Operating Instructions

Directive No. 94/9/EC Machine Group II

Zone 2, Machine Category 3G
Linde Platform Power Pallet Truck
With Gas Warning System PL-G 1000 to EN 1755
T 20 AP
With Electric Motors
141 804 6011 GB
0902
Linde - Your Partner Linde AG Linde Material Handling Division

Linde, an enterprise operating

worldwide in the investment
and service sector, is one of the
large industrial enterprises in
the EC with its three business
segments and six divisions.

Fenwick-Linde, Châtellerault The Linde Material Handling

division is a leading manufac-
turer of industrial trucks and
hydraulics. It includes eight
manufacturing plants in the
Federal Republic of Germany,
France and Great Britain, as
well as subsidiaries and bran-
ches in all economically im-
Werk II, Aschaffenburg-Nilkheim Lansing Linde Ltd., Basingstoke
portant countries.

Linde industrial trucks enjoy a

worldwide reputation - thanks to
their high quality in engineering,
performance and service.

Werk I, Aschaffenburg Werk III, Kahl am Main Linde Heavy Truck Division Ltd., Merthyr Tydfil
 Foreword
Your Linde lift truck The operator (employer) must ensure No changes, especially conversions
offers the best in economy, safety and driving convenience. that the truck is always in safe operating or modifications, may be made on your truck
Therefore it is mainly in the hands of the operator to preserve condition. without the prior permission of the manu-
the qualities of the truck for a long and profitable service life
facturer.
and to make full use of their benefits on the job.
All measures in this manual related to
These operating instructions tell you all you need to know
about starting, operation, running and servicing the truck. explosion protection are identified with . Only qualified and authorised persons
For maintenance and repair work not described in these Please ensure that they are followed. (experts), familiar with explosion protection
operating instructions special technical skill and knowledge,
regulations and authorised by Linde are
measuring equipment and special workshop tools are often
The safety rules for the use of industri- allowed to service the trucks. The manufac-
required. Please contact your authorised Linde dealer for this
service. al trucks, the local regulations and the in- turer recommends you to charge the au-
Only qualified persons (experts) authorised by Linde are structions in this manual must be followed thorised Linde dealer.
allowed to service the trucks.
under all circumstances by the responsible
For some attachments, the proprietary operating instructions
supplied with them are applicable. persons, especially by the operator and When replacing explosion-proof com-
Follow all tips for operating the lift truck and carry out the service personnel. ponents, always install tested explosion-
maintenance and care prescribed in the inspection and
proof parts approved for the truck.

141 804 6011.0902

maintenance schedule regularly, on time and with the spec-
The user, and not Linde, is responsible
ified lubricants.
To keep your warranty valid, all maintenance services must for any danger arising from applications not After changes in the explosion protec-
be performed by qualified persons authorised by Linde. authorised by the manufacturer. tion, the owner (employer) must have the
The terms “front”, “rear”, “left” and “right” refer to the position
truck certified by an expert before taking it
in which the item concerned is installed in the truck in relation
The truck may only be operated in zon- back into operation.
to the forward travel direction.
es with an explosion hazard as certified in
Approved applications the attestation included in this manual.
This Linde electric pallet truck is designed for transporting If you desire to use the truck for applications not mentioned
and lifting the loads stated in the load capacity diagram. in the manual and convert or modify it for this purpose, please
In particular, we refer to the attached safety rules for the contact authorised skilled personnel (experts).
normal and proper use of industrial trucks (VDMA) concern-
ing safe operation and accident prevention of fork lift trucks,
as well as to the traffic regulations.

2
 Technical note Foreword
These operating instructions or excerpts thereof may only be For repairs, use only genuine Linde spare parts to ensure that Pallet truck takeover
copied, translated or transmitted to third parties after prior your Linde fork truck will maintain its original technical stand-
written approval by the manufacturer. ard. Every fork truck undergoes careful inspection before leaving
the factory in order to make sure that it will be in satisfactory
Linde pursues a policy of continuous progress in the design When ordering spare parts, it is important also to give the
condition and fully equipped as ordered when delivered to
and construction of its products. As a result, the illustrations following information:
the customer. Authorised distributors are under obligation to
and technical details referring to design, fittings and engi-
re-inspect the truck before delivery and to hand it over in good
neering of lift trucks are subject to change if progress warrants Lift truck model: _________________________________
order.
it.
Manufacturer’s serial no./Year built: _________________ In order to avoid later complaints and inconvenience to
Therefore, the manufacturer will not accept any claims based
customers, you are requested to ascertain that the truck is in
on the specifications, illustrations and descriptions con-
14361/98 satisfactory condition and fully equipped at the time of deliv-
tained in this operating manual. INERIS ATEX No.: ____________________________
ery and to acknowledge orderly handing/taking over of the
Please submit all enquiries concerning your truck and all truck in the manufacturer’s certificate of conformity.
orders for spare parts to your authorised distributor, making PTB No.: ___________________________________
sure to state your correct shipping address. The following technical manuals are supplied with each
Handing-over date: ______________________________ truck:
When taking over the fork lift truck, transfer the data from the
1 Operating instructions
assembly type plates into this operating manual.
1 EC declaration of conformity
141 804 6011.0902

(The manufacturer declares that the fork lift truck

conforms to EC directive for machines)
1 Rules for the Normal and Proper Use of Industrial
Trucks (VDMA)
1 Certificate for explosion protection

Wishing you satisfactory operation,

Linde AG
Linde Material Handling Division
Aschaffenburg

3
141 804 6011.0902
4
 Type plates Description
1 Identification plate
2 Manufacturer
3 CE symbol
15
(The symbol certifies that EC directive for machines and
all applicable guidelines are fulfilled.)
4 Serial number / year
5 Unladen weight
11 12
6 Battery voltage
7 Minimum battery weight 14
8 Maximum battery weight
9 Nominal load capacity of truck
10 Model
x1411302
11 Slinging label
13
12 Battery safety label 1
13 Manufacturer’s number (stamped)
141 804 6011.0902

14 Explosion protection sign

15 Type plate with INERIS/PTB Atex Type Acceptance
Certificate No.

1 2

10
3
9
4 1
x1411301

8 5

7 6
5
Pallet truck model T 20 AP explosion-protected Description
Advanced technology,
simple and ergonomic operation,
energy-saving, environment-friendly and minimal
maintenance,
solid manufacture
and for availability of your lift truck
nearly all parts manufactured
by Linde.
The success of a company
with about 9600 employees in eight plants.

141 804 6011.0902

The explosion-protected pallet truck
T 20 AP is characterised by its clearcut struc-
ture, appealing design and positive human
engineering.
The shaft and the operating elements are arranged accord-
ing to the latest research in ergonomics. Each operating
element is designed in regard to positioning and operation to
ensure the driver's convenience guaranteeing effortless and x1411303
safe operation.

6
 Table of contents Description
Page Page Page

Foreword ......................................................................... 2 Beginning operation ................................................ 17 Operation ...................................................................... 26

Approved applications ........................................................ 2 Safety rules ........................................................................ 17 Driving ............................................................................... 26
Technical note ..................................................................... 3 Experts .............................................................................. 17 Moving the tiller into driving position ............................ 26
Pallet truck takeover ........................................................... 3 Safety information ............................................................. 19 Travel, change of direction ............................................ 27
Safety check ................................................................ 19 Moving forward .............................................................. 27
Description ..................................................................... 5 Explosion protection check ........................................ 19 Moving backward ........................................................... 27
Type plates .......................................................................... 5 Operation of industrial trucks in the plant area ................ 19 Change of direction ....................................................... 27
Technical data ................................................................... 10 Handling fluids and lubricants .......................................... 19 Steering, belly button, horn .............................................. 28
Technical description ........................................................ 11 Running-in instructions ..................................................... 19 Steering .......................................................................... 28
Drive ............................................................................... 11 Maintenance work prior to initial start-up ......................... 19 Belly button .................................................................... 28
Steering .......................................................................... 11 Daily inspections ............................................................... 19 Operating the horn ........................................................ 28
Hydraulic system ........................................................... 11 Daily checks and servicing before operation .................. 20 Braking, fuses, lifting device ............................................. 29
Braking ........................................................................... 11 Removing the front cover .................................................. 20 Tiller brake (parking brake) ........................................... 29
Driving ............................................................................ 11 Installing the front cover .................................................... 20 Plug brake (service brake) ............................................ 29
General view of truck ........................................................ 12 Disconnecting the battery plug .................................. 20 Fuses ....................................................................... 29
Operating and display elements ...................................... 13 Connecting the battery plug ....................................... 20 Lifting forks ..................................................................... 29
Truck indicator ................................................................... 14 Checking the battery charge ...................................... 21 Lowering forks ............................................................... 29
141 804 6011.0902

Hour meter with battery discharge indicator/ Charging the battery ................................................... 21 Before loading ................................................................... 30
lift cut-out contact ........................................................... 14 Connecting the battery to a suitable Loading ............................................................................. 30
Hour meter ..................................................................... 14 external charger ...................................................... 21 Transporting the load ........................................................ 31
Battery discharge indicator with lift cut-out contact ...... 14 Check the condition, electrolyte level and Depositing the load ........................................................... 31
Gas warning indicator ................................................ 15 specific gravity of the battery ......................................... 22 Before leaving the pallet truck .......................................... 31
Hour meter ..................................................................... 15 Battery change ............................................................ 22 Towing ............................................................................... 32
Battery discharge indicator ............................................ 15 Battery removal with a crane ...................................... 22 Towing the truck ............................................................. 32
Technical description ........................................................ 16 Turning on the key switch ................................................. 23 Towing procedure .......................................................... 32
Gas warning system ................................................ 16 Turning off the key switch ................................................. 23 Hoisting the truck with a crane ......................................... 32
Push in emergency isolator button ............................ 23 Taking the truck out of operation ...................................... 33
Unlock emergency isolator button ............................. 23 Measures before taking the truck out of operation ....... 33
Check the horn ............................................................ 23 Putting the truck back into operation ............................. 33
Check the belly button ...................................................... 24
Check the braking system ................................................ 24
Check the truck for leaks ................................................... 25
Check the load forks ................................................... 25
Check the condition for leakage resistance of the tyres .. 25

7
141 804 6011.0902
8
 Table of contents Description
Page Page

Maintenance ............................................................... 35 1000-hour inspection and maintenance ........ 46

General information .......................................................... 35 Clean hydraulic system oil filter ....................................... 46
Inspection and maintenance after first 50 hours
of operation .................................................................... 35 2000-hour inspection and maintenance ........ 47
Renew the hydraulic oil .................................................... 47
Inspection and maintenance chart ................................... 36 Renew the gearbox oil ...................................................... 47

Inspection and maintenance as required ...... 38 Inspection and maintenance specifications ..................... 48
Clean the truck .................................................................. 38
Check the tyres for damage and foreign objects ............. 38 Lubricant recommendations ............................................. 49
Tighten the wheel fasteners ............................................. 39 Hydraulic oil ................................................................... 49
Inspect the gas warning system sensor ..................... 40 Bio hydraulic oil ............................................................. 49
Inspect the gas warning system ................................. 40 Lubricating grease ........................................................ 49
Clean the gas warning system sensor ...................... 40 Battery grease ................................................................ 49
Gear oil .......................................................................... 49
500-hour inspection and maintenance ........... 41 Troubleshooting guide ...................................................... 51
Hydraulic circuit diagram .................................................. 52
141 804 6011.0902

Check the brake system ................................................... 41

Check the tiller brake ........................................................ 41 Wiring diagram .................................................................. 54
Index .................................................................................. 55
Check the plug brake ........................................................ 41
Check and lubricate other joints ....................................... 41
Lubricate the steering bogie on traction unit ................... 42
Check the gearbox oil level .............................................. 42
Check the hydraulic oil level ............................................ 43
Check the hydraulic system for tightness ........................ 43
Check the electric cables, cable connectors and
connections for condition and tightness ................. 43
Check the mounting of frame parts and body ............ 44
Check the load forks ................................................... 44
Clean the controller with compressed air .................. 44
Clean contactor tips and check for wear ................... 45
Clean the electric motors ........................................... 45
Check the motor brushes, renew if necessary .......... 45
Check the brake system ................................................... 45

9
Technical data Description
Linde Platform Power Pallet Truck EGU
August 2002 Designation VDI 3586
Data Sheet for Material Handling Equipment Abbreviation to VDI 3586
VDI 2198
1.1 Manufacturer Linde
1.2 Model designation T 20 Remarks:
Characteristics

1.3 Power unit: battery, diesel, LPG, mains power battery

1.4 Operation: manu., pedest., stand-on, seated, ord. pic. pedestrian
1) Other batteries available. Different battery sizes change the stated values.
1.5 Load capacity Q [kg] 2000
1.6 Load centre c [mm] 600
1.8 Load distance (lowered/lifted) x [mm] 880 / 962
1.9 Wheelbase y [mm] 1450
2.1 Service weight [kg] 740
T 20
Weight

2.2 Axle load with load, front/rear [kg] 995 / 1745

2.3 Axle load without load, front/rear [kg] 570 / 170
3.1 Tyres, front/rear (SE = CS superelastic, L = pneum.) VG+P / P
Wheels and Tyres

3.2 Tyre size, front [mm] ø 254 x 102

3.3 Tyre size, rear [mm] ø 85 x 105
3.4 Additional wheels (dimensions) [mm] ø 100 x 40
3.5 Wheels, number front/rear (x = driven) 1 x 2 / 2
3.6 Track width, front [mm] 480
3.7 Track width, rear [mm] 395
4.4 Lift h3 [mm 125
4.9 Height with tiller in min./max. driving position h14 [mm] 980 / 1400
4.15 Height with forks lowered h13 [mm] 85
4.19 Overall length l1 [mm] 1827

141 804 6011.0902

4.20 Length to fork face l2 [mm] 677
Dimensions

4.21 Overall width b1/b2 [mm] 725

4.22 Fork dimensions s/e/l [mm] 60 x 165 x 1150
4.25 Max. width of spread forks b5 [mm] 520 / 560
4.26 Platform width (variants 01, 02, 03, 04) b4 [mm] 01, 04: 600 / 02, 03: 630
4.32 Ground clearance, centre of wheel base m2 [mm] 24
4.33 Aisle width with pallet 1000x1200 across Ast [mm] 1990
4.34 Aisle width with pallet 800x1200 lengthwise Ast [mm] 2190
4.35 Turning radius (lowered/lifted) Wa [mm] 1670
5.1 Travel speed, with/without load km/h 6,0 / 6,0
Performance

5.2 Lifting speed, with/without load m/s 0,031 / 0,046

5.3 Lowering speed, with/without load m/s 0,055 / 0,052
5.8 Max. climbing ability with/without load % 12 / 20
5.10 Service brake electromagnetic
6.1 Traction motor, rating (S2 60 min.) kW 1,5
Electr. Motor

6.2 Lift motor, rating (S3 10 %)) kW 1,0

6.3 Battery according to IEC 254-2
6.4 Battery voltage, rated capacity K5 V/Ah 24 / 330 L
6.5 Battery weight kg 320
8.1 Type of control LDC with microprocessor
8.4 Mean noise level at driver's ear dB (A) 70
Others

AST = Wa - x + l6 + a Safety distance a = 200 mm

10
 Technical description Description
The T20AP electric pallet truck with driver platform is de- Hydraulic system Driving
signed for the handling of pallets to a maximum weight of
2000 kg in warehouses, stores and factories. The hydraulic system is a compact unit consisting of a motor The pallet truck can be operated in the pedestrian or stand-
Its stability, its compact dimensions, combined with a very - pump unit with built-in oil tank and oil filter. on mode.
small turning circle, make this pallet truck a highly efficient An emergency isolator button interrupts the electric circuit
tool, particularly when used in confined spaces where access The pump motor is temperature-moni- and also actuates the brake when depressed.
is difficult. tored. The motor switches off automatically The traction switches for forward and reverse travel are
The truck is just as useful for moving pallets around inside the
warehouse itself as it is for loading and unloading trucks. as soon as a specified temperature is located on the two tiller grips. They can be operated with both
hands or with either the right or left hand.
The truck is equipped with a hinged platform and two side reached, and switches back on after cooling
plates (guards). down. The lift and lower buttons, the belly button and pneumatic
horn are easily accessible on the tiller head.
Drive The load forks are raised and lowered by lifting cylinders via
the lifting device. NOTE
The 2 kW drive motor is mounted vertically on the reduction The belly button is only operational when the platform is
gear unit. The driving wheel is driven via a 2-stage gear unit. Fork protective surfaces which come folded up and the side plates folded in (pedestrian mode).
The motor reducer assembly is sprung and a hydraulic ram
automatically regulates the pressure of the drive wheel so as in contact with the ground or the load are
to adapt the truck’s drive ability to suit the operating conditions coated with an approx. 3 mm thick layer of
141 804 6011.0902

and the load carried. brass, copper, stainless steel or a compara-

Power is supplied by a 24 Volt lead-acid storage battery with
a capacity of 190 to 500 Ah according to type of chassis. ble material, or the forks themselves are
The motor power is controlled by the LDC microprocessor- produced from stainless steel.
controlled electronic controller which, thanks to its parame-
terization, adapts perfectly to all requirements. Braking
The T20AP is fitted with 3 braking systems:
Steering
A robust and ergonomical twin-grip tiller steers the driving - Safety/parking braking, provided by an electromagnetic
wheel directly. brake which is actuated when the electrical power is
interrupted. This brake is automatically engaged when
the tiller is released and allowed to return to its upper
position, or when the safety pedal is released.
- Electronic countercurrent braking, triggered by a change
in the direction of travel and controlled by the LBC brake
unit and the LDC controller.
- Automatic braking obtained on releasing the accelerator
and controlled by the LDC controller.

11
General view of truck Description
1 Tiller
1
2 Emergency isolator button

3 Side plate (guard)

4 Front cover 12 2
5 Controller housing

6 Hinged platform
11
7 Drive motor

8 Hydraulic unit 3
9 Gas warning sensor

11 Forks

141 804 6011.0902

10 Load wheels 4
10
12 Battery cover

x1411348
6

8 7

12
 Operating and display elements Description
1 Lift button 3
2 Lower button

3 Horn

4 Traction switch (throttle) 2

5 Belly button (safety reversal in direction of forks)
9
x1411306
6 Key switch
1
7 Emergency isolator button

8 Truck indicator: x1411307

(composite instrument with hour meter/battery
discharge indicator and lift cut-out contact)
5 4
9 Hinged platform (stand-on mode)
141 804 6011.0902

10 Acknowledgement button

11 Gas warning indicator:

(composite instrument with hour meter/battery
discharge indicator)

6
11

10
8
x1411305

13
Truck indicator Description
Hour meter with battery discharge indica-
tor/lift cut-out contact
The battery discharge indicator (9) with lift cut-out contact NOTE - When the red LED's (1) and (2) flash alternately, the
and the hour meter (5) are in a installed in the same housing. When the battery connector is disconnected, the hours are battery is 80% discharged; when this threshold is reached,
The composite instrument face is made from very durable retained in memory. If the hour meter has to be replaced, the lift cut-out contact disables the lift function.
makrolon. make a note of the service hours recorded by the defective - In this event, it will be necessary to recharge or replace the
meter, in the place provided for this purpose adjacent to battery in order to be able to continue using the truck.
Hour meter the hour meter, and in the service booklet.
NOTE
- The hour meter indicates the truck’s hours of operation. Battery discharge indicator with lift cut-out A potentiometer at the rear of the housing allows the cut-
- The meter is activated whenever the power is turned on contact off threshold to be adjusted for any special operating
and the tiller is placed in the drive position. conditions. The normal position is with the arrow pointing
- During metering, the “hour glass” icon (8) flashes slowly. - The LED indicator (9) lights as soon as the battery is towards the letter N. If any special setting is needed for a
connected and shows the charge state of the battery. particular use, please ask your local representative for
- The LCD indicator (5) displays the hours (6) and 1/10ths advice.
of an hour (7). While the truck battery is connected, it - When the battery is fully charged, the green LED (4) lights.
displays the hours stored in memory. - During discharge, the green and orange LED's (3) light NOTE
successively (from right to left, one diode at a time). Maintenance-free batteries require a special setting.

141 804 6011.0902

- When the red LED's (2) lights and flashes, the battery is
approximately 70% discharged.

9 1 2 3 4

0 1/2 1
5 0 1/2 1

8 1
10
1
10

6 7 x1411349 x1411350

14
 Gas warning indicator Description
The composite instrument (1) contains the following controls NOTE Battery discharge indicator
and indicators: When replacing a defective hour meter, the number of effec-
tive service hours has to be noted. Affix this information near Indicates the charging state of the battery when the key switch
NOTE the new hour meter on durable tape. is turned on and the emergency isolator button is unlocked.
The battery discharge indicator (6) of the battery buffer It is also possible to set the replacement hour meter so that It reduces the the current of the control circuit for the hydraulic
and the hour meter (5) are explosion-protected, ie mount- the actual aggregate service hours are displayed. Please lift function when the battery discharge reaches 80 %.
ed in a flameproof enclosure. contact authorised skilled personnel (eg your Linde dealer). The battery is fully charged when the right green LED (9) is
illuminated. As the battery discharges, the illuminated bar (9)
Hour meter moves from right to left.
The hour meter (5) indicates the operating time of the truck in If only the orange LED (8) is illuminated, the battery discharge
hours. It operates only when the key switch is turned on, the is up to 70 % and the battery must be recharged.
emergency isolator button pulled out and the tiller in driving If the orange LED (8) also extinguishes, the two red LEDs (7)
position. begin to flash. The battery discharge is up to approx. 80 % and
The hour meter serves as proof of the operating time of the recharging or changing of the battery is required.
truck and for scheduling inspections and maintenance serv-
ices. NOTE
The cut-out can be adjusted for special applications.
The symbol (4) shows that the hour meter is on. The manufacturer recommends contacting your author-
141 804 6011.0902

The left row of figures (3) displays the full hours of operation, ised Linde dealer.
the right figure (2) indicates tenths of an hour.

1 8
1 7
9
6
1/2 1
1/2 1
6
- +
5 - +
1
10
1
10

4 2

3
x3621307 x1411352 x3621308

15
Technical description Description
Gas warning system
The gas warning system is provided with a gas sensor (1). If a gas concentration of over 10 % of the lower explosion limit The sensor head must be inspected and, if necessary, recal-
The sensor is installed near the ground next to the hydraulic of gas mixtures is detected, a buzzer sounds which can be ibrated every two months. This service must be recorded in
unit. turned off with an acknowledgement button (2) on the instru- the inspection log book stowed in enclosure (3).
ment panel. The sensor head should be renewed about every three years.
Please contact your authorised dealer for this service.
When the top limit (25 %) of the lower explosion limit of gas
mixtures is reached, the buzzer sounds a second time, the
truck release signal is interrupted and the truck makes a
controlled shutdown. Only the steering and regenerative
braking remains activated with this procedure.

NOTE
The steering is operational for 20 seconds after the gas
warning buzzer sounds.

The truck can be returned to operation only after a safe

operating condition is determined. The gas surveillance
device is continuously active.

141 804 6011.0902

1 3

x1411351 2 x1411308

16
 Safety rules Beginning operation
The responsible persons, particularly The explosion protection measures DANGER
the truck operator and servicing personnel, and their implementation on the truck dur- All inspection and maintenance work
must be instructed in the rules for the nor- ing operation are required by law. They re- must be done outside of explosion risk are-
mal and proper use of industrial trucks, the quire particular attention during all work as, and only by authorised skilled person-
applicable national, EC or EEA explosion with, in and on the truck. nel (experts) thoroughly familiar with the
safety regulations, as well with those includ- appropriate technical material and rules and
ed in these operating instructions. The operator (employer) must ensure regulations.
that the employees are instructed in the The manufacturer recommends you to
The employer must ensure that the driver has understood all explosion risk areas (explosion hazard
of the safety information.
charge the authorised Linde dealer.
zones 1 and 2), possible explosion hazards
Please observe the guidelines and safety rules therein for
example:
and the selected protective measures, and Experts
that the operating instructions required for Experts are specially skilled persons who have thorough
- information on the operation of industrial trucks
- rules for roadways and work areas safety are observed. The instruction must knowledge and experience in servicing and testing industrial
- rights, duties and safety rules for the operator be repeated at appropriate intervals. trucks and being furthermore sufficiently familiar with the
- operation in special areas national industrial safety and accident prevention regula-
141 804 6011.0902

- information related to starting, driving and braking tions and all further general technical rules and guidelines
The acceptance tests and certificates (DIN and ISO standards, technical rules arising from EC
- service and repair information
- recurrent inspections, accident prevention check for the truck, the pertinent laws, regulations directives or EEA agreements), so that they can give a
- disposal of greases, oil and batteries and guidelines, and any possible additional qualified judgement upon the safe operating conditions of the
- remaining risks. truck.
requirements by the responsible authori-
The operator (employer) or the responsible person must ties indicate under which conditions and
ensure that the above the guidelines and safety rules appli-
Before commencing inspection and
cable for your truck are observed. where the truck may be operated, serviced maintenance, ensure that no explosion risk
and repaired. exists.

17
Safety rules Beginning operation
As long as no further risk of explosion Work can only commence after the op- When instructing a trained operator (driver), acquaint him
with the
can occur (no explosive gases can enter the erator (owner) or his representative have
- special features of the truck,
working area), it is not necessary to recheck ensured that protective measures are ade-
- special features of the explosion-proof truck ,
for explosion risk during the inspection and quate and effectively implemented. The ef- - special conditions in the work place
maintenance. fectiveness of the protective measures are by training and practicing driving, shifting and steering oper-
to be checked during the progress of the ations until they are completely mastered.
The operator (owner) or his repre- work. The operator (owner) or his repre- After the above has been mastered, commence practice with
sentative must provide the technicians with sentative can only lift the protective mea- stacking operations.
a work assignment (normally written) which sures after all work has been completed and The safety in the work area is ensured if the truck is employed
states work location, commencement, dura- no further explosion risk exists. properly and the operator trained correctly.
tion and the protective measures to be tak-
en against explosion. Before placing the truck back into nor-
mal operation, ensure that the truck’s explo-
In emergency situations where explo- sive protection for the appropriate work
sion risk exists from sparking, or the explo- zones is in order again.

141 804 6011.0902

sive risk can increase during the repair
work, special explosion protective meas-
ures must be taken.

18
 Safety rules Beginning operation
Safety information Explosion protection check
The precautions DANGER, CAUTION, ATTENTION and The operator must maintain the truck in a CAUTION
NOTE in this operating manual are provided to indicate Do not allow hydraulic oil under pressure, for
special dangers or unusual information requiring special
safe operating condition. example at a leak, to penetrate the skin. Medical
identification: aid is required if such an injury occurs.
Operation of industrial trucks in the plant
DANGER area
indicates hazards that may result in personal injury Running-in instructions
or death and/or substantial damage to the product. ATTENTION
Many plant areas are so-called limited public The truck can be operated at full speed directly. Avoid sus-
traffic areas. tained high loads on the motors in the first 50 hours of
CAUTION
We advise you to check if your company liability insurance operation.
indicates hazards that may result in personal
injury and/or substantial damage to the product. covers any damages occurring with your fork truck against
third parties on "limited" public traffic areas. Retighten wheel nuts daily prior to starting operation and after
having changed the wheels until they are seated firmly, i.e.
ATTENTION
until no further tightening is possible.
indicates hazards that may result in damage to or Handling fluids and lubricants
destruction of the product.
Always handle fluids and lubricants as required and Wheel nuts should be tightened crosswise to the torque
as specified by the manufacturer. specified in the operating manual.
141 804 6011.0902

All explosion protection measures are

Only store fluids and lubricants in approved containers at
marked with the symbol at the left of this para- Maintenance work prior to initial start-up*
specified storage places. As they could be inflammable, do
graph. Be certain to follow these measures. not contact them with hot objects or a naked flame. - Check wheel fasteners
Only use clean containers when replenishing fluids and - Check hydraulic oil level
NOTE - Check gearbox oil level
lubricants.
identifies technical information requiring special atten- - Check brake system
tion because the meaning may not even be obvious to Follow the manufacturer’s safety and disposal instructions
- Check belly button
skilled personnel. when using fluids and lubricants and cleaning compounds.
- Battery: check charge, acid level and specific gravity
Avoid spilling fluids and lubricants. Remove any spillage - Check horn
Safety check immediately with a suitable binding agent and dispose of as - Check truck for leaks
specified.
The safety regulations require that the forklift
Also dispose of used or contaminated fluids and lubricants as Daily inspections*
truck must be checked at least once a year for specified.
proper working condition by trained person- - Condition and easy motion of the wheels
Follow laws and regulations. - Brake system
nel. Please contact authorised skilled person- - Battery charge: condition, acid specific gravity and level
Clean the area surrounding the part in question before
nel (experts) in this regard. lubrication, filter renewal or repairs in the hydraulic system. - Check horn
The manufacturer recommends you to Discard parts in a way friendly to the environment. - Forks
charge the authorised Linde dealer.
Additionally, every two weeks a visual check
of the explosion protection equipment is
required.
* Please consult the alphabetical index for a description of
activities.

19
Daily checks and servicing before operation Beginning operation
Removing the front cover Disconnecting the battery plug Connecting the battery plug
The cover must be removed to gain access to the drive units DANGER - Connect battery plugs.
for inspections and servicing. Never disconnect the battery plug in an explo-
sive risk area. There is a risk of sparking when - Reconnect the battery plug (1) and secure with the wing
- Turn the switch off with the switch key (1). the plug is pulled out. nut (3) and retaining bracket (2).

- Depress the emergency isolator button (2). CAUTION

Do not disconnect the battery plug when the key
- Remove the fastening screws and take off the cover. switch is turned on.

- Turn the switch off with the switch key (4).

Installing the front cover - Push in the emergency isolator button (5).
- Put the cover in place from the front. - Remove the wing nut (3).
- Remove the battery plug retaining bracket (2).
- Install and tighten the screws.
- Disconnect the battery plug (1).

141 804 6011.0902

1 2
1
3
2

x1411310 x1411309

20
 Daily checks and servicing before operation Beginning operation
Checking the battery charge Connecting the battery to a suitable
- Insert the battery plugs. CAUTION external charger
For safety’s sake, observe the following instruc- - Lower the forks.
- Unlock the emergency isolator button (3) by turning it in tions. - Disconnect the battery plug.
the arrowed direction. The electrolyte in the batteries is a sulphuric acid - Lead the battery plug through the battery opening.
and water solution, which is poisonous and caus- - Pull the gas warning system back with the grip (2).
- Turn the switch off with the switch key (1). tic. Therefore, wear protective clothing (protec- - Remove the battery lid (1).
tive apron and gloves) and protective glasses when work- - Pull the plug through the battery opening and connect to
- Check the battery charge at discharge indicator (4) in the ing around the batteries. If the battery electrolyte should an external charger.
composite instrument (2). nevertheless contact clothing, the skin or eyes, immedi- - Put the external charger into operation.
ately flush the affected parts with water. Seek medical aid
at once if the eyes are affected! Neutralize spilled battery ATTENTION
electrolyte without delay. The lid (1) must remain open during charging.
Gases are released when batteries are being charged. Do
not expose the battery to sparks or open flames, as an
explosion could result. Rooms in which batteries are CAUTION
Do not smoke. Avoid causing sparks near the
Charging the battery charged or stored must be ventilated accordingly.
battery during charging. Risk of explosion.
DANGER
141 804 6011.0902

NOTE
The battery must be charged outside hazardous Check that the specific gravity of the electrolyte is at least - After charging is completed, close the battery housing
areas. 1.14. The explosion-protected battery must also be safety lid.
inspected. Always charge and service the battery accord-
ing to the manufacturer’s instructions. If you are not in
possession of these instructions, please contact your
distributor. Also follow the operating instructions for the
optional battery charger. If a battery charger is already
available, follow the instructions supplied with it. 2
CAUTION
Do not place any metal parts on the battery - risk
1 of a short!
Do not top up electrolyte before charging. 1
Charge the battery immediately, do not leave the battery
discharged. This applies also to partially discharged bat-
2 teries.

2 3
1/2 1 4
- +
1
10

x362308
x1411311 x1411312

21
Daily checks and servicing before operation Beginning operation
Check the condition, electrolyte level and Battery change Battery removal with a crane
specific gravity of the battery DANGER ATTENTION
- Check the battery for casing cracks, lifted plates and When changing a battery, use only an explosion- Only use a lifting gear meeting explosion protec-
electrolyte leakage. proof battery with enclosure as a replacement. tion regulations, and a crane with a sufficient load
- Unscrew the caps and check the electrolytic level. On capacity (see technical data for battery weight).
batteries with check tubes the acid must be at this level. ATTENTION - Lower the forks completely.
On batteries without check tubes the acid must be approx. The battery labelled as explosion-protected is - Turn the key switch off and push in the emergency isolator
10 – 15 mm above the plates. mounted in a safety-enhanced battery enclosure button.
- If the electrolyte level is low, top up with distilled water only in the battery compartment. - Disconnect the battery plug (1) and buffer circuit plug (2)
(after charging the battery). and lead them through the battery opening.
- Remove corrosion on battery poles and coat with non- ATTENTION - Pull the gas warning system back with the grip (3).
acidic grease. The replacement battery must correspond to the - Remove the battery lid.
- Retighten pole clamps firmly. standard battery both in size and weight. Devia- - Pull the plugs through the battery (4) opening and connect
tions in weight must be compensated by additional weights. to an external charger.
- Check the specific gravity using a hydrometer. The spe-
The battery must be secured against sliding. Please con- - Attach a chain or rope with a hook in the eyelets.
cific gravity of the electrolyte must be between 1.24 and
1.28 kg/l. sult authorised skilled personnel (experts). The manufac- ATTENTION
turer recommends contacting your authorised Linde deal- After attaching the chain or rope in the crane
NOTE er. hook (5) the safety (6) must lock.

141 804 6011.0902

Discharges which are under 20% of the rated capacity When changing the battery, at least 8-10 minutes must elapse DANGER
(specific gravity 1.14 kg/l) are deep discharges. Deep between the disconnection and connection of the batteries. When lifting the battery, ensure that no persons
discharges shorten the service life of the battery. Otherwise the battery discharge indicator will display a false are under or beside the battery.
reading and shut off the working hydraulic system. - Lift the battery up and out of the truck.

ATTENTION
The gas warning system is buffered for up to 6 5 1 2
about 120 minutes by rechargeable batteries.
This ensures that the sensing system remains in opera-
tion even during a change of the truck drive battery so that
a recalibration is not required. There is also a second
connection to the drive battery, so that the warning system
is also powered when the battery is being charged.
If the plug for the permanent power supply of the buffer
circuit is not reconnected, the built-in discharge indicator 3
cuts off the gas warning system when a buffer voltage of
23 V is reached. The gas warning system can only be taken 4
back into operation if the buffer circuit is consciously
acknowledged with an additional key switch.
This key switch must be in the repository of a safety
official, as EN 1755 mandates a recalibration of the sensor
heads before operation.

x1411313

22
 Daily checks and servicing before operation Beginning operation
Turning on the key switch Push in emergency isolator button
- Insert the key (1) into the switch. - Put the truck into motion.

- Turn the key clockwise as far as position I. - Push in the emergency isolator button (2).

Turning off the key switch The truck stops and electrical functions are shut off. To put the
truck back into operation, turn the emergency isolator button
- Turn the key (1) anti-clockwise as far as position 0. in the direction of the arrow until it releases.

Unlock emergency isolator button

- Turn the emergency isolator button (2) in the arrowed
direction until it is unlocked.

- The truck is operational again.

Check the horn

- Squeeze the rubber ball (3) to sound the horn.
141 804 6011.0902

x1411314

23
Daily checks and servicing before operation Beginning operation
Check the belly button Check the braking system
The tiller head has been equipped with a belly button (1) to - Put the truck in motion and check the braking action by
protect the operator from being squeezed. putting the tiller into the upper (1) and lower (2) range.

- Put the tiller into driving position and drive the truck NOTE
forwards. In these ranges the truck is braked electrically and the
traction drive is cut out.
- When the belly button (1) is pressed in, the truck switches
into full reverse for a few yards. - When releasing the tiller in driving range (3), it will return
automatically to the braking range (1) and cut out the
DANGER traction drive.
In the event that defects or wear are noticed on
the belly button, please contact authorised skilled DANGER
personnel (experts). If deficiencies or excessive wear are discovered
The manufacturer recommends contacting your author- in the braking system, contact authorised skilled
ised Linde dealer. personnel (experts).
The manufacturer recommends contacting your author-
ised Linde dealer.

141 804 6011.0902

1

x1411315 x1411316

24
 Daily checks and servicing before operation Beginning operation
Check the truck for leaks Check the load forks Check the condition for leakage resist-
- Upon leaving the parking area, check the ground visually Fork protective surfaces which come in contact with the ance of the tyres
for fluids from leaks. ground or the load are coated with an approx. 3 mm thick layer In order to ensure the leakage resistance of the tyres as stated
of brass, copper, stainless steel or a comparable material, or on the label, the tyres and floor must be free of debris and
- In the event of leakage, find out what kind of fluid is the fork is produced from stainless steel. foreign objects.
involved (hydraulic oil, gearbox oil or battery fluid).
- Check that the fork protective surfaces are still present The truck may have to be cleaned several times a day,
- Check fluid levels. and not damaged. depending upon the application conditions.
If in doubt, check the values. Please contact authorised
- Eliminate the leakage, or inform maintenance crew to If the fork protective surfaces are coated with a non-metallic skilled personnel (experts).
eliminate it. material (rubber or plastic) that is more than 2 mm thick, the The manufacturer recommends your authorised Linde deal-
surface electrical resistance must be less than 109 Ohm (to er for this service.
discharge static electricity).

NOTE
To renew the fork protective surfaces, please contact
authorised skilled personnel (experts).
The manufacturer recommends contacting your author-
141 804 6011.0902

ised Linde dealer.

x1411317 x1411318

25
Driving Operation
Driving Moving the tiller into driving position
CAUTION - Connect the battery plugs (1). - Lower the tiller (7) slightly.
Travel on long slopes over 12 % is generally not The hour meter (6) will start counting.
allowed due to the prescribed minimum brake - Turn the emergency isolator button (4) in the arrowed
applications and truck stability characteristics. Before direction until the button is unlocked. NOTE
driving on steeper slopes, you should consult authorised The vehicle can only be run in tiller position (9). In the lower
skilled personnel (e.g. your Linde dealer). The climbing - Turn on the key switch (2). range (10), and in the upper range (8), the brake is switched
ability rates given in the data sheet were derived from the ON, and the traction motor is switched OFF.
tractive force of the truck and they apply only for the - The battery discharge indicator (5) in the composite
crossing of obstacles and for short differences in level. instrument (3) illuminates.
Always adapt your driving style to suit the conditions of the
roadway (rough surfaces, etc.), especially hazardous work - Releasing the emergency isolator button (4).
areas and the load. The emergency isolator button (4) must be released for
operation of the truck in driving operation.

ATTENTION
In emergency cases, press in the emergency
isolator button (4), after which the power supply

141 804 6011.0902

will be interrupted and the vehicle will immediately come
to a stop.

7
8
5
7 1 9
1/2 1

2 10
3 1
10

6
x1411321 11120 x1411319

26
 Travel, change of direction Operation
Moving forward Moving backward Change of direction
Control the traction (throttle) switch gently at all times since - Slowly and gently press your thumb against the upper part - Release the traction switch and actuate it in the opposite
the truck immediately responds to any actuation, and jolty of the traction switch (3) (turn the traction switch in direc- direction.
starts, braking procedures, or changes of direction should be tion (4)).
avoided. NOTE
The travel speed of the vehicle will increase along with the The direction of travel can be changed while travelling. In
- Press your thumb lightly against the lower part of the travel of the traction switch. such cases, the vehicle is first braked electrically to a
traction switch (1) turn the traction switch in direction (2). stop, after which it is accelerated in the opposite direction.

The travel speed of the vehicle will increase with the travel of
the traction switch.
141 804 6011.0902

4 3
1
x1411322 x1411323

27
Steering, belly button, horn Operation
Steering Belly button Operating the horn
The truck is steered via the tiller with the drive wheel. The tiller (1) is equipped with a belly button to protect the The horn serves as a warning signal - e.g. in dangerous
operator from being squeezed. situations, at blind spots and junctions.
The turning radius (Wa) of the truck depends upon the fork
length (please refer to technical data). - Actuation of the belly button will brake the vehicle and - Squeeze the rubber ball (1) to sound the horn.
switch it into full reverse travel.
- Start the truck and move the tiller to the left and right as far
as the stop.

DANGER
Contact authorised skilled personnel (experts) if
the steering is hard or has too much play. Your
truck may not be operated with a faulty steering system.
The manufacturer recommends contacting your author-
ised Linde dealer.

Tiller angle of lock 190°.

141 804 6011.0902

1

x1411324 x1411315 x1411325

28
 Braking, fuses, lifting device Operation
Tiller brake (parking brake) Plug brake (service brake) Lifting forks
- In the lower (2) and upper (1) braking range, the drive is Electric braking through change of travel direction: - Depress pushbutton (2).
switched OFF and the truck braked.
- During travel, switch the traction switch (3) over into the Lowering forks
- Release the tiller. A gas spring causes it to pivot automat- opposite direction of travel.
ically into the braking range (1), it switches the drive OFF - Depress pushbutton (1).
via a microswitch, and activates the parking brake mech- The truck is slowed down until it comes to a stop.
anism. NOTE
- Release the traction switch. Note the arrow symbol on the lever.

Fuses
The fuses are fitted in an explosion-protected box.
To replace the fuses, contact authorised skilled personnel
(experts). The manufacturer recommends contacting your
authorised Linde dealer.
141 804 6011.0902

x1411326 x1411327 2 x1411328

29
Before loading, loading Operation
Before loading Loading
DANGER DANGER - Approach the load to be picked up carefully and as
The weights given in the vehicle identification The transportation of dangerous loads must be accurately as possible.
plate (1) are only applicable to compact and ho- done with caution. Prevent abnormal bumping,
mogeneous loads. Never exceed the load capacity of the hitting, rubbing, grating or throwing. - Elevate or lower the forks to the required height.
truck. Overloading will reduce truck stability and the
strength of the forks. ATTENTION - Carefully move the truck into the centre of the load until,
Before lifting a load, ensure that it is not too heavy if possible, it contacts the battery box. Take care not to
for the truck. contact adjacent loads.

- Raise the forks until the load rests freely on the forks.

ATTENTION
Check that no loads have been pushed beside or
behind the truck.

141 804 6011.0902

1

x1411329 x1411330

30
 Transporting the load, depositing the load Operation
Transporting the load Depositing the load Before leaving the pallet truck
NOTE - Stop the truck carefully at the intended storage area. ATTENTION
Pick up the load so that it is within the truck loading area Never leave the vehicle with the load elevated
and so that it does not slide, tip over, or fall off. - Slowly lower the load until the load fork is free. when parking it for any reason.

- Carry the load near the ground. - Move the truck out of the load in a straight line. - Deposit the load, or lower the load fork completely.

- Always travel with the load uphill on upgrades and down ATTENTION - Turn off the key switch with the key (1) and remove the key.
grades, and never travel or turn across a slope. Make sure that loads are not pushed to the side
of and behind the stacker. - If the vehicle is not to be used for a longer period of time,
- Always travel with the load centred - no sideshift. the emergency isolator button (2) should be pressed, and
the battery plug should be dismounted.
- If visibility is impaired, work with a guide, drive slowly and
carefully.

- It is recommended that the load is transported in forward

motion.
141 804 6011.0902

x1411331 x1411332

31
Towing, hoisting Operation
Towing the truck Towing procedure Hoisting the truck with a crane
DANGER DANGER DANGER
In an explosion risk area, the truck can only be In an explosion risk zone, do not disconnect the
towed as follows: battery plug. A risk of sparking exists.
When hoisting the truck with a crane
ensure that no persons are located within
- By using a similarily explosive protected fork lift and a - Disconnect the battery plug. the working area of the crane! Do not walk
spark resistant towing device.
- Lower the load, but only so far that the forks will not contact
under a swinging load!
- As a protective measure to eliminate the risk of explo- the ground when towing.
sion when the gearbox or brake is damaged, it is DANGER
possible to raise and move the truck completely either - Remove the load. Only use a lifting sling and crane with a sufficient
with a regular truck having the appropriate lifting ca- load capacity. (For the truck weight see the data
pacity. The same also applies for electrical problems NOTE sheet).
with the electric brake. The parking brake of the truck is operational in ranges (1)
and (2). - Attach a chain or rope with a hook in the eyelets (1).

DANGER
The safety lock (3) must close after inserting the
slings into the crane hook (2).

141 804 6011.0902

3
2
1

1
2

x1411326 x1411333 x1411334

32
 Taking the truck out of operation Operation
Taking the truck out of operation Putting the truck back into operation
If the truck is taken out of operation for over 2 months, it must ATTENTION - Thoroughly clean the truck.
be parked in a well ventilated, frost-free, clean and dry room Block up the truck so that all wheels are clear of - Lubricate the truck.
and the following measures must be carried out. the ground. This will prevent tyre deformation.
- Clean the battery.
Measures before taking the truck out of op- NOTE - Check the condition and electrolyte level of the battery
Do not cover the truck with plastic foil as this enhances the and charge the battery if necessary.
eration formation and collection of condensation water.
- Check the hydraulic oil for condensation water and change
- Thoroughly clean the truck. the oil, if necessary.
NOTE
- Fully elevate the forks several times. If the truck is to be taken out of operation for over - Perform the same services as for commissioning.
- Lower the forks on a support until the chains are slack. 6 months, contact authorised skilled personnel (experts) - Take the truck into operation.
- Check the hydraulic oil level and add oil, if needed. for further measures.
The manufacturer recommends contacting your author-
- Apply a thin film of oil or grease on all unpainted mechan- ised Linde dealer.
ical parts.
- Lubricate the truck.
- Check the condition and electrolyte level of the battery.
141 804 6011.0902

Coat the battery terminals with non-acidic grease. (Follow

the instructions of the battery manufacturer.)

33
141 804 6011.0902
34
 Maintenance
General information Inspection and maintenance after first 50
ATTENTION hours of operation
CAUTION
Explosion protected fork lifts must For all servicing, the truck must be NOTE
For a description of activities, please consult the alphabet-
be maintained on a regular basis. The oper- placed on a level surface and the wheels ical index.
ator (owner) must determine the time peri- secured, the key removed from the key
ods for maintence in accordance with oper- switch and the battery plug disconnected. - Check the brake system.
ating conditions and maintence manuals of - Check the wheel fasteners.
For work on the front end of the truck, secure the mast against
the manufacturer. tilting.
- Check the condition and free spin of the wheels.
Your truck will remain operational only if the maintenance Perform a functional check and trial run after every servicing.
and checks are carried out regularly and according to the No changes, particularly no modifications and additions, - Change the gear oil.
information and instructions in the operating manual. may be made to the truck without the approval of the manu-
facturer. - Check the hydraulic oil level.
The maintenance may only be performed by qualified author-
ised skilled personnel (experts). NOTE
The manufacturer recommends you to charge the authorised - Check the hydraulic system for leaks.
When operating the truck under extreme conditions (i.e.
Linde dealer.
141 804 6011.0902

extreme heat or cold, intensive dust concentration, etc.), - Battery: check charge, condition, acid level and specific
the intervals given in the maintenance schedule should be gravity.
DANGER reduced accordingly.
All inspection and maintenance work - Check cables and electric connections for condition and
Before greasing or servicing the hydraulic system, carefully
must be done outside of an explosion risk clean the area surrounding the related part.
tight fit.
area and only by qualified authorised skilled Only use clean containers when topping up fluids and lubri- - Check frame parts, body and load fork for security.
personnel (experts) who are familiar with all cants.
Follow the manufacturer’s safety and disposal instructions
regulations. when using fluids and lubricants and cleaning compounds.
- Lubricate the steering bogie of the drive unit.
The manufacturer recommends you to Discard replaced parts in a way friendly to the environment.
- Check and lubricate other bearings and joints.
charge the authorised Linde dealer.
ATTENTION
This work can be carried out by authorised skilled personnel Missing or damaged model plates, type plates or
(experts) within a maintenance agreement. The manufactur- notice stickers must be replaced. For location
er recommends you to charge the authorised Linde dealer. and order number see the parts catalogue.
If you wish to do the work yourself, we recommend that the first
three customer service checks be carried out by your distrib- ATTENTION
utor’s mechanic in the presence of the responsible mechanic Follow the precautions for handling fluids and
in your workshop, so that your staff can receive the appropri- lubricants.
ate instruction.

35
Inspection and maintenance chart Maintenance
Services Before initial After first Daily As
(A description of the service can also be located in the index.) operation 50 hours checks required

See page 19 for the services ..................................................................................................................................... l

See page 35 for the services ...................................................................................................................................................................... l

Check the battery discharge level .......................................................................................................................................................................................... l

Check battery condition, acid level and density .................................................................................................................................................................... l

Check condition and easy motion of wheels ................................................................................................................................................................................ l

Check the braking system ............................................................................................................................................................................................................. l

141 804 6011.0902

Check the horn ........................................................................................................................................................................................................................ l

Check the fork protective surfaces ......................................................................................................................................................................................... l

Clean the lift truck ............................................................................................................................................................................................................................................................ l

Tighten the wheel fasteners (every 100 hours minimum) .............................................................................................................................................................................................. l

Check the condition of the wheels (every 100 hours minimum) .................................................................................................................................................................................... l

Inspect the gas warning system sensors (every 2 months minimum) ..................................................................................................................................................................... l

Inspect the gas warning system (by an experts) (once a year minimum) ............................................................................................................................................................... l

Clean the gas warning system sensors .................................................................................................................................................................................................................... l

36
 Inspection and maintenance chart Maintenance
Services Every 500 hours Every 1000 hours Every 2000 hours
(A description of the service can also be located in the index.) or semi-annually or annually or every 2 years

Check the brake system .............................................................................................................................................................................. l

Check and lubricate other joints .................................................................................................................................................................. l

Lubricate the steering bogie on traction unit .............................................................................................................................................. l

Check the gearbox oil level ......................................................................................................................................................................... l

Check the hydraulic oil level ....................................................................................................................................................................... l

Check the hydraulic system for leaks .......................................................................................................................................................... l

Check the electric cables, cable connectors and connections for condition and tightness ............................................................... l

Check the mounting of frame parts, body ............................................................................................................................................ l

141 804 6011.0902

Check the load forks ............................................................................................................................................................................. l

Clean the controller with compressed air ............................................................................................................................................ l

Clean the contactor tips and check for wear ........................................................................................................................................ l

Clean the electric motors ...................................................................................................................................................................... l

Check the motor brushes, renew if necessary ..................................................................................................................................... l

Check the brake system .............................................................................................................................................................................. l

Clean the hydraulic system oil filter ................................................................................................................................................................................................ l

Renew the hydraulic oil ..................................................................................................................................................................................................................................................... l

Renew the gearbox oil ....................................................................................................................................................................................................................................................... l

37
Inspection and maintenance as required Maintenance
Clean the truck Check the tyres for damage and foreign
DANGER DANGER objects
If moisture penetrates into the motor, the explo-
All inspection and maintenance work sion protection must be opened in order to dry the
- Jack up the truck until the wheels are clear of the ground.
- Secure the truck with wooden blocks.
must be done outside of explosion risk are- motor. Contact authorised skilled personnel (experts). - Check the wheels for ease of movement and remove
as. The manufacturer recommends you to charge the author- anything hindering their movement.
ised Linde dealer. - Renew worn or damaged tyres.
NOTE - Lower the truck to the ground.
The necessity of cleaning depends on the use of the truck. When cleaning with compressed air, first remove sticking dirt
If used with aggressive media such as salt water, fertiliser, with a cold cleaner. Clean the oil filler openings along with the
DANGER
surrounding area and the grease nipples prior to lubrication.
chemicals, cement, etc., clean the truck thoroughly after Only use traction wheels with integral brass brush.
every application. Only use wheels approved for this truck.
NOTE
Hot steam or intensive degreasing solutions should be
The more often the truck is cleaned, the more often it must
used with utmost care! The grease in the lubricated-for- NOTE
be oiled and greased.
life bearings will dissolve and leak out. As regreasing is not In order to ensure the grip of the traction wheel, any
possible, the bearings will be damaged. possible wear spots on the traction wheel must be com-
pensated.
- Push in the emergency isolator button. Please contact your authorised skilled personnel (ex-

141 804 6011.0902

- Disconnect the battery plugs. perts). The manufacturer recommends contacting your
authorised Linde dealer.
DANGER
For safety reasons the front axle and the area of
the front axle of the truck should never be cleaned
with a high pressure cleaning device. Water could pene-
trate the explosion-protected enclosures, leading to the
destruction of the controller or other parts (motor). As a
result, the explosion protection is no longer ensured.
This may substantially reduce the braking effect during
the first braking attempts after cleaning.

ATTENTION
When washing with a cleaning device, do not
directly expose the explosion-protected enclo-
sure electrical system, electric motors and insulating
material to the jet, cover them first.
Clean the oil filler openings along with the surrounding
area and the grease nipples prior to lubrication.
When cleaning with compressed air, first remove sticking
dirt with a cold cleaner.

- After cleaning, let the truck dry.

x1411333 x1411335

38
 Inspection and maintenance as required Maintenance
Tighten the wheel fasteners
ATTENTION - Check the stabiliser wheel pivot screws (3) (4 items) for a
Every 100 hours minimum. torque of 110 Nm. They can be accessed from inside the
traction compartment.

ATTENTION - Refit the front cover.

Only use a jack with sufficient lifting capacity.
- Lower the truck.
- Raise the front end of the truck with a jack and secure the
truck on both sides with a wooden block.

- Remove the front cover (4).

- Check the traction wheel fasteners (1) for a torque of

140 Nm.

- Check the load wheel screws (2) for a torque of 80 Nm.

141 804 6011.0902

x1411336 2 x3621301

39
Inspection and maintenance as required Maintenance
Inspect the gas warning system sen- Clean the gas warning system sensor
sor (1) (every 2 months minimum) - Clean the sensor with a dry, clean cloth.
NOTE
Have this service only carried out by authorised personnel In case of stubborn dirt please contact your authorise dealer.
(experts).
The manufacturer recommends having this service per-
formed by your authorised dealer.

Inspect the gas warning system (2)

(once a year minimum)
NOTE
Have this service only carried out by authorised personnel
(experts).
The manufacturer recommends having this service per-
formed by your authorised dealer.

141 804 6011.0902

2

1 x1411353

40
 500-hour inspection and maintenance Maintenance
Check the brake system Check and lubricate other joints
Check the tiller brake Check the plug brake - Clean all joints and hinges, check them for smooth run-
ning and fastening, and spray them.
DANGER - Put the truck into motion.
The truck must not be operated with a faulty brake - Jack up the truck at the front and secure it with wooden
system. - Actuate the drive switch (3) in the opposite direction. The blocks.
truck will slow down until it stops.
- Put the truck into motion and check the braking effect by NOTE
moving the tiller in the upper (1) and lower (2) range. The - Release the drive switch. Use lubricating grease for greasing.
truck is braked electrically in these two ranges.
ATTENTION - Clean the grease nipples (1) on the left and right load
NOTE If the plug braking system shows signs of defects wheels and lubricate until fresh grease emerges at the
As soon as the tiller is released, it automatically turns into or wear, contact authorised skilled personnel bearings.
the braking range (1), and switches the drive OFF. (experts).
The manufacturer recommends contacting your author- - Lower the truck.
ATTENTION ised Linde dealer.
The braking system readjusts automatically. If
defects or wear are detected in the braking sys-
tem, please contact authorised skilled personnel (ex-
141 804 6011.0902

perts).
The manufacturer recommends contacting your author-
ised Linde dealer.

x1411326
3 x1411337 x3621304

41
500-hour inspection and maintenance Maintenance
Lubricate the steering bogie on traction unit Check the gearbox oil level
- Remove the front cover. - Turn the tiller until the gearbox oil level check plug (3) can
be accessed through the holes in the frame.
- Turn the gearbox (2) with the tiller until the grease
nipples (1) (2 items) on the bogie are accessible through - Screw the oil level check plug out with an Allen key, and
the holes in the frame. clean the plug.

NOTE The gearbox oil level must reach the lower edge of the bore.
Use lubricating grease for greasing.
- Replenish gearbox oil, if required.
- Clean both grease nipples (1) and lubricate until fresh
grease emerges at the bearings. - Screw the oil level check plug back in.

141 804 6011.0902

1 2

x1411338 x1411339

42
 500-hour inspection and maintenance Maintenance
Check the hydraulic oil level Check the hydraulic system for tightness Check the electric cables, cable con-
ATTENTION - Check all connections, valves and hydraulic hoses for nectors and connections for condition and
Follow the instructions for handling fluids and tightness. Retighten connections, if required. tightness
lubricants.
- Check lifting cylinders for tightness. NOTE
- Lower the load forks completely. Before beginning with any maintenance work, engage the
- Replace porous hoses. handbrake and push in the emergency isolator button.
- The hydraulic oil level (2) must be located within 45 mm - Check that all outer, visible cable connections are tight.
from the upper edge of the hydraulic tank. - Check hoses for chafing, and replace them, if necessary. - Check that battery plug is tightly connected.
- Check all electrical cables for chafing, damaged insula-
- If required, replenish hydraulic oil through the filler neck. tion and loose clamps.
To do so, unscrew the tank cap (1). - Have damaged cables replaced.
ATTENTION
All electric cables must be secured with clamps
at least every 250 mm.
- Tighten or replace cable ties or clamps
NOTE
141 804 6011.0902

This work is only to be carried out by authorised skilled

personnel (experts).
The manufacturer recommends contacting your author-
ised Linde dealer.

2
x1411340 x1411341 x1411342

43
500-hour inspection and maintenance Maintenance
Check the mounting of frame parts and Check the load forks Clean the controller with compressed
body - Check the load forks for damage. In those places where air
- Check motors and gear mounting, tiller steering and the load forks may come into contact with the ground DANGER
support rollers for tight fitting of the fastening elements (floor) or the load (pallet, barrel), it is coated with brass, This service may only be performed by author-
and wear. copper, stainless steel, or a similar material with a thick- ised skilled personnel (experts).
ness of approx. 3 mm, or it is manufactured with the The manufacturer recommends contacting your author-
- Re-tighten loose screwed connections. abovementioned materials. ised Linde dealer.

- Replace damaged parts. NOTE

If repair of the protective surfaces on the forks, etc. is
- If required, touch up the paint coat. required, contact authorised skilled personnel (experts).
The manufacturer recommends contacting your author-
- Replace damaged and illegible symbol stickers. ised Linde dealer.

- Refit the front cover.

141 804 6011.0902

x1411343 x1411318

44
 500-hour inspection and maintenance Maintenance
Clean contactor tips and check for wear Check the motor brushes, renew if nec- Check the brake system
DANGER essary DANGER
This service may only be performed by author- DANGER The operation of the tiller brake and the plug brake
ised skilled personnel (experts). Contact authorised skilled personnel (experts) must always be ensured. If defects become evi-
The manufacturer recommends contacting your author- for the motor brush check. dent, contact authorised skilled personnel (experts). The
ised Linde dealer. The manufacturer recommends contacting your author- manufacturer recommends contacting your authorised
ised Linde dealer. Linde dealer.
Clean the electric motors
DANGER
DANGER This service should only be performed by your
This service may only be performed by author- authorised Linde dealer.
ised skilled personnel (experts).
The manufacturer recommends contacting your author- - Check the air gap, brake wear and sealing of the brake.
ised Linde dealer.
DANGER
Do not operate your fork truck if the brakes are
faulty.
141 804 6011.0902

x1411344

45
1000-hour inspection and maintenance Maintenance
Clean hydraulic system oil filter
ATTENTION
Follow the instructions for handling fluids and
lubricants.

DANGER
This service may only be performed by author-
ised skilled personnel (experts).
The manufacturer recommends contacting your author-
ised Linde dealer.

141 804 6011.0902

x1411345

46
 2000-hour inspection and maintenance Maintenance
Renew the hydraulic oil Renew the gearbox oil
ATTENTION ATTENTION - Clean the drain plug and screw it back in with a new
Follow the instructions for handling fluids and Follow the instructions for handling fluids and gasket.
lubricants. lubricants. - Replenish gearbox oil up to the lower edge of the bore on
the oil level check plug (2).
DANGER NOTE
This service may only be performed by author- Drain gear lubricant oil at operating temperature NOTE
ised skilled personnel (experts). Fill the oil with short pauses to prevent air bubbles.
The manufacturer recommends you to charge the author- - Jack the truck up and secure it with wooden beams.
ised Linde dealer. - Remove the front cover. - Screw the oil level check plug back in again.
- Move the tiller to position the gearbox so that the drain - Refit the front cover.
plug (1) and the oil level check plug (2) can be accessed - Lower the truck.
through the frame holes.
- Place a drip pan under the gearbox.
- Screw out the oil level check plug (2).
- Screw out the drain plug (1), and drain the gearbox oil into
141 804 6011.0902

the drip pan. Dispose of drained off oil in an environmen-

tally beneficial manner.

x1411345 x1411346

47
Inspection and maintenance specifications Maintenance
No. Aids/ Capacity/
Lubricants Settings

1 Hydraulic system Hydraulic fluid 1.25 l

Filter element 150 µm
Max. pressure 170 bar (start of opening)

2 Reduction gearbox Gearbox oil 1.8 l

3 Traction wheel Wheel nuts Torque setting 140 Nm

Stabiliser wheel Pivot mounting bolt Torque setting 110 Nm
Load wheels Mounting bolt Torque setting 50 Nm

4 Traction motor Fuses Qty: 1 225 A

Pump motor Fuses Qty: 1 100 A
Control harness Fuses Qty: 1 7.5 A

5 Traction motor Brushes New: 32 mm min.: 16 mm

Pump motor Brushes New: 18 mm min.: 10 mm

141 804 6011.0902

6 Battery Distilled water As necessary

7 Bearings Lithium-based grease As necessary

48
 Lubricant recommendations
Hydraulic oil Lubricating grease
Recommendation for normal duty: Linde lithium-based heavy duty grease with EP additives and
Hydraulic oil HLP ISO VG 46 to DIN 51524 T.2 (factory filling), MOS2.
average continuous oil temperature 40 °C to 60 °C. Designation to DIN 51825 KPF 2N-20, (see Parts Catalogue
for Order No.).
Recommendation for heavy duty:
Hydraulic oil HLP ISO VG 68 to DIN 51524 T.2, average Do not mix with greases having another base than lithium.
continuous oil temperature over 60 °C.
Battery grease
Recommendation for light duty at low ambient temperatures:
Non-acidic lubricating grease (terminal grease).
Hydraulic oil HLP ISO VG 32 to DIN 51524 T.2, average
continuous oil temperature under 40 °C.
Gear oil
Recommendation for strongly varying operating condition: Preferably SAE 80 W - 90 API GL5, also suitable is
All the above applications can be covered with an hydraulic SAE 85 W - 90 API GL4 (to DIN 51512).
oil HVLP ISO VG 46 to DIN 51524 T.3.
Such hydraulic oils have a high viscosity index (multigrade
oils).
141 804 6011.0902

Bio hydraulic oil

Biologically fast-degradable pressure fluid
Aral Forbex SE 46

ATTENTION
Do not mix bio-oils with mineral oils. Other fluids
from other manufacturers cannot be recommand-
ed.

NOTE
The above oil recommendations are only guidelines.
If case of doubt we recommend contacting your author-
ised skilled personnel (experts).
The manufacturer recommends you to ask the authorised
Linde dealer.
Recommendations of representatives of the oil industry
should also be checked with your authorised Linde dealer.
Only the above-mentioned oils are approved by the man-
ufacturer. Costly damage can result if other hydraulic oils
are used or mixed.

49
141 804 6011.0902
50
 Troubleshooting guide
Trouble Possible Cause Remedy See Page

Abnormal noise Suction filter restricted. Contact your authorised Linde dealer.

Suction line leaking. Tighten line connections. 25

Oil foaming
Oil level low. Check oil level, top up if necessary. 43

Hydraulic pump damaged, seals faulty,

causing air intake. Contact your authorised Linde dealer.

No or too low pressure in Pump suction faulty, restricted suction filter. Contact your authorised Linde dealer.
system
Pump failure, leakage, pressure valves do not close Contact your authorised Linde dealer.
141 804 6011.0902

Hose leaky. Replace hose or tighten connections. 25

Oil of low viscosity, causing high leakage losses Contact your authorised Linde dealer.

Oil pressure fluctuates Causes as under abnormal noise. See under abnormal noise. 25, 43

Hydraulic oil temperature Pump failure, valves leaking. Contact your authorised Linde dealer.
too high
Oil level too low, wrong oil type. Check oil level; if necessary, top up oil. 43
Contact your authorised Linde dealer.

Failure of the working Battery discharge 80 %. Check battery, recharge or replace. 21, 22
hydraulic system
Faulty fuse. Contact your authorised Linde dealer.

Fault in electric circuit. Contact your authorised Linde dealer.

51
Hydraulic circuit diagram
1 Hydraulic shock absorber

2 Lifting cylinders

3 Slow lowering solenoid valve

4 Pressure filter

5 Pump and pump motor

6 Flow regulator

7 Breather (built into the filling plug)

8 Adjustable pressure reducing valve

9 Reservoir

10 Suction strainer

141 804 6011.0902

11 Non-return valve

12 Pressure sensor

13 Boost pressure lines

14 Filter

15 Hydraulic oil lines

52
 Hydraulic circuit diagram

15 13 14

2 2
141 804 6011.0902

13
13
3

12 4
11
5

6
7
10

x1411347
9 8

53
Wiring diagram
This manual contains no wiring diagrams for safety reasons.
Please contact your authorised dealer if these are needed.

141 804 6011.0902

54
 Index
Page Page Page

A
Approved applications ........................................................ 2 Check the mounting of frame parts and body ............ 44
G
Gas warning indicator ................................................ 15
Check the plug brake ........................................................ 41 Gas warning system ................................................... 16

B
Check the tiller brake ........................................................ 41 Gear oil .............................................................................. 49
Check the truck for leaks ................................................... 25 General information .......................................................... 35
Check the tyres for damage and foreign objects ............. 38 General view of truck ........................................................ 12
Battery change ............................................................ 22 Checking the battery charge ...................................... 21

H
Battery discharge indicator ............................................... 15 Clean contactor tips and check for wear ................... 45
Battery discharge indicator with lift cut-out contact ......... 14 Clean hydraulic system oil filter ....................................... 46
Battery grease ................................................................... 49 Clean the controller with compressed air .................. 44
Battery removal with a crane ...................................... 22 Clean the electric motors ............................................ 45 Handling fluids and lubricants .......................................... 19
Before leaving the pallet truck .......................................... 31 Clean the gas warning system sensor ....................... 40 Hoisting the truck with a crane ......................................... 32
Before loading ................................................................... 30 Clean the truck .................................................................. 38 Hour meter with battery discharge indicator/
Beginning operation ......................................................... 17 Connecting the battery plug ....................................... 20 lift cut-out contact ........................................................... 14
Belly button ........................................................................ 28 Connecting the battery to a suitable Hour meter .................................................................. 14, 15
141 804 6011.0902

Bio hydraulic oil ................................................................ 49 external charger ...................................................... 21 Hydraulic circuit diagram .................................................. 52
Braking .............................................................................. 11 Hydraulic oil ...................................................................... 49

D
Braking, fuses, lifting device ............................................. 29 Hydraulic system ............................................................... 11

C
Change of direction .......................................................... 27
Daily checks and servicing before operation .................. 20
Daily inspections ............................................................... 19
Depositing the load ........................................................... 31
I
Inspect the gas warning system ................................. 40
Charging the battery ................................................... 21 Description .......................................................................... 5 Inspect the gas warning system sensor ..................... 40
Check and lubricate other joints ....................................... 41 Disconnecting the battery plug .................................. 20 Inspection and maintenance after first 50 hours
Check the belly button ...................................................... 24 Drive .................................................................................. 11 of operation .................................................................... 35
Check the brake system ............................................. 41, 45 Driving ......................................................................... 11, 26 Inspection and maintenance as required ........................ 38
Check the braking system ................................................ 24 1000-hour inspection and maintenance .......................... 46

E
Check the condition for leakage resistance of the tyres .. 25 2000-hour inspection and maintenance .......................... 47
Check the condition, electrolyte level and 500-hour inspection and maintenance ............................ 41
specific gravity of the battery ................................... 22 Inspection and maintenance chart ................................... 36
Check the electric cables, cable connectors and Experts ............................................................................... 17 Inspection and maintenance specifications ..................... 48
connections for condition and tightness ................. 43 Explosion protection check ........................................ 19 Installing the front cover .................................................... 20
Check the gearbox oil level .............................................. 42

F
Check the horn ............................................................ 23
Check the hydraulic oil level ............................................ 43
Check the hydraulic system for tightness ........................ 43
Check the load forks ............................................. 25, 44 Foreword ............................................................................. 2
Check the motor brushes, renew if necessary .......... 45 Fuses ........................................................................... 29

55
Index
Page Page

L
Lifting forks ........................................................................ 29
S
Safety check ................................................................ 19
Loading ............................................................................. 30 Safety information ............................................................. 19
Lowering forks ................................................................... 29 Safety rules ........................................................................ 17
Lubricant recommendations ............................................. 49 Steering ....................................................................... 11, 28
Lubricate the steering bogie on traction unit ................... 42 Steering, belly button, horn .............................................. 28
Lubricating grease ............................................................ 49

M T
Taking the truck out of operation ...................................... 33
Maintenance ..................................................................... 35 Technical data ................................................................... 10
Maintenance work prior to initial start-up ......................... 19 Technical description .................................................. 11, 16
Measures before taking the truck out of operation .......... 33 Technical note ..................................................................... 3
Moving backward .............................................................. 27 Tighten the wheel fasteners ............................................. 39

141 804 6011.0902

Moving forward .................................................................. 27 Tiller brake (parking brake) .............................................. 29
Moving the tiller into driving position ............................... 26 Towing procedure ............................................................. 32
Towing the truck ................................................................ 32

O
Towing ............................................................................... 32
Transporting the load ........................................................ 31
Travel, change of direction ............................................... 27
Operating and display elements ...................................... 13 Troubleshooting guide ...................................................... 51
Operating the horn ............................................................ 28 Truck indicator ................................................................... 14
Operation ........................................................................... 26 Turning off the key switch ................................................. 23
Operation of industrial trucks in the plant area ................ 19 Turning on the key switch ................................................. 23
Type plates .......................................................................... 5

P
Pallet truck takeover ............................................................ 3 U
Plug brake (service brake) ................................................ 29 Unlock emergency isolator button ............................. 23
Push in emergency isolator button ............................ 23

W
Putting the truck back into operation ................................ 33

R
Removing the front cover .................................................. 20
Wiring diagram .................................................................. 54

Renew the gearbox oil ...................................................... 47

Renew the hydraulic oil .................................................... 47
Running-in instructions ..................................................... 19

56