Jungheinrich Forklift UPC P1 UPC P2 UPC P4 UPC PS UPC P6 Operating Instructions Manual 51822718 – PD

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Contents A

Correct Use and Application................................................................................

11

1 1.1 1.2 1.3 1.4 1.5 2 2.1 2.2 2.3 2.4 2.5 2.6

Correct use and application of the underride shuttle.........................................

General....................................................................................................................................

Correct application .............................................................................................................

Approved application conditions..................................................................................

Proprietor responsibilities................................................................................................

Adding Attachments or Optional Equipment.........................................................

Correct Use of the Under Pallet Carrier Channel Racking.............................

General....................................................................................................................................

Proprietor responsibilities................................................................................................

Adding attachments and/or optional equipment..................................................

Pallet Quality for the Racking........................................................................................

Approved application conditions..................................................................................

Racking / UPC Shuttle Interface..................................................................................

11 11 12 13 14 14 15 15 15 16 16 17 17

B

Truck Description..........................................................................................................

19

1 2 2.1 2.2 3 3.1 3.2 3.3 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8

19 20 20 22 23 23 28 31 32 32 33 33 35 36 36 37

4.11 4.12 5 5.1 5.2 5.3

Application..............................................................................................................................

Travel direction / pallet location definition...............................................................

Travel direction definition................................................................................................

Pallet location definition...................................................................................................

Assemblies and Functional Description...................................................................

Assembly Overview...........................................................................................................

Functional Description......................................................................................................

Protective and safety equipment.................................................................................

Technical Specifications...................................................................................................

Characteristics......................................................................................................................

Weights....................................................................................................................................

Wheels/Chassis...................................................................................................................

Basic Dimensions...............................................................................................................

Performance data ..............................................................................................................

Electric Motor........................................................................................................................

Miscellaneous.......................................................................................................................

Dimensions of Load Supports to be Transported Depending on the UPC Shuttle Variants.........................................................................................................

EN norms................................................................................................................................

Specifications according to RED guideline (Radio Equipment Directive) for radio units...................................................................................................

Conditions of use................................................................................................................

Electrical requirements.....................................................................................................

Identification Points and Data Plates........................................................................

UPC P1 Shuttle, UPC P2 Shuttle and UPC PS Shuttle (Cambi Shuttle).

UPC P4 Shuttle and UPC P6 Shuttle........................................................................

Data plate................................................................................................................................

39 40 41 42 42 43 44

C

Racking Description....................................................................................................

45

1 2 3

Application..............................................................................................................................

Safety Information for the Racking.............................................................................

Ground.....................................................................................................................................

45 46 48

4.9 4.10

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7

3.1 3.2 3.3 3.4 3.5 4 5 5.1 6

Ground condition .................................................................................................................

Floor capacity........................................................................................................................

Floor sag .................................................................................................................................

Floor tolerances ...................................................................................................................

Special load situations......................................................................................................

Conditions of use ................................................................................................................

Assembly Overview ...........................................................................................................

"Do not Stand on the Racking" Warning Label.. ...................................................

Capacity plate .......................................................................................................................

49 49 49 50 50 50 51 52 53

D

Transport and Commissioning ...........................................................................

55

1 2 3 4 4.1 4.2

Loading the UPC shuttle in the transport pallet... ................................................

Securing the UPC shuttle during transport.............................................................

Removing/ inserting the UPC shuttle from/ into the transport pallet... ... .

Using the Truck for the First Time ...............................................................................

Commissioning .....................................................................................................................

Fitting the bracket with integrated docking station on the lift truck ............ .

55 57 59 62 62 63

E

Battery - Servicing, Recharging, Replacement.. ................................ ..

65

1 1.1 2 2.1 3 4 5 5.1 5.2 5.3 6

Safety instructions for handling lead-acid batteries ...........................................

General notes on handling batteries .........................................................................

Battery types .........................................................................................................................

Dimensions of battery trays and batteries ..............................................................

Opening / closing the battery cover ...........................................................................

Battery removal and installation. ..................................................................................

Charging the battery ..........................................................................................................

Charging the battery within the UPC shuttle .........................................................

Charging the battery away from the UPC shuttle (0) .......................................

Charge the battery in the battery charging station (0) ....................................

Replacement battery concept (0) ..............................................................................

65 66 68 68 70 72 75 77 79 81 85

F

Operation ...........................................................................................................................

87

1 2 2.1 3 3.1

Safety Regulations for the Operation of the UPC Shuttle .............................. .

Safety Regulations for the Operation of the Racking ........................................

Racking Loading ..................................................................................................................

Sensors, Displays and Controls...................................................................................

Sensors, Displays and Controls on the UPC P1 Shuttle, UPC P2 Shuttle and UPC PS Shuttle (Cambi Shuttle)........................................................

Description of the Sensors, Display and Control Elements of the UPC Shuttle P4 and UPC Shuttle P6 ...................................................................................

Operating status display at rear of the UPC shuttle...........................................

Battery status display at rear of the UPC shuttle ................................................

Radio remote control - controls and displays ........................................................

Preparing the UPC shuttle for operation .................................................................

Checks and operations to be performed before starting daily operation.

Operating the UPC shuttle .............................................................................................

Safety regulations for truck operation .......................................................................

Switching the radio remote control on and off ......................................................

Setting the ID of the UPC shuttle on the radio remote control .................... .

Preparing the truck for operation .................................................................................

Switch off the UPC shuttle ..............................................................................................

87 90 97 98

3.2 3.3 3.4 3.5 4 4.1 5 5.1 5.2 5.3 5.4 5.5 8

98 103 109 111 113 125 125 128 128 136 137 138 139

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5.8 5.9 5.10 5.11 5.12 5.13

5.14 5.15 5.16 5.17 6 6.1 6.2 7 7.1 7.2 7.3 7.4 7.5 7.6

Sensor test upon UPC Shuttle Switch-on...............................................................

155 161 163 169 179 191 195 197 197 211 247 247 253 275 278 279 279

Repairing the UPC shuttle..................................................................................... 281

1 2 3 3.1

5 5.1 5.2 5.3 5.4 5.5 5.6 6 6.1 6.2 6.3 7 8

Spare Parts............................................................................................................................

Operational Safety and Environmental Protection .............................................

Maintenance Safety Regulations................................................................................

Working on the electrical system ................................................................................

Consumables and used parts.......................................................................................

Wheels.....................................................................................................................................

Lubricants and Lubrication Schedule........................................................................

Handling consumables safely.......................................................................................

Lubricants and Lubrication Schedule........................................................................

Maintenance and repairs.................................................................................................

Preparing the UPC shuttle for maintenance and repairs.................................

UPC shuttle lifting platform disassembly/ assembly.........................................

Cleaning...................................................................................................................................

Drive chain maintenance.................................................................................................

Fuses........................................................................................................................................

Restoring the UPC shuttle to service after maintenance and repairs.......

Taking the UPC shuttle out of service.......................................................................

Prior to decommissioning................................................................................................

During decommissioning.................................................................................................

Restoring the UPC shuttle to service after decommissioning.......................

Safety tests to be performed at intervals and after unusual incidents......

Final de-commissioning, disposal...............................................................................

H

Regular Checking and inspection of the Racking.............................. 309

1 1.1

Regular Checking of the Racking...............................................................................

Inspection Intervals for the Racking...........................................................................

4 4.1

4.2

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W-LAN......................................................................................................................................

143 144 146 148 154

G

3.2 3.3

cc

Checks and operations to be carried out when the truck is operational..

Emergency stop...................................................................................................................

Emergency Stop Bar.........................................................................................................

Inserting/ removing the UPC shuttle into/ from the pallet channel...........

Storage Direction of Load Support (Pallets) in the Pallet Channel............

Depositing / removing load supports (pallets) in / from the pallet channel.....................................................................................................................................

Cancelling an order manually with the radio remote control.........................

Manual travel, lift and lower in the pallet channel...............................................

Storing/Retrieving with the Last In, First Out (LIFO) Storage Functions.

Storing/Retrieving According to First In, Last Out (FIFO) Storage Function...................................................................................................................................

Transfering Euro pallets during UPC PS shuttle operation.............................

Parking the UPC shuttle securely...............................................................................

Troubleshooting...................................................................................................................

Troubleshooting...................................................................................................................

Recovering the UPC shuttle from the pallet channel........................................

Optional equipment............................................................................................................

Depositing/ removing the UPC shuttle on/ from the support frame.........

Optional storage functions..............................................................................................

Operating the UPC Shuttle with the Truck Terminal..........................................

Cold store version (0)......................................................................................................

281 282 284 285 285 286 287 287 289 290 290 291 294 298 300 305 306 307 307 307 308 308

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309 310 9

1.2 2 3

Visual Inspection/ Check Points for the Racking...............................................

Inspection of the Racking................................................................................................

Racking Conversions........................................................................................................

310 311 311

Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement............................................................................ 313 1 1.1 1.2

Maintenance Contents UPC..........................................................................................

Owner.......................................................................................................................................

Customer Service...............................................................................................................

314 314 316

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