Still LTX-T04 Original Instructions Manual Download Page 78

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Maintenance

Safety regulations for maintenance

Safety measures for maintenance

and repair

To prevent accidents during maintenance and

repair, perform all necessary safety measures

such as:
– Ensure that the truck is secured against in-

advertent movement or accidental starting

(disconnect the battery connector).

Work on the electrical equipment

Work on the electrical equipment of the pallet

stacker is only allowed with the electrical sys-

tem de-energised. Function checks, inspec-

tions and adjustments on live parts may only

be carried out by trained and authorized staff

under observance of suitable precautions.

Rings, metal bracelets, etc must be removed

before working on electric components.
To prevent damage to electrical equipment

with electronic components such as an

electronic travel control, remove them from

the vehicle before doing any electric welding.
Modiﬁcations in the electrical system are only

permitted with our approval.

Safety devices

Reﬁt and check all safety devices for proper

operation after maintenance and servicing.

Settings

Retain the vehicle-speciﬁc settings when

repairing and replacing electric components.

They are speciﬁed in the appropriate sections.

1193 801 16 01 EN - 06/2016

Summary of Contents for LTX-T04

Page 1: ...Original instructions LTX10 LTX20 LTX T04 Tractor 0611 0612 1193 801 16 01 EN 06 2016 ...

Page 2: ......

Page 3: ... components and batteries 8 2 Introduction Technical Description 10 Use of the truck 11 Intended use of the trucks 11 Proper usage 11 Unauthorised use 12 Place of use 12 Residual risks 13 Residual dangers residual risks 13 Stability 14 Special risks associated with using the truck and attachments 14 3 Safety Deﬁnition of terms used for responsible persons 16 Operating company 16 Specialist 16 Driv...

Page 4: ...ery connection cables 26 EMC Electromagnetic Compatibility 26 4 Overviews 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 5 Use Commissioning 42 Before driving 42 Designation 44 Checks before initial use 45 Daily checks before use 46 Checking the working environment 47 Operating inst...

Page 5: ...ices not requiring special qualiﬁcations 69 Ordering spare parts and wear parts 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 Safety devices 72 Settings 72 Daily checks before starting work 73 Checking the travel direction control function 7...

Page 6: ...ntenance overview 86 1000 hour service plan 86 10000 hour service plan 87 Tractor motor 89 Traction motor Cleaning the motor housing 89 Gearbox 89 Servicing the reducer 89 Steering braking wheels 90 Steering wheels brakes 90 Checking the brake air gap 92 Battery 92 Checking the on board charger 92 Battery maintenance 93 Removing replacing the battery 95 7 Technical data Datasheet 102 IV 1193 801 1...

Page 7: ...1 Foreword ...

Page 8: ... the country in which it is being used The driving permit must be obtained from the appropriate ofﬁce The trucks have been ﬁtted with 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 pre...

Page 9: ...e 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...

Page 10: ...tions 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 wit...

Page 11: ...refore 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 writt...

Page 12: ...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 te...

Page 13: ...trations 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 ...

Page 14: ...roperly 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 NOT...

Page 15: ...2 Introduction ...

Page 16: ...vements 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 Pow...

Page 17: ...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 ...

Page 18: ...e for purposes other than those described in these operating instructions is prohibited Transporting people is prohibited 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 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 per...

Page 19: ...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 dif...

Page 20: ...s 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 associated with using the truck and attachme...

Page 21: ...3 Safety ...

Page 22: ...conomic Area This expertise allows him to assess the condition of indus trial trucks in terms of health and safety Drivers This truck may only be driven by suitable persons who are at least 18 years of age have been trained in driving have demonstrated their skills in driving and handling loads and have been speciﬁcally designated to drive the truck Speciﬁc knowledge of the truck is also necessary...

Page 23: ...ibition of use by unauthorised persons The driver is responsible for the truck during working hours He must not allow unautho rised persons to operate the truck When leaving the truck the driver must secure it against unauthorised use 1193 801 16 01 EN 06 2016 17 ...

Page 24: ...roducts may there fore have a negative impact on the design features of the truck and thus impair active and or passive driving safety We recommend that you obtain approval from the manufacturer and if necessary from the relevant regulatory authorities before installing such parts The manufacturer accepts no liability for any da mage caused by the use of non original parts and accessories without ...

Page 25: ...lemented by one or more engineers who are experts in the ﬁeld of industrial trucks and their safety records are kept of the design test s and implementation of the modiﬁcation or alteration appropriate changes are approved and made to the capacity plate s decals labels and operating instructions a permanent and clearly visible label is attached to the truck indicating the nature of the modiﬁcation...

Page 26: ... until a further two inspections have been carried out The inspection date is indicated by an adhe sive label on the truck Arrange for the service centre to perform periodic safety inspections on the truck Observe guidelines for checks carried out on the truck in accordance with FEM 4 004 The operator is responsible for ensuring any defects are remedied without delay Contact your service centre NO...

Page 27: ...re testing the circuit check that it is electrically dead Measure insulation resistance using a suitable meter The insulation resistance is sufﬁcient when it has a nominal value of at least 1000 Ohms V against the chassis Ask our service department Safety regulations for handling consumables Permissible consumables DANGER Failure to observe the safety regulations relating to consumables may result...

Page 28: ...n WARNING Prolonged intensive contact with the skin can result in dryness and irritate the skin Avoid contact and consumption Wear protective gloves After any contact wash the skin with soap and water and then apply a skin care product Immediately change soaked clothing and shoes WARNING There is a risk of slipping on spilled oil particularly when combined with water Spilt oil should be removed im...

Page 29: ...ING Battery acid contains dissolved sulphuric acid This is corrosive When working with battery acid always wear a protection suit and eye protection When working with battery acid never wear a watch or any jewellery Do not allow any acid to get onto clothing or skin or into the eyes if this does happen rinse immediately with plenty of clean water In case of injury seek medical advice immediately I...

Page 30: ...ions The values are determined using the methods set out in the European Standard EN12053 measuring noise emissions from industrial trucks based on Standards ISO 11201 and EN ISO 3744 and in compliance with standard EN ISO 4871 According to these methods the truck generates the following sound pressure levels Permanent sound pressure level in the driver s compartment LpAz 75 dB A However the speci...

Page 31: ...TX20 1 30 1 46 Stand Seat For LTX T04 1 09 1 11 Stand Seat The personal stress on the operator caused by vibrations during a day s work must be noted if necessary at the actual work place so as to be able to consider all the other factors such as the state of the track the intensity of use etc Traction battery emissions Battery charging releases an explosive oxygen hydrogen gas mixture oxyhydrogen...

Page 32: ...ts with NON ORIGINAL battery con nection cables can be dangerous see purchase references in the parts catalogue EMC Electromagnetic Compatibility Electromagnetic Compatibility EMC is a key quality feature of the truck EMC means Limiting electromagnetic interference emissions to a certain level so as to ensure the trouble free operation of other equipment in the environment Ensuring adequate immuni...

Page 33: ...EMC Electromagnetic Compatibility CAUTION The truck must comply with EMC regulations When replacing the truck components EMC pro tection components must be reinstalled and con nected 1193 801 16 01 EN 06 2016 27 ...

Page 34: ...3 Safety EMC Electromagnetic Compatibility 28 1193 801 16 01 EN 06 2016 ...

Page 35: ...4 Overviews ...

Page 36: ...Flashing beacon 2 Adjustable auxiliary seat 3 Hook cable 4 Coupling approach buttons 5 Emergency stop button 6 Hook 7A Load wheels LTX10 LTX20 mounted on main chassis 7B Load wheels LTX T04 mounted on tow platform 30 1193 801 16 01 EN 06 2016 ...

Page 37: ...23 Steering handlebar 24 Horn button 25 Direction switch 26 Stop button NOTE The LTX10 LTX20 tow tractor is equipped with a tow coupling for hitching to a trailer so there is no tow platform The LTX T04 tow tractor has a tow platform and a tow coupling Labels 1 company label truck model label 2 company label 3 forbid transport person label 4 forbid hook label 5 warning label 6 identiﬁcation plate ...

Page 38: ...ric trucks only 6 Min permissible battery weight in kg for electric trucks only 7 Front axle loading in kg 8 Rear axle loading in kg 9 Manufacturer 10 Refer to technical data listed in this operating instructions for more detailed information 11 CE label 12 Towing force 13 Rated drive power in kW 14 Battery voltage in V 15 Payload in KG 32 1193 801 16 01 EN 06 2016 ...

Page 39: ...iller adjustment button 6 Lighting control switch 7 Ticket clip 8 Display unit 9 Power switch 10 Diagnostic interface 11 Forward reverse inching switch 12 Steel cable 13 Tow coupling 14 Auxiliary seat backrest height adjustment cable 15 Forward reverse inching switch 16 Fold down auxiliary seat 17 Turn indicator light switch 1193 801 16 01 EN 06 2016 33 ...

Page 40: ...eck the optional booklet The part No of the booklet is 50988011937 CAUTION Beware of pinching ﬁngers when adjusting the tiller Keep your ﬁngers away from moving parts as shown at the arrow to avoid any risk of injury WARNING Risk of serious injury and or serious damage to the equipment Don t operate the manipulation components which are equipped onthe accessory bar during travelling 34 1193 801 16...

Page 41: ...e main functions of the display unit include displays battery level displays maintenance service hours displays fault codes indicates fault messages by means of ﬂashing indicator light or symbols displays battery charge status equipped with backlight The controller transmits battery power hours fault codes and other information to the display unit over the CAN BUS network Display unit 1193 801 16 ...

Page 42: ...ff Solid light indicates that the vehicle is switched on 5 Error codes Fault codes help service department engineers to correctly diagnose faults 6 Failure or brake worn air gap Cannot operate vehicle 7 Hour meter Indicates the vehicle s working hours The hour meter com mences counting when the vehicle starts working and performs functional opera tions When the hour meter is running the hourglass ...

Page 43: ...nly 2 ADMINISTRA TOR CODE ESSENTIAL FOR ALL ELEC TRONIC KEY SETTINGS 0 0 0 0 0 0 0 0 by default continuous red continuous green 3 Once the LEDs have gone out the electronic key automatically reverts to operating mode New operator code 0 4 5 6 7 8 red off green ﬂashing 2 code accepted Example of new operator code 45678 Allocating operator codes 2 5 4 3 2 1 red off green ﬂashing 2 code accepted 2 op...

Page 44: ...ower switches off automatically after 10 minutes 600 seconds by default if the truck is not in use Setting the time delay of the automatic switch off 3 6 0 red off green ﬂashing 2 value accepted Example automatically switches off after 1 minute 60 seconds if not in use Minimum setting 10 seconds maximum 3000 seconds Deactivating the automatic switch off 2 0 red off green ﬂashing 2 command accepted...

Page 45: ...ice variant consists of a housing 4 containing an inte grated reading device 3 LED 1 1 and LED 2 2 serve as a display element Both LEDs cover the RGB colour space and can reproduce various colours In addition to the visual displays of the two LEDs an integrated signal transmitter can sound corresponding signal tones 1193 801 16 01 EN 06 2016 39 ...

Page 46: ...4 Overviews RF device optional 40 1193 801 16 01 EN 06 2016 ...

Page 47: ...5 Use ...

Page 48: ...egenerative brake function Emergency stop switch function Horn function Operator presence switch Battery lock only for models equipped with battery lock DANGER Risk of death injury and or serious damage to the equipment If the vehicle malfunctions immediately notify the relevant personnel and stop using the vehicle Before driving People in the hazard area Before starting the truck and while you ar...

Page 49: ... and if necessary ﬁtted with ramps so that the truck can cross without jerking There must be sufﬁcient distance between the highest part of the truck or the load and the surrounding ﬁxed installations Consult the technical characteristics Rules regarding the trafﬁc routes and the manoeuvring areas Only trafﬁc routes authorised by the operator or his agent may be used Trafﬁc routes must be obstacle...

Page 50: ...cold indoors and the heat outside causes condensation This water can freeze when the truck goes back into the cold store and jam the moving parts of the truck This is why the length of time the truck remains in the different temperature areas given below for the two operating ranges must be strictly adhered to The temperature of the traction batteries must never fall to the temperature of the cold...

Page 51: ... stays outside for longer than 10 minutes it must remain outside for long enough to allow the condensation to run away This generally takes at least 30 minutes DANGER If the condensation freezes in the cold store the moving parts that have become jammed must not be freed by hand Parking Always park the truck outside the cold store CAUTION The batteries must not remain discharged or un used in the ...

Page 52: ...y for models equipped with battery lock Daily checks before use Completion status Inspection item X Forward reverse travel function Electromagnetic brake function Automatic regenerative brake function Emergency stop switch function Horn function Operator presence switch Battery lock only for models equipped with battery lock 46 1193 801 16 01 EN 06 2016 ...

Page 53: ...coming unbalanced and vibrations in the driver s arms Operating instructions TheLTX10 LTX20 and LTX T04 are for indoor use in non hazardous atmospheres the ambient temperature must be between 10 C and 40 C and the air humidity less than 95 TheLTX10 LTX20 and LTX T04 comply with the requirements of EN12895 on electromag netic compatibility Correct operation of the trucks can no longer be guaranteed...

Page 54: ...r destruction of the equipment The driver s feet must stay within the limits of the platform DANGER Risk of serious injury and or serious damage to the equipment Before setting off in forward or reverse travel look carefully in the direction of travel to ensure that the manoeuvre can be carried out safely CAUTION Risk of deterioration and or destruction of the equipment The driver s platform must ...

Page 55: ...nd the load Use the vehicle on a ﬂat and hard surface Emergency stop switch During normal operation the emergency stop switch 1 must be pulled out In case of danger press down the button 1 to break the electrical circuit and apply the electromagnetic safety brake Determining the drive direction The controls for direction of travel are Forward travel 1 towards the tiller Reverse travel 2 towards th...

Page 56: ...e switch backward with your thumb The vehicle will move backward in the same direction as the direction of the drive switch CAUTION Risk of damage to the components Do not press the switch on one side forward while pressing the switch on the other side backward Steering unit The steering for the LTX10 LTX20 and LTX T 04 is controlled using the ergonomic tiller DANGER Serious risk of personal injur...

Page 57: ...stments Check the battery male connector is ﬁrmly attached Make sure the battery is ﬁxed with ﬁx device Adjust the tiller height Adjust the auxiliary seat height The low step and wide opening on both sides facilitate access to the driver s work station The suspended platform non slip ﬂoor plate and height adjustable auxiliary seat and tiller provide an extremely comfortable driving experience Usin...

Page 58: ...ary seat height by pressing down on the auxiliary seat while standing beside the vehicle Once the auxiliary seat is suitably posi tioned release the handle so that it returns to its original position NOTE The handle must fully return to its original position with the stop pin engaged in the hole CAUTION Risk of an accident Do not adjust the auxiliary seat height while the vehicle is travelling 52 ...

Page 59: ...ess the button indicated by the arrow While holding down the button adjust the tiller angle by hand Once the tiller is suitably positioned release the button to secure the tiller NOTE Do not operate the vehicle if the tiller is at a vertical or near vertical angle Only position the tiller at a vertical angle to facilitate battery replacement CAUTION Risk of hurting the hand It s forbidden to put t...

Page 60: ... Ascending a slope Always travel in forward gear when ascending slopes with a load Unladen vehicles can ascend slopes in forward or reverse gear Descending a slope Always travel in forward gear when descen ding slopes with a load Unladen vehicles must descend slopes in forward gear i e with the tow coupling facing uphill DANGER Risk of death injury and or serious damage to the equipment Slow down ...

Page 61: ...he drive switch on the tiller the vehicle will decelerate to a standstill Turn off the power switch Stopping on a downhill slope Release the drive switch on the tiller the vehicle will decelerate to a standstill Turn off the power switch Starting on a slope Turn on the power switch Push the drive switch on the tiller forward or backward depending on the required direction of travel The electromagn...

Page 62: ...and the vehicle is stationary When the emergency stop switch 2 is operated Brake When the forward reverse switch 1 on the tiller is released the counter current regenerative brake is applied until the vehicle comes to a stop Reverse braking Reverse braking can be performed by chang ing the direction of travel When the vehicle is moving press the drive direction switch 1 in the opposite direction t...

Page 63: ...control panel NOTE Because the vehicle has a mechanical stee ring unit it may not be possible to turn corners safely with one hand unless the operator has sufﬁcient arm strength Therefore to avoid the above situation when travelling turn the lights on or off before driving the vehicle Coupling There are two types of the hook a steel cable pulling device that can be controlled automatically from th...

Page 64: ...wards the trailer ensuring that the tow coupling and tow bar are aligned CAUTION Risk of damage to the equipment Before loading ensure that the total weight of the load and the trailer does not exceed the maximum speciﬁed weight CAUTION Risk of damage to the equipment When coupling or uncoupling the trailer make sure that the tow tractor and trailer are positioned on a level surface Make sure that...

Page 65: ...m the work station CAUTION Never place your feet too close to the vehicle when connecting the tow coupling Wear safety footwear at all times Reverse the tow tractor towards the front of the trailer Stand on the left or right hand side of the tow tractor Press the forward or reverse buttons shown in the ﬁgure depending on the required direction of travel the vehicle will start moving Release the bu...

Page 66: ...cks the trailer in place CAUTION Be careful not to get your ﬁngers caught When coupling the trailer wear protective gloves and pay attention to where you place your hands Uncoupling the trailer Make sure that the trailer remains station ary If the trailer is equipped with a braking device make sure it is engaged If nec essary use wooden blocks to chock the wheels Lift the tow tractor s coupling pi...

Page 67: ...y consider the type of trailer the turning radius and the width of the trailer When approaching your destination reduce speed in advance to stop the vehicle safely DANGER Risk to life and or risk of serious damage to the equipment Transporting passengers on the tow tractor or the trailer is prohibited CAUTION Risk of serious injury and or serious damage to the equipment Ensure that the load is sec...

Page 68: ...N Risk of serious injury and or serious damage to the equipment Ensure that the load is securely stacked on the platform with an even weight distribution is within the tolerance range Precautions before leaving the vehicle Turn off the power switch and remove the key If the truck will not be used for a long time press down the emergency stop switch and disconnect the battery connector CAUTION Risk...

Page 69: ...h two slings The front tie points are the hook holes in both side of the battery box shown in the illustration and the rear tie point is the tow coupling CAUTION During transportation on a lorry or truck always fasten the truck securely Truck storage Measures to be taken prior to truck storage If the tractor will not be used for more than 2 months it should be parked in a well ventilated frost fre...

Page 70: ...tion NOTE Do not use plastic sheeting to cover the tractor because this will exacerbate condensation and aggregation NOTE If the tractor will be out of use for a period of over 6 months please consult the manufactu rer for relevant information Resuming use of the tractor Clean the tractor thoroughly Lubricate the tractor Apply a layer of non acidic grease to the battery terminals Check the battery...

Page 71: ...h collection devices and separators for leaking ﬂuids and degreasing cleaning materials Suitable storage areas must be available for disassembled and partially oil smeared parts as well as for tyres including ﬁre protection measures Suitable storage tanks for ﬂuids such as fuel AdBlue urea solution engine oil hydraulic oil cooling ﬂuid and ﬂuids from air conditioning systems must also be provided ...

Page 72: ...5 Use Disposal of old trucks 66 1193 801 16 01 EN 06 2016 ...

Page 73: ...6 Maintenance ...

Page 74: ... Never mix different qualities of grease or oil If it is absolutely necessary to change brands make sure that you rinse thoroughly beforehand Before changing any ﬁlters clean the surface and area around the part thoroughly All containers used to pour the oil must be clean Staff training and qualiﬁcations for maintenance and repairs Only qualiﬁed and authorized staff may carry out the maintenance T...

Page 75: ...aintenance section of this manual for further information Ordering spare parts and wear parts Spare parts are supplied by our after sales service Refer to the parts list for the required ordering information Only use spare parts recommended by the manufacturer Unauthorised spare parts may increase the risk of accidents due to faults relating to quality or incorrect choices Anyone who uses non comp...

Page 76: ...ubt please contact the After Sales Service Centre Transmission oil Recommended oil SAE 85W 90 API GL4 Multi purpose grease Lithium soap grease with EP agents and MoS 2 KPF 2N 20 complying with the standard DIN 51825 ENVIRONMENT NOTE Used oil must be stored safely until it is disposed of in compliance with environmental protection measures No one should have access to it Do not dispose of used oil ...

Page 77: ...on gear Transmission gear oil 1 3 L Drive wheels Wheel mounting nuts 80 N m Castor wheels Wheel shaft screw 20 N m Support wheel Wheel shaft screw 200 N m for tow tractor 250 N m for platform tractor Traction motor fuse 125 A Control cable fuse 10 A Battery Distilled water As required Hinge points Lithium soap grease As required 1193 801 16 01 EN 06 2016 71 ...

Page 78: ...nd adjustments on live parts may only be carried out by trained and authorized staff under observance of suitable precautions Rings metal bracelets etc must be removed before working on electric components To prevent damage to electrical equipment with electronic components such as an electronic travel control remove them from the vehicle before doing any electric welding Modiﬁcations in the elect...

Page 79: ...l switch 2 The vehicle will travel forward or backward the travel speed depends on how far the drive switch 2 is pushed Checking the brakes CAUTION Do not drive the vehicle if the brake system is faulty Contact an authorised dealer or service engineer if a fault of any kind is discovered in the braking system Automatic braking Start the machine moving Release the drive switch 1 Press the STOP butt...

Page 80: ...ion of the ma chine Carefully test the brake at low speed in a safe open area free from trafﬁc Parking brake The parking brake is applied automatically if one of the following conditions is met The driver leaves the operating platform 3 The power switch is off 4 The travel switch is released and the vehicle slows to a standstill 2 The emergency stop switch 1 is pushed NOTE A switch located under t...

Page 81: ... a fault of any kind is discovered in the steering system Testing safety devices CAUTION Do not drive a vehicle that has a faulty safety device Please contact an authorised dealer or service engineer if a fault of any kind is discovered in the safety devices Emergency stop switch Push the emergency stop switch 1 the vehicle s power supply should shut off The electrical control system and motor pow...

Page 82: ... product Wear gloves and goggles when working on the battery In case of contact with eyes or skin rinse immediately with plenty of clean water then seek medical advice if the situation is severe Charging the battery releases hydrogen which creates an explosive mixture when mixed with oxygen Therefore do not create sparks do not smoke and keep naked ﬂames away from a battery which is being charged ...

Page 83: ...o power on the vehicle Check the battery charge status on the multifunction display 3 Opening the battery hood Stop the vehicle Turn off the key switch 1 Push the emergency stop switch 2 Pull the battery hood out towards the auxiliary seat and remove the hood 3 NOTE It s better to wear protective gloves when operate the battery hood NOTE Beware of getting your hand caught 1193 801 16 01 EN 06 2016...

Page 84: ... socket CAUTION Arcing may occur when the connector makes contact with signiﬁcant risk of electrical damage Do not plug in the connector unless the vehicle is powered off Regularly check the state of the connector contact and replace it immediately if there is arcing damage or charring Strictly adhere to the polarity signs positive and negative on the battery polarity Never reverse the polarity Th...

Page 85: ...d or battery connector are defective stop using the vehicle immediately and contact an authorised dealer or service engineer Removing replacing the battery NOTE NOTE When handling batteries make sure that all lifting equipment used crane hoist slings hooks vehicles handling devices is sufﬁcient for the weight of the battery NOTE If installing a spare battery make sure that the speciﬁcations of the...

Page 86: ...e using the vehicle make sure that the battery connector is securely connected and locked CAUTION There is a risk of damaging the machine Before using the vehicle make sure that the screws on battery ﬁx device is secured Changing the battery using a hoist Switch off the truck and press the emer gency switch Open the battery hood Unplug the battery connector Unscrew the screws 1 of the battery ﬁx d...

Page 87: ...lly controlling the hoist position the battery in the speciﬁed location To install the replacement battery perform the above procedure in reverse order Side access battery changing the battery using a moveable support Switch off the truck and press the emer gency switch Open the battery hood Unplug the battery connector 1193 801 16 01 EN 06 2016 81 ...

Page 88: ...ew the screws 1 of the battery ﬁx device on the battery removed side Lift up the battery ﬁx devices on the battery removed side Unscrew the screws 2 of the side panel The side panel is inserted on a slot Remove the side panel 82 1193 801 16 01 EN 06 2016 ...

Page 89: ...e grease used to lubricate bearings or cause electrical components to become damp Take the necessary protection measures CAUTION Cleaning may lead to deterioration or destruction of the equipment When cleaning the tow tractor do not allow electri cal equipment to be sprayed directly with liquid Be fore cleaning take the necessary protection mea sures If using compressed air ﬁrst remove stubborn di...

Page 90: ...you will need to take out the battery jet wash it and clean the frame NOTE In the event of heavy sulphate build up or excessive electrolyte spillage contact an authorised dealer or service engineer immediately Accessing the electrical compart ment NOTE Before doing any work Push the emergency stop switch Turn off the power switch Disconnect the battery plug CAUTION Risk of burns Brakes motors cabl...

Page 91: ...ght adjustment mechanism sta ble Is the auxiliary seat cushion broken CAUTION Risk of serious accident Do not drive the vehicle if the auxiliary seat is in poor condition NOTE The driver should do these checks before operating the machine If problems are found maintenance must be performed by service engineers Steering tiller check condition the steering tiller is not just a control device it also...

Page 92: ...mend that this work is carried out by a specialised service engineer Inspection and maintenance overview 1000 hour service plan At operating hours Carried out 1000 Preparations If necessary clean the truck Use diagnostic software to read the fault codes Reset the service interval using the diagnostic software Lubricate all pivots and lubricate on grease nipple Traction motor Clean the motor housin...

Page 93: ... the adjustment of the rubber stops on the battery locking system Check that the charger is working Check whether the vehicle s lighting equipment speakers switches etc are work ing properly Coupling and trailer Check whether the tow coupling is in working order Check whether the trailer is properly connected Final inspection Visually inspect the general condition of the undercarriage Test drive t...

Page 94: ...e contactors Switch off the LAC controller and clean it Check and clamp the connection cables and the connectors Check and adjust the battery density and electrolyte level Check the battery cables and connector Check the adjustment of the rubber stops on the battery locking system Check that the charger is working Check whether the vehicle s lighting equipment speakers switches etc are work ing pr...

Page 95: ...en the electrical compartment Clean the motor housing with compressed air Check the electrical wiring and connectors for signs of overheating Check that the connections are tight Gearbox Servicing the reducer Draining the oil NOTE This operation must be carried out by the service centre 1193 801 16 01 EN 06 2016 89 ...

Page 96: ...ound the wheel hubs and bearings Checking that the wheels are tightened Use lifting equipment or a jack to raise the vehicle off the ground then support the vehicle on suitable blocks Remove the front cover Check the tightness of the nuts on the drive wheel recommended torque setting 80 N m Check the tightness of the castor wheels axle torque setting 20 N m Check the tightness of the rear wheel sh...

Page 97: ...le off the ground then support the vehicle on suitable blocks Adjust the height of the castor wheels according to the degree of drive wheel wear Release the screw 2 Release the eccentric pin 1 Engage the pin 1 in the corresponding notch Make sure the standard clearance is 8 mm Tighten the screw 2 again 1193 801 16 01 EN 06 2016 91 ...

Page 98: ...st be adjusted Loosen the three ﬁxing screws 3 Adjust the three banjo bolts 4 to set the air gap to its original value of 0 20 mm Retighten the three mounting screws 3 Check the air gap at 3 points at 120 intervals Make sure that the air gap is equal right around the brake NOTE We recommend that this operation be carried out by our After Sales Service Centre Battery Checking the on board charger C...

Page 99: ...y which is being charged or has re cently been charged To avoid the accumulation of hydrogen charge the battery in a well ventila ted place and keep the battery hood open whilst charging Do not place metal objects on the battery there is a risk of creating a short circuit Measuring the electrolyte level and adding distilled water This check and any required top up with distilled water should be ca...

Page 100: ...vice engineer if the density of the electrolyte in each battery pack is different or the density of some battery packs is very low Charging the battery when the density of the electrolyte is below 1 14 is very detrimental to its operating life Check the condition of the battery cables terminals and connector Make sure that the cable insulation is not damaged and that the connector shows no signs o...

Page 101: ...pacities CAUTION Batteries are heavy and easily damaged handle them with care The wearing of gloves is recommended CAUTION Beware of pinching your ﬁngers when removing and ﬁtting the battery Keep your ﬁngers away from moving parts to avoid any risk of trapping CAUTION There is a risk of damaging the machine Before using the vehicle make sure that the battery connector is securely connected and loc...

Page 102: ...6 Maintenance Battery Unplug the battery connector Unscrew the screws 1 of the battery ﬁx device on both sides Lift up the battery ﬁx devices on both sides 96 1193 801 16 01 EN 06 2016 ...

Page 103: ...To install the replacement battery perform the above procedure in reverse order Side access battery changing the battery using a moveable support Switch off the truck and press the emer gency switch Open the battery hood Unplug the battery connector Unscrew the screws 1 of the battery ﬁx device on the battery removed side 1193 801 16 01 EN 06 2016 97 ...

Page 104: ...aintenance Battery Lift up the battery ﬁx devices on the battery removed side Unscrew the screws 2 of the side panel The side panel is inserted on a slot Remove the side panel 98 1193 801 16 01 EN 06 2016 ...

Page 105: ...lace the battery Be sure that the moveable support is ﬁxed when replacing the battery Lock the wheels of the moveable support Push the battery which is need to be replaced to the moveable support Transport the battery to the charging station and transport the full charged battery to the side of the truck To install the replacement battery perform the above procedure in reverse order 1193 801 16 01...

Page 106: ...6 Maintenance Battery 100 1193 801 16 01 EN 06 2016 ...

Page 107: ...7 Technical data ...

Page 108: ...1 3 Power unit Battery Battery Battery 1 4 Operation Stand on Stand on Stand on 1 5 Load capacity Q kg 1000 2000 400 100010 1 6 Rated drawbar pull F N 190 400 300 1 7 Wheelbase y mm 907 2 907 2 1487 2 Weight 2 1 Service weight kg 620 1 620 1 755 1 2 3 Axel load without load front drive rear load kg 350 280 350 280 460 270 102 1193 801 16 01 EN 06 2016 ...

Page 109: ...1210 1310 2 4 3 Tow coupling height h10 mm 276 276 165 4 4 Load platform height h11 mm NA NA 289 4 5 Load platform length l3 mm NA NA 868 2 4 6 Rear overhang I5 mm 253 9 253 9 531 9 4 7 Load platform width b9 mm NA NA 636 2 4 8 Overall length l1 mm 1315 2 1315 2 2172 2 4 9 Overall width b1 b2 6002 6002 600 636 2 4 10 Ground clearance center of wheelbase m2 mm 40 80 3 40 80 3 80 3 4 11Turning radiu...

Page 110: ...59 cycles 8 Others 8 1 Type of drive control LAC LAC LAC 8 2 Noise level at operator s ear dB 75 75 75 8 3 Vibration to the operator LTX10 LTX20 LTX T04 m s2 1 30 1 46 1 30 1 46 1 09 1 11 Figures for standard version may vary when options equipment is ﬁtted 1 Including item 6 5 battery weight 2 5mm 3 95 4 105 5 100 6 5 7 4mm 8 The number of laps around the standard testing track in one hour 9 With...

Page 111: ...ioning 42 COmmissioning 48 Consumables 21 Disposal 24 Safety information for handling battery acid 23 Safety information for handling oils 22 Copyright and trademark rights 5 Coupling 57 Coupling the trailer 58 Cross references 6 D Daily checks before use 46 Datasheet 102 Date of edition of this manual 5 Deﬁnition of directions 7 Descending a slope 54 Determining the drive direction 49 Display uni...

Page 112: ...n of use by unauthorised persons 17 R Recommended lubricants 70 Removing replacing the battery 79 95 Residual dangers residual risks 13 Resuming use of the tractor 64 S Safety devices Misuse 26 Safety inspection 20 Signals 6 Special risks 14 Specialist 16 Stability 14 Stand on seated driving operation 51 Steering tiller check condition 85 Steering unit 50 Steering wheels brakes 90 Stopping and sta...

Page 113: ......

Page 114: ...STILL GmbH 1193 801 16 01 EN 06 2016 ...

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