Still Tugger train Series User manual

Original instructions
Tugger train
Routenzug-10
Routenzug-16
0504 0506 0508 0510
50988012117 EN - 02/2015

Table of contents
g
1 Foreword
General ............................................................ 2
About these operating instructions ........................................ 2
Issuedateandtopicality ................................................ 3
CElabelling ......................................................... 3
EC declaration of conformity in accordance with Machinery Directive ............... 4
Information about the documentation ...................................... 5
Copyrightandtrademarkrights ........................................... 5
Explanation of informationsymbolsused ................................... 5
Termsanddefinitions .................................................. 5
Environmental considerations ........................................... 7
Packaging .......................................................... 7
Disposalofunitsandhydraulicoil ......................................... 7
2 Introduction
Use of the tugger train ................................................ 10
Intended use ....................................................... 10
Improperuse ....................................................... 10
Requirements for the tow tractor ......................................... 11
Residual risk ....................................................... 12
Residualrisk ....................................................... 12
Danger to employees . . ............................................... 12
3Safety
Definition of terms used for responsible persons ............................. 16
Personnel ......................................................... 16
Operatingcompany .................................................. 16
Specialist .......................................................... 17
Basic principles for safe operation ....................................... 17
Warning regarding non-original parts ..................................... 17
Changes and retrofitting ............................................... 18
Damageanddefectstosafetysystems .................................... 18
Safety regulations for handling consumables ............................... 19
Oils .............................................................. 19
Hydraulicfluid ...................................................... 20
Disposalofconsumables .............................................. 21
50988012117 [EN] I

Table of contents
g
4Overviews
Overall view ........................................................ 24
Eframe ........................................................... 24
AutarkicEframe .................................................... 25
Articulatedsteeringsystem ............................................ 25
Cframe ........................................................... 26
Trolleys ........................................................... 26
Description ........................................................ 27
Eframe ........................................................... 27
AutarkicEframe .................................................... 28
Articulatedsteeringsystem(drivingoverramps) ............................. 29
Cframe ........................................................... 30
Labelling points ..................................................... 31
Identificationplate ................................................... 31
Overview .......................................................... 31
Tugger-train combinations ............................................. 32
Overview .......................................................... 32
E frames with articulatedsteeringsystem(drivingoverramps) ................... 33
Eframeswithstandardtiller ............................................ 34
AutarkicEframe .................................................... 35
Mixing E frames and autarkicEframes .................................... 35
MixingEframesandCframes .......................................... 36
Cframe ........................................................... 37
Autarkicsystem ..................................................... 38
Hydraulicsystem .................................................... 39
Pneumatic system ................................................... 40
Articulated steering system ............................................ 41
Designandfunction .................................................. 41
Components ....................................................... 42
Overview of components .............................................. 45
Positionofthesocketpinsontherigidtiller ................................. 46
Rigidtillerandhingedtiller(twoframes) ................................... 47
Rigid tiller, hinged tiller and compensating hinge (2+2 frames) ................... 48
Equipment ......................................................... 49
Angular frame and tubular frame ......................................... 49
Standard tiller/articulatedsteeringsystem .................................. 50
Variants of hydraulic hose and pneumatic hose . . . ........................... 52
Tillerlengths(standardtiller/articulatedsteeringsystem) ....................... 54
II 50988012117 [EN]

Table of contents
g
5 Operation
Assembling the articulated steering system (driving over ramps) ................. 56
Assembling the hydraulic steering system (hydraulics routed underneath) .......... 56
Installingandremovingthecompensatinghinge ............................. 68
Installing and removing the hinged tiller .................................... 69
Commissioning the E frames ........................................... 7
3
Safety regulations for commissioning the E frame ............................ 73
Checkingthesecuringboltsforcorrectfunction .............................. 74
Coupling and uncoupling theEframes .................................... 76
Loading the E frames . . ............................................... 80
UnloadingtheEframes ............................................... 81
Commissioning the autarkic E frames ..................................... 82
Safety regulations for commissioning ..................................... 82
Coupling and uncoupling the autarkic E frames .............................. 83
Loading the autarkic E frames ........................................... 85
UnloadingtheautarkicEframes ......................................... 86
Commissioning the C frames ........................................... 87
Safety regulations for commissioning ..................................... 87
Checkingthesecuringboltsforcorrectfunction .............................. 88
Changing the loading side of the C frames . . ................................ 89
Coupling and uncouplingtheCframes .................................... 94
Loading the C frames . . ............................................... 98
UnloadingtheCframes ............................................... 99
Adjusting the fork arms ................................................100
Hydraulic/pneumatic coupling ..........................................102
Releasingthepressurefromthehydraulicsystem ............................102
Hydraulic connectiontothetrailer ........................................102
Connecting the plug connector ..........................................105
Disconnecting the plug connector ........................................105
Driving ............................................................107
Safety regulations when driving .........................................107
DrivingoverrampswiththeEframes .....................................109
Driving over ramps withtheCframes .....................................110
Reversetravel ......................................................110
Steering angle ......................................................111
Roadways .........................................................112
MinimumaislewidthsforEframes .......................................112
MinimumaislewidthsforCframes .......................................114
50988012117 [EN] III

Table of contents
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6 Servicing
Safety regulations for maintenance .......................................116
General information ..................................................116
Maintenanceinstructions ..............................................116
Personnelqualifications ...............................................117
Working on the hydraulic equipment ......................................117
Service work (C frames) ...............................................118
Checkingthegasketforleaks ...........................................118
Checking the hydraulic systemforwearpoints ..............................118
Checkingtheliftingfunction ............................................119
Maintenance intervals for the E frames ....................................121
Maintenance intervals for the autarkic E frames ..............................122
Maintenance intervals for C frames .......................................124
Consumables ......................................................125
7 Technical data
Load diagram for the C frames ..........................................128
Technical data for E frames ............................................129
Technical data for autarkic E frames ......................................131
Technical data for C frames ............................................132
IV 50988012117 [EN]

1
Foreword

1Foreword
General
General
About these operating instructions
These operating instructions describe daily
operation of the tugger train in detail and can
be used as a source of information by both
new and trained operators.
The operating instructions are not intended to
be a technical or service manual. For technical
or maintenance issues that are not covered in
these operating instructions, please contact
your authorised service centre.
Manufactured by:
LR Intralogistik GmbH
Siemensstraße 15
84109 Wörth an der Isar
Germany
Distribution and service by:
STILL GmbH
Berzeliusstr. 4
22113 Hamburg
Germany
25
0988012117 [EN]

Foreword 1
General
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.
If you require technical support for the vehicle,
please contact the authorised service centre.
Have a good trip, your partner
STILL GmbH
Berzeliusstr. 10
22113 Hamburg, Germany
CE-Symbol
CE labelling
The manufacturer uses CE labelling to indi-
cate that the frame complies with the stan-
dards and regulations valid at the time the
frame was placed on the market. Compliance
is confirmed by the issue of an EC declaration
of conformity. The CE labelling is attached to
the nameplate.
An unauthorised structural change or addition
to the frame can compromise safety, thus
invalidating the EC declaration of conformity.
The EC declaration of conformity must be
carefully stored and made available to the
relevant authorities.
50988012117 [EN] 3

1Foreword
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.
Personnel authorised to compile the technical documents:
See EC declaration of conformity
LR Intralogistik GmbH
.
45
0988012117 [EN]