Jungheinrich Forklift Truck ETX-Kombi 125 150 Operating Instructions Manual 10003411 by www.heydownloads.com

ETX-Kombi 125 / 150 07.95Operating instructions Ù 10003411 1296

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Foreword

The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide sufficient instruction for the safe operation of the industrial truck. The information is provided clearly and concisely. The chapters are arranged by letter. Each chapter starts with page 1. The page identification consists of a chapter letter and a page number. For example: Page B 2 is the second page in chapter B.

The operating instructions detail different truck models. When operating and servicing the truck, make sure that the instructions apply to your truck model.

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

fUsed before safety instructions which must be observed to avoid danger to personnel.

mUsed before notices which must be observed to avoid material damage.

A Used before notices and explanations.

t Used to indicate standard equipment.

o Used to indicate optional equipment.

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

Jungheinrich Aktiengesellschaft

Am Stadtrand 35

D-22047 Hamburg - Germany

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

www.jungheinrich.com

I1 ACorrect use and application of the truck A1 BDescription of the truck 1 2 2.1 2.2 3 3.1 3.2 3.3 3.3 3.4 3.5 4 4.1 4.2 4.3 Application Assembly description and functional description............ Truck Load lifting device................................................................. Technical data - standard version .................................... Performance data.... Ambient conditions ............................................................... ETX-Kombi 125 dimensions ............................................... ETX-Kombi 150 dimensions EN standards.......................................................................... Remaining risks.................................................................... Location of instruction labels and identification plates... Truck identification plate ...................................................... Load capacity label .............................................................. Braking test data.................................................................... B1 B2 B3 B5 B7 B7 B7 B9 B11 B12 B13 B14 B14 B15 B16 CTransportation and commissioning 1 2 3 3.1 4 4.1 4.2 4.3 Tansportation ......................................................................... Loading .................................................................................. Commissioning ..................................................................... Commissioning after transportation .................................. Moving an incapacitated truck ............................................ Releasing the spring pressure brake on the drive motor ............................................................................. Releasing the load-bearing wheel brake ......................... Rendering the brake system operational ......................... C1 C1 C4 C4 C7 C7 C8 C8 DBattery - Servicing,recharging, replacement 1 2 3 4 5 6 7 8 8.1 8.2 8.3 8.4 Safety regulations governing the handling of lead-acid batteries ............................................................... Battery types .... Exposing the battery ............................................................. Charging the battery Adjusting the battery discharge monitor............................ Removing and installing the battery .................................. Checking the state of the

electrolyte level and the electrolyte density ......................................... Contact rail operation with closed contact rail.................. Description of the operating and display elements for the charging device.......................... Driving...................................................................................... Compensation charge.......................................................... Starting driving operation..................................................... D1 D1 D2 D2 D3 D3 D6 D7 D9 D10 D11 D12

Table of contents

battery, the

1 2 3 Safety regulations governing the operation of the truck.................................. Description of the operating controls and indicators...... Start-up of truck E1 E2 E16 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 Truck operation Safety regulations applicable when operating the truck Driving, steering, braking Driving in narrow aisles Operating the driver cabin .................................................. Operating the load lifting device ........................................ Operating the swivel/traverse fork ..................................... Operating the telescopic fork .............................................. DIS device............................................................................... Commissioning and stacking ............................................. Parking the truck securely................................................... E22 E22 E23 E29 E33 E36 E36 E43 E44 E48 E52 5 5.1 5.2 Central operator display Configuring the display ........................................................ Structure of the user menu ................................................ E53 E53 E55 6 6.1 6.2 6.3 6.4 6.5 6.6 Fault locating operations ..................................................... Emergency lowering of the driver cabin/auxiliary hoist frame .............................................................................. Leaving the driver cabin using the emergency lowering device ..................................................................... Overriding the slack chain safety device .......................... Overriding the drive cut-out ................................................. IF emergency operation ....................................................... Recovering the truck from a narrow aisle ......................... E57 E60 E62 E64 E64 E65 E67 I2

Operation

Description of the servicing and maintenance operations.....................................................

Preparing the truck for servicing and maintenance operations

Removing the cover of the drive compartment................

Checking the position and tightness of the drive wheel

Checking the mechanical brake system..........................

Removing the driverÕs seat

Checking the hydraulic oil level.........................................

Checking the transmission oil level..................................

Checking the brake fluid level

Checking the soiling indicator - hydraulic oil return flow filter .....................................................................

Checking the soiling indicator - pressure filter in the hydraulic steering circuit.......................................... Checking the carbon brush wear

the electrical fuses.............................................

12Safety checks to be performed at regular intervals and following any untoward incidents (Ü: Accident prevention check according to VGB 36).................................F22

F Truck maintenance 1 2 3 4 5 5.1 6 7 7.1 8 9 9.1 Operational safety and environmental protection.......... Safety regulations applicable to truck maintenance...... Servicing and inspection.................................................... Maintenance check list ETX-Kombi 125/150 Lubrication schedule ETX-Kombi 125/150 Fuels, coolants and lubricants .......................................... Maintenace check list SSG

schedule SSG................................................. Fuels, coolants and lubricants........................................... Maintenance check list TG Lubrication schedule TG .................................................... Fuels, coolants and lubricants F1 F1 F3 F4 F7 F7 F8 F9 F9 F10 F11 F11 10 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 10.9 10.10 10.11 10.12 10.13

Lubrication

Checking

Recommissioning of

truck............................................ F12 F12 F13 F13 F14 F14 F14 F15 F15 F16 F16 F17 F18 F20 11 11.1 11.2 11.3 Decommissioning the truck Operations to be performed prior to decommissioning Measures to be taken during decommissioning Recommissioning of the truck F20 F21 F21 F21

the

ACorrect use and application of the truck

Aincluded in the scope of delivery for this truck. The guidelines are part of these operating instructions and must always be heeded. National regulations are fully applicable.

The fork-lift truck described in these operating instructions is a truck that is suitable for lifting and transporting loads. It must be used, operated and maintained according to the information in these operating instructions. Any other uses are outside the design envelope and can lead to injury to persons or damage to equipment and property. Above all, overloading caused by excessively heavy or unbalanced loads must be avoided. The max. admissible load to be picked up is indicated on the identification plate or load diagram label shown on the truck. The fork-lift truck must not be operated in spaces subject to fire or explosion hazards, or in spaces where corrosive or very dusty atmospheres prevail.

Duties of the user:

fined as any natural or legal person who either uses the fork-lift truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting), the user is considered the person, who, in accordance with existing contractual agreements between the owner and the user of the fork-lift truck, is charged with the observance of the operating duties.

The user must ensure that the truck is not abused and only used within its design limits and that all danger to life and limb of the operator, or third parties, is avoided. In addition to this, it must be ensured that the relevant accident prevention regulations and other safety-related provisions, as well as the operating, servicing and maintenance guidelines, are observed. The user must also ensure that all persons operating the truck have read and understood these operating instructions.

m If these Operating Instruction are not observed the warranty becomes void. The same applies if improper works are carried out at the device by the customer and/or third parties without permission of our Customer Service.

Mounting of attachments: The mounting or installation of any attachments which will interfere with, or supplement, the functions of the truck is permitted only after written approval by the manufacturer has been obtained. If necessary, the approval of local authorities has to be obtained.

Any approval obtained from local authorities does not, however, make the approval by the manufacturer unnecessary.

A 1

B Description of the truck

1Application

The ETX-Kombi is a three-wheel commissioner with battery drive. The truck is available as the ETX-Kombi 125 and the ETX-Kombi 150, with different performance data.

The standard performance data are listed in Section 3.1.

The driverÕs cabin is lifted together with the load lifting device so that the operator has quick access to and a clear overview of the individual compartments. All operating functions are carried out at the control desk, independent of the current lifting height. Operation can be carried out in the sitting and standing positions.

As a standard, a swivel/traverse fork (SSG) or a telescopic fork (TG) is used as the load lifting device. The fork can be designed for different loads. In the case of the swivel/traverse fork, the gap between the fork tines can be adjusted. The load can be lifted to a suitable height for commissioning by using the auxiliary lift. A divided control desk (option) simplifies commissioning.

The ETX-Kombi can be equipped with a rail guidance system (SF) or a wire guidance system (IF) for operation in narrow aisles. The driver can fully concentrate on stacking or commissioning. It is possible to simultaneously drive and lift in narrow aisles. The appropriate release is triggered by aisle recognition marks (magnets, optional light barriers). Outside the aisles, the ETX-Kombi can be freely moved at partly limited speeds, depending on the lifting height, and is thus as mobile as a normal fork-lift truck.

The rack systems must be set up for the ETX-Kombi. For the rail guidance system, guide rails must be available in the aisles. Guide rollers made of Vulkollan, which are screwed to the truck chassis, guide the truck between the guide rails. For the wire guidance system, a guide wire must be installed in the floor to provide signals which are picked up by sensors on the truck chassis and processed in the computer.

B2 2Assembly description and functional description 8 9 10 11 12 14 15 16 17 18 19 20 21 22 23 26 1 2 3 4 6 7 5 13 24 25 Item Designation Item Designation 1 Lifting cylinder, main hoist frame14 Collision guard/wheel housing 2 Hoist frame15 Load-bearing wheel 3 Safety chain16 SF Guide rollers 4 Overhead guard17 Battery safety device 5 Mirror18 Battery compartment 6 Central control desk Divided control desk 19 Safety barriers 7 Driver cabin20 Lifting eye, truck chassis 8 SSG Auxiliary lifting mast21 DriverÕs seat 9 SSG Auxiliary lifting cylinder22 Cabin illumination 10 SSG Auxiliary lifting load chain23 Spotlight 11 SSG Fork carrier24 Energy supply 12 SSG Fork25 Load chains, main hoist frame 13 IF IF sensors26 Lifting eye, hoist frame = Standard equipment = Optional equipment SSG = Swivel/traverse forkSF = Rail guidance IF = Wire guidance

Safety equipment: The closed truck contour with rounded edges, a covered drive wheel and a collision guard (14) allow the ETX-Kombi to be safely operated. An overhead guard (4) protects the driver against anything that might fall down.

The EMERGENCY STOP master switch in the control desk can be used to immediately switch off all functions in dangerous situations. The safety barriers (19) attached on both sides of the cabin interrupt all driving and lifting movements when they are opened.

Driving, lifting/lowering and traversing/swivelling movements can only be triggered if the appropriate dead-man key or the two-handed operating element, right or left, for the selected function is actuated. In addition to the safety devices provided as standard equipment, the following safety devices may be available, depending on the application of the truck:

- lifting cut-out for intermediate lifting heights

- traversing cut-out for the 2nd stacking depth

- lifting cut-out with safety frame on the overhead guard

- automatic end of aisle safety device

- overload protection with lifting cut-out

- driving cut-out at specific lifting heights

- static discharge by means of steel roller/copper ribbon

- personnel protection system (PSS).

Chassis and superstructure: Robust tubular steel chassis as torsionally rigid basic body with integrated load-bearing wheel axles, matched to the respective aisle width. All units are esily accessible through doors and protective hoods that can be opened easily.

Drive unit: A drive motor which is arranged in the center and whose speed can be continuously adjusted by an electronic drive current control system, propels the drive wheel via a spur wheel gear. The drive unit can be pivoted by ± 90° .

Brake system: A spring-pressure brake (to be released electromagnetically) on the drive motor and hydraulic inside shoe brakes in the load-bearing wheels act together as a service brake, a parking brake and an emergency stop brake. The brakes are released by actuating the deadman key. The brakes are applied automatically in case of power failure or faulty operational states. Releasing the deadman key also causes immediate braking of the truck. For exact positioning of the truck, the multi-function lever for driving can be swivelled to the opposite direction to brake the truck with counter-current as a service brake.

Steering system: The truck has an electro-hydraulic steering system. A set value transmitter registers the rotating movement at the steering wheel, which is then transmitted to the drive wheel by a proportional valve and a hydraulic motor. LEDs indicate the current position on the wheel position indicator in the control desk. The number of turns to be applied to the steering wheel to effect a full-scale deflection of the drive wheel can be set by the service technicians according to the requirements of the operator. The steering function also depends on the operational state of the guidance system. If the guidance system is not activated, the truck can be freely moved around in the apron with the steering wheel. With wire guidance, steering is carried out automatically by the guide wire in the floor, the sensors, the proportional valve and the hydraulic motor. In the narrow aisle, the steering deflection is limited to ± 1° for the forward direction.

2.1Truck

Hydraulic system: The pump unit, which consists of a direct current motor and a precision high-pressure pump, produces the required oil flow. This oil flow supplies the lifting cylinders and the hydraulic reservoir for the load-bearing wheel brakes. An additional pump unit supplies the steering system and the functions of the load lifting device in all trucks. The lifting and lowering speeds, the functions for moving the load lifting device and the steering system are regulated by electronically controlled proportional valves.

The hydraulic lines consist of high-pressure hoses. Miniature measuring connections are available for pressure measurements.

Electric system: 48 V (ETX-Kombi 125) or 80 V (ETX-Kombi 150) two-wire system, designed according to the applicable EC regulation. Sensitive, continuous adjustment of the driving speed and all hydraulic movements by means of multi-function levers. Central truck control system, controlled via microprocessors, with several computers linked via a bus system. Owing to the modular structure, special functions are easy to integrate. Information and system messages are shown on a central operator display (6) by means of LED indicators and in the form of plain text messages. An extensive diagnosis system and a PC interface are integrated into the control desk for service purposes. The control computers are arranged in a compact manner centrally in the drive compartment, the driverÕs cabin and the control desk. All control fuses are equipped with LEDs, thus allowing easy examination of the control circuits.

Lighting: Indicating lights installed on the front and the rear of the chassis and 360° warning lights (option) on the mast are used to indicate the danger zones of the truck. The cabinÕs lighting system and the spotlight on the overhead guard (option) ensure that the operating and working area are appropriately illuminated.

Wire guidance: Sensors on the truck chassis, a potentiometer and an incremental transmitter at the steering drive provide the input signals for automatic steering of trucks with IF guidance. The truck control converts these signals into control commands for the electro-hydraulic steering system. An emergency stop is triggered in case of an unpermissible deviation from the guide wire, operating errors or technical defects on the truck or the floor system.

Hoist frame: The truck is designed for use with double and triple telescopic masts with optimum visibility. The inner masts and the driverÕs cabin are guided by supporting rollers in the transverse and longitudinal directions. The transverse rollers and the inclination of the supporting rollers ensure that strong axial forces during lateral stacking and retrieval are safely absorbed. The lifting movement is effected using hydraulic cylinders and load chains. The hoist frame is screwed to the truck chassis and anchored by tie rods. Owing to the movable bearing of the hoist frame, the mast can be precisely adjusted.

2.2Load lifting device

A swivel/traverse fork (SSG) or a telescopic fork (TG) is used as the load lifting device. An elastic cable chain leads the hydraulic and electric connections to the load lifting device. With both fork versions, an auxiliary lifting mast can be used to bring the load units to a convenient siezing height for commissioning.

Swivel/traverse fork

The swivel/traverse fork allows stackable load units to be directly picked up from or set down on the ground, either laterally or from the front. During transport runs, the fork is swivelled through 90 ° , with the tines pointing either to the left or the right of the drive direction. Inside the narrow aisles, stacking operations can be carried out on either side.

The load lifting device consists of the lateral traversing frame (28) for lateral movements of the traversing carriage (29) in the horizontal level and the auxiliary lifting mast (8), which can be swivelled through 180 ° , with the fork carrier (30) and the fork tines (12). The auxiliary lift is carried out by the auxiliary lifting cylinder (32) and the auxiliary lift load chain (31).

The traversing movement of the traversing carriage is effected by a hydraulic motor (27) driving a gearwheel shaft; the gearwheels of this shaft engage in two toothed racks attached to the front of the truck.

Two adjustable guide rollers at the top and the bottom guide the traversing carriage in U-beams. These rollers absorb the load moments. A supporting roller on the central path of the lateral traversing frame absorbs the vertical forces.

Two hydraulic cylinders connected by chains effect the swivelling motion of the auxiliary lifting mast around its axis of rotation. Proportional valve control systems allow the fork to smoothly approach all limit positions. Swivelling and traversing can be carried out simultaneously both inside and outside narrow aisles by using a key in the control desk and a multifunction lever. At a 180 ° angle of rotation, the movement is switched off in the limit position. As an option, a separate key in the control desk and a multi-function lever can be used to carry out automatic synchronous swivelling and traversing.

8 27 28 32 31 30 12 29

Telescopic fork

The telescopic fork allows stackable load units to be picked up or set down to the left or the right. The aisle width required is very small (pallet length + 2 x safety distance). For the telescopic fork, the lowest stacking level must be above 250 mm since the height in the lowered position is 300 mm. As an option, a flat telescopic fork (FTG) can be installed, with the lowest stacking level at 100 mm. The fork can only pick up pallets that are open at the bottom. The clearance for introducing the fork must be at least 100 mm.

The telescopic fork consists of the auxiliary lifting mast (33) and the load carriage (35) with the attached fork tines (34). The auxiliary lifting mast can be designed as a single or double telescopic mast with free lift. The auxiliary lifting cylinder carries out the lifting movement (in two stages for the double mast with free lift).

The traversing movement of the telescopic fork is produced by a hydraulic motor and transmitted via pull chains (36). Proportional valve control systems allow the fork to smoothly approach all limit positions, where the respective movement is switched off electrically. In addition, the movements are limited mechanically.

For transport runs, the telescopic fork must be in the centre position; in this position, the traversing movement is automatically switched off. A control lamp indicates whether the fork has reached the transport position.

The fork approaches the limit positions and the centre position in a damped manner.

33 34 35 36

Technical data to VDI 2198. Technical data are subject to alteration and extension in scope.

3.1Performance data

The travelling speeds may be restricted by the electronic drive control system depending on various parameters (e.g. the lifting height, the operational state of the guidance system and the steering angle of the drive wheel).

3.2Ambient conditions

3Technical data - standard version

Designation ETX-Kombi 125 ETX-Kombi 150 Capacity (pallet size 1200 x 1200 mm)1250 1500kg Load centre600 600mm Maximum travelling speed with load (apron/aisle)9 9/10 km/h Lifting speed (main lift) with/without load0.29/0.33 0.33/0.37m/s Lowering speed (main lift) with/without load0.4/0.35 0.45/0.45m/s Lifting speed (aux. lift) with/without load0.3/0.4 0.25/0.36m/s Lowering speed (aux. lift) with/without load0.3/0.2 0.40/0.15m/s Lateral traversing with/without load0.25/0.25 0.25/0.25m/s Swivelling through 180° with load8 8s Synchr. swivelling/traversing 180° /limit position10 10s Designation ETX-Kombi 125 ETX-Kombi 150 Temperature range5 - 405 - 40 ° C Maximum wheel load at standstill 48005400daN Ground pressure for wheel load70 65 daN/cm2 Area load18203100 daN/m2

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• You can download the complete manual from: www.heydownloads.com by clicking the link below

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