Linde Electric Reach Truck Type 115: R14, R14HD, R16, R16HD, R16N, R20, R20N Operating Instructions (User Manual)

Operating Instructions Linde Electric Reach Truck R 14 / R 14 HD / R 16 / R 16 N R 16 HD / R 20 / R 20 N 1206 115 804 2501 GB 115-02

Linde - Your Partner Linde, an enterprise operating worldwide in the investment and service sector, is one of the largest industrial enterprises in the EC with its four divisions and over 80 associated com- panies. Linde is a leading manufacturer of industrial trucks and hydraulics. It includes seven manufacturing plants in the Federal Republic of Germany, France and Great Britain, as well as subsidiaries and branches in all economically important countries. Linde industrial trucks enjoy a worldwide reputation - thanks to their high quality in engineering, performance and service. Linde AG Linde Material Handling Division Werk II, Aschaffenburg-Nilkheim Werk I, Aschaffenburg Linde Material Handling (UK) Ltd., Basingstoke Fenwick-Linde, Châtellerault Werk III, Kahl am Main Linde Heavy Truck Division Ltd., Merthyr Tydfil

2 115 804 2501.1206 Description Your Linde lift trucks offer the best in economy, safety and driving convenience. However, preserving the qualities of the truck for a long and profitable service life, and making full use of their benefits in operation, relies mainly on the operator. This Operating Instructions manual tells you all you must know about starting, running, servicing and maintaining your Linde lift truck. Follow the instructions for operating the lift truck and carry out the maintenance and care prescribed in the maintenance plan regularly and on time. To keep your warranty valid and to ensure safety, all maintenance should only be carried out by qualified persons authorised by Linde. Approved applications Linde trucks are designed for transporting and lifting loads stated on the load capacity plate within a temperature range of 40°C down to -10°C standard, or -30°C as an option. In particular, we refer to the attached booklet (VDMA or BITA for UK market) concerning the safe operation and accident prevention for fork lift trucks, to the safety guidelines for gas vehicles and the regulations for use of the truck on public roads. The booklet for users of industrial and rough terrain trucks (VDMA or BITA for UK market) must be followed under all circumstances by the operator and service personnel. The user, and not Linde, is responsible for any accidents aris- ing from applications not authorised by the manufacturer. Should you want to use the forklift truck for applications not covered in these instructions, please contact your local Linde representative. No modifications or conversions may be made, or additional equipment fitted to your fork lift truck, without prior permission of the manufacturer. For attachments: the operating instructions supplied by the attachment manufacturer are applicable.

3 115 804 2501.1206 Description 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 improvement in design and manufacture of its products. The illustrations and technical details referring to design, fittings and engineering of lift trucks are subject to change or modification as a result of technological progress by Linde. Linde is therefore unable to consider any claims based on the specification, illustrations and descriptions contained in this Operating Instructions manual. Please submit all enquiries concerning Linde fork truck or- ders for spare parts to your local Linde representative, making sure to give the correct delivery address. For repairs use only original Linde spare parts. Only in this way can it be guaranteed that your Linde fork lift truck main- tains its original technical standard. When ordering spare parts, please specify the part number and state the following truck data. Lift Truck Type__________________________________ Manufacturer’s Serial No./Year built :_________________ Delivery Date :____________________________________ Please also specify the production number of the mast, when ordering mast parts. Mast No :________________________________________ Mast Lift Height :_______________________________mm When taking over the fork lift truck, transfer the data from the type plates into this Operating Instructions manual. This information can be found on the type plates on the truck. We rec- ommend that you transfer this information to this manual for ease of future reference. Truck takeover Every Linde lift truck undergoes careful inspection before leaving the factory in order to make sure that it will be in good condition and fully equipped as ordered when delivered. Your local Linde representative is under obligation to re-in- spect the truck before delivery and to hand it over in full working order. In order to avoid later complaints and inconvenience to cus- tomers, you are requested to ascertain that the truck is in satisfactory condition and fully equipped at the time of delivery and to acknowledge the correct installation of the truck in the manufacturers certificate of conformity. The following technical documents belong to each fork lift truck: 1 Operating Instructions manual 1 EC Certificate of Conformity The manufacturer certifies that the industrial truck con- forms to all relevant EC directives. 1 Spare Parts Catalogue 1 Booklet for users of industrial and rough terrain trucks (VDMA or BITA for UK market)

5 115 804 2501.1206 Type plates 1 Truck type/capacity plate 2 Truck type 3 Manufacturer 4 EC symbol (The symbol certifies that all relevant EC directives 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 11 Serial number 12 Attachment capacity plate } Stamped 115-03 10 1 12 11

6 115 804 2501.1206 Electric reach truck R 14, R 14 HD, R 16, R 16 N, R 16 HD, R 20, R 20 N The 115 series of three wheel electric reach trucks fully com- ply with all relevant EC directives, and have been developed to suit a wide range of applications. The main design features result from a thorough analysis of materials handling requirements and will ensure maximum productivity. The operator’s compartment and controls are arranged according to the latest ergonomic findings. Each operating func- tion is tailored to suit the operator both in terms of layout and ease of operation, thus ensuring safe and fatigue-free operation. 115-02

7 115 804 2501.1206 Table of contents Description Approved applications ............................................ 2 Technical note ........................................................ 3 Truck takeover ........................................................ 3 Type plates .............................................................. 5 Technical data ........................................................ 9 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 General view of truck .............................................. 13 Operating controls and indicators - dual pedal ..... 14 Operating controls and indicators - single pedal .. 15 Operator's display .................................................. 16 Multi purpose display ........................................ 16 Hour meter ........................................................ 16 Battery discharge indicator ............................... 17 Drive wheel position indicator .......................... 17 Motor brushwear indicators .............................. 17 Over temperature indicators ............................. 18 Interlock warning indicator ................................ 18 Brake fluid level indicator .................................. 18 Service warning indicator ................................. 18 Parking brake warning ...................................... 19 Battery unlocked warning ................................. 19 Slow speed indicator ........................................ 19 Before operation Safety rules ............................................................. 20 Safety information ................................................... 20 Report of Thorough Examination ........................... 21 Noise emission levels ........................................... 21 Frequency characteristic for human body vibrations ................................................................ 21 Running-in instructions .......................................... 21 Checks prior to initial operation ............................. 21 Daily checks ........................................................... 21 Open the motor cover ....................................... 22 Removing the floorplate ................................... 22 Opening the top cover ....................................... 22 Checking state of battery charge ...................... 23 Charging the battery ......................................... 23 Connecting the battery to an external charger .. 23 Reaching the battery out ................................... 24 Check the battery condition, electrolyte level and specific gravity ............................................ 24 Changing the battery (hoist method) ................. 25 Changing the battery (roll on, roll off) ................ 26 Steering column adjustment .............................. 27 Seat adjustments ............................................... 27 Controls and their operation ............................. 28 Interlock switches ............................................. 28 Operation Driving ..................................................................... 29 Starting on an incline .............................................. 29 Mounting and dismounting the truck ...................... 29 Operating controls - dual pedal ............................. 30 Driving ............................................................... 30 Travel with the forks trailing .............................. 30 Travel with the forks leading ............................. 30 Change the direction of travel ........................... 30 Operating controls - single pedal .......................... 31 Driving ............................................................... 31 Travel with the forks trailing .............................. 31 Travel with the forks leading ............................. 31 Change direction of travel ................................. 31 Braking - dual pedal ............................................... 32 Brakes ............................................................... 32 Regenerative traction brake ............................. 32 Hydraulic footbrake ........................................... 32 Parking brake .................................................... 32 Engaging the parking brake ............................. 32 Releasing the parking brake ............................ 32 Braking - single pedal ............................................ 33 Brakes ............................................................... 33 Regenerative traction brake ............................. 33 Hydraulic footbrake ........................................... 33 Parking brake .................................................... 33 Engaging the parking brake ............................. 33 Releasing the parking brake ............................ 33 Steering ................................................................... 34 Turning radius ........................................................ 34 Operation of mast and attachments (with Linde Load Control) ........................................ 35 Raising the fork carriage ................................... 35 Lowering the fork carriage ................................. 35 Reaching the mast out ...................................... 35 Reaching the mast back .................................... 35 Tilting the fork carriage forward ......................... 35 Tilting the fork carriage back ............................. 35 Operating the sideshift ...................................... 35 Operating the attachments ................................ 35 Operation of mast and attachments (four lever control) ................................................... 36 Raising the fork carriage ................................... 36 Lowering the fork carriage ................................. 36 Reaching the mast out ...................................... 36 Reaching the mast back .................................... 36 Tilting the fork carriage forward ......................... 36 Tilting the fork carriage back ............................. 36 Operating the sideshift ...................................... 36 Operating the attachments ................................ 36 Operation of horn .................................................... 37 Emergency isolator ................................................. 37 Load capacity example ........................................... 38 Positioning the forks ............................................... 39 Destacking a load ................................................... 39 Transporting a load ................................................. 41 Stacking a load ........................................................ 41 Before leaving the truck .......................................... 41 Fuses (main circuit) ............................................... 42

8 115 804 2501.1206 Table of contents (continued) Fuses (ancillary circuits) ........................................ 42 Slinging the truck .................................................... 43 Jack locations when changing wheels .................. 43 Emergency lower .................................................... 44 Emergency steering and parking brake release ... 44 Towing procedure ................................................... 45 Cold store cab ........................................................ 46 Side guidance for drive in racking .......................... 48 360° steering .......................................................... 48 Lift Height Indicator (LHI) ........................................ 49 Height preselector (LPS mode) ............................. 53 Height preselector (LPS0 mode) ........................... 57 Operator code entry ................................................ 60 Data logger ............................................................. 63 Closed circuit television ......................................... 63 Maintenance Maintenance and safety guidelines ....................... 64 General information .......................................... 64 Handling lubricants .......................................... 64 Avoiding accidents ............................................ 65 Safety guidelines .............................................. 65 Measures before taking the truck out of operation 66 Putting the truck back into operation ...................... 66 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 Securing the mast .................................................. 67 Inspection and maintenance after the first 50 hours of operation .................................................. 68 Lubrication intervals ............................................... 68 Inspection and maintenance schedule ................. 69 Inspection and maintenace as required Clean the truck ........................................................ 71 Lubricate the lift chains and mast channels .......... 71 Adjust the lift chains ............................................... 72 Renew the motor brushes ..................................... 72 Renew the hydraulic hoses ................................... 73 Check drive wheel nuts. ......................................... 73 Replace the battery trolley slides ........................... 73 1000 Hour inspection and maintenance (250 hours cold store) Check and adjust the parking brake ...................... 74 Check the hydraulic hoses and pipes for damage 74 Check the mast and lift chains for condition and security .................................................................... 74 Lubricate the mast, mast rollers, lift chains and chain pulleys ........................................................... 75 Lubricate the mast hose pulley assemblies ......... 75 Lubricate the reach channels and rollers .............. 76 Check the condition of the wheels and tyres ......... 76 Check and lubricate the battery trolley slides and associated mechanism ......................................... 77 Check the condition and security of motor and battery connectors and cables ............. 77 Check the hydraulic oil level ................................... 77 Lubricate the fork carriage and sideshift slider pad ................................................................ 78 Check condition of side guide rollers .................... 78 Lubricate cold store cab hinges and door latch .... 78 2000 Hour inspection and maintenance (1000 hours cold store) Visual check of motor brushes .............................. 79 Check the brake fluid level ..................................... 79 Check the traction motor brake band and load wheel shoes for wear and adjustment .................. 80 Renew the hydraulic tank breather filter ................. 80 Check the reach carriage rollers, adjust if required ................................................................ 80 5000 Hour inspection and maintenance (2500 hours cold store) Check condition of brake pipes ............................. 81 Grease the load wheel bearings ........................... 81 Change the hydraulic fluid ...................................... 82 Renew the hydraulic suction line filter ................... 83 10000 Hour or 5 year inspection and maintenance (5000 hours or 30 months cold store) Change the brake fluid ........................................... 84 Inspection and maintenance data ................................. 85 Recommended lubricants ............................................. 86 Hydraulic oil ............................................................ 86 Multipurpose grease .............................................. 86 Gear oil ................................................................... 86 General purpose oil ............................................... 86 Chain Spray ............................................................ 86 Brake fluid ............................................................... 86 Troubleshooting guide (hydraulic system) .................... 87 Hydraulic system piping ................................................. 88 Circuit diagram ............................................................... 89 Circuit diagram - lighting ................................................ 94 Circuit diagram - CCTV .................................................. 95 Circuit diagram - cabin ................................................... 96 Index .......................................................................... 99

9 115 804 2501.1206 Technical data Description m /m 1 2 Q 218 - 1250 wide 224 - 1080 wide e a 2 a 2 a 2 = 100mm b 5 b 2 b 11 b 4 b 3 A st W a b 10 b 1 y l 2 x l 7 l 1 h 4 h 3 h 1 h 2 a b h 6 h 7 h 8 l s c l 4

10 115 804 2501.1206 Technical data Description 1.1 Manufacturer Linde Linde Linde Linde Linde Linde Linde 1.2 Model designation R 14 R 16 R 16 N R 16 HD R 20 R 14 HD R 20 N 1.3 Power unit: battery, diesel, petrol, LP gas, mains power Battery Battery Battery Battery Battery Battery Battery 1.4 Operation: Manual, pedestrian, stand-on, seated, order picker Seated Seated Seated Seated Seated Seated Seated 1.5 Load capacity 1.4 3) (t) 1.6 3) 1.6 3) 1.6 3) 2.0 3) 1.4 3) 2.0 3) 1.6 Load centre 600/500 (mm) 600/500 600/500 600/500 600/500 600/500 600/500 1.8 Axle centre to fork face 311 (mm) 416 346 380 475 270 385 1.9 Wheelbase 2.1 Service weight 2.3 Axle load without load, front (drive)/rear (load) 2.4 Axle load, fork outreached with load, front (drive)/rear (load) 2.5 Axle load, fork retracted with load, front (drive)/rear (load) 1 275 (mm) 1 385 1 385 1 385 1 520 1 275 1 520 2 890 4) kg 2 940 4) 2 820 4) 3 070 4) 3 260 4) 3 020 4) 3 100 4) 1 800/1 090 4) kg 1 900.1 040 4) 1 760.1 060 4) 1 995/1 075 4) 2 120/1 140 4) 2 830/1 190 4) 1 840/1 260 4) 520/3 770 4) kg 530/4 010 4) 465/3 955 4) 420/4 250 4) 630/4 630 4) 500/3 920 4) 600/4 500 4) 1 485/2 805 4) kg 1 690/2 850 4) 1 460/2 960 4) 1 740/2 930 4) 1 960/3 300 4) 1 480/2 940 4) 1 555/3 545 4) 3.1 Tyres, front (drive)/rear (load) C = cushion rubber, P = polyurethane P/P P/P P/P P/P P/P P/P P/P 3.2 Tyre size, front (drive) wheel 3.3 Tyre size, rear (load) wheel 3.5 Wheels, number front (drive)/rear (load) 330 x 135 mm 330 x 135 330 x 135 330 x 135 330 x 135 330 x 135 330 x 135 285 x 100 mm 285 x 100 285 x 100 285 x 100 350 x 100 285 x 100 350 x 100 1x/2 1x/2 1x/2 1x/2 1x/2 1x/2 1x/2 3.6 Track width, front (drive) 3.7 Track width, rear (load) 4.1 Mast/fork carriage tilt, forward/backward 0 mm 0 0 0 0 0 0 1 150 mm 1 150 980 1 150 1 150 1 150 980 2/4 a/b (°) 2/4 2/4 2/4 2/4 2/4 2/4 4.2 Height of mast, lowered 4.3 Free lift 4.4 Lift 4.5 Height of mast, extended 4.7 Height of overhead guard (cabin) 4.10 Height of reach legs 4.19 Overall length 4.20 Length to fork face 4.21 Overall width 4.22 Fork dimensions 2 110 h 1 (mm) 2 110 2 110 2 930 2 476 2 930 2 476 1 261 h 2 (mm) 1 261 1 261 2 081 1 627 2 081 1 627 4 655 1) h 3 (mm) 4 655 1) 4 655 1) 6 355 1) 4 655 1) 6 355 1) 4 655 1) 5 395 h 4 (mm) 5 395 5 395 7 139 5 395 7 139 5 395 2 110 h 6 (mm) 2 110 2 110 2 110 2 110 2 110 2 110 4.8 Height of seat, minimum/maximum 940/1 030 h 7 (mm) 940/1 030 940/1 030 940/1 030 940/1 030 940/1 030 940/1 030 310 h 8 (mm) 310 310 310 373 310 373 2 184 l 1 (mm) 2 189 2 265 2 225 2 261 2 225 2 261 1 184 l 2 (mm) 1 189 1 265 1 225 1 261 5) 1 225 1 361 1 234/1 250 b /b 1 2 (mm) 1 234/1 250 1 054/1 080 1 234/1 250 1 234/1 250 6) 1 234/1 250 6) 1 054/1 080 40 x 80 x 1 000 s/e/l (mm) 45 x 100 x 1 000 45 x 100 x 1 000 45 x 100 x 1 000 45 x 100 x 1 000 45 x 100 x 1 000 45 x 100 x 1 000 4.23 Fork carriage to DIN 15173, class/form A,B 2A 2A 2A 2A 2A 2A 2A 4.24 Width of fork carriage 4.25 Fork spread, minimum/maximum 830 b 3 (mm) 830 830 830 830 830 830 296/690 b 5 (mm) 316/710 316/520 316/710 316/710 316/710 316/520 4.26 Width between reach legs 922 b 4 (mm) 922 752 922 922 922 752 4.28 Reach travel 496 l 4 (mm) 606 536 570 695 460 608 4.32 Ground clearance, centre of wheelbase 75 m 2 (mm) 75 75 75 75 75 75 4.33 Aisle width with pallet 1000 x 1200 across forks 2 655 (2 430) 9) Ast (mm) 2 675(2 425) 9) 2 710 (2 475) 9) 2 705 (2 460) 9) 2 770 (2 500) 5) 9) 2 685 (2 470) 9) 2 810 (2 565) 5) 9) 4.34 Aisle width with pallet 1000 x 1200 along forks 4.35 Turning radius 4.37 Length of chassis 5.2 Lifting speed, with/without load 5.3 Lowering speed, with/without load 5.7 Climbing ability, with/without load, 30 minute rating Characteristics Weights Wheels and tyres Dimensions Performance Drive Other 2 715 (2 630) 9) Ast (mm) 2 720 (2 625) 9) 2 765(2 675) 9) 2 800 (2 660) 9) 2 805 (2 700) 5) 9) 2 750 (2 670) 9) 2 860 (2 765) 5) 9) 1 540 W a (mm) 1 640 1 620 1 640 1 775 1 540 1 750 1 638 l 7 (mm) 1 748 1 754 1 748 1 911 1 638 1 921 5.1 Travel speed, with/without load 12/12.5 4) 10) km/h 12/12.5 4)10) 12/12.5 4)10) 12/12.5 4)10) 12/12.5 4)10) 12/12.5 4)10) 12/12.5 4)10) 0.34/0.6 4) m/s 0.34/0.6 4) 0.34/0.6 4) 0.3/0.48 4) 0.3/0.48 4) 0.32/0.49 4) 0.3/0.48 4) 0.55/0.45 4) m/s 0.55/0.45 4) 0.55/0.45 4) 0.55/0.4 4) 0.55/0.4 4) 0.55/0.45 4) 0.55/0.4 4) 0.15/0.15 4) m/s 0.15/0.15 4) 0.15/0.15 4) 0.15/0.15 4) 0.15/0.15 4) 0.15/0.15 4) 0.15/0.15 4) 5.4 Reach speed, with/without load 4.5/8.2 % 4.7/8.2 4.3/8 3.9/7.1 3.9/7.1 4.5/8.2 3.9/7.2 5.8 Climbing ability, with/without load, 5 minute rating 10/10 % 10/10 10/10 10/10 10/10 10/10 10/10 5.9 Acceleration time, with/without load 5.5/4.8 10) s 5.5/4.8 10) 5.5/4.8 10) 5.8/5 10) 5.8/5 5.8/5 10) 5.8/5 5.10 Service brake Hydraulic/electric Hydraulic/electric Hydraulic/electric Hydraulic/electric Hydraulic/electric Hydraulic/electric Hydraulic/electric 6.1 Drive motor, 60 minute rating 5.4 kW 5.4 5.4 5.4 5.4 5.4 5.4 6.3 Battery according to DIN 43531/35/36 A, B, C, no DIN 43531C DIN 43531C DIN 43531C DIN 43531C DIN 43531C DIN 43531C DIN 43531C 6.4 Battery voltage/rated capacity (5h) 48/420 2) V/Ah 48/420 2) 48/420 2) 48/420 2) 48/560 2) 48/420 2) 48/560 2) 6.5 Battery weight (±5%) 6.6 Power consumption according to VDI cycle 8.1 Type of drive control 8.2 Working pressure for attachments 8.3 Oil flow for attachments 8.4 Noise level at operator's ear 750 kg kW/h 750 746 750 939 750 937 7) 7) 7) 7) 7) 7) 7) Electronic/stepless Electronic/stepless Electronic/stepless Electronic/stepless Electronic/stepless Electronic/stepless Electronic/stepless 200 bar 200 200 200 200 200 200 6.5 l/min 6.5 6.5 6.5 6.5 6.5 6.5 63 8) dB (A) 63 8) 63 8) 63 8) 64 63 64 8) 6.2 Lift motor, 15% rating 12 kW 12 12 12 12 12 12 4.31 Ground clearance, mast 75 m 1 (mm) 75 75 75 75 75 75 / / 8) 8) NOTES: 1. For all other heights, see table. 2. Alternative batteries increase length to fork face and 90° stacking aisle widths. 3. Capacity may be reduced for high lifts. 4. Traction, lift, lower and reach speeds and weights may vary with alternative lift heights. 5. Lift heights 6 400 mm and above increase length to fork face and 90° stacking aisle widths by 27 mm on R 20 and R 20 N 6. Alternative widths over reach legs of 1 400 mm or 1 600 mm are available for R 20 7. Refer to manufacturer for figures. 8. Figure shown without cab; 66dB (A) when cab fitted. 9. Figures shown in brackets are for intrusive stacking. 10. Reduced speed and acceleration on request.

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Linde Electric Reach Truck Type 115: R14, R14HD, R16, R16HD, R16N, R20, R20N Operating Instructions (User Manual)

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