Manufactured by: LR Intralogistik GmbH Siemensstraße 15 84109 Wörth an der Isar Germany Distribution and service by: STILL GmbH Berzeliusstr. 4 22113 Hamburg Germany 50988046101 EN - 02/2017...
Issue date and topicality The issue date of these operating instructions can be found on the title page. STILL makes continuous efforts to enhance and improve its trucks. These operating instructions are subject to change, and any claims based on the information and/or illustrations contained in them cannot be asserted.
Foreword General EC declaration of conformity in accordance with Machinery Directive Declaration LR Intralogistik GmbH Siemensstraße 15 84109 Wörth 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.
Foreword Information about the documentation Information about the documentation Copyright and trademark rights These instructions must not be reproduced, translated or made accessible to third par- ties—including as excerpts—except with the express written approval of the manufacturer. Explanation of information symbols used DANGER Indicates procedures that must be strictly adhered...
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Foreword Information about the documentation be fitted either with a suitable hydraulic power unit, air compressor or electrical system. "Self-sufficient" chassis When using a "self-sufficient" chassis, neither a hydraulic unit nor an air compressor is required. These chassis can raise and lower their load without the need for a hydraulic or pneumatic supply.
Foreword Environmental considerations Tugger train The unit consisting of the frames and a tow tractor is known as the "tugger train". Environmental considerations Packaging When the chassis are delivered, certain parts are packaged to provide protection during transportation. This packaging must be removed completely prior to commissioning.
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Foreword Environmental considerations 50988046101 EN - 02/2017...
Introduction Use of the tugger train Use of the tugger train Intended use The frames are intended solely for the follo- wing purpose: • Picking up and transporting trolleys loaded with equipment in order to transport them to a workplace and replace them with empty trolleys •...
Introduction Use of the tugger train corrosion, or in areas that are particularly dusty. • A chassis must not be loaded or unloaded on slopes or ramps. • Transportation of people is prohibited Requirements for the tow tractor General requirements tow tractor: operating pressure: 180 - 200 bar;...
Introduction Residual risk Autarkic E frame With a reinforced hinged tiller (UPA), the maximum tractive power of the tow tractor • The maximum permitted tractive power of must not exceed 5000 N the tow tractor must not exceed 2,000 N Residual risk Residual risk Residual dangers, residual risks...
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Introduction Residual risk available to the driver. These operating instructions for the frames do not form the operating procedures. A responsible person must be appointed. The structure and equipment of the frames correspond to the Machinery Directive 2006/42/EC and are therefore identified with the CE mark.
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Introduction Residual risk 50988046101 EN - 02/2017...
Safety Definition of terms used for responsible persons Definition of terms used for responsible persons Personnel All operators must: – Have read and understood these operating instructions. – Have completed the appropriate operator training – Observe the basic regulations governing safety at work and accident prevention.
Safety Basic principles for safe operation Specialist A qualified person is defined as a service engineer or a person who fulfils the following requirements: • A completed vocational qualification that demonstrably proves their professional expertise. This proof should consist of a vocational qualification or a similar document.
Safety Basic principles for safe operation CAUTION Installation and/or use of non-original parts may therefore have a negative impact on the design features of the chassis and thus impair active and/or passive driving safety. Before installing such parts, we recommend that approval is obtained from the manufacturer.
Safety Safety regulations for handling consumables Safety regulations for handling consumables Oils DANGER Oils are flammable! – Follow the statutory regulations. – Do not allow oils to come into contact with hot engine parts. – No smoking, fires or naked flames! DANGER Oils are toxic! –...
Safety Safety regulations for handling consumables ENVIRONMENT NOTE Oil is a water-polluting substance! Always store oil in containers that comply • with the applicable regulations. Avoid spilling oils. • Spilt oil should be removed immediately • with oil-binding agents and disposed of according to the regulations.
Safety Safety regulations for handling consumables ENVIRONMENT NOTE Hydraulic fluid is a substance hazardous to water. Always store hydraulic fluid in containers • complying with the regulations. Avoid spilling. • Spilt hydraulic fluid should be removed with • oil-binding agents at once and disposed of according to the regulations.
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Safety Safety regulations for handling consumables 50988046101 EN - 02/2017...
Overviews Overall view Overall view B frame Towing jaws Foot pedal for the locking plates Side guides for the trolley Eccentric for manual lift Wheel Hydraulic/electrical connection Articulated steering system Rigid tiller Hinged tiller 50988046101 EN - 02/2017...
Overviews Overall view Trolleys Euro 1/1 trolley – standard design Frame Euro 1/1 h trolley - raised version (450 mm) Swivel castors (2 x diagonally braked) Euro 1/1 trolley - standard design with ESD-roller (electrically conductive roller) handle Handle 50988046101 EN - 02/2017...
Overviews Description Description B frames The B frame is a device for picking up and transporting roller platforms (trolleys). The trolleys can be loaded with crates, pallets or similar. Between two and a maximum of four B frames can be attached to a single tow tractor. Only articulated frame steering rigs are permitted.
Overviews Description Articulated steering system Design and function Design and function of the articulated steering system Design Articulated frame steering rig 2 Articulated frame steering rig 1 Function Rigid tiller Hinged tiller NOTE The articulated steering system allows driving on ramps and stabilises the tugger train in the vertical plane.
Overviews Tiller system Tiller system Standard tiller/articulated steering system Illustration of the tiller systems Standard system, no driving over ramps Hinged tiller with compensating hinge (only for E frames) Reinforced hinged tiller Standard tiller (only for E frames) Reinforced hinged tiller with compensating Articulated steering system (optional for hinge standard E frames)
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Overviews Tiller system Standard system (A) (no driving over ramps) For standard E frames, no driving over ramps (A1) Standard tiller Between the tow tractor and the first E frame Between the E frames in the standard tugger train Articulated steering system (B) (driving over ramps) Articulated steering system Always for B frames and autarkic E frames* Hinged tiller...
Overviews Tiller system Tiller lengths General A tiller of the appropriate length must be attached to the frame in accordance with the table. Tiller lengths Standard system (standard tiller) Standard tiller Articulated steering system (rigid tiller + hinged tiller) Rigid tiller Hinged tiller Tiller length B frames...
Overviews Tiller system Hose lengths and cable lengths Long hydraulic hose, pneumatic hose and connecting cable The length of the hoses and cables are to be selected depending on the tiller length, as per the table. Overview Connection hose, routed above Connection hose to the tow tractor, routed below Connection hose between E frames, routed...
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Overviews Tiller system Hydraulics Hose length LS Tiller length 1250 mm 478 mm 1500 mm 628 mm 1500 mm 778 mm 1300 mm 478 mm 1400 mm 628 mm 1400 mm 778 mm 720 mm 478 mm 840 mm 628 mm 1050 mm 778 mm Pneumatics (E frame only)
Overviews Articulated steering system Articulated steering system Components for two frames - hydraulic system Quan- Ite- Unit Name tity Piece Rigid tiller with two pre-assembled clamping bolts Piece Hinged tiller with two pre-assembled clamping bolts Piece Alignment bolt (only one required for assembly) Piece Socket pin with linch pin Piece Socket pin with the marking "5"...
Overviews Articulated steering system Components for two frames - electrical system Quan- Ite- Unit Name tity Piece Rigid tiller with two pre-assembled clamping bolts Piece Hinged tiller with two pre-assembled clamping bolts Piece Alignment bolt (only one required for assembly) Piece Socket pin with linch pin Piece Socket pin with the marking "5"...
Overviews Articulated steering system Rigid tiller and hinged tiller (two frames) Positioning the rigid tiller and the hinged tiller on B frames and E frames First frame Second frame Hinged tiller Rigid tiller ⇨ Drive direction NOTE For an overview, also refer to the chapter ent- itled "Tugger train combinations/Overview".
Overviews Articulated steering system Construction overview Articulated steering system for B and E frames (2 rigs/2+2 frames) Hinged tiller Rigid tiller Compensating hinge (required for autarkic and reinforced hinged tiller, otherwise optional) Socket pin with the marking "5" – Unmarked socket pin The socket pin with the marking 5 has a smaller diameter.
Overviews Articulated steering system Rigid tiller, hinged tiller and compensating hinge (2+2 frames) Positioning the rigid tiller, the hinged tiller and the compensating hinge on B and E frames First frame Rigid tiller Second frame Compensating hinge (only required for Third frame autarkic, otherwise optional) Fourth frame...
Overviews Labelling points Labelling points Identification plate Device designation Max. pulling force Device type Year of manufacture Serial no. Manufacturer contact Max. load CE symbol Tare weight Inspection sticker The frame can be identified from the informa- tion on the nameplate. 50988046101 EN - 02/2017...
Overviews Tugger train combinations Tugger train combinations Overview Permissible Driving over Arrange- number of Tiller length Frame Tiller Load ramps ment frames 2 (1+1) Rigid + identification B frames hinged* 4 (2+2) plate identification C frame Standard plate identification plate Standard E frame identification...
Overviews Tugger train combinations Hydraulic system Assembling Tow tractor with a hydraulic power unit and Tow tractor with a hydraulic power unit and a a maximum tractive power of up to 2000 N maximum tractive power of up to 16,000 N (5000 N with reinforced hinged tiller) E frame 50988046101 EN - 02/2017...
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Overviews Tugger train combinations B frame C frame Trolleys Before assembly, refer to the chapters entitled "Tugger train combinations/Overview" and "Re- quirements for the tow tractor". 50988046101 EN - 02/2017...
Overviews Tugger train combinations Electrical system Assembling Tow tractor with a suitable interface and a E frame maximum tractive power of up to 2000 N B frame (5000 N with reinforced hinged tiller) Trolleys 50988046101 EN - 02/2017...
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Overviews Tugger train combinations Before assembly, refer to the chapters enti- tled "Tugger train combinations/Overview" and "Requirements for the tow tractor". 50988046101 EN - 02/2017...
Overviews Tugger train combinations B frames and E frames with articu- lated steering system General Combinations of the B frame or E frame with the articulated steering system Combinations Tow tractor Permissible number of frames Note before assembly; refer to the chapter entitled "Tugger-train combinations/Overview" Mixing B or E frames with autarkic E frames Conditions...
Overviews Tugger train combinations The following conditions must be adhered to: • The autarkic E frames must be positioned behind the hydraulic, pneumatic or electri- cal B and E frames in the tugger train • A mixed rig of this type must be operated as an articulated steering system •...
Operation Commissioning the B frames Commissioning the B frames Testing before initial commissioning Roadways Before initial commissioning, check the tugger train components for any damage that Before initial commissioning, the roadways might have occurred during transport. The must be checked for aisle widths, room for operating instructions, in particular the safety manoeuvring, obstacles, safety distances, information, must be read and understood...
Operation Commissioning the B frames Safety regulations for commission- Driving DANGER Risk of accident from crushing! – Before moving off, make sure that there are no people on or between the individual frames. – Observe markings for pedestrian paths and roadways.
Operation Commissioning the B frames 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 in a way that ensures that the centre of gravity as low as possible.
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Operation Commissioning the B frames WARNING Risk of injury from becoming trapped! – Loading and unloading must be performed only by the driver. Make sure that no other persons are in the vicinity of the frames. WARNING Risk of injury! When actuating the foot pedal to unload the trolley, the trolley may roll towards the driver! –...
Operation Commissioning the B frames Manually lifting the B frames The B frames can be moved only once they have been lifted. For this reason, you can also manually lift the frames if the hydraulic system or the electrical system of the tow tractor is not working or if the frame is not coupled to the tow tractor.
Operation Hydraulic system Hydraulic system Releasing the pressure from the hydraulic system 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. –...
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Operation Hydraulic system CAUTION Risk of component damage! – In the event of incorrect assembly, the coupling will become damaged during operation. – The plug connector and the coupling must always be clean. – Only use hoses in accordance with the table. –...
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Operation Hydraulic system – Turn the ring on the connector sleeve (A) until the two markings on the coupling 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!
Operation Hydraulic system Connecting the plug connector Connecting 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.
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Operation Hydraulic system 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.
Operation Electrical system Electrical system Connection assembly for the electrical system Lower the system – Leave the tow tractor or actuate the lift/lower switch on the tow tractor. Connecting the connection assembly CAUTION Risk of damage! – Protect the plug against contamination and water.
The status LED provides information about the operating status of the motor. DANGER Risk of injury from electrical voltage. Repair work on the electrical system must only be carried out by an authorised STILL technician. Operating status Green LED Red LED Motor ready...
Operation Assembling the articulated steering system Assembling the articulated steering system Assembling the articulated steering system (using the example of an E frame - hydraulics routed underneath) Scope of delivery Scope of delivery for two frames: • Figure 1: 1 x rigid tiller with two pre-assem- bled clamping bolts.
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Operation Assembling the articulated steering system Preparation The following section describes the procedure for a tugger train with two frames when loading and unloading is performed on the left-hand side in the drive direction. The socket pins and the alignment bolts are pre-assembled when delivered.
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Operation Assembling the articulated steering system 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.
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Operation Assembling the articulated steering system – 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.
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Operation Assembling the articulated steering system – Spray the socket pin 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" into the second frame in the drive direction.
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Operation Assembling the articulated steering system – Screw on the tab (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.
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Operation Assembling the articulated steering system – 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. 50988046101 EN - 02/2017...
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Operation Assembling the articulated steering system – Tighten the screws for the tabs (two screws at both ends of the rigid tiller). – Tighten the clamping bolts of the rigid tiller using the dome nuts (tightening torque 30 Nm). – Secure the clamping bolts with nuts (tight- ening torque: 50 Nm).
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Operation Assembling the articulated steering system 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. 50988046101 EN - 02/2017...
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Operation Assembling the articulated steering system – Tighten the clamping bolts of the hinged tiller using the dome nuts (tightening torque 30 Nm). – Secure the clamping bolts with nuts (tight- ening torque: 50 Nm). NOTE The clamping bolts brace the tiller against the frame and protect the tiller against lateral swivel-shift movements.
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Operation Assembling the articulated steering system CAUTION Risk of component damage! In the event of incorrect assembly, the coupling will become damaged during operation. Before assembly, release the pressure from the hydraulic system; refer to the chapter entitled "Hydraulic/pneumatic coupling". 50988046101 EN - 02/2017...
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Operation Assembling the articulated steering system – Attach the pressure line. To do this, push the plug firmly into the coupling. 50988046101 EN - 02/2017...
Operation Assembling the articulated steering system – Couple the hinged tiller with the tow tractor. Connect the wire to the tow tractor. NOTE To release the hydraulic coupling, refer to the chapter entitled "Plug connector". – The tugger train is ready for use. Additional frames can be fitted to the tugger train by following the same procedure as previously described.
Operation Assembling the articulated steering system – Tighten the clamping bolts evenly (tighten- ing torque: 30 Nm) and secure the clamping bolts with nuts (tightening torque: 50 Nm). NOTE This tightening braces the tiller against the frame and provides protection against lateral swivelling movements.
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Operation Assembling the articulated steering system The image shows the hinged tiller (1) with the compensating hinge (2) between two articulated frame steering rigs (required for autarkic E frames and reinforced hinge tillers, otherwise optional). NOTE For tiller variants, refer to the chapter entitled "Tiller lengths (standard tiller/articulated steering system)".
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Operation Assembling the articulated steering system – 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.
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Operation Assembling the articulated steering system – Loosen the nuts and the clamping bolts on the hinged tiller. – Pull out the coupling pin. – Pull out the hinged tiller. 50988046101 EN - 02/2017...
– Do not use devices during travel or when hand- For example, the driver must drive slowly ling loads. around corners, in tight passageways, when – Set the volume so that warning signals can still driving through swing-doors, at blind spots or be heard. on uneven roadways.
Operation Driving Driving over ramps NOTE Articulated steering system required for driving over ramps! WARNING Risk of accident from failing to adjust speed! – Max. speed when driving over ramps: 6 km/h. Gradient on the ramp Comment Up to 7% The ends of the ramp do not have to be rounded Radius between the horizontal and the chamfer, see diagram 7% to 18%...
Operation Driving E frames (standard tiller) CAUTION Components can be damaged by driving on upward or downward gradients! It is forbidden to drive on ramps. Reverse travel Reverse travel Frames, tillers and hydraulic components are severely damaged by reverse travel. The operational safety is then no longer guaranteed! CAUTION...
Operation Driving Steering angle CAUTION Components can 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. For illustrative purposes NOTE Recommendation: Perform a test drive to check the steering angle.
Operation Roadways Roadways Minimum aisle widths for B frames For 90° curves, depending on the length of the train 50988046101 EN - 02/2017...
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Operation Roadways 50988046101 EN - 02/2017...
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Operation Roadways Aisle width "a" Corner Aisle width "c" Minimum aisle Length of train with corner chamfer without corner widths for B Quantity [mm] without a chamfer [mm] "b" [mm] chamfer [mm] frames in 90° B frame tow tractor curves* (without oncoming traffic) with CX-T / LTX 70 LiftRunner 4038...
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Operation Roadways For 180° curves, depending on the length of the train 50988046101 EN - 02/2017...
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Operation Roadways 50988046101 EN - 02/2017...
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Operation Roadways Aisle width Distance [mm] in Aisle width Aisle width between Minimum aisle Length of loading and "d" [mm] "e" [mm] the aisles widths for B Number of train [mm] unloading "f" [mm] frames in 180° B frames without a zones curves* tow tractor...
Maintenance Safety regulations for maintenance Safety regulations for maintenance General information General information To prevent accidents during service work and inspections, all necessary safety measures must be taken, e.g.: • Place the frames on which service work or repair work is to be performed on a level surface in a cordoned-off, safe location.
Maintenance Safety regulations for maintenance • Specific national regulations for the frame or individual components • Outdoor use For maintenance tasks, only use original spare parts, and only use consumables that have been prescribed in the overview of consumables. Personnel qualifications Qualifications of personnel Service work and inspections must be per- formed correctly by qualified and authorised...
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Maintenance Safety regulations for maintenance WARNING Hydraulic hoses become brittle! Hydraulic hoses should not be used longer than 6 years. The specifications of BGR 237 should be complied with. Deviating national laws are to be taken into account. – Check pipe and hose connection screw joints for leaks (traces of oil).
Maintenance Maintenance intervals for B frames Maintenance intervals for B frames Daily Quarterly Unit Task Functional test of the locking mecha- nism Check if the trolley can roll out of the B frame despite the locking plates being raised Functional check of the manual lifting function of the frames;...
Technical data B frames - single loadable B frames - single loadable Top view Side view Manufacturer STILL STILL LiftRunner LiftRunner Manufacturer's type B frame B frame designation 1200 x 800 mm 1200 x 1000 mm Key data Load dimension...
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For multiple trailers, the maximum towing load across the entire tugger train is 4 t (depending on the maximum towing load of the tow tractor). Applies only when using STILL LiftRunner-trolleys. Depending on the tow tractor. NOTE This type sheet, based on VDI directive 2198, states only the technical values of the standard device.
Technical data B frames - triple loadable B frames - triple loadable Top view Side view Manufacturer STILL STILL LiftRunner LiftRunner Manufacturer's type B frame B frame designation triple loadable triple loadable 800 x 600 mm 1000 x 600 mm...
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For multiple trailers, the maximum towing load across the entire tugger train is 4 t (depending on the maximum towing load of the tow tractor). Applies only when using STILL LiftRunner-trolleys. Depending on the tow tractor. NOTE This type sheet, based on VDI directive 2198, states only the technical values of the standard device.
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Technical data B frames - triple loadable 50988046101 EN - 02/2017...
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Index About these operating instructions ..2 EC declaration of conformity ... 4 Aisle widths Electrics B frame ..... . . 81 Cable lengths .
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Index Service work Consumables ....92 Maintenance intervals Steering angle ....80 B frames .
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