Still LTX 70 User manual

Original instructions
Electric tow tractor
LTX 70
LTX 80
LTX-T08
0608 0609 0610 0688 0689
0690
1191 801 15 51 EN - 09/2019

Preface
g
Address of manufacturer and
contact details
STILL GmbH
Berzeliusstraße 10
22113 Hamburg, Germany
Tel. [phone]
Fax: [phone]
Email: [email protected]
Website: http://www.still.de
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Table of contents
g
1 Introduction
Your industrial truck ................................................... 2
General ............................................................ 2
CElabelling ......................................................... 2
Copyrightandpropertyrights ............................................ 2
EC declaration of conformity............................................. 3
Nameplate ......................................................... 4
Rules for the operating company of industrial trucks ........................... 4
Correct use ......................................................... 6
Description of use and climatic conditions ................................... 7
Unauthorised use ..................................................... 7
Explanation of symbols used ............................................ 8
Disposing of components and batteries ..................................... 8
2Safety
Driver safety guidelines ............................................... 10
Safety regulations for handling consumables ............................... 12
Permissibleconsumables ............................................. 12
Oils .............................................................. 12
Hydraulicfluid ...................................................... 13
Batteryacid ........................................................ 13
Disposalofconsumables .............................................. 14
Emissions ......................................................... 15
Noiseemissionvalues ................................................ 15
Vibration values for upper limbs ......................................... 15
Residual dangers, residual risks ......................................... 15
Stability ........................................................... 16
In case of tip-over .................................................... 16
Definition of responsible persons ........................................ 17
Operatingcompany .................................................. 17
Specialist .......................................................... 17
Drivers ........................................................... 17
Safety test ......................................................... 19
Regular safety inspection of the tow tractor . ................................ 19
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3Overviews
Overviews ......................................................... 22
General view of the tow tractor .......................................... 22
General view of the carrier . . . .......................................... 23
Control and display components ......................................... 24
Display ........................................................... 24
Markings .......................................................... 25
Tow tractor labels ................................................... 25
Carrier labels ...................................................... 26
Serialnumber ...................................................... 27
4Use
Technical description ................................................ 30
Checks and actions prior to commissioning ................................. 32
Checkallcontrolsandtheiroperation ..................................... 32
Checking tyre pressure and condition ..................................... 32
Checking the battery chargestatus ....................................... 33
Checkingtheinterlocks ............................................... 33
Checkingthefootbrake ............................................... 34
Check emergency shutdown ........................................... 34
Topupthewindscreenwasherbottle ..................................... 35
Verification of manual tow coupling ...................................... 35
Check the automatic trailercoupling(iffitted) ................................ 36
Truck operating instructions ............................................ 37
The nameplate ...................................................... 38
Display ........................................................... 39
Thetowtractorstart-upscreen .......................................... 39
Steering knobs ...................................................... 39
Usingthedisplay .................................................... 40
Adjustingthedisplay ................................................. 42
Driver's compartment settings .......................................... 44
Safety guidelines for adjustmentwork .................................... 44
Steeringcolumnadjustment ........................................... 44
Seat belt (optional) .................................................. 45
Safety guidelines for driving a tow tractor .................................. 46
Entering and exiting the tow tractor ....................................... 47
Driving the tow tractor ................................................. 48
Definitionofdirections ................................................ 48
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Towtractorignitionusingthekey ........................................ 48
Startingthetowtractorwithanelectronickey ............................... 49
Start-up .......................................................... 50
Dead man's pedal option .............................................. 50
Forwardstravel ..................................................... 51
Backwardsdriving ................................................... 52
Towtractorbraking .................................................. 53
Emergency stop .................................................... 54
OperatingBlueQmode ............................................... 54
Operatingthedriveprogrammeselectionbutton ............................. 55
Operatingthehorn .................................................. 56
Startingonanincline ................................................. 57
Operating the FleetManager™ option ..................................... 58
Description of the FleetManager option .................................... 58
Commissioning a tow tractor equipped with the FleetManager™ option ............ 59
FleetManager™ option: Colour code for the LEDs ........................... 61
Logging off a tow tractor equipped with the FleetManager™ option ............... 63
Lighting ........................................................... 66
Usingthesignallights ................................................ 66
Usingthedirectionindicators ........................................... 67
Using the hazard warninglight .......................................... 68
Usingthecabinteriorlight ............................................. 68
Using the rotating beacon (optional) ...................................... 69
Towing ........................................................... 70
Safetyguidelines .................................................... 70
Using the manual coupling ............................................. 71
Using the automatic coupling ........................................... 72
Using electric tow coupling ............................................. 73
Inchingmodeoption ................................................. 75
Loading the platform . . ............................................... 77
Loading trailers ..................................................... 78
Towingatrailer ..................................................... 78
Liftrunner system equipmentoption ...................................... 80
Optional equipment .................................................. 84
Pedestrian"Slowtravel"option .......................................... 84
Caboption ........................................................ 85
Windscreenwiperoption .............................................. 86
Heating/demistingoption .............................................. 86
Automaticlightsoption ............................................... 87
Electrolyteleveldisplayoption .......................................... 87
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StVZO (German Road Traffic Licensing Regulations) option (intended for the German
market) .........................................................88
Parking the tow tractor ................................................ 89
Battery ........................................................... 90
Batterytype ........................................................ 90
Accessingthebattery ................................................ 91
Battery connection .................................................. 93
Chargingthebatteryusinganexternalcharger .............................. 94
General information on the on-board charger ............................... 96
Using the on-board charger (optional) ..................................... 96
Charging the battery with opportunity charging (optional) ....................... 99
Changing the battery with the Fork Off tool .................................103
Changing the battery with theRollOfftool ..................................106
Handling the truck in an emergency ......................................108
Precautionsbeforetowingthetractor .....................................108
Towingthetractor ...................................................108
Handling the tow tractor in specific situations ................................109
Transportingthetowtractor ............................................109
Slinging the tow tractor ................................................112
Jackingthetowtractor ................................................114
5 Maintenance
General maintenance information ........................................116
General . .........................................................116
Servicing and maintenance personnel training and qualification ..................117
Batterymaintenancestaff ..............................................117
Maintenance operations that do not require special training .....................117
Orderingsparepartsandconsumables ....................................117
Safety guidelines for maintenance .......................................118
Servicing and maintenancemeasures ....................................118
Workingontheelectricalequipment ......................................118
Safetydevices .....................................................118
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Technical data for inspection and maintenance ..............................119
Recommended lubricants .............................................120
Removing the cover to access the technical compartment ......................121
Maintenance schedule as required .......................................123
1000-hour maintenance schedule .......................................123
3000-hour/two-year maintenance plan ....................................124
Chassis, bodywork and fittings ..........................................126
Cleaningthetowtractor ...............................................126
General information on battery maintenance ...............................130
Checkthatthewheelnutsarefittedsecurely ................................131
Checking the condition and pressure of the tyres .............................131
Cleaning the battery and thebatterycompartment ............................131
Checkingtheseatbelt ................................................133
Checking the condition and operation of the signal lights .......................134
Cleaningtheheater ..................................................135
Checking and lubricating the automatic tow coupling ..........................136
Checkingthebrakingsystem ...........................................136
Driver's compartment .................................................138
Checkingandlubricatingthedriver'sseat ..................................138
Checking and lubricating the latches and hinges .............................138
Transmission .......................................................139
Cleaningandcheckingthegearboxbreather ...............................139
Drainingandfillingthedriveaxle ........................................140
Chassis ...........................................................141
Checkingandlubricatingthesteeringchain .................................141
Checking the front suspension ..........................................142
Lubricating the frontsuspension ........................................142
Checking and lubricating the front wheel bearing ............................143
Checkingthebrakefluidlevel ...........................................143
Changing the brake fluid ...............................................144
Checking the front and rear brake shoes . . . ................................145
Checking the drive axle rubber shock mounts ...............................145
Checking the drive axlesuspensionbushes ................................146
Maintaining the Liftrunner system equipment ...............................146
Electrical equipment .................................................147
Checkingthefuses ...................................................14
7
Checkingthebatteryacidlevelandelectrolytedensity ........................148
Checking the condition and secure attachment of electrical connections and ca-
bles ............................................................ 149
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Checking the battery and the condition of the battery cable .....................150
Cleaning the opportunity charging equipment ...............................151
Decommissioning and storage ..........................................1
52
Towtractorstorage ..................................................152
Permanent putting out of commission (destruction) ...........................153
6 Technical specifications
Datasheet for the tow tractor ...........................................156
Towing diagram for the tow tractor .......................................160
Datasheet for the transponder ..........................................164
Towing diagram for the transponder ......................................169
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1
Introduction

1Introduction
Your industrial truck
Your industrial truck
General
The tow tractor described in these operating
instructions complies with the applicable
standards and safety regulations.
If the tow tractor is to be operated on public
roads, it must conform to the existing national
regulations for the country in which it is being
used. The driver's licence must be obtained
from the appropriate authorities.
The tow tractors have been fitted with state-
of-the-art technology. All that is now required
is to handle them in complete safety and keep
them operational.
These operating instructions provide the nec-
essary information to do this. Read and ob-
serve the information provided before com-
missioning the tow tractor. This precaution will
prevent accidents and ensure that the war-
ranty remains valid.
CE-Symbol
CE labelling
The manufacturer uses CE labelling to in-
dicate that the tow tractor complies with the
standards and regulations valid at the time of
marketing. The supplied EC declaration of
conformity confirms this. The CE labelling is
attached to the nameplate.
An independent structural change or an
addition to the tow tractor can compromise
safety, thereby invalidating the EC declaration
of conformity.
The EC declaration of conformity must be
carefully stored and made available to the
responsible authorities.
Copyright and property rights
This manual - and any excerpts thereof - may
not be reproduced, translated or transmitted
in any form to third parties without the express
written permission of the manufacturer.
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Introduction 1
EC declaration of conformity
EC declaration of conformity
Declaration
STILL GmbH
Berzeliusstrasse 10
22113 Hamburg
GERMANY
We declare that the machine
Industrial truck according to these operating instructions
Model according to these operating instructions
conforms to the latest version of the Machinery Directive 2006/42/EC.
Person authorised to compile the technical documents:
See EC compliance declaration
STILL S.A.S.
The manufacturer declares that the truck
complies with the requirements of the EC
directives valid at the time of marketing. This is
confirmed by the EC declaration of conformity
and by the EC labelling on the nameplate.
An independent structural change or addition
to the truck can compromise safety, thus
invalidating the EC declaration of conformity.
The EC declaration of conformity must be
carefully stored and made available to the
relevant authorities.
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1Introduction
Nameplate
1 Model
2 Manufacturer
3 Serial number
4 Year of manufacture
5 Unladen weight (without battery) in kg
6 Battery maximum weight
7 Battery minimum weight
8 Additional weight (ballast weight) in kg
9 Nominal motor power (kW)
10 Battery voltage in V
11 Rated capacity in kg
12 EC conformity symbol
Nameplate
NOTE
Indicate the serial number for all technical
enquiries.
Rules for the operating
company of industrial trucks
In addition to these operating instructions,
a code of practice containing additional
information for the operating companies of
industrial trucks is also available.
This guide provides information for handling
industrial trucks:
• Information on how to select suitable
industrial trucks for a particular area of
application
• Prerequisites for the safe operation of
industrial trucks
• Information on the use of industrial trucks
• Information on transport, initial commis-
sioning and storage of industrial trucks
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Introduction 1
Rules for the operating company of industrial trucks
Internet address and QR code
The information can be accessed at any time
by pasting the address https://m.still.de/vdma
in a web browser or by scanning the QR code.
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1Introduction
Correct use
Correct use
The industrial truck must be used only for
authorised use.
The industrial truck is used to move loads as
specified on the capacity rating plate.
Damage and defects
Damage or other defects to the industrial
trucks or attachments must be reported
immediately to the supervisor. Industrial
trucks and attachments that are dangerous
to use must not be used before being properly
repaired.
The safety systems and switches must not
be removed or switched off. The specified
settings can be modified only with the manu-
facturer's approval.
Danger areas
Danger areas are areas in which the move-
ment of industrial trucks, their operating equip-
ment or their load lifting fixtures (e.g. their at-
tachments) may put people in danger.
This includes areas:
• With objects that could fall
• Which could be affected by the falling or
lowering of equipment or devices in service
Do not stand in the danger area of an industrial
truck.
Work areas
Only areas authorised by the operating
company or its representative can be used for
transport purposes. Loads may be removed
and stored only in places designed for this
purpose.
In operating areas with magnetic fields that
have a magnetic flux density greater than
5 mT, unintentional truck movements cannot
be entirely excluded under unfavourable
circumstances. Under these circumstances,
use components that are specifically designed
for that purpose.
Traffic routes
Traffic routes must be well-paved, flat and free
from obstacles. Drainage channels and level
crossings must be level. If necessary, ramps
must be provided so that trucks can drive over
them with as few bumps as possible.
Industrial trucks must not be used for travelling
on routes with sharp turns, steep gradients or
entrances that are too narroworlow.
Slopes used by industrial trucks must be within
the limits specified by the manufacturer and
must have a sufficiently rough surface. Flat
and gradual transitions at the top and lower
ends should prevent the load from touching
the ground or causing damage to the chassis.
Do not go beyond the authorised area or the
loading points of the traffic areas or routes.
There must be sufficient distance between the
highest part of the truck or the load and the
fixed parts of surrounding areas.
Comply with Directive UE 89/654/EEC (min-
imum health and safety requirements for the
workplace). For countries outside the Euro-
pean Union, the national regulations for that
country should be observed.
Dangerous points along traffic areas or routes
must be secured and signalled by standard
road signs and, if required, by additional
warning signs.
When driving on public roads, observe the
regulations in force as well as the winter
driving restrictions in the country concerned.
Fire protection
The operating company must ensure that
there is suitable fire protection in the vicinity
of the industrial truck. Depending on the type
of use, it must ensure that there is additional
fire protection on the industrial truck. In case
of any doubt, request information from the
responsible supervisory authorities.
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Introduction 1
Description of use and climatic conditions
Attachments
Attachments must only be used for their in-
tended purpose. The driver must be instructed
in the handling of the attachments.
Operating instructions for the attachment are
enclosed for trucks that are delivered and
fitted with an attachment. Before commission-
ing a truck with an attachment, you must check
that loads are handled safely. Depending on
thetypeofattachment,itma
y be necessary
to make adjustments. Corresponding instruc-
tions can be found in the operating instructions
for the attachment.
If the attachments are not supplied with
the industrial truck, the specifications from
the industrial truck manufacturer and the
attachment manufacturer must be observed.
Fitting attachments and connecting the power
supply for the attachments must only be
carried out by specialists in accordance with
the manufacturer's specifications. After every
installation, check the correct operation of the
attachments before use.
Do not exceed the maximum authorised load
capacity for the attachments and the indus-
trial truck (load capacity and load moment)
combined with the attachments; refer to the
additional capacity rating plate.
Modifications, in particular attachments or
conversions, are not permittedtobemadeto
the industrial truck without the manufacturer's
approval.
Trailers
Industrial trucks may be used to tow trailers if
the manufacturer has designed them for that
purpose and they are equipped with a suitable
trailer coupling. Do not exceed the maximum
towed load capacity specified in the operating
instructions for braked or unbraked trailers.
The industrial truck must be operated in such
a way as to ensure safe driving and braking of
the towed vehicle in all circumstances.
Description of use and climatic conditions
Normal use
• Indoor and outdoor use
• Use in a temperature range of -20°C to
+50°C
• If the tow tractor is equipped with a heated
cab, it can also be used between -20°C and
-30°C.
DANGER
Never use a standard tow tractor in areas in which
there is a risk of explosion (gases, vapours or
flammable/explosive powders present).
Tow tractors that operateinsuchenvironments
must be specially protected. They must be ac-
companied by an EC declaration of conformity and
appropriate operating instructions.
Unauthorised use
Any danger caused as a result of unauthorised
use becomes the responsibility of the operator
or driver and not that of the manufacturer.
Use for purposes other than those described
in these operating instructions is prohibited.
Transporting people is prohibited.
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1Introduction
Explanation of symbols used
The tow tractor must not be used in areas
where there is a risk of fire, explosion or
corrosion, or in areas that are particularly
dusty.
Explanation of symbols used
DANGER
Compulsory procedure that must be followed to
avoid life-threatening danger or physical harm.
WARNING
Compulsory procedure that must followed to avoid
injury.
CAUTION
Compulsory procedure that must be followed to
avoid damage to and/or destruction of equipment.
NOTE
For technical requirements that require
special attention.
ENVIRONMENT NOTE
To prevent environmental damage.
Disposing of components and batteries
The truck is made up of different materials.
If components or batteries must be replaced
and scrapped, they must be:
• disposed of
• treated or
• recycled in accordance with regional and
national regulations
NOTE
The documentation provided by the battery
manufacturer must be observed when dispo-
sing of batteries.
ENVIRONMENT NOTE
We recommend working with a waste mana-
gement company when disposing of compo-
nents and batteries.
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2
Safety

2Safety
Driver safety guidelines
Driver safety guidelines
NOTE
The safety rules in this instruction booklet
must be respected at all times. These rules
do not replace the rules described in the
booklet supplied with the tow tractor for users
of industrial and all-terrain trucks (VDMA).
They complement them.
Before the tow tractor can be used or any work
can be done on it, all members of staff involved
(in particular the drivers and the maintenance
staff) must receive training for the standard
and correct use of the tow tractor. This training
must be provided by qualified instructors
in accordance with the safety information
provided with this instruction booklet.
The employer must ensure that the driver has
understood all safety information.
Please adhere to the instructions for use and
the safety rules described in this instruction
booklet, in particular:
• Information on the operation of industrial
tow tractors
• Rules for roadways and work areas
• Rights, duties and safety rules for the driver
• Operation in special areas
• Information related to starting, driving and
braking
• Service and repair information
• Recurrent inspections, accident prevention
check
• Disposal of grease, oil and batteries
The driver or person in charge must ensure
that the above operating guidelines and safety
rules are observed at all times.
During training the driver must fully acquaint
themselves with:
• Special features of the tow tractor (pedals,
control levers and switches, indicators and
forward/reverse selection)
• Additional attachments
• Special operating conditions
The driver must practice driving the vehicle,
using the controls and steering the tow tractor
whilst it is empty until he has complete control
of the vehicle.
DANGER
When using a tow tractor, one of the main causes
of accidents is the driver's failure to comply with or
lack of knowledge of basic safety rules.
In order to ensurethe safety of the driver and others,
a few basic safe operating practices outlined below
must also be followed.
Personal factors
– Only drivers with the correct certification,
issued by qualified instructors, should
operate the tow tractor.
– Drivers must drive responsibly. They must
understand that they are operating valuable
equipment, moving goods in a confined
area, probably where other people work.
– Before starting work, the preliminary checks
described in this booklet must be com-
pleted.
– If the tow tractor shows signs of damage
or malfunction, or if it cannot be used in
complete safety, park it in a safe place,
remove the key and inform your manager.
Do not use a faulty tow tractor.
– To ensure that risks are minimised, keep
the tow tractor in good condition at all times.
– Keep any labels or warnings attached to
the tow tractor in good condition. Replace
illegible labels or warnings.
– Always handle, charge and maintain
batteries according to the manufacturer's
instructions. These are supplied with the
battery.
– Protective equipment, i.e. goggles and
gloves, must be worn at all times when
completing any work involving the batteries.
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