1101 series Electric Pallet

Truck

Operating Instructions

Models EW 27/60, EWR

27/60, EW 36/80, EWR
36/80
1101 series EW/EWR –
11018011540 US – 02-2014
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 Preface
g

Linde − Your Partner

With over 100,000 fork lift trucks and ware- network of sales partners, we are at your
house machines sold annually, Linde is one of service around the clock and around the world.
the world’s leading manufacturers of material
Your local Linde partner can offer you a
handling equipment. There are many reasons
complete package from a single source;
for this success: Linde products are renow-
ranging from expert advice on all aspects of
ned not only for their innovative, cutting-edge
sales and service through appropriate finance
technology, but also for their low energy and
options.
operating costs, which are up to 40 per cent
lower than those of their competitors. Linde Material Handling North America
Corporation
The high quality of Linde products is also
2450 West 5th North Street
matched by the quality of our service. With ten
Summerville, S.C. 29483
production plants worldwide and an extensive
Phone (843) 875-8000
FAX (843) 875-8329

Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014 I

Preface
g

Parts and service

See your Linde dealer for genuine Linde parts
(the only factory-authorized replacements),
factory-trained service personnel and manu-
als for your equipment.

Proposition 65
WARNING
This warning is provided pursuant to California
Health & Safety Code Sections 25249.5 et. seq.
This product contains and emits chemicals known
to the state of California to cause cancer, birth
defects and other reproductive harm.

Copyright and proprietary

rights
This manual - and any excerpts thereof - may
not be reproduced, translated or transmitted
in any form to third parties without the express
written permission of the manufacturer.

II Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014

 Table of contents
g

1 Introduction
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Obligations of the Forklift Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Operator responsibilities ............................................... 3
Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hazard messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 Safety
Before Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operator daily checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operating Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inclines, Ramps, Docks, Elevators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Safety During Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Personnel Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hazardous Substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Operator Warning Decals . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... .. 11
Data plate . . . . . . . . . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... .. 11
No riding decal . . . . . . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... .. 11
Trained operator warning decal ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... .. 12
Test or service warning decal . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... .. 12
Crushed fingers warning decal .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... .. 12
No step warning decal . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... .. 12
Voltage decal . . . . . . . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... .. 12
Coast control warning decal . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... .. 13
Jog button warning decal . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... .. 13
Platform surface warning decal .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... .. 13

Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014 III

Table of contents
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3 Overview
Technical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Truck Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Indicator Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Data Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Decal and Data Plate Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Definition of directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4 Operation
Unloading and Preparing a New Truck for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Turning the Truck On and Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Raising and Lowering the Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Coast Control System (Optional equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Connecting and Disconnecting the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Connecting the Battery to an External Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Changing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Towing the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Hoisting the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

5 Maintenance
Personnel Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Cleaning the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Daily Inspection Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... 43
General Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... 43
Maintenance Every 50 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... 44
Maintenance Every 200 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... 46

IV Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014

 Table of contents
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Maintenance Every 1000 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Scheduled Maintenance Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Fluid and Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Troubleshooting . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 52
Fuses . . . . . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 52
Diagnostic Connector .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 53
Maintenance Intervals ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 53

6 Technical Data
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014 V

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 1

Introduction
1 Introduction
Scope

Scope
This manual contains operating and periodic of the equipment to avoid or correct such
maintenance instructions as well as specifi- potential dangers.
cations for the Linde industrial truck to which
To assist in keeping the truck in good opera-
it applies. Important safety rules and descrip-
ting condition, a separate section devoted to
tions of some lift truck hazards and how to
maintenance is included in this manual. This
avoid them are also included. The manual is
section contains a list of items to be checked
intended to assist the owner and operators in
daily by the operator. It also has a schedule
maximizing safety and efficiency in material
for maintenance procedures to be performed
handling while achieving maximum product
at regular intervals by those responsible for
life. It describes how to correctly and safely
truck maintenance. All of these procedures
operate and maintain the truck and all stan-
are essential for safe operation and maximum
dard variants manufactured by Linde at the
service life of the truck. Scheduled mainten-
time of printing. Special designs, special at-
ance tasks or repairs must only be performed
tachments, or other custom modifications
by qualified forklift technicians. Details and
carried out by Linde to meet specialized custo-
instructions for performing such work are out-
mer requests are not covered in this manual.
side the scope of this manual. This information
This manual is not a training manual and is not is covered in the applicable service manual
to be used as the basis for formal training. It available from Linde.
is intended to supplement such training with
The descriptions and specifications included
information specific to this truck as well as
in this manual were in effect at the time of prin-
applicable good practices and safety rules
ting. Linde Material Handling, North America
which may be general in nature. This manual
Corporation reserves the right to make im-
cannot address every possible hazard or
provements and changes without notice and
potential accident situation. Ultimately it is
without incurring obligation. Please check
the responsibility of the owner and operator(s)
with your local authorized Linde dealer for in-
formation on possible updates or revisions.

Obligations of the Forklift Owner

The Occupational Safety and Health Admi-
nistration (O.S.H.A.) requires employers of
forklift operators to adhere to a number of re-
gulations regarding forklift operation. These
regulations are codified in section 1910.178
of title 29 of the Code of Federal Regulations.
This section establishes a number of specific
rules pertaining to truck operation, inspection
and maintenance, and areas of use. It is up to
the owner to ensure that use and maintenance
of any powered industrial truck is consistent
with these rules.
In addition, 29 CFR 1910.178 describes re-
quired operator training in detail. It requires
employers to establish and maintain a trai-
ning program to ensure that all operators of
powered industrial trucks are competent and
trained in the safe and proper operation of
powered industrial trucks.
Many of the rules set forth in 29 CFR 1910.178
are based on the American National Stan-
dards Institute (ANSI) B56.1 standard.
The owner should be familiar with 29 CFR
1910.178 as well as ANSI B56. Other federal
standards may apply depending on speci-
fic industry. Owners should also be aware
of any state OSHA rules that may differ from
the federal rule. Linde trucks meet all appli-
cable requirements of ANSI B56 at time of
manufacture. 29 CFR 1910.178 prohibits any
modifications and/or additions which affect
capacity or safe operation of industrial trucks
without prior written approval of the manu-
facturer. An owner should consult the local

2 Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014


authorized Linde dealer if the owner’s inten-
ded application for a truck is inconsistent with
the designated performance characteristics
of that truck. Linde Material Handling will not
assume, and expressly disclaims any liability
for injuries or damages arising from or cau-
Operator responsibilities
It is the responsibility of the operator to operate
the lift truck in a safe manner. In order to
do this, all operators must have completed
training in the safe operation of lift trucks.
Operators must know and understand all
general safety rules as well as any safety
information specific to the environment in
which they will be working. They must then
practice these safe operating procedures
whenever using a lift truck.
In addition, all operators must be familiar
with the specific lift truck they use. Therefore
they must be familiar with the procedures for
correct and safe operation explained in this
Proper use
The truck is designed for lifting, transporting,
and, if equipped with a mast, stacking of
palletized or other stable loads. The maximum
load to be lifted is specified on the truck data
plate. The truck is not designed or intended to
lift or transport personnel.
The truck may be operated outdoors or in
buildings only on surfaces that are flat and
stable. Transporting of loads on inclines and
ramps is permitted if the incline surface is
flat and stable. If the truck is equipped with
a mast, the carriage must always remain in
the fully lowered position during transport on
such inclines and ramps. Lifting of loads or
transport of elevated loads is prohibited on
Hazard messages
Hazard symbols and messages are placed in
this manual and on the truck to provide instruc-
Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014
Introduction 1
Operator responsibilities
sed by unauthorized modification, removal,
disconnection or disengagement of any part
from any of its trucks. Linde Material Handling
recommends that all replacement parts be of
OEM (Original Equipment Manufacturer) ori-
gin.
manual. They must understand the potential
hazards and safety precautions covered in the
manual. This manual however, cannot cover
all possible hazards. Operators must be able
to identify any hazards that may exist or arise
in their work environment and know how to
avoid or correct them.
Finally, operators are responsible for identi-
fying and reporting any truck that is in unsafe
condition. They must know how to inspect the
truck they operate and they must perform this
inspection before placing a truck in service
each day. Operators must not operate a lift
truck found to be damaged or malfunctioning.
inclines and ramps. If the truck is operated
on public roads it must be equipped with
lights and any other devices as required
by state or local law. If the truck is to be
operated in refrigerated storage areas, it must
be equipped with an optional cold storage
package suitable for the specific application.
(Not available on all models.) A truck must not
be operated in any hazardous environment
unless the truck carries the designation
appropriate for that environment per 29 CFR
1910.178. It is the responsibility of the owner
to ensure the safety of all operating areas and
surfaces and to restrict the truck to the uses
and areas for which it is designed and rated.
tions and identify specific areas where poten-
tial hazards exist and special precautions
3
1 Introduction
Hazard messages

should be taken. Operators must understand DANGER

the meaning of these symbols and messages.
Indicates an imminently hazardous situation which
Damage to the truck, as well as serious injury if not avoided will result in death or serious injury.
or death to the operator or others may result
if the instructions conveyed by these symbols
and messages are not followed. NOTE

CAUTION Indicates further information presented to

ensure clarification of a particular item
Indicates a potentially hazardous situation, which if
not avoided, may result in minor or moderate injury.
ENVIRONMENT NOTE
The information contained herein must be
WARNING
observed, otherwise environmental damage
Indicates a potentially hazardous situation which if may occur.
not avoided could result in death or serious injury.

4 Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014

 2

Safety
2 Safety
Before Operation
Before Operation
Before using the truck, inspect the work
area. It should be neat, well lit, adequately
ventilated, and free from hazardous material.
Aisles and roadways should be unobstructed
and well marked.
Operators must know the UL classification for
the truck and use the truck only in permissible
areas.
Ensure that there are no loose objects on
the truck or in the operator compartment,
especially on the floor plate where they could
interfere with pedal operation (if equipped) or
foot room.
Fire extinguishers and other emergency
equipment should be visible and easy to
reach. Wear safety equipment when required.
Don’t smoke in "No Smoking" areas, or while
charging batteries or refueling combustion
engine trucks.
Operator daily checklist
At the beginning of each shift, inspect your
truck by using the Linde Operator’s Daily
Checklist. If necessary, refer to the Mainten-
ance section of this manual for details on how
to carry out this inspection. Check for damage
and maintenance problems. Any necessary
repairs must be completed before the truck is
operated. In addition to daily inspection, sche-
duled maintenance is vital to safe operation of
the truck. Adhere to the inspection, lubrication
and maintenance schedule given in the Mai-
ntenance section of this manual.
NOTE
Any repairs or maintenance to the truck must
be performed only by trained and authorized
technicians.
Operating Position
The truck may be operated in either direction
while walking. When operating in reverse
6 Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014
Never operate the truck with greasy hands.
This will make the controls slippery and result
in loss of truck control.
Any questions or concerns about safety
should be brought to the attention of a su-
pervisor. If an accident should occur, it must
be reported immediately.
WARNING
Unauthorized modifications to the truck can result
in injury or death.
Do not remove, disable or modify any safeguards or
other safety devices. These include the overhead
guard, load backrest extension, and if equipped by
the owner, alarm, lights and mirrors. The overhead
guard is intended to provide protection to the
operator from falling objects, but cannot protect
from every possible impact.
ELECTRIC MOTORIZED HAND TRUCK - WITHOUT MAST
OPERATOR’S DAILY CHECKLIST
Truck Serial Number: ____________________ Dept / Shift: __________________ Operator: _______________________
Hour meter reading: _____________________ Date: _______________________ Supervisor: _____________________
Check each of the following items before the start of each shift. Let your supervisor and/or maintenance department know
of any problem. Start at the front of the lift truck and work towards the rear. After checking, mark each item accordingly. Explain
below as necessary.
Check boxes as follows: OK NR, Needs Repair. Circle problem and explain below.
O N O N
VISUAL INSPECTION K R OPERATIONAL INSPECTION
K R
Oil Spots on Floor (check for leaks on truck) Unusual Noise (during any of the operational checks)
Drive Tire (wear, cuts, or embedded objects, rim damage, Emergency Battery Disconnect (check operation)
loose/missing lug nuts) Gauges and Instrumentation (check operation)
Hydraulic Oil (check level) Battery Charge (fully charged)
Steer Axle, Chain, or other mechanism (check for Emergency Reverse Button (check operation)
damage, debris) Forward Driving (accelerates, steers, brakes smoothly)
Motor Covers (Loose fasteners, cracked or broken) Plugging (stops, changes direction smoothly)
Steering; Control Handle (movement, operation) Reverse Driving (accelerates, steers, brakes smoothly)
Throttle Hand Grips (check for wear, damage) Service/Parking Brake (check operation)
Anti-slip Mat (if equipped) (check condition, cleanliness) Hydraulic Controls (operate freely, return to neutral)
Battery Connectors & Cables (damage, cracks, pitting) Hydraulic Oil (excessive noise when forks are fully
Battery Retention (installed correctly, secure) raised is indication of low hydraulic oil)
Battery Case & Vent caps (damage, cracks, loose, Horn (sounds when button pressed)
missing) Backup Alarm (if equipped) (sounds in reverse)
Fork Frame (damage. twist) Travel Alarm (if equipped) (sounds with vehicle in motion)
Load wheels (tire wear, damage, entrapped debris) Work, Strobe, Flashing Lights (if equipped) (check
Warning Decals/Operator’s Manual (in place, legible) operation)
Data Plate / Capacity Plate (in place, legible) Coast Control (if equipped) (check operation)
Coast Control Indicator Light (if equipped) (check
operation)
Explanation of problems marked above (use back of this form if needed):
_____________________________________________________________________________________________
____________________________________________________________________________________________
_____________________________________________________________________________________________
OSHA 1910.178 (p) (1) requires a truck to be taken out of service any time it is found to be in need of repair, or is in any
way defective or unsafe. Place a “Do Not Operate” tag on the truck, remove the key and alert your supervisor. The
Truck may not be placed back into service until necessary repairs are made.
F231 05-2013
(forks leading), always keep both hands on
the control handle. When operating forwards

(forks trailing) keep one hand on the controls
and, if possible, walk ahead and to the side of
the truck.
During operation, always grasp the handle
at the travel control. Keep fingers within the
protected area of the handle at all times.
WARNING
Injury to hands can occur if the handle is grasped
incorrectly.
Keep hands and fingers within the protected area
of the handle.
When walking with the truck, remain at arm’s
length from the control handle. Keep feet clear
of the truck at all times.
Travel
The truck is designed for operation on smooth,
dry surfaces such as warehouse and factory
floors, loading docks or paved areas. Under
all travel conditions operate the truck at a
speed that will permit it to be brought to a stop
in a safe manner. Avoid running over loose
objects on the roadway surface.
WARNING
Loss of control!
Do not travel at excessive speeds; keep your truck
under control at all times.
Always watch for pedestrians. When travelling
in reverse (load end leading) be careful of
drive end swing. The drive end of the truck will
swing out if a turn is made while travelling in
Inclines, Ramps, Docks, Elevators
If you must travel on an incline, do so with
caution. Do not operate truck on a wet incline.
Keep the forks upgrade to maintain control
when travelling up or down an incline with a
loaded truck.
Keep the forks downgrade when travelling up
or down an incline with an empty truck.
Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014
Safety 2
Travel
WARNING
Injury can occur if the truck contacts any part of the
body.
Remain clear of the truck frame at all times.
Operators must not ride the truck unless it is
designed for riding. Trucks designed for riding
have a dedicated riding platform as well as
a dedicated grab bar, seat, or body support.
Always sit in the seat or brace against the body
support before riding. If the truck has a grab
bar, always grasp it before riding. Maintain
contact with the seat, body support, or grab
bar throughout riding operation.
Passengers are not permitted.
reverse. Always use caution when turning into
an aisle. The load wheels can cut the corner
sooner than expected.
Unstable loads are hazardous. Ensure all
loads are secure and evenly positioned across
both forks. Never lift a load with only one fork.
Never carry anything on any part of the truck
except the forks unless a specific area has
been provided by the manufacturer.
During travel, always watch for overhead
obstructions such as lights, wiring, pipes,
sprinkler systems, doorways, etc. Never
overtake another truck at an intersection, blind
spot or other dangerous location. Use the
horn at intersections and any location where
visibility is limited.
DANGER
Tip-over will occur if you turn while travelling on a
ramp or travel at an angle other than straight up or
straight down a ramp.
Never turn on an incline or ramp either loaded or
unloaded. Travel straight up or straight down.
Be aware that when descending an incline
your stopping distance will be greater than
7
2 Safety
Parking

when on a level surface. Reduce your speed,
and ensure that there is adequate clear space
at the bottom of the ramp to stop and turn.
To avoid hazards associated with a dock, you
should personally check that the trailer brakes
have been applied, wheel chocks are in place,
and that any trailer-to-dock locking systems
are being utilized. The impact of moving in and
out of a trailer may cause the trailer to creep
or move. Confirm that the driver will not move
the trailer until you are done.
Do not drive the truck onto an elevator without
specific authorization. Verify that the capacity
of the elevator exceeds the weight of the truck
and the weight of the load. Approach elevators
slowly and ensure that the elevator car is level
with the floor before entering. Enter elevators
squarely with the load end leading. Ensure
that no part of the truck or load contacts any
part of the elevator other than the floor. Once
on the elevator, neutralize the truck controls,
shut off the power, and set the brakes. Any
other personnel should leave the elevator
before the truck is allowed to enter or leave.
Be especially cautious when driving the truck
on ramps or bridge plates. Be sure to maintain
a safe distance from each edge. Before driving
the truck over a ramp or bridge plate, verify that
its position is secured to prevent movement.
Never exceed the rated capacity of a ramp or
bridge plate.

Parking
When you are finished with the truck, observe
proper shutdown procedures.
• Never park on a grade.
• Always come to a complete stop before
leaving truck.
• Place travel controls in neutral.
• Lower forks fully to the floor. If the forks can
be tilted, tilt them forward.
• If the truck has a manual parking brake,
apply it.
• Turn the truck off.
• If the truck has a key switch and the operator
is more than 25 ft (7.5 m) away, or out
of sight of the truck, the key should be
removed.
WARNING
Failure to properly shut down the truck may allow
inadvertent movement and result in a collision.
Never park on a grade. Ensure the parking brake
is applied and turn the truck off. On trucks with a
direction switch, always place it in neutral.
WARNING
Improper parking can interfere with emergency
response.
Do not block stairways, main passageways or
emergency routes. Do not block access to fire
or emergency equipment.

Battery Safety
WARNING
Batteries contain dissolved sulfuric acid, which is
poisonous and caustic. Batteries also can produce
explosive gases.
Remain aware of the following information.
when working with battery acid. If clothing,
skin or eyes come into contact with battery
acid, immediately flush the affected areas
with water. If acid contacts the eyes, seek
medical attention at once. Clean spilled

• Wear protective equipment (protective

apron and gloves) and protective glasses

8 Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014


battery acid immediately with large amounts
of water.
• Remove any metal rings, bracelets, bands,
or other jewelry before working with or near
batteries or electrical components.
• Never expose batteries to open flame or
sparks.
• Areas in which batteries are stored or
charged must be well ventilated to prevent
concentration of explosive gases.
• If a battery is charged while installed in
the truck, the battery cover must remain
Safety During Maintenance
Personnel Qualifications
Only qualified personnel authorized by the
owner are permitted to perform maintenance
or repair work. All items listed in the Scheduled
Maintenance Charts must be performed by
qualified forklift technicians only. They must
have knowledge and experience sufficient
to assess the condition of a forklift truck and
the effectiveness of the protective equipment
according to established principles for testing
forklift trucks. Any evaluation of safety must
Hazardous Substances
Oils
WARNING
Oils are flammable!
 Always comply with applicable
legal regulations.
 Do not allow oil to come into
contact with hot engine parts.
 Do not smoke in areas where oils
are used or stored.
Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014
Safety 2
Safety During Maintenance
completely open during the entire charging
period.
• Shorting of battery terminals can cause
burns, electrical shock, or explosion. Do not
allow metal parts to contact the top surface
of the battery. Make sure all terminal caps
are in place and in good condition.
• Batteries may only be charged, serviced,
or changed by properly trained personnel.
Always follow all instructions provided by
the manufacturers of the battery, charger,
and forklift truck.
be unaffected by operational and economic
conditions and must be conducted solely from
a safety standpoint.
Daily inspection procedures and simple
maintenance checks, e.g. checking the
hydraulic oil level or checking the fluid level
in the battery, may be performed by operators.
This does not require training as described
above.
WARNING
Oils are toxic!
 Avoid skin contact, inhalation, or
ingestion.
 If oil mist or vapors have been
inhaled, seek fresh air.
 If oil comes into contact with the
eyes, flush thoroughly (at least 10
minutes) with water and then seek
medical assistance.
 If oil is swallowed, do not induce
vomiting. Seek medical assi-
stance immediately.
9
2 Safety
Safety During Maintenance
WARNING
Prolonged intensive contact with the
skin can result in loss of natural skin
oils and irritate the skin.
 Avoid skin contact.
 Wear protective gloves, long
sleeves, and eye protection.
 If oil contacts the skin, wash the
affected area with soap and water.
 Change oil-soaked shoes or
clothing immediately.
WARNING
Spilled oil presents a risk of slipping, particularly
when combined with water.
 Immediately treat spilled oil with an oil binding
agent, and then dispose of it according to local
regulations.
ENVIRONMENT NOTE
All oils are potent contaminants of water.
• Recycle used oil if possible.
• Always store oil in appropriate containers.
• Avoid spills.
• Spilled oil should be removed with oil-
binding agents at once and disposed of
according to local regulations.
• If recycling is not possible, dispose of used
oil according to local regulations.
Pressurized Hydraulic Oil
WARNING
Like other oils, hydraulic oil is flammable, toxic, and
a skin irritant.
 Do not allow hydraulic fluid to come into contact
with hot motor parts.
 Avoid inhalation or skin contact of hydraulic oil.
 Refer to the safety information under "Oils".
10 Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014
WARNING
Hydraulic oil is pressurized during operation of the
forklift truck and may remain pressurized after shut
down. An escaping stream of pressurized hydraulic
oil can cause serious injury.
 If pressurized hydraulic oil is found to be esca-
ping from the truck, shut down the truck immedia-
tely and have the leak repaired before returning
the truck to service.
 Only trained service personnel should attempt to
repair any portion of the hydraulic system.
 Do not allow hydraulic fluid to come into contact
with the skin.
 Avoid inhaling spray or mist created by escaping
hydraulic oil.
 Penetration of pressurized fluids into the skin
is particularly dangerous if these fluids escape
at high pressure due to leaks in the hydraulic
system. In case of such injury, immediate
medical assistance is required.
 To help prevent injury, use appropriate personal
protective equipment (e.g. protective gloves,
long sleeves and industrial goggles).
ENVIRONMENT NOTE
Hydraulic oil is a potent contaminant of water.
• Recycle used hydraulic oil if possible.
• Always store hydraulic oil in appropriate
containers.
• Avoid spills.
• Spilled hydraulic oil should be removed with
oil-binding agents at once and disposed of
according to local regulations.
• If recycling is not possible, dispose of used
hydraulic oil according to local regulations.
Battery Acid
WARNING
Battery acid contains dissolved
sulfuric acid. This is toxic.
 Avoid contact and consumption.
 In case of injury, seek medical
advice immediately.
 Safety 2
Operator Warning Decals

WARNING ENVIRONMENT NOTE

Battery acid contains dissolved
sulfuric acid. This is corrosive.  Dispose of used battery acid according to
local regulations.
 When working with battery acid,
always wear protective clothing
and eye protection.
 Do not allow any acid to get
onto clothing or skin or into the
eyes; if this does happen, rinse
immediately with plenty of clean
water.
 In case of injury, seek medical
advice immediately.
 Immediately rinse away spilled
battery acid with plenty of water.

Operator Warning Decals

Data plate MODEL SERIAL #
TRUCK WEIGHT

The data plate is designed to inform personnel

MADE IN (WITHOUT BATTERY +/- 5%)
kg lb

ELECTRICS ONLY BATTERY BATTERY BATTERY WEIGHT

of truck capacity and other important truck

VOLTAGE TYPE MAX MIN

V kg kg

specifications. The operator should locate, BACK

TILT
LIFT
TYPE
lb lb

read, and understand the data plate prior to DRIVE TIRES TRUCK TYPE

using the forklift truck. ATTACHMENT(S) A B C D CAPACITY

mm mm mm mm kg
in in in in lb

DANGER mm
in
mm
in
mm
in
mm
in
kg
lb
AS SHIPPED THIS TRUCK MEETS THE APPLICABLE REQUIREMENTS OF ANSI/ITSDF B56.1 LINDE MATERIAL HANDLING

Risk of tip-over.
0009384611 SUMMERVILLE, SC USA

Never attempt to lift a load greater than the maxi-

mum capacity listed on this plate.

No riding decal
This decal warns personnel that riding is not WARNING
permitted anywhere on the truck. This applies
to operators as well as all others.
Some pallet trucks are designed for riding. If
so, this decal will not be present.

Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014 11

2 Safety
Operator Warning Decals

Trained operator warning decal

This decal states the requirement that only
trained and authorized personnel are to
WARNING
operate truck. TRAINED AND AUTHORIZED
OPERATORS ONLY.
MISUSE OF THIS TRUCK COULD
CAUSE INJURY TO YOURSELF
OR OTHERS WORKING WITH YOU.
READ INSTRUCTIONS IN
OPERATOR’S MANUAL.
0009384608

Test or service warning decal

This decal gives important safety information
for personnel servicing or testing the truck.
WARNING
BEFORE PERFORMING ANY TEST OR SERVICE WHICH
CALLS FOR TESTING UNDER POWER, JACK THE DRIVE
WHEELS OF THE TRUCK OFF THE FLOOR. THE DRIVE
WHEELS MUST BE FREE TO TURN. ENSURE THE TRUCK
IS SECURELY BLOCKED.

DO NOT USE TEST DEVICES OR SYSTEMS ANALYZERS IN

PLACE OF CONTROL BOARDS OR CONTROL MODULES
TO DRIVE THE TRUCK. ATTEMPTS TO DRIVE WITH TEST
DEVICES OR ANALYZERS ARE HIGHLY DANGEROUS. 0009384609

Crushed fingers warning decal

This decal is placed in areas where parts move
WARNING
close together during normal truck operation. KEEP HANDS CLEAR,
The decal warns personnel to keep hands SERIOUS INJURY COULD RESULT.
clear of these areas at all times.
0009384603

No step warning decal

This decal warns personnel of moving parts
WARNING
that are unsafe to step or stand upon. DO NOT STEP OR STAND HERE,
SERIOUS INJURY COULD RESULT.
0009384601

Voltage decal
This decal indicates the proper voltage and
maximum current capacity for batteries to be
24 VOLT
used in the truck. Using a battery of incorrect
voltage could damage the truck. The battery
ONLY
compartment will not accommodate batteries 750Ah (6h) Max
of current capacity greater than specified.
0009384697

12 Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014

 Safety 2
Operator Warning Decals

Coast control warning decal

This decal warns the operator that the truck is WARNING
equipped with a coast control system. When BRAKE WILL NOT AUTOMATICALLY
activated, this system will hold the handle ENGAGE WHEN COAST CONTROL
IS ACTIVATED.
in the operating position and the brake will
COAST
not automatically engage. When the light in CONTROL
WHEN
LIT
the center of the decal is on, it indicates that
ACTIVE
DEACTIVATE COAST CONTROL SYSTEM
the coast control system is active. The coast BEFORE DISCONNECTING POWER.

control system is optional equipment. If the FAILURE TO FOLLOW INSTRUCTIONS

COULD RESULT IN INJURY OR DEATH.
truck is not equipped with coast control, this SEE INSTRUCTIONS IN
decal will not be present. OPERATOR’S MANUAL
0009380211

Jog button warning decal

This decal warns the operator that the truck is WARNING
equipped with buttons on the handle that will
THIS TRUCK IS EQUIPPED WITH
jog the truck forward if the coast control system A "PICK" SYSTEM.
is active. Trucks without the optional coast
WHEN COAST CONTROL IS
control system will not have these buttons or ACTIVATED, DEPRESSING EITHER
this decal. RED BUTTON ON THE SIDE OF
HANDLE WILL CAUSE TRUCK TO
MOVE FORWARD.

READ INSTRUCTIONS IN
OPERATOR'S MANUAL.
0009380212

Platform surface warning decal

This decal warns operators not to operate
the truck if the anti-slip mat on the riding
platform is worn, damaged, or slippery due
to contamination from liquids. This decal is
only present on models designed for riding.

Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014 13

2 Safety
Operator Warning Decals

14 Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014

 3

Overview
3 Overview
Technical Description
Technical Description
General
The 1101 series electric pallet truck is avai-
lable in both a "walkie" version (EW) and a
walk/ride version (EWR). All models are ITA
class 3 trucks. They are designed for handling
loads up to:
6000 pounds (2.7 metric tons) for EW 27/60 &
EWR 27/60
8000 pounds (3.6 metric tons) for EW 36/80 &
EWR 36/80.
This capacity may be downrated in special
circumstances. Exact capacity limits for
individual vehicles are found on the data plate.
Drive unit
The drive unit is comprised of a 24-volt
brushless AC drive motor mounted vertically
to a reduction gear unit. The drive unit pivots in
the chassis via the control handle to determine
drive wheel direction. A mechanical brake is
installed at the top end of the drive motor for
use as a parking brake or emergency brake.
The brake engages whenever the control
handle is released to the vertical position
or forced all the way down to the horizontal
position.
Travel control
Travel speed and direction is controlled
through a twist grip travel control at the
top of the control handle. When the travel
control is released, the truck will decelerate
via regenerative braking. More aggressive
slowing is available by rotating the travel
control in the opposing direction. The degree
of braking for both of these functions is
adjustable in the truck control software.
Hydraulic system
The hydraulic system utilizes fluid pressurized
by a hydraulic pump driven by a DC pump
16 Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014
motor connected to the battery through its own
contactor. The pump motor and contactor is
part of an integrated hydraulic pump unit which
also contains the pump, a manifold block,
a lowering solenoid valve, and a hydraulic
oil reservoir. During lifting, pressurized
hydraulic fluid from the pump is routed through
a check valve to a lift cylinder. The lift cylinder
operates the tie bar linkage to elevate the
forks. Lowering occurs by gravity when the
lowering solenoid is activated. The weight
of the forks (and any load) then acts through
the linkage to force hydraulic fluid out of the
cylinder and back to the reservoir.
Load lifting system
Load on the forks is elevated through a
hydraulically activated linkage. The linkage
consists of a lift shaft at the base of the battery
compartment connected through tie bars to
toggles at each load wheel. The lift shaft is
rotated by the hydraulic lift cylinder described
previously.
Electrical system
The truck is equipped with a 24-volt electrical
system. A single line contactor controls
power to the system once the key switch is
on. All travel and lift function is controlled by
a transistorized main controller. The main
controller contains both control logic and an
array of power transistors for the drive motor.
The control logic processes signals from
sensors, interlocks, and operator controls
and generates the appropriate release and
speed signals to the power transistors to
operate the drive motor. One fuse for the
power circuit is present. A number of control
fuses are used for the remainder of the
system and certain options. A diagnostic
connector is provided in the wiring harness
to connect a handset or laptop computer to
the controller for diagnostics or adjustment of
certain performance parameters.
 Overview 3
Truck Components

Model Illustrations

EW EWR 1101 05242012-01

Truck Components
6 7
5

4 8

3 9

2
1

10

11

12
14 13
1101 03192012-02

1 Control handle 9 Load wheels

2 Dash panel 10 Forks
3 Operator manual storage 11 Battery compartment
4 Grab bar (rider trucks only) 12 Battery retainer
5 Auxiliary buttons (rider trucks only) 13 Riding platform (rider trucks only)
6 Load back rest 14 Casters (standard on walkie trucks; optional
7 Accessory tray (optional) on rider trucks)
8 Battery connector

Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014 17

3 Overview
Controls

Controls
4

6
15
7

1 2 3
14

12

10
13
11
12
1101 03192012-01

1 Horn button 9 Indicator unit

2 Lift button 10 Travel control
3 Lowering button 11 Emergency reverse button
4 Auxiliary lift button (rider trucks only) 12 Jog buttons (optional)
5 Auxiliary lowering button (rider trucks only) 13 Hand guard
6 High speed travel button (rider trucks only) 14 Key switch
7 Auxiliary horn button (rider trucks only) 15 Coast control button (optional)
8 Coast control indicator light (optional)

18 Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014


Indicator Unit
1
0 +
2 1101 04132012-01
The indicator unit is located beside the key
switch. It displays accumulated hours, battery
state of charge, and fault codes. When the key
is first switched on, the red fault LED will briefly
light. If there are no faults, accumulated hours
are displayed for several seconds. Battery
state of charge is then displayed throughout
truck operation.
(1)Fault indicator (red) Flashes when a
fault is present. (This also occurs when a
programmed maintenance interval has been
reached.)
(2)Battery discharge indicator (LEDs) Shows
the current charge state of the battery.
The discharge status of the battery is repre-
sented by five LEDs. The LEDs go out suc-
cessively as the battery becomes increasingly
discharged. All LEDs are lit if the battery is
greater than 80% charged. As the battery dis-
charges, the LEDs will go out from right to left.
The LEDs are color coded. From right to left,
the three green LEDs indicate at least 80%,
60%, and 40% of full charge respectively.
The yellow LED indicates at least 25% of full
charge. Below 25% charge, only the red LED
will remain lit. This LED will then begin to flash
if the battery drops to 5% of full charge.
Above 80% All LEDs lit
60 to 80% Four LEDs lit
Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014
Overview 3
Indicator Unit
-
1
40 to 60% Three LEDs lit
25 to 40% Two LEDs lit
10 to 25% One LED lit
5% or less One LED flashes
(3)Operating hours, battery charge, and fault
code display
When the key is first switched on, the accu-
mulated operating hours are displayed to the
nearest tenth for several seconds. The hour
meter accumulates time only when the truck is
switched on and the handle is in the operating
position. After several seconds, the indicator
unit will display battery state of charge as a
percentage. It will continue to display the bat-
tery charge throughout normal operation. If a
fault is present in the truck, the display will al-
ternate between the associated fault code and
the battery charge. If more than one fault code
is active, each fault code will be successively
displayed.
Faults involving the start-up sequence (handle
or throttle out of position at start-up) will clear
automatically when the handle or throttle is
returned to the proper position. Other faults
will require the key switch to be turned off
and then back on after the fault condition is
corrected in order to clear the fault from the
display.
19
3 Overview
Data Plate

Data Plate
MODEL 1 SERIAL # 2
TRUCK WEIGHT
MADE IN 3 (WITHOUT BATTERY +/- 5%) 4 kg lb

ELECTRICS ONLY BATTERY BATTERY BATTERY WEIGHT

VOLTAGE TYPE MAX MIN
5 V 6 kg kg
7
BACK LIFT lb lb
TILT 8 TYPE 9
DRIVE TIRES TRUCK TYPE

10 11
ATTACHMENT(S) A B C D CAPACITY
mm mm mm mm kg
in in in in lb
12
mm mm mm mm kg
in in in in lb
AS SHIPPED THIS TRUCK MEETS THE APPLICABLE REQUIREMENTS OF ANSI/ITSDF B56.1 LINDE MATERIAL HANDLING
0009384611 SUMMERVILLE, SC USA

(1) MODEL – shows the model design- (9) LIFT TYPE – shows a letter correspon-
ation of the truck. ding to the type of mast construction
(2) SERIAL # – shows the serial number as follows:
of the individual truck. S for single masts
(3) MADE IN – shows the country in which D for double masts
the truck was originally manufactured. T for triple masts
(4) TRUCK WEIGHT – shows the weight Q for quad masts
of the truck (in pounds and kilograms) (10) DRIVE TIRES – shows the required
with forks. This weight does not size and type of drive tire
include the battery on electric trucks. (11) TRUCK TYPE – shows the design-
(5) BATTERY VOLTAGE – (electric ation of the truck with respect to ha-
trucks only) – shows the system zardous environments as outlined in
voltage of the truck. 29CFR1910.178. This designation
(6) BATTERY TYPE – (electric trucks corresponds to the environment(s) in
only) – shows the required battery which the truck is approved for use.
designation, as outlined in ANSI (12) CAPACITY – shows the maximum
B56.1. A battery of the correct load weight (in pounds and kilograms)
designation must be installed in order that can be safely lifted for the
for the TRUCK TYPE designation to corresponding devices listed under
be valid. ATTACHMENT(S). In order to achieve
(7) BATTERY WEIGHT – (electric trucks a listed capacity safely, the lift height
only) – shows the allowable weight must be kept within the corresponding
range (MAX and MIN) for the battery value shown in column C and the
in pounds and kilograms. load center of gravity must be within
(8) BACK TILT – shows the maximum the corresponding values shown in
angle that the mast can be tilted back. columns A, B, and D.
.

20 Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014

 Overview 3
Decal and Data Plate Location

Decal and Data Plate Location

8 7

1
2
3

W
AR
N
IN
G
WA
RN
ING

9 4

150649

750Ah (6h) Max

0009384697

6
7

6 5 8
11
10
4
1 WARNING

(EWR)

9
3 WARNING 5
2 (EW)
1101 03192012-03 v2

1 Data plate 6 Decal, Voltage

2 Warning Decal, Trained Operator 7 Decal, Operator Manual Location
3 (EWR) Warning Decal, Platform Surface 8 Warning Decal, Coast Control (optional)
3 (EW) Warning Decal, No Riders 9 Warning Decal, Jog Buttons (optional)
4 Warning Decal, Pinch Hazard 10 Cold Storage Decal (optional)
5 Warning Decal, Service Work 11 EE Designation Decal (optional)

Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014 21

3 Overview
Definition of directions

Definition of directions 1
(1) Forwards
(2) Right
(3) Reverse
(4) Left 4 2
Directions as seen from the driving position;
the control handle is at the front.

3 1152 01252012-01

Options
Trucks may be equipped with the following
options:
• Load backrest
• Accessory tray
• Battery rollers
• Travel alarm
• Shrink wrap holder
• Various drive tire types
• Caster wheels (standard on walkies with
fork length greater than 59 inches and all
riders)
• Greasable heavy duty caster wheels
• Rubber platform skirt (rider trucks only)
• Coast control system (rider trucks only)
• Wash-down protection
• Cold storage protection

22 Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014

 4

Operation
4 Operation
Unloading and Preparing a New Truck for Operation

Unloading and Preparing a

New Truck for Operation
When unloading a new truck, it may be
necessary to tow or lift the truck. See the
corresponding sections in this manual for
instructions regarding towing or lifting.
Before placing a new truck into service,
perform the Daily Maintenance Inspection
as found in the Maintenance section.
Check the drive wheel nuts for tightness. Drive
wheel nuts must be tightened to 103 ft-lbs (140
Nm).
The truck can then be operated at full speed
immediately upon being placed in service.
However, during the first 50 operating hours,
avoid subjecting the drive motors or hydraulic
system to high continuous loads.

WARNING
Wheel mounting hardware sometimes requires
several cycles of tightening before it fully seats.
For this reason, wheel mounting screws or nuts will
often work loose in the period immediately following
initial tightening.
When placing a new truck into service, the wheel
mounting screws or nuts must be checked for
tightness every 10 hours until no further loosening
is detected.

24 Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014

 Operation 4
Turning the Truck On and Off

Turning the Truck On and Off 2

Switching the truck on 1

To turn the truck on, make sure the travel

control is released to the neutral position. Turn
the key switch (1) clockwise. The indicator
unit (2) should briefly display a row of asterisks
followed by the word "HOURS". This is then
followed by a number which is equal to the
accumulated hours on the truck. After a few
seconds, the display is replaced with the
battery state of charge. Battery charge is
displayed continuously from this point on until
the key switch is turned off.
The truck is equipped with a static-return-to-
neutral function. If the travel control is out of 1101 03142012-05

the neutral position at start-up, fault code 54

will be displayed. This fault may be cleared by
releasing the travel control.
Also, if the lift, lower, emergency reverse, or
high-speed (rider trucks only) buttons are held
in at start-up, then an out-of-sequence fault
(54) will be displayed. After correcting the fault
condition, the key switch must then be turned
off and back on to clear the fault and enable
operation.

Switching the truck off

To turn the truck off, turn the key switch
counter-clockwise to the vertical position.
The indicator unit display will turn off.

Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014 25

4 Operation
Driving

Driving
WARNING
A
Operators must be familiar with all safety procedu-
res that apply to forklift operation before driving.
Read and understand all safety information in
Section 2 before operating the truck.

Forward is defined as forks trailing. Reverse

is defined as forks leading. See section three
if necessary.
 Switch the truck on. See "Turning the truck
on and off" if necessary.
 Raise the fork arms so that any load is clear
of the ground.
1101 02232012-06

 Move the control handle into its operating

range (A).
1
NOTE
The travel function is disabled and the mecha-
nical brake is applied whenever the handle is
2
outside its operating range.

Forward motion 2

 With the control handle in the working

1
range, press the upper part of the travel
control (1) so that it rotates in the direction
shown (2).
The truck will move forward. The speed is 3
proportional to the amount of control rotation.
Remain at arm’s length beside the truck during
forward motion unless riding on a rider (EWR) 3
version. Use only the hand nearest the truck 1101 02232012-03
to operate the travel control during forward
walking operation. Always keep one hand on
the grab bar (EWR models only) if riding.

Reverse
 With the control handle in the working
range, press the lower section of the travel
control so that it rotates in the direction
shown (3).
The truck will move in reverse. The speed is
proportional to the amount of control rotation.

26 Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014

 Operation 4
Driving

Remain in front of the truck while operating in

reverse unless riding on a rider (EWR) version.
Keep two hands on the control handle during
reverse walking operation. Always keep one
hand on the grab bar (EWR models only) if
riding.

Emergency Reverse function

To protect the operator from becoming pinned
against an obstacle by the control handle, an
emergency reverse button (4) is provided at
the end of the control handle. If this button
is pressed during operation, the truck will
move off in reverse until the button is released
or 3 seconds elapses. When the button 4
is released, the truck is ready for normal
operation again.

Changing direction
1101 02232012-04

 To change direction at any time during

travel, release the travel control and rotate it
in the opposite direction. This can be done
while the truck is still moving in the original
direction. The truck will be electrically
braked to a stop and then begin moving
in the new direction.

Riding
Some models are equipped for riding. These
versions have a rigid grab bar (5) to hold while
riding. If the truck does not have the grab
bar, it is not designed for riding and riding is 5
not permitted. Rider versions also have a 6
dedicated platform to stand on while riding.

WARNING
Riding trucks without a grab bar and platform can
cause injury.
Trucks without a grab bar and platform are not 1101 02232012-05
intended for riding. Do not ride any truck that is not
equipped with a grab bar and platform.

Rider models are equipped with a high-speed

travel button (6) located on the grab bar.
This button will allow the truck to reach a
higher speed than that used during walking
operation. After the travel control is moved
out of neutral, pressing the high-speed travel

Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014 27

4 Operation
Driving

button will enable the increased speed range.

The button does not need to be held in. The
high-speed function will latch and remain on
as long as the travel control is not released to
neutral. Whenever the travel control reaches
neutral, the high-speed function is cancelled.
If high speed is desired again, the button
must be pressed again after moving the travel
control out of neutral.
WARNING
Use of the high-speed function if not in a stable
riding position can cause accident and injury.
Always ensure a stable riding position and keep one
hand on the grab bar while using the high-speed
function. Do not use the high-speed function during
walking operation.

28 Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014

 Operation 4
Steering

Steering
Steering the truck is done using the control
handle. Manually moving it to the left or right
will swivel the drive wheel. The truck then
turns in forward or reverse according to the
handle direction.

1101 02272012-01

Horn
Press the horn button (1) on the control handle 1
to sound the horn.
If the truck is a rider model, an additional horn
button (2) is provided on the grab bar. Either
button will sound the horn.

1101 02232012-01

1101 03142012-02

Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014 29

4 Operation
Braking

Braking
The truck has electric braking built in to the
motor control equipment and mechanical
braking through a mechanical drum brake on
the drive unit. Electric braking is controlled
by the position of the travel control. The
mechanical brake is controlled by the position
of the control handle.
Electric braking
1
1101 03142012-01
 While travelling, rotate the travel control
toward the opposite direction until the truck
has been electrically braked to a stop.
The truck will slow to a stop faster than if
the travel control is simply released. After
stopping, the truck will accelerate in the new
direction unless the travel control is then
released.
The truck is also equipped with an anti-rollback
feature. If the truck is stopped on an incline
and the control handle is moved into the
operating position to restart, the truck will
creep down the incline at a slow speed for
approximately one foot and then stop unless
the travel control is used. Always release
the control handle to engage the mechanical
brake if the truck must be held stationary on an
incline. Never leave the truck unattended on
an incline.
Mechanical brake

There are two modes of electric braking. The

first mode activates when the travel control
is eased towards the neutral position. The A
second mode activates if the travel control
is rotated toward the opposing direction.
The braking force is greater with the second
mode than with the first. The second mode
is sometimes referred to as "plugging". Both
modes are regenerative and therefore convert
truck momentum back into energy to recharge
the battery. The amount of braking force that
occurs in each of these modes is adjustable in
the truck control program.
 While travelling, release the travel control
(1). 1101 02232012-06

The truck will slow to a stop depending on the
setting of the electric brake function.
NOTE
Slow or quick release of the travel control into
the neutral position allows the braking action
to be sensitively controlled, from gentle to hard
braking.
The mechanical brake is applied by spring
force acting on the brake shoes in the brake
assembly. When the control handle is moved
into its operating range (A), a mechanical
linkage releases the brake. If the control
handle is released, it will spring back out of
its operating range to its full vertical position
(unless the optional coast control system is
engaged).

30 Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014

 Operation 4
Raising and Lowering the Forks

Whenever the control handle moves out of its
operating range, the mechanical brake begins
to be applied. If the key switch is on, the truck’s
travel function will become disabled. The
further out of the operating range the handle
moves, the harder the brake is applied. If the
handle is completely released to its full vertical
position or held down against its lower stop,
the brake is fully applied. The brake remains
applied as long as the control handle is out of
its operating range. With the handle released
to its full vertical position, the mechanical
brake functions as a parking brake to hold the
truck when unattended.

Raising and Lowering the

Forks 2
1
WARNING
When lowering the forks, feet can become pinched
against the floor.
Make sure all personnel are clear of the forks before
lowering them.

Raising and lowering of the forks is controlled

through buttons on the end of the control
handle. To raise the forks, press the lift 1101 02232012-02
button(1). To lower the forks, press the
lowering button (2). Note the symbols on the
buttons.
On rider models, additional lift and lower
buttons are provided on the grab bar. Their
function is identical to the buttons in the control
handle.

Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014 31

4 Operation
Coast Control System (Optional equipment)

Coast Control System

(Optional equipment) 3
3
Rider trucks may be equipped with an optional
coast control system. This system is intended
to allow efficient movement of the truck for
short distances during order picking activities 1
where materials are placed on or removed
from the truck. The coast control system
provides a band-type brake at the control
handle pivot to hold the handle in the operating 2
position. A red button on each side of the
control handle is also provided to move the
truck forward slightly without having to twist
the travel control. Before these features will
function, the system must be activated by 1101 03152012-02
pushing a button on the back of the auxiliary
button housing. Whenever the system is
active, a yellow indicator light on the chassis
will turn on.
 To use the system, hold the control handle A
within the coast control range (B) and push B
the activation button (1). Confirm that the
yellow indicator (2) comes on. The coast
control handle range is inside the normal
operating range (A).
 Let go of the handle and confirm that it
remains in position. Note that the system
does not lock the handle into position. It only
suppresses the action of the handle return
spring. The handle can be moved manually
at any time if necessary. 1101 03152012-01

WARNING
When the control handle is held in the operating
position, the brake will not be automatically applied.
The truck will coast to a stop after movement.
Before moving the truck, ensure that there is ade-
quate room for the truck to coast to a stop.

WARNING
Allowing the truck to travel unattended can cause
injury if personnel or equipment are in its path.
Always remain with the truck until it comes to a
complete stop. Watch for personnel or equipment
entering the path of the truck. To stop the truck,
release the red button or travel control and move
the handle to the full up or down position.

32 Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014

 Operation 4
Coast Control System (Optional equipment)

 To move the truck forward, stand to one

side of the truck and press either red button
(3) on the side of the control handle. The
truck will move forward as long as the
button is held. The truck will coast to a stop
when the button is released. This operation
allows movement of the truck between pick
locations with greater convenience than
the twist action of the travel control. The
travel control will still operate normally and
can be used to move the truck in forward or
reverse at any time if required. The sides of
the handle may be pushed or pulled to steer
the truck as necessary.
 When finished with order picking activities,
turn the coast control system off by moving
the control handle either up or down out of
the operating range. Verify that the indicator
light goes out. The system may also be
turned off by resuming the correct riding
position, rotating the travel control and
pushing the high-speed button. The system
will automatically disengage any time the
emergency reverse button is activated or if
the truck is turned off with the key switch.
When the system is off, the handle will
return to vertical if not held and the red
buttons are disabled. The activation button
(1) will not turn the system off.

WARNING
Riding the truck with the coast control system
engaged can cause accident and injury.
Never ride the truck with the coast control system
engaged. Always stop the truck and dismount
before engaging the coast control system.

WARNING
Use of coast control on an incline can result in
longer coasting distances.
Do not operated the truck on an incline with the
coast control system active.

Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014 33

4 Operation
Connecting and Disconnecting the Battery

Connecting and Disconnecting the Battery

The battery is connected and disconnected connected and the truck may be switched
at the battery connector (1) on the left-hand on.
side of the chassis. The battery connector
Disconnecting the Battery
also serves as an emergency disconnect if
necessary.  Turn the key switch off.
Connecting the Battery  Grasp the battery connector (1) and pull it
apart. Place the loose cable on the battery
 Ensure the key switch is off.
to guard against damage.
 Align the battery connector halves and
push them together. The battery will be

Connecting the Battery to an External Charger

WARNING
Specialized training is required to charge batteries
safely.
Batteries may only be charged by properly trained
personnel in accordance with the instructions of the
charger manufacturer and the following procedure.
WARNING
Explosive gases are released during battery char-
ging.
Charge batteries only in well ventilated areas.
 On EW/EWR 27/60 models, tilt the load
backrest (if equipped) towards the forks.
 Open the battery cover.
WARNING
Dangerous concentrations of explosive gases can
occur during battery charging if the battery cover is
not open.
The battery cover must be left completely open du-
ring the entire charging period to allow ventilation.
 Unplug the battery connector.

 Park the truck safely.
 Fully lower the forks and turn off the key
switch.
 Remove the accessory tray if equipped.
 Attach the battery connector on the battery
cables to the connector plug of the external
battery charger.
 Charge the battery in accordance with the
charger manufacturer’s instructions.

34 Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014

 Operation 4
Changing the Battery

Changing the Battery 2

1
WARNING
Specialized training is required to handle batteries
safely.
Batteries may only be changed by properly trained
personnel in accordance with the instructions of the
battery manufacturer and the following procedure.

The battery can be changed in various ways:

• Using a crane (taking care to stay within the
permissible load carrying capacity of the
crane and the lifting gear)
• Using an additional truck (taking care to 3
stay within the permissible load carrying 1101 03142012-04
capacity of the truck)
• Using specialized side extraction equip-
ment if the truck is equipped with the optio-
nal battery roller tray.

WARNING
If any lifting equipment (forklift trucks or other lifting
equipment) used to change a battery has insuffi-
cient load carrying capability and/or forks whose
length is too short, there is a risk of accidental injury
or death.
Use only equipment of sufficient size and load
carrying capability to change batteries.

 Park the truck safely. 5

 Fully lower the fork carriage and turn off the 4
key switch. 1101 03142012-03

 Release the control handle to the full vertical

position.
 Disconnect the battery at the battery
connector (1).
 On EW/EWR 27/60 models, tilt the load
backrest (if equipped) towards the forks.
 Remove the optional accessory tray (2) if
equipped.

Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014 35

4 Operation
Changing the Battery

WARNING
Shorting of battery terminals can cause burns,
electrical shock, or explosion.
Do not allow metal parts to contact the top surface
of the battery. Make sure all terminal caps are in
place and in good condition.

 Using a crane or another truck, carefully

move the lifting gear into position over the
battery. If using side extraction equipment,
position it according to the manufacturer’s
instructions.
 Insert the hooks of the lifting gear into the
openings provided for this purpose in the
battery carrier. If using side extraction
equipment, attach it according to the
manufacturer’s instructions.
 Carefully lift the battery until it clears the
side wall (3) of the battery compartment and
move it slowly out of the truck chassis. If the
truck is equipped with the optional battery
rollers (4), remove the battery retainer (5)
on the side from which the battery is to be
removed. The battery may then be rolled
out of the battery compartment without
lifting.
 Check the battery for leaking acid, cracked
housing or raised plates.
 Check that the battery plug and cable are
in good condition and leave the battery in a
safe place.

WARNING
Batteries of incorrect size or weight can reduce
traction and braking ability.
Install only batteries whose weight meets the
specification listed on the truck data plate.

 Carefully position the replacement battery

in the battery box. Disconnect and remove
all lifting equipment.
 If the truck is equipped with battery rollers,
replace the battery retainer plate.

36 Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014

 Operation 4
Towing the Truck

WARNING
On trucks equipped with battery rollers, an unsecu-
red battery can roll out of the truck during operation
and cause severe injury.
Ensure that both battery retainer plates are in place
before operating the truck.

 Plug the battery plug into the battery con-

nector socket (1).
 On EW/EWR 27/60 models, tilt the load
backrest (if equipped) back into position.
 Replace the accessory tray if equipped.

WARNING
Batteries produce explosive gases.
Always store batteries in well ventilated areas.

Towing the Truck

WARNING
With the control handle released, the mechanical
brake will remain applied and the drive wheel will
not turn.
To prevent damage from dragging the drive tire,
always ensure that it is clear of the ground when
towing.

 Remove any load from the forks before

towing.
 If the hydraulic system is functional, raise
the forks.
 Attach towing equipment to the front bum-
per of the chassis. Towing equipment must
be capable of lifting the front of the truck
enough for the drive tire to clear the ground.

WARNING
The control handle will be damaged if towing equip-
ment is attached to it.
Never tow the truck by the control handle.

 Lift the front of the truck enough for the drive

tire to clear the ground but not so much that
the fork tips drag. The truck may then be
towed.

Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014 37

4 Operation
Hoisting the Truck

Hoisting the Truck

This section explains the attachment of
lifting equipment to the truck for the purpose
of hoisting. Many methods of rigging to a
crane or hoist are possible. Explanation of
such methods as well as operation of lifting 2
equipment is outside the scope of this manual.
Both the attachment of lifting equipment to
the truck and the hoisting operation itself must
be performed by personnel experienced in
rigging.

WARNING 1
Lifting equipment of insufficient capacity can fail
and cause severe injury or death.
Ensure that all lifting slings, hardware, or other
1101 05182012-01

equipment has sufficient capacity to carry the

weight of the truck. Refer to the truck data plate
for truck weight. If a battery is installed, its weight
must be added to the truck weight listed on the data
plate.

 Disconnect the battery.

 Use lifting hooks to hook the bottom edge of
the frame rails on each side at the positions
shown (1).
 Attach lifting equipment to the fork tips to
keep the truck approximately horizontal as
it is lifted.
 If no battery is installed, lifting equipment
may be attached at the two rectangular ope-
nings (2) at the bottom of the front (handle
side) wall of the battery compartment. De-
pending on lifting equipment used, the forks
may have to be raised to gain enough clea-
rance inside these openings. When sus-
pended from these openings, trucks with
fork lengths up to 80 inches will balance
acceptably. Trucks with longer fork lengths
will require additional attachment of lifting
equipment at the fork tips.

38 Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014

 5

Maintenance
5 Maintenance
Personnel Qualifications

Personnel Qualifications
Only qualified personnel authorized by the be unaffected by operational and economic
owner are permitted to perform maintenance conditions and must be conducted solely from
or repair work. All items listed in the Scheduled a safety standpoint.
Maintenance Charts must be performed by
Daily inspection procedures and simple
qualified forklift technicians only. They must
maintenance checks, e.g. checking the
have knowledge and experience sufficient
hydraulic oil level or checking the fluid level
to assess the condition of a forklift truck and
in the battery, may be performed by operators.
the effectiveness of the protective equipment
This does not require training as described
according to established principles for testing
above.
forklift trucks. Any evaluation of safety must

Cleaning the Truck

The need for cleaning depends on use of CAUTION
the truck. If highly aggressive media are
Never wash truck when switched on.
involved, e.g. salt water, fertilizer, chemicals,
Switch the truck off and disconnect the battery
cement etc., thorough cleaning is required
before any cleaning operations.
after finishing the work assignment.
Hot steam or cleaning materials with a power-
CAUTION
ful degreasing effect should only be used with
great caution as this will affect the grease filling When cleaning with a water jet (high-pressure or
of bearings with lifetime lubrication, causing steam cleaner etc.), it should not be applied directly
it to escape. As re-lubrication is not possible, to the drive unit, any electric or electronic compo-
nents, connector plugs or insulating material. High
the bearings will be irreparably damaged. pressure water also should not be applied directly
to the operator controls on the control handle.
When using compressed air for cleaning,
remove stubborn soiling with cold cleaner. If this is unavoidable, the parts concerned should
be covered up beforehand or only cleaned with a
During cleaning pay special attention to the oil dry cloth or clean compressed air.
filler openings and the surrounding areas as
well as the lubricating nipples prior to greasing.
Run the truck immediately after cleaning to
check operation and to aid in drying in case
any motors became exposed to moisture.

40 Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014

 Maintenance 5
Daily Inspection

Daily Inspection
Daily Inspection Overview

ELECTRIC MOTORIZED HAND TRUCK - WITHOUT MAST

OPERATOR’S DAILY CHECKLIST

Truck Serial Number: ____________________ Dept / Shift: __________________ Operator: _______________________

Hour meter reading: _____________________ Date: _______________________ Supervisor: _____________________

Check each of the following items before the start of each shift. Let your supervisor and/or maintenance department know
of any problem. Start at the front of the lift truck and work towards the rear. After checking, mark each item accordingly. Explain
below as necessary.

Check boxes as follows: OK NR, Needs Repair. Circle problem and explain below.

O N
VISUAL INSPECTION
K R
Oil Spots on Floor (check for leaks on truck)
Drive Tire (wear, cuts, or embedded objects, rim damage,
loose/missing lug nuts)
Hydraulic Oil (check level)
Steer Axle, Chain, or other mechanism (check for
damage, debris)
Motor Covers (Loose fasteners, cracked or broken)
Steering; Control Handle (movement, operation)
Throttle Hand Grips (check for wear, damage)
Anti-slip Mat (if equipped) (check condition, cleanliness)
Battery Connectors & Cables (damage, cracks, pitting)
Battery Retention (installed correctly, secure)
Battery Case & Vent caps (damage, cracks, loose,
missing)
Fork Frame (damage. twist)
Load wheels (tire wear, damage, entrapped debris)
Warning Decals/Operator’s Manual (in place, legible)
Data Plate / Capacity Plate (in place, legible)
O N
K R OPERATIONAL INSPECTION
Unusual Noise (during any of the operational checks)
Emergency Battery Disconnect (check operation)
Gauges and Instrumentation (check operation)
Battery Charge (fully charged)
Emergency Reverse Button (check operation)
Forward Driving (accelerates, steers, brakes smoothly)
Plugging (stops, changes direction smoothly)
Reverse Driving (accelerates, steers, brakes smoothly)
Service/Parking Brake (check operation)
Hydraulic Controls (operate freely, return to neutral)
Hydraulic Oil (excessive noise when forks are fully
raised is indication of low hydraulic oil)
Horn (sounds when button pressed)
Backup Alarm (if equipped) (sounds in reverse)
Travel Alarm (if equipped) (sounds with vehicle in motion)
Work, Strobe, Flashing Lights (if equipped) (check
operation)
Coast Control (if equipped) (check operation)
Coast Control Indicator Light (if equipped) (check
operation)

Explanation of problems marked above (use back of this form if needed):

_____________________________________________________________________________________________
____________________________________________________________________________________________
_____________________________________________________________________________________________
OSHA 1910.178 (p) (1) requires a truck to be taken out of service any time it is found to be in need of repair, or is in any
way defective or unsafe. Place a “Do Not Operate” tag on the truck, remove the key and alert your supervisor. The
Truck may not be placed back into service until necessary repairs are made.
F231 05-2013

The following inspection tasks in this section operated until such repairs are complete.
should be carried out by the operator or This list does not cover attachments or other
designated service personnel before each truck modifications not manufactured by
shift or at least daily. This inspection is not part Linde. Refer to the respective manufacturer’s
of the regularly scheduled maintenance listed documentation for maintenance information
elsewhere in this chapter and is not intended pertaining to such items.
to replace any of it. Regularly scheduled
A checklist such as the one illustrated may
maintenance must be performed by a qualified
be helpful in performing daily inspection. The
forklift technician at the intervals indicated.
checklist illustrated is intended for a range
If any problem affecting safety is noted, it of pallet truck types, so some items may not
must be repaired immediately by a trained apply.
forklift technician. The truck must not be

Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014 41

5 Maintenance
Daily Inspection
WARNING
To prevent accidents during maintenance activities,
the truck must be secured against unintentional
movement or start-up.
Before beginning any maintenance, the forks
should be fully lowered, and the key switch turned
off. The truck must remain in this state throughout
the maintenance process except for individual
maintenance activities that specifically require
otherwise.
Check for Fluid Leakage
Check the entire truck as well as the surface
beneath it for signs of fluid leakage.
Check Forks and Chassis
Inspect the forks, chassis, and if equipped, the
load back rest for deformity, cracks, or other
damage.
Check Battery Connector
Disconnect and reconnect the battery to
confirm smooth operation. Inspect the battery
connector and its cables for damage.
Check Decal Condition
Inspect all decals and the data/capacity plate
for condition and legibility. Decal locations are
given in the Overview section of this manual.
Any damaged or unreadable decals must be
replaced.
Check Control Handle Pivot
Check the pivot point where the control handle
attaches to the chassis for smooth operation
by moving the handle through its entire range.
Check Operating Controls
Return Spring
Pull the control handle down into its operating
range and release it. It should return to the
vertical position under spring tension.
42 Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014
Brake Interlock - Handle
Operate the truck in forward or reverse. Move
the control handle all the way up or down out
of the operating range without releasing the
travel control. The drive system should switch
off and the mechanical brake should engage.
Brake Interlock - Travel Control
Operate the truck in forward or reverse.
Release the travel control without moving
the control handle out of its operating range.
The truck should slow to a stop using electric
braking.
Emergency Reverse Button
Operate the truck forwards and press the
emergency reverse button. The truck should
stop and then move in the opposite direction
until the button is released.
Perform Operational Check
Before returning the truck to service, perform
an operational check of the following items:
• Mechanical brake
• Multi-function display/battery discharge
indicator
• Horn
• Forward and reverse travel
• Electric braking (plugging)
• Fork lift and lower function (operate through
complete range of motion)
• Working lights (if equipped)
CAUTION
Excessive noise during hydraulic function operation
indicates low hydraulic fluid.
This condition must be checked and corrected
immediately to avoid damage to the hydraulic
pump.

Scheduled Maintenance
General Maintenance Information
This section contains all information required
to determine when the truck must be serviced
and what must be done. This information is
presented as scheduled maintenance charts
on the following pages. Be sure to perform
maintenance within the time limit given in
the maintenance charts. Proper and timely
maintenance is essential to obtain the full
operability, performance and service life from
the truck, and is a prerequisite for any warranty
claims.
Maintenance Intervals
Maintenance intervals are based on operating
hours but are also subject to the maximum
intervals (based on years in service) listed at
the top of each chart.
All lubrication and service intervals must be
reduced for dusty conditions, large tempera-
ture fluctuations or intensive use.
Scheduled Maintenance Charts
The scheduled maintenance charts provide
a list of maintenance tasks and associated
Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014
Maintenance 5
Scheduled Maintenance
time intervals at which they must be carried
out. Charts are provided for all intervals
and are complete for each interval in that
they include all necessary items from lesser
intervals that might come due at the same
time. (For example, a 3000 hour chart would
include all of the items from the 1000 hour
chart plus a few specific 3000 hour items.)
For this reason only one chart is necessary to
cover any given interval. All the intervals at
which a chart applies are listed at the top of the
chart (up to 20,000 hours). A check-off box
is provided beside each interval to allow for a
written record of maintenance completion.
Detailed instructions for performing the mai-
ntenance items listed are found in the service
manual. Use only high-quality lubricants or
other materials meeting the specifications
listed in Fluid and Lubricant Specifications.
All work must be performed only by qualified
forklift technicians. Custom-fitted equipment
is not covered by the scheduled maintenance
charts. If such equipment is installed, refer
to the manufacturer’s documentation for mai-
ntenance requirements.
43
5 Maintenance
Scheduled Maintenance

Maintenance Every 50 Hours

At operating hours
50 100 150 250 300
Carried
350 450 500 550 650 out
700 750 850 900 950  
Maximum interval
Dependent on the driving style and operating conditions, the following procedures
must be carried out at the intervals shown above and every 50 hours thereafter
throughout the life of the truck.
Preparations
Clean the truck (if necessary).
Read out error log and delete.
Enter the next maintenance interval.
Chassis
Grease the load wheel axles.
If the truck is equipped with casters, inspect the height adjustment and tire condition.
Lubricate axles if greasable option is present.
Subsequent tasks
Carry out functional test and test drive.
Attach maintenance sticker.

44 Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014

 Maintenance 5
Scheduled Maintenance

Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014 45

5 Maintenance
Scheduled Maintenance

Maintenance Every 200 Hours

At operating hours
Carried
200 400 600 800 1200 out
1400 1600 1800 2200  
Maximum interval
Dependent on the driving style and operating conditions, the following procedures
must be carried out at the intervals shown above and every 200 hours thereafter
throughout the life of the truck. Reduce this interval to 100 hours for trucks equipped
with wash-down package or cold storage package.
Preparations
Clean the truck (if necessary).
Read out error log and delete.
Enter the next maintenance interval.
Drive motor
Check that the cables and harnesses are correctly routed and in good condition.
Gear unit
Check for gear oil leakage.
Lubricate the drive unit swivel bearing at its two grease fittings.
Chassis
Grease the load wheel axles.
If the truck is equipped with casters, inspect the height adjustment and tire condition.
Lubricate axles if greasable option is present.
Visually check the general condition of the chassis and forks.
Check tire condition.
Check the brake mounting, drum, spring, shoes and linkage.
Check wheel fasteners and tighten if necessary.
If the truck is equipped with casters, lubricate the swivel joints at the grease fittings
provided.
Controls
Check the adjustment and operation of the travel control linkage.
Electrical system
Clean the electrical panel and controller power terminals with compressed air.
Check tightness of the line contactor power terminals. Check contactor tips and
clean or replace as required.
Check condition/secure positioning of cables, wiring, connections and connectors.

46 Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014

 Maintenance 5
Scheduled Maintenance

At operating hours
Carried
200 400 600 800 1200 out
1400 1600 1800 2200  
Check the battery condition, acid level and acid density.
Hydraulics
Check the breather on the hydraulic pump unit. If dirty, remove it, clean with solvent,
then dry with compressed air. Reinstall 2-3 turns past finger-tight.
Check the hydraulic oil level.
Check the pump unit for noises, leaks, and proper operation.
Check the lift cylinder and lines for leaks.
Fork lifting mechanism
Check operation of the lift limit switch by verifying the pump motor stops when forks
reach maximum height.
Lubricate the fork linkage at all grease fittings.
Subsequent tasks
Carry out functional test and test drive.
Attach maintenance sticker.

Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014 47

5 Maintenance
Scheduled Maintenance

Maintenance Every 1000 Hours

At operating hours
Carried
1000 3000 5000 7000 9000 out
11,000 13,000 17,000 19,000  
Maximum interval
Dependent on the driving style and operating conditions, the following procedures
must be carried out at the intervals shown above and every 1000 hours thereafter
throughout the life of the truck.
Preparations
Clean the truck (if necessary).
Read out error log and delete.
Enter the next maintenance interval.
Drive motor
Check that the cables and harnesses are correctly routed and in good condition.

Gear unit
Check for gear oil leakage.
Change the gear oil.
Lubricate the drive unit swivel bearing at its two grease fittings.

Chassis
Grease the load wheel axles.
If the truck is equipped with casters, inspect the height adjustment and tire condition.
Lubricate axles if greasable option is present.
Visually check the general condition of the chassis and forks.
Check tire condition.
Check the brake mounting, drum, spring, shoes and linkage.
Check wheel fasteners and tighten if necessary.
If the truck is equipped with casters, lubricate the swivel joints at the grease fittings
provided.
Check drive motor, gearbox, and control handle mounting.
Lubricate the battery rollers if equipped (optional equipment).
Controls
Check the adjustment and operation of the travel control linkage.
Electrical system
Clean the electrical panel and controller power terminals with compressed air.

48 Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014

 Maintenance 5
Scheduled Maintenance

At operating hours
Carried
1000 3000 5000 7000 9000 out
11,000 13,000 17,000 19,000  
Check tightness of the line contactor power terminals. Check contactor tips and
clean or replace as required.
Check condition/secure positioning of cables, wiring, connections and connectors.
Check the battery condition, acid level and acid density.
Hydraulics
Clean the breather on the hydraulic pump unit. Unscrew the breather, clean with
solvent, then dry with compressed air. Reinstall 2-3 turns past finger-tight.
Change the hydraulic oil.
Check the pump unit for noises, leaks, and proper operation.
Check the lift cylinder and lines for leaks.
Check the brush length and condition on the pump unit motor.
Fork lifting mechanism
Check operation of the lift limit switch by verifying the pump motor stops when forks
reach maximum height.
Lubricate the fork linkage at all grease fittings.
Subsequent tasks
Carry out functional test and test drive.
Attach maintenance sticker.

Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014 49

5 Maintenance
Scheduled Maintenance

Scheduled Maintenance Summary

50 200 1000
DESCRIPTION
hrs hrs hrs
Clean the truck (if necessary). • • •
Read out error log and delete. • • •
Enter the next maintenance interval. • • •
Grease the load wheel axles. • • •
If the truck is equipped with casters, inspect the height adjustment and tire condition. Lubricate axles
• • •
if greasable option is present.
Carry out functional test and test drive. • • •
Attach maintenance sticker. • • •
Check that the cables and harnesses are correctly routed and in good condition. • •
Check for gear oil leakage. • •
Lubricate the drive unit swivel bearing at its two grease fittings. • •
Visually check the general condition of the chassis and forks. • •
Check tire condition. • •
Check the brake mounting, drum, spring, shoes, and linkage. • •
Check wheel fasteners and tighten if necessary. • •
If the truck is equipped with casters, lubricate the swivel joints at the grease fittings. • •
Check the adjustment and operation of the travel control linkage. • •
Clean the electrical panel and controller power terminals with compressed air. • •
Check tightness of the line contactor power terminals. Check contactor tips and clean or replace as
• •
required.
Check condition/secure positioning of cables, wiring, connections and connectors. • •
Check the battery condition, acid level and acid density. • •
Check the breather on the hydraulic pump unit. If dirty, remove it, clean with solvent, then dry with
• †
compressed air. Reinstall 2-3 turns past finger-tight.
Check the hydraulic oil level. • •
Check the pump unit for noises, leaks, and proper operation. • •
Check the lift cylinder and lines for leaks. • •
Lubricate the fork linkage at all grease fittings. • •
Clean the breather on the hydraulic pump unit. Remove it, clean with solvent, then dry with compres-
•
sed air. Reinstall 2-3 turns past finger-tight.
Change the gear oil. •
Check the drive motor, transmission, and control handle mounting. •
Lubricate the battery rollers if equipped. •
Change the hydraulic oil. •
Check the brush length and condition on the pump unit motor •

† denotes a task that is superseded by another for this interval

.

50 Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014

 Maintenance 5
Fluids and Lubricants

Fluids and Lubricants

Fluid and Lubricant Specifications
Hydraulic Oil
Original equipment specification
The following grades of hydraulic oil are supp-
lied from the factory as original equipment:
ISO-L-HM 68 as per ISO 6743-4 for stan-
dard trucks
ISO-L-HM 15 as per ISO 6743-4 for freezer
trucks
ISO-L-HM 32 as per ISO 6743-4 for cooler
trucks

Gear Oil
SAE 80W-90 API GL5, multi-purpose gear
oil, MIL-L-2105 or equivalent.

Grease
Lithium-based grease with MoS2.

NOTE
Do not mix non-lithium-based greases with
lithium-based greases.

Capacities

Assembly Fluid or Lubricant Capacity

Hydraulic system Hydraulic oil 1.4 qts (1.3 l)
Transmission Gear oil 1.9 qts (1.8 l)
.

Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014 51

5 Maintenance
Troubleshooting

Troubleshooting
Fuses
F1
The standard truck has one main power fuse
F2 1F1
and four control fuses. Rider trucks equipped
with the coast control option will have a fifth F3
control fuse. All fuses are mounted to the F4
frame near the battery connector. The 250 F5
amp main power fuse (1F1) protects the drive
motor and the power circuit side of the main
control unit. The control fuses are assigned as
follows:
F1: (15 amp) Protects all key switched
inputs
F2: (4 amp) Protects controller positive
input
F3 (4 amp) Protects horn
1101 03302012-01
F4: (4 amp) Protects fan motor (rider trucks
only)
F5 (4 amp) Protects coast control system
(optional)

WARNING
The motor fuse carries very high currents which
can cause fire or injury if inappropriately handled or
incorrectly installed.
Only trained service personnel should inspect
or replace these fuses. The specific installation
sequence of cables, hardware, and fuses onto
the fuse terminals is vital to proper functioning
of the fuses. Incorrect installation sequence of
these parts can cause premature fuse failure,
overheating, or fire.

52 Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014

 Maintenance 5
Troubleshooting

Diagnostic Connector
The diagnostic connector (1) is located in a
bracket with two harness connectors imme-
diately below the control unit. It provides an 1
interface between the control unit and dia-
gnostic software on a hand programming
unit or laptop computer. The software allows
review/editing of performance parameters,
readout of fault codes, and resetting of mai-
ntenance intervals.

1101 04022012-01

Maintenance Intervals
The truck control system has the capability
to store a programmed maintenance interval.
When the operating hours on the truck reach
this programmed value, the red light beside
the wrench symbol on the indicator unit
will begin flashing. When this occurs, the
maintenance interval value must be increased
to the next desired maintenance interval to
clear the fault. This requires connecting
a hand held programming unit or a laptop
containing the appropriate software to the
diagnostic plug and then resetting the value.
The procedure is explained in the service
manual.

Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014 53

5 Maintenance
Troubleshooting

54 Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014

 6

Technical Data
6 Technical Data
Specifications

Specifications
825 BC

LBR Tilt
h14

h4
S

h3

MFH
h7

L2

h13
m2

L1

L
X
90º
b10

b11
b1

b5

b2
e

Wa

1101 05292012-01

56 Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014

 Technical Data 6
Specifications

General EW 27/60 EWR 27/60 EW 36/80 EWR 36/80

Manufacturer Linde Linde Linde Linde
Manufacturer’s model
EW 27/60 EWR 27/60 EW 36/80 EWR 36/80
designation
Drive type Electric Electric Electric Electric
Operation: manual, accompa- Accompa- Accompa-
nied, standing, seated, order Accompanied nied/ Accompanied nied/
picking Standing Standing
Nominal load capacity
(May be downrated for certain 6000 lbs 6000 lbs 8000 lbs 8000 lbs
masts or attachments. Always (2700 kg) (2700 kg) (3600 kg) (3600 kg)
refer to vehicle data plate.)
Load distance (x) See fork table See fork table See fork table See fork table
Wheelbase (y) See fork table See fork table See fork table See fork table

Weights EW 27/60 EWR 27/60 EW 36/80 EWR 36/80

Refer to Refer to Refer to Refer to
Service weight vehicle data vehicle data vehicle data vehicle data
plate plate plate plate

Wheels and tires EW 27/60 EWR 27/60 EW 36/80 EWR 36/80

Rubber/ Rubber/ Rubber/ Rubber/
Tire type, drive/load/caster
poly/poly poly/poly poly/poly poly/poly
Tire size, drive (dia. x width x
10x7x6.5 in 10x7x6.5 in 10x7x6.5 in 10x7x6.5 in
rim dia.)
Tire size, load (outside dia.) 3.25 in 3.25 in 3.25 in 3.25 in
Number of wheels, front / rear
1x / 2 1x / 2 1x / 2 1x / 2
(x = driven)
Track width, front 27.7 in 27.0 in 27.7 in 27.0 in
(casters) (b10) (704 mm) (686 mm) (704 mm) (686 mm)
Track width, rear (load) (b11) See fork table See fork table See fork table See fork table

Dimensions EW 27/60 EWR 27/60 EW 36/80 EWR 36/80

LBR tilt angle 27° 27° No tilt (fixed) No tilt (fixed)
Fork height, lowered (h13) 3.7 in (94 mm) 3.7 in (94 mm) 3.7 in (94 mm) 3.7 in (94 mm)
Maximum lift height from floor 9.2 in 9.2 in 9.3 in 9.3 in
(MFH) (234 mm) (234 mm) (237 mm) (237 mm)
5.5 in 5.5 in 5.6 in 5.6 in
Lift stroke (h3)
(141 mm) (141 mm) (143 mm) (143 mm)
Extended height, with 48 in 53.6 in (1362 53.6 in 53.7 in 53.7 in
LBR (h4) mm) (1362 mm) (1364 mm) (1364 mm)

Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014 57

6 Technical Data
Specifications

Dimensions EW 27/60 EWR 27/60 EW 36/80 EWR 36/80

Handle height, maximum 59.8 in 59.8 in 59.8 in 59.8 in
(h14) (1519 mm) (1519 mm) (1519 mm) (1519 mm)
7.6 in 7.6 in
Platform height (h7) - -
(193 mm) (193 mm)
Ground clearance, mid- 1.4 in 1.4 in 1.5 in 1.5 in
fork (m2) (35.4 mm) (35.4 mm) (36.8 mm) (36.8 mm)
2.3 in 2.3 in 2.2 in 2.2 in
Fork thickness, mid-fork (s)
(57.6 mm) (57.6 mm) (57.2 mm) (57.2 mm)
Overall length (l1) See fork table See fork table See fork table See fork table
Load wheel distance (x) See fork table See fork table See fork table See fork table
Wheelbase (y) See fork table See fork table See fork table See fork table
36.1 in 44.4 in
Chassis length (l2)/
(918 mm)/ (1129 mm)/ 37.3 in 45.6 in
with optional 9 in battery
31.7 in 40.0 in (948 mm) (1159 mm)
compartment
(805 mm) (1016 mm)
34.3 in 34.3 in
Overall width (b1), standard (872 mm)/ 36.0 in (872 mm)/ 36.0 in
truck / EW with casters 37.9 in (915 mm) 37.9 in (915 mm)
(963 mm) (963 mm)
Fork spread (b5) standard / 27 / 32 in 27 / 32 in 27 / 32 in 27 / 32 in
optional (686 / 813 (686 / 813 (686 / 813 (686 / 813
Add 1 in (25.4 mm) for L .> 60 mm) mm) mm) mm)
in
18 / 23 in 18 / 23 in 18 / 23 in 18 / 23 in
Track width, rear (b11)
(457 / 584 (457 / 584 (457 / 584 (457 / 584
standard / optional
mm) mm) mm) mm)
Fork width (e)
9 in 9 in 9 in 9 in
Add 1 in (25.4 mm) for L .> 60
(229 mm) (229 mm) (229 mm) (229 mm)
in
Turning radius (Wa) See fork table See fork table See fork table See fork table

Fork Lengths EW & EWR 27/60

Turning
Wheelbase (y) Overall
Load wheel radius (Wa)*
Fork length (L) lowered/rai- length (L1)*
distance (X) (lowered)
sed EW/EWR
EW/EWR
51.6 ) / 55.4 in 64.7 / 73.0 in 74.2 / 80.6 in
28.5 in
36 in (914 mm) (1311/1406 (1643/1854 (1883/2045
(724 mm)
mm) mm) mm)
57.6 / 61.4 in 70.7 / 79.1 in 78.2 / 86.5 in
34.5 in
42 in (1067 mm) (1464/1559 (1795/2007 (1986/2197
(876 mm)
mm) mm) mm)

58 Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014

 Technical Data 6
Specifications

Fork Lengths EW & EWR 27/60

63.6 / 67.4 in 76.7 / 85.0 in 84.2 / 92.6 in
40.5 in
48 in (1219 mm) (1616/1711 (1948/2159 (2138 2350
(1029 mm)
mm) mm) mm)
75 / 79.4 in 88.7 / 97.0 in 88.4 / 104.6 in
52.5 in
60 in (1524 mm) (1921/2016 (2253/2464 (2243/2655
(1334 mm)
mm) mm) mm)
* Subtract 4 inches (101.6 mm) from Wa and L1 if optional 9-inch battery compartment

Fork Lengths EW & EWR 36/80

Wheelbase (y) Turning radius Overall
Load wheel
Fork length (L) lowered/rai- (Wa) (lowered) length (L1)
distance (X)
sed EW/EWR EW/EWR
56.6 / 52.9 in 65.9 / 74.1 in 73.4 / 81.6 in
28.5 in
36 in (914 mm) (1437/1342 (1673/1882 (1863/2072
(724 mm)
mm) mm) mm)
62.6 / 58.9 in 71.8 / 80.2 in 79.4 / 87.6 in
34.5 in
42 in (1067 mm) (1589/1494 (1823/2035 (2015/2224
(876 mm)
mm) mm) mm)
68.6 / 64.9 in 77.9 / 86.2 in 85.4 / 93.6 in
40.5 in
48 in (1219 mm) (1741/1646 (1978/2187 (2167/2376
(1029 mm)
mm) mm) mm)
80.6 / 76.9 in 89.9 / 98.2 in 97.4 / 105.6 in
52.5 in
60 in (1524 mm) (2046/1951 (2283/2492 (2472/2681
(1334 mm)
mm) mm) mm)
121.4/129.6
89.1 / 85.4 in 98.4 / 106.7 in
61.0 in in
84 in (2133 mm) (2262/2167 (2499/2708
(1549 mm) (3082/3291
mm) mm)
mm)
133.4/141.6
89.1 / 85.4 in 98.4 /106.7 in
61.0 in in
96 in (2437 mm) (2262/2167 (2499/2708
(1549 mm) (3387/3595
mm) mm)
mm)
133.4/141.6
116.6/112.9 in 125.9/134.1 in
88.5 in in
96 in (2437 mm) (2961/2866 (3198/3406
(2248 mm) (3387/3595
mm) mm)
mm)
137.1/133.4 in 146.4/154.6 in 181. /189.6 in
109 in
144 in (3657 mm) (3482/3387 (3718/3927 (4606/4815
(2769 mm)
mm) mm) mm)

Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014 59

6 Technical Data
Specifications

Performance data EW 27/60 EWR 27/60 EW 36/80 EWR 36/80

8.0 / 9.5 mph 8.0 / 9.5 mph 6.0 / 9.5 mph 6.0 / 9.5 mph
Maximum speed,
(12.9 / 15.3 (12.9 / 15.3 (9.7 / 15.3 (9.7 / 15.3
rated load / no load
km/h) km/h) km/h) km/h)
Acceleration, 6.7 / 4.6 6.7 / 4.6 7.7 / 4.6 7.7 / 4.6
rated load / no load seconds seconds seconds seconds
Gradeability, *
9 / 26% 9 / 26% 5 / 26 % 5 / 26 %
rated load / no load
Service brake type mechanical mechanical mechanical mechanical
* Gradeability is a measure of tractive ability only. The chassis will not clear a 26% transition.

Drive Motor and Battery EW 27/60 EWR 27/60 EW 36/80 EWR 36/80
Drive motor power rating 4.8 hp (3.6 4.8 hp (3.6 4.8 hp (3.6 4.8 hp (3.6
(60 min) kW) kW) kW) kW)
Battery voltage 24 V 24 V 24 V 24 V
Maximum battery capacity
750 Amp-hr 750 Amp-hr 750 Amp-hr 750 Amp-hr
(6h)
13.5 / 9.1 in 13.5 / 9.1 in
Battery compartment length 13.5 in (343 13.5 in (343
(343 / 229 (343 / 229
(BC), standard/optional mm) mm)
mm) mm)
33.1 in (842 33.1 in (842
Battery compartment width 31.4 in (798 31.4 in (798 mm)/ mm)/
(b2), standard/optional mm) mm) 37.4 in (950 37.4 in (950
mm) mm)
900 lbs 900 lbs 900 lbs 900 lbs
Minimum battery weight
(408.24 kg) (408.24 kg) (408.24 kg) (408.24 kg)
1500 lbs 1500 lbs 1500 lbs 1500 lbs
Maximum battery weight
(680.4 kg) (680.4 kg) (680.4 kg) (680.4 kg)
.

60 Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014

 Index
g

NUMBERS AND SYMBOLS Disconnecting the battery . . . . . . . . . . . . 34

Driving . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1000-hour maintenance . . . . . . . . . . . . . 48
200-hour maintenance . . . . . . . . . . . . . . 46 E
50-hour maintenance . . . . . . . . . . . . . . . 44
Electric braking . . . . . . . . . . . . . . . . . . . 30
B Emergency reverse button . . . . . . . . . . . 27
Battery F
connecting and disconnecting . . . . . . 34
Fluid capacities . . . . . . . . . . . . . . . . . . . 51
connecting to charger . . . . . . . . . . . . 34
Fluid specifications . . . . . . . . . . . . . . . . . 51
Battery acid, safety information . . . . . . . . 10
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Battery, changing . . . . . . . . . . . . . . . . . . 35
Before operation . . . . . . . . . . . . . . . . . . . 6 G
Brake system . . . . . . . . . . . . . . . . . . . . . 30
Gear oil
C capacity . . . . . . . . . . . . . . . . . . . . . . 51
specifications . . . . . . . . . . . . . . . . . . 51
California Health & Safety Code . . . . . . . . II
Grease, specification . . . . . . . . . . . . . . . 51
Capacities, fluids and lubricants . . . . . . . 51
Capacity, load H
lifting . . . . . . . . . . . . . . . . . . . . . . . . 20
Hazardous substances ............... 9
Changing the battery . . . . . . . . . . . . . . . 35
Hoisting the truck . . . . . . . . . . . . . . . . . . 38
Cleaning the truck . . . . . . . . . . . . . . . . . 40
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Coast control system (optional
equipment) . . . . . . . . . . . . . . . . . 32 Hydraulic oil
Commissioning, new truck . . . . . . . . . . . 24 capacity . . . . . . . . . . . . . . . . . . . . . . 51
Connecting the battery . . . . . . . . . . . . . . 34 safety information . . . . . . . . . . . . . . . 10
Control handle specifications . . . . . . . . . . . . . . . . . . 51
operating range . . . . . . . . . . . . . . . . . 26
I
steering with . . . . . . . . . . . . . . . . . . . 29
Controls . . . . . . . . . . . . . . . . . . . . . . . . . 18 Inclines, Ramps, Docks, Elevators . . . . . . 7
direction and travel . . . . . . . . . . . . . . 26 Indicator unit . . . . . . . . . . . . . . . . . . . . . 19
emergency reverse button . . . . . . . . . 27 Initial commissioning, (new truck) . . . . . . 24
fork lift and lower buttons . . . . . . . . . . 31
L
horn button . . . . . . . . . . . . . . . . . . . . 29
key switch . . . . . . . . . . . . . . . . . . . . . 25 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Lifting capacity . . . . . . . . . . . . . . . . . . . . 20
D Lifting the truck . . . . . . . . . . . . . . . . . . . . 38
Daily maintenance inspection . . . . . . . . . 41 Load capacity
Data plate . . . . . . . . . . . . . . . . . . . . 11, 20 lifting . . . . . . . . . . . . . . . . . . . . . . . . 20
Description, technical . . . . . . . . . . . . . . . 16 Lowering the forks . . . . . . . . . . . . . . . . . 31
Diagnostic connector . . . . . . . . . . . . . . . 53 Lubricants
Dimensions . . . . . . . . . . . . . . . . . . . . . . 56 capacities . . . . . . . . . . . . . . . . . . . . . 51
specifications . . . . . . . . . . . . . . . . . . 51

Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014 61

Index
g

M R
Maintenance Raising the forks . . . . . . . . . . . . . . . . . . 31
every 1000 hours . . . . . . . . . . . . . . . 48 Regenerative braking . . . . . . . . . . . . . . . 30
every 200 hours . . . . . . . . . . . . . . . . 46
every 50 hours . . . . . . . . . . . . . . . . . 44
S
general information . . . . . . . . . . . . . . 43 Scheduled maintenance (see also
interval information . . . . . . . . . . . . . . 43 Maintenance)
overview . . . . . . . . . . . . . . . . . . . . . . 50 charts . . . . . . . . . . . . . . . . . . . . . . . . 43
Mechanical brake . . . . . . . . . . . . . . . . . . 30 general information . . . . . . . . . . . . . . 43
Shut-down procedure . . . . . . . . . . . . . . . 25
N Specifications
New truck, preparing for operation . . . . . 24 fluids and lubricants . . . . . . . . . . . . . . 51
truck . . . . . . . . . . . . . . . . . . . . . . . . . 56
O Start-up procedure . . . . . . . . . . . . . . . . . 25
Oils Static-return-to-neutral . . . . . . . . . . . . . . 25
capacities . . . . . . . . . . . . . . . . . . . . . 51 Steering . . . . . . . . . . . . . . . . . . . . . . . . . 29
safety information . . . . . . . . . . . . . . . . 9 Symbols, indicator unit . . . . . . . . . . . . . . 19
specifications . . . . . . . . . . . . . . . . . . 51
T
Options . . . . . . . . . . . . . . . . . . . . . . . . . 22
Towing the truck . . . . . . . . . . . . . . . . . . . 37
P Transmission, oil for
Parking . . . . . . . . . . . . . . . . . . . . . . . . . . 8 capacity . . . . . . . . . . . . . . . . . . . . . . 51
Personnel qualifications for mainten- specifications . . . . . . . . . . . . . . . . . . 51
ance . . . . . . . . . . . . . . . . . . . . 9, 40
Proposition 65 . . . . . . . . . . . . . . . . . . . . . II W
Wheel nuts, tightening . . . . . . . . . . . . . . 24
Q
Qualifications for maintenance
personnel . . . . . . . . . . . . . . . . 9, 40

62 Operating Instructions – 1101 series EW/EWR – 11018011540 US – 02-2014

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1101 series EW/EWR – 11018011540 US – 02-2014