Jungheinrich KMS 100, Operating Instructions Manual

Page 1: ...Operating instructions 50047886 KMS 100 G 07 99 04 02...

Page 2: ...explanations are indicated by the following graphics f Used before safety instructions which must be observed to avoid danger to personnel m Used before notices which must be observed to avoid materi...

Page 3: ...0108 GB...

Page 4: ...1 Truck identification label B 10 4 2 Load capacity B 10 C Transportation and commissioning 1 Transport C 1 2 Transportation by crane C 1 3 First commissioning C 2 3 1 Commissioning without battery C...

Page 5: ...for operating mode Drive E 8 5 2 Driving steering braking E 9 5 3 Lifting and lowering outside and inside the shelf aisles E 14 5 4 Combined driving simultaneous driving and lifting E 15 5 5 Commissio...

Page 6: ...hoisting chains F 10 5 5 Repairing the chain F 10 5 6 Changing the transmission oil F 10 5 7 Cleaning the vent filter F 11 5 8 Changing of hydraulic oil filter F 11 5 9 Hydraulic oil F 12 5 10 Hydraul...

Page 7: ...1298 GB I 4...

Page 8: ...or on whose behalf it is used In special cases e g leasing or renting the user is conside red the person who in accordance with existing contractual agreements between the owner and the user of the f...

Page 9: ...1298 GB A 2...

Page 10: ...operation in narrow aisles with racks arranged at the side It is especially designed for driving with lifted load A perfect floor condition is a prerequisite flat and horizontal floor according to the...

Page 11: ...B B 2 2 Description of assemblies and functions Pos Description 1 o Auxiliary lifter 2 t Vertically movable operator stand 3 t Lift mast 4 t Hoist frame 5 t Battery t Standard equipment o Optional equ...

Page 12: ...in stacking operation Load side clear operating panels with a small front part provide good accessibility of the pallets for a high commissioning capacity The driver must never move around to operate...

Page 13: ...1298 GB B 4 3 Technical data of standard version A Technical data is stated according to VDI 2198 Subject to technical changes and supplements...

Page 14: ...front back kg 1690 1740 Wheels travelling gear 3 1 Tire equipment solid rubber superelastic air polyurethane Tractothane 3 2 Tire size front d1 mm 230 115 3 3 Tire size back d2 mm 310 100 3 5 Wheels...

Page 15: ...4 23 Fork carrier DIN 15173 class shape A B 4 24 Fork carrier width b3 mm 830 4 25 Overall distance of fork b5 mm 830 4 27 Width of guide rollers b6 mm 1200 4 29 Reach sidewards b7 mm 4 30 Reach sidew...

Page 16: ...m Overall height retracted DZ h1 mm Free lift for DZ h2 mm Overall height extended h4 mm 300 3000 2380 5320 350 3500 2630 2302 5820 400 4000 2880 2320 6320 450 4500 3130 2320 6820 500 5000 3380 2483 1...

Page 17: ...operator s body is measured according the standard s guidelines as a linearly integrated weighted acceleration in vertical direc tion The acceleration is measured when driving across bumps at steady s...

Page 18: ...ing sign Keep away from under the load lifting device 5 Warning sign Danger of crushing 6 Warning sign Caution Low voltage electronics 7 Attachment point for jack 8 Fill in hydraulic oil 9 Capacity pl...

Page 19: ...Capacity in kg 27 Year of manufacture 22 Battery voltage V Ampere hours Ah 28 Type no 23 Maker 29 Maker s logotype X xx xx xx xx xx Xxx Xxxx Xxxx Xxxx Xxxxxxx Xxxxxx Xxxxxxxx Xxxxxx Xxxxxx Xxxxxxxxx X...

Page 20: ...ied out by trained personnel of the manufacturer Transport regulations and erec tion instructions must be observed 2 Transportation by crane m Ensure that only lifting gear of adequate capacity is use...

Page 21: ...fluid to drain into the brake fluid reservoir Close vent valve and brake fluid re servoir A The operatability of the brake system is restored after inserting the battery and after operating the foot s...

Page 22: ...ngth In order to prepare the truck for work following delivery or transportation the following operations must be performed If necessary install and charge the battery see chapter D sections 4 and 5 C...

Page 23: ...1298 GB C 4...

Page 24: ...ust only be disposed of as stipulated in the na tional environmental protection regulations or waste disposal provisions The manu facturer s specifications for the disposal must be heeded m Before clo...

Page 25: ...ng the recharging operation the tops of the battery cells must be exposed to en sure adequate ventilation Metal objects must not be placed on the battery Prior to starting the recharging operation che...

Page 26: ...ed or disconnected with both the truck and the battery charger switched off Withdraw the battery connector Lift out the chassis lateral part 4 1 Removing and installing using a battery trolly f The ve...

Page 27: ...e a minimum of 10 15mm above the plate top Check the acid density according to the suppliers specifications with an acid pipette and subsequently remount the screw caps If necessary recharge the batte...

Page 28: ...the attachments must immediately be brought to the notice of the person in charge Trucks that cannot be safely operated e g due to worn tires or defective brakes must not be used until they have been...

Page 29: ...anel and the information dis play are arranged at the mast side The infor mation display is arranged under the driver s overhead guard Variant III The operating controls are arranged diagonal ly The d...

Page 30: ...ariant V The operating controls are arranged at the mast side and diagonally The driver is directly or diagonally looking to the left in mast direc tion The operating panel module stearing is addition...

Page 31: ...ction 1 Emergency stop master switch 2 Steering 3 Supporting strap two hand operation 4 Pushbutton lift switch off 5 Pushbutton track guidance drive wheel in straight forward position induction guide...

Page 32: ...the batte ry 18 Display Parking brake on t Illuminates when the parking brake is enga ged 19 Display Emergency STOP t Illuminates when the Emergency STOP has been activated 20 Display Service required...

Page 33: ...oot 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 ag...

Page 34: ...Check whether all safety measures are in good condition and working properly In case of a rail guide check idler pulleys on true running and damages Check brakes for correct function f Only one perso...

Page 35: ...ion and have a sufficient overview of the driving route When loads that obstruct the clear view are transported the truck must travel with the load at the rear If this is not possible a second person...

Page 36: ...d locked in the stipulated manner The foot switch must always be pressed during all movements of the truck Driving outside aisles Close safety barriers 1 Insert key into key switch and switch on Loose...

Page 37: ...driving turn the drive direction switch to its zero position or into the opposite travelling direction the truck is now braked by counter current Braking by means of foot operated switch If the foot s...

Page 38: ...er vehicles in the aisle You must only drive into free narrow aisles If there are persons in the narrow aisle any operation must be stopped immediately A You must only drive into narrow aisles with tr...

Page 39: ...de Drive the truck with reduced speed at an angle towards the guiding wire For tracking in the truck must not be standing in parallel to the guiding wire The tracking in angle must be smaller than 35...

Page 40: ...les operating mode the drive and hydraulic function can only be initiated by two hand control For two hand operation the supporting strap 1 of the operating panel module stearing and the hydraulic con...

Page 41: ...kwise turn lifting Anti clockwise turn lowering A The lifting and lowering speeds are pro portional to the rotary motion of the hy draulic control knob If the line break safety device is activa ted it...

Page 42: ...ltaneously to lift or lower the main lift Clockwise turn lifting Anti clockwise turn lowering A The hydraulics control knob can be used to control the movements of the load lif ting device sensitively...

Page 43: ...f the ground and drive the truck slowly at crawling pa ce backwards m Prerequisite for problem free working is a perfect ground structure Transporting a load Outside the shelf aisle transport the load...

Page 44: ...g released m Avoid pancaking the load in order to prevent damaging the load and the load lifting device Carefully move the load lifting device out of the load Fully lower the load lifting device 5 9 S...

Page 45: ...ated switch not activated Step on foot operated switch Drive switch off activated Press override drive switch off key and leave danger area Drive switch off by aisle protection Switch off automatic dr...

Page 46: ...ncy lowering facility make sure that all personnel stands clear of the danger zone The load lifting device is lowered by a person with the emergency lowering facility located at the lower part Driver...

Page 47: ...oceed as follows Turn the key switch to 0 Push the main switch Emergency STOP Take out the emergency rope down device from the storage container 39 Secure the rope down device to the eyelet 38 to the...

Page 48: ...driving key must be pressed and the driving lever must be operated as described under Driving In this way the truck can be driven a crawling speed 6 6 Lift switch off o If required by the local charac...

Page 49: ...to standstill To continue the travel Briefly release foot switch and press down again The vehicle can be driven out of the narrow aisle at max 2 5 km h 2 Deceleration to 2 5 km h When crossing the end...

Page 50: ...able to resume driving after an Emergency STOP performing the following ac tions is required Determine the possible cause for the Emergency STOP Press the Emergency STOP button and release it again b...

Page 51: ...s 40 at the ma gnetic brake located above the drive motor in order to loosen it Loosen brake of the drive wheel Push tube 39 onto vent connection and insert the other end of the tube into the brake fl...

Page 52: ...turer has service engineers available that have been specifically trained for these tasks We therefore advise to conclude a maintenance contract with the manufacturer s Service Base responsible for th...

Page 53: ...ned Tire equipment The quality of the tires greatly affects the stability and the driving behaviour of the fork lift truck Modifications must only be carried out after discussion with the manufacturer...

Page 54: ...rdingly The following servicing checklist indicates the operations to be performed and the re spective intervals to be observed The following maintenance intervals are defined W1 Every 50 operating ho...

Page 55: ...readability replace if necessary t Drive unit 2 1 Grease seating between drive motor and transmission t 2 2 Check the transmission for noises and leakage t 2 3 Check the transmission oil level t 2 4...

Page 56: ...rect functioning t 6 10 Check hydraulic lines for tightness and damage p t Electrical system 7 1 Check the discharge of static electricity t 7 2 Check function t 7 3 Check all cables for secure connec...

Page 57: ...ck secure attachment at the device and supporting elements t 11 3 Check seatings guides and stops for wear and damage apply grease t Lubrication service 12 1 Grease truck according to lubrication plan...

Page 58: ...F 7 1298 GB s slide faces g grease nipples D Egs G G Egs Eg A B Es D...

Page 59: ...escribed in these operating instructions This instruction may only be ignored if another mixing ratio is explicitly prescribed in this manual Avoid any spilling Spilled liquid must be removed immediat...

Page 60: ...rved refer to chapter C 5 3 Securing the driver platform The driver platform can be secured in elevated position Lift the driver platform until the inner mast 1 is positioned above the carri er of the...

Page 61: ...e rivet heads must be ground off before dismounting This prevents the pin from damaging the borehole when being forced through the intermediate ring respec tively the inner link Dismounted pins and ri...

Page 62: ...lean with compres sed air or cleaning solution m Used filters must be disposed of proper ly 5 9 Changing of hydraulic oil filter Screw off the hydraulic oil filler cap 9 Change the filter insert if th...

Page 63: ...um and maximum mark of the oil dip stick 10 If not refill new hydraulic oil up to the correct level 5 11 Hydraulic hoses The hydraulic hose lines must be replaced after a service life of 6 years see S...

Page 64: ...l fuses for correct rating and replace where required Item Description Protection of Value 12 2F15 Hydraulic system 250 A 13 1F11 Driving 160 A 14 3F10 Steering system 30 A 15 F3 1 Control current 24...

Page 65: ...xcess of six months the service of the manufacturer must be contacted for further measures to be taken 6 15 Operations to be performed prior to decommissioning Thoroughly clean the truck Check the bra...

Page 66: ...ed by a qualified inspector The inspector must assess the condition of the truck from a stand point purely concerned with safety aspects uninfluenced by any company or econo mic circumstances The insp...

Page 67: ...1298 GB F 16...