Jungheinrich HC 110 Operating Instructions Manual
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Jungheinrich HC 110 Operating Instructions Manual

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HC 110
Operating instructions
51135771
04.16
01.09
en-GB
HC 110

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Summary of Contents for Jungheinrich HC 110

  • Page 1 HC 110 01.09 Operating instructions en-GB 51135771 04.16 HC 110...
  • Page 3 Declaration of Conformity Jungheinrich AG, Friedrich-Ebert-Damm 129, 22047 Hamburg, Germany Manufacturer or agent acting in the European Union Model Option Serial no. Year of manufacture HC 110 Additional information On behalf of Date en-GB EC Declaration of Conformity The undersigned hereby declare that the powered industrial truck described below in...
  • Page 5 Indicates a material hazard. Failure to comply with this instruction may result in material damage. Used before notices and explanations. Indicates standard equipment Indicates optional equipment Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG. Jungheinrich Aktiengesellschaft Friedrich-Ebert-Damm 129 22047 Hamburg - Germany Tel: +49 (0) 40/6948-0...
  • Page 6 www.jungheinrich.com...

  • Page 7: Table Of Contents

    Contents Correct Use and Application General Correct application Approved application conditions Proprietor responsibilities Adding attachments and/or optional equipment Truck Description Application Truck models and rated capacity Assemblies and Functional Description Assembly Overview Functional Description Technical Specifications Performance data Dimensions Weights Tyre type EN norms Conditions of use...
  • Page 8 Decommissioning the Industrial Truck Prior to decommissioning During decommissioning Restoring the truck to service after decommissioning Safety tests to be performed at intervals and after unusual incidents Final de-commissioning, disposal Maintenance and Inspection Maintenance Contents HC 110 Owner Customer Service...

  • Page 9: A Correct Use And Application

    A Correct Use and Application General The truck must be used, operated and serviced in accordance with the present instructions. All other types of use are beyond its scope of application and may result in damage to personnel, the industrial truck or property. Correct application NOTICE The maximum load and load distance are indicated on the capacity plate and must...

  • Page 10: Proprietor Responsibilities

    Proprietor responsibilities For the purposes of the present operating instructions the “operating company” is defined as any natural or legal person who either uses the industrial truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting) the proprietor is considered the person who, in accordance with existing contractual agreements between the owner and user of the industrial truck, is charged with operational duties.

  • Page 11: B Truck Description

    B Truck Description Application The industrial truck is a four-wheel electric walkie stacker. It is designed for transporting goods on level surfaces. Open-bottom pallets or roll cages can be lifted. The rated capacity is indicated on the data plate or the capacity plate Qmax. Truck models and rated capacity The rated capacity depends on the model.

  • Page 12: Assemblies And Functional Description

    Assemblies and Functional Description Assembly Overview Item Component Item Component t Mast Front panel t Push handles Brake pedal (parking brake) t Emergency Disconnect Steer wheels switch t Control panel Castor wheel assembly support t Forks Tiller t Load wheels t Standard equipment Optional equipment...

  • Page 13: Functional Description

    Functional Description Safety mechanisms – The wheels are surrounded by a solid castor wheel assembly support. – Activating the Emergency Disconnect switch rapidly cuts out all electrical functions in hazardous situations.

  • Page 14: Technical Specifications

    Design The HC 110 is a four-wheel truck with two steered wheels (9) and two load wheels (6). The electrical components and the hydraulic unit are located under the front cover (7). Controls and displays The lift and lower controls are arranged on the front panel.

  • Page 15: Dimensions

    Dimensions max. min. a/2 = 100 a/2 = 100 Model HC 110 HC 110 HC 110 Lift height 1600 2500 3000 Mast height retracted 1980 1830 2080 Lift 2500 3000 1600 Mast height extended 1980 3570 3070 Ground clearance below mast...

  • Page 16: Weights

    2175 800x1200 length Aisle width 2145 2145 2145 1000x1200 transv. Lift motor, output where Weights Model HC 110 HC 110 HC 110 Lift height 1600 2500 3000 Net weight incl. battery Axle load, w.o. load 250 / 100 310 / 125...

  • Page 17: En Norms

    EN norms Noise emission level – HC 110: 69 dB(A) *+/- 3 dB(A) depending on the truck's equipment in accordance with EN 12053 as harmonised with ISO 4871. The noise emission level is calculated in accordance with standard procedures and takes into account the noise level when travelling, lifting and when idle.

  • Page 18: Identification Points And Data Plates

    Identification Points and Data Plates Item Component Strap points for crane lifting Do not step onto or beneath the load, risk of trapping with moving mast Never reach through the mast Data plate Capacity Qmax Serial number...
  • Page 19 3.8.1 Data plate Item Description Item Description Type Year of manufacture Serial number Load centre (mm) Rated capacity (kg) Output Battery voltage (V) Min./max. battery weight (kg) Net weight w.o. battery (kg) Manufacturer Option Manufacturer’s logo For queries regarding the truck or ordering spare parts always quote the truck serial number (19).
  • Page 20 3.8.2 Truck capacity plate The capacity plate (16) gives the capacity (Q in kg) of the truck for a vertical mast. The maximum capacity is shown as a table with a given load centre of gravity D (in mm) and the required lift height H (in mm). Example of how to calculate the maximum capacity: For a load centre of gravity D of 600 mm and a max.

  • Page 21: C Transport And Commissioning

    C Transport and Commissioning Lifting by crane WARNING! Improper loading by crane can result in accidents Improper use or use of unsuitable lifting gear can cause the truck to crash when being loaded by crane. Prevent the truck from hitting other objects during lifting, and avoid uncontrolled movements.

  • Page 22: Transport

    Transport WARNING! Accidental movement during transport Improper fastening of the truck and mast during transport can result in serious accidents. uLoading must only be performed by specialist personnel trained for this purpose. The specialist personnel must be instructed in securing loads on road vehicles and handling load securing devices.

  • Page 23: Using The Truck For The First Time

    Using the Truck for the First Time Procedure • Check the equipment is complete. • Install the battery (where required), see page 31, do not damage the battery cable. • Charge the battery, see page 29. The truck can now be started, see page 37. When the truck is parked the surface of the tyres will flatten.

  • Page 25: D Battery - Servicing, Recharging, Replacement

    D Battery - Servicing, Recharging, Replacement Safety Regulations Governing the Handling of Lead-Acid Batteries Maintenance personnel Batteries may only be charged, serviced or replaced by trained personnel. These operating instructions and the battery manufacturer's instructions must be observed when performing these operations. Fire Protection Do not smoke and avoid naked flames when handling batteries.
  • Page 26 WARNING! Unsuitable batteries that have not been approved by Jungheinrich for the truck can be hazardous The design, weight and dimensions of the battery have a considerable effect on the operational safety of the truck, in particular its stability and capacity.

  • Page 27: Battery Types

    Battery types Use non-gassing batteries only. Optimum battery useful life is achieved at battery temperatures of 15 °C to 35 °C. Low temperatures reduce the available battery capacity, high temperatures reduce the battery useful life. NOTICE 45 °C is the maximum temperature for batteries, at which point the truck cannot be operated.

  • Page 28: Exposing The Battery

    Exposing the battery CAUTION! Trapping hazard uMake sure there is nothing between the battery cover and the truck when you fit the battery cover. WARNING! An unsecured truck can cause accidents Parking the truck on an incline or with a raised load handler is dangerous and is strictly prohibited.

  • Page 29: Charging The Battery

    The on-board charger consisting of a battery charger and battery controller must not be opened. If faulty, contact the manufacturer’s customer service department. uThe charger must only be used for batteries supplied by Jungheinrich or other approved batteries provided it has been adapted by the manufacturer's customer service department.
  • Page 30 Starting to charge with the on-board charger Mains connection Mains supply: 230 V (+/-10%) Mains frequency: 50 Hz (+/-10%) The mains cable (34) of the charger is contained in the front panel. Charging the battery Requirements – Park the truck securely, see page 41. Procedure •...

  • Page 31: Battery Removal And Installation

    Battery removal and installation WARNING! Accident risk during battery removal and installation Due to the battery weight and acid there is a risk of trapping or burning when the battery is removed and installed. uNote the "Safety regulations for handling acid batteries" section in this chapter. uWear safety shoes when removing and installing the battery.

  • Page 33: E Operation

    E Operation Safety Regulations for the Operation of Forklift Trucks Driver authorisation The 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 34 Hazardous area WARNING! Risk of accidents/injury in the hazardous area of the truck A hazardous area is defined as the area in which people are at risk due to travel or lifting operations of the truck, its load handler or the load. This also includes the area within reach of falling loads or lowering/falling operating equipment.

  • Page 35: Displays And Controls

    Displays and Controls Item Control /Display Function t – Move the truck forward/backward. Push handle t Disconnects the battery supply Emergency Disconnect switch – All electrical functions are deactivated t – Prevent the truck from rolling away. Brake pedal (parking brake) t –...

  • Page 36: Battery Discharge Indicator

    Battery discharge indicator NOTICE Deep discharge can damage the battery standard adjustment battery discharge indicator is for maintenance-free batteries (gel batteries). When using other batteries, the display must be reset. uThis adjustment should only be made by the manufacturer’s customer service department. uThe battery discharge indicator shows the battery’s residual capacity.

  • Page 37: Starting Up The Truck

    Starting up the truck Checks and Operations to Be Performed Before Starting Daily Work WARNING! Damage and other truck or attachment (optional equipment) defects can result in accidents. If damage or other truck or attachment (optional equipment) defects are discovered during the following checks, the truck must be taken out of service until it has been repaired.

  • Page 38: Industrial Truck Operation

    Industrial Truck Operation 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. The truck must only be operated in work areas with sufficient lighting to avoid danger to personnel and materials.
  • Page 39 Negotiating slopes and inclines WARNING! Do not negotiate slopes or inclines. Negotiating lifts, loading ramps and docks Lifts may only be negotiated if they have sufficient capacity, are suitable for driving on and authorised for truck traffic by the owner. The driver must satisfy himself of the above before entering these areas.

  • Page 40: Preparing The Truck For Operation

    Preparing the truck for operation Switching on the truck Requirements – For checks and operations to be performed before starting daily operation, see page 37. – On-board charger mains plug (34) disconnected. Procedure • Pull out the Emergency Disconnect switch (3). •...

  • Page 41: Parking The Truck Securely

    Parking the truck securely WARNING! An unsecured truck can cause accidents Parking the truck on an incline, without the brakes applied or with a raised load or load handler is dangerous and is strictly prohibited. uPark the truck on a level surface. In special cases the truck may need to be secured with wedges.

  • Page 42: Emergency Disconnect, Travel, Steering, Braking

    Emergency Disconnect, Travel, Steering, Braking 4.4.1 Emergency Disconnect CAUTION! Faulty or non-accessible Emergency Disconnect switches can cause accidents A faulty or non-accessible Emergency Disconnect switch can cause accidents. In dangerous situations the operator cannot bring the truck to a halt in time by applying the Emergency Disconnect switch.

  • Page 43: Travel

    Travel WARNING! Collision hazard when operating the truck Collisions with personnel and equipment can result if the truck is operated with open panels. uDo not operate the truck unless the panels and covers are closed and properly locked. Requirements – Start up the truck, see page 37 Procedure •...

  • Page 44: Lifting, Transporting And Depositing Loads

    Manual braking Procedure • Pull push against direction movement. The truck is braked. Braking with the parking brake Procedure • Applying the brake pedal (8). The truck brakes. Lifting, transporting and depositing loads WARNING! Unsecured and incorrectly positioned loads can cause accidents. Before lifting a load unit, the driver must make sure that it has been correctly palletised and does not exceed the truck’s capacity.
  • Page 45 4.8.1 Raising a load Requirements – Load correctly palletised. – Load weight matches the truck's capacity. – Forks evenly loaded for heavy loads. Procedure • Drive the truck carefully up to the pallet. • Slowly insert the forks into the pallet until the fork shank touches the pallet.

  • Page 46: Troubleshooting

    4.8.3 Depositing a load Depositing loads NOTICE Loads must not be deposited on travel or escape routes, in front of safety mechanisms or plant equipment that must be accessible at all times. Requirements – Storage location suitable for storing the load. Procedure •...

  • Page 47: Load Cannot Be Lifted

    Load cannot be lifted Possible Cause Remedy Emergency Disconnect pressed Unlock the Emergency Disconnect Key switch set to O. Set the key switch to “I” Hydraulic oil level too low Checking the hydraulic oil level Battery charge too low Check the battery charge and charge battery if necessary.

  • Page 49: F Industrial Truck Maintenance

    F Industrial Truck Maintenance Operational Safety and Environmental Protection The checks and servicing operations contained in this chapter must be performed in accordance with the maintenance checklist service intervals. WARNING! Risk of accidents and component damage Any modification to the truck, in particular the safety mechanisms, is prohibited. NOTICE Only original spare parts are subject to the manufacturer's quality control.
  • Page 50 CAUTION! Fire hazard Do not use flammable liquids to clean the industrial truck. uAlways disconnect the battery before starting cleaning work. uCarry out all necessary safety measures to prevent sparking before cleaning (e.g. by short-circuiting). Working on the electrical system WARNING! Accident risk uOnly suitably trained electricians may operate on the truck's electrical system.
  • Page 51 NOTICE Testing and replacing hydraulic hoses Hydraulic hoses can become brittle through age and must be checked at regular intervals. The application conditions of the industrial truck have a considerable impact on the ageing of the hydraulic hoses. uCheck the hydraulic hoses at least annually and replace if necessary. uIf the operating conditions become more arduous the inspection intervals must be reduced accordingly.

  • Page 52: Lubricants And Lubrication Schedule

    Lubricants and Lubrication Schedule Handling consumables safely Handling consumables Consumables must always be handled correctly. Follow the manufacturer’s instructions. WARNING! Improper handling is hazardous to health, life and the environment Consumables can be flammable. uKeep consumables away from hot components and naked flames. uAlways keep consumables in prescribed containers.
  • Page 53 CAUTION! Consumables and used parts are an environmental hazard Used parts and consumables must be disposed of in accordance with the applicable environmental-protection regulations. Oil changes should be carried out by the manufacturer's customer service department, whose staff are specially trained for this task.

  • Page 54: Lubrication Schedule

    Lubrication Schedule...

  • Page 55: Consumables

    g Contact surfaces Grease nipple Hydraulic oil filler neck Consumables Order no. Package Component Used for quantity 50 449 669 8.0 l HLP-B 46 Hydraulic system 29 202 050 1.0 kg Grease, Polylube Lubrication GA 352P 29 201 280 0.51 l Chain spray Chains Grease guidelines...

  • Page 56: Maintenance And Repairs

    Maintenance and repairs 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: Procedure • Park the truck on a level surface. •...

  • Page 57: Lifting And Jacking Up The Truck Safely

    Lifting and jacking up the truck safely WARNING! A truck tipover can cause accidents In order to raise the truck, use only suitable lifting gear at the points specially provided for this purpose. uNote the weight of the truck on the data plate. uAlways use a jack with a minimum capacity of 5000 kg kg.

  • Page 58: Front Cover Disassembly

    Front cover disassembly Requirements – Park the truck on a horizontal surface. – Park the truck securely, see page 41. Procedure • Removing the knob (3) from the emergency disconnect switch: • Prevent the switch shaft from rotating using the pin (32) and screw off the knob (3) anticlockwise.

  • Page 59: Checking Electrical Fuses

    Checking electrical fuses Check fuses Requirements – Truck prepared for maintenance and repairs, see page 56. – Remove the front panel, see page 58. Procedure • Check the fuse ratings against the table and replace if necessary. The fuses are now checked. Component To protect Rating (A)

  • Page 60: Restoring The Truck To Service After Maintenance And Repairs

    Restoring the truck to service after maintenance and repairs Procedure • Thoroughly clean the truck. • Lubricate the truck according to the lubrication schedule, see page 54. • Clean the battery, grease the terminals and connect the battery. • Charge the battery, see page 29. •...

  • Page 61: Decommissioning The Industrial Truck

    Decommissioning the Industrial Truck If the truck is to be out of service for more than a month, it must be stored in a frost- free and dry room. All necessary measures must be taken before, during and after decommissioning as described hereafter. When the truck is out of service it must be jacked up so that all the wheels are clear of the ground.

  • Page 62: Prior To Decommissioning

    Prior to decommissioning Procedure • Thoroughly clean the truck. WARNING! Faulty brakes can cause accidents Test the brakes immediately as soon as the truck has been commissioned. uReport any defects immediately to your supervisor. uTag out and decommission a faulty lift truck. uOnly return the truck to service when you have identified and rectified the fault.

  • Page 63: Restoring The Truck To Service After Decommissioning

    Restoring the truck to service after decommissioning WARNING! Faulty brakes can cause accidents Test the brakes immediately as soon as the truck has been commissioned. uReport any defects immediately to your supervisor. uTag out and decommission a faulty lift truck. uOnly return the truck to service when you have identified and rectified the fault.

  • Page 64: Safety Tests To Be Performed At Intervals And After Unusual Incidents

    Safety tests to be performed at intervals and after unusual incidents The truck must be inspected at least annually (refer to national regulations) or after any unusual event by a qualified inspector. The manufacturer offers a safety inspection service which is performed by personnel specifically trained for this purpose.

  • Page 65: Maintenance And Inspection

    G Maintenance and Inspection WARNING! Lack of maintenance can result in accidents Failure to perform regular servicing can lead to truck failure and poses a potential hazard to personnel and equipment. uThorough and expert servicing is one of the most important requirements for the safe operation of the industrial truck.

  • Page 66: Maintenance Contents Hc 110

    Maintenance Contents HC 110 Issued on: 2016-04-05 16:05 Owner To be performed every 50 service hours, but at least once a week. 1.1.1 Maintenance contents 1.1.1.1 Standard equipment Power supply Correct the battery acid level using demineralised water. Hydraulic operations Lubricate the load chains.
  • Page 67 1.1.2 Inspection contents 1.1.2.1 Standard equipment The following points must be checked: Electrical system Function of display and controls The function of the emergency disconnect and for damage Power supply Battery cable connections are secure Travel Wheels for wear and damage Chassis/structure Labels are legible, complete and plausible Hydraulic operations...

  • Page 68: Customer Service

    Customer Service In accordance with the HC 110 service interval, to be performed every 1000 service hours, but at least once a year. 1.2.1 Maintenance contents 1.2.1.1 Standard equipment Electrical system Carry out a chassis insulation-resistance test. Power supply Clean the battery.
  • Page 69 1.2.2 Inspection contents The following points must be checked: 1.2.2.1 Standard equipment Electrical system Function of display and controls The function of the emergency disconnect and for damage Contactors and/or relays for wear and damage Power supply Battery cable connections are secure Travel Wheel bearings and attachment for wear and damage Wheels for wear, damage and secure mounting...
  • Page 70 1.2.3 Maintenance parts The manufacturer recommends the replacement of the following maintenance parts at the specified intervals. 1.2.3.1 Standard equipment maintenance part service hours months...

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