Jungheinrich Forklift ETV 114n ETV 116n ETV 118n ETV 120n Operating Instruction Manual 51209126 – PD

ETV 114n/116n ETV 118n/120n Operating instructions

05.12 -

G

51209126 09.14

ETV 114n ETV 116n ETV 118n ETV 120n

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

M Z

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

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 inferred from the present operating instructions.

Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG.

Jungheinrich Aktiengesellschaft Am Stadtrand 35 22047 Hamburg - GERMANY Telephone: +49 (0) 40/6948-0 www.jungheinrich.com

Table of contents A

Correct Use and Application

1 2 3 4 5

General ............................................................................................... A 1 Correct application .............................................................................. A 1 Approved application conditions ......................................................... A 1 Proprietor responsibilities .................................................................... A 2 Adding attachments and/or accessories ............................................. A 2

B

Truck Description

1 2 2.1 2.2 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 4 4.1 4.2 4.3 4.4

Application ........................................................................................... B 1 Assemblies and Functional Description ............................................. B 2 Truck ................................................................................................... B 3 Load handling ...................................................................................... B 5 Standard Version Specifications ......................................................... B 6 Performance data ................................................................................ B 6 Dimensions ......................................................................................... B 7 Standard mast version dimensions ..................................................... B 9 Weights ............................................................................................... B 9 Tyres/wheels ....................................................................................... B 9 Battery ................................................................................................. B 9 Hydraulics ........................................................................................... B 9 Conditions of use ................................................................................ B 10 Electrical requirements ........................................................................ B 10 Identification points and data plates .................................................... B 11 Truck data plate .................................................................................. B 12 Truck load chart (capacity) .................................................................. B 13 Attachment load chart ......................................................................... B 13 Stability ................................................................................................ B 14

C

Transport and Commissioning

1 2 2.1 3 4

Transport ............................................................................................. C 1 Lifting by Crane ................................................................................... C 2 Lifting the basic truck by crane ............................................................ C 3 Securing the Truck during Transport ................................................... C 4 Using the truck for the first time .......................................................... C 5

D

Battery - Servicing, Recharging, Replacement

1 2 3 4 5

Safety regulations for handling acid batteries ..................................... D 1 Battery types ....................................................................................... D 2 Exposing the battery ........................................................................... D 3 Charge the battery .............................................................................. D 5 Battery removal and installation .......................................................... D 6 I1

I2

E

Operation

1 2 3 3.1 3.2 3.3 3.4 3.5 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 5 5.1 5.2 5.3 6 6.1 6.2 6.3 7 8 9 10 10.1 10.2 10.3 10.4 10.5 10.6

Safety Regulations for the Operation of Forklift Trucks ...................... E 1 Controls and Displays ........................................................................ E 2 Starting up the Truck ........................................................................... E 4 Entry and exit ...................................................................................... E 5 Setting up the operator position .......................................................... E 5 Preparing for operation ....................................................................... E 7 Emergency stop device ....................................................................... E 8 Checks after daily operation ................................................................ E 9 Industrial Truck Operation ................................................................... E 10 Safety regulations for truck operation ................................................. E 10 Procedure in hazardous situations ...................................................... E 11 Emergency Disconnect ....................................................................... E 12 Travel, steering, braking ...................................................................... E 13 Adjusting the forks ............................................................................... E 17 Lifting and depositing load units .......................................................... E 18 Mast Holder Reach ............................................................................. E 19 Mast tilt ................................................................................................ E 19 Emergency lowering ............................................................................ E 21 Operating attachments ........................................................................ E 22 Parking the truck securely ................................................................... E 26 Driver's display .................................................................................... E 27 Driver’s Display Luminous Symbols .................................................... E 31 Driver display switches ........................................................................ E 32 Driver’s Display Warning Messages ................................................... E 32 Keypad (CANCODE) (o) .................................................................... E 39 Code lock ............................................................................................ E 39 Parameter ........................................................................................... E 40 Parameter Settings ............................................................................. E 41 Changing truck parameters ................................................................. E 44 Troubleshooting .................................................................................. E 45 Moving the truck without a battery, recovery ....................................... E 45 Optional equipment ............................................................................. E 49 Work lights .......................................................................................... E 49 Strobe light / beacon (o) ..................................................................... E 50 12 V DC / 24 V DC transformer (o) .................................................... E 51 Parabolic mirror (o) ............................................................................ E 51 Removable load backrest (t) ............................................................. E 52 Assembly and hydraulic ports of additional attachments .................... E 53

F

Industrial Truck Maintenance

1 2 3 4 5 5.1 5.2 5.3 6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 7 7.1 7.2 7.3 8 9

Operational Safety and Environmental Protection .............................. F 1 Maintenance Safety Regulations ........................................................ F 2 Servicing and Inspection ..................................................................... F 6 ETV 114n/116n/118n/120n Maintenance Checklist ............................ F 7 ETV 114n/116n/118n/120n Maintenance Schedule ............................ F 9 Lubricants and Lubrication Schedule .................................................. F 10 Consumables ...................................................................................... F 11 Tank Capacities .................................................................................. F 12 Maintenance Instructions .................................................................... F 12 Prepare the truck for maintenance and repairs ................................... F 12 Checking the wheel attachments ........................................................ F 13 Removing the seat panel .................................................................... F 14 Checking the hydraulic oil level ........................................................... F 14 Opening the fuse cover ....................................................................... F 15 Opening the instrument panel ............................................................. F 15 Checking electrical fuses .................................................................... F 16 Recommissioning ................................................................................ F 17 Decommissioning the industrial truck .................................................. F 17 Prior to decommissioning .................................................................... F 17 While the truck is out of service .......................................................... F 18 Returning the truck to operation after decommissioning ..................... F 18 Safety tests to be performed at intervals and after unusual events .... F 19 Final De-Commissioning, Disposal ..................................................... F 19

I3

I4

A Correct Use and Application 1

General 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.

2

Correct application

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

3

Approved application conditions

not exceed the permissible surface and spot load limits on the travel routes.

F Do 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.

Z

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.

A1

4

Proprietor 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.

The proprietor must ensure that all users have read and understood these operating instructions.

M 5

Adding 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.

A2

B Truck Description 1

Application The ETV series 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.

Model

Capacity

ETV 114n ETV 116n ETV 118n ETV 120n

1400 kg 1600 kg 1800 kg 2000 kg

Load centre of gravity 600 mm 600 mm 600 mm 600 mm

B1

2

Assemblies and Functional Description

1 12

13

14

2

11 10

3 4

10

9

5

8

6 7

Item 1 2 3 4 5 6 7 8

B2

t t t t t t t t t

Component Item Component Clearview mast 9 t Brake pedal Overhead guard 10 t Accelerator pedal Free lift cylinder (not with ZT mast) 11 t Battery trolley unlatch pedal SOLO-PILOT 12 t Driver's display Load wheels 13 t Two stage switch key with spare key (service).

Wheel arms o CANCODE Drive wheel 14 t Emergency Disconnect switch Deadman button Standard equipment o Optional equipment

2.1

Truck

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

Safety mechanisms: An enclosed truck perimeter with rounded edges ensures safe handling of the ETV series. The driver is protected by the overhead guard (2). The drive wheel (7) and the load wheels (5) are protected by a solid skirt.

M

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

Pressing the Emergency Disconnect (14) cuts out 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’s display (12) with widescreen LCD display including residual time display, battery discharge indicator, lift and travel settings and steer 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 disables lifting when the battery is discharged, in order to avoid depletion.

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

The electrical drive current control ensures the smooth rotation of the drive motor and as a result smooth driving, powerful acceleration and electrically controlled braking with energy recovery.

B3

Brake system: The electric brake system consists of independent brake systems.

Applying the brake pedal results in inversion braking (plugging) in the traction motor.

The parking brake is electrically actuated and works mechanically through a compression spring applied to a magnet brake mounted on the drive unit. It 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.

Applying the brake pedal activates the parking brake when the truck is stationary.

Emergency Stop Safety Feature: The emergency stop is controlled by the traction or steering controller. If an error is detected the truck automatically brakes to a halt.

Control indicators 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 2 operating modes in service mode on the driver’s display: – 180° (t) – 360° (o, endless) The adjustable steering wheel acts as a steering transmitter.

Operator position: The driver’s position is ergonomically designed with ample legroom. To achieve the correct seated position, the driver’s seat and steering head can be adjusted by the driver. The accelerator and brake pedals are of “automotive” design.

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 button: The deadman button in the left foot compartment must be depressed in order for the driver to operate the truck. Lifting and travel are inhibited if the driver takes his foot off the foot switch. Steering and braking remain enabled.

The deadman button 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)

B4

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• 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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DOWNLOAD THE COMPLETE MANUAL