Jungheinrich ERC 212, ERC 214, ERC 216, ERC 214z, ERC 216z Operating Instructions 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.

04.19 en-GB

3

04.19 en-GB

4

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:

Z

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.

Used before notices and explanations.

Indicates standard equipment

t

Indicates optional equipment

o

04.19 en-GB

5

Copyright

Copyright of these operating instructions remains with JUNGHEINRICH AG.

Jungheinrich Aktiengesellschaft

Friedrich-Ebert-Damm 129
22047 Hamburg - Germany

Tel: [phone]

www.jungheinrich.com

04.19 en-GB

6

04.19 en-GB

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
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
5 Battery removal and installation 56

Internal Operation in Cold Stores with Cold Store Equipment (o) 13

Charging the battery with an on-board charger (o) 50

7

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

8.2 Setting the truck parameters with CanCode 132

8.3 Parameters 134

8.4 Setting the Battery Parameters with CanCode 140

8.5

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

.

CanCode Keypad (o) 113

CanDis Display Instrument (o) 142

ISM access module (o) 167

F Industrial Truck Maintenance 169

.

1 Operational Safety and Environmental Protection 169
2 Maintenance Safety Regulations 170

04.19 en-GB

8

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

04.19 en-GB

9

10

04.19 en-GB

1

0506.GB

Appendix

JH Traction Battery Operating Instructions

Z

These 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

Z

These operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.

0506.GB 20506.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.

Use the capacity plate to ensure sufficient capacity at the planned lift height, see

u

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.

04.19 en-GB

– 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

11

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.

Special equipment and authorisation are required if the truck is to be constantly

u

used in extreme conditions, especially in dusty or corrosive atmospheres.
The truck cannot be used in areas at risk of explosion.

u

In adverse weather conditions (thunder, lightning) the industrial truck must not be

u

operated outside or in endangered areas.

12

04.19 en-GB

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.

If the battery charge is low do not use the truck in areas of -28 °C to -5 °C.

u

If the battery charge is low it is preferable not to use the truck in areas of -5 °C to

u

+5 °C.
Charge the battery, see page 48.

u

04.19 en-GB

13

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.

14

04.19 en-GB

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.

04.19 en-GB

15

2 Travel direction definition

1

2

4

3

The following determinations have been made for travel direction specification:

Item Travel direction

1 Left

2 Drive direction

3 Load direction

4 Right

04.19 en-GB

16

3 Assemblies and Functional Description

5

8981011131417182012761915

16

3.1 Assembly Overview

04.19 en-GB

17

Item Model Item Model

5

6

7

8

9

10

11

Tiller 12

t

Protective screen panel

t

Load backrest (for cold store

o

13

Load handler

t

Double-deck operation

o

( ERC 212z/214z/216z only)

Folding side arms

o

operation)

Mast 14

t

Travel switch 15

t

Collision safety switch 16

t

Charge status indicator 17

t

CanDis 18

o

Display unit (2-inch display)

o

Key switch 19

t

CanCode 20

o

Front panel

t

Folding operator platform

t

Drive wheel

t

Mains plug (on-board charger)

o

Emergency disconnect switch

t

Battery panel

t

Fixed support wheel (vertically

t

adjustable)

ISM access module

o

Sprung support wheel

o

(hydraulically controlled)

Keypad

o

Transponder reader

o

t = Standard version o = Optional equipment

18

04.19 en-GB

3.2 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). The truck brakes, travels away from the operator and
stops. This prevents the operator from being hit.

The collision safety feature can also be activated for rider mode (o).

Activating the emergency disconnect switch rapidly cuts out all electrical functions in
hazardous situations.

The protective screen or grille (o) protects the operator from moving mast parts and
the load.

Emergency Stop safety feature

The emergency stop is activated by the traction controller. Each time the truck is
switched on, the system carries out a self-diagnosis. The steering controller sends a
system status signal, which is monitored by the traction controller. If the signal fails
to appear or a fault is identified, the truck automatically brakes to a halt. Indicator

lights on the CanDis display instrument (o) or on the display unit (2-inch display)
(o) indicate the emergency stop.

CAUTION!

The truck brakes automatically

If the truck detects that signals which are required have not been received, or if it
detects an error, the system reacts by triggering an emergency stop, either by
braking the truck to a halt or until a valid signal status has been reached.

Remain at a suitable distance from the truck during operation.

u

Operator position

The truck has a folding operator platform and moving side arms (o).

04.19 en-GB

19

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.

Drive system

A fixed AC three-phase motor actuates the drive wheel via a bevel spur gearbox.
The electronic traction controller ensures smooth drive-motor-speed control and
hence smooth starting, powerful acceleration and electrically controlled braking with
energy regeneration. The driver can choose from 3 travel programs depending on
the load and the environment: from high-performance to energy-saving.

Tiller

The driver steers with an ergonomic tiller. All travel and lift operations can be
performed sensitively without having to reach. The tiller has a steering angle of 140°,
which results in a steering angle at the wheel of 180° due to the progressive electric
steering.

Electric steering

The electric steering system is self-monitoring.
The steering controller permanently monitors the entire steering system. If an error is
detected, the traction controller interrupts travel and brakes until the truck comes to
rest. The parking brake then engages.

Electrical system

The truck has an electronic traction controller. The operating voltage of the truck's
electrical system is 24 volts.

Controls and displays

Ergonomic controls ensure fatigue-free operation for sensitive application of the
travel and hydraulic operations. The battery discharge indicator shows the available

battery capacity. The CanDis display instrument (o) or the display unit (2-inch
display) (o) shows the operator key information such as the service hours, battery

capacity and event messages.

20

04.19 en-GB

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). The load backrest

is mounted on the load handler and protects the operator and truck against falling
loads.

Z

3.2.1 Hourmeter

Z

3.2.2 Hourmeter in Pedestrian Mode

Z

The extended mast height (h4) increases according to the load backrest mounted on
the load handler.

WARNING!

Risk of injury from falling loads

Low or small item loads moved above the mast protection pane or grille (o) and
protruding over the load backrest can fall, endangering the operator and truck.

Secure low or small item loads protruding over the load backrest, e.g. by wrapping

u

them in film.

Prepare the truck for operation, see page 74 or see page 113.

Service hours are counted while the truck is operational and the operator is standing
on the platform.

Prepare the truck for operation, see page 74 or see page 113.

04.19 en-GB

Service hours are counted while the truck is operational and one of the following
controls is applied:
– Tiller in travel zone "F", see page 83.
– "Lift" button, see page 94.
– "Lower" button, see page 95.

21

4 Technical Specifications

Z

The technical specifications comply with the German "Industrial Truck Data Sheet"
Guidelines.
Technical modifications and additions reserved.

4.1 Performance data

ERC 212 /

Q Rated capacity 1200 1400 1600 kg

Capacity for mast lift

Capacity for support arm lift

D Load centre distance with

standard fork length

Travel speed without side arms

(t)
with / without rated load

Travel speed with side arms (o)
with / without rated load

Travel speed with side arms (o)
and hydraulic support wheel (o)

with / without rated load

ERC 214 /

212z

1

2

1200 1400 1600

2000 2000 2000

214z

600 600 600

6.0 / 6.0 6.0 / 6.0 6.0 / 6.0

ERC 216 /

216z

kg

kg

mm

km/

h

7.0 / 7.0 7.0 / 7.0 7.0 / 7.0

km/

h

9.0 / 9.0 9.0 / 9.0 9.0 / 9.0
km/

h

Lifting speed with / without rated

0.13 / 0.22 0.16 / 0.25 0.15 / 0.25 m/s

load (adjustable (ZT))

Lowering speed with / without

0.43 / 0.30 0.41 / 0.34 0.41 / 0.34 m/s

rated load (adjustable (ZT))

Max. gradeability (over 5 min)

10 / 16 9 / 16 8 / 16 %

with / without load

Drive motor, output S2 60 min 2.8 2.8 2.8 kW

Lift motor, output

2.0

3

3.0

4

3.0

4

kW

22

1)

Depends on lift height.

2)

Only for ERC 212z-216z.

3)

at S3 12%

4)

at S3 11%

04.19 en-GB

4.2 Dimensions

ERC 212/214/216

04.19 en-GB

23

ERC 212z/214z/216z

24

04.19 en-GB

Reference ERC 212 /

212z

ERC 214 /

214z

ERC 216 /

216z

Standard 290 ZT mast 280 ZT

l

Overall length* 2046 / 2060 2067 / 2081 2067 / 2081 mm

1

l

Headlength* 896 / 910 917 / 931 917 / 931 mm

2

h1Mast height (retracted), for

1950 1950 1950 mm

100 mm lift

(h2) Free lift 100 100 100 mm

h3Lift 2900 2900 2800 mm

h4Mast height (extended) 3375 3375 3325 mm

h

Lowered fork height 90 90 90 mm

13

Tiller height in travel

1158 1158 1158 mm

position (min.)

h

14

Tiller height in travel

1414 1414 1414 mm

position (max.)

y Wheelbase 1336 / 1571 1357 / 1592 1357 / 1592 mm

x Load distance* 688 / 910 688 / 910 688 / 910 mm

b1/b2Overall width 800 800 800 mm

b5Width across forks 570 570

b

Track width, front 507 507

10

b

Track width, rear 400 / 385 400 / 385

11

570

507

400 / 385

mm

mm

mm

s Fork dimensions 56 56 56 mm

e Fork dimensions 185 185 185 mm

l Fork dimensions 1150 1150 1150 mm

Ground clearance, centre

m

2

of wheelbase

30 / 20 30 / 20 30 / 20 mm

Wa Turning radius 1597 / 1826 1618 / 1847 1618 / 1847 mm

Ast Aisle width for pallets 1000

x 1200 crossways

*)**)

Ast Aisle width for pallets 800 x

1200 lengthways

*)***)

2259 / 2266 2280 / 2287 2280 / 2287 mm

2309 / 2316 2330 / 2337 2330 / 2337 mm

Net weight: see "Weights" in chapter 4.3

*)

DZ: x -42 mm, l1 +42 mm, l2 +42 mm

**)

Diagonal in accordance with VDI: +215 mm

***)

Diagonal in accordance with VDI: +138 mm

04.19 en-GB

25

4.3 Weights

Component ERC 212 ERC 214 ERC 216

Standard 290 ZT mast 280 ZT

Net weight (including
battery)

Axle loading with rated
capacity
front / rear

Axle loading, unladen
front / rear

Description ERC 212z ERC 214z ERC 216z

Net weight (including
battery)

Axle loading with rated
capacity
front / rear

Axle loading, unladen
front / rear

4.4 Tyre type

1160

900 / 1460 970 / 1650 990 / 1840 kg

840 / 320 880 / 340 880 / 350 kg

Standard 290 ZT mast 280 ZT

1260

1190 / 1270 1260 / 1460 1300 / 1620 kg

950 / 310 990 / 330 990 / 330 kg

1220 1230

1320 1320

kg

kg

Component ERC 212/ 212z ERC 214/ 214z ERC 216/ 216z

Tyre size, front 230x77 mm

Tyre size, rear (single) 85x110 /

85x95

Tyre size, rear (tandem) 85x85 /

85x75

Castor wheel 140x54 / 180x75 mm

Wheels, number front/rear
(x = driven)

85x110 /

85x95

85x85 /

85 x75

1x+1/ 2

85x110 /

85x95

85x85 /

85x75

mm

mm

26

04.19 en-GB

4.5 EN norms

Noise emission level

– ERC 212/214/216/212z/214z/216z: 68 dB(A)

in accordance with EN 12053 as harmonised with ISO 4871.

Z

Z

Z

The noise emission level is calculated in accordance with standard procedures and
takes into account the noise level when travelling, lifting and when idle. 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

The vibration acceleration acting on the body in the operating position is, in
accordance with standard procedures, the linearly integrated, weighted acceleration
in the vertical direction. It is calculated when travelling over thresholds at constant
speed. These recordings were taken on a single occasion and must not be confused
with the human vibrations of the "2002/44/EC/Vibrations" operator directive. The
manufacturer offers a special service to measure these human vibrations, see
page 193.

The internal accuracy of the measuring chain for at 21 °C at ± 0,02 m/s². Further
deviations may occur in particular through the positioning of the sensor and different
driver weights.

Z

Electromagnetic compatibility (EMC)

The manufacturer confirms that the truck adheres to the limits for electromagnetic
emissions and resistance as well as the static electricity discharge test in
accordance with EN 12895 as well as the standardised instructions contained
therein.

No changes to electric or electronic components or their arrangement may be made
without the written agreement of the manufacturer.

WARNING!

Medical equipment can be damaged by non-ionised radiation

Electrical equipment on the truck emitting non-ionised radiation (e.g. wireless data
transmission) can affect operators' medical equipment (pacemakers, hearing aids
etc.) and result in malfunctions. Consult a doctor or the manufacturer of the medical
equipment to clarify whether it can be used near the industrial truck.

04.19 en-GB

27

4.6 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

Z

Special equipment and authorisation are required if the truck is to be used
continually in conditions of extreme temperature or condensing air humidity
fluctuations.

4.7 Electrical Requirements

The manufacturer certifies compliance with the requirements for the design and
manufacture of electrical equipment, according to EN 1175 "Industrial Truck Safety ­Electrical Requirements", provided the truck is used according to its purpose.

28

04.19 en-GB

5 Identification Points and Data Plates

25

24

292822

26

23

23

27

22

21

Z

Warnings and notices such as capacity charts, strap points and data plates must be
legible at all times. Replace if necessary.

5.1 Indication Points

Item Description

21 Lift height marking corresponding to capacity plate, see page 31

22 Capacity plate, capacity / load centre distance / lift height

23 Prohibition plate: “Do not step under the load handler”

24 Attachment points for lifting by crane

25 Data plate

26 Prohibition plate: "Do not reach through the mast"

27 Inspection plaque

28 Battery data plate

29 Serial number

04.19 en-GB

29

5.2 Data plate

30313332344137

403938

36

35

Z

The illustration shows the standard version for EU member states. The data plate
may differ in other countries.

Z

Item Description Item Description

30 Type 36 Year of manufacture

31 Serial number 37 Load centre (mm)

32 Rated capacity (kg) 38 Output

33 Battery voltage (V) 39 Min./max. battery weight (kg)

34 Net weight w.o. battery (kg) 40 Manufacturer

35 Option 41 Manufacturer’s logo

For queries regarding the truck or ordering spare parts always quote the truck serial
number (31).

04.19 en-GB

30

5.3 Truck capacity plate

22

22

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.

Example of how to calculate the maximum capacity:
The maximum capacity is Q1 at a load centre G within the load centre distance D1
and a lift height up to HH1.

04.19 en-GB

31

Load centre distance

G

D

D

D

G

d

d

d

1

2

2

42

43

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.

Z

The capacity plate for standard load handlers specifies valid load centre distances of
500 mm, 600 mm and 700 mm.

The distances d1 and d2 depicted in the illustration between the load handler and the
actual centre of gravity G of the load must be smaller or equal to the load centre

distance D (d1 ≤ D and d2 ≤ D) to avoid the risk of overturning, see page 96.

Lift height limits

32

The arrow shaped markings on the outer mast (42) and

on the inner mast (43) indicate to the operator when the height limits specified on the
capacity plate have been exceeded.

04.19 en-GB

5.3.1 Example of Use of Capacity Plate

1150 mm

800 mm

(575 mm)

(400 mm)

2900

3200

3600

1200

1050

850

500

1200

1050

850

600

700

700

600

700

SERIAL NO.

kg

mm

mm

Example load (palletised):
– several cardboard boxes of the same size and same weight
– Load height: 800 mm
– Load length: 1150 mm
– Distances between the load centre distance and the load handler:

400 mm vertical, 575 mm horizontal

Z

For loads with an even weight distribution, the load centre distance lies in the
geometrical centre of the volume.

Z

For rectangular loads with an even weight distribution over the entire volume the
load centre distance is in the middle, i.e. half the length, half the height and half the
width of the load.

Load centre distance of the load handler:
– The capacity plate specifies valid load centre distances for the load handler of

500 mm, 600 mm and 700 mm.

– The second load centre distance suits the example load: At 600 mm it is greater

than the distances of 400 mm and 575 mm between the load centre of gravity and
the load handler .

Capacities as specified in the capacity plate depending on the lift heights at a load
centre distance of 600 mm:
– At a lift height of 2900 mm the maximum capacity is 1200 kg.
– At a lift height of 3200 mm the maximum capacity is 1050 kg.
– At a lift height of 3600 mm the maximum capacity is 850 kg.

5.4 Capacity Plate for Stacking and Transport Operations

Z
Z

04.19 en-GB

ERC 212z-216z only

Not for double-decker option

The "stacking and transport operations" capacity plate (44) specifies the capacity (Q
in kg) of the truck during stacking and transport operations:

33

44AB

A= Stacking operations (storing and retrieving loads):

During high-level lift (mast lift) observe the capacity depending on the lift
height, see page 31.

B= Transport operations:

Max. capacity when transporting loads horizontally 2000 kg with the support
arms raised and without high-level lift (mast lift).

Z

Z

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. For lift heights above
1800 mm the low-level lift (support arm lift) must be lowered.

Do not transport loads when they are raised (>500 mm).

04.19 en-GB

34

5.5 Capacity Plate for Stacking, Transport and Double-Deck

44AB

C

Operations

Z
Z

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.

In order not to jeopardize the operational stability, the heavier pallet should always

u

be transported underneath.

Previous capacity plate

The double decker mode capacity plate (44) indicates the capacity Q kg of the truck
while travelling:

04.19 en-GB

A= No transporting with a raised load.

B= Max. capacity for horizontal transporting XXX kg with raised support arms

without mast lift.

C= Double decker mode:

Max. lift height 1800 mm
Max. capacity for high level lifting according ZZZ.
Max. capacity for both high and low level lifting XXX kg.

35

Current capacity plate

44AB

C

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:

A= Stacking operations (storing and retrieving loads):

During high-level lifting (mast lift), observe the capacity depending on the lift
height, see page 31.

Z

Z

Z

B= Transport operations:

Maximum capacity when transporting loads horizontally 2000 kg with the
support arms raised and without high-level lift (mast lift).

C= Double-deck operations:

Max. capacity for high-level lifting (mast lift) is ZZZ kg.
Maximum capacity for concurrent high-level lifting (mast lift) and low-level
lifting (support arm lift) is 2000 kg.

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. For lift heights above
1800 mm the low-level lift (support arm lift) must be lowered.

With the ERC, do not transport loads (>500 mm) when they are raised.
Apart from double-deck operations, do not transport loads with the ERC-z when they
are raised (>500 mm).

The maximum lift height for double-deck operations is 1800 mm.

04.19 en-GB

36

5.6 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.

04.19 en-GB

37

38

04.19 en-GB

C Transport and Commissioning

1 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.

Loading must only be performed by specialist personnel trained for this purpose.

u

The specialist personnel must be instructed in securing loads on road vehicles and
handling load securing devices. In each case correct measurements must be
taken and appropriate safety measures applied.

WARNING!

Improper loading by crane can result in accidents

Improper use or use of unsuitable lifting gear can cause the truck to crash when
being loaded by crane.

Prevent the truck from hitting other objects during lifting, and avoid uncontrolled
movements. If necessary, secure the truck with guide ropes.

The truck may be loaded only by people who are trained in using lifting

u

accessories and lifting gear.
Wear personal protective equipment (e.g. safety shoes, safety helmet, hi-vis

u

jacket, protective gloves) when loading by crane.
Do not stand under suspended loads.

u

Do not walk into or stand in a hazardous area.

u

Always use lifting gear with sufficient capacity (for truck weight, see truck data

u

plate).
Always attach the crane lifting gear to the prescribed attachment points and

u

prevent them from slipping.
Use the lifting accessories only in the prescribed load direction.

u

Crane lifting gear must be fastened in such a way that it does not come into

u

contact with any attachments when lifting.

04.19 en-GB

39

Lifting the truck by crane

24

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.

04.19 en-GB

40

2 Transport

454545

WARNING!

Accidental movement during transport

Improper fastening of the truck and mast during transport can result in serious
accidents.

Loading must only be performed by specialist personnel trained for this purpose.

u

The specialist personnel must be instructed in securing loads on road vehicles and
handling load securing devices. In each case correct measurements must be
taken and appropriate safety measures applied.

The truck must be securely fastened when transported on a lorry or a trailer.

u

The lorry or trailer must have fastening rings.

u

Use wedges to prevent the truck from moving.

u

Use only fastening belts with sufficient strength.

u

Use non-slip materials to securing the load aids (pallet, wedges, ...) e. g. non-slip

u

mats.

Securing the industrial truck for
transport

Requirements

– Load the truck.
– Park the truck securely, see

page 76.

Tools and Material Required

– Lashing straps

Procedure

• Attach the lashing straps (45) to the
industrial truck and the transport
vehicle and tension sufficiently.

The truck can now be transported.

04.19 en-GB

41

3 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.

The truck must only be operated with battery current.

u

Cable connections to the battery (tow leads) must be less than 6 m long and have

u

a minimum cross-section of 50 mm².

Procedure

• Check the equipment is complete.

• If necessary, install the battery, see page 56.

• Charge the battery, see page 48.

The truck can now be started, see page 72.

NOTICE

Do not lift loads if the truck is operated via a tow lead with an external battery.

NOTICE

Cold store trucks

Trucks designed for use in cold stores have a cold store hydraulic oil and a

u

protective frame instead of a mast guard on the mast.
If a truck with cold store oil is used outside the cold store, the lowering speeds

u

may increase.

CAUTION!

Poor visibility through the protector

The mast protection pane protector can impair the operator's visibility.

Remove the protector (transport retainer) from both sides of the mast protection

u

pane.

Wheel flattening

If the truck has been parked for a long period, the wheel surfaces may tend to
flatten. This flattening has a negative effect on the safety and stability of the truck.
Once the truck has covered a certain distance, the flattening will disappear.

42

04.19 en-GB

D Battery - Servicing, Recharging,

Replacement

1 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. Wherever an
industrial truck is parked for charging there must be no inflammable material or
consumables capable of creating sparks within a minimum distance of 2 m from the
truck. The room must be ventilated. Fire protection equipment must be available.

CAUTION!

The use of unsuitable fire protection equipment can result in scalding

Extinguishing fires with water can cause a reaction with the battery acid. This can
result in scalding from the acid.

Use powder extinguishers.

u

Never extinguish a burning battery with water.

u

Battery maintenance

The battery-cell covers must be kept dry and clean. The terminals and cable lugs
must be clean, secure and have a light coating of terminal grease.

WARNING!

Short circuits can result in fire

Damaged cables can cause short circuits, setting the truck and battery on fire.

Before closing the battery cover make sure that the battery cables are not

u

damaged.

Battery disposal

Batteries may only be disposed of in accordance with national environmental
protection regulations or disposal laws. The manufacturer’s disposal instructions
must be observed.

04.19 en-GB

43

WARNING!

Batteries can be hazardous

Batteries contain an acid solution which is poisonous and corrosive. Avoid contact
with battery acid at all times.

Dispose of used battery acid in accordance with regulations.

u

Always wear protective clothing and goggles when working with batteries.

u

Do not let battery acid come into contact with skin, clothing or eyes. If necessary,

u

rinse with plenty of clean water.
In the event of physical damage (e.g. skin or eye contact with battery acid) call for

u

a doctor immediately.
Spilled battery acid should be neutralised immediately with plenty of water.

u

Only batteries with a sealed battery container may be used.

u

Follow national guidelines and legislation.

u

WARNING!

Unsuitable batteries that have not been approved by Jungheinrich for the
truck can be hazardous

The design, weight and dimensions of the battery have a considerable effect on the
operational safety of the truck, in particular its stability and capacity. 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.

Only Jungheinrich-approved batteries may be used on the truck.

u

Battery equipment may only be replaced with the agreement of Jungheinrich.

u

When replacing/installing the battery make sure the battery is securely located in

u

the battery compartment of the truck.
Do not use batteries that have not been approved by the manufacturer.

u

Park the truck securely before carrying out any work on the batteries (see page 76).

44

04.19 en-GB

2 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

Z

Battery type Capacity (Ah) Min. weight

(kg)

24-volt battery 3 PzS 210 230 624X284X537

24-volt battery 3 PzV 225 230 624X284X537

24-volt battery 3 PzS 240 230 624X284X537

24-volt battery 3 PzV 240 230 624X284X537

24-volt battery 3 PzV 261 230 624X284X537

24-volt battery 3 PzS 270 230 624X284X537

24-volt battery 3 PzV 300 273 624X284X628

24-volt battery XFC 316 273 624X284X628

24-volt battery 3 PzV 330 273 624X284X628

24-volt battery 3 PzM 375 273 624X284X628

24-volt battery 3 PzS 375 273 624X284X628

24-volt battery 3 PzS 375 Lib.

Silver

Optionally, the truck can be fitted with a lithium-ion battery, see "Li-Ion battery 24V ­240Ah / 360Ah" operating instructions.

273 624X284X628

Max. dimensions
(mm)

Z

ERC 212z/214z/216z

Battery type Capacity (Ah) Min. weight

(kg)

24-volt battery 2 PzS 250 230 792X212X635

24-volt battery 3 PzV 300 - wf 280 792X212X635

24-volt battery 3 PzV 330 280 792X212X635

24-volt battery 3 PzS 375 280 792X212X635

24-volt battery 3 PzS 375 - trvg 280 792X212X635

24-volt battery 3 PzS 375 Lib.

Silver

24-volt battery 3 PzM 375 280 792X212X635

24-volt battery XFC 177 280 792X212X635

Optionally, the truck can be fitted with a lithium-ion battery, see "Li-Ion battery 24V ­240Ah / 360Ah" operating instructions.

The battery weights can be taken from the battery data plate. Batteries with non
insulated terminals must be covered with a non slip insulating mat.

280 792X212X635

Max. dimensions
(mm)

04.19 en-GB

45

3 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.

Park the truck on a level surface. In special cases the truck may need to be

u

secured with wedges.
Fully lower the load handler.

u

Select a place to park where no other people are at risk of injury from the lowered

u

load handler.
If the brakes are not working, place wedges underneath the wheels of the truck to

u

prevent it from moving.

CAUTION!

Trapping hazard

Make sure there is nothing between the battery cover and the truck when you fit

u

the battery cover.

46

04.19 en-GB

19

18

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

The battery panel is only properly opened at an angle greater than 90°. It is

u

then held by gravity.

The battery is exposed.

04.19 en-GB

47

4 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.

Switch the charging station and truck off first before connecting/disconnecting the

u

charging cable of the battery charging station to/from the battery connector.
The charger must match the battery in terms of voltage, charge capacity and

u

battery type.
Before charging, check all cables and plug connections for visible signs of

u

damage.
Ventilate the room in which the truck is being charged.

u

The battery cover must be open and the battery cell surfaces must be exposed

u

during charging to ensure adequate ventilation.
Do not smoke and avoid naked flames when handling batteries.

u

Wherever an industrial truck is parked for charging there must be no inflammable

u

material or consumables capable of creating sparks within a minimum distance of
2 m from the truck.

Fire-control equipment must be available.

u

Do not place any metallic objects on the battery.

u

Always follow the safety regulations of the battery and charger station

u

manufacturers.

NOTICE

Battery damage

The battery, charger (charge characteristics) and battery parameters must match
each other, otherwise damage may result.

48

04.19 en-GB

4.1 Charging the battery with a stationary charger

46

47

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.

• Start charging in accordance with the charger operating instructions.

The battery is charging.

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

• Complete charging in accordance with the charger operating instructions.

• Disconnect the battery connector (46) from the charging cable (47) of the
stationary charger.

• Attach the battery connector (46) to the industrial truck.

04.19 en-GB

The truck is now ready for operation.

49

4.2

Charging the battery with an on-board charger (o)

DANGER!

Risk of electric shock and fire

Damaged and unsuitable cables can cause electric shocks and can overheat,
resulting in fires.

Always use mains cables with a maximum length of 30 m.

u

Local regulations must be observed.
Unwind the cable reel fully when using it.

u

Always use original manufacturer’s mains cables.

u

Insulation safety, acid and caustic ratings must comply with the manufacturer's

u

mains lead.
The charging connector must be dry and clean when used.

u

WARNING!

Risk of damage to the on-board battery charger or live attachments

Damage to the on-board battery charger or live attachments (mains cable, plug) can
cause a short circuit or electric shock.

Do not trap the mains cable when closing the battery panel.

u

Report any defects immediately to your supervisor.

u

Notify the customer service department.

u

Mark the defective truck and take it out of service.

u

Do not return the industrial truck to service until you have identified and rectified

u

the fault.

NOTICE

Improper use of the on-board charger can cause material damage

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.

The charger must only be used for batteries supplied by Jungheinrich or other

u

approved batteries provided it has been adapted by the manufacturer's customer
service department.

Batteries must never be swapped from truck to truck.

u

Do not connect the battery to two chargers simultaneously.

u

50

04.19 en-GB

4.2.1 Setting the charging characteristics (ELG 2430)

48

49

Z

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!

Remove the mains connector before setting the respective charging curve.

u

Set the charging characteristic

Requirements

– Battery connected.

Procedure

• Turn the setting switch (48) on the charger right to adapt the charging curve to the
battery being used.

• The validity of the new setting is acknowledged by the flashing of the green LED
and the setting takes immediate effect.

The charging characteristic is now set.

04.19 en-GB

51

Flashing sequence / charging curve assignment (ELG 2430)

Flashing sequence Selected charging curves (characteristics)

0 Truck without battery

1

Wet cell battery: PzS with 100 - 300 Ah
Wet cell battery: PzM with 100 - 179 Ah

2 Maintenance-free: PzV with 100 - 149 Ah

3 Maintenance-free: PzV with 150 - 199 Ah

4 Maintenance-free: PzV with 200 - 330 Ah

Wet cell battery: PzS with pulse characteristic 200 ­400 Ah

5

Wet cell battery: PzM with pulse characteristic 180 ­400 Ah
Wet cell battery: PzS with pulse characteristic 200 ­414 Ah

6 Jungheinrich 100 - 300 Ah

NOTICE

All other switch positions (48) block the charger, and the battery is not charged.

u

For PzM batteries with a capacity of less than 180 Ah set characteristic 1, beyond

u

180 Ah set characteristic 5.
With PzS 200-300 Ah wet cell batteries both characteristic curves 1 and 5 can be

u

used. Characteristic 5 achieves a faster charge.
When the battery is connected this allows you to adjust via the charger: If the

u

switch position is valid the green LED flashes according to the position set; if the
switch position is invalid the red LED flashes.

52

04.19 en-GB

4.2.2 Charging the battery

17

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.

Charge the battery

Requirements

– Park the truck securely, see page 76.
– Expose the battery, see page 46.
– Correct charging program set on

charger.

Procedure

• Remove any insulating mats from the
battery.

• The battery connector must remain
plugged.

• Attach the mains connector (17) to a
mains socket.

• Pull the emergency disconnect switch
up.

Z

The flashing LED indicates the charge status or a fault (for flashing codes see
“LED Display” table).

The battery is now charged.

When the mains connector (44) is attached to the mains, all the truck’s electrical
functions are disconnected (electric immobilizer). The truck cannot be operated.

04.19 en-GB

53

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).

• If applicable, place the existing insulating mats back over the battery.

• Close the battery panel securely.

The truck is now ready for operation.

Charging times

The duration of charge depends on the battery capacity.

Z

Charging continues automatically after a mains failure. Charging can be interrupted
by removing the mains connector and continued as partial charging.

54

04.19 en-GB

LED display

50

(50)

Green LED (charge status)

Lit 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)

Lit Overtemperature. Charging is interrupted.

Flashes slowly Safety charging time exceeded. Charging is cancelled.

Mains must be disconnected for charging to restart.

Rapid flash Invalid characteristic curve setting.

Compensation charge

The compensation charge starts automatically when charging is complete.

04.19 en-GB

Partial charging

The charger is designed to automatically adapt to partially charged batteries. This
keeps battery wear to a minimum.

55

5 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.

Note the "Safety regulations for handling acid batteries" section in this chapter.

u

Wear safety shoes when removing and installing the battery.

u

Use only batteries with insulated cells and terminal connectors. If necessary cover

u

them with a rubber mat.
Park the truck on a level surface.

u

Make sure the crane lifting gear has sufficient capacity to replace the battery.

u

Use only approved battery replacement devices (battery roller stand, replacement

u

trolley etc.).
Make sure the battery is securely located in the truck's battery compartment.

u

CAUTION!

Trapping hazard

There is a risk of trapping when you close the battery cover.

Make sure there is nothing between the battery cover and the truck when you

u

close the battery cover.

56

04.19 en-GB

5.1 Changing the battery from the top

51

Z

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.

Z

Z

Place the battery cable on the tray so that it cannot be severed when the battery
is pulled out.

• Attach the crane lifting gear to the eyes (51).

The hooks must be fitted in such a way that when the crane lifting gear is
slackened, they do not fall onto the battery cells. The lifting gear must exert a
vertical pull so that the battery container is not compressed.

• Lift the battery slowly out of the battery compartment using crane lifting gear.

The battery has now been removed.

04.19 en-GB

57

Battery installation

Requirements

– Park the truck securely, see page 76.

Procedure

Z

Z

Z

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.

• Attach the battery connector to the truck connector.

CAUTION!

Trapping hazard

There is a risk of trapping when you close the battery cover.

Do not reach between the battery cover and chassis. Hold the battery cover only

u

by the designated recess.
Close the battery panel carefully and slowly.

u

Close the battery cover.

The battery is now installed.

After installing the battery again, check all cables and plug connections for visible
signs of damage.

58

04.19 en-GB

5.2 Lateral Battery Removal (ERC 212/214/216)

Z

Lateral battery removal is an option only.

CAUTION!

Trapping hazard

Trapping hazard when removing and installing the battery.

When removing and installing the battery do not put your hands between the

u

battery and the chassis.

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.

Z

Place the battery cable on the tray so that it cannot be severed when the battery
is pulled out.

• Turn the battery lock (53) up as far as the stop.

• Move the lever (52) to force the battery slightly beyond the perimeter of the truck.

• Position the battery trolley by the truck.

• Pull the battery (54) slightly towards you.

• Carefully pull the battery from off the truck onto the trolley.

The battery is now removed.

Battery installation

Requirements

– Park the truck securely, see page 76.

Procedure

Z

Z

Assembly is the reverse order. Note the correct assembly position and make sure
the battery is connected correctly.

Place the battery cable on the tray so that it cannot be severed when the battery
is inserted.

• Push the battery into its receptacle.

• Push the battery lock (53) towards the battery tray as far as the stop.

04.19 en-GB

59

• Attach the battery connector to the truck connector.

465354

52

CAUTION!

Trapping hazard

There is a risk of trapping when you close the battery cover.

Do not reach between the battery cover and chassis. Hold the battery cover only

u

by the designated recess.
Close the battery panel carefully and slowly.

u

Close the battery cover.

The battery is now installed.

Z

After installing the battery again, check all cables and plug connections for visible
signs of damage.

04.19 en-GB

60

5.3 Lateral Battery Removal (ERC 212z/214z/216z)

465354

52

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.

• Pull the lock (53) on the battery up.

• Flip the lock further over until the battery retainer (38) can move freely.

• Raise the battery retainer and flip back the lock to secure the retainer in the top
position.

Z

Place the battery cable on the tray so that it cannot be severed when the battery
is pulled out.

• Position the battery trolley next to the truck.

CAUTION!

Trapping hazard

Trapping hazard when removing and installing the battery.

When removing and installing the battery do not put your hands between the

u

battery and the chassis.

Push/pull the battery sideways off the truck.

• Carefully push the battery from off the truck onto the battery replacement station/
trolley.

The battery has now been removed.

04.19 en-GB

61

Battery installation

Requirements

– Park the truck securely, see page 76.

Procedure

Z

Z

Z

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.

• Attach the battery connector to the truck connector.

CAUTION!

Trapping hazard

There is a risk of trapping when you close the battery cover.

Do not reach between the battery cover and chassis. Hold the battery cover only

u

by the designated recess.
Close the battery panel carefully and slowly.

u

Close the battery cover.

The battery is now installed.

After installing the battery again, check all cables and plug connections for visible
signs of damage.

62

04.19 en-GB

E Operation

1 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.

Operator’s rights, responsibilities and rules of conduct

The driver must be informed of his duties and responsibilities and be instructed in
the operation of the truck and shall be familiar with the operating instructions. Safety
shoes must be worn on pedestrian-operated trucks.

Z

It is recommended that safety shoes be worn at all times when using the truck in
ride-on mode to avoid injuries.

Unauthorised use of truck

The operator is responsible for the truck during the time it is in use. The operator
must prevent unauthorised persons from driving or operating the truck. Do not carry
passengers or lift other people.

Damage and faults

The supervisor must be informed immediately of any damage or faults to the truck or
attachment. Trucks which are unsafe for operation (e.g. wheel or brake problems)
must not be used until they have been rectified.

Repairs

The operator must not carry out any repairs or alterations to the truck without
authorisation and the necessary training to do so. The operator must never disable
or adjust safety mechanisms or switches.

04.19 en-GB

63

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.

Instruct unauthorised persons to leave the hazardous area.

u

In case of danger to third parties, give a warning signal in good time.

u

If unauthorised persons are still within the hazardous area, stop the truck

u

immediately.

Safety devices, warning signs and warning instructions

Safety devices, warning signs (see page 29) and warning instructions in the present
operating instructions must be strictly observed.

WARNING!

Removing or disabling safety devices can cause accidents

Removing or disabling safety devices such as the Emergency Disconnect switch,
key switch, buttons, horn, strobe lights, mast protection pane, mast grille, sensors,
panels etc. can result in accidents and injury.

Report any defects immediately to your supervisor.

u

Mark defective truck and take out of service.

u

Do not return the industrial truck to service until you have identified and rectified

u

the fault.

64

04.19 en-GB

2 Displays and Controls

9

8

57

56

5

62

63

6489

8

8

62

57

57

56

56

10

585911

13

13

18616115181717

15

10

5

11,58,59,60

55

60

55

04.19 en-GB

65

ItemControl/display ERC

212/214/216

212z/214z/

216z

Function

55 Display unit

(2-inch display)

Soft keys under
the display unit

56 Fork lifting button

57 Fork lowering

button

10 Charge status

indicator

o

t

t

t

Display for:
– Battery charge status
– Battery capacity
– Service hours
– Travel program
– Warning indicators
– Event messages

Selection of:
– Travel program
– Options

Replaces the key switch
– Truck release by entering master and

access codes

– Raises the lift mechanism at an adjustable

speed.

– Lowers the lift mechanism at an

adjustable speed.

– Indicates the charge/discharge status of

the battery.

CanDis

11 Key switch and

key

58 CanCode

59 ISM access

module

o

t

o

o

Display instrument for:
– Battery charge status
– Battery discharge status
– Service hours
– Event messages
– Parameter settings

– Activates the industrial truck by switching

on the control voltage.

– Removing the key prevents the truck from

being switched on by unauthorised
personnel.

Replaces the key switch
– Activates the truck via a card/transponder
– Travel program selection
– Code setting
– Parameter setting

Replaces the key switch
– Activates the truck via a card/transponder
– Displays readiness for operation
– Operational data logging
– Data exchange with card/transponder

66

04.19 en-GB

ItemControl/display ERC

212/214/216

212z/214z/

216z

Function

60 Keypad

Transponder
reader

61 Terminal board

17 On-board battery

charger mains
connector

8 Travel switch

9 Collision safety

switch

o

o

t
o

t

t

Replaces the key switch
– Provided only as a supplement to the

display unit

– Truck release by entering set-up and

access codes

Replaces the key switch
– Provided only as a supplement to the

display unit

– Activates the truck via a card/transponder

– Paper storage.

Used to charge the battery with an on-board
battery charger (o), see page 50.

– Controls the travel direction and the

speed.

Pedestrian mode:
Safety function when travelling in drive
direction:
– When applied, the truck travels for

approx. 3 seconds in the load direction.
The parking brake then applies. The truck
remains switched off until the travel switch

is set to neutral.
Rider mode:
– No function.

18 Emergency

disconnect switch

62 Warning signal

(horn) button

5 Tiller

o

t

t

t

Pedestrian mode and rider mode:
Safety function when travelling in drive
direction:
– When applied, the truck travels for

approx. 3 seconds in the load direction.

The parking brake then applies. The truck

remains switched off until the travel switch

is set to neutral.

Disconnects the battery supply
– All electric functions are cut out and the

truck is braked.

– Warning signal button

– Set to brake zone (B) (see page 83):

The truck brakes regeneratively.
– Set to travel zone (F) (see page 83):

The mechanical brake is released when

the travel switch truck is moved, and the

truck is ready for operation.

04.19 en-GB

67

ItemControl/display ERC

212/214/216

212z/214z/

216z

Function

13 Folding side arms

15 Folding operator

platform

o

t

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 91.
When the side arms are folded out and the
operator platform folded down:
– Travel and lifting are disabled, see

page 91.
When the side arms are folded out and the
operator platform is laden and folded down:
– Without load backrest: Lifting is disabled

above 1800 mm.
–

With load backrest (o): Lifting is not

disabled above 1800 mm.

Pedestrian mode
– Operator platform up:

Pedestrian travel speed restricted to max.

4.2 km/h.
Rider mode only, standing platform acts as
deadman switch
– Operator platform down and vacated:

Travel inhibited.

– Operator platform down and laden by

operator (both side arms must be folded
fully out or in):
Travel enabled.

68

63 Support-arm lift

button

64 Support-arm

lowering button

t

t

– Lifts the support arms at a constant

speed.

– Lowers the support arms at a constant

speed.

t = Standard equipment o = Optional equipment

04.19 en-GB

04.19 en-GB

69

2.1 Battery discharge monitor

Z

Z

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. If this adjustment is not made, the battery may become
damaged due to deep discharge.

NOTICE

Full discharge can damage the battery

Self-discharge can cause the battery to fully discharge. Full discharge shortens the
useful life of the battery.

Charge the battery at least every 2 months.

u

Charge the battery see page 48.

If the residual capacity falls below the required level, lifting is inhibited. An alternating
display (65) appears. Lifting is only released when the battery connected is at least
70% charged.

70

04.19 en-GB

2.2 Battery discharge indicator

65

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%

Z

Green/orange

flashes at 1 Hz

Red 0–20%

If the LED is red, the load can no longer be lifted. Lifting is only enabled when the
battery connected is at least 70% charged.

If the LED flashes red and the truck is not ready for operation, inform the
manufacturer's service department. Red flashing is a truck controller code. The
flashing sequence indicates the type of fault.

20–30%

04.19 en-GB

71

3 Preparing the Truck for Operation

3.1 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.

Report any defects immediately to your supervisor.

u

Mark defective truck and take out of service.

u

Do not return the industrial truck to service until you have identified and rectified

u

the fault.

Inspection before daily operation

Procedure

• Check the whole of the outside of the truck for signs of damage and leaks.
Damaged hoses must be replaced immediately.

• Check the battery attachment and wire connections for damage and make sure
they are secure.

• Check the battery connectors are secure.

• Check the load handler for visible signs of damage such as cracks, bent or
severely worn forks.

• Check the drive wheel and load wheels for damage.

• Check that the markings and labels are present, clean and legible, see page 29.

• Check the protective screen/grille and check that it is securely attached.

• Make sure the drive panels and covers are secure and check for damage.

• With the load handler lowered, check the mast chains are tensioned and secured
correctly.

• Check tiller return function.

• Check the controls automatically return to the neutral position after use.

• Check lift height sensors on the mast (66) and their cable connection, and, on ZZ
masts, the presence of the magnets and their attachment.

72

04.19 en-GB

66

04.19 en-GB

73

3.2 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).

• Step onto the operator platform (15).

• Pull the emergency disconnect switch (18) to unlock it.

• To switch on the truck:

• Insert the key in the key switch (11) and turn it as far to the right as it will go.

•

Enter the code in CanCode (o) (58).

• Hold the card or transponder in front of the ISM access module and, depending

on the setting, press the green button on the ISM access module (o).

Z

For trucks with a folding platform, the tiller (5) must be in the upper brake zone
"B". If event message "E-0914" is displayed on the CanDis display instrument (o)
or on the display unit (2-inch display) (o), move the tiller to the upper brake zone

"B", see page 83.

The truck is ready for operation.

t The charge status indicator (67) shows the current battery charge status.

o The CanDis display instrument (10) or on the display unit (2-inch display) (o)

shows the current battery charge status and the service hours.

WARNING!

Accidental truck movement can cause injury

Do not press the travel switch when entering or leaving the operator platform.

74

04.19 en-GB

3.3 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.

Report any defects immediately to your supervisor.

u

Mark defective truck and take out of service.

u

Do not return the industrial truck to service until you have identified and rectified

u

the fault.

Procedure

• Test warning indicators and safety devices:

• Test the emergency disconnect function by pressing the emergency disconnect
switch. The main circuit is disconnected and no truck operations can be
performed. Now pull the emergency disconnect switch to unlock it.

• Test the horn by pressing the "warning signal" button.

• Check braking efficiency, see page 89.

• Test the steering, see page 89.

• Test the hydraulic system, see page 93.

• Test travel operations, see page 83.

• Test the safety collision switch by applying it while travelling in the drive
direction in pedestrian mode.

• Test the controls and displays and check for damage, see page 65.

04.19 en-GB

75

3.4 Parking the truck securely

WARNING!

An unsecured truck can cause accidents

Do not leave an unsecured truck.

Park the truck securely when leaving it.

u

Exception: If the operator intends to remain in the immediate vicinity and is leaving

u

the truck for only a short while, the applied parking brake is sufficient to hold the
truck, see page 90. Immediate vicinity is when the operator is able respond to
malfunctions or attempts to use the truck by unauthorised persons immediately.

WARNING!

An unsecured truck can cause accidents

Do not park the truck on an incline. Do not park the truck without the brakes
engaged. Do not park and leave the truck with the load handler raised.

Park the truck on a level surface. In special cases the truck may need to be

u

secured with wedges.
Fully lower the load handler when leaving the truck.

u

Select a place to park where no other people are at risk of injury from the lowered

u

load handler.
If the brakes are not working, place wedges underneath the wheels of the truck to

u

prevent it from moving.

76

04.19 en-GB

Parking the truck securely

1815131167

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:

• Turn the key in the key switch (11) anti-clockwise as far as it will go. Remove
the key from the key switch (11).

•

For CanCode (58), press the O key (o).

•

Press the red key on the ISM access module (o).

• Press the emergency disconnect switch (18).

• Fold in the side arms (13).

• Fold up the folding operator platform (15).

The truck is parked.

04.19 en-GB

77

4 Industrial Truck Operation

4.1 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. Additional equipment is necessary to operate the truck in
areas of insufficient lighting.

WARNING!

Do not exceed the permissible surface and spot load limits on the travel routes.
At blind spots get a second person to assist.

Travel conduct

The operator must adapt the travel speed to local conditions. The truck must be
driven at slow speed when negotiating bends or narrow passageways, when passing
through swing doors and at blind spots. The operator must always observe an
adequate braking distance between the forklift truck and the vehicle in front and
must be in control of the truck at all times. Abrupt stopping (except in emergencies),
rapid U turns and overtaking at dangerous or blind spots are not permitted. Do not
lean out or reach beyond the working and operating area.

Travel visibility

The operator must look in the direction of travel and must always have a clear view
of the route ahead. If the truck is carrying loads that affect visibility, the truck must
travel against the load direction. If this is not possible, a second person must walk
alongside the truck as a lookout to observe the travel route while maintaining eye
contact with the operator. Proceed only at walking pace and with particular care.
Stop the truck as soon as you lose eye contact.

78

04.19 en-GB

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. The industrial truck must
not be turned, operated at an angle or parked on inclines or slopes. Inclines must
only be negotiated at slow speed, with the driver ready to brake at any moment.

Negotiating lifts, loading ramps and docks

Lifts may only be negotiated if they have sufficient capacity, are suitable for driving
on and authorised for truck traffic by the owner. The driver must satisfy himself of the
above before entering these areas. The truck must enter lifts with the load in front
and must take up a position which does not allow it to come into contact with the
walls of the lift shaft. Persons riding in the lift with the forklift truck must only enter
the lift after the truck has come to a rest and must leave the lift before the truck. The
driver must ensure that the loading ramp / dock cannot move or come loose during
loading / unloading.

Type of loads to be carried

The operator must make sure that the load is in a satisfactory condition. Loads must
always be positioned safely and carefully. Use suitable precautions to prevent parts
of the load from tipping or falling down. Prevent liquid loads from sloshing out.

WARNING!

Electromagnetic influence can result in accidents

Strong magnets can cause electronic components such as Hall sensors to become
damaged, resulting in accidents.

Do not use magnets in the operating area of the truck. Exceptions to this rule are

u

commercial, weak clamping magnets for attaching notices.

04.19 en-GB

79

4.2 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:

Abandon the truck.

u

Z

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.

4.3 Emergency Disconnect

CAUTION!

Applying maximum braking can result in accidents

Applying the Emergency Disconnect switch during travel will cause the truck to
decelerate to a halt at maximum force. This may cause the load to slide off the load
handler. There is a higher risk of accidents and injury.

Do not use the Emergency Disconnect switch as a service brake.

u

Use the Emergency Disconnect switch during travel only in emergencies.

u

CAUTION!

Faulty or non-accessible Emergency Disconnect switches can cause
accidents

A faulty or non-accessible Emergency Disconnect switch can cause accidents. In
dangerous situations the operator cannot bring the truck to a halt in time by applying
the Emergency Disconnect switch.

The operation of the Emergency Disconnect switch must not be affected by any

u

objects placed in its way.
Report any defects on the Emergency Disconnect switch immediately to your

u

supervisor.
Mark defective truck and take out of service.

u

Do not return the industrial truck to service until you have identified and rectified

u

the fault.

80

04.19 en-GB

Press the Emergency Disconnect switch

5

18

Procedure

• Press the Emergency Disconnect (18).

All electrical functions are deactivated. The truck brakes to a halt.

Z

Z

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).

Trucks with CanCode and ISM access module remain switched off.

04.19 en-GB

81

4.4 Automatic braking

B

B

Z

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.

If the tiller returns to the brake position slowly or not at all, the truck must be taken

u

out of service until the cause of this fault is be rectified.
Contact the manufacturer's customer service department.

u

82

04.19 en-GB

4.5 Travel

WARNING!

Collision hazard when operating the truck

Collisions with personnel and equipment can result if the truck is operated with open
panels.

Do not operate the truck unless the panels and covers are closed and properly

u

locked.
When travelling through swing doors etc. make sure that the doors do not activate

u

the collision safety button.

WARNING!

Trapping hazard

Be extremely careful when driving and steering, especially if parts of your
body extend outside the perimeter of the truck.

Do not reach between the standing platform and the truck frame when you fold up

u

the platform.
In pedestrian mode make sure that you are a sufficient distance from the truck.

u

Z

CAUTION!

Trapping hazard from the truck during pedestrian mode

In pedestrian mode the truck can pose a trapping hazard for the operator and other
people.

Wear personal protective equipment (e.g. safety shoes, ...).

u

The truck must be operated with particular care and attention in pedestrian mode.

u

Ensure there are no other people standing between the truck and obstacles when

u

operating in pedestrian mode.

It is recommended that safety shoes be worn at all times when using the truck in
rider mode to avoid injuries.

04.19 en-GB

83

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.

oReduced speed when the load handler is fully loweredI

When the load handler is fully lowered the truck can only travel at reduced speed.
The load handler must be raised in order to use the maximum available speed.

Industrial trucks with a folding standing platform and moving tiller

We distinguish between two travel modes:

– Travel in pedestrian mode
– Travel in rider mode

84

04.19 en-GB

Travelling in pedestrian mode

15

8

5

13

Requirements

– Start up the truck, see page 72

Procedure

• Swing both folding side arms (13) in.

Z

Z

Z

Z

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.

• Fold up the operator platform (15).

• Swing the tiller (5)in to the travel zone (F).

• Push the travel switch (8) to the desired travel direction: forward (V) or reverse
(R).

When the travel switch is released, it automatically returns to the neutral position.

• Control the travel speed with the travel switch (8).

The brakes are released and the truck moves in the selected direction.

In pedestrian mode the truck can only operate at reduced speed.

04.19 en-GB

85

Travelling in rider mode

Requirements

– Start up the truck, see page 72

Procedure

•

Leave both folding side arms (13) (o) folded in.

Z

Z

Both side arms must be folded in or folded out at all times otherwise all functions
will be deactivated (E-1926).

• Fold down and step on the operator platform (15).

• Swing the tiller (5)in to the travel zone (F).

• Push the travel switch (8) to the desired travel direction: forward (V) or reverse
(R).

When the travel switch is released, it automatically returns to the neutral position.

• Control the travel speed with the travel switch (8).

The brakes are released and the truck moves in the selected direction.

NOTICE

Travelling is inhibited when the operator platform is vacated and the side arms are

u

not folded out.
If the operator platform is occupied and the gates are not folded out, the truck

u

cannot be operated at high speed.
If the operator platform is occupied and only one side arm is folded out, travel is

u

inhibited (E-1926).
If the travel switch is applied before the platform is loaded, travel is inhibited

u

(E-1908).

86

04.19 en-GB

Travelling in rider mode at a higher speed (o)

Requirements

– Start up the truck, see page 72

Procedure

• Swing both folding side arms (13) out.

Z

Z

Both side arms must be folded in or folded out at all times otherwise all functions
will be deactivated (E-1926).

• Fold down and step on the operator platform (15).

• Swing the tiller (5)in to the travel zone (F).

• Push the travel switch (8) to the desired travel direction: forward (V) or reverse
(R).

When the travel switch is released, it automatically returns to the neutral position.

• Control the travel speed with the travel switch (8).

The brakes are released and the truck moves in the selected direction.

NOTICE

Travelling is inhibited when the operator platform is vacated and the side arms are

u

not folded out.
If the operator platform is occupied and the gates are not folded out, the truck

u

cannot be operated at high speed.
If the operator platform is occupied and only one side arm is folded out, travel is

u

inhibited (E-1926).
If the travel switch is applied before the platform is loaded, travel is inhibited

u

(E-1908).

04.19 en-GB

87

4.5.1 Changing direction during travel

8

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.

After setting off in the opposite direction, apply the travel switch gently or not at all.

u

Do not perform any sudden steering operations.

u

Always face in the direction of travel.

u

Maintain an adequate overview of the route you are travelling.

u

Changing direction during travel

Procedure

• Set the travel switch (8) to the opposite direction while travelling.

The truck decelerates until it starts to travel in the opposite direction.

04.19 en-GB

88

4.6 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.

4.7 Brakes

WARNING!

Accident risk

The brake pattern of the truck depends largely on the ground conditions.

The operator must take into account the travel route conditions when braking.

u

Brake with care to prevent the load from slipping.

u

During normal operation the truck is to be braked only with the service brake.

u

CAUTION!

In hazardous situations swing the tiller to the brake position or press the

u

emergency disconnect switch.

The truck can brake in three different ways:

– By using the service brake (brake zone B).
– With the coasting brake.
– By inversion braking (braking and changing direction).

4.7.1 Braking with the service brake

Procedure

• Move the tiller (5) up or down to one of the brake zones (B).

The truck brakes to a halt regeneratively via the service brake.

Z

When braking regeneratively, energy is returned to the battery, ensuring a longer
service time.

04.19 en-GB

89

8

5

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.

Z

4.7.3 Inversion braking

4.7.4 Parking brake

Z

When braking regeneratively, energy is returned to the battery, ensuring a longer
service time.

Procedure

• Set the travel switch (8) to the opposite direction while travelling, see page 88.

The truck brakes regeneratively until it starts to move in the opposite direction.

The mechanical brake applies automatically when the truck comes to rest.

04.19 en-GB

90

4.8 Switch Matrix / Safety Switch Height

ERC without side restraint mechanism

Operator

platform

Folded up

Folded up

Folded out

Folded out

Lift height Speed km/h

with load

<Sh*

>Sh*

<Sh*

>Sh*

)

)

)

)

4,2 Yes Yes

2,5 Yes Yes

6,0

2,5

Collision safety

switch active

)

No***

)

No***

ERC with side restraint system

Operator

platform

Side arm Lift

height

Speed km/h

with load

Collision

safety switch

Lifting active

active

Folded up Folded in

Folded up Folded in

<Sh*

>Sh*

)

)

4.2 yes yes

2.5 yes yes

Folded up Folded out Any 0 No No

Folded out Folded in

Folded out Folded in

Folded out Folded out

<Sh*

>Sh*

<Sh*

)

)

)

6.0

2.5

See options table below

No***

No***

)

)

Lifting
Active

Yes

Yes

yes

yes

w.o. load backrest

Folded out Folded out

>Sh*

)

0 (0) No No

with load backrest

Folded out Folded out

>Sh*

)

1.6 (2.5)

No***

)

yes

*) Sh = safety switch height approx. 1800 mm (depending on the mast version)

**) TSh = Transport safety height approx. 400 mm (depending on mast version)

***) The collision safety function can be activated optionally for rider mode.

04.19 en-GB

91

Options for ERC with side restraint mechanism

Operator

platform

Side arm Lift

height

Speed km/h

with load

Fixed castor wheel, height-adjustable

Folded out Folded out

Folded out Folded out

<TSh**

>TSh**

<Sh*

)

)

)

7,0

6,0

Sprung castor wheel, hydraulic

Folded out Folded out

Folded out Folded out

<TSh**

>TSh**

<Sh*

)

)

)

9,0

7,0

Load backrest

Folded out Folded out

>Sh*

)

2,5

Options for ERC-Z with side restraint mechanism

Operator

platform

Side

restraint

Lift

height

Speed km/h

with load

Collision

safety switch

active

)

No***

)

No***

)

No***

)

No***

)

No***

Collision

safety switch

active

Lifting active

Yes

Yes

Yes

Yes

Yes

Lifting active

Fixed castor wheel

Folded out Folded out

Folded out Folded out

<TSh**

>TSh**

<Sh*

)

)

)

9,0

7,0

No***

No***

)

)

Yes

Yes

Load backrest

Folded out Folded out

>Sh*

)

2.5

No***

)

Yes

*) Sh = safety switch height approx. 1800 mm (depending on the mast version)

**) TSh = Transport safety height approx. 400 mm (depending on mast version)

***) The collision safety function can be activated optionally for rider mode.

92

04.19 en-GB

4.9 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.
Apart from the driver (in the normal operating position) there should be no other
people in the truck's hazardous area.

Instruct other people to move out of the hazardous area of the truck. Stop working

u

with the truck if people do not leave the hazardous area.
If people do not leave the hazardous area despite the warning, prevent the truck

u

from being used by unauthorised people.
Only carry loads that have been secured and positioned in accordance with

u

regulations. Use suitable precautions to prevent parts of the load from tipping or
falling down.

Never exceed the maximum loads specified on the capacity plate.

u

Never stand underneath a raised load handler.

u

Do not stand on the load handler.

u

Do not lift other people on the load handler.

u

Never reach or climb into moving truck parts.

u

Do not climb onto parts of the building or other trucks.

u

Z

NOTICE

Adapt a slower speed when stacking and retrieving.

NOTICE

Lift heights > 1800 mm are only enabled when the support arms have been lowered
manually. This ensures the truck remains stable. Above a lift height of 1800 mm, the
support arms can no longer be raised (ERC 212z-216z only).

Hydraulic function lock: The default setting is lifting in pedestrian mode only when
the tiller is in the travel zone (F); in rider mode the operator platform must also be
occupied. This does not affect lowering.
The default setting can be changed via a parameter, .

04.19 en-GB

93

4.9.1 Raising the load handler

57566364646356

57

Requirements

– Prepare the truck for operation, see page 74.

Procedure

Press the “Raise load handler”
button (56) until you reach the desired
lift height.

NOTICE

Risk of material damage to the
hydraulic unit

When you have reached the mechanical
stops of the load handler, do not press the
"Raise load handler" button any more.
Otherwise the hydraulic unit could suffer
material damage.

Z

The lift/lower speed can be infinitely
controlled via the movement of the
button (approx. 8 mm).

Short stroke = slow lift / lower
Long stroke = fast lift / lower

The load handler is raised.

Use as an elevated work table

The raised load handler can be used as an elevated work table when the truck is
switched off, see page 105.

04.19 en-GB

94

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.

Z

4.9.3 Raising the wheel arms

Z

The lowering speed can be infinitely adjusted via the travel of the button (approx.
8 mm).

Short switch stroke = slow lower
Long switch stroke = fast lower

The load handler is lowered.

ERC 212z-216z only

Requirements

– Prepare the truck for operation, see page 74.

Procedure

• Press the “support arm raise” button (63) until you reach the desired support arm
lift.

The support arms are raised.

4.9.4 Lowering the wheel arms

Z

ERC 212z-216z only

Requirements

– Prepare the truck for operation, see page 74.

Procedure

• Press the “support arm lower” button (64) until you reach the desired support arm
lift.

The support arms are lowered.

04.19 en-GB

95

4.10 Lifting, transporting and depositing loads

G

D

D

D

G

DD

DD

d

2

d

2

d

1

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.

Observe load centre distances and capacities of the load handler, see page 31.

u

Pick up the load so that its centre of gravity lies between the load arms of the load

u

handler.
Preferably, the load should be configured and picked up so that its centre distance

u

lies within the load centre distance of the load handler (d1 ≤ D and d2 ≤ D, see area
DD in the illustration).
A load with a centre of gravity outside of the load centre distance of the load

u

handler (d1 > D and/or d2 > D) should only be moved very carefully, as this load
case has not been checked on a truck tested according to the test guideline.

Z

Z

96

For loads with an even weight distribution, the load centre distance lies in the
geometrical centre of the volume.

For rectangular loads with an even weight distribution over the entire volume the
load centre distance is in the middle, i.e. half the length, half the height and half the
width of the load.

04.19 en-GB

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.

Instruct other people to move out of the hazardous area of the truck. Stop working

u

with the truck if people do not leave the hazardous area.
Only carry loads that have been correctly secured and positioned. Use suitable

u

precautions to prevent parts of the load from tipping over or falling off the truck.
Damaged loads must not be transported.

u

Never exceed the maximum loads specified on the load diagram.

u

Never stand underneath a raised load handler.

u

Do not stand on the load handler.

u

Do not lift other people on the load handler.

u

Insert the load handler as far as possible underneath the load.

u

CAUTION!

Do not lift long loads at an angle.

u

NOTICE

With the two-stage Duplex mast (ZZ) and the three-stage Triplex mast (DZ) a short,
centre-mounted free lift cylinder initially lifts the load carriage (free lift) without
changing the overall height of the truck.From a truck-specific lift height, travel is
automatically reduced. It increases again when the load is lowered.

NOTICE

Above a lift height of > 1800 mm the truck's travel speed is reduced to 2,5 km/h. The
truck's acceleration is reduced above a lift height of 1800 mm.

04.19 en-GB

97

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).

Z

Z

The load must not extend by more than
50 mm beyond the load handler tips.

• Raise the load handler until the desired height
is reached, (see page 94).

The load is being raised.

NOTICE

Risk of material damage to the hydraulic unit

When the mechanical stops of the load handler have been reached, release the
"raise load handler" button. Otherwise the hydraulic unit may suffer material damage.

The lifting/lowering speed can be infinitely controlled via the movement of the button
(approx. 8 mm).

Short stroke = slow lift / lower
Long stroke = fast lift / lower

ERC 212z-216z only

With the low-level lift (support arm lift) raised, loads can be stored and retrieved up
to a lift height of 1800 mm. For lift heights above 1800 mm the low-level lift (support
arm lift) must be lowered.

98

Two palletised loads can only be lifted on top of each other if the corresponding
optional equipment is available, see page 101.

04.19 en-GB