Page 1 Original instructions Electric tow tractor LTX 70 LTX 80 LTX-T08 0608 0609 0610 0688 0689 0690 1191 801 15 51 EN - 09/2019...
Page 3 Preface Address of manufacturer and contact details STILL GmbH Berzeliusstraße 10 22113 Hamburg, Germany Tel. +49 (0) 40 7339-0 Fax: +49 (0) 40 7339-1622 Email: info@still.de Website: http://www.still.de 1191 801 15 51 EN - 09/2019...
Page 5: Table Of Contents
Table of contents Introduction Your industrial truck ........... 2 General .
Page 6 Table of contents Overviews Overviews ............22 General view of the tow tractor .
Page 7 Table of contents Tow tractor ignition using the key ........48 Starting the tow tractor with an electronic key .
Page 8 Table of contents StVZO (German Road Trafﬁc Licensing Regulations) option (intended for the German market) ............88 Parking the tow tractor .
Page 9 Table of contents Technical data for inspection and maintenance ......119 Recommended lubricants .
Page 10 Table of contents Checking the battery and the condition of the battery cable ..... 150 Cleaning the opportunity charging equipment ....... 151 Decommissioning and storage .
Page 11: Introduction
Introduction...
Page 12: Your Industrial Truck
Introduction Your industrial truck Your industrial truck General The tow tractor described in these operating The tow tractors have been ﬁtted with state- instructions complies with the applicable of-the-art technology. All that is now required standards and safety regulations. is to handle them in complete safety and keep them operational.
Page 13: Ec Declaration Of Conformity
Introduction EC declaration of conformity EC declaration of conformity Declaration STILL GmbH Berzeliusstrasse 10 22113 Hamburg GERMANY We declare that the machine according to these operating instructions Industrial truck according to these operating instructions Model conforms to the latest version of the Machinery Directive 2006/42/EC.
Page 14: Nameplate
Introduction Nameplate Nameplate NOTE Indicate the serial number for all technical enquiries. Model Manufacturer Serial number Year of manufacture Unladen weight (without battery) in kg Battery maximum weight Battery minimum weight Additional weight (ballast weight) in kg Nominal motor power (kW) Battery voltage in V Rated capacity in kg EC conformity symbol...
Page 15 Rules for the operating company of industrial trucks Internet address and QR code The information can be accessed at any time by pasting the address https://m.still.de/vdma in a web browser or by scanning the QR code. 1191 801 15 51 EN - 09/2019...
Page 16: Correct Use
Introduction Correct use Correct use Trafﬁc routes The industrial truck must be used only for authorised use. Trafﬁc routes must be well-paved, ﬂat and free The industrial truck is used to move loads as from obstacles. Drainage channels and level speciﬁed on the capacity rating plate.
Page 17: Description Of Use And Climatic Conditions
Introduction Description of use and climatic conditions Attachments installation, check the correct operation of the attachments before use. Attachments must only be used for their in- tended purpose. The driver must be instructed Do not exceed the maximum authorised load in the handling of the attachments.
Page 18: Explanation Of Symbols Used
Introduction Explanation of symbols used The tow tractor must not be used in areas where there is a risk of ﬁre, explosion or corrosion, or in areas that are particularly dusty. Explanation of symbols used DANGER CAUTION Compulsory procedure that must be followed to Compulsory procedure that must be followed to avoid life-threatening danger or physical harm.
Page 19: Safety
Safety...
Page 20: Driver Safety Guidelines
Safety Driver safety guidelines Driver safety guidelines The driver must practice driving the vehicle, NOTE using the controls and steering the tow tractor The safety rules in this instruction booklet whilst it is empty until he has complete control must be respected at all times. These rules of the vehicle.
Page 21 Safety Driver safety guidelines – Do not install any accessories on the tow – Do not overload the tow tractor with more tractor unless it has been supplied or than its nominal capacity, as stated on the approved by your local distributor. capacity plate.
Page 22: Safety Regulations For Handling Consumables
Safety Safety regulations for handling consumables Safety regulations for handling consumables Permissible consumables WARNING Refer to the maintenance data table for the permissible substances necessary for Consumables can be dangerous. operation. It is necessary to follow the safety regulations when handling these substances.
Page 23: Hydraulic Fluid
Safety Safety regulations for handling consumables Hydraulic ﬂuid WARNING Hydraulic ﬂuid is a water-polluting substance! During operation of the forklift truck, Always store hydraulic ﬂuid in containers hydraulic ﬂuids are pressurised and complying with the regulations. are hazardous to your health. Avoid spilling.
Page 24: Disposal Of Consumables
Safety Safety regulations for handling consumables – Dispose of used battery acid in line with the applicable regulations. Disposal of consumables • Any spillage of ﬂuids such as hydraulic oil, ENVIRONMENT NOTE brake ﬂuid or gear lubricant oil must be Materials that have to be disposed of following immediately soaked up with an oil-binding maintenance, repair and cleaning must be...
Page 25: Emissions
Safety Emissions Emissions Noise emission values Calculated during the test cycle performed NOTE in accordance with standard EN 12053 from Lower or higher noise values may occur when the weighted values for the DRIVE operating using industrial trucks, e.g. due to the mode statuses.
Page 26: Stability
Safety Stability • Falling, tripping etc. when moving on the It is important to adjust the speed of the tow tow truck, especially in the wet, with leaking tractor depending on the load and ground consumables or on icy surfaces conditions.
Page 27: Definition Of Responsible Persons
Safety Deﬁnition of responsible persons Deﬁnition of responsible persons Operating company The operating company is the natural or legal The operating company must ensure that person or group who operates the truck or on all users read and understand the safety whose authority the truck is used.
Page 28 Safety Deﬁnition of responsible persons Prohibition 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.
Page 29: Safety Test
Safety inspection based on time and extraordinary incidents The operating company (see chapter entitled Deﬁnition of responsible persons) must STILL GmbH Hamburg ensure that the tow tractor is checked by a specialist at least once a year or after Regelmäßige Prüfung noteworthy incidents.
Page 30 Safety Safety test 1191 801 15 51 EN - 09/2019...
Page 31 Overviews...
Page 32: Overviews
Overviews Overviews Overviews General view of the tow tractor Cab (optional) Steering axle and front wheel Driver's seat Dipped beam headlights Battery compartment Direction indicator lights Traction motor Rear tow coupling Electronic control Trailer lighting socket Drive axle and rear wheels Rear light unit Solid door (optional) 1191 801 15 51 EN - 09/2019...
Page 33: General View Of The Carrier
Overviews Overviews General view of the carrier Cab (optional) Steering axle and front wheel Driver's seat Dipped beam headlights Battery compartment Direction indicator lights Traction motor Rear tow coupling Electronic control Trailer lighting socket Drive axle and rear wheels Rear light unit Solid door (optional) 1191 801 15 51 EN - 09/2019...
Page 34: Control And Display Components
Overviews Control and display components Control and display components Display Hazard warning light button Reverse travel indicator light Front windscreen wiper button Right turn indicator light Rear window wiper button Left turn indicator light Work light button Start-up screen Blue-Q mode button Menu 1: Battery charge status/Menu 2: Signal lights button Hour meter...
Page 35: Markings
Overviews Markings Markings Tow tractor labels Nameplate (see next page) Automatic coupling label Brand label 12-volt label for the coupling socket Truck model label Periodic check label Tyre pressure label Truck slinging label Slow travel warning label 1191 801 15 51 EN - 09/2019...
Page 36: Carrier Labels
Overviews Markings Carrier labels Nameplate (see next page) Automatic coupling label Brand label 12-volt label for the coupling socket Truck model label Truck slinging label Tyre pressure label Periodic check label Slow travel warning label 1191 801 15 51 EN - 09/2019...
Page 37: Serial Number
Overviews Markings Serial number xx xxxx x xxxxx NOTE Indicate the serial number for all technical enquiries. The serial number contains the following information: 1 Production location 2 Type 3 Year of production 4 Count number 7090_921-004 1191 801 15 51 EN - 09/2019...
Page 38 Overviews Markings 1191 801 15 51 EN - 09/2019...
Page 40: Technical Description
Technical description Technical description Introduction Drive and transmission The tow tractor and the carrier have been de- A powerful 4.5-kW traction motor (AC tech- veloped to meet the most arduous application nology) is mounted transversely on the drive requirements. They comply with all current axle.
Page 41 Technical description - Fork Off system for battery removal and a - Different cab types suitable tool for this use - Different seat types - Roll Off system for battery removal - On-board charger etc. - Wheels or tyres 1191 801 15 51 EN - 09/2019...
Page 42: Checks And Actions Prior To Commissioning
Checks and actions prior to commissioning Checks and actions prior to commissioning Check all controls and their operation Before each shift, check that the tow tractor controls work correctly and are safe: – Check that the braking system works correctly –...
Page 43: Checking The Battery Charge Status
Checks and actions prior to commissioning Checking the battery charge status – Pull the emergency stop button(2). – Switch on the ignition using the key (3). For trucks with digicodes, turn the start-up button to position 1, then enter the PIN code into the digicode keypad.
Page 44: Checking The Foot Brake
Checks and actions prior to commissioning Report any interlock malfunctions to your manager. Do not use the tow tractor or the carrier. Checking the foot brake DANGER Risk of accident Do not use only the electrical brake for emergency braking. –...
Page 45: Top Up The Windscreen Washer Bottle
Checks and actions prior to commissioning Top up the windscreen washer bottle CAUTION Frosty conditions can damage the windscreen washer system. – Always use washer ﬂuid containing antifreeze. The tank for the front and rear windscreen washer ﬂuid is located behind the chair. To ﬁll the windscreen washer system tank (1), proceed as follows: –...
Page 46: Check The Automatic Trailer Coupling (If Fitted)
Checks and actions prior to commissioning Check the automatic trailer coupling (if ﬁtted) WARNING Do not place your hands in the open coupling. There is a risk that it will close on them. Checking that the automatic coupling is working properly. –...
Page 47: Truck Operating Instructions
Truck operating instructions Truck operating instructions The trucks are designed for indoor and Speed must be reduced when moving over outdoor use in non-hazardous atmospheres. obstacles to prevent the truck from becoming The temperature should be between -10°C unbalanced and vibrations in the arms of the and +45°C and the relative humidity of the air operator.
Page 48: The Nameplate
The nameplate The nameplate Before using the truck for the ﬁrst time, it is advisable to read the information on the nameplate (1). This is located inside the battery compartment. Please refer to chapter 1 Nameplate for details. 1191 801 15 51 EN - 09/2019...
Page 49: Display
Display Display The tow tractor start-up screen In menu 1, the main display screen shows: • The battery charge status (1) • The gradient of the slope (2) • The travel speed (3) • The time (4) In menu 2, the main display screen shows: •...
Page 50: Using The Display
Display Using the display Tow tractor signal buttons The Hazard warning light button (1) allows you to switch on the hazard warning lights (Warning) to warn other users of a potential danger. The Work lights button (2) allows you to switch on the work lights.
Page 51 Display – Press once and hold (over 2 seconds) then keep the button pressed: the washer function starts. Operating the button in this way engages the washer systems for the front and rear windscreen wipers at the same time. The Rear demisting button (6) allows you to demist the rear window.
Page 52: Adjusting The Display
Display Adjusting the display The operator can easily adjust the following items on the display: • The language • The time • The date • The daily mileage Proceed as follows: – Push the buttons (1) and (2) at the same time.
Page 53 Display Resetting the hour meter – Navigate to the Daily km ﬁeld (6) to reset the hour meter to zero. – Press the key (5) twice to conﬁrm. – Switch off the tow tractor. – Restart it. The hour meter is reset. 1191 801 15 51 EN - 09/2019...
Page 54: Driver's Compartment Settings
Driver's compartment settings Driver's compartment settings Safety guidelines for adjustment work WARNING Do not make adjustments while driving, as this could cause you to lose control of the tractor. Carry out adjustment work only when the tow tractor is at a standstill. Once the adjustment work is complete, check that the item is positioned and secured correctly.
Page 55: Seat Belt (Optional)
Driver's compartment settings Seat belt (optional) Fastening the seat belt (if ﬁtted) NOTE Sit as far back as possible so that your back is leaning against the seat backrest. The automatic blocking mechanism permits sufﬁcient freedom of movement on the seat. –...
Page 56: Safety Guidelines For Driving A Tow Tractor
Safety guidelines for driving a tow tractor Safety guidelines for driving a tow tractor Operators must obey the same rules within • Stay in the safety area (working area the plant as on the road. They must drive at deﬁned by the manufacturer). speeds appropriate for the driving conditions.
Page 57: Entering And Exiting The Tow Tractor
Entering and exiting the tow tractor Entering and exiting the tow tractor WARNING Risk of falling, tripping or slipping when climbing into/out of the tractor. Face the tractor when entering or exiting. Make sure that the step is clean. – Use the steering wheel (1) to help you enter or exit the tractor –...
Page 58: Driving The Tow Tractor
Driving the tow tractor Driving the tow tractor Deﬁnition of directions Names used in the text: forward travel (1), reverse travel (3), to the right (2) and to the left (4) refer to component installation position with respect to the driver's compartment. The load is positioned at the rear.
Page 59: Starting The Tow Tractor With An Electronic Key
Driving the tow tractor Starting the tow tractor with an electronic key The tow tractor can be started with a driver- speciﬁc code. Drivers enter their codes directly into the display (1). The display is on the dashboard (see chapter 3 Display). The knob must also be turned.
Page 60: Start-Up
Driving the tow tractor Start-up NOTE Check that no commands are activated before starting the tow tractor. – Check that the battery is connected and locked and that the door is closed correctly. – Check the condition of the steps. Enter the tow tractor.
Page 61: Forwards Travel
Driving the tow tractor Forwards travel Initial driving practice must be carried out in an empty space or on a clear roadway. WARNING Identify the direction selection lever. Depending on the model ordered, the selector for forwards travel and reverse travel is found to the right or left of the steering wheel.
Page 62: Backwards Driving
Driving the tow tractor Backwards driving Initial driving practice must be carried out in an empty space or on a clear roadway. WARNING Identify the direction selection lever. Depending on the model ordered, the selector for forwards travel and reverse travel is found to the right or left of the steering wheel.
Page 63: Tow Tractor Braking
Driving the tow tractor Tow tractor braking DANGER Risk of accident – Always use the foot brake (1) for emergency braking. DANGER If you are driving too fast, there is a risk that the truck skids. The truck's braking distance depends on weather and road conditions.
Page 64: Emergency Stop
Driving the tow tractor Emergency stop – During normal operation, the emergency stop button (1) must be pulled out. – In the event of danger, push the emergency stop button (1) to break the electrical circuit and immobilise the tow tractor. Operating Blue Q mode With efﬁciency mode, called Blue Q, you can save battery power.
Page 65: Operating The Drive Programme Selection Button
Driving the tow tractor If Blue Q mode is activated and the operator steps off the truck, the following functions are deactivated: • Main beam lights are switched off The sidelights remain lit • The heating is turned off • The rear defroster is switched off •...
Page 66: Operating The Horn
Driving the tow tractor Below is a list of tow tractor performance and carrier performance depending on the functions activated. Tow tractor speed (km/h) Carrier speed (km/h) Speed Downhill Speed Downhill Standard Standard reduction assistance reduction assistance mode 0 mode 0 mode 1 mode 2 mode 1...
Page 67: Starting On An Incline
Driving the tow tractor Starting on an incline Use the following procedure to start the tow tractor on an incline: – Stop the tow tractor using electrical and hydraulic braking. – To start, press the accelerator. The tow tractor is equipped with a starting aid option for use on an incline.
Page 68: Operating The Fleetmanager™ Option
Operating the FleetManager™ option Operating the FleetManager™ option Description of the FleetManager option The FleetManager option allows you to control GSM: Global System for Mobile Communi- access to the truck. The option is a ﬂeet cation management system. Shock sensor You can access the system: •...
Page 69: Commissioning A Tow Tractor Equipped With The Fleetmanager™ Option
Operating the FleetManager™ option Commissioning a tow tractor equipped with the FleetManager™ option Commissioning a tow tractor equipped with a keypad or an electronic key – Turn the turning knob (1) clockwise. – Enter the PIN code on the keypad. The PIN code consists of ﬁve to eight digits.
Page 70 Operating the FleetManager™ option Commissioning a tow tractor equipped with an RFID reading device – Turn the turning knob (1) clockwise. – Place the RFID transponder card or the RFID transponder (4) in front of the reading device (3). If the card is correct, the LED (1) is not lit. The LED (2) ﬂashes slowly at two-second intervals (green colour).
Page 71: Fleetmanager™ Option: Colour Code For The Leds
Operating the FleetManager™ option FleetManager™ option: Colour code for the LEDs The LEDs can have different statuses and different colours. Below is the list of the most common messages and their meanings. Malfunction Cause Solution LED status Signal transmitter LED 1 LED 2 Reading device variant: no...
Page 72 Operating the FleetManager™ option Malfunction Cause Solution LED status Signal transmitter LED 1 LED 2 Flashes quickly Lit continuously A shock has Reset the shock Red colour Green colour occurred The truck is The truck is switched on but connected via a is not moving.
Page 73: Logging Off A Tow Tractor Equipped With The Fleetmanager™ Option
Operating the FleetManager™ option Logging off a tow tractor equipped with the FleetManager™ option NOTE Operators must not log off intentionally while driving. WARNING Access to the tow tractor must be deactivated. Unauthorised users are not allowed to use the tow tractor.
Page 74 Operating the FleetManager™ option – Turn the turning knob (1) anti-clockwise. The tow tractor is switched off. Logging off a tow tractor equipped with an RFID reading device – Park the tow tractor in a safe place. – Brieﬂy place the RFID card or the RFID transponder (4) in front of the reading device The LED (1) lights up for a second (red colour).
Page 75 Operating the FleetManager™ option – Turn the turning knob (1) anti-clockwise. The tow tractor is switched off. 1191 801 15 51 EN - 09/2019...
Page 76: Lighting
Lighting Lighting Using the signal lights WARNING Risk of accident If the truck must be used outdoors at night, it must be equipped with headlights. We recommend switching off the main beam headlights when the truck is at a standstill. Headlights are available as an option.
Page 77: Using The Direction Indicators
Lighting Adjusting the main beam headlights It may be necessary to adjust the main beam headlights. – Adjust the three screws (2) to adjust the lights Using the direction indicators NOTE Always check the surrounding area before changing direction. WARNING Identify the direction indicator.
Page 78: Using The Hazard Warning Light
Lighting – Check the change of direction information on the display. The left-hand direction indicators operate and indicate your intention to turn left. Using the hazard warning light – Press the hazard warning light button (1) located on the display once. The warnings are switched on.
Page 79: Using The Rotating Beacon (Optional)
Lighting Using the rotating beacon (optional) The truck may be equipped with a rotating beacon depending on the customer's choice. – Press the rotating beacon button (1) once. The rotating beacon is switched on. – Press the rotating beacon button (1) again. The rotating beacon is switched off.
Page 80: Towing
Towing Towing Safety guidelines DANGER WARNING Risk to life Risk of imbalance Hitching or unhitching a trailer on an incline is strictly Hitch the trailer tow bar to the tractor so that the bar prohibited. This work must be performed on level is as horizontal as possible.
Page 81: Using The Manual Coupling
Towing Using the manual coupling DANGER Risk of accident If the trailer hitch pin drops out or is damaged while towing, the load is released and can no longer be controlled. – Use only original trailer hitch pins that have been checked for good condition! –...
Page 82: Using The Automatic Coupling
Towing Using the automatic coupling Coupling a trailer DANGER Incorrect operation of the coupling increases the risk of accidents. Secure coupling can only be veriﬁed by noting the position of the trailer hitch pin (2). The trailer hitch pin must not protrude out of its guide after a trailer has been coupled.
Page 83: Using Electric Tow Coupling
Towing Uncoupling a trailer WARNING Incorrect operation leads to a risk of injury. – Do not reach into the open coupling with your hands or arms. – Take precautions, such as using wheel chocks, to prevent the load you want to disconnect from rolling.
Page 84 Towing – Press the electric coupling button (1) for three seconds. It is located under the 12-volt socket. The status of the icon on the display then changes and indicates that the coupling release request has been validated. Do not press the button for longer than ﬁve seconds.
Page 85: Inching Mode Option
Towing – Close the tow coupling manually. It is also possible to leave it open. Manually opening the electric coupling It is possible to open the coupling in manual mode, but it is not recommended. During normal operation of the tow tractor, this type of coupling is opened in electric mode.
Page 86 Towing – Pull the emergency off switch (3) to restore the power supply 1191 801 15 51 EN - 09/2019...
Page 87: Loading The Platform
Towing Loading the platform CAUTION Ensure that the weight of the load does not exceed the capacity of the tow tractor (150 kg) or the carrier (800 kg). Refer to the nominal capacity speciﬁed on the capacity label for the tow tractor or carrier. It is important that the platform is loaded correctly.
Page 88: Loading Trailers
Towing Loading trailers NOTE Below is a list of guidelines. This list is not exhaustive. DANGER Risk of accident – Never exceed the maximum loads shown! These values apply to compact and homoge- neous loads – It is not permitted to incorrectly load or climb onto the trailer.
Page 89 Towing – Inspect the trailer steering to determine its type. This is particularly important for long trailer trains due to the cut-off effect when cornering NOTE If you need to travel on public roads, ensure that the registration plates conform to local public road regulations.
Page 90: Liftrunner System Equipment Option
Towing Liftrunner system equipment option With the Liftrunner system equipment option, the operator can lift and lower the trailer. The function is automatically available when a hydraulic pipe is connected. Lifting the trailer – Safely park the tow tractor on level ground –...
Page 91 Towing DANGER Risk of crushing feet. Check that no one is next to the trailers before dismounting the tow tractor. The trailer lowers automatically as soon as the operator gets up from the seat. The lowering time is adjustable. The After-Sales Service can set this time.
Page 92 Towing DANGER Risk of injury. Do not connect the pipe when the tow tractor is switched on. Do not mount the tractor when someone is handling the pipe union. Do not connect the pipe to the tow tractor if som- eone is sitting on the seat of the machine.
Page 93 Towing If an error message appears, please contact the After-Sales Service. Operating the Liftrunner system equip- ment option and the Pedestrian slow travel function The Liftrunner system equipment option is compatible with the Pedestrian slow travel option. To use these options together, please follow the instructions below: –...
Page 94: Optional Equipment
Optional equipment Optional equipment Pedestrian "Slow travel" option The "Slow travel" option, known as Pedes- trian, allows you to move the tow tractor for- wards without the need for a forklift operator at the steering wheel. The speed can be set be- tween 1 and 4 km/h.
Page 95: Cab Option
Optional equipment Cab option The tow tractor and carrier can be equipped with a cab featuring various options. Five cab types are available. Depending on the type chosen, the cab may have: • Rigid doors, ﬂexible doors or no door •...
Page 96: Windscreen Wiper Option
Optional equipment Windscreen wiper option The tow tractor and carrier can be ﬁtted with front and rear windscreen wipers. This equipment is offered as an option with the cab. To operate the desired windscreen wiper, proceed as follows: – Press the button (1) on the display for the front windscreen wiper.
Page 97: Automatic Lights Option
Optional equipment Automatic lights option The tow tractor can be equipped with auto- matic signal lights. The side lights and main beam headlights switch on automatically when the forklift operator sits in the driver's seat. To switch the signal lights off, simply press the button (1) on the display.
Page 98: Stvzo (German Road Traffic Licensing Regulations) Option (Intended For The German Market)
Optional equipment SENSOR NOT DETECTED • This message appears when the signal is missing or defective – Contact the After-Sales Service Centre. StVZO (German Road Trafﬁc Licensing Regulations) option (intended for the German market) This option is intended for the German market only and allows the tow tractor to be driven on the road.
Page 99: Parking The Tow Tractor
Parking the tow tractor Parking the tow tractor WARNING Do not stop the tow tractor on an incline. If neces- sary, make sure it is safely secured using chocks. Immobilising the tow tractor – Immobilise the tow tractor. – Switch off the ignition, and remove the key. For tow tractors with digicodes, turn the knob.
Page 100: Battery
Battery Battery Battery type Tow tractors can be ﬁtted with different types of batteries. Comply with the information indicated on your battery's type plate, as well as with its features. WARNING The weight and size of the battery affect the stability of the tow tractor.
Page 101: Accessing The Battery
Battery Accessing the battery WARNING We recommend wearing safety footwear when carrying out any work on the tow tractor. Opening the battery compartment – Immobilise the tow tractor. – Switch off the ignition, and remove the key. – Press the emergency stop button. –...
Page 102 Battery Unlocking the battery – Disconnect the battery. – Turn the handwheel (2) to unlock it. – Lift the stop (3). You can now pull the battery towards you using a suitable tool (see chapter "Battery replacement" below). WARNING Risk of trapping ﬁngers Always wear suitable gloves when handling the battery.
Page 103: Battery Connection
Battery Battery connection CAUTION May cause a short circuit and damage the electrical and electronic components. – Always connect or disconnect the battery connector when the tractor is off. – Open the battery compartment door. See the chapter Accessing the battery. –...
Page 104: Charging The Battery Using An External Charger
Battery Charging the battery using an external charger CAUTION The battery may be damaged if discharged beyond a given limit. – Immediately charge the battery. DANGER Risk of gas escaping. No one must be inside the cab. The cab door must be closed during battery charging.
Page 105 Battery WARNING The electrolyte (diluted sulphuric acid) is toxic and very caustic. Follow the safety rules when handling battery acid. WARNING Explosive gases are generated during battery charging. – Make sure the work area is well ventilated. – Make sure the battery compartment door re- mains open for the entire time the battery is charging.
Page 106: General Information On The On-Board Charger
Battery General information on the on-board charger batteries with a capacity of 210, 225, 300, and CAUTION 330 Ah. It is strictly prohibited to use an on-board charger other than the one recommended. The charger is designed: – To be incorporated inside the carrier or Thanks to the on-board charger, it is no longer outside the tow tractor necessary to use a charging room.
Page 107 Battery CAUTION Risk of damage to the mains cable resulting in electric shock and/or burns! Park the truck close to the mains wall socket. The mains cable of the on-board charger must not be taut when connected and charging. – Open the access door (1) When the access door is opened, a switch automatically turns off the tow tractor.
Page 108 Battery – Check the operation of the fan (2), located behind the seat. Check that no objects are stopping the fan from operating properly. If the fan malfunctions, you must open the door to the battery compartment for ventilation. Contact the After-Sales Service to repair or to change the fan.
Page 109: Charging The Battery With Opportunity Charging (Optional)
Battery Charging the battery with opportunity charging (optional) CAUTION Risk of equipment damage Make sure that the charger is compatible with the tractor's battery in terms of charging voltage and current (refer to the instructions for the external charger). Always follow the manufacturer's instructions supplied with the battery charger.
Page 110 Battery – Switch off the ignition. – Ensure that the side ventilation openings are clear. – Open the access door (1) – Plug the socket of the battery charging sta- tion into the opportunity charging equipment connector. NOTE Opening the door of the battery compartment during charging is recommended whenever possible (risk of gas escaping).
Page 111 Battery Operating the opportunity charging option on the carrier For carriers ﬁtted with the opportunity charging option, a socket (4) is available on the side of the machine. The connector allows you to charge the battery with an external charger. Proceed as follows: –...
Page 112 Battery – Check that the door to the battery compart- ment is closed securely. – Switch on the ignition and check the charg- ing status of the carrier on the display. The carrier is now ready for use. The opportunity charging option and additional equipment It is possible to connect a data terminal to the tow tractor.
Page 113: Changing The Battery With The Fork Off Tool
When changing the battery, it is essential that you use the Fork Off tool sold with the battery by Still. Proceed as follows: – Immobilise the tow tractor in a suitable open area, on even, horizontal ground.
Page 114 Battery – Position the tool up to the stop (1). – Unplug the battery connector (2). Place it in the location provided for this purpose. – Unlock the battery (3). 1191 801 15 51 EN - 09/2019...
Page 115 Battery – Using the Fork Off tool, gently lift the battery and remove it from the battery compartment (4). – Align the battery and chassis in accordance with the visual marking (5). – Change the battery. – Using the tool, push the new battery down to the bottom of the battery compartment (4).
Page 116: Changing The Battery With The Roll Off Tool
Battery Changing the battery with the Roll Off tool WARNING Risk of trapping ﬁngers It is recommended that you wear gloves when changing the battery. It is possible to change the battery using a Roll Off tool. The spare battery is on the tool already.
Page 117 Battery – Disconnect the battery connector. – Push the second battery to the bottom of the battery compartment. WARNING Risk of pinching of the cables Take care not to pinch the battery connector cable. – Lock the battery. – Reconnect the battery connector. –...
Page 118: Handling The Truck In An Emergency
Handling the truck in an emergency Handling the truck in an emergency Precautions before towing the tractor DANGER CAUTION Risk of accident Increased risk of accident due to reduced braking effect. Check the capacity and braking of the vehicle used to tow the tractor.
Page 119: Handling The Tow Tractor In Specific Situations
Handling the tow tractor in speciﬁc situations CAUTION The lift off brake is inoperative when the battery is disconnected. Exercise caution when driving an unpowered towed tractor. WARNING Risk of damage to the wheels and tyres. The mechanical brake must be released. Other- wise, the wheels cannot rotate freely.
Page 120 Handling the tow tractor in speciﬁc situations Tow tractors without a cabin or ﬁtted with a weather protection canopy – Immobilise the tow tractor. – Switch off the ignition and remove the key. – Push the emergency off switch and discon- nect the battery.
Page 121 Handling the tow tractor in speciﬁc situations – Pass a ratchet strap through the rear trailer coupling to prevent the tow tractor from rolling backwards NOTE If the tow tractor has a front tow coupling, pass ratchet straps through both tow couplings to prevent the tow tractor from moving.
Page 122: Slinging The Tow Tractor
Handling the tow tractor in speciﬁc situations Slinging the tow tractor DANGER Risk of injury and death due to broken harnesses – Sharp edges can damage the harnesses. Protect the harnesses from sharp edges. – Only use harnesses with adequate load capa- cities.
Page 123 Handling the tow tractor in speciﬁc situations – Protect all parts that come into contact with the lifting device. – Attach the lifting device as illustrated. – Lift the tow tractor slowly and carefully. DANGER Never step under an elevated load. When lifting the tractor, make sure that no one is in the vicinity.
Page 124: Jacking The Tow Tractor
Handling the tow tractor in speciﬁc situations Jacking the tow tractor DANGER Only use a hydraulic jack with sufﬁcient lifting capacity. Refer to the tow tractor or carrier capacity plate to determine the weight of the truck and battery. DANGER Never work on a jacked tow tractor or carrier or leave it unattended.
Page 125: Maintenance
Maintenance...
Page 126: General Maintenance Information
Maintenance General maintenance information General maintenance information General The following instructions contain all the information required for servicing your tow tractor. Carry out the various maintenance work in compliance with the maintenance plan. This ensures that your tow tractor is reliable and in good working order and that the warranty remains valid.
Page 127: Servicing And Maintenance Personnel Training And Qualification
Maintenance General maintenance information Servicing and maintenance personnel training and qualiﬁcation Truck maintenance must only be carried out The person responsible for carrying out the by qualiﬁed and authorised personnel. inspection must have sufﬁcient knowledge and experience to be able to assess the The annual inspection for prevention of condition of the truck and the efﬁciency of accidents at work must be carried out by a...
Page 128: Safety Guidelines For Maintenance
Maintenance Safety guidelines for maintenance Safety guidelines for maintenance Servicing and maintenance measures To avoid accidents during servicing and – Ensure that there is no risk of the truck maintenance operations, take all necessary moving or starting up unexpectedly. For safety measures.
Page 129: Technical Data For Inspection And Maintenance
Maintenance Technical data for inspection and maintenance Technical data for inspection and maintenance Assembly Material/Lubricant Capacity/Adjustment value Drive axle Gearbox oil 1.2 litres Front 8 bar Tyres Rear 8 bar As required Brake ﬂuid Brake system Brake linings Minimum thickness 2 mm As required Steering chain Chain spray...
Page 130: Recommended Lubricants
Maintenance Recommended lubricants Recommended lubricants Brake ﬂuid DANGER Toxic products. Original ATE DOT4 brake ﬂuid, type “S”, classiﬁcation FMVSS 116 or SAE J 1703 Oils and other consumables are toxic products. It is advisable to handle and use them with the utmost issue 1980 and ISO 4925.
Page 131: Removing The Cover To Access The Technical Compartment
Maintenance Removing the cover to access the technical compartment Removing the cover to access the technical compartment WARNING Pay attention to the weight of the tow tractor cover and the carrier. Do not hesitate to use a lifting system to remove the cover of the tow tractor or the carrier.
Page 132 Maintenance Removing the cover to access the technical compartment Access to the technical compartment of the carrier Proceed as follows to access the technical compartment of the carrier. – Immobilise the carrier in an open area. – Switch off the ignition, and remove the key. –...
Page 133: Maintenance Schedule As Required
Maintenance Maintenance schedule as required Maintenance schedule as required Depending on the application, environmental conditions and driving style, the following proce- dures should be carried out as required Chassis and accessories Cleaning the truck Filling the washer system reservoir (if applicable) Checking the condition and operation of the seat belt (if applicable) Chassis, bodywork and ﬁttings Checking that the wheel nuts are correctly attached...
Page 134: 3000-Hour/Two-Year Maintenance Plan
Maintenance 3000-hour/two-year maintenance plan Chassis, bodywork and ﬁttings Cleaning and checking the gearbox breather Checking and lubricating the steering chain Checking the front suspension Lubricating the front suspension Checking and lubricating the front wheel bearing Checking the brake ﬂuid level Checking the condition of the front and rear brake shoes Checking the drive axle rubber shock mounts Checking the drive axle suspension bushes...
Page 135 Maintenance 3000-hour/two-year maintenance plan Draining then reﬁlling the Liftrunner system equipment with engine oil Visually checking the condition of the air ﬁlter for the agitation pump (on board charger). Cleaning the ﬁlter with water if necessary. 1191 801 15 51 EN - 09/2019...
Page 136: Chassis, Bodywork And Fittings
Maintenance Chassis, bodywork and ﬁttings Chassis, bodywork and ﬁttings Cleaning the tow tractor Precautions before cleaning WARNING Risk of injury due to the use of materials that are corrosive and hazardous to health – Always use appropriate personal protective equipment for cleaning work (industrial goggles and solvent-resistant protective gloves).
Page 137 Maintenance Chassis, bodywork and ﬁttings CAUTION Abrasive cleaning materials can damage compo- nent surfaces! – Using abrasive cleaning materials that are unsuitable for plastics can dissolve plastic parts or make them brittle. It could make the display screen on the display unit cloudy. –...
Page 138 Maintenance Chassis, bodywork and ﬁttings – Clean the oil ﬁlling openings and the sur- rounding area. – Clean all the grease nipples before perform- ing lubrication. – If using compressed air for cleaning, ﬁrst remove stubborn deposits using a cold cleaning agent.
Page 139 Maintenance Chassis, bodywork and ﬁttings Cleaning the windows The cab windows must always be kept clean and free of ice. This helps maintain good visibility. CAUTION Do not damage the rear window heater (inside). – Be very careful when cleaning the rear window, and do not use objects with sharp edges.
Page 140: General Information On Battery Maintenance
Maintenance Chassis, bodywork and ﬁttings General information on battery maintenance DANGER CAUTION Risk of injury Gel batteries are subject to speciﬁc charging, maintenance and treatment instructions. A non- Before carrying out any operations on the electric compatible charger may result in a battery failure. installation, turn the truck power supply off.
Page 141: Check That The Wheel Nuts Are Fitted Securely
Maintenance Chassis, bodywork and ﬁttings Check that the wheel nuts are ﬁtted securely It is advisable to regularly check that the wheel nuts (1) are ﬁtted securely. For effective wheel ﬁxing, tighten the wheel nuts diametrically to 195 Nm. NOTE The wheel bolts must be tightened to the speciﬁed torque.
Page 142 Maintenance Chassis, bodywork and ﬁttings To perform the operations described below, the electrical supply to the tow tractor must be cut off: – Immobilise the tow tractor – Switch off the ignition, and remove the key – Press the emergency stop button –...
Page 143: Checking The Seat Belt
Maintenance Chassis, bodywork and ﬁttings Checking the seat belt NOTE Carry out the following checks on a regular basis. In the event of signiﬁcant strain, a daily check is necessary before each use. Checking the seat belt (if ﬁtted) – Pull out the belt (1) completely, and check for wear.
Page 144: Checking The Condition And Operation Of The Signal Lights
Maintenance Chassis, bodywork and ﬁttings Checking the condition and opera- tion of the signal lights The condition and operation of the signal lights must be checked regularly. – Check the two road lights located at the front Check that the lamp lenses are clean and are not broken, and that the lights work.
Page 145: Cleaning The Heater
Maintenance Chassis, bodywork and ﬁttings Cleaning the heater – Park the tow tractor safely. – Switch off the ignition and remove the key. – Press the emergency off switch. – Open the battery compartment door. – Disconnect the battery connector. –...
Page 146: Checking And Lubricating The Automatic Tow Coupling
Maintenance Chassis, bodywork and ﬁttings Checking and lubricating the automatic tow coupling WARNING Risk of crushing – Do not reach into the open coupling with your hands or arms. It may close. – Lubricate the automatic coupling locking mechanism. For tow tractors equipped with a coupling that can be controlled remotely: –...
Page 147 Maintenance Chassis, bodywork and ﬁttings NOTE It is strongly recommended that this operation and any other adjustments to the braking system are carried out by the after-sales service department. 1191 801 15 51 EN - 09/2019...
Page 148: Driver's Compartment
Maintenance Driver's compartment Driver's compartment Checking and lubricating the driver's seat – Check the driver's seat adjustment mecha- nism for correct operation – Check that the seat locking mechanism engages correctly after adjustment – Lubricate both seat slides and associated adjustment mechanism –...
Page 149: Transmission
Maintenance Transmission Transmission Cleaning and checking the gearbox breather – Park the tow tractor safely – Switch off the ignition and remove the key – Press the emergency stop button – Open the battery compartment door – Disconnect the battery connector –...
Page 150: Draining And Filling The Drive Axle
Maintenance Transmission Draining and ﬁlling the drive axle NOTE To facilitate the ﬂow of oil, draining should preferably be performed when the engine is hot. – Park the tow tractor safely – Switch off the ignition and remove the key –...
Page 151: Chassis
Maintenance Chassis Chassis Checking and lubricating the steering chain – Park the tow tractor safely – Switch off the ignition and remove the key – Press the emergency stop button – Open the battery compartment door – Disconnect the battery connector –...
Page 152: Checking The Front Suspension
Maintenance Chassis Checking the front suspension – Park the tow tractor safely – Switch off the ignition and remove the key – Press the emergency stop button – Open the battery compartment door – Disconnect the battery connector – Jack the truck front and chock securely –...
Page 153: Checking And Lubricating The Front Wheel Bearing
Maintenance Chassis Checking and lubricating the front wheel bearing – Park the tow tractor safely – Switch off the ignition and remove the key – Press the emergency stop button – Open the battery compartment door – Disconnect the battery connector –...
Page 154: Changing The Brake Fluid
Maintenance Chassis – Open the battery compartment door and disconnect the battery – Lift and remove the technical compartment cover – Check the level of the brake ﬂuid reservoir is up to the maximum level (2). The brake ﬂuid level must never drop below the minimum level (1) –...
Page 155: Checking The Front And Rear Brake Shoes
Maintenance Chassis Checking the front and rear brake shoes The brake shoes must be checked every 1000 hours. NOTE We strongly recommend that this operation and other brake adjustments be carried out by the after-sales service department. DANGER Never use a tow tractor with a defective braking system.
Page 156: Checking The Drive Axle Suspension Bushes
Maintenance Chassis Checking the drive axle suspension bushes – Park the tow tractor safely. – Switch off the ignition and remove the key. – Press the emergency off switch. – Open the battery compartment door. – Disconnect the battery connector. –...
Page 157: Electrical Equipment
Maintenance Electrical equipment Electrical equipment Checking the fuses NOTE Do not use automotive fuses even if they are interchangeable. Only the fuses supplied by the manufacturer have sufﬁcient nominal voltage to ensure adequate protection for the voltages used in tow tractors and carriers. –...
Page 158: Checking The Battery Acid Level And Electrolyte Density
Maintenance Electrical equipment Checking the battery acid level and electrolyte density WARNING The electrolyte (diluted sulphuric acid) is poisonous and caustic! – Always wear suitable protective equipment (industrial goggles, safety gloves) when working on a battery – Never wear a watch or jewellery when handling battery acid –...
Page 159: Bles
Maintenance Electrical equipment ENVIRONMENT NOTE Dispose of any used battery acid in accor- dance with the regulations. The tow tractor is compatible with the elec- trolyte level checking sensor. The tow tractor or carrier can be equipped with a battery that features this sensor.
Page 160: Checking The Battery And The Condition Of The Battery Cable
Maintenance Electrical equipment Checking the battery and the condition of the battery cable DANGER Risk of fatal electric shock – Never wear a watch or jewellery when handling a battery – Never place metal objects on the battery – Never touch uninsulated cables –...
Page 161: Cleaning The Opportunity Charging Equipment
Maintenance Electrical equipment Cleaning the opportunity charging equipment The opportunity charging equipment must be cleaned regularly to remove dust. CAUTION Always disconnect the battery connector before working on an electrical component. – Immobilise the tow tractor – Switch off the ignition. –...
Page 162: Decommissioning And Storage
Maintenance Decommissioning and storage Decommissioning and storage Tow tractor storage Precautions must be taken if the tow tractor CAUTION is not used for an extended period of time. We recommend that you do not use a plastic sheet, Procedures depend on the length of time it is as plastic sheets encourage condensation to form.
Page 163: Permanent Putting Out Of Commission (Destruction)
Maintenance Decommissioning and storage Permanent putting out of commission (destruction) When scrapping the tow tractor, you must: – After receiving the authorisation from the competent authorities, remove any compo- – Remove the various parts of the tow tractor nents according to national standards (covers, batteries, chains, motors etc.) –...
Page 164 Maintenance Decommissioning and storage 1191 801 15 51 EN - 09/2019...
Page 165: Technical Specifications
Technical speciﬁcations...
Page 166: Datasheet For The Tow Tractor
Technical speciﬁcations Datasheet for the tow tractor Datasheet for the tow tractor 1191 801 15 51 EN - 09/2019...
Page 167 Technical speciﬁcations Datasheet for the tow tractor DESIGNATION 1.1 Manufacturer KION KION 1.2 Model type LTX 70 LTX 80 Method of propulsion: battery, Battery Battery diesel, petrol, LPG, mains power Driving: manual, pedestrian, Seated Seated standing, seated, order picking Towing capacity 1.5 Load capacity...
Page 168 Turning radius, rear 1115 1115 ±20 Minimum steering angle 180° 2765 2765 ±20 Minimum pivot point distance PERFORMANCE DATA LTX 70 LTX 80 ±5% 5.1 Driving speed, with/without load 11/20 10/20 km/h Tractive force, without load, 60 1400 1600 minute rating...
Page 169 Technical speciﬁcations Datasheet for the tow tractor MISCELLANEOUS LTX 70 LTX 80 8.1 Type of drive control Electronic Electronic 8.4 Noise level at forklift operator's ears ±2.5 See the list of See the list of 8.5 Tow coupling, design/type, DIN...
Page 170: Towing Diagram For The Tow Tractor
Technical speciﬁcations Towing diagram for the tow tractor Towing diagram for the tow tractor Tow tractor LTX 70 Speed (km/h) Permissible haul per hour (m) Drawbar pull (N) Trailer weight (t) Gradient (%) 1191 801 15 51 EN - 09/2019...
Page 171 Technical speciﬁcations Towing diagram for the tow tractor NOTE The load/gradient combinations shown by the full line can be restarted from stationary on the gradient. NOTE The permissible haul per hour is the total distance travelled, including the return journey and any downhill slopes.
Page 172 Technical speciﬁcations Towing diagram for the tow tractor Tow tractor LTX 80 Speed (km/h) Trailer weight (t) Permissible haul per hour (m) Gradient (%) Drawbar pull (N) NOTE The load/gradient combinations shown by the full line can be restarted from stationary on the gradient.
Page 173 Technical speciﬁcations Towing diagram for the tow tractor NOTE The permissible haul per hour is the total distance travelled, including the return journey and any downhill slopes. 1191 801 15 51 EN - 09/2019...
Page 174: Datasheet For The Transponder
Technical speciﬁcations Datasheet for the transponder Datasheet for the transponder Platform tractor without cab 1191 801 15 51 EN - 09/2019...
Page 175 Technical speciﬁcations Datasheet for the transponder Platform tractor with cab 1191 801 15 51 EN - 09/2019...
Page 176 Technical speciﬁcations Datasheet for the transponder Datasheet for the platform tractor DESIGNATION 1.1 Manufacturer KION 1.2 Model type LTX T 08 Method of propulsion: battery, diesel, petrol, Battery LPG, mains power Driving: manual, pedestrian, standing, seated, Seated order picking Towing capacity 1.5 Load capacity 1.7 Rated drawbar pull 1240...
Page 177 Technical speciﬁcations Datasheet for the transponder 4.17 Rear overhang ±5 mm 4.18 Loading platform width ±5 mm 4.19 Overall length ±5 mm 2955 4.21 Overall width ±5 mm 1000 4.32 Ground clearance at centre of wheelbase ±2 mm 4.35 Turning radius, front WaF ±20 mm 2230 Turning radius, rear...
Page 178 Technical speciﬁcations Datasheet for the transponder (1) Based on a level, dry surface with rolling resistance of 200 N/t. Refer to the capacity charts for the speciﬁc conditions of use and when application includes gradients and ramps. (2) The weight of the loaded platform must be added to the rear axle load.
Page 179: Towing Diagram For The Transponder
Technical speciﬁcations Towing diagram for the transponder Towing diagram for the transponder Speed (km/h) Trailer weight (t) Permissible haul per hour (m) Gradient (%) Drawbar pull (N) NOTE The load/gradient combinations shown by the full line can be restarted from stationary on the gradient.
Page 180 Technical speciﬁcations Towing diagram for the transponder NOTE The permissible haul per hour is the total distance travelled, including the return journey and any downhill slopes. 1191 801 15 51 EN - 09/2019...
Page 181 Index Buttons for tow tractor performance ..41 Access to the technical compartment of the carrier ....122 Cab interior light ....68 Access to the technical compartment of the tow tractor .
Page 182 Index Copyright and property rights ..2 Electrical connections and cables Correct use ..... . . 6 Checking the condition and secure attachment .
Page 183 Index General information on battery Maintenance plan maintenance ....130 3000 hours ....124 General information on the on-board Maintenance schedule charger .
Page 184 Index Tow coupling and carrying compart- ment Safety General description ....30 Driver safety guidelines ... 10 Tow tractor ignition using the key .
Page 186 STILL GmbH 1191 801 15 51 EN – 09/2019...

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Still LTX 70 Original Instructions Manual

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