Ba - LPT-80 Gap Delu

Air-Cushion Transport System
LPT – 80 / GAP
ABB Power Grids Brasil
Operating- and Maintenance Manual

- Original –
Type : LPT – 80 / GAP
Serial-Nr. : 12185
Year of Construction : 2021/01
DELU GmbH Rev. 1.0

Deutsche Luftkissensysteme
Gebertstr. 7, 90411 Nürnberg, Germany
Tel. : +49 (0)911 238888-0

Fax : +49 (0)911 238888-28
Internet : http://www.delu-gmbh.de
Blatt:
Operating and Maintenance Manual Page 2 of 58

GerätebName:
System ezeichnung: D atum
Date :
(YYYY-MM-DD):
D ELU G
DELU mbH
GmbH
DeDeutsche
utsches LLuftkissensysteme
uft gleitkissensystem Air Cushion Pallet Transport LPT – 80 / GAP 2021-02-18
Ge b e rt s t ra ße
Gebertstr. 7, 904117 ; D -9 04Nuremberg
11 Nürnberg
Tel. (+49Germany) 0911 / 52 40 15
FTel.
ax +49-(0)911-238888-0
(+49) 0911 / 52 35 07 gültig für FaNo.:
Fabrication br. Nr: Baujaof
Year hr:Construction (MM/YYYY):
Fax +49-(0)911-238888-28 12185 2021/01
The information in this Operating and Maintenance Manual provides general instructions
for the safe operation and basic maintenance of the Air Cushion Transport Vehicle
(hereinafter referred to as "Transporter"). This information is vital and must be clearly
understood by the operators and service personnel. Study this manual thoroughly and
carefully before operating or servicing the Transporter. Do not use or allow anyone else
to use the Transporter until this manual is read and all safety/operating instructions are
understood. In addition, all local accident prevention guidelines and general safety
regulations effective at the implementation site of the Transporter apply.
Even though the Transporter is easy to handle, it should be operated only by specially
trained personnel who are experienced in handling heavy loads and who are aware of the
potential dangers and risks.
Contact DELU GmbH or your local dealer/agent if you have any questions concerning
your Transporter, its operation, service or parts. Keep this Operating and Maintenance
Manual available for reference, preferably with the Transporter, and make sure it is
accessible to everyone involved with the Transporter at all times. If the manual becomes
illegible or is missing, contact DELU GmbH or your local dealer/agent for replacements
immediately.
This manual cannot cover every situation that might result in an accident. It is the
responsibility of the operator to always remain alert for potential hazards and be prepared
to avoid them!
- This Operating and Maintenance Manual may describe various options and model
variants and therefore some of the items covered may not apply to your particular
system. The images shown in this Manual may differ from the actual situation but
are, in general, valid for all types of DELU Air Cushion Systems.
- This Operating and Maintenance Manual is an integral part of the Transporter.

Remember to pass it on when relocating or reselling the Air Cushion Vehicle.
- Do not remove or paint over any of the warning decals attached to the Transporter.
- For your own safety as well as others, never allow this Transporter to be altered or
modified. Modifying or altering equipment to operate in a fashion other than its
original design may cause serious injury or death.
- Customers are strongly advised to contact DELU GmbH or an authorized DELU

dealer/agent in connection with any service problems and adjustments that may
occur.
We have reviewed the contents of this manual to ensure consistency with the Transporter
described. Since variance cannot be precluded entirely, we cannot guarantee full
consistency. However, the information in this manual is reviewed regularly and any
necessary corrections are included in subsequent editions.
Copyright © 2009-2015 DELU Luftkissentechnik GmbH.

The information in this document may be subject to alteration without any obligation to give
prior notification. No part of this publication may be reproduced and/or made public by means
of printing, photocopy, microfilm or in any other way or for any purpose whatsoever, without
the prior, explicit written permission of DELU Luftkissentechnik GmbH.
Blatt:

GerätebName:
Date :
(YYYY-MM-DD):
D ELU G
DELU mbH
GmbH
DeDeutsche
11 Nürnberg
Tel. (+49Germany) 0911 / 52 40 15
FTel.
ax +49-(0)911-238888-0
(+49) 0911 / 52 35 07 gültig für FaNo.:
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TABLE OF CONTENTS
1. HOW TO READ THIS MANUAL ...................................................................... 6
1.1. Explanation of signal words and symbols ................................................................................... 6
Safety Alert Symbol 6
Signal word "DANGER" 6
Signal word "WARNING" 6
Signal word "CAUTION" 6
Signal word "NOTICE" 6
1.2. Text conventions ......................................................................................................................... 7
1.3. Documents .................................................................................................................................. 7
1.4. Certification .................................................................................................................................. 7
2. OVERVIEW AND SYSTEM DESCRIPTION .................................................... 8

2.1. Overview of the Air Cushion Pallet Transport System (Example) ............................................... 8
2.2. General system components....................................................................................................... 8
2.3. Description of Air Cushion Transporter ....................................................................................... 9
2.4. Structure and components of the Air Cushion Transporter ....................................................... 10
2.5. System accessories................................................................................................................... 11
3. SAFETY REGULATIONS .............................................................................. 12

3.1. Introduction ................................................................................................................................ 12
3.2. Intended use .............................................................................................................................. 12
3.3. Specific dangers ........................................................................................................................ 13
Compressed air 13
Moving parts 13
3.4. Personnel requirements ............................................................................................................ 14
3.5. Personal protective equipment (PPE) ....................................................................................... 14
3.6. Safety signs on the Transporter ................................................................................................ 15
3.7. Built-in safety devices ................................................................................................................ 17
Emergency-stop 17
Squeeze protection frame 17
Fail safe mode 17
Hose securing grips on supply hose 18
Signal horn 18
Deadman Controls 18
Reduced speed (optional) 18
3.8. How to handle hazardous situations or accidents ..................................................................... 18
3.9. Spare parts ................................................................................................................................ 19
3.10. Environmental protection ........................................................................................................... 19
Noise level 19
Disposal of lubricants 19
3.11. Responsibilities of the employer / user...................................................................................... 19
Environmental conditions 19
Transporter condition 20
3.12. Safety distances ........................................................................................................................ 21
Safety distance to other objects 21
Pallet clearance 21
4. STORAGE AND TRANSPORT ...................................................................... 22

Blatt:

GerätebName:
Date :
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DELU mbH
GmbH
DeDeutsche
11 Nürnberg
Tel. (+49Germany) 0911 / 52 40 15
FTel.
ax +49-(0)911-238888-0
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4.1. Receipt ...................................................................................................................................... 22

4.2. Packing ...................................................................................................................................... 22
4.3. Storage ...................................................................................................................................... 22
4.4. Unpacking .................................................................................................................................. 23
4.5. Internal transports...................................................................................................................... 23
5. TRANSPORT PALLETS AND LOADING ...................................................... 24

6. INITIAL OPERATION OF THE TRANSPORTER .......................................... 25
7. AIR SUPPLY .................................................................................................. 26
7.1. Main air supply .......................................................................................................................... 26
7.2. Air connection point ................................................................................................................... 26
7.3. Depressurizing the Transporter ................................................................................................. 28
8. OPERATION .................................................................................................. 29
8.1. Description of the operating elements and functions ................................................................ 29
Radio remote control (RRC) 29
Operating panel (OP) on the Air Cushion Transporter 32
System control panel (SCP) 33
Emergency control panel (ECP) 34
8.2. Starting the transporter .............................................................................................................. 35
8.3. Turn off the transporter properly ................................................................................................ 35
8.4. Driving modes............................................................................................................................ 36
longitudinal- and lateral movement 36
driving curves (longitudinal mode) 37
Gap transit 38
Emergency control 41
8.5. Picking up and setting down loads ............................................................................................ 42
Picking up pallets 42
Setting the pallet down 43
9. TECHNICAL DATA ........................................................................................ 44

10. MAINTENANCE ............................................................................................. 45
10.1. Maintenance plan ...................................................................................................................... 45
10.2. Maintenance of the air cushion elements .................................................................................. 47
10.3. Maintenance of the pneumatic components ............................................................................. 48
Air filters and lubricators 48
Height control 50
Main supply hose 50
Remote controlled pressure regulator (RCPR) 50
10.4. Maintenance of mechanical parts.............................................................................................. 51
11. TROUBLESHOOTING ................................................................................... 51

11.1. Troubleshooting electrical components ..................................................................................... 51
radio remote control (RRC) 51
the electrical control 51
11.2. Debugging in the Pneumatic Unit .............................................................................................. 53
11.3. Troubleshooting the electrical height control ............................................................................. 54
11.4. Charging the batteries ............................................................................................................... 54
Charging the Transporter batteries 54
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GerätebName:
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DELU mbH
GmbH
DeDeutsche
11 Nürnberg
Tel. (+49Germany) 0911 / 52 40 15
FTel.
ax +49-(0)911-238888-0
(+49) 0911 / 52 35 07 gültig für FaNo.:
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Charging and replacing the remote control batteries 54

Display and error messages of the charging unit 55
Disposal of batteries 55
12. EC DECLARATION ....................................................................................... 56

13. RECOMMENDED SPARE PARTS LIST........................................................ 57
13.1. Pneumatic .................................................................................................................................. 57
13.2. Electric ....................................................................................................................................... 57
14. APPENDIX ..................................................................................................... 58

14.1. Demands on the floor ................................................................................................................ 58
14.2. Demands on the air supply ........................................................................................................ 58
14.3. Overview drawing – Transporter LPT – 80 / GAP ..................................................................... 58
14.4. Pneumatic diagrams .................................................................................................................. 58
14.5. Electric diagrams ....................................................................................................................... 58
Blatt:

GerätebName:
Date :
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DELU mbH
GmbH
DeDeutsche
11 Nürnberg
Tel. (+49Germany) 0911 / 52 40 15
FTel.
ax +49-(0)911-238888-0
(+49) 0911 / 52 35 07 gültig für FaNo.:
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1. How to read this manual

DANGER OF INJURY DUE TO WRONG USAGE!
 Read and understand this manual before usage or service.
 Carry out procedures carefully according to this manual.
1.1. Explanation of signal words and symbols

Safety symbols are used throughout this manual to alert of potentially hazardous situations.
The following definitions describe the level of severity for each signal word. Learn to recognize
these safety alerts, and follow the recommended precautions and safe practices. The same
symbols are also used for the safety decals on the Transporter.
Safety Alert Symbol

This is the safety alert symbol. It means ATTENTION! BECOME
ALERT! YOUR SAFETY IS INVOLVED! Look for it, both in this
manual and on safety decals on the equipment. It will direct your
attention to information that involves your safety and the safety of
others.
Signal word "DANGER"

DANGER indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury
Signal word "WARNING"

WARNING indicates an imminently hazardous situation which, if not
avoided, could result in death or serious injury.
Signal word "CAUTION"

CAUTION indicates an imminently hazardous situation which, if not
avoided, may result in minor or moderate injury.
Signal word "NOTICE"

NOTICE indicates a property damage message
Blatt:

GerätebName:
Date :
(YYYY-MM-DD):
D ELU G
DELU mbH
GmbH
DeDeutsche
11 Nürnberg
Tel. (+49Germany) 0911 / 52 40 15
FTel.
ax +49-(0)911-238888-0
(+49) 0911 / 52 35 07 gültig für FaNo.:
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1.2. Text conventions

In this manual, lists of different possibilities are indicated as follows:
 Option 1
 Option 2
 ...
The various activities that have to be carried out are indicated as follows:
 Step 1
 Step 2
 ...
1.3. Documents
Store this manual and all other documents concerning the Transporter
carefully for future use.
In addition to this user manual, the Transporter is supplied with the following documents, which can
be found in the appendix:
- Demands on the floor surface,
- Specifications of the air supply,
- As-built drawing of Transporter,
- Pallet drawings,
- Pneumatic diagrams,
- Electrical diagrams,
- Manual(s) of third-party accessory.
This manual is based on the current state of technology and in accordance with ANSI
Z535.6. DELU Luftkissentechnik GmbH reserves the right to make amendments to this
documentation without being obliged to modify previous versions.
1.4. Certification
The Air Cushion System complies with EC requirements; see in this regard the declaration in
Chapter 12.
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GerätebName:
Date :
(YYYY-MM-DD):
D ELU G
DELU mbH
GmbH
DeDeutsche
11 Nürnberg
Tel. (+49Germany) 0911 / 52 40 15
FTel.
ax +49-(0)911-238888-0
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2. Overview and system description

2.1. Overview of the Air Cushion Pallet Transport System (Example)
System components:
1 - Air Cushion Pallet
Transporter(s)
2 - Transport pallet(s)
3 - Floor
4 - Air supply
Figure 1 Example Overview of the Air Cushion Pallet Transport System
2.2. General system components

In general, a DELU Air Cushion Pallet Transport System consists of four components.
- Air Cushion Transporter,
- Transport pallet(s),
- Floor appropriate for Air Cushion usage,
- Compressed air supply.
To ensure correct function of the complete System all components must meet
DELU's required specifications.
Blatt:

GerätebName:
Date :
(YYYY-MM-DD):
D ELU G
DELU mbH
GmbH
DeDeutsche
11 Nürnberg
Tel. (+49Germany) 0911 / 52 40 15
FTel.
ax +49-(0)911-238888-0
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2.3. Description of Air Cushion Transporter
The Air Cushion Pallet Transporter is designed for picking up and moving heavy loads. Its purpose
is the indoor transportation of materials, but not persons. The loads are placed on transport pallets
under which the Transporter can drive in. When the Transporter is positioned under the pallet its
Air Cushion Elements are activated and the pallet with the load will be lifted off the ground by
approximately 12 - 25 mm (0.5 - 1 inch).
The Air Cushion Transporter consists of a welded base frame under which 8 air cushion elements
are mounted. These Air Cushion Elements cast a thin film of air between the floor and the
Transporter which makes it float almost without friction.
The Transporter makes use of the air cushion principle. The load floats on a thin air film and can be
moved in every direction with very little force. This makes it possible to move the floating load with
friction wheel drives.
By means of two integrated drive units the Transporter can be moved in almost every direction,
drive curves and make rotations. The Transporter is operated via radio remote control.
The two friction wheel drives, powered by compressed air, allow the movement of the Transporter
in longitudinal or lateral direction:
- in "off" mode the LPT drives on the wheel gear. In this mode only the drives are active.
- in "load" mode the LPT drives on eight air-cushions. This is necessary for moving loads up to
80 tons.
- It is possible to drive the Transporter in a loaded as well as unloaded state. In order to drive
under the pallet, Transporters are equipped with a swivel castor gear. For picking up the load
the air cushion gear must be activated. The air cushions inflate and lift the load resting on the
pallets off the ground.
The Transporter has an onbuilt hose reel on which the air hose is wound. Via this air hose the
Transporter is connected to the air supply. The operator has to observe and unwind or rewind the
hose when moving Air Cushion Transporter.
Blatt:

GerätebName:
Date :
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DELU mbH
GmbH
DeDeutsche
11 Nürnberg
Tel. (+49Germany) 0911 / 52 40 15
FTel.
ax +49-(0)911-238888-0
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2.4. Structure and components of the Air Cushion Transporter
In the diagram below, the general structure of the Air Cushion Transporter is shown.
Some components can be optional and depend on the design of the System.
Pos. Name Amount

1 air connection coupling 1
2 Hose strain relief 1
3 Main supply hose 1
4 Hose reel 1
5 Dirt filter 1
6 Micro filter 1
7 Control panel 1
pneumatic maintenance
8 2
unit
9 Hose reel unit 1
10 Steering unit 2
11 Drive unit 2
12 Oil demister 3
13 Air-cushion 12
14 USS sensor 4
15 Electric cabinet 1
16 Batteries 2
17 Radio receiver 1
18 Antenna 2
Radio remote control
19 1
desk
20 Crane anchorage point 4
Figure 2 2.4. Structure and components of

the Air Cushion Transporter
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GerätebName:
Date :
(YYYY-MM-DD):
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DELU mbH
GmbH
DeDeutsche
11 Nürnberg
Tel. (+49Germany) 0911 / 52 40 15
FTel.
ax +49-(0)911-238888-0
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2.5. System accessories
The following accessories are within DELU's scope of deliverables:
1 pc. Air Cushion Pallet Transporter: LPT – 80 / GAP,

1 pc. Radio remote control desk incl.1 pc. battery
1 pc. Spare battery for remote control desk
2 pcs. Key for covers
2 pcs. Key for E-Box
1 pc. Charger for Transporter
1 pc. Charger for radio remote control desk
2 pcs. Air cushions 146 LE-KH 4-75 AC
4 pcs. Sealing for air cushion elements
1 pc. 3/2 Electric valve „518 01 002-24V “
1 pc. 3/2 Pneumatic valve „518 01 006“
8 pcs. Filter insert for 40µ „AF40P-060S “
4 pcs. Filter insert for 5µ
1 pc. Tosibox (on loan)
4 pcs. Air-Connection Point Kamlok 1.5”
2 pcs. Teflon tape 12mm x 12m
2 pcs. Antenna
1 pc. Spare key for radio remote control
1 pc. Floor mat 4,5m x 2,5m
1 pc. PTFE Tape 100mm x 30m
1 pc. HDT Tape Black 100mm x 50m
In general, the accessories are packed in boxes and stored inside of the Transporter for shipping.
Covers under which accessory is stored are marked accordingly.
If any of above items are missing, please contact DELU GmbH.
Blatt:

GerätebName:
Date :
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DELU mbH
GmbH
DeDeutsche
11 Nürnberg
Tel. (+49Germany) 0911 / 52 40 15
FTel.
ax +49-(0)911-238888-0
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3. Safety Regulations
In addition to the instructions in this manual, all local accident
prevention guidelines and general safety regulations effective at the
implementation site of the Transporter must be must be observed and
employed at all times.
3.1. Introduction
This product can cause serious injury or death if not used in accordance with the following safety
instructions. We can not anticipate every possible circumstance that might involve a potential
hazard. The warnings, cautions, dangers and safety suggestions are therefore not all inclusive. As
the owner you are responsible for the safe operation of this equipment. Always make sure that
anyone using this equipment or working in the direct vicinity of it has read this manual and follows
the safety warnings to help prevent the possibility of personal injury to the operator or anyone else.
If any operating procedure, installation, maintenance or work method not specifically recommended
is used, you must satisfy yourself that it is safe for you and other persons. You must also ensure
that the product will not be damaged or made unsafe by the procedure you choose.
3.2. Intended use

The Air Cushion Transporting System is not meant for the
transportation of persons. Any abuse is strictly prohibited.
Never exceed the maximum load capacity of the Transporter.
Always place the loads on pallets and never directly onto the
Transporter.
The Air Cushion Pallet Transporter LPT – 80 / GAP is suitable for indoor transportation of
transformers and/or transformer components with a total weight of up to 80 000 kg.
The load is placed on special pallet(s). The pallet(s) can be picked up by the Air Cushion System,
which drives under the pallet. After activating the Air Cushions, the load is lifted from the ground
and can then be moved.
Normal functioning of the Air Cushion Transport System will occur only if the local floor
conditions comply with the requirements as specified in the DELU data sheet No. 100.00 –
100.04 (see chapter 14.1, appendix).
DANGER OF DAMAGE TO THE TRANSPORTER

 Always place the loads on suitable pallets and never directly
onto the Transporter.
 Never exceed the maximum load capacity of the
Transporter.
 The roller castors of the Transporter will be overloaded and
damaged if loads are placed directly onto the Transporter.
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Tel. (+49Germany) 0911 / 52 40 15
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3.3. Specific dangers

Residual risks that have been determined based on a risk analysis are listed below.
Strictly follow the safety instructions listed below and the warning instructions in the other chapters
of this manual to reduce health hazards and to avoid dangerous situations.
Compressed air
DANGER OF INJURY DUE TO COMPRESSED AIR!
 Only have specialized personnel perform work on
components that conduct compressed air.
 Prior to starting service/repair work, block off the
compressed air system, switch it off, and safeguard it from
being switched on again.
 Completely de-pressurize components that conduct or
accumulate compressed air.
 Never open aircouplings under pressure.
 If there is damage, malfunction, or improper operation, air
can escape from lines or individual components under high
pressure and cause severe injury, e.g. to the eyes.
Components which are charged with too much pressure may
explode!
Moving parts
DANGER OF INJURY FROM MOVING PARTS!
 Never operate the Air Cushion Transporter with open and/or
removed covers or without squeeze protection frame.
 Prior to starting service/repair work, turn off the
Transporter, de-pressurize the compressed air system and
safeguard it from being switched on again.
 All repairs to the Transporter should be made only by
authorized and/or trained service personnel.
 Serious injury may occur from moving parts such as drive
wheels, air motors, gear wheels or chains if they come in
contact with you or your clothing. The remote-controlled
Transporter can restart and cause bodily injury when least
expected.
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GerätebName:
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(YYYY-MM-DD):
D ELU G
DELU mbH
GmbH
DeDeutsche
11 Nürnberg
Tel. (+49Germany) 0911 / 52 40 15
FTel.
ax +49-(0)911-238888-0
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3.4. Personnel requirements

There is danger of death, serious bodily injury and/or
property damage when untrained personnel is allowed to
handle THE AIR CUSHION TRANSPORTER!
 Equipment shall be operated only by those who are
responsible and instructed to do so.
 Installation, commissioning, operation and maintenance
may only be performed by qualified, trained and instructed
personnel. The personnel must be thoroughly familiar with
the content of this guide.
Even though the Air Cushion Transporter described in this manual is easy to handle it may be
operated only by personnel qualified for the specific task in accordance with the relevant
documentation for the specific task, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of
identifying risks and avoiding potential hazards when working with the Air Cushion Transporter.
3.5. Personal protective equipment (PPE)

The operator should always wear protective clothing and appropriate safety equipment.
For operating and/or servicing the Air Cushion Transporter we recommend the use of following
Personal Protective Equipment (PPE).
The below mentioned PPE must be worn additionally to any other PPE required by local
regulations and/or company policy.
Safety boots
Durable boots made of leather or rubber that have a steel reinforcement in
the toe to protect the foot against falling objects.
- to be worn by all personnel at all times.
Protective helmet (hard hat)

A lightweight protective helmet, usually of metal or reinforced plastic.
A hard hat is made to protect the head from injury such as from falling
objects.
- to be worn by all personnel at all times.
Eye protection
Protective eyeglasses made with safety frames, tempered glass or plastic
lenses, and temples and side shields that provide eye protection from moderate
impact and particles which could be encountered while working with
pressurized systems such as compressed air.
Safety glasses are also available in prescription form for those persons who
need corrective lenses.
- to be worn while servicing the Transporter
Reflective vest
A vest with high reflective properties or a color that is easily discernible from
any background. For greater visibility during daytime, very bright colors are
used for the main body of the garment by means of fluorescent material.
- to be worn by Transporter operator at all times.
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GerätebName:
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D ELU G
DELU mbH
GmbH
DeDeutsche
11 Nürnberg
Tel. (+49Germany) 0911 / 52 40 15
FTel.
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3.6. Safety signs on the Transporter

danger injury DUE TO MISSING SAFETY DECALS!
 Immediately replace any DANGER, WARNING, CAUTION or
instructional decal on the equipment that is not readable or
is missing.
 The locations and part numbers of these decals are
identified in this section of the manual.
 Safety decals on the equipment warn the user of residual
risks. When missing, it can lead to severe injuries.
Any danger areas encountered during normal operation, maintenance, and servicing are identified
by well visible warning and safety signs (with pictograms) in the immediate vicinity of the danger.
The following table shows the part numbers and location of the safety signs on the Air Cushion
System:
Safety Sign Part No. Location
A-B-0001-EN - 1 decal on each drive

unit
- 4 decals on squeeze
A-B-0003-EN protection frame:
- 1 on each side
A-B-0006-EN - 1 decal next to each air

connection point
- 2 decals on top of side

A-B-0007-EN covers:
- 1 on each side
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Tel. (+49Germany) 0911 / 52 40 15
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Safety Sign Part No. Location
A-B-0008-EN - 1 decal on or near

control panel
A-B-0009-EN - 1 decal on top of front

cover
A-B-0010-EN - 1 on the reaside
A-B-0011-EN - 1 decal under each

hoisting point
A-B-0012-EN - 1 decal next to

emergency control panel
- 2 decals on top of side

A-D-0001-EN covers:
- 1 on each side
Blatt:

GerätebName:
Date :
(YYYY-MM-DD):
D ELU G
DELU mbH
GmbH
DeDeutsche
11 Nürnberg
Tel. (+49Germany) 0911 / 52 40 15
FTel.
ax +49-(0)911-238888-0
(+49) 0911 / 52 35 07 gültig für FaNo.:
Fax +49-(0)911-238888-28 12185 2021/01
3.7. Built-in safety devices

DANGER OF INJURY DUE TO DEFECTIVE SAFETY DEVICES!
 Check the functioning of all safety devices daily.
 In case of any defective safety device the Air Cushion
Transporter must be set out of order until it is repaired.
 Non-functioning safety devices can lead to severe injuries.
Emergency-stop
Only use the emergency stop button in dangerous situations and not for
stopping the machine under normal conditions.
There are two emergency-stop buttons, one on the Transporter, one on the Radio Remote Control
(RRC). Both have the same function. In case the emergency stop button is pressed, the
Transporter will stop immediately and the air cushions will deflate.
To restart the System, the operator must release the emergency stop button and confirm via the
“Start”-button on the RRC.
Squeeze protection frame

If persons stand very close to the Transporter while it is lowering there is danger of serious bodily
injury. The squeeze protection frame prevents injuries due to lifting and lowering of the Transporter.
Fail safe mode

In case of power loss or emergency stops the System will stop and/or turn off. In order to restart
the system, it must be switched on again or the green confirm button on the Radio Remote Control
must be pressed.
Blatt:

GerätebName:
Date :
(YYYY-MM-DD):
D ELU G
DELU mbH
GmbH
DeDeutsche
11 Nürnberg
Tel. (+49Germany) 0911 / 52 40 15
FTel.
ax +49-(0)911-238888-0
(+49) 0911 / 52 35 07 gültig für FaNo.:
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Hose securing grips on supply hose

The supply hose of the transporter is subject to high stress and strains, in particular at the air
connection point. The connection may fracture if overstrain or damage occurs. For this reason, the
supply hose is equipped with a hose securing grip which prevents the hose from coming loose (see
Chapter 7).
Signal horn
The signal horn can be activated via the green press button on the Radio Remote Control.
Deadman Controls
In case the joysticks of the remote control are released, they automatically go back to neutral
position.
Reduced speed (optional)

For critical operations, the operator can switch the Transporter's speed any time from 'normal' to
'slow' via the Radio Remote Control. When switched to 'slow', the speed is reduced to
approximately 50% of the 'normal' speed.
3.8. How to handle hazardous situations or accidents

Immediately stop the Air Cushion Transporter by pressing the emergency stop button on one of
following occasions:
 the Transporter is out of control and moves by itself due to slippery or unlevel floor
 the Transporter does not react to commands
 the Transporter starts to vibrate, shake, swing or jump due to failure in the height control
system or wrong manual pressure setting
 the Transporter makes unusual loud noises due to damaged Air Cushion Elements, air
leakage or damaged pneumatic components
In case an accident with the Air Cushion Transporter has occurred and persons are injured,
follow the first aid instructions as listed below:
 Stay calm.
 If a person is jammed, move the Transporter to free the jammed person or body parts.
 Press the emergency stop button and, if necessary, switch off the main air supply and de-
pressurize the system. Secure the accident site and make sure that no further harm can be
done.
 Administer first aid and call for further aid and/or an emergency doctor if required.
Blatt:

GerätebName:
Date :
(YYYY-MM-DD):
D ELU G
DELU mbH
GmbH
DeDeutsche
11 Nürnberg
Tel. (+49Germany) 0911 / 52 40 15
FTel.
ax +49-(0)911-238888-0
(+49) 0911 / 52 35 07 gültig für FaNo.:
Fax +49-(0)911-238888-28 12185 2021/01
3.9. Spare parts

DANGER OF INJURY DUE TO WRONG SPARE PARTS!
 Immediately replace defect or worn-off parts.
 Only use original spare parts from DELU.
 Wrong, defect or non-original parts may lead to unforeseen
malfunctions and/or serious accidents.
Make sure that the Transporter is regularly checked and maintained according to the vendor's
specifications and maintenance plans. Defective parts are to be replaced immediately. Only use
original spare parts from the vendor.
See Chapter 13 for a list of common spare parts or contact DELU in case you need other spare
parts.
3.10. Environmental protection
Noise level
At a distance of 3'-3" (1 m), the noise level of the Transporter is generally below 70 dB(A).
Disposal of lubricants
Oil is harmful to the environment. Take used oil and/or grease from the
exhaust filter, lubricators, bearings, and, if applicable, the hydraulic
system, to an approved (chemical) waste disposal company.
Work at all times in accordance with local laws and regulations.
Never pour used oils into sewers, drains or on the ground.
Regularly check and empty the oil container of the exhaust
lubricators.
3.11. Responsibilities of the employer / user

The employer of the Air Cushion System has to make sure that the requirements, as described in
this chapter, are fulfilled and followed by the personnel at all times. It is the responsibility of the
employer that the Transporter is serviced and inspected regularly and to make sure the Transporter
is in safe operating condition at all times. Additionally, the employer is responsible for placing
warning signs in accordance with the local laws. The operator(s) have to strictly follow these signs.
Environmental conditions
The environment of the Transporter can have significant influence for its safe operation. In order to
avoid hazardous situations, the environment must meet following requirements.
General conditions
The Air Cushion Transporter is designed for indoor usage only. It may not be used outdoors and
may not be exposed to heat, rain, snow, frost or ice. The permissable temperature is +5 to +40 °C
(+41 to +104 °F) and humidity 10 – 90 % RH (non-condensing).
Floor condition
The Transporter may only be used on suitable floors which are strong and stable, level, smooth
and air-tight. In case the floor is wet, oily, dirty, inclined or wavy, the drive motors may slip and the
Transporter can move on its own.
The floor must strictly meet the requirements as specified in DELU data sheet No. 100.00 – 100.04
(see appendix). Any defects to the floor coating (such as cracks, holes, etc.) must be immediately
repaired.
Blatt:

GerätebName:
Date :
(YYYY-MM-DD):
D ELU G
DELU mbH
GmbH
DeDeutsche
11 Nürnberg
Tel. (+49Germany) 0911 / 52 40 15
FTel.
ax +49-(0)911-238888-0
(+49) 0911 / 52 35 07 gültig für FaNo.:
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Floor markings of the driveways

The working areas and/or driveways of the Air Cushion Transporter should be indicated by good
visible floor markings. Except from the operator(s), no persons are allowed to enter the working
area. While the Transporter is under operation, the working area must be closed for other traffic (as
trucks or forklifts). Additionally, suitable walkways for pedestrians have to be foreseen and must be
indicated accordingly.
Keeping the driveways clean and illuminated

The working area of the Transporter must be well illuminated and free of water, oil or debris. Prior
to each movement of the Air Cushion Transport System the working area of the Transporter(s)
must be inspected and cleaned of production debris and any other excessive dirt or oil.
Air Connection Point(s)

The air connection point(s) have to be equipped with a 3-way ball valve which allow de-
pressurizing the Transporter. Also, the air connection point(s) must be equipped with safety hooks
and/or a chain for securing the hose grip of the Transporter's supply hose. See chapter 7.2 in this
regard.
The safety sign "Warning of compressed air" (part no. A-B-0006-EN, see chapter 3.6) must be
placed next to each air connection point.
High voltage areas

Please consider that the Air Cushion Transporter is equipped with sensitive electronic components.
Never expose the Transporter to high electric fields. Should you have to use the Transporter near
high voltage areas with strong electric fields and/or impulses, make sure to protect it properly by
shielding or earthing it.
During high voltage tests, the Transporter should not be used or parked
within or near the testing area.
Transporter condition
The employer is responsible for the safe operation of the Air Cushion Transport System, the
Transport Pallets and all other system components.
Keep the transporter covers and the electric cabinets closed during normal use.
The employer must make sure that the Air Cushion Transport System and all related devices and
equipment are maintained and checked regularly at least once a year. These regular check-ups
must extend on checking the condition of the components and devices, the completeness and
functioning of the safety devices, as well as on the completeness of the test protocols.
The checks may only be performed by qualified personnel. Qualified personnel are those who,
based on their training and experience, are capable of identifying defects and correctly judge the
condition of the Air Cushion Transporter and all related devices and equipment.
In case no qualified personnel are available, please contact DELU for a professional maintenance
service.
Blatt:

GerätebName:
Date :
(YYYY-MM-DD):
D ELU G
DELU mbH
GmbH
DeDeutsche
11 Nürnberg
Tel. (+49Germany) 0911 / 52 40 15
FTel.
ax +49-(0)911-238888-0
(+49) 0911 / 52 35 07 gültig für FaNo.:
Fax +49-(0)911-238888-28 12185 2021/01
3.12. Safety distances

DANGER OF CRUSHING INJURIES OR DEATH!
 The operator must make sure that they and other persons
keep a sufficient safety distance to the moving Transporter
and the Load.
 Keep in mind that the stopping distance of the fully loaded
Transporter can be 20" (500 mm) or more.
 Also watch the top of the load, not only the Transporter.
 Failure to keep a safety distance can lead to accidents with
severe injuries or death.
Safety distance to other objects

When moving the Air Cushion Transporter around, make sure to keep a safety distance of
minimum 500mm (20 inch between the Transporter (with its load) and other objects like walls,
machines, vehicles, etc.
Please keep in mind that the stopping distance of the Air Cushion Transporter can change,
depending on the load, floor surface, floor levelness, etc. In case the floor is wet or oily, the
stopping distance can increase significantly.
When driving close to other objects or walls use the "slow speed" function on the Radio
Remote Control.
Figure 3 avoidance of crushing hazards
Pallet clearance
When lifting the pallet/load, the clearance between the pallet and the floor must not be higher than
20mm (¾ inch). It must not be possible to move a foot under the gap in order to avoid crushing
injuries.
In case the Transporter lifts the pallet too high check the Height Control Sensors for dirt or
damage.
Blatt:

GerätebName:
Date :
(YYYY-MM-DD):
D ELU G
DELU mbH
GmbH
DeDeutsche
11 Nürnberg
Tel. (+49Germany) 0911 / 52 40 15
FTel.
ax +49-(0)911-238888-0
(+49) 0911 / 52 35 07 gültig für FaNo.:
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4. Storage and transport

4.1. Receipt
Check the goods on receipt for signs of transport damage. If transport damage is found, report it
immediately in written detail to the delivery company and DELU Luftkissentechnik GmbH.
Photograph any damage and keep the packing available for inspection.
4.2. Packing
Unless otherwise agreed, the Air Cushion Transport System will be packed and sealed on wooden
platforms or in wooden boxes.
4.3. Storage
If the Air Cushion Transport System is not going to be put into operation right away, it is
recommended that the structural units which comprise the System be kept in their original packing.
Avoid sudden impacts and excessive vibrations.
The storage area must meet the following specifications:
- Air humidity: 10 – 60 % RH (relative humidity)
- Temperature: 5 to 40 °C (41 to 104 °F).
Blatt:

GerätebName:
Date :
(YYYY-MM-DD):
D ELU G
DELU mbH
GmbH
DeDeutsche
11 Nürnberg
Tel. (+49Germany) 0911 / 52 40 15
FTel.
ax +49-(0)911-238888-0
(+49) 0911 / 52 35 07 gültig für FaNo.:
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4.4. Unpacking
Make sure that no System components become damaged during unpacking!
Check that the delivery is complete from the packing receipt. Any defective or damaged
components or non-conformities should be immediately reported to the transport company and
DELU Luftkissentechnik GmbH.
4.5. Internal transports

DANGER OF INJURY FROM WRONG CRANE HANDLING
 Only use sound and approved lifting gear and transportation
equipment!
 Check the net weight of the Transporter (on the type plate
or in the manual) before choosing the lifting gear.
 Always use all four hoisting points.
 The chain angle should not exceed 45°.
 Don't step under the Transporter when it is lifted by the
crane.
 Use safety supports while performing maintenance works
under the Transporter.
 Only use the four hoisting points for lifting the Transporter.
 Wrong crane handling can lead to severe crushing injuries or
death!

 Disconnect the air supply hose and completely depressurize
the Transporter before lifting it up.
 Always keep the Air Cushion Transporter level.
 The Air Cushion Transporter must be lifted only by crane and
by using the hoisting rings.
 The roller castors of the Transporter will be overloaded and
damaged if loads are placed directly onto the Transporter.
The Air Cushion Transporter can be hoisted using the crane anchorage point situated on each side
of the Transporter.
For crane handling ensure that following measures are taken:

- The Transporter must be unloaded.
- The Transporter must be completely depressurized and
relieved of trapped compressed air in its internal hoses and
pneumatic components.
- The supply hose must be disconnected and completely
wound.
- For service or function tests the wheel pressure must be
turned off (if not, the air bellows can be damaged).
- Don't activate the air cushions while the Transporter is Figure 4 crane anchorage point
raised.
- After each crane transport, the hoist rings must be
completely re-lowered.
Blatt:

GerätebName:
Date :
(YYYY-MM-DD):
D ELU G
DELU mbH
GmbH
DeDeutsche
11 Nürnberg
Tel. (+49Germany) 0911 / 52 40 15
FTel.
ax +49-(0)911-238888-0
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5. Transport pallets and loading
DANGER OF INJURY FROM WRONG LOADING

 The maximum load capacity of the pallet must never be
exceeded.
 Loads must be secured properly, especially if they are tall
and/or have a small contact area with the pallet.
 When necessary, higher loads must be distributed on two
(or more) pallets.
 Wrong loading can cause the load to fall and lead to severe
crushing injuries or death!

 Never place loads directly on the Transporter.
 Always use suitable pallets.
 Placing loads directly on the Transporter will damage the
Transporter's swivel casters, drive units or other
components.
The Air Cushion Transporters may only be used in connection with suitable air cushion transport
pallets. See attached drawings in appendix.
When loading the pallets, the below points must be followed:
- The loads should always be positioned on the pallets so that the center of gravity of the load
matches the center of the pallet.
- The load must stand stable on the pallet and must be secured properly against tilting or falling.
It must be made sure that no loose parts can fall off the load.
WARNING! Take into account that there will be acceleration and

braking forces affecting the load during transport. Loads which are not
secured properly may easily fall and cause severe injuries or death.
- The contact area between the load and the pallet should be as big as possible. In case of a
small contact area, it should be enlarged by a substructure or filling material.
Blatt:

GerätebName:
Date :
(YYYY-MM-DD):
D ELU G
DELU mbH
GmbH
DeDeutsche
11 Nürnberg
Tel. (+49Germany) 0911 / 52 40 15
FTel.
ax +49-(0)911-238888-0
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6. Initial operation of the Transporter

 Clear your plant air lines before System start-up.
 The compressed air line, which is connected to the System, has
to be checked with respect to debris and/or water.
 A cooling dryer for the air supply system is required.
 If necessary, the air lines must be thoroughly blown out and
cleaned.
 If particles (like rust film, iron fillings, etc.) and/or water reach
the Air Cushion Transporter by the compressed air, the System
will not function properly.
We recommend doing the initial commissioning of the Transporter under supervision of a trained
DELU technician. All operators must receive proper and system specific training before they may
use the Air Cushion Transporter(s).
When starting the Air Cushion Transporter, take note of the following factors:
- The Transporter may only be used in connection with a suitable transport pallet (see chapter
5). The drive-in height and width of the pallet(s) must be checked before first usage.
- The Transporter may only be operated on an air supply system with sufficient pressure and
volume flow. See related data sheets in the appendix.
- The Transporter may only be used indoors, in a suitable environment (see chapter 3.11.1)
- The air connecting point for the compressed air hose should be equipped with a 3-way ball
valve, which (when closed) automatically relieves the Transporter of trapped compressed air
in its internal hoses and pneumatic components (see chapter 7.2).
- Put a safety label type "A-B-0006-EN" (see chapter 3.6) next to each air connection point
- The air connecting point should be equipped with a hook to secure the hose grip of the air
hose (see chapter 7).
- After connecting the Air Cushion Transporter to the compressed air supply, the following must
be checked for possible transportation damage:
 Air-tightness of the pneumatic equipment
 Mechanical damage
 Status of the air cushion elements
 Functioning of the safety devices
- The load status of the batteries in the Transporter and the remote control console has to be
checked. Probably they must be charged by means of the supplied power chargers (see
chapter 11.4).
- When the Air Cushion Transporters are delivered, some components may be disassembled
for transportation safety. These components must be installed before starting the System:
 Air Cushion elements
 Radio antenna(s)
 Squeeze protection frame (usually secured with holding straps)
Blatt:

GerätebName:
Date :
(YYYY-MM-DD):
D ELU G
DELU mbH
GmbH
DeDeutsche
11 Nürnberg
Tel. (+49Germany) 0911 / 52 40 15
FTel.
ax +49-(0)911-238888-0
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7. Air supply
DANGER OF INJURY FROM COMPRESSED AIR

 Never open couplings under pressure.
 Always secure hoses using the hose grips while
connected to the air supply.
 Always secure Camlock-type couplings with a locking pin
against unintended opening.
 Never leave unused hoses connected to the air supply.
 Always watch the remaining length of the supply hose.
 Keep hoses clean off sharp edges or objects.
 If pressurized hoses come loose, they can whip in
random direction and cause severe injuries or death!
7.1. Main air supply

The pneumatic connection is made via a hose connection. The main supply hose is stored on an
external hose reel.
When the Transporter moves forward, the hose automatically unwinds and is laid stress-free on the
floor.
To guarantee full performance of the Air Cushion Transporter, the air supply must deliver
sufficient air volume and air pressure. We recommend a system pressure between 7 and 10
bar (100 - 145 psi). The current pressure is displayed on the pressure gauge on the
operating panel.
7.2. Air connection point

The safety sign "Warning of compressed air" (part no. A-B-0006-EN, see
chapter 3.6) must be placed next to each air connection point.
The air connection point(s) (see Figure 5 for example) must be equipped with a 3-way ball valve
and suitable safety hook(s), which allow the hose grip(s) to be attached securely. The air
connection point must have enough stability so it cannot twist or get loose when the hose is
connected and under stress.
In case Camlock-type couplings are used, the couplings must always be secured with safety pins
to prevent accidental opening of couplings under pressure (see Figure 7). Additionally, the supply
hose is equipped with a hose grip (see Figure 8).
The hose grip relieves the coupling of direct stress or strain which can occur when the hose is
pulled. Figure 6 shows how to install the hose grip. The air hose may not be used without a
properly installed hose grip.
Blatt:

GerätebName:
Date :
(YYYY-MM-DD):
D ELU G
DELU mbH
GmbH
DeDeutsche
11 Nürnberg
Tel. (+49Germany) 0911 / 52 40 15
FTel.
ax +49-(0)911-238888-0
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Figure 5 Air connection point (example) Figure 6 Hose grip installation
Figure 7 Camlock-type coupling Figure 8 Supply hose
In Figure 9 and Figure 10 the working principle of the air connection point is explained.
When closing the air supply via the 3-way ball valve at the connection point, the hose is
automatically depressurized and can safely be disconnected. For winding the hose after the supply
hose has been disconnected, the Transporter has built-in air tanks with back pressure valves for
storing some compressed air. There is a button on the control panel via which the hose can be
wound without being connected to the air supply.
In this position the

compressed air is flowing
from the air supply through
the coupling and into the
supply hose of the
Transporter while the noise
absorber is blocked.
Figure 9 Working principle air connection point (On)
For closing the air

connection, the handle must
be pushed in position B.
Now the air supply is locked
and the remaining
compressed air in the
supply hose and the
pneumatic components of
the Transporter is relieved
through the noise absorber.
Figure 10 Working principle air connection point (Off)

Blatt:

GerätebName:
Date :
(YYYY-MM-DD):
D ELU G
DELU mbH
GmbH
DeDeutsche
11 Nürnberg
Tel. (+49Germany) 0911 / 52 40 15
FTel.
ax +49-(0)911-238888-0
(+49) 0911 / 52 35 07 gültig für FaNo.:
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7.3. Depressurizing the Transporter

DANGER OF INJURY FROM COMPRESSED AIR
 Even after depressurizing the Transporter, as described in
this chapter, there may still be some components inside the
Transporter, such as air tanks, which are still under pressure.
 Pay attention to the safety labels on pressure vessels inside
the Transporter.
 When servicing pressure vessels and/or components
connected to them, first make sure they are not still under
pressure.
 Only specially trained personnel may service pressure
vessels like air tanks.
 Compressed air can cause severe injuries or death!
For depressurizing the Transporter, completely close the valve of the air connection point as shown
in Figure 10 (position B) while the supply hose is still connected. After doing so, the Transporter is
relieved of the trapped compressed air in its internal hoses and pneumatic components.
RISK OF INJURY CAUSED BY LOCKED PRESSURE

Even after depressurizing the Transporter, as described in this
chapter, there may still be some components inside the
Transporter which are still under pressure.
While depressurizing, the relieved air is audibly discharged through the noise absorber of the air
connection point.
Always check if the system is really depressurized by squeezing the supply hose with your
hand. If the supply hose feels hard it is still under pressure!
Blatt:

GerätebName:
Date :
(YYYY-MM-DD):
D ELU G
DELU mbH
GmbH
DeDeutsche
11 Nürnberg
Tel. (+49Germany) 0911 / 52 40 15
FTel.
ax +49-(0)911-238888-0
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8. Operation
8.1. Description of the operating elements and functions
Radio remote control (RRC)
Figure 11 Radio Remote Controle Desk
On the radio remote control you find the following operating elements
Right hand side
Element Name Symbol Function(s)
Key switch - securing from unauthorized access

System On
"On-Off" - switching on the radio transmitter
Press button Hose Reel

- Not Applicable in this device
(black)
Left hand side

- Start / activate radio transmission.
Start / - Confirmation after releasing the
Press button Signal Horn / Emergency Stop Button.
(green) Confirm - Bypassing the automatic stop function in
case the hose is completely unwound
- Blowing the signal horn.
Blatt:

GerätebName:
Date :
(YYYY-MM-DD):
D ELU G
DELU mbH
GmbH
DeDeutsche
11 Nürnberg
Tel. (+49Germany) 0911 / 52 40 15
FTel.
ax +49-(0)911-238888-0
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Top side

If the Emergency Stop Button is pressed
down, all functions of the System are
immediately stopped. The Air Cushion
Transporter is lowering on the floor.
Press button Emergency
(red) Stop
After releasing the “EMERGENCY STOP”
button the “START” button (green press
button on left side) must be pressed for
confirmation and returning to normal mode.
Direction of movement
Lateral The transporter moves in lateral direction.

movement The drives rotate 90 ° to drive sideways.
Switch
(3 positions)
Longitudinal The transporter moves in longitudinal
movement direction.
Air Cushion Gear
The Transporter drives on its wheel gear. The

Empty
Air Cushions are turned off.
The Transporter drives on its four outer air

Select switch
Pallet cushions only. This is necessary for moving
(3 pos.)
empty pallets or small loads.
The Transporter drives on all air cushions.

Load
This is necessary for moving heavy loads.
Driving speed
The maximum speed is limited to approx.

Slow 8 m / min.
This speed is only used for fine positioning.
Select switch
(2 pos.)
The Transporter drives on its four outer air
Fast cushions only. This is necessary for moving
empty pallets or small loads.
Blatt:

GerätebName:
Date :
(YYYY-MM-DD):
D ELU G
DELU mbH
GmbH
DeDeutsche
11 Nürnberg
Tel. (+49Germany) 0911 / 52 40 15
FTel.
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Gap Transit
The inner- and intermediate air cushions are

Gap Transit
inflated
position A
The outer air-cushions are deflated
Select switch Gap Transit The inner- and air outer cushions are inflated
(3 pos.) position B The intermediate air-cushions are deflated
The intermediate - and outer air cushions are

Gap Transit
inflated.
position C
The inner air-cushions are deflated
The gap transit is shown in chapter 8.4.3
Joysticks

Steering
During longitudinal mode, the
Longitudinal mode: joystick can be used to set the
Driving direction and direction of travel and
speed speed can be controlled depending
Left Joystick on the lever deflection
(2 pos.)
During lateral mode, the left joystick
Lateral mode:
can be used to control the direction
Driving direction and
and speed of the left drive
speed left (front) drive
depending on the lever deflection
Steering while driving:
- Only the front drive deflects
(depending on the direction of
travel)
Longitudinal mode:
- Used to adjust the direction of
Steering proportional
travel
Right Joystick Steering before driving:
(4 pos.) - Both drives steer out
- Used for tight cornering
During lateral mode, the right
Lateral mode:
joystick can be used to control the
Driving direction and
direction and speed of the right drive
speed right (rear) drive
depending on the lever deflection
The driving behavior when driving longitudinal and latteral is shown in chapter 8.4.1
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DELU mbH
GmbH
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Tel. (+49Germany) 0911 / 52 40 15
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Operating panel (OP) on the Air Cushion Transporter
The Operating Panel, is located on the rear side of the transporter.
The OP gives the operator an overview of the status of the Air Cushion Transporter, as well as
additional functions.
These are:
Control elements
Shows the operating pressure connected to the
SYSTEM PRESSURE Manometer
system
BATTERY LEDs Indicates the charge status of the batteries
By pressing the button the control circuit of the
White button
SYSTEM ON transporter is switched on. When the control
with green LED
circuit is running, the button lights up green
Red push button After pressing the EMERGENCY STOP button,
all functions of the transporter are stopped
immediately. The transporter sets down the
EMERGENCY STOP load.
After the button has been released again, the
Beneth red LED transporter must be released again by pressing
the "Start" button on the radio remote control.
Warn LEDs
There are three LEDs on the operating panel that display error messages and warnings.
The display is coded as follows:
if the LED is permanently lit, the condition on the left applies
if the LED is flashing, the right state applies
LOW PRESSURE The system pressure is too low (≤ 4 bar)
There is a malfunction at the interface between the radio
RADIO ERROR
remote control and the PLC
The hose is almost completely unwound from the hose reel.
HOSE WARNING
The driving speed is set to creep speed
The hose is completely unwound. The transporter stops and
HOSE END
can only be driven backwards
The drives switch between longitudinal and transverse travel,
WHEEL ROTATION the transporter cannot be moved during the process until the
drives are fully aligned
Status LED’s
ACTIVE AIR-
12 Green LED’s Shows the active air-cushions for the gap transit
CUSHIONS
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System control panel (SCP)

The control panel is located in the cabinet on the rear side of the Transporter. On this panel all
pressure regulators can be found in the associated pressure gauges
Figure 12 System control panel (SCP)
Name Function Target

pressure
CONTROL Pressure setting for the pneumatic control circuit 6 – 7 bar
PRESSURE
AUTOMATIC The max. pressure for the automatic air-cushion max. 5 bar
control is limited
HOSE REEL Pressur setting the speed of the hos-reel 2 – 4 bar
WHEEL PRESURE
WHEEL -
Switch to turn of the wheel pressure during the
PRESSURE ON
recovery in case of havarie of the transporter
/ OFF
LOAD adjusting the contact pressure of the drive wheel, while ≈ 4 bar
the transporter is set to load mode
NO LOAD adjusting the contact pressure of the drive wheel, while ≈ 2 bar
the transporter is set to no load mode
RISK OF INJURY CAUSED BY MALOPERATION

The wrong settings can affect the safety of the vehicle.
Change the default settings only for service of the vehicle. After
service, restore to the default settings.
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Tel. (+49Germany) 0911 / 52 40 15
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Emergency control panel (ECP)

The emergency control panel is located in the rear of the transporter. It is used for manual
operation of the transporter (see chapter 8.4.4 Emergency control)
Figure 13 Emergency control panel
Element Function Function

WHEEL
- Switching off the wheel pressure during the transporter
Toggle switch PRESSURE
recovery
ON/OFF
A.C. MANUEL - Switching the air cushion operation between automatic
Toggle switch
ON/OFF height control and manual operation
4 pcs. A.C. Manuel
pressure FRONT LEFT
- Air cushion pressure in manual operation for the
regulators FRONT RIGHT
respective air cushion groups
+ pressure BACK LEFT
gauges BACK RIGHT
selector switch
GAP DRIVE - Change of the air cushion groups during the gap transit
3 - positions

 Use only in an emergency when the automatic control is no
longer working.
 Before you switch off the wheel pressure, make sure that
the transporter is secured against unintentional movements.
 Close the pressure regulators after the movement.
 The emergency stop has no influence on the manual control
of the air cushions!
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Tel. (+49Germany) 0911 / 52 40 15
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8.2. Starting the transporter

In order to set the transporter into operation, the following steps must be followed in
sequence:
 All EMERGENCY STOP switches on the transporter and radio remote control must be
unlocked
 Set all switches on the radio remote control in neutral position:
Driving mode:
longitudinal
Air-cushion mode:
Empty
 Switch on the transporter
SYSTEM ON:
The button lights up green
 Switch on the radio remote control
System on:
The green LED on the RRC flashes
 Press confirmation on the radio remote control
Confirmation:
Transporter gives an acoustic
signal as confirmation
The transporter is now ready for use
8.3. Turn off the transporter properly

In order to turn off the transporter, the following steps must be followed in sequence:
 Put all switches on the radio remote control in neutral position:
Driving mode:
longitudinal
Air-cushion mode:
Empty
 Turn OFF the RRC
System off
The transporter automaticaly turns off after approx. 30 seconds

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D ELU G
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Tel. (+49Germany) 0911 / 52 40 15
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8.4. Driving modes
longitudinal- and lateral movement

the transporter can move in following directions:
Figure 14 driving behaviour while longitudinal and lateral movement
longitudinal:
In longitudinal mode, both drives are controlled via the left joystick and can be
deflected to ± 30 ° via the right joystick.
lateral:
In lateral mode, both drives are controlled independently of the left and right
joystick
Rotation on the spot is possible with opposite control
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driving curves (longitudinal mode)

There are two ways of steering in the longitudinal mode
Figure 15 wide- and tight curves
a) wide curves
Only the front drive (in relation to the direction of movement) deflects while the rear drive remains
straight
For using this mode, the operator must:

 (1.) first move the LPT forward or backward by using the left joystick,
 (2.) while the LPT is moving use the right joystick for steering left/right
b) tight curves
The LPT can also drive very tight curves with about 50% smaller turning radius than normal.
For using this mode, the operator must:

 (1.) first use the right joystick for steering left or right while the LPT is halting,
 (2.) now both drive units are turning and when driving forward/backward by using the left
joystick, the operator can drive around tight curves
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D ELU G
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DeDeutsche
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Tel. (+49Germany) 0911 / 52 40 15
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Gap transit
the transporter can run over gaps in the floor. For this, eight of the twelve air cushions can be
activated in three different constellations.
Figure 16 air-cushion constellations for gap-transit
Gap transit can only be used in longitudinal drive mode!
The active air-cushions are showen on the operating panel at the schematic representation:
“ACTIVE AIR-CUSHIONS”
In order to run the loaded transporter over a gab, the following steps must be followed in
sequence:
 Set all switches on the radio remote control in neutral position:
Driving mode:
longitudinal
Gap Transit:
position A
 Drive with the transporter over the gap untill it passes the gap with the first air-cushion row.
Showen by markings on the pallet.
Figure 17 1st step for gap transit

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 Switch on the radio remote control to gap transit position B
Gap Transit:
position B
 The transporter will set down briefly to switch the air cushion groups
 When air-cushions are inflated again, the transporter can run further until the second air-
cushion row passed the gap.
Figure 18 2nd step for gap transit
 Switch on the radio remote control to gap transit position C
Gap Transit:
position C
 When air-cushions are inflated again, the transporter can run further until the third and fourth
air-cushion rows passed the gap.
Figure 19 3rd step for gap transit

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DeDeutsche
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Tel. (+49Germany) 0911 / 52 40 15
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Gap Transit:
position B
 When air-cushions are inflated again, the transporter can run further until the fith air-cushion
row passed the gap.
Figure 20 4th step for gap transit
Gap Transit:
position A
 When air-cushions are inflated again, the transporter can run further until the sixth air-cushion
row passed the gap
Figure 21 5th step for gap transit
 The transporter has passed the gap. Now the transporter can continue to drive in any required
drive mode
Gap transit can also be used in manual moder, see chapter 8.4.4 Emergency control.
The sequence is the same as showen obove. To change the active air-cushions use the switch on
the Emergency Control Panel.
The labelingon the Emergency Control Pannel corresponds to the labelingon the radio
remote control
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Tel. (+49Germany) 0911 / 52 40 15
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Emergency control
In an emergency (failure of the PLC, interruption of the radio link, etc.), the transporter can be
operated with a load using the emergency control.
 The necessary components for the emergency control are part of the control panel inside the
cabinet of the transporter
Figure 22 emergency control
 Deactivate the wheel pressure with the toggle switch ①

 Make sure that the pressure regulators are completely closed (turned as much as possible
counter clockwise) ③
 Activate manual air cushion control with the toggle switch ②
 Increase the pressure of the air cushions slowly and evenly until the transporter glides ③
 In case the gap transit is required while manauel air-cushion control the air-cushions can be
swiched with leaver ④ in the same way as on the RRC
If the pressure has been set correctly, the transporter can be moved using a forklift.

 Use only in an emergency when the automatic control is no
longer working.
 Before switching off the wheel pressure, make sure that the
vehicle is secured against unintentional movements.
 Close the pressure regulators after the movement.
 The emergency stop has no influence on the manual control
of the air cushions!
After using the emergency control, reset the above measures in reverse order.
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Tel. (+49Germany) 0911 / 52 40 15
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8.5. Picking up and setting down loads

With the Air Cushion Transporter, it is possible to transport different loads by placing them on
special transport pallets (TAP – see chapter 5) which exactly fit to the Transporter shape. The
loads must always be put on the pallets and never directly on the Transporter. If loads are placed
directly on the Transporter, this will cause damages to the wheel castors which are only designed
to carry the own weight of the Transporter.
When placing a load on the pallet take care that its center of gravity is close to the center of the
pallet. The load capacity of the pallet can be determined from the corresponding load diagram (see
chapter 5).
Picking up pallets
 Step 1)
Make shure every switch on the RRC is in neutral position
Driving mode:
longitudinal
Air-cushion mode:
Empty
 Step 2)
Now the Transporter is driving on swivel castors and can drive under the pallet. While driving
under the pallet make sure the drive-in angle is not too big and that there is enough space
between the load bars of the Transporter and the pallet.
 Step 3)
After the Transporter is standing centered under the pallet, the air cushions can be activated
by switching to "Load" on the RRC:
Air-cushion mode:
Load (with load on the pallet)
 Step 4)
After activating the air cushions, they will inflate and lift up the pallet. Depending on the load,
this process can take up to 1 minute. If the load is not distributed evenly it may happen that
one side or corner comes up faster than the rest. Eventually, the pallet should have a
clearance of at least 10 mm (3/8 in.), but no more than 25 mm (1 in.)
Always check the lifting height on all sides of the pallet before starting movements. Immediately
stop the Transporter and check for defect components or other problems if the lifting height is too
high or too low. The Transporter may only be driven after the pallet has reached the correct lifting
height. Close the pressure regulators after the movement.
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D ELU G
DELU mbH
GmbH
DeDeutsche
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Tel. (+49Germany) 0911 / 52 40 15
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DANGER OF INJURY CAUSED BY NO ACTIVE EMERGENCY

STOP WHILE USING MANUAL CONTROL
The emergency stop has no influence on the manual control of
the air cushions!
After checking the lifting height, you may start moving the Transporter.
Setting the pallet down
 Step 1)
Position the Transporter with the load and/or the pallet to the desired end position and switch
the air cushion gear to "off".
Air-cushion mode:
Empty
 Step 2)
The air cushions will deflate and the pallet sinks to the ground. Also, the wheel pressure will
be deactivated and the bellows of the drive unit deflate, which takes about 15 seconds. During
this time the Transporter can not be moved.
Now the Transporter may be driven out from under the pallet.
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Tel. (+49Germany) 0911 / 52 40 15
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9. Technical data
 Type: LPT – 80 / GAP
 Nominal load capacity 80.000 kg
 Maximum load capacity 116.000 kg

 (8 air-cushion at 4 bar)
 Dimensions:
o Length loading bars 5.296 mm
o Width 1.990 mm
o Height loading bars 335 mm
o Length total 5.396 mm
 Empty weight 3.250 kg
 Air-cushion type 146 LE-KH 4-74 AC

o Amount 10 pcs.
o Lifting height of the air cushion ca. 25 mm
 Air-cushion control
o Type USS
o Sensor name UNAM 12U9914/S14
 Drive unit
o Type DAL-1000-DP10-0
o Amount 2 pcs
o Driving speed (slow) 0 - 8 m/min
o Driving speed (fast) 0 - 15 m/min
 Braking distance
o Without load < 100 mm
o With load < 250 mm
 Supply hose 1½“; 50m
 Air-connection
o Air connection coupling Camlock (1.5“)
o Required air pressure min. 7 bar
 Noise level 70dB ca.
 Environmental conditions for operation

o Operating temperature 0 – 50 °C
o Position indoors only
o Humidity (environment) 10 – 90 % RH
(relative humidity)
not condensing
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D ELU G
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10. Maintenance
10.1. Maintenance plan
half
Maintenance task weekly monthly yearly
year
Transporter
Clean Transporter inside and outside with
vacuum cleaner and remove oily areas with x
solvent.
Drive Unit
Check tightness of nuts and bolts x
Lubricate drive chains x
Check chain tension x
Visually check drive wheels for damage x
Check air bellows for damage x
Check tension of the steering regulator’s tooth
x
belt –  don’t change, check only!
Check oil levels of the oilers – refill if necessary x
Check drop frequency of the oilers
x
(~ 4-6 drops per minute)
Empty oil Exhaust Filter/Noise Absorber x
Change Filter Insert of Exhaust Filter/Noise
x
Absorber
Electric Height Control
Clean electric sensors x
Check and re-tighten loose bolts of holder x
Air Cushion Elements
Dismantle air cushions and wash them with
warm soapy water then rinse with cold water x
and dry them with a cloth.
Check air cushions for damage then brush them
x
with french chalk (talcum powder)
Check cellular rubber on the air inlet for damage x
Re-install air cushions (check for correct
x
positioning)
Maintenance Plan, Part 1 / 2
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GerätebName:
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half
Maintenance task Weekly monthly yearly
year
Pneumatic Components
Check main supply hose for abnormal wear or
x
damage (should be replaced after 6 years)
Check hose pull relief x
Check tightness of the hose connections x
Check pneumatic installation for audible air loss x
Clean Main Filter x
Change Filter Insert of Main Filter x
Clean Micro Filter x
Change Filter Insert of Micro Filter x
Squeeze protection frame
Test function x
Check brush rail x
Check for damage x
Batteries
Charge batteries of remote control panel daily
Charge the batteries of the Transporter
x
(take note of the indicators on the Transporter)
Operation Panel (OP)
Check condition of OP daily
Check proper functioning of all switches x
Check condition and assembly of the antennas x
Radio Remote Control Console (RRC)
Check condition of RRC daily
Check proper functioning of all switches x
Function Test
Complete proper functioning testing of the
x
Transporter
Maintenance Plan, Part 2 / 2
Above indicated intervals are just recommendations. The user is free to adapt the intervals
reasonably to their own requirement.
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Tel. (+49Germany) 0911 / 52 40 15
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10.2. Maintenance of the air cushion elements
The air cushions should be checked once a month or when they have come into contact with oil or
other aggressive liquids.
 Access to the air cushion elements is easy, only the anti-crushing frame has to be removed or
lifted. After opening the air cushion locks, the elements can be pulled out of the cassettes (see
figure below).
 Check the air cushion elements for damage and replace if necessary. Defective air cushion
elements may only be repaired by DELU.
 Clean the air cushion elements with a cloth or a brush (not a metal brush)
 If an air cushion element has come into contact with oil or aggressive liquids, wash it off with
warm soapy water, rinse it with clear cold water and dry it with a cloth.
 Check whether the air inlet is dirty.
 Check that the rubber seal on the air inlet is in good condition.
 Finally, brush the air cushion elements with talcum powder. This keeps the rubber elastic and
extends its useful life.
 Before you pack the air cushion elements back into their cassettes, check whether the
cassettes are damaged.
Damaged air cushion elements can be sent to DELU for repair and
overhaul. Call us or send us an email for more information.
Figure 23 Disassembly of the air cushion elements

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D ELU G
DELU mbH
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Tel. (+49Germany) 0911 / 52 40 15
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10.3. Maintenance of the pneumatic components
Air filters and lubricators

If no others are indicated it is only allowed to use the following lubricants.
DANGER OF INJURY CAUSED BY COPRESSED AIR

 Never open the lubricator while system is under pressure
 Wear Eye Protection Glasses
 Compressed air can cause severe injuries or death!
RISK OF DAMAGE THE TRANSPORTER BY WRONG

LUBRIKATION
 Do not overfill the oil tank, else the oil is flowing back into
the filter and can cause malfunction in the control circuit
 Take care of the oil level and the function of the lubricator,
otherwise the drive motors can damage rapidly!
Name Instructions Picture

The plastic reservoir on the bottom has to be emptied
monthly, depending on the hours the Transporter is in
use.
WARNING!
Overflow of the reservoir may cause a slippery surface
Exhaust filter on the floor,
which could cause the drive wheels to slip.
The filter elements must be changed every 2000 hours
(about 2 years) of operation.
The drained oil from the exhaust filter must be
disposed of in accordance with local regulations.
The filter elements must be checked monthly. In case

a filter element is very dirty, it has to be changed.
Micro filter
Open the outlet screw on the bottom of the glass to
drain water or oil.
The pre-filter(s) are located near the outlet of the

Transporter's hose reel. They can best be accessed
from below (lift up the Transporter with crane). These
Pre-filter
pre-filters prevent the intrusion of rough, large particles
like rust into the pneumatic system. They should be
checked annually.
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GerätebName:
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Tel. (+49Germany) 0911 / 52 40 15
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The filter elements must be checked monthly. In case

any filter element is very dirty, it has to be changed.
Filter
Open the outlet screw to empty water or oil.
The oil level must be checked weekly and if necessary,

refilled.
Air lubricator The amount of oil must be adjusted between 4 and 6
drops per minute.
See instructions below, how to adjust the lubricator.
Do not overfill the oil tank. Doing so will cause the oil to flow back into the filter and can
cause malfunction in the control circuit.
Constantly monitor the oil level and proper functioning of the lubricator. In case of a
malfunction the drive motors can become rapidly damaged.
How to adjust the lubricator:
 Switch off the wheel application force on the Emergency Control Panel (ECP)
WHEEL PRESSURE: OFF
 Activate Air Cushion Gear (Switch to "Pallet Mode") via the RRC
Air-cushion mode:
Load (with load on the pallet)
Now the Air Cushion Transporter is off the ground and the drive wheels can turn without any
contact with the floor.
Take care that the Transporter is not gliding away, after switching off
the wheel pressure. After finishing the adjustment, switch on the wheel
pressure again on the ECP.
 Use left joystick on the RRC for turning the drive wheels.
 Now you can adjust the rear lubricator while the drive is rotating, as follows:
On the top of the lubricator is an inspection glass with a green adjusting screw. If you turn the
adjusting screw clockwise “-” the drop frequency will decrease. Turning counterclockwise “+”
will increase the frequency.
 Repeat the preceding two steps likewise for adjusting the front lubricator.
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GerätebName:
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Tel. (+49Germany) 0911 / 52 40 15
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Height control
Electric height sensor

The sensors of the electric height control should be gently cleaned with a dry, soft cloth every
month or when dirty. If the sensor is malfunctioning because of dirt, the Transporter will give a
continuous acoustic beeping signal and the air cushions will deflate.
The sensor membrane is sensitive – clean carefully.
Main supply hose

Check main supply hose(s) regularly for scratches, wear and aging. In any case, when there are
signs that may foresee a reduction of functionality of the hose(s), it is important to arrange the
immediate substitution of the hose(s) or at least an accurate verification. The main supply hose(s)
should be changed latest after 6 years.
DANGER OF INJURY FROM BRAKING SUPPLY HOSE

Old, scratched or worn hoses can cause serious injuries in case of
sudden crack or break.
Remote controlled pressure regulator (RCPR)
On the inlet of each Air Cushion Cassette, inside the Transporter, there is an RCPR. In case it
cannot switch off it might be due to dirt inside of the regulator.
 Open cover and remove spring and valve pin.

 Clean the entire RCPR, particularly the valve pin, as shown below.
Fig. 1) Cleaning of Remote Controlled Pressure Regulator

Blatt:

GerätebName:
Date :
(YYYY-MM-DD):
D ELU G
DELU mbH
GmbH
DeDeutsche
11 Nürnberg
Tel. (+49Germany) 0911 / 52 40 15
FTel.
ax +49-(0)911-238888-0
(+49) 0911 / 52 35 07 gültig für FaNo.:
Fax +49-(0)911-238888-28 12185 2021/01
10.4. Maintenance of mechanical parts
The chains of the drive units, steering and

hose reel should be lubricated every year, to
prevent rust or corrosion.
Chains
You can use any kind of chain lubricant.
Also check the tension of the chains.
Check twice a year the proper functioning

Squeeze
and condition of the squeeze protection
protection
frame. If necessary, change brushes and
frame
repair.
11. Troubleshooting
First, check whether the problem or malfunction occurs in the electrical or pneumatic equipment.
11.1. Troubleshooting electrical components
If the LED in the "System on" button on the control panel does not light up, the reason for the
problem or malfunction is probably a defective fuse (battery or main fuse, switch box), or the
accumulator battery is completely discharged.
Replace fuses (pay attention to the correct amperage on the replacement fuse) Information on the
position of the switch box can be found in "Fehler! Verweisquelle konnte nicht gefunden
werden. Fehler! Verweisquelle konnte nicht gefunden werden. "
If a command cannot be executed, it might be because:
radio remote control (RRC)
Checking the radio remote control (RRC) is very simple: Unscrew the cover of the radio receiver
(see chapter Fehler! Verweisquelle konnte nicht gefunden werden. Fehler! Verweisquelle
konnte nicht gefunden werden.) and check whether the corresponding LED lamp in the radio
receiver lights up. Only the manufacturer, DELU GmbH, can resolve the problem or malfunction.
the electrical control
If the commands are not transmitted to the executing elements in a correctly functioning radio
remote control (electrical valves), the problem or the fault in the electronics or the wiring must be
determined. To do this, you can check the LED lamps of the valve modules in the switch box (see
chapter 2.4).
Every action on the radio remote control (RRC) should generate the corresponding action on the
valve module (the corresponding LED lamp should light up)
You can also check the function of the electrical valves manually using the DIP switches without
using the radio remote control. The electric valves are the connection between the electric control
and the pneumatic control.
The DIP switches have three positions. The name of the positions is printed on the board next to
the LED of the DIP switch.
Blatt:

GerätebName:
Date :
(YYYY-MM-DD):
D ELU G
DELU mbH
GmbH
DeDeutsche
11 Nürnberg
Tel. (+49Germany) 0911 / 52 40 15
FTel.
ax +49-(0)911-238888-0
(+49) 0911 / 52 35 07 gültig für FaNo.:
Fax +49-(0)911-238888-28 12185 2021/01
The valve modules can only be used for troubleshooting purposes.

Set all DIP switches of the valve module to the standard position "REMOTE" after each test.
Otherwise, the system will not work properly.
Position DIP-switch
Function
name position
All valves are controlled via an
external control unit, such as the radio
REMOTE Right
remote control or a PLC.
This is the default position
The corresponding action is switched
off and all signals from the radio
OFF Middle remote control are blocked. The
electric valve should now be in the
neutral position. Figure 24 Valve Block
The corresponding action is carried
out directly via the DIP switch, and all
DIRECT Left signals from the radio remote control
are blocked. The electric valve should
now respond.
The following table gives you an overview of the short designations of the valve modules and their
corresponding numbers in the compressed air diagrams:
Module Name Valve-Pos. Description

2RI 40.2 Rear drive unit steering right hand side
2LE 40.2 Rear drive unit steering left hand side
1RE 40.1 Front drive unit steering right hand side
1LE 40.1 Front drive unit steering left hand side
14U1
2FST 37.2 Rear drive unit drives fast
1FST 37.1 Front drive unit drives fast
2DEA 29.2 Activate rear drive unit
1DEA 29.1 Activate front drive unit
HOSE 53 Activate hose reel
ON 7 Activate control pressure
WPL 16 Activate load wheel pressure
WPO 22 Deactivate wheel pressure
15U1
LIN 97 Activate inner aircushion row
LMID 96 Activate middle aircushion row
LOUT 95 Activate outer aircushion row
PALL 79 Activate air-cushion
With the valve module you can check all the important functions of the transporter by switching the
corresponding electrical valves on ("DIRECT" position) or off ("OFF" position). Using this method,
you can quickly determine whether the problem or malfunction in the electrical or pneumatic
system is justified.
If you test a certain function via the radio remote control or by switching the corresponding DIP
switch to "DIRECT", and there is no reaction from the corresponding valve while the LED lamp
lights up at the same time, the fault is in the valve, its wiring or connectors. In this case, check the
voltage at the valve connector (or check whether the LED lamp on the valve lights up).
If the voltage at the plug is OK and the electrical valves are working, then the fault must be in the
compressed air circuit or in the compressed air components.
Blatt:

GerätebName:
Date :
(YYYY-MM-DD):
D ELU G
DELU mbH
GmbH
DeDeutsche
11 Nürnberg
Tel. (+49Germany) 0911 / 52 40 15
FTel.
ax +49-(0)911-238888-0
(+49) 0911 / 52 35 07 gültig für FaNo.:
Fax +49-(0)911-238888-28 12185 2021/01
11.2. Debugging in the Pneumatic Unit

Symptom Cause Elimination
Low Pressure LED Break down of the air-supply (more air Add another compressor
is lighting is required than supplied)
Filters full of dirt Check all filters (Prefilter, Filter,
Microfilter etc)
Air cushions are Pressure in air cushions too low Check operating pressure and
not lifting high pressure setting
enough The altitude control sensor(s) is (are) Readjust the altitude control
set too low sensor (s)
Ball valve of the compressed air Check and open completely
connection point not fully open
Dirty or damaged pressure regulator Clean or replace the pressure
regulator (s)
Leaks in the lines Repair or replace
Floor with bumps, holes, or a hard Repair the floor
surface
Dirt or foreign bodies under the air Clean or remove any dirt
cushion element (s)
Defective air cushion element (s) Replace defective air cushion
elements
Air cushion element (s) not inserted Insert correctly (check the position
correctly of the air inlet)
Air-cushion are Pressure in air-cushion to high Check if the Remote-controlled
lifting to high pressure regulators are full of dirt.
Dirty or damaged compressed air Clean or replace the pressure
regulator regulator (s)
The altitude control sensor (s) is (are) Readjust the altitude control
set too high sensor (s)
Transporter begins Pressure in air cushions too high Increase the load
to vibrate or because the weight of the load is too
bounce when the low
air cushions are
switched on
Transporter drifts Wheel pressure too low Increase the wheel pressure for
(drive wheels slip) "Load"
Too great a slope of the floor Repair / level the floor
Floor slippery (wet / oily) Clean and dry the floor
The transporter The wheel pressure of the drive units for Set the pressure for "Empty"
cannot drive out idle movements (no load) is set too high correctly
from under the Quick exhaust valves on the drive Clean the vent valve or replace it
pallet when the air bellows do not let out any air
cushions are Quick exhaust valves of the air cushions Check the correct function and the
switched off do not let out any air control pressure
Drive unit columns are dirty and trapped Clean and lubricate the columns
Blatt:

GerätebName:
Date :
(YYYY-MM-DD):
D ELU G
DELU mbH
GmbH
DeDeutsche
11 Nürnberg
Tel. (+49Germany) 0911 / 52 40 15
FTel.
ax +49-(0)911-238888-0
(+49) 0911 / 52 35 07 gültig für FaNo.:
Fax +49-(0)911-238888-28 12185 2021/01
Symptom Cause Elimination

Commands are not - No control pressure - Check the control pressure
carried out - Defective valves - Replace defective valves
(electrical ok) - Hose lines interrupted - Repair lines
- Executing elements (motors, - Repair or replace defective
cylinders, bellows) are defective components
After adjusting the - The values for longitudinal and - Repeat the adjustment process,
steering, it no transverse travel have been set to making sure that you save the
longer works the same value correct values for the longitudinal
and lateral direction settings.
11.3. Troubleshooting the electrical height control

If there is a problem with the electric height control, the van emits a high-frequency, repetitive beep.
This can have the following reasons:
 defective or dirty sensor

 broken sensor wire
 The transporter is switched on and is being lifted by a crane
 there are obstacles under the sensor
11.4. Charging the batteries
Only use the original charging units provided with the Transporter. Make sure the
permissible voltage and frequency as indicated on the unit's type plate matches with your
local power system. If you need a different charging unit please contact DELU.
Charging the Transporter batteries

The electric components of the Transporter are powered by 2x 12V batteries. When the capacity of
the batteries is low, the load status of the batteries is indicated with several LED’s. When the green
LED is shining, the batteries are fully charged. When the red LED is shining, you have to charge
the batteries.
Charging and replacing the remote control batteries
DANGER OF INJURY FROM EXPLODING BATTERY

 Only use original batteries.
 You can purchase the batteries directly from DELU.
 Failure to observe may result in explosion hazard. Escaping
chemicals and flying parts may cause irreparable damages.
The battery status of the remote control is constantly monitored by the sender electronics. When
reaching a low voltage, the operator gets an acoustic warning (buzzing sound) from the remote
control for about 30 seconds. After that, the sender gives a command by which the Transporter is
brought into a secure condition.
For charging the batteries, a special charging unit is provided together with the Transporter.
Note: The batteries must be fully charged before starting up the Transporter. The charging unit
must be stored on a clean and dry place.
 Put the empty battery into the charging unit

 Now the charging procedure is started
Blatt:

GerätebName:
Date :
(YYYY-MM-DD):
D ELU G
DELU mbH
GmbH
DeDeutsche
11 Nürnberg
Tel. (+49Germany) 0911 / 52 40 15
FTel.
ax +49-(0)911-238888-0
(+49) 0911 / 52 35 07 gültig für FaNo.:
Fax +49-(0)911-238888-28 12185 2021/01
The display of the charging unit is described in chapter 11.4.3. The charging time is about 2-4
hours. When the battery is fully charged the green "Ready" LED will light up.
The battery charger is equipped with charging state recognition. When the batteries are fully
charged, the charger automatically switches over to trickle charging.
Hint: In order to avoid downtimes, we recommend to always having a fully charged battery
pack ready. An extra battery pack is supplied with every remote control.
Display and error messages of the charging unit
LED display of the charging unit
- Charging process running: yellow LED ① flashing

- Fast charging: yellow ① and red ② LED flashing, after activating
the fast charge button ②
- Charging process completed: green LED ③ flashing, trickle charging is running
Error messages of the charging unit
- No LED is flashing: rechargeable battery is damaged

- Yellow LED ① is blinking: short circuit in the battery block
In both cases, the battery may no longer be used!
Figure 26 Charger Controls
Figure 25 HETRONIC charging unit with 3,6V battery
Disposal of batteries
Rechargeable battery packs are to be treated as hazardous waste and
have to be disposed properly. Work at all times in accordance with local
laws and regulations.
Never dispose batteries in your normal trash.
Blatt:

GerätebName:
Date :
(YYYY-MM-DD):
D ELU G
DELU mbH
GmbH
DeDeutsche
11 Nürnberg
Tel. (+49Germany) 0911 / 52 40 15
FTel.
ax +49-(0)911-238888-0
(+49) 0911 / 52 35 07 gültig für FaNo.:
Fax +49-(0)911-238888-28 12185 2021/01
12. EC declaration
CE-Konformitätserklärung
EC Conformity Declaration
im Sinne der EG-Maschinen-Richtlinie 2006/42/EG, Anhang II A
according to EC-Machine-Directive 2006/42/EG, Annex II A
DELU Luftkissen Transportgerätetechnik GmbH

Gebertstrasse 7
D-90411 Nürnberg
Tel. +49 (0)911 23 8888 0

Fax +49 (0)911 23 8888 28
DELU GmbH erklärt in alleiniger Verantwortung, dass das folgende Luftkissen System
herewith declares, that the following Air Cushion System
Typ / Type: LPT – 80 / GAP

Fabr. No 12185
Baujahr / Year of constr.: 2021/01
übereinstimmt mit der EG-Maschinen-Richtlinie (2006/42/EG)

is in accordance with EC-Machine-Directive (2006/42/EG)
Folgende harmonisierte Normen wurden angewandt

The following harmonised standards have been applied
EN 12100-1, EN 12100-2, EN 349, EN 1050
Folgende nationale Sicherheitsvorschriften wurden angewandt

The following national safety standards have been applied
BGV A1, BGV D27
DELU Luftkissen Transportgeräte GmbH
Nürnberg, 20.10.2020
Dipl. Ing (FH) Peter Kluge, Managing Director

Blatt:

GerätebName:
Date :
(YYYY-MM-DD):
D ELU G
DELU mbH
GmbH
DeDeutsche
11 Nürnberg
Tel. (+49Germany) 0911 / 52 40 15
FTel.
ax +49-(0)911-238888-0
(+49) 0911 / 52 35 07 gültig für FaNo.:
Fax +49-(0)911-238888-28 12185 2021/01
13. Recommended spare parts list

13.1. Pneumatic
Pos. Name Amount Order No.

1. Air Cushion Element 2 146 LE-N 4-75AC
Air inlet sealing for air cushion
2. 12 LKD-80/22
elements
Remote controlled Pressure re-
3. 1 R119-04J
gulator for drive
Remote controlled pressure
4. 1 R119-04JX71
regulator for Air Cushions
5. Micro filter inserts for EF504 4 EK504VY
6. Mini regulator 1 R 374-01-C
7. Electric 3/2-way valve 1 518 01 002
8. Electric Valve 5/2-way 1 518 01 021-24V=
9. Manometer 0-6bar 1 MF4001-06
10. Air bellow for drive unit 4 DAL1000 DPS-05.0
13.2. Electric
POS. DESCRIPTION AMOUNT ORDER NO.

1. Height control sensor, electric 1 UNAM 12U9914/S14
2. Battery for remote control 1 1,2AH

Blatt:

GerätebName:
Date :
(YYYY-MM-DD):
D ELU G
DELU mbH
GmbH
DeDeutsche
11 Nürnberg
Tel. (+49Germany) 0911 / 52 40 15
FTel.
ax +49-(0)911-238888-0
(+49) 0911 / 52 35 07 gültig für FaNo.:
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14. APPENDIX
14.1. Demands on the floor

(see DELU data sheet no. 100.00 – 100.04 in appendix)
14.2. Demands on the air supply

(see DELU data sheet no. 101.01 in appendix)
14.3. Overview drawing – Transporter LPT – 80 / GAP

(Drawing No. N-1364 – 0)
14.4. Pneumatic diagrams

(Drawing No. N – 1364 – 65)
14.5. Electric diagrams

(see appendix)
Kenndatenblatt:
Anforderungen an die Bodenbeschaffenheit
Demands on the floor surface Nr.: 100.00
1. Warum werden an den Fußboden besondere Anforderungen gestellt?

Folgendes Bild zeigt die Funktion des Luftkissenelementes im Querschnitt. In der
Auftriebskammer mit der Belastungsfläche φD muß der Überdruck gehalten werden, d.h.
keine scharfkantigen Stufen dürfen hochstehen. Auch Risse und Löcher im Boden durch
die die Druckluft entweichen kann sind nicht erlaubt.
Der Luftspalt zwischen Luftkissenbalg und Fußboden ist hauchdünn, somit ist für den
Einsatz von Luftkissentransportgeräten die Qualität der Fußbodenoberfläche
entscheidend. Denn diese beeinflußt zum einen direkt den Luftverbrauch und zum
anderen entscheidet sie darüber ob sich überhaupt ein Überdruck in der Auftriebskammer
aufbauen kann.
1. Why special requirements on the floor surface?

The picture below shows the function of an air cushion. Inside of the lifting chamber with
the load area φD the overpressure has to be kept constantly higher than the load.
For that reason there are no joints, gaps or cracks allowed, which could cause a
deaeration of the lifting chamber.
The gap between the bellow of the air cushion and the floor is very thin. Due to this fact the
quality of the floor surface is very important for the use of air cushions, because it affects
on the one hand directly the air-consumption and on the other hand it determins the
possibility to get overpressure inside of the lifting chamber.
Last: F
thickness of the air film
load:F
Stärke des Luftfilms
lifting height
Hubhöhe
Druckluft
compressed air
φD
Auftriebskammer
lifting chamber
D ELU
NÜRNBERG
R
DELU GmbH, Gebertstraße 7, D-90411 Nürnberg
Deutsche Luftkissentransportsysteme
Tel.: +49 (0)911-238888-0, Fax: +49 (0)911-238888-28
Release 1.2/ Stand 04/2013
Kenndatenblatt:
2. Übersicht der Anforderungen an die Fußbodenbeschichtungs-

oberfläche und -material
Demands on the covered floor surface and the coating material
Anforderungen Bemerkung
Demands Annotations
Glatter, maschinengeschliffener versiegelter Die Oberflächengüte des Fußbodens
- Material Hartbetonboden oder glatte Kunststoff- beieinflusst stark den Luftbedarf und
gießharzbeschichtung (evtl. schlagfest mit den Verschleiß am Luftkissenbalg
Material Glasfasergewebeschicht). aufgrund von Reibung.
Für Daueranwendungen ist generell eine
Kunststoffbeschichtung erforderlich.
Smooth, polished and sealed concrete floor or The surface of the floor can affect the
smooth synthetic-resin coated floor (best air consumption and wear due to
shock resistant through additional glass fibre friction between the air cushion bellow
layer). For permanent use a synthetic resin and the floor.
coating is generally required
- max. Flächenpressung P < 50 N/mm² In der Fußbodenbeschichtung dürfen
Rad/Fußboden keine Eindrücke feststellbar sein.
Maximum surface pressure The surface must be hard enough to resist
wheel/floor any indentations from the wheels..
- min. Haftreibung µ = 0,4 (trocken/dry) Nach VW-Betriebsmittelvorschrift

Gummisohle/Fußboden
Minimum of static friction According to VW production facility
shoe sole/floor specifications
Abhängig von Anwendungsfall nach Die Neigung des Fußbodens beeinflußt
- Ebenheit und Welligkeit Tabelle 1 stark die erforderlichen Zugkräfte
Even- and waveness
According to table 1 depending on The slope affects directly the necessary
case of application towing forces
- Oberflächenbeschaffenheit Rauhigkeit/roughness Güteklasse 2, Rauhigkeitsgrößen nach DIN

Surface roughness Ra: 6,3µm - 12,5µm 4768, Teil 1, Oberfläche glatt wie Papier.
Angegebene Druckluftverbräuche im
Datenblatt basieren auf Güteklasse 1,
d.h. Ra<6,3µm.
Rauhigkeitsklasse/roughness-grade Classification 2, roughness values

N9 - N10 according DIN 4768, part 1, surface as
smooth as paper.
Air-consumptions indicated in Datasheets
are referring to Classification 1, Ra<6,3µm
- Fugen, Risse und Stufen keine erlaubt Luftdichte Ausführung

Joints, cracks and steps none permitted Airtight finish
- Dehnungsfugen Luftdichte, stufenfreie Ausführung Material auf Polyurethanbasis, Shorehärte

Fugenform: V-Form (Winkel 90°) 7 5 ± 5 , m i t s e h r h o h e m
Expansion gaps Rückfederungsvermögen, ohne
Fugenbreite: min 60mm Volumenvergrößerung bei Kompression.
Airtight, infinitly finish Material based on Polyurethane, shore-

Gap form: V-form (angle 90°) hardness 75 ±5, with very high resilence
Width of gap: min. 60mm capacity, without volume expansion
during compression.
D ELU
NÜRNBERG
R
Tel.: +49 (0)911-238888-0, Fax: +49 (0)911-238888-28
Kenndatenblatt:
3. Ebenheit 3. Evenness
Da der Reibungskoeffizient bei einem aktiven The friction coefficient of an active air cushion is nearly
Luftkissen nahezu Null beträgt, muß der Fußboden zero. Therefore even the smallest slope causes a
eben sein, sonst besteht vor allem bei schweren downward gliding of the load. This could create a
Lasten die Gefahr, daß das Transportgut abgleitet. dangerous situation, because especially heavy loads
Die nachfolgende Tabelle zeigt mögliche could get uncontrollable.
Ebenheitstoleranzen für den Fußboden. Die Art der The following table shows possible tolerances for the
Ausführung hängt vom Anwendungsfall ab. evenness of the floor. The kind of execution depends
on the case of application.
Tabelle 1 Ebenheitstoleranz in [mm] bei Abstand der

Table 1 Meßpunkte
Evenness tolerance in [mm] depending of the
Pos. Art der Ausführung distance between the measuring points
Kind of execution 0,1 m 1m 4m 10 m 15 m
1 Normalausführung entspr.
DIN 18202 Teil 5, Zeile 3
2 4 10 12 15
Standard execution according
DIN 18202 part 5, line 3
2 Erhöhte Genauigkeit entspr.

DIN 18202 Teil 5, Zeile 4 1 3 9 12 15
Enhanced exactness according
DIN 18202 part 5, line 4
3 Nivellierter Boden 1 3 4 6 6
Out levelled surface
4 Nivellierter Boden mit erhöhter

Genauigkeit 1 1 3 5 5
Out levelled surface with
enhanced exactness
4. Stufen 4. Steps
Scharfkantige Stufen schneiden das Druckpolster in Steps and sharp edges are "cutting" the pressure
der Auftriebskammer durch und das System bricht cushion inside of the lifting chamber and the
zusammen (Abb. 4.1). system breaks down (Fig. 4.1).
Ist eine Stufe vorhanden, so muß die Kante The edge of the steps have to be chamfered to a
abgeschrägt werden, so daß eine Rampe entsteht ramp (Fig. 4.2).
(Abb. 4.2). When designing a ramp the resulting descending
Bei der Gestaltung von Rampen sollten die forces should be taken into account. These have to
möglichen Hangabtriebskräfte berücksichtigt be eliminated through securing the system with
werden. Diese müssen entweder mit Seilen oder winches (manual systems) or by means of inbuilt
ähnlichem (bei manuellen Systemen) oder drives (automatic systems) .
eingebauten Antrieben (bei automatischen
Geräten) aufgenommen werden.
Abb. 4.1: Das Druckpolster in der Auftriebskammer wird durch Abb. 4.2: Mit einer Rampe lassen sich problemlos Stufen
Stufen unterbrochen. überwinden, ohne daß der Luftfilm abreißt, oder das
Luftkissen beschädigt wird.
Fig. 4.1: In case of steps or sharp edges the pressure cushion Fig. 4.2: By means of a ramp it is easy to drive over steps
inside of the lifting chamber is breaking down. without disturbing the air film or damaging the air
cushion bellow.
D ELU
NÜRNBERG
R
Tel.: +49 (0)911-238888-0, Fax: +49 (0)911-238888-28
Kenndatenblatt:
5. Risse 5. Cracks
Der Estrichboden ist der am häufigsten The most available floor is polished concrete. This kind
vorkommende Fußboden. Dieser hat allerdings of floor has one important disadvantage. It gets very
einen bedeutenden Nachteil, er bekommt oft Risse. often cracks. Due to this fact it could happen that the
Diese bewirken, daß die Luft unter dem Luftkissen air below the air-cushion, inside of the lifting chamber,
entweichen kann. Die Folge ist, das Luftpolster flows away through the crack. The air-cushion breaks
bricht zusammen, ein Transport ist nicht mehr down and it isn't possible to continue with the
möglich. transport.
Risse müssen mit Epoxydharz oder ähnlichem Cracks have to be filled with synthetic resin or
gefüllt werden (Abb. 5.1). Bestehen zwischen den something similar (Fig. 5.1). If the height difference
Rissen Höhenunterschiede, die mehr als 0,5mm between both sides of a crack is more than 0.5mm it
betragen, so sollten diese abgeschliffen werden has to be levelled out (Fig. 5.2).
(Abb. 5.2).
< 0,2 - 0,5 mm

> 0,2 - 0,5 mm
Riß Epoxydharzfüllung
Crack Synthetic resin
Abb. 5.1: Risse werden mit Epoxydharz luftdicht Abb. 5.2: Höhendifferenz zwischen beiden Seiten größer
verschlossen. Höhendifferenz weniger als 0,2 - als 0,2 - 0,5 mm (Betriebsdruckabhängig), die
0,5 mm (Betriebsdruckabhängig). eine Seite muß abgeschrägt werden.
Fig. 5.1: Airtight sealing of a crack with synthetic resin. Fig. 5.2: Height difference more than 0.2 - 0.5 mm
Height difference less than 0.2 - 0.5 mm (depending on operating pressure), both sides
(depending on operating pressure). have to be levelled out.
6. Dehnfugen 6. Expansion Gaps

Häufig lassen sich, aufgrund von baulichen Very often, it is not possible to avoid expansion
Gegebenheiten, Dehnfugen im Fußboden nicht gaps in the floor, because of structural demands.
vermeiden. The filling material should be based on
Das Füllmaterial auf Polyurethanbasis sollte eine Polyurethane with a shore-hardness of 75 ±5.
Shorehärte von 75 ±5 haben. To avoid damages to the edges of the floor and to be
Damit die Dehnfuge dem Druck der Antriebe sure that the expansion gap will be rigid enough for
standhält und nicht die Kanten der Fugen the pressure, it should be executed in an angle of
beschädigt werden (Fugenbruch), sollte sie in 90°.
einem 90° Winkel ausgeführt werden. To keep the loss of air at a minimum, the surface of
Um den Luftverlust an der Dehnfuge zu minimieren, the filling should be cambered (Fig. 6.1).
sollte die Füllung leicht nach außen gewölbt sein A concave surface curvature is not allowed,
(Abb. 6.1). because the air-cushion can’t affect to the surface
Eine konkave Wölbung der Oberfläche ist nicht and to much air gets lost (Fig. 6.2).
erlaubt, da sich das Luftkissen nicht anschmiegen
kann (Abb. 6.2).
Abb. 6.1: Optimale Fugenform mit leichter Wölbung nach Abb. 6.2: Eine konkave Oberflächenwölbung ist nicht
außen. gestattet.
Fig. 6.1: Correct gap form, with gentle convex curvature. Fig. 6.2: Wrong gap form.
D ELU
NÜRNBERG
R
Tel.: +49 (0)911-238888-0, Fax: +49 (0)911-238888-28
Kenndatenblatt:
7. Anforderungen an die Fugen und den Fugenbereich

Demands on joints and joint areas
Anforderungen
Demands
- Fugenform V-Form (90°, Breite 60 mm, Tiefe min. 20 mm)
Joint shape
V-shaped (90°, 60 mm wide, min. 20 mm deep)
- Fugenmaterial
Material for joint Sika Icosit KC 340/7
- Fugenvorbereitung Nach dem Fräsen müssen die Fugen gereinigt und staubgesaugt werden.
Preperation of joint Im staubfreien Zustand muss eine Haftbrücke (Primer: Sika KC 330) zur
Gewährleistung eines guten Haftverbundes zwischen Beton und
Fugenmaterial realisiert werden.
After milling, the joint must be cleaned and vacuumed dust-free. In order
to reach a good bond between concrete and joint material, a bond bridge
(Primer: Sika KC 330) must be established.
- Fugenoberfläche und Fuß- - Haarrisse, Risse und Stufen sind in keiner Form zugelassen.
bodenoberfläche links und Cracks, micro cracks and steps are not allowed in any way.
rechts der Fuge:
Joint surface and floor sur- - Ebenheit und Welligkeit in der Querrichtung der Fuge nach folgender
face next to the joint on the Tabelle:
left and right. Even and waveness in lateral direction of the joint according to following
table:
Abstand der Messpunkte 0,1m 0,5m 1,0m 2,0m

Distance between check points
Toleranz / Tolerance 0,5mm 1,0mm 1,5mm 2,5mm
Bemerkung / Remark: Die Toleranzen werden vom höchsten
Punkt des Fußbodens gemessen.
The tolerances are measured from the
highest point of the floor.
90°
- Skizze
Sketch 60
Icosit nach Aushärtung

KC 340/7 abschleifen
abrade after
0,5
curing
min. 20
Primer KC 330
Füllmaterial
Filling material
D ELU
NÜRNBERG
R
Tel.: +49 (0)911-238888-0, Fax: +49 (0)911-238888-28
Kenndatenblatt:
Anforderungen an die Druckluftversorgung
Specification for Air-supply Nr.: 101.00
Anforderungen:
R Druckluftqualität ISO 8573-1 Klasse F
R Druckluftleitungen sollten aus einem nichtkorrodierendem Material bestehen (Edelstahl, Verzinkte
Rohre, Kunststoff). Da sich sonst Rost ansetzt, welcher Ventile blockieren, bzw. beschädigen kann.
R Die Dimensionierung erfolgt gemäß Datenblatt 110.00.
R Versorgungsdruck min. 6 bar am Druckluftanschlusspunkt. Bei Anlagen mit hohem Luftverbrauch (>15
Nm³/min) sollte der Netzdruck min. 10 bar sein, damit die Verluste möglichst gering gehalten werden.
(Im Zweifelsfall bitte DELU kontaktieren)
D ELU
NÜRNBERG
R
Tel.: (+49) 0911 524015, Fax: (+49) 0911-523507
Kenndatenblatt:
Anforderungen an die Druckluftversorgung
Nr.: 101.01 Demands to the Air-supply
Demands:
R Air-Quality according to ISO 8573-1 Class F
R Air- pipes should be made of non corrosive material (Stainless Steel, Galvanised Steel, Plastic).
Otherwise rust and dirt can occur which can block or damage valves.
R Dimensioning according to our Data Sheet 110.00.
R Supply Pressure min. 6 bar at the connecting point. Devices with high air-consumption (>15 Nm³/min)
should have min. 10 bar, to minimise the pressure losses. (In case of doubts, please contact DELU)
D ELU
NÜRNBERG
R
Tel.: (+49) 0911 524015, Fax: (+49) 0911-523507
1
26
3
17
25
39 Zylinderschraube ISO4762-M10x35 16 8.8zn 0.034
24 37 Scheibe DIN125-6.4 vz 4 ST-vz 0.001
contained herein without the written consent of the company DELU GmbH. All copyrights, trademarks, patents and other
23 35 Zylinderschraube ISO4762-M12x30 4 8.8zn 0.045

rights in connection herewith are expressly reserved to the company DELU GmbH and no license is created hereby.
5
NOTE: The information or material contained in this document is STRICTLY CONFIDENTIAL and any recipient
of this document shall not disclose or divulge, directly or indirectly, this document or the information or material
34 Scheibe DIN125-5.3 vz 8 ST-vz 0.000

18 33 Senkschraube m. Innensechskant DIN7991-M8x20 2 8.8zn 0.010
32 Senkschraube m. Innensechskant DIN7991-M6x30 4 8.8zn 0.007
21 29 31 Scheibe DIN125-A10.5 vz 28 ST-vz 0.004
13 30 Zylinderschraube ISO4762-M10x20 6 8.8zn 0.025
29 Federring DIN128-A10 34 FSt-zn 0.002
28 Funkempfänger RS 232 Z100476.A 1 Bestellung durch E- Abitron 1.094

Abteilung
28 27 Batterie 12V 42Ah LC-P1242AP 2 L 197 x B 165 x H 175 Panasonic 13.498
16 26 E-Box B300 x H600 x T 155 EB 1578.500 1 Rittal 10.137
27 25 Verteiler 2"-4x3/4"-2" Vert_4-Fach 1 80x138x154 3.3535 (EN-AW 5754) 2.200
ALMG3
24 Verteiler 2"-6x3/4"-2" Vert_6-Fach_V3 1 80x138x230 3.3535 (EN-AW 5754) 3.413

4 ALMG3
Rotguss Rg7 alternativ
19 23 Schmutzfänger R2" mit Edelstahlsieb 10104782 1
2.1090 (CuSn7ZnPb)
2.275
9 22 NOT-Steuertafel englisch kpl. S-1364-NOT Steuertafel 1 --- 2.340

englisch kpl
21 Antriebseinheit 1/2" S-PAE-01-0 2 --- 7.072
8 20 Lenkrolle 9650 MOP 125x50 P63 015946 4 Ihnken - Tente 4.877

19 Alu-Schlauchtrommel D.1600 SHI 1A-FL4K+2A 68 1600 405L 1 Alfons Haar 36
18 Schlauchtrommelantrieb S-STA-18-DP-0L-V5 1 --- 13.839
17
17 Lenkeinheit für Druckluftantrieb S-LDA-Z20-V3-0 2 --- 24.722
7 16 Druckluftantrieb S-DAL-1000-DP10-0 2 --- 128.470
14 15 Luftgleitkissenellemet 146 LE-N 4-75AC 12 --- 8,1
2 14 Innenschlauchführung für DN25-63 SFI-02-63-0 3 --- 3.629
11 13 Klemmschutzrahmen kpl. S-1364-KLR-0 1 --- 85.711
12 Schlauch Baugruppe S-1364-50-0 1 --- 13.334
11 Steuertafel kpl. S-1364-35-0 1 --- 1.472
10 Führung Klemmschutzrahmen S-1364-12 2 20x20x145 PA Typ 6 0.063
12
9 PE-Platte Rund S-1364-11 1 Ø260x10 PE 0.501
14 8 Kettenrad mit Distanz S-1364-10-0 1 --- 1.951

7 PE-Platte S-1364-09 1 130x160x8 PE 0.147
6 PE Distanzstück S-1364-08 4 35x8x100 PE 0.026
5 Schlauchstütze S-1364-07-0 1 --- 0.407
HINWEIS: Sämtliche Informationen, die in diesem Dokument enthalten sind, sind STRENG VERTRAULICH. Jeder Empfänger
Zustimmung der Firma DELU GmbH an Dritte weitergeben oder offenlegen. Die Firma DELU GmbH behält sich alle Rechte in
4 Schlauchstütze S-1364-06-0 3 --- 0.316

Bezug auf Urheberrechtsgesetz, Patent- und Gebrauchsmusterschutz vor. Lizenzrechte werden hierdurch nicht erteilt.
dieses Dokuments darf die darin enthaltenen Informationen, direkt oder indirekt, nur mit ausschliesslicher, schriftlicher
3 Utraschallsensor S-1364-05-0 3 --- 0.219

2 Rammschutz und Lastleisten S-1364-03-0 1 --- 51.769
1 Tragrahmen LPT-80 S-1364-01-0 1 --- 2365.756
Pos. Beschreibung Sachnummer/Norm-Kurzbez. Stück Abmessungen Werkstoff Gewicht/kg
Maßstab 1:20 3024.574 kg

Kantenbemaßung Oberfläche
Allgemeintoleranzen Allgemeintoleranzen für
für Bearbeitung nach Schweißkonstruktionen DIN 6784 DIN/ISO 1302 Gewicht
DIN ISO 2768-mK DIN EN ISO 13920-AE +0 -0
- 0,1 +0,1 12,5 6,3 Material ---
Abmessungen
Behandlung
Datum Name Benennung
Luftgleitkissen Paletten
Bearb. 24.09.2020 Leo
Gepr.
Deckel und Abdeckungen siehe S-1364-04-0 Norm
SolidWorks A2 Transporter LPT 80/ GAP
Verbindungselemente nur teilweise dargestellt. Zeichnungsnummer Blatt
1
DELU Luftkissentransportgerätetechnik GmbH
Gebertstraße 7, D-90411 Nürnberg
S-1364-0 3 Bl.
Zust. Änderung Datum Name Ers.f.: Ers.d.:
Tel.: +49-(0)911-238888-0, Fax: +49-(0)911-238888-28
http://www.delu-gmbh.de, Email: info@delu-gmbh.de
B 90° (1 : 5) A 270° (1 : 5)
1890 Abdeckung für NOT-Steuerung
14 29 30 22 1 11
Transporterhöhe auf Lenkrollen
ohne Lasteisten
335
320
1978
2 13 3066
Schnitt G-G M (1 : 2)
249
B-Command nach oben drehen 114
Z
Schlauchtrommel umbauen:
Kettenrad um 15mm mit
Distanzen tiefer setzen
B-Command um 90° drehen
166
17 16 F 25 37 38 24 4 23 9 19 E 18 D 21
40
114
G
G
1149
B A
Schnitt T-T M (1 : 2)
14 6
33
C H C
T T
14
66 Schlauch
90
5
F E 20
26 27
D 7 33 28 12 14
5296
5396
contained herein without the written consent of the company DELU GmbH. All copyrights, trademarks, patents and other
rights in connection herewith are expressly reserved to the company DELU GmbH and no license is created hereby.
NOTE: The information or material contained in this document is STRICTLY CONFIDENTIAL and any recipient
of this document shall not disclose or divulge, directly or indirectly, this document or the information or material
Untersicht
3473 Lenkrollenabstand
3398 Antriebsradabstand
Detail Z M (1 : 1)
10
1392
32
HINWEIS: Sämtliche Informationen, die in diesem Dokument enthalten sind, sind STRENG VERTRAULICH. Jeder Empfänger
Zustimmung der Firma DELU GmbH an Dritte weitergeben oder offenlegen. Die Firma DELU GmbH behält sich alle Rechte in
Bezug auf Urheberrechtsgesetz, Patent- und Gebrauchsmusterschutz vor. Lizenzrechte werden hierdurch nicht erteilt.
dieses Dokuments darf die darin enthaltenen Informationen, direkt oder indirekt, nur mit ausschliesslicher, schriftlicher
Maßstab 1:10; 1:5; 1:1 3024.574 kg

Kantenbemaßung Oberfläche
für Bearbeitung nach Schweißkonstruktionen DIN 6784 DIN/ISO 1302 Gewicht
DIN ISO 2768-mK DIN EN ISO 13920-AE +0 -0
- 0,1 +0,1 12,5 6,3 Material ---
Abmessungen
Behandlung
Bearb. 24.09.2020 Leo
Gepr.
15 Norm
SolidWorks A0 Transporter LPT 80/ GAP
Zeichnungsnummer Blatt
2
S-1364-0 3 Bl.
Zust. Änderung Datum Name Ers.f.: Ers.d.:
Tel.: +49-(0)911-238888-0, Fax: +49-(0)911-238888-28
HINWEIS: Sämtliche Informationen, die in diesem Dokument enthalten sind, sind STRENG VERTRAULICH. Jeder Empfänger NOTE: The information or material contained in this document is STRICTLY CONFIDENTIAL and any recipient
dieses Dokuments darf die darin enthaltenen Informationen, direkt oder indirekt, nur mit ausschliesslicher, schriftlicher of this document shall not disclose or divulge, directly or indirectly, this document or the information or material
Zustimmung der Firma DELU GmbH an Dritte weitergeben oder offenlegen. Die Firma DELU GmbH behält sich alle Rechte in contained herein without the written consent of the company DELU GmbH. All copyrights, trademarks, patents and other
Bezug auf Urheberrechtsgesetz, Patent- und Gebrauchsmusterschutz vor. Lizenzrechte werden hierdurch nicht erteilt. rights in connection herewith are expressly reserved to the company DELU GmbH and no license is created hereby.
34
36
Durchgang für Elektrik und Pneumatik
120
13,5
37
38
Schnitt D-D M (1 : 5)
Schnitt F-F M (1 : 5)
Schnitt E-E M (1 : 5)
35
50
Schnitt C-C
218
17
Durchgang für Elektrik und Pneumatik
bis mitte Kettenrad

von Ok. Bodenplatte
K
Höhe Luftanschluß an der Schlauchtrommel
J
Distanzbleche 0 -6mm für Toleranzausgleich

Theoretetisches Einbaumaß =1,5
6 von Oberkante Schlauchtrommel
210 Auflagefläche für Alu Deckel
15**
10
20
29
39
* Schlauchtrommelkettenrad umbauen
9
320
ohne Lasteisten
335
Zust.
50
Motor mit Bremse 40F8U-B
Transporterhöhe
DIN ISO 2768-mK
Änderung
** Radhalter mit 10mm Distanz unterbauen
Datum
DIN EN ISO 13920-AE
für Bearbeitung nach Schweißkonstruktionen
Schnitt H-H M (1 : 5)
Name
Norm
Gepr.
+0
- 0,1
Detail J M (1 : 5)
DIN 6784
Detail K M (1 : 2)
SolidWorks
Kantenbemaßung
-0
Datum
+0,1
Bearb. 24.09.2020

12,5

A1
Tel.: +49-(0)911-238888-0, Fax: +49-(0)911-238888-28

Leo
8
Name
Oberfläche
6,3
DIN/ISO 1302
117
Ers.f.:
Distanzblech 5mm
Material
Benennung
Behandlung
zur Höheneinstellung
Abmessungen
*15mm mit Distanzen in

Maßstab 1:10
---
der Schlauchtrommel
S-1364-0
Zeichnungsnummer
80= Einstellmass
USS bis Boden 25
PE Scheibe ist Auflage für Alu Deckbleche,
Ers.d.:
Senkung für Schraubenköpfe ausreichend tief senken.
Gewicht
Transporter LPT 80/ GAP

Blatt
3
3 Bl.
3024.574 kg
26
25
24
23
22 3/2 Wegeventil el./ 3/2 way valve el. 518 01 002-24V= 1
21 Oderglied / Or valve OS-PK3 1
20 Manometer / Pressure gauge M-DH-40-0/06-1/8-KU 1
19 Miniaturregler / Pressure regulator R374-01C 1
15 Kippschalter / Select switch TV-3S-M5 1
14
13
12
11
10
8 Verteilerblock / Distributor FR-12-PK-3-B 1
7 3/2-Magnetventil./ 3/2 solenoid valve VP542KT-5YZ1-02FA 1
6 Druckschalter / pressure switch DMM/N/2/F/2/1 1
3 Mikrofilter / Micro Filter F504-02-AG 1
2 Schmutzfänger / Prefilter 1½" 1½" 1
1 Kamlock Kupplung 1½"/Couplin 1½" 150-D-AL A 1

Thick-
Piece
Design No. / Annotation /

ness
Breite Länge
Pos.
Benennung / Description Mate-rial

Standard breadth length Weights
Dokument.-Verantw.
Maßstab Gewicht
Datum Werk Abt.
Toleranzen für Maße Werkstoff/Halbz.
Form und Lage ohne Rohteil-Nr.
Angabe in der Zeichnung
Bearb. Sep 20 Scholz
DIN-7168 (mittel) Geprüft Pneumatik Scheme
Norm Air-Cushion Transporter LPT-80 Gap
Konstr.Abt.
Oberfl.Beschaffenheit Sachnummer Blatt
N-1364-65 3 7
Enst. aus: Auftrag: 15362 ABB Brasilien
52
51
Drosselrückschlagventil / One-way flow
50 DRV 3/8" 2
control
49 3/2 Wegeventil el./ 3/2 way valve el. 518 01 002-24V 2
48 Miniaturregelventil/ Proportional regulator RP020/0-8/3/2 2
47 5/2 Wege-Ventil el. / 3/2 way valve el. 5180 1002-24 V 2
46
45 Druckluftbalg / Air bellow Dal1000 DPS-05.0 8

Schnellentlüftungventil / Quick deareating
44 SEU-1/8 2
valve
43 Sicherheitsventil / Security valve A06A-4bar 2
Ferngesteuerter Regler
42 R119-02J 2
Remote controlled regulator
41 Lenkmotor / Steeringmotor 63-029F03 2
VF5323KT-5YZ1-
40 5/3 Wegeventil el./ 5/3 way valve el. 2
03F
39 Abluftfilter Schalldämper / Exhaust Filter SFE-08 2
Drosselrückschlagventil / One-way flow
38 DRVB-1/2 natur 2
control
EGV-111-A78-1 BN-
37 2/2-Wegeventil / 2/2 way valve 2
00
36 Antriebsmotor / Driving motor 40F8U-B 2
35 3/2 Wegeventil / 3/2 way valve 518 01 006 2
34 3/2 Wegeventil / 3/2 way valve 518 01 006 2

33 P4Q-CA-16 2
valve
32 P4Q-CA-16 2
valve
31 R119-04J 2
30 R119-04J 2
VP742KT-5YZ1-
29 3/2 Wegeventil el./ 3/2 way valve el. 2
04FA
AL40-F04-8-A mit
28 Öler / Lubricator 2
Sensor
AF40-F04 /
27 Filter / Filter 2
00086101
Thick-
Piece

ness
Breite Länge
Pos.

Dokument.-Verantw.
Maßstab Gewicht 0,00 Kg
Datum Werk Abt.
Konstr.Abt.
N-1364-65 4 7
78
77
76
75
74
73
72
71
70
69
68
67
66
65
64
63
88130757
62 Taster / Button + 3/2 Wegeventil 1
30701009
61 Kupplung / Coupling DN 7,2 1
60 Rückschlagventil / Back pressure valve H-3/8B 1
59 Rückschlagventil / Back pressure valve H-3/8B 1
58 Schlauchtrommelmotor / Hose reel motor 63-046F03Z 1

57 R119-03J 1

Thick-
Piece

ness
Breite Länge Mate-

Pos.
Benennung / Description
Standard breadth length rial Weights
Dokument.-Verantw.
Maßstab Gewicht
Datum Werk Abt.
Angabe in der Zeichnung Bearb. Scholz
Sep 20
Konstr.Abt.
N-1364-65 5 7
104
101 3/2 Wegeventil / 3/2 way valve 51801006 1

3/2 Wegeventil / 3/2 way valve 307 01 009 +
99 2
+ 1× Wahlschalter 3-Stellungen 881 30 767
97 3/2 Wegeventil el./ 3/2 way valve el. 518 01 004-24V
94' 3/2 Wegeventil / 3/2 way valve 51801006 1
91' Oderglied / Or valve OS-PK-3-6/3 1
90
89
87 1
86 Kippschalter / Select switch TV-3S-M5 1
85
82
81
80

Thick-
Piece

ness
Breite Länge
Pos.

Dokument.-Verantw.
Maßstab Gewicht
Datum Werk Abt.
Konstr.Abt.
N-1364-65 6 7
130
129
128
127
126
125
120 2/2 Wegeventil / 2/2 way valve PGV-231-B77-3/8BP 4

119 R119-04JX71 4
117 R119-04JX71 4
116 Luftgleitkissen / Air-cushion 146 LE-N 4-75AC 12

114 R119-04JX71 4
113
112
111 Druckbehälter / Pressure tank 4
110 2/2-Wege-Elektromagnetventil ETN-2M-24VDC 4
109 2/2-Wege-Elektromagnetventil ET-2-24VDC-M5 4
108

Thick-
Piece

ness
Breite Länge Mate-

Pos.
Benennung / Description
Standard breadth length rial Weights
Dokument.-Verantw.
Maßstab Gewicht
Datum Werk Abt.
Angabe in der Zeichnung Bearb. Scholz
Sep 20
Konstr.Abt.
N-1364-65 7 7

Ba - LPT-80 Gap Delu

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Air-Cushion Transport System

ABB Power Grids Brasil

Operating- and Maintenance Manual

DELU GmbH Rev. 1.0

Tel. : +49 (0)911 238888-0

Operating and Maintenance Manual Page 2 of 58

- This Operating and Maintenance Manual is an integral part of the Transporter.

- Customers are strongly advised to contact DELU GmbH or an authorized DELU

Copyright © 2009-2015 DELU Luftkissentechnik GmbH.

Operating and Maintenance Manual Page 3 of 58

2. OVERVIEW AND SYSTEM DESCRIPTION .................................................... 8

3. SAFETY REGULATIONS .............................................................................. 12

4. STORAGE AND TRANSPORT ...................................................................... 22

Operating and Maintenance Manual Page 4 of 58

4.1. Receipt ...................................................................................................................................... 22

5. TRANSPORT PALLETS AND LOADING ...................................................... 24

9. TECHNICAL DATA ........................................................................................ 44

11. TROUBLESHOOTING ................................................................................... 51

Operating and Maintenance Manual Page 5 of 58

Charging and replacing the remote control batteries 54

12. EC DECLARATION ....................................................................................... 56

14. APPENDIX ..................................................................................................... 58

Operating and Maintenance Manual Page 6 of 58

1. How to read this manual

1.1. Explanation of signal words and symbols

Safety Alert Symbol

Signal word "DANGER"

Signal word "WARNING"

Signal word "CAUTION"

Signal word "NOTICE"

Operating and Maintenance Manual Page 7 of 58

1.2. Text conventions

Operating and Maintenance Manual Page 8 of 58

2. Overview and system description

Figure 1 Example Overview of the Air Cushion Pallet Transport System

2.2. General system components

Operating and Maintenance Manual Page 9 of 58

2.3. Description of Air Cushion Transporter

Operating and Maintenance Manual Page 10 of 58

2.4. Structure and components of the Air Cushion Transporter

Pos. Name Amount

Figure 2 2.4. Structure and components of

Operating and Maintenance Manual Page 11 of 58

2.5. System accessories

The following accessories are within DELU's scope of deliverables:

1 pc. Air Cushion Pallet Transporter: LPT – 80 / GAP,

Operating and Maintenance Manual Page 12 of 58

3.2. Intended use

DANGER OF DAMAGE TO THE TRANSPORTER

Operating and Maintenance Manual Page 13 of 58

3.3. Specific dangers

Operating and Maintenance Manual Page 14 of 58

3.4. Personnel requirements

3.5. Personal protective equipment (PPE)

Protective helmet (hard hat)

Operating and Maintenance Manual Page 15 of 58

3.6. Safety signs on the Transporter

Safety Sign Part No. Location

A-B-0001-EN - 1 decal on each drive

A-B-0006-EN - 1 decal next to each air

- 2 decals on top of side

Operating and Maintenance Manual Page 16 of 58

Safety Sign Part No. Location