Mototok SPACER 8600 MA User manual

Version SPACER E V5.2 / 2978-150311
Operation Manual
SPACER 8600 MA
The New Standard of
Manoeuvrability.
Property of American Airlines

Version SPACER E V5.2 / 2978-150311
2
CONTENT
1. SAFETY ADVICE . . . . . . . . . . . . . . . . . . . . . . . 4
1.1. Instructions for operators 5
1.2. Safety briefing 8
1.3. Generic alarm output 10
1.4. Adjusting the contact pressure of the sliding table 11
1.5. Safety advise when lifting the nose gear 12
2. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 13
2.1. Service 14
2.2. Transport 14
2.3. Maintenance 15
2.4. Warranty 15
2.5. Stability 16
2.6. Inspection for defects 16
2.7. Recycling 16
2.8. Emergency stop system / Emergency switch 17
3. OPERATIONS I . . . . . . . . . . . . . . . . . . . . . . . 18
3.1. Display and dashboard 19
3.2. Remote control 20
3.3. Panel 21
3.4. Display 22
4. OPERATIONS II . . . . . . . . . . . . . . . . . . . . . . . 23
4.1. The Nose Wheel Platform 24
4.2. Nose wheel reception 25
4.3. Fully automated nose wheel reception 25
4.4. Oversteering Protection 27
5. EMERGENCY PROCESSES . . . . . . . . . . . . . . . . . . . 28
5.1. Override procedure – sensor fault correction 29
5.2. Malfunction of the hydraulic pump 30
5.3. Braking system 31
6. BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . 32
6.1. Batteries for the radio remote control 33
6.2. Batteries for the mototok 34
7. TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . 43
7.1. Spacer 8600 MA 44
7.2. Dimensions 45
7.3. Motor / Braking System 46
8. DECLARATIONS . . . . . . . . . . . . . . . . . . . . . . . 48
Property of American Airlines

Version SPACER E V5.2 / 2978-150311
3
9. PLANS . . . . . . . . . . . . . . . . . . . . . . . . . . 53
9.1. Current supply circuit diagram 54
9.2. Control system 55
9.3. Emergency stop circuit 56
9.4. Automatic switch off 57
9.5. Remote control 58
9.6. Bill of material – remote control receiver 62
9.7. Bill of material – radio remote control 63
9.8. Hydraulic plan 64
10. MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . 65
10.1. Annual maintenance check list 66
10.2. Lifetime of parts 67
10.3. Testing the oversteering protection 68
10.4. Hydraulic Oil 69
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 E V5.2 / 2978-150311
1. SAFETY ADVICE
1.1. Instructions for operators
1.2. Safety briefing
1.3. Generic alarm output
1.4. Adjusting the contact pressure of the sliding table
1.5. 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
nosewheel 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 E V5.2 / 2978-150311
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 nosewheel(s) slipping out of the mouth of the MOTOTOK, the unit is secured
by a nose-wheel securing mechanism. Please note the following safety precautions:
❐Hydraulic nosewheel 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 E V5.2 / 2978-150311
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 E V5.2 / 2978-150311
Property of American Airlines

1. SAFETY ADVICE / SAFETY BRIEFING 8
✔
✔
✔
1.2. SAFETY BRIEFING
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 nosegear 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 suffi cient 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 fl oor 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 fl oor, 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 defl ection 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 E V5.2 / 2978-150311
Property of American Airlines

1. SAFETY ADVICE / SAFETY BRIEFING 9
Warning! Danger!
❐It is not permitted to stand in the path of the Mototok’s pivot area during movements.
Version SPACER E V5.2 / 2978-150311
Property of American Airlines

1. SAFETY ADVICE / GENERIC ALARM OUTPUT 10
1.3. GENERIC ALARM OUTPUT
The generic alarm output uses a sequency of long and short pulsed alarm interleaved with
short and long pauses. The following signals are used in the priority as shown in the table
Priority Signal Graphic Representation
1 Reaching the maximum permissible
steering power *)
............
2 Loss of the camera tracking line (AGV) *) .......
3 Reached maximum allowed power .–.–.–.–.–.–.–
4 Battery low ––– ––– ––– –––
*) Only with suitable equipment
Version SPACER E V5.2 / 2978-150311
Property of American Airlines

1. SAFETY ADVICE / ADJUSTING THE CONTACT PRESSURE OF THE SLIDING TABLE 11
1.4. ADJUSTING THE CONTACT PRESSURE OF THE
SLIDING TABLE
For aircraft with small nose wheels or tires with low pressure it may be necessary to
reduce the maximum contact pressure of the sliding table.
1. Rotate the upper black locking ring to unlock the lower orange setting rings.
2. Set the upper orange ring to the desired maximum pressure. For small nose wheels or
tires with low infl ation pressure, we recommend a value of approximately 50.
Watch out! This value is only suitable for small nose wheels or tires with low infl a-
tion pressure!
At constant exchange of different wheel sizes or fi lling pressure values , select a value
that ensures that large nose wheels or tires with high infl ation pressures are clamped
securely.
3. Set the lower orange ring to the desired minimum pressure. The value should always
be greater than 30.
4. Attention! Close the upper black locking ring to prevent an independent change of the
values by vibration during operation.
The factory setting is:
Maximum pressure (upper ring): 70
Minimum pressure (lower ring): 40
2. maximum
pressure
1. locking ring
3. minimum
pressure
Version SPACER E V5.2 / 2978-150311
Property of American Airlines

1. SAFETY ADVICE / SAFETY ADVISE WHEN LIFTING THE NOSE GEAR 12
1.5. SAFETY ADVISE WHEN LIFTING THE NOSE GEAR
Please note, that if lifting the nose gear upwards, the tail of the aircraft will move down.
The lowering of the tail may multiple times bigger than the lifting of the nose gear due to
the geometry of the aircraft.
Warning!
❐Please be sure not to leave any items like tools on the airfoils or stepladders leaning against the airfoils.
Damage may cause and people may injure because of dropping items.
❐Please be sure that the lowering tail may not collide with any other aircraft or items in narrow situations.
Version SPACER E V5.2 / 2978-150311
Property of American Airlines

2. GENERAL INFORMATION
Version SPACER E V5.2 / 2978-150311
2. GENERAL INFORMATION
2.1. Service
2.2. Transport
2.3. Maintenance
2.4. Warranty
2.5. Stability
2.6. Inspection for defects
2.7. Recycling
2.8. Emergency stop system / Emergency switch
Property of American Airlines

2. GENERAL INFORMATION / SERVICE 14
Version SPACER E V5.2 / 2978-150311
Important!
❐Use only these four eyebolts when transporting the MOTOTOK.
2.2. TRANSPORT
Transport of the Unit in Case of Repair
The MOTOTOK has four [sic] suspension points. These points are covered
with black screw caps.
Screw the pink eyebolts provided into the suspension points.
2.1. SERVICE
In case of a defect, you must contact a MOTOTOK Service Technician. If your contact person
is not available, please contact directly:
MOTOTOK International GmbH
Tel. [phone]
e-Mail: [email protected]
or mobile:
Mr. Kersten Eckert [phone]
Property of American Airlines

2. GENERAL INFORMATION / MAINTENANCE 15
Version SPACER E V5.2 / 2978-150311
2.3. MAINTENANCE
❐The owner and/or the distributor of the MOTOTOK is/are responsible for ensuring that
devices for the wireless transmission of control commands are checked by a technical
expert regularly, but at a minimum once a year.
❐A technical expert is a person who, because of his technical training and competence,
has sufficient knowledge in the field of wireless transmission of control commands
and is familiar enough with the corresponding federal occupational safety rules,
accident prevention regulations, generally accepted technical guidelines (amongst
others DIN-Standards, VDE Regulations (German Association for Electrical, Electronic
and Information Technologies) and technical regulations of other member states
of the European Union or other contracting states of the Treaty on the European
Economic Area to be able to evaluate the operational safety of equipment for wireless
transmission of control commands.
2.4. WARRANTY
The terms of use are published here: http://www.mototok.com/generalconditions.html
Technical specifications and information are current at time of press. The MOTOTOK-manu-
facturer reserves the right to make changes without previous notification.
Attention!
❐Only service technicians of the manufacturer are allowed to work or supervise work on the
MOTOTOK.
❐Before operation or maintenance of the MOTOTOK, make yourself thoroughly familiar with
this handbook.
Property of American Airlines

2. GENERAL INFORMATION / STABILITY 16
Version SPACER E V5.2 / 2978-150311
2.5. STABILITY
Transporting ground equipment must be operated in such way that stability is guaranteed
to prevent overturning.
❐MOTOTOK’s load may overturn, e.g. because of:
❐Driving too fast in a turn.
❐Driving against an obstacle (including above the roadway )
❐Turning and cutting corners on downhill and uphill inclines
❐Shifting of the load to the downhill side on downhill and uphill inclines
❐Driving on bumpy roads
❐Overloading
2.6. INSPECTION FOR DEFECTS
The operating personnel must check the MOTOTOK for noticeable damage every day before
beginning operation and monitor the unit for damage during operation. If security defects
are detected, beginning of operation or continued use is not allowed. Any damage detect-
ed must be reported immediately.
Before continuing to operate the MOTOTOK, the owner has to repair any damage that may
affect security.
Safety defects are for example:
❐Too much play in the steering wheel
❐Faulty tires
❐Ineffective foot brake and hand brake
❐Cracks in load-bearing components
2.7. RECYCLING
Attention!
❐Avoid environmental pollution.
❐Electronic devices and parts thereof are a disposable problem.
This is particularly true of rechargeable battery packs.
❐Contract a company to deal with recycling and disposal.
❐Damaged battery packs can be disposed of directly with ABITRON.
Property of American Airlines

2. GENERAL INFORMATION / EMERGENCY STOP SYSTEM / EMERGENCY SWITCH 17
Version SPACER E V5.2 / 2978-150311
2.8. 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.
Property of American Airlines

3. OPERATIONS I
Version SPACER E V5.2 / 2978-150311
3. OPERATIONS I
3.1. Display & dashboard
3.2. Remote control
3.3. Panel
3.4. Display
Property of American Airlines

3. OPERATIONS I / DISPLAY AND DASHBOARD 19
Version SPACER E V5.2 / 2978-150311
3.1. DISPLAY AND DASHBOARD
1. The main switch turns on the remote control and the DC/AC converter. Only then can
the radio remote control switch on the vehicle be activated.
2. Red signal lamp, indicates the process of automatic engaging or disengaging of the
nosewheel.
3. Display showing the battery voltage, operating time and error analysis. The two driv-
ing computers are shown in the bottom left corner. Here the OK will be replaced by an
error code if there is an error. The battery symbol shows how much power remains in
the battery.
4. The direction lights help the driver to recognise in what direction the vehicle is moving
while operating the joystick of the remote. When operating the joystick, first an
approval process takes place and the electric brakes are released. The direction light
comes on.
5. Switch for toggle between full automatic and manual loading of the nose wheel.
6. Reset-Button.
1
2
5
3
4
6
Property of American Airlines

3. OPERATIONS I / REMOTE CONTROL 20
Version SPACER E V5.2 / 2978-150311
3.2. REMOTE CONTROL
Q1
schwarz
black
S3
DK9
schwarz
black
S2
DK27
schwarz
black
DK10
S9
S4DK
7
S3 S1
S2 S9
grün
green
DK1/2
S1
T
T
S6DK
4
5
T
STOP
S0
DK31(S/NO)
DK32(Ö/NC)
rot
red
S8S7
2 3 41
yellowd
greengreen
belg
nürgnürg
(DK28)
(DK29)
H1H0
Nm
S5
T
DK
12/3
T
11/3
P-
P+
(
S
/
N
O
e
d
Emergency
Stop Switch
Forward
Backward
Left
Right
D
K
A
F J
N
m
G/H
8
S
8
I
DK
S
1
N
S
2
K
27
L
S
3
K
M
DK
S
9
O
K
7
B
D
11/3
C
4
P
+
D
S
6
E
A. Green LED shows that the main instrument is switched on.
B. The switch for the sliding table can be pushed upwards (sliding table
moves backwards) and downwards (sliding table moves forward). The
switch jumps back automatically to the middle position. When actuating
the switch, the sliding table will be moved towards the tire of the nose
wheel until the hydraulic push button switches off. When the hydraulic
push button has switched and the elevating platform has not been raised,
it is not possible to drive. The driving function is interrupted until the plat-
form is located in the upper fi nal raised position.
C. The safety clamp sensing device can be pushed upwards and downwards.
Hereby the safety clamp moves towards the nose wheel and back. The
switch jumps back automatically to the middle position. If the sensing
device is pushed for longer than necessary an overfl ow valve opens to
ensure that there is always suffi cient pressure on the nose wheel and that
it is not overstrained. The safety clamp’s job is to prevent the nose wheel
from lifting. This is especially important for aircraft whose engines are
located behind the main fuselage.
D. Touch switch for headlights and working lights.
E. Non-stop fl ashing red LED light shows a connection loss. If the LED fl ash-
es very fast, the radio transmission to the vehicle is malfunctioning. If the
LED slowly fades out, there is an interruption of the CANBUS transmission
from the remote control to the control board.
F. Green LED – shows the established connection between transmitter and
receiver (fast fl ashing)
G. Rotary selection switch: Einstellung des Schwellenwertes der Oversteer-
ing Protection
Position 1: 2300 Nm
Position 2: 2500 Nm
Position 3: 2800 Nm
Position 4: 3000 Nm
H. Rotary selection switch for vehicles with automatic track guiding, all models.
Position 1: normal speed as preselected with switch I
Position 2: vehicle drives with lowered platform at normal fast speed /
with raised platform at slow speed.
Position 3: track guiding system is switched off, vehicle drives at the same
speed as it does with track guiding
Position 4: track guiding system is switched on
I. Rotary switch for setting the speed slow and fast (rabbit or snail)
J. Green control LED to indicate that the fastest speed has been selected.
K. On/off switch for remote control. By turning the black rotary knob the ve-
hicle is switched on. The black rotary knob can be pulled out and is a key. If
the key switch is turned clockwise, two acoustic signals will sound, which
means that the remote control has found a free channel. Now only the
green reset N has to be pushed and the vehicle is ready for use
L. Only military version. Switch from white to red light (combat lighting)
M. Only models with automatic door: Button for mouth door open and door
close. If the button is pushed repeatedly, the door moves in the opposite
direction. Only vehicles with automatic doors.
N. The green button must always be pushed after switching on the remote
control. It is used for controlling the safety systems. The safety systems
have to go through a function test before every start-up. If there is no RE-
SET (green button) the Mototok does not react to the joystick or any other
button command.
O. Button for raising and lowering the lifting platform. Raising the lifting
platform is done by clicking twice within 0.5 seconds as with a computer
mouse. When the platform is up, it can be lowered by clicking once. If the
platform is lowered, the sliding table moves back automatically.
Property of American Airlines