Jungheinrich HC 110 User manual

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

2

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
detail complies with the European Directives 2006/42/EG (Machinery Directive) and
2014/30/EU (Electromagnetic Compatibility - EMC) including amendments as well as
the legislative decree to incorporate the directives in national law. The signatories
are in each case individually authorised to compile the technical documents.
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Foreword
Notes on the operating instructions
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide
sufficient instruction for the safe operation of the industrial truck. The information is
provided clearly and concisely. The chapters are arranged by letter and the pages
are numbered continuously.
The operator manual details different industrial truck models. When operating and
servicing the industrial truck, make sure that the particular section applies to your
truck model.
Our trucks are subject to ongoing development. We reserve the right to alter the
design, equipment and technical features of the system. No guarantee of particular
features of the truck should therefore be assumed from the present operating
instructions.
Safety notices and text mark-ups
Safety instructions and important explanations are indicated by the following
graphics:
DANGER!
Indicates an extremely hazardous situation. Failure to comply with this instruction will
result in severe irreparable injury and even death.
WARNING!
Indicates an extremely hazardous situation. Failure to comply with this instruction
may result in severe irreparable injury and even death.
CAUTION!
Indicates a hazardous situation. Failure to comply with this instruction may result in
slight to medium injury.
NOTICE
Indicates a material hazard. Failure to comply with this instruction may result in
material damage.
ZUsed before notices and explanations.
tIndicates standard equipment
oIndicates optional equipment
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Friedrich-Ebert-Damm 129
22047 Hamburg - Germany
Tel: [phone]
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www.jungheinrich.com
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Contents
.
A Correct Use and Application 9
.
1 General 9
2 Correct application 9
3 Approved application conditions 9
4 Proprietor responsibilities 10
5 Adding attachments and/or optional equipment 10
.
B Truck Description 11
.
1 Application 11
1.1 Truck models and rated capacity 11
2 Assemblies and Functional Description 12
2.1 Assembly Overview 12
2.2 Functional Description 13
3 Technical Specifications 14
3.1 Performance data 14
3.2 Dimensions 15
3.3 Weights 16
3.4 Tyre type 16
3.5 EN norms 17
3.6 Conditions of use 17
3.7 Electrical Requirements 17
3.8 Identification Points and Data Plates 18
.
C Transport and Commissioning 21
.
1 Lifting by crane 21
2 Transport 22
3 Using the Truck for the First Time 23
.
D Battery - Servicing, Recharging, Replacement 25
.
1 Safety Regulations Governing the Handling of Lead-Acid Batteries 25
2 Battery types 27
3 Exposing the battery 28
4 Charging the battery 29
5 Battery removal and installation 31
.
E Operation 33
.
1 Safety Regulations for the Operation of Forklift Trucks 33
2 Displays and Controls 35
2.1 Battery discharge indicator 36
3 Starting up the truck 37
3.1 Checks and Operations to Be Performed Before Starting Daily Work 37
4 Industrial Truck Operation 38
4.1 Safety regulations for truck operation 38
4.2 Preparing the truck for operation 40
4.3 Parking the truck securely 41
4.4 Emergency Disconnect, Travel, Steering, Braking 42
4.5 Travel 43
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4.6 Steering 43
4.7 Brakes 43
4.8 Lifting, transporting and depositing loads 44
5 Troubleshooting 46
5.1 Load cannot be lifted 47
.
F Industrial Truck Maintenance 49
.
1 Operational Safety and Environmental Protection 49
2 Maintenance Safety Regulations 49
3 Lubricants and Lubrication Schedule 52
3.1 Handling consumables safely 52
3.2 Lubrication Schedule 54
3.3 Consumables 55
4 Maintenance and repairs 56
4.1 Preparing the truck for maintenance and repairs 56
4.2 Lifting and jacking up the truck safely 57
4.3 Front cover disassembly 58
4.4 Installing the Front Panel 58
4.5 Checking electrical fuses 59
4.6 Restoring the truck to service after maintenance and repairs 60
5 Decommissioning the Industrial Truck 61
5.1 Prior to decommissioning 62
5.2 During decommissioning 62
5.3 Restoring the truck to service after decommissioning 63
6 Safety tests to be performed at intervals and after unusual incidents 64
7 Final de-commissioning, disposal 64
.
G Maintenance and Inspection 65
.
1 Maintenance Contents HC 110 66
1.1 Owner 66
1.2 Customer Service 68
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A Correct Use and Application
1 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.
2 Correct application
NOTICE
The maximum load and load distance are indicated on the capacity plate and must
not be exceeded.
The load must rest on the load handler or be lifted by an attachment approved by the
manufacturer.
The load must be fully raised, (→ TARGET NOT FOUND).
– Lifting and lowering loads.
– Stacking / retrieving loads.
– Transporting lowered loads.
– Do not travel with a raised load (>500 mm).
– Do not transport or lift passengers.
– Do push or pull load units.
3 Approved application conditions
DANGER!
Do not exceed the permissible surface and point loading on the travel lanes.
At blind spots get a second person to assist.
The driver must ensure that the loading dock /dock leveller cannot be removed or
come loose during loading/unloading.
– Operation in industrial and commercial environments.
– Permissible temperature range 5°C to 40°C.
– Operation only on secure, level surfaces with sufficient capacity.
– Operation only on routes that are visible and approved by the operating company.
– Do not negotiate inclines.
– Operation in partially public traffic.
– Operation in workplaces with sufficient lighting (observe national regulations).
ZSpecial equipment and authorisation are required if the truck is to be constantly used
in extreme conditions.
The truck is not authorised for use in areas at risk of explosion.
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4 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.
The proprietor must ensure that the industrial truck is used only for the purpose it is
intended for and that danger to life and limb of the user and third parties are
excluded. Furthermore, accident prevention regulations, safety regulations and
operating, servicing and repair guidelines must be followed. The operating company
must ensure that all users have read and understood these operating instructions.
NOTICE
Failure to comply with the operating instructions invalidates the warranty. The same
applies if improper work is carried out on the truck by the customer or third parties
without the permission of the manufacturer.
5 Adding attachments and/or optional equipment
The mounting or installation of additional equipment which affects or enhances the
performance of the industrial truck requires the written permission of the
manufacturer. Local authority approval may also need to be obtained.
Local authority approval however does not constitute the manufacturer’s approval.
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B Truck Description
1 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.
1.1 Truck models and rated capacity
The rated capacity depends on the model. The rated capacity can be derived from
the model name.
HC110
HC Model name
1 Series
10 Rated capacity x 100 kg
The rated capacity is not generally the same as the permissible capacity. The
capacity can be found on the capacity plate attached to the truck.
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2 Assemblies and Functional Description
2.1 Assembly Overview
1
2
3
4
5
6
7
8
9
10
11
Item Component Item Component
1tMast 7 tFront panel
2tPush handles 8 tBrake pedal (parking brake)
3tEmergency Disconnect
switch
9tSteer wheels
4tControl panel 10 tCastor wheel assembly
support
5tForks 11 tTiller
6tLoad wheels
tStandard equipment oOptional equipment
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2.2 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.
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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.
The truck is equipped with a battery discharge indicator.
Steering
The tiller (11) is used to steer within a range of approx. 90° on either side.
Brake system
The parking brake is actuated via the brake pedal (8).
Hydraulic system
Lifting and lowering are applied via the lift and lower buttons. The pump unit starts
with lifting is activated. The hydraulic oil is pumped from the oil reservoir into the
cylinder. The forks (5) are raised.
Electrical system
12 volt system.
3 Technical Specifications
ZThe technical specification is given according to the German guideline "Type sheets
for industrial trucks". Technical modifications and additions reserved.
3.1 Performance data
HC 110
Q Rated capacity 1000 kg
c Load centre distance for standard fork
length *) 600 mm
Lift speed with / without load 90 / 140 mm/s
Lower speed with / without load 120 / 100 mm/s
*) For trucks with longer forks the load centre is in the centre of the fork.
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3.2 Dimensions
Ast
W
a
a/2 = 100 a/2 = 100
b11
h1
l2
l1
h13
h3
h4
l
c
Q
y
s
h14
min.
951
b1b10 b5
e
h14
max.
Model
Lift height
HC 110
1600
HC 110
2500
HC 110
3000
h1Mast height retracted 1980 1830 2080 mm
h3Lift 1600 2500 3000 mm
h4Mast height extended 1980 3070 3570 mm
h13
Ground clearance
below mast 85 85 85 mm
y Wheel distance 1160 1160 1160 mm
s/e/l Fork dimensions 60/180/1100 60/180/1100 60/180/1100 mm
l1Overall length 1720 1720 1720 mm
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l2Headlength 620 620 620 mm
b1Truck width 762 762 762 mm
b5Outer fork distance 570 570 570 mm
b11 Track width, rear 390 390 390 mm
Ast Aisle width
800x1200 length 2175 2175 2175 mm
Ast Aisle width
1000x1200 transv. 2145 2145 2145 mm
Lift motor, output where
s3 15% 1,5 1,5 1,5 kW
3.3 Weights
Model
Lift height
HC 110
1600
HC 110
2500
HC 110
3000
Net weight incl. battery 350 435 450 kg
Axle load, w.o. load
front/rear + battery 250 / 100 310 / 125 325 / 125 kg
Axle load, w. load
front/rear + battery 420 / 930 460 / 975 475 / 975 kg
Battery weight 45 45 45 kg
ZThe battery size must be adhered to for duplex masts, as the battery weight must be
present in the truck to act as a counterweight.
3.4 Tyre type
HC 110
Tyre size, rear 180 x 50 mm
size, load section Ø74 x 93
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3.5 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.
ZThe noise emission level is calculated in accordance with standard procedures and
takes into account the noise level when travelling, lifting and when idle. The noise
level is measured at the level of the driver's ear.
Electromagnetic compatibility (EMC)
The manufacturer confirms that the truck adheres to the limits for electromagnetic
emissions and resistance as well as the static electricity discharge test in
accordance with EN 12895 as well as the standardised instructions contained
therein.
ZNo changes to electric or electronic components or their arrangement may be made
without the written agreement of the manufacturer.
WARNING!
Damage to medical equipment due to non-ionising radiation
Electrical equipment on the truck carrier emitting non-ionising radiation (e.g. wireless
data transmission) can affect operators' medical equipment (pacemakers, hearing
aids Etc.) and result in malfunctions. Consult a doctor or the manufacturer of the
medical equipment to clarify whether it can be used near the industrial truck.
3.6 Conditions of use
Ambient temperature
– operating at 5°C to 40°C
ZSpecial equipment and authorisation are required if the truck is to be used
continually in conditions of extreme temperature or condensing air humidity
fluctuations.
3.7 Electrical Requirements
The manufacturer certifies compliance with the requirements for the design and
manufacture of electrical equipment, according to EN 1175 "Industrial Truck Safety -
Electrical Requirements", provided the truck is used according to its purpose.
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3.8 Identification Points and Data Plates
12
13
14
15
16
17
13
Item Component
12 Strap points for crane lifting
13 Do not step onto or beneath the load, risk of trapping with moving mast
14 Never reach through the mast
15 Data plate
16 Capacity Qmax
17 Serial number
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3.8.1 Data plate
18
19
21
20
22
29
25
28
27
26
24
23
Item Description Item Description
18 Type 24 Year of manufacture
19 Serial number 25 Load centre (mm)
20 Rated capacity (kg) 26 Output
21 Battery voltage (V) 27 Min./max. battery weight (kg)
22 Net weight w.o. battery (kg) 28 Manufacturer
23 Option 29 Manufacturer’s logo
ZFor queries regarding the truck or ordering spare parts always quote the truck serial
number (19).
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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:
16
For a load centre of gravity D of 600 mm and a max. lift height h3 of 3600 mm the
maximum capacity Q is 1105 kg.
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