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Still Tugger train Autarkic E Frame, Original Instructions Manual

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Still Tugger train Autarkic E Frame Original Instructions Manual Download Page 69

Operation

5

Assembling the articulated steering system (driving over ramps)

– Tighten the screws for the tabs (two screws

at both ends of the rigid tiller).

– Tighten the clamping bolts on the rigid tiller

(tightening torque: 30 Nm).

– Secure the clamping bolts with nuts (tight-

ening torque: 50 Nm).

NOTE

The clamping bolts brace the tiller against the

E frame and protect the tiller against lateral

swivelling movements.

50988012117 [EN]

63

Summary of Contents for Tugger train Autarkic E Frame

Page 1: ...Original instructions Tugger train Routenzug 10 Routenzug 16 0504 0506 0508 0510 50988012117 EN 02 2015 ...

Page 2: ......

Page 3: ...sposal of units and hydraulic oil 7 2 Introduction Use of the tugger train 10 Intended use 10 Improper use 10 Requirements for the tow tractor 11 Residual risk 12 Residual risk 12 Danger to employees 12 3 Safety Definition of terms used for responsible persons 16 Personnel 16 Operating company 16 Specialist 17 Basic principles for safe operation 17 Warning regarding non original parts 17 Changes an...

Page 4: ...arkic E frame 35 Mixing E frames and autarkic E frames 35 Mixing E frames and C frames 36 C frame 37 Autarkic system 38 Hydraulic system 39 Pneumatic system 40 Articulated steering system 41 Design and function 41 Components 42 Overview of components 45 Position of the socket pins on the rigid tiller 46 Rigid tiller and hinged tiller two frames 47 Rigid tiller hinged tiller and compensating hinge ...

Page 5: ...ding the autarkic E frames 85 Unloading the autarkic E frames 86 Commissioning the C frames 87 Safety regulations for commissioning 87 Checking the securing bolts for correct function 88 Changing the loading side of the C frames 89 Coupling and uncoupling the C frames 94 Loading the C frames 98 Unloading the C frames 99 Adjusting the fork arms 100 Hydraulic pneumatic coupling 102 Releasing the pre...

Page 6: ...e gasket for leaks 118 Checking the hydraulic system for wear points 118 Checking the lifting function 119 Maintenance intervals for the E frames 121 Maintenance intervals for the autarkic E frames 122 Maintenance intervals for C frames 124 Consumables 125 7 Technical data Load diagram for the C frames 128 Technical data for E frames 129 Technical data for autarkic E frames 131 Technical data for ...

Page 7: ...1 Foreword ...

Page 8: ...ined operators The operating instructions are not intended to be a technical or service manual For technical or maintenance issues that are not covered in these operating instructions please contact your authorised service centre Manufactured by LR Intralogistik GmbH Siemensstraße 15 84109 Wörth an der Isar Germany Distribution and service by STILL GmbH Berzeliusstr 4 22113 Hamburg Germany 2 50988...

Page 9: ...Have a good trip your partner STILL GmbH Berzeliusstr 10 22113 Hamburg Germany CE Symbol CE labelling The manufacturer uses CE labelling to indi cate that the frame complies with the stan dards and regulations valid at the time the frame was placed on the market Compliance is confirmed by the issue of an EC declaration of conformity The CE labelling is attached to the nameplate An unauthorised stru...

Page 10: ...an der Isar We declare that the Device description Corresponding to these operating instructions Device type Corresponding to these operating instructions conforms to the latest version of the Machinery Directive 2006 42 EC Personnel authorised to compile the technical documents See EC declaration of conformity LR Intralogistik GmbH 4 50988012117 EN ...

Page 11: ...that must be strictly adhered to in order to prevent the risk of injuries CAUTION Indicates procedures that must be strictly adhered to in order to prevent material damage and or destruction NOTE For technical requirements that require special attention ENVIRONMENT NOTE To prevent environmental damage Terms and definitions Chassis The chassis is a trailer for picking up loads It is suitable for pic...

Page 12: ... model is only available for E chassis Articulated steering system An articulated steering system consists of a rigid tiller and a hinged tiller The articulated steering system allows driving on ramps and stabilises the tugger train in the vertical plane prevents the frames from rocking Hinged tiller The hinged tiller connects two articulated frame steering rigs and the tow tractor to a tugger tra...

Page 13: ...VIRONMENT NOTE The packaging material must be properly disposed of after delivery of the chassis Disposal of units and hydraulic oil It may be necessary to exchange units as part of maintenance work Exchanged units must then be disposed of A chassis is made of different materials Each of these materials must be disposed of treated or recycled in accordance with regional and national regulations EN...

Page 14: ...1 Foreword Environmental considerations 8 50988012117 EN ...

Page 15: ...2 Introduction ...

Page 16: ... If a tow tractor is used that can travel faster than 15 km h its maximum speed must be limited to 15 km h in order to guarantee safe operation of the chassis The chassis may only be used for its proper purpose as set out and described in these operating instructions If the chassis is to be used for purposes other than those specified in the operating instructions the approval of the manufacturer a...

Page 17: ... be fitted to the tow tractor operating pressure 180 200 bar flow rate approx 10 l min coupling in accordance with ISO 16028 There must be at least 2 litres of hydraulic oil HLP46 in the hydraulic system The hydraulic connection must be fitted close to the tow coupling of the tow tractor The maximum permitted tractive force of the tow tractor must not exceed 16 000 N Hydraulic E frame A suitable hydr...

Page 18: ...eact immediately in the event of any malfunction incident or breakdown etc WARNING All persons that are in the vicinity of the chassis must be instructed regarding these risks that arise through use of the chassis In addition attention must be drawn to the safety regulations in these operating instructions The risks can include Escape of consumables due to leakages rupture of lines and containers ...

Page 19: ...pment so as to comply with the local pro visions for deployment The result must be documented 6 Arb SchG When deployment of the frames in volves similar hazard situations the results may be summarised This summary is de signed to help to meet the requirements of this regulation The summary specifies the primary hazards that in the event of non com pliance are the most frequent causes of acci dents ...

Page 20: ...2 Introduction Residual risk 14 50988012117 EN ...

Page 21: ...3 Safety ...

Page 22: ... is the natural or legal person or group who uses the chassis or on whose authority the chassis are used The operating company must ensure that the chassis are used only for their intended purpose and that they are used in compliance with the safety regulations set out in these operating instructions The operating company must ensure that all operators of the chassis read and understand the safety...

Page 23: ...s based on the results of a hazard assessment or a daily inspection Recent professional involvement in the field of the industrial truck test in question and an appropriate further qualification are essential The qualified person must have experience of carrying out the test in question or of carrying out similar tests Moreover this person must be aware of the latest technological developments regard...

Page 24: ... retrofitting Changes to the E frames that will adversely affect stability load capacity and safety systems among other things must not be made without the manufacturer s approval The E frames must not be converted without written approval from the manufacturer Approval from the relevant authority must be obtained where applicable Damage and defects to safety systems The operator must report any da...

Page 25: ... least 10 minutes with water and then consult an eye specialist If swallowed do not induce vomiting Seek immediate medical attention WARNING Prolonged intensive contact with the skin can result in dryness and irritate the skin Avoid contact and consumption Wear protective gloves After any contact wash the skin with soap and water and then apply a skin care product Immediately change soaked clothin...

Page 26: ...sed during operation of the truck and are hazardous to your health Do not spill the fluids Follow the statutory regulations Do not allow the fluids to come into contact with hot motor parts WARNING These fluids are pressurised during operation of the truck and are hazardous to your health Do not allow to come into contact with the skin Avoid inhaling spray Penetration of pressurised fluids into the sk...

Page 27: ... consumables ENVIRONMENT NOTE Materials that accumulate during repair maintenance and cleaning must be collected properly and disposed of in accordance with the national regulations for the country in which the truck is being used Work must only be carried out in areas designated for that purpose Care must be taken to minimise any environmental pollution Soak up any spilt fluids such as hydraulic o...

Page 28: ...3 Safety Safety regulations for handling consumables 22 50988012117 EN ...

Page 29: ...4 Overviews ...

Page 30: ...w Overall view E frame 1 Frame 2 Ejector 3 Hydraulic pneumatic connection 4 Foot pedal 5 Securing bolts 6 Wheel 7 Lift cylinder 8 Wheel 9 Tiller figure shows standard tiller 10 Hydraulic pneumatic connection 24 50988012117 EN ...

Page 31: ...frame 1 Frame 2 Ejector 3 Edge protection 4 Foot pedal 5 Load wheel 6 Securing bolts 7 Main load bearer 8 Lift cylinder 2x at rear 9 Drive wheel 10 Rigid tiller Articulated steering system B Rigid tiller A Hinged tiller 50988012117 EN 25 ...

Page 32: ...Tyre 5 Foot pedal 6 Securing bolts 7 Fork arms 8 Tiller 9 Collision protection Trolleys A Euro 1 1 trolley standard design B Euro 1 1 h trolley 1 Frame 2 Swivel castors 2 x with wheel brakes arranged diagonally The black wheel prevents electrostatic charges 26 50988012117 EN ...

Page 33: ...e located on the wheel axle so that the trolley wheels are no longer in contact with the ground Loading can performed from the left hand side or the right hand side depending on the alignment of the coupling Loads are secured automatically by the securing bolts These bolts are locked by inserting the trolley The E frame has an ejector This ejector is used to remove the trolleys when changing troll...

Page 34: ...he E frame The accumulator on the hydraulic unit is charged during travel The hydraulic unit therefore has the required energy to lift and lower the autarkic E frame The accumulator must then be recharged Driving the tugger train recharges the accumulator The pressure required to lift the frame is generated over a distance of 20 m depending on the ground conditions The trolleys are raised by 40 mm...

Page 35: ...ually for unloading If the tugger train drives over a chamfer it may result in not all frames being raised the compensating hinge prevents the tugger train from twisting in such cases Articulated steering system driving over ramps Function The articulated steering system allows driving on ramps and stabilises the tugger train in the vertical plane There is no rocking of the frames 50988012117 EN 2...

Page 36: ...ls by hydraulic cylinders allowing the trolleys that the frame holds to be lifted up and set down The trolleys are hydraulically raised by 80 mm for transportation Flexible positioning of the fork arms allows the frame to be adapted for different trolleys The C frame has a load securing system This system is used to secure the trolleys during transport By depressing the foot pedal the interlock se...

Page 37: ... Device designation 3 Manufacturer 4 CE symbol 5 Inspection sticker 6 Manufacturer contact 7 Year of manufacture 8 Max load 9 Device number serial number The frame can be identified from the informa tion on the nameplate Overview Position of the identification plate 50988012117 EN 31 ...

Page 38: ... option For E frames the articulated frame steering rig must consist of two frames of the same type angular frame angular frame or tubular frame tubular frame In general articulated frame steering rigs must be moved with an even number of trailers two or a maximum of four trailers 1 The tiller length for each E frame must be adapted to the preceding frame when viewed in the drive direction refer t...

Page 39: ...eering system driving over ramps General Combinations of the E frame with the articu lated steering system Combinations a Tow tractor b Permissible number of frames Note before assembly refer to the chapter entitled Tugger train combinations Overview 50988012117 EN 33 ...

Page 40: ...ard tiller General Combinations with standard tiller Combinations a Tow tractor b Permissible number of frames for combina tion no 4 max weight of load 4 t Note before assembly refer to the chapter entitled Tugger train combinations Overview 34 50988012117 EN ...

Page 41: ...r to the chapter entitled Tugger train combinations Overview NOTE Combinations with 2 2 frames require a compensating hinge between the second frame and the third frame Mixing E frames and autarkic E frames Mixing E frames with autarkic E frames The mixing of E frames and autarkic E frames is permitted in principle provided that certain conditions are complied with 50988012117 EN 35 ...

Page 42: ... for the train apply weight size length of tillers Mixing E frames and C frames Mixing E frames and C frames The mixing of E frames and C frames is permitted in principle provided that certain conditions are complied with The following conditions must be adhered to C frames and E frames can be connected together using a C E adaptor The C frame must always be connected in front of any E frame All o...

Page 43: ...ain combinations C frame General Combinations of the C frame Combinations a Tow tractor b Permissible number of frames Note before assembly refer to the chapter entitled Tugger train combinations Overview 50988012117 EN 37 ...

Page 44: ...r train combinations Autarkic system General Assembling Autarkic system A Tow tractor B Autarkic E frame C Trolleys Note before assembly refer to the chapter entitled Tugger train combinations Overview 38 50988012117 EN ...

Page 45: ...inations Hydraulic system General Assembling Hydraulic system A Tow tractor with hydraulic unit B E frame C C frame D Trolleys Note before assembly refer to the chapter entitled Tugger train combinations Overview 50988012117 EN 39 ...

Page 46: ...in combinations Pneumatic system General Assembling Pneumatic system A Tow tractor with compressor B E frame C Trolleys Note before assembly refer to the chapter entitled Tugger train combinations Overview 40 50988012117 EN ...

Page 47: ...ering rig 1 Function B Articulated steering tiller A Hinged tiller NOTE The articulated steering system in combina tion with the hinged tiller allows driving on ramps and stabilises the tugger train in the vertical plane All frames remain in contact with the ground on ramps The hinged tiller prevents the frames from being lifted into the air by the tillers when transitioning from level surfaces on...

Page 48: ...with two pre assembled clamping bolts 2 1 Piece Hinged tiller with two pre assembled clamping bolts 3 2 Piece Alignment bolt only one required for assembly 4 1 Piece Socket pin with linch pin 5 1 Piece Socket pin with the marking 5 and linch pin 6 2 Piece Hydraulic hose with rotation lock NOTE The socket pins and the alignment bolts are pre assembled when delivered 42 50988012117 EN ...

Page 49: ...led clamping bolts 2 1 Piece Hinged tiller with two pre assembled clamping bolts 3 2 Piece Alignment bolt only one required for assembly 4 1 Piece Socket pin with linch pin 5 1 Piece Socket pin with the marking 5 and linch pin 6 2 Piece Pneumatic hose NOTE The socket pins and the alignment bolts are pre assembled when delivered 50988012117 EN 43 ...

Page 50: ...o pre assembled clamping bolts 2 1 Piece Hinged tiller with two pre assembled clamping bolts 3 2 Piece Alignment bolt only one required for assembly 4 1 Piece Socket pin with linch pin 5 1 Piece Socket pin with the marking 5 and linch pin NOTE The socket pins and the alignment bolts are pre assembled when delivered 44 50988012117 EN ...

Page 51: ...teering system 2 rigs 2 2 frames A Hinged tiller B Rigid tiller C Compensating hinge 5 Socket pin with the marking 5 Unmarked socket pin The socket pin with the marking 5 has a smaller diameter It must always be fitted to the rear bolted end of the rigid tiller 50988012117 EN 45 ...

Page 52: ...socket pins on the rigid tiller Position of the rigid tiller and the socket pins B Rigid tiller 5 Socket pin with the marking 5 Drive direction NOTE For an overview also refer to the chapter entitled Articulated steering system Compo nents 46 50988012117 EN ...

Page 53: ...inged tiller two frames Position of the rigid tiller and the hinged tiller 1 First frame 2 Second frame A Hinged tiller B Rigid tiller Drive direction NOTE For an overview also refer to the chapter ent itled Tugger train combinations Overview 50988012117 EN 47 ...

Page 54: ...d tiller the hinged tiller and the compensating hinge 1 First frame 2 Second frame 3 Third frame 4 Fourth frame A Hinged tiller B Rigid tiller C Compensating hinge only required for autarkic frames Drive direction NOTE For an overview also refer to the chapter ent itled Tugger train combinations Overview 48 50988012117 EN ...

Page 55: ...th tubular frame On the 1600 x 1200 mm standard frames the outer frame 2 is a tubular frame Smaller frames have angular frames 1 NOTE For E frames the articulated frame steering rig must consist of two frames of the same type angular frame angular frame or tubular frame tubular frame Refer to the chapter ent itled Tugger train combinations Overview 50988012117 EN 49 ...

Page 56: ...ramps A1 Standard tiller B Articulated steering system for driving over ramps always present on autarkic frames optional on standard E frames B1 Hinged tiller B1a Hinged tiller with compensating hinge B2 Reinforced hinged tiller B2a Reinforced hinged tiller with compensating hinge B3 Rigid tiller C Compensating hinge 50 50988012117 EN ...

Page 57: ...em B For autarkic E frames always Hinged tiller B1 B2 Between the tow tractor and the first autarkic E frame Hinged tiller with compen sating hinge B1a B2a Between two articulated frame steering rigs 2 frames 1 articulated frame steering rig Rigid tiller B3 Between two autarkic E frames in the articulated steering system Compensating hinge C Between two articulated frame steering rigs for autarkic ...

Page 58: ...u matic hose The lengths of hoses must be adjusted depending on the lengths of the tillers in accordance with the table Overview A Connection hose routed above B Connection hose to the tow tractor routed below C Connection hose between E frames routed below D Pneumatic connection hose 52 50988012117 EN ...

Page 59: ...er length 1250 mm 478 mm 1500 mm 628 mm A 1500 mm 778 mm 1300 mm 478 mm 1400 mm 628 mm B 1400 mm 778 mm 720 mm 478 mm 840 mm 628 mm C 1050 mm 778 mm Pneumatics Hose length LS Tiller length 1030 mm 478 mm 1150 mm 628 mm D 1500 mm 778 mm 50988012117 EN 53 ...

Page 60: ... Hinged tiller L1 Tiller length E frame Tiller length L1 1200 x 800 478 mm 1200 x 1000 628 mm 1600 x 1200 778 mm The tiller for each E frame must be adapted to the preceding frame when viewed in the drive direction The frame with the largest dimensions must be placed in the first position in the tugger train the second largest frame in the second position etc Exception to this rule As soon as a sma...

Page 61: ...5 Operation ...

Page 62: ...amping bolts Hydraulic hose routed underneath to connect two E frames Figure 3 1 x hinged tiller with two pre assembled clamping bolts Hydraulic hose routed underneath to connect the tow tractor and the E frames Figure 4 2 x alignment bolts only one required for assembly Figure 5 1 x socket pin with the marking 5 see arrow with linch pin Figure 6 1 x socket pin with linch pin 7 1 x tiller support ...

Page 63: ...rame Arrow in drive direction Assembling the rigid tiller WARNING Risk of injury through crushing The frames are heavy Never place hands or feet underneath the raised frames When raising the frame always use appropriate devices wedges wooden blocks to prevent rolling or tipping Use only approved hardwood blocks Use appropriate means wooden blocks to place the frames and the rigid tiller in a horiz...

Page 64: ...system driving over ramps The two socket pins with and without the marking 5 are pre installed when delivered Release the linch pins and pull out the socket pins Screw on the tab see arrow for the second frame in the drive direction 58 50988012117 EN ...

Page 65: ...over ramps Do not tighten the screws The tab see arrow must be loose NOTE The welded on ring on the tab see arrow must be on the underside Rotate the tab if necessary Insert the rigid tiller into the tabs on the second frame in the drive direction 50988012117 EN 59 ...

Page 66: ...n with the marking 5 with Teflon spray Insert the socket pin with the marking 5 tab must be loose CAUTION Component damage due to incorrect socket pin Insert the socket pin with the marking 5 in the second E frame in the drive direction Secure the socket pin using the linch pin 60 50988012117 EN ...

Page 67: ...b see arrow for the first frame in the drive direction Do not tighten the screws The tab must be loose NOTE The welded on ring on the tab see arrow must be on the top Rotate the tab if neces sary Insert the rigid tiller into the tabs on the first frame in the drive direction 50988012117 EN 61 ...

Page 68: ... system driving over ramps Spray the unmarked socket pin with Teflon spray Insert the unmarked socket pin into the first frame in the drive direction If necessary drive in with a Teflon hammer Secure the socket pin using the linch pin 62 50988012117 EN ...

Page 69: ... screws at both ends of the rigid tiller Tighten the clamping bolts on the rigid tiller tightening torque 30 Nm Secure the clamping bolts with nuts tight ening torque 50 Nm NOTE The clamping bolts brace the tiller against the E frame and protect the tiller against lateral swivelling movements 50988012117 EN 63 ...

Page 70: ...ving over ramps Assembling the hinged tiller Before assembly remove the alignment bolt from the first frame in the drive direction Then attach the spring and insert the tiller into the towing jaws Insert the alignment bolt and lock it in place 64 50988012117 EN ...

Page 71: ... Tighten the clamping bolts on the hinged tiller tightening torque 30 Nm Tighten the nuts on the clamping bolts tightening torque 50 Nm NOTE The clamping bolts brace the tiller against the E frame and protect the tiller against lateral swivelling movements 50988012117 EN 65 ...

Page 72: ...fluid escapes from the hydraulic system due to leaks penetration of hydraulic fluids into the skin is particularly dangerous In case of such injury immediate medical assistance is required To avoid injury use appropriate personal pro tective equipment e g protective gloves pro tection goggles skin protection and skin care products CAUTION Risk of component damage In the event of incorrect assembly t...

Page 73: ...Operation 5 Assembling the articulated steering system driving over ramps Attach the pressure line To do this push the plug firmly into the coupling 50988012117 EN 67 ...

Page 74: ...e procedure as previously described Always install the hinged tiller and the rigid tiller alternately refer to the relevant chapters relating to the position of the components Installing and removing the compen sating hinge The following section describes the procedure when loading and unloading is performed on the left hand side in the drive direction Optional for attaching a second articulated f...

Page 75: ...es the tiller against the E frame and provides protection against lateral swivelling movements Removing Loosen the nuts and the clamping bolts Release the coupling pin and remove the compensating hinge from the towing jaws Installing and removing the hinged tiller Installing The following section describes the procedure when loading and unloading is performed on the left hand side in the drive dir...

Page 76: ... two articulated frame steering rigs only for autarkic frames and special frames NOTE For tiller variants refer to the chapter entitled Tiller lengths standard tiller articulated steering system Insert the hinged tiller into the front towing jaws of the second articulated frame steer ing rig Insert the coupling pin and lock it in place 70 50988012117 EN ...

Page 77: ...me and provides protection against lateral swivelling movements Insert the hinged tiller on the second articulated frame steering rig into the towing jaws of the compensating hinge Insert the coupling pin and lock it in place The illustration shows the hinged tiller with the compensating hinge between two articulated frame steering rigs The figure shows the hinged tiller when loading and unloading ...

Page 78: ...ing Unlock the coupling pin for the compensat ing hinge and pull out the hinged tiller of the rear articulated frame steering rig from the towing jaws of the compensating hinge Loosen the nuts and the clamping bolts on the hinged tiller Pull out the coupling pin 72 50988012117 EN ...

Page 79: ...ident from crushing Before moving off make sure that there are no people on or between the individual E frames Observe markings for pedestrian paths and roadways CAUTION Components can be damaged by incorrect driving Reverse travel with the tugger train is prohibited Tugger trains may only drive over ramps when articulated frame steering rigs are used 50988012117 EN 73 ...

Page 80: ...ts Loading CAUTION Components can be damaged by incorrect loading The E frames must not be loaded or unloaded on gradients Make sure that the trolleys are correctly inserted in the E frames The securing bolts must be fully visible We recommend attaching four E frames to the tow tractor If the maximum possible number of five E frames is used the total load of 4 t across the whole train must not be e...

Page 81: ...ition The securing bolts see arrow must extend at least 26 mm locking position When the foot pedal is actuated no inter lock the securing bolts must retract again Checking the securing system for correct function Check if the trolley can roll out of the lowered E frame despite the securing bolt being extended 50988012117 EN 75 ...

Page 82: ...t the opening is on the right hand side in the drive direction E chassis NOTE The tiller s orientation when it is mounted on the chassis depends on whether the trolleys are to be loaded into the chassis from the left or right NOTE Appearance of the frame and tiller may vary slightly from the figure Coupling the E frames WARNING Risk of trapping or crushing Do not reach into the open coupling The to...

Page 83: ...rive direction Tighten the clamping bolts on the standard tiller tightening torque 30 Nm Tighten the nuts on the clamping bolts tightening torque 50 Nm NOTE This tightening braces the tiller against the E frame and provides protection against lateral swivelling movements Fasten the standard tiller to the frame using an alignment bolt Insert the towing eye of the standard tiller into either the tow...

Page 84: ...draulic system In case of such injury immediate medical assistance is required To avoid injury use appropriate personal protec tive equipment e g protective gloves industrial goggles skin protection and skin care products All other chassis must be attached to chas sis in front of them and must be connected to the pressure lines To do this proceed as described above Uncoupling the E frames WARNING ...

Page 85: ...ne refer to the chapter entitled Disconnecting the plug connector Release then pull out the alignment bolt for the towing eye Remove the standard tiller from either the towing jaws of the tow tractor or from the holding fixture of a preceding frame Re insert the alignment bolt and secure it in place NOTE The alignment bolt prevents the frames beco ming uncoupled accidentally It uses spring force to...

Page 86: ... bolts must be fully visible CAUTION Trolleys with heavy and tall loads may tip over when cornering Lash the load to the trolleys if necessary Place the load on the trolleys with the centre of gravity as low as possible Apply the parking brake on the tow tractor to secure it against rolling away The driver must leave the tow tractor to lower the frames This deactivates the driver detection system ...

Page 87: ...nloading the trolleys Never unload on chamfers or gradients When unloading the trolleys ensure that there is sufficient space to unload the trolleys safely and to manoeuvre the trolleys safely Depending on how heavily a trolley is loaded the driver must be prepared to exert a greater amount of force to brake or steer the trolley if necessary WARNING Risk of injury from becoming trapped Loading and ...

Page 88: ...cure it against rolling away The driver must leave the tow tractor to lower the frames The frames can now be unloaded Actuate the foot pedal of the frame to be unloaded until the securing bolts are fully retracted unlocked The ejector automatically knocks the trolley to make the trolley roll out of the frame Pull the trolley straight out of the frame Commissioning the autarkic E frames Safety regu...

Page 89: ...ccording to the side on which the Trolleys are to be loaded and unloaded Loading and unloading trolleys from left Position the frames so that the opening is on the left hand side in the drive direction Loading and unloading trolleys from right Position the frames so that the opening is on the right hand side in the drive direction NOTE The tiller s orientation when it is mounted on the frame depen...

Page 90: ... torque 50 Nm NOTE The clamping bolts brace the tiller against the E frame and protect the tiller against lateral swivelling movements Fasten the hinged tiller to the frame using an alignment bolt Insert the towing eye of the standard tiller into either the towing jaws of the tow tractor or into the compensating hinge of a preceding articulated frame steering rig Fasten the towing eye using an ali...

Page 91: ...ding must only be performed by the driver The driver must ensure that no other persons are in the vicinity of the frames The frames must not be loaded or unloaded on gradients Make sure that the trolleys are correctly inserted into the frames The securing bolts must be fully visible CAUTION Trolleys with heavy and tall loads may tip over when cornering Lash the load to the trolleys if necessary Pl...

Page 92: ...ing the autarkic E frames Unloading the autarkic E frames DANGER Risk of crushing when unloading the trolleys Never unload on chamfers or gradients When unloading the trolleys ensure that there is sufficient space to unload the trolleys safely and to manoeuvre the trolleys safely Depending on how heavily a trolley is loaded the driver must be prepared to exert an appropriate amount of force to brak...

Page 93: ...secure it against rolling away Actuate the foot pedal until resistance is felt the frame is lowered The ejector automatically knocks the trolley to make the trolley roll out of the frame Pull the trolley straight out of the frame Commissioning the C frames Safety regulations for commission ing DANGER Risk of accident from crushing Before moving off make sure that there are no people on or between ...

Page 94: ...tow tractor or the attached frames can result in accidents If damage or other defects are identified on the frames during the following inspections do not use these frames until they have been repaired properly Do not remove or deactivate safety systems or switches Checking the securing bolts for correct function Move the ejector into the rear end position The securing bolt must extend at least 26 ...

Page 95: ... the C frames The C frame can be loaded from the left hand side or the right hand side as seen in the drive direction Care must be taken to ensure that the tiller and the towing jaws are correctly fitted CAUTION Risk of damage When uncoupling the C frames disconnect the hydraulic line between multiple frames or the hydraulic line from the tow tractor The system must be depressurised when uncoupling...

Page 96: ...5 Operation Commissioning the C frames Coil the hydraulic line into a loose loop and insert into the holding device Detach the chain on the tiller Remove the linch pin from the pin 90 50988012117 EN ...

Page 97: ...n 5 Commissioning the C frames Push the bolt out of the tiller support Pull out the bolt from the tiller support Carefully set down the tiller Remove the towing jaws Remove the tiller support 50988012117 EN 91 ...

Page 98: ...osition To do this tighten the mounting screws of the towing jaws by hand Tighten the mounting screws of the towing jaws tightening torque 200 Nm Fix the tiller support in a new position To do this tighten the mounting screws of the towing jaws by hand 92 50988012117 EN ...

Page 99: ...nting screws of the tiller support tightening torque 200 Nm Insert the tiller into the support mounting and push in the bolt Secure the bolt using the linch pin Attach the chain to the eyelet Connect the hydraulic hose line to the C frame 50988012117 EN 93 ...

Page 100: ... C frames Align the frames in the drive direction The frames are aligned according to the side on which the trolleys are to be loaded and unloaded Loading and unloading trolleys from left Position the frames so that the opening is on the left hand side in the drive direction Loading and unloading trolleys from right Position the frames so that the opening is on the right hand side in the drive dir...

Page 101: ...c system In case of such injury immediate medical assistance is required To avoid injury use appropriate personal pro tective equipment e g protective gloves pro tection goggles skin protection and skin care products CAUTION Risk of damage The system must be depressurised when uncoup ling When coupling and uncoupling the frames always disconnect the pressure line between multiple frames or the pre...

Page 102: ...n by 90 and lock it in place or insert the coupling jaw bolt from the frame and secure the bolt in place Attach the safety chain to the eyelet on the tiller Attach the pressure line to the tow tractor or a preceding frame Depending on the design of the tugger train these lines are either hydraulic lines or pneumatic lines refer to the chapter entitled Connecting the plug connector Check whether th...

Page 103: ...ctor Disconnect the pressure line refer to the chapter entitled Disconnecting the plug connector Make sure that the safety chain on the tiller is attached to the eyelet on the tiller Release and remove the towing pin from the tow tractor or a preceding frame To do this depending on the version press down the towing pin in the tow coupling on the tow tractor turn the towing pin 90 and pull it out o...

Page 104: ...e securing bolts are fully visible CAUTION Trolleys with tall heavy loads may tip over when cornering Lash the load to the trolleys if necessary Place the load on the trolleys with the centre of gravity as low as possible Apply the parking brake on the tow tractor to secure it against rolling away Lower the frame by actuating the lowering switch on the tow tractor Adjust the position of the fork a...

Page 105: ...safely Depending on how heavily a trolley is loaded the driver must be prepared to exert a greater amount of force to brake or steer the trolley if necessary WARNING Risk of injury from becoming trapped Loading and unloading must only be performed by the driver Before lowering the frames the driver must ensure that there are no other persons near the trolleys WARNING Risk of injury If you press th...

Page 106: ...ks the trolley to make the trolley roll out of the frame Pull the trolley straight out of the frame and take to the required unloading site Adjusting the fork arms WARNING Risk of trapping or crushing Do not reach between the frame and the fork arms To release the interlock turn the locking lever in an anti clockwise direction 100 50988012117 EN ...

Page 107: ... locking lever hits the frames so that it cannot be turned sufficiently to release or secure the lock it can be reset To do this pull out the locking lever towards the retaining spring and turn against the desired direction of rotation Then re engage the locking lever and turn in the desired direction of rotation again Repeat this procedure as required until the interlock on the fork arm is fully r...

Page 108: ...roducts Releasing the pressure from the hy draulic system Leave the tow tractor and or actuate the lift lower switch on the tow tractor Lift and lower the frame repeatedly until the frame no longer lifts only on autarkic version Hydraulic connection to the trailer Connecting the rotation lock WARNING Hydraulic fluid is pressurised during operation and is hazardous to your health Do not allow the flu...

Page 109: ...ng the rotation lock WARNING Hydraulic fluid is pressurised during operation and is hazardous to your health Do not allow the fluid to come into contact with the skin Avoid inhaling spray Penetration of hydraulic fluids into the skin is particularly dangerous if these fluids escape at high pressure due to leaks in the hydraulic system In case of such injury immediate medical assistance is required To ...

Page 110: ...oupling are aligned B Press the ring on the connector sleeve in the direction of the ball B and disconnect the plug connector C NOTE The ball on the coupling must lie in the groove on the connector sleeve NOTE Appearance of theguard plateonthe hydraulic coupling may vary slightly from the figure 104 50988012117 EN ...

Page 111: ...assistance is required To avoid injury use appropriate personal pro tective equipment e g protective gloves pro tection goggles skin protection and skin care products CAUTION Risk of damage The plug connector and the coupling must always be clean Only use hoses in accordance with the table Couple the frames Release the pressure from the system Attach the pressure line To do this push the plug firml...

Page 112: ... system In case of such injury immediate medical assistance is required To avoid injury use appropriate personal pro tective equipment e g protective gloves pro tection goggles skin protection and skin care products Release the pressure from the system Turn the ring on the connector sleeve until the two markings on the coupling are aligned Gently press the ring on the connector sleeve in the direc...

Page 113: ...signals can still be heard WARNING In areas where the use of mobile phones is prohi bited it is absolutely not permitted to use a mobile phone or radio telephone Switch off the devices CAUTION Components can be damaged by incorrect driving Reverse travel with the tugger train is prohibited Tugger trains with the autarkic system must always be equipped with an articulated steering system for stabil...

Page 114: ...aintain a safe braking distance from vehicles and persons in front and must always have the tugger train under control He must avoid stopping suddenly turning at speed and overtaking in dangerous places or in blind spots Initial driving practice must be carried out in an empty space or on a clear roadway The following are forbidden when driving Carrying passengers on the frames or the fork arms Wa...

Page 115: ...nt Up to 7 The ends of the ramp do not have to be rounded 7 to 18 Between the start of the ramp and the middle section section A and between the middle section and the end of the ramp see figure not to scale Diagram A Distance between the start of the ramp and the end of the ramp r Radius min 40 m E frames standard tiller CAUTION Components can be damaged by driving on upward or downward gradients ...

Page 116: ...e middle section section A and between the middle section and the end of the ramp see figure not to scale Diagram A Distance between the start of the ramp and the end of the ramp r Radius min 40 m Reverse travel Reverse travel Frames tillers and hydraulic components are severely damaged by reverse travel The operational safety is then no longer guaranteed CAUTION Components can be damaged by incorr...

Page 117: ...be damaged by incorrect driving At the maximum permitted steering angle the tillers must not make contact with either the frames or the hydraulic components Steering angle NOTE Recommendation Perform a test drive to check the steering angle 50988012117 EN 111 ...

Page 118: ...ncoming traffic with CX T or R 06 b in cm without oncoming traffic with CX T or R 06 c in cm with CX T or R 06 In loading and unloading zone a in cm with CX T or R 06 2 374 200 220 240 200 290 3 561 200 260 280 200 290 4 748 200 300 320 200 290 1210 x 810 5 935 200 340 360 200 290 2 402 230 250 270 200 330 3 603 230 290 310 200 330 4 804 230 330 350 200 330 1210 x 1010 5 1005 230 370 390 200 330 112...

Page 119: ...0 3 753 250 340 360 200 370 4 1004 250 400 420 200 370 1610 x 1210 5 1255 250 460 480 200 370 This table shows only the technical values for a standard frame Different dimensions additional units etc may produce different values 50988012117 EN 113 ...

Page 120: ...ng traffic with CX T or R 06 b in cm without oncoming traffic with CX T or R 06 c in cm with CX T or R 06 In loading and unloading zone a in cm with CX T or R 06 1 384 275 275 80 390 2 768 300 300 80 390 3 1152 325 325 80 390 2000 x 1200 4 1536 350 350 80 390 This table shows only the technical values for a standard frame Different dimensions additional units etc may produce different values 114 509...

Page 121: ...6 Servicing ...

Page 122: ...eely and it is possible to work while maintaining an ergonomic posture Safety devices After service work and repair work all safety devices must be reinstalled and checked to ensure that they are in working order Maintenance instructions Maintenance work must be carried out in ac cordance with the following maintenance in tervals The intervals are defined for standard use Shorter maintenance interv...

Page 123: ...d personnel using suitable tools The annual testing must be conducted by a specialist The specialist s evaluation must be unaffected by operational and economic conditions and be conducted solely from a safety standpoint The specialist must have the sufficient knowl edge and experience to be able to assess the condition of the frames and the effectiveness of the protective devices according to tech...

Page 124: ...oil Checking the hydraulic system for wear points Checking the hydraulic system for wear points WARNING Hydraulic oil under pressure can escape from leaking lines and cause injuries to the skin Wear suitable protective gloves protection goggles etc WARNING Hydraulic hoses become brittle over time Hydraulic hoses must not be used for a period longer than six years The BGR 237 specifications must be ...

Page 125: ...s heavily damaged or corroded Pipes must be replaced if There is abrasion and a loss of material There are any unnatural deformations and bending stress is detected They are leaking Checking the lifting function Checking the lifting function WARNING Hydraulic fluid is pressurised during operation It is hazardous to your health Do not allow the fluid to come into contact with the skin Avoid inhaling ...

Page 126: ... work C frames Couple the C frame to the tow tractor and connect the hydraulic connection hose Enter the tow tractor and actuate the lifting lowering switch on the tractor All frames must lift or lower 120 50988012117 EN ...

Page 127: ...d correct operation spray the bolts x Check the bearings on the securing bolts ease of movement x Clean the mechanism on the E frame x Check the mechanism for general ease of movement x Check that all bolts and nuts are present and that they are securely fitted x Check for the red warning colour on the securing bolts x Chassis Check that the springs are operating correctly x Check the pressure line...

Page 128: ...an the securing bolts on the E frame check the bolts for damage and correct operation spray the bolts x Check the bearings on the securing bolts ease of movement x Clean the mechanism on the E frame x Check the mechanism for general ease of movement x Check that all bolts and nuts are present and that they are securely fitted x Check for the red warning colour on the securing bolts x Check that the...

Page 129: ...Servicing 6 Maintenance intervals for the autarkic E frames Wheels Check the wheels for wear and ease of movement x Drive Check the drive belt for wear and replace if necessary x 50988012117 EN 123 ...

Page 130: ...ement x Clean the mechanism on the C frame x Check the mechanism for general ease of movement x Check that all bolts and nuts are present and that they are securely fitted x Check for the red warning colour on the secur ing bolts x Chassis Check that the springs are operating correctly x Check the pressure lines and pressure connec tions for leaks x Check the hoses for wear points leaks x Hy drauli...

Page 131: ...for the wheels Grease Lubricating grease KP 2 K 30 DIN 51825 E frame Unit Consumables Specification Securing bolts Lubricant PTFE Longlife Teflon spray E chassis mechanism Lubricant PTFE Longlife Teflon spray Lubricating nipple for the wheels Grease Lubricating grease KP 2 K 30 DIN 51825 Securing bolts Colour Red warning colour Autarkic E frame Unit Consumables Specification Securing bolts Lubricant P...

Page 132: ...6 Servicing Consumables 126 50988012117 EN ...

Page 133: ...7 Technical data ...

Page 134: ...7 Technical data Load diagram for the C frames Load diagram for the C frames A Load centre of gravity distance B Load kg 128 50988012117 EN ...

Page 135: ...70 1666 Length l3 mm 1390 1390 1790 Length l4 mm 1900 2040 2650 Length l5 mm 355 355 555 Width b1 mm 1007 1207 1417 Width b2 mm 837 1037 1240 Height h1 mm 228 228 228 Dimensions Height h2 mm 310 310 310 Max driving speed depending on the tow tractor km h 15 15 15 Turning circle CX T R 06 tow tractor 2 x Wa mm 3900 4200 4200 4500 5500 5800 Turning radius CX T R 06 tow tractor Wa mm 1950 2100 2100 2...

Page 136: ...ical data Technical data for E frames For load carriers up to a maximum width of 810 mm For load carriers up to a maximum width of 1010 mm For load carriers up to a maximum width of 1210 mm 130 50988012117 EN ...

Page 137: ...90 1090 1490 Length l2 mm 1270 1270 1666 Length l3 mm 1390 1390 1790 Length l4 mm 1900 2040 2650 Length l5 mm 355 355 555 Width b1 mm 1007 1207 1417 Width b2 mm 837 1037 1240 Height h1 mm 228 228 228 Dimensions Height h2 mm 310 310 310 Max driving speed depending on the tow tractor km h 15 15 15 For load carriers up to a maximum width of 810 mm For load carriers up to a maximum width of 1010 mm Fo...

Page 138: ...h l1 mm 2000 Length l2 mm 2760 Length l3 mm 4140 Width b1 mm 1540 Width b2 mm 1250 Height h1 mm 228 Dimensions Height h2 mm 755 Max driving speed depending on the tow tractor km h 15 Turning circle 2xWa mm 6200 Turning radius Wa mm 3100 Maximum dimensions of load carrier mm 1900 x 1200 For load carriers up to 1210 mm wide CX T or R 06 tow tractor 132 50988012117 EN ...

Page 139: ...ifting function 119 Consumables Consumables for service work 125 Disposal 21 Safety information for handling oils 19 Copyright and trademark rights 5 Coupling and uncoupling Autarkic E frame 83 C frame 94 E frame 76 Coupling and uncoupling the frames Autarkic E frame 83 C frame 94 E frame 76 D Daily checks Checking the securing bolts for correct function C frames 88 Checking the securing bolts for...

Page 140: ... Autarkic E frame 85 C frame 98 Changing the loading side of the C frames 89 E frame 80 Loading the frames Autarkic E frame 85 C frame 98 E frame 80 M Maintenance intervals Autarkic E frame 122 C frames 124 E frame 121 O Oils 19 Operating company 16 P Packaging 7 Personnel 16 Plug connector Connecting 105 Disconnecting 105 Hydraulic connection to the trailer 102 Pneumatics Connecting the plug conn...

Page 141: ...Tiller lengths standard tiller articulated steering system 54 Tiller systems Standard tiller articulated steering system for E frames 50 Tugger train combinations Autarkic E frame 35 Autarkic system 38 C frame 37 E frames with articulated steering system 33 E frames with standard tiller 34 Hydraulic system 39 Mixing E frames and autarkic E frames 35 Mixing E frames and C frames 36 Overview of comb...

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Page 144: ...STILL GmbH Berzeliusstrasse 10 D 22113 Hamburg Ident no 50988012117 EN ...

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