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Operating Instructions 50441301 ETM/V 214-325 G 10.0403.12

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Declaration of Conformity

Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg Manufacturer or authorized representative in the Community

Type OptionSerial No.Year of Construction

ETM 214

ETV 214

ETM 216

ETV 216

ETM 320

ETV 320

ETM 325

ETV 325

Additional information

Authorised signatory

Date

G EU Declaration of Conformity

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:

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

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

Used before notices and explanations.

Used to indicate standard equipment.

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 inferred from the present operating instructions.

Jungheinrich Aktiengesellschaft

Am Stadtrand 35

22047 Hamburg - GERMANY

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

www.jungheinrich.com

I 1

ACorrect Use and Application 1General ...............................................................................................A 1 2Correct application ..............................................................................A 1 3Approved application conditions .........................................................A 1 4Proprietor responsibilities ....................................................................A 2 5Adding attachments and/or accessories .............................................A 2 BTruck Description 1Application .............. ...........B 1 2Assemblies and Functional Description ..............................................B 2 2.1Truck ...................................................................................................B 3 2.2Load handling .............. .........B 6 3Standard Version Specifications ............. ...........B 7 3.1Performance Data .............. .........B 7 3.2Dimensions .........................................................................................B 9 3.3Standard mast version dimensions ......... ...........B 11 3.4Weights ................ .........B 11 3.5Wheels/tyres .......................................................................................B 12 3.6Battery ............... .........B 12 3.7Hydraulics ...........................................................................................B 12 3.8Mast weights ................. .........B 13 3.9EN norms ............. .........B 15 3.10Conditions of use ................................................................................B 15 3.11Electrical requirements .... .........B 16 4Identification points and data plates ............... .........B 17 4.1Truck data plate ....... .........B 18 4.2Truck load chart (capacity) .. ..................B 19 4.3Attachment load chart ........ .........B 19 4.4 Stability ....... .........B 20 CTransport and Commissioning 1Transport ................ ...........C 1 2Lifting by crane ......... .........C 2 2.1Lifting the basic truck by crane ............. ..................C 3 2.2Lifting the basic truck and cabin by crane ...... .........C 4 3Securing the truck during transport ......... ...........C 5 4Using the truck for the first time ........... ..................C 6

Table of Contents

I 2 DBattery Maintenance, Charging & Replacement 1Safety regulations for handling acid batteries ......... ...........D 1 2Battery types ................. .........D 2 3Exposing the battery .......... .........D 3 4Charging the battery ........... .........D 5 5Battery removal and installation ........... ..................D 6 EOperation 1Safety Regulations for the Operation of Forklift Trucks ......................E 1 2Controls and Displays ......... .......E 2 3Starting up the truck ........ .........E 6 3.1Entry and exit ................ .........E 6 3.2Setting up the operator position .............. ...........E 7 3.3To prepare the truck for operation .......................................................E 12 3.4Emergency stop device ........ .......E 13 3.5Testing after daily operation ..................E 14 4Industrial Truck Operation .. .........E 15 4.1Safety regulations for truck operation ............ .........E 15 4.2Procedure in extraordinary situations ..................................................E 16 4.3Emergency Disconnect .......... ...........E 17 4.4Travel, steering, braking .. .........E 18 4.5Adjusting the forks ........... .........E 21 4.6Lifting and depositing loads .... ...........E 21 4.7Emergency lowering (-10/07) ..............................................................E 26 4.8Emergency lowering (10/07-) .......E 26 4.9Operating Attachments .......................................................................E 27 4.10Parking the truck safely .......................................................................E 32 5Driver’s display ( ) ................ ...........E 33 5.1Driver’s Display LED Buttons ..............................................................E 37 5.2Driver Display Switches ..... .........E 38 5.3Driver’s Display Warning Messages ...................................................E 38 6On board computer ( ) .......................................................................E 44 6.1On board computer display symbols ...................................................E 45 7Keypad (CANCODE) ( ) ....................................................................E 49 7.1Code Lock .............. ...........E 49 7.2Parameters ..........................................................................................E 50 7.3Parameter Settings ......... .........E 51 8ISM ( ) ...............................................................................................E 54 9Changing truck parameters .................................................................E 54 10Troubleshooting .......... .........E 55 11Moving the truck without a battery, recovery .......................................E 55

I 3 12Optional equipment .............................................................................E 58 12.1Headlights ..........................................................................................E 58 12.2Beacon / strobe ..................................................................................E 58 12.3Limit switch system / electrical lift limit switch .....................................E 59 12.4Seat heating .......................................................................................E 60 12.512 V DC / 24 V DC transformer .............. ...........E 60 12.6180°/360° steering angle display ........................................................E 61 12.7Sideshift centre position .....................................................................E 61 12.8Forks horizontal button .......................................................................E 62 12.9Weigher ..............................................................................................E 62 12.10Clamp button ................ .........E 63 12.11Weatherproof cab ...............................................................................E 64 12.12Parabolic mirror ...................................................................................E 65 12.13Removable load backrest ....................................................................E 66 12.14Rack Height Select ..............................................................................E 67 12.15ISM access module .............................................................................E 68 12.16Assembly and hydraulic ports of additional attachments ....................E 69 FIndustrial Truck Maintenance 1Operational Safety and Environmental Protection ..............................F 1 2Maintenance safety regulations ..........................................................F 2 3Servicing and Inspection .....................................................................F 6 4ETM/V 214-325 Maintenance Checklist ..............................................F 7 5ETM/V 214-325 Maintenance Schedule .............................................F 9 5.1Lubricants and Lubrication Schedule ..................................................F 10 5.2Consumables .....................................................................................F 11 5.3Reservoir capacity ...............................................................................F 12 6Maintenance Instructions ....................................................................F 13 6.1Preparing the truck for maintenance and repairs ................................F 13 6.2Remove seat panel .............................................................................F 14 6.3Check the hydraulic oil level ................................................................F 14 6.4Opening the fuse cover .......................................................................F 15 6.5Opening the instrument panel cover ...................................................F 15 6.6Checking electrical fuses ....................................................................F 16 6.7Checking the wheel attachments. .......................................................F 17 6.8Recommissioning ................................................................................F 17 7Decommissioning the industrial truck ..................................................F 17 7.1Prior to decommissioning: ...................................................................F 17 7.2During decommissioning: ....................................................................F 18 7.3Returning the truck to operation after decommissioning .....................F 18 8Safety checks to be performed at regular intervals and following any unusual incidents ...........F 19 9Final de-commissioning, disposal ........... ...........F 19 10 Human vibration measurement ...........F 19

ACorrect Use and Application

1General

The industrial truck described in the present operating instructions is designed for lifting, lowering and transporting load units.

It must be used, operated and serviced in accordance with the present instructions. All other types of use lie beyond the scope of application and can result in damage to personnel, the truck or property.

2Correct application

The maximum load and load distance are indicated on the load chart and must not be exceeded.

The load must rest on the load handler or be lifted by an attachment approved by the manufacturer. The load must rest on the back of the fork carriage and centrally between the forks.

–Lifting and lowering of loads.

–Transporting lowered loads over long distances.

–Do not travel with a raised load (>30 cm).

–Do not carry or lift passengers.

–Do push or pull load units.

3Approved application conditions

Do not exceed the permissible surface and spot load limits on the travel routes. At blind spots get a second person to assist.

The driver must ensure that the loading ramp / bridge cannot move or come loose during loading / unloading.

–Operation in industrial and commercial environments.

–Permissible temperature range -20 °C to 40 °C.

–Operation only on secure, level surfaces with sufficient capacity.

–Operation only on routes that are visible and approved by the proprietor.

–Negotiating inclines up to a maximum of 15 %.

–Do not negotiate inclines crosswise or at an angle. Loads must always be carried on the end of the truck facing uphill.

–Operation in partially public traffic.

Special equipment and authorisation are required if the truck is to be constantly used in extreme conditions.

The truck is not authorised for use in areas at risk of explosion.

A 1

4Proprietor responsibilities

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

5Adding attachments and/or accessories

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

A 2

BTruck Description 1Application

The ETM/V 214-325 is a three wheel electric side seat, clear view reach truck. It is designed for use on level floors to lift and transport goods. Open bottom pallets or pallets with transverse boards can be lifted inside or outside the area of the load wheels or roll cage. Loads can be stacked or unstacked and transported over long distances. The capacity can be obtained from the data plate.

B 1

Model Capacity Load centre of gravity ETM/V 214 1400 kg 600 mm ETM/V 216 1600 kg 600 mm ETM/V 320 2000 kg 600 mm ETM/V 325 2500 kg 600 mm

2Assemblies and Functional Description

B 2

ItemModelItemModel

Brake

1 Clearview mast9

pedal

Accelerator

2 Overhead guard10 pedal 3 Free lift cylinder (not with ZT mast)11 Battery trolley unlatch pedal 4 Multi-Pilot12 Driver’s display Solopilot On board computer

EMERGENCY

switch Standard Equipment Optional Equipment 1 2 3 4 5 6 7 8 9 10 11 12 13 14

5 Load wheels13 Two stage switch key with spare key (service).

6 Outriggers CANCODE 7 Drive wheel ISM Access Module

Deadman switch14

DISCONNECT

The truck can only be moved with or without a load when the mast support is retracted, the mast tilted back and the load handler lowered.

Safety mechanisms: A closed truck contour with rounded edges facilitates safe handling of the ETM/V 214-325. The driver is protected by the overhead guard (2). The drive wheel (7) and the load wheels (5) are protected by a solid skirt.

A slight danger remains for third parties, even when a drive wheel cover is used.

Pressing the EMERGENCY DISCONNECT switch (14) disconnects all electrical functions in hazardous situations.

Line brake safety devices in the lift cylinders limit the load lowering speed in the event of a hydraulic system failure.

Displays: Driver Display (12) with large TFT display ( ) or on board computer with LCD ( ), each with integrated resi dual time display, battery discharge indicator, lift and travel profile settings and steering angle mode display. The battery discharge indicator and hourmeter are combined on the driver’s display (12). The discharge indicator is designed as a monitor which cuts out lifting when the battery is discharged, in order to avoid depletion.

Drive: The entire drive unit is enclosed in the truck chassis. A fixed, 6.9kW threephase motor governs the drive wheel (7) via a bevel spur gearbox

The electronic traction controller ensures the smooth rotation of the drive motor and as a result smooth driving, powerful acceleration and electrically controlled braking with energy recovery.

The degree of energy recovery can be adjusted in the driver’s display.

Free Lift Speed Increase ( ): For post-06/2008 trucks with lift heights over 5600mm the free lift traverse and tilt speed is raised to improve turnover. These high speeds cannot be achieved for mast lift. When you change from free lift to mast lift, the traverse and tilt speeds are automatically reduced.

Slip control ( ): The slip control system prevents the drive wheel from blocking during braking. This improves the truck’s steering during braking and reduces tyre wear.

When the truck accelerates it prevents the drive wheel from spinning uncontrollably on smooth surfaces. In some circumstances the stopping distance may be extended.

The stopping distance may be extended when the reversing brake is used and the maximum speed may be restricted immediately after replacing a wheel.

Brake system: The electric braking system consists of three independent braking systems. Applying the brake pedal results in inversion braking (plugging) in the traction motor. Where required the load carrying brakes are switched on via the vehicle’s brake control system.

The safety brake is electrically operated and works mechanically through a compression spring applied to a magnet brake mounted on the drive unit. This brake is also used for emergency braking. A warning indicator appears when the brake is applied.

Faults in the steering and brake systems (which trigger an emergency stop) are shown on the driver’s display or the on board computer.

B 3 2.1Truck

Emergency Stop Safety Feature: The emergency stop is controlled by the steering and traction controllers. If an error is detected the truck automatically brakes to a halt. Control displays on the driver’s display indicate the emergency stop. Every time the truck is switched on, the system performs a self-diagnosis which only releases the parking brake (emergency stop) if the functionality test is positive.

Steering: Electrical steering which turns the transmission via a spur gear. You can choose between 3 operating modes in service mode on the driver’s display or the onboard computer:

–180° ( )

–360° (endless) ( )

–Switch between 180 - 360° via the ( ) key

The adjustable steering wheel acts as a steering transmitter.

Operator position: The driver’s position is ergonomically designed with ample legroom. The driver’s seat, steering arm and Multi-Pilot can be adjusted by the driver to ensure a comfortable posture.

The accelerator pedal and brake pedal are of “automotive” design.

Mast reach damping ( ): Damping of vibration of extended mast and speed reduction to inching when the load is extended beyond free lift.

Curve Control: Automatic speed reduction for cornering. Curve Control limits the speed and acceleration when cornering. This reduces the risk of oscillations or tipovers.

Deadman switch: The foot switch in the left foot compartment must be depressed to allow the driver to operate the truck. Lifting and travelling are inhibited if the driver removes his foot from the foot switch. Steering and braking remain enabled. The deadman switch can be adjusted so that when the foot switch is released the parking brake applies after a set time. (prevents the truck from accidentally rolling away)

B 4

B 5

Brake

Accelerator

ItemModelItemModel 1 Clearview mast9

pedal 2 Overhead guard10 pedal 3 Free lift cylinder (not with ZT mast)11 Battery trolley unlatch pedal 4 Multi-Pilot12 Driver’s display Solopilot On board computer

ISM

8 Deadman

EMERGENCY DISCONNECT switch Standard Equipment Optional Equipment 1 2 3 4 5 6 7 8 9 10 11 12 13 14

5 Load wheels13 Two stage switch key with spare key (service).

6 Outriggers CANCODE

Drive wheel

Access Module

switch14

• Thank you very much for reading the preview of the manual.

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

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

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