Jungheinrich ERC 212 User manual

ERC 212/214/216/212z/214z/216z 03.11
Operating instructions
51147713
04.19
en-GB
ERC 212
ERC 214
ERC 216
ERC 212z
ERC 214z
ERC 216z

2

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). 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 23
4.3 Weights 26
4.4 Tyre type 26
4.5 EN norms 27
4.6 Conditions of use 28
4.7 Electrical Requirements 28
5 Identification Points and Data Plates 29
5.1 Indication Points 29
5.2 Data plate 30
5.3 Truck capacity plate 31
5.4 Capacity Plate for Stacking and Transport Operations 33
5.5 Capacity Plate for Stacking, Transport and Double-Deck Operations 35
5.6 Wind loads 37
.
C Transport and Commissioning 39
.
1 Lifting by crane 39
2 Transport 41
3 Using the Truck for the First Time 42
.
D Battery - Servicing, Recharging, Replacement 43
.
1 Safety Regulations Governing the Handling of Lead-Acid Batteries 43
2 Battery types 45
3 Exposing the battery 46
4 Charging the battery 48
4.1 Charging the battery with a stationary charger 49
4.2 Charging the battery with an on-board charger (o) 50
5 Battery removal and installation 56
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5.1 Changing the battery from the top 57
5.2 Lateral Battery Removal (ERC 212/214/216) 59
5.3 Lateral Battery Removal (ERC 212z/214z/216z) 61
.
E Operation 63
.
1 Safety Regulations for the Operation of Forklift Trucks 63
2 Displays and Controls 65
2.1 Battery discharge monitor 70
2.2 Battery discharge indicator 71
3 Preparing the Truck for Operation 72
3.1 Checks and Operations to Be Performed Before Starting Daily Work 72
3.2 Preparing the truck for operation 74
3.3 Checks and operations to be carried out when the truck is operational 75
3.4 Parking the truck securely 76
4 Industrial Truck Operation 78
4.1 Safety regulations for truck operation 78
4.2 How to act in hazardous situations 80
4.3 Emergency Disconnect 80
4.4 Automatic braking 82
4.5 Travel 83
4.6 Steering 89
4.7 Brakes 89
4.8 Switch Matrix / Safety Switch Height 91
4.9 Load handler raise/lower 93
4.10 Lifting, transporting and depositing loads 96
4.11 Use as a Lift Work Table 105
5 Troubleshooting 106
5.1 Truck does not start 107
5.2 Load cannot be lifted 108
6 Operating the truck without its own drive system 109
6.1 Release and activate the drive wheel brake 109
7 Load handler emergency lowering 111
7.1 ERC 212/212z 111
7.2 ERC 214/216/214z/216z 112
8 Optional equipment 113
8.1 CanCode Keypad (o) 113
8.2 Setting the truck parameters with CanCode 132
8.3 Parameters 134
8.4 Setting the Battery Parameters with CanCode 140
8.5 CanDis Display Instrument (o) 142
8.6 Display unit (2 inch display) 144
8.7 Keyless Access System 149
8.8 General Information about the Use of Keyless Access Systems 150
8.9 Commissioning the Keypad and the Transponder Reader 150
8.10 Using the Display: 153
8.11 Using the Keypad 158
8.12 Operating the transponder reader 163
8.13 ISM access module (o) 167
.
F Industrial Truck Maintenance 169
.
1 Operational Safety and Environmental Protection 169
2 Maintenance Safety Regulations 170
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2.1 Working on the electrical system 171
2.2 Consumables and used parts 171
2.3 Wheels 171
2.4 Hydraulic system 172
2.5 Lift Chains 173
3 Lubricants and Lubrication Schedule 174
3.1 Handling consumables safely 174
3.2 Lubrication Schedule 176
3.3 Consumables 178
4 Maintenance and repairs 179
4.1 Preparing the truck for maintenance and repairs 179
4.2 Front cover disassembly 180
4.3 Lifting and jacking up the truck safely 181
4.4 Cleaning 182
4.5 Checking the hydraulic oil level 185
4.6 Check wheel attachment and wear 187
4.7 Checking electrical fuses 189
4.8 Restoring the truck to service after maintenance and repairs 190
5 Decommissioning the Industrial Truck 191
5.1 Prior to decommissioning 191
5.2 Action to be taken during decommissioning 191
5.3 Restoring the truck to service after decommissioning 192
6 Safety tests to be performed at intervals and after unusual incidents 193
7 Final de-commissioning, disposal 193
8 Human vibration measurement 193
.
G Maintenance and Inspection 195
.
1 Maintenance Contents ERC 212/214/216 196
1.1 Owner 196
1.2 Customer Service 200
2 Maintenance Contents ERC 212z/214z/216z 207
2.1 Owner 207
2.2 Customer Service 211
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1
0506.GB
Appendix
JH Traction Battery Operating Instructions
ZThese operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.
1
0506.GB
Appendix
JH Traction Battery Operating Instructions
ZThese operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.

0506.GB
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0506.GB
2

A Correct Use and Application
1 General
The 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 96.
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 31.
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 48.
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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 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. The rated capacity of the truck is shown on the
identification plate or the data capacity plate Qmax.
1.1 Truck models and rated capacity
The rated capacity depends on the model. The rated capacity can be derived from
the model name.
ERC Model name
2 Series
14 Rated capacity x 100 kg
z Initial lift
The rated capacity is not generally the same as the permissible capacity. The
permissible 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
4
3
Item Travel direction
1 Left
2 Drive direction
3 Load direction
4 Right
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3 Assemblies and Functional Description
3.1 Assembly Overview
5
8
9
8
10
11
13
14
17
18
20
12
7
6
19
15
16
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Item Model Item Model
5tTiller 12 tLoad handler
6
tProtective screen panel oDouble-deck operation
( ERC 212z/214z/216z only)
oLoad backrest (for cold store
operation)
13 oFolding side arms
7tMast 14 tFront panel
8tTravel switch 15 tFolding operator platform
9tCollision safety switch 16 tDrive wheel
10 tCharge status indicator 17 oMains plug (on-board charger)
oCanDis 18 tEmergency disconnect switch
oDisplay unit (2-inch display)
11 tKey switch 19 tBattery panel
oCanCode 20 tFixed support wheel (vertically
adjustable)
oISM access module oSprung support wheel
(hydraulically controlled)
oKeypad
oTransponder reader
t = Standard version o = Optional equipment
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