Jungheinrich ETX 513 User manual

ETX 513 / ETX 515 03.11
Operating instructions
51190312
04.19
en-GB
ETX 513
ETX 515

2

Declaration of Conformity
Manufacturer
Jungheinrich AG, 22039 Hamburg, Germany
Description
Industrial truck
Type Option Serial no. Year of
manufacture
ETX 513
ETX 515
On behalf of
Date
EU DECLARATION OF CONFORMITY
The undersigned hereby declare that the powered truck described in detail complies
with the current versions of European Directives 2006/42/EG (Machinery Directive)
and 2014/30/EU (Electromagnetic Compatibility - EMC). The manufacturer is
authorised to compile the technical documentation.
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Foreword
Notes on the operating instructions
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 and the pages
are numbered continuously.
The operator manual details different industrial truck models. When operating and
servicing the industrial truck, make sure that the particular section applies to your
truck model.
Our trucks are subject to ongoing development. We reserve the right to alter the
design, equipment and technical features of the system. No guarantee of particular
features of the truck should therefore be assumed from the present operating
instructions.
Safety notices and text mark-ups
Safety instructions and important explanations are indicated by the following
graphics:
DANGER!
Indicates an extremely hazardous situation. Failure to comply with this instruction will
result in severe irreparable injury and even death.
WARNING!
Indicates an extremely hazardous situation. Failure to comply with this instruction
may result in severe irreparable injury and even death.
CAUTION!
Indicates a hazardous situation. Failure to comply with this instruction may result in
slight to medium injury.
NOTICE
Indicates a material hazard. Failure to comply with this instruction may result in
material damage.
ZUsed before notices and explanations.
tIndicates standard equipment
oIndicates optional equipment
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Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Friedrich-Ebert-Damm 129
22047 Hamburg - Germany
Tel: [phone]
www.jungheinrich.com
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Contents
.
A Correct Use and Application 11
.
1 General 11
2 Correct application 11
3 Approved application conditions 12
4 Proprietor responsibilities 14
5 Adding attachments and/or accessories 14
.
B Truck Description 15
.
1 Application 15
2 Travel direction definition 17
3 Assemblies and Functional Description 18
3.1 Functional Description 18
3.2 Assembly Overview 24
4 Technical Specifications 26
4.1 Performance data 26
4.2 Dimensions (as per data plate) 28
4.3 Mast versions 36
4.4 Weights 38
4.5 Wheels, chassis 41
4.6 Engine Data 42
4.7 EN norms 42
4.8 Conditions of use 44
4.9 Electrical requirements 45
5 Identification points and data plates 46
5.1 Data plate 48
5.2 Truck capacity plate 49
5.3 Attachment capacity plate 50
5.4 Jack contact points 50
6 Stability 51
.
C Transport and Commissioning 53
.
1 Transport 53
2 Lifting by crane 54
2.1 Lifting by crane with mast assembled 54
2.2 Lifting the basic truck by crane 56
2.3 Lifting the mast by crane 58
2.4 Lifting the battery by crane 60
3 Securing the truck during transport 62
3.1 Basic truck transport retainer 62
3.2 Mast transport retainer 64
3.3 Transport retainer for basic truck with the mast assembled 66
4 Using the Truck for the First Time 68
4.1 Moving the industrial truck without a battery 68
4.2 Installing and removing the mast 69
4.3 Commissioning 70
4.4 Tilt safety device 72
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.
D Battery - Servicing, Recharging, Replacement 73
.
1 Safety Regulations Governing the Handling of Lead-Acid Batteries 73
1.1 General notes on handling batteries 74
2 Battery types 75
2.1 Dimensions of the battery compartment 76
3 Exposing the battery 78
4 Charging the battery 80
5 Battery removal and installation 84
5.1 Removing and installing the battery with a battery roller stand (single
part batteries) 84
5.2 Battery assembly / removal using a fork lift truck (two part batteries) 88
6"Battery lock" sensors (o) 92
.
E Operation 95
.
1 Safety Regulations for the Operation of the
Forklift Truck 95
2 Displays and Controls 97
2.1 Controls and displays on the control panel 97
2.2 Driver's display 103
2.3 Hourmeter 109
2.4 "Bar display" battery discharge indicator 110
2.5 "Percentage display" battery discharge indicator (o) 112
2.6 Driver's display function symbols 114
3 Preparing the Truck for Operation 124
3.1 Checks and operations to be performed before starting daily operation 124
3.2 Entry and exit 128
3.3 Setting up the operator position 128
4 Industrial Truck Operation 134
4.1 Safety regulations for truck operation 134
4.2 Preparing the truck for operation 139
4.3 Preparing the truck for operation with an additional access code (o) 140
4.4 Checks and operations to be carried out when the truck is operational 142
4.5 Main Lift referencing 144
4.6 Date and time setting 148
4.7 Emergency Disconnect 150
4.8 Travel 152
4.9 Steering 154
4.10 Brakes 154
4.11 Negotiating narrow aisles 156
4.12 Diagonal travel 167
4.13 Lifting / lowering – outside and inside narrow aisles 168
4.14 Traversing / rotating outside and inside narrow aisles 172
4.15 Parking the truck securely 180
5 Order picking and stacking 184
5.1 Adjusting the forks 184
5.2 Replacing the forks 186
5.3 Lifting, transporting and depositing loads 190
6 Troubleshooting 198
6.1 Troubleshooting 198
6.2 Emergency stop device 201
6.3 Load handler emergency lowering 201
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6.4 Travel cutout override (o) 205
6.5 Lift cutout override (o) 207
6.6 Lower cutout override (o) 209
6.7 End of aisle safety device (o) 211
6.8 WG emergency operation (event messages 3670 / 3752) 213
6.9 Recovering the truck from a narrow aisle / Moving the truck without a
battery 214
7Personal safety system (o) 233
7.1 Personal Protection System (PPS) 233
7.2 Functional description 234
7.3 Environmental awareness 235
7.4 Cleaning the laser scanner front screen 236
7.5 Displays on the seven segment display and indicator light (LED) 237
7.6 Daily checks before starting the Personal Protection System 239
7.7 Personal safety system 240
8 Optional equipment 243
8.1 Laser beam rack compartment display (o) 243
8.2 Telescopic table (o) 244
8.3 Sideshifter / Fork positioner (o) 251
8.4 Telescopic forks (o) 255
8.5 Operator-specific settings (o) 258
8.6 ISM access module (o) 262
8.7 Rack Height Select (o) 262
8.8 Horizontal positioning (o) 276
8.9 Weighing system (o) 292
8.10 Camera system 294
8.11 Rear view mirror (o) 295
8.12 Working platform (o) 296
8.13 Floor-Spot (o) 308
8.14 Fire extinguisher (o) 314
.
F Industrial Truck Maintenance 315
.
1 Operational Safety and Environmental Protection 315
2 Maintenance Safety Regulations 317
3 Lubricants and Lubrication Schedule 323
3.1 Handling consumables safely 323
3.2 Lubrication Schedule 325
3.3 Consumables 327
4 Maintenance and repairs 328
4.1 Preparing the truck for maintenance and repairs 328
4.2 Opening / closing the drive compartment cover 330
4.3 Checking electrical fuses 332
4.4 Prevent the load handler / mast from accidentally lowering 336
4.5 Lift chain servicing 340
4.6 Lubricate the lift chains, clean and grease the contact surfaces in the
mast sections 340
4.7 Lift chain inspection 342
4.8 Hydraulic system 344
4.9 Checking the hydraulic oil level 346
4.10 Restoring the truck to service after maintenance and repairs 350
5 Decommissioning the industrial truck 352
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5.1 Prior to decommissioning 353
5.2 During decommissioning 354
5.3 Restoring the truck to service after decommissioning 355
6 Safety tests to be performed at intervals and after unusual incidents 356
7 Final de-commissioning, disposal 357
8 Human vibration measurement 357
.
G Maintenance, Inspection and Changing of Maintenance
Parts Requiring Replacement 359
.
1 Maintenance Contents ETX 513-515 360
1.1 Owner 360
1.2 Customer Service 365
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1
0506.GB
Appendix
JH Traction Battery Operating Instructions
ZThese operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.
1
0506.GB
Appendix
JH Traction Battery Operating Instructions
ZThese operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.

0506.GB
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0506.GB
2

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.
Any other type of use is beyond the scope of application and can result in damage to
personnel, the industrial truck or property.
2 Correct application
NOTICE
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, lowering and order picking of loads.
– Always transport a load outside the narrow aisle as low as possible, allowing for
ground clearance.
– Do not carry or lift passengers.
– Do push or pull load units.
– Do not negotiate slopes or inclines.
– Do not negotiate loading ramps / docks.
– Towing a trailer is prohibited.
– Do not transport suspended loads.
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3 Approved application conditions
DANGER!
Do not exceed the permissible surface and spot load limits on the travel routes.
At blind spots get a second person to assist.
NOTICE
The industrial truck must not be used in fire or explosion endangered areas, or areas
threatened by corrosion or excessive dust. Furthermore, the truck must not be
operated in the vicinity of unprotected active components of electrical systems.
– Operation in industrial and commercial environments.
– Permissible temperature range 5°C to 40°C.
– Application only on level surfaces in accordance with VDMA guideline.
ZSpecial equipment and authorisation are required if the truck is to be used in
extreme conditions or areas at risk of explosion.
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Safety distances (interpreted safety distance)
ZThe racking systems must be set up for the ETX. The safety distances stipulated by
Jungheinrich (interpreted safety distance) must always be observed.
– For a rail-guided truck there must be a minimum safety distance on both sides
of100 mm between:
– the swivel traverse frame and the rack, as well as the stored goods.
– the load handler and the rack, as well as the stored goods.
– the raised load and the rack, as well as the stored goods.
– For a wire-guided truck there must be a minimum safety distance on both sides of
125 mm between:
– the swivel traverse frame and the rack, as well as the stored goods.
– the load handler and the rack, as well as the stored goods.
– the raised load and the rack, as well as the stored goods.
ZThe safety distance may however be increased if special attachments are fitted.
WARNING!
An insufficient safety distance between the guided truck and the rack can
result in accidents
Failure to maintain the required and prescribed safety distance can result in
collisions between the guided truck and the rack.
uThe maximum travel speeds are reduced if the required and prescribed safety
distances are not maintained.
uYou must observe the minimum safety distance in accordance with EN 1726-2
item 7.3.2 90 mm. Do not operate the truck in these narrow aisles.
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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 for
which it is intended and that there is no danger to life and limb of the user and third
parties. Furthermore, accident prevention regulations, safety regulations and
operating, servicing and repair guidelines must be followed. The proprietor must
ensure that all users have read and understood these operating instructions.
NOTICE
Failure to comply with the operating instructions shall invalidate the warranty. The
same applies if improper work is carried out on the truck by the customer or third
parties without the permission of the manufacturer.
5 Adding attachments and/or accessories
Adding 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.
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B Truck Description
1 Application
The ETX with a standard attachment is an electric three-way order picker.
The ETX with a telescopic table is an electric two-way order picker.
The ETX is designed to transport and pick goods on level surfaces in accordance
with the VDMA guideline.
Open bottom pallets or pallets with diagonal boards can be lifted outside the range of
the load wheels. Loads can be stacked, unstacked and transported over long
distances.
If the ETX is used for assembly work with an correspoding working platform, the
working platform must be supplied or approved in writing by the manufacturer.
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Safety distances (interpreted safety distance)
ZThe racking systems must be set up for the ETX. The safety distances stipulated by
Jungheinrich (interpreted safety distance) must always be observed.
– For a rail-guided truck there must be a minimum safety distance on both sides
of100 mm between:
– the swivel traverse frame and the rack, as well as the stored goods.
– the load handler and the rack, as well as the stored goods.
– the raised load and the rack, as well as the stored goods.
– For a wire-guided truck there must be a minimum safety distance on both sides of
125 mm between:
– the swivel traverse frame and the rack, as well as the stored goods.
– the load handler and the rack, as well as the stored goods.
– the raised load and the rack, as well as the stored goods.
ZThe safety distance may however be increased if special attachments are fitted.
WARNING!
An insufficient safety distance between the guided truck and the rack can
result in accidents
Failure to maintain the required and prescribed safety distance can result in
collisions between the guided truck and the rack.
uThe maximum travel speeds are reduced if the required and prescribed safety
distances are not maintained.
uYou must observe the minimum safety distance in accordance with EN 1726-2
item 7.3.2 90 mm. Do not operate the truck in these narrow aisles.
ZThe ground surface must comply with the VDMA guideline.
Guide rails must be provided in the narrow aisles for the rail guidance system.
Vulkollan guide wheels attached to the truck chassis guide the truck between the
guide rails.
A guide wire must be routed in the ground for the wire guidance system. The signals
from the wire are received by sensors on the chassis and processed by the on-board
computer.
ZThe capacity is shown on the data plate.
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2 Travel direction definition
The following determinations have been made for travel direction specification:
1
4
2
3
1
4
2
3
Item Travel direction
1 Left
2 Drive direction
3 Load direction
4 Right
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3 Assemblies and Functional Description
3.1 Functional Description
Safety mechanisms
– An enclosed truck geometry with rounded edges ensures safe truck handling. The
overhead guard protects the driver from falling objects.
– The drive wheel and the load wheels are protected by a solid skirt. A slight danger
nevertheless remains for third parties.
– The Emergency Disconnect immediately disables all truck operations in
hazardous situations.
– Travelling, lifting and lowering can only be activated when the deadman button is
pressed.
– Traverse and swivel operations can only be activated when the deadman button is
not pressed.
– Line brake safety valves in the lift cylinders stop the load lowering speed in the
event of a hydraulic system failure.
Deadman button
After the truck is ready for operation (see page 139 or see page 140) the deadman
button in the footwell must:
– be pressed and held down to allow the driver to carry out travel and hydraulic
operations with the industrial truck. Lifting and travel are inhibited if the driver
takes his foot off the foot switch. Steering and braking remain enabled. When the
deadman button is released and the industrial truck is stationary, the parking
brake engages (prevents the truck from rolling away).
– not be pressed to allow the driver to carry out traverse and swivel operations work
with the industrial truck. Steering and braking remain enabled. When the
deadman button is released and the industrial truck is stationary, the parking
brake engages (prevents the truck from rolling away).
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