Operating Instructions

Directive No. 94/9/EC Machine Group II

Zone 2, Machine Category 3G
Linde Electric Reach Truck
x1151461
With Gas Warning System PL-G 1000 to EN 1755
R 14 / R 16 / R 20
With Electric Motors
115 804 2581 GB
0505
Linde - Your Partner Linde Material Handling GmbH & Co. KG

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.
The operator or owner must ensure
that the truck is always in a safe operating
condition.
All measures in this manual related to
explosion protection are identified with .
Please ensure that they are followed.
The rules for the authorised and proper
use of industrial trucks according to direc-
tive 94/9EC and the safety rules in these
operating instructions must always be fol-
lowed by the operating and service person-
nel.
Foreword
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).
No changes, especially conversions
or modifications, may be made on your fork
truck without the prior permission of the
manufacturer.
Only qualified and authorised persons
(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.

115 804 2581.0505

Follow all tips for operating the lift truck and carry out the
maintenance and care prescribed in the inspection and
The user, and not Linde, is responsible When replacing explosion-proof com-
maintenance schedule regularly, on time and with the spec- for any danger arising from applications not ponents, always install identical tested parts
ified lubricants. authorised by the manufacturer. approved for the truck.
To keep your warranty valid, all maintenance services must
be performed by qualified persons authorised by Linde. Operate the truck only in the hazardous After changes in the explosion protec-
The terms “front”, “rear”, “left” and “right” refer to the position zones for which it is certified according to tion, the operator (employer) must have the
in which the item concerned is installed in the truck in relation
the accompanying certificate. truck certified by an expert before taking it
to the forward travel direction.
back into operation.
Approved applications
Linde fork lift trucks are 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

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 engineering 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 fork truck and all
orders for spare parts to your authorised distributor, making
sure to state your correct shipping address.
115 804 2581.0505
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: _________________
3001 x
INERIS 02 ATEX No.: _________________________
Handing-over date: ______________________________
When ordering parts for the mast assembly also specify the
serial number of the mast.
Mast no.: _______________________________________
Mast lifting height: ____________________________ mm
When taking over the fork lift truck, transfer the data from the
assembly type plates into this operating manual.
Foreword
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 fork
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 and much success,
Your
Linde Material Handling GmbH & Co. KG
Aschaffenburg
3
115 804 2581.0505
4
 Type plates Description
1 Vehicle identification plate
2 Truck type
3 Manufacturer
4 CE symbol
(The symbol certifies that EC directive for machines and
all applicable guidelines are fulfilled.)
5 Battery voltage
6 Unladen mass
7 Battery mass
8 Rated capacity
9 Serial number/year of manufacture
10 Mast number (Stamped)
11 Serial number (Stamped)
12 Leakage resistance (glued)
115 804 2581.0505

13 Attachment capacity plate

14 Type plate INERIS Atex type test no. (on flameproof
enclosure on left-hand side of truck)

1 2 3
x1151429

6 5 4
5
Electric reach truck R 14, R 16, R 20 explosion-proof 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.

115 804 2581.0505

The driver’s position and the controls are arranged in accord-
ance with state-of-the-art human engineering. The arrange-
ment and operation of each control is adapted to the driver so
that fatigue-free and therefore safe working is ensured.

x1151436

6
 Table of contents
Page
Foreword ......................................................................... 2
Approved applications ........................................................ 2
Technical note ..................................................................... 3
Truck takeover ..................................................................... 3
Description ..................................................................... 5
Type plates .......................................................................... 5
Technical data ................................................................... 10
Technical description ........................................................ 12
Introduction .................................................................... 12
Operator’s compartment and controls .......................... 12
Chassis .......................................................................... 12
Drive and transmission .................................................. 12
Electrical system ............................................................ 12
Steering .......................................................................... 12
Mast, hydraulics and reach frame ................................. 12
Braking ........................................................................... 12
115 804 2581.0505
Gas warning system ................................................ 13
General view of truck ........................................................ 14
Operating controls and indicators - dual-pedal model .... 15
Operating controls and indicators - single-pedal model . 16
Operator's display ............................................................. 17
Multi-purpose display .................................................... 17
Hour meter for truck ....................................................... 17
Battery discharge indicator ............................................ 18
Drive wheel position indicator ...................................... 18
Motor brushes wear indicator ....................................... 18
Overheating warning lights ........................................... 19
Condition display ........................................................... 19
Brake fluid level warning light ....................................... 19
Service warning light ..................................................... 19
Parking brake warning light .......................................... 20
Battery unlocked warning light ...................................... 20
Slow speed indicator ..................................................... 20
Composite instrument for gas warning system ........ 21
Hour meter ..................................................................... 21
Battery discharge indicator ............................................ 21
Overheating warning lights ....................................... 22
Traction motor overheating warning lights ................... 22
Lift pump motor overheating warning light ................... 22
Steering motor overheating warning light .................... 22
Overheating warning light for traction motor brake or
straddle leg wheel brake ............................................... 22
Gas warning system (compression-proof enclosure)
overheating monitoring warning light) .......................... 22
Page
Beginning operation ................................................ 23
Safety rules ........................................................................ 23
Experts .............................................................................. 23
Safety information ............................................................. 25
Handling fluids and lubricants .......................................... 25
Safety inspection ........................................................ 26
Explosion protection check ........................................ 26
Operation of industrial trucks in the plant area ................ 26
Noise emission data ......................................................... 26
Frequency characteristic for human body vibrations ...... 26
Running-in instructions ..................................................... 26
Daily checks and services before operation .................... 27
Checks and services prior to initial operation
of the truck ...................................................................... 27
Daily checks ...................................................................... 27
Check the condition for leakage resistance
of the traction wheel ................................................ 27
Open the motor compartment cover ................................. 28
Removing the floor plate ................................................... 28
Opening the top cover ...................................................... 28
Checking state of battery charge ...................................... 29
Charging the battery ......................................................... 29
Reaching the battery out ................................................... 30
Connecting the battery (Version 1) to an external
charger ........................................................................... 30
Connect the version 2 battery (protected against
accumulations of dust) to a suitable external battery
charger ........................................................................... 31
Check the battery condition, electrolyte
level and specific gravity ............................................... 31
Changing the battery (hoist method) ................................ 32
Changing the battery (roll on, roll off) .............................. 33
Steering column adjustment ............................................. 34
Seat adjustments ............................................................... 34
Controls and their operation ............................................. 35
Check the forks and fork quick-releases ................... 35
Operation ...................................................................... 36
Driving ............................................................................... 36
Mounting and dismounting the truck ............................. 36
Starting on an incline ..................................................... 36
Dual-pedal model ............................................................. 37
Driving ............................................................................ 37
Travel with the forks trailing .......................................... 37
Description
Page
Travel with the forks leading ......................................... 37
Change the direction of travel ....................................... 37
Single-pedal model .......................................................... 38
Braking (dual-pedal model) .............................................. 39
Regenerative traction brake .......................................... 39
Hydraulic footbrake ....................................................... 39
Parking brake ................................................................. 39
Engaging the parking brake .......................................... 39
Releasing the parking brake ......................................... 39
Braking (single-pedal model) ........................................... 40
Steering system ................................................................. 41
Steering .......................................................................... 41
Central control lever (joystick) operation of mast and
attachments .................................................................... 42
Raising the fork carriage ............................................... 42
Lowering the fork carriage ............................................ 42
Reaching the mast out .................................................. 42
Reaching the mast back ................................................ 42
Tilting the fork carriage forward .................................... 42
Tilting the fork carriage back ......................................... 42
Operating the attachments ............................................ 42
Operating the sideshift .................................................. 42
Single control lever operation of mast and
attachments .................................................................... 43
Operation of horn .............................................................. 44
Emergency isolator button ................................................ 44
Before loading ................................................................... 45
Positioning the forks ......................................................... 46
Loading ............................................................................. 46
Transporting a load ........................................................... 48
Unloading .......................................................................... 48
Before leaving the truck .................................................... 48
Fuses ................................................................................. 49
Fuses (ancillary circuits) ................................................ 49
Fuses (main circuit) ....................................................... 49
Slinging the truck .............................................................. 50
Wheel change ................................................................... 50
Jack locations when changing wheels ......................... 50
Emergency lower .............................................................. 51
Emergency steering and parking brake release ............. 51
Towing instructions ........................................................... 52
Transporting the truck on a lorry or low-bed trailer ......... 52
Hoisting the truck with a crane ......................................... 52
Side guidance ................................................................... 53
Side guidance for drive-in racking ................................ 53
7
115 804 2581.0505
8
 Table of contents Description
Page Page Page

360° steering ..................................................................... 54 Securing the mast ............................................................. 67

Height preselector system ................................................ 55
Initialising the system .................................................... 55
Displaying the current selected zone ........................... 55
Selecting a new zone .................................................... 55
Stacking a load .............................................................. 56
Destacking a load .......................................................... 56
Cancelling a selection/operation .................................. 56
Lift height indicator ............................................................ 57
Operation (shelf mode) .................................................. 57
Stacking a load (shelf mode) ........................................ 57
Destacking a load (shelf mode) .................................... 57
Operator code entry .......................................................... 58
Logging on ..................................................................... 58
Logging off ..................................................................... 58
Accessing supervisor menus ........................................ 58
Changing the supervisor PIN ........................................ 59
115 804 2581.0505
Inspection and maintenance after the first 50 hours of
operation ........................................................................ 67
Inspection and maintenance chart ................................... 68
Inspection and maintenance as required ...... 70
Clean the lift truck ............................................................. 70
Lubricate the lift chains and mast channels ..................... 70
Adjust the lift chains .......................................................... 70
Check the condition of the wheels and tyres ................... 71
Replace the motor brushes .............................................. 71
Check the insulation and leakage resistance ........... 71
Renew/replace the hydraulic hoses ................................. 71
Check drive wheel nuts .................................................... 72
Inspect and recalibrate the gas
warning system sensors ......................................... 72
5000-hour inspection and maintenance ........ 80
Check condition of brake pipes ........................................ 80
Grease the load wheel bearings ...................................... 80
Change the hydraulic fluid ................................................ 81
Renew the hydraulic return line filter ............................... 82
10000-hour or 5-year inspection
and maintenance ................................................... 83
Change the brake fluid ..................................................... 83
Inspection and maintenance data .................................... 85
Recommended lubricants ................................................ 86
Hydraulic oil ................................................................... 86
Multipurpose grease ..................................................... 86

Disable/enable the truck ............................................... 59
Adding/deleting operator PIN numbers ........................ 59
List operator PIN numbers ............................................ 60
Set/reset learner operation ............................................ 60
Truck Data Management (LFM) ........................................ 61
Truck data acquisition ................................................... 61
Condition code .............................................................. 61
Operation ....................................................................... 61
Truck data acquisition - default setting
(PIN number and condition code) ................................. 62
Truck data acquisition - special setting (PIN number) . 63
Closed circuit television .................................................... 64
Maintenance ............................................................... 65
Maintenance and safety guidelines ................................. 65
General information .......................................................... 65
Handling lubricants ........................................................... 65
Safety guidelines .............................................................. 65
Taking the truck out of operation ...................................... 66
Measures before taking the truck out of operation .......... 66
Putting the truck back into operation ................................ 66
Mast unit and reach frame ................................................ 67
Work on the mast and the reach frame part of the truck .. 67
Mast removal ..................................................................... 67
Securing the reach frame against reaching in or out ...... 67
The mast ............................................................................ 67
Inspect and recalibrate the gas Gear oil .......................................................................... 86
warning system ........................................................ 72 Steering drive gears ...................................................... 86
Clean the gas warning system sensors ..................... 72 General purpose oil ....................................................... 86
Chain Spray ................................................................... 86
Brake fluid ...................................................................... 86
1000-hour inspection and maintenance ........ 73 Troubleshooting guide (hydraulic system) ...................... 87
Check and adjust the parking brake ................................ 73 Hydraulic system piping ................................................... 88
Check the hydraulic hoses and pipes for damage .......... 73 Electric circuit diagram (standard equipment) ................. 90
Check the mast and lift chains for condition and security .... 73 Electric circuit diagram (Gas warning system) ................. 96
Lubricate the mast, mast rollers, lift chains and chain Index .................................................................................. 98
pulleys ............................................................................ 74
Lubricate the reach channels and rollers ........................ 75
Lubricate the battery trolley slides and associated
mechanism .................................................................... 76
Check the condition and security of
motor and battery connectors and cables .................... 76
Check the hydraulic oil level ............................................ 76
Lubricate the fork carriage and sideshift slider pad ........ 77
Check condition of side guide rollers ............................... 77
2000-hour inspection and maintenance ........ 78
Perform the motor brushes wear check ........................... 78
Check the brake fluid level ............................................... 78
Check the traction motor brake band and load wheel
shoes for wear and adjustment ..................................... 79
Renew the hydraulic tank breather filter .......................... 79

9
Technical data Description

115 804 2581.0505

10
115 804 2581.0505
Technical data Description

11
Technical description
Introduction
The electric three wheel reach truck models R14, R16,
R20 which all comply with all relevant EC directives, have
been developed to meet the most arduous application re-
quirements. The main design features result from a thorough
analysis of today’s warehouse logistics to achieve maximum
productivity. The overall design concept ensures excellent
operator comfort contributing significantly to high work
throughput with minimum fatigue.
Operator’s compartment and controls
The operator’s compartment has been designed totally with
the operator in mind. Every aspect of form and function to
maximise the combined efficiency of man and machine for
increased productivity has been evaluated. The advanced,
ergonomic layout of all operating controls ensures optimum
comfort and efficiency. The purpose-built suspension seat
supports every operational body movement and its full later-
Electrical system
These trucks are fitted with an advanced high frequency
digital control system for traction, steering and load handling.
This system reacts progressively to operator demand and
provides extremely smooth movements. It also incorporates
regenerative electric braking (LBC) on release of the accel-
erator. This technology ensures maximum efficiency from the
truck and a high number of work cycles from the battery.
Parameter adjustment allows the trucks to be tailored to suit
a particular requirement and integrated diagnostics ensure
rapid servicing and maximum uptime.
All components and connectors are at least of protection
class IP54.
Steering
Electrical 'fly by wire' steering reduces operator fatigue,
ensures excellent manoeuvrability and generally improves
work handling. The steering system provides feedback to the
Description
Comprehensive mast dampening measures means seam-
less mast function under all conditions since the control
system automatically smooths out any sharp joystick move-
ments the operator might make.
Braking
The trucks have three independent braking systems.
1. Hydraulic footbrake operating on drive and load wheels.
2. Parking brake operating on drive motor.
3. Regenerative electric braking occurs when the acceler-
ator is released fully or the opposite direction of travel is
selected.

115 804 2581.0505

al, lumbar and weight adjustments suit all operations. Finger
light joysticks provide precise control of all load handling
functions.
Chassis
The chassis has been designed to achieve maximum strength
and rigidity. The rear lower chassis consists of a steel casting
giving a low centre of gravity for stability and excellent
residual capacities at high lift. The operator’s compartment,
motors, and electronics, are protected within the rugged
structure, with easy accessibility for maintenance.
Drive and transmission
A powerful fixed 5.4 kW (SEM) shunt drive motor is mounted
above a turntable gearbox assembly. Power is transmitted to
the drive wheel via a spur and bevel transmission. Reduced
traction performance is available with the parking brake
applied to enable safe starting on gradients without over-
loading the transmission or parking brake.
steering wheel, ensuring full operator confidence. 360° Steer-
ing is available as an option.
Mast, hydraulics and reach frame
The new concept low deflection triplex clearview fixed mast
with tilting carriage gives a completely free view through the
mast at all stages of lift for faster, safer load handling. The
unique design uses only two hydraulic cylinders mounted
behind the mast uprights.
The tilting carriage, fitted with an integral sideshift, reduces
forward load movement to a minimum to provide excellent
residual capacities at all lift heights.
Through-the-mast reeving for up to four hydraulic functions
eliminates the need for hose reels. Sealed for life angled
rollers ensure smooth, rapid, lift/lower movements.
Integral outer mast and reach frame allows excellent forward
visibility of the forks and load at low levels.
A powerful electronically pulse controlled pump motor with
automatic slowdown at full lift, gives rapid lift movement,
whilst automatic slowdown at both ends of the reach move-
ment ensures smooth, fast, safe and accurate load handling
cycles.

12
 Technical description
Gas warning system
The gas warning system is provided with two sensor heads
(1). One sensor head is located near the drive axle, the
other at the level of the operator’s head outside the overhead
guard.
If a gas concentration of over 10 % of the lower explosion limit
of gas mixtures is detected, a buzzer sounds which can be
turned off with an acknowledgement button (2) on the instru-
ment panel. 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 shut down. 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 .
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.
115 804 2581.0505

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

2
1

1 P

x1151476 x1151445 g3352304

13
General view of truck Description
1 Mast unit
2 Lift cylinders
3 Protection screen
4 Control panel cover 27
5 Battery connector
6 Battery
7 Lift motor and pump unit
8 Hydraulic tank 26 1
9 Load wheels
10 Hydraulic control valve
11 Reach rollers 25
12 Sensor head
13 Drive wheel
14 Gearbox
15 Reach jack 24 2
16 Traction motor
17 Horn
18 Brake fluid reservoir
19 Seat mounting/motor cover 23

115 804 2581.0505

20 Traction motor brake
21 Power steering motor/gearbox/controller 3
22 Seat
23 Steering wheel 22 4
24 Gas warning system (on the left side of the truck)
25 Instrument for gas warning system 5
28
26 Sensor head
31 6
27 Lift chains 21
28 Fork latches
7
29 Forks
30 20
30 Fork carriage
31 Sideshift jack 19 8
18
17
16
15 x1151437
9
14
13 10
29
12 11

14
 Operating controls and indicators - dual-pedal model Description
1 Pneumatic-operated horn
2 Parking brake switch
26 1 2 3 4 5 6
3 Light switch*
4 Traction motor overheating warning light
5 Brake overheating warning light for traction P
motor and straddle leg wheels
6 Gas warning system (compression-proof
enclosure) overheating monitoring warning 1 2 3
light 4 5 6
8 7
7 Steer motor overheating warning light 7 8 9
8 Lift motor overheating warning light 0 #
*
9 Keypad*
9 10 11 12 13
10 Gas warning system warning light 14
11 Key switch or keypad* main switch
12 Gas warning reset switch 15
115 804 2581.0505

13 Display
14 Emergency isolator button 16
15 Control lever (lift)
16 Control lever (reach out)
25
17 Control lever (tilt)
P
17
18 Control lever (sideshift)*
19 Reverse accelerator pedal 18
20 Brake pedal
21 Forward accelerator pedal
22 Control lever
(lift and reach)
22 23 24
23 Control lever
(tilt and sideshift)
24 Control lever (attachments)
25 Steering wheel
*
26 LFM keypad*

x1151504

* Option 21 20 19
15
Operating controls and indicators - single-pedal model Description
1 Pneumatic horn
2 Parking brake switch
27 1 2 3 4 5 6
3 Light switch*
4 Traction motor overheating warning light
5 Overheating warning light for traction motor brake or P
straddle leg wheel brake
6 Gas warning system (compression-proof enclosure)
overheating monitoring warning light 1 2 3

7 Steer motor overheating warning light 4 5 6

8 7
8 Lift motor overheating warning light 7 8 9

9 Keypad* * 0 #

10 Gas warning system warning light 9 10 11 12 13

11 Key switch or keypad* main switch
14
12 Gas warning reset switch
15
13 Display

115 804 2581.0505

14 Emergency isolator button
15 Control lever (lifting) 16
16 Control lever (mast advance)
26
17 Control lever (tilting) P
17
18 Control lever (sideshifting)*
19 Direction switch
20 Accelerator pedal 18
21 Brake pedal
22 Foot interlock switch
23 Control lever
(lift and reach) 23 24 25
24 Control lever
(tilt and sideshift)
25 Control lever (attachments) *
26 Steering wheel
27 LFM keypad*

x1151505

* Option 22 21 20 19
16
 Operator's display Description
A display mounted in front of the operator displays the Multi-purpose display Hour meter for truck
following information:
An LED display (1) is used to convey information to the - When the keyswitch is turned on, the hourglass symbol (1)
- Hour meter/multi-purpose display operator. illuminates, and the multi-purpose display (2) shows the
Mode indicators illuminate to qualify the information being operating time (keyswitch on and seat occupied) of the
- Battery discharge indicator
displayed as follows: truck in hours.
- Drive wheel position indicator
- Motor brushes wear indicator (1) Fork height * The display continuously shows this information until the
keyswitch is turned off.
- Overheating warning light (2) Time of day
- Interlock warning indicator (3) Error code (testing only)
- Brake fluid level warning light (4) Help prompt
- Service warning light (5) Hour meter
- Parking brake warning light
NOTE
- Battery unlocked warning As standard the multi-purpose display shows truck oper-
- Slow speed indicator ating time.
- Transmitter range*
115 804 2581.0505

- Preselected height*

* Option

1 1 2

1
5 4 3 2

2 x1151306 x1151307 x1151308

17
Operator's display
Battery discharge indicator
The battery charge is shown as a horizontal bar graph of 10
segments.
There are, in right to left order, five green (3), three yellow (2)
and two red (1) segments of this display.
Only one segment will be illuminated at any time.
A fully charged battery will cause the right green segment to
be illuminated.
As the battery is discharged the display will decrement
accordingly until at 28% residual capacity the left red led will
be illuminated and flashing.
Truck performance will be reduced when the battery has
been discharged 80%, leaving 20% residual capacity
NOTE
At 80% discharge, the reduced performance indicator (4)
Drive wheel position indicator
- When the keyswitch is on, the drive wheel orientation is
displayed by opposite green arrow heads (1), which will
rotate as the steering wheel is operated.
- The two central green arrows display the direction select-
ed.*
Description
Motor brushes wear indicator
On the display a combination of two warning lights is used to
inform the driver of worn motor brushes in the
traction motor and hydraulic lift pump motor.
NOTE
The power-assisted steering system uses a brushless
motor.
- Both the red motor brush wear warning light (1) as well as
the yellow warning light (3) come on, when the traction
motor brushes must be renewed.
- Both the red motor brush wear warning light (1) as well as
the yellow warning light (2) come on, when the hydraulic
lift pump motor brushes must be renewed.
Please contact your authorised Linde dealer when the motor
brush wear indicator illuminates.

115 804 2581.0505

will illuminate when the lift lever is operated.
The battery must be recharged or replaced.

* Option

0 1 1

1 2 3
2 3
1
4
x1151309 x1151310 x1151311

18
 Operator's display Description
Overheating warning lights Condition display Brake fluid level warning light
Should prolonged overload conditions exist, the motors or When starting to drive, a diagnosis of the truck’s operational The red indicator (1) illuminates if the brake fluid level is low.
controller may become too hot. The display utilises a combi- state is made. The following parameters are sensed and
nation of two indicators to notify the operator of this condition. displayed in display (3) in case of malfunction. DANGER
Immediately fill the brake fluid reservoir and check
- Both the red temperature warning indicator (1) and amber
Seat The seat switch is not operated for leaks.
indicator (3) illuminate if the traction motor has overheated.
H,br The parking brake is applied
- Both the red temperature warning indicator (1) and amber f,br The footbrake pedal is operated. Service warning light
indicator (2) illuminate if the pump motor has overheated. No An optional interlock is inhibiting the function
- Both the red temperature warning indicator (1) and amber Stop The lift stop input is active - If the red indicator (2) flashes, then a fault condition exists.
indicator (4) illuminate if the steering motor has overheated. VaLVe No valve detected at power up Please contact your authorised Linde dealer.
Joy One or more joysticks operated at power-up
NOTE L,boot Lift controller failed self test or the battery is flat NOTE
If a motor or the controller becomes too hot, then it's T, boot Traction controller failed self test As an option, the red indicator (2) can be programmed to
performance will be reduced until it has cooled to normal L,Foot The left foot switch not operated notify that a service is due. The indicator will illuminate and
operating temperature. The amber slow speed indicator (5) (single-pedal trucks) the multi purpose display will show 'serv!' briefly when the
will illuminate to notify the operator of reduced performance. keyswitch is turned on. Please contact your authorised
NOTE Linde dealer.
115 804 2581.0505

CAUTION Standar interlock states are indicated with warning indica-

Contact your authorised Linde dealer if one of the tor (1). Serious malfunctions such as “VaLVE, Joy, L, boot
motors or the controller has continously over- and T,boot” are indicated with warning indicator (2). Please
heated. contact your authorised Linde dealer.

1 2
5

1
1
3

2 3 4
x1151312 x1151463 x1151314

19
Operator's display Description
Parking brake warning light Battery unlocked warning light Slow speed indicator
The red indicator (1) illuminates whilst the parking brake is The red indicator (2) illuminates if the battery is not locked The red indicator (3) illuminates when the performance of the
applied. firmly in place. selected function is reduced.

DANGER NOTE
If the red indicator (1) flashes, then brake wear is Slow speed traction is available with the battery reached out
excessive. Please contact your authorised Linde to allow battery changing. The slow speed indicator will
dealer. Never operate a truck with defective braking. illuminate to notify the operator.

DANGER
Do not use the truck with the battery reached
forward.

115 804 2581.0505

1 2 3

x1151315 x1151316 x1151317

20
 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.
115 804 2581.0505
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.
21
 Overheating warning lights
NOTE
If one of the following warning lights comes on, the truck will
carry out a controlled automatic shutoff.
Resume operation only after the truck has cooled. If the fault
reoccurs, please contact your authorised Linde dealer.
Traction motor overheating warning lights
The red warning light (1) comes on if the maximum traction
motor surface temperature is exceeded.
1 2 3
x1151448
22
Lift pump motor overheating warning light
As soon as the red warning light (5) comes on the maximum
hydraulic lift pump motor surface temperature is exceeded.
Steering motor overheating warning light
As soon as the red warning light (4) comes on the maximum
steering motor surface temperature is exceeded.
Description
Overheating warning light for traction motor
brake or straddle leg wheel brake
As soon as the red warning light (2) comes on the maximum
surface temperature of one of the brakes is exceeded.
Gas warning system (compression-proof
enclosure) overheating monitoring warning
light)
As soon as the red warning light (3) comes on the maximum
surface temperature of the gas warning system enclosure is
exceeded.
115 804 2581.0505
 Safety rules
The responsible persons, particularly
the truck operator (ie employer) and service
personnel, must be instructed in the rules
for the normal and proper use of industrial
trucks, the applicable national, EC or EEA
explosion safety regulations, as well with
those included in these operating instruc-
tions.
The operator 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 material handling trucks
- rules for roadways and work areas
- rights, duties and safety rules for the operator
- operation in special areas
115 804 2581.0505
- 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 (ie 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 during
operation are required by law. They require
particular attention during all work with, in
and on the truck.
The operator must ensure that the em-
ployees are instructed in the hazardous ar-
eas (explosion hazard zone 2), possible ex-
plosion hazards and the selected protective
measures, and that the operating instruc-
tions 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 hazardous areas,
and only by authorised skilled personnel
(experts) thoroughly familiar with the appro-
priate technical material and rules and regu-
lations.
The manufacturer recommends your author-
ised Linde dealer for this service.
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.
23
Safety rules
Further protective measures are not
required after the elimination of the explo-
sion hazard and a renewed formation of a
hazardous atmosphere during the repair is
excluded.
The operator (employer) 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 when perform-
ing repairs where an explosion hazard ex-
ists from sparking, or the explosive hazard
can result from the repair work, appropriate
explosion protective measures must be tak-
en.
24
Beginning operation
Work can only commence after the op-
erator or his representative have ensured
that protective measures are adequate and
effectively implemented. The effectiveness
of the protective measures must be checked
while the work is in progress. The operator
or his representative can only lift the protec-
tive measures after all work has been com-
pleted and no further hazards exist.
Before resuming operation after re-
pairs, ensure that the truck’s explosion pro-
tection required for normal operation is ef-
fective again.
115 804 2581.0505
The tightness of all electrical compo-
nents must be ensured.
 Safety rules
When instructing a trained operator (driver), acquaint him
with the
- special features of the fork lift truck (double-pedal steer-
ing, central control lever),
- special features of the explosion-proof fork lift
truck , destruction of the product.
- optional equipment,
- special conditions in the plant and work place
by training and practising driving, shifting and steering oper-
ations until they are completely mastered.
After the above has been mastered, commence practice with
stacking operations.
ATTENTION
The driver must be retrained or reinstructed if the
traction and brake parameters of the LDC control
are modified afterwards.
115 804 2581.0505
The safety in the work area is ensured if the truck is employed
properly and the operator trained correctly.
Should the truck tip over during an unauthorised application
or due to incorrect operation, always follow the instructions
depicted in the small boxes on this page.
Safety information
The precautions DANGER, CAUTION, ATTENTION and
NOTE in this manual are provided to indicate special dangers
or unusual information requiring special identification:
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.
ATTENTION
indicates hazards that may result in damage to or
This note is found in places on the truck where
special attention is required. Read the appro-
priate section of your operating instructions.
Other warning symbols are also used for your safety. Please
observe the various symbols.
All explosion protection measures are
marked with the symbol at the left of this
paragraph. Be certain to follow these meas-
ures.
NOTE
identifies technical information requiring special attention
because the meaning may not even be obvious to skilled
personnel.
x1151434
Beginning operation
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.
CAUTION
Improper handling of brake fluid can endanger
your health and the environment.
25
Safety rules
Safety inspection
The accident prevention regulations require
that the forklift truck must be inspected 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 your
authorised Linde dealer for this service.
A visual check of the explosion protection
equipment is also required every two weeks.
Explosion protection check
The operator (employer) 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.
26
Beginning operation
Noise emission data Running-in instructions
Determined in a test cycle in accordance with EN 12053 from The truck can be operated at full speed directly. Avoid sus-
the weighted values in the operating modes DRIVING, LIFT- tained high loads on the working hydraulic system and the
ING, IDLING. travel drive in the first 50 hours of operation.
Noise level at driver’s station
R 14 - R 20 LPAZ = 68 dB (A) Tighten wheel fasteners daily prior to starting operation or
after a wheel change until they are seated firmly, ie until no
Uncertainty K PA = 4 dB (A)
further tightening is possible.
NOTE
Tighten opposite wheel fasteners to a torque of 140 Nm.
Higher or lower noise emissions can exist during opera-
tion of the truck, eg due to different operation, influence of
the surroundings and additional noise emission sources.
NOTE
Refer to the tightening instructions on the tag attached to
the steering column.
Frequency characteristic for human body
vibrations
The values are determined in conformance with EN 13059 on
115 804 2581.0505
trucks with standard equipment according to the technical
data sheet (driving over test course with bumps).
Frequency characteristic acc. to EN 12096
Measured frequency characteristic a w.zs = 0.7 m/s²
Uncertainty K = 0.2 m/s²
Frequency characteristic given for hand and arm vibrations
Frequency characteristic < 2.5 m/s²
NOTE
The frequency characteristic for the human body can not
be used to determine the actual frequency load during
operation. This load depends on the working conditions
(condition of roadway, type of operation, etc.) and must
therefore be determined at the site, if necessary.
The specification of hand and arm vibrations is required by
law, even if the values, as in this case, do not signal any
danger.
 Daily checks and services before operation Beginning operation
Checks and services prior to initial opera- Tighten the wheel fasteners Check the condition for leakage resist-
tion of the truck* - Check all wheel fasteners for tightness. ance of the traction wheel
- Check the wheel fasteners for tightness In order to ensure the leakage resistance as stated on the
- Tighten opposite wheel fasteners to a torque of 140 Nm. label (1), the tyre (2) and floor must be free of debris and
- Check the hydraulic oil level
foreign objects.
- Check the battery state of charge, electrolyte level and
The truck may have to be cleaned several times a day,
specific gravity
depending upon the application conditions.
- Check the braking system If in doubt, check the values. Please contact authorised
- Check the steering system skilled personnel (experts).
The manufacturer recommends your authorised Linde deal-
- Check the horn er for this service.
- Check the mast and attachments
ATTENTION
- Check condition and tightness of electric cables, connec-
The approved anti-static tyres must be perma-
tors and connections
nently marked accordingly.
Daily checks*
115 804 2581.0505

- Check the battery charge

- Check the braking system
- Check the horn
- Check the forks and fork quick-releases
- Check the condition for leakage resistance of the traction
wheel
- Check the hydraulic oil level
- Check all controls for proper functioning

* The description of the services can also be located in the

index. x1151318 2 x1151497

27
Daily checks and services before operation Beginning operation
Open the motor compartment cover Opening the top cover
For ease of access to the motors and hydraulic tank, the seat CAUTION - Turn the keyswitch off.
unit is mounted on a pivot which enables it to be swung out Manual handling risk. The seat assembly is heavy.
from the chassis as a complete unit. Assistance should be sought if it is to be com- - Depress the emergency isolator button (2).
pletely removed.
- Remove the securing screw (1). - Unplug the battery.
- Swing the seat assembly out from the chassis. For addi- Removing the floor plate
tional access the hinged flap (2) at the rear of the cover - Undo the two socket head screws in the cover (1). Open
- Open the motor compartment cover. the cover fully.
may be raised.
- Remove the two securing screws (1).
CAUTION - Reverse the procedure to close the cover.
- Lift the floor plate from the truck.
The motors can become very hot. Risk of scald-
ing.

- To close, swing the seat assembly back into the chassis.

- Replace and tighten the securing screw (1).
- To remove the seat assembly completely, disconnect the

115 804 2581.0505

seat wiring, and lift the assembly from the pivot.

1 2

1
x1151319 x1151320 1 x1151462

28
 Daily checks and services before operation
Checking state of battery charge
- Lift the emergency isolator button (3).
- Turn the keyswitch (1) on.
- Check the battery state of charge on the operator's
display (2).
Charging the battery
CAUTION
For the safe operation and maintenance of the
battery, follow the following instructions. The elec-
trolyte in the batteries is a sulphuric acid and
water solution, which is both poisonous and caus-
tic. Therefore, wear protective clothing and pro-
tective glasses when working around batteries.
Gases are released when batteries are being
charged, do not expose the battery to sparks or
115 804 2581.0505
NOTE
Check that the specific gravity of the electrolyte is
at least 1.14.
Always charge and service the battery according to the
manufacturer's instructions.
If you are not in possession of these instructions, please
contact your local Linde dealer. Also follow the operating
instructions for the battery charger.
CAUTION
Do place any metal objects on the battery which
could cause a short circuit.
CAUTION
Do not top up the electrolyte before charging.
Beginning operation
NOTE
The gas warning system is buffered for up to about
120 minutes by rechargeable batteries. This ensures that
the sensing system remains in operation 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 (4) 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.

open flames, as an explosion could result. Rooms

in which batteries are charged or stored must be
ventilated accordingly.
Version 1 Version 2

1 2
3 4 4

x1151491 x1151477 x1151500

29
Daily checks and services before operation Beginning operation
Reaching the battery out Connecting the battery (Version 1) to an ex-
The battery must be reached out for inspection or routine ternal charger
maintenance. - Lower the forks.

- Lower the forks to just above the ground. - Apply the parking brake, turn the keyswitch off.

- Return the mast to the fully reached back position. - Depress the emergency isolator button.

- Lift the battery trolley locking lever (1) and reach the battery
forward. The battery unlocked warning indicator (2) on the
operator's display will illuminate.
- To relocate the battery, operate the reach lever to reach
the battery in until the battery unlocked warning indicator
on the operator's display extinguishes.
CAUTION
Ensure that the battery cables are not twisted
when reaching the battery back.
- Release the battery connector locking plate (1) and un-
plug the battery connector (2) (Version 1).
- Insert the charger connector (3) into the battery connector (2)
(Version 1).
- Switch on the battery charger.
ATTENTION
Before reconnecting the battery to the truck,
ensure the keyswitch is turned off, and the emer-
gency isolator button is depressed.

115 804 2581.0505

DANGER
Do not use the truck with the battery reached
forward.
Version 1

1
2
2

x1151325 x1151316 x1151478

30
 Daily checks and services before operation
Connect the version 2 battery (protected
against accumulations of dust) to a suitable
external battery charger
- Lower the forks.
- Apply the parking brake, turn the keyswitch off.
- Depress the emergency isolator button.
- Release the clip (5) and fold the cover (4) back to the rear.
- Push with a screwdriver into the openings (2) to release
the levers (3).
- Disconnect the battery connector (6).
- Insert the battery charger connector into the battery con-
nector (1).
- Switch on the battery charger.
ATTENTION
Before reconnecting the battery to the truck,
115 804 2581.0505
ensure the keyswitch is turned off, and the emer-
gency isolator button is depressed.
Version 2
1 deep discharges. Deep discharges shorten the service
6 5
x1151501
Check the battery condition, electrolyte
level and specific gravity
CAUTION
For the safe operation and maintenance of the
battery, follow the following instructions. The elec-
trolyte in the batteries is a sulphuric acid and
water solution, which is both poisonous and caus-
tic. Therefore, wear protective clothing and pro-
tective glasses when working around batteries.
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 accordingly.
For version 2, (dust accumulation protection):
This battery is specially shock- and vibration-
proof and enclosured in a high safety tray.
x1151326
Beginning operation
- Check the battery for casing cracks, lifted plates and
electrolyte leakage.
- Unscrew the caps and check the electrolyte level.
- On batteries with check tubes, the fluid should be at the
bottom of the tubes. On batteries without tubes, the fluid
should be 10 - 15 mm above the plates.
- If the electrolyte level is low, top up with distilled water
only.
- Remove corrosion on battery poles and coat with non-
acidic grease.
- Retighten pole clamps firmly.
- Check the specific gravity using a hydrometer. The spe-
cific gravity of the electrolyte should be between 1.24 and
1.28.
NOTE
Discharges which are under 20 % of the rated capacity are
life of the battery.
31
Daily checks and services before operation
Changing the battery (hoist method)
DANGER
When lifting the battery with a crane, ensure that
no persons are within the vicinity. Never step
under an elevated load.
Use lifting equipment of sufficient capacity for the weight of
the battery. (See Battery Plate).
- Reach battery fully forward.
- Apply the parking brake, turn the keyswitch off, and
depress the emergency isolator button.
- Release the battery connector locking plate and unplug
the battery (2) from the truck.
- Disconnect the buffer circuit plug (1).
- Connect the lifting equipment to the battery and lift the
battery up and outwards from the truck. Ensure the battery
does not hit the mast or power unit chassis.
WARNING
Manual handling risk. The battery is heavy. Take care
when manoeuvring the battery from the chassis.
1 negative terminal is nearest to the truck bulkhead.
2 The replacement battery must be identical in size
x1151479
32
ATTENTION
Before reconnecting the battery to the truck,
ensure the keyswitch is turned off, and the emer-
gency isolator button is depressed.
- Reverse the procedure to fit the battery.
- Reconnect the battery (2), ensuring the battery connector
locking plate is engaged.
- Connect the buffer circuit plug (1).
NOTE
The gas warning system is buffered for up to about
120 minutes by rechargeable batteries. This ensures that
the sensing system remains in operation 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.
Beginning operation
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.
- Turn the keyswitch on and operate the reach lever to reach
the battery in until the battery unlocked warning indicator
on the operator's display extinguishes.
CAUTION
Ensure that the battery cables are not twisted
when reaching the battery back.
115 804 2581.0505
ATTENTION
The battery cable is designed to minimise the free
cable projecting beyond the battery face.
In order to maintain this condition it is necessary to replace
the battery so that the face adjacent to the cable route and
With some batteries the positive terminal is also on the
same face as the cable route.
CAUTION
It is essential that the battery is correctly seated
on the battery trolley before reaching back and
locking into position.
DANGER
and weight to the original battery.
In case of any deviations in size or weight, please contact your
authorised Linde dealer.
 Daily checks and services before operation
Changing the battery (roll on, roll off)*
CAUTION
Manual handling risk. The battery is heavy. Take
care when manoeuvring battery on and off the
roller stand.
- Drive the truck up to the battery roller stand (1).
- Reach the battery forward, manoeuvre the truck until the
battery is aligned with the vacant track on the roller stand.
- Apply the parking brake, turn the keyswitch off, and
depress the emergency isolator button.
- Release the battery connector locking plate and unplug
the battery from the truck.
- Disconnect the buffer circuit plug.
- Open the latch (2) on the roller stand.
115 804 2581.0505
NOTE
The latch hinges over to secure one battery alternately.
* Option
2 4
1 the sensing system remains in operation even during a
x1151328
- Undo the securing latch clamp (4) and release the battery
securing latch (3) on the truck battery trolley.
- Push the battery from the truck onto the roller stand. Hinge
the securing latch (2) over to retain the battery.
ATTENTION
Before reconnecting the slave lead, ensure the
keyswitch is turned off, and the emergency iso-
lator button is depressed.
- Connect a slave lead between the charged battery and
truck battery plug.
- Release the emergency isolator button, switch on and
manoeuvre the truck to align the truck battery trolley with
the charged battery.
- Push the charged battery onto the truck trolley and secure
with the securing latch (3), ensuring clamp (4) is tight-
ened.
3 the battery is being charged.
x1151329
Beginning operation
- Apply the parking brake, turn the keyswitch off, and
depress the emergency isolator button.
- Disconnect the slave lead.
ATTENTION
Before reconnecting the battery to the truck,
ensure the keyswitch is turned off, and the emer-
gency isolator is depressed.
- Connect the battery plug.
- Connect the buffer circuit plug.
CAUTION
Ensure that the battery cables are not twisted
when reaching the battery back.
DANGER
The replacement battery must be identical in size
and weight to the standard battery.
Any deviations in size or weight, please contact your author-
ised Linde dealer.
NOTE
The gas warning system is buffered for up to about
120 minutes by rechargeable batteries. This ensures that
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
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.
33
Daily checks and services before operation
Steering column adjustment
The steering column can be adjusted for height and rake.
- Slacken the steering column clamping knob (1).
- Adjust the steering column to the desired position.
- Tighten the steering column clamping knob.
CAUTION
Only make adjustments to the steering column
while the truck is stationary.
1 4
x1151464
34
Beginning operation
Seat adjustments
- To move the seat forward or back, lift lever (4) and while - Lever (1) must be lifted to alter the rake of the seat back.
sat on the seat slide to the required position and release The rake can be adjusted to three positions.
the lever (4) to lock into the nearest notch.
CAUTION
- The handwheel (3) is for suspension tension adjustment. Only make adjustments to the seat while the
Rotate the handwheel clockwise to raise the tension. truck is stationary.
Rotate the handwheel anticlockwise to lower the tension.
NOTE
- Lever (2) is used to set the height of the seat. Prolonged sitting can put excessive strain on the spine.
Prevent strain with regular light exercising.
- To raise, sit on the seat, and move the lever right to release
the locking mechanism. Allow the seat to rise slowly to the
desired height, and move the lever left to re-engage the
locking mechanism.
- To lower, sit on the seat, and move the lever right to
release the locking mechanism. Allow the seat to lower
115 804 2581.0505
slowly to the desired height, and move the lever left to re-
engage the locking mechanism.
2
x1151496
 Daily checks and services before operation
Controls and their operation
Check all truck controls for correct and safe operation.
- Check function of braking system.
- Check function of steering system.
- Check function of traction and hydraulic systems.
- Check function of operator's display.
NOTE
When the keyswitch is turned on, all indicators on the
operator's display should illuminate briefly. Should any of
the indicators fail to illuminate, then report to supervision.
DANGER
Never use a truck which has faulty controls.
115 804 2581.0505
x1151450
DANGER
For your own safety, and the safety of others, the
truck is fitted with various interlocks. Under no
circumstances should the operation of these interlocks be
interfered with.
CAUTION
In order to achieve correct traction operation, the
accelerator sensor can only be adjusted by trained
skilled personnel using special equipment. Please contact
your authorised Linde dealer.
x1151480
Beginning operation
Check the forks and fork quick-releases
The forks (2) must be plated with brass, copper, stainless steel
or an equivalent material at least 3 mm thick at the places
coming in contact with the ground (floor) of the load (pallet,
barrel), or be manufactured from stainless steel.
- Inspect the forks (2) for visible bends, wear and damage.
- Replace the load pick-up devices if the plating thickness
is less than 1 mm.
- Inspect the fork quick-releases (1) and fork stop bolts for
proper seating and damage.
- Replace any damaged parts.
NOTE
If a renewal of the plating is required, please contact
authorised skilled personnel (experts).
The manufacturer recommends your authorised Linde
dealer for this service.
2 x1151498
35
Driving Operation
ATTENTION Mounting and dismounting the truck Starting on an incline
Operating on long slopes over a 10% gradient is
not advisable due to the prescribed minimum When mounting or dismounting the truck always use the When the truck is to be stopped and started on an incline the
brake applications and the truck stability characteristics, handle (1) provided. procedure is as follows:
contact your authorised Linde dealer before driving on
long slopes. CAUTION - Stop the truck under controlled electrical and hydraulic
Never use the steering wheel or hydraulic levers braking.
The climbing ability rates given in the data sheet are based as a means of pulling yourself onto the truck.
on the tractive force of the truck and they apply only for - Apply the parking brake.
crossing obstacles and minor differences in the floor/road DANGER
level. Always turn the keyswitch to the off position - To move off, press the accelerator. The drive motor holds
before leaving the operators driving position. the truck under reduced power.
NOTE
Always adapt your driving style to the conditions of the DANGER - Release the parking brake.
roadway (rough surfaces, etc.), particularly hazardous Never alight from a moving truck.
work areas and the load being transported.

CAUTION
Always drive with the mast lowered and the car-

115 804 2581.0505

riage reached fully back.

x1151438 x1151335

36
 Dual-pedal model Operation
Driving Travel with the forks trailing Change the direction of travel
- Connect the battery. - Gently press the left accelerator pedal (5). The truck will - Release the depressed accelerator pedal.
- Sit on the seat. move in the forks trailing direction. The travel speed will
depend on how far the pedal is pressed. - Press the pedal for the opposite direction. The truck will
- Lift the emergency isolator button (4) if it has been pressed. be electrically braked to a standstill and then accelerated
NOTE in the opposite direction.
NOTE Depressing the accelerator pedal fully will not increase
Ensure no controls are being operated. the rate of acceleration as maximum acceleration is - The accelerator pedals can be changed directly from
controlled automatically. forward to reverse travel.
- Insert the key (2) and turn fully clockwise. The operator's
display (3) will illuminate. - Travel control will be easier if feet rest on both accelerator
Travel with the forks leading
- Raise the forks to clear the ground. Tilt the carriage back pedals.
and retract the mast. - Press the right accelerator pedal (6) the truck will move in
the forks leading direction. The travel speed will depend NOTE
- Release the parking brake (1). on how far the pedal is pressed. Depressing the accelerator pedal fully will not increase
the rate of acceleration as maximum acceleration is con-
NOTE trolled automatically.
Depressing the accelerator pedal fully will not increase
the rate of acceleration as maximum acceleration is
115 804 2581.0505

controlled automatically.

1 2 3
4
6

P
5

x1151451 x1151336 x1151337

37
Single-pedal model Operation
Driving Change direction of travel
- Connect the battery. - Gently press the accelerator pedal (7). The travel speed - Press the opposite end of direction switch (5) to change
- Sit on the seat. will depend on how far the pedal is pressed. the direction of travel.

- Lift the emergency isolator button (4) if it has been pressed.
NOTE
Ensure no controls are being operated.
- Insert the key (2) and turn fully clockwise. The operator's
display (3) will illuminate.
- Raise the forks to clear the ground. Tilt the carriage back
and retract the mast.
Travel with the forks trailing
- Select forks trailing direction of travel by pressing the left
end (A) of the direction switch (5).
NOTE - The truck is electrically braked until it stops and then
Depressing the accelerator pedal fully will not increase restarts in the opposite direction of travel.
the rate of acceleration as maximum acceleration is con- - The direction of travel can be changed without releasing
trolled automatically. the accelerator pedal or applying the brake.
- Left end (A) for forward travel.
Travel with the forks leading
- Right end (B) for reverse travel.
- Select forks leading direction of travel by pressing the
right end (B) of the direction switch (5). NOTE
Depressing the accelerator pedal fully will not increase
- Press the left foot interlock pedal (6).
the rate of acceleration as maximum acceleration is con-
- Release the parking brake (1).
trolled automatically.
- Press the accelerator pedal (7). The travel speed will
depend on how far the pedal is pressed.
NOTE

115 804 2581.0505

- Press the left foot interlock pedal (6).
Depressing the accelerator pedal fully will not increase
- Release the parking brake (1). the rate of acceleration as maximum acceleration is con-
trolled automatically.

1 2 3
7
4 B
6 5
A

5 x1151452 x1151339 x1151489

38
 Braking (dual-pedal model) Operation
Regenerative traction brake Parking brake
- Release the depressed accelerator pedal or depress the For your own safety always use the parking brake to park the NOTE
pedal for the opposite direction. truck, and during stacking and destacking operations. The parking brake will be applied automatically under
certain fault conditions, and can be programmed to 'auto
Hydraulic footbrake Engaging the parking brake apply' for certain events such as the seat being vacated.

- Release the accelerator pedals (1 or 3).
- Press brake pedal (2).
NOTE
Depressing the brake pedal, hydraulically operates the
brake on the traction motor and both load wheel brakes.
CAUTION
For emergency stops press the brake pedal (2).
It is recommended, that before taking the truck
into service, operators acquaint themselves with the func-
tion and effect of this emergency brake while the truck is
115 804 2581.0505
- If the parking brake is released, push the momentary
switch (2). The parking brake will engage and the parking
brake applied warning indicator (1) on the operator's
display will illuminate.
Releasing the parking brake
- If the parking brake is engaged, push the momentary
switch (2). The parking brake will release and the parking
brake applied warning indicator (1) on the operator's
display will extinguish.
ATTENTION
Only use the parking brake when the truck is
stationary. Do not use the parking brake as a
means of stopping the truck under normal driving condi-
tions.
DANGER
Contact your authorised Linde dealer, if signs of
wear, or faults become evident in the braking
system. Never operate a truck with a faulty braking sys-
tem.

in an unladen condition.

1
3 2 P
2
1

x1151341 x1151453

39
Braking (single-pedal model) Operation
Regenerative traction brake Parking brake
- Release the accelerator pedal (2) or select the opposite For your own safety always use the parking brake to park the NOTE
direction of travel or neutral using direction switch (3). truck, and during stacking and destacking operations. The parking brake will be applied automatically under
certain fault conditions, and can be programmed to 'auto
Hydraulic footbrake Engaging the parking brake apply' for certain events such as the seat being vacated.

- Release the accelerator pedal (2).
- Press brake pedal (1).
NOTE
Depressing the brake pedal, hydraulically operates the
brake on the traction motor and both load wheel brakes.
CAUTION
For emergency stops press the brake pedal (1).
It is recommended, that before taking the truck
into service, operators acquaint themselves with the func-
tion and effect of this emergency brake while the truck is
- If the parking brake is released, push the momentary
switch (2). The parking brake will engage and the parking
brake applied warning indicator (1) on the operator's
display will illuminate.
Releasing the parking brake
- If the parking brake is engaged, push the momentary
switch (2). The parking brake will release and the parking
brake applied warning indicator (1) on the operator's
display will extinguish.
ATTENTION
Only use the parking brake when the truck is
stationary. Do not use the parking brake as a
means of stopping the truck under normal driving condi-
tions.
DANGER
Contact your authorised Linde dealer, if signs of
wear, or faults become evident in the braking
system. Never operate a truck with a faulty braking sys-
tem.

115 804 2581.0505

in an unladen condition.

2 1
1 2 P

3
x1151454 x1151453

40
 Steering system
Steering
The electric steering system provides effortless manoeu-
vring and is invaluable when working in narrow aisles.
A steering knob (1) is provided and should be held at all times
the truck is in motion.
Operation
Turning radius
R 14 ...................................................................... 1540 mm
R 16 ...................................................................... 1640 mm
R 20 ...................................................................... 1775 mm

DANGER
Do not operate a truck with a defective steering
system.
115 804 2581.0505

1 x1151455

41
Central control lever (joystick) operation of mast and attachments
DANGER
Use the lifting device and attachments only for
authorised applications. The operator must be
instructed in the handling of the lifting device and attach-
ments. Observe the maximum lift height. Do not put your
hands or any other part of the body into the lift mast or the
space between the mast and truck.
Always operate the joysticks smoothly without jerking. The
lifting, lowering, tilting and reaching speed is determined by
how far the joystick is moved. The joysticks return automat-
ically to the neutral position when released.
NOTE
Note the operating symbols with arrows.
NOTE
On the single lever model both functions are operated
simultaneously (e.g. lifting and tilting) when the control
lever is moved to an intermediate position (about 45°).
Raising the fork carriage
Tilting the fork carriage forward
- Move joystick (2) to the right.
Tilting the fork carriage back
- Move joystick (2) to the left.
Operating the attachments
ATTENTION
Attachments (e.g. clamp or rotate) can be mount-
ed on the reach truck as optional equipment.
Observe the operating pressure and operating instruc-
tions for the attachment. Up to two additional joysticks can
be fitted for these operations.
NOTE
For some attachments e.g. clamp, the joystick (3) will have
an interlock fitted and must be depressed to initiate
Operation
NOTE
For some attachments, sideshift operation is disabled.
NOTE
For each attachment a load capacity plate is provided on
the reach truck and a symbol sticker must be affixed
adjacent to the relevant joystick.
Operating the sideshift
- Move the joystick (2) forward to shift left.
- Move the joystick (2) back to shift right.
DANGER
Attachments not delivered with the reach truck
may only be employed if your authorised Linde
dealer has determined that safe working is assured in
respect to load capacity and truck stability.

115 804 2581.0505

movement.
WARNING
Do not step on the raised forks. Increased danger
of falling and being squeezed.

- Move joystick (1) back.

The fork carriage is bought to a smooth stop at maximum
lift by switching off the pump motor automatically shortly
before maximum lift.

Lowering the fork carriage

- Move joystick (1) forward.

Reaching the mast out

- Move joystick (1) to the right.
The mast is bought to a smooth stop at the end of travel by
switching off the pump motor automatically shortly before
the reach frame is fully reached out.

Reaching the mast back

- Move joystick (1) to the left.
The mast is bought to a smooth stop at the end of travel by
1 2 3
switching off the pump motor automatically shortly before
the reach frame is fully reached back.
x1151465 x1151466

42
 Single control lever operation of mast and attachments
DANGER
Use the lifting device and attachments only for
authorised applications. The operator must be
instructed in the handling of the lifting device and attach-
ments. Observe the maximum lift height. Do not put your
hands or any other part of the body into the lift mast or the
space between the mast and truck.
Always operate the levers smoothly without jerking. The
lifting, lowering, tilting and reaching speed is determined by
how far the lever is moved. The levers return automatically to
the neutral position when released.
NOTE
Note the operating symbols with arrows.
Raising the fork carriage
DANGER
Do not step on the raised forks. Increased danger
of falling and being squeezed.
115 804 2581.0505
Lowering the fork carriage
- Move the lever (1) forward.
Reaching the mast out
- Move the lever (2) forward.
The mast is bought to a smooth stop at the end of travel
by switching off the pump motor automatically shortly
before the reach frame is fully reached out.
Reaching the mast back
- Move the lever (2) back.
The mast is bought to a smooth stop at the end of travel
by switching off the pump motor automatically shortly
before the reach frame is fully reached back.
Tilting the fork carriage forward
Operation
Operating the attachments
ATTENTION
Attachments (e.g. clamp or rotate) can be mount-
ed on the reach truck as optional equipment.
Observe the operating pressure and operating instruc-
tions for the attachment. Up to two additional joysticks can
be fitted for these operations.
NOTE
For some attachments e.g. clamp, the joystick will have an
interlock fitted and must be depressed to initiate move-
ment.
NOTE
For some attachments, sideshift operation is disabled.
NOTE
For each attachment a load capacity plate is provided on

the reach truck and a symbol sticker must be affixed

- Move the lever (1) back.
- Move the lever (3) forward. adjacent to the relevant joystick.
The fork carriage is bought to a smooth stop at maximum
lift by switching off the pump motor automatically shortly
before maximum lift. Tilting the fork carriage back Operating the sideshift
- Move the lever (3) back. - Move the lever (4) forward to shift left.
- Move the lever (4) back to shift right.

DANGER
Attachments not delivered with the reach truck
may only be employed if your authorised Linde
dealer has determined that safe working is assured in
respect to load capacity and truck stability.

1 2 3 4
x1151467

43
Horn, emergency isolator button
Operation of horn
The pneumatic-operated horn serves as warning signal eg.
on junctions and in passages with poor view.
- Depress the knob (1) to sound the horn.
NOTE
After having sounded the horn pull up the knob (1) again.
1 2
x1151468
44
Operation
Emergency isolator button
The emergency isolator button (2) isolates all electrical
power and applies the parking brake when pressed.
ATTENTION
Only use the emergency isolator button in an
emergency or to isolate electrical power when
the truck is left unattended. Do not use the emergency
isolator button as a means of stopping the truck under
normal driving conditions.
To restore electrical power, pull the red knob (2) up until it is
released.
NOTE
If the emergency isolator button has been depressed, then
the correct start up procedure should be followed in order
for the truck to operate.
115 804 2581.0505
x1151456
 Before loading Operation
Before picking up a load, observe the load capacity plate (1). Example
Similarly, observe the load capacity plate diagram indications Load centre distance ............................................... 600 mm
(2) for auxiliary equipment.
Height of lift ........................................................... 7255 mm
DANGER
Values stated in the diagram are applicable for The maximum load in this case is ......................... 1600 kg.
compact and uniform loads, and must not be
exceeded otherwise the stability of the truck and the
strength of the mast and forks will no longer be guaran-
teed.

The maximum load is determined by the lift height and the

distance between the centre of gravity of the load and the heel
of the forks.

NOTE
Reduce the load capacity and consult your authorised
Linde dealer when:
115 804 2581.0505

- transporting off centre loads.

- a load with a long distance to the centre of gravity.
- fitting optional auxiliary equipment.

x1151439 x1151351

45
Positioning the forks, Loading Operation
Positioning the forks Loading
- Lift fork latches (1) up. DANGER - Fully insert the forks by reaching the mast out, ensuring
- Adjust the spacing of the forks to suit the load to be lifted. Do not step on raised forks. Increased danger of fork tips do not foul loads behind the stack and that the load
falling and being squeezed. rests against the front face of the forks or load backrest if
- Position the forks equidistant from the centre of the fork fitted.
carriage. - Before operating the sideshift, ensure that the forks/load
- Lift the load slowly and carefully clear of stack.
- Check that the latches engage correctly in a castellation. is either fully reached out or raised clear of the reach legs.
- Tilt the forks backward just sufficient to stabilise the load.
- The sideshift provides a final positioning movement of
CAUTION 100 mm each side of centre. - Reach the mast fully back.
Manual handling risk. The forks are heavy, take
- Lower the load carefully to just above the reach legs.
care when positioning the forks. NOTE
Centralise the fork carriage before fully lowering the mast CAUTION
NOTE to prevent fouling the reach legs. Before reaching the carriage back or lowering
The centre of gravity of the load must be located at the mid
the fork carriage, make sure that the load fits
point between the two forks. - Approach the load and align the forks as carefully and
accurately as possible. The centre of gravity of the load
should be central between the forks.
- Stop with the truck at the face of the stack, make sure the

115 804 2581.0505

forks are horizontal and apply the parking brake.
- Raise the forks to a position for clear entry into the pallet
or load.

x1151352 x1151353 x1151354

46
 Loading Operation

DANGER
Do not allow any person to stand or pass under an
elevated load. Always travel with the carriage
reached in, with the load lowered just above the reach legs
and with the forks tilted back.
115 804 2581.0505
DANGER
Never allow persons to be elevated on the forks
unless the truck has been fitted with a purposely
designed working platform. Ensure the platform and se-
curing method is suitable for the truck. Please contact
your authorised Linde dealer.

e3362301 x1151444

47
Transporting a load, unloading Operation
Transporting a load Unloading
NOTE - Carefully drive the truck to the face of the stack. - Reach the mast fully back.
In goods traffic, the consignor of the shipment must load - Apply the parking brake CAUTION
and, if necessary, fasten the goods to be transported. If the forks or load jam or catch during the stack-
Therefore take care to stack the goods properly and not to - Raise the fork carriage with the load just above the
required stacking height. ing operation, do not attempt to free them by
damage the packaging and pallets. The hauler is respon- reaching through the mast. Never park or leave the reach
sible for the safe handling of the goods. - If necessary, release the parking brake and drive forward truck unattended with the load lifted.
to bring the truck closer to the stack.
- Drive forward for good visibility.
- Apply the parking brake.
- Travel with the mast fully reached back, forks tilted back-
- Reach the mast out. Before leaving the truck
wards, load centred against the fork carriage or backrest*,
with the forks/load to a height just above the reach legs. DANGER - Ensure the truck is parked so as not to cause a hazard or
Take care not to dislodge or damage loads adja- obstruction.
- Truck speed must be reduced on unlevel or wet surfaces
cent to the stack. - Fully reach the mast back.
and in areas of reduced visibility.
- Tilt the carriage until the forks are horizontal. - Fully lower the forks
- When travelling on slopes the load must always face
- Slowly lower the fork carriage until the load is positioned
uphill. - Apply the parking brake (1).
on the stack.
- Never drive or turn across a slope. - Turn off the keyswitch and remove the key (2).

115 804 2581.0505

CAUTION
- Work with a guide if your vision is obscured. Lower the fork carriage until the forks are free of - Press the emergency isolator button (3).
- Never transport unstable loads. the load. Do not let the forks rest on the pallet or
- Disconnect the battery if the truck is not being used for a
racking.
* Option prolonged period.

1 2
3

x1151357 x1151358 x1151457

48
 Fuses Operation
Fuses (ancillary circuits) Fuses (main circuit)
- Open the motor compartment. The fuses can be accessed by removing the mounting plate (7).
- Remove the floor plate.
- Remove the mounting plate.
- Remove the cover.
The fuses for the main power circuit are:
The fuses for the ancillary circuits are:
8 Traction motor, hydraulic pump motor 1F1 425 A
1 1F2 5A Key switch and truck control current
2 5F1 5A Display 9 Steering motor 3F1 50 A
3 1F6 5A Seat heating and horn
4 1F8 5A Parking brake
5 6F1 5A Lighting*
6 1F4 5A Voltage converter

NOTE
Although these fuses are interchangeable with automo-
115 804 2581.0505

tive fuses, automotive fuses must not be used. Only

genuine Linde fuses have a sufficient voltage rating to
ensure correct operation at truck voltages.
* Option

7 6 5 4 3 2 1

x1151482 x1151481

49
Slinging the truck and wheel change
Slinging the truck
DANGER
Use lifting equipment of suitable capacity. See
truck and battery plates for capacity.
Operation
Jack locations when changing wheels
DANGER
Only use a jack with sufficient lifting capacity. See
truck and battery plates for capacity.

DANGER
When lifting the truck with a crane, ensure that no
persons are within the vicinity. Never step under
an elevated load.
- Reach the mast fully back.
- Fix two double loop slings around the mast upper cross
member.
- Protect the truck parts in contact with the slings.
- Place the jack under the power unit chassis (1) to lift the
drive unit clear of the floor.
- Position the jack under each reach leg (2) to work on the
load wheels.
DANGER
Do not raise the truck higher than necessary and
always block the raised truck securely after jack-
ing.
It is advisable, if possible to secure the mast at the top with
rope to a strong overhead beam for extra security.

115 804 2581.0505

2
1

2
x1151440
1 x1151441

50
 Emergency lower, steering and parking brake release
Emergency lower
In the event of power failure, the forks can lowered manually
in order that the truck can be moved to a safe position.
To manually lower the forks, use the emergency lower valve (2)
located on the right hand side of the reach frame.
- Remove the protective cap screw (1).
- Insert the Allen key into the opening and slowly release
the valve to allow the fork carriage to be lowered.
- Ensure valve is retightened and the protective cap
screw (1) replaced once the forks are lowered.
Emergency steering and parking brake re-
lease
NOTE
In the unlikely event of complete electrical failure, then the
parking brake will be applied and steering becomes una-
vailable. In order to remove the truck from an aisle the
following procedure must be followed:
- Open the motor cover.
- Install three M5x20 screws (1) into the brake disc to force
the brake pads away from the disc.
- Special tool (2), which engages on the gearbox toothed
ring, allows the drive wheel to be turned manually using
an extension bar and ratchet.
Operation
- Attach the towing vehicle (with sufficient tractive force)
with a suitable rope or sling around the chassis.
- Using extreme caution, very slowly manouevre the truck
from the aisle.
CAUTION
The above procedure should only be used in
order to remove the truck from an aisle. Once
clear of the aisle, remove the load and follow the normal
towing procedure.

NOTE
115 804 2581.0505

Apply a small amount of grease to hole (3) before using

special tool (2).

1 2

2
x1151469 x1151365

51
Towing instructions, Transporting the truck on a lorry or low-bed trailer Operation
Towing instructions Hoisting the truck with a crane
DANGER - One person should be on the truck being towed to operate WARNING
The power steering, hydraulic system and trac- the brakes if necessary. Tow the reach truck but do not
tion is inoperative if the battery plug is discon- exceed the maximum recommended speed of 2.5 km/h.
When hoisting the truck with a
nected. Therefore the reach truck can only be stopped with
- After towing, put chocks behind the wheels.
crane make sure that no persons are within
the brake pedal. the working range of the crane!
- Reach the mast unit out and lower the load.
NOTE Do not step under the elevated load!
When towing on slopes, reduce speed to an absolute
- Remove the load. minimum and keep chocks at hand. CAUTION
Only use a lifting sling and crane with a sufficient
- Attach the towing vehicle (with sufficient tractive and load capacity. For the truck weight incl. battery see
braking force) with a suitable rope or chain to the fork the manufacturer’s plate.
carriage.
- Disconnect the battery plug.
Transporting the truck on a lorry or low-bed To hoist with a crane, attach the lifting slings at the points
provided. The points on your lift truck are not extra identified.
trailer
- Raise the drive wheel using a suitable maintenance dolly
- Lower the mast.
or fork lift truck.
- Apply the parking brake.
- Chock the truck.
DANGER

115 804 2581.0505

- Lash down the truck.
Only raise the drive wheel sufficiently to clear the
ground.

x1151366 x1151483

52
 Side guidance* Operation
Side guidance for drive-in racking
- This system uses the aisle way with spigots to support
each pallet.

- Ensure the guide rollers (4) are aligned with the guide
rails (3) before entry into the aisle.

- Elevate the load/pallet (1) to the required stacking level.

Enter the aisle and proceed to the desired spigot point.

- Lower the pallet onto the spigots (2).

This system provides maximum use of the aisle and racking

but load stacking must be rotated systematically.
115 804 2581.0505

* Option

x1151372

53
360° steering*
360° steering
This system has no stops on the steering turntable so that the
direction of the truck can be reversed by continuing to rotate
the steering wheel.
- Connect the battery.
- Sit on the seat.
- Lift the emergency isolator (4) if it has been pressed.
- Insert the key and turn fully clockwise. The operator's
display will illuminate and two diametrically opposite
LEDs (1 and 2) on the steering indicator will illuminate
indicating the orientation of the steer wheel.
- Raise the forks to clear the ground. Tilt the carriage back
and retract the mast.
Operation
NOTE
The direction selection switch will return to the neutral
position when released.
- The steering indicator will stop flashing, and a single LED
(1) will indicate the direction of travel.
- Release the parking brake.
- Gently press the accelerator pedal. The travel speed will
depend on how far the pedal is pressed.
NOTE
Depressing the accelerator pedal fully will not increase
the rate of acceleration as maximum acceleration is con-
trolled automatically.

- Press the left foot interlock pedal. NOTE

- Select the required direction of travel by pressing the If the seat is vacated, or the left foot interlock pedal

115 804 2581.0505

direction selection switch (3). Left hand end (A) for for- released, then a direction of travel must again be selected
ward travel. Right hand end (B) for reverse travel. in order for traction to be available. A short delay is
provided for intermittent releases.
* Option

1 4
B
3
A
P

2
x1151373 x1151458 x1151459

54
 Height preselector system*
The height preselector system enables the truck operator to
accurately stack or destack loads by entering shelf heights on
a keypad mounted on the steering binnacle.
The height preselector can be programmed to stack or
retrieve loads from up to 25 shelf levels in 4 different zones.
NOTE
The operator's display will convey preselector informa-
tion as standard if the system is fitted. This information will
also be displayed on a slave display mounted on the
overhead guard.
The display comprises two direction indicator LEDs (1 and 2),
numeric display (3), stack/destack LEDs (4 and 5) and mode
indicator (6).
115 804 2581.0505
Operation
Initialising the system Selecting a new zone
NOTE - Turn the keyswitch on.
If the truck is switched on when the forks are above the - Press the '#' key, followed by the desired zone number (1
reference height, then only slow lift will be available. The
to 4) on the keypad.
amber slow speed indicator (7) will illuminate to notify the
operator of reduced performance.
NOTE
- Turn the keyswitch on. The keys must be pressed within ½ second.
- Lower the forks to below the reference height.
NOTE
NOTE A zone can only be selected if there are shelf levels
In order to prevent slow lift, always lower the forks to the
programmed into it. Please contact your authorised Linde
ground before turning the truck off.
dealer.
Displaying the current selected zone - The display briefly shows the current selected zone.
- Turn the keyswitch on.
NOTE
- Press the '#' key on the keypad. Zone selection is preserved when the keyswitch is turned
- The display briefly shows the current selected zone. off. However, if the battery is disconnected, then zone 1 will

be selected on battery re-connection.

NOTE
Zone selection is preserved when the keyswitch is turned
off. However, if the battery is disconnected, then zone 1 will
* Option be selected on battery re-connection.

2 3 4

1 6 5
7

x1151376 x1151377 x1151378

55
Height preselector system*
Stacking a load
- Turn the keyswitch on, and if necessary reference the
system.
- Ensure the correct zone is selected.
- Pick up the load to be stacked.
- Position the truck within the aisle at the face of the correct
storage location.
- Tilt the forks fully forward.
- Using the keypad, enter a one or two digit number repre-
senting the shelf height required (1 to 25), followed by the
"#" key.
NOTE
For levels greater than 9, the keys must be pressed within
½ second.
NOTE
If the selected level has not been programmed, then a long
bleep is sounded and "Err" will be displayed.
- The display (3) will indicate the selected level and LED (4)
- Operate the lift/lower control fully within 5 seconds, ac-
cording to the display. Lift/lower will operate at full speed,
before slowing down, and then stopping at the level
selected. Mode indicator (6) will flash during the complete
operation to indicate automatic mode.
- Release the lift/lower control. The height selector will now
revert back to manual mode. The mode indicator (6) will
stop flashing and the display (3) will show the height to the
nearest level.
- Operate the reach control to position the load into the
racking.
- Operate the lift/lower control to deposit the load manually.
- Operate the reach control to withdraw the forks from the
pallet.
Destacking a load
- Turn the keyswitch on, and if necessary reference the
Operation
- Position the truck within the aisle at the face of the correct
storage location.
- Tilt the forks fully forward.
- Using the keypad, enter a one or two digit number repre-
senting the shelf height required (1 to 25).
NOTE
For levels greater than 9, the keys must be pressed within
½ second.
NOTE
If the selected level has not been programmed, then a long
bleep is sounded and "Err" will be displayed.
- The display (3) will indicate the selected level and LED (6)
will illuminate, indicating destacking mode.
- One of the direction LED's (1 or 2) will illuminate to indicate

115 804 2581.0505

lift or lower.
will illuminate, indicating stacking mode. system. - Operate the lift/lower control fully within 5 seconds, ac-
- One of the direction LED's (1 or 2) will illuminate to indicate - Ensure the correct zone is selected. cording to the display. Lift/lower will operate at full speed,
lift or lower. before slowing down, and then stopping at the level
* Option selected. Mode indicator (6) will flash during the complete
operation to indicate automatic mode.
- Release the lift/lower control. The height selector will now
revert back to manual mode. The mode indicator (6) will
stop flashing and the display (3) will show the height to the
nearest level.
- Operate the reach control to position the forks into the
pallet.
2 3 4 - Operate the reach control to position the load into the
racking.
- Operate the lift/lower control to raise the load manually.
- Operate the reach control to withdraw the load from the
racking.

Cancelling a selection/operation
To cancel any selection, or revert back to manual mode at any
time during a sequence, either release the lift/lower control,
do not operate the lift/lower control within 5 seconds, or
operate the control and release immediately.

1 5 6
x1151379 x1151380

56
 Lift height indicator*
The lift height indicator displays the position of the forks.
NOTE
The operator's display will convey height information as
standard when a lift height indicator is fitted. This informa-
tion will also be displayed on a slave display* mounted on
the overhead guard.
The display comprises two direction indicator LEDs (1 and 2),
two part numeric display (3 and 4) and stack/destack LEDs
(5 and 6).
The lift height indicator offers two display modes. Actual
height mode displays the height of the forks in mm. Shelf
mode displays shelf number and indicates via LEDs when the
forks are in the stack or destack position.
NOTE
Mode of operation cannot be set by the operator.
NOTE
115 804 2581.0505
Operation (shelf mode)
NOTE
The lift height indicator does not operate below free lift
height. During free lift the display shows five horizontal
bars.
- Raise the forks above the free lift height.
- The two left hand digits (3) display shelf level.
- The three right hand digits (4), when read in conjunction
with LEDs (1 or 2), indicate the distance and direction from
the shelf level (3). Example below, raise the forks 300mm
to reach shelf level four.
- On reaching a shelf level both direction LEDs (1 and 2) will
extinguish.
Operation
Stacking a load (shelf mode)
- Raise the load until the desired shelf level is displayed.
- Continue to raise load until LED (5) illuminates.
NOTE
LED (6) will illuminate and extinguish as the load is raised.
- The load is now at the correct height and can be placed
in the racking.
Destacking a load (shelf mode)
- Raise the forks until the desired shelf level is displayed.
- Continue to raise the forks until LED (6) illuminates.
- The forks are now at the correct height and the load can
be picked up.

The lift height indicator is purely a height indicator, it does

not slow or stop lift.

* Option

2 3 4 5

kg
?

1 6

x1151381

57
Operator code entry* Operation
The operator code entry unit comprises a twelve digit keypad (2) Logging off Accessing supervisor menus
mounted on the steering binnacle.
- Press and hold the 'CLR' button (3) for one second. NOTE
The unit requires the operator to enter a five-digit personal - Turn the rotary switch off. The main menu setting can only be accessed by author-
PIN number in order to operate the truck, thus preventing ised skilled staff (supervisor). Please contact your fleet
unauthorised use. manager.
NOTE
If the operator's seat is vacated for any length of time the - Turn the rotary switch (1) on.
truck will automatically log off and the operator will have - Using the keypad, enter the supervisor five-digit PIN
Logging on to re-enter this personal PIN number in order to operate the number followed by '0'.
truck. NOTE
- Turn the rotary switch (1) on.
The default supervisor PIN is 98765. It is recommended
- Using the keypad (2) enter your personal five digit PIN that the supervisors change their PIN when taking delivery
number of the truck.
- Press the 'ENT' button.
NOTE
The default operator PIN is 12345. The system is now ready for a valid supervisor command to
be entered.
- Press the 'ENT' (4) button. Valid supervisor commands are :

115 804 2581.0505

'001' = Change supervisor PIN
'002' = Enable/disable the truck
'004' = Add/delete operator pin numbers
'005' = List operator PIN numbers
* Option '006' = Set/reset learner operator

2 1

3 4

x1151460 x1151383 x1151384

58
 Operator code entry* Operation
Changing the supervisor PIN Disable/enable the truck Adding/deleting operator PIN numbers
- Log on as supervisor and access the supervisor com- - Log on as supervisor and access the supervisor com- - Log on as supervisor and access the supervisor com-
mand menus. mand menus. mand menus.
- Using the keypad, enter '001'. - Using the keypad, enter '002'. - Using the keypad, enter '004'.
- Press the 'ENT' button. - Press the 'ENT' button. - Press the 'ENT' button.
- Enter the new supervisor PIN. - Enter '0' to disable the truck. All operator PIN's become - To delete an existing operator PIN:-
- Re-enter the new supervisor PIN to confirm. invalid and the truck inoperable. Enter the operator PIN number
Enter '1' to confirm deletion, or '0' to cancel.
NOTE - To add a new operator PIN number:-
Supervisor pin remains valid. Enter the new PIN number
Enter '1' to confirm new PIN, or '0' to cancel.
- Enter 'CLR' to log off.
- Enter '1' to enable the truck. All operator PIN's become
valid and the truck can be operated as normal.
- Enter 'CLR' to log off.
115 804 2581.0505

* Option

x1151385 x1151386 x1151387

59
Operator code entry* Operation
List operator PIN numbers Set/reset learner operation
- Log on as supervisor and access the supervisor com- The supervisor is able to set novice operators as 'learners'. Enter '1' to set the operator as a learner. Truck performance
mand menus. This will reduce truck performance for these operators, ena- will be reduced for this operator.
- Using the keypad, enter '005'. bling them to safely practice driving, control and steering
operations until they are fully acquainted with truck operation. Enter '0' to set the operator as non learner. Full truck perform-
- Press the 'ENT' button. ance will be available for this operator.
- The display will show the first operator PIN number. - Log on as supervisor and access the supervisor com-
mand menus.
- Use the 'ENT' key to scroll through all operator PIN
numbers. - Using the keypad, enter '006'.
- Press the 'ENT' button.
NOTE
The display will show five dashes to indicate the end of list. - To set/reset learner operation:-
Enter the operator pin.
- Press the 'CLR' button at any time to exit.
NOTE
The display will show '1' if the selected operator is already
a learner, or '0' if not a learner.

115 804 2581.0505

* Option

x1151388 x1151389

60
 Truck Data Management (LFM)* Operation
Truck data acquisition Condition code
The truck data input terminal (1) is located at the front left NOTE NOTE
overhead guard leg. The code indicates the state of the truck. If you notice one of these conditions (eg driving problem)
The terminal has a keypad (3) with 12 keys. With the standard The following code numbers are available: only after you have first logged in with condition code 0
setting, a 5-digit PIN number assigned to the operator en- (truck in working order), you must first log out (turn the
0 = Truck in working order
sures that only authorised personnel can operate the truck. rotary knob anticlockwise as far as possible) and log in
1 = Request Service (truck cannot be started)
The truck can only be started after this PIN number and maybe again with condition code 3 (driving problem).
2 = Request Maintenance (truck can be started)
a condition code (depending on the setting) has been en- 3 = Driving problem
tered. 4 = Lifting problem
5 = Steering problem
NOTE 6 = Damaged in accident
The PIN number can be enlarged from 5 to 8 digits. 7 = User-defined**
Before entry of the PIN number, please request your truck 8 = User-defined**
pool manager to give you the number of digits of the PIN 9 = User-defined**
number and the setting of the truck.
** The condition codes 7, 8, 9 can be defined by the user
as he chooses.
Please contact your truck pool manager for the defini-
tion of these condition codes.
115 804 2581.0505

* Option

61
Truck Data Management (LFM)*
Truck data acquisition - default setting (PIN
number and condition code)
Logging in and starting the truck:
- Engage the parking brake.
- Press any key to take the terminal into operation.
The green LED (2) flashes.
- Enter your PIN number and condition code (factory
setting = 0 0 0 0 0).
On a truck in proper working order as the following PIN
No.: 00000 0.
NOTE
In case the incorrect PIN number was entered, it can be
corrected after pressing the key (4) with the asterisk.
- Confirm the entry by pressing the #-key (3).
The green LED (2) is on steadily.
* Option
62
NOTE
If the red LED (1) comes on, an incorrect PIN number was
entered. Press the key (4) with the asterisk and enter the
correct number. After more than three incorrect inputs
(factory setting), the red LED (1) is on steadily and the
green LED (2) flashes. A valid PIN input is disabled for 10
minutes. The disable period can be terminated by entering
a special PIN number. Please contact your pool manager.
- Turn the rotary knob clockwise as far as possible and start
the truck.
NOTE
If the truck does not start properly at the first attempt, the
starting procedure can be repeated until the rotary knob
is returned to zero and the PIN number is deleted from
memory after the expiration of the delay period.
Operation
NOTE
If the green (2) and red (1) LEDs are both illuminated
steadily, the data must be read out. Please inform your
pool manager at once.
Turning the truck off and logging out:
- Turn the rotary knob anticlockwise as far as possible to
turn off the engine.
- After an delay period (factory setting = 10 seconds), the
red LED (1) comes on briefly and then the green (2) and
red (1) LEDs flash about 3 seconds. During this time the
truck can be started any time. The LEDs then go out and
the PIN number is no longer stored.
NOTE
The delay time can be set between 10 seconds and 10
115 804 2581.0505
minutes with the FDE configuration software. Please con-
tact your Linde dealer in this regard.
NOTE
Pressing the key (3) with the #-symbol after the engine is
turned off terminates the delay period at once and the PIN
number is deleted from memory.
 Truck Data Management (LFM)*
Truck data acquisition - special setting (PIN
number)
Logging in and starting the truck:
- Engage the parking brake.
- Press any key to take the terminal into operation.
The green LED (2) flashes.
- Enter your PIN number (factory setting = 0 0 0 0 0).
NOTE
In case the incorrect PIN number was entered, it can be
corrected after pressing the key (4) with the asterisk.
115 804 2581.0505
- Confirm the entry by pressing the #-key (3).
The green LED (2) is on steadily.
NOTE
If the red LED (1) comes on, an incorrect PIN number was
entered. Press the key (4) with the asterisk and enter the
correct number. After more than three incorrect inputs
(factory setting), the red LED (1) and the green LEDs (2)
flash. A valid PIN input is disabled for 10 minutes. The
disable period can be terminated by entering a special PIN
number. Please contact your pool manager.
- Turn the rotary knob clockwise as far as possible and start
the truck.
NOTE
Operation
NOTE
If the green (2) and red (1) LEDs are both illuminated
steadily, the data must be read out. Please inform your
pool manager at once.
Turning the truck off and logging out:
- Turn the rotary knob anticlockwise as far as possible to
turn off the engine.
- After an delay period (factory setting = 10 seconds), the
red LED (1) comes on briefly and then the green (2) and
red (1) LEDs flash about 3 seconds. During this time the
truck can be started any time. The LEDs then go out and
the PIN number is no longer stored.
NOTE
The delay time can be set between 10 seconds and 10

If the truck does not start properly at the first attempt, the
starting procedure can be repeated until the rotary knob
is returned to zero and the PIN number is deleted from
* Option memory after the expiration of the delay period.
minutes with the FDE configuration software. Please con-
tact your Linde dealer in this regard.
NOTE
Pressing the key (3) with the #-symbol after the engine is
turned off terminates the delay period at once and the PIN
number is deleted from memory.

63
Closed circuit television* Operation
Closed circuit television
Closed circuit television enables the operator to stack and
destack loads at high levels without having to look upwards,
thus avoiding neck and shoulder strain.
The monitor can be adjusted to a comfortable viewing posi-
tion by releasing the clamping knobs (1).

The monitor controls are:

2 Power on/off
3 Brightness adjustment
4 Contrast adjustment
5 Standby button

NOTE
By using the standby button, the monitor is switched off but
the camera heater remains on. Use the standby button to
switch the monitor off for short periods.

115 804 2581.0505

The monitor screen must conform to protection class IP54
minimum.

* Option

1
1

2 3 4 5
x1151391

64
 Maintenance and safety guidelines
General information
Your truck will remain operational only if the maintenance
and checks are carried out regularly and according to the
information and instructions in this operating manual. The
maintenance may only be carried out by qualified authorised
personnel. This work can be carried out by your authorised
Linde dealer under a service contract.
If you wish to do the work yourself, we recommend that the first
three customer service checks be carried out by your local
Linde representative's service engineer in the presence of
the responsible mechanic in your workshop, so that your staff
can receive the appropriate instruction.
For all servicing, the truck must be placed on a level surface
and the wheels secured.
No changes, particularly no modification and additions, may
be made to the truck without the approval of the manufacturer.
Perform a functional check and trial run after every service.
115 804 2581.0505
NOTE
When operating the truck under extreme conditions (i.e.
extreme heat or cold, intensive dust concentration etc.),
the intervals given in the maintenance schedule should be
reduced accordingly.
ATTENTION
It is imperative, that before working on the control
system, that the battery is disconnected, and the
steering capacitor voltage is discharged.
Check that the voltage between 3F1 and the main negative
is less than 5V before working on the truck.
Failure to carry out this procedure can lead to damage of the
can interface drivers. Components must not be removed or
replaced with the truck live.
ATTENTION
If the battery has been disconnected, before
reconnecting, ensure that the emergency isola-
tor is depressed and the keyswitch is turned off.
DANGER
Should major electrical work or dissassembly be
carried out on the truck, then the Electrical Safety
Checks as detailed in the Service Training Manual must be
carried out before the truck is returned to service.
Handling lubricants
Always handle lubricants safely and as specified by the
manufacturer.
Only store lubricants in approved containers at specified
storage locations. As they could be inflammable, do not let
them come in contact with hot objects or naked flames.
Clean the area surrounding the part in question before
lubrication, filter renewal or repairs in the hydraulic system.
Only use clean containers when replenishing fuels and
lubricants.
ATTENTION
Follow the manufacturer's safety and disposal
instructions when using lubricants and cleaning
compounds.
Avoid spilling lubricants. Remove any spillage immediate-
ly with a suitable binding agent and dispose of as specified.
Always dispose of used or contaminated lubricants as
specified. Follow laws and regulations.
Dispose of used parts, filters etc., in an environmentally
friendly manner.
DANGER
All inspection and maintenance work
must be done outside of an hazardous area
and only by qualified authorised skilled per-
sonnel (experts) who are familiar with all
regulations.
The manufacturer recommends your au-
thorised Linde dealer for this service.
Maintenance
Safety guidelines
DANGER
Before attempting any repair work, apply the
parking brake, turn the keyswitch off, disconnect
the battery, and, unless the particular routine being per-
formed requires otherwise, chock the load wheels secure-
ly front and rear.
DANGER
Before carrying out any electrical maintenance
or checks, raise the drive wheel clear of the
ground and securely chock the truck in position.
DANGER
Take the necessary fire precautions when work-
ing on batteries.
DANGER
Before attempting repairs or adjustments on the
reach frame, the raised fork carriage or mast,
always ensure that they are secured against accidental
movement.
DANGER
Always ensure any lifting equipment, is of suffi-
cient capacity, and has the relevant certification.
All blocks, jacks and chains etc. are subject to regular
examination and must only be used for the purpose intend-
ed.
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.
CAUTION
Protective equipment i.e. goggles and mask must
be worn at all times when using compressed air.
65
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
- Clean the truck thoroughly.
- Fully elevate the fork carriage several times, tilt the mast
forward and back and, if fitted, operate the attachment
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.
Coat the battery terminals with non-acidic grease. (Follow
the instructions of the battery manufacturer.)
- Make sure that the voltage of the buffer battery does not
drop below 23V.
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 vehicle is to be taken out of operation for over 6
months, contact authorised skilled personnel (experts)
for further measures.
The manufacturer recommends your authorised Linde
dealer for this service.
66
Putting the truck back into operation
- Clean the truck thoroughly.
- Lubricate the truck.
- Clean the battery.
- Check the condition and electrolyte level of the battery
and charge the battery if necessary.
- Check the voltage of the buffer battery.
- Check the hydraulic oil for condensation water and change
the oil, if necessary.
- Perform the same services as for initial commissioning.
- Take the truck into operation.
ATTENTION
The gas warning system must be recalibrated
every 2 months or after a complete discharge
and cut-out of the buffer battery.
General information
ATTENTION
Explosion-protected fork trucks must
be serviced at a regular intervals. The oper-
ator (owner) must determine the time peri-
ods for maintenance in accordance with
operating conditions and the maintenance
manuals of the manufacturer.
Your truck will remain operational only if the maintenance
and inspections 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 your authorised Linde deal-
er for this service.
Maintenance
This work can be carried out by authorised skilled personnel
(experts) under a maintenance agreement. The manufactur-
er recommends your authorised Linde dealer for this service.
If you wish to do the work yourself, we recommend that the first
three inspections be carried out by your dealer in the pres-
ence of the responsible mechanic in your workshop so that
your staff can receive the appropriate instruction.
CAUTION
For all services the truck must be
placed on a level surface, the wheels must
be chocked, the key removed and the bat-
tery plugs disconnected.
When working on the truck with the load lifting device (forks
115 804 2581.0505
or attachments) elevated, secure it against inadvertent low-
ering.
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 manufacturer.
ATTENTION
Missing or damaged type plates or stickers must
be replaced. For their location and order number
see the parts catalogue.
NOTE
When operating the truck under extreme conditions (ie
extreme heat or cold, intensive dust concentration, etc.),
the intervals given in the maintenance schedule should be
reduced accordingly.
ATTENTION
Follow the precautions for handling fluids and
lubricants.
 Mast unit and reach frame
Work on the mast and the reach frame part
of the truck
DANGER
Before attempting repairs or adjustments on the
reach frame, the raised fork carriage or mast,
always ensure that the following safety procedures are
carried out.
Mast removal
DANGER
This work must only be carried out by the trained
personnel of your authorised Linde dealer.
Securing the reach frame against reaching
in or out
DANGER
115 804 2581.0505
Before work in front of or behind the reach frame,
securing against reaching in or out is required.
- Apply the parking brake firmly.
- Lower the fork carriage fully.
x1151392
Maintenance
Securing the mast
ATTENTION
- Reach the reach frame out. Follow maintenance and safety guidelines.
- Insert a wood block (1) between the mast and the battery
- Raise the forks.
tray.
- Reach the frame back until it is stopped by the wood block. - Close the chain after passing it over the outer mast cross
member (2) and under the centre mast cross member (3).
- Switch off and remove the key.
- Lower the mast until it comes into contact with the chain.
- Depress the emergency isolator button.
- Lower the fork carriage until it rests in the end stop.
- Disconnect the battery plug.
Inspection and maintenance after the first
The mast
50 hours of operation
OPERATION
NOTE
The fork carriage rises up to the free lift height by means of
the chain of the primary jack. The secondary lift jack lifts the
How to perform these functions can be found in the index.
inner mast. The inner mast is raised via the chain pulley at
- Check all controls and their operation.
twice the speed. The secondary jack is fitted on the extensible
middle mast. - Check the brake operation.
- Tighten the wheel nuts (at least every 100 hours).
- Check the tyres for damage and foreign objects.
- Renew the hydraulic return line filter.
- Lubricate tilt and sideshift slider pad.
- Mast and lift chain: lubricate with chain spray.
- Tighten the steering wheel securing screw.
- Tighten all electrical connections.
2
- Check cables and PG glands for damage and security.
x1151492
67
Inspection and maintenance chart Maintenance

Services before initial

after first 50 hours daily checks as required
(A description of the service can also be located in the index.) operation

See page 27 for service .............................................................................................................................................. 

See page 67 for service ............................................................................................................................................................................... 

Check battery state of charge .......................................................................................................................................................................................................... 

Check all controls and their operation ............................................................................................................................................................................................ 

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

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

Check the forks and fork quick-releases ..................................................................................................................................................................................... 

115 804 2581.0505

Check the condition for leakage resistance of the traction wheel .......................................................................................................................................... 

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

Clean the truck ................................................................................................................................................................................................................................................................... 

Lubricate the lift chains and mast channels ...................................................................................................................................................................................................................... 

Adjust the lift chains ........................................................................................................................................................................................................................................................... 

Check the condition of the wheels and tyres .................................................................................................................................................................................................................... 

Replace the motor brushes ........................................................................................................................................................................................................................................ 

Renew the hydraulic hoses ............................................................................................................................................................................................................................................... 

Check the drive wheel nuts ............................................................................................................................................................................................................................................... 

Inspect and recalibrate the gas warning system sensors (every 2 months) ............................................................................................................................................................. 

Inspect and recalibrate the gas warning system (by an expert) (every 2 months) ................................................................................................................................................... 

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

68
 Inspection and maintenance chart Maintenance

Services every 1000 hours every 2000 hours every 5000 hours every 10000 hours or 5 years
(A description of the service can also be located in the index.)

Check the parking brake, adjust if required .............................................................................. 

Check the hydraulic hoses and pipes for damage ................................................................... 
Check the mast and lift chains for condition and security ........................................................ 
Lubricate the mast, mast rollers, lift chains and chain pulleys ................................................. 
Lubricate the reach channels and rollers ................................................................................. 
Lubricate the battery trolley slides and associated mechanism .............................................. 
Check the condition and security of motor and battery connectors and cables ...................... 
Check the hydraulic oil level ..................................................................................................... 
Lubricate the fork carriage and sideshift slider pad ................................................................. 
Check condition of side guide rollers* ...................................................................................... 
115 804 2581.0505

Perform the motor brushes wear check

(visual inspection once after the first 2000 h, then every 1000 h) ......................................................................... 
Check the brake fluid level ........................................................................................................................................... 
Check the brake band and load wheel shoes for wear and adjustment .................................................................... 
Renew the hydraulic tank breather filter ...................................................................................................................... 

Check condition of brake pipes ..................................................................................................................................................................... 

Grease the load wheel bearings ................................................................................................................................................................... 
Change the hydraulic fluid ............................................................................................................................................................................. 
Renew the hydraulic return line filter ............................................................................................................................................................ 

Change the brake fluid .................................................................................................................................................................................................................................... 

* Option

69
Inspection and maintenance as required
Clean the lift truck
DANGER
All inspection and maintenance work
must be done outside of hazardous areas.
NOTE
The necessity of cleaning depends on the use of the truck.
If used with aggressive media such as salt water, fertiliser,
chemicals, cement, etc., clean the truck thoroughly after
every application.
Hot steam or intensive degreasing solutions should be
used with utmost care! The grease in the lubricated-for-
life bearings will dissolve and leak out. As regreasing is not
possible, the bearings will be damaged.
- Depress the emergency isolator button.
- Disconnect the battery plugs.
CAUTION
Follow maintenance and safety guidelines.
Lubricate the lift chains and mast channels
CAUTION
Mast chains are safety components. The use of
cold cleaners, chemical cleaning agents and caus-
tic or acidic and chlorinated fluids can be a direct cause of
failure.
- The mast channels should be lubricated with Linde chain
spray over the full working length. Extend the mast to full
lift height to gain access to the areas of the roller track that
would normally be covered when the mast is closed.
Maintenance
Adjust the lift chains
NOTE
When the truck is being used, chains are subject to elon-
gation and consequently have to be regularly adjusted.
DANGER
The examination and adjustment of lift chains
should only be carried out by certified personnel
who have received the relevant training. Do not adjust or
make an assessment of chain condition unless you have
been certified to do so. Please contact your authorised
Linde dealer.

115 804 2581.0505

DANGER
For safety reasons the front axle and the area of
the front axle of the truck should never be cleaned
with a high pressure cleaning device. Water could pene-
trate the flameproof enclosures, leading to the destruc-
tion of the controller or other parts (motor). As a result, the
explosion protection is no longer ensured.
This may substantially reduce the braking action during
the subsequent first braking attempts.

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

- Dry the truck after cleaning.

x1151395 x1151396

70
 Inspection and maintenance as required
Check the condition of the wheels and tyres
- Lift the truck clear of the ground and block securely.
- Check the wheels rotate freely and remove all swarf,
metal, stone and other matter embedded in the tyres.
- Replace worn tyres, wheels and bearings.
DANGER
Worn tyres can effect truck stability.
115 804 2581.0505
x1151443
Replace the motor brushes
To the check the motor brushes please contact authorised
skilled personnel (expert).
The manufacturer strongly recommends having this service
performed by your authorised Linde dealer.
Check the insulation and leakage re-
sistance
For the insulation and leakage resistance test please contact
authorised skilled personnel (expert). The manufacturer
strongly recommends having this service performed by your
authorised Linde dealer.
x1151398
Maintenance
Renew/replace the hydraulic hoses
Hydraulic hoses should be replaced as required.
Have the hydraulic hoses checked by authorised skilled
personnel (expert).
The manufacturer strongly recommends having this service
performed by your authorised Linde dealer.
x1151399
71
Inspection and maintenance as required
Check drive wheel nuts
CAUTION
Check drive wheel nuts at least every 100 hours.
Tighten the wheel nuts after a wheel change until they are
seated firmly, i.e. until the correct torque figure is consistently
obtained.
- Lift the truck at the drive end using a jack (1).
- Support each side with wood blocks.
- Rotate drive unit until drive wheel studs face the chassis
cut away.
- Check the tightness of the wheel nuts (2).
For effective wheel fixing, tighten wheel nuts in accordance
with the sequence below.
Maintenance
Inspect and recalibrate the gas warn- Clean the gas warning system sensors
ing system sensors (every 2 months) - Remove and clean the protective caps (1).
NOTE
Have this service only carried out by authorised personnel - Clean the sensors only with a dry, clean cloth.
(experts).
The manufacturer recommends having this service per- - Refit the protective caps.
formed by your authorised Linde dealer.
In case of stubborn dirt please contact your authorised Linde
dealer.
Inspect and recalibrate the gas warn-
ing system (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 Linde dealer.

115 804 2581.0505

Recommended torque: ........................................... 140 Nm.

1
2

x1151400
1 x1151495 x1151476

72
 1000-hour inspection and maintenance
Check and adjust the parking brake
NOTE
Have the parking brake checked by authorised skilled
personnel (expert).
The manufacturer strongly recommends having this serv-
ice performed by your authorised Linde dealer.
DANGER
Never use a truck with a defective braking sys-
tem.
115 804 2581.0505
Check the hydraulic hoses and pipes for
damage
- Examine the outer cover of hoses for signs of embrittle-
ment, tears, blisters, ballooning or cracks.
- Check that hoses are not twisted, kinked, crushed or
under tension.
- Replace any defective hoses.
- Check that all clips that support hoses are fitted and
replace any worn or damaged clips that may cut or
damage the hose.
- Check for signs of chafing and ensure that hoses are
routed clear of both very hot and moving parts.
NOTE
Should hoses be subject to acids, solvents, steam clean-
ing, salt water or ozone, the inspection period should be
reduced.
x1151399
Maintenance
Check the mast and lift chains for condition
and security
NOTE
The lift chains must be checked regularly according to the
valid legal regulations.
DANGER
The examination and adjustment of lift chains
should only be carried out by certified personnel
who have received the relevant training. Do not adjust or
make an assessment of chain condition unless you have
been certified to do so. Please contact your authorised
Linde dealer.
ATTENTION
Only fit replacement chains, chain anchors, an-
chor pins and integral anchors as specified and
approved by your authorised Linde dealer.
x1151401
73
1000-hour inspection and maintenance Maintenance
Lubricate the mast, mast rollers, lift chains
and chain pulleys
- The mast channels should be lubricated over the full
working length with Linde chain spray. Extend the mast
to full lift height to gain access to the areas of the roller track
that would normally be covered when the mast is closed.
- The mast chains should be lubricated over the full working
length with Linde chain spray.
- Grease the chain pulleys, the primary lift jack pulley.
- Grease the mast rollers*.
- Grease the fork carriage rollers.

ATTENTION
Mast chains are safety devices. The chain can be
damaged by the use of cold or chemical deter-
gents, acids or corrosive or chlorine based liquids.

115 804 2581.0505

x1151402

74
 1000-hour inspection and maintenance Maintenance
Lubricate the reach channels and rollers
- Lubricate the front reach rollers on both sides (1).
- Apply chain spray to the reach channels (2) on both sides.
Operate the reach to ensure all working surfaces of the
reach channel have been lubricated and to gain access
to the rear reach rollers.
115 804 2581.0505

x1151404

75
1000-hour inspection and maintenance
Lubricate the battery trolley slides and as-
sociated mechanism
- Lubricate with general purpose grease the battery trolley
slides.
- Lubricate the battery rollers.
CAUTION
Manual handling risk. The battery and battery
trolley are heavy. Take care when manoeuvring
battery or trolley.
Maintenance
Check the condition and security of Check the hydraulic oil level
motor and battery connectors and cables - Carry out this operation with forks in the lowered position
- Unplug the battery connector. and with the mast reached in.
- Check the tightness of connections and remove all traces - Open the motor cover.
of corrosion. - Observe the hydraulic oil level against the fluid level
- Check that battery cables are undamaged and well insu- marks (1) on the hydraulic tank.
lated.
NOTE
- Check electric motor cable connections for security, and The tank has two level marks labeled 184 and 187. These
make sure that there are no signs of corrosion. labels refer to the mast type fitted on the truck. The mast
- Check that all motor cables are undamaged and well type can be determined from the mast serial number which
insulated. is stamped on the mast.

NOTE - If necessary, remove the filler cap (2) and replenish the
Corroded connections and damaged cables cause volt- tank to the correct level with clean oil.
age drops and overheating which can lead to operating - Replace the filler cap (2).
problems.

115 804 2581.0505

ATTENTION
- Eliminate all traces of corrosion and renew damaged Follow maintenance and safety guidelines.
cables.

x1151406 x1151484 x1151485 1

76
 1000-hour inspection and maintenance
Lubricate the fork carriage and sideshift
slider pad
- Lubricate the fork carriage top edges (1) with general
purpose grease.
Maintenance
Check condition of side guide rollers*
- Check for wear or damage on side guidance rollers.
- Check that rollers are secure and free to rotate.

CAUTION
Manual handling risk. The forks are heavy. Take
care when manoeuvring the forks on the carriage
plate.

- Lubricate the sideshift slider pad (2) with general pur-

pose grease.

NOTE
The sideshift slider pad should be lubricated every time
the truck is cleaned.
115 804 2581.0505

* Option

2
x1151409 x1151410

77
2000-hour inspection and maintenance
Perform the motor brushes wear check
NOTE
This service should only be performed by authorised
skilled personnel (expert).
The manufacturer strongly recommends having this serv-
ice performed by your authorised Linde dealer.
Maintenance
Check the brake fluid level
NOTE
A brake fluid level indicator is fitted, and will indicate when
the brake fluid level is low. However it is advisable to check
the brake fluid level every 2000 hours.
- Remove the floor plate or advance the reach frame with
the battery.
- Check the level of the brake fluid reservoir is up to the
maximum mark (1). The level must never drop below the
minimum mark (2).
- Top up with brake fluid if necessary, in accordance with
the lubrication table.

ATTENTION
Follow maintenance and safety guidelines.

115 804 2581.0505

1 1

2
2

x1151413 x1151493

78
 2000-hour inspection and maintenance
Check the traction motor brake band and
load wheel shoes for wear and adjustment
NOTE
We strongly recommend that this operation and other
brake adjustments be carried out by your authorised
Linde dealer.
Maintenance
Renew the hydraulic tank breather filter
- Fully lower the forks.
- Open the motor compartment cover.
- Pull out the breather/filler cap (1) and discard.

DANGER - Fit a new breather/filler cap.

Never use a truck with a defective braking sys-
tem. ATTENTION
Follow the instructions for handling fluids and
lubricants.
115 804 2581.0505

x1151414 x1151487

79
5000-hour inspection and maintenance Maintenance
Check condition of brake pipes Grease the load wheel bearings
NOTE NOTE
We strongly recommend that this operation and other To grease load wheel bearings please contact your au-
brake adjustments be carried out by your authorised Linde thorised Linde dealer.
dealer.

DANGER
Never use a truck with a defective braking sys-
tem.

115 804 2581.0505

x1151417

80
 5000-hour inspection and maintenance Maintenance
Change the hydraulic fluid
- Carry out this operation with forks in the lowered position ATTENTION
and with the mast reached in. Failure to do this will cause the pump to run dry
- Open the motor compartment cover. and result in premature pump failure.

- Remove the breather/filler cap (1). NOTE

- Empty reservoir using a suitable handpump. The tank has two level marks labeled 184 and 187. These
labels refer to the mast type fitted on the truck. The mast
ATTENTION type can be determined from the mast serial number
Follow the instructions for handling fluids and which is stamped on the mast.
lubricants.
CAUTION
CAUTION Check correct hydraulic operation after refilling
The hydraulic fluid can become very hot. Risk of the system.
scalding.
ATTENTION
- Replenish the tank to the correct level on the tank with Follow maintenance and safety guidelines.
clean oil.
115 804 2581.0505

- Loosen the hose clamp (2) and pull the hose (3) off.
- Fill clean oil as far as the edge of the hose.

x1151494

81
5000-hour inspection and maintenance Maintenance
Renew the hydraulic return line filter
- Open the motor cover. ATTENTION
- Slacken the securing clip (1) on the outlet pipe. Failure to do this will cause the pump to run dry
and result in premature pump failure.
- Pull pipe from the filter assembly.
- Release and remove the filter cap by squeezing the two ATTENTION
tabs (2). Follow maintenance and safety guidelines.
- Lift the filter (3) from the tank. Allow to drain and discard.

CAUTION
The hydraulic fluid can become very hot. Risk of
scalding.

- Place a new filter element (3) into the tank and replace the
filter cap.
- Fill clean oil up to the edge of the hose (4).
- Replace outlet pipe, ensuring clip (1) is secure.

115 804 2581.0505

2
2
1

x1151488

82
 10000-hour or 5-year inspection and maintenance Maintenance
Change the brake fluid
ATTENTION
It is recommended the brake fluid should be
changed every 10000 hours or 5 years, whichev-
er is earlier.

NOTE
We strongly recommend that this operation and other
brake adjustments be carried out by your authorised
Linde dealer.

ATTENTION
Follow maintenance and safety guidelines.
115 804 2581.0505

x1151490

83
115 804 2581.0505
84
 Inspection and maintenance data Maintenance

No. Assembly Aids/Lubricants Capacity/Settings

1 Hydraulic system return line filter Filter element

2 Wheels Drive 140 Nm

3 Braking system Brake fluid approx. 300 cc

4 Electrical system
Steer pump motor Fuse 1 x 50 A
Traction motor Fuse 1 x 425 A
Ancillary circuits Fuses 6x5A

5 Electric motors
Traction motor Motor brushes max 40 mm / min 17 mm
Hydraulic lift pump motor Motor brushes max 32 mm / min 17 mm
115 804 2581.0505

6 Battery Distilled water As required

Non acidic grease As required

7 Mast channels Chain spray As required

8 Chain rollers Grease As required

9 Mast chains Chain spray As required

10 Reach channels Chain spray As required

85
Recommended lubricants
Hydraulic oil Multipurpose grease
Hydraulic oil grade HLP to DIN 51524 part 2 Lithium-based grease to DIN51825, KP2K-20
Viscosity ISO VG 46.
Cloud point lower than -10°C when tested to IP 216.82 Gear oil
NOTE Use only oil of classification SHC,
The above specification is a high Viscosity Index oil, which e.g. Mobil SHC 75W90
allows the use of hydraulics in ambient temperatures
between -30°C and +40°C (Oil temperatures between Steering drive gears
-30°C and +80°C)
Multi purpose grease containing 5% Molybdenum Disul-
NOTE phide
The above oil recommendations are approximate values. e.g. Shell Aeroshell 17
In case of doubt we recommend contacting your author-
ised Linde dealer. General purpose oil
Engine Oil SAE 20W50

Chain Spray

115 804 2581.0505

Linde chain spray

Brake fluid
Brake fluid DOT3 acc. to SAE J 1703 (eg. ATE type S) or DOT4
acc. to SAE J 1704 or FMVSS 116 (eg. ATE type SL).

NOTE
For any further information, we recommend that you con-
tact your authorised Linde dealer.

86
 Troubleshooting guide (hydraulic system)

Trouble Possible Cause Remedy See Page

Abnormal noise Filter restricted. Replace filter. 82
Suction hoses leak, oil foams. Check oil level, top up if necessary. Tighten hose connections. 71, 73

Hydraulic pump damaged, seals faulty, causing air Have inspected by your authorised dealer.
intake.

Oil of wrong viscosity, low oil level in tank. Change oil, use specified viscosity. Top up oil. 81, 86

No or too low pressure in sys- Pump suction faulty, noises. Change oil, add oil. 81, 86
tem
Pump failure, pressure valves do not close, valve seat Have inspected by your authorised dealer.
damage.

Pipeline broken or leaky. Replace pipe or tighten connections. 73

Oil of low viscosity, causing high leakage losses. Change oil, use specified viscosity. 81, 86
115 804 2581.0505

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

Lift and tilt cylinders have tight spots. Have seals replaced by your authorised dealer.

Mast does not extend completely or retracts slightly Top up oil. 76

after being extended.

Hydraulic oil temperature too Pump failure, valves leaking. Have repaired by your authorised dealer.
high
Oil level too low. Check oil level; if necessary, top up oil. 76

Failure of the working hydraulic Battery discharge at 80 %. Check, charge or replace the battery. 29, 30, 31
system
Faulty fuse. Renew the fuse 49

Truck does not drive (cont’d) Temperature sensors triggered (warning light on). Operate the truck only after a cooling-off period. Contact your 22
authorised dealer if the problem occurs again.

Gas warning system has triggered 2nd warning Make the truck operationally safe. 13
(> 25 % of lower explosion limit of gas mixtures).

Gas warning system buffer batteries discharged. Charge the buffer batteries and turn on the gas warning system
again with the separate key switch. Recalibrate the warning
system. Contact your authorised dealer for this service.

87
Hydraulic system piping
1. Hydraulic tank

2. Filter

3. Main Hydraulic Pump

4. Main Pump Motor

5. Hydraulic Control Valve

6. Lift Cylinders

7. Lift Cylinder Flow Control Valve

8. Sideshift Cylinder

9. Tilt Cylinders

10. Reach Cylinder

115 804 2581.0505

88
 Hydraulic system piping

5
4
m1
M

3 MP
6
P A
T
T1
A1.1
7

m2

m3
115 804 2581.0505

B1

A1

m4
25bar 8
m5

B2
9
A2

m6

m7

B3
10
A3

m8

m9
2
B4
A4

1 m10
x1151421

89
Electric circuit diagram (standard equipment)
A Truck data management (LFM) * 5F1 Lighting fuse 5A X3 Connector emergency isolator switch
1A1 Power module for traction and hydraulic lift pump 6F1 Driver’s display fuse 5A X5 Connector switch lock
motor G1 Battery - 48V X8 Connector voltage converter
1A2 LDC controller X10 Battery plug
1A4 Accelerator assy. H1 Temperature cut-off monitoring lamp 1M1 X12 Connector charging circuit
2A2 LLC controller H2 Temperature cut-off monitoring lamp 2M1 X48 Connector steer CAN bus
3A1 Steering controller H3 Temperature cut-off monitoring lamp 3M1 X49 Connector steer wheel position inputs
H4 Temperature cut-off monitoring lamp control housing X50 Connector steering angle sending unit
B1 Battery lock sensor H5 Temperature cut-off monitoring lamp brake 1X4 Connector parking brake switch
1B3 Actual current sensor 1X6 Connector current sensor
1B5 Reversing buzzer 24V* K1 Main line contactor 1X7 Connector motor sensors 1M1
1B6 Traction motor temperature switch 120°C ± 5°C K2 Charge circuit relay 1X9 Connector horn button/forward/reverse selector switch
1B10 Control box temperature switch 80°C ± 5°C K3 Charge circuit relay 1X10 Connector accelerator assy.
1B12 Lift sensor * K4 Relay for warning light drive 1X11 Connector LDC controller
1B13 Brake temperature switch 65°C ± 5°C KV1 Cut-off relay 1X12 Connector LDC controller
1B14 Brake temperature switch 65°C ± 5°C 1K1 Emergency isolator contactor 1X13 Connector power module
1B15 Brake temperature switch 65°C ± 5°C 1K13 Parking brake solenoid 1X14 Connector stop pedal switch
1B16 Brake temperature switch 65°C ± 5°C 1X15 Connector diagnostics
1B17 Brake temperature switch 1M1 120°C ± 5°C 1M1 Traction motor 1X19 Connector parking brake solenoid

115 804 2581.0505

1B18 Brake temperature switch 1M1 120°C ± 5°C 2M1 Lift motor 1X32 Connector seat support
2B7 Lift motor temperature switch 120°C ± 5°C 3M1 Steer motor 1X34 Connector travel buzzer
2B8 Lift motor speed sensor 9M1 Fan (electrical system) 1X36 Connector reference sensor 8.5m
2B15 Joystick 1 (lift/lower/reach carriage) 9M2 Fan (traction motor) 1X38 Connector foot interlock switch (dead man)
2B16 Joystick 2 (tilting/sideshifting) 2X1 Connector LLC controller
2B17 Joystick 3 (auxiliary functions)* 6P1 Driver’s display 2X6 Connector reach carriage sensors
2B18 Sensor (reach carriage position) 2X7 Connector motor sensors 2M1
2B19 Sensor (lift stop)* R1 Charging circuit resistor 2X15 Connector joystick 1
2B20 Sensor (lift stop/slow) R2 Charging circuit resistor 2X17 Connector valve block
2B21 Sensor (reach carriage position) 6R1 Resistor for CAN-bus terminator 2X19 Connector auxiliary hydraulics
3B1 Steer wheel unit 6R2 Resistor for CAN-bus terminator 2X20 Connector reach cables
3B2 Steer sensor 90° 2X26 Connector joystick 2
3B3 Steer sensor 180° S1 Key switch 2X27 Connector joystick 3
3B4 Steer sensor 360° * S2 Emergency isolator button 2X81 Connector sensor 2B20
3B5 Steer motor temperature switch 120°C ± 5°C S3 Brake fluid level switch 2X81A Connector lift stop sensor/slow
6B1 Temperature/brush wear sensor (1M1) 1S1 Seat switch 2X83 Connector speed sensor 2M1
6B3 Temperature/brush wear sensor (2M1) 1S4 Parking brake switch 3X1 Connector steering controller
8B5 Reference sensor * 1S5 Stop pedal switch 3X4 Connector power steering
8B6 Load sensor * 1S11 Foot interlock switch (dead man)* Encoder/motor speed controller
1S13 Direction switch, single pedal model 3X8 Connector steer sensor 3B2
D1 Diode 2S13 Sensor for lift speed reduction 8.5m 3X9 Connector steer sensor 3B3
3X10 Connector steer sensor 3B4
1F1 Traction and pump motor fuse 425A U1 Voltage converter 24V 3X15 Connector steer interlocks
1F2 Control circuit fuse 5A 4X1 Connector horn
1F4 Control circuit fuse 5A 1V1 Monitoring unit 5X1 Connector lighting
1F6 Fuse 5A 2V11 Diode 6X1 Connector driver’s display
1F8 Control current fuse 5A
3F1 Steer motor fuse 50A X1 Connector battery lock sensor * Option

90
 Electric circuit diagram (standard equipment)
6X63 Connector attachments*
8X23 Connector reference sensor
8X25 Connector height encoder
8X30 Connector mast cables
8X57 Connector load sensor *
9X1 Connector fan 9M1
9X2 Connector fan 9M2

2Y1 Lift valve

2Y2 Lowering valve
2Y8 Valve, reach out
2Y9 Valve, reach back
2Y11 Valve, tilting forward
2Y12 Valve, tilting back
2Y13 Valve, sideshift left
2Y14 Valve, sideshift right
2Y15 Valve, attachment 1
2Y16 Valve, attachment 2
2Y21 Valve, rotate
115 804 2581.0505

2Y22 Valve, clamp

RV1 Series resistor inside indicator light

RV2 Series resistor inside indicator light
RV3 Series resistor inside indicator light
RV4 Series resistor inside indicator light
RV5 Series resistor inside indicator light

XG10 Connector battery buffer

XG12 Connector charging/discharging circuit
XGA Connector warning/indicator lights
XGF1 Connector fuses
XGS Connector cut-off relay
XGT Connector temperature switches
XK1 Connector main line contactor

* Option

91
Electric circuit diagram (standard equipment)

115 804 2581.0505

92
115 804 2581.0505
Electric circuit diagram (standard equipment)

93
Electric circuit diagram (standard equipment)

115 804 2581.0505

94
115 804 2581.0505
Electric circuit diagram (standard equipment)

95
Electric circuit diagram (Gas warning system)
4A1 Gas warning system

1B19 Temperature switch gas warning system 80°C ± 5°C

1B20 Temperature switch gas warning system 80°C ± 5°C
4B1 Sensor head 1
4B2 Sensor head 2

1Z... Recovery diode

D2 Decoupling diode
D3 Isolation diode

6F21 Fuse gas monitoring 1A

6F22 Fuse rechargeable battery 1A
6F23 Fuse rechargeable battery 1A
6F24 Fuse gas monitoring 1A

G2 Buffer battery

H6 Acoustic alarm 10% gas concentration

115 804 2581.0505

P1 Potentiometer buffer voltage
6P3 Composite instrument gas warning system

S5 Reset button gas warning

S6 Keyswitch / release gas warning system 4A1

U2 Voltage transformer 48/24V

U3 Voltage transformer buffer circuit

X2 Connector continuous voltage

X81 Connector voltage transformer U2

HD1 Indicator light gas warning system

KG1 Relay buzzer cut-off
KP1 Relay current stop
KP2 Relay cut-off low battery voltage
KV1 Relay cut-off
RV6 Protective resistor buffer batteries 3R3

96
115 804 2581.0505
Electric circuit diagram (Gas warning system)

97
Index
Page
A
Accessing supervisor menus ............................................ 58
Adding/deleting operator PIN numbers ........................... 59
Adjust the lift chains .......................................................... 70
Approved applications ........................................................ 2
B E
Battery discharge indicator ......................................... 18, 21
Battery unlocked warning light ......................................... 20
Before leaving the truck .................................................... 48
Before loading ................................................................... 45
Beginning operation ......................................................... 23
Brake fluid ......................................................................... 86
Brake fluid level warning light .......................................... 19
Braking (dual-pedal model) .............................................. 39
Braking (single-pedal model) ........................................... 40
Braking .............................................................................. 12
C
Cancelling a selection/operation ..................................... 56
Central control lever (joystick) operation of mast and
attachments .................................................................... 42
Chain Spray ...................................................................... 86
Change the brake fluid ..................................................... 83
Change the direction of travel .......................................... 37
Change the hydraulic fluid ................................................ 81
Changing the battery (hoist method) ................................ 32
Changing the battery (roll on, roll off) .............................. 33
Changing the supervisor PIN ........................................... 59
Charging the battery ......................................................... 29
Chassis .............................................................................. 12
Check and adjust the parking brake ................................ 73
Check condition of brake pipes ........................................ 80
Check condition of side guide rollers ............................... 77
Check drive wheel nuts .................................................... 72
Check the battery condition, electrolyte
level and specific gravity ............................................... 31
98
Page
Check the brake fluid level ............................................... 78
Check the condition and security of
motor and battery connectors and cables .................... 76
Check the condition for leakage resistance
of the traction wheel ................................................ 27
Check the condition of the wheels and tyres ................... 71
Check the forks and fork quick-releases ................... 35
Check the hydraulic hoses and pipes for damage .......... 73
Check the hydraulic oil level ............................................ 76
Check the insulation and leakage resistance ........... 71
Check the mast and lift chains for condition
and security .................................................................... 73
Check the traction motor brake band and load wheel
shoes for wear and adjustment ..................................... 79
Checking state of battery charge ...................................... 29
Checks and services prior to initial operation
of the truck ...................................................................... 27
Clean the gas warning system sensors ..................... 72
Clean the lift truck ............................................................. 70
Closed circuit television .................................................... 64
Composite instrument for gas warning system ........ 21
Condition code .................................................................. 61
Condition display .............................................................. 19
Connect the version 2 battery (protected against
accumulations of dust) to a suitable external battery
charger ........................................................................... 31
Connecting the battery (Version 1) to an external
charger ........................................................................... 30
Controls and their operation ............................................. 35
D
Daily checks and services before operation .................... 27
Daily checks ...................................................................... 27
Description .......................................................................... 5
Destacking a load (shelf mode) ....................................... 57
Destacking a load ............................................................. 56
Disable/enable the truck ................................................... 59
Displaying the current selected zone ............................... 55
Page
Drive and transmission ..................................................... 12
Drive wheel position indicator .......................................... 18
Driving ............................................................................... 36
Dual-pedal model ............................................................. 37
Electric circuit diagram (Gas warning system) ................. 96
Electric circuit diagram (standard equipment) ................. 90
Electrical system ............................................................... 12
Emergency isolator button ................................................ 44
Emergency lower .............................................................. 51
Emergency steering and parking brake release ............. 51
115 804 2581.0505
Engaging the parking brake ............................................. 39
Experts .............................................................................. 23
Explosion protection check ........................................ 26
F
Foreword ............................................................................. 2
Frequency characteristic for human body vibrations ...... 26
Fuses (ancillary circuits) ................................................... 49
Fuses (main circuit) ........................................................... 49
Fuses ................................................................................. 49
G
Gas warning system ................................................... 13
Gas warning system (compression-proof enclosure)
overheating monitoring warning light) .......................... 22
Gear oil .............................................................................. 86
General information .......................................................... 65
General purpose oil .......................................................... 86
General view of truck ........................................................ 14
Grease the load wheel bearings ...................................... 80
 Index
Page
H
Handling fluids and lubricants .......................................... 25
Handling lubricants ........................................................... 65
Height preselector system ................................................ 55
Hoisting the truck with a crane ......................................... 52
Hour meter for truck .......................................................... 17
Hour meter ........................................................................ 21
Hydraulic footbrake ........................................................... 39
Hydraulic oil ...................................................................... 86
Hydraulic system piping ................................................... 88
I pulleys ............................................................................ 74
Initialising the system ........................................................ 55
115 804 2581.0505
Inspect and recalibrate the gas
warning system ........................................................ 72
Inspect and recalibrate the gas
warning system sensors ......................................... 72
Inspection and maintenance after the first 50 hours of
operation ........................................................................ 67
Inspection and maintenance as required ........................ 70
1000-hour inspection and maintenance .......................... 73
2000-hour inspection and maintenance .......................... 78
5000-hour inspection and maintenance .......................... 80
10000-hour or 5-year inspection and maintenance ........ 83
Inspection and maintenance chart ................................... 68
Inspection and maintenance data .................................... 85
Introduction ........................................................................ 12
J
Jack locations when changing wheels ............................ 50
L
Lift height indicator ............................................................ 57
Lift motor overheating warning light ................................. 22
Lift pump motor overheating warning light ...................... 22
Page
List operator PIN numbers ................................................ 60
Loading ............................................................................. 46
Logging off ........................................................................ 58
Logging on ........................................................................ 58
Lowering the fork carriage ................................................ 42
Lubricate the battery trolley slides and associated
mechanism .................................................................... 76
Lubricate the fork carriage and sideshift slider pad ........ 77
Lubricate the lift chains and mast channels ..................... 70
Lubricate the mast, mast rollers, lift chains and chain
Lubricate the reach channels and rollers ........................ 75
M P
Maintenance ..................................................................... 65
Maintenance and safety guidelines ................................. 65
Mast removal ..................................................................... 67
Mast unit and reach frame ................................................ 67
Mast, hydraulics and reach frame .................................... 12
Measures before taking the truck out of operation .......... 66
Motor brushes wear indicator ........................................... 18
Mounting and dismounting the truck ................................ 36
Multi-purpose display ....................................................... 17
Multipurpose grease ......................................................... 86
N
Noise emission data ......................................................... 26
O
Open the motor compartment cover ................................. 28
Opening the top cover ...................................................... 28
Operating controls and indicators - dual-pedal model .... 15
Operating controls and indicators - single-pedal model . 16
Operating the attachments ................................................ 42
Page
Operating the sideshift ...................................................... 42
Operation ..................................................................... 36, 61
Operation (shelf mode) ..................................................... 57
Operation of horn .............................................................. 44
Operation of industrial trucks in the plant area ................ 26
Operator code entry .......................................................... 58
Operator’s compartment and controls .............................. 12
Operator’s display ............................................................. 17
Overheating warning light for traction motor brake or
straddle leg wheel brake ............................................... 22
Overheating warning lights ................................ 19, 22
Parking brake warning light .............................................. 20
Parking brake .................................................................... 39
Perform the motor brushes wear check ........................... 78
Positioning the forks ......................................................... 46
Putting the truck back into operation ................................ 66
R
Raising the fork carriage ................................................... 42
Reaching the battery out ................................................... 30
Reaching the mast back ................................................... 42
Reaching the mast out ...................................................... 42
Recommended lubricants ................................................ 86
Regenerative traction brake ............................................. 39
Releasing the parking brake ............................................ 39
Removing the floor plate ................................................... 28
Renew the hydraulic return line filter ............................... 82
Renew the hydraulic tank breather filter .......................... 79
Renew/replace the hydraulic hoses ................................. 71
Replace the motor brushes .............................................. 71
Running-in instructions ..................................................... 26
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Index
Page Page

S
Safety guidelines .............................................................. 65
Safety information ............................................................. 25
Safety inspection ........................................................ 26
Safety rules ........................................................................ 23
Seat adjustments ............................................................... 34
Securing the mast ............................................................. 67
Securing the reach frame against reaching in or out ...... 67
Selecting a new zone ....................................................... 55
Service warning light ........................................................ 19
Set/reset learner operation ............................................... 60
Side guidance for drive-in racking ................................... 53
Side guidance ................................................................... 53
Single control lever operation of mast and
attachments .................................................................... 43
Transporting a load ........................................................... 48
Transporting the truck on a lorry or low-bed trailer ......... 52
Travel with the forks leading ............................................. 37
Travel with the forks trailing .............................................. 37
Troubleshooting guide (hydraulic system) ...................... 87
Truck data acquisition - default setting
(PIN number and condition code) ................................. 62
Truck data acquisition - special setting (PIN number) ..... 63
Truck data acquisition ....................................................... 61
Truck Data Management (LFM) ........................................ 61
Truck takeover ..................................................................... 3
Type plates .......................................................................... 5

115 804 2581.0505

Single-pedal model .......................................................... 38
Slinging the truck .............................................................. 50
Slow speed indicator ........................................................ 20 Unloading .......................................................................... 48
Stacking a load (shelf mode) ............................................ 57
Stacking a load .................................................................. 56
Starting on an incline ........................................................ 36
Steering column adjustment ............................................. 34
Steering drive gears ......................................................... 86
W
Wheel change ................................................................... 50
Steering motor overheating warning light ........................ 22 Work on the mast and the reach frame part of the truck .. 67
Steering system ................................................................. 41
Steering ....................................................................... 12, 41
360° steering ..................................................................... 54

T
Table of contents ................................................................. 7
Taking the truck out of operation ...................................... 66
Technical data ................................................................... 10
Technical description ........................................................ 12
Technical note ..................................................................... 3
The mast ............................................................................ 67
Tilting the fork carriage back ............................................ 42
Tilting the fork carriage forward ........................................ 42
Towing instructions ........................................................... 52
Traction motor overheating warning lights ...................... 22

100