Table of contents. 1.0 Assembly procedure for pallet live storage Supplemental information for "VARIOFIX" roller conveyor system - 2 -

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1 Table of contents Page 1.0 Assembly procedure for pallet live storage Supplemental information for "VARIOFIX" roller conveyor system Information on alignment and test run Operating and maintenance manuals for pallet live storage Manual removal of goods and empty pallets Operating instructions for Euroroll flap access doors Maintenance instructions Operating and maintenance manuals for push-in pallet shelving Maintenance instructions Work instructions for gravity conveyors Appendix (assembly drawings, parts lists, etc.) FB 05-78/A/ Page -1 -

2 1.0 Assembly procedure: Pallet live storage with C-Profil 80/40/8x3 and U-Pofil 80/40x3 1. Fasten in-feed guide on the roller conveyor loading element (see assembly drawing). Caution! is also screwed on in the left running direction and the "right-hand design" is also screwed on in the right running direction, i.e.: the in-feed guide must connect with the bent part on the roller conveyor end with the roller conveyor must not protrude over it. 2. Fasten roller conveyor connector with screwed on the following roller conveyor element (see assembly drawing). 3. After this centre the roller conveyor to the shelf channel. (see "Instructions for alignment and test run of gravity conveyor") 4. After alignment the roller conveyors are fastened tightly with clamp plates (or clamp hooks, depending on type of beam) + hex.bolts M8x35 + large washer Ø28/9 + locknut M8/985 on the beams. Caution! - The fastening screw M8x35 must absolutely lie as close as possible to the beam. - Underpadding between beam and conveyor must not be done in any case on the 1st and 2nd beam (removal) and on the last beam (loading). - Absolutely 2 clamp plates or clamp hooks must be fastened on the storing and retrieval beams. 1.1 Supplemental information for "VARIOFIX" model roller conveyor The roller conveyor frames are assembled as described above. Pay attention to the perpendicularity of the installation. The carrying rollers are inserted in the slots provided after assembling the roller conveyor frames (pay attention to roller spacing!). The in-feed guide is fastened onto the roller conveyor loading element after inserting the rollers (see assembly drawing). FB 05-78/A/ Page -2 -

3 1.2 Instructions for alignment and test run of gravity conveyor 1. Screw together the roller conveyor elements from the retrieval side starting with the connector. 2. Align in the channel 3. Perform the test run with light (approx kg) load carrier according to the order. 4. Test run results If the load carrier does not run right or left: then the sequence is correct and the roller conveyor can be fastened according to the assembly instructions or assembly drawing If the load carrier runs right or left: Possible pallet run causes - Running surface of the load carrier is not correct - Carrier roller is not perpendicular to the roller conveyor profile Correction option - Replace load carrier - Readjust roller conveyor or restore angularity though alignment After successful corrective measures a new test run is necessary. FB 05-78/A/ Page -3 -

4 2.0 Operating and maintenance manuals for pallet live storage Preliminary remarks: Proper and careful handling of the product is required for smooth function and trouble-free process in a pallet live storage. Furthermore, a proper pallet must be inserted. The (euro/industrial) pallet is proper if: a) it has the correct dimensions (800x1200 or 1000x1200) and standardised (UIC standard) design. b) e.g. not damaged, no dirt on the runners, not shrink wrapped or wet. Warning: A pallet live storage must basically only be used in the running direction, since otherwise important functional elements (separator, brake roller). Pushing the pallets back against the direction of travel is not permitted and can possibly lead to damage. Storing: Move in pallet as far as possible in channel approx. 50 mm over roller protection in the centre between the in-feed guides. Lower the forklift mast and tilt somewhat forwards until the pallet is on the carrier rollers. Move the forklift forks from the channel. Caution! Lift the pallet carefully. Setting the storage goods down hard must be avoided! Letting the pallets "fall" during storing can possibly damage the storage goods, the pallet or the roller conveyor! When moving the forklift forks out make especially sure that the pallet is not pulled back. Retrieving: Move in with the forklift forks in the centre under the pallet, lift the pallet approx mm (absolutely no higher, since the function of the separator will be negatively affected) and quickly remove from the channel. Caution! Exception A pallet that has already been lifted must absolutely not be set down again or a halfway or completely removed pallet must not be pushed back in the channel, since the separator will be damaged. Pallet separator with snapper (mech. locking mechanism) FB 05-78/A/ Page -4 -

5 2.1 Manual removal of goods and empty pallets (Order picking area): The pallets must not be stood on during picking, the danger exists that the pallets could be pushed back. An exception is if a slide back safety is installed! Removal of the empty pallets should be done in one step, i.e. the operator must slightly lift the pallets in the front area and in one movement pull them back smoothly over the carrier rollers. After removal of the empty pallet the mech. locking mechanism (snapper / separating rocker) must be activated to unlock the separator / separating rocker. Complete or partially picked pallets are removed with a manual lift truck. If the separation by the separator does not work, the picked pallets must always be removed with the manual lift truck or forklift and the service personnel informed. Removing manually is not allowed in this case, due to the increased safety risk! After repairing the separator the picking may be put back into operation. 2.2 Operating instructions for Euroroll flap access doors Longitudinal folding a) Unfolding the roller conveyor segments Before folding the roller conveyor segments it must be ensured that no more conveying goods is located on the roller conveyor. The folding process is started on the loading side. The support foot construction securing pin must be removed (opposite from the rotation point). Now the roller conveyor segment can be folded. The complete segment must be manually folded to the stopping point and secured against falling down with the safety chain. Then the following roller conveyor segments can be opened according to the same scenario as described above. FB 05-78/A/ Page -5 -

6 b) Closing the roller conveyor segments Before closing it must be ensured that no objects are located in the area of the roller conveyor. The floor around the foot supports must be swept clean and free of interfering contours. Closing of the foldable roller conveyor segments is done starting from the removal side. The safety chains are removed. Here care must be taken that the element to be folded is not held by the chain, otherwise there is a danger that the roller conveyor element will fall down! The roller conveyor segment is carefully let down and set with the feet on the floor. The feet must be aligned 90 degrees to the roller axis (if necessary the operator must realign). After alignment the support foot construction pin safety is inserted and secured with the cotter pin. The operator must check visually whether the roller conveyor is horizontal and if there are any interfering contours in the area of the roller conveyor (e.g., holding chains, etc.). Then the following roller conveyor segments can be closed according to the same scenario as described above. 2.3 Maintenance instructions: Maintenance must be done at regular intervals of at least every 12 months after commissioning. Maintenance work must only be performed from trained maintenance technicians! Gravity conveyors are dynamically loaded systems, i.e. all screwed connections must be checked regularly and retightened if necessary. The braking rollers hold the conveyor speed constant in the live storage shelving. The process speed of a braking roller should never be faster than 0.3 m/s, otherwise it will be damaged. The braking roller must be checked in intervals of every 12 months and readjusted if necessary. FB 05-78/A/ Page -6 -

7 3.0 Operating and maintenance manuals for push-in pallet shelving Preliminary remarks: Proper and careful handling of the product is required for smooth function and troublefree process in push-in pallet shelving. Furthermore, a proper pallet must be inserted. A pallet is proper if: a) it has the correct dimensions and the correct design (according to offer/order confirmation). b) e.g. not damaged, no dirt on the runners, not shrink wrapped or wet. Storing: The mast of the forklift is inclined slightly to the driver corresponding to the incline of the roller conveyor. The pallet is lifted by approx. 50 mm over the end stop and driven in centred to the roller conveyor. If there are already pallets on the roller conveyor, these are carefully pushed further with the pallets to be stored. Only push the pallets far enough so that they can be set immediately behind the end stop. Lower the forklift forks and tilt the mast somewhat forwards until the pallet is on the carrier rollers. Carefully move the forklift out of the pallet. FB 05-78/A/ Page -7 -

8 Retrieving: Drive in with the forklift forks centred under the pallet and lift this approx mm (above the end stop). Move forward slightly, then carefully move back, since this determines the running speed of the pallets rolling afterwards. Do not pull off the contact of the pallets one after another! 3.1 Maintenance instructions Gravity conveyors are dynamically loaded systems, i.e. all screwed connections must be checked regularly and retightened if necessary. The braking roller (if installed) controls the storing speed constantly in the push-in shelf. It is normally installed in the second pallet location. The process speed of a braking roller should never be faster than 0.3 m/s, otherwise it will be damaged. The braking roller must be checked in intervals of every 12 months by technicians and readjusted if necessary. FB 05-78/A/ Page -8 -

9 4.0 Work instructions For gravity conveyors Area of application Service / inspections of floor and shelf gravity conveyors Risks for people and the environment Risks during work and inspection of gravity conveyors include: - Danger of falling - Danger of slipping - Danger of crushing - Injuries on sharp edges Protective measures and code of practice Follow the instructions given in your work area. Before inspecting the system it must be ensured that the channel to be inspected is blocked. During the work a filling of the channel must be prevented. Work must only be performed with the appropriate protective equipment. (hand protection / foot protection / head protection) Driving of the SKRB in the shelving must only be performed with suitable means. (forklift with work basket / lifting work stages / lifting work platform) The employee is obligated to use safety equipment, if there is no falling safety or catching equipment available or possible. For possible standing load carries the employee / fitter must always be located (in direction of conveyance) behind the load carrier. A load carrier must only be pushed and not pulled (for this aids such as e.g. pry bars / pushing rods can be very helpful) The operating company is responsible to provide operating instructions for warehouse equipment. Any defects of warehouse equipment discovered which could lead to risks must be immediately and professionally repaired. The warehouse equipment must be blocked for use until they are repaired. Version: January 2008 FB 05-78/A/ Page -9 -