ERC/ERC-Z 12/14/16: Operating Instructions

ERC/ERC-Z 12/14/16 10.
01-
G
Operating instructions
50126632
06.02
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Foreword
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. Each chapter
starts with page 1. The page identification consists of a chapter letter and a page
number.
For example: Page B 2 is the second page in chapter B.
The operating instructions detail different truck models. When operating and servicing
the truck, make sure that the instructions apply to your truck model.
Safety instructions and important explanations are indicated by the following

graphics:
f Used before safety instructions which must be observed to avoid danger to

personnel.
m Used before notices which must be observed to avoid material damage.

A Used before notices and explanations.
t Used to indicate standard equipment.
o 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.
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Am Stadtrand 35
22047 Hamburg - GERMANY
Telephone: +49 (0) 40/6948-0

www.jungheinrich.com
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0108.GB

Table of contents
A Correct use and application of the truck
B Truck description
1 Application ........................................................................................... B 1
2 Assemblies ......................................................................................... B 2
3 Technical data - standard version ....................................................... B 3
3.1 Performance data ................................................................................ B 3
3.2 Dimensions ......................................................................................... B 4
3.3 EN standards ...................................................................................... B 5
3.4 Conditions for application .................................................................... B 5
4 Location of instruction labels and identification labels ........................ B 6
4.1 Truck identification plate ..................................................................... B 7
4.2 Load capacity ...................................................................................... B 7
4.3 Load capacity, wheel-arm lifting device .............................................. B 8
4.4 Label/Order/Inventory/Service No. ..................................................... B 8
C Transportation and commissioning
1 Transportation by crane ...................................................................... C 1

2 First commissioning ............................................................................ C 1
3 Moving the truck with the drive unit inoperative .................................. C 2
D Battery - Servicing, recharging, replacement
1 Safety regulations governing the handling of lead-acid batteries ........ D 1

2 Battery type ......................................................................................... D 2
3 Exposing the battery ........................................................................... D 2
4 Charging the battery ............................................................................ D 3
4.1 Charging the battery with stationary battery charger .......................... D 3
4.2 Recharging the battery with integrated battery charger (o) ................ D 4
5 Removing and installing the battery .................................................... D 7
5.1 Remove battery by lifting it upwards (truck without
wheel-arm lifting device) ..................................................................... D 7
5.2 Remove battery by lifting it upwards (truck with wheel-arm
lifting device) ....................................................................................... D 8
5.3 Lateral battery change (o) .................................................................. D 9
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E Operation
1 Safety regulations governing the operation of the fork lift truck .......... E 1
2 Description of controls and indicating instruments .............................. E 2
3 Starting up the truck ............................................................................ E 6
4 Operation of the fork lift truck .............................................................. E 8
4.1 Safety regulations applicable when operating the truck ...................... E 8
4.2 Driving, steering, braking .................................................................... E 9
5 Picking up and setting down loads ...................................................... E 12
5.1 Safe parking of the truck ..................................................................... E 16
6 Keyboard (CANCODE) (o) ................................................................. E 17
6.1 Functions ............................................................................................. E 17
6.2 Commissioning .................................................................................... E 18
6.3 Indicators ............................................................................................. E 19
6.4 Keys .................................................................................................... E 20
6.5 Master mode ....................................................................................... E 20
6.6 Parameter ........................................................................................... E 22
7 Display instrument (CANDIS) (o) ....................................................... E 26
7.1 Discharge monitor function ................................................................. E 27
7.2 Operating hours display ...................................................................... E 27
7.3 Switch-on test ...................................................................................... E 27
8 Fault location ....................................................................................... E 28
F Maintenance of the fork lift truck
1 Operational safety and environmental protection ................................ F 1

2 Safety regulations applicable to truck maintenance ............................ F 1
3 Servicing and inspection ..................................................................... F 3
4 Maintenance checklist ....................................................................... F 4
5 Lubrication schedule .......................................................................... F 6
5.1 Fuels, coolants and lubricants ............................................................. F 7
6 Notes on maintenance ........................................................................ F 8
6.1 Preparation of the truck for servicing and maintenance operation ...... F 8
6.2 Opening the front cover ....................................................................... F 8
6.3 Check hydraulic oil level ...................................................................... F 9
6.4 Check the transmission oil level .......................................................... F 9
6.5 Checking the electric fuses ................................................................. F 10
6.6 Recommissioning the truck ................................................................. F 11
7 Decommissioning the fork lift truck ..................................................... F 11
7.1 Operations to be performed prior to decommissioning ....................... F 11
7.2 Measures to be taken during decommissioning .................................. F 11
7.3 Recommissioning the truck ................................................................. F 12
8 Safety checks to be performed at regular intervals and following
any untoward incidents (D: Accident prevention check
according to VBG 36) .......................................................................... F 12
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A Correct use and application of the truck
A The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are
included in the scope of delivery for this truck. The guidelines are part of these oper-
ating instructions and must always be heeded. National regulations are fully applica-
ble.
The fork lift truck described in these operating instructions is a truck that is suitable
for lifting and transporting loads.
It must be used, operated and maintained according to the information in these oper-
ating instructions. Any other uses are outside the design envelope and can lead to
injury to persons or damage to equipment and property. Above all, overloading
caused by excessively heavy or unbalanced loads must be avoided. The max. admis-
sible load to be picked up is indicated on the identification plate or load diagram label
shown on the truck. The fork lift truck must not be operated in spaces subject to fire
or explosion hazards, or in spaces where corrosive or very dusty atmospheres pre-
vail.
Duties of the user: A “user” within the meaning of these operating instructions is de-
fined as any natural or legal person who either uses the fork lift truck himself, or on
whose behalf it is used. In special cases (e.g. leasing or renting), the user is consid-
ered the person, who, in accordance with existing contractual agreements between
the owner and the user of the fork lift truck, is charged with the observance of the op-
erating duties.
The user must ensure that the truck is not abused and only used within its design lim-
its and that all danger to life and limb of the operator, or third parties, is avoided. In
addition to this, it must be ensured that the relevant accident prevention regulations
and other safety-related provisions, as well as the operating, servicing and mainte-
nance guidelines, are observed. The user must also ensure that all persons operating
the truck have read and understood these operating instructions.
m If these operating instructions are not observed the warranty becomes void. The
same applies if improper works are carried out at the device by the customer and/or
third parties without permission of our Customer Service.
Mounting of attachments: The mounting or installation of any attachments which

will interfere with, or supplement, the functions of the truck is permitted only after writ-
ten approval by the manufacturer has been obtained. If necessary, the approval of
local authorities has to be obtained.
Any approval obtained from local authorities does not, however, make the approval
by the manufacturer unnecessary.
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B Truck description
1 Application
The truck is an electric pedestrian stacker in four-wheel construction with foldable

driver platform.
It is designed for transporting and lifting goods on level ground. The wheel arm lift (on-
ly for ERC-Z trucks) increases the ground clearance for transport over unevenground.
Depending on the design, the hoist frame permits loads to be stacked and retrieved
up to a max. height of 5.35 m and to be transported over longer distances. The truck
capacity is indicated on the identification label or the capacity label Qmax.
Due to its high travelling speed, the ERC 14/16 is equipped with safety extensions.
Truck types, capacities and motor output
Typ Capacity Motor output

ERC / ERC-Z 12 1,200kg 2.0kW
ERC / ERC-Z 14 1,400kg 2.0kW
ERC / ERC-Z 16 1,600kg 2.0kW
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B1

2 Assemblies
6
5
3
2
1
7
14
8
13
9
10
12
11
Item Designation Item Designation

1 o Keyboard 8 t Wheel arms
(CANCODE)
2 o Display instrument 9 o Lifting linkage (Only for wheel-arm-
(CANDIS) lifting)
3 t Key switch 10 o Charger
4 t Control shaft 11 t Supporting wheel
5 t Controller 12 t Hinged driver standing platform
6 t Free-view hoist frame 13 t Driven wheel
7 t Master switch 14 o Safety extension*)
t = Standard equipment o = Optional equipment

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*) not with vehicles with load bearing capacity of 1200kg
B2

3 Technical data - standard version
A Indication of technical data according to VDI 2198,

subject to modification and supplementing.
3.1 Performance data
Designation ERC 12 ERC 14 ERC 16

ERC-Z12 ERC-Z14 ERC-Z16
Q Rated capacity 1,200 1,400 1,600 kg
c Load centre distance 600 600 600 mm
Travelling speed 6.0 / 6.0 7.5 / 8.5 7.0 / 8.5 km/h
with / without rated load
Lifting speed 19/26 18/26 17/26 cm/s
with / without rated load (controllable (ZT))
Lowering speed 43/43 43/43 43/43 cm/s
with / without rated load (controllable (ZT))
Max. climbing capacity (5 min.) 9/16 8/16 7/16 %
with / without rated load
h4
h3
l
c
h14 max
h1
h14 min
h2
983
Q
167
x
h13
h5
m2
s
l2
y 188 428
l1
e
500
b11
b1
b5
Wa
a/2
a/2
Ast
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B3

3.2 Dimensions
(all dimensions in mm)
Designation ERC 12/ ERC 14/ ERC 16/

ERC-Z12 ERC-Z14 ERC-Z16
l2 Design length of front 856*)/888*) 856*)/888*) 856**)/888**)
h13 Height of fork when lowered 90 90 90
h1 Design height 1,700 - 2,600 1,700 - 2,600 1,700 - 2,600
(depending on the mast)
h2 Free lift (ZZ and DZ) 1,219 - 2,119 1,219 - 2,119 1,169 - 2,069
h3 Lift (depending on the mast) 2,500 - 5,350 2,500 - 5,350 2,400 - 5,250
h4 Extended height of mast 2,981 - 5,831 2,981 - 5,831 2,931 - 5,781
(depending on the mast)
h5 Initial lift 122 122 122
y Wheelbase 1,357/1,599 1,357/1,599 1,357/1,599
B/b1 Overall width 800/836 800/836 800/836
Wa Turning radius 1,565/1,804 1,565/1,804 1,565/1,804
Ast Width of aisle with pallets 2,414*)/ 2,414*)/ 2,414**)/
800 × 1,200 lengthwise 2,483*) 2,483*) 2,483**)
Ast Width of aisle with pallets 2,441*)/ 2,441*)/ 2,441**)/
1,000 × 1,200 crossways 2,565*) 2,565*) 2,565**)
Dead weight Refer to truck identification label
*) at DZ+35
**) at DZ+43
h4
h3
l
c
h14 max
h1
h14 min
h2
983
Q
167
x
h13
h5
m2
s
l2
y 188 428
l1
e
500
b11
b1
b5
Wa
a/2
a/2
Ast
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B4

3.3 EN standards
Continuous sound level: 68 dB(A)
according to EN 12053 as stipulated in ISO 4871
A The continuous sound level is a value averaged according to standard regulations,

taking the sound pressure level into account when driving, lifting and idling. The
sound pressure level is measured at the ear.
Vibration: 0.96 m/s2
according to prEN 13059
A The swinging acceleration acting on the body in its operating position is, according to
standard regulations, the linear integrated, weighted acceleration in the vertical pla-
ne. It is determined by driving over bumps with a constant speed.
Electromagnetic compatibility (EMC)

The manufacturer confirms compliance with the limit va-
lues for electromagnetic emission and interference im-
munity as well as testing of static electricity discharge ac-
cording to prEN 12895 and the references to other
standards contained therein.
A Electrical or electronic components and their arrangement may only be modified after
written approval by the manufacturer has been obtained.
3.4 Conditions for application
Ambient temperature:
- during operation: 5°C to 40°C
A Industrial trucks must be specially equipped and approved for continuous use in en-
vironments with temperatures below 5°C or in cold stores respectively with extreme
temperatures or humidity changes.
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B5

4 Location of instruction labels and identification labels
17
Xxx
Xxxx
18
Xxxxxxx Xxxxxx
Xxxxxxxxx Xxxxxx
Xxxxxxxxx Xxxxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxx

Xxxxxxxxxx kg Xxxxxxxxxxxxxxxxx mm Xxxxxxxxxxxxxxxxxxx kg
Xxxxxxxxx Xxxxxxxxxxxxxxxxxxx xxxxxxxxxx

Xxxxxxxxxx V Xxxxxxxxxxxxxxxxx kW xxxxxxxx kg
Xxxxxxx
Xxxxxx
Xxxxx Xxxxxxxxxxxxxxxx
Xxxx Xxxxxxxxxxxxxxxxxx
16 19
15
20 1
11
12
2 1
9 8 7
0
200
3
6 4
17 5
21
17
22
23
Item Designation
15 Capacity (only ERC-Z)
16 Truck identification plate
17 Attachment point of hooks for transportation by crane
18 Prohibitive sign “Keep away from under the load lifting device”
19 Prohibitive sign “Do not reach through the hoist frame”
20 UVV control label
21 Capacity
22 Battery identification plate (located in battery compartment)
23 Label “CAUTION: Low-voltage electronics”
A The capacity label (21) indicates the maximum capacity of the truck as Qmax. The
rated capacity as shown must not be exceeded.
The “CAUTION: Low-voltage electronics” warning signs (23) are visible after opening
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the corresponding hood (refer to chapter F).
B6

4.1 Truck identification plate
24 36
25 Xxx
Xxxx
35
Xxxxxxx Xxxxxx
Xxxxxxxxx Xxxxxx
26 Xxxxxxxxx Xxxxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxx 34

Xxxxxxxxxx kg Xxxxxxxxxxxxxxxxx mm Xxxxxxxxxxxxxxxxxxx kg
27 Xxxxxxxxx
Xxxxxxxxxx V
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxx kW
xxxxxxxxxx
xxxxxxxx kg
Xxxxxxx
33
28 Xxxxxx
Xxxxx
Xxxx
Xxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx
32
29
30 31
Item Designation Item Designation

24 Type 31 Drive power in kW
25 Serial No. 32 Customer no.
26 Rated capacity in kg 33 Min./max. battery weight in kg
27 Battery: Voltage V 34 Dead weight without battery in kg
28 Manufacturer 35 Year of manufacture
29 Order no. 36 Manufacturer logo
30 Load centre distance in mm
A In the event of queries relating to the truck or spare part orders, please state the serial
No. (25) of the truck.
4.2 Load capacity
f The label (21) includes a table indicating

the loading capacity (Q in kg) in relation
21
to the load centre distance (D in mm)
and the lifting height (H in mm). -Nr.
Serien-Nr.
Qkg
Hmm
Dmm
The arrow-shaped markings on the inner mast (37) and outer mast
(38) show the driver when he has reached the lifting height limits that 37 38
is defined on the load capacity label (21).
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4.3 Load capacity, wheel-arm lifting device
Trucks with a wheel-arm lifting device are provided with an extra label (15) indicating
the permissible assignment to wheel-arm lifting device and main lifting device.
4.4 Label/Order/Inventory/Service No.

39
40
41
Item Description
39 Order no.
40 Inventory No.
41 Full Service No.
A This label contains the Full Service No. and is only handed out when a service con-
tract is being concluded.
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B8

C Transportation and commissioning
1 Transportation by crane
f Only use lifting equipment with sufficient bearing capacity (loading weight see identi-
fication label on truck).
If trucks are to be lifted that are provided with a wheel-arm lifting device, be careful
not to protrude the lifting cylinders while the truck is being lifted. If the device is com-
pletely protruded, there is the risk that the cylinder protection is being released due
to overloading.
A A hoisting point (2) is provided at the hoist frame for loading the truck with the help of
hoisting gear.
Trucks that are provided a with wheel-arm lifting device, have two more hoisting
points (1) for loading.
– Park the truck and render it safe

(refer to chapter E).
– Attach the hoisting gear to the stop (2)
on the hoisting mast. 2
– In case of trucks that are provided with
1
a wheel-arm lifting device, the hoisting
gear can also be attached to the stops
(1) on the vehicle chassis.
m Secure the hoisting gear to the hoisting

points ensuring that the hoisting gear will
not slip! The hoisting gear must be atta-
ched in such a way that it does touch any
add-on parts while the truck is being lif-
ted.
Trucks with wheel-arm lifting device
must hang horizontally or slightly incli-
ned in the direction of the lifting device.
2 First commissioning
m The truck must only be operated on battery current. Rectified alternate current will da-
mage the electronics. Cables connected to the battery (towing cable) must be less
than 6 meters in length.
f It is prohibited to hoist loads when the truck is operated via a towing cable with an
external battery.
In order to prepare the truck for work following delivery or transportation, the following
operations must be performed:
– Check whether the equipment is complete and in perfect condition.

– If required, mount the battery, make sure not to damage the battery cable
(see chapter D).
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A At trucks with an optionally built-in battery charger, adjust the characteristics (loading
cam) (see chapter D).
– Load the battery (see chapter D).

– If required, check whether the settings of the combined instrument correspond to
the battery (see chapter D).
– Commission the truck as prescribed
(see chapter E).
A If the truck is parked for longer periods, the running surfaces of the wheels may be
flattened. However, this flattening will disappear quickly when the truck is being
driven.
3 Moving the truck with the drive unit inoperative
f This operating mode is not permitted when negotiating inclines and gradients.
If the truck has to be moved after a failure has rendered it immobile, proceed as fol-
lows:
– Set the master switch to position “OFF”.

– Set the key switch to position “OFF” (“0”)
and remove the key.
4
– If a code lock is installed, the
o-key must be pressed. 3
– Ensure that the truck cannot accidentally
move.
– Open the front cover and set it down 3
(refer to chapter F).
– Slacken the lock nuts (3) and tighten the
screws (4).
The brake has now been released and the
truck can be moved.
f After arriving at the repair bay, ensure that

the brake is put back to its initial state. The
truck must on no account be parked with
the brake in the released condition.
– Loosen the screws (4) by approx. 5 mm and lock by tightening the lock nuts (3).
The brake is now applied again.
– Mount the front cover.
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C2

D Battery - Servicing, recharging,
replacement
1 Safety regulations governing the handling of lead-acid batteries
The truck must be parked and rendered safe before any operations on batteries are
undertaken (refer to chapter E).
Servicing staff: Recharging, servicing and replacing of batteries must only be per-
formed by qualified personnel. The instructions contained in this operating manual,
and the instructions of the manufacturer of the battery and of the battery recharging
station, must be observed when performing the above operations.
Fire protection measures: Smoking and naked flames are not permitted when
handling batteries. No inflammable substances or spark-generating materials must
be present or stored within a distance of 2 meters of the truck parked for battery re-
charging. The location must be well ventilated and fire fighting equipment must be
kept ready.
Servicing of batteries: The battery cell screw caps must be kept dry and clean. Ter-
minals and cable shoes must be clean, lightly greased with pole grease and must be
securely tightened. Batteries with bare terminal posts must be covered using a non-
skid insulating mat.
Disposal of the battery: Batteries must only be disposed of as stipulated in the na-
tional environmental protection regulations or waste disposal provisions. The manu-
facturer’s specifications for the disposal must be heeded.
m Before closing the battery hood, make sure that the battery cable cannot be dama-
ged.
f Batteries contain dissolved acid which is toxic and caustic. For this reason, protective
clothing and goggles must be worn whenever work is undertaken on batteries. Avoid
physical contact with battery acid.
If clothing, skin or eyes accidentally come into contact with battery acid, liberally flush
the affected parts with clean water. Consult a doctor when skin or eyes come into con-
tact with battery acid. Spilled battery acid must be immediately neutralized.
m Only batteries with closed tray may be used.
f Battery weight and dimensions have considerable influence on operational safety of

the truck. Changing the battery equipment is not permitted without prior approval by
the manufacturer.
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2 Battery type
Depending on the use, the truck is equipped with different types of batteries.
The table below shows the capacity of the batteries and also the combinations used
as standard equipment:
24V - 3PzSL - Battery 240Ah

For the battery weight, refer to the battery identification plate.
m When changing / replacing the battery you must make sure that the battery is safely
fastened in the battery compartment of the truck.
3 Exposing the battery
f Park the truck and render it safe (refer to chapter E).
– Fold up battery hood (1).
f Carefully open or close the battery hood.
– Installation is in the reverse order.
f All covers and connections must be restored to the normal operating condition before
the truck is started up for work.
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D2

4 Charging the battery
As default, the truck is to be loaded with a stationary battery charger. The truck wit-
hout wheel-arm lifting device can optionally be supplied with an integrated battery
charger.
m For recharging the battery, the truck has to parked in-doors in a sufficiently ventilated
environment.
A Charging condition display (refer to chapter E).
4.1 Charging the battery with stationary battery charger
– Park the truck and render it safe (refer to chapter E).
m Connection / disconnecting battery connector and socket as well as pressing the ma-
ster switch (2) may only be performed with truck and battery charger being switched
off.
– Expose the battery (refer to section 3).
f During the recharging operation the tops of the battery cells must be exposed to en-
sure adequate ventilation. Metal objects must not be placed on the battery. Prior to
starting the recharging operation, check all cable connections and plugged connec-
tions for visible damage.
The safety instructions provided by the battery supplier and battery charger supplier
must be strictly observed.
– Pull battery connector (3) from the plug and socket connection of the truck.
– Remove insulation mat from battery, if necessary.
– Connect the charging cable (4) of the battery recharging station with the battery
connector (3) and switch on the battery charger.
m Recharge the battery observing the instructions provided by the battery supplier and
by the battery charger supplier.
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D3

4.2 Recharging the battery with integrated battery charger (o)
f The battery charger must not be opened. If it is damaged, it has to be exchanged.
A Due to safety reasons, intermediate positions are available between the regulation
positions “1” to “6” of the switch (7).
If the truck is delivered without battery, an intermediate position is pre-selected as de-
fault. The red light-emitting diode (5) flashes - the battery cannot be recharged.
6 5
Select charging curve in the integrated battery charger

Use switch (7) at the battery charger to adjust the charging curves to the appropriate
battery according to the following table.
m The power plug must be pulled before the corresponding charging curve is to be ad-
justed!
Provided that a battery is connected, a new setting can be acknowledged via the
LEDs (cf., indicator) which will then be immediately effective.
Position of switch (7) selected charging curves (characteristics)

1 Wet batteries: 100 - 330 Ah
2 Maintenance-free: 100 - 140 Ah
5 Free
6 Free
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D4

Adjusting the charging curve
The charging curve can be adjusted by performing the following steps:
Connect the battery This permits to use the battery

charger as an adjustment aid
Turn the adjustment switch to The red LED flashes fast no valid
the right (i.e. clockwise) until it charging curve sel-
touches the limit stop. ected
Turn the adjustment switch to After 3 seconds the green LED charging curve 1
the left (i.e. anticlockwise) until flashes only once selected
it touches the limit stop.
Select the desired charging The red LED starts to flash in
curve by turning the adjust- the intermediate positions.
ment switch to the right If a valid charging curve is sel-
ected, the green LED starts to
flash in the relevant switch po-
sition.
Starting the recharging process with integrated battery charger
f During the recharging operation the tops of the battery cells must be exposed to en-
sure adequate ventilation. Metal objects must not be placed on the battery. Prior to
starting the recharging operation, check all cable connections and plugged connec-
tions for visible damage. The safety instructions provided by the battery supplier and
battery charger supplier must be strictly observed.
Mains supply
Line voltage: 230 V (+10/-15%)
Line frequency: 50 Hz / 60 Hz
The power plug (8) of the battery charger can be found in the battery compartment.

– Remove insulation mat from battery, if necessary.
– Pull out master switch (2) (position “ON”).
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– Connect power plug (8) with a power socket.
D5

A The master switch (2) may only be operated with truck and battery charger being swit-
ched off.
The flashing LED indicates the charging status and/or a fault (flashing codes see ta-
ble “LED display”).
A If the power plug (8) is connected to the mains, all electric functions of the truck are
interrupted (electric driving lock). No operation of the truck is possible.
– Pull plug (8) from the power socket and place it in the battery compartment.
A The recharge procedure is automatically continued after a power failure.

The recharge procedure can be interrupted by pulling the power plug and can be con-
tinued in steps.
f The mains cable must not be damaged.

Before commissioning the truck, the battery hood must be properly closed.
Charging times
The time required for recharging depends on the capacity of the battery.
LED display
Green LED (6) Red LED (5) Indication

(charging (fault)
status)
is lit ---
Recharge procedure is finished; battery is full.
(charging break, fill-up charge or equalization
charge)
flashes slowly --- Charging process
flashes fast --- Indicates the start of a recharge procedure or that a
new charging curve was adjusted. The number of
the flashing pulses corresponds to the adjusted
charging curve.
--- is lit Excess temperature. Recharge process is interrup-
ted.
--- flashes slowly Safety charging interval exceeded. Recharge pro-
cess is interrupted. Disconnection from the mains is
required for restarting the charging process.
--- flashes fast charging curve setting is invalid.
--- --- Power failure and/or no battery connected.
Fill-up charge
The fill-up charge begins automatically after the recharge procedure has ended.
Partial recharging
The battery charger is designed in such a way that it automatically adapts to the char-
ging status of partially recharged batteries. This permits to reduce wear and tear of
the battery.
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D6

5 Removing and installing the battery
f The truck must stand horizontally. Batteries with exposed terminals or connectors
must be covered with a rubber mat to prevent short-circuits. Place battery connector
and battery cable in such a way that they do not get caught within the truck interior
when the battery is pulled out.
f When replacing batteries, ensure that a battery of the same type is fitted. Supplemen-
tary weights may not be removed or changed in their position.
f After reinstallation of the battery, visually check all leads and connectors for damage.
Before commissioning the truck, the battery hood must be properly closed.
A When changing the battery with the aid of a lifting gear, ensure that the lifting gear is
of adequate capacity (the battery weight is indicated on the battery identification plate
at the battery trough). The battery must be lifted vertically to prevent crushing of the
battery trough. The hooks are to be attached to the battery hoisting ears (9) that they
cannot fall onto the battery cells when the hoisting gear is released.
5.1 Remove battery by lifting it upwards (truck without wheel-arm lifting device)
– Withdraw the battery connector.

– Attach hoisting gear to the hoisting ears (9).
– Lift out the battery.
The re-assembly can be performed by reversing the above actions; pay attention to
the correct mounting position and battery connection.
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D7

5.2 Remove battery by lifting it upwards (truck with wheel-arm lifting device)
– Withdraw the battery connector (3).
f The battery cable of the truck must be laterally led outside. While removing the bat-
tery, make sure that the cable is not squeezed.
– Attach hoisting gear to the hoisting ears (9).

– Lift out the battery.
9 3
1001.GB
D8

5.3 Lateral battery change (o)
– Withdraw the battery connector.

– Pull the locking mechanism (12) of the battery cover upwards while firmly holding
the battery cover (13).
– Lift out the battery cover (13) and keep it in a safe location.
– Position battery trolley next to the truck.
– Push cautiously battery (11) from the truck onto the battery trolley / battery change
station.
f Be careful not to place your fingers between partition wall of the truck and the battery.
Heed the operating instructions of the battery change station.
Mounting the battery:
– Insert battery up to battery stop (10).

– Press in the battery stop and keep it in that position.
– Pull battery into the truck.
10
11
12
13
1001.GB
D9

1001.GB
D 10

E Operation
1 Safety regulations governing the operation of the fork lift truck
Driving permission: The fork lift truck must only be operated by persons who have
been trained in the operation of trucks, who have demonstrated to the user or his re-
presentative their capability of moving and handling loads, and who have expressly
been charged by the user or his representative with the operation of the truck.
Rights, duties and conduct of the driver: The driver must be: informed of his rights
and duties; trained in the operation of the fork lift truck; and familiar with the contents
of these operating instructions. All necessary rights must be granted to him.
If the fork lift truck can be used in the pedestrian-controlled mode, the driver must
wear safety boots when operating the truck.
Prohibition of unauthorised use: The driver is responsible for the fork lift truck du-
ring working time. He must forbid unauthorised persons to drive or operate the fork
lift truck. The transport or lifting of persons is forbidden.
Damage and defects: Damage or defects noted on the fork lift truck or on the attach-
ments must immediately be brought to the notice of the person in charge. fork lift
trucks that cannot be safely operated (e.g. due to worn tyres or defective brakes)
must not be used until they have been properly repaired.
Repairs: Without specific training and express authorisation, the driver is not allowed
to perform any repairs or modifications on the fork lift truck. Under no circumstances
must the driver change the setting of switches or safety installations or render them
ineffective.
Danger area: A “danger area” is considered to be the area within which persons are
endangered by the travelling or lifting movements of the fork lift truck or its load lifting
devices (e.g. fork or attachments), or by the loads being transported. This also inclu-
des the area within reach of falling loads or falling / lowering truck attachments.
f Unauthorised persons must be asked to leave the danger area. The driver must give
a warning signal whenever a situation presenting danger to persons might develop.
The fork lift truck must immediately be brought to a standstill if persons, although as-
ked, do not leave the danger area.
Safety devices and warning labels: The safety devices, warning labels and warning
notes described in the present operating instructions must always be heeded.
0602.GB
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2 Description of controls and indicating instruments
Item Controls or ERC ERC ERC-Z Function

indicating instrument 12 14/16 12/14/16
respectively
1 Keyboard o o o Code settings
(CANCODE) Travel programme enable
2 Display instrument o o o Operating hours meter
(CANDIS) Battery capacity display
Shows the residual capacity of
the battery as well as the
accumulated operating hours
of the truck.
3 Key switch t t t Switches control voltage on
and off.
Removing the key secures the
truck against switching on by
unauthorised personnel.
4 Control shaft t t t Steering and braking the truck.
5 Button - warning t t t Trigger warning signal.
signal (horn)
6 Button - wheel arms - - t Wheel arms are lowered
lowering with constant speed
7 Button - wheel arms - - t Wheel arms are lifted
lifting with constant speed
8 Driving regulator t t t Controls the driving direction
driving speed.
9 Bumper safety switch t t t Pedestrian-controlled operati-
on:
Safety function, which causes
the vehicle to move for about 3
secs in drive direction “R”
(Backward) and then switches
off until the controller is briefly
moved to the neutral position.
Ride-on mode:
Non-functional.
0602.GB
E2

5 5
9
6 7 10 11
8
3
2
1 12
13
14
15
17
16
0602.GB
E3

Pos. Controls or ERC ERC ERC-Z Function
indicating instrument 12 14/16 12/14/16
respectively
10 Button - t t t Lifting the lifting device.
Lifting the lifting device The lifting speed can be conti-
nuously adjusted with this key
(adjustment range 8 mm).
11 Button - t t t Lowering the lifting device.
Lowering the lifting de- The lowering speed can be
vice continuously adjusted with
this key (adjustment range 8
mm).
12 Terminal strip t t t Depositing of freight docu-
ments.
13 Master switch t t t The circuit is interrupted, all
(Emergency Stop) electric functions are switched
off. The truck is compulsory
braked.
14 Control lamp at the o o Indicates the loading states
battery charger (see chapter D).
15 Integrated battery char- o o Used for recharging the batte-
ger ry.
16 Hinged driver standing t t t Pedestrian-controlled operati-
platform on:
Driver standing platform in fol-
ded- up position:
=>Truck travelling speed is li-
mited to 6.0 km/h.
Stand-on operating mode:

standing platform serves as
deadman's switch function:
Unweighted standing platform
in folded-down position:
=>travelling function blocked.
Standing platform in folded-
down position, driver stan-
ding on platform:
=>travelling function rleased.
17 Hinged safety extensi- - t t*) The travelling function is blok-
ons ked if the safety extensions
are not folded out when the
standing platform is folded
down.
t = Standard equipment o = Optional equipment
*)only at ERC-Z 14/16

0602.GB
E4

5 5
9
6 7 10 11
8
3
2
1 12
13
14
15
17
16
0602.GB
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3 Starting up the truck
f Before starting or operating the truck, or before lifting any loads, the driver has to
make sure that nobody is within the danger area.
The electronic driving and steering systems automatically control their functions. If an
error or fault occurs, the driving and steering functions are stopped.
f Before the truck is restarted, it is required to perform the relevant troubleshooting ac-
tions.
Checks and operations to be performed before starting daily work
– Visually check the entire truck (especially the wheels and the load lifting device) for
visible damage.
– Check the steering play.
– Visual inspection of cable connection.
– Switch for safety switching height (18), visually inspect its cable connections and
magnetic fastening.
f Do not operate the controller (8) when climbing on the truck.

.
8
18
18
0602.GB
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Switching on the truck
– Pull up the master switch (13).
– Insert the key in the key switch (3) and turn the key clockwise towards the “I”
position until reaching the stop.
– When a code lock is installed, you must enter an operator code
(refer to section 6.6).
– Check the horn (5) for correct functioning.
A The combination instrument (CANDIS (o) (2)) shows the available battery capacity.
f When swivelling the driver’s standing platform (16) upwards, do not reach between
the driver’s standing platform and the truck’s side wall.
– To initialise the truck, actuate the controller (8) once while the driver’s standing plat-
form (16) is folded up.
– Check the service and counter-current brake for correct functioning
The truck is now ready for operation.
1
2
3
13
16
0602.GB
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4 Operation of the fork lift truck
4.1 Safety regulations applicable when operating the truck
Driving lanes and work areas: Only such lanes and routes that are specially alloca-
ted for truck traffic must be used. Unauthorized persons must stay away from work
areas. Loads must only be stored at places specially provided for this purpose.
Driving conduct: The travelling speed must be adapted to the prevailing local con-
ditions. The truck must be driven at slow speed when negotiating bends or narrow
passages, when passing through swing doors and at blind spots. The driver must al-
ways observe an adequate braking distance between the fork lift truck and the vehicle
in front and he must be in control of his truck at all times. Sudden stopping (except in
emergencies), rapid U-turns and overtaking at dangerous or blind spots is not permit-
ted. It is forbidden to lean out of or reach beyond the working and operating area.
Visibility: The driver must look in the direction of travel and must always have a clear
view of the route ahead. When loads blocking the view are carried, the fork lift truck
must be driven with the load at the rear. If this is not possible, a second person must
walk in front of the fork lift truck to give suitable warnings.
Negotiating slopes and inclines: Negotiating of slopes and inclines is permitted

only when they are recognised lanes, when they are clean and non-slipping, and
when the technical specification of the truck permits safe driving on such slopes or
inclines. Loads must always be carried at that end of the truck facing uphill. U-turns,
cutting obliquely over slopes or inclines and parking of the fork lift truck on slopes or
inclines is not permitted. Inclines must only be negotiated at slow speed, with the
driver ready to brake at any moment.
Use of lifts and driving on loading platforms: Lifts and loading platforms must only
be used if they are of adequate load bearing capacity, if suitable for driving on, and if
authorised by the user of the truck for truck traffic. The fork lift truck driver has to sa-
tisfy himself accordingly before driving into lifts or on to loading platforms. The truck
must enter lifts with the load in front and must take up a position which does not allow
it to come into contact with the walls of the lift shaft.
Persons riding in the lift together with the fork lift truck must only enter the lift after the
fork lift truck has come safely to a standstill, and must leave the lift before the fork lift
truck.
Nature of the loads carried: Only loads that have been safely and correctly secured
must be carried. Never transport loads stacked higher than the top of the fork carria-
ge, or stacked higher than the guard grille.
Towing trailers: The maximum trailer load given for the fork lift truck for braked and/
or unbraked trailers must not be exceeded. The trailer load must be properly secured
and must not exceed the dimensions permitted for the driving routes. After attaching
the trailer but before starting driving, the driver must check that the trailer attachment
is secured against detachment. Towing fork lift trucks must be operated in such a
manner that safe driving and braking of the truck and the trailer is guaranteed for all
driving movements.
0602.GB
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4.2 Driving, steering, braking
f Be extremely careful when driving and steering, especially when parts of the body
protrude from the truck contour.
Emergency cut-out
– Depress the master switch (13).
This will switch off all electric functions. The truck is compulsory braked.
Emergency stop
When the control shaft (4) is released, the truck is automatically braked (emergency
stop). The control shaft will automatically move into the upper braking range (B).
f If the control shaft is sluggish in moving into the braking range, the cause must be
established and eliminated. If necessary, the return spring must be replaced.
13
0602.GB
E9

Driving
f When swivelling the driver’s standing platform (16) upwards, do not reach between
the driver’s standing platform and the truck’s side wall.
There are three different travelling modes:
– Pedestrian-controlled operation:
Swivel the safety extensions (17)*) inwards and then fold up
driver platform (16).
– Ride-on mode:
Fold down driver platform (16).
– Ride-on mode with increased speed:
Swivel the safety extensions (17)*) outwards and then fold down
driver platform (16).
A The travelling function is blocked if the driver is not standing on the platform and the
safety extensions* are not folded out.
*) not with vehicles with load bearing capacity of 1200kg
f Do not drive the truck unless the hoods are closed and locked in the stipulated man-
ner. When passing through swing doors, or similar, take care that the anti-collision
button (1) is not inadvertently operated.
– Start up the truck (refer to section 3).
– Swivel the control shaft (4) into driving range “F”.
– Turn the controller (8) in the desired travelling direction: forward (V) or reverse (R).
The truck will move in the selected direction.
A The travelling speed is controlled by means of the controller (8).
B
R
V 8
F
4
17
V
16
0602.GB
E 10

Driving up an incline
m The load must be transported facing the incline!
Safety measures against “rolling down” of the truck:

With the controller (8) set to neutral, the service brake is automatically applied after a
brief jolt (the controller detects the truck’s rolling down on an incline). The controller
(8) is used to release the service brake; the speed and driving direction are set as
desired.
m When the service personnel has switched off the coast-down brake, only the service
and/or the counter-current brake can be used.
Steering
f In narrow bends, the driver will be positioned at the outer contours of the truck.
– Swivel the control shaft (4) to left or right.

The position of the control shaft corresponds to the position of the steered driven
wheel.
Electrical steering
The electric steering system is self-monitoring.
The steering control systems monitors the fault frequency over a certain period. If the
same fault is detected several times during this period, the steering control reduces
the driving speed of the truck to low speed. If such a fault occurs, the driving speed
is not reset to normal speed by switching the truck off and on again. This method pre-
vents the cancellation of a fault without eliminating the fault.
Braking
f The braking behaviour of the truck strongly depends on the state of the floor. This
must be taken into account by the driver for his driving behaviour.
The truck may be braked in three ways:

– either by counter-current braking (controller (8))
– or by means of the service brake (control shaft (4))
– or by using the generator brake (coasting)
f In case of emergencies, the truck must only be braked using the service brake
(control shaft (4)).
m During normal operation, the generator brake and counter-current braking should be
applied. These methods of braking reduce wear and require less energy (energy
recovery).
0602.GB
E 11

Braking by means of the service brake:
– Swivel the control shaft (4) into one of the braking ranges “B” or release the control
shaft altogether.
The drive motor will then be braked by means of the motor brake.
A When the control shaft is released, it will automatically swivel into the upper braking
range “B”. When the truck is parked, the motor brake will act as a parking brake.
Counter-current braking
– Setting the controller (8) to the opposite drive direction while travelling.
The truck is braked by counter-current until it starts moving into the opposite direction.
A The braking effect depends on the setting of the controller.

Braking by means of the generator brake (coasting)
– Release the controller (8) - controller in home position (“0”).

Depending on the setting, the truck is braked by the generator braked, coasting to a
stop.
A The degree of speed reduction can be set by the manufacturer service.
m When the service personnel has switched off the coast-down brake, only the service
and/or the counter-current brake can be used.
5 Picking up and setting down loads
f Before picking up a load, the driver has to make sure that it is correctly palletised and
that the capacity of the truck is not exceeded.
Do not grab into the hoist frame during lifting and lowering.
– Pass the fork tines as far as possible under the load. Picking up long loads cross-
wise is not permitted.
m Pick up the load, ensuring that it does not project excessively from the tips of the lifting
device (less than 50 mm).
A In the case of the double-lift dual mast (ZZ) and the double-lift triple mast (DZ), the
initial lift of the load carriage (free lift), without any changes to the design height, is
provided by a short, centrally arranged free-lift cylinder.
0602.GB
E 12

Lifting and lowering
Lifting
– Press the “Lift the lifting device”
button (10) until the desired height
has been reached.
Lowering
– Press the “Lower the lifting de-

vice” button (11) until the desired
height has been reached.
10 11
A The lifting/lowering speed can be
continuously adjusted with this button (adjustment range 8 mm).
Small button adjustment range = slow lifting / lowering

Large button adjustment range = fast lifting / lowering
– Avoid any abrupt lowering of the load unit.
Safety switching height

For lifting starting at approx. 1.8 m:
– Lifting stop depends on the safety frame setting

(refer to switching matrix / safety switching height).
– “Locking” the support roller (the lifting hydraulics acts on the support roller cylinder
with a noticeable alignment of the truck).
– Travel speed reduction above the safety switching height.
– Lowering the wheel-arm lift above the safety switching height.
0602.GB
E 13

Switching matrix / safety switching height
ERC / ERC-Z 12
Platform Lifting Speed (km/h) Collision guard button Lifting

height with load functions
active active
)
Folded up <Sh * 4.3 Yes Yes
)
Folded up >Sh * 4.3 Yes Yes
)
Folded out <Sh * 6.0 No Yes
Folded out >Sh *) 4.3 No Yes
ERC / ERC-Z 14/16
Platform Safety Lifting Speed (km/h) Collision guard button Lifting

frame height with load functions
active active
Folded Folded <Sh *) 4.3 Yes Yes
up in
Folded Folded >Sh *) 4.3 Yes Yes
up in
Folded Folded <Sh *) 0 No No
up out
Folded Folded >Sh *) 0 No No
up out
Folded Folded <Sh *) 6,0 No Yes
out in
Folded Folded >Sh *) 4,3 No Yes
out in
Folded Folded <Sh *) 7.5 / 7.0 No Yes
out out
Folded Folded >Sh *) 0 **) No No **)
out out
*) Sh = Safety switching height approx.1,800 mm (depending on lifting mast version)

**) optionally travelling (4.3 km/h) and lifting with the safety frames folded out
above 1,800 mm in conjunction with a load guard is possible.
0602.GB
E 14

Wheel-arm lifting device (only ERC-Z) (t)
A The “Lift wheel arms” and “Lower wheel arms” can be used to perform the lifting or
lowering movement with a fixed speed.
f To ensure the stability of the truck, the wheel arms will be automatically lowered from
a specific lifting height of the fork onwards, depending on the used hoist frame type.
From this lifting height onwards, the wheel-arm lifting device can no longer be used.
The lowering movement cannot be interrupted! (Danger of injuries)
Lifting the wheel arms

– Press the “Lift wheel arms” (7) button.
Keep the button pressed, until the desi-
red lifting height has been reached.
Lowering the wheel arms
– Press the “Lower wheel arms” (6) but-

ton. Keep the button pressed, until the
desired lowering height has been rea-
ched.
6 7
Emergency lowering
f No other personnel is allowed in the danger zone when using emergency lowering.
If the lifting device cannot be lowered due to a failure of the lifting controller, the
emergency lowering procedure must be performed.
– Set key switch (3) in position “0” and
push master switch (13) to position
“OFF”.
– Unplug the battery plug
(refer to chapter D).
– Open front hood (refer to chapter F).
– Loosen the screw at the valve block
(19).
A The hex socket wrench required

(2.5 mm) is attached to the valve block.
The lifting device is lowered.

19
– After emergency lowering, fully screw
in screw (19) again.
Setting the truck to operation after removing the fault.
0602.GB
E 15

5.1 Safe parking of the truck
If the truck is left unattended, even for

only short periods of time, it must be
rendered safe.
3
f Do not park the truck on slopes! The

load lifting device must always be 13
completely lowered.
17
– Park the truck on level ground.
– Completely lower the fork.
– Set the key switch (3) to position “0” 16
and remove the key from the
switch.
– If a code lock is installed, the o-key
must be pressed.
– Set the master switch (emergency
cut-out) (13) to position “OFF”.
– Fold in hinged safety extensions
(only with vehicles with a load bearing capacity of 1400 kg and 1600 kg).
f When swivelling the driver’s standing platform upwards, do not reach between the
driver’s standing platform and the truck’s side wall.
0602.GB
E 16

6 Keyboard (CANCODE) (o)
The keyboard is provided with a key switch function. It is equipped with a 10-key
numeric keypad and two special keys. After entering the correct code the control
circuit is switched on.
6.1 Functions
The keyboard can only administer one master code and 600 operator codes. It is
possible to assign a unique code to each truck. Only operator who know this code can
use the truck. Alternatively, you can assign a unique code to each driver. All operator
codes that are to be enabled for this truck must be stored in the keyboard.
A When shipped to the customer one operator and one master code is factory-set
(2580 and 7295).
m Change the master and operator codes when setting the truck into operation for the
first time!
All possible codes are preset to one length (4, 5, or 6 digits). The length of the
operator code is predefined by the length of the master code. The code is
automatically checked after the corresponding number of keys is pressed.
The travel parameters for the operating mode can only be adapted in master mode.
Moreover, the master mode permits setting the battery type and the special functions.
0602.GB
E 17

6.2 Commissioning
After switching on the master switch and the key switch the LED (20) lights up steady
red also during operation.
If the keyboard is used as code switch, the control circuit switches on after entering
the correct operator code (factory-set to 2580). LED (20) now lights up steady green.
When an incorrect code has been entered, LED (20) light up red for two seconds.
After that you can enter a new code.
The travel programme (travel speed, deceleration and acceleration intensity are set)
is activated, which is indicated by the greed LEDs (22, 23,42) on key 1, 2, or 3.
22 23 24
Set key (21) has no function in operating
mode.
The control circuit is switched off by

actuating the o-key (25). To switch on
1 2 3
again, re-enter the code.
4 5 6
Switching off by o-key, key switch, or
automatically, if the truck is not used for a 7 8 9
preset time (automatic switch-off after a Set 0 25

period between 10 seconds and 30 minutes 21
can be activated in master mode).
20
0602.GB
E 18

6.3 Indicators
Status displays of the individual LEDs
– steady (red)
– steady (green)
– flashing red
– flashing green
– off
LED (20) steady (red) Truck off (not ready for operation)
steady (green) Truck on (operating mode)
flashing red Truck with error message
flashing green Truck on (master mode)
LED (22) steady (green) Travel programme

flashing green Code change: old code, input

flashing green Code change: new code, first input

flashing green Code change: new code,
confirmation
Keyboard error messages
The following errors are indicated by a red flashing LED:
– New master code is already operator code.

– New operator code is already master code.
– Operator code to be changed does not exist.
– Tried to change the operator code to an existing code.
– Operator code to be deleted does not exist.
– Code memory full.
0602.GB
E 19

6.4 Keys
o-key (25)
The o-key (25) is always active and has the highest priority. It is used to set the truck
from any state to the basic state (truck switched off and not ready for operation) and
vice versa. It is exclusively used for switching off or resetting the truck.
Set key (21)
No function for the operator. In master mode, the entered values are confirmed by the
Set key.
Numeric keys
Keys 1, 2, 3, 4, 5, 6, 7, 8, 9, 0 are used for entering codes.
6.5 Master mode
Parameter changes must be made carefully and only by trained personnel. Changing
the parameters results in changed travel behaviour of the truck.
Changes are only saved when DIL switch no. 8 on the controller is set to “ON”.
To enter the master mode, the following is required:
– o-key (if in operating mode),

– enter master code.
Display instrument LED (20) LED (22) LED (23) LED (24)
(CANDIS)
Operating hours green off off off
are indicated 284.9 flashing
Enter a parameter number and confirm with Set key (21).
If an invalid input is entered (LED (20) flashes red) you return to the basic state of the
master mode by actuating Set key (21). Enter a new parameter number and confirm
with Set key (21).
The following example show the setting of the acceleration parameter (parameter
101) in the travel programme.
0602.GB
E 20

Acceleration example
Display instrument LED (20) LED (22) LED (23) LED (24)
(CANDIS)
current green off off off
setting
is displayed
101 6 flashing
changed green off off off

setting
is displayed
101 8 flashing
Parameter Parameter
number setting
value
After entering parameter number 101 and pressing the Set key, the current value 6 is
read out and displayed
Change the value to 8 and confirm with Set key (21).

0602.GB
E 21

6.6 Parameter
Parameter groups
The parameter number is composed of three digits. The first digit designated the
parameter group according to table 1. The second and third digits are sequentially
numbered from 00 to 99.
No. Parameter group

0xx Code lock settings
(Codes, travel programme enable, automatic switch-off, etc.)
1xx Travel programme
(Acceleration, coasting brake, speed, etc.)
4xx Programme-independent parameters
0602.GB
E 22

Truck parameter list
No. Function Range Default Comments

Setting value Setting
value
Code lock - internal
000 Change master code 0000 - 9999 (LED 22 flashes)
The length of the master or Enter the current
code determines the 00000 - 99999 code
length of the operator or
code. As long as operator confirm (Set)
000000 - 999999
codes have been
programmed, only new (LED 23 flashes)
codes with the same Enter a new code
length can be entered. If
the code length is to be Confirm (Set)
changed, all operator
codes must be deleted (LED 24 flashes)
first. Repeat new code
Confirm (Set)
001 Add operator code 0000 - 9999 (LED 23 flashes)
or Enter a code
00000 - 99999
Confirm (Set)
or
000000 - 999999 (LED 24 flashes)
Repeat the code
entry
Confim (Set)
002 Change operator code 0000 - 9999 (LED 22 flashes)
or Enter the current
00000 - 99999 code
or
Confirm (Set)
000000 - 999999
(LED 23 flashes)
Enter a new code
Confirm (Set)
(LED 24 flashes)
Repeat the code
entry
Confirm
LED 22-24 are located in the key pad fields 1-3.

0602.GB
E 23

No. Function Range Standard Comments
value
Code lock - internal
003 Delete operator code 0000 - 9999 (LED 23 flashes)
or Enter a code
00000 - 99999
or Confirm (Set)
000000 - 999999
(LED 24 flashes)
Repeat the code
entry
Confirm (Set)
004 Clear code memory 3265 3265 = delete
(deletes all operator
codes) other entry = do not
delete
010 automatic switch-off 00 - 31 00 00 = none
Switch-off
01 to 30 =
Switch-off time in
minutes
31 = Switch-off in 10
seconds
030 Display of assigned
operator codes
0602.GB
E 24

No. Function Range Standard Comments
value
Travel programme
101 Acceleration 0-9 6
102 Coasting brake with 0-9 6
enable
104 Drive direction: 0-9 6
Maximum speed
105 Drive direction: 0-9 6
Pedestrian controller
speed
108 Fork direction: 0-9 6
Maximum speed
109 Fork direction: Pedestrian 0-9 6
controller speed
Programme-independent parameters
411 Battery type (normal/high- 0-2 0 0 = Normal (wet)
power/dry)
1 = High-power
(wet)
2 = Dry
(maintenance-free)
0602.GB
E 25

7 Display instrument (CANDIS) (o)
The instrument indicates:

27
– Battery discharge condition
(LED bars (27)),
– Operating hours 26
28
(LC display (29)).
In addition, error messages of the electronic 29
components and parameter changes are
displayed.
Discharge status indication
Depending on the battery type set, switch-on limits for the additional “Warning” (26)
and “Stop” (28) indicators may result.
Numb Charging Wet battery Maintenance-free battery

er condition LED (yellow) LED (red) LED (yellow) LED (red)
Bars Warning Stop Warning Stop
10 90.1- 100% Off Off Off Off
9 80.1 - 90% Off Off Off Off
5 40.1 - 50% Off Off On Off
4 30.1 - 40% Off Off On On
3 20.1 - 30% On Off On On
2 10.1 - 20% On On On On
Avoid falling below the 20% limit for wet batteries resp. 40% limit
for maintenance-free batteries.
0602.GB
E 26

7.1 Discharge monitor function
With the discharge monitor function enabled, the lifting function switches of when
reaching the discharge limit (the Stop LED switches on). Travelling and lowering is
still possible. For wet batteries the residual capacity is 20%, for maintenance-free
batteries it is 40%. At 30% resp. 50% the batteries should be recharged (the yellow
LED lights up as warning indication).
7.2 Operating hours display
Display range between 0.0 and 99,999.0 hours. Travel and lifting movements are
logged. This is a backlit display.
A For maintenance-free batteries a “T” symbol is shown in the display.
Error messages
The operating hours display is also used for indicating errors. The display shows a
“C” for a component and then a three-digit component number. When an error occurs,
an “E” is shown with a three-digit error number.
If several errors occur they are displayed one after the other. Errors are displayed as
long as they persist. The operating hours display is overwritten with an error
message. Most errors cause the emergency stop to be triggered. The error display is
maintained until the control circuit is switched off (key switch).
A The service personnel has access to detailed component descriptions and error
codes.
Display for parameter changes (travel programmes)
The parameter numbers are shown in the display. This is done in conjunction with the
keyboard (CANCODE).
The display has the format “PPPVVV”. “P” is the parameter number, “V” is a value.
After a few seconds the display is overwritten again by the operating hours display.
7.3 Switch-on test
After switching on the display shows:
– the software version

– the operating hours
– the charging condition
0602.GB
E 27

8 Fault location
This chapter helps the operator to locate and fix simple malfunctions or the results of
operating errors him- or herself. The order of the work stated in the table must be ob-
served for fault location.
Fault Possible cause Remedy

Truck does not – Battery connector – Check the battery connector
move not connected and reconnect it, if necessary
– Master switch (EMERGENCY – Release master switch (EMER-
STOP) pressed GENCY STOP)
– Key switch in position “0”. – Set the key switch to position
“I”.
– No driver on folded-out plat- – Stand on folded-out platform
form, lifting and travel function
not active
– Battery voltage too low – Check the charging status of
the battery and recharge, if ne-
cessary
– Control shaft not swivelled into – Swivel control shaft into driving
driving range (F) range (F)
– Faulty fuse – Check fuses F1 and 1F1
– Truck battery charger is con- – Disconnect the truck battery
nected charger from the mains
Load cannot – Truck not operative. – Perform all troubleshooting
be lifted measures that are mentioned
under “truck does not drive”
– refer to switching matrix / safety
switching height
– No driver on folded-out plat- – Stand on folded-out platform
form, lifting and travel function
not active
– Hydraulic oil level too low – Check hydraulic oil level
– Faulty fuse – Check fuse 2F1
– load too high – Pay attention to the maximum
bearing capacity (see identifi-
cation label)
– Discharge monitor is triggered – Check the charging status of
(STOP icon) the battery and recharge, if
necessary
A If it is not possible to rectify the fault by performing the indicated “remedial actions”,
please contact the Customer Service, as more intricate faults can only be rectified by
specially trained and qualified service personnel.
0602.GB
E 28

F Maintenance of the fork lift truck
1 Operational safety and environmental protection
The checks and servicing operations contained in this chapter must be performed in
accordance with the intervals as indicated in the servicing checklists.
f Modifications of fork lift truck assemblies, especially of the safety installations, are not
permitted. On no account must the operational speeds of the truck be changed.
m Only original spare parts have been certified by our quality assurance service. To en-
sure safe and reliable operation of the fork lift truck, only spare parts of the manufac-
turer must be used. Used parts, oils and fuels must be disposed of in accordance with
the applicable environmental protection regulations. For oil changes, the oil service
of the manufacturer is available to you.
Upon completion of any checking and servicing activities, the operations contained in
the section “Recommissioning” must be performed (refer to chapter F).
2 Safety regulations applicable to truck maintenance
Servicing and maintenance personnel: The fork lift truck must only be serviced and
maintained by trained personnel of the manufacturer. The service organization of the
manufacturer has external technicians trained especially for these assignments. We
thus recommend signing a maintenance contract with the relevant service location of
the manufacturer.
Lifting and jacking up: When a fork lift truck is to be lifted, the lifting gear must only
be secured to the points specially provided for this purpose. When the truck is to be
jacked up, suitable measures must be taken to prevent the truck from slipping or tip-
ping over (use of wedges, wooden blocks). Work underneath the raised load lifting
device must only be carried out when the fork is immobilised and supported by a
chain of adequate strength.
Cleaning operations: No inflammable liquids must be used when cleaning the fork
lift truck. Prior to commencing cleaning operations, all safety measures that are re-
quired to prevent sparking (e.g. by short-circuits) have to be taken. For battery-ope-
rated fork lift trucks, the battery plug must be removed. Only weak indraft, weak com-
pressed air and non-conducting, antistatic brushes must be used for the cleaning of
electric or electronic assemblies.
m If the fork lift truck is to be cleaned using a water jet or a high-pressure cleaner, all
electric and electronic components must be carefully covered beforehand because
moisture can lead to incorrect functioning.
Cleaning by means of a steam jet is not permitted.
Upon completion of cleaning work, the operations detailed in the section “Recommis-
sioning” must be performed.
1001.GB
F1

Work on the electric system: Work on the electric system of the truck must only be
performed by personnel specially trained for such operations. Before commencing
any work on the electric system, all measures required to prevent electric shocks
have to be taken. For battery-operated fork lift trucks, the truck must also be depowe-
red by removing the battery plug.
Welding operations: To prevent any damage to electric or electronic components,
these have to be removed from the fork lift truck before any welding operations are
undertaken.
Settings: When repairing or replacing hydraulic, electric or electronic components or
assemblies, all truck-specific settings have to be retained.
Tyres: The quality of the tyres greatly affects the stability and the driving behaviour
of the fork-lift truck. The factory-mounted tyres must only be replaced by original spa-
re parts of the manufacturer, since otherwise the specification of the data sheet
cannot be met. When replacing wheels or tyres, it must be ensured that the fork-lift
truck remains level (tyres and wheels must always be replaced in pairs, i.e. left and
right together).
Lift chains: The lift chains wear rapidly if not lubricated. The intervals in the service
checklist apply to normal duty. If requirements are higher (dust, temperature), lubri-
cation is required more often. The specified chain spray must be used as specified.
The external application of grease does not provide sufficient lubrication.
Hydraulic hoses: The hoses must be renewed every six years. When replacing hy-
draulic components, also renew the hoses in this hydraulic system.
1001.GB
F2

3 Servicing and inspection
Thorough and expert servicing is one of the most important preconditions for safe
operation of the fork lift truck. The neglect of regular servicing intervals can lead to
fork lift truck failure and constitutes a potential hazard to personnel and equipment.
m The indicated servicing intervals are based on single-shift operation under normal
operating conditions. For applications in dusty environments, or involving large tem-
perature fluctuations or multiple-shift operation, the servicing intervals must be shor-
tened accordingly.
The following servicing checklist indicates the operations to be performed and the re-
spective intervals to be observed. The servicing intervals are defined as follows:
W1 = every 50 operating hours, but at least once per week
M3 = every 500 operating hours, but at least every 3 months
A The W1 maintenance intervals must be carried out by the operator / customer.
In the running-in phase of the truck, the following additional operations have to be car-
ried out:
After the first 50 - 100 hours of operation, at least after 2 months:

– Tighten pole screws of battery and check condition of the cell connectors.
– Perform visual inspection of the electronic and mechanic components.
– Check lift chains for equal tension.
– Check arresting and limitation of the fork tines.
– Check transmission for leakages.
– Check screw connections and mechanical safety retentions for tight fit.
– Check the wheel nuts for security and retighten, if required.
– Change all hydraulic oil filters.
– Check the hydraulic connections for leakages and retighten, if required.
– Check glide pieces at mast and adjust, if necessary.
1001.GB
F3

4 Maintenance checklist
Maintenance intervals
Standard = t W M M M
Cold-storage depot = k 1 3 6 12
Chassis/ 1.1 Check all load bearing elements for damage t
Design: 1.2 Check all bolted connections t
1.3 Check platform for correct functioning and damage t
Drive unit: 2.1 Check the transmission for noises and leakage t
2.2 Check the transmission oil level t
2.3 Change the transmission oil l t
Wheels: 3.1 Check for wear and damage t
3.2 Check the wheel bearings for correct fasteninga) l t
Steering: 4.1 Check the steering wheel play t
4.2 Check the steering chain and chain sprocket for wear, l t
adjust and grease
4.3 Check mechanical parts of steering column and grease, t
if required
Brake 5.1 Performance and adjustment check t
system: 5.2 Check the brake linings for wear t
5.3 Check the brake linkage; adjust and grease, if necessary l t
5.4 Gas pressure spring (tiller shaft) to reset function, t
check for tightness and damages
Hoist frame: 6.1 Visual inspection of rollers l t
6.2 Check fork tines and fork carrier for wear and damage l t
6.3 Check secure attachment of hoist frame t
6.4 Check lift chains and chain guide for wear, adjust and t
grease them.
6.5 Check the lateral clearance of the mast profiles and t
whether they are parallel to each other
6.6 Check safety devices for proper attachment l t
and damages
Lifting de- 7.1 Check function, wear and tear and adjustment t
vice: 7.2 Visual check of rollers, slide pieces and stops l t
7.3 Check fork tines and fork carrier for wear and damage l t
Hydr. system: 8.1 Check function k t
8.2 Check all connections for leakage and damage b) k t
8.3 Check hydraulic cylinders for leakage, damage and k t
secure attachment
8.4 Check the oil level k t
8.5 Change hydraulic oil c) k t
8.6 Change filter t
8.7 Check the pressure relief valves for correct functioning k t
1001.GB
F4

Maintenance intervals
Standard = t W M M M
Cold-storage depot = k 1 3 6 12
Electr. 9.1 Check function t
system: 9.2 Check all cables for secure connection and damage t
9.3 Check the fuses for correct amperage t
9.4 Check switches and trip cams for proper functioning and t
seating
9.5 Check contactors and relays, replace wearing parts, if t
necessary
9.6 Check functioning of warning devices and safety circuits k t
Electric 10.1 Check wear of carbon brushes t
motors: 10.2 Check the motor for secure attachment t
10.3 Suck out engine block, check wear of collector k t
Battery: 11.1 Check acid density, acid level and cell voltage l t
11.2 Check the terminals for secure attachment and apply l t
pole grease
11.3 Clean battery connections, check for tight fit l t
11.4 Check the battery cables for damage and replace, if t
necessary
11.5 Check the battery lock for proper functioning t
Lubrication 12.1 Grease truck according to lubrication schedule l t
service:
General mea- 13.1 Check electrical system for short to ground t
surements: 13.2 Check driving speed and braking distance t
13.3 Check lifting and lowering speed t
13.4 Check safety facilities and switch-off devices t
Demonstrati- 14.1 Perform a trial run under a nominal load t
on: 14.2 Demonstrate the truck to a person charged with inspec- l t
tion upon completion of the maintenance of the truck
a) First check of the wheel nuts after approx. 100 operating hours for tight fit. Re-tighten if
necessary. For starting torque, see maintenance plan.
b) Hydraulic connections to be first checked for leakage after approx. 100 operating hours;
tighten, if necessary.
c) 1. exchange after 500 hours of operation / if required, change coarse sieve.
A The maintenance intervals refer to normal service conditions. If you are working un-
der difficult conditions, reduce the intervals, if required.
1001.GB
F5

5 Lubrication schedule
g E F
G s F E
2)
ERC/Z
g s F E
1)
A A+C
3)
1)
B B+C
4)
b 1,25 - 1,3 l
MA = 105 Nm
a
g Slide faces
s Grease nipple
Filler neck for hydraulic oil
b Filler neck Gear oil
a Drain plug Gear oil
Cold store usage 1.25l - 1.3l;
1) Mixing proportion for application in cold-storage depots 1:1
2) only ERC-Z
3) Filling level see “Check hydraulic oil level”
1001.GB
4)
1.25l - 1.3l; depending on the drive type
(always up to the lower edge of the filler neck).
F6

5.1 Fuels, coolants and lubricants
Handling consumption type material: Consumption type material must always be

handled properly. Manufacturer's instructions to be observed.
f Improper handling is injurious to health, life, and environment. Consumption type ma-
terials must be stored in adequate containers. They might be inflammable and, the-
refore, must not come into contact with hot components or open fire.
When filling in consumption type materials use clean containers only. It is prohibited
to mix consumption type materials of different grades or qualitiies resp., except if mi-
xing is expressively prescribed in these operating instructions.
Avoid spilling. Spilt liquid must be removed immediately using a suitable binding
agent, and the mixture of consumption type material and binding agent is to be dis-
posed of according to the regulations.
Code Order-no. Supply Qty Designation Used for:

A 29 200 670 5,0 l H-LP 46, DIN 51524 Hydraulic system
B 29 200 680 5,0 l CLP 100, DIN 51517 Transmission
C 29 200 810 5,0 l H-LP 10, DIN 51524 Transmission,
hydraulic system
E 29 201 430 1,0 kg Grease, DIN 51825 Lubrication
F 29 200 100 1,0 kg Grease, TTF52 Lubrication
G 29 201 280 0,4 l Chain spray Chains
Grease Data
Code Saponification Dropp. Worked penetr. NLG1 class Service tempe-

point °C at 25° C rat. °C
E Lithium 185 265-295 2 -35/+120
F -- -- 310-340 1 -52/+100
1001.GB
F7

6 Notes on maintenance
6.1 Preparation of the truck for servicing and maintenance operation
All required safety measures must be taken to prevent any accidents in the course of
the servicing and maintenance operations. The following preparatory operations
must be performed:

– Disconnect the battery connector to prevent accidental or unauthorised truck ope-
ration.
f When working under raised forks or the raised vehicle, they should be secured so that
the possibility of them dropping, tipping or slipping is excluded. When the vehicle is
raised, the instructions in the Chapter ”Transport and commissioning” must also be
observed.
The vehicle should be secured against rolling away before doing any work on the ser-
vice / parking brakes.
6.2 Opening the front cover
Truck equipped with hinged driver standing platform:
– Fold down the stand-on platform (1) and fold out safety frame (2).
General:
– Unscrew screws (3) with a hex. socket wrench (socket width 8) (Key (4) in battery
compartment).
– Lift front hood (3), remove it from the truck and keep it in a safe place.
– Installation is in the reverse sequence of operations.
f Drive only with closed and properly locked hoods!
1
1001.GB
F8

6.3 Check hydraulic oil level
– Prepare the truck for servicing and maintenance operations (refer to chapter F, sec-
tion 6.1).
– Open the front hood (see section 6.2).
– Check the hydraulic oil level of the hydraulic tank (see section 5).
A There are markings on the hydraulic tank (see section 5). The oil level must be chek-
ked with the lifting device being lowered.
– If required, top up with hydraulic oil with the required characteristics

(see section 6.3; see table).
Marking Litre Lifting heights (h3)

ZT ZZ DZ
4 ca. 8,3 - - > 5300
3 ca. 8,0 - > 4100 < 5300
2 ca. 6,8 > 3100 > 2800 -
1 ca. 5,1 < 3100 < 2800 -
A Mounting is performed in reverse order.
6.4 Check the transmission oil level
– Prepare the truck for servicing and maintenance operations (see section 6.1).
– Open the front hood (see section 6.2).
– Loosen 2 x screws (3) using the key (4).
– Check gear-oil level - oil level must reach the filler neck
(see section 5).
– If required, top up with gear oil with the required characteristics (see section 5.1).
– Mounting is performed in reverse order.
1001.GB
F9

6.5 Checking the electric fuses
– Prepare the truck for the performance of servicing and maintenance operations
– Open the front cover (refer to section 6.2).
– Check all fuses for correct ratings and possible damage according to the table and
exchange them, if required.
– Mount the front cover (refer to section 6.2).
9
5
8
7 6
Item Description Protection of: Value

5 F1 Total control fuse 10 A
6 1F1 Drive motor (in parallel to 1F10) 150 A
7 2F1 Pump motor 150 A
8 1F10 Drive motor (in parallel to 1F1) 40 A
9 6F1 Discharge indicator/operating hour meter 10 A
1001.GB
F 10

6.6 Recommissioning the truck
Recommissioning of the truck following the performance of cleaning or maintenance

work is permitted only after the following operations have been performed:
– Check the horn for proper functioning.

– Check the master switch for correct functioning.
– Check the brake for correct functioning.
– Lubricate truck according to lubrication schedule.
– Refer to chapter “Starting up the truck”.
7 Decommissioning the fork lift truck
If the fork lift truck is to be decommissioned for more than two months, it must be par-
ked in a frost-free and dry location and all measures to be taken before, during and
following decommissioning must be performed as detailed below.
m During decommissioning, the fork lift truck must be jacked up, ensuring that the
wheels are clear of the ground. Only this measure will ensure that wheels and wheel
bearings do not suffer damage.
If the fork lift truck is to be decommissioned for more than 6 months, additional mea-
sures must be discussed with the Service Department of the manufacturer.
7.1 Operations to be performed prior to decommissioning
– Thoroughly clean the fork lift truck.

– Check the brakes for correct function.
– Check the hydraulic oil level and top up if required (refer to chapter F).
– Apply a thin film of oil or grease to all parts not protected by a paint coating.
– Grease the fork lift truck as detailed in the lubrication chart (refer to chapter F).
– Recharge the battery (refer to chapter D).
– Disconnect and clean the battery. Apply pole grease to the battery poles.
A In addition to this, all instructions given by the battery supplier must be observed.
– Spray all exposed electrical contacts with a suitable contact spray.
7.2 Measures to be taken during decommissioning
Every 2 months:
m Battery-operated fork lift trucks:

Regular recharging of the battery is very important; otherwise, exhaustive depletion
of the battery caused by self-discharging would occur. Owing to sulfatisation, this will
result in the destruction of the battery.
1001.GB
F 11

7.3 Recommissioning the truck
– Thoroughly clean the fork lift truck.

– Lubricate the fork lift truck according to the lubrication chart (refer to chapter F).
– Clean the battery. Grease the pole screws using pole grease and reconnect the
battery.
– Check if the gear oil contains condensed water and change if required.
– Check if the hydraulic oil contains condensed water and change if required.
– Start up the fork lift truck (refer to chapter E).
A Battery-operated fork lift trucks:

If switching troubles are experienced in the electric system, spray the exposed con-
tacts with contact spray and remove any oxide layer on the contacts of the operating
controls by repeated operation.
f Perform several brake tests immediately after recommissioning the truck.
8 Safety checks to be performed at regular intervals and following any untoward

incidents (D: Accident prevention check according to VBG 36)
At least once yearly, or after any untoward incident, the fork lift truck has to be chek-
ked by a qualified inspector. The inspector must assess the condition of the truck from
a standpoint purely concerned with safety aspects, uninfluenced by any company or
economic circumstances. The inspector must be adequately informed and experi-
enced to be able to assess the condition of the fork lift truck and the effectiveness of
the safety installations based on the technical rules and principles governing the in-
spection of fork lift trucks.
The inspection must comprise a comprehensive check of the technical condition of
the fork lift truck with regard to accident prevention aspects. Apart from this, the fork
lift truck must be thoroughly inspected for damage possibly caused by incorrect use
of the fork lift truck. The inspection results must be recorded in an inspection report
which must be kept available for a period spanning at least the next two inspection
intervals.
The user has to ensure that all defects are eliminated without delay.
A The manufacturer has set up a special safety service with specially qualified staff. As
visual proof that the fork lift truck has passed the safety inspection, a plaque is affixed
to it. This plaque indicates in which month of which year the next test will be due.
1001.GB
F 12

ERC/ERC-Z 12/14/16: Operating Instructions

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ERC/ERC-Z 12/14/16: Operating Instructions

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ERC/ERC-Z 12/14/16 10.

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Safety instructions and important explanations are indicated by the following

f Used before safety instructions which must be observed to avoid danger to

m Used before notices which must be observed to avoid material damage.

Copyright of these operating instructions remains with JUNGHEINRICH AG.

Telephone: +49 (0) 40/6948-0

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C Transportation and commissioning

1 Transportation by crane ...................................................................... C 1

D Battery - Servicing, recharging, replacement

1 Safety regulations governing the handling of lead-acid batteries ........ D 1

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F Maintenance of the fork lift truck

1 Operational safety and environmental protection ................................ F 1

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Mounting of attachments: The mounting or installation of any attachments which

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The truck is an electric pedestrian stacker in four-wheel construction with foldable

Truck types, capacities and motor output

Typ Capacity Motor output

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Item Designation Item Designation

t = Standard equipment o = Optional equipment

*) not with vehicles with load bearing capacity of 1200kg

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A Indication of technical data according to VDI 2198,

3.1 Performance data

Designation ERC 12 ERC 14 ERC 16

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(all dimensions in mm)

Designation ERC 12/ ERC 14/ ERC 16/

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Continuous sound level: 68 dB(A)

according to EN 12053 as stipulated in ISO 4871

A The continuous sound level is a value averaged according to standard regulations,

Vibration: 0.96 m/s2

according to prEN 13059

Electromagnetic compatibility (EMC)

3.4 Conditions for application

- during operation: 5°C to 40°C

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Xxxxxxxxx Xxxxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxx

Xxxxxxxxx Xxxxxxxxxxxxxxxxxxx xxxxxxxxxx

the corresponding hood (refer to chapter F).

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26 Xxxxxxxxx Xxxxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxx 34

Item Designation Item Designation

4.2 Load capacity

f The label (21) includes a table indicating

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4.4 Label/Order/Inventory/Service No.

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– Park the truck and render it safe

m Secure the hoisting gear to the hoisting

– Check whether the equipment is complete and in perfect condition.

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– Load the battery (see chapter D).

3 Moving the truck with the drive unit inoperative

– Set the master switch to position “OFF”.

f After arriving at the repair bay, ensure that