Jungheinrich EJC 212-220 Operating Instructions Manual
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Jungheinrich EJC 212-220 Operating Instructions Manual

Jungheinrich EJC 212-220 Operating Instructions Manual

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EJC 212-220
12.05 -
G
Operating Instructions
50460011
03.07

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Summary of Contents for Jungheinrich EJC 212-220

  • Page 1 EJC 212-220 12.05 - Operating Instructions 50460011 03.07...
  • Page 2 Used to indicate standard equipment. Used to indicate optional equipment. Our trucks are subject to ongoing development. Jungheinrich reserves the right to alter the design, equipment and technical features of the truck. No guarantee of particular features of the truck should therefore be inferred from the present operating instructions.

  • Page 4: Table Of Contents

    Index: Correct use and application Truck Description Application ................... B 1 Assemblies ..................B 2 Standard Version Specifications ............B 3 Performance data for standard trucks ..........B 3 Dimensions EJC 212/214 ..............B 3 Dimensions EJC 216/220 ..............B 4 EN norms ....................
  • Page 5 Operation Safety Regulations for the Operation of Forklift Trucks ...... E 1 Controls and Displays ................. E 2 Starting up the truck ................E 6 Using the industrial truck ..............E 8 Safety regulations for truck operation ..........E 8 Travelling, Steering, Braking ...............
  • Page 6 Appendix JH Traction Battery Operating Instructions These operating instructions apply only to Jungheinrich battery models. If using another brand, refer to the manufacturer's operating instructions.

  • Page 8: A Correct Use And Application

    A Correct use and application The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are supplied with the truck. The guidelines form part of these operating instructions and must be observed. National regulations apply in full. The truck described in the present operator manual is an industrial truck designed for lifting and transporting load units.

  • Page 10: B Truck Description

    B Truck Description Application The EJC is a four wheel, tiller guided electric truck with a steered drive wheel. It is designed for use on level floors to lift and transport palletised goods. Open bottom pallets or roll cages can be lifted. The capacity can be obtained from the data plate.

  • Page 11: Assemblies

    Assemblies Item EJC 212-220 Description Charge display Key switch CANCODE keypad ISM Access Module Battery discharge indicator /hourmeter CANDIS display instrument Tiller and grip Crawl button Travel switch Collision safety switch Mast Mast guard; optional protective frame Battery panel Battery connector (emergency disconnect)

  • Page 12: Standard Version Specifications

    Standard Version Specifications Technical specification details in accordance with VDI 2198. Technical modifications and additions reserved. Performance data for standard trucks Description EJC 212 EJC 214 EJC 216 EJC 220 Q Rated capacity 1200 1400 1600 2000 Load centre distance Standard fork length Travel speed 6,0 / 6,0...

  • Page 13: Dimensions Ejc 216/220

    Dimensions EJC 216/220 Description EJC 216 EJC 220 h1 Height (retracted) ZT 1750 – 2650 1750 – 2650 h1 Height (retracted) ZZ 1700 – 2600 1700 – 2600 h1 Height (retracted) DZ 1830 – 2250 1830 – 2250 h2 Free lift ZT h2 Free lift ZZ 1173 –...
  • Page 14 max. min.

  • Page 15: En Norms

    EN norms Noise emission: 65 dB(A) in accordance with EN 12053 as harmonised with ISO 4871. 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 driver’s ear.

  • Page 16: Identification Points And Data Plates

    Identification points and data plates Item Description Capacity "Do not reach through the mast" warning Truck data plate Attachment point for lifting by crane (with ZZ mast in the middle) “Do not step under the load handler” warning Serial number Battery data plate “No passengers”...

  • Page 17: Capacity

    Truck data plate Item Description Item Description Type Manufacturer’s logo Serial no. Min./max. battery weight (kg) Rated capacity (kg) Output (kW) Battery voltage (V) Load centre of gravity (mm) Net weight w.o. battery (kg) Year of manufacture Manufacturer Option For queries regarding the truck or ordering spare parts always quote the truck serial number (30).

  • Page 18: Plate, Order, Inventory And Service Nos. (O)

    The arrow shape markings (42 and 43) on the inner mast and bottom and outer tie bar indicate to the driver when he has exceeded the height limits specified by the capacity plate (18). Plate, order, inventory and service nos. (o) Item Description Order no.
  • Page 19 B 10...

  • Page 20: C Transport And Commissioning

    C Transport and Commissioning Lifting by crane Only use lifting gear with sufficient capacity (for transport weight see truck data plate). The strap points (1) on the mast are for loading the truck with crane lifting gear. – Park the truck securely (see Chapter E). –...

  • Page 21: Securing The Truck During Transport

    Securing the truck during transport The truck must be securely fastened when transported on a lorry or a trailer. The lorry / trailer must have fastening rings. – To secure the truck attach the tensioning belt to the strap points (1) and secure them to the fastening rings.

  • Page 22: Using The Truck For The First Time

    Using the truck for the first time In order to disconnect the power supply immediately in an emergency, the battery connector (not supplied) must be connected to the truck’s emergency disconnect. The truck must not be operated without the emergency disconnect. Only operate the truck with battery current.

  • Page 23: Operating The Truck Without Its Own Drive System

    Operating the truck without its own drive system This operating mode is not permitted when negotiating inclines and gradients. To operate the truck in emergency conditions, the electromagnetically applied brake must be released. – Remove the front panel (see Chapter F). –...

  • Page 24: D Battery Maintenance, Charging & Replacement

    D Battery Maintenance, Charging & Replacement Safety regulations for handling acid batteries Park the truck securely before carrying out any work on the batteries (see Chapter E). Maintenance personnel: Batteries may only be charged, serviced or replaced by trained personnel. The present operator manual and the manufacturer’s instructions concerning batteries and charging stations must be observed when carrying out the work.

  • Page 25: Battery Types

    Battery types Depending on the model, the EJC comes with different battery types. The battery weights can be taken from the battery data plate. When replacing or installing batteries, ensure that the battery is correctly secured in the battery compartment of the truck. The following table shows which combinations are included as standard: Chassis version Truck type...

  • Page 26: Charging The Battery

    Charging the battery The EJC 212-220 is fitted as standard with an onboard charger (for charging: see section 4.1). The EJC 212-220 can be optionally fitted with a stationary charger (for charging: see section 4.2). To charge the battery, the truck must be dry and parked in closed and properly ventilated rooms.
  • Page 27 Maintenance-free: 200 - 300 Ah Wet cell batteries: 200 - 400 Ah pulse characteristic Wet cell batteries: Jungheinrich 100 - 300 Ah All other switch (3) positions block the charger, and the battery is not charged. Setting the charging characteristics...
  • Page 28 Starting to charge with the onboard charger – Park the truck securely (see Chapter E). When charging, the tops of the battery cells must be exposed to provide sufficient ventilation. Do not place any metal objects on the battery. Before charging, check all cables and plug connections for visible signs of damage.

  • Page 29: Charging The Battery With A Stationary Charger (O)

    The flashing LED indicates the charge status or a fault (for flashing codes see “LED Display” table). If the mains connector (5) is connected to the mains, all the truck’s electrical functions will be interrupted (electrical start block). The truck cannot be operated. –...
  • Page 30 When charging, the tops of the battery cells must be exposed to provide sufficient ventilation. Do not place any metal objects on the battery. Before charging, check all cables and plug connections for visible signs of damage. All safety instructions as provided by the battery supplier and battery charger supplier must be strictly observed.

  • Page 31: Battery Removal And Installation

    Battery removal and installation – Expose the battery (see Section 3). The truck must be parked on level ground. To prevent short circuits, batteries with exposed terminals or connectors must be covered with a rubber mat. Place the battery connector or the battery cable in such a way that they will not get caught on the truck when the battery is removed.

  • Page 32: Lateral Battery Replacement (O)

    Lateral battery replacement (o) – Open the battery panel. – Disconnect the battery. – Pull the battery panel lock (9) up while holding onto the battery panel (11). – Lift out the battery panel and keep it in a safe place. –...

  • Page 33: Battery Discharge Indicator

    Battery discharge indicator Battery Discharge Indicator (t) When the truck has been released via the key switch or CANCODE, the battery charge status is displayed. The colours of the LEDs (12) represent the following conditions: LED colour Rating Green Standard battery residual capacity 40 - 100 % Maintenance free battery residual capacity 60 - 100 %...

  • Page 34: Candis Display Instrument (O)

    Candis display instrument (o) Battery Discharge Indicator: Shows the battery discharge status in 10% increments through 10 bars on the battery symbol (13). The bars go out from top to bottom as the battery continues to discharge. When using maintenance free batteries the instrument must be set so that that the symbol (T) (15) appears next to the hourmeter display.
  • Page 35 D 12...

  • Page 36: Safety Regulations For The Operation Of Forklift Trucks

    E Operation Safety Regulations for the Operation of Forklift Trucks Driver authorisation The forklift 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.

  • Page 37: Controls And Displays

    Controls and Displays Item Control / Function Display 212-220 Battery connector Interrupts the circuit, all electrical functions are cut out. The truck automatically brakes. (Emergency Stop) Charging display Indicate the charge status (see Chapter D). on charger Key switch Switches control current on and off. Removing the key prevents the truck from being switched on by unauthorised personnel.
  • Page 39 Item Control / Function Display 212-220 Collision safety Truck moves away from the operator and switch stops. 10 Load fork raise Raises load forks. switch The lift speed can be infinitely controlled via the switch stroke (8 mm). 11 Load fork lower Lowers the load forks.

  • Page 41: Starting Up The Truck

    Starting up the truck Before the truck can be commissioned, operated or a load unit lifted, the driver must ensure that there is nobody within the hazardous area. The electronic traction and steering controllers monitor their own operation. They inhibit travel in the event of an error. Checks and operations to be performed before starting daily work –...

  • Page 43: Using The Industrial Truck

    Using the industrial truck 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. Driving conduct: The driver must adapt the travel speed to local conditions.

  • Page 44: Travelling, Steering, Braking

    Travelling, Steering, Braking Never carry passengers. Emergency Disconnect – Remove the battery connector (1). All electrical functions are deactivated. Automatic braking Automatic braking occurs when the tiller is released – the tiller automatically sets itself to the upper brake zone (B). If the tiller moves slowly to the upper brake zone, the cause of this fault must be rectified.
  • Page 45 Crawl speed The driver must be particularly careful when applying the “Crawl speed” switch (7). The truck can be operated with a vertical tiller (6) (e.g. in congested areas / travel seat). – Press the crawl speed button (7). – Set the controller (8) to the required direction (fwd. or rev.). The brake is released.
  • Page 46 Braking with the Coasting Brake: If the travel switch is set to 0, the truck automatically brakes regeneratively. In hazardous situations set the tiller to the brake position. The coasting brake is adjustable (controller parameter setting, see chapter E). Parking brake: The mechanical brake (handbrake) applies when the truck comes to rest.

  • Page 47: Collecting And Depositing Loads

    Collecting and depositing loads Before lifting a load, the driver must ensure that it is correctly palletised and that the capacity of the truck is not exceeded. – Drive the truck with forks as far as possible underneath the load. With the two-stage Duplex mast (ZZ) a short, centre-mounted free lift cylinder initially lifts the load carriage (free lift) without changing the overall height of the truck.

  • Page 48: Emergency Lowering

    Emergency lowering Keep all personnel out of the hazardous area when applying emergency lowering. If the mast cannot be lowered any further due to a fault in the controller, manually activate the valve (14) on the hydraulic unit.. – Set key switch (3) to “0”. –...

  • Page 49: Park The Truck Securely

    Park the truck securely When you leave the truck it must be securely parked even if you only intend to leave it for a short time. Do not park the truck on a slope. The load forks must always be lowered to the ground.
  • Page 50 Starting the truck for the first time The LED (15) goes red when you connect the battery and if necessary switch on the key switch. When you enter the correct operator code (factory setting 2-5-8-0) the LED (15) turns green. If the wrong code is entered LED (15) flashes red for two seconds.

  • Page 51: Travel Programs

    Travel programs Press the digit keys 1, 2, and 3 to select any of three travel programs. The activated programme is indicated by the green LEDs (17), (18), (19) in the corresponding key. The travel programs differ with respect to travel speed, acceleration and deceleration force.

  • Page 52: Parameter Settings

    Parameter Settings To change the truck setting you must enter the master code. The factory setting for the master code is 7-2-9-5. When starting the truck for the first time, change the master code. Safety instructions for trucks with a display instrument (CANDIS (o)) –...
  • Page 53 Setting procedure for trucks with and without display instrument (CANDIS (o)): – Enter the three digit parameter number, confirm with the Set key (16). – The display instrument (CANDIS (o)) continues to display the operating hours. If the display changes, cancel the setting with the o-key (20) and restart from the beginning.
  • Page 54 Function Range Standard Comments Setting Setting Procedure Code Lock 002 Change user code 0000 - 9999 (LED 17 flashes) Enter current code 00000 - 99999 Confirm (Set) 000000 - 999999 (LED 18 flashes) Enter new code Confirm (Set) (LED 19 flashes) Repeat code entry confirm...
  • Page 55 Function Range Standard Comments Setting Setting Procedure Code Lock 020 Start travel program 1 - 3 1 = Travel program 1 2 = Travel program 2 3 = Travel program 3 021 Travel program 1 0 or 1 0 = Travel program Release not enabled 1 = Travel program...

  • Page 56: Travel Parameters

    Travel parameters For trucks without a display instrument (CANDIS (o)) the code lock parameters can only be set by the manufacturer's service department. The following example shows the parameter setting for the acceleration of travel program 1 (parameter 101). Acceleration example Display instrument LED (20) LED (17)
  • Page 57 The following parameters may be entered. Travel programs Function Range Standard Comments Setting Setting Travel program 1 101 Acceleration 0 - 9 (0.2 – 2.0 m/s 0.4 m/s 102 Coasting brake 0 - 9 (0.2 – 1.1 m/s (0,5 m/s 104 Maximum speed in drive 0 - 9 depending on...
  • Page 58 Function Range Standard Comments Setting Setting Travel program 3 301 Acceleration 0 - 9 (0.2 – 2.0 m/s (1.0 m/s 302 Coasting brake 0 - 9 (0.2 – 2.0 m/s 0.8 m/s 304 Maximum speed in tiller 0 - 9 depending on direction using travel travel switch...

  • Page 59: Display Instrument (Candis) (O)

    Display instrument (CANDIS) (o) The instrument indicates: – battery residual charge status (LED bars (22)), – Service hours (LC display (24)). In addition, service messages for the electronic components parameter changes are displayed. Discharge status display Setting limits for the additional “Warning” (21) and “Stop” (23) displays will depend on the battery type.

  • Page 60: Discharge Monitor Function

    Discharge monitor function When the discharge monitor function is enabled, lifting is cut out when the discharge limit is reached (the Stop LED is lit). Travel and lowering are still possible. For standard batteries the residual capacity is 20%, for maintenance-free batteries it is 40%.

  • Page 61: Troubleshooting

    Troubleshooting This chapter is designed to help the user identify and rectify basic faults or the results of incorrect operation. When locating a fault, proceed in the order shown in the table. Fault Possible cause Action Truck does not – Battery plug not connected. –...

  • Page 62: F Forklift Truck Maintenance

    F Forklift Truck Maintenance Operational safety and environmental protection The servicing and inspection duties contained in this chapter must be performed in accordance with the intervals indicated in the maintenance checklists. Any modification to the forklift truck assemblies, in particular the safety mechanisms, is prohibited.
  • Page 63 Electrical System: Only suitably trained personnel may operate on the truck’s electrical system. Before working on the electrical system, take all precautionary measures to avoid electric shocks. For battery-operated trucks, also de-energise the truck by removing the battery connector. Welding: To avoid damaging electric or electronic components, remove these from the truck before performing welding operations.

  • Page 64: Servicing And Inspection

    The application conditions of an industrial truck have a considerable impact on the wear of the service components. We recommend that a Jungheinrich customer adviser carries out an application analysis on site to determine specific service intervals to prevent damage caused by wear.

  • Page 65: Maintenance Checklist

    Maintenance Checklist Maintenance intervals Standard = W A B C Cold store= Brakes 1.1 Check effectiveness of operating and parking brakes, adjust where necessary and measure braking distance. 1.2 Check the brake lining wear Electrics 2.1 Test operation of instruments, displays and control switches 2.2 Test warning and safety device 2.3 Check fuse ratings...
  • Page 66 Maintenance intervals Standard = W A B C Cold store= Hydraulic 7.1 Check mast bearings operation 7.2 Check setting of slide pieces and stops, and adjust if necessary 7.3 Visually inspect the mast rollers and check contact surface wear level 7.4 Check lateral clearance of mast connections and of fork carriage 7.5 Check load chain setting and tighten if necessary...

  • Page 67: Ejc 212 - 220 Maintenance Schedule

    EJC 212 – 220 Maintenance Schedule Contact surfaces Hydraulic oil filler plug Hydraulic oil drain plug Compound ratio for cold store usage 1:1...

  • Page 68: Consumables

    Consumables Handling consumables: Consumables must always be handled correctly. Follow the manufacturer’s instructions. Improper handling is hazardous to health, life and the environment. Consumables must only be stored in appropriate containers. They may be flammable and must therefore not come into contact with hot components or naked flames. Only use clean containers when filling up with consumables.

  • Page 69: Maintenance Instructions

    Maintenance Instructions Preparing the truck for maintenance and repairs All necessary safety measures must be taken to avoid accidents when carrying out maintenance and repairs. The following preparations must be made: – Park the truck securely (see Chapter E). – Disconnect the battery (1) to prevent the truck from accidentally starting. When working under a raised lift truck, secure it to prevent it from tipping or sliding away.

  • Page 70: Checking The Hydraulic Oil Level

    Checking the hydraulic oil level – Prepare the truck for maintenance and repairs (see Chapter 6.1). – Remove the front panel (see Section 6.2). – Check hydraulic oil level in hydraulic reservoir. There are markings on the hydraulic reservoir. The oil level must be checked when the load forks are lowered.

  • Page 71: Flushing The Gauze Filter, Replacing The Gauze Filter

    Flushing the gauze filter, Replacing the gauze filter – Preparing the truck for maintenance and repairs (see Section 6.1). – Remove the front panel (see Section 6.2). – Undo the union (8). – Remove connection and take out the gauze filter –...

  • Page 72: Checking Electrical Fuses

    Checking electrical fuses – Preparing the truck for maintenance and repairs (see Section 6.1). – Remove the front panel (see Section 6.2). – Check the fuse rating and condition in accordance with the table; replace if necessary. 9 10 11 12 Item Description To protect:...

  • Page 73: Recommissioning

    Recommissioning The truck may only be restored to service after cleaning or repair work, once the following operations have been performed. – Test horn. – Test EMERGENCY DISCONNECT switch. – Test brakes. – Lubricate the truck in accordance with the maintenance schedule. Decommissioning the industrial truck If the industrial truck is to be decommissioned for more than two months, e.g.

  • Page 74: Restoring The Truck To Operation After Decommissioning

    Restoring the truck to operation after decommissioning – Thoroughly clean the truck. – Lubricate the truck in accordance with the maintenance schedule (see Chapter F). – Clean the battery, grease the terminals and connect the battery. – Charge the battery (see Chapter D). –...
  • Page 75 F 14...
  • Page 76 Jungheinrich traction battery Table of contents Jungheinrich traction battery ..........2-6 with positive tubular plates type EPzS and EPzB Type plate Jungheinrich traction battery..........7 Instruction for use ............8-12 Aquamatic/BFS III water refilling system Jungheinrich traction battery Maintenance free traction batteries with positive tubular plates type EPzV ....................13-17...

  • Page 77: Jungheinrich Traction Battery

    Jungheinrich traction battery with positive tubular plates type EPzS and EPzB Rating Data 1. Nominal capacity C5: See type plate 2. Nominal voltage: 2,0 V x No of cells 3. Discharge current:: C5/5h 4. Nominal S.G. of electrolyte* Type EPzS:...
  • Page 78 Ignoring the operation instructions, repair with non-original parts or using additives for the electrolyte will render the warranty void. For batteries in classes I and II the instructions for maintaining the appropriate protection class during operation must be complied with (see relevant certificate). 1.
  • Page 79 Battery container lids and the covers of battery compartments must be opened or re- moved. The vent plugs should stay on the cells and remain closed. With the charger switched off connect up the battery, ensuring that the polarity is cor- rect.
  • Page 80 3. Maintenance 3.1 Daily Charge the battery after every discharge. Towards the end of charge the electrolyte level should be checked and if necessary topped up to the specified level with purified water. The electrolyte level must not fall below the anti-surge baffle or the top of the separator or the electrolyte „min“...
  • Page 81 5. Storage If batteries are taken out of service for a lengthy period they should be stored in the fully charged condition in a dry, frost-free room. To ensure the battery is always ready for use a choice of charging methods can be made: 1.

  • Page 82: 7. Type Plate, Jungheinrich Traction Battery

    7. Type plate, Jungheinrich traction battery Baujahr T ype Year of manufacture Serien-Nr. Lieferanten Nr. Serial-Nr. Supplier No. Nennspannung Kapazität Nominal V oltage Capacity Zellenzahl Batteriegewicht min/max Number of Cells Battery mass min/max Hersteller Jungheinrich AG, D-22047 Hamburg, Germany Manufacturer...

  • Page 83: Aquamatic/Bfs Iii Water Refilling System

    Aquamatic/BFS III water refilling system for Jungheinrich traction battery with EPzS and EPzB cells with tubular positive plates Aquamatic plug arrangement for the Operating Instructions Cell series* Aquamatic plug type (length) EPzS EPzB Frötek (yellow) (black) 2/120 – 10/ 600 2/ 42 –...
  • Page 84 Diagrammatic view Equipment for the water refilling system 1. Water tank 2. Level switch 3. Discharge point with ball valve 4. Discharge point with sole- noid valve 5. Charger 6. Sealing coupler 7. Closing nipple 8. Ion exchange cartridge with conductance meter and solenoid valve 9.
  • Page 85 4. Filling (manual/automatic) The batteries should be filled with battery water as soon as possible before the battery charging comes to an end; this ensures that the refilled water quantity is mixed with the electrolyte. In normal operation it is usually sufficient to fill once a week. 5.
  • Page 86 8. Battery hose connections Hose connections for the individual plugs are laid along the existing electric circuit. No changes may be made. 9. Operating temperature The temperature limit for battery operation is set at 55° C. Exceeding this temperature damages the batteries. The battery filling systems may be operated within a tempe- rature range of >...
  • Page 87 10.2.1 Clamping ring tool The clamping ring tool is used to push on a clamping ring to increase the contact pres- sure of the hose connection on the plugs' hose couplings and to loosen it again. 10.3 Filter element For safety reasons a filter element (ident no.: 50307282) can be fitted into the batte- ry's main supply pipe for supplying battery water.

  • Page 88: Jungheinrich Traction Battery

    Jungheinrich traction batterie Maintenance free Jungheinrich traction batterie with positive tubular plates type EPzV and EPzV-BS Rating Data 1. Nominal capacity C5: See type plate 2. Nominal voltage: 2,0 Volt x No of cells 3. Discharge current: C5/5h 4. Rated temperature: 30°...
  • Page 89 Ignoring the operation instructions, repair with non-original parts and non authorised interventions will render the warranty void. For batteries in classes I and II the instructions for maintaining the appropriate protection class during operation must be complied with (see relevant certificate). 1.
  • Page 90 With the charger switched off connect up the battery, ensuring that the polarity is cor- rect (positive to positive, negative to negative). Now switch on the charger. When charging the temperature of the battery rises by about 15° C, so charging should only begin if the battery temperature is below 35°...
  • Page 91 3.2 Weekly Visual inspection after recharging for signs of dirt and mechanical damage. 3.3 Quarterly After the end of the charge and a rest time of 5 h following should be measured and recorded: • the voltages of the battery •...

  • Page 92: 7. Type Plate, Jungheinrich Traction Battery

    Batteries with this sign must be recycled. Batteries which are not returned for the recycling process must be disposed of as hazardous waste! We reserve the right make technical modification. 7. Type plate, Jungheinrich traction battery Baujahr T ype Year of manufacture Serien-Nr.

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