ESE 220/320 - Jungheinrich...04.19 en-GB ESE 220 ESE 320 2 Declaration of Conformity Manufacturer Jungheinrich AG, 22039 Hamburg, Germany Description Industrial truck Type Option Serial

ESE 220/320 03.10

Operating instructions

5116370304.19

en-GB

ESE 220ESE 320

2

Declaration of Conformity

Manufacturer

Jungheinrich AG, 22039 Hamburg, Germany

Description Industrial truck

Type Option Serial no. Year ofmanufacture

ESE 220ESE 320

On behalf of

Date

EU DECLARATION OF CONFORMITY

The undersigned hereby declare that the powered truck described in detail complieswith the current versions of European Directives 2006/42/EG (Machinery Directive)and 2014/30/EU (Electromagnetic Compatibility - EMC). The manufacturer isauthorised to compile the technical documentation.

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ForewordNotes on the operating instructions

The present ORIGINAL OPERATING INSTRUCTIONS are designed to providesufficient instruction for the safe operation of the industrial truck. The information isprovided clearly and concisely. The chapters are arranged by letter and the pagesare numbered continuously.

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

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

Safety notices and text mark-ups

Safety instructions and important explanations are indicated by the followinggraphics:

DANGER!Indicates an extremely hazardous situation. Failure to comply with this instruction willresult in severe irreparable injury and even death.

WARNING!Indicates an extremely hazardous situation. Failure to comply with this instructionmay result in severe irreparable injury and even death.

CAUTION!Indicates a hazardous situation. Failure to comply with this instruction may result inslight to medium injury.

NOTICEIndicates a material hazard. Failure to comply with this instruction may result inmaterial damage.

Z Used before notices and explanations.

t Indicates standard equipmento Indicates optional equipment

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Copyright

Copyright of these operating instructions remains with JUNGHEINRICH AG.

Jungheinrich Aktiengesellschaft

Friedrich-Ebert-Damm 12922047 Hamburg - Germany

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

www.jungheinrich.com

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Contents.A Correct Use and Application 11.1 General 112 Correct application 113 Approved application conditions 124 Proprietor responsibilities 135 Adding attachments and/or optional equipment 13.B Truck Description 15.1 Application 151.1 Truck models and rated capacity 152 Travel direction definition 163 Assemblies and Functional Description 173.1 Assembly Overview 173.2 Functional Description 184 Technical Specifications 204.1 Performance data 204.2 Dimensions 214.3 Weights 234.4 Tyre type 234.5 EN norms 244.6 Specifications according to RED guideline (Radio Equipment

Directive) for radio units 254.7 Conditions of use 254.8 Electrical Requirements 255 Identification Points and Data Plates 265.1 Data plate 275.2 Truck capacity plate 28.C Transport and Commissioning 29.1 Lifting by crane 292 Transport 303 Using the Truck for the First Time 32.D Battery - Servicing, Recharging, Replacement 33.1 Safety Regulations Governing the Handling of Lead-Acid Batteries 332 Battery types 353 Exposing the battery 364 Charging the battery 385 Battery removal and installation 406 Checking the battery acid level 44.E Operation 47.1 Safety Regulations for the Operation of Forklift Trucks 472 Displays and Controls 492.1 Battery discharge indicator 522.2 Battery discharge monitor 533 Preparing the Truck for Operation 54

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3.1 Checks and Operations to Be Performed Before Starting Daily Work 543.2 Entry and exit 553.3 Adjusting the driver’s seat 563.4 Adjusting the Floor-Plate Height 563.5 Preparing the truck for operation 583.6 Checks and operations to be carried out when the truck is operational 593.7 Parking the truck securely 604 Industrial Truck Operation 614.1 Safety regulations for truck operation 614.2 Emergency Disconnect 644.3 Deadman button 664.4 Travel 664.5 Steering 684.6 Brakes 694.7 Load handler raise/lower 714.8 Lifting, transporting and depositing loads 735 Troubleshooting 765.1 Truck does not start 775.2 Load cannot be lifted 776 Operating the truck without its own drive system 787 Optional equipment 817.1 Brake Pedal in Footwell with ESE 220 817.2 Display and control unit 827.3 Setting the time 837.4 Keypad (CanCode) (o) 847.5 ISM access module (o) 1027.6 Floor-Spot 103.F Industrial Truck Maintenance 105.1 Operational Safety and Environmental Protection 1052 Maintenance Safety Regulations 1062.1 Working on the electrical system 1072.2 Consumables and used parts 1072.3 Wheels 1072.4 Hydraulic system 1083 Lubricants and Lubrication Schedule 1093.1 Handling consumables safely 1093.2 Lubrication Schedule 1113.3 Consumables 1124 Maintenance and repairs 1134.1 Preparing the truck for maintenance and repairs 1134.2 Lifting and jacking up the truck safely 1134.3 Cleaning 1144.4 Checking the hydraulic oil level 1184.5 Tightening the wheel nuts 1194.6 Checking electrical fuses 1204.7 Restoring the truck to service after maintenance and repairs 1215 Decommissioning the Industrial Truck 1225.1 Prior to decommissioning 1225.2 During decommissioning 1225.3 Restoring the truck to service after decommissioning 1236 Safety tests to be performed at intervals and after unusual incidents 124

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7 Final de-commissioning, disposal 1248 Human vibration measurement 124.G Maintenance, Inspection and Changing of Maintenance

Parts Requiring Replacement 125.1 Maintenance Contents ESE 220 1261.1 Owner 1261.2 Customer Service 1302 Maintenance Contents ESE 320 1372.1 Owner 1372.2 Customer Service 141.H Traction Battery Appendix 149.1 Correct Use and Application 1492 Data plate 1493 Safety Instructions, Warning Indications and other Notes 1504 Lead acid batteries with armour plated cells and liquid electrolyte 1514.1 Description 1514.2 Operation 1534.3 Servicing lead-acid batteries with armour plated cells 1565 PzV and PzV-BS lead-acid batteries with sealed armour plated cells 1585.1 Description 1585.2 Operation 1595.3 Servicing PzV and PzV-BS lead-acid batteries with sealed armour

plated cells 1626 Aquamatik water replenishment system 1636.1 Water replenishment system design 1636.2 Functional Description 1646.3 Adding water 1646.4 Water pressure 1646.5 Filling time 1656.6 Water quality 1656.7 Battery tubing 1656.8 Operating temperature 1656.9 Cleaning measures 1656.10 Service mobile vehicle 1657 Electrolyte circulation 1667.1 Functional Description 1668 Cleaning batteries 1689 Storing the battery 17010 Troubleshooting 17011 Disposal 170

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A Correct Use and Application1 General

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

2 Correct application

NOTICEThe maximum load and load distance are indicated on the capacity plate and mustnot be exceeded.The load must rest on the load handler or be lifted by an attachment approved by themanufacturer.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 conditionsUsing the truck under extreme conditions can result in malfunctions and accidents.uSpecial equipment and authorisation are required if the truck is to be constantly

used in extreme conditions, especially in dusty or corrosive atmospheres.uThe truck cannot be used in areas at risk of explosion.uIn adverse weather conditions (thunder, lightning) the industrial truck must not be

operated outside or in endangered areas.

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4 Proprietor responsibilitiesFor the purposes of the present operating instructions the “operating company” isdefined as any natural or legal person who either uses the industrial truck himself, oron whose behalf it is used. In special cases (e.g. leasing or renting) the proprietor isconsidered the person who, in accordance with existing contractual agreementsbetween the owner and user of the industrial truck, is charged with operationalduties.The proprietor must ensure that the industrial truck is used only for the purpose it isintended for and that danger to life and limb of the user and third parties areexcluded. Furthermore, accident prevention regulations, safety regulations andoperating, servicing and repair guidelines must be followed. The operating companymust ensure that all users have read and understood these operating instructions.

NOTICEFailure to comply with the operating instructions invalidates the warranty. The sameapplies if improper work is carried out on the truck by the customer or third partieswithout the permission of the manufacturer.

5 Adding attachments and/or optional equipmentThe mounting or installation of additional equipment which affects or enhances theperformance of the industrial truck requires the written permission of themanufacturer. 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 Description1 Application

The ESE 220/320 is a four-wheel, electric side-seated pallet truck with a driver's seatequipped with an electric steering wheel system.The ESE 220/320 is designed to transport goods on level surfaces. The truck can liftopen bottom or diagonal board pallets beyond the area of the load wheels as well asroll cages. It can transport low stacked loads over long distances. The capacity isshown on the load chart, Qmax.

1.1 Truck models and rated capacityThe rated capacity depends on the model. The rated capacity can be derived fromthe model name.

ESE220

ESE Model name2 Series

20 Rated capacity x 100 kg

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

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2 Travel direction definitionThe following determinations have been made for travel direction specification:

1

2 3

4

Item Travel direction1 Left2 Drive direction3 Load direction4 Right

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3 Assemblies and Functional Description

3.1 Assembly Overview

5 6 7 8 7 9

10

12

13

16

14

17

18

15

11

Item Description Item Description5 t Charge status indicator 12 t Armrest6 t Key switch 13 t Floor-plate height adjuster7 o Control/display unit 14 t Steering wheel8 o CanCode code lock 15 t Load rollers9 o ISM access module 16 t Battery

10 t multiPILOT 17 t Deadman switch11 t Emergency disconnect switch 18 t Seat panel

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 ofthe truck. The wheels are surrounded by a solid skirt offering collision protection.

Activating the emergency disconnect switch rapidly cuts out all electrical functions inhazardous situations.

Emergency stop safety concept

The emergency stop is activated by the traction controller. Each time the truck isswitched on, the system carries out a self-diagnosis. The steering controller sends asystem status signal, which is monitored by the traction controller. If the signal failsto appear or a fault is identified, the truck automatically brakes to a halt. Controldisplays 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. Alltravel and lift operations can be performed sensitively without having to reach. Theergonomic steering wheel provides secure control of the truck.

Deadman switch

The deadman switch ensures that the driver's feet do not extend outside the truckduring travel. The deadman switch in the foot compartment must be depressed toenable the driver to operate the truck. Lifting and travel are inhibited if the operatortakes 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 fromthe oil reservoir to the lift cylinder.

When the lift button is pressed, the support arms are raised at an even speed; whenthe 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 andhence smooth starting, powerful acceleration and electrically controlled braking withenergy regeneration. The driver can choose from 3 travel programs depending onthe load and the environment: from high-performance to energy-saving.

Steering

The operator steers with an ergonomically inclined steering wheel. The steeringmotion is transmitted from the steering controller via a steer motor directly to the ringgear of the pivoted drive system. The drive wheel can be rotated ± 90°. Automatictravel speed reduction as a function of the steer angle (Curve Control o) isoptionally available.

Electrical system

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

Controls and displays

Ergonomic controls ensure fatigue-free operation for sensitive application of thetravel and hydraulic operations. The charge indicator shows the available batterycapacity. The control and display unit (o) shows the key operator information suchas 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 ispressed.

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4 Technical Specifications

Z The technical specification is given according to the German guideline "Type sheetsfor 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 10/12.5 km/h

Lift speedwith/without load 0.06/0.07 m/s

Lowering speedwith/without load 0.06/0.05 m/s

Max. gradeabilitywith/without load 8/13 %

Drive motor,output S2 60 min 2.8 kW

Lift motor,output S3 15% 1.5 kW

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4.2 Dimensions

Q

c

l

l2

l1

h3

x h13

Asta/2 a/2

b1

Wa

e

b11

b5

ESE 220 ESE 320 c Load centre distance 600 mmx Load distance 868 mmy Wheelbase 15351 15412 mm

h3 Lift 125 mmh7 Seat height 1020 mmh13 Lowered height 90 mm

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ESE 220 ESE 320 l1 Overall length 2009 mml2 Length

including fork shank 859 mm

b2/b1 Overall width 820 930 mm

b5 Overall width of the loadhandler 540 mm

b10 Track 544 645 mmb11 Track 385 mm

s / e /l

Load-handler dimensions 60 / 185 / 1150 mm

m2 Ground clearance, centre ofwheelbase 25 mm

Ast Aisle width forpallet 800x1200 lengthways 21973 22153 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 loadfront / rear 1896 / 1142 1902 / 1182 kg

Axle load without loadfront / rear 258 / 808 264 / 816 kg

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

Wheels, number front/rear(x = driven) 2 - 1x / 4

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4.5 EN normsContinuous sound pressure level

– ESE 220/320: 73 dB(A)

in accordance with EN 12053 as harmonised with ISO 4871.

Z The continuous sound pressure level is calculated according to standard proceduresand 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.

Z The vibration acceleration acting on the body in its operating position is the linearlyintegrated, weighted acceleration in the vertical axis according to the standard. It iscalculated when travelling over thresholds at constant speed (standard truckversion). These recordings were taken on a single occasion for the truck and mustnot be confused with the human vibrations of the operator directive. Themanufacturer 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 electromagneticemissions and resistance as well as the static electricity discharge test inaccordance with EN 12895 as well as the standardised instructions containedtherein.

Z No changes to electric or electronic components or their arrangement may be madewithout the written agreement of the manufacturer.

WARNING!

Medical equipment can be damaged by non-ionised radiationElectrical equipment on the truck emitting non-ionised radiation (e.g. wireless datatransmission) can affect operators' medical equipment (pacemakers, hearing aidsetc.) and result in malfunctions. Consult a doctor or the manufacturer of the medicalequipment to clarify whether it can be used near the industrial truck.

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

Z The table contains any components installed according to the European Directive2014/53/EU. The table shows the affected frequency range and the emittedtransmission power for each component.

Component Frequency range Transmission powerRadio module (ISM Online) 433,05 - 434,79 MHz < 10 mWGateway (ISM Online) 433,05 - 434,79 MHz < 10 mWGateway (ISM Online) GSM 850/900 MHz 2 WGateway (ISM Online) GSM 1800/1900 MHz 1 WGateway (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 usedcontinually in conditions of extreme temperature or condensing air humidityfluctuations.

4.8 Electrical RequirementsThe manufacturer certifies compliance with the requirements for the design andmanufacture 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

22

23

25

27

24

26

Item Description19 Load handler lift/lower20 Truck capacity plate21 multiPILOT22 Floor-plate adjustment23 Data plate24 Inspection plaque25 Attachment points for loading by crane26 Model description27 Serial number

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5.1 Data plate

28 29 3130 32

39

35

38

37

36

3433

Item Description Item Description28 Type 34 Year of manufacture29 Serial number 35 Load centre distance (mm)30 Rated capacity (kg) 36 Nominal power31 Battery voltage (V) 37 Min./max. battery weight (kg)32 Net weight without battery (kg) 38 Manufacturer33 Option 39 Manufacturer's logo

Z For queries regarding the truck or when ordering spare parts, always quote the truckserial 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 inkg assuming the load on the load handler is evenly distributed.

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C Transport and Commissioning1 Lifting by crane

WARNING!

Improper loading by crane can result in accidentsImproper use or use of unsuitable lifting gear can cause the truck to crash whenbeing loaded by crane.Prevent the truck from hitting other objects during lifting, and avoid uncontrolledmovements. If necessary, secure the truck with guide ropes.uThe truck may be loaded only by people who are trained in using lifting

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

jacket, protective gloves) when loading by crane.uDo not stand under suspended loads.uDo not walk into or stand in a hazardous area.uAlways use lifting gear with sufficient capacity (for truck weight, see truck data

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

prevent them from slipping.uUse the lifting accessories only in the prescribed load direction.uCrane lifting gear must be fastened in such a way that it does not come into

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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25

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2 Transport

WARNING!

Uncontrolled movement during transportImproper fastening of the truck and mast during transport can result in seriousaccidents.uLoading is only to be carried out by specially trained staff. The specialist personnel

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

uThe truck must be securely fastened when transported on a lorry or a trailer.uThe lorry or trailer must have lashing rings.uUse wedges to prevent the truck from moving.uUse only lashing straps with sufficient load rating.uUse anti-slip material to secure loading aids (pallets, wedges,...), e. g. anti-slip

mats.

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41

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 vehicleand the load handler.

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

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

The truck can now be transported.

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3 Using the Truck for the First TimeIf the truck is delivered in multiple parts, setup and commissioning must only beperformed by trained, authorised personnel.

NOTICE

Cold store trucksuTrucks designed for use in cold stores have a cold store hydraulic oil.uIf a truck with cold store oil is used outside the cold store, the lowering speeds

may increase.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-AcidBatteries

Maintenance personnel

Batteries may only be charged, serviced or replaced by trained personnel. Theseoperating instructions and the manufacturer’s instructions concerning batteries andcharging stations must be observed when carrying out the work.

Fire Protection

Do not smoke and avoid naked flames when handling batteries. Wherever anindustrial truck is parked for charging there must be no inflammable material orconsumables capable of creating sparks within a minimum distance of 2,5 m fromthe truck. The room must be ventilated. Fire protection equipment must be available.

CAUTION!

The use of unsuitable fire protection equipment can result in scaldingExtinguishing fires with water can cause a reaction with the battery acid. This canresult in scalding from the acid.uUse powder extinguishers.uNever extinguish a burning battery with water.

Battery maintenance

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

WARNING!

Short circuits can result in fireDamaged cables can cause short circuits, setting the truck and battery on fire.uBefore closing the battery cover make sure that the battery cables are not

damaged.

Battery disposal

Batteries may only be disposed of in accordance with national environmentalprotection regulations or disposal laws. The manufacturer’s disposal instructionsmust be observed.

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WARNING!

Batteries can be hazardousBatteries contain an acid solution which is poisonous and corrosive. Avoid contactwith battery acid at all times.uDispose of used battery acid in accordance with regulations.uAlways wear protective clothing and goggles when working with batteries.uDo not let battery acid come into contact with skin, clothing or eyes. If necessary,

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

a doctor immediately.uSpilled battery acid should be neutralised immediately with plenty of water.uOnly batteries with a sealed battery container may be used.uFollow national guidelines and legislation.

WARNING!

Unsuitable batteries that have not been approved by Jungheinrich for thetruck can be hazardousThe design, weight and dimensions of the battery have a considerable effect on theoperational safety of the truck, in particular its stability and capacity. The use ofunsuitable batteries that have not been approved for the truck by Jungheinrich, canlead to a deterioration of the braking characteristics of the truck during energyrecovery, causing considerable damage to the electric controller and resulting inserious danger to the health and safety of individuals.uOnly Jungheinrich-approved batteries may be used on the truck.uBattery equipment may only be replaced with the agreement of Jungheinrich.uWhen replacing/installing the battery make sure the battery is securely located in

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

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

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2 Battery typesDepending on the model, the truck will be supplied with different battery types. Thefollowing table shows which combinations are included as standard:

Battery type Capacity Weight24 volt battery796 x 210 x 782 mm (LXWXH) 3 PzS 465 Ah 380 kg

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

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3 Exposing the battery

CAUTION!

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

the battery cover.

WARNING!

An unsecured truck can cause accidentsParking the truck on an incline or with a raised load handler is dangerous and isstrictly prohibited.uPark the truck on a level surface. In special cases the truck may need to be

secured with wedges.uFully lower the load handler.uSelect a place to park where no other people are at risk of injury from the lowered

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

prevent it from moving.

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Requirements– 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 beaccessed.The battery retainer (42) is accessible onthe ESE 220.

43

42

12

On the ESE 320 the battery latch (44) ison the right-hand side of the truck.

44

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4 Charging the battery

WARNING!

The gases produced during charging can cause explosionsThe battery produces a mixture of nitrogen and hydrogen (electrolytic gas) duringcharging. Gassing is a chemical process. This gas mixture is highly explosive andmust not be ignited.uSwitch the charging station and truck off first before connecting/disconnecting the

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

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

damage.uVentilate the room in which the truck is being charged.uThe battery cover must be open and the battery cell surfaces must be exposed

during charging to ensure adequate ventilation.uDo not smoke and avoid naked flames when handling batteries.uWherever an industrial truck is parked for charging there shall be no inflammable

material or lubricants capable of creating sparks within 2,5 m around the truck.uFire protection equipment must be on hand.uDo not lay any metallic objects on battery.uIt is essential to follow the safety regulations of the battery and charger station

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

NOTICEIf charging has been interrupted, the full battery capacity will not be available.Requirements– The battery is fully charged.

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Procedure• Complete charging in accordance with the charger operating instructions.• Disconnect the battery connector (43) from the charging cable (46) of the

stationary charger.• Attach the battery connector (43) to the industrial truck.

The truck is now ready for operation.

43

46

45

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5 Battery removal and installation

WARNING!

Accident risk during battery removal and installationDue to the battery weight and acid there is a risk of trapping or scalding when thebattery is removed and installed.uNote the "Safety regulations for handling acid batteries" section in this chapter.uWear safety shoes when removing and installing the battery.uUse only batteries with insulated cells and terminal connectors.uPark the truck on a level surface to prevent the battery from sliding out.uMake sure the crane slings have sufficient capacity to replace the battery.uUse only approved battery replacement devices (battery roller stand, replacement

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

CAUTION!

Unsecured batteryAn unsecured battery can result in trapping and injuryuWear safety shoes when removing and installing the battery.uDo not reach between the battery and the chassis.

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ESE 220

Removing the battery

Requirements– Park the truck securely, see page 60.– Expose the battery, see page 36.

Tools and Material Required– Battery replacement trolley (o)

Procedure• Remove the battery connector (43)

from the truck.• Place the battery connector (43) on the

battery (48).• Pull the battery lock (47) up and anti-

clockwise 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.

43

47

48

Installation is carried out in the reverse order.

CAUTION!

Trapping hazardTrapping hazard when removing and installing the battery.uWhen removing and installing the battery do not put your hands between the

battery and the chassis.

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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.

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

Z Observe the operating instructions for the battery replacement station.

The battery is now installed.

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6 Checking the battery acid level

43

47

48

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!


• 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.

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• 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!


• 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.

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Checking the battery acid level on the ESE 320

Requirements– Park the truck on a horizontal surface.– Park the truck securely, see page 60.– Expose the battery, see page 36.

Procedure• Remove the battery connector (43) from the truck.• 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 ifnecessary.

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

48 44

47

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E Operation1 Safety Regulations for the Operation of Forklift Trucks

Driver authorisation

The truck may only be used by suitably trained personnel, who have demonstratedto the proprietor or his representative that they can drive and handle loads and havebeen 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 inthe operation of the truck and shall be familiar with the operating instructions. Safetyshoes 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 operatormust prevent unauthorised persons from driving or operating the truck. Do not carrypassengers or lift other people.

Damage and faults

The supervisor must be informed immediately of any damage or faults to the truck orattachment. 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 withoutauthorisation and the necessary training to do so. The operator must never disableor adjust safety mechanisms or switches.

Hazardous area

WARNING!

Risk of accidents/injury in the hazardous area of the truckA hazardous area is defined as the area in which people are at risk due to travel orlifting operations of the truck, its load handler or the load. This also includes the areawithin reach of falling loads or lowering/falling operating equipment.uInstruct unauthorised persons to leave the hazardous area.uIn case of danger to third parties, give a warning signal in good time.uIf unauthorised persons are still within the hazardous area, stop the truck

immediately.

Safety devices, warning signs and warning instructions

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

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WARNING!

Removing or disabling safety devices can cause accidentsRemoving or disabling safety devices such as the emergency disconnect switch, keyswitch, buttons, horn, strobe lights, sensors, panels, etc. can result in accidents andinjury.uReport any defects immediately to your supervisor.uMark defective truck and take it out of service.uDo not return the truck to service until you have identified and rectified the fault.

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2 Displays and Controls

5, 7 10 49 50 51 52 53 11

14

13

54

55

56

17

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Item Control/display Function5 Charge/discharge

indicatort Shows the battery charge status

52 Key switch and key t – Activates the truck by applying thecontrol voltage

– Removing the key prevents the truckfrom being switched on by unauthorisedpersonnel

CanCode code lock o Replaces the key switch– Entering the appropriate code activates

the truck– Travel program selection– Code setting

ISM access module o Replaces the key switch– Activates the truck via a card/

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

7 Display and control unit o Displays key travel and lift parameters,warning indicators, notification of incorrectoperation and event messages, replacesthe charge/discharge indicator

10 multiPILOT t Function operation– Forward/reverse travel

11 Emergency disconnectswitch

t Disconnects the battery supply– All electrical functions are deactivated

and the truck is braked13 Floor-plate height

adjustert Button for releasing and adjusting the floor-

plate height14 Steering wheel t Steers the truck17 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 t Warning signal button50 "Raise load handler"

buttont Button for lifting the load handler

51 "Lower load handler"button

t Button for lowering the load handler

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Item Control/display Function53 "Seat heater" switch o – Switches the seat heating on and off

– Indicates when the seat heating isswitched on

54 Seat adjustment lever t Adjusts the driver's seat horizontally55 Seat cushioning adjusting

wheelt Sets the ideal seat cushioning for the

driver's weight56 Backrest adjustment

lever Adjusts the backrest tilt

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2.1 Battery discharge indicator

When the truck has been released via the keyswitch, CanCode or ISM, the battery charge statusis displayed. The LED colours (57) represent thefollowing conditions:

LED colour Charge statusGreen 40–100%Orange 30–40%

Green/orangeflashes at 1 Hz 20–30%

Red 0–20%

Z If the LED is red, the load can no longer be lifted. Lifting is only enabled when thebattery connected is at least 70% charged.If the LED flashes red and the truck is not ready for operation, inform themanufacturer's service department. Red flashing is a truck controller code. Theflashing sequence indicates the type of fault.

57

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2.2 Battery discharge monitor

Z The standard setting for the battery discharge indicator / discharge monitor is basedon standard batteries. When using maintenance-free or special batteries, the displayand cut-out points of the battery discharge monitor must be set by manufacturer'sservice department. If this adjustment is not made, the battery may becomedamaged due to deep discharge.

If the residual capacity falls below the required level, lifting is inhibited. An alternatingdisplay (57) appears. Lifting is only released when the battery connected is at least70% charged.

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3 Preparing the Truck for Operation

3.1 Checks and Operations to Be Performed Before Starting DailyWork

WARNING!

Risk of accident due to damage to or other defects in the truck and optionalfeaturesIf damage or other truck or attachment (optional equipment) defects are discoveredduring the following checks, the truck must be taken out of service until it has beenrepaired.uReport any defects immediately to your supervisor.uMark defective truck and take out of service.uDo not return the industrial truck to service until you have identified and rectified

the fault.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.

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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.

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3.3 Adjusting the driver’s seat

CAUTION!

An unsecured driver's seat can cause injuryAn unsecured driver's seat can slide out of its guide during travel, resulting inaccidents.uThe driver's seat must be locked in position.uDo not adjust the driver’s seat while travelling.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.

55

54

56

3.4 Adjusting the Floor-Plate HeightProcedure• 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.

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• Set the floor plate (59) to the correct height by standing on it / discharging it.• Release the floor plate height adjustment button (13).

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

59 13

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3.5 Preparing the truck for operationSwitching 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.

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3.6 Checks and operations to be carried out when the truck isoperational

WARNING!

Risk of accident due to damage to or other defects in the truck and optionalfeaturesIf damage or other truck or attachment (optional equipment) defects are discoveredduring the following checks, the truck must be taken out of service until it has beenrepaired.uReport any defects immediately to your supervisor.uMark defective truck and take out of service.uDo not return the industrial truck to service until you have identified and rectified

the fault.Procedure• Test warning indicators and safety devices:

• Test the Emergency Disconnect function by pressing the EmergencyDisconnect switch. The main circuit is disconnected and no truck operationscan 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.

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3.7 Parking the truck securely

WARNING!

An unsecured truck can cause accidentsParking the truck on an incline, without the brakes applied or with a raised load orload handler is dangerous and is strictly prohibited.uPark the truck on a level surface. In special cases the truck may need to be

secured with wedges.uFully lower the load handler.uSelect a place to park where no other people are at risk of injury from the lowered

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

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 thekey 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.

60

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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 thirdparties must stay away from work areas. Loads must only be stored in placesspecially designated for this purpose.The truck must only be operated in work areas with sufficient lighting to avoid dangerto personnel and materials. Additional equipment is necessary to operate the truck inareas 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 orcome loose during loading/unloading.

Travel conduct

The operator must adapt the travel speed to local conditions. The truck must bedriven at slow speed when negotiating bends or narrow passageways, when passingthrough swing doors and at blind spots. The operator must always observe anadequate braking distance between the forklift truck and the vehicle in front andmust 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 notlean out or reach beyond the working and operating area.

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Travel visibility

The operator must look in the direction of travel and must always have a clear viewof the route ahead. If the truck is carrying loads that affect visibility, the truck musttravel against the load direction. If this is not possible, a second person must walkalongside the truck as a lookout to observe the travel route while maintaining eyecontact 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 accidentsIf the truck is in danger of tipping over, incorrect operator action can result in seriousinjury and death.uDo not jump off the truck if it tips over.uIf the truck tips over on the right side of the load direction, hold onto the option bar

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

wheel or the display panel with both hands.uNever hold onto the side where the truck is about to tip over.uTilt your body in the opposite direction of fall.

Negotiating slopes and inclines

Negotiating slopes and inclines up to 13 % is only permitted when they arerecognised 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 mustnot be turned, operated at an angle or parked on inclines or slopes. Inclines mustonly be negotiated at slow speed, with the driver ready to brake at any moment.

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Negotiating lifts, loading ramps and docks

Lifts may only be negotiated if they have sufficient capacity, are suitable for drivingon and authorised for truck traffic by the owner. The driver must satisfy himself of theabove before entering these areas. The truck must enter lifts with the load in frontand must take up a position which does not allow it to come into contact with thewalls of the lift shaft. Persons riding in the lift with the forklift truck must only enterthe lift after the truck has come to a rest and must leave the lift before the truck. Thedriver must ensure that the loading ramp / dock cannot move or come loose duringloading / unloading.

Type of loads to be carried

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

WARNING!

Electromagnetic influence can result in accidentsStrong magnets can cause electronic components such as Hall sensors to becomedamaged, resulting in accidents.uDo not use magnets in the operating area of the truck. Exceptions to this rule are

commercial, weak clamping magnets for attaching notices.

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4.2 Emergency Disconnect

CAUTION!

Applying maximum braking can result in accidentsApplying the Emergency Disconnect switch during travel will cause the truck todecelerate to a halt at maximum force. This may cause the load to slide off the loadhandler. There is a higher risk of accidents and injury.uDo not use the Emergency Disconnect switch as a service brake.uUse the Emergency Disconnect switch during travel only in emergencies.

CAUTION!

Faulty or non-accessible Emergency Disconnect switches can causeaccidentsA faulty or non-accessible Emergency Disconnect switch can cause accidents. Indangerous situations the operator cannot bring the truck to a halt in time by applyingthe Emergency Disconnect switch.uThe operation of the Emergency Disconnect switch must not be affected by any

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

supervisor.uMark defective truck and take out of service.uDo not return the industrial truck to service until you have identified and rectified

the fault.

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Press the Emergency Disconnect switch

Procedure• Press the Emergency Disconnect (11).

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

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 thetruck was operational before the Emergency Disconnect was pressed).

Z Trucks with CanCode and ISM access module remain switched off.

6,8

11

17

10

32

7

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4.3 Deadman buttonThe deadman button must be pressed to lift, lower or travel.

If the deadman button is released during travel, the truck decelerates at themaximum rate until it stops.

If the deadman button is released during lifting or lowering, the respective functioncuts out immediately.

4.4 Travel

WARNING!

Collision hazard when operating the truckCollisions with personnel and equipment can result if the truck is operated with openpanels.uDo not operate the truck unless the panels and covers are closed and properly

locked.Requirements– Start up the truck, see page 58.

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 neutralposition and the truck brakes.

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

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

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4.4.1 Changing direction during travel

CAUTION!

Danger when changing direction during travelChanging direction during travel causes the truck to decelerate rapidly. When thetruck changes direction, it can start travelling at high speed in the opposite directionunless the Multi-Pilot is released in time.uAfter setting off in the opposite direction, apply the Multi-Pilot gently or not at all.uDo not perform any sudden steering operations.uAlways face the direction of travel.uMaintain an adequate overview of the route you are travelling.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.

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4.5 SteeringRequirements– 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.

1014 7

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4.6 Brakes

WARNING!

Accident risk while brakingThe truck’s braking response depends largely on the floor condition and the type ofsurface. The truck’s braking distance increases when the ground is wet or dirty.uThe operator must be aware of floor conditions and take them into account when

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

The truck can brake in two ways:

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

CAUTION!uIn emergencies, only use the service brake for braking.Braking with the service brake

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

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 ahalt. The parking brake then applies.

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

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17

10

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4.7 Load handler raise/lower

WARNING!

Accident risk when lifting and loweringOther 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 themovement of the truck including the load handler, etc. This also includes areas whichcan be reached by falling loads, operating equipment, etc.Apart from the driver (in the normal operating position) there should be no otherpeople in the truck's hazardous area.uInstruct other people to move out of the hazardous area of the truck. Stop working

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

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

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

uNever exceed the maximum loads specified on the capacity plate.uDo not stand on the load handler.uDo not lift other people on the load handler.uNever reach or climb into moving truck parts.uDo not climb onto parts of the building or other trucks.

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4.7.1 Raising the load handler

Requirements– Prepare the truck for operation, see

page 58.– Deadman switch actuated, see

page 66.

Procedure• Press the "raise load handler" button

(50) on the multiPILOT.

Z Hold down the button until the loadhandler has reached the maximumheight.

The load handler is raised.

1050 51

4.7.2 Lowering the load handlerRequirements– 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.

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

The load handler is lowered.

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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 correctlypalletised and does not exceed the truck’s capacity.uInstruct other people to move out of the hazardous area of the truck. Stop working

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

precautions to prevent parts of the load from tipping over or falling off the truck.uDamaged loads must not be transported.uNever exceed the maximum loads specified on the load diagram.uNever stand underneath a raised load handler.uDo not stand on the load handler.uDo not lift other people on the load handler.uInsert the load handler as far as possible underneath the load.

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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 palletis against the back of the loadhandler (see graphic to theright).

Z The load must not extend bymore than 50 mm beyond theload handler tips.

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

The load is being raised.

NOTICE

Risk of material damage to the hydraulic unitWhen 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 theload 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 safetyinstallations 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 downabruptly.

• 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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5 TroubleshootingThis chapter enables the operator to localize and rectify basic faults or the results ofincorrect operation himself. When trying to locate a fault, proceed in the order shownin the remedy table.

Z If, after carrying out the following remedial action, the truck cannot be restored tooperation or if a fault in the electronics system is displayed with a correspondingerror code, contact the manufacturer’s service department.Troubleshooting must only be performed by the manufacturer’s customer servicedepartment. The manufacturer has a service department specially trained for thesetasks.In order for customer services to react quickly and specifically to the fault, thefollowing 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 startPossible Cause RemedyBattery connector not inserted Check the battery connector

and insert if necessaryEmergency Disconnect switch pressed Release the Emergency Disconnect

switch, see page 64Key switch set to O Set the key switch to “I”Deadman switch not pressed Press deadman switchBattery charge too low Check battery charge,

Charge battery if necessary, see page 38

Faulty fuse Check fuses see page 120Incorrect ISM access moduletransponder used Use correct transponder

Incorrect CANCode PIN entered Enter correct PIN, see page 86

5.2 Load cannot be liftedPossible Cause RemedyTruck not operational Carry out all measures listed under

“Truck does not start”.Hydraulic oil level too low Checking the hydraulic oil levelBattery discharge monitor has switchedoff

Charge the battery

Faulty fuse Check fusesExcessive load Note maximum capacity, see data plate.Switch in mast implausible (E-2124) Emergency recovery (travel at max. 1.5

km/h and lowering possible when truck isin rider mode). Contact themanufacturer's service department.

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6 Operating the truck without its own drive system

WARNING!

Accidental truck movementWhen the brakes are de-activated the truckmust be parked on a level surface, since thebrakes are no longer effective.uDo not release the brake on slopes or

inclines.uDo not park the truck with the brake

released.uApply the brake again when you reach your

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

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

7.1 Brake Pedal in Footwell with ESE 220

62

Item Control/display Function62 Brake pedal (electric) o Pedal for reducing the travel speed and for

braking the truck to a halt

Braking with the brake pedal

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

deceleration.

The truck decelerates.

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

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7.2 Display and control unit

68

77 79 807876

75

73

71

63 64 65 66 67 57 69

70

72

74

Item Description63 STOP64 Parking brake applied65 WARNING66 Displays the current steer angle (drive wheel direction)67 Steer mode, displays possible travel directions68 Time display (hours: minutes)57 Battery charge status69 Discharge indicator70 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 pressed74 Information display75 Service mode active (icon illuminated),

service interval expired (symbol flashes)76 Overtemperature77 Slow travel button, when illuminated the 71 icon illuminates78 Parking brake button (void)79 Shift key, to set the time80 Profile key, selects the travel profile

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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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7.4 Keypad (CanCode) (o)

7.4.1 Code lockThe 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 isconfigured with a master code and is described in the following sections in thischapter.

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

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

Parameter Description

0-0-0 – Change master code(see page 87)

0-0-1 – Add user codes(see page 89)

0-0-2 – Change a user code(see page 91)

0-0-3 – Delete a user code(see page 93)

0-0-4 – Delete all user codes(see page 95)

0-1-0 – Switch on the truck automatically(see page 97)

0-2-4 – Assign travel programs to the user codes(see page 99)

In the as-supplied condition, the code is indicated on a sticker. When using the truckfor 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

Z When allocating the codes, ensure the rider trucks are given a different code thanpedestrian trucks.

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The keypad consists of 10 digit keys, a Set key (85)and a o key (87).

Digit keys

The digit keys are used to enter the user or mastercode 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 itto "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.

85

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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, thetravel program selected is indicated by the corresponding LEDs (82,83,84) andthe truck is switched on.

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

7.4.3 Switching off the truck with the keypad (CanCode)Switching off the truck

Procedure• Press the O key (87).

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

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

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7.4.4 Changing the Set-up Code

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. Ifthere are still user codes stored in the code lock, the master code to be changedmust 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).


• 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.


85

82 83 84

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Error displays changing the master code

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

Cause Remedy

– New master code is alreadyoccupied by a user code

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

– The master code entered isnot the same length as the

user code

– 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






• 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 thepreviously entered master code. The new user code must also be different fromthe existing master code.


• Enter the new user code again with the digit keys.• Confirm with the SET key (85).



• 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 travelprogram setting is shown by the illumination of the corresponding LEDs(82,83,84) and the truck is switched on.


85

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Error displays adding a user code


Cause Remedy– The user code entered is

not the same length as themaster code

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

code is the same length as the user code.– New user code is already

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

– The newly entered usercodes do not match

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

– Code log full.– 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






• Enter the user code to be changed with the digit keys.• Confirm with the SET key (85).


• 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 thepreviously entered master code. The new user code must also be different fromthe existing master code.


• Enter the new user code again with the digit keys.• Confirm with the SET key (85).



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



85

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Error displays changing a user code





code is the same length as the user code.– Operator code to be

changed does not exist.– Switch off the truck, see page 86.– Check the user code entered.

– The user codes to bechanged do not match

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

– Tried to change the operatorcode to another user code

that already exists.

– 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






• Enter the user code to be deleted with the digit keys.• Confirm with the SET key (85).


• 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.


• 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 remainsswitched off.

• Press the O key (87).The truck remains switched off and the LED (86) is lit red.

85

82 83 84

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Error displays deleting individual user codes





code is the same length as the user code.– Tried to delete an operator

code that does not exist.– Switch off the truck, see page 86.– Check the user code entered.

– The user codes to bechanged do not match

– 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,






• 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.


• 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 remainsswitched off.

• Press the O key (87).The truck remains switched off and the LED (86) is lit red.

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

Z The master code is factory set to a four-digit entry: If necessary, the four-digit mastercode can be changed to a five or six-digit entry. Before the master code length canbe 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.


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 changedand user codes have been added.

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7.4.10 Setting the automatic truck cutout (timeframe)



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, thetravel program selected is indicated by the corresponding LEDs (82,83,84) andthe 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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Error displays setting the automatic cutout period of the truck


Cause Remedy

– Cutout time entered is out ofrange

– 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 programThe travel programs are fixed to the user code and can be released or blocked witha configuration code. The configuration code can also be used to assign a startingtravel program to each user code.

Z The starting travel program is the travel program that is activated when the truck isswitched on and is displayed by the (82,83,84) LEDs.LED (82) lit = travel program 1 activatedLED (83) lit = travel program 2 activatedLED (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 startingtravel program is travel program 2.

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Specifying a configuration code:

Setting Description

1st digit0 – Travel program 1 is blocked for the user code

selected

1 – Travel program 1 is enabled for the user codeselected

2nd digit0 – Travel program 2 is blocked for the user code

selected


3rd digit0 – Travel program 3 is blocked for the user code

selected


4th digit

0 – When the truck has been switched on with theselected user code, no travel program is activated

1 – When the truck has been switched on with theselected user code, travel program 1 is activated



Z 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 2is activated

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Adapting the travel program configuration to theuser code


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



• Enter the valid user code with the digit keys.• Confirm with the SET key (85).


• Enter the configuration code (4 digit) for the travel programs.• Confirm with the SET key (85).


• Enter the configuration code (4 digit) for the travel programs again using the digitkeys.

• Confirm with the SET key (85).Wait until the LED (86) flashes green. The travel programs are now assigned tothe user code.


• Checking the travel program configuration to the user code:• Switch on the truck with the configured user code, see page 86



• If necessary, repeat the procedure for other user codes.

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Error displays configuring the travel programs


Cause Remedy– Blocked travel program

defined as start travelprogram

– Switch off the truck, see page 86.– Try again, making sure the configuration code is

entered correctly.

7.5 ISM access module (o)

Z If the truck is equipped with an ISM access module or Can Code refer to the “ISMAccess Module” operator manual.

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7.6 Floor-SpotThe floor spot serves as an auxiliary device and projects a coloured dot onto theground.

CAUTION!

Risk of accident due to restricted viewLooking directly at the LED light can dazzle and temporarily impair eyesight.uDo not look directly at the LED light.uPractise travelling and working with the floor spot carefully.uDo not change the factory setting.

88

Item Description88 Floor-Spot

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7.6.1 Additional information on Floor-Spot blue

CAUTION!

Risk of retinal damage due to blue lightThe Floor-Spot on the truck is classified in risk group 2 according to the standardIEC 62471: medium risk. In the range of 400 nm to 780 nm, blue light can potentiallydamage the retina of the human eye.uCheck that the warning notice: "Caution! Potentially dangerous optical radiation" is

present and legible, and replace if necessary.uDo not look directly into the light beam of the Floor-Spot.uWhen performing maintenance and repairs, take the Floor-Spot out of service, e.g.

by disconnecting the battery, and secure it against unintentional recommissioning.

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F Industrial Truck Maintenance1 Operational Safety and Environmental Protection

The inspections and maintenance tasks listed in chapter "Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement" must be performedaccording to the defined service intervals (see page 125).

The manufacturer recommends the replacement of the maintenance parts also listedin chapter "Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement" according to the specified replacement intervals (see page 125).

WARNING!

Risk of accidents and component damageAny modification to the truck, in particular the safety mechanisms, is prohibited.

NOTICEOnly original spare parts are subject to the manufacturer's quality control. To ensuresafe and reliable operation, use only the manufacturer's spare parts.

Exception: Operating companies should only make changes or have changes madeto powered industrial trucks if the manufacturer is no longer operating in the field andthere is no successor to the business; operating companies must however:– Ensure that the changes to be made are planned, tested and performed by a

specialist engineer in industrial trucks taking safety into account.– Keep permanent graphic records of the plans, tests and completion of the

changes– Carry out and have authorised the respective changes to the capacity data plates,

decals and stickers as well as the operator and service manuals.– Attach permanent and clearly visible marking to the truck indicating the types of

changes made, the date of the changes and the name and address of theorganisation responsible for the work.

Z On completion of inspection and service work, carry out the operations listed in the“Recommissioning the truck after cleaning or maintenance work” section (see page 121).

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2 Maintenance Safety Regulations

Maintenance and repair personnel

Z The manufacturer has a customer service department specially trained for thesetasks. A maintenance contract with the manufacturer will support trouble-freeoperation.

Truck maintenance, repair work and changing of parts requiring replacement mustonly be carried out by specialist personnel. The activities to be carried out aredivided into the following target groups.

Customer Services

Customer Services are specially trained in the use of the truck and are able to carryout maintenance and repairs independently. Customer Services are aware of therelevant standards, guidelines and safety regulations as well as potential risks.

Operating company

The maintenance personal of the operating company has the technical expertise andexperience to perform the activities in the maintenance check list for the operatingcompany. The maintenance and repair work to be performed by the operatingcompany are also written down, see page 113.

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2.1 Working on the electrical system

WARNING!

Electrical current can cause accidentsMake sure the electrical system is voltage-free before starting work on it. Thecapacitors in the controller must be completely discharged. The capacitors arecompletely discharged after approximately 10 minutes. Before starting maintenanceon the electrical system:uOnly suitably trained electricians may operate on the truck's electrical system.uBefore working on the electrical system, take all precautionary measures to avoid

electric shocks.uPark the truck securely (see page 60).uRemove the battery, see page 36.uRemove any rings, metal wristbands etc.

2.2 Consumables and used parts

CAUTION!

Consumables and used parts are an environmental hazardUsed parts and consumables must be disposed of in accordance with the applicableenvironmental-protection regulations. Oil changes should be carried out by themanufacturer's customer service department, whose staff are specially trained forthis task.uNote the safety regulations when handling these materials.

2.3 Wheels

WARNING!

The use of wheels that do not comply with the manufacturer's specificationscan result in accidentsThe quality of wheels affects the stability and driving characteristics of the truck.Uneven wear affects the truck's stability and increases the stopping distance.uAfter replacing wheels, make sure the truck is not skewed.uAlways replace wheels in pairs, i.e. the left- and right-hand wheels at the same

time.

Z When replacing wheels fitted at the factory, only use the manufacturer’s originalspare parts. Otherwise the manufacturer's specification will not be adhered to.

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2.4 Hydraulic system

WARNING!

Leaky hydraulic systems can result in accidentsHydraulic oil can escape from leaky and faulty hydraulic systems.uReport any defects immediately to your supervisor.uMark defective truck and take out of service.uDo not return the industrial truck to service until you have identified and rectified

the fault.uRemove any spilled hydraulic immediately with an appropriate bonding agent.uThe bonding agent / consumable mixture must be disposed of in accordance with

regulations.

WARNING!

Faulty hydraulic hoses can result in injury and infectionPressurised hydraulic oil can escape from fine holes or hairline cracks in thehydraulic hoses. Brittle hydraulic hoses can burst during operation. People standingnear the truck can be injured by the hydraulic oil.uCall for a doctor immediately in the event of an injury.uDo not touch pressurised hydraulic hoses.uReport any defects immediately to your supervisor.uMark defective truck and take it out of service.uDo not return the industrial truck to service until you have identified and rectified

the fault.

NOTICE

Testing and replacing hydraulic hosesHydraulic hoses can become brittle through age and must be checked at regularintervals. The application conditions of the industrial truck have a considerableimpact on the ageing of the hydraulic hoses.uCheck the hydraulic hoses at least annually and replace if necessary.uIf the operating conditions become more arduous the inspection intervals must be

reduced accordingly.uIn normal operating conditions a precautionary replacement of the hydraulic hoses

is recommended after 6 years. The owner must carry out a risk assessment toensure safe, prolonged use. The resulting protection measures must be observedand the inspection interval reduced accordingly.

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3 Lubricants and Lubrication Schedule

3.1 Handling consumables safely

Handling consumables

Consumables must always be handled correctly. Follow the manufacturer’sinstructions.

WARNING!

Improper handling is hazardous to health, life and the environmentConsumables can be flammable.uKeep consumables away from hot components and naked flames.uAlways keep consumables in prescribed containers.uAlways fill consumables in clean containers.uDo not mix up different grades of consumable. The only exception to this is when

mixing is expressly stipulated in the operating instructions.

CAUTION!

Spilled consumables can cause slipping and endanger the environmentRisk of slipping from spilled consumables. The risk is greater when combined withwater.uDo not spill consumables.uSpilled consumables must be removed immediately with an appropriate bonding

agent.uThe bonding agent / consumable mixture must be disposed of in accordance with

regulations.

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WARNING!

Improper handling of oils can be hazardousOils (chain spray / hydraulic oil) are flammable and poisonous.uDispose of used oils in accordance with regulations. Store used oil safely until it

can be disposed of in accordance with regulations.uDo not spill oil.uSpilled oils must be removed immediately with an appropriate bonding agent.uThe mixture consisting of the bonding agent and oil must be disposed of in

accordance with regulations.uObserve national regulations when handling oils.uWear safety gloves when handling oils.uPrevent oil from coming into contact with hot motor parts.uDo not smoke when handling oil.uAvoid contact and digestion. If you swallow oil do not induce vomiting but seek

medical assistance immediately.uSeek fresh air after breathing in oil fumes or vapours.uIf oil has come into contact with your skin, rinse your skin with water.uIf oil has come into contact with your eyes, rinse them with water and seek medical

assistance immediately.uReplace oil-soaked clothing and shoes immediately.

CAUTION!

Consumables and used parts are an environmental hazardUsed parts and consumables must be disposed of in accordance with the applicableenvironmental-protection regulations. Oil changes should be carried out by themanufacturer's customer service department, whose staff are specially trained forthis task.uNote the safety regulations when handling these materials.

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3.2 Lubrication Schedule

C1,05 l

A + BA

E

1)

E

a

**

g Contact surfaces k Cold Store Applications Grease nipple a Transmission oil drain plug

Hydraulic oil filler neck

1 Compound ratio for cold store usage 1:1

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3.3 ConsumablesCode

Order no. Quantity Description Used for

A51132826 * 1.0 l Jungheinrich

hydraulic oil Hydraulic system51132827 * 5.0 l

B 510818755.0 l Renolin MR 310 cold

store hydraulic oil

Hydraulic systemAdditive for use incold stores

C 50449961 5.0 l SAE 75W-90 TransmissionE 29201430 1.0 kg Grease, DIN 51825 Lubrication

*The trucks are factory-equipped with a special hydraulic oil (the Jungheinrichhydraulic oil with a blue colouration) and the cold store hydraulic oil (redcolouration). The Jungheinrich hydraulic oil can only be obtained from theJungheinrich service department. The use of named alternative hydraulic oils isnot prohibited but may lead to a decline in functionality. The Jungheinrichhydraulic oil may be mixed with one of the named alternative hydraulic oils.

Z For cold store operations the Jungheinrich hydraulic oil and the cold store hydraulicoil must be mixed in a 1:1 ratio.

Grease guidelines

Code Saponification Dew point°C

Workedpenetrationat 25 °C

NLG1 class Applicationtemperature°C

E Lithium 185 265 - 295 2 -35/+120

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4 Maintenance and repairs

4.1 Preparing the truck for maintenance and repairsProcedure• Park the truck securely, see page 60.• Disconnect the battery to prevent the truck from being switched on accidentally.

4.2 Lifting and jacking up the truck safely

WARNING!

Lifting and jacking up the truck safelyIn order to raise the truck, the lifting gear must only be secured to the pointsspecially provided for this purpose.In order to raise and jack up the truck safely, proceed as follows:uJack up the truck only on a level surface and prevent it from moving accidentally.uAlways use a jack with sufficient capacity. When jacking up the burden carrier, take

appropriate measures to prevent it from slipping or tipping over (e.g. wedges,wooden blocks).

uIn order to raise the truck, the lifting accessories must only be secured to thepoints specially provided for this purpose, see page 29.

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4.3 Cleaning

4.3.1 Cleaning the truck

Z The truck may only be cleaned in the designated locations, which adhere to thestipulations of the country of use.

CAUTION!

Fire hazardDo not use flammable liquids to clean the industrial truck.uDisconnect the battery before starting cleaning work.uCarry out all necessary safety measures to prevent sparking before cleaning (e.g.

by short-circuiting).

CAUTION!

Risk of component damage when cleaning the truckCleaning with a pressure washer can result in malfunctions due to humidity.uCover all electronic system assemblies (controllers, sensors, motors etc.) before

cleaning the truck with a pressure washer.uDo not hold the jet of the pressure washer by the marked points to avoid damaging

them (see page 26).uDo not clean the truck with pressurised water.

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Cleaning the truck

Requirements– Prepare the truck for maintenance and repairs (see page 113).

Tools and Material Required– Water-based solvents– Sponge or cloth

Procedure• Clean the surface of the truck with water-based solvents and water. Use a sponge

or cloth to clean.• In particular, clean the following areas:

• Window(s)• Oil filler ports and their surroundings• Grease nipples (before lubrication)

• Dry the truck after cleaning, e.g. with compressed air or a dry cloth.• Carry out all the tasks in the section "Recommissioning the truck after cleaning or

maintenance work" (see page 121).

The truck is now clean.

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4.3.2 Cleaning the electrical system assemblies

CAUTION!

Risk of electrical system damageCleaning the assemblies (controllers, sensors, motors etc.) of the electronic systemwith water can damage the electrical system.uDo not clean the electrical system with water.uClean the electrical system with weak suction or compressed air (use a

compressor with a water trap) and not a conductive, anti-static brush.Cleaning the electrical system assemblies

Requirements– Prepare the truck for maintenance and repairs (see page 113).

Tools and Material Required– Compressor with water separator– Non-conductive, antistatic brush

Procedure• Expose the electrical system, see page 117.• Clean the electrical system assemblies with weak suction or compressed air (use

a compressor with a water trap) and not a conductive, anti-static brush.• Fit the electrical system panel, see page 117.• Carry out all the tasks in the section "Recommissioning the truck after cleaning or

maintenance work" (see page 121).

The electrical system assemblies are now clean.

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4.3.3 Drive compartment cover disassembly/assembly

Remove the drive compartmentcover

Requirements– Prepare the truck for maintenance

and repairs (see page 113).

Tools and Material Required– Allen key

Procedure

Z Hold onto the cover (89) whenremoving the screws.

Remove the four screws (90) with theAllen key.

The drive compartment cover is now disassembled.

90

89

Fitting the drive compartment panel

Tools and Material Required– Allen key

Procedure

CAUTION!

Arm trapping hazardThere is a risk of trapping when you close the drive compartment cover.uMake sure there is nothing between the cover and the truck when you close the

cover.

Insert the cover (89) into the truck chassis.• Secure the cover to the truck using the four screws (90).

The drive compartment cover is now fitted.

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4.4 Checking the hydraulic oil level

Checking the hydraulic oil level andreplenishing

Requirements– Fully lower the load handler.– Prepare the truck for maintenance and

repairs, see page 113.

Procedure• Remove the front panel, see page 117.• Check the oil level in the hydraulic

reservoir (93).

Z The hydraulic reservoir (93) has twomarkings (91). With the load handlercompletely lowered, the hydraulic oil level inthe reservoir should lie between the min. andmax. markings (91).

• Add hydraulic oil if necessary:• Turn the lid (92) anti-clockwise from the hydraulic reservoir (93).• Add hydraulic oil of the correct grade until the oil level lies between the

markings (see page 112).• Turn the lid (92) clockwise on the hydraulic reservoir (93).

• Install the front panel, see page 117.• To restore the industrial truck to service after maintenance or repair work, see

page 121.

The hydraulic oil level is now checked.

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Z If a leak is discovered in the hydraulic system (cylinder; unions, lines), the truck mustbe decommissioned and repaired by specialist personnel.

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4.5 Tightening the wheel nuts

Z The wheel nuts on the drive wheel must be retightened in accordance with themaintenance intervals indicated in the maintenance checklist, see page 125.Tightening the wheel nuts

Requirements– Prepare the truck for maintenance and repairs, see page 113.

Tools and Material Required– Torque wrench

Procedure• Position the drive wheel (96) so that the wheel nuts (95) can be pulled through the

hole (94).• Tighten all the wheel nuts (95) through the hole (94) in the impact buffer with the

socket wrench.

To do this, tighten the wheel nuts in the prescribed order.• First of all tighten to 10 Nm.• and then to 150 Nm.

The wheel nuts have now been tightened.

95 96

94

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4.6 Checking electrical fusesCheck fuses

Requirements– Truck prepared for maintenance and repairs.

Procedure• Fold up the arm rest.• Check the fuse ratings against the table and replace if necessary.• Close the armrest.

The fuses are now checked.

F15 F1 6F1 9F22 3F1 F17

Description To protect Rating (A)F 15 Main fuse 300F1 Main control fuse 106F1 Discharge indicator / hourmeter 29F22 Electromechanical components 103F1 Steer motor 30F17 Not used 10

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4.7 Restoring the truck to service after maintenance and repairsProcedure• Thoroughly clean the truck, see page 114.• Lubricate the truck according to the lubrication diagram, see page 111.• Clean the battery, grease the terminals and connect the battery.• Charge the battery, see page 38.• Start up the truck, see page 54.

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5 Decommissioning the Industrial TruckIf the truck is to be out of service for more than a month, it must be stored in a frost-free and dry room. All necessary measures must be taken before, during and afterdecommissioning as described hereafter.

When the truck is out of service it must be jacked up so that all the wheels are clearof the ground. This is the only way of ensuring that the wheels and wheel bearingsare not damaged.

Z Jack up the truck, see page 113.

If the truck is to be out of service for more than 6 months, agree further measureswith the manufacturer's customer service department.

5.1 Prior to decommissioningProcedure• Thoroughly clean the truck, see page 114.• Prevent the truck from rolling away accidentally.• Check the hydraulic oil level and replenish if necessary, see page 112.• Apply a thin layer of oil or grease to any non-painted mechanical components.• Lubricate the truck according to the lubrication schedule, see page 111.• Charge the battery, see page 38.• Disconnect the battery, clean it and grease the terminals.

Z In addition, follow the battery manufacturer’s instructions.

5.2 During decommissioningNOTICE

Full discharge can damage the batterySelf-discharge can cause the battery to fully discharge. Full discharge shortens theuseful life of the battery.uCharge the battery at least every 2 months.

Z Charge the battery see page 38.

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5.3 Restoring the truck to service after decommissioningProcedure• Thoroughly clean the truck, see page 114.• Lubricate the truck according to the lubrication schedule, see page 111.• Clean the battery, grease the terminal screws and connect the battery.• Charge the battery, see page 38.• Start up the truck, see page 54.

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6 Safety tests to be performed at intervals and after unusualincidentsThe truck must be inspected at least annually (refer to national regulations) or afterany unusual event by a qualified inspector. The manufacturer offers a safetyinspection service which is performed by personnel specifically trained for thispurpose.

A complete test must be carried out on the technical condition of the truck withregard to safety. The truck must also be examined thoroughly for damage.

The operating company is responsible for ensuring that faults are rectifiedimmediately.

7 Final de-commissioning, disposal

Z Final de-commissioning or disposal of the truck in must be performed in accordancewith the regulations of the country of use. In particular, regulations governing thedisposal of batteries, consumables and electronic and electrical systems must beobserved.The truck must only be disassembled by trained personnel in accordance with theprocedures as specified by the manufacturer.

8 Human vibration measurement

Z Vibrations that affect the operator over the course of the day are known as humanvibrations. Excessive human vibrations will cause the operator long term healthproblems. The European "2002/44/EC/Vibration" operator directive has thereforebeen established to protect operators. To help operators to assess the applicationsituation, the manufacturer offers a service of measuring these human vibrations.

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G Maintenance, Inspection and Changing ofMaintenance Parts RequiringReplacement

WARNING!

Lack of maintenance can result in accidentsFailure to perform regular maintenance and inspections can lead to truck failure andposes a potential hazard to personnel and equipment.uThorough and expert maintenance and inspections are among the most important

requirements for the safe operation of the industrial truck.

NOTICEThe application conditions of an industrial truck have a considerable impact oncomponent wear. The following service, inspection and replacement intervals arebased on single-shift operation under normal operating conditions. The intervalsmust be reduced accordingly if more stringent requirements are placed on theequipment, e.g., use in conditions of extreme dust, temperature fluctuations ormultiple shifts.uTo prevent damage due to wear, the manufacturer recommends an on-site

application analysis to agree on appropriate intervals.

The following chapter defines the tasks to be performed, the respective intervals tobe observed and the maintenance parts for which replacement is recommended.

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1 Maintenance Contents ESE 220Issued on: 2019-04-24 12:00

1.1 OwnerTo be performed every 50 service hours, but at least once a week.

1.1.1 Maintenance contents

1.1.1.1 Standard equipment

BrakesTest the function of the brakes

Hydraulic operationsCorrect the hydraulic oil level.

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1.1.1.2 Optional equipment

Lead-acid battery, international

Power supplyCorrect the battery acid level using demineralised water.

Lead-acid battery


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1.1.2 Inspection contents

1.1.2.1 Standard equipmentThe following points must be checked:

Electrical systemWarning and safety devices are in accordance with the operating instructionsFunction of display and controlsThe function of the emergency disconnect and for damage

Power supplyBattery and battery components for damageThe function and secure seating of the battery connector and for damage

TravelWheels for wear and damage

Chassis/structureIndustrial truck for damage and leaksLabels are legible, complete and plausibleDoors and/or covers for damageProtective mechanism against trapping and shearing is present, secure, functionscorrectly and is free of dirt and damage

Hydraulic operationsThe function of the hydraulic systemThe forks or load handler for wear and damage

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1.1.2.2 Optional equipmentThe following points must be checked:


Power supplyBattery and battery components for damageBattery cable connections are secure

Lead-acid battery

Power supplyBattery cable connections are secure

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1.2 Customer Service

1.2.1 Maintenance contentsIn accordance with the ESE 220 service interval, to be performed every 1000 servicehours, but at least once a year.


BrakesTest the function of the brakesMeasure the air gap of the magnetic brake.

Electrical systemTest the contactors and/or relays.Carry out a chassis insulation-resistance test.Clean the motor (engine?) with compressed air.

Chassis/structureCheck that the panels and covers as well as the floor plate with mounting brackets aresecure. Ensure that they function correctly and are safe.

Hydraulic operationsTest the function of the lift-limit cut-off/lift cut-off.Adjust the lift mechanism.Correct the hydraulic oil level.Test the pressure relief valve.

Agreed servicesCarry out a test run with the rated load or a customer-specific load.Demonstration after maintenance.Lubricate truck according to the lubrication diagram.

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Data radio

System componentsClean the scanner and terminal.


Power supplyClean and grease the battery terminals.Clean the battery.Measure the acid density and battery voltage.Correct the battery acid level using demineralised water.

Lead-acid battery


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1.2.2 Inspection contentsThe following points must be checked:


Electrical systemCables and engine are secure and for damageWarning and safety devices are in accordance with the operating instructionsFunction of display and controlsThe function of the emergency disconnect and for damageContactors and/or relays for wear and damageThe electric wiring for damage (insulation damage, connections) and the fuse ratingsCarbon brushes for wear

Power supplyThe function of the battery latch and battery attachment and for damageThe function and secure seating of the battery connector and for damage

TravelThe function of the deadman switch and for damageDrivetrain bearings for wear and damageTransmission for noise and leaksWheel bearings and attachment for wear and damageWheels for wear, damage and secure mounting

Chassis/structureIndustrial truck for damage and leaksThe secure seating of the chassis and screw connections and for damageLabels are legible, complete and plausibleThe function and secure seating of the adjustable floor plate and make sure it is secureDriver's seat for damageThe secure seating of the driver's seat and the function of the adjustment mechanismOperator mat and steps are non-slip and free of damageProtective mechanism against trapping and shearing is present, secure, functionscorrectly and is free of dirt and damage

Hydraulic operationsThe function of the "hydraulic system" controls and for legibility, completeness andplausibilityThe secure seating of the lift-limit cut-off/lift cut-off and for damageThe function of the lift mechanism and for wear and damageThe secure seating of the cylinders and piston rods and for leaks and damageSlides and stops for wear and damage

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Hydraulic operationsMast rollers and their running surfaces for wear and damageThe function of the hydraulic systemThe secure seating of the hydraulic connections, hoses and pipes and for leaks anddamageThe forks or load handler for wear and damageTie/plunger rods are uniformly adjusted and for wear and damageThe secure seating of the hoses, pipes and connections and for wear, leaks, damage,blisters and kinks

SteeringThe function of the electric steering and its components and for wear and damageThe steering head bearings, steering play and steering gear teeth or steering chain forwear and damage

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Electrolyte circulation

Power supplyThe function of the hose connections and pump

Aquamatik

Power supplyThe function of the Aquamatik plug, hose connections and float and for leaksThe function of the flow indicator and for leaks

Load backrest

Hydraulic operationsProper securing of the attachment to the truck and the load-bearing components forsecure fit and damage

Shock sensor / data recorder

Electrical systemThe shock sensor/data recorder is secure and for damage

Data radio

System componentsThe function and secure seating of the scanner and terminal and for damageFuse ratingsThe secure seating of the cables and for damage

Access module

Electrical systemAccess module is secure and functions correctly and for damage

Entry skids/rollers

Hydraulic operationsThe function of entry skids or entry rollers and for damage and wear


Power supplyThe secure seating of the battery, battery cables and cell connectors and for damageThe presence of safety labels are present and for damage

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Lead-acid battery

Power supplyThe secure seating of the battery, battery cables and cell connectors and for damage

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1.2.3 Maintenance partsThe manufacturer recommends the replacement of the following maintenance partsat the specified intervals.


maintenance part service hours monthsHydraulic oil 2000 12Hydraulic system - breather filter 2000 12Hydraulic oil filter 2000 12Hydraulic system - venting plug 2000 12Transmission oil 10000


Cold-store application

maintenance part service hours monthsHydraulic oil 1000 12Hydraulic oil additive 1000 12

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2 Maintenance Contents ESE 320Issued on: 2019-04-24 12:00

2.1 OwnerTo be performed every 50 service hours, but at least once a week.

2.1.1 Maintenance contents


BrakesTest the function of the brakes

Hydraulic operationsCorrect the hydraulic oil level.

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Lead-acid battery


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2.1.2 Inspection contents

2.1.2.1 Standard equipmentThe following points must be checked:

Electrical systemWarning and safety devices are in accordance with the operating instructionsFunction of display and controlsThe function of the emergency disconnect and for damage

Power supplyBattery and battery components for damageThe function and secure seating of the battery connector and for damage

TravelWheels for wear and damage

Chassis/structureIndustrial truck for damage and leaksLabels are legible, complete and plausibleDoors and/or covers for damageProtective mechanism against trapping and shearing is present, secure, functionscorrectly and is free of dirt and damage

Hydraulic operationsThe function of the hydraulic systemThe forks or load handler for wear and damage

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2.1.2.2 Optional equipmentThe following points must be checked:


Power supplyBattery and battery components for damageBattery cable connections are secure

Lead-acid battery

Power supplyBattery cable connections are secure

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2.2 Customer Service

2.2.1 Maintenance contentsIn accordance with the ESE 320 service interval, to be performed every 1000 servicehours, but at least once a year.


BrakesTest the function of the brakesMeasure the air gap of the magnetic brake.

Electrical systemTest the contactors and/or relays.Carry out a chassis insulation-resistance test.Clean the motor (engine?) with compressed air.

Chassis/structureCheck that the panels and covers as well as the floor plate with mounting brackets aresecure. Ensure that they function correctly and are safe.

Hydraulic operationsTest the function of the lift-limit cut-off/lift cut-off.Adjust the lift mechanism.Correct the hydraulic oil level.Test the pressure relief valve.

Agreed servicesCarry out a test run with the rated load or a customer-specific load.Demonstration after maintenance.Lubricate truck according to the lubrication diagram.

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Data radio

System componentsClean the scanner and terminal.



Lead-acid battery


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2.2.2 Inspection contentsThe following points must be checked:


Electrical systemCables and engine are secure and for damageWarning and safety devices are in accordance with the operating instructionsFunction of display and controlsThe function of the emergency disconnect and for damageContactors and/or relays for wear and damageThe electric wiring for damage (insulation damage, connections) and the fuse ratingsCarbon brushes for wear

Power supplyThe function of the battery latch and battery attachment and for damageThe function and secure seating of the battery connector and for damage

TravelThe function of the deadman switch and for damageDrivetrain bearings for wear and damageTransmission for noise and leaksWheel bearings and attachment for wear and damageWheels for wear, damage and secure mounting

Chassis/structureIndustrial truck for damage and leaksThe secure seating of the chassis and screw connections and for damageLabels are legible, complete and plausibleThe function and secure seating of the adjustable floor plate and make sure it is secureDriver's seat for damageThe secure seating of the driver's seat and the function of the adjustment mechanismOperator mat and steps are non-slip and free of damageProtective mechanism against trapping and shearing is present, secure, functionscorrectly and is free of dirt and damage

Hydraulic operationsThe function of the "hydraulic system" controls and for legibility, completeness andplausibilityThe secure seating of the lift-limit cut-off/lift cut-off and for damageThe function of the lift mechanism and for wear and damageThe secure seating of the cylinders and piston rods and for leaks and damageSlides and stops for wear and damage

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Hydraulic operationsMast rollers and their running surfaces for wear and damageThe function of the hydraulic systemThe secure seating of the hydraulic connections, hoses and pipes and for leaks anddamageThe forks or load handler for wear and damageTie/plunger rods are uniformly adjusted and for wear and damageThe secure seating of the hoses, pipes and connections and for wear, leaks, damage,blisters and kinks

SteeringThe function of the electric steering and its components and for wear and damageThe steering head bearings, steering play and steering gear teeth or steering chain forwear and damage

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Electrolyte circulation

Power supplyThe function of the hose connections and pump

Aquamatik

Power supplyThe function of the Aquamatik plug, hose connections and float and for leaksThe function of the flow indicator and for leaks

Load backrest

Hydraulic operationsProper securing of the attachment to the truck and the load-bearing components forsecure fit and damage

Shock sensor / data recorder

Electrical systemThe shock sensor/data recorder is secure and for damage

Data radio

System componentsThe function and secure seating of the scanner and terminal and for damageFuse ratingsThe secure seating of the cables and for damage

Access module

Electrical systemAccess module is secure and functions correctly and for damage

Entry skids/rollers

Hydraulic operationsThe function of entry skids or entry rollers and for damage and wear


Power supplyThe secure seating of the battery, battery cables and cell connectors and for damageThe presence of safety labels are present and for damage

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Lead-acid battery

Power supplyThe secure seating of the battery, battery cables and cell connectors and for damage

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2.2.3 Maintenance partsThe manufacturer recommends the replacement of the following maintenance partsat the specified intervals.


maintenance part service hours monthsHydraulic oil 2000 12Hydraulic system - breather filter 2000 12Hydraulic oil filter 2000 12Hydraulic system - venting plug 2000 12Transmission oil 10000


Cold-store application

maintenance part service hours monthsHydraulic oil 1000 12Hydraulic oil additive 1000 12

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H Traction Battery Appendix1 Correct Use and Application

Failure to observe the operating instructions, carrying out repairs with non-originalspare parts, tampering with the battery or using electrolyte additives will invalidatethe warranty.

Observe the instructions for maintaining the safety rating during operation forbatteries in accordance with Ex I and Ex II (see relevant certification).

2 Data plate

97

98

101

103

38

31

34

99

102

100

10539

106

104

97 Model (battery name)34 Production week / production year98 Serial number99 Supplier number31 Rated voltage100 Capacity101 Number of cells102 Weight103 Part no.104 Acid quantity38 Manufacturer39 Manufacturer's logo105 CE mark (for batteries above 75 V only)106 Safety instructions and warning information

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3 Safety Instructions, Warning Indications and other Notes

Used batteries must be treated as hazardous waste.These batteries are marked with the recycling symbol and the signshowing a crossed-out rubbish bin, and should not be disposed of withordinary household waste.Buy-back terms and type of recycling are to be agreed with themanufacturer as described in § 8 of the battery legislation.

Do not smoke!No naked flames, glowing embers or sparks near the battery - fire andexplosion hazard!

Avoid fire and explosion hazards and short circuits due to overheating!

Keep away from naked flames and strong heat sources.

Always wear protective clothing (e.g. safety goggles and safetygloves) when working on cells and batteries. Always wash your hands after completing the work. Use onlyinsulated tools. Do not mechanically machine the battery, strike, crush,compress, notch, dent or modify it in any way.Hazardous electric voltage! The metal parts of the battery cells arepermanently live. Therefore do not place any foreign objects or toolson the battery.Observe national health and safety regulations.

If the materials leak, do not inhale the fumes. Wear safety gloves.

Follow the user instructions and keep them in a visible position in thecharging area.Work on the batteries should be performed only as instructed byspecialist personnel.

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4 Lead acid batteries with armour plated cells and liquidelectrolyte

4.1 DescriptionJungheinrich traction batteries are lead acid batteries with armour plated cells andliquid electrolyte. The names of the traction batteries are PzS, PzB, PzS Lib andPzM.

Name Explanation

PzS– Lead acid battery with "Standard" armour plated cells and liquid

electrolyte– Battery cell width: 198 mm

PzB– Lead acid battery with "British Standard" armour plated cells

and liquid electrolyte– Battery cell width: 158 mm

PzS Lib – Lead acid battery with "Standard" armour plated cells and liquidelectrolyte

– Lead acid battery with extended maintenance interval– Battery cell width: 198 mm

PzM

Electrolyte

The rated density of the electrolyte assumes a temperature of 30°C and the ratedelectrolyte level is fully charged. Higher temperatures will reduce, lowertemperatures will increase the electrolyte density.The corresponding adjustment factor is ± 0.0007 kg/l per K, e. g. electrolyte density1.28 kg/l at 45 °C corresponds to a density of 1,29 kg/l at 30 °C.

The electrolyte must comply with the purity regulations of DIN 43530 Part 2.

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4.1.1 Battery nominal data

1. Product Traction battery2. Nominal voltage 2.0 V x number of cells3. Rated capacity C5 See data plate4. Discharge current C5/5h5. Nominal electrolyte density1 1.29 kg/l6. Nominal temperature2 30 °C7. System rated electrolyte level up to "Max" electrolyte level marking Limit temperature3 55 °C

1) Reached within the first 10 cycles.

2) Higher temperatures shorten the useful life, lower temperatures reduce the available capacity.

3) Not permissible as operating temperature.

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4.2 Operation

4.2.1 Commissioning unfilled batteries

Z The operations required must be carried out by the manufacturer's customer servicedepartment or a customer service organisation authorised by the manufacturer.

4.2.2 Commissioning filled and charged batteries

Battery cell cross section Top view of a battery cell

107 108 109

107 108 109

Checks and operations to be performed before starting daily work

Procedure• Make sure the battery is in physically good condition.• Make sure the terminals are correct (positive to positive and negative to negative)

and check that contacts on the battery terminal conducting system are secure.• Check the M10 terminal screws of the conductors and connectors are secure and

if necessary torque to 23 ±1 Nm.• Charge the battery, see page 154.• Check the electrolyte level of each battery cell after charging and top up if

necessary:• Open the plug (107).

Z The electrolyte level should not be less than the "Min" electrolyte marking (108)and must not exceed the "Max" (109) marking.• If necessary, add electrolyte with pure water up to the "Max" electrolyte level

marking (109), see page 156.• Close the plug (107).

The test is now complete.

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4.2.3 Discharging the battery

Z To achieve an optimum useful life avoid operational discharge of more than 80% ofnominal capacity (full discharge). This corresponds to a minimum electrolyte densityof 1.13 kg/l at the end of the discharge.Fully or partially discharged batteries must be re-charged immediately and not leftunattended.

4.2.4 Charging the battery

WARNING!

The gases produced during charging can cause explosionsThe battery gives off a mixture of oxygen and hydrogen (electrolytic gas) duringcharging. Gassing is a chemical process. This gas mixture is highly explosive andmust not be ignited.uAlways disconnect the charger and truck before connecting or disconnecting the

charger and battery.uThe charger must be adapted to the battery in terms of voltage, charge capacity

and battery technology.uBefore charging, check all cables and plug connections for visible signs of

damage.uVentilate the room in which the truck is being charged.uBattery cell surfaces must remain exposed during charging in order to ensure

sufficient ventilation, see truck operating instructions, chapter D, Charging theBattery.

uDo not smoke and avoid naked flames when handling batteries.uWherever an industrial truck is parked for charging there must be no inflammable

material or consumables capable of creating sparks within a minimum distance of2,5 m from the truck.

uFire protection equipment must be available.uDo not place any metallic objects on the battery.uAlways follow the safety regulations of the battery and charger station

manufacturers.

NOTICEThe battery must only be charged with DC current. All charging procedures inaccordance with DIN 41773 and DIN 41774 are permissible.

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Z The electrolyte temperature rises by approx. 10°C during charging. Charging shouldtherefore only begin when the electrolyte temperature is below 45°C. The electrolytetemperature of batteries must be at least +10°C before charging. Otherwise thebattery will not charge correctly. Below 10°C the battery is insufficiently charged withstandard charging systems. Charging the battery

Requirements– Permissible electrolyte temperature 10°C to 45°C).

Procedure• Open or take off the tray lid or covers from the battery compartment.

Z Deviations are outlined in the truck's operating instructions. The plugs remain onthe cells or remain closed.

• Connect the battery to the switched off charger, ensuring the terminals areconnect (positive to positive and negative to negative).

• Switch on the charger.

The battery is charged.

Z Charging is considered to be complete when the electrolyte density and batteryvoltage remain constant for more than 2 hours.

Compensation charging

Compensation charging is used to ensure the useful life and maintain capacity afterfull discharge and repeated insufficient charging. The maximum compensationcharge current is 5 A/100 Ah rated capacity.

Z Compensation charging should be carried out weekly.

Trickle charging

Battery trickle charging is partial charging that extends the daily application time.Higher average temperatures occur during trickle charging which reduce the usefullife of the batteries.

Z Trickle charges should only be performed when the charge level is below 60 %. Usereplacement batteries instead of regular trickle charging.

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4.3 Servicing lead-acid batteries with armour plated cells

4.3.1 Quality of Water for Adding Electrolyte

Z The quality of the water used to add electrolyte must correspond to purified ordistilled water. Purified water can be produced through distillation or ion exchangersand is then suitable for the production of electrolyte.

4.3.2 Daily

Battery cell cross section Top view of a battery cell

107 108 109

107 108 109

– Charge the battery after each discharge.– After charging, check the electrolyte level of each battery cell and replenish as

required:– Open the plug (107).– If necessary, add electrolyte with pure water up to the "Max" electrolyte level

marking (109).– Close the plug (107).

Z The electrolyte level should not be less than the "Min" electrolyte marking (108) andmust not exceed the "Max" (109) marking.

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4.3.3 Weekly– After re-charging, carry out a visual inspection for dirt and physical damage.– If the battery is charged regularly according to the IU characteristic, carry out a

compensation charge.

4.3.4 Monthly– Towards the end of the charging process measure and record the voltages of all

the cells with the charger switched on.– After charging measure and record the electrolyte density and the electrolyte

temperature in all the cells.– Compare the results with the previous ones.

Z If you find significant differences compared with the previous measurements ordifferences between the cells, contact the manufacturer's customer servicedepartment.

4.3.5 Annually– Measure the insulation resistance of the truck in accordance with EN 1175-1.– Measure the insulation resistance of the battery in accordance with DIN EN

1987-1.

Z In accordance with DIN EN 50272-3 the battery insulation resistance should not beless than 50 Ω per volt of rated voltage.

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5 PzV and PzV-BS lead-acid batteries with sealed armourplated cells

5.1 DescriptionPzV batteries are sealed batteries with fixed electrolytes, to which no water can beadded over the entire lifespan of the battery. Relief valves are used as plugs whichare destroyed when opened. During operation the same safety requirements applyto the sealed batteries as for batteries with liquid electrolyte. This is to avoid electricshock, explosion of the electrolyte charging gases or hazardous electrolyte burns ifthe cell vessels are destroyed.

Z PzV batteries are low gassing, but not gassing-free.

Electrolyte

The electrolyte is sulphuric acid which is fixed in gel. The density of the electrolytecannot be measured.

Name Explanation

PzV– Lead acid battery with "Standard" closed armour plated cells

and electrolyte in gel compound– Battery cell width: 198 mm

PzV-BS– Lead acid battery with "British Standard" closed armour plated

cells and electrolyte in gel compound– Battery cell width: 158 mm

5.1.1 Battery nominal data

1. Product Traction battery2. Nominal voltage 2.0 V x number of cells3. Rated capacity C5 See data plate4. Discharge current C5/5h5. Rated temperature 30°C Limit temperature4 45°C, not permissible as operating

temperature 6. Rated density of the electrolyte Cannot be measured7. System rated electrolyte level Cannot be measured

4) Higher temperatures shorten the useful life, lower temperatures reduce the available capacity.

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5.2 Operation

5.2.1 CommissioningChecks and operations to be performed before starting daily work

Procedure• Make sure the battery is in physically good condition.• Make sure the terminals are correct (positive to positive and negative to negative)

and check that contacts on the battery terminal conducting system are secure.• Check the M10 terminal screws of the conductors and connectors are secure and

if necessary torque to 23 ±1 Nm.• Charge the battery, see page 159.

The test is now complete.

5.2.2 Discharging the battery

Z To achieve an optimum useful life avoid operational discharges of more than 60% ofnominal capacity.

Z If the battery is discharged during operation by more than 80% of rated capacity theuseful life of the battery will reduce significantly. Fully or partially discharged batteriesmust be re-charged immediately and not left unattended.

5.2.3 Charging the battery

WARNING!

The gases produced during charging can cause explosionsThe battery gives off a mixture of oxygen and hydrogen (electrolytic gas) duringcharging. Gassing is a chemical process. This gas mixture is highly explosive andmust not be ignited.uAlways disconnect the charger and truck before connecting or disconnecting the

charger and battery.uThe charger must be adapted to the battery in terms of voltage, charge capacity

and battery technology.uBefore charging, check all cables and plug connections for visible signs of

damage.uVentilate the room in which the truck is being charged.uBattery cell surfaces must remain exposed during charging in order to ensure

sufficient ventilation, see truck operating instructions, chapter D, Charging theBattery.

uDo not smoke and avoid naked flames when handling batteries.uWherever an industrial truck is parked for charging there must be no inflammable

material or consumables capable of creating sparks within a minimum distance of2,5 m from the truck.

uFire protection equipment must be available.uDo not place any metallic objects on the battery.uAlways follow the safety regulations of the battery and charger station

manufacturers.

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NOTICE

Charging the battery incorrectly can result in material damage.Incorrect battery charging can result in overloading of the electric wires and contacts,hazardous gas formation and electrolyte leakage from the battery cell.uAlways charge the battery with DC current.uAll DIN 41773 charging procedures are permitted in the format approved by the

manufacturer.uAlways connect the battery to a charger that is appropriate to the size and type of

the battery.uIf necessary have the charger checked by the manufacturer's customer service

department for suitability.uDo not exceed the limit curents in accordance with DIN EN 50272-3 in the gassing

area.

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Charging the battery

Requirements– Electrolyte temperature between +15°C and +35°C

Procedure• Open or take off the tray lid or covers from the battery compartment.• Connect the battery to the switched off charger, ensuring the terminals are

connect (positive to positive and negative to negative).• Switch on the charger.

Z The electrolyte temperature rises by approx. 10°C during charging. If thetemperatures are permanently higher than 40°C or lower than 15°C, atemperature-dependent constant voltage control of the charger is required. Theadjustment factor must be applied with -0.004 V/C per °C.

The battery is charged.

Z Charging is considered to be complete when the electrolyte density and batteryvoltage remain constant for more than 2 hours.

Compensation charging

Compensation charging is used to ensure the useful life and maintain capacity afterfull discharge and repeated insufficient charging.

Z Compensation charging should be carried out weekly.

Trickle charging

Battery trickle charging is partial charging that extends the daily application time.Higher average temperatures occur during trickle charging which can reduce theuseful life of the batteries.

Z Trickle charges should only be performed when the charge level is below 50%. Usereplacement batteries instead of regular trickle charging.

Z Avoid trickle charging with PzV batteries.

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5.3 Servicing PzV and PzV-BS lead-acid batteries with sealed armourplated cells

Z Do not add water!

5.3.1 Daily– Charge the battery after each discharge.

5.3.2 Weekly– Visually inspect for dirt and physical damage.

5.3.3 Every three months– Measure and record the overall voltage.– Measure and record the individual voltages.– Compare the results with the previous ones.

Z Carry out the measurements after full charging and subsequent resting for at least 5hours.

Z If you find significant differences compared with the previous measurements ordifferences between the cells, contact the manufacturer's customer servicedepartment.

5.3.4 Annually– Measure the insulation resistance of the truck in accordance with EN 1175-1.– Measure the insulation resistance of the battery in accordance with DIN EN

1987-1.

Z In accordance with DIN EN 50272-3 the battery insulation resistance should not beless than 50 Ω per volt of rated voltage.

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6 Aquamatik water replenishment system

6.1 Water replenishment system design110

111

112

113

114

115

> 3 m

+ -

110 Water container111 Tap connection with ball cock112 Flow indicator113 Shut-off cock114 Locking coupling115 Battery lock connector

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6.2 Functional DescriptionThe Aquamatik water replenishment system is used to adjust the rated electrolytelevel automatically on traction batteries for industrial trucks.

The battery cells are interconnected through hoses and are attached to the watersupply (e.g. water container) through a plug connection. When the shut-off cock isopened all the cells are filled with water. The Aquamatik plug controls the amount ofwater required and, at the relevant water pressures, ensures the water supply is shutoff and the valve is closed securely.

The plug systems have an optical level indicator, a diagnostic port to measure thetemperature and electrolyte density and a degassing port.

6.3 Adding waterWater should be added to the batteries just before the battery is fully charged. Thisensures that the amount of water added is mixed with the electrolyte.

6.4 Water pressureThe water replenishment system must be operated with a water pressure in thewater line of 0.3 bar - 1.8 bar. Any deviations from the permissible pressure rangeswill affect the operation of the systems.

Water drop

Assembly height above battery surface is between 3 - 18 m.1 m corresponds to 0.1 bar.

Pressure water

The pressure regulating valve is adjusted to suit the system and must lie between0.3 - 1.8 bar.

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6.5 Filling timeThe filling time for a battery depends on the electrolyte level, the ambienttemperature and the filling pressure. Filling ends automatically. The water supply linemust be disconnected from the battery when the water has been filled.

6.6 Water quality

Z The quality of the water used to fill up electrolyte must correspond to purified ordistilled water. Purified water can be produced through distillation or ion exchangersand is then suitable for the production of electrolyte.

6.7 Battery tubingThe tubing of the individual plugs is in accordance with the existing electric circuit.No changes should be made.

6.8 Operating temperatureBatteries with automatic water replenishment systems should only be stored inrooms with temperatures > 0°C, as otherwise the systems could freeze.

6.9 Cleaning measuresThe plug systems must only be cleaned with purified water in accordance with DIN43530-4. No parts of the plugs must come into contact with solvent-based materialsor soap.

6.10 Service mobile vehicleMobile water filling vehicle with pump and filling gun to fill individual cells. Theimmersion pump in the container generates the necessary filling pressure. Theservice mobile must be at exactly the same height as the battery base.

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7 Electrolyte circulation

7.1 Functional DescriptionElectrolyte circulation ensures the supply of air during charging to mix the electrolyte,thereby preventing any acid layer, shortening the charge time (charge factor approx.1.07) and reducing the formation of gas during charging. The charger must besuitable for the battery and electrolyte circulation.

A pump in the charger produces the necessary compressed air which is introducedto the battery cells via a hose system. The electrolyte is circulated via the inlet airand the electrolyte density level is constant over the entire length of the electrode.

Pump

In the event of a fault, e.g. if the pressure control system responds for an unknownreason, the filters must be checked and replaced if necessary.

Battery connection

A hose is attached to the pump module which together with the charge leads isrouted from the charger to the charging connector. The air is passed on to thebattery via the electrolyte circulation coupling ducts in the connector. When routingmake sure the hose is not bent.

Pressure-monitoring module

The electrolyte circulation pump is activated when charging begins. The pressuremonitoring module monitors the build-up of pressure during charging. This ensuresthat the required air pressure is provided for electrolyte circulation charging.

In the event of malfunctions, a visual error message appears on the battery charger.Some examples of malfunctions are listed below:– No connection between the air coupling of the battery and the recirculation

module (for separate coupling) or faulty air coupling– Leaking or faulty hose connections on battery– Contaminated intake filter

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NOTICEIf an installed electrolyte circulation system is seldom used or not used at all, or if thebattery is subjected to severe temperature fluctuations, the electrolyte may flow backinto the hose system.uAttach a separate coupling system to the air inlet line, such as: locking coupling to

the battery side and through-coupling to the air supply side.

Schematic illustration

Electrolyte circulation on the battery and air supply via the charger.

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8 Cleaning batteriesBatteries and trays must be cleaned in order to– Maintain cell insulation and protect cells from ground or external conductive parts.– Avoid damage from corrosion and stray currents.– Avoid excessive and varying automatic discharge of the individual cells or block

batteries due to stray currents.– Avoid electric sparking due to stray currents.

When cleaning the batteries make sure that:– The assembly site chosen for cleaning is close to a drainage system for

processing the electrolytic rinsing water.– All health and safety as well as water and waste disposal regulations are

observed when disposing of used electrolyte or rinsing water.– Protective goggles and clothing are worn.– Cell plugs are not removed or opened.– Clean the plastic components of the battery, in particular the cell containers, only

with water or water-based cloths without any additives.– After cleaning, the top of the battery is dried with suitable equipment, e.g.

compressed air or cloths. – Any fluid that has entered the battery tray must be suctioned off and disposed of

in accordance with the above-mentioned regulations.

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Cleaning the battery with a high pressure cleaner

Requirements– Cell connectors tight, plugged in securely– Cell plugs closed

Procedure• Follow the high pressure cleaner's user instructions.• Do not use any cleaning additives.• Observe the permissible cleaning device temperature setting of 140°C.

Z This generally ensures that the temperature does not exceed 60°C at a distanceof 30cm behind the outlet nozzle.

• Observe the maximum operating pressure of 50 bar.• Observe a minimum distance of 30 cm from the top of the battery.• The battery should be sprayed over its entire surface to avoid localised

overheating.

Z Do not clean one spot for more than 3 seconds with the jet to avoid exceeding themaximum battery surface temperature of 60°C.

• After cleaning dry the battery surface with suitable materials e.g. compressed airor cleaning cloths.

Battery cleaned.

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9 Storing the battery

NOTICEThe battery should not be stored for longer than 3 months without charging asotherwise it will no longer be functional.

If the battery is to be taken out of service for a long period, it should be stored fullycharged in a dry room protected from frost. To ensure the availability of the batterythe following charges can be selected:

– Monthly compensation charge for PzS and PzB batteries or 4-monthly full chargefor PzV batteries.

– Trickle charge for a charging voltage of 2.23 V x number of cells for PzS, PzM andPzB batteries or 2.25 V x number of cells for PzV batteries.

If the battery is to be taken out of service for a long period ( > 3 months), it should,as far as possible, be charged to 50% of its charge level and stored in a dry roomprotected from frost.

10 TroubleshootingIf any faults are found on the battery or charger, contact the manufacturer's customerservice department immediately.

Z The operations required must be carried out by the manufacturer's customer servicedepartment or a customer service organisation authorised by the manufacturer.

11 Disposal

Batteries marked with the recycling symbol and the sign showing acrossed-out rubbish bin should not be disposed of with ordinaryhousehold waste.

Buy-back terms and type of recycling are to be agreed with the manufacturer asdescribed in § 8 of the battery legislation.

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Documents

ESE 220/320 - Jungheinrich...04.19 en-GB ESE 220 ESE 320 2 Declaration of Conformity Manufacturer Jungheinrich AG, 22039 Hamburg, Germany Description Industrial truck Type Option Serial