User manual Interroll Cart Pushback
Contents
1. A Content falls to the floor Cart Pushback INTERROLL Troubleshooting In the event of a failure gt Stop using the lane and any lane which may be damaged by the failure gt Secure the area and set up appropriate signage gt Only qualified maintenance personnel should repair the failure gt Never try to hold back a container freed during a manipulation gt Before restarting the system check the integrity of the lane the rack and its en vironment e g sprinklers Follow the maintenance procedures of the various products racks environ ment There may be many reasons causing a container to be blocked and preventing it from starting this is not necessarily a defect in the installation Inserting a new container usually corrects the problem gt If a container is jammed in the middle of a lane load another container into the front of the lane The train of containers may be freed by pushing gt Once the cart and the container have reached the front empty the lane and the surrounding lanes Then inspect the lane in which the containers become jammed gt Check whether the lane or the rack were damaged by the blocked container Never try to free a Pushback cart manually gt If content has fallen to the floor you must secure the area before taking any further action Version 1 2 Jan 2015 Troubleshooting EN Translated from French Failure Container train jammed Version 1 2 Jan2. INTERROLL INSPIRED BY EFFICIENCY User manual Interroll Cart Pushback PF 2430 Version 1 2 Jan 2015 EN Translated from French Manufacturer Interroll Dynamic Storage 310 rue du Clair Bocage Zone d Activit Beaupuy 2 85000 Mouilleron le Captif France Tel 33 251 37 12 32 Fax 33 157 67 99 71 www interroll com dynamicstorage interroll com Copyright for this manual Interroll Dynamic Storage holds the copyright on this manual The manual contains standards drawings and illustrations which may not be disclosed published or duplicated either fully or in part nor used for any other purpose than the installation referred to in this manual without the prior written consent of Interroll Downloadable manual available at the following address http www interroll com en downloads dynamic_storage ds_user_manual Version 1 2 Jan 2015 EN Translated from French Version 1 2 Jan 2015 EN Translated from French Cart Pushback INTERROLL Contents About this manual Remarks concerning the use of this Manual ccccecceeeeeeeeeeeeeeeeeeeeees 4 Warnings in this CGOCUMENL cccecceeeceeeeeeceeeseeeeeeceeeseeeseesaeeaeeeaeeseeeaeeegs 5 Additional symbols a secterrat ccctucigtcer achinea aneamaedsndeunne cennsadeted aaedaanapnedndammeatestienene 5 Safety General safety instructions ccccccccececeeeceeeeeeeceeeeseeeseeeeaeeaeeeseeeseeesaeeeaes 6 daien e e t
3. Loading a container Warning Risk of injury in case of improper handling gt Only load containers into the lane from the front gt In the event of a blocked container remove it and determine the cause of the blockage Notice Damage in case of improper handling gt Load carefully so as not to damage the lane or the products stored in it gt Never touch the carts tracks or the rack with the forks of the forklift gt Do not use containers that may become nested or snagged By way of example ee ae re gt Check the bottom of the container in order to detect any possible damage or breakage of the runners or the presence of nails or foreign matter Damaged containers should not be used in a dynamic lane they should be removed from the storage zone p gt Make sure that the container to be loaded is one of those described in the order confirmation Version 1 2 Jan 2015 EN Translated from French Start up and operation 35 Cart Pushback INTERROLL Unloading a container Warning Risk of injury in case of improper handling gt Unload the containers in the lane on the front side only gt Never touch the trolleys rails or the rack with the forks of the forklift gt In the event of a blocked container remove it and determine the cause of the blockage Notice Precautions to avoid damaging the product and its environment gt Unload carefully so as not to damage the lane or th
4. A Never deposit a container so that it is resting on the front beam Version 1 2 Jan 2015 EN Translated from French Start up and operation 45 46 Cart Pushback INTERROLL gt Reverse the forklift and return the forks to the horizontal position Make sure that the forks do not touch the carts VA When the lane is full and no more containers can be loaded the multi purpose push plates are no longer visible at the front Version 1 2 Jan 2015 Start up and operation EN Translated from French Cart Pushback INTERROLL Unloading forklift with tilting mast or forks Unloading gt Advance in the axis of the lane with the forks horizontal the first container gt As the forklift advances gradually tilt the forks towards the rear Make sure that the forks do not touch the carts Z Ag a or S Version 1 2 Jan 2015 EN Translated from French Start up and operation 47 48 Cart Pushback INTERROLL gt Carefully lift the containers to a height of 50 mm above the angle beam m 3 4 3 _ Si gt mm min Version 1 2 Jan 2015 Start up and operation EN Translated from French Cart Pushback INTERROLL gt Slowly reverse at a constant speed The forklift checks and regulates the speed at which the containers in the lane descend 7 A l Max 0 3 m s Version 1 2 Jan 20
5. 2015 EN Translated from French Cart Pushback Troubleshooting INTERROLL Technical data in the order confirmation is noted below by the abbreviation OCTD Cause Pallet characteristics type dimen sions weight and stored load not compliant with the OCTD Foreign bodies attached to the con tainer plastic film pieces of wood cardboard Load unevenly distributed on the con tainer Gap between the tracks not constant Particles in the grooves in the tracks Cart lift out protectors bent Lift out guides bent Particles on the tracks Damaged rack see the rack mainte nance procedure Troubleshooting Correction gt Remove the container from opera tion gt Remove the foreign bodies gt Repackage the container gt Replace the tracks or gt Check the gauge bars or gt Check that the tracks are attached to the angle beams gt Remove the particles gt Remove the carts and straighten the hooks gt f they are too fragile replace the cart gt Remove the carts and straighten the guides gt f they are too fragile replace the track gt Remove the particles gt Replace the rack if necessary 57 Recommendation for protecting the environment Cart Pushback INTERROLL Decommissioning and scrapping Waste disposal As far as possible the packaging should be disposed of in an environmentally friendly way The speed control rollers
6. Ing grinding and the duration of maintenance operations for cold rooms e Specifications particular to the company where the installation is used e Technical data provided in the order confirmation e Maintenance procedures of the various products dynamic lanes racks envi ronment e g sprinklers gt Define a safety zone around the working area gt The safety zone includes the entire height of the bay as well as the two adjacent bays gt Secure the zone and set up appropriate signage nets etc gt Remove everything from the lane involved in the intervention before starting gt Make sure that the area of intervention has sufficient lighting gt At the end of the intervention make a visual inspection of the repaired section to ensure that you did not leave any foreign materials or tools which may alter the correct operation of the installation gt Before restarting the system check the integrity of the lane the rack and its en vironment e g sprinklers Lane maintenance can be performed using the following equipment e Platform with a rotary barrier e Strap Platform The platform may be used for maintenance from the alleys on the loading un loading side at the front Use a safety harness and always attach yourself before moving Version 1 2 Jan 2015 Cleaning maintenance and repair EN Translated from ereneh Cart Pushback INTERROLL Strap The strap is used e to secure the car
7. 0 1 is permitted gt Interroll shall not be held liable for any malfunctions if the rack is not properly installed gt If the Cart Pushback is interfaced with any other systems use the same point of reference as the other systems when positioning the frames gt Always meet the specifications of the rack height between two levels gt Never handle pallets whose straps have already been cut risk of falling Method 1 assembly with a scissor lift Step 1 Rack gt Use a scissor lift measuring less than 1 meter in width to assemble the rack The scissor lift must be capable of reaching the highest lane gt Start by securing the frames to the ground at the rear of the lane Start by assembling the highest lane and work downwards gt Before installing the beams of the lower levels completely finish the assembly of the Cart Pushback on the next higher level gt Attach the angle beams at the rear of the lane on every level in order to secure the rack Angle beams at the rear of the lane ee Box beam a CF Fi zp a A E V4 Optional box beam Version 1 2 Jan 2015 14 Assembly and installation EN Translated from French Cart Pushback INTERROLL gt Continue to assemble the frames Frame spacer Version 1 2 Jan 2015 EN Translated from French Assembly and installation 15 Cart Pushback INTERROLL Step 2 Assembling the tracks Arrangement of the tracks gt St
8. 4 Version 1 2 Jan 2015 62 Appendix EN Translated from French xX O OQ E aw v A _ _ 4 O INTERROLL Oopyrig ht To find your local contacts consult Version 1 2 Jan 2015 interroll com contacts EN Translated from French
9. Jan 2015 EN Translated from French Start up and operation 41 42 Cart Pushback INTERROLL gt Push the container until it is fully inserted in the lane It must be positioned beyond the two multi purpose push plates Version 1 2 Jan 2015 Start up and operation EN Translated from French Cart Pushback INTERROLL gt Carefully place the container on the top cart without jarring the container The container must not be placed abruptly gt Reverse the forklift and return the forks to the horizontal position Make sure that the forks do not touch the carts L i Version 1 2 Jan 2015 EN Translated from French Start up and operation 43 44 Loading the last container Cart Pushback INTERROLL If the multi purpose push plate moves backwards with the containers as they are loaded one against another then the operator knows that no more containers can be loaded When this happens reverse and load the container by pushing the push plates gt Tilt the forks of the forklift towards the rear by 3 Version 1 2 Jan 2015 EN Translated from French Start up and operation Cart Pushback INTERROLL gt Push the container until it is fully inserted in the lane The container must be pushed beyond the angle beam at the front gt Carefully deposit the container on the tracks without jarring The container must not be placed abruptly
10. PTEE E T A E ENA E EE ee eee 6 Unintended IS Gwenn arrestin donc ges atures ve ence nett teiit eihcnaranctlooatcie denies 6 Qualified personnel cccccecccceeececeeeececaeceeceeeeeeeeececaeeceeseeeeeseaeessaeeessaaees 7 Br Peete este sree ate asd eta nic a sce tag atuntad E stnwonne eee at eeatenosecnedae F Product information FFOGUICT OC SCID WOM cs asec ceiae oscar eciet a giie ET EE EA S 8 COMDE oe ee Ree ne nen ee eee eee eee ee 8 Technical characteristics of the Cart PUSNHDACK cece ceeceseeeeeeeeaeeeaees 9 Transportation and storage SAMS OCHA OM esana e sel auarneb nui tastadamedbeewesa pda ntund atau 11 SN e E EOE ee E E E E 11 Assembly and installation Warnings concerning assembly ccccseccseccceeeeeeeceeeeseeeeeeeseeeeeeesseeeseeeaes 12 PAGS SEMI IIS erana a a shat dation EE 12 PRS S SIND see E E teat E E E E E ess 14 Start up and operation Warnings concerning operations cc cece ceccceeeceeceeeeseeeceeeseueeseeeseeeseeeees 32 Checks before the initial Start Up 2 00 0 cccceccccecceeeeeeeeseeeseeeeseeeaeeesaeeseeees 33 Forklift requirements 2 ccic0cvo2ccisesasne deudsedsncoudendesineiatensues leudeseiuxeuteeensdandelantces 34 OPE Nic cases rset eerste ce Sse nc eset eee neocons AE O EE 35 Loading forklift with tilting mast Or forks cccceececeecee cece eeeseeeaeeeeaeeeaees 38 Unloading forklift with tilting mast Or fOrKS cccccceccseeeeeeeeeeeeeeeeeeee
11. carts on the tracks gt The person on the tracks holds the set of carts by the rear cross tie of the upper cart then adjusts the position of the carts such that the wheel flanges are inserted in the guides A There is a risk of hands being trapped between the carts when installing Version 1 2 Jan 2015 EN Translated from French Assembly and installation 29 30 Cart Pushback INTERROLL gt Then cut and remove the plastic straps securing the carts gt Lower the carts towards the front of the lane Check that the lift out protectors of the carts pass under the lift out guides of the tracks Version 1 2 Jan 2015 EN Translated from French Assembly and installation Version 1 2 Jan 2015 EN Translated from French Cart Pushback INTERROLL gt Pull the top cart towards the rear of the lane Since the carts are linked to one another the second third and so on carts should follow the top cart gt Once the carts are fully stretched out release them and they should return to their position at the front Repeat this operation for each lane gt Repeat the procedure for the lower levels starting with the carts on the highest level and working downwards Level 2 Level 1 gt Once the bay is completed proceed with the assembly of the adjacent bay and so on Assembly and installation 31 Cart Pushback INTERRO
12. 1 200 x 800 mm e Industrial pallets 1 200 x 1 000 mm e GKN Chep 1 200 x 1 000 mm e Euro pallets 1 165 x 1 165 mm e Other containers please contact Interroll Forklifts Specified in the order confirmation Version 1 2 Jan 2015 EN Translated from French Product information 9 Cart Pushback INTERROLL Atmospheric conditions Ambient tem during 28 C to 40 C perature operation during 28 C to 40 C assembly for transportation 28 C to 80 C and storage Humidity Up to max 90 without condensation Environment The Cart Pushback is not suitable for use in an environ ment presenting the following risks e Oxidisation either atmospheric or via chemical attacks e Projection e Decomposition e Vibration e Explosion e Radioactive radiation e Electromagnetic radiation Exceptions are possible please contact Interroll Load contents The contents of the loads and their containers must not e Oxidise e Corrode e Decompose Block the lane s components Pollute steel components e Prevent correct operation of any mechanisms The Cart Pushback must not be used in direct contact with food products Version 1 2 Jan 2015 19 Product information EN Translated from French Cart Pushback INTERROLL Transportation and storage Transportation gt Only qualified and authorised personnel should transport the equipment gt Use slings or appropriate lifting equipment to transport the
13. 15 EN Translated from French Start up and operation 49 50 Cart Pushback INTERROLL In the example below the forklift reversed too quickly Make sure that the container being removed always remains in contact with the A train of containers in the lane beam l Max 0 3 m s Version 1 2 Jan 2015 Start up and operation EN Translated from French Cart Pushback INTERROLL gt Once the line of containers is resting against the front angle beam the forklift can reverse freely Free reverse ee T Version 1 2 Jan 2015 EN Translated from French Start up and operation 51 52 Preparing an intervention Performing an intervention Maintenance equipment Cart Pushback INTERROLL Cleaning maintenance and repair Cleaning Notice Damage in case of improper cleaning rN gt Do not use abrasive products pressurised jets or products which may cause oxidisation or damage the equipment gt Clean the lane using dry cloths Remark in case of maintenance and repair Warning Risk of injury in case of improper intervention gt Maintenance must only be carried out by qualified and regularly trained personnel in compliance with safety and other instruc tions gt Wear Personal Protective Equipment PPE Before any intervention you must take into account e Safety instructions concerning the work area e g movements in the area weld
14. Cart Pushback you must follow the recommendations in this manual and the data in the order confirmation e Keep this manual near the Cart Pushback e Give this manual to any operator or subsequent user of the Cart Pushback Interroll shall not be held responsible for damages or failures which may result from ignoring the recommendations in this manual Contact Interroll Customer Service if you have any questions after reading this manual The last page lists the details of the person to contact in your country Version 1 2 Jan 2015 About this manual EN Translated from French Cart Pushback INTERROLL Warnings in this document The warnings in this document concern dangers which may arise while using the Cart Pushback For relevant warnings see Safety page 6 and the warnings at the beginning of each chapter There are three categories of danger indicated by the following key words e Danger e Warning e Caution Key word Meaning Danger Indicates a hazardous situation which if not avoided may result in death or serious injury Warning Indicates a hazardous situation which if not avoided may result in death or serious injury Caution Indicates a hazardous situation which if not avoided may result in a minor or moderate injury Structure of warnings Danger Nature and source of hazard Possible consequences of non observance gt Information about how to avoid the hazard Notice This symbol identi
15. LL Start up and operation Warnings concerning operations Warning Risk of injury in case of improper handling gt Always load containers in Pushback lanes in the right direction Check that the front and the depth of the container comply with the recommendations included in the confirmation of the order gt Load and unload the pallets at a constant speed max 0 3 m s When unloading the forklift must restrain the train of pallets gt Never load a container from the rear of the lane gt Never attempt to load a pallet in a lane that is full When the lane is full the yellow multi purpose push plates at the front are no longer visible gt Do not insert containers in the lane if they do not enter com pletely into it gt Immediately remove any containers that stick out from the lane or are resting in full or in part on the push plates Notice Damage in case of improper handling Note the following remarks gt Load carefully so as not to damage the lane the rack the con tainers or the products stored in them gt Never touch the carts or the rack with the forks of the forklift gt Never use the side shifter in the lane gt Only use the forklifts described in the order confirmation gt In the event of a malfunction or if you see any signs of damage immediately stop the lane and set up appropriate signage gt Immediately inform the company s Maintenance Department of any damage due to impact on a ra
16. ading at all levels of the installation e Use a forklift truck with tilting forks and not a tilting mast to handle loads that are more than 4 metres high The forklift s technical characteristics must be suitable for the containers to be stored as well as for the height of the loading and unloading zones Refer to the manufacturer of the forklift It is recommended to use forklifts with the following equipment e An onboard camera system on the forks for lanes at heights above 6 meters e Check the residual capacity weight of the forklift and the height e Visual markers yellow multi purpose push plates Version 1 2 Jan 2015 Start up and operation EN Translated from French Cart Pushback INTERROLL Operation Close down a lane if you observe any of the following e Suspicious noise e A visibly worn component e Un contenant bloqu e A deteriorated rack e A defective attachment between the lane and the rack e Wheel racks not held in parallel e A component which has failed or which is not operating correctly Checks before each Check that everyone present is informed and trained on the use of the system start up and that no one is in a position of danger gt Check that there is no visible degradation to the lanes or the rack gt Check that there is no foreign material preventing correct operation of the installation gt Check that all signage is in place load capacity and restrictions for use
17. art by assembling tracks in the highest lane and work downwards Use a fork lift to lift the tracks m pe _ _____________t __ _ ___ygg rr sSsesssS EC L_____y i ____Y a LLL ____ Inserting the tracks gt Pull the tracks on the beams i ACO ee AS i A_ Mtl am y 4 i Version 1 2 Jan 2015 16 Assembly and installation EN Translated from French Version 1 2 Jan 2015 EN Translated from French Cart Pushback INTERROLL Adjusting the position of the tracks gt Position two tracks in each lane One on the left and one on the right Check that the lift out guides face inwards The centre to centre distance between the tracks is shown on the assembly plan gt Check that the tracks rest on all the beams Lift out guides Loading side Securing the tracks gt Use the inserts to attach each end of the tracks to the angle beams The holes in the angle beams correspond to the gap required between the tracks Check that the centre to centre distance between the tracks matches the distance shown on the assembly plan O12 contact washer M12 30 screw 89 Nm Assembly and installation 17 18 Cart Pushback INTERROLL Option box beams gt If box beams are installed at the rear of the lane remember to assemble the stop angle Use the fixing angles to attach the tracks to the box beams M12 30 screw 89 Nm ae O12 contact washe
18. ck carts or tracks gt If metal parts from the Cart Pushback are found on the floor immediately stop every level of the bay and the neighbouring bays Set up appropriate signage gt In the event of a blocked container remove it and determine the cause of the blockage If the container appears to be defective set it aside from the storage zone gt In order to prevent loads from tipping over provide safety equipment such as grates or nets Version 1 2 Jan 2015 Start up and operation EN Translated from French Version 1 2 Jan 2015 EN Translated from French Cart Pushback INTERROLL E Before starting up the installation all operations staff must be informed about e The specific use of a dynamic storage installation All the risks inherent in a dynamic storage system such as falling loads moving loads cut offs Checks before the initial start up gt When connecting the storage lanes and other equipment in the warehouse perform a risk analysis of the entire installation gt In order to use the installation in a safe configuration verify the suitability of the width of the rows the height of the installation and the characteristics of the forklifts e g original manufacturer s protections turning radius stability and maximum load compared to the height gt Check that the racks and lanes do not have any visible damage gt Check that there is no foreign material in the working area gt Ch
19. contain lead The rollers and speed controllers contain plastic The tracks and trucks are in steel They do not contain plastic components The paint is lead free gt For all maintenance work and when disposing of equipment please comply with environmental standards and use appropriate disposal methods gt In the event of cleaning with substances which may harm the environment store those substances in suitable containers which may be handled Close and dispose of them using appropriate methods Comply with the warnings on the packaging of harmful substances Version 1 2 Jan 2015 Decommissioning and scrapping EN Tensed fron French Cart Pushback INTERROLL Appendix Spare parts Spare parts illustrations Tracks Track gauge bar foo Loading Track insert Top cart Version 1 2 Jan 2015 EN Translated from French Appendix 59 Cart Pushback INTERROLL Pallet guide Multi purpose push plates Bottom ca 5 6 oe we we oe oe 60 A di Version 1 2 Jan 2015 PPenaIx EN Translated from French Spare parts list Machine no No Name Right hand track 1 2 Left hand track 3 Track gauge bar 4 Track insert 5 Top cart 6 Wheel 7 Pallet guide 8 Lift out protector Right hand multi pur pose push plate _ Left hand multi pur pose push plate Bottom cart _ _ V
20. e products stored in it gt Never touch the trolleys rails or the rack with the forks of the forklift gt Ensure that the container and its contents are stable and secure before unloading gt Insert the forks of the forklift under the container gt Raise the container gently gt Slowly approach the installation on the front side gt Align and centre the container correctly in the lane gt Reverse the forklift slowly so as to control the descent of the accumulated line of pallets in the lane Version 1 2 Jan 2015 Start up and operation EN Translated from French Cart Pushback INTERROLL Loading height Do not exceed the maximum loading heights on the highest level in accordance with the distance d shown on the forklift Only in case of tiltable mast Maximum loading height according to d 450 mm 400 mm 350 mm 300 mm 250 mm 2 pallets p 3 pallets 200 mm ea cee cid _ 4 pallets po _ _ 5 amp 6 pallets 150 mm ea Distance d 100 mm 50 mm 0 mm LSEEELEFEEKEELEFEEFEEKEEEKE DED VQ OO OC CO LC LO CO LC LC CO LO LC LO LO LC LC SOD OD OA DAD AD AD AD LH LD LO a a gt a Aa oo o2 aS a g No oY 9 Ss Q we Loading height of the pallet Version 1 2 Jan 2015 EN Translated from French Start up and operation 37 38 Loading the first container A Cart Pushback INTERROLL Loading forklift with tilting mast or forks In LIFO lan
21. eck that all signage is in place load capacity plate restrictions for use w m Content Container Always make sure that the push plates are securely attached to the cart before A use gt If the yellow multi purpose push plate is missing from the front or if any of the plates appear to be out of order e g loose close the entire bay and proceed with the maintenance operations described in Cleaning maintenance and repair page 52 Start up and operation 33 Cart Pushback The forks A Lifting height Technical characteristics Recommended equipment 34 INTERROLL Forklift requirements The forklifts are described in the order confirmation e The forks must be suitable for the depth of the container e The fork spacing changes according to the type of pallet used so as to carry the loads in a stable manner without damaging the container e The forks of the forklift must not protrude beyond the container e If the forks of the forklift stick out then use packers make sure the center of gravity remains on the forks This operation can be performed thanks to the re sidual capacity of the cart The handling systems used type of forklift and width of the aisles must allow the containers to be loaded and unloaded parallel to the axis of the corridor Take care when using articulated forklifts e The maximum lifting height of the forklift should enable risk free loading and un lo
22. eees 47 Cleaning maintenance and repair CTO AIAN e satssc seas E dee sceen cape saueee ete E E A TT 52 Remark in case of maintenance and repair cccceccececeecaeeeseeeeaeeeaees 52 List of maintenance and inspection OperatiONnS ccccececeeeceeeeeeeeaeeeees 54 Troubleshooting In the event Of a failure 2 0 ccccecccececeeeceeecceeecaeecaeeeaueeseeecuecaueeseeeaeeeses 56 Troubleshooting es sscensetecne st cteet scene i EEEE EENAA 57 Decommissioning and scrapping VAI EELSE E eee E A A A E T S nee E 58 Appendix SPADA r E E E T E E E EE 59 Replacing the tracks and Calrts ccccscccscceseceeeceeeceeceeesseceseceneseeseeeseees 61 3 Manual contents Validity of this manual O This manual is an integral part of the product Cart Pushback INTERROLL About this manual Remarks concerning the use of this manual This manual provides remarks and important information about the various oper ating phases of the Cart Pushback e Transport assembly and start up e Safe operation maintenance troubleshooting waste disposal This manual describes the Cart Pushback as it is delivered by Interroll In the event of an installation involving non standard containers or contents specific recommendations specific operations modes and all contractual doc uments are provided along with this manual e To ensure safe reliable operation and to benefit from the guarantee before us ing the
23. equipment gt If the content is unstable unload the container unit by unit and not by truck Storage gt Store equipment indoors gt Never store the equipment outdoors or in a dusty or humid environment gt Respect the ambient conditions gt Do not stack additional loads on the Cart Pushback cart and track pallets Version 1 2 Jan 2015 EN Translated from French Transportation and storage 11 12 cD Qualified personnel Cart Pushback INTERROLL Assembly and installation Warnings concerning assembly Warning Risk of injury in case of incorrect assembly gt As the Cart Pushback is the subsystem of the overall installa tion you need to perform a risk analysis of the entire installa tion gt Identify the protective measures required concerning risks related to the local conditions at the site and to usage gt Define a safety zone in the working area gt Secure the zone and set up proper signalling and appropriate protection gt For assembling tracks and carts on the rack refer to the safety rules concerning working at height gt Never lean or walk on carts installed on the Cart Pushback tracks unless the carts are securely strapped in place gt During assembly wear appropriate Personal Protective Equip ment gloves safety shoes safety harness helmet etc Assembly rules The Pushback lanes are subsystems of the overall installation They are delivered in compliance w
24. ersion 1 2 Jan 2015 EN Translated from French Cart Pushback INTERROLL Before placing your order have Interroll confirm the reference numbers by pro viding us with the machine number indicated on the rating plate Recommended inventory status A Keep in stock B Recommended stock C Optional stock Reference Quantity Inventory sta tus C C C C C A06060766 A A09051961 C C O Long 5 and 6 pallet places A09073161 3D Short 2 to 4 pallet places A09091762 3D Long 5 and 6 pallet places A09073163 3D C Short 2 to 4 pallet places A09091761 3D C These components should be replaced exclusively by qualified maintenance per sonnel This table provides an indication of requirements for most users Each user should determine the stock levels required according to their actual usage Replacing the tracks and carts When replacing a track or cart refer to the table below and inform Interroll of the part number Also specify the type of pallet used e g Euro pallet GKN CHEP longway GKN CHEP crossway or other and the order number For all other technical configurations that are different from the configuration specified in the manual contact Interroll with the order number or the drawing supplied with the delivery Appendix 61 Cart Pushback INTERROLL Lane for 2 pallet places near Cart 1 2 Lane for 3 pallet places Lane for 4 pallet places yr Cart 6 4 Cart 7
25. es like the Cart Pushback loading and unloading both take place at the front Never load or unload a container from the rear gt Align and centre the container in the axis of the lane gt Tilt the forks of the forklift towards the rear by 3 in the axis of the lane Never use the side shifter when the load is inside the structure Version 1 2 Jan 2015 EN Translated from French Start up and operation Cart Pushback INTERROLL gt The container must touch the pallet guide Version 1 2 Jan 2015 EN Translated from French Start up and operation 39 Cart Pushback INTERROLL gt Carefully place the container on the top cart without jarring the container The container must not be placed abruptly gt Reverse the forklift and return the forks to the horizontal position Make sure that the forks do not touch the carts Tem 7 Version 1 2 Jan 2015 40 Start up and operation EN Translated from French Cart Pushback INTERROLL Loading gt Tilt the forks of the forklift towards the rear by 3 the second container uy A E lamm gt Push the first container towards the rear of the lane using the second container Push the containers one against another Position as close as possible to the multi purpose push plates and adjust the height of the forks when maneuver ing Ni mw E Version 1 2
26. fies possible material damage gt Information about how to avoid damage Additional symbols This symbol displays safety instructions This symbol marks useful and important information This symbol marks the steps that have to be carried out Version 1 2 Jan 2015 EN Translated from French About this manual 5 Cart Pushback INTERROLL Safety General safety instructions The Cart Pushback is designed according to the technical state of the art How ever certain risks may still arise e Risks of physical injury or death to the user or bystanders e Damage caused to the Cart Pushback or to other material Disregarding the warnings in this manual may lead to serious injury or even death gt Always read this manual carefully and make sure you follow the safety instruc tions gt Only qualified and specially trained personnel may work with the Cart Pushback gt Always keep this manual at hand and make it accessible to all personnel gt Always comply with the relevant national safety regulations in your company gt Contact Interroll Customer Service if you have any questions after reading this manual The last page lists the details of the person to contact in your country Intended use The Cart Pushback is reserved exclusively for industrial use in suitable environ ments The installed lanes are intended for dynamic gravity based storage only of foreseen and previously approved isolated l
27. guides Check the gap between the tracks Cart Pushback INTERROLL List of maintenance and inspection operations In order to keep the installation in perfect operational condition you must system atically replace any damaged components Maintain a log of the checks and maintenance performed on the installation Fail ing which the operator shall be held responsible in case of an incident or an ac cident on the installation and cannot claim any guarantee nor indemnity from Interroll Date Work required Performed by Check the carts for fragments of pallets cardboard or plastic film Clean with a brush if necessary There must be no bumps or dips in the tracks If there are replace the tracks The lift out guides are welded on the inside of the tracks Check for damage Replace them if necessary Interroll can send a quote for replacement The track guides are welded on the outside of the tracks Check for damage Replace the track if necessary Interroll can send a quote for replacement Also check that the groove in the tracks is clean no fragments of pallets cardboard or plastic film etc so that the carts can move smoothly The gap between the tracks must be identical at the front in the middle and at the rear of the lane If the gap varies check that the track gauge bars are properly positioned Also check the inserts at each end of the tracks If the inserts are defective replace the trac
28. ith the technical data indicated in the order confirmation The supply of Pushback lanes comprises tracks and movable carts These com ponents must be assembled and installed on a rack Any changes to the components and their position in the lane eliminates Inter roll s responsibility and will be considered as unintended use of the Cart Push back Make sure that the available height between two levels complies with the spec ifications of the rack The assembly and installation must be carried out by qualified personnel in com pliance with the instructions concerning assembly and installation and with safety instructions The manager of the team responsible for assembling the lanes must be techni cally competent and trained concerning the following e The products and their use e The dangers inherent in the assembly of heavy or cumbersome components in high places e The risks related to incorrect assembly Uncontrolled speeds or propulsion of loads stored on the lane may may cause serious accidents e The adjustments required for correct operation of the lanes Interroll can provide dedicated training on the Cart Pushback We will send a quote on request Version 1 2 Jan 2015 Assembly and installation EN Translated from French Cart Pushback General rules INTERROLL gt Check the stability of the tracks and carts on the containers before cutting the straps gt Cut the retaining straps on the pallet D
29. ks Version 1 2 Jan 2015 Cleaning maintenance and repair O Translated from ereneh Cart Pushback PF 2430 Component Carts Gauge bar Tasks Checks Check that no wheels are miss ing Check the lift out protectors Check that the multi purpose push plates are attached to the lowest cart Check that the pallet guide is attached to the top cart Visual inspection Tightening Version 1 2 Jan 2015 EN Translated from French Cart Pushback INTERROLL Date Work required Performed by Pull the train towards the rear and check that each cart is sta ble If a cart is unstable check the wheel attachments Four lift out protectors are welded beneath the carts Move the carts and check that these hooks are not in contact with the tracks The screws on the push plates must be tightened to 89 Nm Tighten if necessary If any of the screws and or nuts are defective only replace with screws or nuts supplied by Interroll A The screws of the guide must be tightened to 89 Nm If any of the screws and or nuts are defective only replace with screws or nuts supplied by Interroll A Inspection no impacts or folds Replace if signs of impacts are present If necessary tighten to 89 Nm A If any of the screws and or nuts are defective only replace with screws or nuts supplied by Interroll Cleaning maintenance and repair 55 56 Container jammed or derailed
30. me spacer Front angle beam Version 1 2 Jan 2015 EN Translated from French Assembly and installation 23 wall amp F pig j E Cart Pushback Step 2 Assembling the tracks Arrangement of the tracks Start by assembling tracks in the lowest lane and work upwards gt Use a forklift to position the tracks AAN NI Inserting the tracks gt Pull the tracks on the beams H E kI i ty oF a JET a Version 1 2 Jan 2015 EN Translated from French Assembly and installation 24 Cart Pushback Version 1 2 Jan 2015 EN Translated from French INTERROLL Adjusting the position of the tracks gt Position two tracks in each lane One on the left and one on the right Check that the lift out guides face inwards gt Check that the tracks rest on all the beams Lift out guides Loading side Securing the tracks gt Use the inserts to attach each end of the tracks to the angle beams The holes in the angle beams correspond to the gap required between the tracks gt Check that the centre to centre distance between the tracks matches the dis tance shown on the assembly plan 012 contact washer M12 30 screw 89 Nm Assembly and installation 25 26 Cart Pushback INTERROLL Option box beams gt If box beams are installed at the rear of the lane remember to assemble the stop angle Use the fixing angles
31. o not cut the plastic straps linking the carts to one another before they are installed in the rack gt Once the straps have been cut do not move the container gt Make sure you do not damage the tracks and carts during assembly gt Recommended tightening torque of the tracks on the beams 89 Nm gt Clean the work site at the end of the installation Do not leave any components or tools in the installation area Make sure that the plastic straps linking the carts to one another are removed gt Test the lanes one by one as they are assembled Adjusting the slope gt The beams supplied automatically adjust the slope of the Cart Pushback tracks to 3 gt Make sure that each type of beam is installed in the right place in accordance with the rack drawings Version 1 2 Jan 2015 EN Translated from French Assembly and installation 13 Cart Pushback INTERROLL Assembly The Cart Pushback can be assembled using two methods Choose the solution that is best suited to the applicable safety rules Certain companies may require scissor lifts to be used for work at heights General rules Start by determining the height settings on the ground amp The rack must be attached to the ground such that the complete system is rigid before installing the tracks and carts of the Cart Pushback gt When assembling the frames check that the frame uprights are vertical and that the beams are horizontal A tolerance of
32. oads They are reserved exclusive ly for storing referenced or standardised containers Any other use is considered inappropriate The installation configurations must be applied They are defined in the order con firmation and in this manual All other changes concerning the components and their location in the lane are not authorised To load and unload containers in the lanes a suitable forklift must be used This forklift must meet all the following functions e inclinable upright or forks e upright height adapted to the rack height e sufficient power to push and restrain the containers in the lane Comply with the maximum loads recommended by the rack manufacturer and indicated on the load plate The content must not exceed the maximum load specified by the container supplier or by the standards Unintended use The Cart Pushback may not be used to transport people bulk products or small parts Applications which do not comply with the planned use of the Cart Pushback re quire prior written approval from Interroll Version 1 2 Jan 2015 EN Translated from French Safety A Personal injury Rotating parts Version 1 2 Jan 2015 EN Translated from French Cart Pushback INTERROLL Qualified personnel Qualified personnel are persons who read and understand this manual and tak ing national regulations into account can completely execute incidental work Only qualified and trained personnel may work wi
33. r Stop angle O12 contact washer Drill screw 6 Fixing angle gt Evenly position the track gauge bar s along the lane The gauge bar must not come into contact with the beams Use the most suitable holes gt Check that the centre to centre distance matches the distance on the drawing supplied with the lane 12 contact washer M12 30 screw 89 Nm gt Then secure the gauge bar s in the same way Version 1 2 Jan 2015 Assembly and installation EN Translated from French Cart Pushback INTERROLL Step 3 Assembling the carts Handling the carts gt Take a set of carts using the forks of the forklift Check that the Pushback carts are properly secured by the plastic straps before handling them The forks of the forklift must be suited to the length of the Push back carts Plastic strap Version 1 2 Jan 2015 EN Translated from French Assembly and installation 19 Cart Pushback INTERROLL Start by assembling carts in the highest lane and work downwards gt Deposit the set of Pushback carts on the tracks D INIA gt The person in the scissor lift holds the set of carts by the rear cross tie of the upper cart then adjusts the position of the Pushback carts such that the wheel flanges are inserted in the guides A There is a risk of hands being trapped between the carts when installing Version 1 2 Jan 2015 20 Assembly and installation EN Transla
34. ry such as necklaces or bracelets gt Do not walk on the tracks or carts Only authorized maintenance staff can enter the lanes Safety 7 Cart Pushback INTERROLL Product information Product description The Cart Pushback is used to store heavy loads in LIFO configuration The last pallet loaded into the lane is the first pallet available in the front These heavy loads may be pallets steel or plastic containers or other types of rigid containers They must all the fitted with runners perpendicular to the aisle The containers are stored on movable carts The Cart Pushback is made up of movable carts and tracks attached to the rack Components Multi purpose push plates a rA Lift out protectors Lift out guide Pallet guide Gauge bar Carts Wheel guide Flanged wheel Product inf ti Version 1 2 Jan 2015 ee E EN Translated from French Cart Pushback INTERROLL Possible configurations The Cart Pushback is used to store different types of pallets or containers The standard dimensions offered by Interroll are shown below Please refer to the drawings supplied with the order for specific containers 1 165 mm 1165mm Technical characteristics of the Cart Pushback Gravity based system Load 150 to 1 400 kg per pallet place Regulated speed 0 1 to 0 3 m sec Slope Specified in the order confirmation Generally recommended slope 3 Compatible pallets e Euro pallets
35. ted from French Version 1 2 Jan 2015 EN Translated from French Cart Pushback INTERROLL gt Then cut and remove the plastic straps securing the carts gt Lower the carts towards the front of the lane Check that the lift out protectors of the carts pass under the lift out guides of the tracks Assembly and installation 21 22 Cart Pushback INTERROLL gt Pull the top cart towards the rear of the lane Since the carts are linked to one another the second third and so on carts should follow the top cart gt Once the carts are fully stretched out release them and they should return to their position at the front Repeat this operation for each lane Se e ee ee ee ee 1 SS SS ee ee SL gt Repeat the procedure for the lower levels proceeding from the top lane down wards Level 2 Level 1 gt Once the bay is completed proceed with the assembly of the adjacent bay and so on Version 1 2 Jan 2015 Assembly and installation EN Translated from French Cart Pushback INTERROLL Method 2 assembly without a scissor lift Step 1 Rack gt Start by securing the frames to the ground at the rear of the lane Start by assembling the lowest lane and work upwards gt Secure the beams of the two lowest levels to stabilise the structure Angle beam at the rear of the lane _ Box beam Optional box beam Fra
36. th the Cart Pushback taking the following into account e The relevant manuals and diagrams e The warnings and safety instructions in this manual e The system specific regulations and requirements see Assembly and installa tion page 12 e National or local regulations and requirements for safety and accident preven tion Risks The following list informs you about the various types of dangers or damage that may occur when installing or working with the Cart Pushback gt The equipment may be used by qualified personnel only in any of its operations modes gt Comply with the technical data provided in the order confirmation The contain ers must be sufficiently rigid to withstand the load The size ratio between the base and the height must ensure proper stability of the container gt Follow the assembly and operating instructions gt Use suitable forklifts only gt Check the installation and perform maintenance on a regular basis gt Make sure that no one is near to or beneath the loads Take all necessary pre cautions to prevent the presence of personnel within the lanes Pushback gt Make sure that the loading unloading rows include sufficient lighting so as not to hinder handling operations gt Do not walk on the carts or tracks of the Cart Pushback gt Wear suitable work clothes and Personal Protection Equipment safety shoes gloves etc gt Tie up long hair or wear a cap gt Remove jewelle
37. to attach the tracks to the box beams M12 30 screw 89 Nm ae O12 contact washer Stop angle O12 contact washer Drill screw 6 Fixing angle gt Evenly position the track gauge bar s along the lane The gauge bar must not come into contact with the beams Use the most suitable holes gt Check that the centre to centre distance matches the distance on the drawing supplied with the lane 12 contact washer M12 30 screw 89 Nm gt Then secure the gauge bar s in the same way Always wear a harness and a hard hat in order to move about the installed tracks in safety Version 1 2 Jan 2015 Assembly and installation EN Translated from French Cart Pushback INTERROLL gt Once the tracks have been secured on the lowest level climb onto these tracks to secure the tracks on the next higher level Version 1 2 Jan 2015 EN Translated from French Assembly and installation 27 Cart Pushback INTERROLL Step 3 Assembling the carts Handling the carts gt Take a set of carts using the forks of the forklift Check that the Pushback carts are properly secured by the plastic straps before handling them The forks of the forklift must be suited to the length of the Push back carts Plastic strap Version 1 2 Jan 2015 EN Translated from French 28 Assembly and installation Cart Pushback INTERROLL gt Deposit the set of Pushback
38. ts in position at the front e to prevent the operator from sliding on the carts Walk on the strapped carts with a Strap the carts safety harness Working in a lane Before working in a lane it must be safe e All maintenance operations must be performed by at least two people e Use lifting equipment that complies with the local legislations e g a scissor lift When working on carts in a high lane it is often easier to gain access from un derneath To do this empty and make safe the lane underneath Warning Risk of falling parts due to wheeled carts gt Never walk on carts that are not strapped to the front angle beam gt Use the lifting equipment to approach the lane in which opera tions are to be performed while respecting the local legislation gt Strap the carts at the front The strap must secure the train of carts to the angle beam on the loading unloading side gt Attach yourself to the rack using the safety harness gt Climb onto the carts gt Perform the maintenance gt When the operation is complete move off the carts and remove the harness gt Remove the strap from the front Version 1 2 Jan 2015 EN Translated from Erench Cleaning maintenance and repair 53 Cart Pushback PF 2430 Component Tracks 54 Tasks Checks Check that the rolling surface is clean Check that the slope of the tracks is con stant Check the lift out guides Check the track
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