Jungheinrich ESE 220, ESE 320, ESD 220 Operating Instructions Manual

ESE 220/320

03.10

Operating instructions

51163703

04.19

en-GB

ESE 220
ESE 320

2

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). The manufacturer is
authorised to compile the technical documentation.

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Foreword

Notes on the operating instructions

The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide
sufficient instruction for the safe operation of the industrial truck. The information is
provided clearly and concisely. The chapters are arranged by letter and the pages
are numbered continuously.

The operator manual details different industrial truck models. When operating and
servicing the industrial truck, make sure that the particular section applies to your
truck model.

Our trucks are subject to ongoing development. We reserve the right to alter the
design, equipment and technical features of the system. No guarantee of particular
features of the truck should therefore be assumed from the present operating
instructions.

Safety notices and text mark-ups

Safety instructions and important explanations are indicated by the following
graphics:

Z

DANGER!

Indicates an extremely hazardous situation. Failure to comply with this instruction will
result in severe irreparable injury and even death.

WARNING!

Indicates an extremely hazardous situation. Failure to comply with this instruction
may result in severe irreparable injury and even death.

CAUTION!

Indicates a hazardous situation. Failure to comply with this instruction may result in
slight to medium injury.

NOTICE

Indicates a material hazard. Failure to comply with this instruction may result in
material damage.

Used before notices and explanations.

Indicates standard equipment

t

Indicates optional equipment

o

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Copyright

Copyright of these operating instructions remains with JUNGHEINRICH AG.

Jungheinrich Aktiengesellschaft

Friedrich-Ebert-Damm 129
22047 Hamburg - Germany

Tel: [phone]

www.jungheinrich.com

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Contents

.

A Correct Use and Application 11

.

1 General 11
2 Correct application 11
3 Approved application conditions 12
4 Proprietor responsibilities 13
5 Adding attachments and/or optional equipment 13

.

B Truck Description 15

.

1 Application 15

1.1 Truck models and rated capacity 15
2 Travel direction definition 16
3 Assemblies and Functional Description 17

3.1 Assembly Overview 17

3.2 Functional Description 18
4 Technical Specifications 20

4.1 Performance data 20

4.2 Dimensions 21

4.3 Weights 23

4.4 Tyre type 23

4.5 EN norms 24

4.6 Specifications according to RED guideline (Radio Equipment
Directive) for radio units 25

4.7 Conditions of use 25

4.8 Electrical Requirements 25

5 Identification Points and Data Plates 26

5.1 Data plate 27

5.2 Truck capacity plate 28

.

C Transport and Commissioning 29

.

1 Lifting by crane 29
2 Transport 30
3 Using the Truck for the First Time 32

.

D Battery - Servicing, Recharging, Replacement 33

.

1 Safety Regulations Governing the Handling of Lead-Acid Batteries 33
2 Battery types 35
3 Exposing the battery 36
4 Charging the battery 38
5 Battery removal and installation 40
6 Checking the battery acid level 44

.

E Operation 47

.

1 Safety Regulations for the Operation of Forklift Trucks 47
2 Displays and Controls 49

2.1 Battery discharge indicator 52

2.2 Battery discharge monitor 53

3 Preparing the Truck for Operation 54

7

3.1 Checks and Operations to Be Performed Before Starting Daily Work 54

3.2 Entry and exit 55

3.3 Adjusting the driver’s seat 56

3.4 Adjusting the Floor-Plate Height 56

3.5 Preparing the truck for operation 58

3.6 Checks and operations to be carried out when the truck is operational 59

3.7 Parking the truck securely 60

4 Industrial Truck Operation 61

4.1 Safety regulations for truck operation 61

4.2 Emergency Disconnect 64

4.3 Deadman button 66

4.4 Travel 66

4.5 Steering 68

4.6 Brakes 69

4.7 Load handler raise/lower 71

4.8 Lifting, transporting and depositing loads 73

5 Troubleshooting 76

5.1 Truck does not start 77

5.2 Load cannot be lifted 77

6 Operating the truck without its own drive system 78
7 Optional equipment 81

7.1 Brake Pedal in Footwell with ESE 220 81

7.2 Display and control unit 82

7.3 Setting the time 83

7.4

7.5

Keypad (CanCode) (o) 84
ISM access module (o) 102

7.6 Floor-Spot 103

.

F Industrial Truck Maintenance 105

.

1 Operational Safety and Environmental Protection 105
2 Maintenance Safety Regulations 106

2.1 Working on the electrical system 107

2.2 Consumables and used parts 107

2.3 Wheels 107

2.4 Hydraulic system 108

3 Lubricants and Lubrication Schedule 109

3.1 Handling consumables safely 109

3.2 Lubrication Schedule 111

3.3 Consumables 112

4 Maintenance and repairs 113

4.1 Preparing the truck for maintenance and repairs 113

4.2 Lifting and jacking up the truck safely 113

4.3 Cleaning 114

4.4 Checking the hydraulic oil level 118

4.5 Tightening the wheel nuts 119

4.6 Checking electrical fuses 120

4.7 Restoring the truck to service after maintenance and repairs 121

5 Decommissioning the Industrial Truck 122

5.1 Prior to decommissioning 122

5.2 During decommissioning 122

5.3 Restoring the truck to service after decommissioning 123

6 Safety tests to be performed at intervals and after unusual incidents 124

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7 Final de-commissioning, disposal 124
8 Human vibration measurement 124

.

G Maintenance, Inspection and Changing of Maintenance

Parts Requiring Replacement 125

.

1 Maintenance Contents ESE 220 126

1.1 Owner 126

1.2 Customer Service 130

2 Maintenance Contents ESE 320 137

2.1 Owner 137

2.2 Customer Service 141

.

H Traction Battery Appendix 149

.

1 Correct Use and Application 149
2 Data plate 149
3 Safety Instructions, Warning Indications and other Notes 150
4 Lead acid batteries with armour plated cells and liquid electrolyte 151

4.1 Description 151

4.2 Operation 153

4.3 Servicing lead-acid batteries with armour plated cells 156

5 PzV and PzV-BS lead-acid batteries with sealed armour plated cells 158

5.1 Description 158

5.2 Operation 159

5.3 Servicing PzV and PzV-BS lead-acid batteries with sealed armour
plated cells 162

6 Aquamatik water replenishment system 163

6.1 Water replenishment system design 163

6.2 Functional Description 164

6.3 Adding water 164

6.4 Water pressure 164

6.5 Filling time 165

6.6 Water quality 165

6.7 Battery tubing 165

6.8 Operating temperature 165

6.9 Cleaning measures 165

6.10 Service mobile vehicle 165

7 Electrolyte circulation 166

7.1 Functional Description 166

8 Cleaning batteries 168
9 Storing the battery 170
10 Troubleshooting 170
11 Disposal 170

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10

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A Correct Use and Application

1 General

The truck must be used, operated and serviced in accordance with the present
instructions. All other types of use are beyond its scope of application and may result
in damage to personnel, the industrial truck or property.

2 Correct application

NOTICE

The maximum load and load distance are indicated on the capacity plate and must
not be exceeded.
The load must rest on the load handler or be lifted by an attachment approved by the
manufacturer.
The load must be fully raised, see page 73.

The following operations are in accordance with regulations and are permitted:
– Lifting and lowering loads.
– Transporting lowered loads.

The following operations are prohibited:
– Carrying and lifting passengers.
– Pushing or pulling loads.

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3 Approved application conditions

– Operation in industrial and commercial environments.
– Permissible temperature range 5°C to 40°C.
– Operation only on secure, level surfaces with sufficient capacity.
– Do not exceed the permissible surface and point loading on the travel paths.
– Operation only on travel paths that are clearly visible and approved by the

operating company.
– Negotiating slopes up to a maximum of 13 % (without load).
– Do not travel across or at an angle on slopes. Transporting with the load facing

uphill.
– Operation in partially public traffic.

WARNING!

Use under extreme conditions

Using the truck under extreme conditions can result in malfunctions and accidents.

Special equipment and authorisation are required if the truck is to be constantly

u

used in extreme conditions, especially in dusty or corrosive atmospheres.
The truck cannot be used in areas at risk of explosion.

u

In adverse weather conditions (thunder, lightning) the industrial truck must not be

u

operated outside or in endangered areas.

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4 Proprietor responsibilities

For the purposes of the present operating instructions the “operating company” is
defined as any natural or legal person who either uses the industrial truck himself, or
on whose behalf it is used. In special cases (e.g. leasing or renting) the proprietor is
considered the person who, in accordance with existing contractual agreements
between the owner and user of the industrial truck, is charged with operational
duties.
The proprietor must ensure that the industrial truck is used only for the purpose it is
intended for and that danger to life and limb of the user and third parties are
excluded. Furthermore, accident prevention regulations, safety regulations and
operating, servicing and repair guidelines must be followed. The operating company
must ensure that all users have read and understood these operating instructions.

NOTICE

Failure to comply with the operating instructions invalidates the warranty. The same
applies if improper work is carried out on the truck by the customer or third parties
without the permission of the manufacturer.

5 Adding attachments and/or optional equipment

The mounting or installation of additional equipment which affects or enhances the
performance of the industrial truck requires the written permission of the
manufacturer. Local authority approval may also need to be obtained.
Local authority approval however does not constitute the manufacturer’s approval.

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B Truck Description

1 Application

The 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. It can transport low stacked loads over long distances. The capacity is
shown on the load chart, Qmax.

1.1 Truck models and rated capacity

The rated capacity depends on the model. The rated capacity can be derived from
the model name.

ESE220

ESE Model name

2 Series

20 Rated capacity x 100 kg

The rated capacity is not generally the same as the permissible capacity. The
capacity can be found on the capacity plate attached to the truck.

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2 Travel direction definition

1

2

3

4

The following determinations have been made for travel direction specification:

Item Travel direction

1 Left

2 Drive direction

3 Load direction

4 Right

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3 Assemblies and Functional Description

56787

9

10

12

13

1614171815

11

3.1 Assembly Overview

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Item Description Item Description

5

6

7

8

9

10

11

Charge status indicator 12

t

Key switch 13

t

Control/display unit 14

o

CanCode code lock 15

o

ISM access module 16

o

multiPILOT 17

t

Emergency disconnect switch 18

t

Armrest

t

Floor-plate height adjuster

t

Steering wheel

t

Load rollers

t

Battery

t

Deadman switch

t

Seat panel

t

t = Standard equipment o = Optional equipment

17

3.2 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.

Emergency stop safety concept

The emergency stop is activated by the traction controller. Each time the truck is
switched on, the system carries out a self-diagnosis. The steering controller sends a
system status signal, which is monitored by the traction controller. If the signal fails
to appear or a fault is identified, the truck automatically brakes to a halt. Control

displays on the control and display unit (o) indicate the emergency stop.

Operator position

The driver's seat and floor plate can be adjusted to suit different sized operators. All
travel and lift operations can be performed sensitively without having to reach. The
ergonomic steering wheel provides secure control of the truck.

Deadman switch

The deadman switch ensures that the driver's feet do not extend outside the truck
during travel. The deadman switch in the foot compartment must be depressed to
enable the driver to operate the truck. Lifting and travel are inhibited if the operator
takes his foot off the deadman switch. Steering and braking remain enabled.

Hydraulic system

When lifting is activated, the pump unit starts to operate, supplying hydraulic oil from
the oil reservoir to the lift cylinder.

When the lift button is pressed, the support arms are raised at an even speed; when
the lower button is pressed, the support arms are lowered.

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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.

Steering

The operator steers with an ergonomically inclined steering wheel. The steering
motion is transmitted from the steering controller via a steer motor directly to the ring
gear of the pivoted drive system. The drive wheel can be rotated ± 90°. Automatic

travel speed reduction as a function of the steer angle (Curve Control o) is
optionally available.

Electrical system

The truck has electronic traction, lift and steering controllers. The operating voltage
of the truck's electrical system is 24 volts.

Controls and displays

Ergonomic controls ensure fatigue-free operation for sensitive application of the
travel and hydraulic operations. The charge indicator shows the available battery

capacity. The control and display unit (o) shows the key operator information such
as battery capacity, service hours and event messages.

3.2.1 Hourmeter

Z

Prepare the truck for operation, see page 58 or see page 84.

Service hours are counted while the truck is operational and the deadman button is
pressed.

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4 Technical Specifications

Z

The technical specification is given according to the German guideline "Type sheets
for industrial trucks". Technical modifications and additions reserved.

4.1 Performance data

ESE 220 ESE 320

Q Rated capacity 2000 kg

Travel speed

with/without load

Lift speed

with/without load

Lowering speed

with/without load

Max. gradeability

with/without load

Drive motor,

output S2 60 min

Lift motor,

output S3 15%

10/12.5 km/h

0.06/0.07 m/s

0.06/0.05 m/s

8/13 %

2.8 kW

1.5 kW

20

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4.2 Dimensions

Q

c

l

l2

l1

h3

x

h13

Ast

a/2

a/2

b1

Wa

e

b

11

b5

ESE 220 ESE 320

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c Load centre distance 600 mm

x Load distance 868 mm

y Wheelbase

h3 Lift 125 mm

h7 Seat height 1020 mm

h13 Lowered height 90 mm

1535

1

1541

2

mm

21

ESE 220 ESE 320

l1 Overall length 2009 mm

l2 Length

including fork shank

859 mm

b2/b1 Overall width 820 930 mm

Overall width of the load

b5

handler

540

mm

b10 Track 544 645 mm

b11 Track 385 mm

s / e /lLoad-handler dimensions

m2

Ground clearance, centre of
wheelbase

Ast Aisle width for

pallet 800x1200 lengthways

60 / 185 / 1150

3

2197

25

2215

3

mm

mm

mm

Wa Turning radius 1665 1683 mm

1) Load handler lowered: +90 mm

2) Load handler lowered: +95 mm

3) Diagonal: +90 mm

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4.3 Weights

ESE 220 ESE 320

Net weight including battery 1062 1074 kg

Axle load with load
front / rear

Axle load without load
front / rear

Battery weight 380 kg

4.4 Tyre type

ESE 220 ESE 320

Tyre size, drive 230 x 78 mm

Tyre size, load section 85 x 85 mm

Castor wheel (twin roller) 140 x 54 mm

1896 / 1142 1902 / 1182 kg

258 / 808 264 / 816 kg

Wheels, number front/rear
(x = driven)

2 - 1x / 4

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4.5 EN norms

Continuous sound pressure level

– ESE 220/320: 73 dB(A)

in accordance with EN 12053 as harmonised with ISO 4871.

Z

Z

The continuous sound pressure level is calculated according to standard procedures
and takes into account the sound pressure level when travelling, lifting and idling.
The sound pressure level is measured at the operator's ear.

Vibration

– ESE 220/320: 0,42 m/s²

in accordance with EN 13059.

The vibration acceleration acting on the body in its operating position is the linearly
integrated, weighted acceleration in the vertical axis according to the standard. It is
calculated when travelling over thresholds at constant speed (standard truck
version). These recordings were taken on a single occasion for the truck and must
not be confused with the human vibrations of the operator directive. The
manufacturer offers a special service to measure these human vibrations, see
page 124.

Electromagnetic compatibility (EMC)

The manufacturer confirms that the truck adheres to the limits for electromagnetic
emissions and resistance as well as the static electricity discharge test in
accordance with EN 12895 as well as the standardised instructions contained
therein.

Z

No changes to electric or electronic components or their arrangement may be made
without the written agreement of the manufacturer.

WARNING!

Medical equipment can be damaged by non-ionised radiation

Electrical equipment on the truck emitting non-ionised radiation (e.g. wireless data
transmission) can affect operators' medical equipment (pacemakers, hearing aids
etc.) and result in malfunctions. Consult a doctor or the manufacturer of the medical
equipment to clarify whether it can be used near the industrial truck.

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4.6 Specifications according to RED guideline (Radio Equipment Directive) for radio units

Z

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 < 10 mW

Gateway (ISM Online) 433,05 - 434,79 MHz < 10 mW

Gateway (ISM Online) GSM 850/900 MHz 2 W

Gateway (ISM Online) GSM 1800/1900 MHz 1 W

Gateway (ISM Online) LTE 850/900 MHz 3,2 W (35 dBm)

Gateway (ISM Online) LTE 1800/1900 MHz 1,6 W (32 dBm)

Access module (ISM Online) 13,56 MHz < 100 mW

4.7 Conditions of use

Ambient temperature

– operating at 5°C to 40°C

Z

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

4.8 Electrical Requirements

The manufacturer certifies compliance with the requirements for the design and
manufacture of electrical equipment, according to EN 1175-1 "Industrial Truck Safety

- Electrical Requirements", provided the truck is used according to its purpose.

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5 Identification Points and Data Plates

19

20

21

2223252724

26

26

Item Description

19 Load handler lift/lower

20 Truck capacity plate

21 multiPILOT

22 Floor-plate adjustment

23 Data plate

24 Inspection plaque

25 Attachment points for loading by crane

26 Model description

27 Serial number

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5.1 Data plate

28293130323935

383736

34

33

Z

Item Description Item Description

28 Type 34 Year of manufacture

29 Serial number 35 Load centre distance (mm)

30 Rated capacity (kg) 36 Nominal power

31 Battery voltage (V) 37 Min./max. battery weight (kg)

32 Net weight without battery (kg) 38 Manufacturer

33 Option 39 Manufacturer's logo

For queries regarding the truck or when ordering spare parts, always quote the truck
serial number (29).

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5.2 Truck capacity plate

40

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.

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C Transport and Commissioning

25

25

1 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. If necessary, secure the truck with guide ropes.

The truck may be loaded only by people who are trained in using lifting

u

accessories and lifting gear.
Wear personal protective equipment (e.g. safety shoes, safety helmet, hi-vis

u

jacket, protective gloves) when loading by crane.
Do not stand under suspended loads.

u

Do not walk into or stand in a hazardous area.

u

Always use lifting gear with sufficient capacity (for truck weight, see truck data

u

plate).
Always attach the crane lifting gear to the prescribed attachment points and

u

prevent them from slipping.
Use the lifting accessories only in the prescribed load direction.

u

Crane lifting gear must be fastened in such a way that it does not come into

u

contact with any attachments when lifting.

Lifting the truck by crane

Requirements

– Park the truck securely, see page 60.

Tools and Material Required

– Lifting gear
– Crane lifting gear

Procedure

• Secure the lifting slings to the strap
points (25).

The truck can now be lifted by crane.

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2 Transport

WARNING!

Uncontrolled movement during transport

Improper fastening of the truck and mast during transport can result in serious
accidents.

Loading is only to be carried out by specially trained staff. The specialist personnel

u

must be instructed in the securing of loads on road vehicles and in the use of load­securing equipment. When securing the truck, the appropriate measures must be
determined and applied for each individual case.

The truck must be securely fastened when transported on a lorry or a trailer.

u

The lorry or trailer must have lashing rings.

u

Use wedges to prevent the truck from moving.

u

Use only lashing straps with sufficient load rating.

u

Use anti-slip material to secure loading aids (pallets, wedges,...), e. g. anti-slip

u

mats.

30

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41

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.

• Attach the lashing straps (41) to the industrial truck and the transport vehicle and
tension sufficiently.

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Z

Use edge protectors to protect the truck and the lashing straps.

The truck can now be transported.

31

3 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

Trucks designed for use in cold stores have a cold store hydraulic oil.

u

If a truck with cold store oil is used outside the cold store, the lowering speeds

u

may increase.

Procedure

• Check the equipment is complete.

• Install the battery if necessary, see page 40.

• Charge the battery, see page 38.

Z

The truck settings must match the battery type.

The truck can now be started, see page 54.

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D Battery - Servicing, Recharging,

Replacement

1 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. Wherever an
industrial truck is parked for charging there must be no inflammable material or
consumables capable of creating sparks within a minimum distance of 2,5 m from
the truck. The room must be ventilated. Fire protection equipment must be available.

CAUTION!

The use of unsuitable fire protection equipment can result in scalding

Extinguishing fires with water can cause a reaction with the battery acid. This can
result in scalding from the acid.

Use powder extinguishers.

u

Never extinguish a burning battery with water.

u

Battery maintenance

The battery-cell covers must be kept dry and clean. The terminals and cable lugs
must be clean, secure and have a light coating of terminal grease.

WARNING!

Short circuits can result in fire

Damaged cables can cause short circuits, setting the truck and battery on fire.

Before closing the battery cover make sure that the battery cables are not

u

damaged.

Battery disposal

Batteries may only be disposed of in accordance with national environmental
protection regulations or disposal laws. The manufacturer’s disposal instructions
must be observed.

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WARNING!

Batteries can be hazardous

Batteries contain an acid solution which is poisonous and corrosive. Avoid contact
with battery acid at all times.

Dispose of used battery acid in accordance with regulations.

u

Always wear protective clothing and goggles when working with batteries.

u

Do not let battery acid come into contact with skin, clothing or eyes. If necessary,

u

rinse with plenty of clean water.
In the event of physical damage (e.g. skin or eye contact with battery acid) call for

u

a doctor immediately.
Spilled battery acid should be neutralised immediately with plenty of water.

u

Only batteries with a sealed battery container may be used.

u

Follow national guidelines and legislation.

u

WARNING!

Unsuitable batteries that have not been approved by Jungheinrich for the
truck can be hazardous

The design, weight and dimensions of the battery have a considerable effect on the
operational safety of the truck, in particular its stability and capacity. 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.

Only Jungheinrich-approved batteries may be used on the truck.

u

Battery equipment may only be replaced with the agreement of Jungheinrich.

u

When replacing/installing the battery make sure the battery is securely located in

u

the battery compartment of the truck.
Do not use batteries that have not been approved by the manufacturer.

u

Park the truck securely before carrying out any work on the batteries (see page 60).

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2 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
796 x 210 x 782 mm (LXWXH)

The battery weights can be taken from the battery data plate. Batteries with non
insulated terminals must be covered with a non slip insulating mat.

3 PzS 465 Ah 380 kg

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3 Exposing the battery

CAUTION!

Trapping hazard

Make sure there is nothing between the battery cover and the truck when you fit

u

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.

Park the truck on a level surface. In special cases the truck may need to be

u

secured with wedges.
Fully lower the load handler.

u

Select a place to park where no other people are at risk of injury from the lowered

u

load handler.
If the brakes are not working, place wedges underneath the wheels of the truck to

u

prevent it from moving.

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Requirements

43

42

12

44

– Park the truck on a level surface.
– Park the truck securely, see page 60.

Procedure

• 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.

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4 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.

Switch the charging station and truck off first before connecting/disconnecting the

u

charging cable of the battery charging station to/from the battery connector.
The charger must be adapted to the battery in terms of voltage and charge

u

capacity.
Before charging, check all cables and plug connections for visible signs of

u

damage.
Ventilate the room in which the truck is being charged.

u

The battery cover must be open and the battery cell surfaces must be exposed

u

during charging to ensure adequate ventilation.
Do not smoke and avoid naked flames when handling batteries.

u

Wherever an industrial truck is parked for charging there shall be no inflammable

u

material or lubricants capable of creating sparks within 2,5 m around the truck.
Fire protection equipment must be on hand.

u

Do not lay any metallic objects on battery.

u

It is essential to follow the safety regulations of the battery and charger station

u

manufacturers.

Charging the battery

Requirements

– Expose the battery, see page 36.
– Correct charging program set on charger.

Procedure

• Remove the battery connector (43) from the truck plug (45).

• Remove any insulating mats from the battery.

• Connect the battery connector (43) to the charging cable (46) of the stationary
charger.

• Start charging in accordance with the charger operating instructions.

• Switch on the charger / charging begins automatically.

The battery is now charged.

Completing battery charging, restoring the truck to operation

NOTICE

If charging has been interrupted, the full battery capacity will not be available.

Requirements

– The battery is fully charged.

38

04.19 en-GB

Procedure

434645

• 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.

04.19 en-GB

39

5 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.

Note the "Safety regulations for handling acid batteries" section in this chapter.

u

Wear safety shoes when removing and installing the battery.

u

Use only batteries with insulated cells and terminal connectors.

u

Park the truck on a level surface to prevent the battery from sliding out.

u

Make sure the crane slings have sufficient capacity to replace the battery.

u

Use only approved battery replacement devices (battery roller stand, replacement

u

trolley etc.).
Make sure the battery is securely located in the truck's battery compartment.

u

CAUTION!

Unsecured battery

An unsecured battery can result in trapping and injury

Wear safety shoes when removing and installing the battery.

u

Do not reach between the battery and the chassis.

u

40

04.19 en-GB

ESE 220

434748

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.

• Place the battery connector (43) on the
battery (48).

• Pull the battery lock (47) up and anti­clockwise as far as it will go

• Pull the battery (48) off the truck.

Z

Observe the battery replacement trolley operating instructions.

The battery is now removed.

Installation is carried out in the reverse order.

CAUTION!

Trapping hazard

Trapping hazard when removing and installing the battery.

When removing and installing the battery do not put your hands between the

u

battery and the chassis.

04.19 en-GB

41

ESE 320

48

44

47

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.

• Place the battery connector on the battery.

• Turn the battery lock (44) over and pull it up.

• Flip the battery retainer (47) over.

• Pull the battery (48) off the truck.

Z

Observe the battery replacement trolley operating instructions.

The battery has now been removed.

04.19 en-GB

42

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.

Z

Z

Place the battery cable on the battery tray so that it cannot be damaged when the
battery is installed.

• Push the battery (48) into the battery compartment.

• Flip the battery retainer (47) back.

• Insert the battery stop (44) in the truck chassis and flip it over.

• Attach the battery connector (43) to the truck connector.

Observe the operating instructions for the battery replacement station.

The battery is now installed.

04.19 en-GB

43

6 Checking the battery acid level

434748

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).

• Pull the battery lock (47) up.

CAUTION!

Unsecured battery

An unsecured battery can result in trapping and injury

Wear safety shoes when removing and installing the battery.

u

Do not reach between the battery and the chassis.

u

• Pull the battery (48) half way off the truck.

• Release the battery lock (47).

• Keep pulling the battery (48) out of the truck until the lock engages on the battery
again.

04.19 en-GB

44

• 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

Wear safety shoes when removing and installing the battery.

u

Do not reach between the battery and the chassis.

u

• Push the battery (48) into the truck

• Release the battery lock (47).

• Keep pushing the battery (48) into the truck until the lock engages on the battery
again.

The acid level has now been checked.

04.19 en-GB

45

Checking the battery acid level on the ESE 320

48

44

47

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.

• Place the battery connector on the battery.

• Flip the battery retainer (47) over so that the wider side is over the battery.

• Flip the battery stop (44) over and pull it up.

• Pull the battery (48) out of the truck.

• Keep pulling the battery out of the truck until the battery is resting against the
battery retainer.

• Check the battery acid level.
All indicators must show sufficient acid level. Add battery water if necessary.

• Push the battery (48) into the truck.

• Insert the battery stop (44) and turn it over.

• Check that the battery is firmly installed.

Z

Battery widths may vary slightly. The battery stop (44) must be adjusted if
necessary.

• Connect the battery connector (43) to the truck.

04.19 en-GB

46

E Operation

1 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.

Operator’s rights, responsibilities and rules of conduct

The driver must be informed of his duties and responsibilities and be instructed in
the operation of the truck and shall be familiar with the operating instructions. Safety
shoes must be worn on pedestrian-operated trucks.

Unauthorised use of truck

The operator is responsible for the truck during the time it is in use. The operator
must prevent unauthorised persons from driving or operating the truck. Do not carry
passengers or lift other people.

Damage and faults

The supervisor must be informed immediately of any damage or faults to the truck or
attachment. Trucks which are unsafe for operation (e.g. wheel or brake problems)
must not be used until they have been rectified.

Repairs

The operator must not carry out any repairs or alterations to the truck without
authorisation and the necessary training to do so. The operator must never disable
or adjust safety mechanisms or switches.

Hazardous area

WARNING!

Risk of accidents/injury in the hazardous area of the truck

A hazardous area is defined as the area in which people are at risk due to travel or
lifting operations of the truck, its load handler or the load. This also includes the area
within reach of falling loads or lowering/falling operating equipment.

Instruct unauthorised persons to leave the hazardous area.

u

In case of danger to third parties, give a warning signal in good time.

u

If unauthorised persons are still within the hazardous area, stop the truck

u

immediately.

04.19 en-GB

Safety devices, warning signs and warning instructions

Safety devices, warning signs (see page 26) and warning instructions in the present
operating instructions must be strictly observed.

47

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.

Report any defects immediately to your supervisor.

u

Mark defective truck and take it out of service.

u

Do not return the truck to service until you have identified and rectified the fault.

u

48

04.19 en-GB

2 Displays and Controls

5, 7104950515253

11

14

1354555617

04.19 en-GB

49

Item Control/display Function

5 Charge/discharge

indicator

52 Key switch and key

CanCode code lock

ISM access module

7 Display and control unit

Shows the battery charge status

t

– Activates the truck by applying the

t

control voltage

– Removing the key prevents the truck

from being switched on by unauthorised
personnel

Replaces the key switch

o

– Entering the appropriate code activates

the truck
– Travel program selection
– Code setting

Replaces the key switch

o

– Activates the truck via a card/

transponder
– Displays readiness for operation
– Operational data logging
– Data exchange with card/transponder

Displays key travel and lift parameters,

o

warning indicators, notification of incorrect
operation and event messages, replaces
the charge/discharge indicator

10 multiPILOT

Function operation

t

– Forward/reverse travel

11 Emergency disconnect

switch

Disconnects the battery supply

t

– All electrical functions are deactivated

and the truck is braked

13 Floor-plate height

adjuster

14 Steering wheel

Button for releasing and adjusting the floor-

t

plate height

Steers the truck

t

17 Deadman switch Deadman switch actuated

– Travel and lifting enabled.
Deadman switch not actuated
– Travel and lifting are deactivated.
– The truck brakes to a halt.

49 Horn button

50 "Raise load handler"

Warning signal button

t

Button for lifting the load handler

t

button

51 "Lower load handler"

Button for lowering the load handler

t

button

50

04.19 en-GB

Item Control/display Function

53 "Seat heater" switch

54 Seat adjustment lever

55 Seat cushioning adjusting

wheel

56 Backrest adjustment

lever

– Switches the seat heating on and off

o

– Indicates when the seat heating is

switched on

Adjusts the driver's seat horizontally

t

Sets the ideal seat cushioning for the

t

driver's weight

Adjusts the backrest tilt

04.19 en-GB

51

2.1 Battery discharge indicator

57

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%

Z

Green/orange

flashes at 1 Hz

Red 0–20%

If the LED is red, the load can no longer be lifted. Lifting is only enabled when the
battery connected is at least 70% charged.

If the LED flashes red and the truck is not ready for operation, inform the
manufacturer's service department. Red flashing is a truck controller code. The
flashing sequence indicates the type of fault.

20–30%

04.19 en-GB

52

2.2 Battery discharge monitor

Z

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. If this adjustment is not made, the battery may become
damaged due to deep discharge.

If the residual capacity falls below the required level, lifting is inhibited. An alternating
display (57) appears. Lifting is only released when the battery connected is at least
70% charged.

04.19 en-GB

53

3 Preparing the Truck for Operation

3.1 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.

Report any defects immediately to your supervisor.

u

Mark defective truck and take out of service.

u

Do not return the industrial truck to service until you have identified and rectified

u

the fault.

Inspection before daily operation

Procedure

• Check the whole of the outside of the truck for signs of damage and leaks.
Damaged hoses must be replaced immediately.

• Check that the battery is securely mounted and that the cable connections are
free of damage and firmly secured.

• Check the battery connector is secure.

• Check the load handler for visible signs of damage such as cracks, bent or
severely worn forks.

• Check the drive wheel and load wheels for damage.

• Check that the markings and labels are all present and legible (see page 26).

• Make sure the drive panels and covers are secure and check for damage.

54

04.19 en-GB

3.2 Entry and exit

58

Requirements

– Load handler fully lowered.

Procedure

Z

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.

04.19 en-GB

55

3.3 Adjusting the driver’s seat

555456

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.

The driver's seat must be locked in position.

u

Do not adjust the driver’s seat while travelling.

u

Adjusting the driver’s seat

Procedure

• Sit down on the driver’s seat.

• Loosen the seat lock (54) and push it forward or backward to the desired position.

• Lock the seat in position again.

• Undo the backrest lock (56) and bring the backrest into its required position.

• Lock the backrest in position again.

• Set the seat cushioning to the required level by turning the adjusting wheel (55).

The driver's seat is now set in the correct position for the controls.

3.4 Adjusting the Floor-Plate Height

Procedure

• Sit down on the driver’s seat.

• Press and hold down on the floor plate height adjustment button (13).

The floor plate can now be adjusted.

04.19 en-GB

56

• Set the floor plate (59) to the correct height by standing on it / discharging it.

59

13

• Release the floor plate height adjustment button (13).

The floor plate is now adjusted and locked at the required height

04.19 en-GB

57

3.5 Preparing the truck for operation

6,8

11

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.

• Pull the emergency disconnect switch (11) to unlock it.

• To switch on the truck:

• Insert the key in the key switch (6) and turn it as far to the right as it will go.

•

Enter the code in the code lock (8) (o).

• Hold the card or transponder in front of the ISM access module and, depending

on the setting, press the green button on the ISM access module (o).

The truck is ready for operation.

04.19 en-GB

58

3.6 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.

Report any defects immediately to your supervisor.

u

Mark defective truck and take out of service.

u

Do not return the industrial truck to service until you have identified and rectified

u

the fault.

Procedure

• Test warning indicators and safety devices:

• Test the Emergency Disconnect function by pressing the Emergency
Disconnect switch. The main circuit is disconnected and no truck operations
can be performed. Now pull the Emergency Disconnect switch to unlock it.

• Test the horn by pressing the "warning signal" button.

• Test the effectiveness of the brakes, see page 69.

• Test the steering, see page 68.

• Test the hydraulic system, see page 71.

• Test travel operations, see page 66.

• Test the controls and displays and check for damage, see page 49.

• Check the controls are automatically restored to the neutral position after being
applied.

04.19 en-GB

59

3.7 Parking the truck securely

60516,8

11

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.

Park the truck on a level surface. In special cases the truck may need to be

u

secured with wedges.
Fully lower the load handler.

u

Select a place to park where no other people are at risk of injury from the lowered

u

load handler.
If the brakes are not working, place wedges underneath the wheels of the truck to

u

prevent it from moving.

Parking the truck securely

Procedure

• Park the truck on a level surface.

• Fully lower the load handler (60):

• Press the lower button (51).

• Turn the drive wheel to the "straight-ahead" position.

• Switch off the truck. To do this:

• Turn the key in the key switch (6) anti-clockwise as far as it will go. Remove the
key from the key switch (6).

•

For CanCode (8), press the O key (o).

•

Press the red key on the ISM access module (o).

• Press the emergency disconnect switch (11).

The truck is parked.

04.19 en-GB

60

4 Industrial Truck Operation

4.1 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. Additional equipment is necessary to operate the truck in
areas of insufficient lighting.

DANGER!

Do not exceed the permissible surface and point loading on the travel lanes.
At blind spots get a second person to assist.
The driver must ensure that the loading dock /dock leveller cannot be removed or
come loose during loading/unloading.

Travel conduct

The operator must adapt the travel speed to local conditions. The truck must be
driven at slow speed when negotiating bends or narrow passageways, when passing
through swing doors and at blind spots. The operator must always observe an
adequate braking distance between the forklift truck and the vehicle in front and
must be in control of the truck at all times. Abrupt stopping (except in emergencies),
rapid U turns and overtaking at dangerous or blind spots are not permitted. Do not
lean out or reach beyond the working and operating area.

04.19 en-GB

61

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. Proceed only at walking pace and with particular care.
Stop the truck as soon as you lose eye contact.

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.

Do not jump off the truck if it tips over.

u

If the truck tips over on the right side of the load direction, hold onto the option bar

u

with both hands.
If the truck tips over on the left side in the load direction, hold onto the steering

u

wheel or the display panel with both hands.
Never hold onto the side where the truck is about to tip over.

u

Tilt your body in the opposite direction of fall.

u

Negotiating slopes and inclines

Negotiating slopes and inclines up to 13 % is only permitted when they are
recognised lanes. The slopes and inclines must be clean, have a non-slip surface,
and negotiating them safely must be within the technical specifications of the truck.
The truck must always be driven with the load facing uphill. The industrial truck must
not be turned, operated at an angle or parked on inclines or slopes. Inclines must
only be negotiated at slow speed, with the driver ready to brake at any moment.

62

04.19 en-GB

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. Persons riding in the lift with the forklift truck must only enter
the lift after the truck has come to a rest and must leave the lift before the truck. The
driver must ensure that the loading ramp / dock cannot move or come loose during
loading / unloading.

Type of loads to be carried

The operator must make sure that the load is in a satisfactory condition. Loads must
always be positioned safely and carefully. Use suitable precautions to prevent parts
of the load from tipping or falling down. Prevent liquid loads from sloshing out.

WARNING!

Electromagnetic influence can result in accidents

Strong magnets can cause electronic components such as Hall sensors to become
damaged, resulting in accidents.

Do not use magnets in the operating area of the truck. Exceptions to this rule are

u

commercial, weak clamping magnets for attaching notices.

04.19 en-GB

63

4.2 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.

Do not use the Emergency Disconnect switch as a service brake.

u

Use the Emergency Disconnect switch during travel only in emergencies.

u

CAUTION!

Faulty or non-accessible Emergency Disconnect switches can cause
accidents

A faulty or non-accessible Emergency Disconnect switch can cause accidents. In
dangerous situations the operator cannot bring the truck to a halt in time by applying
the Emergency Disconnect switch.

The operation of the Emergency Disconnect switch must not be affected by any

u

objects placed in its way.
Report any defects on the Emergency Disconnect switch immediately to your

u

supervisor.
Mark defective truck and take out of service.

u

Do not return the industrial truck to service until you have identified and rectified

u

the fault.

64

04.19 en-GB

Press the Emergency Disconnect switch

6,8

11171032

7

Procedure

• Press the Emergency Disconnect (11).

All electrical functions are deactivated. The truck brakes to a halt.

Z

Z

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).

Trucks with CanCode and ISM access module remain switched off.

04.19 en-GB

65

4.3 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.

4.4 Travel

WARNING!

Collision hazard when operating the truck

Collisions with personnel and equipment can result if the truck is operated with open
panels.

Do not operate the truck unless the panels and covers are closed and properly

u

locked.

Requirements

– Start up the truck, see page 58.

Z

Procedure

• Press the deadman switch (17).

• Set the Multi-Pilot (10) to the required travel direction.

• Move the Multi-Pilot (10) in the load direction (3):
Travel in the load direction.

• Move the Multi-Pilot (10) in the drive direction (2):
Travel in the drive direction.

• Control the travel speed by moving the Multi-Pilot (10):

• The further the Multi-Pilot (10) is moved, the greater the travel speed.

Z

When the Multi-Pilot (10) is released, it automatically returns to the neutral
position and the truck brakes.

The brakes are released and the truck moves in the selected direction.

The travel direction is indicated on the display (7) (o).

66

04.19 en-GB

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.

After setting off in the opposite direction, apply the Multi-Pilot gently or not at all.

u

Do not perform any sudden steering operations.

u

Always face the direction of travel.

u

Maintain an adequate overview of the route you are travelling.

u

Changing direction during travel

Procedure

• Set the Multi-Pilot (10) to the opposite direction while travelling.

The truck decelerates until it starts to travel in the opposite direction.

04.19 en-GB

67

4.5 Steering

10147

Requirements

– Start up the truck, see page 58.

Procedure

• Turn the steering wheel (14) to the left or right.

Z

The wheel position is indicated on the display (7) (o).

The truck is steered in the required direction.

04.19 en-GB

68

4.6 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.

The operator must be aware of floor conditions and take them into account when

u

braking.
Brake with care to prevent the load from slipping.

u

The truck can brake in two ways:

– Using the service brake (deadman switch).
– Using the regenerative brake (coasting brake).

CAUTION!

In emergencies, only use the service brake for braking.

u

Braking with the service brake

Procedure

• During travel, take your foot off the deadman switch (17).

Z

The truck decelerates regeneratively at the maximum rate until it comes to a halt.
The parking brake then applies.

Regenerative braking

Procedure

• While travelling, release the Multi-Pilot (10).

The Multi-Pilot reverts to the neutral position. The truck brakes regeneratively to a
halt. The parking brake then applies.

The brake force can be set by the manufacturer’s customer service department.

04.19 en-GB

69

17

10

04.19 en-GB

70

4.7 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.
Apart from the driver (in the normal operating position) there should be no other
people in the truck's hazardous area.

Instruct other people to move out of the hazardous area of the truck. Stop working

u

with the truck if people do not leave the hazardous area.
If people do not leave the hazardous area despite the warning, prevent the truck

u

from being used by unauthorised people.
Only carry loads that have been secured and positioned in accordance with

u

regulations. Use suitable precautions to prevent parts of the load from tipping or
falling down.

Never exceed the maximum loads specified on the capacity plate.

u

Do not stand on the load handler.

u

Do not lift other people on the load handler.

u

Never reach or climb into moving truck parts.

u

Do not climb onto parts of the building or other trucks.

u

04.19 en-GB

71

4.7.1 Raising the load handler

105051

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.

Z

4.7.2 Lowering the load handler

Z

Hold down the button until the load
handler has reached the maximum
height.

The load handler is raised.

Requirements

– Prepare the truck for operation, see page 58.
– Deadman switch actuated, see page 66.

Procedure

• Press the "lower load handler" button (51) on the multiPILOT.

Hold down the button until the load handler is fully lowered.

The load handler is lowered.

04.19 en-GB

72

4.8 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.

Instruct other people to move out of the hazardous area of the truck. Stop working

u

with the truck if people do not leave the hazardous area.
Only carry loads that have been correctly secured and positioned. Use suitable

u

precautions to prevent parts of the load from tipping over or falling off the truck.
Damaged loads must not be transported.

u

Never exceed the maximum loads specified on the load diagram.

u

Never stand underneath a raised load handler.

u

Do not stand on the load handler.

u

Do not lift other people on the load handler.

u

Insert the load handler as far as possible underneath the load.

u

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73

4.8.1 Raising a load

Requirements

– Load correctly palletised.
– Load weight matches the

truck's capacity.

– Load handler evenly loaded

for heavy loads.

Procedure

• Drive the truck carefully up to
the pallet.

• Drive the load handler slowly
into the pallet until the pallet
is against the back of the load
handler (see graphic to the
right).

Z

The load must not extend by
more than 50 mm beyond the
load handler tips.

• Raise the load handler until
the desired height is reached,
(see page 72).

The load is being raised.

NOTICE

Risk of material damage to the hydraulic unit

When the mechanical stops of the load handler have been reached, release the
"raise load handler" button. Otherwise the hydraulic unit may suffer material damage.

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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.

• Travel at a constant speed.

• Be prepared to brake at all times.

• Brake gently in normal circumstances.

• Only stop suddenly in dangerous situations.

• Watch out for other traffic at crossings and passageways.

• Always travel with a lookout at blind spots.

• Do not travel across or at an angle on inclines. Do not turn on slopes and inclines,
and always drive with the load facing uphill (see graphic).

4.8.3 Depositing a load

CAUTION!

Loads must not be set down on transport or escape routes, in front of safety
installations or factory equipment that must be accessible at all times.

Requirements

– Storage location suitable for storing the load.

Procedure

• Drive the truck carefully up to the storage location.

• Lowers the load handler.

Z

To avoid damaging the load and the load handler, avoid setting the load down
abruptly.

• Lower the load handler so that it is clear of the load (see page 72).

• Carefully drive the load handler out from beneath the pallet.

The load is deposited.

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75

5 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.

Z

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.
Troubleshooting must only be performed by the manufacturer’s customer service
department. The manufacturer has a service department specially trained for these
tasks.
In order for customer services to react quickly and specifically to the fault, the
following information is essential:

- Truck serial number

- Event message from the display unit (if applicable)

- Error description

- Current location of truck.

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5.1 Truck does not start

Possible Cause Remedy

Battery connector not inserted Check the battery connector

Emergency Disconnect switch pressed Release the Emergency Disconnect

Key switch set to O Set the key switch to “I”

Deadman switch not pressed Press deadman switch

Battery charge too low Check battery charge,

Faulty fuse Check fuses see page 120

and insert if necessary

switch, see page 64

Charge battery if necessary, see
page 38

Incorrect ISM access module
transponder used

Incorrect CANCode PIN entered Enter correct PIN, see page 86

5.2 Load cannot be lifted

Possible Cause Remedy

Truck not operational Carry out all measures listed under

Hydraulic oil level too low Checking the hydraulic oil level

Battery discharge monitor has switched
off

Faulty fuse Check fuses

Excessive load Note maximum capacity, see data plate.

Switch in mast implausible (E-2124) Emergency recovery (travel at max. 1.5

Use correct transponder

“Truck does not start”.

Charge the battery

km/h and lowering possible when truck is
in rider mode). Contact the
manufacturer's service department.

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77

6 Operating the truck without its own drive system

61

6,8

11

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.

Do not release the brake on slopes or

u

inclines.
Do not park the truck with the brake

u

released.
Apply the brake again when you reach your

u

destination.

Releasing the brake

Tools and Material Required

– Two M5x45 screws
– Spanner wrench

Procedure

• Switch off the truck, to do this:

• Turn the key in the key switch (6) anti-

clockwise as far as it will go. Remove the
key from the key switch (6).

•

For CanCode (8)(o) press the O key.

• Press the red button on the ISM access

module(o).

• Press the Emergency Disconnect switch
(11).

• Disconnect the battery.

• Use wedges to prevent the truck from
moving.

• Remove the drive compartment cover, see
page 117.

• Insert two M5x45 screws (61) as far as the
stop and lift up the anchor plate.

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The brake is now released. The truck can be moved.

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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

The covers (battery cover, side panels, drive compartment cover etc.) must be

u

closed during operation.

Fit the drive compartment cover, see page 117.

The brakes are now applied again. The brake is now be applied without current.

WARNING!

Only return the truck to service when you have identified and rectified the fault.

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7 Optional equipment

62

7.1 Brake Pedal in Footwell with ESE 220

Z

Item Control/display Function

62 Brake pedal (electric)

Braking with the brake pedal

Procedure

• Press down the brake pedal (62) during travel until you reach the required
deceleration.

The truck decelerates.

The brake force can be set by the manufacturer's customer service department.

Pedal for reducing the travel speed and for

o

braking the truck to a halt

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81

7.2 Display and control unit

68

77798078767573

716364656667576970

72

74

Item Description

63 STOP

64 Parking brake applied

65 WARNING

66 Displays the current steer angle (drive wheel direction)

67 Steer mode, displays possible travel directions

68 Time display (hours: minutes)

57 Battery charge status

69 Discharge indicator

70 Set travel speed for current profile (max = 5 bars)

71 Slow travel activated (reduced travel speed)

72 Profile number (travel profile 1, 2 or 3)

73 Deadman button not pressed

74 Information display

75 Service mode active (icon illuminated),

service interval expired (symbol flashes)

76 Overtemperature

77 Slow travel button, when illuminated the 71 icon illuminates

78 Parking brake button (void)

79 Shift key, to set the time

80 Profile key, selects the travel profile

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82

7.3 Setting the time

807977

81

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).

• Set the minutes with the Up (77) and Down (81) keys.

• Confirm with the Shift (79) or profile (80) keys to return to normal operating mode.

The time is now set.

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83

7.4

7.4.1 Code lock

Keypad (CanCode) (o)

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.

When you have entered the valid user code the truck will be operational. The truck
will be able to perform travel, steering and hydraulic operations.

When you have entered the valid master code the truck will be switched on. Travel
operations are inhibited. The truck will be able to perform steering and hydraulic
operations. The code lock is in programming mode. When you enter one of the
following parameters the settings in the code lock can be changed.

Parameter Description

0-0-0

0-0-1

0-0-2

0-0-3

0-0-4

0-1-0

0-2-4

In the as-supplied condition, the code is indicated on a sticker. When using the truck
for the first time, change the master and user codes and remove the sticker.
– Default user code: 2-5-8-0
– Default master code: 7-2-9-5

– Change master code

(see page 87)

– Add user codes

(see page 89)

– Change a user code

(see page 91)

– Delete a user code

(see page 93)

– Delete all user codes

(see page 95)

– Switch on the truck automatically

(see page 97)

– Assign travel programs to the user codes

(see page 99)

Z

84

When allocating the codes, ensure the rider trucks are given a different code than
pedestrian trucks.

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The keypad consists of 10 digit keys, a Set key (85)

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86

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.

o key

Pressing the o key switches the truck off and sets it
to "non operational" status.

The o key indicates the follow operating conditions via a red / green LED (86):
– Code lock function (commissioning the truck).
– Error display configuring the user code.
– Adjusting the travel program depending on the setting and truck.
– Setting and changing parameters.

SET key

When you change the parameters the SET key (85) acts as a confirmation key.

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85

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.

Z

7.4.3 Switching off the truck with the keypad (CanCode)

Z

If the LED (86) flashes red this means the wrong code has been entered. Enter
the code again.
The Set key (85) has no function in operating mode.

Switching off the truck

Procedure

• Press the O key (87).

The truck is switched off and the LED (86) is lit red.

The truck can cut out automatically after a specified time. If no travel, steering or
hydraulic operations are performed within a set time, the truck switches off
automatically. When you enter a valid code again the truck will be operational. The
code lock parameter responsible for automatic cutout must be set, see page 97.

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7.4.4 Changing the Set-up Code

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Z

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.

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.

• Enter the parameters 0-0-0 with the digit keys.

• Confirm with the SET key (85).

The LEDs (82,86) flash green.

• Enter the valid master code again with the digit keys.

• Confirm with the SET key (85).

The LEDs (83,86) flash green.

• Enter the valid master code with the digit keys.

Z

The new master code must be different from existing user codes.

• Confirm with the SET key (85).

The LEDs (84,86) flash green.

• Enter the new master code again with the digit keys.

• Confirm with the SET key (85).

Wait until the LED (86) flashes green. The setting is saved.

• Press the O key (87).

The truck is switched off and the LED (86) is lit red.

• Check the new master code:

• Switch on the truck with the new master code, see page 86

When you enter the valid master code the LED (86) flashes green.

• Press the O key (87).

The truck is switched off and the LED (86) is lit red.

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87

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

occupied by a user code

– Change the user code so that the required

master code can be used, see page 91.

– Delete the user code so that the required

master code can be used, see page 93.

– The master codes to be

changed do not match

– The master code entered is

not the same length as the

user code

– Switch off the truck, see page 86.
– Enter the master code again, see page 87.

– Switch off the truck, see page 86.
– Repeat the entry, making sure that the length of

the master code matches that of the user code.

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7.4.5 Add operator code

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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.

• Enter the parameters 0-0-1 with the digit keys.

• Confirm with the SET key (85).

The LEDs (83,86) flash green.

• Enter the new user code with the digit keys.

Z

The length (4-6 digit) of the new user code must be the same as that of the
previously entered master code. The new user code must also be different from
the existing master code.

• Confirm with the SET key (85).

The LEDs (84,86) flash green.

• Enter the new user code again with the digit keys.

• Confirm with the SET key (85).

Wait until the LED (86) flashes green. The setting is saved.

• Press the O key (87).

The truck is switched off and the LED (86) is lit red.

• Check the new user code:

• Switch on the truck with the new user code, see page 86

After entering the valid user code the LED (86) lights up green, the travel
program setting is shown by the illumination of the corresponding LEDs
(82,83,84) and the truck is switched on.

• Press the O key (87).

The truck is switched off and the LED (86) is lit red.

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89

Error displays adding a user code

For the following events the LED (86) flashes red:

Cause Remedy

– The user code entered is

not the same length as the

master code

– New user code is already

occupied by a master code

– The newly entered user

codes do not match

– Code log full.

– Switch off the truck, see page 86.
– Repeat the entry, making sure that the master

code is the same length as the user code.

– Switch off the truck, see page 86.
– Choose a different user code, see page 89.

– Switch off the truck, see page 86.
– Add the user code again, see page 89.

– Switch off the truck, see page 86.
– Delete individual user codes, see page 93.
– Delete all user codes, see page 95.

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7.4.6 Change operator code

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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.

• Enter the parameters 0-0-2 with the digit keys.

• Confirm with the SET key (85).

The LEDs (82,86) flash green.

• Enter the user code to be changed with the digit keys.

• Confirm with the SET key (85).

The LEDs (83,86) flash green.

• Enter the new user code with the digit keys.

Z

The length (4-6 digit) of the new user code must be the same as that of the
previously entered master code. The new user code must also be different from
the existing master code.

• Confirm with the SET key (85).

The LEDs (84,86) flash green.

• Enter the new user code again with the digit keys.

• Confirm with the SET key (85).

Wait until the LED (86) flashes green. The setting is saved.

• Press the O key (87).

The truck is switched off and the LED (86) is lit red.

• Check the new user code:

• Switch on the truck with the new user code, see page 86

After entering the valid user code the LED (86) lights up green, the travel
program setting is shown by the illumination of the corresponding LEDs
(82,83,84) and the truck is switched on.

• Press the O key (87).

The truck is switched off and the LED (86) is lit red.

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91

Error displays changing a user code

For the following events the LED (86) flashes red:

Cause Remedy

– The user code entered is

not the same length as the

master code

– Operator code to be

changed does not exist.

– The user codes to be

changed do not match

– Tried to change the operator

code to another user code

that already exists.

– Switch off the truck, see page 86.
– Repeat the entry, making sure that the master

code is the same length as the user code.

– Switch off the truck, see page 86.
– Check the user code entered.

– Switch off the truck, see page 86.
– Change the user code again, see page 91.

– Switch off the truck, see page 86.
– Choose a different user code, see page 91.

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7.4.7 Delete individual user codes

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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.

• Enter the parameters 0-0-3 with the digit keys.

• Confirm with the SET key (85).

The LEDs (83,86) flash green.

• Enter the user code to be deleted with the digit keys.

• Confirm with the SET key (85).

The LEDs (84,86) flash green.

• Enter the user code to be deleted again with the digit keys.

• Confirm with the SET key (85).

Wait until the LED (86) flashes green. The user code is now deleted.

• Press the O key (87).

The truck is switched off and the LED (86) is lit red.

• Check that the user code has been deleted:

• Switch the truck on with the user code to be deleted, see page 86

After entering the user code the LED (86) flashes red and the truck remains
switched off.

• Press the O key (87).

The truck remains switched off and the LED (86) is lit red.

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93

Error displays deleting individual user codes

For the following events the LED (86) flashes red:

Cause Remedy

– The user code entered is

not the same length as the

master code

– Tried to delete an operator

code that does not exist.

– The user codes to be

changed do not match

– Switch off the truck, see page 86.
– Repeat the entry, making sure that the master

code is the same length as the user code.

– Switch off the truck, see page 86.
– Check the user code entered.

– Switch off the truck, see page 86.
– Delete the user code again, see page 93.

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7.4.8 Delete all user codes,

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86

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.

• Enter the parameters 0-0-4 with the digit keys.

• Confirm with the SET key (85).

The LEDs (84,86) flash green.

• Enter the code 3-2-6-5 with the digit keys.

• Confirm with the SET key (85).

Wait until the LED (86) flashes green. All user codes are deleted.

• Press the O key (87).

The truck is switched off and the LED (86) is lit red.

• Check that the user codes have been deleted:

• Switch on the truck with a previous user code, see page 86.

After entering the user code the LED (86) flashes red and the truck remains
switched off.

• Press the O key (87).

The truck remains switched off and the LED (86) is lit red.

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95

7.4.9 Choose length of the new master code (4-6 digit) and add user codes

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Z

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. The length of the user code (4-6 digit)
is always determined by the length of the master code.

Requirements

– To prepare the truck for operation, see page 86.

Procedure

• Delete all user codes, see page 95.

• Enter the new master code (4-6 digit), see
page 87.

• Add user codes again, see page 89.

The length of the new master code is now changed
and user codes have been added.

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96

7.4.10 Setting the automatic truck cutout (timeframe)

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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.

• Enter the 0-1-0 parameter with the digit keys.

• Confirm with the SET key (85).

Wait until the LED (86) flashes green.

• Set the truck automatic cutout (time period) with the digit keys:

• 00:

Automatic truck cutout is deactivated.

• 01 - 30:

Set time period (in minutes) after which the truck automatically cuts out
(minimum cutout time is 1 minute,
maximum cutout time is 30 minutes).

• 31:

After 10 seconds the truck cuts out automatically.

• Confirm with the SET key (85).

Wait until the LED (86) flashes green. The setting is saved.

• Press the O key (87).

The truck is switched off and the LED (86) lights up red.

• Checking the truck's automatic cutout:

• Switch on the truck with a valid operator code, see page 86.

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.

• Do not perform any travel, steering or hydraulic operations with the truck.

• Wait until the truck automatically cuts out at the end of the time period.

The truck is switched off and the LED (86) lights up red.

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97

Error displays setting the automatic cutout period of the truck

For the following events the LED (86) flashes red:

Cause Remedy

– Cutout time entered is out of

range

– Switch off the truck, see page 86.
– Enter the time again while making sure it is

within range.

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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.

Z

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.
LED (82) lit = travel program 1 activated
LED (83) lit = travel program 2 activated
LED (84) lit = travel program 3 activated

The configuration code is four-digit and is comprised as follows:
– 1st digit: Specifies the authorisation for travel program 1:
– 2nd digit: Specifies the authorisation for travel program 2:
– 3rd digit: Specifies the authorisation for travel program 3:
– 4. digit: Specifying the starting travel program

When you add or change a user code all travel programs are enabled, the starting
travel program is travel program 2.

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99

Specifying a configuration code:

Setting Description

1st digit

2nd digit

3rd digit

4th digit

0

1

0

1

0

1

0

1

2

– Travel program 1 is blocked for the user code

selected

– Travel program 1 is enabled for the user code

selected

– Travel program 2 is blocked for the user code

selected

– Travel program 2 is enabled for the user code

selected

– Travel program 3 is blocked for the user code

selected

– Travel program 3 is enabled for the user code

selected

– When the truck has been switched on with the

selected user code, no travel program is activated

– When the truck has been switched on with the

selected user code, travel program 1 is activated

– When the truck has been switched on with the

selected user code, travel program 2 is activated

Z

3

The default setting for the travel program configuration code is:
1-1-1-2.

Meaning:

Travel programs 1, 2 and 3 are enabled.
When the truck has been switched on with the selected user code, travel program 2
is activated

– When the truck has been switched on with the

selected user code, travel program 3 is activated

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