Page 1 ERC 212/214/216/212z/214z/216z 03.11 Operating instructions en-GB 51147713 04.19 ERC 212 ERC 214 ERC 216 ERC 212z ERC 214z ERC 216z...
Page 3 Declaration of Conformity Manufacturer Jungheinrich AG, 22039 Hamburg, Germany Description Industrial truck Type Option Serial no. Year of manufacture ERC 212 ERC 214 ERC 216 ERC 212z ERC 214z ERC 216z 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).
Page 5 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.
Page 6 Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG. Jungheinrich Aktiengesellschaft Friedrich-Ebert-Damm 129 22047 Hamburg - Germany Tel: +49 (0) 40/6948-0 www.jungheinrich.com...
Page 7: Table Of Contents
Contents Correct Use and Application General Correct application Lifting Passengers Approved application conditions Internal Operation Combined with Brief External or Cold Store Operation (t) Internal Operation in Cold Stores with Cold Store Equipment (o) Proprietor responsibilities Adding attachments and/or optional equipment Truck Description Application Truck models and rated capacity...
Page 8 Changing the battery from the top Lateral Battery Removal (ERC 212/214/216) Lateral Battery Removal (ERC 212z/214z/216z) Operation Safety Regulations for the Operation of Forklift Trucks Displays and Controls Battery discharge monitor Battery discharge indicator Preparing the Truck for Operation Checks and Operations to Be Performed Before Starting Daily Work...
Page 9 Restoring the truck to service after decommissioning Safety tests to be performed at intervals and after unusual incidents Final de-commissioning, disposal Human vibration measurement Maintenance and Inspection Maintenance Contents ERC 212/214/216 Owner Customer Service Maintenance Contents ERC 212z/214z/216z Owner Customer Service...
Page 11 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.
Page 13: A Correct Use And Application
A Correct Use and Application General The truck must be used, operated and serviced in accordance with the present instructions. All other types of use are beyond its scope of application and may result in damage to personnel, the industrial truck or property. Correct application NOTICE The maximum load and load distance are indicated on the capacity plate and must...
Page 14: Approved Application Conditions
Approved application conditions – Operation in industrial and commercial environments. – Operation only on secure, level surfaces with sufficient capacity. – Do not exceed the permissible surface and spot load limits on the travel routes. – Operation only on routes that are visible and approved by the operating company. –...
Page 15: Internal Operation Combined With Brief External Or Cold Store Operation (T)
Internal Operation Combined with Brief External or Cold Store Operation (t) In addition to the permissible application conditions in industrial and commercial environments, the truck may also be used in outdoor environments, cold stores and fresh food areas. Secure parking is only permissible indoors or in a cold store environment.
Page 16: Proprietor Responsibilities
Proprietor responsibilities For the purposes of the present operating instructions the “operating company” 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.
Page 17: B Truck Description
B Truck Description Application The industrial truck is an electric pallet truck with a folding platform. It is designed for lifting and transporting goods on level floors. Wheel arm lift (ERC 212z/214z/216z only) increases the ground clearance when transporting goods on uneven surfaces. Loads can be stacked or unstacked up to 5.35 m high and transported over long distances.
Page 18: Travel Direction Definition
Travel direction definition The following determinations have been made for travel direction specification: Item Travel direction Left Drive direction Load direction Right...
Page 19: Assemblies And Functional Description
Assemblies and Functional Description Assembly Overview...
Page 20 Item Model Item Model t Tiller 12 t Load handler t Protective screen panel o Double-deck operation ( ERC 212z/214z/216z only) o Load backrest (for cold store 13 o Folding side arms operation) t Mast 14 t Front panel t Travel switch 15 t Folding operator platform t Collision safety switch 16 t Drive wheel...
Page 21: Functional Description
Functional Description Safety mechanisms An enclosed, smooth truck geometry with rounded edges ensures safe handling of the truck. The wheels are surrounded by a solid skirt. When released, a gas strut pushes the tiller up and activates braking. If the truck touches a person, the red collision safety switch changes the travel direction in pedestrian mode when travelling in drive direction with the platform and the side arms folded up (o).
Page 22 Hydraulic System Lifting and lowering are activated via the lift and lower buttons. Pressing the lifting button starts the pump unit, supplying hydraulic oil from the oil reservoir to the lift cylinder. With the two-stage Duplex mast (ZZ) (o) or three-stage telescopic mast (DZ) (o) a short, centre-mounted free lift cylinder initially lifts the load handler (free lift) without changing the overall height of the truck.
Page 23 Mast The high strength steel sections are narrow, enabling excellent visibility of the load handler. The lift rails and the load handler run on permanently-lubricated and hence maintenance-free angled rollers. Load backrest (o) A load backrest is recommended as an additional protective mechanism to move low or small item loads above the mast protection frame or grille (o).
Page 24: Technical Specifications
Technical Specifications The technical specifications comply with the German "Industrial Truck Data Sheet" Guidelines. Technical modifications and additions reserved. Performance data ERC 212 / ERC 214 / ERC 216 / 212z 214z 216z Rated capacity 1200 1400 1600 1200 1400...
Page 25: Dimensions
Dimensions ERC 212/214/216...
Page 26 ERC 212z/214z/216z...
Page 27 Reference ERC 212 / ERC 214 / ERC 216 / 212z 214z 216z Standard 290 ZT mast 280 ZT Overall length* 2046 / 2060 2067 / 2081 2067 / 2081 mm Headlength* 896 / 910 917 / 931 917 / 931...
Page 28: Weights
Axle loading, unladen 950 / 310 990 / 330 990 / 330 front / rear Tyre type Component ERC 212/ 212z ERC 214/ 214z ERC 216/ 216z Tyre size, front 230x77 Tyre size, rear (single) 85x110 / 85x110 / 85x110 /...
Page 29: En Norms
The noise level is measured at the level of the driver's ear. Vibration – ERC 212/214/216/212z/214z/216z, Fixed castor wheel: 0,88 m/s² – ERC 212/214/216/212z/214z/216z, Sprung castor wheel: 0,70 m/s² in accordance with EN 13059...
Page 30: Conditions Of Use
Conditions of use Ambient temperature – without cold store equipment: operating at -10 °C to +40 °C, see page 13 – with cold store equipment: operating at -28 °C to +25 °C, see page 13 Special equipment and authorisation are required if the truck is to be used continually in conditions of extreme temperature or condensing air humidity fluctuations.
Page 31: Identification Points And Data Plates
Identification Points and Data Plates Warnings and notices such as capacity charts, strap points and data plates must be legible at all times. Replace if necessary. Indication Points Item Description Lift height marking corresponding to capacity plate, see page 31 Capacity plate, capacity / load centre distance / lift height Prohibition plate: “Do not step under the load handler”...
Page 32: Data Plate
Data plate The illustration shows the standard version for EU member states. The data plate may differ in other countries. Item Description Item Description Type Year of manufacture Serial number Load centre (mm) Rated capacity (kg) Output Battery voltage (V) Min./max.
Page 33: Truck Capacity Plate
Truck capacity plate Previous capacity plate Current capacity plate The capacity plate (22) indicates the maximum capacity Q (in kg) for a given load centre distance D (in mm) and corresponding lift height H (in mm) for the truck when raising a load.
Page 34 Load centre distance The load centre distance D of the load handler is specified as the horizontal distance from the front face and the vertical distance from the upper edge of the load handler. The capacity plate for standard load handlers specifies valid load centre distances of 500 mm, 600 mm and 700 mm.
Page 35: Capacity Plate For Stacking And Transport Operations
5.3.1 Example of Use of Capacity Plate (575 mm) 1150 mm SERIAL NO. 3600 3200 1050 1050 2900 1200 1200 Example load (palletised): – several cardboard boxes of the same size and same weight – Load height: 800 mm – Load length: 1150 mm –...
Page 36 Stacking operations (storing and retrieving loads): During high-level lift (mast lift) observe the capacity depending on the lift height, see page 31. Transport operations: Max. capacity when transporting loads horizontally 2000 kg with the support arms raised and without high-level lift (mast lift). During stacking operations with the low-level lift (support arm lift) raised, loads can be stored and retrieved up to a lift height of 1800 mm.
Page 37: Capacity Plate For Stacking, Transport And Double-Deck Operations
Capacity Plate for Stacking, Transport and Double-Deck Operations ERC 212z-216z only For double decker option only CAUTION! Risk to operational stability In order not to jeopardize the operational stability, pay attention to the weight when transporting two pallets so that the truck does not tip over. uIn order not to jeopardize the operational stability, the heavier pallet should always be transported underneath.
Page 38 Current capacity plate The capacity plate for stacking, transport and double-deck operations (44) specifies the truck capacity Q (in kg) during stacking, transport and double-deck operations: Stacking operations (storing and retrieving loads): During high-level lifting (mast lift), observe the capacity depending on the lift height, see page 31.
Page 39: Wind Loads
Wind loads Wind forces can affect the stability of a truck when lifting, lowering and transporting loads with large surface areas. Light loads must be especially secured when they are subjected to wind forces. This will prevent the load from sliding or falling. Stop the truck in both cases.
Page 41: C Transport And Commissioning
C Transport and Commissioning Lifting by crane WARNING! All persons involved in loading by crane must be trained Incorrect crane loading procedures due to untrained personnel can cause the truck to fall. There is a risk of injury to personnel and a risk of material damage to the truck.
Page 42 Lifting the truck by crane Requirements – Park the truck securely, see page 76. Tools and Material Required – Lifting gear – Crane lifting gear Procedure • Secure the lifting slings to the strap points (24). The truck can now be lifted by crane.
Page 43: Transport
Transport WARNING! Accidental movement during transport Improper fastening of the truck and mast during transport can result in serious accidents. uLoading must only be performed by specialist personnel trained for this purpose. The specialist personnel must be instructed in securing loads on road vehicles and handling load securing devices.
Page 44: Using The Truck For The First Time
Using the Truck for the First Time WARNING! The use of unsuitable energy sources can be hazardous Rectified AC current will damage the assemblies (controllers, sensors, motors etc.) of the electronic system. Unsuitable cable connections (too long, insufficient wire cross-section) to the battery (tow cables) can overheat, setting the truck and battery on fire.
Page 45: D Battery - Servicing, Recharging, Replacement
D Battery - Servicing, Recharging, Replacement Safety Regulations Governing the Handling of Lead-Acid Batteries Maintenance personnel Batteries may only be charged, serviced or replaced by trained personnel. These operating instructions and the manufacturer’s instructions concerning batteries and charging stations must be observed when carrying out the work. Fire Protection Do not smoke and avoid naked flames when handling batteries.
Page 46 The use of unsuitable batteries that have not been approved for the truck by Jungheinrich, can lead to a deterioration of the braking characteristics of the truck during energy recovery, causing considerable damage to the electric controller and resulting in serious danger to the health and safety of individuals.
Page 47: Battery Types
Battery types Depending on the model, the truck will be supplied with different battery types. The following table shows which combinations are included as standard: ERC 212/214/216 Battery type Capacity (Ah) Min. weight Max. dimensions (kg) (mm) 24-volt battery 3 PzS 210...
Page 48: Exposing The Battery
Exposing the battery WARNING! An unsecured truck can cause accidents Parking the truck on an incline or with a raised load handler is dangerous and is strictly prohibited. uPark the truck on a level surface. In special cases the truck may need to be secured with wedges.
Page 49 Requirements – Park the truck on a horizontal surface. – Park the truck securely, see page 76. Procedure • Press the emergency disconnect switch (18). • Open the battery panel (19). • Where necessary, remove the insulating mat from the battery. CAUTION! A closing battery panel can pose a trapping hazard uThe battery panel is only properly opened at an angle greater than 90°.
Page 50: Charging The Battery
Charging the battery WARNING! The gases produced during charging can cause explosions The battery gives off a mixture of oxygen and hydrogen (electrolytic gas) during charging. Gassing is a chemical process. This gas mixture is highly explosive and must not be ignited. uSwitch the charging station and truck off first before connecting/disconnecting the charging cable of the battery charging station to/from the battery connector.
Page 51: Charging The Battery With A Stationary Charger
Charging the battery with a stationary charger Charging the battery Requirements – Expose the battery, see page 46. Procedure • Disconnect the battery connector (46) from the truck connector. • Connect the battery connector (46) to the charging cable (47) of the stationary charger.
Page 52: Charging The Battery With An On-Board Charger (O)
The on-board charger consisting of a battery charger and battery controller must not be opened. If faulty, contact the manufacturer’s customer service department. uThe charger must only be used for batteries supplied by Jungheinrich or other approved batteries provided it has been adapted by the manufacturer's customer service department.
Page 53 4.2.1 Setting the charging characteristics (ELG 2430) The factory setting for trucks without a battery is the 0 position. A battery discharge indicator, a charge/discharge indicator, a CanDis or a bipolar LED can be attached to the connector (49). CAUTION! uRemove the mains connector before setting the respective charging curve.
Page 54 400 Ah Wet cell battery: PzS with pulse characteristic 200 - 414 Ah Jungheinrich 100 - 300 Ah NOTICE uAll other switch positions (48) block the charger, and the battery is not charged. uFor PzM batteries with a capacity of less than 180 Ah set characteristic 1, beyond 180 Ah set characteristic 5.
Page 55 4.2.2 Charging the battery Starting to charge with the on-board charger – ELG mains connection Mains supply: 230 V / 110 V (+10/-15%) Mains frequency: 50 Hz / 60 Hz The mains cable and the mains connector (17) of the battery charger are integrated into the storage compartment in the dashboard panel.
Page 56 Completing battery charging, restoring the truck to operation NOTICE If charging has been interrupted, the full battery capacity will not be available. Requirements – The battery is fully charged. Procedure • Remove the mains connector (44) from the mains socket and store it along with the cable in the storage compartment (47).
Page 57 LED display (50) Green LED (charge status) Charging complete, battery full. (Charge interval, float or compensation charge). Flashes slowly Charging. Rapid flash Display at beginning of charge or after setting a new characteristic curve. Number of flash pulses corresponds to the characteristic curve set. Red LED (fault) Overtemperature.
Page 58: Battery Removal And Installation
Battery removal and installation WARNING! Accident risk during battery removal and installation Due to the battery weight and acid there is a risk of trapping or scalding when the battery is removed and installed. uNote the "Safety regulations for handling acid batteries" section in this chapter. uWear safety shoes when removing and installing the battery.
Page 59: Changing The Battery From The Top
Changing the battery from the top ERC 212/214/216 Removing the battery Requirements – Park the truck securely, see page 76. – Expose the battery, see page 46. Tools and Material Required – Crane lifting gear Procedure • Disconnect the battery connector from the truck connector.
Page 60 Battery installation Requirements – Park the truck securely, see page 76. Procedure Installation is the reverse order. When reinstalling the batteries, make sure they are installed in the correct position and properly connected. Place the battery cable on the tray so that it cannot be severed when the battery is inserted.
Page 61: Lateral Battery Removal (Erc 212/214/216)
Lateral Battery Removal (ERC 212/214/216) Lateral battery removal is an option only. CAUTION! Trapping hazard Trapping hazard when removing and installing the battery. uWhen removing and installing the battery do not put your hands between the battery and the chassis.
Page 62 • Attach the battery connector to the truck connector. CAUTION! Trapping hazard There is a risk of trapping when you close the battery cover. uDo not reach between the battery cover and chassis. Hold the battery cover only by the designated recess. uClose the battery panel carefully and slowly.
Page 63: Lateral Battery Removal (Erc 212Z/214Z/216Z)
Lateral Battery Removal (ERC 212z/214z/216z) Battery removal Requirements – Park the truck securely, see page 76. – Expose the battery, see page 46. Tools and Material Required – Battery replacement station / trolley Procedure • Disconnect the battery connector from the truck connector. •...
Page 64 Battery installation Requirements – Park the truck securely, see page 76. Procedure Installation is in the reverse order. When reinstalling the batteries, make sure they are installed in the correct position and properly connected. Place the battery cable on the tray so that it cannot be severed when the battery is inserted.
Page 65: Operation
E Operation Safety Regulations for the Operation of Forklift Trucks Driver authorisation The truck may only be used by suitably trained personnel, who have demonstrated to the proprietor or his representative that they can drive and handle loads and have been authorised to operate the truck by the proprietor or his representative.
Page 66 Hazardous area WARNING! Risk of accidents/injury in the hazardous area of the truck A hazardous area is defined as the area in which people are at risk due to travel or lifting operations of the truck, its load handler or the load. This also includes the area within reach of falling loads or lowering/falling operating equipment.
Page 67: Displays And Controls
Displays and Controls 11,58,59,60 57 56...
Page 68 Control/display Function 212/214/216 212z/214z/ 216z Display unit Display for: (2-inch display) – Battery charge status – Battery capacity – Service hours – Travel program – Warning indicators – Event messages Soft keys under Selection of: the display unit – Travel program –...
Page 69 Control/display Function 212/214/216 212z/214z/ 216z 60 Keypad Replaces the key switch – Provided only as a supplement to the display unit – Truck release by entering set-up and access codes Transponder Replaces the key switch reader – Provided only as a supplement to the display unit –...
Page 70 Control/display Function 212/214/216 212z/214z/ 216z 13 Folding side arms When the side arms are folded out (side restraints) and the operator platform is laden and folded out: – At lift heights below the transport safety height (approx. 400 mm depending on the mast version), higher travel speeds are possible in rider mode than with folded-in side arms or without side arms, see...
Page 72: Battery Discharge Monitor
Battery discharge monitor The standard setting for the battery discharge indicator / discharge monitor is based on standard batteries. When using maintenance-free or special batteries, the display and cut-out points of the battery discharge monitor must be set by manufacturer's service department.
Page 73: Battery Discharge Indicator
Battery discharge indicator When the truck has been released via the key switch, CanCode or ISM, the battery charge status is displayed. The LED colours (65) represent the following conditions: LED colour Charge status Green 40–100% Orange 30–40% Green/orange 20–30% flashes at 1 Hz 0–20% If the LED is red, the load can no longer be lifted.
Page 74: Preparing The Truck For Operation
Preparing the Truck for Operation Checks and Operations to Be Performed Before Starting Daily Work WARNING! Damage and other truck or attachment (optional equipment) defects can result in accidents. If damage or other truck or attachment (optional equipment) defects are discovered during the following checks, the truck must be taken out of service until it has been repaired.
Page 76: Preparing The Truck For Operation
Preparing the truck for operation Switching on the truck Requirements – Checks and operations to be performed before starting daily work, see page 72. Procedure • Depending on the operating mode and truck model, fold out the side arms (13) and the operator platform (15).
Page 77: Checks And Operations To Be Carried Out When The Truck Is Operational
Checks and operations to be carried out when the truck is operational WARNING! Risk of accident due to damage to or other defects in the truck and optional features If damage or other truck or attachment (optional equipment) defects are discovered during the following checks, the truck must be taken out of service until it has been repaired.
Page 78: Parking The Truck Securely
Parking the truck securely WARNING! An unsecured truck can cause accidents Do not leave an unsecured truck. uPark the truck securely when leaving it. uException: If the operator intends to remain in the immediate vicinity and is leaving the truck for only a short while, the applied parking brake is sufficient to hold the truck, see page 90.
Page 79 Parking the truck securely Procedure • Park the truck on a level surface. • Fully lower the load handler (67): • Press the lower button (57). • Using the tiller (5) turn the drive wheel to "forward travel". • Switch off the truck, to do this: •...
Page 80: Industrial Truck Operation
Industrial Truck Operation Safety regulations for truck operation Travel routes and work areas Only use lanes and routes specifically designated for truck traffic. Unauthorised third parties must stay away from work areas. Loads must only be stored in places specially designated for this purpose. The truck must only be operated in work areas with sufficient lighting to avoid danger to personnel and materials.
Page 81 Negotiating slopes and inclines Negotiating slopes and inclines up to 16 % is only permitted when they are recognised lanes. The slopes and inclines must be clean, have a non-slip surface, and negotiating them safely must be within the technical specifications of the truck. The truck must always be driven with the load facing uphill.
Page 82: How To Act In Hazardous Situations
How to act in hazardous situations CAUTION! If the truck is in danger of tipping over or falling off a loading ramp, proceed as follows: uAbandon the truck. When travelling on a loading ramp, avoid steering and fold in the side arms as required to facilitate leaving the truck if it tips over.
Page 83 Press the Emergency Disconnect switch Procedure • Press the Emergency Disconnect (18). All electrical functions are deactivated. The truck brakes to a halt. Press the Emergency Disconnect switch on in emergencies. Releasing the Emergency Disconnect switch Procedure • Pull the Emergency Disconnect switch (18) to unlock it. All electrical functions are enabled and the truck is operational again (provided the truck was operational before the Emergency Disconnect was pressed).
Page 84: Automatic Braking
Automatic braking When the tiller is released, it returns automatically to the upper brake zone (B) and the brakes are applied automatically. WARNING! Risk of collision due to a defective tiller Operating the truck with a defective tiller can lead to collisions with persons or objects.
Page 85: Travel
Travel WARNING! Collision hazard when operating the truck Collisions with personnel and equipment can result if the truck is operated with open panels. uDo not operate the truck unless the panels and covers are closed and properly locked. uWhen travelling through swing doors etc. make sure that the doors do not activate the collision safety button.
Page 86 The Curve Control option helps the driver to operate the truck safely taking into consideration safety regulations. When cornering, the maximum travel speed is adapted to the steer angle. Anti-roll back device for slow travel on inclines If the truck does not have sufficient speed to travel up an incline, it may roll back. Rolling back is detected by the truck's controller and the truck brakes to a halt immediately.
Page 87 Travelling in pedestrian mode Requirements – Start up the truck, see page 72 Procedure • Swing both folding side arms (13) in. Both side arms must be folded in at all times otherwise all functions will be deactivated (E-1926). With a load backrest (o) all functions are not deactivated if both side arms are folded out in pedestrian mode.
Page 88 Travelling in rider mode Requirements – Start up the truck, see page 72 Procedure • Leave both folding side arms (13) (o) folded in. Both side arms must be folded in or folded out at all times otherwise all functions will be deactivated (E-1926).
Page 89 Travelling in rider mode at a higher speed ( Requirements – Start up the truck, see page 72 Procedure • Swing both folding side arms (13) out. Both side arms must be folded in or folded out at all times otherwise all functions will be deactivated (E-1926).
Page 90 4.5.1 Changing direction during travel CAUTION! Danger when changing direction during travel Changing direction during travel causes the truck to decelerate sharply. When the truck changes direction, it can start travelling at high speed in the opposite direction unless the travel switch is released in time. uAfter setting off in the opposite direction, apply the travel switch gently or not at all.
Page 91: Steering
Steering CAUTION! When driving around sharp corners, the driver extends beyond the contours of the industrial truck. Procedure • Move the tiller (5) to the left or right. The truck is steered in the required direction. Brakes WARNING! Accident risk The brake pattern of the truck depends largely on the ground conditions.
Page 92 4.7.2 Braking with the coasting brake Procedure • If the travel switch (8) is set to (0), the truck automatically brakes regeneratively. The truck brakes to a halt regeneratively via the coasting brake. When braking regeneratively, energy is returned to the battery, ensuring a longer service time.
Page 93: Switch Matrix / Safety Switch Height
Switch Matrix / Safety Switch Height ERC without side restraint mechanism Operator Lift height Speed km/h Collision safety Lifting platform with load switch active Active Folded up <Sh* Folded up >Sh* Folded out <Sh* No*** Folded out >Sh* No*** ERC with side restraint system Operator Side arm Lift...
Page 94 Options for ERC with side restraint mechanism Operator Side arm Lift Speed km/h Collision Lifting active platform height with load safety switch active Fixed castor wheel, height-adjustable Folded out Folded out <TSh** No*** Folded out Folded out >TSh** No*** <Sh* Sprung castor wheel, hydraulic Folded out Folded out...
Page 95: Load Handler Raise/Lower
Load handler raise/lower WARNING! Accident risk when lifting and lowering Other people can be injured in the truck's hazardous area. The hazardous area is defined as the area in which people are at risk from the movement of the truck including the load handler, etc. This also includes areas which can be reached by falling loads, operating equipment, etc.
Page 96 4.9.1 Raising the load handler Requirements – Prepare the truck for operation, see page 74. Procedure Press “Raise load handler” button (56) until you reach the desired lift height. NOTICE Risk material damage hydraulic unit When you have reached the mechanical stops of the load handler, do not press the "Raise load handler"...
Page 97 4.9.2 Lowering the load handler Requirements – Prepare the truck for operation, see page 74. Procedure • Press the "Lower load handler" button (57) until you reach the desired lift height. The lowering speed can be infinitely adjusted via the travel of the button (approx. 8 mm).
Page 98: Lifting, Transporting And Depositing Loads
4.10 Lifting, transporting and depositing loads WARNING! Risk of accident when the centre of gravity of the load is outside of the load centre distance If the centre of gravity G of a raised load lies outside the load centre distance D specified for the load handler in the horizontal or vertical planes, under unfavourable conditions the raised load and also the truck can tip over while working.
Page 99 WARNING! Unsecured and incorrectly positioned loads can cause accidents. Before lifting a load unit, the driver must make sure that it has been correctly palletised and does not exceed the truck’s capacity. uInstruct other people to move out of the hazardous area of the truck. Stop working with the truck if people do not leave the hazardous area.
Page 100 4.10.1 Raising a load Requirements – Load correctly palletised. – Load weight matches the truck's capacity. – Load handler evenly loaded for heavy loads. Procedure • Drive the truck carefully up to the pallet. • Drive the load handler slowly into the pallet until the pallet is against the back of the load handler (see graphic to the right).
Page 101 4.10.2 Transporting a load Requirements – Load picked up correctly. – Mast lowered for proper transport (approx. 150 - 500 mm above the ground). Do not travel with a raised load (>500 mm). In double decker mode: Load handler lowered as far as possible but without touching the lower load, see page 103.
Page 102 4.10.3 Depositing a load CAUTION! Loads must not be set down on transport or escape routes, in front of safety installations or factory equipment that must be accessible at all times. Requirements – Storage location suitable for storing the load. Procedure •...
Page 103 4.10.4 Lifting two palletised loads ERC 212z-216z only For double decker option only CAUTION! Risk to operational stability In order not to jeopardize the operational stability, pay attention to the weight when transporting two pallets so that the truck does not tip over. uIn order not to jeopardize the operational stability, the heavier pallet should always be transported underneath.
Page 104 The additional pallet stop allows double pallets to be stacked without the subsequent need to align the pallets on top of each other.
Page 105 4.10.5 Transporting two palletised loads above each other ERC 212z-216z only For double decker option only CAUTION! Risk to operational stability In order not to jeopardize the operational stability, pay attention to the weight when transporting two pallets so that the truck does not tip over. uIn order not to jeopardize the operational stability, the heavier pallet should always be transported underneath.
Page 106 4.10.6 Lowering two palletised loads in turn ERC 212z-216z only For double decker option only CAUTION! Loads must not be deposited on travel or escape routes, in front of safety mechanisms or plant equipment that must be accessible at all times. Requirements –...
Page 107: Use As A Lift Work Table
4.11 Use as a Lift Work Table The load handler can remain in a raised position to be used as a lift work table when the truck is switched off, provided the operator is close to the truck. Immediate vicinity of the truck is when the operator is able to respond to malfunctions or attempts to use the truck by unauthorised persons immediately.
Page 108: Troubleshooting
Troubleshooting This chapter enables the operator to localize and rectify basic faults or the results of incorrect operation himself. When trying to locate a fault, proceed in the order shown in the remedy table. If, after carrying out the following remedial action, the truck cannot be restored to operation or if a fault in the electronics system is displayed with a corresponding error code, contact the manufacturer’s service department.
Page 109: Truck Does Not Start
Truck does not start Possible cause Actions Battery connector not plugged in. Check the battery connector and connect if necessary. Emergency disconnect switch pressed Unlock the emergency disconnect switch Key switch in position "O" Set the key switch to position "I" Battery charge too low Check battery charge and charge the battery if necessary...
Page 110: Load Cannot Be Lifted
Load cannot be lifted Possible cause Actions Truck not operational Carry out all actions listed under "Truck does not start" Hydraulic oil level too low Check the hydraulic oil level, see page 185 Battery discharge monitor has switched Charge the battery, see page 48 Faulty fuse Check fuses, see page 189 Excessive load...
Page 111: Operating The Truck Without Its Own Drive System
Operating the truck without its own drive system Release and activate the drive wheel brake WARNING! Accidental truck movement When the brakes are de-activated the truck must be parked on a level surface, since the brakes are no longer effective. uDo not release the brake on slopes or inclines.
Page 112 Activating the brake Procedure • Use wedges to prevent the truck from moving. • Remove the two M5x50 screws (68) from the brake (69). CAUTION! Open covers can cause injury and accidents uThe covers (battery cover, side panels, drive compartment cover etc.) must be closed during operation.
Page 113: Load Handler Emergency Lowering
ERC 212/212z Load handler emergency lowering Requirements – Load handler is not in the rack.
Page 114: Erc 214/216/214Z/216Z
ERC 214/216/214z/216z Load handler emergency lowering Requirements – Load handler is not in the rack. Tools and Material Required – Key (SW8) – Torque wrench setting range 1-4 Nm Procedure • Park the truck securely, see page 76. • Open the front panel, see page 180. •...
Page 115: Optional Equipment
Optional equipment CanCode Keypad (o) 8.1.1 Code lock The code lock allows a user or group of users to assign an individual user code. Travel programs can also be assigned to the individual user codes. The user code is configured with a master code and is described in the following sections in this chapter.
Page 116 The keypad consists of 10 digit keys, a Set key (75) and a o key (77). Digit keys The digit keys are used to enter the user or master code and select the travel program. The green LEDs of the digit keys 1, 2 and 3 (72, 73, 74) show the travel program setting.
Page 117 8.1.2 Preparing the truck for operation with the keypad (CanCode) Preparing the truck for operation by entering a valid operator code Procedure • Pull the Emergency Disconnect to unlock it, see page 80. The LED (76) lights up red. • Enter the operator code with the digit keys. When you have entered a valid operator code the LED (76) lights up green, the travel program selected is indicated by the corresponding LEDs (72,73,74) and the truck is switched on.
Page 118 8.1.4 Changing the master code To change the length of the master code you must follow the procedure in "Changing the master code", see page 116. If there are still user codes stored in the code lock, the master code to be changed must be the same length as the saved user codes.
Page 119 Error displays changing the master code For the following events the LED (76) flashes red: Cause Remedy – Switch off the truck, see page 115. – Choose a different master code, see page 116. – New master code is already –...
Page 120 8.1.5 Add operator code Requirements – To prepare the truck for operation, see page 115. Procedure • Press the O key (77). • Enter the valid master code with the digit keys. When you enter the valid master code the LED (76) flashes green.
Page 121 Error displays adding a user code For the following events the LED (76) flashes red: Cause Remedy – The user code entered is – Switch off the truck, see page 115. not the same length as the – Repeat the entry, making sure that the master master code code is the same length as the user code.
Page 122 8.1.6 Change operator code Requirements – To prepare the truck for operation, see page 115. Procedure • Press the O key (77). • Enter the valid master code with the digit keys. When you enter the valid master code the LED (76) flashes green.
Page 123 Error displays changing a user code For the following events the LED (76) flashes red: Cause Remedy – The user code entered is – Switch off the truck, see page 115. not the same length as the – Repeat the entry, making sure that the master master code code is the same length as the user code.
Page 124 8.1.7 Delete individual user codes Requirements – To prepare the truck for operation, see page 115. Procedure • Press the O key (77). • Enter the valid master code with the digit keys. When you enter the valid master code the LED (76) flashes green.
Page 125 Error displays deleting individual user codes For the following events the LED (76) flashes red: Cause Remedy – The user code entered is – Switch off the truck, see page 115. not the same length as the – Repeat the entry, making sure that the master master code code is the same length as the user code.
Page 126 8.1.8 Delete all user codes, Requirements – To prepare the truck for operation, see page 115. Procedure • Press the O key (77). • Enter the valid master code with the digit keys. When you enter the valid master code the LED (76) flashes green.
Page 127 8.1.9 Choose length of the new master code (4-6 digit) and add user codes The master code is factory set to a four-digit entry: If necessary, the four-digit master code can be changed to a five or six-digit entry. Before the master code length can be changed, all user codes must be deleted.
Page 128 8.1.10 Setting the automatic truck cutout (timeframe) Requirements – To prepare the truck for operation, see page 115. Procedure • Press the O key (77). • Enter the valid master code with the digit keys. When you enter the correct master code the LED (76) flashes green.
Page 129 This setting can be changed if required.
Page 130 8.1.11 Assigning the travel program The travel programs are fixed to the user code and can be released or blocked with a configuration code. The configuration code can also be used to assign a starting travel program to each user code. The starting travel program is the travel program that is activated when the truck is switched on and is displayed by the (72,73,74) LEDs.
Page 131 Specifying a configuration code: Setting Description – Travel program 1 is blocked for the user code selected 1st digit – Travel program 1 is enabled for the user code selected – Travel program 2 is blocked for the user code selected 2nd digit –...
Page 132 Adapting the travel program configuration to the user code Procedure • Press the O key (77). • Enter the valid master code with the digit keys. When you enter the valid master code the green LED (76) flashes green. • Enter the parameters 0-2-4 with the digit keys. •...
Page 133 Error displays configuring the travel programs For the following events the LED (76) flashes red: Cause Remedy – Blocked travel program – Switch off the truck, see page 115. defined as start travel – Try again, making sure the configuration code is program entered correctly.
Page 134: Setting The Truck Parameters With Cancode
Setting the truck parameters with CanCode CAUTION! Faulty entry Without CanDis only CanCode internal parameters can be changed. Traction controller parameters can only be changed with CanDis, without CanDis the settings must be performed by the manufacturer's service department. CAUTION! Altering settings for the travel, steering and hydraulic functions can result in accidents Increasing or decreasing the settings for travel, steering and hydraulic functions can...
Page 135 The truck is now in travel mode and can be checked. To continue setting, confirm with the Set key (75) again. Saving travel parameters Requirements – Enter all parameters. Procedure • Run "SaveParameters" by pressing 1-2-3-Set. • Confirm with the O key (77).
Page 136: Parameters
Parameters Travel program 1 Function Setting Standard Comments range setting Rider mode Operator platform 0256 32 - 104 acceleration 0.42 m/s2 folded down, side arms folded out Maximum speed in 0264 15 - 70 load direction 7.0 km/h Maximum speed in 0268 15 / 70 drive direction...
Page 137 Travel program 2 Function Setting Standard Comments range setting Rider mode Operator platform 0272 32 - 104 acceleration 0.7 m/s2 folded down, side arms folded out Maximum speed in 0280 15 / 70 load direction 7.0 km/h Maximum speed in 0284 15 / 70 drive direction...
Page 138 Travel program 3 Function Setting Standard Comments range setting Rider mode Operator platform 0288 32 - 104 acceleration 1.0 m/s2 folded down, side arms folded out Maximum speed in 0296 15 / 70 load direction 7.0 km/h Maximum speed in 0300 15 / 70 drive direction...
Page 139 Common parameters Function Standard Range Setting Reduction brake (0.52 m/s (0.52 m/s 125 - 330 Service Brake (1.25 m/s (1.25 - 3.3 m/s 56 - 104 Body protection acceleration (1.04 m/s (0.56 - 1.04 m/s Standard travel program 0 - 3 Battery parameters Function Setting...
Page 140 Hydraulic function lock parameters 5 , 6 Function Range Standard Comments setting 2338 Lifting, 0 - 15 0 = Lifting and lowering always lowering released 1 = Lifting only with authorisation 2 = Lifting only when stationary 3 = Lifting only with authorisation and only when stationary 4 = Lowering only when stationary 5 = Lifting and lowering only with...
Page 141 7 , 8 Function Range Standard Comments setting 2338 Lifting and 0 - 15 13 = Lifting and lowering only with lowering authorisation, lowering only when stationary 14 = Lifting and lowering only when stationary, lowering only with authorisation 15 = Lifting and lowering only with authorisation and only when stationary 7) With release = with tiller in travel range (F) in pedestrian mode;...
Page 142: Setting The Battery Parameters With Cancode
Setting the Battery Parameters with CanCode WARNING! Altering parameters can cause accidents uAltering the settings can cause accidents. uThis requires greater attention on the part of the operator The following example shows the parameter setting for the battery type (parameter 1377) to "dry - maintenance-free".
Page 143 The parameter is now saved. Testing an altered parameter Requirements – The parameter is now saved. Procedure • Press the O key (77). • Enter the master code. • Enter the four-digit parameter number "1377" and confirm with the Set key. •...
Page 144: Candis Display Instrument (O)
CanDis Display Instrument (o) The instrument indicates: Battery charge display (on board charger only) LED bars for battery charge status "Warning" symbol (yellow), Battery charge recommended "Stop" symbol (red); lift cut-off, Battery charge essential No symbol when battery type set to normal or enhanced performance wet cell battery "T"...
Page 145 8.5.1 Discharge monitor function The discharge limit has been reached when the "Stop" symbol (81) lights up. When the discharge monitor function is activated lifting operations are disabled. Travel and lowering are still possible. Lifting is only enabled again when the battery is 70% charged.
Page 146: Display Unit (2 Inch Display)
Display unit (2 inch display) Item Control or Function display Information field Displays event messages Battery capacity display Battery discharge status Icon field Displays the icons, see page 147. Battery type Shows the set battery type or characteristics (characteristics) 1 = Maintenance-free gel/dry battery 2 = Special battery, for example XFC Travel program Shows the travel program selected.
Page 147 8.6.1 Button allocation of the display Key allocation in main menu Symbol Meaning Travel program down: To switch the travel program down Travel program up: To switch the travel program up Settings (o): To change to the menu to administer the codes or transponders Switch off (o): Allows the truck to be switched off Switch off is only available in the display if the truck is switched on with...
Page 148 Key allocation in menu for managing codes or transponders (o) Symbol Meaning Change Set-Up Code: To change the set-up code and to activate the keypad or the transponder reader. Edit access code / transponder: To add or delete access codes and transponders. Up selection: To select access codes or transponders.
Page 149 8.6.2 Symbols in the display Any number of pictograms can be displayed in the pictogram field (86). Which pictograms are shown in the pictogram field depends on the operating and truck status. Symbol Meaning Colour Function Stop notice Functions deactivated due to truck malfunction Warning yellow...
Page 150 Symbol Meaning Colour Function Support arm lift yellow Illuminates if "Lift support arms" button lifting limit pressed if the support arm lift lifting limit has been reached. Support arm lift yellow Illuminates if "Lower support arms" button lowering limit pressed if the support arm lift lowering limit has been reached.
Page 151: Keyless Access System
Keyless Access System The keyless access systems serve as a replacement for the key switch to release the truck. The keyless access system allows an individual code to be allocated to each operator or group of operators. Item Description Display unit (EasyAccess Softkey): –...
Page 152: General Information About The Use Of Keyless Access Systems
General Information about the Use of Keyless Access Systems The default code is to be found on a sticker. When using the truck for the first time, change the set-up code and remove the sticker! – Default code: 1-2-3-4 – Factory set-up code: 2-4-1-2 When allocating the codes, ensure the rider trucks are given a different code than pedestrian trucks.
Page 153 8.9.1 Activating the keypad Procedure • Release the emergency disconnect switch, see page 80. • Enter the default code 1-2-3-4 using the keys below the display unit (55). The truck is switched on. • Press the key below the "Settings" symbol (93).
Page 154 8.9.2 Activating the transponder reader Procedure • Release the emergency disconnect switch, see page 80. • Enter the default code 1-2-3-4 using the keys below the display unit (55). The truck is switched on. • Press the key below the "Settings" symbol (93).
Page 155: Using The Display
8.10 Using the Display: 8.10.1 Switch on the truck with the access code. Procedure • Release the emergency disconnect switch, see page 80. • Enter the access code with the buttons below the display (55). The truck is switched on. 8.10.2 Switching off the truck Procedure...
Page 156 8.10.3 Changing the Set-up Code Requirements – The truck is switched on, see page 158. Procedure • Press the key below the "Settings" symbol (93). • Press the key below the "Change set- up code" symbol (94). • Enter the set-up code using the keys below the display unit (55).
Page 157 8.10.4 Adding a new access code Requirements – The truck is switched on, see page 158. Procedure • Press the key below the "Settings" symbol (93). • Press the key below the "Edit access code" symbol (99). The set-up code is requested. •...
Page 158 8.10.5 Deleting an access code Requirements – The truck is switched on, see page 158. Procedure • Press the key below the "Settings" symbol (93). • Press the key below the "Edit access code" symbol (99). The set-up code is requested. •...
Page 159 8.10.6 Displaying the Log-in Process The use of the last different access codes is displayed during the log-in process. The last log-in is displayed first. If multiple access codes are logged as being displayable simultaneously, the display area can be moved by scrolling forward or back. Requirements –...
Page 160: Using The Keypad
8.11 Using the Keypad 8.11.1 Switch on the truck with the access code. Procedure • Release the emergency disconnect switch, see page 80. • Enter the access code with the keypad (60). The truck is switched on. Procedure • Press the key under the "Switch off" symbol (98) in the display unit. •...
Page 161 8.11.3 Changing the Set-up Code Requirements – The truck is switched on, see page 158. Procedure • Press the key below the "Settings" symbol (93). • Press the key below the "Change set- up code" symbol (94). • Enter the set-up code using the keypad (60).
Page 162 8.11.4 Adding a new access code Requirements – The truck is switched on, see page 158. Procedure • Press the key below the "Settings" symbol (93). • Press the key below the "Edit access code" symbol (99). The set-up code is requested. •...
Page 163 8.11.5 Deleting an access code Requirements – The truck is switched on, see page 158. Procedure • Press the key below the "Settings" symbol (93). • Press the key below the "Edit access code" symbol (99). The set-up code is requested. •...
Page 164 8.11.6 Displaying the Log-in Process The use of the last different access codes is displayed during the log-in process. The last log-in is displayed first. If multiple access codes are logged as being displayable simultaneously, the display area can be moved by scrolling forward or back. Requirements –...
Page 165: Operating The Transponder Reader
8.12 Operating the transponder reader NOTICE Take care not to damage the transponder. If the transponder is damaged, the truck cannot be switched on. 8.12.1 Switching on the truck with the transponder Procedure • Release the Emergency Disconnect switch, see page 80. •...
Page 166 8.12.3 Changing the Set-up Transponder Requirements – The truck is switched on, see page 163. Procedure • Press the key below the "Settings" symbol (93). • Press the key below the "Change set-up code" symbol (94). • Place the set-up transponder on the transponder reader (92).
Page 167 8.12.4 Adding a new transponder Requirements – The truck is switched on, see page 163. Procedure • Press the key below the "Settings" symbol (93). • Press below "Edit transponder" symbol (99). The set-up transponder is requested. • Place the set-up transponder on the transponder reader (92).
Page 168 8.12.5 Deleting transponders Requirements – The truck is switched on, see page 163. Procedure • Press the key below the "Settings" symbol (93). • Press the key below the "Edit transponder" symbol (99). set-up transponder requested. • Place the set-up transponder on the transponder reader (92).
Page 169: Ism Access Module (O)
8.12.6 Displaying the Log-in Process The use of the last different transponders is displayed during the log-in process. The last log-in is displayed first. If multiple transponders are logged as being displayable simultaneously, the display area can be moved by scrolling forward or back. Requirements –...
Page 171: F Industrial Truck Maintenance
F Industrial Truck Maintenance Operational Safety and Environmental Protection The checks and servicing operations contained in this chapter must be performed in accordance with the maintenance checklist service intervals. WARNING! Risk of accidents and component damage Any modification to the truck, in particular the safety mechanisms, is prohibited. Exception: Operating companies should only make changes or have changes made to powered industrial trucks if the manufacturer is no longer operating in the field and there is no successor to the business;...
Page 172: Maintenance Safety Regulations
Maintenance Safety Regulations Maintenance and repair personnel The manufacturer has a service department specially trained for these tasks. A maintenance contract with the manufacturer will ensure trouble-free operation. Truck maintenance and repair work must only be carried out by specially trained personnel.
Page 173: Working On The Electrical System
Working on the electrical system WARNING! Electrical current can cause accidents Make sure the electrical system is voltage-free before starting work on it. The capacitors in the controller must be completely discharged. The capacitors are completely discharged after approximately 10 minutes. Before starting maintenance on the electrical system: uOnly suitably trained electricians may operate on the truck's electrical system.
Page 174: Hydraulic System
Hydraulic system WARNING! Leaky hydraulic systems can result in accidents Hydraulic oil can escape from leaky and faulty hydraulic systems. uReport any defects immediately to your supervisor. uMark defective truck and take out of service. uDo not return the industrial truck to service until you have identified and rectified the fault.
Page 175: Lift Chains
Lift Chains WARNING! Non-lubricated and incorrectly cleaned lift chains can cause accidents Lift chains are safety-critical parts. They must not contain any serious contamination. Lift chains and pivot pins must always be clean and well lubricated. uLift chains should only be cleaned with paraffin derivatives e.g. petroleum or diesel fuels.
Page 176: Lubricants And Lubrication Schedule
Lubricants and Lubrication Schedule Handling consumables safely Handling consumables Consumables must always be handled correctly. Follow the manufacturer’s instructions. WARNING! Improper handling is hazardous to health, life and the environment Consumables can be flammable. uKeep consumables away from hot components and naked flames. uAlways keep consumables in prescribed containers.
Page 177 WARNING! Improper handling of oils can be hazardous Oils (chain spray / hydraulic oil) are flammable and poisonous. uDispose of used oils in accordance with regulations. Store used oil safely until it can be disposed of in accordance with regulations. uDo not spill oil.
Page 178: Lubrication Schedule
Lubrication Schedule ERC 212/214/216 1,05 l g Contact surfaces Cold-store application b Transmission oil filler neck Grease nipple a Transmission oil drain plug Hydraulic oil filler plug Compound ratio for cold store usage 1:1 Gear oil values are guidelines only. The spur wheel should be dipped approx.
Page 179 ERC 212z/214z/216z 1,05 l g Contact surfaces Cold-store application b Transmission oil filler neck Grease nipple a Transmission oil drain plug Hydraulic oil filler plug Compound ratio for cold store usage 1:1 Gear oil values are guidelines only. The spur wheel should be dipped approx. 2mm in the oil.
Page 180: Consumables
The Jungheinrich hydraulic oil may be mixed with one of the named alternative hydraulic oils. For cold store operations the Jungheinrich hydraulic oil and the cold store hydraulic oil must be mixed in a 1:1 ratio.
Page 181: Maintenance And Repairs
Maintenance and repairs Preparing the truck for maintenance and repairs All necessary safety measures must be taken to avoid accidents when carrying out maintenance and repairs. The following preparations must be made: Procedure • Park the truck securely, see page 76. •...
Page 182: Front Cover Disassembly
Front cover disassembly Removing the front panel (trucks with folding operator platform) Requirements – Folding operator platform (15) folded down. – Side restraints (13) folded out. Tools and Material Required – Allen key (A/F 8) Procedure • Undo the screws on the front panel (104) with an Allen key (A/F 8). •...
Page 183: Lifting And Jacking Up The Truck Safely
Lifting and jacking up the truck safely WARNING! Lifting and jacking up the truck safely In order to raise the truck, the lifting gear must only be secured to the points specially provided for this purpose. You may only work under a raised load handler if it has been secured with a sufficiently strong chain or the fastening bolt.
Page 184: Cleaning
Cleaning 4.4.1 Cleaning the truck CAUTION! Fire hazard Do not use flammable liquids to clean the industrial truck. uDisconnect the battery before starting cleaning work. uCarry out all necessary safety measures to prevent sparking before cleaning (e.g. by short-circuiting). CAUTION! Risk of component damage when cleaning the truck Cleaning with a pressure washer can result in malfunctions due to humidity.
Page 185 Cleaning the truck Requirements – Prepare the truck for maintenance and repairs (see page 179). Tools and Material Required – Water-based solvents – Sponge or cloth Procedure • Clean the surface of the truck with water-based solvents and water. Use a sponge or cloth to clean.
Page 186 4.4.2 Cleaning the electrical system assemblies CAUTION! Risk of electrical system damage Cleaning the assemblies (controllers, sensors, motors etc.) of the electronic system with water can damage the electrical system. uDo not clean the electrical system with water. uClean the electrical system with weak suction or compressed air (use a compressor with a water trap) and not a conductive, anti-static brush.
Page 187: Checking The Hydraulic Oil Level
If a leak is discovered in the hydraulics (cylinder; unions, lines), the truck must be decommissioned and repaired by specialist personnel. Mark Litres Lift heights (h Approx. 8.3 Approx. 7.5 ERC 214-216 Approx. 6.5 ERC 212-216 ERC 212-216 ERC 212 Mark Litres Lift heights (h Approx. 8.3 Approx. 7.5 214z-216z Approx.
Page 188 After adding hydraulic oil tighten the lock to 10 Nm. M=10 Nm...
Page 189: Check Wheel Attachment And Wear
Check wheel attachment and wear Replace the wheels if the wear limit (107) has been reached. The wheel nuts on the drive wheel must be retightened in accordance with the maintenance intervals indicated in the maintenance checklist, see page 195. Tightening the wheel nuts Requirements –...
Page 191: Checking Electrical Fuses
Checking electrical fuses Check fuses Requirements – Truck prepared for maintenance and repairs, see page 179. – Front cover removed, see page 180. Procedure • Check the fuse ratings against the table and replace if necessary. The fuses are now checked. Item Component To protect Rating...
Page 192: Restoring The Truck To Service After Maintenance And Repairs
Restoring the truck to service after maintenance and repairs Procedure • Thoroughly clean the truck, see page 182. • Lubricate the truck according to the lubrication diagram, see page 176. • Clean the battery, grease the terminals and connect the battery. •...
Page 193: Decommissioning The Industrial Truck
Decommissioning the Industrial Truck If the truck is to be out of service for more than a month, it must be stored in a frost- free and dry room. All necessary measures must be taken before, during and after decommissioning as described hereafter. When the truck is out of service it must be jacked up so that all the wheels are clear of the ground.
Page 194: Restoring The Truck To Service After Decommissioning
Restoring the truck to service after decommissioning Procedure • Thoroughly clean the truck, see page 182. • Lubricate the truck according to the lubrication schedule, see page 176. • Clean the battery, grease the terminal screws and connect the battery. •...
Page 195: Safety Tests To Be Performed At Intervals And After Unusual Incidents
Safety tests to be performed at intervals and after unusual incidents The truck must be inspected at least annually (refer to national regulations) or after any unusual event by a qualified inspector. The manufacturer offers a safety inspection service which is performed by personnel specifically trained for this purpose.
Page 197: G Maintenance And Inspection
G Maintenance and Inspection WARNING! Lack of maintenance can result in accidents Failure to perform regular servicing can lead to truck failure and poses a potential hazard to personnel and equipment. uThorough and expert servicing is one of the most important requirements for the safe operation of the industrial truck.
Page 198: Maintenance Contents Erc
Maintenance Contents ERC 212/214/216 Issued on: 2019-04-26 12:00 Owner To be performed every 50 service hours, but at least once a week. 1.1.1 Maintenance contents 1.1.1.1 Standard equipment Brakes Test the function of the brakes Hydraulic operations Lubricate the load chains.
Page 199 1.1.1.2 Optional equipment Lead-acid battery, international Power supply Correct the battery acid level using demineralised water. Lead-acid battery Power supply Correct the battery acid level using demineralised water.
Page 200 1.1.2 Inspection contents 1.1.2.1 Standard equipment The following points must be checked: Electrical system Warning and safety devices are in accordance with the operating instructions Function of display and controls The function of the emergency disconnect and for damage Power supply Battery and battery components for damage The function and secure seating of the battery connector and for damage Travel...
Page 201 1.1.2.2 Optional equipment The following points must be checked: Standard on-board charger Battery charger The mains plug and mains cable for damage Lead-acid battery, international Power supply Battery and battery components for damage Battery cable connections are secure Lead-acid battery Power supply Battery cable connections are secure...
Page 202: Customer Service
Customer Service 1.2.1 Maintenance contents In accordance with the ERC 212/214/216 service interval, to be performed every 1000 service hours, but at least once a year. 1.2.1.1 Standard equipment Brakes Test the brake with the tiller in the maximum vertical and horizontal positions.
Page 203 1.2.1.2 Optional equipment Standard on-board charger Battery charger Test the immobiliser on trucks with on-board chargers. Carry out a potential measurement on the chassis while charging is in progress. Data radio System components Clean the scanner and terminal. Lead-acid battery, international Power supply Clean and grease the battery terminals.
Page 204 1.2.2 Inspection contents The following points must be checked: 1.2.2.1 Standard equipment Electrical system Cables and engine are secure and for damage Warning and safety devices are in accordance with the operating instructions Function of display and controls The function of the emergency disconnect and for damage Contactors and/or relays for wear and damage The electric wiring for damage (insulation damage, connections) and the fuse ratings Carbon brushes for wear...
Page 205 Hydraulic operations Mast rollers and their running surfaces for wear and damage The function of the hydraulic system The forks or load handler for wear and damage The secure seating of the hoses, pipes and connections and for wear, leaks, damage, blisters and kinks Steering Lateral play of the tiller...
Page 206 1.2.2.2 Optional equipment Standard on-board charger Battery charger The mains plug and mains cable for damage The secure seating of the cables and electrical connections and for damage Electrolyte circulation Power supply The function of the hose connections and pump Aquamatik Power supply The function of the Aquamatik plug, hose connections and float and for leaks...
Page 207 Lead-acid battery Power supply The secure seating of the battery, battery cables and cell connectors and for damage...
Page 208 1.2.3 Maintenance parts The manufacturer recommends the replacement of the following maintenance parts at the specified intervals. 1.2.3.1 Standard equipment maintenance part service hours months Hydraulic oil 2000 Hydraulic system - breather filter 2000 Hydraulic oil filter 2000 Transmission oil 10000 1.2.3.2 Optional equipment...
Page 209: Maintenance Contents Erc 212Z/214Z/216Z
Maintenance Contents ERC 212z/214z/216z Issued on: 2019-04-26 12:00 Owner To be performed every 50 service hours, but at least once a week. 2.1.1 Maintenance contents 2.1.1.1 Standard equipment Brakes Test the function of the brakes Hydraulic operations Lubricate the load chains. Correct the hydraulic oil level.
Page 210 2.1.1.2 Optional equipment Lead-acid battery, international Power supply Correct the battery acid level using demineralised water. Lead-acid battery Power supply Correct the battery acid level using demineralised water.
Page 211 2.1.2 Inspection contents 2.1.2.1 Standard equipment The following points must be checked: Electrical system Warning and safety devices are in accordance with the operating instructions Function of display and controls The function of the emergency disconnect and for damage Power supply Battery and battery components for damage The function and secure seating of the battery connector and for damage Travel...
Page 212 2.1.2.2 Optional equipment The following points must be checked: Standard on-board charger Battery charger The mains plug and mains cable for damage Lead-acid battery, international Power supply Battery and battery components for damage Battery cable connections are secure Lead-acid battery Power supply Battery cable connections are secure...
Page 213: Customer Service
Customer Service 2.2.1 Maintenance contents In accordance with the ERC 212z/214z/216z service interval, to be performed every 1000 service hours, but at least once a year. 2.2.1.1 Standard equipment Brakes Test the brake with the tiller in the maximum vertical and horizontal positions. Measure the air gap of the magnetic brake.
Page 214 2.2.1.2 Optional equipment Standard on-board charger Battery charger Test the immobiliser on trucks with on-board chargers. Carry out a potential measurement on the chassis while charging is in progress. Data radio System components Clean the scanner and terminal. Lead-acid battery, international Power supply Clean and grease the battery terminals.
Page 215 2.2.2 Inspection contents The following points must be checked: 2.2.2.1 Standard equipment Electrical system Cables and engine are secure and for damage Warning and safety devices are in accordance with the operating instructions Function of display and controls The function of the emergency disconnect and for damage Contactors and/or relays for wear and damage The electric wiring for damage (insulation damage, connections) and the fuse ratings Carbon brushes for wear...
Page 216 Hydraulic operations The function of the hydraulic system The forks or load handler for wear and damage Tie/plunger rods are uniformly adjusted and for wear and damage The secure seating of the hoses, pipes and connections and for wear, leaks, damage, blisters and kinks Steering Lateral play of the tiller...
Page 217 2.2.2.2 Optional equipment Standard on-board charger Battery charger The mains plug and mains cable for damage The secure seating of the cables and electrical connections and for damage Electrolyte circulation Power supply The function of the hose connections and pump Aquamatik Power supply The function of the Aquamatik plug, hose connections and float and for leaks...
Page 218 Lead-acid battery Power supply The secure seating of the battery, battery cables and cell connectors and for damage...
Page 219 2.2.3 Maintenance parts The manufacturer recommends the replacement of the following maintenance parts at the specified intervals. 2.2.3.1 Standard equipment maintenance part service hours months Hydraulic oil 2000 Hydraulic system - breather filter 2000 Hydraulic oil filter 2000 Transmission oil 10000 2.2.3.2 Optional equipment...
Page 221 Foreword Notes to the operating instructions The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide sufficient instruction for the safe operation of the traction battery. The information is presented in a precise and clear manner. The chapters are arranged by letter and the pages are numbered continuously.
Page 222 Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG. Jungheinrich Aktiengesellschaft Friedrich-Ebert-Damm 129 22047 Hamburg - Germany Tel: +49 (0) 40/6948-0 www.jungheinrich.com...
Page 223 Contents Traction battery ............... Correct Use and Application..............Data plate ....................Safety Instructions, Warning Indications and other Notes ....... Lead acid batteries with armour plated cells and liquid electrolyte..Description....................Operation....................Servicing lead-acid batteries with armour plated cells......PzV and PzV-BS lead-acid batteries with sealed armour plated cells..Description....................
Page 225 A Traction battery Correct Use and Application This appendix does not apply to trucks with lithium-ion batteries. Further documentation for lithium-ion batteries can be obtained from the supplied documents. Failure to observe the operating instructions, carrying out repairs with non-original spare parts, tampering with the battery or using electrolyte additives will invalidate the warranty.
Page 226 Safety instructions and warning information...
Page 227 Safety Instructions, Warning Indications and other Notes Used batteries must be treated as hazardous waste. These batteries are marked with the recycling symbol and the sign showing a crossed-out rubbish bin, and should not be disposed of with ordinary household waste. Buy-back terms and type of recycling are to be agreed with the manufacturer as described in §...
Page 228 Lead acid batteries with armour plated cells and liquid electrolyte Description Jungheinrich traction batteries are lead acid batteries with armour plated cells and liquid electrolyte. The names of the traction batteries are PzS, PzB, PzS Lib and PzM. Name Explanation –...
Page 229 4.1.1 Battery nominal data Product Traction battery Nominal voltage 2.0 V x number of cells Rated capacity C5 See data plate Discharge current C5/5h Nominal electrolyte density 1.29 kg/l Nominal temperature 30 °C System rated electrolyte level up to "Max" electrolyte level marking Limit temperature 55 °C 1.
Page 230 Operation 4.2.1 Commissioning unfilled batteries The operations required must be carried out by the manufacturer's customer service department or a customer service organisation authorised by the manufacturer. 4.2.2 Commissioning filled and charged batteries Battery cell cross section Top view of a battery cell Checks and operations to be performed before starting daily work Procedure •...
Page 231 4.2.3 Discharging the battery To achieve an optimum useful life avoid operational discharge of more than 80% of nominal capacity (full discharge). This corresponds to a minimum electrolyte density of 1.13 kg/l at the end of the discharge. Fully or partially discharged batteries must be re-charged immediately and not left unattended.
Page 232 The electrolyte temperature rises by approx. 10°C during charging. Charging should therefore only begin when the electrolyte temperature is below 45°C. The electrolyte temperature of batteries must be at least +10°C before charging. Otherwise the battery will not charge correctly. Below 10°C the battery is insufficiently charged with standard charging systems.
Page 233 Servicing lead-acid batteries with armour plated cells 4.3.1 Quality of Water for Adding Electrolyte The quality of the water used to add electrolyte must correspond to purified or distilled water. Purified water can be produced through distillation or ion exchangers and is then suitable for the production of electrolyte. 4.3.2 Daily Battery cell cross section Top view of a battery cell...
Page 234 4.3.3 Weekly – After re-charging, carry out a visual inspection for dirt and physical damage. – If the battery is charged regularly according to the IU characteristic, carry out a compensation charge. 4.3.4 Monthly – Towards the end of the charging process measure and record the voltages of all the cells with the charger switched on.
Page 235 PzV and PzV-BS lead-acid batteries with sealed armour plated cells Description PzV batteries are sealed batteries with fixed electrolytes, to which no water can be added over the entire lifespan of the battery. Relief valves are used as plugs which are destroyed when opened.
Page 236 Operation 5.2.1 Commissioning Checks and operations to be performed before starting daily work Procedure • Make sure the battery is in physically good condition. • Make sure the terminals are correct (positive to positive and negative to negative) and check that contacts on the battery terminal conducting system are secure. •...
Page 237 NOTE Charging the battery incorrectly can result in material damage. Incorrect battery charging can result in overloading of the electric wires and contacts, hazardous gas formation and electrolyte leakage from the battery cell. Always charge the battery with DC current. All DIN 41773 charging procedures are permitted in the format approved by the manufacturer.
Page 238 Charging the battery Requirements – Electrolyte temperature between +15°C and +35°C Procedure • Open or take off the tray lid or covers from the battery compartment. • Connect the battery to the switched off charger, ensuring the terminals are connect (positive to positive and negative to negative).
Page 239 Servicing PzV and PzV-BS lead-acid batteries with sealed armour plated cells Do not add water! 5.3.1 Daily – Charge the battery after each discharge. 5.3.2 Weekly – Visually inspect for dirt and physical damage. 5.3.3 Every three months – Measure and record the overall voltage. –...
Page 240 Aquamatik water replenishment system Water replenishment system design > 3 m Water container Tap connection with ball cock Flow indicator Shut-off cock Locking coupling Battery lock connector...
Page 241 Functional Description The Aquamatik water replenishment system is used to adjust the rated electrolyte level automatically on traction batteries for industrial trucks. The battery cells are interconnected through hoses and are attached to the water supply (e.g. water container) through a plug connection. When the shut-off cock is opened all the cells are filled with water.
Page 242 Filling time The filling time for a battery depends on the electrolyte level, the ambient temperature and the filling pressure. Filling ends automatically. The water supply line must be disconnected from the battery when the water has been filled. Water quality The quality of the water used to fill up electrolyte must correspond to purified or distilled water.
Page 243 Electrolyte circulation Functional Description Electrolyte circulation ensures the supply of air during charging to mix the electrolyte, thereby preventing any acid layer, shortening the charge time (charge factor approx. 1.07) and reducing the formation of gas during charging. The charger must be suitable for the battery and electrolyte circulation.
Page 244 NOTE If an installed electrolyte circulation system is seldom used or not used at all, or if the battery is subjected to severe temperature fluctuations, the electrolyte may flow back into the hose system. Attach a separate coupling system to the air inlet line, such as: locking coupling to the battery side and through-coupling to the air supply side.
Page 245 Cleaning batteries Batteries and trays must be cleaned in order to – Maintain cell insulation and protect cells from ground or external conductive parts. – Avoid damage from corrosion and stray currents. – Avoid excessive and varying automatic discharge of the individual cells or block batteries due to stray currents.
Page 246 Cleaning the battery with a high pressure cleaner Requirements – Cell connectors tight, plugged in securely – Cell plugs closed Procedure • Follow the high pressure cleaner's user instructions. • Do not use any cleaning additives. • Observe the permissible cleaning device temperature setting of 140°C. This generally ensures that the temperature does not exceed 60°C at a distance of 30cm behind the outlet nozzle.
Page 247 Storing the battery NOTE The battery should not be stored for longer than 3 months without charging as otherwise it will no longer be functional. If the battery is to be taken out of service for a long period, it should be stored fully charged in a dry room protected from frost.

This manual is also suitable for:

Erc 214 Erc 216 Erc 214z Erc 216z Erc 212z

Jungheinrich ERC 212 Operating Instructions Manual

A Correct Use and Application

B Truck Description

C Transport and Commissioning

D Battery - Servicing, Recharging, Replacement

Operation

F Industrial Truck Maintenance

G Maintenance and Inspection

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