Linde Electric Reach Truck Type 1120: R14, R16, R20, R25 Operating Instructions (User Manual)

Electric reach truck Original instructions R14, R16, R20, R25 1120 801 1501 EN – 10/2012

Preface g Linde − Your Partner With over 100,000 fork lift trucks and ware- house machines sold annually, Linde is one of the world’s leading manufacturers of material handling equipment. There are many reasons for this success: Linde products are renowned not only for their innovative, cutting-edge tech- nology, but also for their low energy and operating costs, which are up to 40 per cent lower than those of their competitors. The high quality of Linde products is also matched by the quality of our service. With ten production plants worldwide and an extensive network of sales partners, we are at your service round the clock and around the world. Your local Linde partner can offer you a complete package from a single source; ranging from expert advice on all aspects of sales and service through, of course, to appropriate ﬁnance options. Our leasing, hire or lease-purchase agreements provide you with the ﬂexibility to tailor decision-making to your individual business requirements. Linde Material Handling GmbH Carl-von-Linde-Platz 63743 Aschaffenburg Telephone +49 (0) 6021 99-0 Fax +49 (0) 6021 99-1570 Mail: info@linde-mh.com Web: http://www.linde-mh.com Operating Instructions – 1120 801 1501 EN – 10/2012 I

Table of contents g 1 Introduction Your industrial truck ................................................... 2 Intended use ........................................................ 2 Impermissible use .................................................... 4 Description of use and climatic conditions ................................... 4 Symbols used ....................................................... 5 General description ................................................... 6 Taking delivery of the industrial truck ....................................... 7 Legal requirements for placing on the market ................................ 8 2 Safety Safety guidelines .................................................... 10 Inclines, ramps, docks and lifts .......................................... 12 Residual risks ...................................................... 12 Stability ........................................................... 13 In the event of tip-over ................................................ 13 Handling consumables ................................................ 14 Competent person ................................................... 14 Regulations ........................................................ 14 3 Overview Identiﬁcation plates and labels .......................................... 18 Nameplate ......................................................... 19 Capacity rating plate ................................................. 20 Controls and indicators ............................................... 22 Operator’s display ................................................... 26 Lift height indicator (LHI) .............................................. 34 Deﬁnition of direction of travel ........................................... 36 4 Operation Instructions for running-in .............................................. 38 Pre-shift checks ..................................................... 39 Service plan ........................................................ 39 Check the battery state of charge ........................................ 40 Operating Instructions – 1120 801 1501 EN – 10/2012 III

Table of contents g Check all controls and their operation ..................................... 40 Check the battery securing latch ......................................... 41 Check general condition of truck ......................................... 41 The battery ........................................................ 42 Operator adjustments ................................................ 48 Braking – twin pedal .................................................. 50 Braking – single pedal ................................................ 52 Driving – twin pedal .................................................. 54 Driving – single pedal ................................................. 56 Driving on upward and downward slopes .................................. 59 Operating the mast and attachments (with two joystick control) .................. 60 Operating the mast and attachments (with four joystick control) .................. 64 Working with a load .................................................. 67 Before picking up a load ............................................... 67 Picking up a load .................................................... 70 Driving with a load ................................................... 71 Setting down loads ................................................... 71 Before exiting the truck ................................................ 72 Special equipment ................................................... 73 Lighting (options) .................................................... 73 360° Steering (Option) ................................................ 75 Opposite direction steering (Option) ...................................... 76 Linde Forklift data Management – LFM (Option) ............................. 77 Closed circuit television ............................................... 81 IV Operating Instructions – 1120 801 1501 EN – 10/2012

Table of contents g 5 Maintenance Maintenance safety guidelines .......................................... 84 Covers and cowlings ................................................. 86 Fuses ............................................................ 89 Emergency lower .................................................... 91 Emergency steering and parking brake release .............................. 91 Jacking the truck .................................................... 92 Hoisting the truck .................................................... 94 Securing for transportation ............................................. 96 Towing procedure ................................................... 97 Mast unit .......................................................... 98 Lubricants and operating materials ....................................... 100 Inspection and maintenance data ........................................ 102 Routine inspection and maintenance ..................................... 103 Maintenance schedules — standard ...................................... 104 Service plan — as required ............................................. 104 1000-hour service plan ................................................ 105 3000 h Service plan .................................................. 107 6000 h Service plan .................................................. 109 Maintenance schedules — cold store ..................................... 111 Service plan — as required (cold store version) .............................. 111 500-hour service plan (cold store version) .................................. 112 1500-hour service plan (cold store version) ................................. 114 3000-hour service plan (cold store version) ................................. 116 Motor ............................................................. 118 Check the parking brake gap ........................................... 118 Chassis, bodywork and fittings .......................................... 119 Clean the truck ...................................................... 119 Check the battery trolley slides and associated mechanism ..................... 120 Lubricate the cabin hinges and door latch (if fitted) ............................ 121 Check condition of side guide rollers (if fitted) ............................... 121 Undercarriage ...................................................... 122 Checking the condition and security of the wheels and tyres ..................... 122 Check the brake fluid level ............................................. 123 Check condition of brake pipes .......................................... 124 Check the load wheel brake shoes for wear ................................. 124 Change the brake fluid ................................................ 125 Operating Instructions – 1120 801 1501 EN – 10/2012 V

Table of contents g Electrics/electronics .................................................. 126 Check the condition of the battery and battery cables .......................... 126 Check the condition and security of electrical connections and cables ............. 127 Hydraulic system .................................................... 128 Check the hydraulic hoses and pipes for damage ............................ 128 Hydraulic system: Checking the oil level ................................... 129 Check the hydraulic return line filter ....................................... 130 Replace the hydraulic tank breather filter ................................... 130 Changing the hydraulic oil ............................................. 131 Replace the hydraulic return line filter ..................................... 133 Load lift system ..................................................... 134 Check the lift chains for condition and security ............................... 134 Lubricate the mast channels, mast rollers, lift chains, chain pulleys and mast hose pulley assemblies .................................................. 134 Lubricate the reach channels and rollers ................................... 135 Check the reach carriage rollers, adjust if required ............................ 136 Lubricate the fork carriage ............................................. 136 Lubricate the tilt and sideshift slider pad ................................... 137 Shutting down ...................................................... 138 Taking the truck out of operation ......................................... 138 Decommissioning the truck ............................................ 138 VI Operating Instructions – 1120 801 1501 EN – 10/2012

Table of contents g 6 Technical data Dimensions ........................................................ 140 Type sheet R14N (narrow version), as at 07/2012 ............................ 141 Type sheet R14, as at 07/2012 .......................................... 144 Type sheet R14HD (heavy load version), as at 07/2012 ........................ 147 Type sheet R16N (narrow version), as at 07/2012 ............................ 150 Type sheet R16, as at 07/2012 .......................................... 153 Type sheet R16HD (heavy load version), as at 07/2012 ........................ 156 Type sheet R20N (narrow version), as at 07/2012 ............................ 159 Type sheet R20, as at 07/2012 .......................................... 162 Type sheet R16HD (heavy load version), as at 07/2012 ........................ 165 Type sheet R25, as at 07/2012 .......................................... 168 Mast variations ..................................................... 171 Battery data ........................................................ 174 Wheels and tyres .................................................... 177 Noise emission levels ................................................. 177 Vibration characteristics for body vibrations ................................ 178 Operating Instructions – 1120 801 1501 EN – 10/2012 VII

1 Introduction

1 Introduction Intended use Your industrial truck offers optimum efficiency, safety and driving comfort. It is primarily down to you to maintain these characteristics for a long time and to take advantage of the resulting benefits. During manufacture: • All safety requirements of the relevant EC directives were observed • All conformity assessment procedures stipulated in the applicable directives were carried out This is confirmed by the CE mark on the nameplate. These operating instructions contain every- thing you need to know about commissioning, driving and maintenance. Carry out the specified work regularly, at the due times and using the consumables envisaged for this purpose in accordance with the inspection and maintenance overview. Please make sure that you record any work performed in the registration document for the industrial truck; this is essential for any warranty claims. Servicing work not described here will require specialist knowledge, measuring devices and often also special tools. Please ask your authorised dealer to carry out this work. Servicing should only be carried out by qual- ified personnel approved by Linde (special- ists). When ordering parts, please specify the following along with the parts numbers: Truck model: Serial number/year of manufacture: Handover date: The production number must also be specified for parts from the following units: en- gine, lift mast, hydraulic variable displacement pump, planetary transmission and steering axle. Lift mast number: Lift mast lift: When taking over the truck, this data should be copied from the identification plates of the units into these operating instructions. NOTE In the event of repairs, only use genuine Linde spare parts. This is the only way to guarantee that your truck remains in the same technical condition as at the time of reception. Please address all queries and orders for spare parts relating to your truck only to your authorised dealer, stating your mailing address. Linde is constantly engaged in the further development of its products. We ask for your understanding that figures and technical data are subject to technical modifications in terms of form, equipment and expertise in the interest of progress. For this reason, no claims can be made on the basis of the following data, figures and descriptions in these operating instructions. These operating instructions must not be reproduced, translated or made accessible to third parties—even in part—except with the express written approval of the manufacturer. Intended use The industrial truck may only be used as permitted. The industrial truck is used for moving and lifting the loads indicated on the capacity rating plate. 2 Operating Instructions – 1120 801 1501 EN – 10/2012

Introduction 1 Intended use Damages and defects Damages and other defects to industrial trucks or to attachments must be reported to the Supervisor immediately. Industrial trucks and attachments which are not safe to operate may not be used until they have been properly repaired. Safety installations and switches may not be removed or rendered unusable. Specified settings may only be changed with the approval of the manufacturer. Danger areas Danger areas are those areas in which persons are in danger as a result of the movements of industrial trucks, their operating equipment, their load carrying devices (e.g. their attachments) or the loaded goods. This also includes the area which can be reached by falling goods or lowering or falling operating equipment and devices. No other persons may stand in the danger area of an industrial truck. Working areas Only the areas approved by the operator or his representative may be used for transportation purposes. Loads may only be deposited or stored at the intended places. Driving routes Driving routes shall be sufficiently paved, level and free of objects. Drain channels and railways crossings, etc., shall be levelled and, if necessary, covered with ramps in such a way that they can be driven over without bumps as far as possible. Industrial trucks shall only be used on routes without sharp curves, excessive slopes and gates which are too narrow or too low. Inclines used by industrial trucks shall not ex- ceed the limits specified by the manufacturer and must have an adequately rough surface. Level and smooth transitions at the upper and lower end shall prevent the load from touching the floor or causing damages to the chassis. The admissible area and point load of driving lanes or routes may not be exceeded. There shall be an adequate clearance between the highest parts of industrial trucks or the load and the fixed parts of the surrounding areas. The EU Directive 89/654/EEC (Minimum Regulations for Health and Safety at Work) shall be observed. The respective national regulations apply for non-EU countries. Danger points on driving lanes or routes shall be secured or marked by the customary road traffic signs and by additional warning signs, if necessary. When driving on public roads, the corresponding regulations must be observed, as well as country-specific restrictions for winter road conditions. Fire protection The operator is responsible for adequate fire protection in the vicinity of the industrial truck. Depending on the form of use, he is responsible for additional fire protection on the industrial truck. Enquiries should be directed to the responsible supervisory authority in case of doubt. Attachments Attachments shall only be used as permitted. The driver shall be instructed in the handling of attachments. The attachment operating instructions are en- closed for trucks that are delivered from the factory with an attachment. Before commissioning a truck with an attachment, you must check that loads are handled securely. De- pending on the type of attachment, it may be necessary to make adjustments, e.g. pres- sure settings or adjusting stops and operating speeds. See the attachment operating instructions for the corresponding instructions. If attachments are not supplied with the industrial truck, the specifications of the industrial Operating Instructions – 1120 801 1501 EN – 10/2012 3

Linde Electric Reach Truck Type 1120: R14, R16, R20, R25 Operating Instructions (User Manual)

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