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Table of Contents
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Summary of Contents for Jungheinrich HC 110
- Page 1 HC 110 12.05 - Operator Manual 51017163 07.08...
- Page 2 Used to indicate standard equipment. Used to indicate optional equipment. Our trucks are subject to ongoing development. Jungheinrich reserves the right to alter the design, equipment and technical features of the truck. No guarantee of particular features of the truck should therefore be inferred from the present operating instructions.
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Page 4: Table Of Contents
Table of contents Correct use and application Truck Description Application ................... B 1 Assemblies ..................B 2 Truck ....................B 3 Standard Version Specifications ............B 4 Performance data for standard trucks ..........B 4 Dimensions ..................B 4 EN norms .................... B 6 Conditions of use ................ - Page 5 Industrial Truck Maintenance Operational Safety and Environmental Protection ......F 1 Maintenance Safety Regulations ............F 1 Servicing and Inspection ..............F 3 Maintenance checklist ................ F 4 Lubrication Schedule ................F 5 Consumables ..................F 6 Maintenance Instructions ..............F 7 Preparing the truck for maintenance and repairs ........
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Page 6: A Correct Use And Application
A Correct use and application The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are supplied with the truck. The guidelines form part of these operating instructions and must be observed. National regulations apply in full. The truck described in the present operating instructions is an industrial truck designed for lifting and transporting loads. -
Page 8: B Truck Description
The truck is designed for transporting goods on level surfaces. Open bottom pallets or roll cages can be lifted. The capacity is shown on the data capacity plate Q Truck types, capacity and motor output: Model Rated capacity Engine output HC 110 1,000 kg 1.6 kW... -
Page 9: Assemblies
Assemblies Item Description Mast Control panel Fork Load wheels Battery charging lead 230 volts AC (on-board battery charger) Front panel Castor wheel assembly support Steer wheels Parking brake Brake pedal (parking brake) Tiller Battery connector (Emergency Disconnect) Push handles t = Standard equipment o = Optional Equipment The truck must not be operated without the Emergency Disconnect (see page C 2). -
Page 10: Truck
Truck Structure: The HC is a four-wheel truck with two steer wheels (8) and two load wheels (9). An smooth opening panel provides easy access to all the components. The controls are arranged on the panel. Safety mechanisms: – The castor wheel assembly support (7) protects the operator’s feet. Controls and Displays: The lift and lower controls are arranged on the panel. -
Page 11: Standard Version Specifications
Load centre of gravity distance Lift speed (lift) w / w.o. load 8 / 10 cm/sec Lift speed (lower) w / w.o. load 27 / 15 cm/sec Dimensions Description HC 110 HC 110 HC 110 Lift height 1600 2500 3000 Height 2100... -
Page 13: Norms
EN norms Electromagnetic compatibility (EMC) The manufacturer confirms compliance with the limit values for electromagnetic emission and interference immunity as well as testing of static electricity discharge according to EN 12895 and the references to other standards contained therein. No changes to electric or electronic components or their arrangement may be made without the written agreement of the manufacturer. -
Page 14: Identification Points, Warning Labels And Data Plates
Identification points, warning labels and data plates 1000 Item Description Strap point for crane lifting "Do not reach through the mast" warning “Do not step under the load handler” warning Truck data plate Serial number Residual capacity Capacity... -
Page 15: Truck Data Plate
Truck data plate Item Description Model Year of manufacture Serial no. Net weight in kg Manufacturer Rated capacity (kg) Option For queries regarding the truck or ordering spare parts always quote the truck serial number (23). -
Page 16: Capacity
Capacity The capacity data with respect to lift height and load centre of gravity distance can be found on the truck's capacity plate (28). Depending on the mast fitted, the truck will have one of the following two capacity plates (28, 29): (illustrations for reference purposes only) The capacity plate to the right (28) shows the capacity (Q in kg) for different load centres of gravity (D in mm) in... - Page 17 B 10...
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Page 18: C Transport And Commissioning
C Transport and Commissioning Lifting by crane Only use lifting gear with sufficient capacity (for transport weight see truck data plate). The strap points (1) on the mast are for loading the truck with crane lifting gear. – Park truck securely (see Chapter E). -
Page 19: Securing The Truck During Transport
Securing the truck during transport The truck must be securely fastened when transported on a lorry or a trailer. The lorry / trailer must have fastening rings. – To secure the truck attach the tensioning belt to the strap points (2) and the push handles (3) and attach it to the fastening rings. -
Page 20: D Battery Maintenance, Charging & Replacement
D Battery Maintenance, Charging & Replacement Safety regulations for handling acid batteries Park the truck securely before carrying out any work on the batteries (see Chapter E). Maintenance personnel: Batteries may only be charged, serviced or replaced by trained personnel. The present operator manual and the manufacturer’s instructions concerning batteries and charging stations must be observed when carrying out the work. -
Page 21: Battery Types
Battery types If the truck is fitted with maintenance-free batteries, do not add distilled water. The cell covers are fixed tight. If you open them, the battery will be damaged. Note the instructions on the battery. When replacing or installing batteries, ensure that the battery is correctly secured in the battery compartment of the truck. - Page 22 Mains connection Mains voltage: 230 V ±10% Mains frequency: 50 Hz ±4%...
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Page 23: Battery Removal And Installation
Battery removal and installation – Park the truck securely (see Chapter E). – Undo the screws and remove the front panel. Place the battery cable in such a way that it cannot get caught on the battery when the battery is removed. –... -
Page 24: Battery Displays
Battery Displays Charge status display When the charger has been connected to a mains socket, the LED (5) indicates the battery charge status. The LED (5) colours represent the following conditions: Flashes green Battery is being charged Lit green Battery fully charged, charge conservation Flashes red Battery faulty, charge circuit interrupted, no mains supply Not lit... -
Page 26: E Operation
E Operation Safety Regulations for the Operation of Forklift Trucks Driver authorisation: The forklift truck may only be used by suitably trained personnel, who have demonstrated to the proprietor or his representative that they can drive and handle loads and have been authorised to operate the truck by the proprietor or his representative. -
Page 27: Controls And Displays
Controls and Displays Item Control / Display Function Battery discharge Battery charge status. indicator Charger LED status Indicates the charge status (see Chapter D). Key switch Switches control current on and off. Removing the key prevents the truck from being switched on by unauthorised personnel. -
Page 29: Starting Up The Truck
Starting up the truck Before the truck can be started, operated or a load lifted, the driver must ensure that there is nobody within the hazardous area. Checks and operations to be performed before starting daily work – Visually inspect the entire truck (in particular wheels and load handler) for obvious damage. -
Page 30: Using The Industrial Truck
Using the industrial truck Safety regulations for truck operation Travel routes and work areas: Only use lanes and routes specifically designated for truck traffic. Unauthorised third parties must stay away from work areas. Loads must only be stored in places specially designated for this purpose. Travel conduct: The driver must adapt the travel speed to local conditions. -
Page 31: Travel, Steering, Braking
Travel, steering, braking Never carry passengers. Emergency Disconnect – Disconnect the battery (19). All electrical functions are deactivated. Traction Do not drive the truck unless the panels are closed and properly locked. – Start up the truck (see Section 3). –... -
Page 32: Lifting And Depositing Loads
Brakes The braking pattern of the truck depends largely on the ground conditions. The driver must take this into account. The truck can brake in two different ways: – Manually (by pulling or pushing against the direction of movement) – Brake pedal (parking brake only) Travelling on inclines Loads must always be carried at that end of the truck facing uphill. -
Page 33: Troubleshooting
Troubleshooting This chapter allows the user to identify and rectify basic faults or the effects of incorrect operation. When trying to locate a fault, proceed in the order shown in the table. Fault Probable Cause Action Truck does not – Battery connector not plugged –... -
Page 34: F Industrial Truck Maintenance
F Industrial Truck Maintenance Operational Safety and Environmental Protection The servicing and inspection duties contained in this chapter must be performed in accordance with the intervals indicated in the maintenance checklists. Any modification to the forklift truck assemblies, in particular the safety mechanisms, is prohibited. - Page 35 Electrical System: Only suitably trained personnel may operate on the truck’s electrical system. Before working on the electrical system, take all precautionary measures to avoid electric shocks. For battery-operated trucks, also de-energise the truck by removing the battery connector. Welding: To avoid damaging electric or electronic components, remove these from the truck before performing welding operations.
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Page 36: Servicing And Inspection
Servicing and Inspection Thorough and expert servicing is one of the most important requirements for the safe operation of the industrial truck. Failure to perform regular servicing can lead to truck failure and poses a potential hazard to personnel and equipment. The service intervals stated are based on single shift operation under normal operating conditions. -
Page 37: Maintenance Checklist
Maintenance checklist Maintenance Intervals = t W A B C Standard Cold store Chassis/ 1.1 Check all load bearing components for damage Super- 1.2 Check screw connections structure: Wheels: 3.1 Check wheels for wear and damage 3.2 Check suspension and attachment Steering: 4.1 Check slack Brake... -
Page 38: Lubrication Schedule
Lubrication Schedule Contact surfaces Hydraulic oil filler neck... -
Page 39: Consumables
Consumables Handling consumables: Consumables must always be handled correctly. Follow the manufacturer’s instructions. Improper handling is hazardous to health, life and the environment. Consumables must only be stored in appropriate containers. They may be flammable and must therefore not come into contact with hot components or naked flames. Only use clean containers when filling up with consumables. -
Page 40: Maintenance Instructions
Maintenance Instructions Preparing the truck for maintenance and repairs All necessary safety measures must be taken to avoid accidents when carrying out maintenance and repairs. The following preparations must be made: – Park the truck securely (see Chapter E). – Disconnect the battery to prevent the truck from being switched on accidentally When working under a raised lift truck, secure it to prevent it from tipping or sliding away. -
Page 41: Checking Electrical Fuses
Checking electrical fuses – Prepare the truck for maintenance (see Chapter 6.1). – Remove panel. – Check all fuse ratings in accordance with the table; replace if necessary. Item Description To protect: Control fuse Power fuse 250 A... -
Page 42: Recommissioning
Recommissioning The truck may only be restored to service after cleaning or repair work, once the following operations have been performed. – Test EMERGENCY DISCONNECT connector. – Test brakes. – Lubricate the truck in accordance with the maintenance schedule. Decommissioning the industrial truck If the industrial truck is to be decommissioned for more than six months, e.g. -
Page 43: Returning The Truck To Operation After Decommissioning
Carry out a safety check in accordance with national regulations. Junheinrich recommends checks in accordance with FEM Guideline 4.004. Jungheinrich has a special safety department with trained personnel to carry out such checks. The truck must be inspected at least annually (refer to national regulations) or after any unusual event by a qualified inspector.
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