05 - Hyster - Eu Order Pickers k1 0 k1 0h Product Training

HIGH LEVEL ORDER PICKER K1.0 – K1.
0H
ORDER PICKERS
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HIGH LEVEL ORDER PICKER K1.0 – K1.0H
Applications Ergonomics
Useful Guidelines Dependability
Guidance Productivity
Serviceability
Options
Cost of Ownership
HOW IS THE MHLOP ORDER PICKER USED?
APPLICATIONS
SPARE PARTS
Type of operation
Intense operation. Often 24 hours. Key customer
challenge is managing unsupervised operators
working in narrow aisles.
Pick up to 10m
Frequent request for dual or front side controls
Truck Specifications
Larger Trucks
Lift height to 10,000mm
Management information (to understand driver
utilisation and damage) is very important
Trucks are normally leased and fast service response
is key
Typical customers
JCB, FIAT, HYG Nijmegen
Buying/Customer Behaviour
Strong site buyer, used to purchasing many items
Many sites have unionised workforce so driver
influence on decision making is strong
Order picker is a key truck, but sites normally also
have PPTs, RPs, ECBs and LLOPs
SPARE PARTS
What does the customer care about in the

Spare parts application?
What are his buying motives?

24 hour service response
Monthly total lease cost
Driver comfort
Management Information
FURNITURE AND CONSUMER GOODS
Type of operation
Used for picking slower moving items
Aisle height and widths vary
Loads may be an awkward size and require
a 2 man operation
Variety of truck types, many with SPED
requirements
Variety of Lift heights and aisle widths
Most trucks require walk on platform
VNA preferred in some cases
Typical customers
Harvey Norman, John Lewis, El Corte Ingles
Buying/Customer Behaviour
Large national chains
Central purchasing for major warehouses
Lease and outright purchase
FURNITURE AND CONSUMER GOODS
What does the customer care about in a furniture and

consumer goods application?

Bespoke solution to meet their requirements
Operator safety
Service response
Partnership (new product development etc)
PHARMACEUTICAL / CHEMICAL
Type of operation
High value, slow moving items
The operation is normally not intensive. Often
1 shift to relatively low heights
May involve fewer trucks so service response
time is very important
Depending on operation may want K1.0L or
K1.0M
Normally Supplementary Lift
Often narrow aisle with roller or wide guidance
Typical customers
Avon, Roche, Bayer
Buying / Customer Behaviour

Central buyer, MHE not a major priority
High value goods, so minimum downtime is
more important than low acquisition cost
More likely to buy or have full service lease
PHARMACEUTICAL / CHEMICAL
What does the customer care about in a

Pharmaceutical / Chemical application?
Uptime (May consider spare truck)
Location and guaranteed response time
Driver comfort
USEFUL GUIDELINES
USEFUL GUIDELINES
Low level
Picking on ground or 1st level
20% operator time is driving and 80% is picking activities and administration
Medium level
Picking heights of 2.5 to 6.0m
Operator remains working in aisle over 80% of time
High level
Picking heights of 6.0m and above
Operator remains working in aisle over 80% of time
Above 10m normally use VNA
USEFUL ORDER PICKING GUIDELINES
A: floor = 0 level
B: operator cabin platform level
C: picking height from operator cabin platform

floor between 1.5 – 1.7m (higher than h12 value)
D: Operator picking height (between 1.5 and C

1.7m) Note: The height of the rack is not
the height of the truck D
h12: platform height from warehouse floor B

Remember: h12
Allow suffient platform height in relation to A
pallet which allows the operator to pick from
the rear of the pallet
WHAT DO THE ABBREVIATIONS MEAN?
SL = Supplementary Lift
– Standard on all trucks
FC = Fixed Cab
– Only available on K1.0L
WP = Walk-on Platform
– Only available on K1.0L and K1.0H
SL = SUPPLEMENTARY LIFT – K1.0L, K1.0M, K1.0H
Standard on all trucks

Rising cabin
Supplementary lift of the forks
Closed cabin and overhead guard above 1200mm
Type of application
Frequent access to medium heights
The operator can drive with platform raised
Heavy loads
Medium to high density storage (quantity/m3)
Use guidance systems in standard and narrow
aisles (Better use of the space)
FC = FIXED CABIN – K1.0L
Available on K1.0L only
K1.0L FC 0.7 780 mm

K1.0L FC 1.5 1500 mm
Type of application
Low level applications with need for lifting forks
When roller guided applications operate in aisles
Ideal for closed bottom pallets
WP – WALK ON PLATFORM – K1.0L, K1.0M
Available on K1.0L and K1.0H

Direct access on to the pallet
Protective cage around the platform
Pallet detection system
Rising cabin
Lifting barriers with automatic function cut off
Closed cabin and over head guard
Type of application
Frequent picking to medium heights
Large and bulky loads
High quantity of picks
Use guidance systems in standard and
narrow aisles (Better use of the space)
SUMMARY OF WHAT EACH TRUCK DOES
Max. picking
Rated Max. cabin Chassis Battery Operator
height Battery
Model capacity height width Compartment platform SL, FC, WP
h12 + size
@600mm (kg) h12 (mm) b1 / b2 (mm) (Ah) Width (mm)
1600mm
560/620 780 or 940 SL

K1.0L 1000 4807 6400 1000/1000 24V 780 or 940 WP
500 (FC only) 796 FC
K1.0M 1000 4920 6720 1000/1000 48V 280 – 310 950 SL
420 – 465 1050

1100/1100 SL
K1.0H 1000 9145 10745 48V 1150 (opt)
1100/1200 FC
560 – 620 (opt) 1240 (opt)
K1.0 – K1.0H - BATTERIES
Battery type Battery Battery charger

Model Weight ± 5%
DIN43531 A /B dimension l x p x h V/Ah
K1.0 48V 250-320L Ah 832 x 308 x 784 530 - 575 kgs 48V / 60-80 Ah
DIN 43531 A
K1.0M 48V 375-480 Ah 1032 x 350 x 784 730 – 760 kgs 48V / 80-100 Ah
(b1=1100mm) DIN 43531B
K1.0H 48V 500-640 Ah 1032 x 440 x 784 940 – 990 kgs 48V / 100 Ah
(b1=1200 mm) DIN 43531B
ERGONOMICS
ERGONOMICS
Safety gates on cabin sides
The cabin gates are compulsory on trucks

with h12 >= 1200
Cabin lifted up to the height h12<1200mm,
traction, lifting and lowering always
enabled, also when the gates are open
Cabin lifted higher than h12>=1200 mm
traction, lifting and lowering are enabled
only when the gates are closed
The lower part is protected against cutting. It

remains lifted in case in should be leant on an
obstacle as for example the operator foot
Advantage
Operator cannot exit the truck when
operating above 1200mm
Ergonomics Dependability Productivity Serviceability Cost of ownership
ERGONOMICS
ERGONOMICS
Dashboard / front panel

1. Key switch
2. Emergency switch
3. Forward / reverse traction control butterfly
4. Main lift / lowering minilever control
5. Emergency brake minilever
6. Horn
7. Preset performances selector
8. Override preset lift stop
9. Load Weight scale push button
10. Wire guidance Warning light (optional)
11. WG – Manual selector (optional)
12. Spot light switch (optional)
13. Dome light switch (optional)
14. Cab fan switch (optional)
15. Handle warming switch (optional)
16. Two hand checker
17. Forward “pedestrian “ control (backing)
18. Fork lowering button
19. Fork lifting button
Rear panel / bulk head

20. Forks lift / lowering allowing button
21. Fork lifting button
22. Fork lowering button
ERGONOMICS
Operator platform
Platform with wide free surface, no obstacle
for feet
Covered handle
Low platform: only 250mm from the ground
Easy access
Optimum visibility around and beyond the
dashboard
Control position suitable for any driver size
Advantages
Optimum driver comfort. This allows them to
concentrate on the picking operation.
Will help maximise loads moved per shift
ERGONOMICS
Floor controls
Wide space to find a comfortable
position for legs and feet
Wide active surface for the sensor
“operator presence”
 the “operator presence” sensor is
located on the floor
 enables the traction when pressed
 apply park brake when released
 the operator feet are always inside
the truck
Advantage
Optimises driver comfort
ERGONOMICS
Operator work space

Platform “Soft” cushioned to absorb
vibrations during the running
Complete dashboard
Pocket to store working and daily tools
Reading desk for notes (opt)
Advantage
Work area designed around operator to
ensure maximum performance
ERGONOMICS
Steering
Covered steering wheel with knob
Low effort steering: Fly by Wire (AC
electronic control steering)
Adjustable steering stiffness to
personalise the mechanical feeling
Adjustable No. of revolutions
Advantages
The steering wheel dimension is
designed to be comfortable for the
maximum range of users.
Truck can be operated comfortably by
every type of operator
ERGONOMICS
Steering
Drive wheel automatic centering at the start
Steering wheel rotation of 180°
Automatic speed reduction during the curve
(“cornering“ function) more than 10.8°
Advantages
Easy, safe and intuitive steering for all
operators
Immediate familiarity for most of the operators
Better truck control
ERGONOMICS
Traction control console

“butterfly control” provides easy control of:
 travel direction
 direction change
 reverse braking
The red emergency push button can be easily
reached by both hands
The horn can be easily reached by both hands
Advantage
Easy for operator to drive truck
ERGONOMICS
Hydraulic control console

User friendly
Low enabling effort
Precise adjustment of the upward
movement
position by controlling the pump motor
speed
Precise adjustment of the downward
movement position by controlling the
regenerative speed of pump motor
Advantage
Easy use for rapid lifting and lowering
ERGONOMICS
Control console
Two series of push buttons installed on all
models (four for each side of the cabin)
Pedestrian mode (operator beside the

truck) :
 Move forward: after positioning the
drive wheel to the centre, the truck
moves at reduced speed
 Move reverse: after positioning the
drive wheel to the centre, the truck
moves at reduced speed
 lower: the forks (SL) are lowered
 lift: the forks (SL) are lifted CD
With operator on board : DC
 A/B Position the drive wheel to the B B
centre (the forward running is not
enabled) A A
 C/D Lower/Lift the forks (SL)
ERGONOMICS
Control console
Use in pedestrian mode (operator beside the truck) :
 Button A) Move forward: after positioning the drive wheel
to the centre, the truck moves at reduced speed
 Button B) Move reverse: after positioning the drive wheel
to the centre, the truck moves at reduced speed
 Button C) lower: the forks (SL) are lowered
 Button D) lift: the forks (SL) are lifted
Advantage
Operator can walk alongside truck for frequent picking at ground level
ERGONOMICS
Display control console

10 number keyboard
20 PIN codes to allow the access of the
qualified drivers
One level height pre-selector. Height can be
personalised as you like
Advantages
Allows manager to control access to truck
Height pre-selector improves driver
productivity
ERGONOMICS
Display control console

1. Battery charge indicator
2. Traction preset performance selected
3. Speed reduction indicator
4. Truck in “corridor” Indicator
5. Corridor end stop and speed reduction “sensors”
counter
6. Steering wheel direction indicator
7. Total worked hours, speed, forks height, alarms
8. “Enter” button
9. Menu up arrow
10. Exit button
11. Menu down arrow
12. Lift / lowering forks indicator
13. Lift / lowering main lift indicator
14. Truck inside corridor
15. WG engaged
16. Park brake or “slow” performance selected
17. Time running icon
18. Main lift / lowering preset performance selected
19. Key pad
ERGONOMICS
Lifting mast
Wide visibility through the mast
Cushioned lifting and lowering movements:
 Automatic slowing down 100 mm before
the upward movement end of stroke
 Automatic slowing down 100 mm before
the downward movement end of stroke
Advantages
Operator feels comfortable lifting and
lowering loads
Loads moved per hour is increased
Product damage is minimised
ERGONOMICS
Supplementary lift of the forks

Very comfortable operator position
during the picking
Lifting cylinder provided with system for
braking at the end of stroke
Possibility to select “pallet” forks or
“FEM” forks type
Minimum transversal clearances,
maximum load stability
Advantages
Operator can choose optimum position
for placing picked item at all times
Reduces shaking of the loads
ERGONOMICS
Supplementary lift controls

Made up of three push buttons on the backrest inner side
The operator must use both hands in order to operate
them (= safety)
Two push buttons are used for selecting the movement
direction (lifting and lowering),
A third push button allows the movement
Advantages
Operator can choose optimum position for placing picked
item at all times
Operation is simple and safe
DEPENDABILITY
DEPENDABILITY
Delta mast
Stronger design
Reduce mast sway and torsion
Two stages
h12 from 3520 to 6920mm
Three stages
h12 from 5095 to 9145mm
Advantage
Mast is strong with excellent
performance at height
DEPENDABILITY
Lifting mast
Choice among a large selection of masts
heights
Strengthened lifting mast for higher lifting
High rated capacity
Automatic speed reduction according to the
platform height (safety rules)
Advantage
Strong mast will perform in intense lifting
environments in multi-shift operations
DEPENDABILITY
AC Technology
AC Steering system, motors and
steering reduction gear like the ones of
the reach and VNA trucks
MOSFET controller for traction , pump
and steering
Advantages
Component already successfully
installed on other products
High reliability
Integrated auto diagnosis
Thermal protection
Forced ventilation
DEPENDABILITY
Chassis
Sturdy structure chassis
Support legs with reduced deflection
Low profile legs
Advantage
Chassis design will minimise potential
damage
PRODUCTIVITY
PRODUCTIVITY
Three different chassis

54 mast options
Choice of pallet fork or FEM fork
Advantage
Wide variety of masts ensures there is
an option for every type of application
PRODUCTIVITY
AC Technology
AC Traction motor (6,4kW)
High speed empty or loaded truck
Quick acceleration
Regenerative braking
High braking torque
4 pre-setting performance levels

1. Hard: high performance for quick movements
2. Standard: suitable for intensive work load with
frequent movements
3. Soft: handling of delicate loads or particular
applications
4. Slow: very delicate operations, driving school
Advantage
Truck designed to be adapted for operational
conditions and driver experience
PRODUCTIVITY
Pump motor (12kW)

 High main lifting speed
High fork lifting speed
 Adjustable parameters of pump
performance
 Regenerative descent control
Advantage
Strong motor ensures smooth and rapid
lift and lowering
PRODUCTIVITY
Mid/High level picking
Guided travel aisle width reduced

 Allows travel speed to be
maximised in the aisle
Diagonal travel allows operator to
concentrate on accessing pick location
for increased productivity
Speed related to the cab /forks height
GUIDANCE
Why Guidance?
Loads need to be deposited at the same spot every
time. Guidance positions the truck allowing the
required precise deposit and with average 100mm
each side of the truck guidance is essential
Guidance Types
Rail
 Infrared cells detect presence of guide rails
 Truck senses in aisle condition and aligns
drive wheel in the straight ahead position,
disabling the steering
 Adjustable height guide wheels
Wire
 Line driver / sunken wire
 Both options can use guide wheels if dual
operation
 Aisle end magnets etc
RAIL GUIDANCE
Low Profile Rail

40mm x 40mm
Using the slim fork option the truck can
still lift a pallet from the floor
High Profile Rail

100mm high x 75mm
The first pallet needs to be placed on a
beam
WIRE GUIDANCE
Electronics sense the signal from the line

driver and straddle it making steering
adjustments to keep the signal strength
even on each sensor side.
Wire hidden under the surface of the floor
Invisible signal
WIRE GUIDANCE
6 sensors on the truck

3 in the front
3 in the rear
Straddle the wire and communicate with
the steering to make corrections
WHICH GUIDANCE?
Type of guidance Rail Wire
Advantage  Lower costs on smaller systems or systems with  Floor level pick-up and drop maximizes cube
many trucks utilization
 Chassis can be made wider and thus, give great  No shock loads to the truck, components, driver
capacities
 Increases productivity through reduced
maintenance
Disadvantage  Shock loads transmitted to truck and components  Remote Risk of Truck coming off wire
 Loss of cube (pallets cannot be retrieved at floor
level) Eliminated with the use of low-profile rail  Re-bar and expansion joint placement become
 Rails are a catch-all for debris, can’t clean behind critical to signal clarity
the rail
Indicative set up Rail installed per m € 80.00 Wire installed per m € 12.00
cost Aisle entry system € 300 per aisle Line Driver € 1000
Rail Guidance system € 1000 Wire Guidance € 8000
Breakeven – Wire seen as more cost effective for lengths above 200m
SERVICEABILITY
SERVICEABILITY
Battery Compartment
Flip up cover for service access to the
battery
Quick release locking device
no special tools required
On board battery rollers standard
Advantage
Easy access for day to day battery
maintenance and periodic maintenance
SERVICEABILITY
AC Technology
Reduced maintenance
Few components
 no brush
 no contactors
 no commutator
Advantage
Service intervals can be extended and
planned
SERVICEABILITY
Master drive unit (MDU)

Fixed traction motor: the feed cables do not kink
Gear to gear steering: no adjusting intervention
or chain maintenance
The drive wheel can be easily reached, wide
operation space
Ventilated motor,
The motor bonnet can be open also in narrow
aisles
Advantage
Improved service access, reduces time for
planned service and breakdown repairs
SERVICEABILITY
Lifting unit
Hydraulic lifting units for main lift and SL managed
by the on /off solenoid valves
Easy ordinary and extraordinary maintenance
Oil level is visible
Incorporated filters easy to check and clean
Large pump motor provide good performance
Advantage
Lifting unit gives strong performance and is easy to
maintain
SERVICEABILITY
CAN bus Can i/o Controller
Controller Area Network

Simplifies the wiring by reducing the Display
number of
cables necessary for the controls and
the uses Steer
motor
All the truck components are connected
and
share the information
Hydraulic
The failure diagnosis is improved motor
Higher reliability in transmitting the data
Traction
motor
Mast / carriage
I/O
SERVICEABILITY
Electronic sensors
Replace the mechanical microswitches
On the mast
“Man presence” sensor
Steering sensors
SL mast lift limit
SERVICEABILITY
Dashboard display
Simplify the maintenance controls
Detect failures
The error messages can be read
Maintains a list of all errors
Easily adjustable parameters
The driver can be identified by means of
PIN code (20)
Advantage
Display aids maintenance and
management control
SERVICEABILITY
Seagull wing opening door type

Easy access to all main components
Easy service access also inside the aisle
Advantage
Allows rapid response to problems
COST OF OWNERSHIP
WHAT IMPACTS ON COST OF OWNERSHIP?
Acquisition cost
Service cost
Horizontal speed
Lifting speed
Lowering speed
Efficiency of picking
OPTIONS
Options available
Stop device located on the O.H.G.
Lexan protection on the O.H.G.
Mesh guard on the O.H.G.
Cab light:
Dome light
Working light (toward the shelf)
Fork side light
Cab fan
Battery roller table (external to truck)
HIGH LEVEL ORDER PICKERS
K1.0 – K1.0H

05 - Hyster - Eu Order Pickers k1 0 k1 0h Product Training

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HIGH LEVEL ORDER PICKER K1.0 – K1.

Useful Guidelines Dependability

What does the customer care about in the

What are his buying motives?

What does the customer care about in a furniture and

What are his buying motives?

Buying / Customer Behaviour

What does the customer care about in a

What are his buying motives?

Uptime (May consider spare truck)

Location and guaranteed response time

Above 10m normally use VNA

B: operator cabin platform level

C: picking height from operator cabin platform

D: Operator picking height (between 1.5 and C

h12: platform height from warehouse floor B

Standard on all trucks

Available on K1.0L only

K1.0L FC 0.7 780 mm

Available on K1.0L and K1.0H

560/620 780 or 940 SL

K1.0M 1000 4920 6720 1000/1000 48V 280 – 310 950 SL

420 – 465 1050

Battery type Battery Battery charger

Safety gates on cabin sides

The cabin gates are compulsory on trucks

The lower part is protected against cutting. It

Ergonomics Dependability Productivity Serviceability Cost of ownership

Ergonomics Dependability Productivity Serviceability Cost of ownership

Dashboard / front panel

Rear panel / bulk head

Ergonomics Dependability Productivity Serviceability Cost of ownership

Ergonomics Dependability Productivity Serviceability Cost of ownership

Ergonomics Dependability Productivity Serviceability Cost of ownership

Operator work space

Ergonomics Dependability Productivity Serviceability Cost of ownership

Ergonomics Dependability Productivity Serviceability Cost of ownership

Ergonomics Dependability Productivity Serviceability Cost of ownership

Traction control console

Ergonomics Dependability Productivity Serviceability Cost of ownership

Hydraulic control console

Ergonomics Dependability Productivity Serviceability Cost of ownership

Pedestrian mode (operator beside the

Ergonomics Dependability Productivity Serviceability Cost of ownership

Display control console

Ergonomics Dependability Productivity Serviceability Cost of ownership

Display control console

Ergonomics Dependability Productivity Serviceability Cost of ownership

Ergonomics Dependability Productivity Serviceability Cost of ownership

Supplementary lift of the forks

Ergonomics Dependability Productivity Serviceability Cost of ownership

Supplementary lift controls

Ergonomics Dependability Productivity Serviceability Cost of ownership

Ergonomics Dependability Productivity Serviceability Cost of ownership

Ergonomics Dependability Productivity Serviceability Cost of ownership

Ergonomics Dependability Productivity Serviceability Cost of ownership

Ergonomics Dependability Productivity Serviceability Cost of ownership

Three different chassis

Ergonomics Dependability Productivity Serviceability Cost of ownership

4 pre-setting performance levels

Ergonomics Dependability Productivity Serviceability Cost of ownership

Pump motor (12kW)

Ergonomics Dependability Productivity Serviceability Cost of ownership