CHAPTER 1, SECTION 1 TXL-838

LOADER

Chapter 1, Section 1: Description

Table of contents
I. WARNINGS, CAUTIONS, NOTES ...................................................................................................................................... 2

II. CONFIGURATIONS......................................................................................................................................................... 2

II.A. Aircraft and Cargo Compatibility......................................................................................................................... 3

II.B. The TXL-838 Models .......................................................................................................................................... 6
II.C. Vehicle Drive Systems ....................................................................................................................................... 8
II.D. Cargo Transfer on the Bridge ............................................................................................................................ 9
II.E. Cargo Transfer on the Elevator ........................................................................................................................ 11
II.F. Safety Features ................................................................................................................................................ 11

III. OVERALL SPECIFICATIONS ........................................................................................................................................ 14

III.A. Bridge Specifications ....................................................................................................................................... 15

III.B. Elevator Specifications .................................................................................................................................... 16
III.C. Vehicle Drive Specifications ............................................................................................................................ 17
III.D. Hydraulic, Electrical, Miscellaneous ................................................................................................................ 18

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I. Warnings, Cautions, Notes

In this manual, the following conventions are used to denote special information:

Danger of injury or death.

Danger of damage to equipment.
NOTE: Procedures for easier or faster operation or helpful information.

II. Configurations
The TXL-838 is offered in five models:
TXL-838 STD: Standard (std width, standard height bridge)
TXL-838 WID: Wide (wide option, std height bridge)
TXL-838 COM: Combination (std width, main deck bridge)
TXL-838 UNI: Universal (wide option, main deck bridge)
TXL-838 SUP: Superior (wide option, main deck bridge, and
high deck elevator options)

NOTE: The descriptions above present an overview of TLD Loader models. For
details about aircraft compatibility, cargo capabilities, and actual deck heights,
see following pages.

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II. Configurations, continued

The TXL-838 is a self-propelled loader with dual-platforms on scissor lifts. Cargo and lift systems are designed for
loading and unloading cargo weighing up to 7 500 kg (16,700 lbs).

Operator’s
Console

Bridge
Elevator Platform
Platform

Engine
Module

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II.A. Aircraft and Cargo Compatibility

The TXL-838 is designed to service aircraft as follows:

The TXL-838 is designed to handle cargo as follows:

-Containers: LD-1 through LD-11
-Pallets: 224 x 318 cm (88” x 125”) and 244 x 318 cm (96” x 125”)

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II.A. Aircraft and Cargo Compatibility, continued

The TXL-838 feature fold-down bridge trays to accommodate door sizes as follows:

Aircraft Door: Aircraft Door:

178 cm (70”) 254 cm (100”)

TXL-838 STD and TXL-838 C0M (Standard width loaders)

Aircraft Door: Aircraft Door:

178 cm (70”) Aircraft Door:
254 cm (100”) 356 cm (140”)

TXL-838 WID, TXL-838 UNI and TXL-838 SUP (Wide Loaders)

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II.B. The TXL-838 Models

The TXL-838 models are available as follows:

TXL-838 STD

TXL-838 COM

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II.B. The TXL-838 Models, continued

The 838 models are available as follows:

TXL-838 W ID TXL-838 UNI

TXL-838 SUP

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II.C. Vehicle Drive Systems

Several diesel engine options are available to power a single hydraulic pump for vehicle drive, power steering, elevator
and bridge lifts — as well as for all cargo handling systems.

Heavy-duty hydraulic motors are wheel-mounted on the front axle, along with drum brakes on both wheels. Rear bogey
wheels provide a full range of adjustment (optional), with or without a load, to align the fully down elevator with cargo
transport dollies. Two stabilizers are provided as standard equipment for loading stability and also to use as a parking
brake.

Engine
Module

Fully Adjustable
Bogey Wheels
(Optional)

Dual Front Wheels

Stabilizers/ With Power Steering
Parking Brake

Hydraulic system is controlled by a 24V DC electrical system, equipped with standard safety
interlocks. Automotive quick-connect electrical devices are used throughout. A user-friendly
Digital LCD Interface (see figure beside) simplifies troubleshooting.

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II.D. Cargo Transfer on the Bridge

The TXL-838 bridge side shift option features a combination of PDU (Power Drive Unit), MDW’s (Multi-Directional
Wheels) and solid rollers for positive cargo transfer along the length of bridge and elevator (straight transfer), providing
excellent traction all along the deck. The TXL-838 Bridge end load features steel rollers for straight transfer.

Bridge/elevator interface features cargo stops, which go down (
) automatically when the elevator platform reaches
the bridge. When the elevator approaches the bridge, it slows down smoothly and stops with fail-safe action. Full width
powered roller at the front of the bridge operates automatically with straight transfer and ensures skewed-free transition
to/from the Aircraft.

Powered
Fold-down Front Roller
Bridge Tray

Txl-838’s bridge with different PDU configurations

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II.D. Cargo Transfer on the Bridge, continued

Fold-down front tray(s) accommodate various door sizes (see article II.A. Aircraft Compatibility). Tray is optionally
powered on the TXL-838-STD and TXL-838-COM. All 3 bridge trays come powered on the TXL-838-WID, TXL-838-UNI
and TXL-838-SUP.

Left bridge handrail could fold down to open door of some aircraft, as
required. Handrail also features slide-out extension to close gap between
loader and aircraft. Right side walkway extension is available, optionally
powered, to close gap between loader and aircraft. Moving console is also
available, optionally powered, to ease access to aircraft controls.

Bridge tilt raises and lowers left front corner of bridge to compensate for
changes in pitch of the aircraft while loading. Bridge tilt is optional on TXL-
838, all models.

Side guides on the bridge are powered for side-to-side adjustment. Guides
remain up (  ), although one or both can be removed by hand and
stowed.

Cargo stop is provided at the front of TXL-838 loaders with main deck
bridge lift (TXL-838 COM/UNI/SUP). Stop prevents cargo from being
transferred, accidentally, off the front of the bridge, controlled automatically
by a low deck / high deck interlocking switch.

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II.E. Cargo Transfer on the Elevator

TXL-838 – P0 end load option for 838, all models, front and rear straight transfer still operate independently — but there
is no side load, no rotate, no side rollers, plus side guides are fixed.
TXL-838 - P4 option features a combination of PDU, MDW’s and rollers for straight transfer, independently-operated for
front and rear zones of the elevator. Side load and containers / pallets rotate on the rear zone of the elevator using
PDU’s.
TXL-838 – P6 option offers side shift/loading/unloading at the back zone and improves the rotation of pallets.
TXL-838 – P8 option provides, in addition to above, side shift for front zones.

Txl-838’s elevator with different PDU configurations

Side guides on the elevator are powered to go up and down. A cargo stop is provided at the rear of the elevator. Guides
and stop may be raised and lowered independently. For safety, guides and stop automatically go up (  ) above 75 cm
(30”) from ground, regardless of control switch setting.
Powered rollers around the periphery of the elevator rotate automatically in the same direction as elevator cargo transfer
(no side rollers on 838 elevator P0 configuration). While performing rotation, both side rollers rotate inward to help
keeping the load centered.

II.F. Safety Features

Regarding safety features, the 838 loaders feature the following:
Two safety supports are provided on each platform (bridge and elevator) — for use when working under a raised
platform for maintenance.

An emergency stop button is provided at ground level (front of main electric box) and up on the bridge platform
(operator’s console) — to cut all power to the loader.

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II.F. Safety Features, continued

- Engine cannot be started and no load functions will operate if either one or the other
emergency stop button is depressed.
- A manual fuel shut-off valve is provided at the fuel tank in the event smoke or fire is detected.
- Safety interlock provides starter lockout when drive selector switch is in forward or reverse. Engine can
be started only when loader is in neutral (N).
- Two stabilizers are provided with safety interlock to prevent cargo loading when stabilizers are not in the
fully down (
) position (load mode).
- Safety interlock prevents load mode (stabilizers down
) when loader is not in neutral.
- Safety interlock disables drive mode from being activated in the forward or reverse position, when
loader is in load mode (stabilizers down
).
- Safety interlock ensures that elevator platform must be in the fully down (
) position before loader
can be placed in drive mode (stabilizers up  ).
- All cargo load controls return to center (neutral) position when released — to prevent
unintentional cargo movement on either platform.
- All cargo load controls are located ergonomically to prevent inadvertent operation.
- Cargo load controls feature gentle-touch action to avoid repetitive stress injuries.
- In load mode (stabilizers down) back-up lights turn on automatically to illuminate work area.
- In reverse drive mode, back-up lights turn on automatically and warning horn sounds.
- Warning horn sounds automatically when elevator is being lowered or raised.
- Turn signals and 4-way emergency flashers are provided as standard equipment.
- Bridge handrail extends to close the gap between loader and aircraft.
- When elevator is above 75 cm (30”), side guides/rear cargo stop go up (  ) automatically, a manual
override is available to lower the guides when platform is above 75 cm (30”), except at bridge interface.
- An optional interlock is available to prevent elevator side guides and rear cargo stop from being lowered
when the platform is above a certain height, such as above 150 cm (60”).
- To prevent cargo from being inadvertently conveyed off the front convey system of the raised elevator
platform during elevator-to-bridge shuttle.
- Elevator side guides and rear cargo stop are locked in the up (  ) position when the elevator is
interfaced with the bridge — to prevent cargo from being conveyed off the side of the raised elevator
platform inadvertently.
- Front cargo stop is provided as standard equipment on TXL-838 loaders with main deck bridge (TXL-
838 COM, UNI & TXL-838 SUP), including a safety interlock in “high deck” mode, making sure cargo
stop is up during bridge-to-aircraft shuttle — to prevent cargo from being conveyed off the side or end of
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the raised bridge platform inadvertently.

II.F. Safety Features, continued

- Dynamic braking ensures that loader will come to a full stop when accelerator pedal is not pressed —
even when brake pedal has not been pressed.
- Brake lights turn on when accelerator pedal is released (dynamic braking engaged).

To protect equipment, the TXL-838 loaders feature the following:

- Engine safety shutdown protects engine when sensing indicator low oil pressure, or high engine
temperature.
- Low fuel option is available to prevent running the loader completely out of fuel.
- Starter lockout protection is provided to prevent the ignition from being engaged when the engine is
already running.
- Two stabilizers are provided as a parking brake with safety interlock to prevent vehicle drive from
functioning when stabilizers are not in the fully up position.
- Stabilizer sensing ensures that, in the unlikely event of bleed-down during loading, hydraulic power
automatically engages for pressure to return stabilizers to the fully down position.
- Time delay prevents drive selector switch from being actuated until loader is stopped.
- Battery powered emergency pump is provided as standard equipment — to lower (
)
platforms, remove cargo, and raise (  ) stabilizers in case of engine malfunction.
- Using a manual bypass valve stabilizer can be returned into a stowed position for towing — this is
provided for the possibility of low battery power preventing the use of emergency pump.
- Creep mode is automatically engaged (drive speed reduced / dynamic braking increased) when bridge
is up (  ) — to prevent damage to aircraft during approach.
- Low speed mode is available on TXL-838’s — to prevent damage to aircraft during approach.
- Dynamic braking (loader slows to a stop when accelerator is released) is more aggressive when loader
is in low speed mode — to prevent damage to aircraft during approach.
- Powered, fold-down tray(s) cannot be raised or lowered unless bridge is fully down (
) — to prevent
damage to aircraft while loader is interfaced with aircraft door.
- Bridge handrail folds down to prevent damage to aircraft during door opening phase.

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III. Overall Specifications

Wheel Base
TXL-838, all models 455 cm (179”)

Track Width
TXL-838, all models 208 cm (82”) — front
264 cm (104”) — rear

Overall Height
TXL-838 STD & WID 295 cm (116”) — lowered
485 cm (191”) — raised
TXL-838 UNI & SUP 302 cm (119”) — lowered
686 cm (270”) — raised

Overall Size
TXL-838 STD, COM 384W x 965L cm (151”W x 380”L)
TXL-838 WID, UNI, & SUP 411W x 965L cm (162”W x 380”L)

Shipping Dimensions
TXL-838 STD, COM 307W x 965L x 198H cm (121”W x 380”L x 78”H)
TXL-838 WID, UNI, & SUP 366W x 965L x 198H cm (144”W x 380”L x 78”H)

Gross Weight (approx.)

TXL-838 STD 17 450 kg (38,300 lbs)
TXL-838 WID 18 350 kg (40,300 lbs)
TXL-838 COM 19 750 kg (43 450 lbs)
TXL-838 UNI & SUP 20 500 kg (45,000 lbs)

Variable 2-Speed Front Wheel Drive

TXL-838 Low: (F or R) 8 km/h (0-5 mph)
TXL-838 High: (F or R) 16 km/h (1-10 mph)

Transfer Capacity
TXL-838, all models 7 600 kg (16,700 lbs.) — each platform

Bridge Height
TXL-838 STD & WID 178 cm (70”) — lowered
371 cm (146”) — raised
TXL-838 COM, UNI & SUP 193 cm (76”) — lowered
570 cm (225”) — raised

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III.A. Bridge Specifications

Overall Bridge Length

TXL-838, all models 426 cm (168”)

Overall Bridge Width

TXL-838 STD, COM 378 cm (149”)
TXL-838 WID, UNI, & SUP 409 cm (161”)

Width Capacity
TXL-838 STD, COM 249 cm (98”)
TXL-838 WID, UNI, & SUP 325 cm (128”)

Lift Capacity
TXL-838, all models 7 600 kg (16,700 lbs.)

Lift System
TXL-838 STD & WID Single scissors with dual lift cylinders
TXL-838 COM, UNI & SUP Dual scissors with dual lift cylinders

Cargo Transfer
TXL-838 end load P0 Rollers for straight transfer

TXL-838 P1, P2 & P3 Combination of PDU’s, MDW’s & powered rollers for straight transfer & side shift

Rear Cargo Stop Normally up, mechanically lowered

when elevator interfaces with bridge

Front Cargo Stop

TXL-838 STD & WID Not required
TXL-838 UNI, COM & SUP Included, with low deck / high deck interlocking control

Side Guides One or both can be removed and stowed

TXL-838 STD 158 cm (62”) or 249 cm (98”) wide
Adjustable ± 7,6 cm (3”) side-to-side, forward ends
TXL-838 WID, UNI, & SUP 158 cm (62”), 249 cm (98”), or 325 cm (128”) wide
Adjustable ± 7,6 cm (3”) side-to-side, forward ends

Bridge Tilt
TXL-838, all models Option: ± 4 cm (1.6”)

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III.B. Elevator Specifications

Elevator Height
TXL-838 STD, WID,COM, & UNI 45 to 54 cm (18” to 21.2”) — lowered
371 cm (146”) — raised
TXL-838 SUP 43 to 54 cm (17” to 21.2”) — lowered
480 cm (189”) — raised
Overall Elevator Length
TXL-838, all models 528 cm (208”) — overall
TXL-838, all models 422 cm (166”) — between stops

Overall Elevator Width

TXL-838 STD 295 cm (116”)
TXL-838 WID, UNI, & SUP 361 cm (142”)

Width Capacity
TXL-838 STD 249 cm (98”)
TXL-838 WID, UNI, & SUP 325 cm (128”)

Lift Capacity
TXL-838, all models 7 600 kg (16,700 lbs.)

Lift System
TXL-838, all models Scissors with grasshopper lift mechanism
Single lift cylinder on each side,
with integrated counterbalance valves
Lift Speed
TXL-838, all models 15 m/min (50 ft/min)

NOTE: Lift performance may be influenced by altitude, temperature, and failure

to perform engine maintenance adequately.
Cargo Transfer
TXL-838 end load 0: Rollers for straight transfer.Straight transfer in front & rear zones operate
Independently, no side load, no rotate, no side rollers, and side guides are fixed

TXL-838 P4 option: Combination of PDU’s, Rollers & MDW’s for straight transfer, side load, side shift & container
& pallet rotation
TXL-838 P6 option:
TXL-838 STD, COM Combination of PDU’s & rollers for straight transfer, side load, side shift & container &
pallet rotation.
TXL-838 WID, UNI, & SUP Combination of PDU’s, Rollers & MDW’s for straight transfer, side load, side shift &
container & pallet rotation

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III.B. Elevator Specifications continued

TXL-838 P8 option:

TXL-838 STD, COM Combination of PDU’s & rollers for straight transfer, side load, side shift & container &
pallet rotation.
TXL-838 WID, UNI, & SUP Combination of PDU’s, Rollers & MDW’s for straight transfer, side load, side shift &
container & pallet rotation

Powered Rollers Around periphery, automatic in direction of transfer

(no side rollers for TXL-838 end load P0)

Rear Cargo Stop Powered to raise and lower, using operator controls,
or select automatic lower, elevator below 75 cm (30”)
75 cm (30”), regardless of control setting

Side Guides Powered to raise and lower, independently-operated, or select automatic lower, elevator below
75 cm (30”) — for safety, stop goes up automatically above 75 cm (30”), regardless of control
setting

TXL-838 STD, COM Fixed at 249 cm (98”) wide

TXL-838 WID, UNI, & SUP Fixed at 325 cm (128”) — instead of 249 cm (98”)

III.C. Vehicle Drive Specifications

Diesel Engines Swing-out Engine Module

Tier regulation compliant diesel engines, range between 80 to 115 Hp
Fuel Tank Capacity
TXL-838, all models 121 liters (32 US gallons); 227 liters (60 US gallons) optional
Vehicle Power One engine-driven hydraulic pump provides
power for vehicle drive, power steering, elevator
and bridge lifts—plus all cargo handling systems
Vehicle Drive Heavy-duty, front-wheel-mounted drive motors
Braking Automatic hydrostatic braking, as well as
front-wheel-mounted, outboard drum brakes
Front Wheels
TXL-838, all models Two (2): Solid rubber, 32” x 12.1” x 15”

Rear Wheels
TXL-838, all models Four (4): dual tandems, both sides
Solid polyurethane, 12” x 5” x 8”

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III.C. Vehicle Drive Specifications, continued

Driving speeds and stopping distances
“Creep Mode” (bridge NOT at frame):
Approximately 5 km/hr (3 mph) to zero:
92 cm (3 ft) with dynamic braking AND service brakes (brake pedal)
122 cm (4 ft) with dynamic braking alone
“Slow Mode” (bridge at frame):
Approximately 8 km/hr (5 mph) to zero:
305 to 366 cm (10 to 12 ft) with dynamic braking AND service brakes
366 to 427 cm (12 to 14 ft) with dynamic braking alone
“Fast Mode” (838’s only):
Approximately 16 km/hr (10 mph) to zero:
427 to 488 cm (14 to 16 ft) with dynamic braking AND service brakes
488 to 549 cm (16 to 18 ft) with dynamic braking alone
Gradeability 7%
Steering Angle ± 60°
Turning Performance Radius: 5m (16 ft)
Wall-to-wall: 13m (43 ft) diameter
III.D. Hydraulic, Electrical, Miscellaneous
Hydraulic Pump Pressure See chart chapter 5

Hydraulic Valves 24V DC solenoid-operated

Hydraulic Tank Capacity 246 liters (65 US gallons)

Recommended Hydraulic Fluid

Ambient Temperature –26°C (–15°F) to +18°C (+65°F)
Hydraulic Fluid Mobil DTE-13 or 13M (ISO grade 32) or equivalent
Ambient Temperature –9°C (+15) to +38°C (+100°F)
Hydraulic Fluid Mobil DTE-15 or 15M (ISO grade 46) or equivalent
Ambient Temperature +4°C (+40F) to +54°C (+130°F)
Hydraulic Fluid Mobil DTE-16 or 16M (ISO grade 68) or equivalent
Note: Maximum fluid temperature = 71°C (160°F).
See temperature on level gauge. NO ATF FLUID

Standard Electrical System 24V DC with starter protection

LCD screen for diagnostic and communication.

Ambient Operating Temperature –40°C to 52°C (–40°F to 125°F) with special options

Wind Speed During Operation 96 km/hr (60 mph)

Withstand 160 km/hr (100 mph)
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