Still LTX10 User manual

Original instructions
LTX10, LTX20, LTX-T04
Tractor
0611 0612
1193 801 16 01 EN - 06/2016

Table of contents
g
1 Foreword
Your industrial truck ................................................... 2
General ............................................................ 2
ECdeclarationofconformity ............................................. 3
Information about documentation ......................................... 3
Documentationscope ................................................. 3
Date of edition and latest update of this manual ............................... 5
Copyrightandtrademarkrights ........................................... 5
Explanation of symbols used ............................................ 6
Explanation of the cross-references ....................................... 6
Definitionofdirections ................................................. 7
Illustrations ......................................................... 7
Environmental considerations ........................................... 8
Packaging .......................................................... 8
Disposal of components andbatteries ...................................... 8
2 Introduction
Technical Description ................................................. 10
Use of the truck ..................................................... 11
Intended use of the trucks .............................................. 11
Proper usage ....................................................... 11
Unauthorised use .................................................... 12
Placeofuse ........................................................ 12
Residual risks ...................................................... 13
Residual dangers, residual risks ......................................... 13
Stability ........................................................... 14
Specialrisksassociatedwithusingthetruckandattachments ................... 14
3Safety
Definition of terms used for responsible persons ............................. 16
Operating company .................................................. 16
Specialist .......................................................... 16
Drivers ........................................................... 16
Basic principles for safe operation ....................................... 18
Insurance cover on company premises .................................... 18
Warning regarding non-original parts ..................................... 18
Modifications andrefitting .............................................. 18
Medicalequipment .................................................. 19
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Safety tests ........................................................ 20
Regularsafetyinspectionofthetruck ..................................... 20
Electricalinsulationtest ............................................... 20
Safety regulations for handling consumables ............................... 21
Permissibleconsumables ............................................. 21
Oils .............................................................. 22
Batteryacid ........................................................ 23
Disposalofconsumables .............................................. 24
Emissions ......................................................... 24
Safety devices ...................................................... 26
Damage, defects and misuse of safety devices . . . ........................... 26
Battery connection cables............................................. 26
EMC - Electromagnetic Compatibility ..................................... 26
4Overviews
General view ....................................................... 30
Labels ............................................................ 31
Identification plate ................................................... 32
Operating devices 1193 ............................................... 33
Accessory bar (optional) ............................................... 34
Display unit ........................................................ 35
Electronic key (option) ................................................ 37
RF device (optional) .................................................. 38
5Use
Commissioning ..................................................... 42
Before driving ...................................................... 42
Designation ........................................................ 44
Checks before initial use .............................................. 45
Daily checks before use ............................................... 46
Checking the working environment ....................................... 47
Operating instructions ................................................ 47
Commissioning ..................................................... 48
Emergency stopswitch ............................................... 49
Determining the drive direction .......................................... 49
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Table of contents
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Forward/reverse travel ................................................ 50
Steering unit ....................................................... 50
Stand-on/seated driving operation ....................................... 51
Drivingonaslope ................................................... 54
Brake, horn and lighting ............................................... 56
Coupling .......................................................... 57
Coupling the trailer ................................................... 58
Driving the truck with cargo ............................................. 61
Transporting the truck ................................................ 63
Truck storage ...................................................... 63
Measurestobetakenpriortotruckstorage ................................. 63
Resuming use of the tractor ............................................ 64
Disposal of old trucks ................................................. 65
6 Maintenance
General maintenance information ........................................ 68
General ........................................................... 68
Staff training and qualifications for maintenance and repairs . . . ................. 68
Battery maintenance personnel ......................................... 68
Services not requiringspecialqualifications ................................ 69
Orderingsparepartsandwearparts ...................................... 69
Recommended lubricants ............................................. 70
Technical inspection and maintenance characteristics ......................... 71
Safety regulations for maintenance ....................................... 72
Safety measures for maintenance and repair ............................... 72
Work on the electrical equipment ........................................ 72
Safetydevices ...................................................... 72
Settings ........................................................... 72
Daily checks before starting work ........................................ 73
Checkingthetraveldirectioncontrolfunction ................................ 73
Checkingthebrakes ................................................. 73
Testing the steeringunit ............................................... 75
Testingsafetydevices ................................................ 75
Checkingthebatterychargingstatus ..................................... 76
Opening the batteryhood .............................................. 77
Plugging in/unplugging the battery connector ............................... 78
Checking the condition of cables, terminals and battery connector ................ 79
Removing/replacingthebattery ......................................... 79
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Maintenance plan as required ........................................... 83
Cleaning . ......................................................... 83
Accessing the electrical compartment ..................................... 84
Checkingtheauxiliaryseatcondition ..................................... 85
Steeringtiller:checkcondition ........................................... 85
Checkfuses ........................................................ 86
Inspection and maintenance overview .................................... 86
1000hourserviceplan ................................................ 86
10000hourserviceplan ............................................... 87
Tractor motor ....................................................... 89
Traction motor:Cleaning the motor housing ................................. 89
Gearbox .......................................................... 89
Servicingthereducer ................................................. 89
Steering/braking/wheels .............................................. 90
Steering/wheels/brakes ............................................... 90
Checkingthebrakeairgap ............................................. 92
Battery ........................................................... 92
Checking the on-board charger .......................................... 92
Batterymaintenance ................................................. 93
Removing/replacingthebattery ......................................... 95
7 Technical data
Datasheet .........................................................102
IV 1193 801 16 01 EN - 06/2016

1
Foreword

1Foreword
Your industrial truck
Your industrial truck
General
The truck described in these operating instruc-
tions corresponds to the applicable standards
and safety regulations.
If the truck is to be operated on public roads, it
must conform to the existing national regula-
tions for the country in which it is being used.
The driving permit must be obtained from the
appropriate office.
Thetruckshavebeenfittedw
ith state-of-the-
art technology. All that remains is to handle
the truck safely and maintain its functionality.
These operating instructions provide the
necessary information to do this. Read and
observe the information provided before
commissioning the truck. This will prevent
accidents and ensure that the warranty
remains valid.
21
193 801 16 01 EN - 06/2016

Foreword 1
Information about documentation
EC declaration of conformity
Declaration
KSAS (KION South Asia Pte Ltd)
5 Loyang Way,
508720, Singapore
We declare that the machine
Industrial truck according to these operating instructions
Model according to these operating instructions
complies with the most recent version of machinery directive 2006/42/EC.
Personnel authorised to compile the technical documents:
See EC compliance declaration
Documentation department
STILL GmbH
EC declaration of conformity
The manufacturer declares that the truck com-
plies with the requirements of the EC machin-
ery directive and any other EC directives, if
applicable, that are valid at the time of plac-
ing on the market. This is confirmed by the
EC declaration of conformity and by the CE
labelling on the nameplate.
The EC declaration of conformity document
is delivered with the truck. The declaration
shown explains the conformity with the re-
quirements of the EC machinery directive.
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
responsible authorities if applicable. It must
also be handed over to the new owner if the
truck is sold on.
Information about documentation
Documentation scope
• Operating instructions
• Operating instructions for attachment parts
(special equipment)
• Spare parts list
• VDMA rules for the proper use of industrial
trucks (EU countries only)
1193 801 16 01 EN - 06/2016 3

1Foreword
Information about documentation
These operating instructions describe all mea-
sures necessary for the safe operation and
proper maintenance of the truck in all possible
variants at the time of printing. Special de-
signs to meet customer requirements are doc-
umented in separate operating instructions. If
you have any questions, please contact your
service centre.
Enter the production number and the year of
production located on the nameplate in the
field provided:
Production no. ...........................................
Year of production
...................................................
Please quote these numbers for all technical
enquiries.
Operating instructions are provided with each
truck. These instructionsmustbestored
carefully and must be available to the driver
and operator at all times.
If the operating instructions are lost, the oper-
ator must immediately request a replacement
from the manufacturer.
The operating instructions are included in the
spare parts list and can be reordered there as
a spare part.
Personnel responsible for operating and
maintaining the equipment must be familiar
with these operating instructions.
The operating company (see ⇒ Chapter "Def-
inition of terms used for responsible per-
sons", P. 16) must ensure that all operators
have received, read and understood these
instructions.
Thank you for reading and complying with
these operating instructions. If you have any
questions or suggestions for improvements,
or if you have found any faults, please contact
your service centre.
41
193 801 16 01 EN - 06/2016