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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Table of contents
g
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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Table of contents
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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.
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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.
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Foreword 1
Information about documentation
Date of edition and latest update of
this manual
The publication date of these operating
instructions is printed on the cover sheet.
The manufacturer makes continuous efforts
to improve its industrial trucks, and therefore
reserves the right to implement changes and
to accept no claims concerning the information
provided in this manual.
To receive technical assistance, please
contact the service centre authorised by your
closest manufacturer.
Copyright and trademark rights
These instructions must not be reproduced,
translated or made accessible to third par-
ties—including as excerpts—except with the
express written approval of the manufacturer.
1193 801 16 01 EN - 06/2016 5

1Foreword
Information about documentation
Explanation of symbols used
DANGER
Compulsory procedure that must be followed to
avoid danger to life or physical harm.
WARNING
Compulsory procedure that must followed to avoid
injury.
CAUTION
Compulsory procedure that must be followed to
avoid material damage and/or destruction.
NOTE
For technical requirements that require
special attention.
ENVIRONMENT NOTE
To prevent environmental damage.
Explanation of the cross-references
Cross references are used to direct the reader
to the appropriate section or chapter.
Examples:
• Cross reference to a section: ⇒ Chap-
ter "Explanation of the cross-refer-
ences", P. 1-6
• Cross reference to a chapter: ⇒ Chap-
ter "Definition of terms used for responsible
persons", P. 16
61
193 801 16 01 EN - 06/2016

Foreword 1
Information about documentation
Definition of directions
The directions front (1), rear (3), right (2)
and left (4) are seen from the position of the
operator; the load is at the rear.
Illustrations
At many points in this documentation the
(mostly sequential) operation of certain func-
tions or operating procedures is explained. To
illustrate these operations, schematic repre-
sentations of an truck are used.
NOTE
These schematic representations do not
represent the design state of the documented
truck. They only serve to illustrate operating
procedures.
1193 801 16 01 EN - 06/2016 7

1Foreword
Environmental considerations
Environmental considerations
Packaging
During delivery of the truck, certain parts
are packaged to provide protection during
transport. This packaging must be removed
completely prior to initial start-up.
ENVIRONMENT NOTE
The packaging material must be disposed of
properly after delivery of the truck.
Disposal of componentsand
batteries
The truck is composed of different materials. If
components or batteries need to be replaced
and disposed of, they must be:
•disposedof,
• 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 for disposal purposes.
81
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2
Introduction

2Introduction
Technical Description
Technical Description
Maximum design load capacity of LTX10,
LTX20 and LTX–T04 type 1193 tow tractors:
LTX10 1000 kg
LTX20 2000 kg
LTX–T04 400/1000 kg
These tractors are used in seated /standing
mode.
NOTE
The platform of LTX-T04 can load 400kg
cargo, and at the same time, the truck can
tow 1000kg cargo.
The LTX10, LTX20 and LTX-T04 are config-
ured:
– As standard with a 3 point wheel base and 2
castor wheels
10 km/h in forward gear, 3 km/h in reverse
gear, laden and unladen for the LTX10.
- 8 km/h in forward gear, 3 km/h in reverse
gear, laden and unladen for the LTX20.
- 8 km/h in forward gear,3km/hinreverse
gear, laden and unladen for the LTX-T04.
– Optional forward/reverse coupling ap-
proach control for coupling to a trailer.
LTX10, LTX20 travels a distance of 0.3 m
each time the button (forward or reverse) is
held down.
LTX-T04travelsadi
stance of 4 m each time
the button (forward) is held down.
These tractors offer excellent performance,
thanks to their structure that includes:
• a fixed front chassis with the mechanical
and electrical units necessary for truck
movements
• a battery (technical compartment)
• a driver’s compartment
• a driving platform
• a tractor chassis at the rear
Maintenance and programming the truck is fa-
cilitated by the on-board Can Bus technology.
Drive
The traction and travel of the tractor are
provided by:
• a.1.5 kW traction motor.
• a drive unit placed in the centre of the
chassis.
• two stabilisers fixed on the right and the left
of the chassis.
Power is supplied by a 24 volt lead-acid battery
with a capacity of 200 Ah.
The power supply to the traction motor is con-
trolled by an L.A.C controller which provides
perfect control of speed, acceleration and
braking.
Braking
The LTX10, LTX20 and LTX-T04 Type 1193
are equipped with two braking systems:
– An electromagnetic safety brake that also
serves as a parking brake.
The latter is applied automatically in the
following situations:
• the driver leaves the driving platform.
• truck stationary, direction reverser in
neutral.
• power off.
The safety brake is applied automatically in the
eventofafaultinth
e traction and/or steering
control systems.
– A counter-current electrical brake that is
applied automatically when the control is
released and when the direction of travel is
reversed.
Balancing mechanism
The 3-point chassis has 2 height-adjustable
fixed castor wheels.
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Introduction 2
Use of the truck
Towing system
Nominal load:
– LTX10:1000 kg
– LTX20:2000 kg
– LTX-T04:400/1000 kg
Coupling options:
single position of LTX10: 276 mm
single position of LTX20: 276 mm
single position of LTX-T04:165 mm
Driver’s compartment
The standard equipment in the driver’s com-
partment comprises:
–A dashboard with:
- a multifunction display;
- an ignition key or digicode allowing the truck
to be used by authorised personnel without an
ignition key;
- an emergency stop button;
- a diagnostic connector;
- trays for pens and pencils;
– A suspended platform with operator pres-
ence sensor.
– A height-adjustable auxiliary seat, incorpo-
rating:
– height adjustment locking handle
Use of the truck
Intended use of the trucks
CAUTION
This machine was designed for the transport and
storage on racks (pallet stackers only) of loads
packed on pallets or in industrial containers de-
signed for this purpose.
The dimensions and capacity of the pallet or contai-
ner must be adapted to the load being transported
and must ensure stability.
The table of characteristics and performance atta-
ched to this user manual gives you the information
you need to check that the equipment is suitable for
the work being carried out.
Any specific usage must be authorised by the
site manager; an analysis of the potential risks
associated with this usage will enable him to put in
place any necessary additional safety measures.
Proper usage
The truck described in these operating instruc-
tions is suitable for transporting loads.
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2Introduction
Use of the truck
The truck may only be used for its proper
purpose as set out and described in these
operating instructions.
If the truck is to be used for purposes other
than those specified in the operating instruc-
tions, the approval of the manufacturer and, if
applicable, the relevant regulatory authorities
must be obtained beforehand to prevent haz-
ards.
The maximum load is specified on the capacity
rating plate (load diagram) and must not
be exceeded; see also the chapter entitled
"Before picking up a load".
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.
The tow tractor must notbeusedinareas
wherethereisariskoffire, explosion or
corrosion, or in areas that are particularly
dusty.
Place of use
The truck can be used outdoors and in build-
ings. The truck must not be used outside in
bad weather! Operation on public roads is
permitted only if the special equipment speci-
fied in the Road Traffic Licensing Regulations
is installed.
The various regulations applicable in different
countries for driving the truck on public roads
must be observed.
The sites on which the truck is used must
comply with the current regulations (condition
of the ground, lighting etc.).
The ground must have sufficient load capacity
(concrete, asphalt). The driveways, work
areas and working widths must correspond
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Introduction 2
Residual risks
with the specifications in the operating manual
(see⇒ Chapter "Before driving", P. 5-42 ).
The truck can be operated on a slope in
compliance with the data and specifica-
tions indicated (see ⇒ Chapter "Before driv-
ing", P. 5-42).
If your truck is to be used in a refrigerated stor-
age area, it must be configured accordingly
and, if necessary, approved for that environ-
ment (see ⇒ Chapter "Designation", P. 5-44).
The operator (see ⇒ Chapter "Definition of
terms used for responsible persons", P. 16)
must ensure adequate fire protection in the
vicinity of the truck for its use. Depending
on the use, additional fire protection must be
provided on the truck. If in doubt, contact the
relevant authorities.
Residual risks
Residual dangers, residual risks
Despite all operational precautions and
compliance with standards and rules, the
possibility of additional risks when using the
tow tractor cannot be entirely excluded.
The tow tractor and all its components comply
with the regulations relating to current applica-
ble safety rules.
Persons in the vicinity of the tow tractor must
be particularly cautious and react immediately
in the event of any malfunction, incident,
breakdown etc.
WARNING
Personnel in contact with the tow tractor must be
informed of the risks related to using the tow tractor.
These operating instructions draw your attention to
the safety rules.
The risks are:
• Escape of consumables due to leaks,
ruptured lines and tanks etc.
• Risk of accident when driving over difficult
ground such as slopes, soft or irregular
surfaces or in poor visibility etc.
• Falling, tripping etc. when moving on the
tow truck, especially in the wet, with leaking
consumables or on icy surfaces
• Loss of stability due to the load being
unstable or the load slipping etc.
• Risk of fire and explosion due to batteries
and electrical voltages
• Human error — disregarding safety regula-
tions
It is important to adjust the speed of the tow
tractor depending on the load and ground
conditions.
The stability of the tow tractor has been tested
to the latest standards. These standards only
takeaccountofthestatic and dynamic tilting
forces that can arise during operation that
complies with the specifications and operating
rules. Risks caused by misuse or incorrect
operation that jeopardise the stability cannot
be ruled out in extreme situations.
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2Introduction
Residual risks
Stability
The stability of the truck has been tested to
the latest technological standards and is
guaranteed if the truck is used properly and
according to its intended purpose. These
standards only take into account the static
and dynamic tipping forces that can arise
during specified use in accordance with the
operating rules and intended purpose. The
risk of exceeding the moment of tilt that arises
from improper use or incorrect operation
cannot be excluded in extreme cases, and
will impact stability.
The risks can include:
• loss of stability due to unstable or sliding
loads etc.
• cornering at excessive speeds.
• moving with a load that is protruding to the
side.
• turning and driving diagonally across
slopes.
• driving on slopes with the load on the
downhill side.
• loads that are too wide.
• swinging loads.
• ramp edges or steps.
Special risks associatedwithusing
the truck and attachments
Approval from the manufacturer and attach-
ment manufacturer must be obtained each
time the truck is used in a manner that falls
outside the scope of normal use, and in cases
where the driver is not certain that he can use
the truck correctly and without the risk of acci-
dents.
14 1193 801 16 01 EN - 06/2016