Still LTX20 User manual

Original instructions
LTX20, LTX-T04
Tractor
0611 0612
11938011500 EN - 05/2015

Table of contents
g
1 Foreword
Your industrial truck ................................................... 2
General ............................................................ 2
Legal requirements for placing on the market ................................ 3
Information about documentation ......................................... 4
Documentationscope ................................................. 4
Date of edition and latest update of this manual ............................... 6
Copyrightandtrademarkrights ........................................... 6
Explanation of symbols used ............................................ 7
Explanation of the cross-references ....................................... 7
Definitionofdirections ................................................. 8
Illustrations ......................................................... 8
Environmental considerations ........................................... 9
Packaging .......................................................... 9
Disposal of components andbatteries ...................................... 9
2 Introduction
Technical Description ................................................. 12
Use of the truck ..................................................... 13
Intended use of the trucks .............................................. 13
Proper usage ....................................................... 13
Unauthorised use .................................................... 14
Placeofuse ........................................................ 14
Residual risks ...................................................... 15
Residual dangers, residual risks ......................................... 15
Stability ........................................................... 15
Specialrisksassociatedwithusingthetruckandattachments ................... 16
3Safety
Definition of terms used for responsible persons ............................. 18
Operating company .................................................. 18
Specialist .......................................................... 18
Expert ............................................................ 19
Driver ............................................................ 19
Basic principles for safe operation ....................................... 21
Insurance cover on company premises .................................... 21
Warning regardingnon-originalparts ..................................... 21
Modificationsandrefitting .............................................. 21
Medicalequipment .................................................. 22
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Safety tests ........................................................ 23
Regularsafetyinspectionofthetruck ..................................... 23
Electricalinsulationtest ............................................... 23
Safety regulations for handling consumables ............................... 24
Permissibleconsumables ............................................. 24
Oils .............................................................. 25
Hydraulicfluid ...................................................... 26
Batteryacid ........................................................ 27
Disposalofconsumables .............................................. 28
Emissions ......................................................... 28
Safety devices ...................................................... 30
Damage, defects and misuse ofsafetydevices .............................. 30
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Battery connection cables ............................................. 30
4Overviews
General view ....................................................... 32
Labels ............................................................ 33
Identification plate ................................................... 34
Operating devices 1193 ............................................... 36
Display unit ........................................................ 36
5Use
Commissioning ..................................................... 40
Before driving ...................................................... 40
Designation ........................................................ 42
Checks before initial use .............................................. 44
Daily checks before use ............................................... 44
Checking the working environment ....................................... 45
Operating instructions ................................................ 45
Commissioning ..................................................... 46
Emergency stop switch ............................................... 47
Determining the drive direction .......................................... 47
Forward/reverse travel ................................................ 48
Steering unit ....................................................... 48
Stand-on/seated driving operation ....................................... 49
Drivingonaslope ................................................... 52
Brake, horn and lighting ............................................... 54
Coupling .......................................................... 55
Coupling the trailer ................................................... 55
Driving the truck with cargo ............................................. 58
6 Maintenance
General maintenance information ........................................ 62
General ........................................................... 62
Staff training and qualifications for maintenance and repairs . . . ................. 62
Battery maintenance personnel ......................................... 62
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Servicesnotrequiringspecialqualifications ................................ 63
Orderingsparepartsandwearparts ...................................... 63
Recommended lubricants . . . .......................................... 64
Technicalinspectionandmaintenancecharacteristics ......................... 64
Safety regulations for maintenance ....................................... 65
Safety measures for maintenance and repair ............................... 65
Workontheelectricalequipment ........................................ 65
Safetydevices ...................................................... 65
Settings ........................................................... 65
Daily checks before starting work ........................................ 66
Checkingthetraveldirectioncontrolfunction ................................ 66
Checkingthebrakes ................................................. 66
Testingthesteeringunit ............................................... 68
Testingsafetydevices ................................................ 68
Checking the battery chargingstatus ..................................... 69
Opening the battery hood .............................................. 70
Plugging in/unplugging the battery connector ............................... 71
Checking the condition ofcables,terminalsandbatteryconnector ................ 72
Removing/replacingthebattery ......................................... 72
Maintenance plan as required ........................................... 76
Cleaning . ......................................................... 76
Accessingtheelectricalcompartment ..................................... 77
Checking the seat condition . . .......................................... 78
Steering tiller:checkcondition ........................................... 78
Checkfuses ........................................................ 79
Inspection and maintenance overview .................................... 79
1000 hour service plan ................................................ 79
10000hourserviceplan ............................................... 80
Tractor motor ....................................................... 82
Traction motor:Cleaning the motor housing ................................. 82
Gearbox .......................................................... 83
Servicingthereducer ................................................. 83
Steering/braking/wheels .............................................. 83
Steering/wheels/brakes ............................................... 83
Checkingthebrakeairgap ............................................. 85
Battery ........................................................... 85
Checkingtheon-boardcharger .......................................... 85
Batterymaintenance ................................................. 86
Removing/replacingthebattery ......................................... 88
IV 11938011500 [EN]

Table of contents
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7 Technical data
Datasheet ......................................................... 94
11938011500 [EN] V

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
1938011500 [EN]

Foreword 1
Your industrial truck
Legal requirements for placing on the market
Declaration
KSAS (KION South Asia Pte Ltd)
5 Loyang Way,
508720, Singapore
We declare that the machine
Industrial truck Tractor
Model LTX20, LTX-T04
complies with the most recent version of machinery directive 2006/42/EC.
Personnel authorised to compile the technical documents:
Name: Christian Baerwolff
Address: Berzeliusstrasse 10, 22113
Hamburg, Germany
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
11938011500 [EN] 3

1Foreword
Information about documentation
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
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 instructions must be stored
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.
41
1938011500 [EN]

Foreword 1
Information about documentation
The operating company (see ⇒ Chapter "Def-
inition of terms used for responsible per-
sons", P. 18) 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.
11938011500 [EN] 5

1Foreword
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.
61
1938011500 [EN]

Foreword 1
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.1-7
• Cross reference to a chapter: ⇒ Chap-
ter "Definition of terms used for responsible
persons", P. 18
11938011500 [EN] 7

1Foreword
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.
81
1938011500 [EN]

Foreword 1
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 components and
batteries
The truck is composed of different materials. If
components or batteries need to be replaced
and disposed of, 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 for disposal purposes.
11938011500 [EN] 9

1Foreword
Environmental considerations
10 11938011500 [EN]

2
Introduction

2Introduction
Technical Description
Technical Description
Maximum design load capacity of LTX20 and
LTX–T04 type 1193 tow tractors:
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 LTX20 and LTX-T04 are configured:
– As standard with a 3 point wheel base and 2
castor wheels
- 8 km/h in forward and reverse gear, laden
and unladen for the LTX20.
- 8 km/h in forward and reverse gear, laden
and unladen for the LTX-T04.
– Optional forward/reverse coupling ap-
proach control for coupling to a trailer.
LTX20travelsadistanceof0.3meachtime
the button (forward or reverse) is held down.
LTX-T04travelsadistanceof4meachtime
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 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
eventofafaultinthetraction 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.
Towing system
Nominal load:
12 11938011500 [EN]