Table of Contents
Advertisement
Advertisement
Table of Contents
Related Manuals for Jungheinrich KMS 100
Summary of Contents for Jungheinrich KMS 100
- Page 1 KMS 100 07.99- Operating instructions 50047886 04.02...
- 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.
-
Page 4: Table Of Contents
Table of contents Correct use and application of the truck ......A 1 Truck description Description of application ..............B 1 Description of assemblies and functions ..........B 2 Description of truck ................B 3 Technical data of standard version ............. B 4 General technical data ................ - Page 5 Operation Safety regulations governing the operation of the truck ...... E 1 Operating panel arrangement variants ..........E 2 Description of controls and indicating instruments ......E 4 Operating controls and displays at the instrument panel ....E 4 Operating controls and indications at the Display ......E 5 Symbols indicating the truck’s operating status ........
- Page 6 Operational safety and protection of the environment ......F 1 Safety regulations for repair ..............F 1 Maintenance and service ..............F 3 Maintenance checklist KMS 100 ............F 4 Operating material ................F 8 Description of servicing operations ............F 9 Prepare the truck for the performance of servicing and maintenance operations ...............F 9...
-
Page 8: A Correct Use And Application Of The Truck
A Correct use and application of the truck 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 ope- rating instructions and must always be heeded. National regulations are fully applica- ble. -
Page 10: B Truck Description
B Truck description Description of application The commissioner KMS 100 is an industrial truck with powered mechanism according to DIN 15140. It is operated from the vertically movable driver position and approved for one operating person. The load carrying area can always be moved to a convenient working height with the auxiliary fork lift. -
Page 11: Description Of Assemblies And Functions
Description of assemblies and functions Pos. Description Auxiliary lifter Vertically movable operator stand Lift mast Hoist frame Battery t = Standard equipment o = Optional equipment... -
Page 12: Description Of Truck
Description of truck Integrated information display to display all important information to the driver, like steering wheel position, platform height, truck status signals (e.g. malfunctions, ent- rance doors open, etc.), operating hours, battery capacity, time as well as status of the inductive guidance, etc. -
Page 13: Technical Data Of Standard Version
Technical data of standard version Technical data is stated according to VDI 2198. Subject to technical changes and supplements. -
Page 14: General Technical Data
General technical data Identification Type index of the manufacturer KMS 100 Drive electric, diesel, fuel, fuel gas, net electric Electric Operation hand, walking, standing, seat, com- Commissioner missioner Capacity/load Q (t) Load centre distance c (mm) Load spacing x (mm) - Page 15 Basic dimensions Height with hoist frame retracted (mm) 3830 Free lift (mm) Length of lift (mm) 5500 Height with hoist frame extended (mm) 7820 Height above vehicle shed (cabin) (mm) 2300 Seating/standing height (mm) 4.11 Auxiliary lifter (mm) 4.12 Total length of lift (mm) 6340 4.14 Commissioning height...
-
Page 16: Hoist Frame Construction
Performance data Driving speed with / without load km/h 10,0 / 10,5 Lifting speed with/without load 0,28/0,35 Lowering speed with / without load 0,40/0,40 Traverse speed with/without load Hill climbing ability with/without capacity max. hill-climbing ability with/without load Acceleration time with/without load 5.10 Service brake dynamic 5.11 Parking brake/dead man... -
Page 17: En Standards
EN Standards Continuous sound level: 65 dB(A) according to prEN 12053 as stipulated in ISO 4871. The permanent sound level is an average value determined according to the stan- dard’s guidelines and takes into consideration the sound level when driving, lifting and in idle mode. -
Page 18: Location Of Instruction Labels And Identification Labels
Location of instruction labels and identification labels Pos. Description Truck identification label Sign “Emergency lowering device” Warning sign “Lifting of persons prohibited” Warning sign “Keep away from under the load lifting device” Warning sign “Danger of crushing” Warning sign “Caution: Low-voltage electronics” Attachment point for jack Fill in hydraulic oil Capacity plate... -
Page 19: Truck Identification Label
Truck identification label Xxxx Xxxx Xxxx Xxxxxxx Xxxxxx Xxxxxx Xxxxxx Xxxxxxxx Xxxxxxx Xxxxxx Xxxxxx Xxxxxx Xxxxxx Xxxxxxxxxxxxxx Xxxxxxxxxxxxxxx Xxxxxxx Xxxxxxxxx Xxxxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxxxx Xxxxxxxxxx Xxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxxxxx Xxxxxxxxx Xxxxxxxxxxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxxx Xxxxxxxxx Xxxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxxxx Xxxxx Xxxxxxxxxxxxxxxxxx Xxxxx Xxxxxxxxxxxxxxxxxx Xxxxx Xxxxxxxxxxxxxxxxxxxxxx Xxxxx Xxxxxxxxxxxxxxxxxx Xxxxxxx Xxxxxxxxxx Xxxxxx Xxxxxxxxx... -
Page 20: C Transportation And Commissioning
C Transportation and commissioning Transport Depending on the overall height of the hoist frame and local conditions the on-site transport can be carried out in one of three different ways: – Standing, with hoist frame and load lifting device mounted (for low height versions) –... -
Page 21: First Commissioning
First commissioning Commissioning without battery This operating mode is not permitted when negotiating inclines and gradients (no bra- ke!). If the truck is operated without battery, the load bearing wheel brake must be released before commissioning. – Screw off the protective cover (5) of the vent valve. -
Page 22: Commissioning
Commissioning 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. In order to prepare the truck for work following delivery or transportation, the following operations must be performed: –... -
Page 24: D Battery - Servicing, Recharging, Replacing
Battery type Truck type 48V 560 AH KMS 100 48V 600 AH KMS 100 The battery weights can be seen from the battery identification plates. Battery weight and dimensions have a considerable influence on the stability of the truck. -
Page 25: Charging The Battery
Charging the battery Park the truck and render it safe (see chapter E). – Turn the key switch to “0” (Zero) and push the Emergency stop switch. – Lift the battery hood to its full extent. The battery connector and socket must only be connected or disconnected with both the truck and the battery charger switched off. -
Page 26: Removing And Installing The Battery
Removing and installing the battery Batteries with exposed terminals or connectors must be covered with a rubber mat to prevent short-circuits. When replacing batteries, ensure that a battery of the same type is fitted. Additional weights must not be removed and their position must not be changed. –... -
Page 27: Checking Battery Condition, Acid Level, And Acid Density
Checking battery condition, acid level, and acid density – The service instructions of the battery supplier apply. – Check the battery casing for cracks and acid leaks. – Remove oxidation residues from the battery terminals and lightly grease with acid- free pole grease. -
Page 28: Safety Regulations Governing The Operation Of The Truck
E Operation Safety regulations governing the operation of the truck Driving licence: The truck must only be operated by personnel that have been ade- quately trained and have proved to the persons in charge or their representatives their ability to handle the truck correctly and who have been explicitly entrusted with the operation of the truck. -
Page 29: Operating Panel Arrangement Variants
Operating panel arrangement variants Variant I In case of standard equipment the operating panels are arranged at the front, i.e. in front of the auxiliary lifter. Accordingly the information display under the driver's overhead guard is also arranged in load direction. Variant II The operating panel and the information dis- play are arranged at the mast side. - Page 30 Variant IV The operating controls are arranged at the load side and diagonally. The driver is directly or diagonally looking to the left in load direc- tion. The operating panel module "stearing" is additionally available at the mast side. The in- formation display is located at the load side under the overhead guard of the driver.
-
Page 31: Description Of Controls And Indicating Instruments
Description of controls and indicating instruments Operating controls and displays at the instrument panel Pos. Function Emergency stop master switch Steering Supporting strap (two-hand operation) "Pushbutton“ lift switch-off "Pushbutton“ track guidance = drive wheel in straight forward position induction guide = induction guide on Drive control knob Horn Hydraulic control knob (two-hand operation) -
Page 32: Operating Controls And Indications At The Display
Operating controls and indications at the Display Pos. Operating control Function resp. display t Drive is switched to crawling pace 12 Display “Crawling pace” 13 Steering position indicator Indicates the current position of the drive wheel referring to neutral position Aisle recognition track-in possible, track-in in progress, vehic- le on track... -
Page 33: Symbols Indicating The Truck's Operating Status
Symbols indicating the truck’s operating status After switching on the truck’s operating status is indicated in the display. Barriers open Foot-operated switch not activated If the following symbols are displayed, a reference run must be carried out according to the indication, i.e. the main lift must be lifted by approx. 30 cm and lowered again. Then the control gives a release to carry out all movements of the truck with full speed. -
Page 34: Putting Vehicle In Operation
Putting vehicle in operation Before starting or operating the truck, or before lifting any loads, the driver has to make sure that nobody is within the danger area. Checks and actions before routine start-up – Perform a visual check of the entire truck for obvious damages or leakages. –... -
Page 35: Working With The Truck
Working with the truck Safety regulations for operating mode Drive Routes and working areas: Only such lanes and routes that are specially allocated for truck traffic may be used. Unauthorised third parties must stay away from the wor- king area. Loads may only be stored at places specially provided for this purpose. Driving the vehicle: The driver must choose a driving speed suitable for the local conditions. -
Page 36: Driving, Steering, Braking
Driving, steering, braking Emergency stop – Push master switch (2) down. All electrical functions are switched off. Do not impair the operation of the main switch by laying objects onto the instrument panel! Driving Two different operating modes are available for driving: freely travelling or restricted guidance. - Page 37 Steering Outside narrow aisles the truck is steered using the steering wheel. The angle of the drive wheel is indicated in the display (13). Braking The braking behavior of the truck strongly depends on the state of the floor. This must be taken into account by the driver for his driving behavior.
- Page 38 Driving in narrow aisles Unauthorized persons must stay away from narrow aisles (travelling routes of trucks in shelf systems without safety measures for persons walking in opposite direction); through-traffic is prohibited for persons. These work areas must be marked accordin- gly.
- Page 39 – Press push-button “Induction guide on” (23). – The drive wheel is automatically adju- sted in straight direction and the indi- cator light “Induction guide on” (24) illuminates. The manual steering is now inoperative. – To prepare starting, grasp the handle of the handrest with the left hand (two- hand operation).
- Page 40 The forced induction control takes over the truck steering and slues the truck to the guiding wire. After the truck has been exactly tracked- in to the guiding wire, the tracking-in pro- cess is terminated. The indicator (36) changes to „Induction guided“ and the audible signal is turned off.
-
Page 41: Lifting And Lowering Outside And Inside The Shelf Aisles
Lifting and lowering outside and inside the shelf aisles In elevated position the operator is not permitted to leave the operator's seat - it is prohibited to climb onto building structures or other vehicles. Lifting - lowering (main lifter) – Step on the foot-operated button. –... -
Page 42: Combined Driving (Simultaneous Driving And Lifting)
Combined driving (simultaneous dri- ving and lifting). – Step on the foot-operated button (1). – Trun driving control knob (3) accor- ding to the desired driving direction and speed (see chapter "Driving, stea- ring, decelerating"). Swing hydraulic control knob (2) simultaneously to lift or lower the main lift. -
Page 43: Commissioning And Stacking
Commissioning and stacking Picking up, transporting and setting down of loads Before picking up a load, the driver has to make sure that it is correctly palletized and that the capacity of the truck is not exceeded. Observe the capacity diagram! –... -
Page 44: Safe Parking Of The Truck
Setting down a load – Carefully approach the storage location. Before setting down a load the driver must see for himself that the storage location is suited for the load (measurements and adequate load bearing capacity). – Lift the load lifting device to a height sufficient to drive to the storage location wit- hout bumping. -
Page 45: Fault Location
Fault location This chapter enables the user to locate and to remedy simple faults or the conse- quences of operating errors. The disturbances are shown on the display. The order of the work stated in the table must be observed for fault location. Fault Possible cause Remedy... -
Page 46: Emergency-Stop
Emergency-STOP When the automatic emergency stop facility has been activated (if, for example, the guidance is lost, the electrical steering fails or the safety device is activated) the truck is decelerated until standstill. Before putting it into operation again you must determi- ne cause for the malfunction and eliminate the fault. -
Page 47: Leaving The Driver's Cabin Using The Emergency Rope-Down Facility
Leaving the driver’s cabin using the emergency rope-down facility In addition to an emergency lowering device, load-handling trucks with a liftable ope- rator seat having a reach of more than 3 m are equipped with a facility (emergency rope-down facility) for the operator to reach the floor in the event the movement of the elevated operator seat is blocked. -
Page 48: Slack Chain Protection (Acknowledge Signal)
Slack chain protection (acknowledge signal) If the slack chain protection is activated, e.g. if the lift chain is slack or broken, all functions are deactivated. After moving the adjusting levers to neutral position, the cabin can be lifted by using (acknowledging) the operating switch (slack chain). Before continuing with any operation the damage must be repaired. -
Page 49: End Of Aisle Safety Device (O)
End of aisle safety device (o) Vehicles with end of aisle safety device are decelerated before the aisle exit or in the branch aisle. There are two basic versions: 1. Deceleration to standstill 2. Deceleration to 2.5 km/h Other versions (affecting the subsequent travel speed, affecting the lifting height, etc.) are available. -
Page 50: Ig Emergency Operation
IG Emergency operation If the guiding antenna of the truck leaves the predetermined level area of the guiding wire when operating the truck in induction guided operating mode, an emergency stop is initiated immediately. If the truck is travelling exactly in parallel along the guiding wire, no drive switch-off will occur. -
Page 51: Recovering The Truck From A Narrow Aisle
Recovering the truck from a narrow aisle To recover the truck from the narrow aisle, disengage brakes. Deactivating the brakes may only be carried out by authorized and trained personnel! If the brakes are deactivated, the truck must be parked at even floor level, since there is no braking action. -
Page 52: F Truck Maintenance
F Truck maintenance Operational safety and protection of the environment The checks and servicing operations contained in this chapter must be performed in accordance with the intervals as indicated in the servicing checklists. Modifications of truck assemblies, especially of the safety installations, are not per- mitted. - Page 53 Working on the electrical installation: All work on the electrical installation must be carried out only by electrotechnically skilled personnel. Before commencing any work on the electric system, all measures required to prevent electric shocks have to be taken. For battery-operated floor conveyors, the floor conveyor must also be depowe- red by removing the battery plug.
-
Page 54: Maintenance And Service
Maintenance and service 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 failure and constitutes a potential hazard to personnel and operation. The indicated servicing intervals are based on single-shift operation under normal operating conditions. -
Page 55: Maintenance Checklist Kms 100
Maintenance checklist KMS 100 Maintenance intervals = t W M M M Standard 1 3 6 12 Chassis/ 1.1 Check all load bearing elements for damage superstruc- 1.2 Check all bolted connections ture: 1.3 Check Operator platform for correct functioning and dama- 1.4 Check marking locations, identification labels and warning... - Page 56 Maintenance intervals = t W M M M Standard 1 3 6 12 Hydraulic 6.1 Check function system: 6.2 Check all connections for leakage and damage 6.3 Check hydraulic cylinders for leakage, damage and secure attachment 6.4 Check the oil level 6.5 Check the hose line for correct functioning and damage 6.6 Check breather and vent filters at the hydraulic reservoir 6.7 Change breather and vent filters at the hydraulic reservoir...
- Page 57 Maintenance intervals = t W M M M Standard 1 3 6 12 Lifting device 10.1 Apply grease to rollers and side run areas of idler pulleys in the hoist frame profiles. 10.2 Check secure attachment of hoist frame 10.3 Check hoisting chains and chain guide for wear; adjust and grease 10.4 Visual check of rollers, slide pieces and stops 10.5 Check hoisting frame seatings...
- Page 58 E g s E gs slide faces grease nipples...
-
Page 59: Operating Material
Operating material Handling operating material: Consumption type material must always be handled properly. Manufacturer's instructions to be observed. Improper handling endangers health, life and environment. Operating material must only be stored in containers conforming to specification. They might be inflammable and must not come into contact with hot components or open fire. -
Page 60: Description Of Servicing Operations
Description of servicing operations Prepare the truck for the performance of servicing and maintenance operations 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: –... -
Page 61: Inspecting The Hoisting Chains
Inspecting the hoisting chains Excessive wear and exterior damages: According to the official regulations a chain is to be considered as worn-off, when it has stretched by 3% in the section around the guide pulley. For safety reasons, the manufacturer recommends to replace the chain when it has stretched by 2%. If exterior damages are noticeable the chain is to be replaced immediately, since the- se damages will lead to fatigue fractures. -
Page 62: Cleaning The Vent Filter
Cleaning the vent filter Screw out the vent filter together with the oil dip stick (8) and clean with compres- sed air or cleaning solution. Used filters must be disposed of proper- Changing of hydraulic oil filter – Screw off the hydraulic oil filler cap (9). –... -
Page 63: Hydraulic Oil
5.10 Hydraulic oil – Prepare the truck for the performance of servicing and maintenance operations. Under no circumstances oil may be allowed to enter the ground or the sewer system. Waste oil must be securely stored until it is disposed of properly. Draining the oil: Take out the vent filter (8) and remove oil by suction. -
Page 64: Checking The Electric Fuses
5.13 Checking the electric fuses – Prepare the truck for the performance of servicing and maintenance operations (re- fer to chapter F). – Referring to the table, check all fuses for correct rating and replace, where required. Item Description Protection of: Value 2F15 Hydraulic system... -
Page 65: Recommissioning The Truck
5.14 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 main switch (Emergency-STOP) for correct function. –... -
Page 66: Recommissioning The Truck
6.17 Recommissioning the truck – Thoroughly clean the truck. – Grease the truck as detailed in the lubrication chart (refer to chapter F). – Clean the battery. Grease the terminal screws using pole grease and reconnect the battery. – Recharge the battery (see chapter D). –... - Page 67 F 16...
Need help?
Do you have a question about the KMS 100 and is the answer not in the manual?
Questions and answers