Jungheinrich EJC 214 User manual

EJC 214-220 / EJC 212z-220z 11.10
Operating instructions
51141056
04.19
en-GB
EJC 212z
EJC 214z
EJC 216z
EJC 220z
EJC 214
EJC 216
EJC 220

2

Declaration of Conformity
Manufacturer
Jungheinrich AG, 22039 Hamburg, Germany
Description
Industrial truck
Type Option Serial no. Year of
manufacture
EJC 212z
EJC 214z
EJC 216z
EJC 220z
EJC 214
EJC 216
EJC 220
On behalf of
Date
EU DECLARATION OF CONFORMITY
The undersigned hereby declare that the powered truck described in detail complies
with the current versions of European Directives 2006/42/EG (Machinery Directive)
and 2014/30/EU (Electromagnetic Compatibility - EMC). The manufacturer is
authorised to compile the technical documentation.
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Foreword
Notes on the operating instructions
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide
sufficient instruction for the safe operation of the industrial truck. The information is
provided clearly and concisely. The chapters are arranged by letter and the pages
are numbered continuously.
The operator manual details different industrial truck models. When operating and
servicing the industrial truck, make sure that the particular section applies to your
truck model.
Our trucks are subject to ongoing development. We reserve the right to alter the
design, equipment and technical features of the system. No guarantee of particular
features of the truck should therefore be assumed from the present operating
instructions.
Safety notices and text mark-ups
Safety instructions and important explanations are indicated by the following
graphics:
DANGER!
Indicates an extremely hazardous situation. Failure to comply with this instruction will
result in severe irreparable injury and even death.
WARNING!
Indicates an extremely hazardous situation. Failure to comply with this instruction
may result in severe irreparable injury and even death.
CAUTION!
Indicates a hazardous situation. Failure to comply with this instruction may result in
slight to medium injury.
NOTICE
Indicates a material hazard. Failure to comply with this instruction may result in
material damage.
ZUsed before notices and explanations.
tIndicates standard equipment
oIndicates optional equipment
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Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Friedrich-Ebert-Damm 129
22047 Hamburg - Germany
Tel: [phone]
www.jungheinrich.com
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Contents
.
A Correct Use and Application 11
.
1 General 11
2 Correct application 11
2.1 Lifting Passengers 11
3 Approved application conditions 12
3.1 Internal Operation Combined with Brief External or Cold Store
Operation (t) 13
3.2 Internal Operation in Cold Stores with Cold Store Equipment (o) 13
4 Proprietor responsibilities 14
5 Adding attachments and/or optional equipment 14
.
B Truck Description 15
.
1 Application 15
1.1 Truck models and rated capacity 15
2 Travel direction definition 16
3 Assemblies and Functional Description 17
3.1 Assembly Overview 17
3.2 Functional Description 19
4 Technical Specifications 22
4.1 Performance data 22
4.2 Dimensions 24
4.3 Weights 30
4.4 Tyre type 31
4.5 EN norms 32
4.6 Specifications according to RED guideline (Radio Equipment
Directive) for radio units 33
4.7 Conditions of use 33
4.8 Electrical Requirements 33
5 Identification Points and Data Plates 34
5.1 Indication Points 34
5.2 Data plate 36
5.3 Truck capacity plate 37
5.4 Wind loads 40
5.5 Capacity Plate for Stacking and Transport Operations 40
5.6 Capacity Plate for Stacking, Transport and Double-Deck Operations 41
.
C Transport and Commissioning 43
.
1 Lifting by crane 43
2 Transport 45
3 Using the Truck for the First Time 47
.
D Battery - Servicing, Recharging, Replacement 49
.
1 Safety Regulations Governing the Handling of Lead-Acid Batteries 49
2 Battery types 51
3 Exposing the battery 54
4 Charging the battery 55
4.1 Charging the battery with a stationary charger 56
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4.2 Charging the battery with an on-board charger (o) 57
5 Battery removal and installation 65
5.1 Changing the battery from the top 66
5.2 Removing the battery from the side 68
.
E Operation 73
.
1 Safety Regulations for the Operation of Forklift Trucks 73
2 Displays and Controls 75
2.1 Battery discharge monitor 79
2.2 Battery discharge indicator 80
3 Preparing the Truck for Operation 81
3.1 Checks and Operations to Be Performed Before Starting Daily Work 81
3.2 Preparing the truck for operation 82
3.3 Checks and operations to be carried out when the truck is operational 83
3.4 Parking the truck securely 84
4 Industrial Truck Operation 85
4.1 Safety regulations for truck operation 85
4.2 Emergency Disconnect 87
4.3 Automatic braking 89
4.4 Travel 90
4.5 Slow travel 93
4.6 Steering 94
4.7 Brakes 94
4.8 Load handler raise/lower 97
4.9 Lifting, transporting and depositing loads 100
4.10 Use as a Lift Work Table 108
5 Troubleshooting 109
5.1 Truck does not start 110
5.2 Load cannot be lifted 112
6 Operating the truck without its own drive system 113
6.1 Release and activate the drive wheel brake 113
7 Load handler emergency lowering 115
7.1 EJC 214/216/220 115
7.2 EJC 212z / 214z / 216z / 220z 116
8 Optional equipment 117
8.1 Emergency operation with service key GF60 117
8.2 CanCode Keypad (o) 119
8.3 Setting the truck parameters with CanCode 138
8.4 Parameters 140
8.5 Setting the Battery Parameters with CanCode 145
8.6 Set ELH 2415 / 2425 / 2435 Charger Characteristics with CanCode 147
8.7 CanDis Display Instrument (o) 149
8.8 Display unit (2 inch display) 151
8.9 Keyless Access System 156
8.10 General Information about the Use of Keyless Access Systems 157
8.11 Commissioning the Keypad and the Transponder Reader 157
8.12 Using the Display: 160
8.13 Using the Keypad 165
8.14 Operating the transponder reader 170
8.15 ISM access module (o) 174
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.
F Industrial Truck Maintenance 175
.
1 Operational Safety and Environmental Protection 175
2 Maintenance Safety Regulations 176
2.1 Working on the electrical system 177
2.2 Consumables and used parts 177
2.3 Wheels 177
2.4 Hydraulic system 178
2.5 Lift Chains 179
3 Lubricants and Lubrication Schedule 180
3.1 Handling consumables safely 180
3.2 Lubrication Schedule 182
3.3 Consumables 183
4 Maintenance and repairs 184
4.1 Preparing the truck for maintenance and repairs 184
4.2 Front cover disassembly 185
4.3 Lifting and jacking up the truck safely 186
4.4 Cleaning 187
4.5 Checking the hydraulic oil level 190
4.6 Check wheel attachment and wear 192
4.7 Checking electrical fuses 194
4.8 Restoring the truck to service after maintenance and repairs 195
5 Decommissioning the Industrial Truck 196
5.1 Prior to decommissioning 196
5.2 Action to be taken during decommissioning 196
5.3 Restoring the truck to service after decommissioning 197
6 Safety tests to be performed at intervals and after unusual incidents 198
7 Final de-commissioning, disposal 198
8 Human vibration measurement 198
.
G Maintenance, Inspection and Changing of Maintenance
Parts Requiring Replacement 199
.
1 Maintenance Contents EJC 212z/214z/216z 200
1.1 Owner 200
1.2 Customer Service 204
2 Maintenance Contents EJC 214/216 211
2.1 Owner 211
2.2 Customer Service 215
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1
0506.GB
Appendix
JH Traction Battery Operating Instructions
ZThese operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.
1
0506.GB
Appendix
JH Traction Battery Operating Instructions
ZThese operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.

0506.GB
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2

A Correct Use and Application
1 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.
2 Correct application
NOTICE
The maximum load and load distance are indicated on the capacity plate and must
not be exceeded.
The load must rest on the load handler or be lifted by an attachment approved by the
manufacturer.
The load must be fully raised, see page 100.
Permissible activities
– Lifting and lowering loads.
– Stacking and retrieving loads.
– Transporting lowered loads.
Prohibited activities
– Travelling with a raised load (>500 mm).
In double-deck operation, the load handler must not be raised higher than
1800 mm. The bottom load must be heavier than the top load.
– Carrying and lifting passengers (see"Lifting Passengers" on page 11).
– Pushing or pulling loads.
2.1 Lifting Passengers
WARNING!
Risk of accident when using a work cage
When working with a work cage, high dynamic forces act on the truck, which can
impair its operational stability. When using a work cage, a minimum capacity of
1500 kg is required at the lift height of the work cage.
uUse the capacity plate to ensure sufficient capacity at the planned lift height, see
page 37.
Lifting passengers with a work cage may be permitted in some countries. This must
be verified by the operating company. The following (non-exhaustive) list contains
example standards with further information.
– Germany: DGUV information 208-031 (BGI/GUV- 5183) Use of Working Platforms
on Industrial Trucks with Mast
– Australia: AS 2359.1 Powered Industrial Trucks, General Requirements; AS
2359.2 Powered Industrial Trucks, Operations
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3 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.
– Negotiating inclines up to a maximum of 16%.
– Do not travel across or at an angle on inclines. Travel with the load facing uphill.
– Operation in partially public traffic.
WARNING!
Use under extreme conditions
Using the truck under extreme conditions can result in malfunctions and accidents.
uSpecial equipment and authorisation are required if the truck is to be constantly
used in extreme conditions, especially in dusty or corrosive atmospheres.
uThe truck cannot be used in areas at risk of explosion.
uIn adverse weather conditions (thunder, lightning) the industrial truck must not be
operated outside or in endangered areas.
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3.1 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.
– Permissible temperature range -10 °C to +40 °C.
– Secure parking is only permissible at +5 °C to +40 °C.
– Maximum air humidity 95% non-condensing.
– The application areas can be changed, but in general this should be minimised
due to thawing and possible corrosion.
– Thawing is permissible only if the truck can be subsequently dried thoroughly.
– Do not charge the battery below +5 °C.
3.2 Internal Operation in Cold Stores with Cold Store Equipment (o)
In addition to the permissible operating conditions in industrial and commercial
environments, the truck remains primarily in cold stores. The truck should only leave
the cold store briefly to hand over a load.
– Permissible temperature range -28 °C to +25 °C.
– Maximum air humidity 95% non-condensing.
– Thawing is permissible only if the truck can be subsequently dried thoroughly.
– In cold store areas below -10 °C the truck must be operated permanently and
should not be parked securely for more than 15 minutes.
– Do not charge the battery below +5 °C.
NOTICE
Battery damage
As the temperature becomes increasingly cold, the battery can be damaged if the
battery charge is low.
uIf the battery charge is low do not use the truck in areas of -28 °C to -5 °C.
uIf the battery charge is low it is preferable not to use the truck in areas of -5 °C to
+5 °C.
uCharge the battery, see page 55.
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4 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.
The proprietor must ensure that the industrial truck is used only for the purpose it is
intended for and that danger to life and limb of the user and third parties are
excluded. Furthermore, accident prevention regulations, safety regulations and
operating, servicing and repair guidelines must be followed. The operating company
must ensure that all users have read and understood these operating instructions.
NOTICE
Failure to comply with the operating instructions invalidates the warranty. The same
applies if improper work is carried out on the truck by the customer or third parties
without the permission of the manufacturer.
5 Adding attachments and/or optional equipment
The mounting or installation of additional equipment which affects or enhances the
performance of the industrial truck requires the written permission of the
manufacturer. Local authority approval may also need to be obtained.
Local authority approval however does not constitute the manufacturer’s approval.
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B Truck Description
1 Application
The EJC 214-220 / EJC 212z-220z is a four-wheel, tiller-operated electric stacker
with a steered drive wheel.
It is designed for use on level floors to lift and transport goods. Open bottom pallets
or roll cages can be lifted. The rated capacity is shown on the data plate. The
capacity with respect to lift height and load centre of gravity is indicated on the
capacity plate.
1.1 Truck models and rated capacity
The rated capacity depends on the model. The rated capacity can be derived from
the model name.
EJC 214 / 216 / 220 / EJC 212z / 214z / 216z / 220z
EJC 214 / 216 / 220
EJC 212z / 214z / 216z /
220z
Type
2 Series
14 Rated capacity x 100 kg
z Initial lift
The rated capacity is not generally the same as the permissible capacity. The
capacity can be found on the capacity plate attached to the truck.
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2 Travel direction definition
The following determinations have been made for travel direction specification:
1
2
3
4
Item Travel direction
1 Left
2 Drive direction
3 Load direction
4 Right
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3 Assemblies and Functional Description
3.1 Assembly Overview
12
14
13
15
17
19
21
16
11
10
9
8
7
5
6
20
18
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Item Description Item Description
5tTravel switch 14 tCharge status indicator
6tCollision safety switch oCanDis
oDisplay unit (2-inch display)
7tMast 15 tKey switch
8tProtective screen panel oCanCode
oProtective grille
(for cold store application)
oISM access module
oKeypad
oTransponder reader
16 oOn-board battery charger
9tEmergency disconnect switch 17 oMains plug (on-board charger)
10 tBattery panel 18
t
Document storage compartment
(for storage of the operating
instructions)
11 tLoad handler
o
Double-deck operation
(EJC 212z / 214z / 216z / 220z
only) 19 tDrive wheel
12 tSlow-travel button 20 tFront panel
13 tTiller 21 tSupport wheel
t = Standard version o = Option
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