Page 1 Original instructions Tugger train Routenzug-10 Routenzug-16 0504 0506 0508 0510 50988012117 EN - 02/2015...
Page 3: Table Of Contents
Table of contents Foreword General ............2 About these operating instructions .
Page 4 Table of contents Overviews Overall view ............24 E frame .
Page 5 Table of contents Operation Assembling the articulated steering system (driving over ramps) ....56 Assembling the hydraulic steering system (hydraulics routed underneath) ..56 Installing and removing the compensating hinge .
Page 6 Table of contents Servicing Safety regulations for maintenance ........116 General information .
Page 7: Foreword
Foreword...
Page 8: General
Manufactured by: LR Intralogistik GmbH Siemensstraße 15 84109 Wörth an der Isar Germany Distribution and service by: STILL GmbH Berzeliusstr. 4 22113 Hamburg Germany 50988012117 [EN]...
Page 9: Issue Date And Topicality
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.
Page 10: Ec Declaration Of Conformity In Accordance With Machinery Directive
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.
Page 11: Information About The Documentation
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...
Page 12 Foreword Information about the documentation with either a hydraulic power unit or an air compressor. "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.
Page 13: Environmental Considerations
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.
Page 14 Foreword Environmental considerations 50988012117 [EN]...
Page 15: Introduction
Introduction...
Page 16: Use Of The Tugger Train
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 exchange them for empty Trolleys.
Page 17: Requirements For The Tow Tractor
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 for the tow tractor The tow tractor must have a steered front axle.
Page 18: Residual Risk
Introduction Residual risk Pneumatic E frame • Depending on the design of the E frames, the tow tractor must have a compressor of the corresponding size: - For frames with a 600 kg load capacity: 7 bar working pressure - For frames with a 1000 kg load capacity: 10 bar working pressure Residual risk Residual risk...
Page 19 Introduction Residual risk must determine and assess hazards during operation, and establish the occupational health and safety measures required for employees. The operating company must therefore draw up appropriate operating procedures (§ 6 ArbSchG) and make them available to the driver. These operating instructions for the frames do not form the operating procedures.
Page 20 Introduction Residual risk 50988012117 [EN]...
Page 21: Safety
Safety...
Page 22: Definition Of Terms Used For Responsible Persons
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.
Page 23: Specialist
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.
Page 24: Changes And Retrofitting
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.
Page 25: Safety Regulations For Handling Consumables
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! –...
Page 26: Hydraulic Fluid
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.
Page 27: Disposal Of Consumables
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.
Page 28 Safety Safety regulations for handling consumables 50988012117 [EN]...
Page 29: Overviews
Overviews...
Page 30: Overall View
Overviews Overall view Overall view E frame Frame Wheel Ejector Lift cylinder Hydraulic/pneumatic connection Wheel Foot pedal Tiller (ﬁgure shows standard tiller) Securing bolts Hydraulic/pneumatic connection 50988012117 [EN]...
Page 31: Autarkic E Frame
Overviews Overall view Autarkic E frame Frame Securing bolts Ejector Main load bearer Edge protection Lift cylinder (2x at rear) Foot pedal Drive wheel Load wheel Rigid tiller Articulated steering system Rigid tiller Hinged tiller 50988012117 [EN]...
Page 32: C Frame
Overviews Overall view C frame Frame Securing bolts Ejector Fork arms Hydraulic cylinder Tiller Tyre Collision protection Foot pedal Trolleys Euro 1/1 trolley – standard design Swivel castors (2 x with wheel brakes, Euro 1/1 h trolley arranged diagonally) Frame The black wheel prevents electrostatic charges.
Page 33: Description
Overviews Description Description E frame The E frame is a device for picking up and transporting roller platforms, known as trol- leys. Two up to a maximum of ﬁve E frames (stan- dard) are connected to the tow tractor and can transport trolleys that are loaded with crates, pallets or similar to the desired workplace.
Page 34: Autarkic E Frame
Overviews Description Autarkic E frame The autarkic E frame is a device for picking up and transporting roller platforms, known as trolleys. Two or four E frames are connected to a tow tractor. These E frames can transport trolleys loaded with crates, pallets or similar to the desired workplace.
Page 35: Articulated Steering System (Driving Over Ramps)
Overviews Description NOTE If trains with four autarkic E frames are used, a compensating hinge must be ﬁtted between the second E frame and the third E frame. The autarkic frames are lowered individually for unloading. If the tugger train drives over a chamfer, it may result in not all frames being raised;...
Page 36: C Frame
Overviews Description C frame The C frame is a device for picking up and transporting roller platforms, known as trol- leys. The tugger train can pull up to four C frames, depending on the tow tractor. The four-wheel design allows driving on ramps while maintaining a high level of tracking stability thanks to four-wheel steering.
Page 37: Labelling Points
Overviews Labelling points Labelling points Identiﬁcation plate Device type Manufacturer contact Device designation Year of manufacture Manufacturer Max. load CE symbol Device number (serial number) Inspection sticker The frame can be identiﬁed from the informa- tion on the nameplate. Overview Position of the identiﬁcation plate 50988012117 [EN]...
Page 38: Tugger-Train Combinations
Overviews Tugger-train combinations Tugger-train combinations Overview Permissible Driving number of Tiller length over Frame Tiller Load range- frames ramps ment identiﬁcation – – C frame Standard plate identiﬁcation plate Standard E frame identiﬁcation plate Rigid + 2 (1+1) hinged* 4 (2+2) (optional) identiﬁcation 2 (1+1)
Page 39: E Frames With Articulated Steering System (Driving Over Ramps)
Overviews Tugger-train combinations E frames with articulated steering system (driving over ramps) General Combinations of the E frame with the articu- lated steering system Combinations Tow tractor Permissible number of frames Note before assembly; refer to the chapter entitled "Tugger-train combinations/Overview" 50988012117 [EN]...
Page 40: E Frames With Standard Tiller
Overviews Tugger-train combinations E frames with standard tiller General Combinations with standard tiller Combinations Tow tractor 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" 50988012117 [EN]...
Page 41: Autarkic E Frame
Overviews Tugger-train combinations Autarkic E frame General Combinations of the autarkic E frame Combinations Tow tractor Permissible number of frames Note before assembly; refer 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.
Page 42: Mixing E Frames And C Frames
Overviews Tugger-train combinations The following conditions must be adhered to: • The autarkic E frames must be positioned behind the hydraulic or pneumatic E frames in the tugger train • A mixed rig of this type must be operated as an articulated steering system •...
Page 43: C Frame
Overviews Tugger-train combinations C frame General Combinations of the C frame Combinations Tow tractor Permissible number of frames Note before assembly; refer to the chapter entitled "Tugger-train combinations/Overview" 50988012117 [EN]...
Page 44: Autarkic System
Overviews Tugger-train combinations Autarkic system General Assembling Autarkic system Tow tractor Trolleys Autarkic E frame Note before assembly; refer to the chapter entitled "Tugger-train combinations/Overview" 50988012117 [EN]...
Page 45: Hydraulic System
Overviews Tugger-train combinations Hydraulic system General Assembling Hydraulic system Tow tractor with hydraulic unit C frame E frame Trolleys Note before assembly; refer to the chapter entitled "Tugger-train combinations/Overview" 50988012117 [EN]...
Page 46: Pneumatic System
Overviews Tugger-train combinations Pneumatic system General Assembling Pneumatic system Tow tractor with compressor E frame Trolleys Note before assembly; refer to the chapter entitled "Tugger-train combinations/Overview" 50988012117 [EN]...
Page 47: Articulated Steering System
Overviews Articulated steering system Articulated steering system Design and function Design and function of the articulated steering system (driving over ramps) Design Articulated frame steering rig 2 Articulated frame steering rig 1 Function Articulated steering tiller 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.
Page 48: Components
Overviews Articulated steering system Components Components of the articulated steering system Components for two E frames - Hydraulic Quan- Item 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"...
Page 49 Overviews Articulated steering system Components for two E frames - Pneumatic Quan- Item 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"...
Page 50 Overviews Articulated steering system Components for two autarkic E frames Quan- Item 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"...
Page 51: Overview Of Components
Overviews Articulated steering system Overview of components Articulated steering system (2 rigs/2+2 frames) Hinged tiller Rigid tiller Compensating hinge 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.
Page 52: Position Of The Socket Pins On The Rigid Tiller
Overviews Articulated steering system Position of the socket pins on the rigid tiller Position of the rigid tiller and the socket pins Rigid tiller Socket pin with the marking 5 ⇨ Drive direction NOTE For an overview, also refer to the chapter entitled "Articulated steering system/Compo- nents".
Page 53: Rigid Tiller And Hinged Tiller (Two Frames)
Overviews Articulated steering system Rigid tiller and hinged tiller (two frames) Position of the rigid tiller and the hinged tiller 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".
Page 54: Rigid Tiller, Hinged Tiller And Compensating Hinge (2+2 Frames)
Overviews Articulated steering system Rigid tiller, hinged tiller and compensating hinge (2+2 frames) Position of the rigid tiller, the hinged tiller and the compensating hinge First frame Rigid tiller Second frame Compensating hinge (only required for Third frame autarkic frames) Fourth frame ⇨...
Page 55: Equipment
Overviews Equipment Equipment Angular frame and tubular frame Frame designs Standard 1200 x 800 mm E frame with Standard 1600 x 1200 mm E frame with angular frame tubular frame On the 1600 x 1200 mm standard frames, the outer frame (2) is a tubular frame. Smaller frames have angular frames (1).
Page 56: Standard Tiller/Articulated Steering System
Overviews Equipment Standard tiller/articulated steering system Illustration of the tiller systems Standard system, no driving over ramps Hinged tiller with compensating hinge Standard tiller Reinforced hinged tiller Articulated steering system for driving over Reinforced hinged tiller with compensating ramps (always present on autarkic frames, hinge optional on standard E frames) Rigid tiller...
Page 57 Overviews Equipment 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 For autarkic E frames (always)* Hinged tiller...
Page 58: Variants Of Hydraulic Hose And Pneumatic Hose
Overviews Equipment Variants of hydraulic hose and pneumatic hose Variants of hydraulic hose and pneu- matic hose The lengths of hoses must be adjusted depending on the lengths of the tillers in accordance with the table. Overview Connection hose, routed above Connection hose between E frames, routed Connection hose to the tow tractor, routed below...
Page 59 Overviews Equipment 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 Hose length LS...
Page 60: Tiller Lengths (Standard Tiller/Articulated Steering System)
Overviews Equipment Tiller lengths (standard tiller/articu- lated steering system) 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...
Page 61: Operation
Operation...
Page 62: Assembling The Articulated Steering System (Driving Over Ramps)
Operation Assembling the articulated steering system (driving over ramps) Assembling the articulated steering system (driving over ramps) Assembling the hydraulic steering system (hydraulics routed underneath) Scope of delivery Scope of delivery for 2 x E frames: • Figure 1: 1 x rigid tiller with two pre-assem- bled clamping bolts.
Page 63 Operation Assembling the articulated steering system (driving over ramps) The socket pins and the alignment bolts are pre-assembled when delivered. The rigid tiller must (see ﬁgure) be ﬁtted between the ﬁrst E frame and the second E frame. (Arrow in drive direction). Assembling the rigid tiller WARNING Risk of injury through crushing!
Page 64 Operation Assembling the articulated steering 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.
Page 65 Operation Assembling the articulated steering system (driving 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.
Page 66 Operation Assembling the articulated steering system (driving over ramps) – 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! –...
Page 67 Operation Assembling the articulated steering system (driving over ramps) – 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.
Page 68 Operation Assembling the articulated steering 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. –...
Page 69 Operation 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).
Page 70 Operation Assembling the articulated steering system (driving 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. –...
Page 71 Operation Assembling the articulated steering system (driving over ramps) – 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.
Page 72 Operation Assembling the articulated steering system (driving over ramps) – To prevent the coupling (C) from rotating, lock the rotation lock (A) on the hydraulic connection into the guard plate (B). WARNING Hydraulic ﬂuid is pressurised during operation and is hazardous to your health. –...
Page 73 Operation Assembling the articulated steering system (driving over ramps) – Attach the pressure line. To do this, push the plug ﬁrmly into the coupling. 50988012117 [EN]...
Page 74: Installing And Removing The Compensating Hinge
Operation Assembling the articulated steering system (driving over ramps) – Couple the hinged tiller with the tow tractor. Connect the hydraulic line to the tow tractor. NOTE To release the hydraulic coupling, refer to the chapter entitled "Hydraulic/pneumatic coupling". – The tugger train is ready for use. Additional E frames can be ﬁtted to the tugger train by following the same procedure as previously described.
Page 75: Installing And Removing The Hinged Tiller
Operation Assembling the articulated steering system (driving over ramps) – 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 E frame and provides protection against lateral swivelling movements.
Page 76 Operation Assembling the articulated steering system (driving over ramps) The illustration shows the hinged tiller (1) with the compensating hinge (2) between 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)".
Page 77 Operation Assembling the articulated steering system (driving over ramps) – Evenly tighten the clamping bolts on the hinged tiller (tightening torque: 30 Nm) and secure the clamping bolts with nuts (tightening torque: 50 Nm). NOTE This tightening braces the tiller against the E frame and provides protection against lateral swivelling movements.
Page 78 Operation Assembling the articulated steering system (driving over ramps) Removing – 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. –...
Page 79: Commissioning The E Frames
Operation Commissioning the E frames – Pull out the hinged tiller. Commissioning the E frames Safety regulations for commission- ing the E frame Driving DANGER Risk of accident from crushing! – Before moving off, make sure that there are no people on or between the individual E frames.
Page 80: Checking The Securing Bolts For Correct Function
Operation Commissioning the E frames Coupling together CAUTION Components can be damaged if coupled together incorrectly! The E frames, which cannot be lowered, may only be driven as an articulated steering system. The articulated frame steering rig must contain an even number of frames (two or four trailers).
Page 81 Operation Commissioning the E frames Checking the securing bolts for correct function – Move the ejector into the rear end position. – 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.
Page 82: Coupling And Uncoupling The E Frames
Operation Commissioning the E frames Coupling and uncoupling the E frames Aligning chassis in drive direction The chassis are aligned according to the side on which the Trolleys are to be loaded and unloaded. Loading and unloading the trolleys from the left: –...
Page 83 Operation Commissioning the E frames CAUTION Risk of damage! Before coupling and uncoupling the frames, always disconnect the pressure line between multiple frames or the pressure line from the tow tractor. – The system must be depressurised when uncoupling. – Only use tillers/hoses in accordance with the table.
Page 84 Operation Commissioning the E frames NOTE In the hydraulics version, both the chassis and the pressure lines are already ﬁlled with hydraulic ﬂuid at the factory. – Connect the pressure lines on the individual frames together or to the pressure lines on the tow tractor.
Page 85 Operation Commissioning the E frames WARNING Risk of trapping or crushing! – Do not reach into the open coupling. – The tow tractor and the trailer must be on level ground and must be secured so they cannot roll away. CAUTION Risk of damage! Before coupling and uncoupling the frames, always...
Page 86: Loading The E Frames
Operation Commissioning the E frames Loading the E frames WARNING Risk of injury from becoming trapped! – Loading and unloading must only be performed by the driver. Make sure that no other persons are in the vicinity of the frames. –...
Page 87: Unloading The E Frames
Operation Commissioning the E frames – Push the trolley into the open side of the E frame until it reaches the stop. – When doing so, ensure that the securing bolts (see arrow) are fully extended (locking position) once the trolley has been inserted. –...
Page 88: Commissioning The Autarkic E Frames
Operation Commissioning the autarkic E frames WARNING Risk of injury! If you press the foot pedal to unload the trolley, this action will push the trolley out towards you. – Remove your foot from the foot pedal immedia- tely after actuating the foot pedal. –...
Page 89: Coupling And Uncoupling The Autarkic E Frames
Operation Commissioning the autarkic E frames Coupling CAUTION Components can be damaged by incorrect coup- ling! – Tugger trains with the autarkic system are only permitted with an articulated steering system. – If trains with four autarkic E frames are used, a compensating hinge must be ﬁtted between the second E frame and the third E frame.
Page 90 Operation Commissioning the autarkic E frames CAUTION Components can be damaged by incorrect coup- ling! Tugger trains with the autarkic system are always equipped with an articulated steering system (rigid tiller + hinged tiller) for stability reasons. These tugger trains can be operated with two or four E frames (articulated frame steering rig).
Page 91: Loading The Autarkic E Frames
Operation Commissioning the autarkic E frames Uncoupling the autarkic E frames – Release the alignment bolt for the towing eye. – Remove the hinged tiller from either the towing jaws of the tow tractor or from the compensating hinge of a preceding articulated frame steering rig.
Page 92: Unloading The Autarkic E Frames
Operation Commissioning the autarkic E frames – Push the trolley into the open side of the E frame until it reaches the stop. The E frame is raised by 40 mm and the trolley wheels turn freely. A prerequisite for this is sufﬁcient pressure in the accumulator.
Page 93: Commissioning The C Frames
Operation Commissioning the C frames WARNING Risk of injury! If you press the foot pedal to unload the trolley, this action will push the trolley out towards you. – Remove your foot from the foot pedal immedia- tely after actuating the foot pedal. –...
Page 94: Checking The Securing Bolts For Correct Function
Operation Commissioning the C frames CAUTION Components can be damaged by incorrect opera- tion! – Reverse travel with the tugger train is prohibited. Checking the securing bolts for correct function WARNING Damage or other defects to the tow tractor or the attached frames can result in accidents.
Page 95: Changing The Loading Side Of The C Frames
Operation Commissioning the C frames – Actuating the foot pedal must cause the securing bolt to retract (no interlock). Checking the securing system for correct function – Check if the trolley can roll out of the lowered C frame despite the securing bolt being extended.
Page 96 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. 50988012117 [EN]...
Page 97 Operation 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]...
Page 98 Operation Commissioning the C frames – Fix the towing jaws in a new position. 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). –...
Page 99 Operation Commissioning the C frames – Tighten the mounting 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. –...
Page 100: Coupling And Uncoupling The C Frames
Operation Commissioning the C frames – Attach the tiller to the tow tractor or a preceding frame. – Connect the hydraulic hose line to the tow tractor. – Perform a functional test. Coupling and uncoupling the C frames Aligning the C frames –...
Page 101 Operation Commissioning the C frames Coupling the C frames WARNING Risk of trapping or crushing! – Do not reach into the open coupling. – The tow tractor and the trailer must be on level ground and must be secured so they cannot roll away.
Page 102 Operation Commissioning the C frames – 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, or release the towing jaw bolt on the frame and pull it out.
Page 103 Operation Commissioning the C frames Uncoupling the C frames WARNING Risk of trapping or crushing! – Do not reach into the open coupling. – The tow tractor and the frames must be on level ground and must be secured so they cannot roll away.
Page 104: Loading The C Frames
Operation Commissioning the C frames Loading the C frames WARNING Risk of injury from becoming trapped! – Loading and unloading must only be performed by the driver. The driver must ensure that no other persons are in the vicinity of the frames. –...
Page 105: Unloading The C Frames
Operation Commissioning the C frames – Push the trolley into the open side of the C frame until the trolley reaches the stop. When doing so, ensure that the securing bolts are fully extended (locking position) once the trolley has been inserted. The trolley is now secured against rolling out.
Page 106: Adjusting The Fork Arms
Operation Commissioning the C frames – Actuate the foot pedal 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 and take to the required unloading site.
Page 107 Operation Commissioning the C frames – Align the fork arms on the frame so there is a 30-mm gap between the trolley and the frame after insertion. – To lock the fork arm in place, turn the locking lever in a clockwise direction. NOTE If the locking lever hits the frames so that it cannot be turned sufﬁciently to release or...
Page 108: Hydraulic/Pneumatic Coupling
Operation Hydraulic/pneumatic coupling Hydraulic/pneumatic coupling 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. –...
Page 109 Operation Hydraulic/pneumatic coupling 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. –...
Page 110 Operation Hydraulic/pneumatic coupling – 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!
Page 111: Connecting The Plug Connector
Operation Hydraulic/pneumatic coupling 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.
Page 112 Operation Hydraulic/pneumatic coupling 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.
Page 113: Driving
Risk of accident! – Do not use devices during travel or when hand- ling loads. – Set the volume so that warning 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.
Page 114 Operation Driving The driver must use an appropriate turning circle depending on the train to be towed and must not corner at more acute angles than this. The speed must be appropriate to the local conditions. For example, the driver must drive slowly around corners, in tight passageways, when driving through swing-doors, at blind spots or on uneven roadways.
Page 115: Driving Over Ramps With The E Frames
Operation Driving Driving over ramps with the E frames E frame 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...
Page 116: Driving Over Ramps With The C Frames
Operation Driving Driving over ramps with the C frames 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 Between the start of the ramp and the middle section (section A) and between the middle section and the end of the ramp, 7% to 18%...
Page 117: Steering Angle
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. Steering angle NOTE Recommendation: Perform a test drive to check the steering angle.
Page 118: Roadways
Operation Roadways Roadways Minimum aisle widths for E frames Minimum aisle widths depending on the length of the tugger train In loading a in cm b in cm Length (without (without Number of without tow c in cm with unloading E frame oncoming oncoming...
Page 119 Operation Roadways 280/300 340/360 1610 x 1210 1004 400/420 1255 460/480 This table shows only the technical values for a standard frame. Different dimensions, additional units etc. may produce different values. 50988012117 [EN]...
Page 120: Minimum Aisle Widths For C Frames
Operation Roadways Minimum aisle widths for C frames Minimum aisle widths depending on the length of the tugger train In loading a in cm b in cm Length (without (without Number of without tow c in cm with unloading C frame oncoming oncoming trailers...
Page 121: Servicing
Servicing...
Page 122: Safety Regulations For Maintenance
Servicing 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.
Page 123: Personnel Qualifications
Servicing 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...
Page 124: Service Work (C Frames)
Servicing Service work (C frames) Service work (C frames) Checking the gasket for leaks Check the gasket on the hydraulic cylinders for leaks – Lift the C frames hydraulically. – The cylinder rod (see arrow) must be moistened with only a thin ﬁlm of oil. –...
Page 125: Checking The Lifting Function
Servicing Service work (C frames) – Perform a visual inspection of the hydraulic hoses on the C frame in order to identify wear points or porous areas. – If damaged, replace the hydraulic hoses and gaskets. Hose lines must be replaced if: •...
Page 126 Servicing Service 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. 50988012117 [EN]...
Page 127: Maintenance Intervals For The E Frames
Servicing Maintenance intervals for the E frames Maintenance intervals for the E frames Summary table of maintenance tasks for the E frames. Daily Quarterly Unit Task Check if the trolley can roll out of the lowered E frame despite the securing bolt being extended Carry out a functional test on the securing bolts and the lifting function...
Page 128: Maintenance Intervals For The Autarkic E Frames
Servicing Maintenance intervals for the autarkic E frames Maintenance intervals for the autarkic E frames Summary table of maintenance tasks for the autarkic E frames. NOTE Before performing maintenance, enter the tow tractor and drive approx. 25 m. The hydraulic accumulators in the frames are now charged.
Page 129 Servicing Maintenance intervals for the autarkic E frames Check the wheels for wear and ease Wheels of movement Check the drive belt for wear and Drive replace if necessary 50988012117 [EN]...
Page 130: Maintenance Intervals For C Frames
Servicing Maintenance intervals for C frames Maintenance intervals for C frames Maintenance in accordance with the maintenance schedule Daily Quarterly Annually Unit Task Carry out a functional test on the securing bolts and the lifting function (of the C frames) Check if the trolley can roll out of the lowered C frame despite the securing bolt being extended Clean the securing bolts on the C frame, check...
Page 131: Consumables
Servicing Consumables Consumables Consumables for service work on the standard frames C frame Speciﬁcation Unit Consumable Lubricating nipple bearing Lubricating grease KP 2 K-30 Grease wheel guides DIN 51825 Securing bolts PTFE Longlife Teﬂon spray Lubricant Ejector tread PTFE Longlife Teﬂon spray Lubricant Moving parts of the fork arms PTFE Longlife Teﬂon spray...
Page 132 Servicing Consumables 50988012117 [EN]...
Page 133: Technical Data
Technical data...
Page 134: Load Diagram For The C Frames
Technical data Load diagram for the C frames Load diagram for the C frames Load centre of gravity distance (%) Load (kg) 50988012117 [EN]...
Page 135: Technical Data For E Frames
Technical data Technical data for E frames Technical data for E frames 600 kg 600 kg (1210/810) (1210/1010) 1000 kg Technical data and equipment for the E frames (1610/1210) 1000 kg 1000 kg (1210/810) (1210/1010) Load capacity 600/1000 600/1000 1000 Net weight 158/170 188/200...
Page 136 Technical 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 50988012117 [EN]...
Page 137: Technical Data For Autarkic E Frames
Technical data Technical data for autarkic E frames Technical data for autarkic E frames Technical data and equipment for the autarkic E 1210/810 1210/1010 1610/1210 frames Load capacity 600/1000 600/1000 1000 Net weight 158/170 188/200 Length 1090 1090 1490 Length 1270 1270 1666...
Page 138: Technical Data For C Frames
Technical data Technical data for C frames Technical data for C frames Technical data and equipment for the C frames Load capacity 1600 Net weight Length 2000 Length 2760 Length 4140 Dimensions Width 1540 Width 1250* Height Height Max. driving speed (depending on the tow tractor) km/h Turning circle** 2xWa...
Page 139 Index Coupling and uncoupling Autarkic E frame ....83 About these operating instructions ..2 C frame ..... . . 94 Adjusting the fork arms .
Page 140 Index Hydraulic system Maintenance intervals Checking the hydraulic system for Autarkic E frame ....122 wear points ....118 C frames .
Page 141 Index Safety regulations for maintenance Tugger-train combinations Working on the hydraulic equip- Autarkic E frame ....35 ment ..... 117 Autarkic system .
Page 144 STILL GmbH Berzeliusstrasse 10 D-22113 Hamburg Ident no. 50988012117 EN...

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Tugger train c frame Tugger train e frame Tugger train autarkic e frame

Still Tugger train Series Original Instructions Manual

1 Foreword

2 Introduction

3 Safety

4 Overviews

5 Operation

6 Servicing

7 Technical Data

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