Page 1 EJC 212/214/216/220 /z /b 03.18 Operating instructions en-GB 51731458 04.23 EJC 212 EJC 214 EJC 216 EJC 220 EJC 212z EJC 214z EJC 216z EJC 220z EJC 212b EJC 214b EJC 216b EJC 220b...
Page 3: Declaration Of Conformity
Declaration of Conformity Manufacturer Jungheinrich AG, 22039 Hamburg, Germany Description Industrial truck Type Option Serial no. Year of manufacture EJC 212 EJC 214 EJC 216 EJC 220 EJC 212z EJC 214z EJC 216z EJC 220z EJC 212b EJC 214b EJC 216b...
Page 4 Declaration of Conformity (o) Product: EJC 212/214/216/220 /z /b Serial number/type number Manufacturer: Jungheinrich Aktiengesellschaft 22039 Hamburg, Germany UK representative: Jungheinrich UK Ltd Sherbourne House Sherbourne Drive Tilbrook Milton Keynes MK7 8HX Authorised to compile documentation: The manufacturer is authorised to compile the technical documentation and its...
Page 5 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.
Page 6 Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG. Jungheinrich Aktiengesellschaft Friedrich-Ebert-Damm 129 22047 Hamburg - Germany Tel: +49 (0) 40/6948-0 www.jungheinrich.com...
Page 7: Table Of Contents
Contents Correct Use and Application General Correct application Lifting Passengers Approved application conditions Instructions for trucks with lithium-ion batteries Internal Operation Combined with Brief External or Cold Store Operation (t) Internal Operation in Cold Stores with Cold Store Equipment (o) Wind loads Proprietor responsibilities Adding attachments and/or optional equipment...
Page 8 Battery - Servicing, Recharging, Replacement Notes on types of battery technology General safety regulations for batteries Lead-acid battery Safety instructions for handling lead-acid batteries Battery types Exposing the battery Removing or installing the battery Charging the battery Replaceable Lithium-Ion Battery Battery types Battery charge status Exposing the battery...
Page 9 Load handler emergency lowering Optional Equipment Display Units Keyless Access System Fleet Management System Floor-Spot (o) Transmitter (o) Fine weighing (o) positionCONTROL (o) operationCONTROL (o) Lift Limit (o) 8.10 Overload Display (o) 8.11 Foot Protection Tiller 8.12 Forks Truck maintenance Spare Parts Operational Safety and Environmental Protection Maintenance Safety Regulations...
Page 10 Owner Customer Service...
Page 11: A Correct Use And Application
A Correct Use and Application General The truck must be used, operated and serviced in accordance with these operating instructions. All other types of use are beyond its scope of application and may result in damage to persons, material assets and/or the truck. Correct application NOTICE The maximum load and load distance are indicated on the capacity plate and must...
Page 12: Lifting Passengers
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. uUse the capacity plate to ensure sufficient capacity at the planned lift height, see page 58.
Page 13: Approved Application Conditions
Approved application conditions WARNING! Use under extreme conditions Using the truck under extreme conditions can result in malfunctions and accidents. uSpecial equipment and authorisation are required if the truck is to be constantly used in extreme conditions, especially in dusty or corrosive atmospheres. uThe truck cannot be used in areas at risk of explosion.
Page 14 Special equipment and authorisation are required if the truck is to be used continually in conditions of extreme temperature fluctuations or condensing air humidity.
Page 15: Instructions For Trucks With Lithium-Ion Batteries
Instructions for trucks with lithium-ion batteries WARNING! Danger of accidents due to regenerative braking fault Regenerative braking faults can result in extended stopping distances and accidents, particularly when travelling on inclines. Other persons can be injured in the truck's hazardous area. uKeep all persons out of the hazardous area during travel operations.
Page 16: Internal Operation Combined With Brief External Or Cold Store Operation (T)
Internal Operation Combined with Brief External or Cold Store Operation (t) In addition to the permissible operating conditions in industrial and commercial environments, the truck can also be used in outdoor environments, cool stores and fresh food areas. Secure parking is only permissible indoors or in a cold store environment.
Page 17: Internal Operation In Cold Stores With Cold Store Equipment (O)
Internal Operation in Cold Stores with Cold Store Equipment (o) NOTICE Cold store trucks uTrucks designed for use in cold stores have a cold store hydraulic oil and a protective frame instead of a mast guard on the mast. uIf a truck with cold store oil is used outside the cold store, the lowering speeds may increase.
Page 18: Wind Loads
3.3.4 Replaceable Lithium-Ion Battery See the separate operating instructions for the lithium-ion battery. 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.
Page 19: Proprietor Responsibilities
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.
Page 21: B Truck Description
Truck models and rated capacity The rated capacity depends on the model. The rated capacity can be derived from the model name. EJC 212/214/216 z/b Model name Series Rated capacity x 100 kg...
Page 22: Travel Direction Definition
Travel direction definition The following determinations have been made for travel direction specification: Item Travel Direction Left Load direction Drive direction Right...
Page 23: Assemblies And Functional Description
Assemblies and Functional Description Assembly Overview Item Description Protective screen panel (not suitable for cold store operation) Protective grille Mast Load backrest Load fork...
Page 24 Item Description Slow-travel button Support arms Tiller Emergency disconnect switch Charge status indicator Display unit with 2-inch display Transponder reader Keypad Key switch Transponder reader Plus Document storage compartment On-board charger Battery panel Drive wheel Hydraulic unit Mains plug (on-board charger) Support wheel Front panel...
Page 25 4.1.1 Overview of optional components Options bracket Item Description Wide-angle mirror Tray USB charging module Touch-mode units Shrink wrap holder DIN A4 writing board Beacon Red or blue LED light (Floor-Spot) RAM mount 6" display...
Page 26 Load backrest Item Model Load backrest, large Load backrest, small...
Page 27: Item Description
Mast cover Item Description Protective screen panel (not suitable for cold store operation) (t) Protective grille (o)
Page 28 4.1.2 Comfort Charging Socket for the Lithium-Ion Battery Item Description Comfort charging socket for the lithium-ion battery...
Page 29: Functional Description
Functional Description Controls and displays The ergonomic tillers enable non-fatigue operation for sensitive and gradual travel and hydraulics movements. The colour driver's display shows all the information important to the operator and enables control of the truck functions. There are various possible versions of the driver's display and its combinations.
Page 30 Hour meter Service hours are counted while the truck is operational and one of the following controls is actuated: – Tiller in travel zone "F", see page 133. – "Slow travel button", see page 135. – Button for lifting or lowering the load handler, see page 140. USB charging module (o) The USB charging module is used as a power supply for external devices.
Page 31 Automatic lower sequence of support arm lift (o) Only available with: EJC 212z - 220z With the support arm lift raised, loads can be stacked and retrieved with the load fork up to a lift height of 2200 mm (EJC 212z-216z) / 1580 mm (EJC 220z). For higher lift heights, the support arm lift must be lowered.
Page 32: Protective And Safety Equipment
Protective and safety equipment CAUTION! Automatic braking can cause accidents 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. uRemain at a suitable distance from the truck during operation.
Page 33 Automatic reset of the controls – The long tiller provides a maximum safety distance from the truck. On release, a gas strut presses the tiller upwards into the brake position and the truck brakes, see page 132. – The travel switch must be held in the travel position to move the truck. When released, the travel switch moves to the neutral position and the truck brakes, see page 138.
Page 34 Floor-Spot (o) The activated Floor-Spot forewarns people of the truck travel path by projecting a coloured light dot onto the floor at the set distance. The Floor-Spot is available in two versions: – With blue light dot – With red light dot Further information: see page 199 and see page 199.
Page 35: Technical Specifications
Technical Specifications The technical specification is given according to the German guideline "Type sheets for industrial trucks". Technical modifications and additions reserved. In accordance with VDI 2198, the load centre is indicated by the letter "c" in this section. In the other sections and on the capacity plate, the letter "D" is used in accordance with EN ISO 3691-1.
Page 36: Dimensions
Dimensions EJC 212/214/216/220 Values for battery compartment S-VBE (EJC 212); M-VBE (EJC 214/216); ZT2800/2900 mast...
Page 37 Description EJC 212 EJC 214 EJC 216 EJC 220 Overall length 1827 1916 1988 Headlength Mast height retracted 1950 2100 Free lift Lift 2900 2800 2840 Mast height extended 3375 3325 3495 Fork arms height lowered Tiller height in travel position (min.)
Page 38 Tyre size, rear Tandem: Ø85 x 75 mm With DZ mast: l + 42 mm With battery compartment M-VBE: EJC 212 l1 + 68 mm; L-VBE or L-SBE: l1 + 140 mm l (overall length) With DZ mast: l + 42 mm...
Page 39 EJC 212z/214z/216z/220z Values for battery compartment LX-SBE; ZT2800/2900 mast; support arms raised...
Page 40 Designation 212z 214z 216z 220z Overall length 1981 2002 Headlength Mast height retracted 1950 2100 Free lift Lift 2900 2800 2840 Mast height extended 3375 3325 3495 Lowered height Tiller height in travel position (min.) Tiller height in travel 1305 position (max.) Wheelbase 1571...
Page 41 Additional data Specification Note With DZ mast: x - 42 mm x (load distance) With lowered support arms: x + 54 mm y (wheelbase) With lowered support arms: x + 54 mm Tyre size, rear Tandem: Ø85 x 85 mm With DZ mast: l + 42 mm (identical for all battery compartments)
Page 42 EJC 212b/214b/216b/220b Values for battery compartment M-VBE (ERC 212b) or L-VBE (ERC 214b/216b); ZT2800/2900 mast...
Page 43 Model 212b 214b 216b 220b Overall length 1963 2060 Headlength Mast height retracted 1950 2100 Free lift Lift 2900 2800 2840 3470 Mast height extended 3370 3495 Tiller height in travel position (min.) Tiller height in travel 1305 position (max.) Wheelbase 1347 1409...
Page 44: Specification
Specification Note 1100 mm / 1270 mm / 1470 mm (incremental acc. to Overall width b track width) Fork carriage width b Optional: 975 mm available Aisle width (pallet Diagonal acc. to VDI: Ast + 133 mm / + 133 mm / + 800 mm ×...
Page 45: Performance Data
Performance data EJC 212/214/216/220 EJC 212 EJC 214 Rated capacity 1200 1400 Load centre distance with standard fork length Travel speed with/without 6.0 / 6.0 km/h load Lift speed with/without 0.2 / 0.4 0.16 / 0.3 load Lowering speed with/ 0.45 / 0.35...
Page 46 EJC 212z/214z/216z/220z EJC 212z EJC 214z Rated capacity 1200 1400 Capacity with support 2000 arm lift Load centre distance with standard fork length Travel speed with/without km/h 6.0 / 6.0 load Lift speed with/without 0.2 / 0.4 0.16 / 0.3 load Lowering speed with/ 0.45 / 0.35...
Page 47: Gradeability
EJC 212b/214b/216b/220b EJC 212b EJC 214b Rated capacity 1200 1400 Load centre distance with standard fork length Travel speed with/without 6.0 / 6.0 km/h load Lift speed with/without 0.2 / 0.4 0.16 / 0.3 load Lowering speed with/ 0.45 / 0.35 without load Lift motor, output Energieverbrauch nach...
Page 48: Weights
Weights EJC 212/214/216/220 EJC 212 EJC 214 EJC 216 EJC 220 Net weight incl. 1039 1044 1207 battery Axle load with rated 660/1420 974/1645 814/1830 878/2329 load front/rear Axle load, w.o. load 590/290 721/318 724/320 805/402 front/rear EJC 212z/214z/216z/220z EJC 212z...
Page 49: Tyre Type
Tyre type EJC 212/214/216/220 EJC 212 EJC 214 EJC 216 EJC 220 Tyre size, front 230 x 70 Tyre size, rear 85 x 110 / 85 85 x 85 Additional wheels 140 x 54 Wheels, number front / rear 1 x + 1 / 2...
Page 50: Norms
Continuous sound pressure level – EJC 212/214/216/220 /z /b: 63 dB(A) in accordance with EN 12053 as harmonised with ISO 4871. The continuous sound pressure level is calculated according to standard procedures and takes into account the sound pressure level when travelling, lifting and idling.
Page 51: Specifications According To Red Guideline (Radio Equipment Directive) For Radio Units
Specifications according to RED guideline (Radio Equipment Directive) for radio units The table contains any components installed according to the European Directive 2014/53/EU. The table shows the affected frequency range and the emitted transmission power for each component. Transmission Component Frequency range power WMT 110...
Page 52: Electrical Requirements
Transmission Component Frequency range power Telematics box Plus 2.4 GHz (WLAN) < 100 mW 3G/2G INT 5 GHz (WLAN) < 100 mW 2.4 GHz (Bluetooth) < 10 mW 850/900 MHz (2G) < 2 W 1800/1900 MHz (2G) < 1 W 800/850/900/1900/2100 MHz (3G) <...
Page 53: Usb Charging Module
5.11 USB charging module Component Output current Output voltage USB charging module (2-way) 2,4 A...
Page 54: Identification Points And Data Plates
Identification Points and Data Plates Warnings and notices such as capacity plates, attachment points and data plates must be legible at all times. Replace if necessary. Indication Points SERIAL NO. SERIAL NO. Item Description Warning notice: "Danger! Optical radiation" (on trucks with blue Floor-Spot) Truck capacity plate Prohibition plate: "Do not reach through the mast"...
Page 55 Item Description – EJC 212/214/216/220/EJC 212b/214b/216b/220b: No plate – EJC 212z/214z/216z/220z: Capacity plate for stacking and transport operations – EJC 212z/214z/216z/220z with double-deck function: Capacity plate for stacking, transport and double-deck operations Prohibition plate: "No passengers" Data plate "Cold-store equipment" plate...
Page 56 6.1.1 Equipment-dependent marking points Marking points of blue Floor-Spot (o) A blue Floor-Spot has an additional warning notice on the left and right on the housing. From 2022, there is an overhauled version of the Floor-Spot. Item Description Floor-Spot version until 2022 Warning notice: "Danger! Optical radiation"...
Page 57: Data Plate
Data plate Item Description Item Description Rated capacity (kg) Load centre distance (mm) Battery voltage (V) Output (kW) Net weight without battery (kg) Min./max. battery weight (kg) Option Manufacturer Type QR code Serial number Manufacturer's logo Year of manufacture For queries regarding the truck or when ordering spare parts, always quote the truck serial number (59).
Page 58: Capacity Plate
Capacity plate SERIAL NO. The capacity plate (43) 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.
Page 59 6.3.1 Example of Use of Capacity Plate (575 mm) 1150 mm SERIAL NO. 3600 3200 1050 1050 2900 1200 1200 Example load (palletised): – several cardboard boxes of the same size and same weight – Load height: 800 mm – Load length: 1150 mm –...
Page 60 6.3.2 Lift height markings The arrow markings on the outer mast (67) and the inner mast (68) show the operator when the lift height limits prescribed by the capacity plate are reached.
Page 61: Capacity Plate For Stacking And Transport Operation
Capacity plate for stacking and transport operation Only EJC 212z/214z/216z/220z Not for EJC 212z/214z/216z/220z with double-deck function (o) The stacking and transport operation capacity plate indicates the capacity Q (in kg) of the truck during stacking and transport operation. Stacking operations (stacking and retrieving loads) in mast lift –...
Page 62: Capacity Plate For Stacking, Transport And Double-Deck Operation
Capacity plate for stacking, transport and double-deck operation 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. uIn order not to jeopardize the operational stability, the heavier pallet should always be transported underneath.
Page 63: C Transport And Commissioning
C Transport and Commissioning 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.
Page 64 Lifting the truck by crane Requirements – Park the truck securely, see page 123. Tools and Material Required – Lifting gear – Crane lifting gear Procedure • Secure the crane lifting gear to the strap points (75). The truck can now be lifted by crane.
Page 65: Transport
Transport WARNING! Danger due to uncontrolled movement of the truck or the mast during transport If the truck and mast are not properly secured during transport, serious accidents can occur. Slipping lashing straps can lead to uncontrolled movements of the truck or mast and even a fall during transport.
Page 66: Using The Truck For The First Time
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.
Page 67 Carrying out initial commissioning Procedure • Check the equipment is complete. • Install the battery (if required) – see page 69. • Charge the battery – see page 69. • Check the hydraulic oil level and correct if necessary – see page 236. •...
Page 69: D Battery - Servicing, Recharging, Replacement
D Battery - Servicing, Recharging, Replacement Notes on types of battery technology Lead-acid battery The truck is fitted with a lead-acid battery as standard. Integrated modular lithium-ion battery (o) The truck is optionally fitted with an integrated modular lithium-ion battery. All notes and information concerning lithium-ion batteries can be found in these operating instructions.
Page 70: General Safety Regulations For Batteries
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.
Page 71: Lead-Acid Battery
Lead-acid battery Safety instructions for handling lead-acid batteries WARNING! Risk of accidents and injuries when handling acid batteries Batteries contain dissolved acid, which is toxic and caustic. Above all, avoid any contact with battery acid. uDispose of used battery acid in accordance with regulations. uWear protective clothing and eye protection when working with acid batteries.
Page 72: Battery Types
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. EJC 212/214/216/220 & EJC 212b/214b/216b/220b - battery tray S1 Battery type Capacity (Ah) Min. weight Max.
Page 73 EJC 212/214/216/220 & EJC 212b/214b/216b/220b - battery tray S4 Battery type Capacity (Ah) Min. weight Max. dimensions 24 V battery 166 kg 662 x 148.5 x 686 mm 2PzVB 24 V battery 166 kg 662 x 148.5 x 686 mm...
Page 74 EJC 212/214/216/220 & EJC 212b/214b/216b/220b - battery tray L1 Battery type Capacity (Ah) Min. weight Max. dimensions 24 V battery 230 kg 624 x 284 x 537 mm 3PzV 24 V battery 230 kg 624 x 284 x 537 mm...
Page 75 EJC 212z/214z/216z/220z - battery tray M1.2 Battery type Capacity (Ah) Min. weight Max. dimensions 24 V battery 204 kg 624 x 212 x 628 mm 24 V battery 204 kg 624 x 212 x 628 mm 2PzV 24 V battery 204 kg 624 x 212 x 628 mm 2PzV...
Page 76 EJC 212z/214z/216z/220z - battery tray LX Battery type Capacity (Ah) Min. weight Max. dimensions 24 V battery 280 kg 792 x 212 x 635 mm 24 V battery 280 kg 792 x 212 x 635 mm 3PzV 24 V battery 280 kg 792 x 212 x 635 mm 3PzV...
Page 77: Exposing The Battery
Exposing the battery CAUTION! A closing battery panel can pose a trapping hazard If the battery cover is not opened fully, it can suddenly close on its own and cause bruising. The battery cover is only properly opened at an angle greater than 90°. It is then held by gravity.
Page 78: Removing Or Installing The Battery
Removing or installing the battery 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. uNote the safety regulations governing the handling of lead-acid batteries, see page 71.
Page 79 3.4.1 Removing the battery from the top Removing the battery Requirements – Truck parked securely, see page 123. – Options bracket in maintenance position, see page 232. Tools and Material Required – Crane lifting gear Procedure • Disconnect the battery connector from the truck connector. Place the battery cable on the battery tray so that it cannot be severed when the battery is extracted.
Page 80 3.4.2 Removing the battery from the side CAUTION! Trapping hazard Trapping hazard when removing and installing the battery. uWhen removing and installing the battery do not put your hands between the battery and the chassis. Lateral battery removal is an option only. Battery removal Requirements –...
Page 81 Procedure • Disconnect the battery connector from the truck connector. Place the battery cable on the battery tray so that it cannot be severed when the battery is extracted. • Unlock the battery latch (79). • If present, position the battery replacement station (81) at the truck. •...
Page 82: Charging The Battery
Charging the battery WARNING! Risk of electric shock and fire due to insufficient or inappropriate residual current devices A lack of residual current devices or the use of inappropriate residual current devices can result in fatal injury due to electric shocks or electrical fires in the event of a fault. uThe owner must conduct an operational risk assessment of the usage location.
Page 83 Simultaneous charging with two battery chargers Simultaneous charging with two battery chargers (the stationary battery charger and the on-board charger) is not permitted. Partial charging Charging can be interrupted on the battery charger and continued as partial charging. The charging process is automatically adapted to the charge status of the battery;...
Page 84 Procedure • Check the battery cable and battery connector on the truck as well as the connector and cable of the stationary battery charger for visible signs of damage before charging. If damage is identified, mark the affected truck or affected battery charger accordingly and take out of service.
Page 85 NOTICE Material damage due to incorrect use of the on-board charger uThe on-board charger must not be opened. In the event of faults, contact the manufacturer’s customer service department. uThe battery charger must only be used for the batteries supplied or other approved batteries provided they have been adapted by the manufacturer's customer service department.
Page 86 Charging the battery Requirements – Truck parked securely – see page 123. – Battery exposed – see page 77. Procedure • Check the cable and mains plug (24) of the on-board charger for visible damage before charging. If damage is identified, mark the truck accordingly and take it out of service. Have the truck repaired by the manufacturer or by a specialist authorised by the manufacturer.
Page 87 Ending battery charging Procedure • Remove the mains plug (24) from the mains socket and store it fully along with the mains cable in the storage compartment (84). • If applicable, place the insulating mat back over the battery. • Securely close the battery panel. Battery charging is complete.
Page 88: Replaceable Lithium-Ion Battery
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. EJC 212/214/216/220 & EJC 212b/214b/216b/220b - battery tray M1.1 Battery type Capacity (Ah) Min. weight Max.
Page 89: Battery Charge Status
Battery charge status 0,0 km/h The charge status of the lithium ion battery is shown on the display of the display unit (85). The display of the display unit also indicates important information on the operating condition of the lithium-ion battery as required (e.g. low charge status, excessively high or low temperature) –...
Page 90 4.5.2 Charging the battery with an on-board charger DANGER! Risk of electric shock and fire Damaged and unsuitable cables can cause electric shocks and can overheat, resulting in fires. uAlways use mains cables with a maximum length of 30 m. Local regulations must be observed.
Page 91 Immobiliser WARNING! Moving of a connected industrial truck with the mains socket switched off If an industrial truck is being charged at an external mains socket, the automatic immobiliser detects this process and deactivates the truck travel functions. When charging an industrial truck at a mains socket that can be switched off, the industrial truck can start moving when the socket is switched off because the immobiliser detects only live mains sockets.
Page 92 Procedure • Check the cable and mains plug (24) of the on-board charger for visible damage before charging. If damage is identified, mark the truck accordingly and take it out of service. Have the truck repaired by the manufacturer or by a specialist authorised by the manufacturer.
Page 93: Integrated Modular Lithium-Ion Battery
The truck is optionally fitted with an integrated modular lithium-ion battery. All notes and information concerning lithium-ion batteries can be found in these operating instructions. The Jungheinrich lithium-ion batteries are maintenance-free batteries with rechargeable high-performance energy cells. The batteries' daily operating time can be extended through intermediate charges.
Page 94: Safety Regulations For Handling Lithium-Ion Batteries
Safety regulations for handling lithium-ion batteries 5.1.1 Correct application WARNING! Do not open the battery! If external influences (e.g. force, fire, flooding) cause unusual conditions or situations, the following instructions must be observed: – The battery cells inside the lithium-ion battery contain substances that can be flammable if they come into contact with oxygen or water.
Page 95 5.1.2 Disposal Used lithium-ion batteries are recyclable commodities. These lithium-ion batteries must be treated as hazardous waste. Lithium-ion batteries marked with the recycling symbol and the sign showing a crossed-out waste bin must not be disposed of with ordinary household waste. Return or recycling of batteries must be ensured, for example, in accordance with the Battery Directive 2006/66/EG.
Page 96 5.1.3 Shipping information The Jungheinrich lithium-ion battery is a hazardous material. The applicable ADR regulations must be observed during transport. ADR = Accord européen relatif au transport international des marchandises Dangereuses par Route. If in doubt, contact the manufacturer's customer service department.
Page 97 5.1.6 Touch voltage hazard WARNING! Touch voltage hazard Hazardous touch voltages may occur in the event of a technical or mechanical defect on the battery. Touch voltages also occur on seemingly discharged batteries. Touching the battery terminals or live attachments (battery cable, battery connector etc.) can result in dangerous current flows through the body.
Page 98: Lithium-Ion Battery Data Plate
Lithium-ion battery data plate Item Designation Lithium-ion secondary battery Battery type Production (year/month) Serial number Supplier number Rated capacity in ampere-hours [Ah] Rated voltage in volts [V] Rated energy (C5) in watt-hours [Wh] – Calculation of the rated energy (C5): rated capacity C5 multiplied by the rated voltage Battery material number Battery weight in kilogrammes [kg]...
Page 99 5.2.1 Safety and warning information Used batteries are recyclable commodities. These batteries must be treated as hazardous waste. As indicated by the marking showing the recycling symbol and a crossed-out waste bin, batteries must not be disposed of as domestic waste. Return or recycling of batteries must be ensured, for example, in accordance with the Battery Directive 2006/66/EG.
Page 100: Battery Types
Battery types Depending on the version, the truck is equipped with different battery types. The following table shows the different battery types. Nominal battery data Lithium-ion battery Product 130/260/390 Ah 25.6 V Nominal voltage (3.2 V x 8 cells) 130 Ah 8 (1 unit with 8 cells) Number of cells 260 Ah...
Page 101: Battery Charge Status
Battery charge status 0,0 km/h The charge status of the lithium ion battery is shown on the display of the display unit (85). The display of the display unit also indicates important information on the operating condition of the lithium-ion battery as required (e.g. low charge status, excessively high or low temperature) –...
Page 102: Charging The Battery
Charging the battery WARNING! Risk of electric shock and fire due to insufficient or inappropriate residual current devices A lack of residual current devices or the use of inappropriate residual current devices can result in fatal injury due to electric shocks or electrical fires in the event of a fault. uThe owner must conduct an operational risk assessment of the usage location.
Page 103 Intermediate charging NOTICE Intermediate charging A lithium-ion battery that is not fully discharged can be recharged at any time either in part of in full. In order to ensure the reliable operation of the lithium-ion battery, the following must be borne in mind: uIn the event of frequent intermediate charging, charge the lithium-ion battery fully every 4 weeks.
Page 104 5.7.1 Charging the battery with a stationary battery charger Incorrect charging NOTICE Damage to the lithium-ion battery due to incorrect charging If a lithium-ion battery is charged directly via the battery connector (82) rather than via the comfort charging socket (41), the battery may be damaged. uNever connect an external battery charger directly to the battery connector (82) of the lithium-ion battery.
Page 105 Charging the battery Requirements – Battery charger operational. – Truck parked securely – see page 123. Procedure • Check the cable and charge connector (104) of the battery charger (103) for visible damage before charging. If damage is identified, mark the affected battery charger accordingly and take out of service.
Page 106 Ending battery charging WARNING! There is a danger of sparks if charging is improperly interrupted Owing to the high charge currents, there is a risk of spark discharge if the charge connector is removed while charging is active. There is a risk of injury and of damage to the electrical contacts.
Page 107 5.7.2 Charging the battery with an on-board charger DANGER! Risk of electric shock and fire Damaged and unsuitable cables can cause electric shocks and can overheat, resulting in fires. uAlways use mains cables with a maximum length of 30 m. Local regulations must be observed.
Page 108 Immobiliser WARNING! Moving of a connected industrial truck with the mains socket switched off If an industrial truck is being charged at an external mains socket, the automatic immobiliser detects this process and deactivates the truck travel functions. When charging an industrial truck at a mains socket that can be switched off, the industrial truck can start moving when the socket is switched off because the immobiliser detects only live mains sockets.
Page 109 Charging the battery Requirements – Truck parked securely – see page 123. Procedure • Check the cable and mains plug (24) of the on-board charger for visible damage before charging. If damage is identified, mark the truck accordingly and take it out of service. Have the truck repaired by the manufacturer or by a specialist authorised by the manufacturer.
Page 111: E Operation
E Operation Safety Regulations for the Operation of Forklift Trucks 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.
Page 112 Damage and defects 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.
Page 113: Displays And Controls
Displays and controls...
Page 114 Item Control/display Function “Slow travel” button t If the tiller is in the upper braking zone, braking can be overridden by pressing the switch, and the truck can move at reduced speed (slow travel), see page 135. t Used to brake the truck with maximum force and Emergency disconnect switch to interrupt the truck functions in an emergency.
Page 115 Item Control/display Function Touch-mode control unit Enables operation of certain travel and lift functions from an operating position at the side of the truck. o Lowers the support arms at a constant speed. "Lower support arms" button "Lift support arms" button o Raises the support arms at a constant speed. t Raises the load fork at a variable speed.
Page 116: Available Display Elements And Controls
Available display elements and controls The truck may be equipped with the following control and display elements depending on the equipment: Access systems with key – Charge status indicator and key switch (t) – Display unit (2-inch display) and key switch (o) Keyless Access System –...
Page 117 2.1.1 Charge Status Indicator and Key Switch 2.1.1.1 Key switch The key switch is used to switch on and off a truck with standard equipment. When the key is removed, this prevents the truck from being switched on by unauthorised personnel.
Page 118 2.1.1.2 Charge Status Indicator The charge status indicator (13) uses two LEDs to display the battery charge status. Display on an operational truck After switching on the truck, the charge status of the battery is displayed. The LED colours represent the following conditions: LED colour Charge status Green...
Page 119 Red LED (fault) Overtemperature. Charging is interrupted. Slow flash Safety charging time exceeded. Charging is cancelled. Mains interruption required to begin charging again. Rapid flash Characteristic-curve setting is invalid. 2.1.2 Battery discharge monitor NOTICE Full discharge can damage the battery Self-discharge can cause the battery to fully discharge.
Page 120: Preparing The Truck For Operation
Preparing the Truck for Operation Checks and Operations to Be Performed Before Starting Daily Work WARNING! Truck damage or defects can result in accidents If damage or other truck defects are discovered during the following checks, the truck must be taken out of service until it has been repaired. uReport any defects immediately to your supervisor.
Page 121: Preparing The Truck For Operation
Preparing the truck for operation Switching On the Truck Requirements – Checks and operations before starting daily work completed, see page 120. Procedure • Unlock the emergency disconnect switch (12) – see page 130. • Switch on the truck; if necessary. •...
Page 122: Visual Inspections And Activities To Be Performed After Establishing Operational Readiness
Visual inspections and activities to be performed after establishing operational readiness 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.
Page 123: Parking The Truck Securely
Parking the truck securely WARNING! An unsecured truck can cause accidents Do not leave an unsecured truck. uPark the truck securely when leaving it. uException: If the operator intends to remain in the immediate vicinity and is leaving the truck for only a short while, the applied parking brake is sufficient to hold the truck, see page 139.
Page 124 Parking the truck securely Procedure • Park the truck on a level surface. • Fully lower the load handler, see page 140. • Set the drive wheel to "straightahead travel" using the tiller (11). • Switch off the truck; to do this, •...
Page 125: Working With The Truck
Working with the truck Safety regulations for travel mode Travel paths and work areas DANGER! Do not exceed the permissible surface and spot load limits on the travel routes. At blind spots get a second person to assist. The driver must ensure that the loading ramp / dock cannot move or come loose during loading / unloading.
Page 126 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.
Page 127 4.1.1 Negotiate slopes and inclines When negotiating slopes and inclines, observe the following: – Negotiating slopes and inclines in accordance with the technical specifications is permissible only if they are marked as traffic lanes. – Before negotiating slopes, ensure that the truck has sufficient gradeability – see page 47.
Page 128 4.1.1.2 Empty journey When travelling unladen in pedestrian mode, the load handler must be oriented towards the downslope, irrespective of the travel direction.
Page 129 4.1.1.3 Transport run When travelling laden in pedestrian mode, the load handler must be oriented towards the upslope, irrespective of the travel direction.
Page 130: Emergency Disconnect
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. uDo not use the Emergency Disconnect switch as a service brake.
Page 131 Unlocking the emergency disconnect switch Procedure • Turn the emergency disconnect switch (12) to unlock it. All electrical functions are enabled and the truck is operational again (provided the truck was operational before the emergency disconnect switch was pressed).
Page 132: Automatic Braking
Automatic braking WARNING! Faulty tillers can result in collisions Operating the truck with a faulty tiller can result in collisions with other people and objects. uIf the tiller moves too slowly or not at all to the upper brake zone, the truck must be taken out of service until the cause of this fault is rectified.
Page 133: Travel
Travel WARNING! Collision hazard when operating the truck Collisions with personnel and equipment can result if the truck is operated with open panels. uDo not operate the truck unless the panels and covers are closed and properly locked. uWhen travelling through swing doors etc. make sure that the doors do not activate the collision safety button.
Page 134 Trucks can be equipped with an optional foot protection tiller. In this case, the travel speed is reduced in the upper range (o) of the travel zone F, see page 29. Requirements – Truck is ready for operation – see page 120 Procedure •...
Page 135 Roll-back protection on inclines (speedCONTROL) (o) 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. Automatic speed reduction (o) On trucks with automatic speed reduction, travel with the load handler lowered is possible at reduced speed only.
Page 136 Switching off slow travel Procedure • Release the slow travel button (9). In zone "B", the brake applies and the truck stops. In zone "F", the truck continues at slow travel speed. • Release the travel switch (110). Slow travel ends and the truck can now travel again at normal speed. 4.4.2 Changing the direction of travel CAUTION!
Page 137: Steering
Steering Procedure • Move the tiller (11) to the left or right. The truck is steered in the required direction. The electric steering has been designed such that the truck can still be steered should the electrical systems fail – see page 164.
Page 138: Brakes
Brakes WARNING! Accident risk The brake pattern of the truck depends largely on the ground conditions. uThe operator must take into account the travel route conditions when braking. uBrake with care to prevent the load from slipping. uDuring normal operation the truck is to be braked only with the service brake. CAUTION! Applying maximum braking can result in accidents Applying the Emergency Disconnect switch during travel will cause the truck to...
Page 139 4.6.1 Braking with the service brake Procedure • Move the tiller (11) up or down to one of the brake zones (B). The truck brakes to a halt regeneratively via the service brake. 4.6.2 Braking with the coasting brake Procedure •...
Page 140: Raising Or Lowering The Load Handler
Raising or Lowering the Load Handler WARNING! Risk of accidents during lifting and lowering People can be injured in the hazardous area of the truck. The hazardous area is defined as the area in which people are at risk from movements of the truck including the load handler etc.
Page 141 Automatic lower sequence of support arm lift (o) Only available with: EJC 212z - 220z With the support arm lift raised, loads can be stacked and retrieved with the load fork up to a lift height of 2200 mm (EJC 212z-216z) / 1580 mm (EJC 220z). For higher lift heights, the support arm lift must be lowered.
Page 142 4.7.1 Raising or Lowering the Load Fork Requirements – Truck ready for operation and switched on see page 121. Raising the load fork • Actuate the "raise load fork" button (108) until the desired lift height is reached. The load fork is raised. Lowering the load fork •...
Page 143 Lift limit (o) On trucks with lift limit, the load fork stops automatically when the lift height selected by the operating company is reached during a lifting operation. On trucks with the corresponding specification, the lift limit can be bypassed – see page 211.
Page 144 1800 mm 400 mm Procedure Requirements – EJC 212z/214z/216z/220z: Support arm lift fully raised (118). – Load fork height: 400 mm - 1800 mm. Procedure • Walk alongside the truck. • Press and hold the "lift" (116) or "lower" (117) inching button as required. •...
Page 145 Two-hand operation To allow the two-hand operation to release the lifting or lowering function, the operating sequence outlined must be adhered to. If a button is released, movement stops. If the button is pressed again within 5 seconds, the movement continues. In the event of a longer interruption, the operating sequence must be repeated.
Page 146 4.7.2 Raising or Lowering the Support Arms Only EJC 212z/214z/216z/220z Requirements – Truck ready for operation and switched on see page 121. Raising the support arms • Actuate the "raise support arms" button (107) until the desired support arm lift is reached.
Page 147 Procedure • Press the “Raise support arms” button (107) twice in quick succession. The support arms are raised continuously up to the maximum lift height. When the emergency disconnect switch is actuated, the automatic lift function is interrupted. The status and usage of automatic lifting are shown in the display unit, see page 167.
Page 148: Lifting, Transporting And Depositing Loads
Lifting, transporting and depositing loads WARNING! Unsecured and incorrectly positioned loads can cause accidents Before lifting a load, the operator must make sure that it has been correctly palletised and does not exceed the truck’s capacity. uInstruct other people to move out of the hazardous area of the truck. Stop working with the truck if people do not leave the hazardous area.
Page 149 4.8.1 Load Centre 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.
Page 150 4.8.2 Picking up loads with the load fork CAUTION! Danger when travelling with a raised load Travelling with a raised load on the load fork and no load on the support arms impairs the driving characteristics of the truck and cause it to tip over. uTravelling with a raised load on the load fork is permitted only when picking up and putting down a second load in double-deck mode.
Page 151 4.8.3 Lifting loads with support arms Only EJC 212z/214z/216z/220z Requirements – Load correctly palletised. – Capacity of the truck is sufficient for the load – see page 58. – Load handler evenly loaded for heavy loads. Procedure • Drive the truck slowly up to the pallet. •...
Page 152 4.8.4 Picking up the load with the double-decker function (o) CAUTION! Danger when travelling with a raised load Travelling with a raised load on the load fork and no load on the support arms impairs the driving characteristics of the truck and cause it to tip over. uTravelling with a raised load on the load fork is permitted only when picking up and putting down a second load in double-deck mode.
Page 153 When transporting, the load fork with the upper load must be lowered as close as possible to the lower load without being deposited on the lower load. 4.8.5 Transporting a load Requirements – Load raised correctly. – Load fork lowered to transport height (approx. 150 - 500 mm above the ground). –...
Page 154 4.8.5.1 Transporting a load with the double-deck function (o) 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. uIn order not to jeopardize the operational stability, the heavier pallet should always be transported underneath.
Page 155 4.8.6 Depositing a load NOTICE Avoid depositing the load suddenly to avoid damaging the load, load handler and the rack. Place of set-down for loads Loads must not be deposited on travel or escape routes, in front of safety mechanisms or operating equipment that must be accessible at all times. Requirements –...
Page 156 4.8.7 Stacking or unstacking the load WARNING! Increased risk of accidents during stacking and retrieving When stacking and retrieving, the truck is moved with the load raised, which increases the risk of tipover. uAdopt an appropriate, slower speed when stacking and retrieving. uAvoid cornering when stacking and retrieving.
Page 157: Use As A Lift Work Table
Use as a Lift Work Table WARNING! A raised load handler can cause accidents A stationary truck with a raised load handler is potentially hazardous in work areas. uPrevent any risk to personnel and materials. uNever load or discharge loads manually with a raised load handler in areas that are hazardous, with limited visibility or insufficient lighting.
Page 158: Troubleshooting
Troubleshooting This chapter enables the operator to localize and rectify basic faults or the results of incorrect operation himself. When trying to locate a fault, proceed in the order shown in the remedy table. If, after carrying out the following remedial action, the truck cannot be restored to operation or if a fault in the electronics system is displayed with a corresponding error code, contact the manufacturer’s service department.
Page 159: Truck Does Not Start
Truck does not start Event message Possible cause Action Battery connector not – Check the battery inserted connector and plug it in if necessary Emergency disconnect – Unlock the emergency switch pressed disconnect switch – see page 130 Truck switched off at key –...
Page 160: Truck Operates Only In Slow Travel In Rider Mode
Event message Possible cause Action E-0914 Tiller not in brake – Swing the tiller into position when the truck is the top or the bottom switched on brake zone, see page 133 E-1953 Travel switch actuated Follow the operating for more than 0.5 sequence: seconds with the tiller –...
Page 161: Load Cannot Be Lifted
Load cannot be lifted Event message Possible cause Action Truck not operational – Carry out all measures listed under “Truck does not start” Hydraulic oil level too low – Check the hydraulic oil level, see page 236 Battery discharge – Charge the battery, monitor has switched off see page 69 Faulty fuse...
Page 162: Moving A Truck Without Its Own Drive System
Moving a truck without its own drive system Drive Wheel Brake Assembly and Disassembly WARNING! Accidental truck movement When the brakes are deactivated, the truck must be parked on a level surface, as the brakes are no longer effective. uDo not install or remove the brake on slopes or inclines. uThe brake may only be installed or removed by the manufacturer's customer service department.
Page 163 • Disconnect the electrical plug connection (120) of the brake. • Unscrew three M5x45 screws (119) until the brake can be removed from the motor shaft. • Remove the brake. • Remove the wedges. The truck can be moved. Assembling the brake Requirements –...
Page 164: Emergency Feature Of The Electric Steering
Emergency feature of the electric steering WARNING! Report any defects immediately to your supervisor. Tag out the defective truck and take it out of service. Return the truck to service only when you have identified and rectified the fault. The drive motor contains mechanical stops that allow the truck to be steered should the electric steering fail.
Page 165: Load Handler Emergency Lowering
Load handler emergency lowering WARNING! Load handler emergency lowering uInstruct other people to move out of the hazardous area of the truck during emergency lowering. uNever step or stand underneath a raised load handler. uOnly operate the emergency lowering valve when standing next to the truck. uWhen the load handler is in the racking, emergency lowering is not permitted.
Page 166 • Prepare for emergency lowering at the mast lift valve (122). • Open the knurled screw (121) on the mast lift valve a few turns. • Perform emergency lowering at the lowering valve (123). • Carefully open and close the hex nut (124) on the lowering valve again to gradually lower the load handler.
Page 167: Optional Equipment
Optional Equipment Display Units 8.1.1 Versions The display unit and truck display are available in different versions. The operating concept and display are largely identical on all versions. Display or control Item Function element Display Depending on the selection, shows general information on the truck or information on the selected function.
Page 168 8.1.2 Display unit with 2-inch display 0,0 km/h Item Display or control Function element Battery charge The higher the fill level on the charge status status indicator, the higher the residual capacity of the battery. Function symbols The functions shown as function symbols are operated using the function key located underneath, see page 177.
Page 169 8.1.3 Display unit with 6-inch display The optional display unit with 6-inch display serves as an additional display for the assistance systems and simplifies control of the assistance and basic functions of the truck. The indicator lamps that appear on the display unit are dependent on the truck equipment.
Page 170 Item Display or control Function element Current load weight Shows the weight of the raised load. Rack height select Shows the currently selected lift height storage slot. (storage slot) Currently selected Shows the height to which the active rack height lift height select is assigned.
Page 171 8.1.4 Information field Display of event messages Current event messages are shown in the left section of the information line (128). Further information on the event messages shown: see page 158. Speed display (o) The right section of the information line shows the truck speed in km/h or mph. The setting for the displayed units can be configured by the manufacturer's customer service department.
Page 172: Symbol Meaning
8.1.5 Display symbols Any number of symbols can be shown in the display area. The symbols shown during operation depend on the operating and truck status. Symbol Meaning Colour Function Emergency stop Lights up in the case of automatic function deactivation due to truck malfunctions.
Page 173 Symbol Meaning Colour Function Double-click lifting: Green Lights up to indicate operational Continuous lifting readiness of the automatic lift function. up to intermediate Yellow Flashes when the load handler is height or lift limit raised via the automatic lift function. Lithium-ion battery Yellow Lights up to indicate a low temperature...
Page 174 Symbol Meaning Colour Function “Automatic support Green Lights up green when the function for arm lift lowering” automatic lowering of the support arm function active lift is active. The support arms Flashes Flashes yellow while the support arms are lowered. yellow are being lowered by the "automatic support arm lift lowering"...
Page 175 Symbol Meaning Colour Function Fine weighing Green Illuminates when the "fine weighing" function is active. Flashes during a measurement movement. Yellow Illuminates when tare mode is active. Flashes during a measurement movement while taring. Fine weighing Grey Appears during a measurement measurement movement in place of the weight.
Page 176 Symbol Meaning Colour Function Lift height limit Yellow The mast-lift lift limit has been reached. reached The lift limit cannot be circumvented. Lift height limit Flashing The mast-lift lift limit has been reached. reached green The lift limit can be circumvented. Missing lift height Flashing Flashes when sensor signals from the...
Page 177 8.1.6 Function Symbols Functions and operator menus that can be operated via the icons and keys of the display unit depend on the operating situation as well as the scope and settings of the truck. General Symbol Meaning Function Function selection Switches through the various functions and displays of the display unit.
Page 178 Symbol Meaning Function Storage Support Activates or deactivates the storage support. (positionCONTROL) ECO mode Activates or deactivates ECO mode. Settings Opens the Settings menu. Load centre Switches through the various load centre (operationCONTROL) presettings. Transmitter Mutes the transmitter or restores sound. Rack type preselection Switches through the preset rack types.
Page 179 Submenus Symbol Meaning Function Confirm To confirm an entry or a transponder code. Adding To add new access codes. Delete To delete selected access codes. Selection up For selecting the access codes or transponders and to scroll back during the log-in process.
Page 180 8.1.7 Using the Display: 8.1.7.1 Switching on the truck with an access code Procedure • Release emergency disconnect switch, see page 130. • Enter the access code with the buttons below the display (14). The truck is switched on. 8.1.7.2 Switching off the truck Procedure •...
Page 181 8.1.7.3 Changing the set-up code Requirements – The truck is switched on, see page 180. Procedure • Press the key below the "Settings" symbol (139). • Press the key below the "Change set- up code" symbol (140). • Enter the set-up code using the keys below the display unit (14).
Page 182 8.1.7.4 Adding a new access code Requirements – The truck is switched on, see page 180. Procedure • Press the key below the "Settings" symbol (139). • Press the key below the "Edit access code" symbol (144). The set-up code is requested. •...
Page 183 8.1.7.5 Deleting an access code Requirements – The truck is switched on, see page 180. Procedure • Press the key below the "Settings" symbol (139). • Press the key below the "Edit access code" symbol (144). The set-up code is requested. •...
Page 184 8.1.7.6 Displaying the log-in history The use of the last different access codes is displayed during the log-in process. The last log-in is displayed first. If multiple access codes are logged as being displayable simultaneously, the display area can be moved by scrolling forward or back. Requirements –...
Page 185: Keyless Access System
Keyless Access System The keyless access systems serve as a replacement for the key switch to release the truck. The keyless access system allows an individual code to be allocated to each operator or group of operators. Item Description Display unit (EasyAccess Softkey): –...
Page 186 8.2.1 General Information about the Use of Keyless Access Systems The default code is to be found on a sticker. When using for the first time, change the set-up code and remove the sticker! – Default code: 1-2-3-4 – Factory set-up code: 2-4-1-2 When allocating the codes, ensure the rider trucks are given a different code than pedestrian trucks.
Page 187 8.2.2.1 Activating the keypad Procedure • Release emergency disconnect switch, see page 130. • Enter the default code 1-2-3-4 using the keys below the display unit (14). The truck is switched on. • Press the key below the "Settings" symbol (139). •...
Page 188 8.2.2.2 Activating the transponder reader Procedure • Release emergency disconnect switch, see page 130. • Enter the default code 1-2-3-4 using the keys below the display unit (14). The truck is switched on. • Press the key below the "Settings" symbol (139).
Page 189 8.2.3 Using the Keypad 8.2.3.1 Switching on the truck with an access code Procedure • Release the emergency disconnect switch, see page 130. • Enter the access code with the keypad (16). The truck is switched on. Procedure • Press the key under the "Switch off" symbol (138) in the display unit. •...
Page 190 8.2.3.3 Changing the set-up code Requirements – The truck is switched on, see page 189. Procedure • Press the key below the "Settings" symbol (139). • Press the key below the "Change set- up code" symbol (140). • Enter the set-up code using the keypad (16).
Page 191 8.2.3.4 Adding a new access code Requirements – The truck is switched on, see page 189. Procedure • Press the key below the "Settings" symbol (139). • Press the key below the "Edit access code" symbol (144). The set-up code is requested. •...
Page 192 8.2.3.5 Deleting an access code Requirements – The truck is switched on, see page 189. Procedure • Press the key below the "Settings" symbol (139). • Press the key below the "Edit access code" symbol (144). The set-up code is requested. •...
Page 193 8.2.3.6 Displaying the log-in history The use of the last different access codes is displayed during the log-in process. The last log-in is displayed first. If multiple access codes are logged as being displayable simultaneously, the display area can be moved by scrolling forward or back. Requirements –...
Page 194 8.2.4 Operating the transponder reader NOTICE Take care not to damage the transponder. If the transponder is damaged, the truck cannot be switched on. 8.2.4.1 Switching on the truck with a transponder Procedure • Release the Emergency Disconnect switch, see page 130. •...
Page 195 8.2.4.3 Changing the set-up transponder Requirements – The truck is switched on, see page 194. Procedure • Press the key below the "Settings" symbol (139). • Press the key below the "Change set-up code" symbol (140). • Place the set-up transponder on the transponder reader (15).
Page 196 8.2.4.4 Adding a new transponder Requirements – The truck is switched on, see page 194. Procedure • Press the key below the "Settings" symbol (139). • Press below "Edit transponder" symbol (144). The set-up transponder is requested. • Place the set-up transponder on the transponder reader (15).
Page 197 8.2.4.5 Deleting a transponder Requirements – The truck is switched on, see page 194. Procedure • Press the key below the "Settings" symbol (139). • Press the key below the "Edit transponder" symbol (144). set-up transponder requested. • Place the set-up transponder on the transponder reader (15).
Page 198: Fleet Management System
• To return to the main menu, press the key below the "Back" symbol (143). The log-in process is displayed. Fleet Management System If equipped with a Jungheinrich fleet management component, see the "Jungheinrich fleet management system" operating instructions.
Page 199: Floor-Spot (O)
Floor-Spot (o) CAUTION! Risk of retinal damage due to blue light from blue Floor-Spot In accordance with IEC 62471, the blue floor spot is classified as risk group 2: Medium risk. Blue light can potentially damage the retina within a range of 400 nm to 780 nm.
Page 200: Transmitter (O)
Transmitter (o) The display unit with 6-inch display features a transmitter that informs the operator of the following: – operationCONTROL (o): Approaching the remaining lift height – SNAP function (o): Stopping of the load handler at a saved height. The transmitter can be muted. A corresponding symbol then appears on the display unit.
Page 201: Fine Weighing (O)
Fine weighing (o) As standard, the load weight is indicated with an accuracy of 50 kg. Activating the "fine weighing" function increases the accuracy to up to 10 kg. The display accuracy depends on the load weight. Load weight Accuracy with "fine weighing" function Up to 200 kg ±10 kg Up to 700 kg...
Page 202 Taring To adjust to the truck configuration, the "fine weighing" function must be tared as a one-off. Taring forms part of the initial commissioning of the truck and does not need to be repeated so long as no changes are made to the truck. Observe the instructions for lifting or lowering the load fork –...
Page 203 Using the "fine weighing" function Observe the instructions for lifting or lowering the load fork – see page 142. Requirements – Load on load fork. – Load fork raised slightly (>400 mm), but not beyond the free lift. – EJC 212z/214z/216z/220z: Support arms fully lowered. –...
Page 204: Positioncontrol (O)
(o) A Jungheinrich assistance system supports the operator, but does not release them from their responsibilities: When using the assistance system, responsibility for the safe operation of the truck lies with the operator. The operator must also be familiar with the system amenities, as well as potential hazards in the event of a failure.
Page 205 Display symbols Symbol Meaning Colour Function Active rack height Green Shows the currently active rack height select select. On the symbol shown, lift (positionCONTROL) height 3 is active. Currently selected White Shows the height to which the active lift height rack height select is assigned.
Page 206 Saving lift heights Procedure • Truck with rack type preselection: Press the "rack type preselection" function key to select the required rack type. Rack types are represented by capital letters (A-D). • Press the "rack height select" function key to select the required lift height storage slot.
Page 207 8.7.1 SNAP Function The SNAP function makes it easier for the operator to approach the saved lift heights when lifting and lowering the load fork. Procedure • When the load fork gets near a saved lift height during lifting or lowering, briefly ease off the "raise load fork"...
Page 208 8.7.2 Storage Support When storage support is activated, the load handler stops 100 mm above the preselected lift height. Procedure • Press the "storage support" function button. The load handler stops 100 mm above the saved lift heights. When using the SNAP function, the storage support is activated automatically. Function button assignment Symbol Meaning Function...
Page 209: Operationcontrol (O)
(o) A Jungheinrich assistance system supports the operator, but does not release them from their responsibilities: When using the assistance system, responsibility for the safe operation of the truck lies with the operator. The operator must also be familiar with the system amenities, as well as potential hazards in the event of a failure.
Page 210 8.8.1 Load centre preselection (o) The load centre preselection (136) allows the operator to set the area of the load handler in which the load centre is currently located. Procedure • Press the "load centre" function key until the desired load centre selection appears on the display.
Page 211: Lift Limit (O)
Lift Limit (o) On trucks with a lift limit, the load fork stops automatically when a set lift height is reached during the lifting process. In addition to the fixed end height, it is also possible to set intermediate heights, which can be overridden. Display symbols Symbol Meaning Colour...
Page 212 Overriding an intermediate height • Raise the load fork to the automatic cut-out. The display symbol flashes green. • Release the "raise load fork" button. The green display symbol lights up continuously. • Press the "raise load fork" button twice in quick succession and hold (double- click).
Page 213: Overload Display (O)
8.10 Overload Display (o) 0,0 km/h Shortly before a load leaves the permissible area according to the capacity plate, the operator is informed as follows: – The display area of the display unit is highlighted red (see figure). – The transmitter issues an acoustic signal – see page 200. In this case, the load is raised slowly and stops fully before leaving the permissible area.
Page 214: Foot Protection Tiller
8.11 Foot Protection Tiller When the tiller is slightly deflected (range o), the operator is very close to the truck. In this case the speed of the industrial truck is reduced, thus increasing safety for the operator. The display unit shows the "slow travel" symbol in yellow. As soon as the tiller is deflected more, normal travel speed is enabled and the symbol goes out.
Page 215: Forks
8.12 Forks Item Description Fork arms Locking lever Fork stop Fork carriage Retaining bolts...
Page 216 8.12.1 Adjusting the forks WARNING! Unsecured and incorrectly adjusted forks can cause accidents Before adjusting the forks make sure the retaining bolts (154) are fitted. uAdjust the forks so that both forks are equidistant from the outside edge of the fork carriage.
Page 217 8.12.2 Replacing the forks WARNING! Unsecured forks can cause injury You can injure your legs when replacing the forks. uNever pull the forks towards your body. uAlways push the forks away from your body. uSecure heavy forks with lifting slings and a crane before pushing them down from the fork carriage.
Page 219: F Truck Maintenance
The manufacturer cannot be held liable for damage caused by the use of non-original spare parts. product-related electronic spare parts catalogue found (www.jungheinrich.de/spare-parts-search) by entering the serial number. The serial number can be found on the data plate, see page 57.
Page 220: Operational Safety And Environmental Protection
Operational Safety and Environmental Protection WARNING! Risk of accidents and component damage Any modification to the truck, in particular the safety mechanisms, is prohibited. Exception: Operating companies should only make changes or have changes made to powered industrial trucks if the manufacturer is no longer operating in the field and there is no successor to the business;...
Page 221: Maintenance Safety Regulations
Maintenance Safety Regulations Maintenance and repair personnel The manufacturer has a customer service department specially trained for these tasks. A maintenance contract with the manufacturer will support trouble-free operation. Truck maintenance, repair work and changing of parts requiring replacement must only be carried out by specialist personnel.
Page 222: Working On The Electrical System
Working on the electrical system WARNING! Risk of accidents due to electrical current Make sure the electrical system is voltage-free before starting work on it. The capacitors in the control unit must be completely discharged. The capacitors are fully discharged approx. 10 minutes after disconnecting the electrical system from the battery.
Page 223: Hydraulic System
Hydraulic system WARNING! Leaky hydraulic systems can result in accidents Hydraulic oil can escape from leaky and faulty hydraulic systems. uReport any defects immediately to your supervisor. uMark defective truck and take out of service. uDo not return the industrial truck to service until you have identified and rectified the fault.
Page 224: Lift Chains
Lift Chains WARNING! Risk of accident from non-lubricated and incorrectly cleaned lift chains Lift chains are safety-critical parts. Lift chains must not show signs of serious contamination. Lift chains and pivot pins must always be clean and sufficiently lubricated. uThe lift chains are cleaned by wiping or brushing. Significant contamination can be softened by a paraffin derivative such as petroleum.
Page 225: Lubricants And Lubrication Schedule
Lubricants and Lubrication Schedule Handling consumables safely WARNING! Improper handling is hazardous to health, life and the environment Consumables can be flammable. uKeep consumables away from hot components and naked flames. uAlways keep consumables in prescribed marked containers. uAlways fill consumables in clean containers. uDo not mix up different grades of consumable.
Page 226 CAUTION! Consumables and used parts are an environmental hazard Used parts and consumables must be disposed of in accordance with the applicable environmental-protection regulations. Oil changes should be carried out by the manufacturer's customer service department, whose staff are specially trained for this task.
Page 227: Lubrication Schedule
Lubrication Schedule EJC 212/214/216/220 g Contact surfaces Cold store application b Gear oil filler neck Grease nipple Hydraulic oil filler plug...
Page 228 EJC 212z/214z/216z/220z g Contact surfaces Cold store application b Gear oil filler neck Grease nipple Hydraulic oil filler plug...
Page 229 EJC 212b/214b/216b/220b g Contact surfaces Cold store application b Gear oil filler neck Grease nipple Hydraulic oil filler plug...
Page 230 The Jungheinrich hydraulic oil is available only from the Jungheinrich service department. Use of a named alternative hydraulic oil is permitted, but may lead to a decline in functionality. The Jungheinrich hydraulic oil may be mixed with one of the named alternative hydraulic oils.
Page 231: Maintenance And Repairs
Maintenance and repairs Preparing the truck for maintenance and repair work WARNING! Risk of accident when working under the load handler or truck when not correctly secured Failure to secure the raised load handler or truck correctly can result in uncontrolled lowering of the load handler or can cause the truck to tip or slip, which in turn can lead to fatal injuries.
Page 232: Placing The Options Bracket In The Maintenance Position
Removing the front panel (truck with folding stand-on platform) Requirements – Truck prepared for maintenance and repair work – see page 231. Tools and Material Required – Allen key (size 5) Procedure • Undo the screws on the front panel (155) with the Allen key. •...
Page 233: Lifting And Jacking Up The Truck Safely
Lifting and jacking up the truck safely WARNING! Risk of injury when lifting and jacking up the truck When lifting and jacking up the truck, there is a risk of the truck unexpectedly tipping or slipping. uJack up the truck on level ground. uSecure the truck against unintentional movement.
Page 234: Cleaning
Cleaning 5.5.1 Cleaning the truck CAUTION! Risk of fire due to use of flammable cleaning agents Using flammable cleaning agents increases the risk of fire. uDo not use any flammable cleaning agents when cleaning. uDisconnect the battery before starting cleaning work. uBefore cleaning, take necessary safety measures to prevent spark formation (e.g.
Page 235 5.5.2 Cleaning the electrical system assemblies NOTICE Risk of electrical-system damage Cleaning the electronic system assemblies (controllers, sensors, motors etc.) with water can damage the electrical system. uDo not clean the electrical system with water. uClean the electrical system with weak suction or compressed air (use a compressor with a water trap) and a non-conductive, anti-static brush.
Page 236: Checking The Hydraulic Oil Level
Checking the hydraulic oil level 5.6.1 Performing the check NOTICE If a leak is detected in the hydraulic system, the truck must be decommissioned and repaired by specialist personnel. Marking Volume approx. 8.3 l approx. 7.5 l approx. 6.5 l Checking the oil level Requirements –...
Page 237 5.6.2 Hydraulic oil level setpoints EJC 212/214/216/220, EJC 212b/214b/216b/220b Volume (marking) Mast type Lift height 214-216 212b 214b-216b 220b < 3600 mm ≥ 3600 mm < 3600 mm ≥ 3600 mm < 6000 mm 6000 mm < 4500 mm ≥ 4500 mm...
Page 238: Checking The Attachment And Wear Of The Wheels
Checking the attachment and wear of the wheels Replace the wheels if the wear limit (161) has been reached. The wheel nuts on the drive wheel must be retightened in accordance with the maintenance intervals indicated in the maintenance checklist, see page 245. Tightening the wheels nuts Requirements –...
Page 239: Checking The Electrical Fuses
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. Checking the electrical fuses Item Description Protection...
Page 240 • Clean the battery, grease the terminals and connect the battery. • Charge the battery, see page 69. • Start up the truck, see page 120.
Page 241: Decommissioning The Industrial Truck
Decommissioning the Industrial Truck If the truck is to be out of service for more than a month, it must be stored in a frost-free and dry room. All necessary measures must be taken before, during and after decommissioning as described hereafter. When the truck is out of service it must be jacked up so that all the wheels are clear of the ground.
Page 242: Restoring The Truck To Service After Decommissioning
Restoring the truck to service after decommissioning Procedure • Thoroughly clean the truck – see page 234. • Lubricate the forklift truck according to the lubrication schedule – see page 227. • Equipped with lead-acid battery (t): Clean the battery, grease the battery terminal screws with terminal grease and connect the battery.
Page 243: Final De-Commissioning, Disposal
Final de-commissioning, disposal Final de-commissioning or disposal of the truck in must be performed in accordance with the regulations of the country of use. In particular, regulations governing the disposal of batteries, consumables and electronic and electrical systems must be observed.
Page 245: Maintenance, Inspection And Changing Of Maintenance Parts Requiring Replacement
G Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement WARNING! Lack of maintenance can result in accidents Failure to perform regular maintenance and inspections can lead to truck failure and poses a potential hazard to personnel and equipment. uThorough and expert maintenance and inspections are among the most important requirements for the safe operation of the industrial truck.
Page 246: Maintenance Contents Ejc/B
Maintenance Contents EJC/B 210/212/214/216/218/220 Issued on: 2023-03-08 10:00 Owner To be performed every 50 service hours, but at least once a week. 1.1.1 Maintenance contents 1.1.1.1 Standard equipment Brakes Test the brake. Hydraulic operations Lubricate the load chains. Correct the hydraulic-oil level. Steering Test the tiller return function.
Page 247 Travel Collision safety switch for functionality and damage Check wheels for wear and damage Chassis/structure Industrial truck for damage and leaks Check labels for legibility, completeness and plausibility Check doors or covers for damage Mechanism to protect against trapping and shearing is present, secure, functions correctly and is free of dirt and damage Protective screen panel or protective grille for damage Hydraulic operations...
Page 248: Customer Service
Lead-acid battery, international Power supply Check the battery cable connections for secure attachment Check battery and battery components for damage Warning zone lights, red/blue Electrical system Test lighting and check for damage Lead-acid battery Power supply Check the battery cable connections for secure attachment Customer Service In accordance with the EJC/B 210/212/214/216/218/220 service interval, to be performed every 1000 service hours, but at least once a year.
Page 249 Agreed services Carry out a test run with the rated capacity or a customer-specific load. Lubricate the truck according to the lubrication schedule. Demonstration after maintenance. Steering Test the tiller return function. 1.2.1.2 Optional Equipment Standard on-board charger Battery charger Test the immobiliser on trucks with an on-board charger.
Page 250 Power supply Clean the battery. Clean and grease the battery terminals. Measure acid density and battery voltage. Correct the battery-acid level using demineralised water. Lead-acid battery Electrical system Perform insulation inspection. Power supply Clean the battery. Clean and grease the battery terminals. Measure acid density and battery voltage.
Page 251 Chassis/structure Industrial truck for damage and leaks Check chassis connections and screw connections are securely attached and check for damage Check labels for legibility, completeness and plausibility Check mast is securely attached Mechanism to protect against trapping and shearing is present, secure, functions correctly and is free of dirt and damage Protective screen panel or protective grille for damage Hydraulic operations...
Page 252 Aquamatic Power supply Aquamatic plug, hose connections and float for functionality and sealing Flow indicator for functionality and sealing Lateral battery removal Power supply Battery latch and battery attachment for correct function and damage Shock sensor/data recorder Electrical system Check shock sensor/data recorder is securely attached and check for damage Radio data System components Scanner and terminal for secure fit, functionality and damage...
Page 253 Strobe light/warning beacon Electrical system Test strobe light/warning beacon and check for damage On-board charger 35A Battery charger Mains plug and mains cable for damage Fan for correct functionality and damage Cables and electrical connections for secure fit and damage Double-click lifting Hydraulic operations Sensors for secure fit and damage...
Page 254 1.2.3.1 Standard equipment maintenance part service hours months Gear oil 10000 Hydraulic system breather filter 2000 Hydraulic oil 2000 Hydraulic oil filter 2000 1.2.3.2 Optional Equipment Cold store application maintenance part service hours months Hydraulic oil 1000 Hydraulic oil additive 1000...
Page 255: Maintenance Contents Ejcz
Maintenance Contents EJCz 210/212/214/216/220 Issued on: 2023-03-08 10:00 Owner To be performed every 50 service hours, but at least once a week. 2.1.1 Maintenance contents 2.1.1.1 Standard equipment Brakes Test the brake. Hydraulic operations Lubricate the load chains. Correct the hydraulic-oil level. Steering Test the tiller return function.
Page 256 Travel Collision safety switch for functionality and damage Check wheels for wear and damage Chassis/structure Industrial truck for damage and leaks Check labels for legibility, completeness and plausibility Check doors or covers for damage Protective screen panel or protective grille for damage Hydraulic operations Test hydraulic system Check hydraulic connections, hoses and pipes are securely attached and check for leaks...
Page 257 On-board charger 35A Battery charger Mains plug and mains cable for damage Daytime running light / lighting Electrical system Test lighting and check for damage Lead-acid battery, international Power supply Check the battery cable connections for secure attachment Check battery and battery components for damage Warning zone lights, red/blue Electrical system Test lighting and check for damage...
Page 258 Hydraulic operations Test the sensors. Adjust the slide pieces. Adjust the load chains. Lubricate the load chains. Test emergency lowering. Correct the hydraulic-oil level. Test the pressure relief valve. Agreed services Carry out a test run with the rated capacity or a customer-specific load. Lubricate the truck according to the lubrication schedule.
Page 259 On-board charger 35A Battery charger Test the immobiliser on trucks with an on-board charger. Clean the fan. Carry out a potential measurement on the chassis while charging is in progress. Double-click lifting Hydraulic operations Test the sensors. Test the hydraulic function and safety circuit. Lead-acid battery, international Electrical system Perform insulation inspection.
Page 260 2.2.2.1 Standard equipment Electrical system Cables and motor for secure fit and damage Warning and safety equipment in accordance with the operating instructions Functionality of display and controls Test emergency disconnect switch and check for damage Contactors and/or relays for wear and damage Check electrical wiring for damage (insulation damage, connections) and check whether the fuse ratings are correct Check carbon brushes for wear...
Page 261 Hydraulic operations Check hydraulic connections, hoses and pipes are securely attached and check for leaks and damage Check fork arms or load handler for wear and damage Check mast and fork carriage stops are present and secure Check cylinder seals for leaks and damage Tie/plunger rods for uniform adjustment, wear and damage Check the hoses, pipes and connections are securely attached and check for wear, leaks, damage, blisters and kinks...
Page 262 Radio data System components Scanner and terminal for secure fit, functionality and damage Fuses for correct ratings Check cables are securely attached and check for damage Electric steering Steering Electric steering and its components for function, wear and damage Weigher sensors/switches Electrical system Weigher for damage Access module...
Page 263 Double-click lifting Hydraulic operations Sensors for secure fit and damage Daytime running light / lighting Electrical system Test lighting and check for damage Lead-acid battery, international Power supply Check battery, battery cables and cell connectors are securely attached and check for damage Ensure safety labels are present and check for damage Warning zone lights, red/blue...

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Jungheinrich EJC 212 Operating Instructions Manual

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