage Contactors and/or relays for wear and damage Check electrical wiring for damage (insulation damage, connections) and check whether the fuse ratings are correct...
  • Page 167 Hydraulic operations Check slide pieces and stops for wear and damage Check mast rollers and their running surfaces for wear and damage Test hydraulic system Check hydraulic connections, hoses and pipes are securely attached and check for leaks and damage Check fork arms or load handler for wear and damage Tie/plunger rods for uniform adjustment, wear and damage Check the hoses, pipes and connections are securely attached and check for wear, leaks,...
  • Page 168 Access module Electrical system Check access module is securely attached, test and check for damage Entry skids/rollers Hydraulic operations Check entry skids or entry rollers for damage and wear, and test their function Lead-acid battery, international Power supply Check battery, battery cables and cell connectors are securely attached and check for damage Ensure safety labels are present and check for damage Lead-acid battery...

  • Page 169: Maintenance Contents Ese

    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 Gear oil 10000 Hydraulic system breather filter 2000 Hydraulic oil 2000 Hydraulic oil filter 2000 Hydraulic system –...
  • Page 170 Lead-acid battery Power supply Correct the battery-acid level using demineralised water.
  • Page 171 2.1.2 Inspection contents 2.1.2.1 Standard equipment The following points must be checked: Electrical system Warning and safety equipment in accordance with the operating instructions Functionality of display and controls Test emergency disconnect switch and check for damage Power supply Check battery and battery components for damage Battery connector for secure fit, functionality and damage Travel Check wheels for wear and damage...

  • Page 172: Customer Service

    Customer Service In accordance with the ESE 320 service interval, to be performed every 1000 service hours, but at least once a year. 2.2.1 Maintenance contents 2.2.1.1 Standard equipment Brakes Test the brake. Measure the air gap of the magnetic brake. Electrical system Test the contactors and/or relays.
  • Page 173 Power supply Clean the battery. Clean and grease the battery terminals. Measure acid density and battery voltage. Correct the battery-acid level using demineralised water. Lead-acid battery Electrical system Carry out a frame leakage test. Power supply Clean the battery. Clean and grease the battery terminals. Measure acid density and battery voltage.
  • Page 174 2.2.2 Inspection contents The following points must be checked: 2.2.2.1 Standard equipment Electrical system Cables and motor for secure fit and damage Warning and safety equipment in accordance with the operating instructions Functionality of display and controls Test emergency disconnect switch and check for damage Contactors and/or relays for wear and damage Check electrical wiring for damage (insulation damage, connections) and check whether the fuse ratings are correct...
  • Page 175 Hydraulic operations Check slide pieces and stops for wear and damage Check mast rollers and their running surfaces for wear and damage Test hydraulic system Check hydraulic connections, hoses and pipes are securely attached and check for leaks and damage Check fork arms or load handler for wear and damage Tie/plunger rods for uniform adjustment, wear and damage Check the hoses, pipes and connections are securely attached and check for wear, leaks,...
  • Page 176 Access module Electrical system Check access module is securely attached, test and check for damage Entry skids/rollers Hydraulic operations Check entry skids or entry rollers for damage and wear, and test their function Lead-acid battery, international Power supply Check battery, battery cables and cell connectors are securely attached and check for damage Ensure safety labels are present and check for damage Lead-acid battery...
  • Page 177 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 Gear oil 10000 Hydraulic system breather filter 2000 Hydraulic oil 2000 Hydraulic oil filter 2000 Hydraulic system –...

This manual is also suitable for:

Ese 320

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