Jungheinrich Forklift UPC P1 UPC P2 UPC P5 UPC P6 Operating instructions Manual 51179477 by www.heydownloads.com

G Under Pallet Carrier Lagersystem os.10 Operating instructions 51179477 05.18 UPC P1 UPC P2 UPC PS UPC P6 fiUNGHEINRICH

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Foreword

Notes on the operating instructions

The safe operation of the shuttle compact warehouse system requires the application of expertise contained in the present ORIGINAL OPERATING INSTRUCTIONS. The information is presented in a precise and clear manner The chapters are arranged by letter and the pages are numbered continuously

The operating instructions detail different shuttle variants and the racking system . When operating and carrying out service work, make sure that the particular section applies to your shuttle type.

Our equipment and racking systems are subject to ongoing development. We reserve the right to alter the design, features and technical aspects of the equipment. 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 .

Indicates a material hazard. Failure to comply with this instruction may result in material damage.

Used before notices and explanations.

Indicates standard equipment

Indicates optional equipment

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NOTE

Friedrich-Ebert-Damm 129 22047 Hamburg - Germany

Tel: +49 (0) 40/6948-0

www.jungheinrich.com

6 Copyright

of these operating instructions

with JUNGHEINRICH AG.

remains

Jungheinrich Aktiengesellschaft

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Contents A Correct Use and Application .... .... .... .... .... ... .... .... ..... .... ... .... .... 11 1 Correct use and application of the underride shuttle............................... 11 1.1 General.................................................................................................... 11 1.2 Correct application................................................................................... 12 1.3 Approved application conditions.............................................................. 13 1.4 Proprietor responsibilities 14 1.5 Adding attachments and/or optional equipment...................................... 14 2 Correct Use of the Under Pallet Carrier Channel Racking 15 2.1 General.................................................................................................... 15 2.2 Proprietor responsibilities ....... ................ ............. ............... ............... ...... 15 2.3 Adding attachments and/or optional equipment...................................... 16 2.4 Pallet Quality for the Racking .... .............. ... ............. .............. ............... ... 16 2.5 Approved application conditions.............................................................. 17 2.6 Racking/ UPC Shuttle Interface.............................................................. 17 B Truck Description.................................................................... 19 1 Application 19 2 Travel direction/ pallet location definition................................................ 20 2.1 Travel direction definition......................................................................... 20 2.2 Pallet location definition........................................................................... 22 3 Assemblies and Functional Description................................................... 23 3.1 Functional Description 23 3.2 Assembly Overview................................................................................. 28 4 Technical Specifications.......................................................................... 33 4.1 Performance data 33 4.2 Dimensions (as per data plate)................................................................ 34 4.3 Weights.................................................................................................... 36 4.4 Wheels, chassis....................................................................................... 36 4.5 Engine Data............................................................................................. 38 4.6 Dimensions of Load Supports to be Transported Depending on the UPC Shuttle Variants 38 4.7 EN norms................................................................................................. 39 4.8 Conditions of use..................................................................................... 40 4.9 Electrical requirements............................................................................ 41 5 Identification Points and Data Plates....................................................... 42 5.1 UPC P1 Shuttle, UPC P2 Shuttle and UPC PS Shuttle (Cambi Shuttle). 42 5.2 UPC P6 shuttle........................................................................................ 44 5.3 Data plate ...... ................ .......... .... ............ .............. ............... ............... .... 46 C Racking Description................................................................ 47 1 Application .. ............. ............... ................ ............ ............... ............... ....... 4 7 2 Safety Information for the Racking ................ ............. .............. ...... ... ...... 48 3 Ground..................................................................................................... 49 3.1 Ground condition ......... ... ........... ............... ............. ............... ................ ... 50 z 3.2 Floor capacity ......... ............... ................ ............. ............... ............... ....... 50 UJ 3.3 Cl0 Floor sag.................................................................................................. 50 .... 3.4 LO Floor tolerances....................................................................................... 51 0 7

o o o 3.5 Special load situations ............................................................................ . 51 4 Conditions of use 51 5 Assembly Overview ................................................................................ . 52 5.1 "Do not Stand on the Racking" Warning Label 53 6 Capacity plate 54 D Transport and Commissioning ............................................... . 57 1 Loading the UPC shuttle in the transport pallet.. 57 2 Securing the UPC shuttle during transport 60 3 Removing/ inserting the UPC shuttle from/ into the transport pallet.. .. .. 62 4 Using the Truck for the First Time 65 4.1 Commissioning 65 4.2 Fitting the bracket with integrated docking station on the lift truck 66 E Battery - Servicing, Recharging, Replacement ...................... . 67 1 Safety Regulations Governing the Handling of Lead-Acid Batteries ...... . 67 1.1 General notes on handling batteries 69 2 Battery types 70 2.1 Dimensions of battery trays and batteries .............................................. . 70 3 Opening / closing the battery cover 72 4 Battery removal and installation 74 5 Charging the battery ............................................................................... . 76 5.1 Charging the battery within the UPC shuttle 78 5.2 Charging the battery away from the UPC shuttle ( ) ............................ .. 80 5.3 Charge the battery in the battery charging station ( ) 82 6 Replacement battery concept ( ) 86 F Operation ............................................................................... . 87 1 Safety Regulations for the Operation of the UPC Shuttle 87 2 Safety Regulations for the Operation of the Racking ............................ .. 90 2.1 Racking Loading 97 3 Sensors, Displays and Controls 98 3.1 Sensors, Displays and Controls on the UPC P1 Shuttle, UPC P2 Shuttle and UPC PS Shuttle (Cambi Shuttle) 98 3.2 Sensors, Displays and Controls on the UPC P6 Shuttle 106 3.3 Operating status display at rear of the UPC shuttle .............................. .. 112 3.4 Battery status display at rear of the UPC shuttle 114 3.5 Radio remote control - controls and displays ........................................ .. 116 4 Preparing the UPC shuttle for operation 127 4.1 Checks and operations to be performed before starting daily operation 127 5 Operating the UPC shuttle ...................................................................... . 130 5.1 Safety regulations for truck operation 130 5.2 Switching the radio remote control on and off 138 5.3 Setting the ID of the UPC shuttle on the radio remote control ................ . 139 5.4 Preparing the truck for operation 140 5.5 Switch off the UPC shuttle 141 5.6 Checks and operations to be carried out when the truck is operational .. 145 5.7 Emergency Disconnect. 146 5.8 Emergency Disconnect bar ................................................................... .. 148 5.9 5.10 Inserting / removing the UPC shuttle into / from the pallet channel.. Storage Direction of Load Support (Pallets) in the Pallet Channel 150 z 158 w CIC) 5.11 Depositing / removing load supports (pallets) in / from the pallet channel 159 ..... LO 0 8

o 5.12 Cancelling an order manually with the radio remote control.................... 166 5.13 Manual travel, lift and lower in the pallet channel.................................... 168 5.14 Storing/Retrieving with the Last In, First Out (LIFO) Storage Functions. 174 5.15 Storing/Retrieving According to First In, Last Out (FIFO) Storage Function 184 5.16 Transfering Euro pallets during UPC PS shuttle operation...................... 196 5.17 Parking the UPC shuttle securely............................................................ 200 6 Troubleshooting....................................................................................... 202 6.1 Troubleshooting....................................................................................... 202 6.2 Recovering the UPC shuttle from the pallet channel............................... 216 7 Optional equipment .. .................... ................ ............. ............... ............ ... 246 7.1 Depositing/ removing the UPC shuttle on/ from the support frame....... 246 7.2 Optional storage functions....................................................................... 252 7.3 Operating the UPC Shuttle with the Truck Terminal................................ 274 7.4 Cold store version ( ) 277 G Repairing the UPC shuttle ....................................................... 279 1 Operational Safety and Environmental Protection................................... 279 2 Maintenance Safety Regulations............................................................. 281 2.1 Working on the electrical system............................................................. 282 2.2 Consumables and used parts.................................................................. 282 2.3 Wheels 283 3 Lubricants and Lubrication Schedule ...................................................... 284 3.1 Handling consumables safely.................................................................. 284 3.2 Lubricants and Lubrication Schedule 286 4 Maintenance and repairs......................................................................... 288 4.1 Preparing the UPC shuttle for maintenance and repairs......................... 288 4.2 UPC shuttle lifting platform disassembly/ assembly............................... 289 4.3 Cleaning ............... .............. ...... ... ................... ................ ........... .. ............ 292 4.4 Drive chain maintenance......................................................................... 296 4.5 Fuses....................................................................................................... 298 4.6 Restoring the UPC shuttle to service after maintenance and repairs...... 304 5 Taking the UPC shuttle out of service..................................................... 305 5.1 Prior to decommissioning ............. .. ............... ............. ...... .. ............ .. ....... 306 5.2 During decommissioning 306 5.3 Restoring the UPC shuttle to service after decommissioning.................. 306 6 Safety tests to be performed at intervals and after unusual incidents ..... 307 7 Final de-commissioning, disposal............................................................ 307 H Regular Checking and inspection of the Racking ... .... .... ... ..... 309 1 Regular Checking of the Racking .................. ........... .. ............. ............. ... 309 1.1 Inspection Intervals for the Racking 31 O 1.2 Visual Inspection/ Check Points for the Racking.................................... 310 2 Inspection of the Racking........................................................................ 311 3 Racking Conversions............................................................................... 311 Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement. .......................................................... 313 1 Maintenance Contents UPC.................................................................... 314 iii 1.1 Owner 314 Cl0 1.2 Customer Service .................................................................................... 316 .... LO 0 9