Jungheinrich ERC 212 User manual

ERC 212/214/216/212z/214z/216z 03.11
Operating instructions
51147713
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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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