Jungheinrich ETVC 20 User manual

Operating instructions
50052734
ETVC 16/20
G
05.99-
12.07

1
0903.GB
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)
– Standing, with martially mounted lifting mast tilted towards the overhead guard (for
trucks with medium overall height). Hydraulic line for the lifting function is interrup-
ted.
– Standing, with the lifting mast dismounted (for trucks with large overall height)
Safety Instructions for Assembly and Commissioning
fThe assembly of the truck on site, commissioning the truck and instructing the driver
must be carried out by personnel trained and authorised by the manufacturer
Connect the hydraulic lines to the basic machine / mast interface and commission the
truck only after having installed the mast as per the instructions.
1
0903.GB
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)
– Standing, with martially mounted lifting mast tilted towards the overhead guard (for
trucks with medium overall height). Hydraulic line for the lifting function is interrup-
ted.
– Standing, with the lifting mast dismounted (for trucks with large overall height)
Safety Instructions for Assembly and Commissioning
fThe assembly of the truck on site, commissioning the truck and instructing the driver
must be carried out by personnel trained and authorised by the manufacturer
Connect the hydraulic lines to the basic machine / mast interface and commission the
truck only after having installed the mast as per the instructions.

0903.GB
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0903.GB
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0108.GB
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.
ZUsed before notices and explanations.
tUsed to indicate standard equipment.
oUsed 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: [phone]
www.jungheinrich.com
0108.GB
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.
ZUsed before notices and explanations.
tUsed to indicate standard equipment.
oUsed 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: [phone]
www.jungheinrich.com

0108.GB
0108.GB

I 1
0106.GB
Table of contents
A Correct use and application of the truck
B Description of the truck
1 Application ........................................................................................ B 1
2 Assembly description and functional description ............................ B 2
2.1 Truck ................................................................................................ B 3
2.2 Load lifting system ........................................................................... B 5
3 Technical data - Standard version ................................................... B 6
3.1 Output data for standard truck version ............................................. B 6
3.2 Standard hoist frame versions ......................................................... B 6
3.3 Dimensions ...................................................................................... B 7
3.4 EN standards ................................................................................... B 8
3.5 Conditions for application ................................................................. B 8
4 Location of instruction labels and identification plates .................... B 9
4.1 Truck identification plate ................................................................ B 10
4.2 Load diagram / capacity / load centre / lifting height ...................... B 10
4.3 Load diagram, capacity / lateral traversing device ......................... B 11
4.4 Pick-up points for lifting jack ........................................................... B 11
C Transportation and commissioning
1 Loading and unloading of trucks by crane ....................................... C 1
2 Commissioning ................................................................................. C 1
3 Moving a defective truck .................................................................. C 2
D Battery - servicing, recharging,
replacement
1 Safety regulations governing the handling of lead-acid batteries ..... D 1
2 Battery type ...................................................................................... D 1
3 Exposing the battery ........................................................................ D 2
3.1 Bypassing the drive current interruption ........................................... D 3
3.2 Battery trolley emergency unlocking system .................................... D 3
4 Charging the battery ......................................................................... D 3
5 Removing and installing the battery ................................................. D 4
6 Battery discharge indicator, battery discharge monitor and
hour meter ..................................................................................... D 5
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0106.GB
Table of contents
A Correct use and application of the truck
B Description of the truck
1 Application ........................................................................................ B 1
2 Assembly description and functional description ............................ B 2
2.1 Truck ................................................................................................ B 3
2.2 Load lifting system ........................................................................... B 5
3 Technical data - Standard version ................................................... B 6
3.1 Output data for standard truck version ............................................. B 6
3.2 Standard hoist frame versions ......................................................... B 6
3.3 Dimensions ...................................................................................... B 7
3.4 EN standards ................................................................................... B 8
3.5 Conditions for application ................................................................. B 8
4 Location of instruction labels and identification plates .................... B 9
4.1 Truck identification plate ................................................................ B 10
4.2 Load diagram / capacity / load centre / lifting height ...................... B 10
4.3 Load diagram, capacity / lateral traversing device ......................... B 11
4.4 Pick-up points for lifting jack ........................................................... B 11
C Transportation and commissioning
1 Loading and unloading of trucks by crane ....................................... C 1
2 Commissioning ................................................................................. C 1
3 Moving a defective truck .................................................................. C 2
D Battery - servicing, recharging,
replacement
1 Safety regulations governing the handling of lead-acid batteries ..... D 1
2 Battery type ...................................................................................... D 1
3 Exposing the battery ........................................................................ D 2
3.1 Bypassing the drive current interruption ........................................... D 3
3.2 Battery trolley emergency unlocking system .................................... D 3
4 Charging the battery ......................................................................... D 3
5 Removing and installing the battery ................................................. D 4
6 Battery discharge indicator, battery discharge monitor and
hour meter ..................................................................................... D 5

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E Operation
1 Safety regulations governing the operation of the truck ................... E 1
2 Description of the operating controls and indicators ........................ E 2
3 Start-up of truck ................................................................................ E 6
3.1 How to use the safety belt o ........................................................... E 7
4 Truck operation ................................................................................ E 9
4.1 Safety regulations applicable when operating the truck ................... E 9
4.2 Driving, steering, braking ............................................................... E 10
4.3 Adjusting the fork tines ................................................................... E 12
4.4 Picking up and setting down loads ................................................. E 12
4.5 Picking up, lifting and transporting of loads .................................... E 14
4.6 Operating an attachment ................................................................ E 15
4.7 Rendering truck safe when parking ................................................ E 16
5 Information and service display (LISA) .......................................... E 17
5.1 LED warning lamps ........................................................................ E 18
5.2 Key assignment .............................................................................. E 18
5.3 Displays .......................................................................................... E 19
5.4 Changing truck parameters ............................................................ E 20
6 Fault locating operations ................................................................ E 21
7 Auxiliary electrical systems ............................................................ E 22
7.1 Seat heating ................................................................................... E 22
7.2 Floodlight ....................................................................................... E 22
7.3 360°warning light .......................................................................... E 23
7.4 Flash lamp ...................................................................................... E 23
7.5 DC/DC transformer on/off switch ................................................... E 23
7.6 Override switch (ESA / Electrical lifting limitation) .......................... E 24
7.7 LED Lateral traversing device in centre position ............................ E 24
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E Operation
1 Safety regulations governing the operation of the truck ................... E 1
2 Description of the operating controls and indicators ........................ E 2
3 Start-up of truck ................................................................................ E 6
3.1 How to use the safety belt o ........................................................... E 7
4 Truck operation ................................................................................ E 9
4.1 Safety regulations applicable when operating the truck ................... E 9
4.2 Driving, steering, braking ............................................................... E 10
4.3 Adjusting the fork tines ................................................................... E 12
4.4 Picking up and setting down loads ................................................. E 12
4.5 Picking up, lifting and transporting of loads .................................... E 14
4.6 Operating an attachment ................................................................ E 15
4.7 Rendering truck safe when parking ................................................ E 16
5 Information and service display (LISA) .......................................... E 17
5.1 LED warning lamps ........................................................................ E 18
5.2 Key assignment .............................................................................. E 18
5.3 Displays .......................................................................................... E 19
5.4 Changing truck parameters ............................................................ E 20
6 Fault locating operations ................................................................ E 21
7 Auxiliary electrical systems ............................................................ E 22
7.1 Seat heating ................................................................................... E 22
7.2 Floodlight ....................................................................................... E 22
7.3 360°warning light .......................................................................... E 23
7.4 Flash lamp ...................................................................................... E 23
7.5 DC/DC transformer on/off switch ................................................... E 23
7.6 Override switch (ESA / Electrical lifting limitation) .......................... E 24
7.7 LED Lateral traversing device in centre position ............................ E 24

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0106.GB
F Maintenance of the fork-lift truck
1 Operational safety and environmental protection ..............................F 1
2 Safety regulations applicable to truck maintenance ..........................F 1
3 Servicing and inspection ...................................................................F 3
4 Maintenance Check .........................................................................F 4
5 Lubrication Schedule .........................................................................F 6
5.1 Fuels, coolants and lubricants ...........................................................F 7
5.2 Reservoir filling level .........................................................................F 7
6 Instructions for the servicing operations ............................................F 8
6.1 Preparing the truck for the performance of servicing and
maintenance operations ....................................................................F 8
6.2 Opening the arm rest ........................................................................F 8
6.3 Opening the hood ..............................................................................F 9
6.4 Opening the battery doors and the seat hood ...................................F 9
6.5 Checking the hydraulic oil level .......................................................F 10
6.6 Checking the brake fluid level .........................................................F 10
6.7 Check fixing of the wheels ..............................................................F 10
6.8 Safety belt maintenance o .............................................................F 11
6.9 Checking electrical fuses ................................................................F 12
6.10 Recommissioning the truck .............................................................F 13
7 Decommissioning the truck .............................................................F 13
7.1 Operations to be performed prior to decommissioning ...................F 13
7.2 Measures to be taken during decommissioning ..............................F 13
7.3 Recommissioning the truck .............................................................F 14
8 Safety checks to be performed at regular intervals and following
any untoward incidents (D: Accident prevention check
according to BGV D27) ...................................................................F 14
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0106.GB
F Maintenance of the fork-lift truck
1 Operational safety and environmental protection ..............................F 1
2 Safety regulations applicable to truck maintenance ..........................F 1
3 Servicing and inspection ...................................................................F 3
4 Maintenance Check .........................................................................F 4
5 Lubrication Schedule .........................................................................F 6
5.1 Fuels, coolants and lubricants ...........................................................F 7
5.2 Reservoir filling level .........................................................................F 7
6 Instructions for the servicing operations ............................................F 8
6.1 Preparing the truck for the performance of servicing and
maintenance operations ....................................................................F 8
6.2 Opening the arm rest ........................................................................F 8
6.3 Opening the hood ..............................................................................F 9
6.4 Opening the battery doors and the seat hood ...................................F 9
6.5 Checking the hydraulic oil level .......................................................F 10
6.6 Checking the brake fluid level .........................................................F 10
6.7 Check fixing of the wheels ..............................................................F 10
6.8 Safety belt maintenance o .............................................................F 11
6.9 Checking electrical fuses ................................................................F 12
6.10 Recommissioning the truck .............................................................F 13
7 Decommissioning the truck .............................................................F 13
7.1 Operations to be performed prior to decommissioning ...................F 13
7.2 Measures to be taken during decommissioning ..............................F 13
7.3 Recommissioning the truck .............................................................F 14
8 Safety checks to be performed at regular intervals and following
any untoward incidents (D: Accident prevention check
according to BGV D27) ...................................................................F 14

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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.