Mototok SPACER 195 User manual

Version SPACER 195 EN V1.0 / 3622-161117
Operation Manual
SPACER 195
The New Standard of
Manoeuvrability.
Property of American Airlines

Version SPACER 195 EN V1.0 / 3622-161117
2
CONTENT
1. SAFETY ADVICE . . . . . . . . . . . . . . . . . . . . . . . 4
1.1. Instructions for operators 5
1.2. Safety briefing when shunting 8
1.3. Safety advise when lifting the nose gear 11
2. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 12
2.1. Maintenance 13
2.2. Warranty 13
2.3. Stability 14
2.4. Inspection for defects 14
2.5. Recycling 14
2.6. Emergency stop system / Emergency switch 15
3. OPERATIONS I . . . . . . . . . . . . . . . . . . . . . . . 16
3.1. Display and dashboard 17
3.2. Remote Control 18
3.3. Panel 19
3.4. Display 20
4. OPERATIONS II . . . . . . . . . . . . . . . . . . . . . . . 21
4.1. The Nose Wheel Platform 22
4.2. Nose wheel reception 23
4.3. Fully automated nose wheel reception 23
4.4. Over steering Protection 26
4.5. Generic alarm output 28
4.6. Adjusting the contact pressure of the sliding table 29
4.7. Adjusting the contact pressure of the Securing clamps 30
5. EMERGENCY PROCESSES . . . . . . . . . . . . . . . . . . . 31
5.1. Override procedure – sensor fault correction 32
5.2. Malfunction of the hydraulic pump 33
5.3. Braking system 35
6. BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . 37
6.1. Batteries for the radio remote control 38
6.2. Batteries for the mototok 39
7. TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . 48
7.1. Technical Data 49
7.2. Dimensions 50
7.3. Motor / Braking System 51
8. DECLARATIONS . . . . . . . . . . . . . . . . . . . . . . . 52
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Version SPACER 195 EN V1.0 / 3622-161117
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9. PLANS . . . . . . . . . . . . . . . . . . . . . . . . . . 57
9.1. Current supply circuit diagram 58
9.2. Control system 59
9.3. Emergency stop circuit 60
9.4. Automatic switch off 61
9.5. Remote control 62
9.6. Bill of material – remote control receiver 66
9.7. Bill of material – radio remote control 67
9.8. Hydraulic plan 68
10. MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . 69
10.1. Annual maintenance check list 70
10.2. Lifetime of parts 72
10.3. Oversteering Protection 73
10.4. Hydraulic Oil 79
Responsible for all content
Mototok International GmbH
Mr. Kersten Eckert
Hohenzollernstr. 47
D-47799 Krefeld
Germany
Phone: [phone]
Fax: [phone]
Property of American Airlines

1. SAFETY ADVICE
Version SPACER 195 EN V1.0 / 3622-161117
1. SAFETY ADVICE
1.1. Instructions for operators
1.2. Safety briefing when shunting
1.3. Safety advice when lifting the nose gear
Property of American Airlines

1. SAFETY ADVICE / INSTRUCTIONS FOR OPERATORS 5
Attention!
❐Please read the MOTOTOK Instruction Manual thoroughly and carefully.
❐Do not use the MOTOTOK before checking that it is in perfect technical condition and for any external damage
1.1. INSTRUCTIONS FOR OPERATORS
Operation of the MOTOTOK is allowed only by qualified persons who are physically and
mentally capable to do so.
Valid Operator Actions
The operator is allowed to take only the following actions:
❐Turning the MOTOTOK on and off
❐Navigating the MOTOTOK with the provided ABITRON industrial hand held
remote control.
❐All persons working with the remote control must be:
– Qualified and instructed in conformity with the requirements.
– Follow the instruction manual precisely.
When putting away the remote control, the operator must make sure that there is abso-
lutely no access for persons who are not authorized either by removing the key switch or
by securing the remote control in locked storage.
The operating company must:
❐Supply the manual to the operator.
❐Make sure that the operator has read and understood the instruction manual
completely.
1.1.1. IMPORTANT OPERATING PRECAUTIONS
❐Store the remote control only in a safe and dry place; shut down the key switch and
turn the remote off (only possible by turning the key switch counter clockwise to
position “0”).
❐Make sure that the power supply system is disconnected before any assembly,
maintenance or repair work.
❐Never remove or change the safety equipment.
❐Never drive without lights in the dark.
❐Never start the unit improperly.
❐Do not drive the MOTOTOK into walls or objects: The unit could become damaged.
❐Never exceed the permitted lifting capacity of the unit.
❐Never drive directly towards a person from in front or from behind. Remember: The
unit drives with a beeper that can sometimes not be heard in a load environment.
❐The moveable parts of the MOTOTOK should not be touched during operation.
❐Don’t move the aircraft with the main landing gear backwards against any obstacles
like chocks or tools lying on the ground! The aircraft may rear up and the tail may hit
the ground.
❐Brake slowly when manoeuvring the MOTOTOK. This way you will avoid the nose
wheel slipping accidentally out of the holding on the MOTOTOK.
❐It is forbidden to operate the unit from the cockpit of the aircraft.
❐Don’t move too far away from the unit. At too great distance, it is hard to still be able
to judge exactly the distance to other obstacles. Control commands are also sent out
of sight of the unit and through or around obstacles.
Version SPACER 195 EN V1.0 / 3622-161117
Property of American Airlines

1. SAFETY ADVICE / INSTRUCTIONS FOR OPERATORS 6
1.1.2. SAFETY MEASURES IN THE WORK AREA
❐Ensure a slip-proof stand.
❐The MOTOTOK is designed only for even, flat and hard ground, so be sure to park on a
non-slip surface and to drive safely. Driving surface conditions may be unfavourably
influenced by wet, dirty or icy conditions.
❐Before turning on the remote control, always make sure that there are no people in
the work area are unaware of the MOTOTOK starting up.
❐Use the remote control only with the carrier aid provided.
1.1.3. SAFETY EQUIPMENT
The MOTOTOK will shut down in following cases:
❐Using the red stop switch (EMERGENCY SHUT DOWN) on the control panel of the
remote and the two Emergency Shut Down switches located on the MOTOTOK.
❐The remote control is out of signal range of the receiver of the MOTOTOK.
❐The receiver fails.
❐By physically removing the batteries out the battery compartment of the MOTOTOK.
❐A 450 ms (ca. 0. 5 sec.) delay after switching-off the remote.
❐When the MOTOTOK is idle for an extended period of time it will power down,
(2 min, adjustable).
This safety equipment
❐is installed for the security of operating personnel and their equipment.
❐may not be altered, disassembled or circumvented in any way.
Extra safety is guaranteed
❐by the safety frame of the MOTOTOK. It protects against involuntary start-up and
prevents accidental control commands.
Securing the Aircraft
To avoid the nose wheel slipping out of the mouth of the MOTOTOK, the unit is secured by
a nose wheel securing mechanism.
Attention!
❐Don’t put hands or any other body parts underneath the lifting gear or under the MOTOTOK. Take care also
that no objects are left lying around in this area.
❐While crossing hangar door guide rails, the ground clearance must be at least around 8,8 cm.
❐Transporting people on the MOTOTOK is forbidden. The MOTOTOK is not designed for passenger
transportation.
❐Operating error or abuse can hurt the operators or other people and/or damage the MOTOTOK plus other
material assets.
Version SPACER 195 EN V1.0 / 3622-161117
Property of American Airlines

1. SAFETY ADVICE / INSTRUCTIONS FOR OPERATORS 7
1.1.4. MOTOTOK SECURITY SYSTEMS
Emergency Stop System / Emergency Switch
The emergency system consists of 2 or 4 emergency stop switches, depending on the
model. The switches are red plastic covers which can be activated by hitting them and are
located on the MOTOTOK at each corner. Each switch interrupts the supply of current to the
vehicle. On the remote control there is an emergency stop switch with a red plastic cover
in the middle of the panel. If it is pressed, it can only be reactivated by turning it to the left.
Warning!
❐Turn the machine off immediately if an error is found during testing. Inform your dealer or the technician
responsible immediately in order to have the cause removed. Never work with a machine whose
EMERGENCY STOP system is not working perfectly.
❐Personal injury or physical damage may be caused if this instruction is not followed.
❐All measures representing an infringement of this regulation may lead to the loss of your operating license
and the guarantee.
❐Use the EMERGENCY STOP system only if mototok drives arbitrarily. If the emergency stop button is
used, the electric system shuts off completely. That means, that the generator brakes and the steering are
functionless. During towing an aircraft the stopping distance may increase and the Mototok may turn to one
side itself.
Version SPACER 195 EN V1.0 / 3622-161117
Property of American Airlines

1. SAFETY ADVICE / SAFETY BRIEFING WHEN SHUNTING 8
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1.2. SAFETY BRIEFING WHEN SHUNTING
Before starting to move an aircraft
make sure to do a visual check by walking around the aircraft:
a. Is the tail of the plane free to move? When the MOTOTOK lifts the front nose gear of the
aircraft, the tail is slightly lowered. This can cause the stabilizer or the side rudder to
bump against a wall or another aircraft if sufficient clearance is not taken in accordance
before lifting.
b. Is the main driving axle secured with brake shoes against inadvertent rolling?
c. All cables and tubes that are lying on the floor must be removed from the operating
area of the MOTOTOK. The cables and tubes would otherwise be crushed or severed due
to the heavy weight of the MOTOTOK’s and its hard tires.
d. Remove any tie down cables and the ground power cable from the plane.
e. If the doors of the hangar have rails that stand up high from the floor, are there cross-
ramps and are they properly positioned?
f. Is the nose wheel steering dismounted or is the hydraulic pressure control valve un-
latched and secured? For aircraft that have no nose wheel release, the check-mark for
the maximum control swing/steering deflection has to be observed.
The position of the operator should be such that all critical points of the aircraft can be
observed. In addition, the Operator must at all times have a complete overview.
Version SPACER 195 EN V1.0 / 3622-161117
Property of American Airlines

1. SAFETY ADVICE / SAFETY BRIEFING WHEN SHUNTING 9
Warning! Danger!
❐It is not permitted to stand in the path of the Mototok’s pivot area during movements.
Version SPACER 195 EN V1.0 / 3622-161117
Property of American Airlines

1. SAFETY ADVICE / SAFETY BRIEFING WHEN SHUNTING 10
Attention!
❐Please only change direction after the machine has completely come to a halt.
DO NOT!
STOP!
Version SPACER 195 EN V1.0 / 3622-161117
Property of American Airlines