Jungheinrich HC 110, Operator'S Manual

Page 1: ...Operator Manual 51017163 HC 110 G 12 05 07 08 ...

Page 2: ...tiengesellschaft Am Stadtrand 35 22047 Hamburg GERMANY Telephone 49 0 40 6948 0 www jungheinrich com 0108 GB 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 co...

Page 3: ...0108 GB 0108 GB ...

Page 4: ...ng E 6 4 3 Lifting and depositing loads E 7 4 4 Parking the truck safely E 7 4 5 Troubleshooting E 8 I 1 0708 GB Table of contents A Correct use and application B Truck Description 1 Application B 1 2 Assemblies B 2 2 1 Truck B 3 3 Standard Version Specifications B 4 3 1 Performance data for standard trucks B 4 3 2 Dimensions B 4 3 3 EN norms B 6 3 4 Conditions of use B 6 4 Identification points w...

Page 5: ...at regular intervals and following any unusual incidents F 10 9 Final de commissioning disposal F 10 0708 GB I 2 F Industrial Truck Maintenance 1 Operational Safety and Environmental Protection F 1 2 Maintenance Safety Regulations F 1 3 Servicing and Inspection F 3 4 Maintenance checklist F 4 5 Lubrication Schedule F 5 5 1 Consumables F 6 6 Maintenance Instructions F 7 6 1 Preparing the truck for ...

Page 6: ...e required Approval of the local authorities however does not constitute the manufacturer s approval A 1 1004 GB A Correct use and application Z 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 op...

Page 7: ...1004 GB A 2 1004 GB A 2 ...

Page 8: ...Qmax Truck types capacity and motor output Model Rated capacity Engine output HC 110 1 000 kg 1 6 kW B 1 1004 GB B Truck Description 1 Application 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 Qmax Truck types capacity and motor output Model Rated capacity Engine output HC 110 1 000 kg...

Page 9: ...sconnect 1 13 t Push handles t Standard equipment o Optional Equipment 1 2 3 4 5 6 7 8 9 10 11 12 13 1004 GB B 2 2 Assemblies M 1 The truck must not be operated without the Emergency Disconnect see page C 2 Item Description 1 t Mast 2 t Control panel 3 t Fork 4 t Load wheels 5 t Battery charging lead 230 volts AC on board battery charger 6 t Front panel 7 t Castor wheel assembly support 8 t Steer ...

Page 10: ...ped from the oil reservoir into the cylinder The load fork 3 raises Electrical System 12 volt system B 3 1004 GB 2 1 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 Con...

Page 11: ...1 6 1 6 1 6 kW Battery voltage rated capacity k5 12 70 12 100 12 100 V Ah Battery weight 24 38 38 kg 1004 GB B 4 3 Standard Version Specifications Z Technical specification details in accordance with VDI 2198 Technical modifications and additions reserved 3 1 Performance data for standard trucks 3 2 Dimensions F The battery size must be adhered to for the duplex mast as the battery weight must be ...

Page 12: ...B 5 1004 GB B 5 1004 GB ...

Page 13: ... 5 C to 25 C or in a cold store or in extreme temperatures or conditions of fluctuating air humidity 1004 GB B 6 3 3 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 there...

Page 14: ...ning 17 Truck data plate 18 Serial number 19 Residual capacity 20 Capacity 14 15 16 17 18 19 20 1000 B 7 1004 GB 4 Identification points warning labels and data plates Item Description 14 Strap point for crane lifting 15 Do not reach through the mast warning 16 Do not step under the load handler warning 17 Truck data plate 18 Serial number 19 Residual capacity 20 Capacity 14 15 16 17 18 19 20 1000...

Page 15: ...23 Serial no 24 Net weight in kg 25 Manufacturer 26 Rated capacity kg 27 Option 21 22 23 24 25 26 27 1004 GB B 8 4 1 Truck data plate Z For queries regarding the truck or ordering spare parts always quote the truck serial number 23 Item Description 21 Model 22 Year of manufacture 23 Serial no 24 Net weight in kg 25 Manufacturer 26 Rated capacity kg 27 Option 21 22 23 24 25 26 27 ...

Page 16: ...he load centre of gravity distance D in mm and lift height H in mm in tabular form 28 Dmm Hmm Qkg 29 B 9 1004 GB 4 2 Capacity F 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 ca...

Page 17: ...1004 GB B 10 1004 GB B 10 ...

Page 18: ... such a way that they do not come into contact with any parts of the truck when it is being raised 1 C 1 1004 GB C Transport and Commissioning 1 Lifting by crane F Only use lifting gear with sufficient capacity for transport weight see truck data plate Z The strap points 1 on the mast are for loading the truck with crane lifting gear Park the truck securely see Chapter E Secure the lifting slings ...

Page 19: ...urface of the tyres will flatten The flattening will disappear after a short period of operation 2 3 1004 GB C 2 2 Securing the truck during transport F 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 rin...

Page 20: ...al safety of the truck Battery equipment may only be replaced with the agreement of the manufacturer D 1 1004 GB D Battery Maintenance Charging Replacement 1 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 opera...

Page 21: ... should not be used If the LED 3 goes out during charging check if the mains supply is still applied 1004 GB D 2 2 Battery types M 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 M When replacing or installing batteries ensure that the battery is corre...

Page 22: ...D 3 1004 GB Mains connection Mains voltage 230 V 10 Mains frequency 50 Hz 4 1 2 3 D 3 1004 GB Mains connection Mains voltage 230 V 10 Mains frequency 50 Hz 4 1 2 3 ...

Page 23: ...lose the battery panel carefully and slowly Do not reach between the battery panel and the chassis 4 1004 GB D 4 4 Battery removal and installation Park the truck securely see Chapter E Undo the screws and remove the front panel M Place the battery cable in such a way that it cannot get caught on the battery when the battery is removed Undo the terminal screws 4 and remove the battery cable from t...

Page 24: ...ion Flashes red Battery faulty charge circuit interrupted no mains supply Not lit Truck faulty 5 6 7 D 5 1004 GB 5 Battery Displays 5 1 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 5 2 Battery discharge indicator When the truck has been released via the key switch 6 the...

Page 25: ...1004 GB D 6 1004 GB D 6 ...

Page 26: ...s and warning signs Safety devices warning signs and warning instructions shall be strictly observed E 1 1004 GB E Operation 1 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 ope...

Page 27: ...ctivated 11 Push handles t Move the truck forward backward t Standard equipment o Optional Equipment 1004 GB E 2 2 Controls and Displays M 1 The truck must not be operated without the Emergency Disconnect see page C 2 Item Control Display Function 1 Battery discharge indicator t Battery charge status 2 Charger LED status t Indicates the charge status see Chapter D 3 Key switch t Switches control c...

Page 28: ...E 3 1004 GB 1 2 3 4 5 6 7 8 9 10 11 E 3 1004 GB 1 2 3 4 5 6 7 8 9 10 11 ...

Page 29: ...plying the control lever Test the brakes see section 4 2 The truck is now operational 12 13 14 15 16 1004 GB E 4 3 Starting up the truck F 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 hand...

Page 30: ...ore be taken in particular when accelerating braking and negotiating bends to avoid sudden movements E 5 1004 GB 4 Using the industrial truck 4 1 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...

Page 31: ... the left or right M On narrow bends the tiller extends outside the truck s geometry R V 17 18 19 20 1004 GB E 6 4 2 Travel steering braking F Never carry passengers Emergency Disconnect Disconnect the battery 19 All electrical functions are deactivated Traction M Do not drive the truck unless the panels are closed and properly locked Start up the truck see Section 3 Release the parking brake by s...

Page 32: ...e brake pedal 26 To release the brake step on the brake release mechanism 24 or 26 21 22 23 24 25 26 E 7 1004 GB Brakes F 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 M Lo...

Page 33: ...Load is too heavy Note maximum capacity see data plate Charge capacity below 40 Charging the battery 1004 GB E 8 4 5 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 Z If the fault cannot be rectified after carrying out the remedial procedure notify the manuf...

Page 34: ...ised water After cleaning the truck carry out the activities detailed in the Recommissioning section F 1 0708 GB F Industrial Truck Maintenance 1 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 F Any modification to the forklift truck assemblies i...

Page 35: ...d every six years When replacing hydraulic components also replace the hoses in the hydraulic system 0708 GB F 2 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 Weldin...

Page 36: ...after approx 100 service hours the owner must check the wheel nuts bolts and re tighten if necessary F 3 0708 GB 3 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 M The service interval...

Page 37: ...cutouts t Demon stration 13 1 After carrying out maintenance present the truck to the supervisor k t 0708 GB F 4 4 Maintenance checklist Maintenance Intervals Standard t W A B C Cold store k Chassis Super structure 1 1 Check all load bearing components for damage t 1 2 Check screw connections t Wheels 3 1 Check wheels for wear and damage t 3 2 Check suspension and attachment k t Steering 4 1 Check...

Page 38: ...F 5 0708 GB 5 Lubrication Schedule g Contact surfaces Hydraulic oil filler neck gE A G F 5 0708 GB 5 Lubrication Schedule g Contact surfaces Hydraulic oil filler neck gE A G ...

Page 39: ...ew point C Worked penetr at 25 C NLG1 class Application temperature C E Lithium 185 265 295 2 35 120 0708 GB F 6 5 1 Consumables Handling consumables Consumables must always be handled correctly Follow the manufacturer s instructions F 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...

Page 40: ...port and Commissioning section When working on the parking brake prevent the truck from rolling away F 7 0708 GB 6 Maintenance Instructions 6 1 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...

Page 41: ...replace if necessary Item Description To protect HC 1 F1 Control fuse 8 A 2 2F1 Power fuse 250 A 1 2 0708 GB F 8 6 2 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 HC 1 F1 Control fuse 8 A 2 2F1 Power fuse 250 A 1 2 ...

Page 42: ...es a constant compensation charge it will not need to be charged every 6 months to prevent depletion F 9 0708 GB 6 3 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 7 Decommissioning the industrial ...

Page 43: ...ons governing the disposal of batteries fuels and electronic and electrical systems must be observed 0708 GB F 10 7 3 Returning the truck to operation after decommissioning Thoroughly clean the truck Lubricate the truck in accordance with the maintenance schedule see Chapter F Clean the battery grease the terminals and connect the battery Charge the battery see Chapter D Check hydraulic oil for co...