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: +49 (0) 40/6948-0
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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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
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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
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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.
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