Jungheinrich Forklift ETV C16 ETV C20 Operating Instructions Manual 51069863 – PDF DOWNLOAD

ETV C16/C20

06.08 -

Operating Instructions

G

51069863 03.15

ETV C16 ETV C20

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Declaration of Conformity

Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg Manufacturer or authorized representative in the Community Type ETV C16 ETV C20

Option

Serial No.

Year of Construction

Additional information

Authorised signatory

Date

G EU Declaration of Conformity

1

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 3.10 3.11 4 4.1 4.2 4.3 4.4

Application ........................................................................................... B 1 Assemblies and Functional Description .............................................. B 2 Truck ................................................................................................... B 3 Load handling ...................................................................................... B 6 Standard Version Specifications ......................................................... B 7 ETV C16/C20 Performance Data ........................................................ B 7 ETV C16/C20 Dimensions .................................................................. B 8 Standard mast version dimensions ..................................................... B 10 Weights ............................................................................................... B 10 Wheels/tyres ....................................................................................... B 10 Battery ................................................................................................. B 10 Hydraulics ........................................................................................... B 10 Mast weights ....................................................................................... B 11 EN norms ............................................................................................ B 12 Conditions of use ................................................................................ B 12 Electrical requirements ........................................................................ B 13 Identification points and data plates .................................................... B 14 Truck data plate .................................................................................. B 15 Truck load chart (capacity) .................................................................. B 16 Attachment load chart ......................................................................... B 16 Stability ................................................................................................ B 17

C

Transport and Commissioning

1 2 2.1 2.2 3 4

Transport ............................................................................................. C 1 Lifting by crane .................................................................................... C 2 Lifting the basic truck by crane ............................................................ C 3 Lifting the basic truck and cabin by crane ........................................... C 4 Securing the truck during transport ..................................................... C 5 Using the truck for the first time .......................................................... C 6

I1

I2

D

Battery Maintenance, Charging & Replacement

1 2 3 3.1 3.2 4 5

Safety regulations for handling acid batteries ..................................... D 1 Battery types ....................................................................................... D 2 Exposing the battery ........................................................................... D 3 Solo Pilot: ............................................................................................ D 3 Multi Pilot: ............................................................................................ D 5 Charging the battery ............................................................................ D 7 Battery removal and installation .......................................................... D 8

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 5 5.1 5.2 5.3 6 6.1 6.2 6.3 7 8 9 10 11 11.1 11.2 11.3

Safety Regulations for the Operation of Forklift Trucks ...................... E 1 Controls and Displays ........................................................................ E 2 Starting up the truck ............................................................................ E 6 Entry and exit ...................................................................................... E 6 Setting up the operator position .......................................................... E 7 To prepare the truck for operation ....................................................... E 14 Emergency stop device ....................................................................... E 15 Testing after daily operation ................................................................ E 16 Industrial Truck Operation ................................................................... E 17 Safety regulations for truck operation ................................................. E 17 Procedure in extraordinary situations .................................................. E 18 Emergency Disconnect ....................................................................... E 19 Travel, steering, braking ...................................................................... E 20 Adjusting the forks ............................................................................... E 23 Lifting and depositing loads ................................................................. E 23 Mast Support Reach ........................................................................... E 25 Emergency lowering ............................................................................ E 28 Operating Attachments ....................................................................... E 29 Parking the truck safely ....................................................................... E 34 Driver’s display (t) ............................................................................. E 35 Driver’s Display LED Buttons .............................................................. E 39 Driver Display Switches ...................................................................... E 40 Driver’s Display Warning Messages ................................................... E 40 Keypad (CANCODE) (o) .................................................................... E 47 Code lock ............................................................................................ E 47 Parameters .......................................................................................... E 48 Parameter Settings ............................................................................. E 49 ISM (o) ............................................................................................... E 52 Changing truck parameters ................................................................. E 52 Troubleshooting .................................................................................. E 53 Moving the truck without a battery, recovery ....................................... E 53 Optional equipment ............................................................................. E 56 Headlights .......................................................................................... E 56 Beacon / strobe .................................................................................. E 56 Limit switch system / electrical lift limit switch ..................................... E 57

11.4 Seat heating ....................................................................................... E 58 11.5 12 V DC / 24 V DC transformer .......................................................... E 58 11.6 Sideshift centre position ..................................................................... E 59 11.7 Weigher .............................................................................................. E 59 11.8 Clamp button ...................................................................................... E 60 11.9 Weatherproof cab ............................................................................... E 61 11.10 Parabolic mirror ................................................................................... E 62 11.11 Removable load backrest .................................................................... E 63 11.12 ISM access module ............................................................................. E 64 11.13 Assembly and hydraulic ports of additional attachments .................... E 65

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

Operational Safety and Environmental Protection .............................. F 1 Maintenance safety regulations .......................................................... F 2 Servicing and Inspection ..................................................................... F 6 ETV C16/C20 Maintenance Checklist ................................................. F 7 Maintenance Schedule ........................................................................ F 9 Lubricants and Lubrication Schedule .................................................. F 10 Consumables. ..................................................................................... F 11 Reservoir capacity ............................................................................... F 12 Maintenance Instructions .................................................................... F 13 Preparing the truck for maintenance and repairs ................................ F 13 Remove seat panel ............................................................................. F 14 Check hydraulic oil level ...................................................................... F 14 Opening the fuse cover ....................................................................... F 15 Opening the instrument panel cover ................................................... F 15 Checking electrical fuses .................................................................... F 16 Check wheel attachment and wear ..................................................... F 17 Recommissioning ................................................................................ F 17 Decommissioning the industrial truck .................................................. F 18 Prior to decommissioning: ................................................................... F 18 During decommissioning: .................................................................... F 19 Returning the truck to operation after decommissioning ..................... F 19 Safety checks to be performed at regular intervals and following any unusual incidents .......................................................................... F 20 Final de-commissioning, disposal ....................................................... F 20 Human vibration measurement ........................................................... F 20

9 10

I3

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.

The following operations are permitted: – Lifting and lowering loads.

– Transporting lowered loads.

The following operations are prohibited: – Travelling with a raised load (>30 cm).

– Transporting hanging loads. If the truck is to be operated with hanging loads, proof of sufficient safety distance under local operating conditions must be obtained from a specialist assessor.

– Carrying and lifting passengers.

– Pushing or pulling 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 C16/C20 is a three wheel electric side seat, clear view reach truck. It is designed for internal and external use 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, unstacked and transported over long distances.

The capacity can be obtained from the data plate.

Model ETV C16 ETV C20

Capacity 1,600 kg 2,000 kg

Load centre of gravity 600 mm 600 mm

B1

2

Assemblies and Functional Description 1 2

11

12 13 14

3 4

10 9 8

7 Item Description 1 t Clearview mast 2 t Overhead guard 3 t Free lift cylinder (not with ZT mast) 4 t Solo-Pilot o Multi-Pilot 5 6 7

t Load wheels t Outriggers t Drive wheel

8

t Deadman button t Standard Equipment

B2

6

5

Item Description 9 t Brake pedal 10 t Accelerator pedal 11 t Battery trolley unlatch pedal 12 13

14

t Driver’s display t Two stage switch key with spare key (service). o CANCODE o ISM Access Module t EMERGENCY DISCONNECT switch o Optional Equipment

2.1

Truck

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

Safety mechanisms: An enclosed truck geometry with rounded edges ensures safe handling of the ETV C16/C20. 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 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’s display (12) with widescreen LCD display (t) including residual 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, 6.9 kW 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.

Slip control (o): 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.

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

B3

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.

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 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: 180° electrical steering which turns the transmission via a spur gear. 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 Solo Pilot / Multi Pilot (o) can be adjusted to suit the driver.

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 travel 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)

B4

1 2

11

12 13 14

3 4

10 9 8

7 Item Description 1 t Clearview mast 2 t Overhead guard 3 t Free lift cylinder (not with ZT mast) 4 t Solo-Pilot o Multi-Pilot 5 6 7

t Load wheels t Outriggers t Drive wheel

8

t Deadman switch t Standard Equipment

6

5

Item Description 9 t Brake pedal 10 t Accelerator pedal 11 t Battery trolley unlatch pedal 12 13

14

t Driver’s display t Two stage switch key with spare key (service). o CANCODE o ISM Access Module t EMERGENCY DISCONNECT switch o Optional Equipment

B5

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