Jungheinrich Forklift ETX 125 150 Operating instructions Manual 50002975 – PDF DOWNLOAD

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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.

Copyright

Copyright of these operating instructions remains with JUNGHEINRICH AG

Jungheinrich Aktiengesellschaft

Am Stadtrand 35

D-22047 Hamburg - Germany

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

www.jungheinrich.com

regulations applicable when operating the truck................................................................................... Driving, steering, braking..................................................... Driving in narrow aisles

Lifting/lowering the load lifting device............................... Operation of the reach-and-rotate forks

Operation of the telescopic reach forks Picking up, transporting and setting down loads............ Stacking and de-stacking loads in pre-selected disposal points with height preselection and/or horizontal

after an emergency stop with inductive guidance

safety and environmental protection..............

and inspection....................................................

checklist ETX 125/150 .....

Lubrication chart ETX 125/150 Service materials .................................................................

Maintenance checklist reach-and-rotate forks SX Lubrication chart reach-and-rotate forks SX ..................

materials.................................................................. Maintenance checklist reach-and-rotate forks SR

chart reach-and-rotate forks SR ..................

checklist TG

Description of the service and maintenance activities ........................................................

Preparing the truck for service and maintenance activities......................................................... Removing the battery and hydraulic compartment covers Opening and securing the tractor compartment cover . Removing the floor plate Checking the mounting and security of the drive wheel .....................................................................................

the hydraulic oil level Checking the drive unit oil level ........................................

the brake fluid level ...........................................

the load wheel brakes

the electric fuses ................................................

the truck ...............................................

required prior to decommissioning .................

required during decommissioning ................

14Safety checks to be performed at regular intervals and following any untoward incidents (Ü: Accident prevention check according to VBG 36).................................F21

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.

B Description of the truck

1Application

The ETX 125/150 is an electric side loading fork truck which picks up, transports and lifts the load outside of the wheel base. It can be used to stack pallets according to DIN 15142, box pallets according to DIN 15144 and other loads on pallets inside the plant. If the ETX 125/150 is used for assembly work with a suitable work platform, the load lifting device must either be supplied or approved by JUNGHEINRICH AG. To optimise the work cycle, it is possible to work diagonally, i.e. to drive and lift simultaneously.

The standard load lifting devices are the reach-and-rotate forks (SR) and (SX) or the telescopic reach forks (TG) and (FTG). The forks can be dimensioned for various load units. The spread of the reach-and-rotate forks is adjustable.

For operation in narrow aisles, the ETX 125/150 can either be equipped with a rail guidance system (SF) or with an inductive guidance system (IF). The driver can so concentrate fully on stacking and retrieving the load. Simultaneous driving and lifting is allowed in the aisle. The function is enabled by the straight-ahead position of the steering. Outside the aisle, the ETX 125/150 can be driven freely within the range of some speed limits dependent upon the lift height, and it is therefore as mobile as a normal fork truck.

The racking must be equipped accordingly for the ETX 125/150. Guide rails must be installed in the narrow aisles for the rail guidance system (SF). Polyurethane guide rollers bolted to the truck frame guide the truck between the guide rails. For the inductive guidance system (IF), a guide wire must be installed in the floor, whose signals are picked up by sensors on the truck frame and processed in the computer.

Definition of the direction of travel

The direction of travel is defined as follows:

Safety features: A closed vehicle contour with round edges, covered drive wheel and a bumper allow safe handling of the ETX 125/150. An overhead guard (16) protects the driver against falling objects. In an emergency, all functions can be switched off quickly with the master emergency cut-out switch.

Travel is only possible when the dead man's switch is depressed. In adddition to the standard safety features, the following duty-dependent safety features are available:

-Lift cut-out for intermediate lifting heights

-Reach cut-out for 2nd stacking depth

-Automatic end-of-aisle safety device

-Reduced truck speed at certain lifting heights.

Chassis and superstructure: Rugged frame construction in skeleton design. The driver's seat (15) and cover can be swivelled out 180°. All covers can be folded down or are easy to remove for the best possible access to all electronic and hydraulic assemblies.

Travel drive and traction control: The ETX 125/150 is driven by a powerful series motor. The fully electronic microprocessor pulse control with regenerative braking allows particularly sensitive and safe acceleration and braking of the vehicle. Due to continuous speed monitoring, the truck speed is always adapted to the particular working conditions. When the travel direction is reversed or the accelerator pedal is released, the microprocessor pulse control brakes the vehicle with the traction motor, which is then working as a generator, in a controlled and pre-defined manner. The generated energy is fed back into the battery, extending the battery charging intervals.

Brake system: Both load wheels (11) are braked hydraulically with the brake pedal when travelling at full speed. The spring-operated brake is applied at the same time. to the load wheels and the drive wheel. The braking is supported by the generator. Braking deceleration increases with the stroke of the brake pedal. At reduced truck speed, the drive wheel is only braked with the spring-operated brake on the traction motor when the brake pedal is depressed. The spring-operated brake can also be operated with the dead man's switch.

Steering system: The electric steering ensures easy and precise steering of the vehicle.

Hoist frame: The mast (1) is a special construction of double T-sections with two externally mounted lift cylinders (3). All masts are of the free-view type. The mast is mounted at four points on the frame and it is adjusted with eccentric pins. Larger masts are installed with braces (18).

Hydraulic system: The hydraulic unit is controlled by a pulse control. the directly flange-mounted internal gear pump runs in the oil reservoir. A control lever affords sensitive and infinitely-variable control of all movements of the hydraulically-controlled assemblies. Proportional valves installed in the vehicle ensure jerk-free starting and a smooth end of travel. The oil flow for reach-and-rotate movements is controlled with the motor speed. All hydraulic assemblies are protected by separate pressure relief valves.

Electrical system: The electrical system is designed for a nominal voltage of 80 V. The pulse controls for the traction and hydraulic drive are designed as compact controls. Both are provided with a fault diagnostic programme, which indicates any errors in the electronic assemblies immediately at the battery charge and fault indicator in the tractor compartment. All faults are stored in memory and can be retrieved by JUNGHEINRICH service personnel. The 80/24 V voltage converter supplies the central freely programmable control unit and the control PCB. The control unit logically connects all sensors and actuators. The commands for the actuators are processed by the cyclical interrogation of the switching state of the sensors and by performing the instructions contained in the programme memory (EPROM). Modifications in the programme, for xample with changing operating conditions, are possible. For this, the CPU must be exchanged by JUNGHEINRICH service personnel.

Lighting: An optional rotating beacon mounted on the overhead guard warns of the danger zone of the vehicle. Optional cab lighting and working lights (17) mounted on the overhead guard provide a good lighting of the operating and working area.

Inductive guidance: A control unit senses the signals of the IF sensors on the truck frame (10) when automatic steering is on and the signals of the increment sensor on the steering wheel when manual steering is selected, compares them with the value of the potentiometer for sensing the position of the wheels and controls the position of the drive wheel as needed. An emergency stop is triggered if there is an inadmissible departure from the guide wire or a fault in the system.

Electronic height pre-selector "HICONT": The load lifting device stops automatically at the stacking height pre-selected on the control panel. Depending on the position of the load sensor on the load lifting device, the stop occurs in the stacking or de-stacking position (load lifting device with/without pallet). The height pre-selector operates up and down. The actual fork height and the pre-selected stacking level are displayed.

Automatic stacking: The automatic stacking works in connection with the electronic height pre-selector "HICONT". After reaching the pre-selected stacking level, the driver starts automatic stacking or retrieval of the pallet in the racking by briefly operating the control lever.

Electronic horizontal positioning: The vehicle stops automatically at the pre-selected stop position. The electronic horizontal positioning works in connection with the electronic height pre-selector "HICONT". The driver pre-selects the complete address (storage area, stacking level, line of racks and stop position) of a storage place on the control panel. All inputs and the current operating states are indicated. The address of a storage place can be entered with the keyboard on the control panel, with a bar code reader or the guidance system.

2.2Load lifting device

The reach-and-rotate fork models SR and SX or the telescopic reach fork models TG and FTG are used. The hydraulic and electrical connections are routed with a flexible cable chain to the load lifting device.

SX and SR reach-and-rotate forks

General: These load lifting devices can be used for picking up stackable load units from the ground. Pallets with skids can be picked up at any height. During transport, the reachand-rotate forks are rotated 90° to the left or right of the direction of travel. In the aisle, stacking is possible in both directions. Both reach-and-rotate forks consist of the mast carriage (5) guided in the mast by rollers, the reach carriage (6) for horizontal movement, the fork carriage (7), which can be rotated 180°, and the forks (19). The forks can be adjusted manually or hydraulically with the fork spreader. The width of the mast carriage is adapted to the aisle.

The SR reach-and-rotate forks also have an additional side reach carriage (20), which allows two-fold telescoping to the right and left. Equipped with these load lifting devices, the ETX 125/150 can be used in narrow aisles of various widths.

Reach carriage: The reach carriage is locked hydraulically when a load is being transported to prevent any sliding of the load during travel. The reach movement is realised by means of a hydraulic motor via a sprocket chain, toothed shaft and two toothed rods mounted on the mast carriage. The reach carriage is guided in three horizontal channels in the mast carriage. The top and bottom rollers are guided laterally and they absorb the tilting torque. The large roller on the centre channel absorbs the vertical forces.

Side reach carriage (SR only): The side reach carriage is guided in three horizontal channels in the mast carriage. The top and bottom rollers run in U-sections and they absorb the tilting torque. The large rollers on the centre channel absorb the vertical forces. The movement of the side reach carriage is realised by means of a double-acting cylinder, whose continuous piston rod is installed on the mast carriage and whose barrel is mounted on the side reach carriage.

Fork carriage: The fork carriage is rotated by two hydraulic cylinders, which turn the sprocket on the rotating shaft with a chain. The fork spread can be adjusted to the width of the load unit. The fork carriage is locked hydraulically in the transport position.

Electric and hydraulic control: The hydraulic hoses and the electric control cables are routed from the truck to the reach-and-rotate forks in a guide chain. The proportional valves provide snubbing of the reach movement in the end positions, which allows a soft starting and stopping of the reach movement. The helical gearing ensures quiet operation at all load conditions.The control lever allows simultaneous reaching and rotating movements. The transport position of the reach-and-rotate forks is sensed by an electric limit switch. If the reach carriage is not in the end position or the fork carriage is not locked, the truck speed is automatically reduced to 2.5 km/h. All hydraulic functions are protected with pressure relief valves.

TG and FTG telescopic reach forks

General: There is no difference between the two telescopic reach forks in regard to operation. Both forks can pick up and set down load units - without skids - on the left or right side. Picking up a load from or or depositing one directly on the ground is not possible. For this pickup or transfer stations (centring station, roller conveyor, etc.) must be installed. The difference between the TG and FTG model is that the load units must be picked up or set down at a different minimum height (250 mm for TG or 100 mm for FTG).

Load carriage: The load carriage (22)is guided in the mast by rollers (21). The forks (25), which are guided in double T-sections (23), are bolted onto the load carriage.

Telescopic reach forks: The telescopic reach forks telescope to the left or right. Telescoping is carried out by means of a combination of two chain drives (24). They are driven by a hydraulic motor (26).

Electric and hydraulic control: The hydraulic hoses and the electric control cables are routed from the truck to the telescopic reach forks in a guide chain. Controls and indicator lights are located in the control panel on the vehicle. The relay bracket and valve block are mounted as compact assemblies in the load carriage. The reach movement is limited electrically with a gear limit switch. The gear limit switch is actuated by a chain. An inching circuit slows down the reach speed in the end positions. It is also possible to traverse the entire reaching distance at inching speed. The load sensor is used to achieve the correct height when stacking or de-stacking with automatic height pre-selection.

• 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.