x1491372

Operating Instructions
Directive No. 94/9/EC Machine Group II
Zone 2, Machine Category 3G
Linde Order Picking Truck
With Gas Warning System PL-G 1000 to EN 1755
N 20 - N 25
With Electric Motors
149 804 6001 GB
0904
Linde - Your Partner Linde AG Linde Material Handling Division

Linde, an enterprise operating

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

Fenwick-Linde, Châtellerault The Linde Material Handling

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

Linde industrial trucks enjoy a

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

Werk I, Aschaffenburg Werk III, Kahl am Main Linde Heavy Truck Division Ltd., Merthyr Tydfil

Your Linde lift truck
offers the best in economy, safety and driving convenience.
Therefore it is mainly in the hands of the operator to preserve
the qualities of the truck for a long and profitable service life
and to make full use of their benefits on the job.
These operating instructions tell you all you need to know
about starting, operation, running and servicing the truck.
For maintenance and repair work not described in these
operating instructions special technical skill and knowledge,
measuring equipment and special workshop tools are often
required. Please contact your authorised Linde dealer for this
service.
Only qualified persons (experts) authorised by Linde are
allowed to service the trucks.
For some attachments, the proprietary operating instructions
supplied with them are applicable.
Follow all tips for operating the lift truck and carry out the
maintenance and care prescribed in the inspection and
maintenance schedule regularly, on time and with the spec-
ified lubricants.
To keep your warranty valid, all maintenance services must
be performed by qualified persons authorised by Linde.
The terms “front”, “rear”, “left” and “right” refer to the position
in which the item concerned is installed in the truck in relation
to the forward travel direction.
Approved applications
This Linde electric pallet truck is designed for transporting
and lifting the loads stated in the load capacity diagram.
In particular, we refer to the attached safety rules for the
normal and proper use of industrial trucks (VDMA) concern-
ing safe operation and accident prevention of fork lift trucks,
as well as to the traffic regulations.
2
The operator (employer) must ensure
that the truck is always in safe operating
condition.
All measures in this manual related to
explosion protection are identified with . Only qualified and authorised persons
Please ensure that they are followed.
The safety rules for the use of industri-
al trucks, the local regulations and the in-
structions in this manual must be followed
under all circumstances by the responsible
persons, especially by the operator and
service personnel.
The user, and not Linde, is responsible
for any danger arising from applications not
authorised by the manufacturer.
The truck may only be operated in zon-
es with an explosion hazard as certified in
the attestation included in this manual.
If you desire to use the truck for applications not mentioned
in the manual and convert or modify it for this purpose, please
contact authorised skilled personnel (experts).
Foreword
No changes, especially conversions
or modifications, may be made on your truck
without the prior permission of the manu-
facturer.
(experts), familiar with explosion protection
regulations and authorised by Linde are
allowed to service the trucks. The manufac-
turer recommends you to charge the au-
thorised Linde dealer.
When replacing explosion-proof com-
ponents, always install tested explosion-
proof parts approved for the truck.
149 804 6001.0904
After changes in the explosion protec-
tion, the owner (employer) must have the
truck certified by an expert before taking it
back into operation.

Technical note
These operating instructions or excerpts thereof may only be
copied, translated or transmitted to third parties after prior
written approval by the manufacturer.
Linde pursues a policy of continuous progress in the design
and construction of its products. As a result, the illustrations
and technical details referring to design, fittings and engi-
neering of lift trucks are subject to change if progress warrants
it.
Therefore, the manufacturer will not accept any claims based
on the specifications, illustrations and descriptions con-
tained in this operating manual.
Please submit all enquiries concerning your truck and all
orders for spare parts to your authorised distributor, making
sure to state your correct shipping address.
149 804 6001.0904
For repairs, use only genuine Linde spare parts to ensure that
your Linde fork truck will maintain its original technical stand-
ard.
When ordering spare parts, it is important also to give the
following information:
Lift truck model: _________________________________
Manufacturer’s serial no./Year built: _________________
INERIS 02 ATEX No.: 3006X
_________________________
Handing-over date: ______________________________
When taking over the fork lift truck, transfer the data from the
assembly type plates into this operating manual.
Foreword
Pallet truck takeover
Every fork truck undergoes careful inspection before leaving
the factory in order to make sure that it will be in satisfactory
condition and fully equipped as ordered when delivered to
the customer. Authorised distributors are under obligation to
re-inspect the truck before delivery and to hand it over in good
order.
In order to avoid later complaints and inconvenience to
customers, you are requested to ascertain that the truck is in
satisfactory condition and fully equipped at the time of deliv-
ery and to acknowledge orderly handing/taking over of the
truck in the manufacturer’s certificate of conformity.
The following technical manuals are supplied with each
truck:
1 Operating instructions
1 EC declaration of conformity
(The manufacturer declares that the fork lift truck
conforms to EC directive for machines)
1 Rules for the Normal and Proper Use of Industrial
Trucks (VDMA)
1 Certificate for explosion protection
Wishing you satisfactory operation,
Linde AG
Linde Material Handling Division
Aschaffenburg
3
149 804 6001.0904
4
 Type plates Description
1 Identification plate
1 2 3
2 Manufacturer

3 CE symbol 10
(The symbol certifies that EC directive for machines and
all applicable guidelines are fulfilled.)
9
4 Battery voltage

5 Empty weight 8
6 Minimum battery weight

7 Maximum battery weight

7
8 Nominal truck capacity
6 5 4
9 Serial number / year
149 804 6001.0904

10 Model 17
11 Slinging label
14
12 Battery safety label

13 Maker’s number (etched) 11 12

14 Driver walking symbol

15 Explosion protection sign

16 Buffer battery plate

17 Type plate with INERIS/Atex Type Acceptance Certifi-

cate No.

16

13 15
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5
Pallet truck models N 20 - N 25 explosion protected Description
Advanced technology,
simple and ergonomic operation,
energy-saving, environment-friendly and minimal
maintenance,
solid manufacture
and for availability of your lift truck
nearly all parts manufactured
by Linde.
The success of a company
with about 9600 employees in eight plants.

149 804 6001.0904

The explosion-protected order pickers
are characterised by their clearcut struc-
x1491374
ture, appealing design and positive human
engineering.
The tiller and operating elements are arranged according to
the latest research in ergonomics. Each operating element is
designed in regard to positioning and operation to ensure the
driver's convenience guaranteeing effortless and safe oper-
ation.

6
 Table of contents
Page
Foreword ......................................................................... 2
Approved applications ........................................................ 2
Technical note ..................................................................... 3
Pallet truck takeover ........................................................... 3
Description ..................................................................... 5
Type plates .......................................................................... 5
Technical data ................................................................... 10
Technical description ........................................................ 11
Drive ............................................................................... 11
Lifting ............................................................................. 11
Steering .......................................................................... 11
Braking ........................................................................... 11
Operation ....................................................................... 11
Temperature monitor ............................................... 11
General view of truck ....................................................... 12
149 804 6001.0904
Operating and display elements ...................................... 13
Multifunctional display ...................................................... 14
Adjusting the contrast .................................................... 18
Adjusting the lighting ..................................................... 18
Adjusting the date/time .................................................. 18
Composite instrument for gas warning system ............... 19
Hour meter ..................................................................... 19
Battery discharge indicator ............................................ 19
Technical description ........................................................ 20
Gas warning system ................................................ 20
Beginning operation ................................................ 21
Safety rules ........................................................................ 21
Experts .............................................................................. 21
Report of Thorough Examination ..................................... 23
Accident prevention check ......................................... 23
Explosion protection check ........................................ 23
Operation of industrial trucks in the plant area ................ 23
Handling fluids and lubricants .......................................... 23
Running-in instructions ..................................................... 23
Maintenance work prior to initial start-up ......................... 23
Daily inspections ............................................................... 23
Daily checks and servicing before operation .................. 24
Check FORW/BACK and lift/lower controls ..................... 24
Check electrical steering .................................................. 24
Check braking ................................................................... 24
Checking operation of the emergency isolator button ... 24
Description
Page Page
Check the horn ............................................................ 25 Transporting the truck ....................................................... 36
Check the battery charge ........................................... 25 Taking the truck out of operation ...................................... 37
Charging the battery ................................................... 26 Measures before taking the truck out of operation ....... 37
Opening battery cover ...................................................... 26 Putting the truck back into operation ............................. 37
Connecting/disconnecting battery connector ............ 26
Recharging the battery with an external charger ...... 27 Maintenance ............................................................... 38
Closing and battery cover ................................................. 27 General information .......................................................... 38
Check the battery condition, electrolyte level and Inspection and maintenance after first 50 hours
specific gravity ......................................................... 28 of operation .................................................................... 39
Battery change ............................................................ 29
Battery change with a hoist ........................................ 29 Inspection and maintenance chart ................................... 40
Battery change with a trolley ...................................... 29
Operation ...................................................................... 30
Driving ............................................................................... 30
Approved use ................................................................. 30
Starting up ...................................................................... 30
Directions of travel identification ................................... 31
Forward travel ................................................................ 31
Reverse travel ................................................................ 31
Reversing the direction of travel ................................... 31
Operating the emergency isolator button ..................... 31
Operation in the pedestrian mode ................................ 32
Starting on a slope ........................................................ 32
Steering .......................................................................... 32
Steering direction in forward travel ............................... 32
Braking, lifting, lowering, horn .......................................... 33
Regenerative brake ....................................................... 33
LBC brake ...................................................................... 33
Electro-hydraulic braking .............................................. 33
Lifting the fork ................................................................. 33
Lowering of the fork ....................................................... 33
Operating the horn ........................................................ 33
Before loading ................................................................... 34
Loading ............................................................................. 34
Transporting the load ........................................................ 34
Depositing the load ........................................................... 35
Picking up the load at the first level ................................. 35
Before leaving the truck .................................................... 35
Stand-by function of truck ................................................. 35
Hoisting, blocking up, towing ........................................... 36
Hoisting the truck with a crane ...................................... 36
Blocking up the pallet truck ........................................... 36
Towing ............................................................................ 36
7
149 804 6001.0904
8
 Table of contents Description
Page Page

Inspection and maintenance as required ...... 42
Cleaning the truck ............................................................. 42
Opening the motor compartment cover ............................ 42
Checking the tightness of wheel fasteners ...................... 42
Checking the wheels for damage and foreign objects .... 42
Fixing and adjusting the stabiliser wheel ........................ 43
Checking the fuses ........................................................... 43
Removing the platform surface covering ......................... 43
Cleaning the dead man’s zone on the platform ............... 43
Checking the condition of battery connector,
terminals and cables ..................................................... 44
Servicing/cleaning the battery
and battery compartment ............................................... 44
Checking the battery tray .................................................. 44
Inspecting the gas warning system measuring head 45
Inspecting and calibrating the gas warning system .. 45
Cleaning the gas warning system measuring head . 45
149 804 6001.0904
2000-hour inspection and maintenance ........ 52
Replacing the hydraulic oil ............................................... 52
Filling ................................................................................. 52
Replacing the reduction gear oil ...................................... 52
Filling ................................................................................. 52
Inspection and maintenance specifications ..................... 53
Lubricant recommendations ............................................. 54
Hydraulic oil ................................................................... 54
Bio hydraulic oil ............................................................. 54
Gear oil .......................................................................... 54
Lubricating grease ........................................................ 54
Battery grease ................................................................ 54
Troubleshooting guide ...................................................... 55
Electric circuit diagram (basic equipment) ....................... 56
Electric circuit diagram (gas warning system) ................. 58

Checking the pump motor brushes, Hydraulic circuit diagram .................................................. 60

replacing the motor if necessary ............................. 45 Index .................................................................................. 62

500-hour inspection and maintenance ........... 46

Greasing the turntable bearing of the motor unit ............. 46
Cleaning of steering ring and pinions .............................. 46
Checking reduction gear oil level .................................... 46
Checking hydraulic oil level ............................................. 47
Checking tightness of hydraulic circuit ............................ 47
Checking condition and fixing of electrical cables and
connections ............................................................. 47
Cleaning and checking wear of contacts .................. 48
Checking and, if necessary, replacing
traction motor brushes ............................................ 48
Checking and, if necessary, replacing
the steering motor brushes ..................................... 48
Adjusting the electro-hydraulic brake .............................. 49
Checking the various hinges ............................................ 50
Checking/readjusting the battery cover catch .................. 48

1000-hour inspection and maintenance ........ 51

Cleaning the non-return valve hydraulic oil filter ............ 51
Checking mechanical fixing of the components .............. 51

9
Technical data Description
LINDE
Order-Picker Technical Data for VDI 2198
Designation VDI 3586 Electric Trucks Abbreviation to VDI 3586 Registration

March 2004 Manufacturer’s data and design characteristics List acc. to manufacturers, types, models
1.1 Manufacturer Linde Linde Linde
1.2 Model designation N 20 N 20 N 25
Characteristics

1.3 Power unit: battery, diesel, LPG, mains power battery battery battery
1.4 Operation: manu., pedest., stand-on, seated, ord. pic. Order picker Order picker Order picker
1.5 Load capacity Q [kg] 2000 1) 2000 1) 2500 1)
1.6 Load centre c [mm] 600 1200 600
1.8 Load distance, lowered/lifted x [mm] 962/895 1762/1695 962/895
1.9 Wheelbase (forks lowered) y [mm] 1442 2242 1442
2.1 Service weight incl. battery [kg] 840 2) 875 2) 840 2)
Weight

2.2 Axle load with load, front/rear [kg] 1200 / 1640 1200 / 1645 1330 / 2010
2.3 Axle load without load, front/rear [kg] 695 / 160 720 / 120 695 / 160
3.1 Rubber tyres (G), polyurethane tyres (P) G+P/P G+P/P G+P/P
Wheels and Tyres

3.2 Tyre size, operator end Ø 254 x 102 Ø 254 x 102 Ø 254 x 102
3.3 Tyre size, load end Ø 85 x 80 Ø 85 x 80 Ø 85 x 80
3.4 No. of tyres, operator end/load end Ø 140 x 60 Ø 140 x 60 Ø 140 x 60
3.5 Wheels, number on operator end/load end (x = driven) 1 x + 1/2 1 x + 1/2 1 x + 1/2
3.6 Track width, front [mm] 495 495 495
3.7 Track width, rear [mm] 355 355 355
4.4 Lift h3 [mm 125 125 125

149 804 6001.0904

4.9 Height of tiller in driving position h14 [mm] 1140 1140 1140
4.15 Height with forks lowered h13 [mm] 88 88 88
4.19 Overall length l1 [mm] 2432 3632 2432
Dimensions

4.20 Length to fork face l2 [mm] 1282 1282 1282

4.21 Overall width b1/b2 [mm] 792 792 792
4.22 Fork dimensions s/e/l [mm] 60 x 165 x 1150 3) 60 x 165 x 2350 3) 60 x 165 x 1150 3)
4.25 Max. width of spread forks b5 [mm] 520 520 520
4.32 Ground clearance, centre of wheel base m2 [mm] 26 26 26
4.33 Aisle width with pallet 1000x1200 across Ast [mm] 2750 3840 2750
4.34 Aisle width with pallet 800x1200 lengthwise Ast [mm] 2750 3840 2750
4.35 Turning radius Wa [mm] 2240/2295 2940 2240/2295
5.1 Travel speed, with/without load km/h 9,5 / 12 9,5 / 12 9/12
Performance

5.2 Lifting speed, with/without load m/s 0,036 / 0,052 0,036 / 0,052 0,030 / 0,052
5.3 Lowering speed, with/without load m/s 0,061 / 0,059 0,061 / 0,059 0,061 / 0,059
5.8 Max. climbing ability with/without load (KB 5 min.) % 9,5 / 15 9,5 / 15 8 / 15
5.10 Service brake Electric/hydraulic Electric/hydraulic Electric/hydraulic
6.1 Traction motor, rating (S2 60 min.) kW 2,0 2,0 2,0
Electr. Motor

6.2 Lift motor, rating 15 % ED kW 1,0 1,0 1,0 Ast = Wa + (l6-x)2 + (b6)2 + 200 a : safety distance = 200 mm
2
6.3 Battery according to IEC - - -
6.4 Battery voltage, rated capacity K5 V/Ah 24 / 360 24 / 360 24 / 360
6.5 Battery weight kg 305 305 305
800x1200 2x800x1200 1000x1200 1000x1200 2 roller 2 roller 3 roller
8.1 Type of control LDC with LDC with LDC with pallets pallets pallets pallets containers containers containers
microprocessor microprocessor microprocessor lengthwise lengthwise across lengthwise

8.4 Mean noise level at driver's ear dB (A) < 69 < 69 < 69 Fork length l (mm) 1150 2350 1000 1150 1450 1550 2100

1) With load equally distributed.

Centre of gravity c (mm) 600 1200 500 600 700 800 1200
Others

2) With battery acc. to line 6.4. Distance

3) For other fork dimensions, see tabel beside. over forks b5 (mm) 520 520 680 560 520 520 520

Fork overhang x1 (mm) 188 600 188 188 400 400 600

Aisle width Ast (mm) 2750 3840 2535 2750 2880 3080 3640

Turning radius Wa (mm) 2240 2940 2230 2240 2200 2400 2740

10
 Technical description
The trucks are designed for picking orders weighing up to 2
tonnes with the N20 and 2.5 tonnes with the N 25.
They can be operated either in the rider or pedestrian mode.
They are also designed for transporting pallets; their highly
compact size, advanced platform and automatic return elec-
trical steering give these trucks very high performance in the
control initiating stages and very good manoeuvrability when
in motion.
The layout and comfort of the operation stand allow optimi-
sation of the driver’s work.
Drive
It is driven by a 2-kW electric traction motor acting on the
traction wheel via a gearbox.
The required energy is supplied by a 24V battery with a
capacity of between 270 and 600 Ah, depending on the fork
length and chassis. The battery is installed behind the plat-
149 804 6001.0904
form and secured by a lockable battery cover.
The LDC (Linde Digital Control) pulse control with LBC
(Linde Brake Control) allows infinite control of forward and
reverse motion.
This allows easy control of the speed, gentle starting and
braking.
A stabiliser wheel stabilises the truck when making turns.
Lifting
The push bar and levers lifting system is actuated by 2 jacks.
The lifting jacks are powered by a motor-driven pump unit
with a 1 kW motor.
The hydraulic unit is an assembly that includes: motor, tank,
pump, valves and filter.
Steering
The motor unit is mounted on a live ring; the steering employs
an electrical gear motor which positions the turret. The
steering motor is controlled by an electronic drive unit, which
receives, from one direction, the information coming from the
control lever, and from the other, the information on the
wheel’s orientation.
This steering handlebar combines all the advantages of lever
and of steering-wheel steering, and further adds automatic
return to zero. In pedestrian mode, the driver no longer has
to manually reset the steering to the straight position before
getting off the truck.
Braking
The N 20 and N 25 trucks are equipped with three different
brake circuits:
- The safety and parking brakes are operated via an elec-
tro-hydraulic brake, which is activated as soon as the
power is cut out. It is actuated when leaving the dead
man’s zone (after motor braking) or when the emergency
isolator switch is operated. The braking moment depends
on the pressure in the lift cylinders and adapts automat-
ically to the transported load. In this way the truck never
veers when braking.
- Electronic regenerative braking, triggered by reversal of
the direction of travel and controlled by the LDC drive unit.
- Automatic braking occurs when the accelerator is re-
leased and is controlled by the LDC drive unit.
Description
Operation
The order picker can be operated in the rider or pedestrian
mode.
The platform allows excellent visibility in both directions of
travel.
The design provides the operator with the greatest ergonom-
ic operation possible. This includes the power-assisted steer-
ing and the clustered controls.
The controls for forward and reverse drive, lifting and lower-
ing, horn and emergency isolator switch are located on the
steering and control device.
Further lift and lower buttons are mounted on the holding rod
behind the backrest.
The emergency isolator switch initiates braking by opening
the electric circuit.
When the truck is stopped, it automatically goes into the
standby mode after a few seconds, thus saving battery power.
Temperature monitor
The trucks are equipped with a temperature monitor. In case
of overheating of the motor or brakes, the drive and lift
functions are cut out. Only steering is still possible.
11
General view of truck Description
1 Controller enclosure, fuses / relays

2 Controller enclosure, monitoring unit for gas warning 1

system/steering control electronics
12
3 Hydraulic unit with pump motor

4 Stabiliser wheel
11
5 Gas warning system sensor

6 Drive wheel

7 Reduction gear

8 Steering gear 2
10
9 Traction motor

149 804 6001.0904

10 Electrohydraulic brake

11 Steering motor
9
12 Composite instrument for gas warning system (hour 3
meter/battery discharge indicator)

x1491423
4
7

6 5

12
 Operating and display elements Description
1 Lift button (on holding rod mounting)

2 Lower button (on holding rod mounting)

1
3 Gas warning system acknowledgement button

4 Gas warning system indicator light (green)

6 2
5 Pedestrian control button

6 Composite instrument for gas warning system (hour

meter/battery discharge indicator)
3
7 Emergency isolator switch
4
8 Handlebar

9 Accelerator
5
18
149 804 6001.0904

10 Lower button (on handlebar)

11 Horn

12 Handlebar up button 9 10 11 12
8 13
13 Accelerator
19
14 Multifunctional display panel for truck

15 Key switch 7
18 14
16 Cubby hole

17 Dead man’s switch (operator’s platform)

18 Pedestrian mode button

19 Buffer battery plug 16

15
17 x1491424

13
Multifunctional display Description
The multifunctional display is located onto the right-hand side
of the steering handlebar console. It is used as a warning 13 14 1 2 3 4
indicator and as information display.
The following information is displayed:

1 Battery charge indicator (in %) 12 100% 5

2 Battery charge indicator bar graph 22/12/01

3 Hour glass symbol for service hours 11 STOP 16:00 SET

4 Function button (+)

6
5 Function button (-)
6 Function button (SET) 10 9 8 7
7 Active key panel indicator
8 Date display
9 Time display 100%
10 STOP symbol indicator (red)
12345.6 h 15

149 804 6001.0904

11 Battery symbol indicator (red)
STOP Nächste Wartung: SET
12 Temperature symbol indicator (red)
13 Driver present symbol indicator (green)
14 Service reminder symbol indicator (red)
15 Hour meter
16 Display
17 Wheel position indicator
100%
STOP SET
16

100%
17
STOP SET

x1491375
14
 Multifunctional display Description

13 14 1 2 3 4 Display element Purpose Possible malfunctions/Remedy

Battery charge indicator (1) Indica- 100% = battery fully charged
12 100% 5 tion in percent 10% = battery charge low
0%= battery discharged
-
-
Battery should be charged soon.
Battery must be charged immediately.
22/12/01
11 Battery charge indicator (2) Indica- 100% = 5-bar indicator NOTE:
STOP 16:00 SET
tion in form of 5-bar diagram 10% = 2-bar indicator 0% corresponds to an 80% discharge to
0% = 1 bar protect the battery before deep discharg-
x1491376
6 ing sets in. The lifting function is restricted.
Service hours symbol (3) When the truck is started, A warning buzzer sounds.
10 9 8 7 (hour glass) (key switch „ON“), the hour glass
flashes and the truck is operational.

Function button + (4) Function selector down

Function button - (5) Function selector up

149 804 6001.0904

Function button (SET) (6) Setting of selected function

Indicator (7) Indicates active

function button
Date display (8)

Time display (9) The time is shown in 24-hour mode. The display can be set to 12-hour indication
The time is set with the function with the diagnostic unit. Please please
buttons (4, 5, and 6). contact your authorised Linde dealer.

STOP symbol indicator (10) Illuminates in case of an error in the The truck is not operational
STOP (colour red) electric system. - Restart truck by operating the key switch.
In case of starting failure:Please contact
your authorised Linde dealer.

Battery symbol indicator (11) Flashes in case battery charge is The display shows the message:
(colour red) less or equal 10%. "Battery charge low"
- The battery should be charged as soon
as possible.

Battery is discharged if lit steadily. The display shows the message:

"Charge = 0%"
The lifting function is restricted.
- The battery must be charged immediately.

15
Multifunctional display Description

Display element Purpose Possible malfunctions/Remedy

12 100%
22/12/01 Temperature symbol indi- If the lamp is comes on, the allowed The truck is not operational.
cator (12) (colour red) controller temperature is exceeded. - Let the truck cool down.
STOP 16:00 SET

x1491377

13 Driver present symbol in- Flashing symbol means:

dicator (13) „Driver not present“

100% (Dead man’s switch not operated).

A steady light means:

22/12/01 „Driver present“
STOP 16:00 SET
(Dead man’s switch operated)
The steady light stays on 10s after

149 804 6001.0904

leaving the driver’s platform.
x1491378

14
Service reminder symbol The display indicates when the next
100% indicator (14) servicing is required.

22/12/01
STOP 16:00 SET

x1491379

Display of service hours (15) Shows the truck service hours. NOTE
The hours indicated serves as a In case a defective indicator is replaced,

100% record for the operating time of the

truck and for the inspection and
maintenance services.
the previous service hours must be re-
corded. Affix the information on an adhe-
sive label near the indicator. It is also pos-
12345.6 h 15 sible to update the new indicator retroac-
STOP Nächste Wartung: SET tively. Please contact your authorised
Linde dealer.

x1491380

16
 Multifunctional display Description
After the electrical system is turned on,"Linde" (2) and By pressing " + " function button onces, the display changes By pressing the " + " function button again, the display jumps to
"Welcome" (1) appears in the display and the self-test (3) is to the service hours mode (5). the address of your Service (6) and steering position mode (7).
carried out.
By pressing the " - " function button you return to the main By pressing the " - " function button you return to the main
After the successful conclusion of the self-test (3), the main screen (4). screen (4).
screen (4) appears.
149 804 6001.0904

2 3 4

100%
22/12/01
100% Adresse
Willkommen 16:00
SET

12345.6 h Kundendienst

1
6 7
5
x1491382 x1491383 x1491384

17
Multifunctional display Description
Adjusting the contrast Adjusting the lighting Adjusting the date/time
Starting from the main screen, press the "SET" function Starting from the main screen, invoke the brightness (2) Starting from the Service address or steering position mode,
button once to invoke contrast adjustment (1) in the control setting by pressing the "SET" function button twice in the invoke the date/time setting by pushing the "SET" function
panel. control panel. button in the control panel once.

- Adjust the contrast with the " +" or " - " function button.
If no input is made within 5 seconds, the last set value is
assumed automatically and stored.
Then the main screen appears automatically again.
- Adjust the brightness as desired by pressing the "+" or
"-" function button.
If no input is made within 5 seconds, the last set value is
assumed automatically and stored.
Then the main screen reappears automatically.
- Adjust the date/time in succession with the "+" or "-"
function button.
If no input is made within 5 seconds, the last set value is
assumed automatically and stored.
Then the main screen reappears automatically.

149 804 6001.0904

100% Kontrast
100% Beleuchtung 100%
2
1
22/12/01
16:00 SET

x1491385 x1491386 x1491381

18
 Composite instrument for gas warning system
The composite instrument (1) contains the following warning
lights and indicators:
NOTE
The battery discharge indicator (3) and the hour meter (2)
are explosion-protected, ie mounted in a flameproof enclo-
sure.
Hour meter
The hour meter (2) is running, but it has absolutely no
relevance to the gas warning system.
149 804 6001.0904
Description
Battery discharge indicator
It indicates the charging state of the buffer battery even when
the key switch is turned off and the emergency isolator button
is not released. It reduces the speed of the working hydraulics
when battery discharge has reached 80 %.
The buffer battery is fully charged when the right green LED
(6) is illuminated. As the battery discharges, the illuminated
bar (6) moves from right to left.
If only the orange LED (5) is illuminated, the battery discharge
is up to 70 % and the battery must be recharged.
If the orange LED (5) also extinguishes, the red LED (4)
illuminates. The buffer battery discharge is up to approx.
80 % and recharging or changing of the battery is required.
CAUTION
After a complete shutoff the gas warning system
must be recalibrated.
x1491387
19
Technical description
Gas warning system
The gas warning system is provided with one measuring If a gas concentration of over 10 % of the lower explosion limit
head (1) located near the traction wheel. of gas mixtures is detected, a buzzer sounds which can be
turned off with an acknowledgement button (2) on the instru-
The gas warning system is functioning properly if the green ment panel.
indicator light (3) is on. When the top limit (25 %) of the lower explosion limit of gas
mixtures is reached, the truck release signal is interrupted and
the truck makes a controlled shutdown. Only the steering and
regenerative braking remains activated with this procedure.
Description
The sensor heads must be inspected and, if necessary,
recalibrated every two months. This service must be recorded
in the inspection log book stowed in enclosure (4).
The sensor heads should be renewed about every three
years. Please contact your authorised Linde dealer for this
service.

NOTE
The steering is in operation for 20 seconds after the
release signal is cut off by the gas warning system.

The truck can be returned to operation only after a safe

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

149 804 6001.0904

ATTENTION
The gas warning system must be recalibrated
every 2 months or after a complete discharge
and cut-out of the buffer battery.

2
3

x1491372 x1491390

20
 Safety rules
The responsible persons, particularly
the truck operator and servicing personnel,
must be instructed in the rules for the nor-
mal and proper use of industrial trucks, the
applicable national, EC or EEA explosion
safety regulations, as well with those includ-
ed in these operating instructions.
The employer must ensure that the driver has understood all
of the safety information.
Please observe the guidelines and safety rules therein for
example:
- information on the operation of industrial trucks
- rules for roadways and work areas
- rights, duties and safety rules for the operator
- operation in special areas
149 804 6001.0904
- information related to starting, driving and braking
- service and repair information
- recurrent inspections, accident prevention check
- disposal of greases, oil and batteries
- remaining risks.
The operator (employer) or the responsible person must
ensure that the above the guidelines and safety rules appli-
cable for your truck are observed.
The explosion protection measures
and their implementation on the truck dur-
ing operation are required by law. They re-
quire particular attention during all work
with, in and on the truck.
The operator (employer) must ensure
that the employees are instructed in the
explosion risk areas (explosion hazard
zones 1 and 2), possible explosion hazards
and the selected protective measures, and
that the operating instructions required for
safety are observed. The instruction must
be repeated at appropriate intervals.
The acceptance tests and certificates
for the truck, the pertinent laws, regulations
and guidelines, and any possible additional
requirements by the responsible authori-
ties indicate under which conditions and
where the truck may be operated, serviced
and repaired.
Beginning operation
DANGER
All inspection and maintenance work
must be done outside of explosion risk are-
as, and only by authorised skilled person-
nel (experts) thoroughly familiar with the
appropriate technical material and rules and
regulations.
The manufacturer recommends you to
charge the authorised Linde dealer.
Experts
Experts are specially skilled persons who have thorough
knowledge and experience in servicing and testing industrial
trucks and being furthermore sufficiently familiar with the
national industrial safety and accident prevention regula-
tions and all further general technical rules and guidelines
(DIN and ISO standards, technical rules arising from EC
directives or EEA agreements), so that they can give a
qualified judgement upon the safe operating conditions of the
truck.
Before commencing inspection and
maintenance, ensure that no explosion risk
exists.
21
Safety rules
As long as no further risk of explosion
can occur (e.g. explosive gases can enter
the working area), it is not necessary to
recheck for explosion risk during the in-
spection and maintenance.
The operator (owner) or his repre-
sentative must provide the technicians with
a work assignment (normally written) which
states work location, commencement, dura-
tion and the protective measures to be tak-
en against explosion.
In emergency situations where explo-
sion risk exists from sparking, or the explo-
sive risk can increase during the repair
work, special explosion protective meas-
ures must be taken.
22
Work can only commence after the op-
erator (owner) or his representative have
ensured that protective measures are ade-
quate and effectively implemented. The ef-
fectiveness of the protective measures are
to be checked during the progress of the
work. The operator (owner) or his repre-
sentative can only lift the protective mea-
sures after all work has been completed and
no further explosion risk exists.
Before placing the truck back into nor-
mal operation, ensure that the truck’s explo-
sive protection for the appropriate work
zones is in order again.
Beginning operation
When instructing a trained operator (driver), acquaint him
with the
- special features of the truck,
- special features of the explosion-proof truck ,
- special conditions in the work place
by training and practicing driving, shifting and steering oper-
ations until they are completely mastered.
After the above has been mastered, commence practice with
stacking operations.
The safety in the work area is ensured if the truck is employed
properly and the operator trained correctly.
149 804 6001.0904
 Safety rules
Report of Thorough Examination
The accident prevention rules in some countries require that
the fork lift truck must be checked periodically for proper
operation by trained personnel.
In the UK, the specific requirement of LOLER 1998 and
PUWER 1998, state that lift truck users are required by law
to ensure that their lift trucks are thoroughly examined peri-
odically by a competent person, and that supporting records
are available for inspection. Non compliance with these
requirements may result in legislative action.
Please contact your local Linde reresentative.
DANGER
indicates hazards that may result in personal
injury or death and/or substantial damage to the
product.
CAUTION
indicates hazards that may result in personal
injury and/or substantial damage to the product.
149 804 6001.0904
ATTENTION
indicates hazards that may result in damage to or
destruction of the product.
All explosion protection measures are
marked with the symbol at the left of this para-
graph. Be certain to follow these measures.
NOTE
identifies technical information requiring special atten-
tion because the meaning may not even be obvious to
skilled personnel.
Accident prevention check
The accident prevention regulations require
that the forklift truck must be checked at
least once a year for proper working condi-
tion by trained personnel. Please contact
authorised skilled personnel (experts) in this
regard. The manufacturer recommends you
to charge the authorised Linde dealer.
Additionally every two weeks a visual check
of the explosion protection equipment is
required.
Explosion protection check
The operator must maintain the truck in a
safe operating condition.
Operation of industrial trucks in the plant
area
ATTENTION
Many plant areas are so-called limited public
traffic areas.
We advise you to check if your company liability insurance
covers any damages occurring with your fork truck against
third parties on "limited" public traffic areas.
Handling fluids and lubricants
Always handle fluids and lubricants as required and
as specified by the manufacturer.
Only store fluids and lubricants in approved containers at
specified storage places. As they could be inflammable, do
not contact them with hot objects or a naked flame.
Only use clean containers when replenishing fluids and
lubricants.
Follow the manufacturer’s safety and disposal instructions
when using fluids and lubricants and cleaning compounds.
Avoid spilling fluids and lubricants. Remove any spillage
immediately with a suitable binding agent and dispose of as
specified.
Also dispose of used or contaminated fluids and lubricants as
specified.
Follow laws and regulations.
Clean the area surrounding the part in question before
lubrication, filter renewal or repairs in the hydraulic system.
Discard parts in a way friendly to the environment.
CAUTION
Do not allow hydraulic oil under pressure, for
example at a leak, to penetrate the skin. Medical
aid is required if such an injury occurs.
Beginning operation
Running-in instructions
The truck can be operated at full speed directly. Avoid sus-
tained high loads on the motors in the first 50 hours of
operation.
Retighten wheel nuts daily prior to starting operation and after
having changed the wheels until they are seated firmly, i.e.
until no further tightening is possible.
Wheel nuts should be tightened crosswise to the torque
specified in the operating manual.
Maintenance work prior to initial start-up*
- Check the accelerator control for proper operation
- Check fork lifting/lowering
- Check the composite instrument indicators
- Check the braking function
- Check the emergency isolator switch
- Check the horn
- Check the steering system
- Check the battery condition, electrolyte level and specific
gravity
- Check the battery cable
- Check the hydraulic oil level
- Check the reduction gear oil level
- Check the hydraulic system for leakage
- Check the wheel fasteners for tightness
Daily inspections*
ATTENTION
Before starting, the truck operating controls must
be checked, especially the safety devices.
- Check the accelerator control for proper operation
- Check fork lifting/lowering
- Check the steering system
- Check the braking function
- Check the emergency isolator switch
- Check the horn
- Check the battery condition, electrolyte level and specific
gravity
* Please consult the alphabetical index for a description of
activities.
23
Daily checks and servicing before operation
NOTE
Before initial operation, the gas warning system must be
turned on and calibrated by your authorised Linde dealer.
For safety reasons, the truck’s electrical control only
turns on if the gas warning system is working properly.
Check FORW/BACK and lift/lower controls
- Check if these controls are working properly; see opera-
tion chapter
Check electrical steering
- Forward movement at very low speed
- Turn the handlebar clockwise, and the truck should turn
right
- Turn the handlebar in the other direction and the truck
should turn left.
- Release the handlebar, and it should return to neutral
position, and the truck will move straight forwards.
x1491312
24
Beginning operation
NOTE Checking operation of the emergency
If there is a problem with the steering, a safety device stops
the truck and applies the brake.
isolator button
- Press the emergency isolator button (1).
DANGER The electrical power supply of the truck will be cut off.
Do not operate your truck with a faulty steering The electrical controls and the motors no longer receive
system. power.
Please contact your authorised Linde dealer if you discov- The electrohydraulic brake is applied.
er any problem with the steering system.
- To resume work, turn the key switch (2) anticlockwise as
Check braking far as possible and turn it on again clockwise.
- Drive the truck
- Remove feet from the presence zone (1)
NOTE
The truck is braked and the motor’s power supply is cut off.
DANGER
149 804 6001.0904
Your truck should not be operated with a faulty
braking system.
Please contact your authorised Linde dealer if you discov-
er any problem with the braking system.
1
x1491313 2 x1491391
 Daily checks and servicing before operation
Check the horn
The horn serves as a warning signal, for example on road-
ways with reduced visibility and at junctions.
- Squeeze the rubber ball (1) to sound the horn.
Beginning operation
Check the battery charge
- Before starting work, check that the battery is properly - Turn on the truck with the key switch (3).
charged.
- Check the charge of the battery on multifunctional indica-
- Connect the battery connector (2). tor (4) (see battery discharge indicator.)

- Place the connector retaining bracket (1) over the battery

connector.
149 804 6001.0904

1
1
2

x1491392 x1491398 3 x1491393

25
Daily checks and servicing before operation
Charging the battery
CAUTION
For safety’s sake, observe the following instruc-
tions.
The electrolyte in the batteries is a sulphuric acid and
water solution, which is poisonous and caustic. Therefore,
wear protective clothing (protective apron and gloves) and
protective glasses when working around the batteries. If
the battery electrolyte should nevertheless contact cloth-
ing, the skin or eyes, immediately flush the affected parts
with water. Seek medical aid at once if the eyes are
affected!
Neutralize spilled battery electrolyte without delay.
DANGER
Gases are released when batteries are being
charged. Do not expose the battery to sparks or
open flames, as an explosion could result. Rooms in which
batteries are charged or stored must be ventilated accord-
ingly.
NOTE
Check that the specific gravity of the electrolyte is at least
1.14. The explosion-protected battery must also be safety
inspected. Always charge and service the battery accord-
ing to the manufacturer’s instructions. If you are not in
possession of these instructions, please contact your
distributor. Also follow the operating instructions for the
optional battery charger. If a battery charger is already
available, follow the instructions supplied with it.
CAUTION
Do not place any metal parts on the battery - risk
of a short!
Do not top up electrolyte before charging.
26
Opening battery cover
- Stop the truck, lower the forks
- Switch off and remove key
- Unlock the battery cover by pulling the grip (1) towards the
front of the truck.
- Move the battery cover towards the back (2).
Disconnecting the battery connector
NOTE
The battery connector is located behind the holding rod
mount.
- Stop the truck, switch it off by pressing the emergency
isolator button and remove the switch key.
- Push the connector retaining bracket (3) to the side.
- Pull the battery connector (4) out with the grip.
2
x1491394
Beginning operation
Connecting the battery connector
- Be sure the polarity of the battery connector is correct.
- Push the connector retaining bracket (3) to the side.
- Insert or connect the battery connector (4).
CAUTION
Never disconnect the connector if there is a
current in the circuit; this creates a high risk of
arc and destruction of the contacts.
Regularly check the state of the connector contacts, replace
them if there are signs of arcing and carbonisation.
Follow the polarity signs + and - ; always connect + with + and
- with - . Do not reverse the connectors.
Each connector half has a code pin; check if it is present and
in good condition. They prevent any risk of reversal (of
connectors).
149 804 6001.0904
- Refit the connector retaining bracket.
3
4
x1491399
 Daily checks and servicing before operation
Recharging the battery with an exter-
nal charger
- Drive the truck to the charging station.
- Stop the truck, switch it off and remove the switch key (1).
- Push the connector retaining bracket (3) to the side.
- Pull the battery connector (4) out.
- Open the battery cover (5).
- Connect the battery cable connector to the charging
station.
- Turn on the battery charger in accordance with the oper-
ating instructions supplied with the charger.
- Upon completion of the charging procedure, disconnect
the battery connector from the charger and re-insert it in
the truck.
- Refit the connector retaining bracket.
- Close the battery cover. Switch on the truck and check the
state of charge at the multifunctional indicator (2). The
truck can resume operation with the charged battery.
149 804 6001.0904
2
1 x1491395
Beginning operation
Closing and battery cover
- Close the battery cover.
CAUTION The latch engages.
To avoid any sparking, always connect the bat- - Check that the battery cable insulators are not squeezed
tery connector before starting the charger, and up or damaged.
disconnect it after the charger has stopped.
NOTE
NOTE The battery tray is locked by:
Make sure the charger is compatible with the truck battery - The stop hinge (7) located in the central notch of the
in terms of voltage and charge current (see charger battery case.
instructions). - The side plates (6) of the battery cover.
- The lock (8) which holds the cover shut.
- When connecting the battery to the charger, be sure the
polarity (+ and - poles) are correct. Do not interchange ATTENTION
connectors. The connectors have a code pin to prevent Always check that the battery cover is secured
false polarity. Make sure the pin is present and in a good before using the truck.
state.
3 5
4 6
7
x1491399 8 x1491400
27
Daily checks and servicing before operation Beginning operation
Check the battery condition, electro-
lyte level and specific gravity
NOTE - If the electrolyte level is low, top up with distilled water only NOTE
The following services apply for lead batteries with liquid (after charging the battery). Discharges which are under 20% of the rated capacity
electrolyte. - Remove any corrosion on battery poles and coat with non- (specific gravity 1.14) are deep discharges. Deep dis-
For gel batteries follow the operating instructions of the acidic grease. charges shorten the service life of the battery.
manufacturer. - Retighten pole clamps firmly.
- Check the specific gravity with a hydrometer. The specific
CAUTION gravity of the electrolyte must be between 1.24 and 1.28.
Avoid all contact with the acid and do not cause The specific gravity of a discharged battery should not fall
shorts. below 1.14.
- Refit the battery caps on each cell.
- Switch off the truck, open the battery cover and remove the
battery connector. ATTENTION
- Unscrew the caps of each cell. Only use distilled water for topping up.
- Check the battery for casing cracks, lifted plates and Never top up water before charging (risk of run-
electrolyte leakage. ning over).
- Check the electrolyte level.

149 804 6001.0904

- In batteries without level marks the acid must be approx. For further information refer to the battery operating instruc-
10 - 15 mm above the plates. tions.

x1491322

28
 Daily checks and servicing before operation
ATTENTION
The gas warning system is buffered for up to
about 120 minutes by rechargeable batteries.
This ensures that the sensing system remains in opera-
tion even during a change of the truck drive battery so that
a recalibration is not required. There is also a second
connection to the drive battery, so that the warning system
is also powered when the battery is being charged.
If the plug for the permanent power supply of the buffer
circuit is not reconnected, the built-in discharge indicator
cuts off the gas warning system when a buffer voltage of
23 V is reached. The gas warning system can only be taken
back into operation if the buffer circuit is consciously
acknowledged with an additional key switch.
This key switch must be in the repository of a safety
official, as EN 1755 mandates a recalibration of the sensor
heads before operation.
149 804 6001.0904
2 3
1 x1491401
Beginning operation
Battery change
DANGER - Replace the battery by carrying out the operations in the
The replacement battery must correspond to the reverse order.
standard battery both in size and weight. Devia- - Reposition the notch of the case opposite the catch (5)
tions in weight must be compensated by additional weights. and lower back into place.
Please contact your authorised Linde dealer for this serv- - Close the cover.
ice.
The admissible minimum and maximum battery weight are Battery change with a trolley*
stated on the truck identification plate. The load capacity of
- Position the trolley (6) beside the battery compartment
hoisting gear, chains and hoist must be sufficient for the and brake it.
battery (battery weight given on identification plate). - Adjust the height of the deck to that of the edge of the trolley.
- Disconnect the battery connector (1).
Battery change with a hoist - Disconnect the plug from the buffer battery (2).
- Open the battery cover (4).
- Lower the forks fully. - Raise the safety catch (5).
- Disconnect the battery connector (1) - Pull the battery onto the trolley and secure it.
- Disconnect the buffer battery connector (2). - Replace the battery by carrying out these operations in
- Open battery case cover (4). the reverse order.
- Remove the safety catch (5). - Reposition the notch of the case opposite the catch (5)
- Attach the slinging hooks to the battery case (3). and lower back into place.
- Remove the battery. - Close the cover (4).
* Option
1
2
4
5 x1491396
6 x1491397
29
Driving Operation
Approved use Starting up
The N 20 and N 25 trucks are designed for indoor use in non- - Connect the battery connector (1).
hazardous zones. The ambient temperature should be be-
tween -10 °C and +40 °C, the relative humidity under 95%. - Take position on the operator platform (2).
The floor must be level. The ground clearance below the
reduction gear is 34 mm, but the N20 and N 25 can handle - Step on the yellow dead man’s zone (3).
gradients of up to 16% with the forks raised.
- Release the emergency isolator switch.
The floor bearing capacity must be 40 kg/cm².
The maximum practicable slope advisable over a short - Turn the key switch (4) to the right as far as it will go.
distance is limited to 10% for braking and stability reasons.
The truck can only handle pallets up to a maximum weight of - The battery discharge indicator lights up and the hour
2 tonnes (N 20) or 2.5 tonnes (N 25), evenly distributed over meter (5) is on.
the length of the fork arms. Loads must be homogeneous and
of a max. recommended height of 2 m. - The electro-hydraulic brake is released automatically.
If you wish to use the truck for other applications than the
above, please first contact your authorised Linde dealer.

149 804 6001.0904

CAUTION
Always adapt your driving style to the conditions
of the roadway (rough surfaces, etc. ) especially
hazardous work areas and the load.

ATTENTION
Before starting off, lift the forks about half way so
that the lower parts of the lifting device do not
slide on the ground. 1

4
5

3 2 x1491402

30
 Driving
Directions of travel identification
On a pallet truck the conventional directions are:
- Forward travel (2) (in opposite direction of forks)
- Reverse travel (3) (in direction of forks)
CAUTION
Slow down for tight turns. Driving too fast in turns
can cause the truck to tip over.
149 804 6001.0904
Forward travel
- Step on the operator platform.
- Step on the yellow dead man’s zone (1) to release the
brake.
- Grasp the two hand-grips (6) of the control handlebar.
- Operate the top part (4) of the accelerator with the thumb
(right or left hand) to drive the truck forward (2).
The truck speed depends on how far the accelerator is
pushed.
Reverse travel
- Stand sideways on the platform, hold the holding rod with
one hand and the steering grip with the other.
- Operate the bottom part (5) of the accelerator with the
thumb (right or left hand).
The truck reverses (3).
The truck speed depends on how far the accelerator is
Operation
Reversing the direction of travel
- Release the accelerator and slowly operate it in the
opposite direction of travel.
The direction can also be changed while the truck is
moving.
The truck is first braked electrically to a stop and than accel-
erated in the opposite direction of travel.
- The maximum braking force is controlled by the electronic
controller.
Operating the emergency isolator button
- In an emergency, the truck can be shut down by pressing
the emergency isolator button (7). This applies the elec-
tro-hydraulic brake and stops the truck.

pushed.

6 4 4
6

5 7
5

2 x1491403 x1491404 x1491405

31
Driving
Operation in the pedestrian mode
CAUTION
The truck may be operated in the pedestrian mode
only over short distances when manoeuvring.
- The truck can be moved at a low speed, without the
operator having to be on the platform.
- Take a position at the right or the left of the truck.
DANGER
Note the steering position of the truck. There is a
danger of being crushed in case of non-observ-
ance.
- Actuate one of the two push-buttons (1) located on either
side of the chassis.
- The truck moves forwards only while the button remains
pressed in.
- Releasing the push button activates the regenerative
braking of the truck.
1
x1491406
32
Starting on a slope
When it is necessary to stop and then restart on a slope,
proceed as follows:
- Stop the truck by releasing the accelerator.
- Step off the dead man’s zone to apply the electro-hydrau-
lic brake.
- To restart, actuate the accelerator in the desired direction;
the traction motor is then powered with reduced voltage
and current.
- Step on the dead man’s zone to release the electro-
hydraulic brake and start off.
x1491407
Operation
Steering
The handlebar, with its compact size, allows the truck to be
steered with ease.
- Release the steering device. The steering device will
return to the zero position and the truck drives straight
ahead.
- The electrically-assisted steering allows the driver to
guide the truck with precision and with little effort.
Steering direction in forward travel
- Turn the handlebar clockwise, and the truck turns right.
- Turn the handlebar in the other direction and the truck
turns left.
Max. steering angle ...................................................... 180°
The steering radius (Wa) depends on the length of the forks
(see technical data).
149 804 6001.0904
x1491312
 Braking, lifting, lowering, horn Operation
Regenerative brake Electro-hydraulic braking Lifting the fork
Electric braking is possible by reversing the direction of The electro-hydraulic parking and emergency brake is ap- - Press lift switch (3).
travel. plied by leaving the dead man’s zone (2) or by pressing the
emergency isolator button. Lowering of the fork
- Select the opposite direction of travel with the left or right The braking force is adjusted automatically to the load on the
accelerator (1) until the truck stops, then release the forks in order to achieve effective braking. - Press lower switch (4).
accelerator.
The maximum braking force of the regenerative brake NOTE
(LBC) is set by the LDC control. The truck can only be driven with the accelerator if the
dead man’s zone (2) is activated. Operating the horn
LBC brake - Squeeze the rubber ball to sound the horn.
- When the accelerator is released, the regenerative brake
is activated automatically, braking the truck to a standstill.
149 804 6001.0904

4 3 ;;;;;;
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2
3
1
4

x1491408 x1491334 x1491409

33
Before loading, loading, transporting the load
Before loading
CAUTION
Before picking up a load, ensure that it is not too
heavy for the capacity of the truck.
- Refer to the type plate on the truck for the nominal
capacity.
DANGER
The values given in the capacity diagram or plate
apply for compact, homogeneous loads. Do not
exceed these values as the stability of the truck and the
strength of the forks will be reduced.
The specified weight only applies for compact and homoge-
neous loads and should never be exceeded as overloading
reduces truck stability and the strength of the forks. Pick up the
loads in such a way that they do not project beyond the fork
tips and cannot slide, tip over or fall off.
CAUTION
Take care not to touch nearby loads next to or in
front of the load being handled.
- Arrange the loads in alignment, with a small space be-
tween each one.
x1491335
34
Loading
DANGER
Do not step on elevated forks. There is an in-
creased danger of falling and being crushed.
DANGER
Stow the loads so that they do not project over the
load area limits and cannot slide, fall or fall off.
- Approach the load to be picked up carefully and as
accurately as possible.
- Elevate or lower the forks to the required height.
- Carefully move the truck into the centre of the load until,
if possible, it contacts the battery box. Take care not to
contact adjacent loads.
- If the load is shorter than the forks, move the forks only so
far under the load that the fork tips do not project beyond
the end of the load.
- Raise the forks until the load rests freely on the forks.
- Reverse the truck slowly and straight out of the load.
- Lower the forks so that the load is a few centimetres from
the ground.
x1491336
Operation
Transporting the load
- Do not drive with a laterally displaced load.
- Transport the load near the floor.
- Drive in the forward direction as much as possible to
ensure better visibility.
- When driving on slopes, always drive with the load on the
slope end and never drive across the slope or make a U-
turn.
- Drive in reverse only when depositing loads. As visibility
is poor in this direction of travel, drive only very slowly.
- In case of poor visibility, work with a guide and drive slowly
and carefully.
DANGER
When the forks are fully lowered, braking is not
power-assisted (no pressure in the hydraulic
circuit).
149 804 6001.0904
In this case, do not move with a load resting on the forks, since
the hydraulic braking assistance (which is absent) is no
longer related to the weight of the moving truck.
x1491337
 Depositing the load Operation
Depositing the load Picking up the load at the first level Before leaving the truck
- Move the truck carefully to the desired place. For “first-level order picking”, the upper working area can be CAUTION
reached over steps. Always park the truck on a level surface and
- Move the load forward carefully to the place where it is to outside the aisles.
be put down. - Stand on the platform. Never park and leave the truck with the load raised.

- Lower the load until the fork arms are clear.
CAUTION
Take care not to touch adjacent loads or loads
located behind the truck.
- Move the truck away, keeping the movement straight.
149 804 6001.0904
- Place one foot on the tread over the platform.
- Place the other foot on the tread on the chassis, holding
on to the mast with one hand.
NOTE
All treads have anti-skid coating.
- Fully lower the forks.
- Turn the switch key anti-clockwise as far as possible and
remove it.
- When stopping for a long period, disconnect the battery.
Stand-by function of truck
Standby mode comes on automatically after stopping a few
seconds, thus allowing battery power to be saved.
The control circuit is reset by the following controls:
- Step on the dead man’s zone,
- push the lift/lower button,

- push the button for pedestrian mode.

x1491335 x1491338

35
Hoisting, blocking up, towing
Hoisting the truck with a crane
DANGER
When hoisting the truck with a crane
ensure that no persons are located within
the working area of the crane! Do not walk
under a swinging load!
DANGER
Only use a lifting gear and crane with a sufficient
load capacity. For the truck weight, including
battery, see the data sheet or type plate.
Protect all parts coming in contact with the lifting gear. For
hoisting with a crane, attach the lifting slings at the points
provided.
Blocking up the pallet truck
CAUTION
Use a jack with sufficient capacity. See the tech-
nical data type sheet for the capacity.
Always shut the truck down and block it up with squared
timbers.
For some maintenance work the pallet truck has to be blocked
up
- To lift the front of the truck place the jack under the sides
of the chassis (1).
- Secure the raised truck with suitable squared timbers (2).
- For maintenance of load wheels, the jack must be placed
under the forks at the places indicated (1).
CAUTION
Always park the truck as specified and secure it
Operation
Towing
- In case the electrical system fails or the battery is removed,
the truck can not be towed as the steering is not operation-
al and the electro-hydraulic brake is not released.
- The truck can only be towed by lifting it at the front (1).
Transporting the truck
When transporting the truck on a lorry or semi-trailer, be sure
it is properly fastened against sliding and tipping and protect-
ed against the influence of weathers.
- Lash the truck down.

149 804 6001.0904

with squared timbers after jacking it up.

2
1
2

x1491411 x1491410

36
 Taking the truck out of operation
Taking the truck out of operation
If the truck is taken out of operation for over 2 months, it must
be parked in a well ventilated, frost-free, clean and dry room
and the following measures must be carried out.
Measures before taking the truck out of op-
eration
- Thoroughly clean the truck.
- Fully elevate the forks several times.
- Lower the forks on a support until the chains are slack.
- Check the hydraulic oil level and add oil, if needed.
- Apply a thin film of oil or grease on all unpainted mechan-
ical parts.
- Lubricate the truck.
- Check the condition and electrolyte level of the battery.
149 804 6001.0904
Coat the battery terminals with non-acidic grease. (Follow
the instructions of the battery manufacturer.)
ATTENTION
Block up the truck so that all wheels are clear of
the ground. This will prevent tyre deformation.
NOTE
Do not cover the truck with plastic foil as this enhances the
formation and collection of condensation water.
NOTE
If the truck is to be taken out of operation for over
6 months, contact authorised skilled personnel (experts)
for further measures.
The manufacturer recommends contacting your author-
ised Linde dealer.
Operation
Putting the truck back into operation
- Thoroughly clean the truck.
- Lubricate the truck.
- Clean the battery.
- Check the condition and electrolyte level of the battery
and charge the battery if necessary.
- Check the hydraulic oil for condensation water and change
the oil, if necessary.
- Perform the same services as for commissioning.
- Take the truck into operation.
37
Maintenance
General information
ATTENTION
Explosion protected fork lifts must
be maintained on a regular basis. The oper-
ator (owner) must determine the time peri-
ods for maintence in accordance with oper-
ating conditions and maintence manuals of
the manufacturer.
Your truck will remain operational only if the maintenance
and checks are carried out regularly and according to the
information and instructions in the operating manual.
The maintenance may only be performed by qualified author-
ised skilled personnel (experts).
The manufacturer recommends you to charge the authorised
Linde dealer.
DANGER
All inspection and maintenance work
must be done outside of an explosion risk
area and only by qualified authorised skilled
personnel (experts) who are familiar with all
regulations.
The manufacturer recommends you to
charge the authorised Linde dealer.
This work can be carried out by authorised skilled personnel
(experts) within a maintenance agreement. The manufactur-
er recommends you to charge the authorised Linde dealer.
If you wish to do the work yourself, we recommend that the first
three customer service checks be carried out by your distrib-
utor’s mechanic in the presence of the responsible mechanic
in your workshop, so that your staff can receive the appropri-
ate instruction.
38
CAUTION
For all servicing, the truck must be
placed on a level surface and the wheels
secured, the key removed from the key
switch and the battery plug disconnected.
For work on the front end of the truck, secure the mast against
tilting.
Perform a functional check and trial run after every servicing.
No changes, particularly no modifications and additions,
may be made to the truck without the approval of the manu-
facturer.
NOTE
When operating the truck under extreme conditions (i.e.
149 804 6001.0904
extreme heat or cold, intensive dust concentration, etc.),
the intervals given in the maintenance schedule should be
reduced accordingly.
Before greasing or servicing the hydraulic system, carefully
clean the area surrounding the related part.
Only use clean containers when topping up fluids and lubri-
cants.
Follow the manufacturer’s safety and disposal instructions
when using fluids and lubricants and cleaning compounds.
Discard replaced parts in a way friendly to the environment.
ATTENTION
Missing or damaged model plates, type plates or
notice stickers must be replaced. For location
and order number see the parts catalogue.
ATTENTION
Follow the precautions for handling fluids and
lubricants.
 Inspection and maintenance chart Maintenance
Inspection and maintenance after first 50
hours of operation
NOTE
For a description of activities, please consult the alphabet-
ical index.

- Check the brake system.

- Check the wheel fasteners.

- Check the condition and free spin of the wheels .

- Change the gear oil.

- Check the hydraulic oil level.

- Check the hydraulic system for tightness.

149 804 6001.0904

- Battery: check charge, condition, acid level and specific

gravity .

- Check cables and electric connections for condition and

tight fit .

- Check frame parts, body and load fork .

- Lubricate the steering bogie of the drive unit.

- Check and lubricate various hinges.

39
Inspection and maintenance chart Maintenance
Services Before initial After first Daily As
(A description of the service can also be located in the index.) operation 50 hours checks required

See page 23 for the services .....................................................................................................................................

See page 39 for the services ......................................................................................................................................................................

Check FORW/BACK control ..........................................................................................................................................................................................................

Check lift/lower control ...................................................................................................................................................................................................................

Check electrical steering ...............................................................................................................................................................................................................

Check braking ................................................................................................................................................................................................................................

Check the emergency isolator switch .....................................................................................................................................................................................

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

149 804 6001.0904

Check the battery charge ........................................................................................................................................................................................................

Check the battery condition, electrolyte level and specific gravity ........................................................................................................................................

Cleaning the truck ............................................................................................................................................................................................................................................................

Checking the tightness of wheel fasteners .....................................................................................................................................................................................................................

Checking the wheels for damage and foreign objects ...................................................................................................................................................................................................

Fixing and adjusting the stabiliser wheel .......................................................................................................................................................................................................................

Checking the fuses ..........................................................................................................................................................................................................................................................

Cleaning the dead man’s zone on the platform ..............................................................................................................................................................................................................

Checking the condition of battery connector, terminals and cables ..............................................................................................................................................................................

Cleaning the battery and its compartment ......................................................................................................................................................................................................................

Checking the battery tray .................................................................................................................................................................................................................................................

Inspecting the gas warning system measuring head (every 2 months) ..................................................................................................................................................................

Inspecting and calibrating the gas warning system (by an expert) (every 2 months) ............................................................................................................................................

Cleaning the gas warning system measuring head .................................................................................................................................................................................................

Checking the pump motor brushes, replacing the motor if necessary ....................................................................................................................................................................

40
 Inspection and maintenance chart Maintenance
Services Every 500 hours Every 1000 hours Every 2000 hours
(A description of the service can also be located in the index.) or semi-annually or annually or every 2 years

Greasing the turntable bearing of the motor unit ........................................................................................................................................

Cleaning of steering ring and pinions .........................................................................................................................................................

Checking reduction gear oil level ...............................................................................................................................................................

Checking hydraulic oil level ........................................................................................................................................................................

Checking tightness of hydraulic circuit .......................................................................................................................................................

Checking condition and fixing of electrical cables and connections ...................................................................................................

Cleaning and checking wear of contacts .............................................................................................................................................

Checking and, if necessary, changing traction motor brushes ............................................................................................................

Checking and, if necessary, changing steering motor brushes ..........................................................................................................

Adjusting the electro-hydraulic brake .........................................................................................................................................................

Checking the various hinges .......................................................................................................................................................................

149 804 6001.0904

Checking the locking and adjusting the battery cover handle ...................................................................................................................

Cleaning the non-return valve hydraulic filter .................................................................................................................................................................................

Checking mechanical fixing of the components .............................................................................................................................................................................

Replacing the hydraulic oil ................................................................................................................................................................................................................................................

Replacing the reduction gear oil .......................................................................................................................................................................................................................................

41
Inspection and maintenance as required
Cleaning the truck
Disconnect the battery before cleaning. Use steam jet or
highly degreasing cleaning products only with great care,
since they dilute the grease of bearings with lifetime lubrica-
tion. Given that subsequent greasing is not an option, these
cleaning methods cause deterioration of the bearings.
ATTENTION
When using cleaning equipment, do not expose
the electrical circuits, motors and insulating pan-
els to direct jets; protect them before cleaning.
When using compressed air, first remove stubborn dirt with
a cold detergent. Before lubricating jobs, clean the oil filler
openings and their surroundings, as well as oilers, with
particular care.
Dry the truck after cleaning
If despite all precautions, water has penetrated into the
motors, the truck must be put into operation to avoid the
formation of rust (drying with its own heat). The motors may
also be dried with compressed air.
x1491412
42
NOTE
If a truck is cleaned frequently it must also be greased
more often.
Opening the motor compartment cover
- Remove the screws (1) using a hollow hexagonal span-
ner
- Open the cover (2) of the platform
To close the cover, carry out these operation in reverse order.
ATTENTION
Before any work on the truck:
- Press on the emergency isolator button.
- Disconnect the battery.
Checking the tightness of wheel fasteners
- Raise the truck until the wheels are not touching the
ground. To secure, place squared timbers underneath
the truck.
x1491341
Maintenance
- Check the tightness of the traction wheel nuts - required
torque: ................................................................. 140 Nm
- Check the tightness of the loadwheel fixing screws -
required torque: .................................................... 50 Nm
Checking the wheels for damage and for-
eign objects
- Raise the truck until the wheels are not touching the
ground. To secure, place squared timbers underneath
the truck.
- Check that the wheels rotate freely and remove all poten-
tial obstacles to them.
- Change worn or damaged wheels.
- First check the front wheels, then the load wheels.
ATTENTION
149 804 6001.0904
Any foreign objects tangled in the wheel hubs and
bearings must be removed; otherwise there is a
risk of rapid deterioration of the wheels.
x1491413
 Inspection and maintenance as required Maintenance
Fixing and adjusting the stabiliser wheel Checking the fuses Cleaning the dead man’s zone on the plat-
To ensure the truck is horizontal: Remove the motor cover (1) to gain access to the fuses form
- There are 4 possible settings of the stabiliser wheel to located on the electric plate. When cleaning or carrying out servicing, the dead man’s
compensate for the wear of the traction wheel. - The 225 A fuse protects the power circuit of the traction zone must be treated with care. Do not, in particular, bend the
motor. yellow area (1).
- It is the position of the screws (1) in the housings I, II, III and - The 100 A fuse protects the power circuit of the pump
IV that determines the height of the wheel. motor.
- The 30 A fuse protects the circuit of the steering motor.
- Check the tightness of the fixing screws of the stabiliser - The 10 A fuse protects the control circuits.
wheel pivot (2) - required torque: ........................ 45 Nm
Removing the platform surface covering
- Remove the motor cover.
- Disconnect the connector on the cable loom from the dead
man’s zone.
- Remove the cable bushing.
- Remove the platform covering.
Installation is in the reverse order of removal.
149 804 6001.0904

1
1 2
x1491342 x1491414 x1491343

43
Inspection and maintenance as required
Checking the condition of battery connec-
tor, terminals and cables
- Check that the cables for damage and traces of overheat-
ing in the area of the terminals.
- Check that the (+) and (-) battery terminals are not sulphat-
ed (presence of white salt).
- Check state of battery connector contacts. Do not damage
the relevant code pins.
ATTENTION
All of the damages mentioned above can lead to
malfunctions. Please contact your authorised
Linde dealer.
Servicing/cleaning the battery and battery
compartment
CAUTION
The following instructions must be followed for
the safe operation and maintenance of batteries.
The battery contains dissolved sulphuric acid, which is
poisonous and caustic. When working with battery acid
therefore, always wear personal protective gear (protec-
tive apron and gloves) and eye protectors.
If battery acid gets on clothing, skin or eyes nevertheless,
flush the affected parts immediately with water. In case
acid contacts the eyes, seek medical help immediately.
Neutralise spilled battery acid immediately.
NOTE
The battery must always be serviced and maintained
according to the battery maintenance instructions of the
manufacturer. If the battery maintenance instructions are
Maintenance
Checking the battery tray
- Verify there is no electrolyte at the bottom of the case, by
connecting the suction syringe provided with the battery
to the plastic plunger tube.
- Pump (out) any electrolyte that has spilled between cells
and discard in an environment-friendly way.
- Clean the top of the elements with a wet rag
ATTENTION
Please contact your authorised Linde dealer in
case of heavy sulphur deposits or acid running
out.
ATTENTION
Follow the instructions for handling fluids and
lubricants.

149 804 6001.0904

missing, please contact your authorised Linde dealer.

x1491415 x1491346

44
 Inspection and maintenance as required
Inspecting the gas warning system
measuring head (every 2 months)
NOTE
Have this service only carried out by authorised personnel
(experts).
The manufacturer recommends having this service per-
formed by your authorised dealer.
Maintenance
Cleaning the gas warning system mea- Checking the pump motor brushes,
suring head replacing the motor if necessary
- Clean the measuring head only with a dry, clean cloth. NOTE
Please contact your authorised Linde dealer for this serv-
In case of stubborn dirt please contact your authorised dealer. ice.

Inspecting and calibrating the gas warn-

ing system (by an expert) (every 2 months)
NOTE
Have this service only carried out by authorised personnel
(experts).
The manufacturer recommends having this service per-
formed by your authorised dealer.
149 804 6001.0904

x1491416 x1491417

45
500-hour inspection and maintenance Maintenance
Greasing the turntable bearing of the motor Cleaning of steering ring and pinions Checking reduction gear oil level
unit - Check that the pinion (2) and the toothed ring (3) are not ATTENTION
NOTE clogged with impurities. Follow the instructions for handling fluids and
Please only use grease as specified in the lubricant re- lubricants.
commendations. - If necessary, clean them with solvent, then dry them with
compressed air. - Position the wheel to allow access to the level plug (4).
- Open the motor cover.
- Then lubricate the pinion and wheel with silicon from an - Unscrew the plug (4); the oil should be flush with the
- Clean the 2 nipples (1). aerosol. bottom of the bore.

- Inject grease into each nipple until clean grease comes ATTENTION - If necessary, top up to the desired level.
out of the bearing race. Do not lubricate with any other product, as this will
create a risk of dust agglutination. - Screw the plug back on.
NOTE
There is an optional automatic (dot-) greasing unit, which - Check that there are no traces of leakage.
allows the bearing of the turntable ring to be lubricated for
a set period (3 or 6 months or 1 year, depending on
maintenance frequency).

149 804 6001.0904

4

3 2
x1491348 1 1 x1491349 x1491350

46
 500-hour inspection and maintenance Maintenance
Checking hydraulic oil level Checking tightness of hydraulic circuit
ATTENTION - Inspect the hydraulic circuit: tubes, hoses and connec- - Check the cable connections for tightness and oxidation
Follow the instructions for handling fluids and tions between the motor-driven pump unit and the jacks residues (arrows).
lubricants. for leaks. - Check the battery cable for security.
- Check electric cables for chafing, damaged insulation
- Lower the forks fully. - Tighten connections, if necessary. and security.

- The oil level (1) should be in the middle between the MIN.
and MAX. level markings of the tank (middle marking)
- Top up the level if necessary, after unscrewing the plug (2).
ATTENTION
Use only hydraulic oil in accordance with the
specifications (see lubricant recommendations).
- Screw the plug back on.
149 804 6001.0904
- Check of the two lifting jacks for leaks.
- Check the hoses for security and wear.
If you detect leaks, please contact your authorised Linde
dealer.
Checking condition and fixing of elec-
trical cables and connections
- Switch off the key switch.
NOTE
Oxidized connections and broken cables lead to drops in
voltage and heating, which can cause malfunctions.
- Remove any oxidation residues and replace damaged
cables.
NOTE
Protect the electrical board against humidity. Any adjust-
ments and repairs should be carried out by your author-
ised Linde dealer.

- Disconnect the battery connector.

- Blow compressed air on the electrical board.

1 x1491418 x1491352 x1491419

47
500-hour inspection and maintenance Maintenance
Cleaning and checking wear of con- Checking and, if necessary, replacing Checking and, if necessary replacing
tacts traction motor (1) brushes the steering motor (2) brushes
ATTENTION ATTENTION ATTENTION
Please contact your authorised Linde dealer for Please contact your authorised Linde dealer for Please contact your authorised Linde dealer for
this service. this service. this service.

149 804 6001.0904

2

x1491427

48
 500-hour inspection and maintenance Maintenance
Adjusting the electro-hydraulic brake
DANGER - Turn the 3 hollow screws (2) to adjust the air gap to the
The mechanical braking moment is factory set original value of 0.2 mm.
and the pressure in the lifting circuit assists this - Tighten the 3 fixing screws (1) again.
braking.
- Check the air gap at 3 points 120° apart.
- The brake must be checked in the “brake on” position with - Ensure the air gap is even all around the brake.
no load on the forks, i.e. with the power cut off with the key
- Supply power to the brake by pressing the on presence
switch.
zone and check that the brake releases fully.
- Check the air gap of the brake with a set of feeler gauges.
The original air gap is 0.2 mm, the max. air gap after partial NOTE
wear of the disk is 0.5 mm; thereafter there is a risk of Please contact your authorised Linde dealer for this ad-
incomplete brake release and of overheating. justment.
- If the air gap is close to or over the maximum value of
0.5 mm, it must be adjusted.
- Disconnect the brake power supply.
- Loosen the 3 fixing screws (1).
149 804 6001.0904

2
x1491358

49
500-hour inspection and maintenance
Checking the various hinges
- Check and grease the various hinge pins.
- Use an aerosol lubricant or oil.
- Refit the motor cover.
Checking/adjusting the battery cover catch
The correct seat of the battery in the tray depends on the
proper closing of the battery cover.
- Open the cover.
- Ensure that the retaining hinge goes properly down into
the central cut-out of the battery cover.
- Lower the cover; it should lock automatically.
Maintenance
The elasticity of the battery cover handle depends on the
polyurethane blocks. Measure dimension (a), adjusting it if
necessary.
- Tighten the two nuts (4) to obtain a compression measure-
ment for the blocks of:
- 38 mm on trucks with low batteries (height 630 mm).
- 36 mm on trucks with high batteries (height 787 mm).

- If not, loosen the two screws (1) and adjust the height of ATTENTION
the catch (2) in relation to the position of the latch (3). Always make sure that the battery is properly
secured before using the truck.
- Retighten the screws (1).

149 804 6001.0904

3 2

x1491421 x1491359 x1491360 4

50
 1000-hour inspection and maintenance
Cleaning the non-return valve hydraulic oil
filter
- Remove the motor-pump unit.
- The filter (3) is under the plug (1).
- Remove the plug (1).
- Take out and clean the filter (3).
ATTENTION
When disassembling, take care not to lose spring
(4) and ball (5) of the non-return valve.
- Check the sealing ring (2).
- Install the non-return valve (1-5).
- Refit the motor-pump unit, reconnect the hoses and fill
hydraulic oil up to the MAX mark.
Maintenance
Checking mechanical fixing of the compo-
nents
- Check the sub-assemblies are properly attached: motor/
reduction gear, load wheels, traction wheel, stabiliser
wheel and operator platform.
- Check the battery cover for proper locking.
- Check the tightness of the screws and nuts.
- Check that the forks are in good condition.
- Replace defective parts.
- Retouch paintwork if necessary.

NOTE - Refit the motor compartment cover.

Please contact your authorised Linde dealer for this ser-
149 804 6001.0904

vice.

1
2
3
4
5

x1491363 x1491420

51
2000-hour inspection and maintenance
Replacing the hydraulic oil
ATTENTION
Follow the instructions for handling fluids and
lubricants.
- Remove the motor cover.
- Disconnect the hydraulic lines and electric cables at the
motor-driven pump unit.
- Remove the pump unit and set vertical.
- Remove the 2 half-collars (2).
- Remove the hydraulic oil tank (1), empty and discard the
oil in an environment-friendly way.
Maintenance
Filling Replacing the reduction gear oil
ATTENTION ATTENTION
Follow the instructions for handling fluids and Follow the instructions for handling fluids and
lubricants. lubricants.
NOTE
- Re-attach the tank (1) onto the motor-driven pump unit, Before this operation, run the reduction gear to make the
taking care to replace seal (4) correctly. oil heat up.
- Raise the truck.
- Replace the pump unit on the chassis. - Position the reduction gear unit, using the steering han-
dlebar, until the drain plug (2) and level plug (1) are
- Reconnect the hydraulic lines and electric cables. accessible.
- Place a receptacle under the reduction gear unit
- Unscrew the filling plug (6). - Unscrew the level plug (1).
- Unscrew the magnetic drain plug (2).
- Fill hydraulic oil through hole (5) in the tank (1) up to the - Clean and re-screw the magnetic drain plug (1), after
MAX marking. replacing the oil seal.

- Clean the suction and return strainers (3). - Operate the lifting system several times to drain the circuit. Filling

149 804 6001.0904

- Fill gearoil through the upper hole (1) as far as its lower
NOTE Capacity .................................................. approx. 1.25 litres edge
Please contact your authorised Linde dealer for this serv- - Screw the level plug (1) back on.
ice. - Refit the motor cover.
Capacity .................................................... approx. 1.5 litres

1
3

1 5 4

2
2
6 x1491364 x1491365

52
 Inspection and maintenance specifications Maintenance
No. Aids/ Capacity/
Lubricants Settings

1 Hydraulic system Hydraulic fluid 1.25 l

Filter element Efficiency: 150 µm
Max. pressure 165 bar (start of opening) N 20
180 bar (start of opening) N 25

2 Reduction gear Reduction gear oil 1.5 l

3 Wheels:
Traction wheel Wheel nuts Thread torque 140 Nm
Stabiliser wheel Pivot attachment screw Thread torque 45 Nm
Load wheels Fastening screws Thread torque 50 Nm

4 Electrical system:
Traction motor Fuse 1 x 225 A
Pump motor Fuse 1 x 100 A
Control bank Fuse 1 x 10 A
149 804 6001.0904

Steering motor Fuse 1 x 30 A

5 Battery Distilled water As required

6 Hinges Lithium soap grease As required

53
Lubricant recommendations
Hydraulic oil Gear oil
Recommendation for regular duty: Preferably SAE 80 W - 90 API GL5, also suitable is
Hydraulic oil ISO-L-HM 46 to ISO 6743-4 or HLP ISO VG 46 SAE 85 W - 90 API GL4 (to DIN 51512).
to DIN 51524 T.2 (factory filling), average continuous oil
temperature 40 °C to 60 °C. Lubricating grease
Recommendation for heavy duty: Linde lithium-based heavy duty grease with EP additives and
Hydraulic oil ISO-L-HM 68 to ISO 6743-4 or HLP ISO VG 68 MOS2.
to DIN 51524 T.2, average continuous oil temperature over
Designation to DIN 51825 - KPF 2K-30, KPF 2K-20, KPF 2N-
60 °C.
30 (see Parts Catalogue for Order No.).
Recommendation for light duty at low ambient temperatures:
Do not mix with greases having another base than lithium.
Hydraulic oil ISO-L-HM 32 to ISO 6743-4 or HLP ISO VG 32
to DIN 51524 T.2, average continuous oil temperature under
50 °C.
Battery grease
Recommendation for strongly varying operating condition: Non-acidic lubricating grease (terminal grease).
All the above applications can be covered with an hydraulic
oil ISO-L-HV 46 to ISO 6743-4 or HVLP ISO VG 46 to DIN
51524 T.3.

149 804 6001.0904

Such hydraulic oils have a high viscosity index (multigrade
oils).

Bio hydraulic oil

Biologically fast-degradable pressure fluid
Aral Forbex SE 46

ATTENTION
Do not mix bio-oils with mineral oils. Other fluids
from other manufacturers cannot be recommend-
ed at this time.

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

54
 Troubleshooting guide
Trouble Possible Cause Remedy See Page

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

Suction line leaking. Tighten line connections. 47

Oil foaming
Oil level low. Check oil level, top up if necessary. 47

Hydraulic pump damaged, seals faulty,

causing air intake. Contact your authorised Linde dealer.

No or too low pressure in Pump suction faulty, restricted suction filter. Contact your authorised Linde dealer.
system
Pump failure, leakage, pressure valves do not close Contact your authorised Linde dealer.
149 804 6001.0904

Hose leaky. Replace hose or tighten connections. 47

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

Oil pressure fluctuates Causes as under abnormal noise. See under abnormal noise.

Hydraulic oil temperature Pump failure, valves leaking. Contact your authorised Linde dealer.
too high
Oil level too low, wrong oil type. Check oil level; if necessary, top up oil. 47
Contact your authorised Linde dealer.

Failure of the working Battery discharge 80 %. Check battery, recharge or replace. 25-29
hydraulic system
Faulty fuse. Contact your authorised Linde dealer.

Fault in electric circuit. Contact your authorised Linde dealer.

55
Electric circuit diagram (basic equipment)
1A1 LDC traction controller S1 Key switch 3X4 Steering diagnostic plug
1A7 Interface 1S9 Dead man’s zone microswitch (driver’s platform) 3X6 Connector to electronic steering unit
3A1 LES electronic steering unit 1S10 „Slow speed in pedestrian mode“ pushbutton 6X2 Connector, multifunctional display
7A1 Encoding board 1S11 „Slow speed in pedestrian mode“ pushbutton 6X4 Diagnostic connector, multifunctional display
7A3 Monitoring unit 1S21 Accelerator forwards microswitch 7X3 Connector, monitoring unit
1S22 Accelerator reverse microswitch 7X6 Connector, brake
1B1 Accelerator potentiometer 2S6 Forks down microswitch (at handlebar)
1B2 Traction motor speed sensor 2S61 Forks down microswitch (at holding rod mounting) Y1 Electromagnetic brake
1B3 „Forks lowered“ / slow speed sensor 2S7 Forks up microswitch (at handlebar) 2Y2 Lowering solenoid valve
1B5 Traction motor 1M1, 120°C temperature switch 2S71 Forks up microswitch (at holding rod mounting)
1B6 Brake 120°C temperature switch 7S7 Emergency isolator button Z2 Freewheel diode
1B10 Controller enclosure 90°C ±5°C temperature switch Z3 Decoupling diode
2B2 „Forks raised“ sensor X1 Battery connector
2B5 Lift motor 120°C temperature switch X10 Connector
3B2 Steering unit desired-actual value potentiometer Gas warning system supply voltage
3B3 Traction wheel desired-actual value potentiometer XT Connector, temperature switch
3B5 Steering motor 120°C temperature switch 1X1 Connector, traction controller
3B7 Steering control temperature switch 1X2 Connector, 1B2
1X4 Traction controller diagnostic connector

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1F1 Traction motor line fuse 225A 1X5 Connector, interface
1F3 Control current fuse 10 A 1X8 Connector, interface
1F4 Backup circuit fuse 5A 1X9 Connector, dead man’s switch
2F1 Pump motor line fuse 100 A 1X10 Connector, pedestrian mode
3F1 Steering motor line fuse 30A 1X11 Connector, pedestrian mode
1X13 Encoding board plug
G1 Battery 1X20 Connector, controller enclosure
1X21 Connector, controller enclosure
KV1 Gas warning unit shutoff relay 1X3 Connector, 1B2 steering potentiometer
KT1 Temperature shutoff relay 1X24 Connector, gas warning system shutoff
1K0 Power-up contactor 1K 1X31 Connector, tiller
1K1 Isolator switch relay 1X32 Connector, tiller
1K11 Forwards directional contactor (in opposite direction 1X71 Connector, interface
of forks) 1X72 Connector, interface
1K12 Reverse directional contactor (in forks direction) 1X73 Connector, interface
2K1 Pump contactor 1X74 Connector, emergency isolator
2K2 Lift cut-off relay „forks high position“ 1X75 Connector, key switch
3K1 Steering control safety relay 1X81 Connector, interface
2X7 Connector, sensor 2B2
1M2 Traction motor 2X9 Connector, lifting / lowering (handlebar)
2M1 Pump motor 3X1 Connector, electronic steering unit
3M1 Steering motor 3X2 Connector to pot 3B2
3X3 Connector to pot 3B3
6P4 Multifunctional display for truck

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Electric circuit diagram (basic equipment)

57
Electric circuit diagram (gas warning system)
7A2 Gas warning system

7B1 measuring head 1

7B2 measuring head 2 *
7B19 Temperature switch, gas warning system 80°C ± 5°C
7B20 Temperature switch, gas warning system 80°C ± 5°C

D3 Isolation diode

7F21 Fuse, gas surveillance 1A

7F22 Fuse, rechargeable battery 1A
7F23 Fuse, rechargeable battery 1A
7F24 Fuse, gas surveillance 1A

G2 Buffer battery

H6 Warning sensor, gas concentration 10% / 25%

7H1 Indicator light, gas warning system

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KG1 Relay, buzzer cut-off
KP1 Relay, switch-on inhibitor
KP2 Relay, low battery voltage cut-off
KV1 Relay, gas warning system shutoff

P1 Potentiometer, buffer voltage

6P3 Composite instrument, gas warning system

RV6 Series resistor, buffer batteries 3R3

7S5 Acknowledgement button, gas warning

S6 Key switch / enable gas warning system 7A2

U3 Voltage converter buffer circuit

1X24 Connector, gas warning system shutoff

X2 Connector, continuous power
XGH6 Connector, warning sensor H6

1Z... Freewheel diode

* Option

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Electric circuit diagram (gas warning system)

59
Hydraulic circuit diagram
1 Lifting jacks
2 Connection
3 Filter
4 Lowering solenoid valve
5 Reducer
6 Pressure relief valve
7 Breather (incorporated into filling plug)
8 Return line strainer 150 µm
9 Hydraulic oil reservoir
10 Suction strainer – 450 µm
11 Hydraulic pump
12 Non-return valve
13 Pressure filter 150 µm
14 Electrohydraulic brake

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15 Brake hose

1M1 Traction motor

2M1 Pump motor

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 Hydraulic circuit diagram

15

14
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3
4

13
5

12
6
7
11
10
8
9

x1491366

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Index
Page
A
Accident prevention check ......................................... 23
Adjusting the contrast ....................................................... 18
Adjusting the date/time ..................................................... 18
Adjusting the electro-hydraulic brake .............................. 49
Adjusting the lighting ........................................................ 18
Approved applications ........................................................ 2
Approved use .................................................................... 30
B
Battery change ............................................................ 29
Battery change with a hoist ........................................ 29
Battery change with a trolley ...................................... 29
Battery discharge indicator ............................................... 19
Battery grease ................................................................... 54
Before leaving the truck .................................................... 35
Before loading ................................................................... 34
Beginning operation ......................................................... 21
Bio hydraulic oil ................................................................ 54
Blocking up the pallet truck .............................................. 36
Braking .............................................................................. 11
Braking, lifting, lowering, horn .......................................... 33
C
Charging the battery ................................................... 26
Check braking ................................................................... 24
Check electrical steering .................................................. 24
Check FORW/BACK and lift/lower controls ..................... 24
Check the battery charge ........................................... 25
Check the battery condition, electrolyte level and
specific gravity ......................................................... 28
Check the horn ............................................................ 25
Checking and, if necessary, replacing
the steering motor brushes ..................................... 48
Checking and, if necessary, replacing
traction motor brushes ............................................ 48
Checking condition and fixing of electrical cables and
connections ............................................................. 47
62
Page
Checking hydraulic oil level ............................................. 47
Checking mechanical fixing of the components .............. 51
Checking operation of the emergency
isolator button .......................................................... 24
Checking reduction gear oil level .................................... 46
Checking the battery tray .................................................. 44
Checking the condition of battery connector,
terminals and cables ..................................................... 44
Checking the fuses ........................................................... 43
Checking the pump motor brushes,
replacing the motor if necessary ............................. 45
Checking the tightness of wheel fasteners ...................... 42
Checking the various hinges ............................................ 50
Checking the wheels for damage and foreign objects .... 42
Checking tightness of hydraulic circuit ............................ 47
Checking/readjusting the battery cover catch .................. 48
Cleaning and checking wear of contacts .................. 48
Cleaning of steering ring and pinions .............................. 46
Cleaning the dead man’s zone on the platform ............... 43
Cleaning the gas warning system measuring head . 45
Cleaning the non-return valve hydraulic oil filter ............ 51
Cleaning the truck ............................................................. 42
Closing and battery cover ................................................. 27
Composite instrument for gas warning system ............... 19
Connecting/disconnecting battery connector ............ 26
D
Daily checks and servicing before operation .................. 24
Daily inspections ............................................................... 23
Depositing the load ........................................................... 35
Description .......................................................................... 5
Directions of travel identification ...................................... 31
Drive .................................................................................. 11
Driving ............................................................................... 30
E
Electric circuit diagram (basic equipment) ....................... 56
Page
Electric circuit diagram (gas warning system) ................. 58
Electro-hydraulic braking .................................................. 33
Experts .............................................................................. 21
Explosion protection check ........................................ 23
F
Filling ................................................................................. 52
Fixing and adjusting the stabiliser wheel ........................ 43
Foreword ............................................................................. 2
Forward travel ................................................................... 31
G
149 804 6001.0904
Gas warning system ................................................... 20
Gear oil .............................................................................. 54
General information .......................................................... 38
General view of truck ....................................................... 12
Greasing the turntable bearing of the motor unit ............. 46
H
Handling fluids and lubricants .......................................... 23
Hoisting the truck with a crane ......................................... 36
Hoisting, blocking up, towing ........................................... 36
Hour meter ........................................................................ 19
Hydraulic circuit diagram .................................................. 60
Hydraulic oil ...................................................................... 54
I
Inspecting and calibrating the gas warning system .. 45
Inspecting the gas warning
system measuring head .......................................... 45
Inspection and maintenance after first 50 hours
of operation .................................................................... 39
Inspection and maintenance as required ........................ 42
 Index
Page
1000-hour inspection and maintenance .......................... 51
2000-hour inspection and maintenance .......................... 52
500-hour inspection and maintenance ............................ 46
Inspection and maintenance chart ................................... 40
Inspection and maintenance specifications ..................... 53
L
LBC brake ......................................................................... 33
Lifting the fork .................................................................... 33
Lifting ................................................................................. 11
Loading ............................................................................. 34
Lowering of the fork .......................................................... 33
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Lubricant recommendations ............................................. 54
Lubricating grease ............................................................ 54
M S
Maintenance ..................................................................... 38
Maintenance work prior to initial start-up ......................... 23
Measures before taking the truck out of operation .......... 37
Multifunctional display ...................................................... 14
O Steering ....................................................................... 11, 32
Opening battery cover ...................................................... 26
Opening the motor compartment cover ............................ 42
Operating and display elements ...................................... 13
Operating the emergency isolator button ........................ 31
Operating the horn ............................................................ 33
Operation ..................................................................... 11, 30
Operation in the pedestrian mode .................................... 32
Operation of industrial trucks in the plant area ................ 23
P
Pallet truck takeover ........................................................... 3
Picking up the load at the first level ................................. 35
Page
Putting the truck back into operation ................................ 37
R
Recharging the battery with an external charger ............ 27
Regenerative brake .......................................................... 33
Removing the platform surface covering ......................... 43
Replacing the hydraulic oil ............................................... 52
Replacing the reduction gear oil ...................................... 52
Report of Thorough Examination ..................................... 23
Reverse travel ................................................................... 31
Reversing the direction of travel ....................................... 31
Running-in instructions ..................................................... 23
Safety rules ........................................................................ 21
Servicing/cleaning the battery
and battery compartment ............................................... 44
Stand-by function of truck ................................................. 35
Starting on a slope ............................................................ 32
Starting up ......................................................................... 30
Steering direction in forward travel .................................. 32
T
Table of contents ................................................................. 7
Taking the truck out of operation ...................................... 37
Technical data ................................................................... 10
Technical description .................................................. 11, 20
Technical note ..................................................................... 3
Temperature monitor ........................................................ 11
Towing ............................................................................... 36
Transporting the load ........................................................ 34
Transporting the truck ....................................................... 36
Troubleshooting guide ...................................................... 55
Type plates .......................................................................... 5
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