Jungheinrich ERC 212 Operating Instructions Manual Download

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Summary of Contents for ERC 212

Page 1: ...4880 ERC 212 214 216 Z12 Z14 Z16 ERC 212 214 216 Z12 Z14 Z16 Operating instructions Operating instructions G G ERC 214 ERC 214 ERC 216 ERC 216 ERC Z12 ERC Z12 ERC 212 ERC 212 ERC Z14 ERC Z14 ERC Z16 E...

Page 2: ...ruck conforms to the EU Directive 2006 42 EC Machine Directive and 2004 108 EEC Electro the EU Directive 2006 42 EC Machine Directive and 2004 108 EEC Electro Magnetic Compatibility EMC including thei...

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Page 4: ...tructions operating instructions Safety notices and text mark ups Safety notices and text mark ups Safety instructions and important explanations are indicated by the following Safety instructions and...

Page 5: ...h Aktiengesellschaft Jungheinrich Aktiengesellschaft Am Stadtrand 35 Am Stadtrand 35 22047 Hamburg Germany 22047 Hamburg Germany Tel 49 0 40 6948 0 Tel 49 0 40 6948 0 www jungheinrich com www junghein...

Page 6: ...0 20 3 4 3 4 Tyr Tyre e typ type e 20 20 3 5 3 5 EN EN nor norms ms 21 21 3 3 6 6 Co Cond ndit itio ions ns of of us use e 22 22 3 3 7 7 El Elec ectr tric ical al re requ quir irem ement ents s 22 22...

Page 7: ...t t st star art t 68 68 5 5 2 2 Lo Load can ad cannot be lift not be lifted ed 68 68 6 6 Op Oper erat atin ing g th the e tr truc uck k wi with thou out t it its s ow own n dr driv ive e sy syst stem...

Page 8: ...mis issi sion onin ing g 10 104 4 8 8 3 3 Re Rest stor orin ing th g the tr e truc uck to se k to serv rvic ice af e afte ter de r deco comm mmis issi sion onin ing g 10 105 5 9 9 Fi Fina nal l de de...

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Page 10: ...ons Z Z These operating instructions apply only to Jungheinrich battery models If using These operating instructions apply only to Jungheinrich battery models If using another brand refer to the manuf...

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Page 12: ...and centrally between the forks Lifting and lowering of loads Lifting and lowering of loads Transporting lowered loads Transporting lowered loads Do not travel with a raised load 500 mm Do not travel...

Page 13: ...revention regulations safety regulations and operating servicing and repair guidelines must be followed The proprietor must operating servicing and repair guidelines must be followed The proprietor mu...

Page 14: ...truck is shown on the data plate or the data capacity plate Qmax plate or the data capacity plate Qmax Due to its high travel speed the ERC 214 216 has side restraints Due to its high travel speed th...

Page 15: ...ll le er r 1 11 1 t t Drive wheel Drive wheel 5 5 t t K Ke ey y s sw wi it tc ch h 1 12 2 o o Lift linkage wheel arm lift only Lift linkage wheel arm lift only 6 6 o o C Ca an nD Di is s 1 13 3 o o Ch...

Page 16: ...Tiller for reliable control of the industrial truck Tiller for reliable control of the industrial truck The The industrial industrial truck truck has has a a folding folding standing standing platfor...

Page 17: ...is displays show The optional CanDis displays show the key driver information and the key driver information and travel program travel program service hours battery capacity and error messages service...

Page 18: ...e d e dis ist tan ance ce wi with th standard fork length standard fork length 6 60 00 0 6 60 00 0 6 60 00 0 mm mm Travel speed with restraint Travel speed with restraint system system w w o rated loa...

Page 19: ...88 8 4 42 28 8 9 9 8 8 3 3 h h 1 1 4 4 m m i i n n b b 1 1 h h 1 1 4 4 m m a a x x h h 1 1 h h 2 2 h h 3 3 h h 5 5 h h 1 1 3 3 s s b b 5 5 5 5 0 0 0 0 b b 1 1 1 1 a a 2 2 R R e e h h 4 4 l l x x c c...

Page 20: ...36 6 1 13 35 57 7 1 13 35 57 7 m mm m x x L Lo oa ad d d di is st ta an nc ce e 6 68 88 8 6 68 88 8 6 68 88 8 m mm m b b1 1 O Ov ve er ra al ll l w wi id dt th h 8 80 00 0 8 80 00 0 8 80 00 0 m mm m...

Page 21: ...1 16 65 50 0 9 99 90 0 1 18 84 40 0 kg kg Axle load w o load Axle load w o load front rear front rear 8 84 40 0 3 32 20 0 8 88 80 0 3 34 40 0 8 88 80 0 3 35 50 0 kg kg N Na am me e E ER RC C 2 21 12 2...

Page 22: ...d when travelling over thresholds travelling over thresholds at constant speed These recordings were taken on a single occasion and must not at constant speed These recordings were taken on a single o...

Page 23: ...ns of extreme temperature or air humidity fluctuations 3 3 7 7 E Ele lec ct tr ri ica cal re l req qu ui ir re em me en nt ts s The manufacturer certifies compliance with the requirements for the desi...

Page 24: ...ri ia al n l nu um mb be er r 2 24 4 B Ba at tt te er ry y d da at ta a p pl la at te e kg kg k kg g m mm m k kg g Xxx Xxx Xxxx Xxxx Xxxxxxx Xxxxxxx Xxxxxxxxx Xxxxxxxxx Xxxxxxxxx Xxxxxxxxx Xxxxxxxxxx...

Page 25: ...io on n 2 25 5 T Ty yp pe e 3 31 1 Y Ye ea ar r o of f m ma an nu uf fa ac ct tu ur re e 2 26 6 S Se er ri ia al l n nu um mb be er r 3 32 2 L Lo oa ad d c ce en nt tr re e m mm m 2 27 7 R Ra at te ed...

Page 26: ...ity With a load centre of gravity distance C of 600 mm and a maximum lift height H of With a load centre of gravity distance C of 600 mm and a maximum lift height H of 3600 mm the max capacity Q is 11...

Page 27: ...ift and Main Lift 4 4 4 4 Pl Plat ate o e ord rder er in inve vent ntor ory an y and se d serv rvic ice n e nos os Z Z The capacity plate with the full service number is only issued when a service The...

Page 28: ...tand in a hazardous area Always Always use use lifting lifting gear gear with with sufficient sufficient capacity capacity for for truck truck weight weight see see truck truck data data plate plate A...

Page 29: ...st be securely fastened when transported on a lorry or a trailer The lorry trailer must have fastening rings The lorry trailer must have fastening rings Use wedges to prevent the truck from moving Use...

Page 30: ...i ent is com s comple plete te If nece If necessary i ssary install nstall the bat the battery tery see B see Battery attery remova removal and in l and installa stallation o tion on page n page 42 42...

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Page 32: ...s capable of creating sparks within 2 m around the truck The room must be lubricants capable of creating sparks within 2 m around the truck The room must be ventilated Fire protection equipment must b...

Page 33: ...y and capacity of the industrial truck Changing the battery features operational safety and capacity of the industrial truck Changing the battery features requires the manufacturer s approval as compe...

Page 34: ...h a raised load handler is dangerous and is Parking the truck on an incline or with a raised load handler is dangerous and is strictly prohibited strictly prohibited Always park the Always park the tr...

Page 35: ...ocedure Dep Depres ress the Eme s the Emerge rgency Di ncy Disco sconne nnect 8 ct 8 Ope Open th n the ba e batte ttery p ry pane anel 4 l 41 1 CAUTION CAUTION A closing battery panel can pose a trapp...

Page 36: ...nsure adequate ventilation Do not smoke and avoid naked flames when handling batteries Do not smoke and avoid naked flames when handling batteries Wherever an industrial truck is parked for charging t...

Page 37: ...available Requirements Requirements Battery charging is complete Battery charging is complete Procedure Procedure Sw Swit itch o ch off t ff the c he cha harg rger er Dis Discon connec nect the bat t...

Page 38: ...of a battery charger and battery controller must not be opened For faults contact the manufacturer s service department be opened For faults contact the manufacturer s service department The charger m...

Page 39: ...ster charge When the battery is connected this allows you to adjust via When the battery is connected this allows you to adjust via the charger If the switch the charger If the switch position is vali...

Page 40: ...arging program set on charger Procedure Procedure Remove Remove any i any insulat nsulating m ing mats f ats from t rom the ba he battery ttery The The batter battery co y connecto nnector mu r must r...

Page 41: ...he cable compartment with the cable If appli If applicable p cable place the e lace the existin xisting insul g insulating ma ating mats back ov ts back over the bat er the battery tery Clo Close th s...

Page 42: ...ation charge Fl Flas ashe hes sl s slow owly ly Ch Char argi ging ng Ra Rapi pid fl d flas ash h Di Disp spla lay a y at b t beg egin inni ning ng of of ch char arge ge or or after setting a new chara...

Page 43: ...nsulated cells and terminal connectors If necessary cover them with a rubber mat them with a rubber mat Park the truck on a level surface Park the truck on a level surface Make sure the crane lifting...

Page 44: ...ear to t to the e he eyes yes 48 48 Z Z The crane lifting gear must exert a vertical pull The hooks of the lifting gear must The crane lifting gear must exert a vertical pull The hooks of the lifting...

Page 45: ...ar to t to the e he eyes yes 48 48 Z Z The crane lifting gear must exert a vertical pull The hooks of the lifting gear must The crane lifting gear must exert a vertical pull The hooks of the lifting g...

Page 46: ...truck Pos Positi ition th on the bat e batter tery tro y trolle lley by th y by the e truck truck Pul Pull the ba l the batte ttery 50 ry 50 sli slight ghtly tow ly toward ards s you you Carefu Caref...

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Page 48: ...achment Trucks which are unsafe for operation e g wheel or brake problems attachment Trucks which are unsafe for operation e g wheel or brake problems must not be used until they have been rectified m...

Page 49: ...3 1 1 1 1 E E N N 48 48 2 2 D Di is sp pl la ay ys s a an nd d C Co on nt tr ro ol ls s 53 53 54 54 5 5 2 2 58 58 57 57 14 14 9 9 7 7 6 6 4 4 59 59 8 8 60 60 56 56 55 55 53 53 https www besttruckmanua...

Page 50: ...mechanism 5 58 8 Lo Low we er r b bu ut tt to on n t t t t t t Lowers the lift mechanism Lowers the lift mechanism 2 2 T Tr ra av ve el l s sw wi it tc ch h t t t t t t Controls the Controls the direc...

Page 51: ...operator platform acts as a Rider mode operator platform acts as a deadman deadman Operator platform down and vacated Operator platform down and vacated travel inhibited travel inhibited Operator pla...

Page 52: ...ly enabled again when the battery connected is at least 70 charged when the battery connected is at least 70 charged If the LED flashes red and the truck is not ready for operation inform the If the L...

Page 53: ...replaced immediately Check the ba Check the battery at ttery attachme tachment and wire con nt and wire connecti nections for dama ons for damage and make su ge and make sure re they are secure they...

Page 54: ...y in he key in the key s the key switch witch 5 and tu 5 and turn it to rn it to the righ the right as far t as far as it wil as it will go l go posit position I ion I or for CAN or for CANCODE CODE 7...

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Page 56: ...ing forks forks Parking the truck securely Parking the truck securely Procedure Procedure Ful Fully l ly lowe ower th r the lo e load h ad hand andler ler Set th Set the driv e drive whee e wheel to S...

Page 57: ...ot made the battery may become damaged through excessive depletion become damaged through excessive depletion If the residual capacity falls below the required level lifting is If the residual capacit...

Page 58: ...be in control of the truck at all times Abrupt control of the truck at all times Abrupt stopping except in emergencies rapid U turns stopping except in emergencies rapid U turns and overtaking at dang...

Page 59: ...n the lift with the forklift truck must only enter the lift the lift shaft People travelling in the lift with the forklift truck must only enter the lift after the truck has come to a halt and must ex...

Page 60: ...brake Pre Press ss the the Eme Emerge rgency ncy Dis Discon connec nect t 8 8 All electrical functions are deactivated The truck brakes to a halt All electrical functions are deactivated The truck br...

Page 61: ...up the truck on page Start up the truck see Starting up the truck on page 52 52 Procedure Procedure Mov Move bot e both fol h foldin ding sid g side arm e arms 9 s 9 in in Z Z Both side arms must alwa...

Page 62: ...the trav Set the travel switch 2 el switch 2 to the desire to the desired travel dire d travel direction ction forward V forward V or reverse R or reverse R Z Z When the travel switch is released it...

Page 63: ...travel route conditions The driver must take this into account when travelling driver must take this into account when travelling The truck can brake in different ways The truck can brake in different...

Page 64: ...ive braking Procedure Procedure If the trave If the travel switch is set to 0 th l switch is set to 0 the truck auto e truck automatica matically uses reg lly uses regenerat enerative brake ive brakes...

Page 65: ...er people on the load handler Insert the forks as far as possible underneath the load Insert the forks as far as possible underneath the load NOTE NOTE The operator platform 14 must be occupied by the...

Page 66: ...the Lower load ha ower load handler bu ndler button 58 un tton 58 until the for til the forks are clear of th ks are clear of the load e load Z Z Avoid depositing the load to prevent damage to the lo...

Page 67: ...te gradua dually lly Adapt yo Adapt your trave ur travel speed to th l speed to the condit e conditions of the r ions of the route and th oute and the load you a e load you are re transporting transpo...

Page 68: ...h h 4 4 2 2 Y Ye es s Y Ye es s F Fo ol ld de ed d u up p S Sh h 2 2 5 5 Y Ye es s Y Ye es s F Fo ol ld de ed d o ou ut t S Sh h 6 6 0 0 N No o Y Ye es s F Fo ol ld de ed d o ou ut t S Sh h 2 2 5 5 N...

Page 69: ...t if applicable Error description Error description Current location of truck Current location of truck 5 5 1 1 T Tr ru uc ck k d do oe es s n no ot t s st ta ar rt t 5 5 2 2 L Lo oa ad c d ca an nn n...

Page 70: ...Requ quir ired ed Two M5x45 screws Two M5x45 screws Spanner wrench Spanner wrench Procedure Procedure Tur Turn of t n of the ke he key swi y switch tch Can CanCod Code e o o Switch Switch off off the...

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Page 72: ...key sw y swit itch ch 5 t 5 to 0 o 0 Dep Depres ress the Eme s the Emerge rgency Di ncy Disco sconne nnect 8 ct 8 see Emer see Emergency Disc gency Disconnect onnect on page on page 59 59 Lift o Lift...

Page 73: ...the first time operator codes when you use the truck for the first time Z Z Set different codes for rider and pedestrian trucks Set different codes for rider and pedestrian trucks Starting the Truck...

Page 74: ...different codes for rider and pedestrian trucks Changing the truck settings Changing the truck settings Procedure Procedure Pr Pres ess t s the he O k O key ey 6 68 8 En Ente ter th r the ma e mast st...

Page 75: ...LED 67 flashes LED 67 flashes Repeat new code Repeat new code Confirm Confirm Set 69 Set 69 0 00 01 1 A Ad dd d c co od de e m ma ax x 2 25 50 0 0 00 00 00 0 9 99 99 99 9 or or 00000 99999 00000 99999...

Page 76: ...1 released 2 digit travel program 2 release 0 blocked or 1 released 2 digit travel program 2 release 0 blocked or 1 released 3 digit travel program 3 release 0 blocked or 1 released 3 digit travel pr...

Page 77: ...n an gain and confi d confirm wit rm with SET h SET Rep Repeat th eat the proc e procedu edure for o re for othe ther code r codes s Th Then en pr pres ess t s the he O k O key ey The travel programs...

Page 78: ...the S th the SET key ET key 69 69 Z Z The parameter and sub index are displayed alternately with the current reading The parameter and sub index are displayed alternately with the current reading 0256...

Page 79: ...Se et tt ti in ng g range range Standard Standard setting setting Comments Comments 1 10 01 1 A Ac cc ce el le er ra at ti io on n 0 0 9 9 6 6 1 10 02 2 C Co oa as st ti in ng g b br ra ak ke e w wi i...

Page 80: ...meters match the battery parameters N No o F Fu un nc ct ti io on n S Se et tt ti in ng g range range Standard Standard setting setting Comments Comments 4 41 11 1 B Ba at tt te er ry y t ty yp pe e n...

Page 81: ...diately If no more LED bars If no more LED bars are illuminated the Stop indicator are illuminated the Stop indicator 74 lights up Lifting is 74 lights up Lifting is now now inhibited The battery must...

Page 82: ...number If several errors occur simultaneously they are displayed one after the other The If several errors occur simultaneously they are displayed one after the other The errors are displayed until th...

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Page 84: ...pare ensure safe and reliable operation of the truck use only the manufacturer s spare parts parts For safety reasons only components which have been specially agreed by the For safety reasons only co...

Page 85: ...ard Do not use flammable liquids to clean the industrial truck Do not use flammable liquids to clean the industrial truck Always disconnect the battery before starting cleaning work Always disconnect...

Page 86: ...parts oils and fuels must be disposed of in accordance with the relevant environmental protection regulations To change the oil contact the manufacturer s environmental protection regulations To chang...

Page 87: ...identified and rectified the fault Spilled fluids must be removed immediately with Spilled fluids must be removed immediately with an appropriate bonding agent The an appropriate bonding agent The bo...

Page 88: ...if the truck is to be used in operating conditions They must be reduced accordingly if the truck is to be used in conditions of extreme dust temperature fluctuations or multiple shifts conditions of...

Page 89: ...g for damage insulation Check electric wiring for damage insulation damage connections damage connections Make sure wire connections are secure Make sure wire connections are secure t t Maintenance in...

Page 90: ...heck check for d for damage amage t t 6 3 6 3 Check cylinders and piston rods for Check cylinders and piston rods for damage and leaks and make damage and leaks and make sure they are secure sure they...

Page 91: ...r se serv rvic icin ing g k k t t 3 3 Lu Lubr bric icat ate tru e truck ac ck acco cord rdin ing to th g to the lub e lubri rica cati tion sc on sche hedu dule le k k t t Maintenance intervals Mainten...

Page 92: ...ding agent consumable mixture must be disposed of in accordance with regulations regulations WARNING WARNING Oils chain spray hydraulic oil are flammable and poisonous Oils chain spray hydraulic oil a...

Page 93: ...s must be disposed of in accordance with the relevant environmental protection regulations To change the oil contact the manufacturer s environmental protection regulations To change the oil contact t...

Page 94: ...2mm in the oil in the oil g g C Co on nt ta ac ct t s su ur rf fa ac ce es s C Co ol ld d S St to or re e A Ap pp pl li ic ca at ti io on n s s Grease nipple Grease nipple b b Transmission oil filler...

Page 95: ...with one of the named alternative hydraulic oils the named alternative hydraulic oils C Co od de e O Or rd de er r n no o P Pa ac ck ka ag ge e quantity quantity N Na am me e U Us se ed d f fo or r A...

Page 96: ...en working under a ra ing under a raised lift tr ised lift truck secu uck secure it to preve re it to prevent it from low nt it from lowering t ering tipping ipping or sliding away or sliding away WAR...

Page 97: ...m the truck and place it sec k and place it securely ne urely next to the xt to the truck truck The front panel is now disassembled The front panel is now disassembled Remove the front panel industria...

Page 98: ...d he hydraulic raulic reserv reservoir oir If necess If necessary add tran ary add transmissi smission oil of the corr on oil of the correct grade ect grade see Cons see Consumable umables on s on pag...

Page 99: ...screws of th ws of the fron e front pane t panel 77 l 77 Remove Remove the fro the front pane nt panel 78 l 78 and pla and place it in ce it in a safe l a safe locatio ocation n Che Check th ck the t...

Page 100: ...ck for for mainte maintenance and re nance and repairs on pa pairs on page ge 95 95 To Tool ols s an and d Ma Mate teri rial al Re Requ quir ired ed Torque wrench Torque wrench Procedure Procedure Pos...

Page 101: ...the table an e table and replac d replace if neces e if necessary sary The fuses are now checked The fuses are now checked I It te em m N Na am me e T To o p pr ro ot te ec ct t R Ra at ti in ng g A...

Page 102: ...ent is specially trained to carry out The manufacturer s customer service department is specially trained to carry out these operations these operations WARNING WARNING Faulty brakes can cause acciden...

Page 103: ...r shall be sufficiently instructed and experienced to be able to assess the condition of the truck and the effectiveness of experienced to be able to assess the condition of the truck and the effectiv...

Page 104: ...ruck take appropriate measures to prevent it from slipping or tipping over e g wedges wooden blocks tipping over e g wedges wooden blocks When the truck is out of service it must be jacked up so that...

Page 105: ...ge the battery Full discharge can damage the battery Self discharge can cause the battery to fully discharge Full discharge shortens the Self discharge can cause the battery to fully discharge Full di...

Page 106: ...ck Tag out and decommission a faulty lift truck Only return the truck to service when you have identified and rectified the fault Only return the truck to service when you have identified and rectifie...

Page 107: ...the driver long vibrations will cause the driver long term health problems The European 2002 44 EC Vibration operator directive has term health problems The European 2002 44 EC Vibration operator dire...

Page 108: ...raction battery Type plate Jungheinrich traction battery 7 7 Instruction for use Instruction for use Aquamatic BFS III water refilling sy Aquamatic BFS III water refilling system stem 8 12 8 12 2 2 J...

Page 109: ...s when working on batteries on batteries Pay attention to the accident prevention rules as well as DIN EN 50272 3 DIN Pay attention to the accident prevention rules as well as DIN EN 50272 3 DIN 50110...

Page 110: ...al trucks plies to the operation traction batteries in industrial trucks 2 1 Discharging 2 1 Discharging Be sure that all breather holes are not sealed or covered Be sure that all breather holes are n...

Page 111: ...ust not be closed until at least half an hour after charging has past packs must not be closed until at least half an hour after charging has past 2 3 Equalising charge 2 3 Equalising charge Equalisin...

Page 112: ...department should be requested should be requested 3 4 Annually 3 4 Annually In accordance with DIN VDE 0117 at least In accordance with DIN VDE 0117 at least once per year the insulation resistance o...

Page 113: ...f the battery 6 Malfunctions 6 Malfunctions If malfunctions are found on the battery If malfunctions are found on the battery or the charger our service department should or the charger our service de...

Page 114: ...1 12 2 N Nu um mb be er r o of f b ba at tt te er ry y c ce el ll ls s 6 6 D De el li iv ve er ry y d da at te e 1 13 3 B Ba at tt te er ry y w we ei ig gh ht t 7 7 B Ba at tt te er ry y m ma an nu uf...

Page 115: ...he respective protection class during structions on maintaining the respective protection class during operation see asso operation see asso ciated certification ciated certification Cell Cell series...

Page 116: ...the hose connections in the individual Aquamatic BFS plugs coupler through the hose connections in the individual Aquamatic BFS plugs 2 Application 2 Application The Aquamatic BFS battery water refil...

Page 117: ...is set from The pressure reducing valve in the Aquamatic System is set from 0 2 bars to 0 6 bars 0 2 bars to 0 6 bars and from 0 3 bars to 1 8 and from 0 3 bars to 1 8 bars in the BFS system bars in...

Page 118: ...quamatic plugs or a 7 5 mm diameter BFS plugs 7 5 mm diameter BFS plugs 9 2 Float 9 2 Float Different floats are used depending on the cell design and type Different floats are used depending on the c...

Page 119: ...upply system at the battery charging station by means of a sealing coupler system On the battery side a closing nipple station by means of a sealing coupler system On the battery side a closing nipple...

Page 120: ...es to be carried out by skilled personnel only out by skilled personnel only Use protective glasses Use protective glasses and clothes when and clothes when working on batteries working on batteries P...

Page 121: ...ition condition To achieve the optimum life for the battery operating discharges of more than 60 To achieve the optimum life for the battery operating discharges of more than 60 of the rated capacity...

Page 122: ...iredamp hazard or Ex II in potentially explosive areas The attention pictograms has to be respected The attention pictograms has to be respected 2 3 Equalising charge 2 3 Equalising charge Equalising...

Page 123: ...nt tracking currents Clea The battery should always be kept clean and dry to prevent tracking currents Clea ning must be done in accordance with the ZVEI code of practice The Cleaning of ning must be...

Page 124: ...n n I It te em m D De es si ig gn na at ti io on n 1 1 L Lo og go o 8 8 R Re ec cy yc cl li in ng g s sy ym mb bo ol l 2 2 B Ba at tt te er ry y d de es si ig gn na at ti io on n 9 9 D Du us st tb bi...

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Jungheinrich ERC 212, Operating Instructions Manual

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