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Related Manuals for Jungheinrich ETVC 20
Summary of Contents for Jungheinrich ETVC 20
- Page 1 ETVC 16/20 05.99- Operating instructions 50052734 12.07...
- Page 2 Important notes on transporting and mounting load lifting devices to reach trucks Transport Depending on the overall height of the lifting mast and the local conditions transport can be performed in three different ways – Standing, with the lifting mast mounted (for trucks with low overall height) –...
- Page 4 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.
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Page 6: Table Of Contents
Table of contents Correct use and application of the truck Description of the truck Application ..................B 1 Assembly description and functional description ......B 2 Truck ....................B 3 Load lifting system ................B 5 Technical data - Standard version ........... B 6 Output data for standard truck version .......... - Page 7 Operation Safety regulations governing the operation of the truck ....E 1 Description of the operating controls and indicators ......E 2 Start-up of truck ................E 6 How to use the safety belt o ............E 7 Truck operation ................E 9 Safety regulations applicable when operating the truck ....
- Page 8 Maintenance of the fork-lift truck Operational safety and environmental protection ......F 1 Safety regulations applicable to truck maintenance ......F 1 Servicing and inspection ..............F 3 Maintenance Check .................F 4 Lubrication Schedule .................F 6 Fuels, coolants and lubricants ............F 7 Reservoir filling level .................F 7 Instructions for the servicing operations ..........F 8 Preparing the truck for the performance of servicing and maintenance operations ..............F 8...
- Page 10 Appendix JH Traction Battery Operating Instructions These operating instructions apply only to Jungheinrich battery models. If using another brand, refer to the manufacturer's operating instructions.
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Page 12: A Correct Use And Application Of The Truck
A Correct use and application of the truck The „Guidelines for the Correct Use and Application of Industrial Trucks“ (VDMA) are included in the scope of delivery for this truck. The guidelines are part of these ope- rating instructions and must always be heeded. National regulations are fully applica- ble. -
Page 14: B Description Of The Truck
Loads can be stacked in and out and transported across greater distances. Its capacity is shown on the identification label. Type Capacity Load centre distance ETVC 16 1600 kg 600 mm ETVC 20 2000 kg 600 mm... -
Page 15: Assembly Description And Functional Description
Assembly description and functional description Item Designation Item Designation t Clear-view lifting mast t Drive wheel t Overhead guard t Footstep t Free-lift cylinder t Foot switch o Auxiliary hydraulics (ZH2) t Battery trolley unlocking system t Control lever „Mast tilting“ t Parking brake t Control lever „Traversing of t Key switch... -
Page 16: Truck
Truck Safety installations: The enclosed truck contour featuring rounded edges ensures safe handling of the ETVC 16/20 truck. The driver is protected by the overhead guard (2). The drive wheel (10) and the load-bearing wheels (8) are enclosed by a sturdy collision guard. - Page 17 Item Designation Item Designation t Clear-view lifting mast t Drive wheel t Overhead guard t Footstep t Free-lift cylinder t Foot switch o Auxiliary hydraulics (ZH2) t Battery trolley unlocking system t Control lever „Mast tilting“ t Parking brake t Control lever „Traversing of t Key switch Mast“...
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Page 18: Load Lifting System
Operating controls and indicators: The operating controls and indicators are clear- ly laid out and arranged at the driver position. Control lever (5) is used to operate the “Mast tilting” function, control lever (6) to ope- rate the “Forward/backward traversing of mast” function. The following functions are operated with the Solo Pilot (7): –... -
Page 19: Technical Data - Standard Version
Technical data to VDI 2198. Technical data are subject to alteration and extension in scope. Output data for standard truck version Description ETVC 16 ETVC 20 Q Capacity (where C = 600 mm) 1600 2000 C Load centre of gravity Travel speed w / w.o. -
Page 20: Dimensions
Dimensions Description ETVC 16 ETVC 20 (ZT/DZ) (DZ) Lowered fork height Height above overhead guard 2155 / 2270 2295 Overall length 2132 / 2154 a) 2195,5 a) Reach 717 / 695 b) 687,5 b) Length over outriggers 1953 2060 Max. width... -
Page 21: En Standards
EN standards Continuous sound level: 67 dB(A) according to EN 12053 as stipulated in ISO 4871. The continuous sound level is a value averaged according to standard regulations, taking the sound pressure level into account when driving, lifting and idling. The sound pressure level is measured at the ear. -
Page 22: Location Of Instruction Labels And Identification Plates
Location of instruction labels and identification plates 1,5 V UNGHEINRICH Kundendienst Regelmäßige Prüfung nach UVV VBG 36 §37 durch Sachkundigen Nächste Prüfung Ihr Kundendienst-Partner Item Designation Drive direction when locking the steering wheel (option) Load diagram, capacity / lateral traversing device Load diagram, capacity / load centre / lifting height Sign „Put on safety belt“... - Page 23 Truck identification plate Item Designation Item Designation Type Manufacturer Serial No. Min./max. battery weight in kg Rated capacity in kg Drive power in kW Battery: Voltage V Load centre distance in mm Empty weight without battery in kg Year of manufacture Manufacturer logo Option In event of queries relating to the truck or spare part orders, please state the serial...
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Page 24: Load Diagram, Capacity / Lateral Traversing Device
Load diagram, capacity / lateral traversing device The load diagram (20) shows the redu- ced capacity Q in kg with the lateral tra- versing device extended. Pick-up points for lifting jack The "Jack contact point" decal (29) indi- cates where the truck may be lifted and jacked up (refer to chapter F). - Page 25 B 12...
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Page 26: C Transportation And Commissioning
C Transportation and commissioning Loading and unloading of trucks by crane Ensure that the lifting gear is of adequate capacity. (Transportation weight = net weight + battery weight; see truck identification plate) – To load the truck with lifting gear, lay the loop of the rope around the strut of the overhead guard (1). -
Page 27: Moving A Defective Truck
Moving a defective truck – Secure the towing device to the recovery vehicle and to the truck to be towed away. – Disconnect the battery connector. – Release the parking brake. The towed truck must be steered by a person seated on the truck seat. Tow the truck at a walking pace. -
Page 28: D Battery - Servicing, Recharging, Replacement
D Battery - servicing, recharging, replacement Safety regulations governing the handling of lead-acid batteries The truck must be parked and rendered safe, before any operations on batteries are to be undertaken (refer to chapter E). Servicing staff: Recharging, servicing and replacing of batteries must only be per- formed by qualified personnel. -
Page 29: Exposing The Battery
Exposing the battery – Sit on the driver´s seat. – Render the truck ready for operation (refer to chapter E). – Tilt the control lever (1) in direction of arrow (U), drive mast holder to its limit stop position towards the battery and release control lever (1) (mast is in final position). –... -
Page 30: Bypassing The Drive Current Interruption
Bypassing the drive current interruption – Switch on the switch “Cut-back speed” (3). If the battery is protruding, the truck may only be driven at cut-back speed in the bat- tery charging station! Battery trolley emergency unlocking system – Render the truck ready for operation (refer to chapter E). -
Page 31: Removing And Installing The Battery
Removing and installing the battery – Expose the battery (refer to section 3). Batteries with open poles, or open cell bridges, must be covered with a rubber mat to prevent short-circuiting. When using a crane in battery replacing operations, ensure that the crane is of adequate capacity (refer to the battery weight indicated on the bat- tery identification plate located at the battery trough). -
Page 32: Battery Discharge Indicator, Battery Discharge Monitor And Hour Meter
Battery discharge indicator, battery discharge monitor and hour meter Battery discharge indicator: The charging state of the battery (13) is indicated in 10% steps in the LISA display. The standard setting of the battery discharge indicator / discharge monitor is made using standard batteries. When using maintenance-free batteries, the indication has to be adjusted in a way that the symbol (T) (14) comes up... -
Page 34: Safety Regulations Governing The Operation Of The Truck
E Operation Safety regulations governing the operation of the truck Driving permission: The truck must only be operated by persons who have been trained in the operation of trucks, who have demonstrated to the user or his represen- tative their capability of moving and handling loads, and who have expressly been charged by the user or his representative with the operation of the truck. -
Page 35: Description Of The Operating Controls And Indicators
Description of the operating controls and indicators Item Operating Function control /indicator Control lever Operates the following function: „Inclining of mast“ – Tilting the hoist frame forward / backward Control lever Operates the following function: „Inclining of fork“ – Pushing forward / retracting the mast holder Solo-pilot Operates the following functions: –... - Page 37 Item Operating Function control /indicator 15 Master switch The power circuit is interrupted and all electrical (emergency stop) functions are switched off. 16 Information and ser- Display of essential driving parameters, lifting para- vice display (LISA) meters, warning signals, operating error indications and service indications (refer to section 5).
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Page 39: Start-Up Of Truck
Start-up of truck The driver must make sure that nobody is within the danger area of the truck, before the truck is switched on or operated, or before a load is lifted. Checks and operations to be performed before starting daily work –... -
Page 40: How To Use The Safety Belt O
Adjusting the steering column – Loosen the steering column locking (10) and adjust steering wheel (20) to desired position. – Tighten steering column locking me- chanism. Switching on the truck – Pull up the master switch (15). – Insert the key in the key switch (13) and turn clockwise against the stop to position "I". - Page 41 Behaviour in unusual situations Proceed as follows, if there is danger of the floor conveyor tipping over. – Press the upper part of your body against the the backrest. – Keep both hands at the steering wheel and use your feed for additional support.
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Page 42: Truck Operation
Truck operation Safety regulations applicable when operating the truck Driving lanes and work areas: Only such lanes and routes that are specially alloca- ted for truck traffic must be used. Unauthorized persons must stay away from work areas. Loads must only be stored at places specially provided for this purpose. Driving conduct: The travelling speed must be adapted to the prevailing local con- ditions. -
Page 43: Driving, Steering, Braking
Driving, steering, braking Emergency cut-out – Depress the master switch (15). This will switch off all electric functions. Functioning of the switch must not be af- fected by object placed on it. Driving Do not drive the truck unless the hoods are closed and locked in the stipulated manner. - Page 44 Steering When the steering wheel is actuated, the steering booster is automatically switched on and the position of the drive wheel is set accordingly. Contradirectional steering (standard version) When travelling forward (travel direction switch (21) set to V = drive direction), turning the steering wheel to the left results in a left turn and turning the wheel to the right in a right turn.
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Page 45: Adjusting The Fork Tines
Adjusting the fork tines To ensure safe picking up of loads, the tines should be apart as far as possible and set centrally to the truck. The load centre must be located centrally bet- ween the fork tines. – Swivel the locking lever (22) upwards. –... - Page 46 The fork must be free before they can be lowered from the rack. Do not start before the fork is completely lowered. Pushing the mast holder forward Do not reach between the mast and the battery hood. – Tilt the control lever (2) in the T direc- tion to push the mast holder forward and in the U direction to retract it.
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Page 47: Picking Up, Lifting And Transporting Of Loads
Picking up, lifting and transporting of loads – Tilt the control lever (1) in the V or the R direction to bring the fork tines into a hori- zontal position. – Move the truck up to the load. – Tilt the control lever (2) in the T direction to push the mast holder forward. –... -
Page 48: Operating An Attachment
Operating an attachment Lateral traversing device The directions „to the left“ and „to the right“ refer to the load lifting device as seen from the operator’s position. Moving the lateral traversing device to the left: – Press the switch (21) in the X1 direc- tion. -
Page 49: Rendering Truck Safe When Parking
Rendering truck safe when parking When the truck is parked and left unattended, it has to be rendered safe, even if it is left unattended for only a short period of time. Never park the truck on a slope or incline. The load lifting device must always be com- pletely lowered. -
Page 50: Information And Service Display (Lisa)
Information and service display (LISA) The display (25) of the LCD information and service display (LISA) shows the opera- tion data, the battery charge, the service hours as well as service data and diagnosti- cal data. Below the display there are six LEDs (26) - (31). The keyboard (four keys (32) - (35) serves for the selection, the reading and the modification of vehicle para- meters. -
Page 51: Led Warning Lamps
LED warning lamps Six red light-emitting diodes indicate the following states: Item Function Direction of motion forward (drive direction) (green LED) Parking brake applied (red LED) Direction of motion backward (load direction) (green LED) Brake liquid level too low (red LED) Lateral traversing device in center position (green LED) Battery unlocked (red LED) Key assignment... -
Page 52: Displays
Displays The display shows operating data and fault messages. The user menu permits the setting of the following driving parameters: Here the time between maximum actua- A C C E L E R A T I O N tion of the driving pedal and 100% com- pensation of the electronics is set. -
Page 53: Changing Truck Parameters
Changing truck parameters Changing of truck parameters will also change the driving behaviour of the truck. This must be taken into account when commissioning the truck! Parameters may only be changed while the truck is at a standstill and no lifting movements are performed. -
Page 54: Fault Locating Operations
Fault locating operations This chapter enables the user to locate and to remedy simple faults or the conse- quences of operating errors. Fault locating operations should be performed in the or- der as set out in the table below. Fault Possible cause Remedy Truck does not... -
Page 55: Auxiliary Electrical Systems
Auxiliary electrical systems Seat heating All auxiliary electrical systems are activated regardless of the key switch position. The battery master switch must have been switched on (see section 3, “Switching on the truck”). To prevent discharge of the battery after the truck has been parked, always heed sec- tion 4.7, “Rendering vehicle safe when parking”. -
Page 56: 360° Warning Light
360° warning light Item Designation o 360° warning light o Switch - 360° warning light ON/OFF Flash lamp Item Designation o Flash lamp o Switch - flash lamp ON/OFF DC/DC transformer on/off switch Switches the DC/DC transformer 48/24V or 48/12V respectively on or off. Item Designation o Switch DC/DC transformer. -
Page 57: Override Switch (Esa / Electrical Lifting Limitation)
Override switch (ESA / Electrical lifting limitation) Item Designation o Override switch Bridge switch Lateral traversing device If the load carriage is below the safety height in front of the wheel arms, the mast hol- der retraction motion is blocked by the limit switches. When the lateral traversing device is between the wheel arms and below the safety height, the lateral traversing movement is blocked by limit switches. -
Page 58: F Maintenance Of The Fork-Lift Truck
F Maintenance of the fork-lift truck Operational safety and environmental protection The checks and servicing operations contained in this chapter must be performed in accordance with the intervals as indicated in the servicing checklists. Modifications of fork-lift truck assemblies, especially of the safety installations, are not permitted. - Page 59 Work on the electric system: Work on the electric system of the truck must only be performed by personnel specially trained for such operations. Before commencing any work on the electric system, all measures required to prevent electric shocks have to be taken. For battery-operated fork-lift trucks, the truck must also be depowe- red by removing the battery plug.
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Page 60: Servicing And Inspection
Servicing and inspection Thorough and expert servicing is one of the most important requirements for the safe operation of the industrial truck. Failure to perform regular servicing can lead to truck failure and poses a potential hazard to personnel and equipment. The service intervals stated are based on single shift operation under normal opera- ting conditions. -
Page 61: Maintenance Check
Maintenance Check Maintenance intervals = t W A B C standard cold store Chassis and 1.1 Check all load bearing elements for damage superstruct.: 1.2 Check all bolted connections 1.3 Check driver’s protective roof and load guard for secure fastening Drive unit: 2.1 Check the transmission for noises and leakage 2.2 Check whether the drive support plate and screws are fit-... - Page 62 Maintenance intervals = t W A B C standard cold store Electrical 7.1 Performance check system: 7.2 Check all cables for secure connection and damage 7.3 Check the fuses for correct amperage 7.4 Check switches and trip cams for secure attachment and correct functioning 7.5 Check the warning installation for correct functioning 7.6 Check contactors, replace wearing parts, if necessary...
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Page 63: Lubrication Schedule
Lubrication Schedule D 0,2 l Min. = 16l Max.= 23l ETV-C16 = 4,5l ETV-C20 = 5,3l 205 Nm Gliding surfaces Grease nipples Filter plug hydraulic oil Drain plug hydraulik oil Filter plug gear oil Drain plug gear oil Filter plug brake fluid Cold store usage 1) Compound cold store 1:1 2) Filling level: refer to the table on section 5.2... -
Page 64: Fuels, Coolants And Lubricants
Fuels, coolants and lubricants Handling consumption type material: Consumption type material must always be handled properly. Manufacturer's instructions to be observed. Improper handling is injurious to health, life, and environment. Consumption type ma- terials must be stored in adequate containers. They might be inflammable and, the- refore, must not come into contact with hot components or open fire. -
Page 65: Instructions For The Servicing Operations
Instructions for the servicing operations Preparing the truck for the performance of servicing and maintenance operati- All required safety measures must be taken to prevent any accidents in the course of the servicing and maintenance operations. The following preparatory operations must be performed: –... -
Page 66: Opening The Hood
Opening the hood – Unlock the hood (4) using the service key (3). – Swing the hood upward. Controls and truck fuses are easily accessible for servicing. Opening the battery doors and the seat hood – Unlock the battery door (5) using the service key and remove it. –... -
Page 67: Checking The Hydraulic Oil Level
Checking the hydraulic oil level – Prepare the truck for servicing and maintenance (refer sections 6.1). – Open the seat hood (see section 6.4). – Check the hydraulic oil level in the hydraulic reservoir (8) The oil level must be checked at the hydraulic reservoir with the load lifting device completely lowered. -
Page 68: Safety Belt Maintenance O
Safety belt maintenance o It is recommended that the driver checks daily condition and function of the safety belt daily before starting up the floor conveyor. Only regular checks ensure that a fault or defective is detected in time. – Pull out the belt completely and check the fibres for wear and tear. –... -
Page 69: Checking Electrical Fuses
Checking electrical fuses – Prepare the truck for servicing and maintenance (refer section 6.1). – Check all fuses for correct value according to table, replace if necessary. Item Description Rating / type Fuse Options 10 A 4F10 Fan fuse 10 A Travel and lift electronics control fuse Interface control fuse Overall control fuse... -
Page 70: Recommissioning The Truck
6.10 Recommissioning the truck Recommissioning of the truck following the performance of cleaning or maintenance work is permitted only, after the following operations have been performed: – Check the horn for proper functioning. – Check the master switch for correct function. –... -
Page 71: Recommissioning The Truck
Recommissioning the truck – Thoroughly clean the truck. – Lubricate the truck according to the lubrication chart (refer section 5). – Clean the battery. Grease the pole screws using pole grease and reconnect the battery. – Recharge the battery (refer to chapter D). –... - Page 72 Jungheinrich traction battery Table of contents Jungheinrich traction battery ..........2-6 with positive tubular plates type EPzS and EPzB Type plate Jungheinrich traction battery..........7 Instruction for use ............8-12 Aquamatic/BFS III water refilling system Jungheinrich traction battery Maintenance free traction batteries with positive tubular plates type EPzV ....................13-17...
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Page 73: Jungheinrich Traction Battery
Jungheinrich traction battery with positive tubular plates type EPzS and EPzB Rating Data 1. Nominal capacity C5: See type plate 2. Nominal voltage: 2,0 V x No of cells 3. Discharge current:: C5/5h 4. Nominal S.G. of electrolyte* Type EPzS:... - Page 74 Ignoring the operation instructions, repair with non-original parts or using additives for the electrolyte will render the warranty void. For batteries in classes I and II the instructions for maintaining the appropriate protection class during operation must be complied with (see relevant certificate). 1.
- Page 75 Battery container lids and the covers of battery compartments must be opened or re- moved. The vent plugs should stay on the cells and remain closed. With the charger switched off connect up the battery, ensuring that the polarity is cor- rect.
- Page 76 3. Maintenance 3.1 Daily Charge the battery after every discharge. Towards the end of charge the electrolyte level should be checked and if necessary topped up to the specified level with purified water. The electrolyte level must not fall below the anti-surge baffle or the top of the separator or the electrolyte „min“...
- Page 77 5. Storage If batteries are taken out of service for a lengthy period they should be stored in the fully charged condition in a dry, frost-free room. To ensure the battery is always ready for use a choice of charging methods can be made: 1.
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Page 78: 7. Type Plate, Jungheinrich Traction Battery
7. Type plate, Jungheinrich traction battery Baujahr T ype Year of manufacture Serien-Nr. Lieferanten Nr. Serial-Nr. Supplier No. Nennspannung Kapazität Nominal V oltage Capacity Zellenzahl Batteriegewicht min/max Number of Cells Battery mass min/max Hersteller Jungheinrich AG, D-22047 Hamburg, Germany Manufacturer... -
Page 79: Aquamatic/Bfs Iii Water Refilling System
Aquamatic/BFS III water refilling system for Jungheinrich traction battery with EPzS and EPzB cells with tubular positive plates Aquamatic plug arrangement for the Operating Instructions Cell series* Aquamatic plug type (length) EPzS EPzB Frötek (yellow) (black) 2/120 – 10/ 600 2/ 42 –... - Page 80 Diagrammatic view Equipment for the water refilling system 1. Water tank 2. Level switch 3. Discharge point with ball valve 4. Discharge point with sole- noid valve 5. Charger 6. Sealing coupler 7. Closing nipple 8. Ion exchange cartridge with conductance meter and solenoid valve 9.
- Page 81 4. Filling (manual/automatic) The batteries should be filled with battery water as soon as possible before the battery charging comes to an end; this ensures that the refilled water quantity is mixed with the electrolyte. In normal operation it is usually sufficient to fill once a week. 5.
- Page 82 8. Battery hose connections Hose connections for the individual plugs are laid along the existing electric circuit. No changes may be made. 9. Operating temperature The temperature limit for battery operation is set at 55° C. Exceeding this temperature damages the batteries. The battery filling systems may be operated within a tempe- rature range of >...
- Page 83 10.2.1 Clamping ring tool The clamping ring tool is used to push on a clamping ring to increase the contact pres- sure of the hose connection on the plugs' hose couplings and to loosen it again. 10.3 Filter element For safety reasons a filter element (ident no.: 50307282) can be fitted into the batte- ry's main supply pipe for supplying battery water.
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Page 84: Jungheinrich Traction Battery
Jungheinrich traction batterie Maintenance free Jungheinrich traction batterie with positive tubular plates type EPzV and EPzV-BS Rating Data 1. Nominal capacity C5: See type plate 2. Nominal voltage: 2,0 Volt x No of cells 3. Discharge current: C5/5h 4. Rated temperature: 30°... - Page 85 Ignoring the operation instructions, repair with non-original parts and non authorised interventions will render the warranty void. For batteries in classes I and II the instructions for maintaining the appropriate protection class during operation must be complied with (see relevant certificate). 1.
- Page 86 With the charger switched off connect up the battery, ensuring that the polarity is cor- rect (positive to positive, negative to negative). Now switch on the charger. When charging the temperature of the battery rises by about 15° C, so charging should only begin if the battery temperature is below 35°...
- Page 87 3.2 Weekly Visual inspection after recharging for signs of dirt and mechanical damage. 3.3 Quarterly After the end of the charge and a rest time of 5 h following should be measured and recorded: • the voltages of the battery •...
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Page 88: 7. Type Plate, Jungheinrich Traction Battery
Batteries with this sign must be recycled. Batteries which are not returned for the recycling process must be disposed of as hazardous waste! We reserve the right make technical modification. 7. Type plate, Jungheinrich traction battery Baujahr T ype Year of manufacture Serien-Nr.
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