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
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04.19 en-GB
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Foreword
Notes on the operating instructions
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide
sufficient instruction for the safe operation of the industrial truck. The information is
provided clearly and concisely. The chapters are arranged by letter and the pages
are numbered continuously.
The operator manual details different industrial truck models. When operating and
servicing the industrial truck, make sure that the particular section applies to your
truck model.
Our trucks are subject to ongoing development. We reserve the right to alter the
design, equipment and technical features of the system. No guarantee of particular
features of the truck should therefore be assumed from the present operating
instructions.
Safety notices and text mark-ups
Safety instructions and important explanations are indicated by the following
graphics:
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
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5
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
8.8General Information about the Use of Keyless Access Systems150
8.9Commissioning the Keypad and the Transponder Reader150
8.10Using the Display: 153
8.11Using the Keypad158
8.12Operating the transponder reader163
8.13
.
CanCode Keypad (o)113
CanDis Display Instrument (o)142
ISM access module (o)167
FIndustrial Truck Maintenance169
.
1Operational Safety and Environmental Protection169
2Maintenance Safety Regulations170
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8
2.1Working on the electrical system171
2.2Consumables and used parts171
2.3Wheels171
2.4Hydraulic system172
2.5Lift Chains173
3Lubricants and Lubrication Schedule174
3.1Handling consumables safely174
3.2Lubrication Schedule176
3.3Consumables178
4Maintenance and repairs179
4.1Preparing the truck for maintenance and repairs179
4.2Front cover disassembly180
4.3Lifting and jacking up the truck safely181
4.4Cleaning182
4.5Checking the hydraulic oil level185
4.6Check wheel attachment and wear187
4.7Checking electrical fuses189
4.8Restoring the truck to service after maintenance and repairs190
5Decommissioning the Industrial Truck191
5.1Prior to decommissioning191
5.2Action to be taken during decommissioning191
5.3Restoring the truck to service after decommissioning192
6Safety tests to be performed at intervals and after unusual incidents193
7Final de-commissioning, disposal193
8Human vibration measurement193
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 usinganother brand, refer to the manufacturer's operating instructions.
0506.GB 20506.GB
2
ACorrect Use and Application
1General
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.
2Correct 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.
2.1Lifting 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
3Approved 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.
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04.19 en-GB
3.1Internal 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
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4Proprietor 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.
5Adding 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
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BTruck Description
1Application
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.
1.1Truck models and rated capacity
The rated capacity depends on the model. The rated capacity can be derived from
the model name.
ERCModel name
2Series
14Rated capacity x 100 kg
zInitial lift
The rated capacity is not generally the same as the permissible capacity. The
permissible capacity can be found on the capacity plate attached to the truck.
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2Travel direction definition
1
2
4
3
The following determinations have been made for travel direction specification:
ItemTravel direction
1Left
2Drive direction
3Load direction
4Right
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3Assemblies and Functional Description
5
8981011131417182012761915
16
3.1Assembly Overview
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ItemModelItemModel
5
6
7
8
9
10
11
Tiller12
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)
Mast14
t
Travel switch15
t
Collision safety switch16
t
Charge status indicator17
t
CanDis18
o
Display unit (2-inch display)
o
Key switch19
t
CanCode20
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 versiono = Optional equipment
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3.2Functional 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).
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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
3.2.1Hourmeter
Z
3.2.2Hourmeter 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
4Technical Specifications
Z
The technical specifications comply with the German "Industrial Truck Data Sheet"
Guidelines.
Technical modifications and additions reserved.
4.1Performance data
ERC 212 /
QRated capacity120014001600kg
Capacity for mast lift
Capacity for support arm lift
DLoad 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)
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.
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
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4.6Conditions 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.
4.7Electrical 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.
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04.19 en-GB
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