Linde T 16 User manual

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Operating instructionsOperating instructions
T 16 - T 18 - T 20T 16 - T 18 - T 20
360 804 25 11360 804 25 11
03/9703/97

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LinLin
de - Yde - Y
our Paour Pa
rtnerrtner
Linde AGLinde AG
Linde Material Handling DivisionLinde Material Handling Division
Linde, an enterprise operatingLinde, an enterprise operating
worldwide in the investment andworldwide in the investment and
service sector, is one of theservice sector, is one of the
large industrial enterprises inlarge industrial enterprises in
the EC with its three businessthe EC with its three business
segments and six divisions.segments and six divisions.
The Linde Material HandlingThe Linde Material Handling
division is a leading manufac-division is a leading manufac-
turer of industrial trucks andturer of industrial trucks and
hydraulics. It includes eighthydraulics. It includes eight
manufacturing plants in themanufacturing plants in the
Federal Republic Federal Republic
of Germany,of Germany,
France and Great Britain, asFrance and Great Britain, as
well as subsidiaries and bran-well as subsidiaries and bran-
ches in all economically impor-ches in all economically impor-
tant countries.tant countries.
Linde industrial trucks enjoy aLinde industrial trucks enjoy a
worldwide reputation - thanks toworldwide reputation - thanks to
their high quality in engineering,their high quality in engineering,
performance and service.performance and service.
Werk II, Aschaffenburg-NilkheimWerk II, Aschaffenburg-Nilkheim
Werk I, AschaffenburgWerk I, Aschaffenburg
Lansing Linde Ltd., BasingstokeLansing Linde Ltd., Basingstoke
Fenwick-Linde, ChâtelleraultFenwick-Linde, Châtellerault
Werk III, Kahl am MainWerk III, Kahl am Main
Linde Heavy Truck Division Ltd., Merthyr TydfilLinde Heavy Truck Division Ltd., Merthyr Tydfil
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Acceptance of the lift-truckAcceptance of the lift-truck
Before leaving our factory, the truck is subjected to detailedBefore leaving our factory, the truck is subjected to detailed
checks in order to ensure that the equipment reaches youchecks in order to ensure that the equipment reaches you
in perfect operational condition and fully equipped asin perfect operational condition and fully equipped as
ordered. Your local representative will then conduct a finalordered. Your local representative will then conduct a final
inspection and, on delivery of the equipment, will provideinspection and, on delivery of the equipment, will provide
you with all necessary information for its operation andyou with all necessary information for its operation and
servicing.servicing.
In order to avoid any subsequent claims, please make aIn order to avoid any subsequent claims, please make a
careful and personal inspection in order to ensure that thecareful and personal inspection in order to ensure that the
truck is in perfect order, complete with all fittings, at thetruck is in perfect order, complete with all fittings, at the
time of delivery.time of delivery.
The truck is supplied with the following documents:The truck is supplied with the following documents:
1 1
--
OperOper
atinatin
g g
manumanu
al.al.
1 -1 -
SpaSpa
re parts catare parts cata
loglog
ue.ue.
1 1
--
BatterBatter
y serviciy servici
ng manung manu
alal
(electric trucks delivered with battery).(electric trucks delivered with battery).
1 1
--
Charger instCharger inst
ruction maruction ma
nualnual
(for trucks delivered with separate chargers).(for trucks delivered with separate chargers).
1 1
--
CertifiCertifi
cate of confocate of confo
rmity (manrmity (man
ufactuufactu
rer’s certifrer’s certif
icatioicatio
n n
thatthat
the machine complies with European standards).the machine complies with European standards).
1 -1 -
VDMA booVDMA boo
klet regardiklet regardi
ng directing directi
ves on the use ofves on the use of
Handling Trucks in accordance with specifiedHandling Trucks in accordance with specified
applications and regulations.applications and regulations.
We wish you good use and complete satisfaction.We wish you good use and complete satisfaction.
Technical notesTechnical notes
It is expressly prohibited to photocopy, translate or conveyIt is expressly prohibited to photocopy, translate or convey
this manual or any part thereof to a third party withoutthis manual or any part thereof to a third party without
written permission from LINDE.written permission from LINDE.
LINDE is constantly striving to improve its products. ForLINDE is constantly striving to improve its products. For
this reason, we reserve the right to modify designs,this reason, we reserve the right to modify designs,
equipment and technical specifications without notice.equipment and technical specifications without notice.
Consequently, no claims can be entertained in relation toConsequently, no claims can be entertained in relation to
the specifications, illustrations or descriptions appearingthe specifications, illustrations or descriptions appearing
in this manual.in this manual.
If you have any queries about your truck, or any orders forIf you have any queries about your truck, or any orders for
spare parts, please submit these to your localspare parts, please submit these to your local
representative along with your address.representative along with your address.
For repairs, be sure to use only oFor repairs, be sure to use only o
riginal LINDE parts. Onlyriginal LINDE parts. Only
by doing so will you be able to maintain your truck to itsby doing so will you be able to maintain your truck to its
technical standard when first delivered.technical standard when first delivered.
When ordering spare parts, give the following informationWhen ordering spare parts, give the following information
in addition to the part numbers:in addition to the part numbers:
- Truck type;- Truck type;
- Manufacturer’s number /- Manufacturer’s number /
year of year of
manufacture;manufacture;
- Mast serial number- Mast serial number
(for fork-lift (for fork-lift
trucks).trucks).
Upon delivery of your truck, we suggest that you make aUpon delivery of your truck, we suggest that you make a
note of its numbers on this page.note of its numbers on this page.
LINDE truck offers you the best in perforLINDE truck offers you the best in perfor
mance, safety andmance, safety and
driving comfort. It is up to you to ensure a driving comfort. It is up to you to ensure a
long life for theselong life for these
qualities, and to learn how to make the most of theirqualities, and to learn how to make the most of their
benefits.benefits.
Accessories must be used in conformity with the direc-Accessories must be used in conformity with the direc-
tions for use supplied with the equipment. Follow thetions for use supplied with the equipment. Follow the
instructions applicable to the truck delivered to you, andinstructions applicable to the truck delivered to you, and
carry out regular inspections and services in accordancecarry out regular inspections and services in accordance
with the maintenance schedule, using the specifiedwith the maintenance schedule, using the specified
materials.materials.
This manual contains everything you need to know aboutThis manual contains everything you need to know about
running in, driving, servicing and maintaining your truck.running in, driving, servicing and maintaining your truck.
Where they appear in the text, the Where they appear in the text, the
terms ‘front’, ‘rear’, ‘right’terms ‘front’, ‘rear’, ‘right’
and ‘left’ refer to the fitted position of components inand ‘left’ refer to the fitted position of components in
relation to the forward motion of the truck.relation to the forward motion of the truck.
Special usesSpecial uses
The LINDE lift-truck is designed for stacking andThe LINDE lift-truck is designed for stacking and
transporting the loads indicated in the “load capacity”transporting the loads indicated in the “load capacity”
table. Please pay attention to the VDMA booklet “Safetytable. Please pay attention to the VDMA booklet “Safety
rules governing the use of handling trucks”.rules governing the use of handling trucks”.
The safety rules governing the use of handling trucks The safety rules governing the use of handling trucks
mustmust
be observed by service personnel and by the user.be observed by service personnel and by the user.
The user must take responsibility for any failure to observeThe user must take responsibility for any failure to observe
these rules; in this event, the manufacturer disclaims allthese rules; in this event, the manufacturer disclaims all
responsibility.responsibility.
Should you wish to use the truck for operations other thanShould you wish to use the truck for operations other than
those indicated in the directions for use, please contactthose indicated in the directions for use, please contact
your local representative.your local representative.
No modification may be made on your truck, in particularNo modification may be made on your truck, in particular
the fitting of accessories, or any structural changes, withoutthe fitting of accessories, or any structural changes, without
the manufacturer’s approval.the manufacturer’s approval.
Servicing operations must be carried out by qualifiedServicing operations must be carried out by qualified
personnel authorised by LINDE. These operations mustpersonnel authorised by LINDE. These operations must
be recorded in a service booklet, as both the validity of thebe recorded in a service booklet, as both the validity of the
guarantee and the perfect operation of the equipmentguarantee and the perfect operation of the equipment
depend on their being properly carried out.depend on their being properly carried out.
YourYour
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Plates and labelsPlates and labels
99
1010
1515
1414
1111
1313
1212
Identification platesIdentification plates
 1. 1.
IdentiIdenti
ficatificati
on plateon plate
2.2.
ManMan
ufaufa
cturctur
erer
 3. 3.
EC EC
mama
rkrk
(this plate certifies that the machine(this plate certifies that the machine
conforms to European regulationsconforms to European regulations
applicable to handling trucks)applicable to handling trucks)
4.4.
Serial Serial
number number
/ yea/ yea
rr
 5. 5.
UnlUnl
aden weaden we
ightight
6.6.
BatteBatte
ry ry
voltagevoltage
 7. 7.
MinimMinim
um batum bat
tery wetery we
ightight
8.8.
MaximMaxim
um baum ba
ttery ttery
weightweight
9.9.
NominaNomina
l load cal load ca
pacity of pacity of
trucktruck
10.10.
ModMod
elel
11.11.
ManufaManufa
cturer’s number (stampedcturer’s number (stamped
))
LabelsLabels
12.12.
SlinginSlingin
g labeg labe
ll
13.13.
BatterBatter
y safety labey safety labe
ll
(inside cover)(inside cover)
14.14.
Charger Charger
labellabel
15.15.
BatterBatter
y labey labe
ll
Note: regularly check that the equipment inNote: regularly check that the equipment in
service is fitted with these various platesservice is fitted with these various plates
and labelsand labels
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Description
Plates a
nd labe
ls
..........
..........
..........
..........
.........
..........
..
3
Tech
nica
l
spec
ific
ation
s
.........
..........
..........
..........
..........
6
Techn
ical
desc
ripti
on
..........
..........
.........
..........
..........
.....
7
Genera
l
view
.........
..........
..........
..........
.........
..........
..........
.
8
Con
tro
ls
..........
.........
..........
..........
..........
..........
.........
........
9
Indi
cat
ors
..........
..........
.........
..........
..........
..........
..........
...
10
Combination
hour
meter
(operation)
....
....
....
....
....
....
...
10
Discharge
limiter
/
indicator
....
....
....
....
....
....
....
....
....
....
.
10
Operation
Daily checks and tasks prior to operation
Safety
rules
.........
..........
..........
..........
..........
.........
..........
.
11
Defini
tion of
safet
y
terms
..........
..........
..........
..........
......
11
Use of materials
.........
..........
..........
..........
..........
.........
..
11
Periodic
inspections
of
the
truck
....
....
....
....
....
....
....
....
..
12
Operating
recommenda
tions
....
....
....
....
....
....
....
....
....
...
12
Checks
prior
to
initial
operation
....
....
....
....
....
....
....
....
...
12
Daily checks prior to
use
..........
..........
..........
..........
......
12
Checking the forward/reverse
and
lift/lo
wer
contr
ols
..........
.........
..........
..........
..........
...
13
Checking braking sys
tem
.........
..........
..........
..........
........
13
Checking the
safety rever
se button
....
....
....
....
....
....
....
.
13
Check
ing
the
horn operation
.........
..........
..........
..........
.
13
Checking
the battery
charge
state
....
....
....
....
....
....
....
...
14
Openin
g
the
batter
y
cover
..........
..........
.........
..........
......
14
Connecting / disconnecting the battery
con
nec
tor
..........
..........
.........
..........
..........
..........
..........
...
15
Charging the
battery with
a in-built
charger*
.........
........
16
Replacing the mains plug on the truck
after
recharging
..........
..........
.........
..........
..........
..........
....
16
Automatic disconnection of charging
in the event of a probleme
..........
..........
..........
..........
......
16
Electrical characteristics of the
charger
..........
..........
.....
16
Recharging the battery using an external
cha
rge
r
.........
..........
..........
.........
..........
..........
..........
........
17
Checking the condition of the battery cables,
termin
als
and
conne
ctor
.........
..........
..........
..........
........
17
Checking the electrolyte level,
and topping up with water
..........
..........
.........
..........
......
18
Checking the
electrolyte specific
gravity
....
....
....
....
....
..
18
Removal/replacement
of
the
battery
....
....
....
....
....
....
....
19
Changing the battery using a
hoist................................
..
19
Changing the battery using a gantry
(front
exit
model)...
......
......
......
.......
......
......
......
..
.........
........
19
Fu
se
s
.........
..........
.........
..........
..........
..........
..........
..........
32
Checking the electrolyte level, and topping up
with
water
.........
..........
..........
..........
..........
..........
.........
....
32
Checking the
electrolyte specific
gravity
....
....
....
....
....
..
32
Checking the condition of the battery cables,
termin
als and
conne
ctor
.........
..........
.........
..........
........
33
Cleaning the
battery and
battery compartment
....
....
..
33
Maintenance every 500 hours
Checking and adjusting the brake control
....
....
....
....
..
34
Checking and adjusting
the belt tension
....
....
....
....
....
34
Checking the
hydraulic
fluid level
....
....
....
....
....
....
....
....
35
Checking for leaks in the hydraulic sy
stem
....
....
....
....
35
Checking the condition and fastening of
electrical
cables
and
connections
....
....
....
....
....
....
....
...
36
Cleani
ng
the
elect
rical panel
.........
..........
..........
..........
.
36
Cleaning and chec
king contacts for
wear
....
....
....
....
...
36
Inspection/replacement of the traction
motor
brus
hes
.........
..........
.........
..........
..........
..........
......
37
Checking
miscellaneous
joints
....
....
....
....
....
....
....
....
...
37
Maintenance every 1000 hours
Inspection/replacement of the pump
motor
brus
hes
.........
..........
.........
..........
..........
..........
......
38
Cleani
ng
the
hydra
ulic filter
.........
..........
..........
.........
....
38
Checking the mechanical fit
ting of components......
..
38
Maintenance every 2000 hours
Changi
ng
the
hydra
ulic fluid
..........
..........
..........
..........
.
39
Recommend
ed
lubrica
nts
....
....
....
....
....
....
....
....
....
....
....
40
Hydra
ulic
syste
m
diagr
am
.........
..........
..........
..........
.....
41
Electrical
circuit
diagram
....
....
....
....
....
....
....
....
....
....
42-49
Index
.........
.........
..........
..........
..........
..........
.........
........5
0/51
Driving
Instr
uction
s for use
..........
..........
..........
..........
..........
......
20
Start
ing
..........
..........
..........
.........
..........
..........
..........
.......
20
Indication of
the direction
of travel
....
....
....
....
....
....
....
...
20
Forward
travel
/
Reverse
travel
....
....
....
....
....
....
....
....
....
.
21
Reversing
the
direction
of
travel
....
....
....
....
....
....
....
....
..
21
Safety rever
se button
..........
..........
.........
..........
..........
....
21
Starti
ng on a
slope
..........
..........
..........
..........
..........
......
22
Stee
ring
.........
..........
..........
.........
..........
..........
..........
.......
22
Turni
ng angle
..........
..........
..........
..........
.........
..........
......
22
Braking, lifting, lowering, horn
Mecha
nical brakes
.........
..........
..........
..........
.........
.........
23
Count
ercur
rent
braki
ng
.........
..........
.........
..........
..........
.
23
Automat
ic
LBC
brak
ing
.........
..........
.........
..........
..........
.
23
Liftin
g /
lower
ing the forks
.........
.........
..........
..........
.......
23
Horn
contr
ol
.........
..........
..........
..........
.........
..........
..........
23
Loadhandling
Lo
adi
ng
.........
..........
..........
.........
..........
..........
..........
.......
24
Trans
porti
ng the
load
.........
..........
..........
.........
..........
....
24
Un
loa
di
ng
..........
.........
..........
..........
..........
..........
.........
...
25
Before leav
ing the truck
.........
..........
.........
..........
..........
.
25
Lifting, towing
Slingi
ng the truck
.........
..........
..........
..........
.........
..........
.
26
Jack
ing the
truck
..........
..........
..........
..........
..........
.........
.
26
Transport
and
storage
of
the truc
k.......
....
....
....
....
....
....
26
Maintenance
Gener
al informatio
n..................
..........
..........
..........
.......
27
Inspection and maintenance after first
50 hours of
opera
tion *
.........
..........
.........
..........
..........
.
27
Inspection and maintenance schedule.......
....
....
..
28-29
Maintenance as required
Clean
ing the truc
k
..........
..........
..........
.........
..........
.........
30
Checking the tightness
of the wheel nuts
....
....
....
....
...
30
Checking the
condition of
the wheels
....
....
....
....
....
....
.
30
Fitting and adjustment of
the stabiliser wheel
....
....
...
30
Openin
g
the front
cover
.........
..........
.........
..........
..........
.
31
Pull the flexible cover clear to access the
reduction
gearbox
and
the
motor
....
....
....
....
....
....
....
....
.
31
P
a
g
e
P
a
g
e
P
a
g
e
T
able of
contents
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e
c
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n
i
c
a
l
s
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e
c
i
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i
c
a
t
i
o
n
s
D
e
s
c
r
i
p
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i
o
n
https://www.besttruckmanuals.com/

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T 16, T 18 and T 20 pallet trucks are high-performance
machines, designed for intensive use.
Their small size, ease of handling and responsiveness
make them particularly suitable for loading and unloading
operations.
The range of these machines covers the capacities of
1600, 1800 and 2000 kg.
Drive
Power is supplied by a 24 V high-capacity drive battery.
An automatically ventilated electric motor, equipped with
sensors on the most powerful models to regulate the
speed, drives the drive wheel through a 2-stage gearbox:
- 1st stage by belt and pulley
- 2nd stage by gears greased for life contained in a
housing.
The traction motor is controlled by a speed controller with
MOSFET transistors, specifically developed by LINDE for
this product range.
This controller offers excellent efficiency and allows opti-
mum control of the speed, acceleration and reverse
braking.
On the most recent models equipped with the LDC (Linde
Digital Control) controller, this is controlled by a
microprocessor which offers numerous adjustment
possibilities and is equipped with a failure auto-diagnosis
system.
NB:
As an alternative, there is a more traditional starting
system with resistors and contactors.
On this latter model, the speed changes are, however,
controlled by an electronic circuit.
Hydraulic system
A compact motor pump unit, consisting of a motor, pump,
tank, filter and descent valve, supplies the two lifting jac
ks
of the fork arms.
Lifting system
-
Thi
s is acti
vate
d by 2 jack
s, and is e
qui
pped w
ith 2 to
rque
arms, activating the bogies.
-
All t
he hi
nge pi
ns are t
reat
ed to b
e abra
sion
-pro
of and
corrosion-resistant, and the pivot rings are self-lubricating.
Handling
A long, sturdy and ergonomic drawbar allows the truck
driver to steer the drive and guide wheel effortlessly.
The various controls - forward, reverse, raising and
lowering of the fork and horn - are grouped
together at the
end of the drawbar.
For safety reasons, the drawbar
, under the action of a gas
jack
,
auto
matic
ally
rise
s
to
an
upr
ight
posi
tion
when
released.
Braking
A shoe brake situated on the countershaft of the gearbox
is controlled by the position of the drawbar.
The parking brake is applied automatically when the
drawbar is released.
Gradual and controlled reverse braking is obtained by the
inversion of the direction of movement.
On some models, this braking is automatically controlled
on the release of the accelerator; this is the LBC (Linde
Brake Control) automatic braking system.
Built-in charger*
This totally automatic charger, of the high-frequency
switching power supply type, provides full and satisfactory
recharging of the 24 V batteries from 160 to 240 Ah.
The charging is controlled by a microprocessor and
indicator lights situated on the control panel of the pallet
truck.
- Single-phase supply 220 V 50 Hz **
- Effective current input 8 A
- Charging current 30 A at start of charging
**Other voltages and frequencies available as an option.
* OPTIONAL EXTRA
T
e
c
h
n
i
c
a
l
d
e
s
c
r
i
p
t
i
o
n
D
e
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c
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i
p
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i
o
n
https://www.besttruckmanuals.com/

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General view T 16-18-20
 1.
Batte
ry plu
g hand
le
2.
Battery cover opening handle
 3.
Electr
ic con
trol
unit
 4
.
Motor-pum
p assemb
ly
5.
Bat
ter
y
cove
r
 6.
Bat
ter
y
 7.
Ho
rn
 8.
Load w
heel
s
 9.
Fo
rks
10.
Lift
cylinde
rs
11.
Tractio
n wh
eel
12.
Reducti
on gear
box
13.
Stabil
izer whe
els
14.
Tractio
n mot
or
15.
Power cable com
partmen
t
16.
In buil
t charge
r*
17.
Front
cover
18.
Till
er
19.
Docume
nt hol
der
* Optional equipment
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0
4
Controls
 1.
Key
swit
ch
 2.
Hor
n bu
tto
n
3.
Safet
y reve
rse s
witch
4.
Tra
vel
cont
rol
5.
Lif
t c
ont
rol
 6.
Lowerin
g cont
rol
7.
Batte
ry cover op
ening ha
ndle
 8.
Batte
ry plu
g han
dle
9.
Bat
ter
y p
lug
10.
Hour meter*/Di
scharge limite
r*
11.
Built-
in charger indicator
s*
12.
Charger i
nterloc
k
13.
Additi
onal key swit
ch
* Optional equipment
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Indicators
Combination hour meter /
Discharge limiter/indicator
The battery discharge limiter/indicator (9) and the hour
meter (5) are combined in a single housing.
The face of the dial is made from extremely durable
makrolon.
Hour meter operation
-
The ho
ur met
er ind
icat
es the tr
uck’
s hour
s of oper
ati
on.
-
The co
unt
er sta
rts wh
en th
e truc
k is swi
tch
ed on an
d the
safety pedal is depressed.
-
Duri
ng met
erin
g, the “eg
g-t
ime
r” icon (8
) flash
es slow
ly.
-
The LC
D indi
cat
or (5) d
ispl
ays th
e hour
s (6) an
d 1/10
ths
of an hour (7). While the truck battery is connected, it
displays the hours stored in memory.
NOTE
When the battery connector is disconnected, the hours are
retained in memory.
If the hour meter has to be replaced, make a note of the
service hours recorded by the defective meter, in the place
provided for this purpose adjacent to the hour meter, and
in the service booklet.
Operation of the discharge limiter/indicator
-
The LE
D indi
cat
or (9) li
ght
s when th
e batt
ery is con
nect
ed
and the truck is switched on, and s
hows the charge state
of the battery.
-
When t
he bat
ter
y is ful
ly cha
rged
, the gr
een di
ode (4
)
lights.
-
Duri
ng dis
char
ge, t
he gre
en and o
rang
e diod
es (3) li
ght
successively (from right to left, one diode at a time).
-
When t
he red d
iod
e (2) li
ght
s and fl
ashe
s, the b
att
ery is
approximately 70% discharged.
-
When t
he red d
iode
s (1) an
d (2) fl
ash al
ter
nat
ely, t
he
battery is 80% discharged; when this threshold is reached,
the limiter prevents operation of the lift motor.
-
In th
is ev
ent,
it w
ill b
e nec
essary
to r
echarge
the
battery
in order to be able to continue using the truck.
NOTE:
A potentiometer at the rear of the housing allows the cut-
off threshold to be adjusted for any special operating
conditions. The normal position is with the arrow pointing
towards the letter N. If any special setting is needed for a
particular use, please ask your local representative for
advice.
N.B.
Batteries with gel electrolyte require a special setting.
Description
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Use of materials
Materials must always be used in conformity with the
instructions supplied by the manufacturer.
Materials must be stored only in regulation containers,
and only in the locations designated for this purpose.
Ingredients may be flammable, and must therefore not be
placed in contact with any flame or hot object.
Use only the proper receptacles for draining liquids.
Observe any safety and recycling recommendations
provided by the manufacturer of the material or cleaning
product concerned.
Avoid any spillage of
materials.
Use absorbent materials
to clean any floor spillage, and recycle such materials
correctly.
Old or exhausted materials must be recycled in conformity
with regulations.
Comply with legal regulations.
Clean the parts concerned before carrying out lubrication,
changing filters, or working on the hydraulic system.
Any worn-out parts removed must be recyc
led in conformity
with regulations for protection of the environment.
CAUTION
Accidental penetration of pressurised hydraulic
fluid under the skin is dangerous. In the event of
injury, consult a doctor immediately.
CAUTION
Incorrect handling of cooling products or addi-
tives is hazardous to health and to the
environment.
Definition of terms relating to safety
The terms DANGER, CAUTION, ATTENTION and NOTE
are used in this manual to indicate a particular risk or to
give any special information which requires attention:
DANGER
Meaning: Non-observance entails the risk of
death, or of serious material damage.
CAUTION
Meaning: Non-observance entails the risk of
serious injury, and/or serious material damage.
ATTENTION
Meaning: Non-observance entails the risk of
deterioration or destruction of the equipment.
NOTE
Meaning: Special attention must be paid to a particular
technical point which may not be immediately obvious,
even to an expert.
Safety rules
This instruction manual, and the VDMA booklet “Directive
s
governing the use of handling trucks in conformity with
specifications and regulations” supplied with the truck,
must be given to the relevant persons, a
nd in particular to
personnel responsible for driving and servicing the truck.
The employer must ensure that the truck operator has
properly understood this information, particularly in rela-
tion to safety.
Please comply with the enclosed directives and safety
rules, with particular regard to the following:
-
Inf
orm
ati
on reg
ard
ing th
e use of h
and
lin
g truc
ks.
-
Reg
ulat
ions re
gard
ing tr
aff
ic lan
es and wo
rkin
g area
.
-
Dri
ving co
ndu
ct, and th
e drive
r’s rig
hts and ob
liga
tio
ns.
-
Us
e in
spe
cia
l en
vi
ron
me
nt
s.
-
Inf
orm
ati
on rega
rdin
g start
ing
, drivi
ng and brak
ing
.
-
Inf
orm
ati
on rega
rdi
ng mai
nten
ance a
nd rep
air.
-
Reg
ular
chec
ks an
d te
chni
cal
insp
ect
ions
.
-
Rec
ycli
ng o
f gr
eas
es,
oils
and
bat
teri
es.
-
Re
si
du
al h
az
ar
ds
.
It is recommended that both the user and the person in
charge (employer) take care to comply with all safety rules
regarding the use of handling trucks.
During the instruction of truck operators, particular
emphasis should be placed on the following points:
-
spec
ial c
hara
cter
ist
ics o
f th
e tru
ck,
-
sp
ec
ia
l
ac
ce
ss
ori
es,
-
spec
ial
fea
ture
s of
the
work
plac
e.
The user should be trained in driving and mast manoeu-
vres until the truck is fully under control.
Then, and only then, should pallets be moved or stac
ked.
The stability of the lift-truck is guaranteed when used
correctly. If, in the event of improper use or driver err
or, the
truck shows any tendency to overbalance, it is essential
that the instructions below are followed.
Before operation
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Periodic inspection of trucks
The head of the establishment concerned must conduct
periodic general inspections of the truck, or arrange for
these to be conducted, in order to ensure early detection
of any potentially dangerous deterioration. (Article R. 233-
11 of the working code introduced by Decree No. 93-41.)
The Order of 9 June 1993 gives the list of apparatus
affected, as well as the content and intervals of the inspec-
tions.
Stacker trucks and trucks with an on-boar
d driver must be
inspected every six months by an authorised person. The
results of these inspections must be recorded in a written
report.
NOTE :
The small walking pallet trucks are exempt from these
inspections
Operating recommendations
Your new truck is ready for immediate use. However, we
recommend that you avoid subjecting it to excessively
intensive use during the first 50 hours of service.
During the initial period of service, and after every wheel
change, wheel nuts should be checke
d for perfect tightness
several days in succession.
NOTE :
The torque setting for crosswise tightening of the wheel
nuts is given in the maintenance section.
Before operation
Daily checks prior to operation *
IMPORTANT
Before each shift, it is essential for the following operational
checks to be conducted on the equipment, with particular
reference to safety fittings.
-
Chec
k forwa
rd/r
ever
se and rai
se/
lowe
r contr
ols
-
Ch
ec
k
br
ak
in
g
-
Ch
ec
k ho
rn o
pe
ra
ti
on
-
Che
ck ba
tt
ery c
ha
rge s
ta
te
.
* NOTE
These checks are detailed in the following pages.
Checks prior to initial operation
-
Che
ck f
orwa
rd a
nd r
ever
se c
ont
rols
-
Ch
eck l
if
t and l
ow
er co
nt
ro
ls
-
Che
ck
ope
rati
on
of
indi
cat
ors
-
Ch
ec
k
br
ak
in
g
-
Ch
ec
k ho
rn o
pe
ra
ti
on
-
Check
batter
y el
ectrolyt
e l
evel
and
specific
gravity
-
Che
ck
bat
tery
cabl
e c
onne
cti
ons
-
Ch
eck h
yd
rau
li
c fl
ui
d le
vel
-
Ch
ec
k f
or
oi
l l
ea
ks
-
Ch
eck
ti
ght
nes
s of
wh
ee
ls
NOTE:
The last 3 operations above are detailed in the mainte-
nance section.
CAUTION
In the event of any anomaly, notify the
person in
charge immediately. Do not use the equipment.
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4
1
2
3
4
Before operation
Daily checks and tasks prior to operation
Checking forward/reverse and raise/lower
controls
-
For c
hecking
the c
orrect
operati
on of
these
control
s, see
the “driving” chapter.
Checking braking system
Drive the pallet truck and check the braking ac
tion by tilting
the tiller to the upper area (1) and the lower area (2).
In both these areas, the truck is braked mechanically.
NOTE
A gas cylinder automatically returns the tiller to
position (1).
Checking the safety reverse button
-
Put t
he til
ler t
o the
drive p
osition
and mo
ve the
truck
forwards.
-
When p
ressed,
the s
afety
reverse
button
(3) wi
ll rev
erse
the truck for several meters.
NOTE
Contact your authorized distributor for any adjustments.
ATTENTION
Please contact your local representative if you
detect any anomaly in the steering mechanism.
Checking horn operation
-
Pre
ss the h
orn bu
tto
n (4) on t
he con
tro
l mod
ule.
-
T
he h
or
n s o
un
ds
.
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0
4
1
2
Daily checks and tasks prior to operation
Checking the battery charge state
-
Before
the st
art of
the shi
ft, ch
eck that
the ba
ttery i
s
correctly charged.
-
Pl
ug in t
he ba
tt
ery c
on
nec
to
r.
-
Ac
ti
vat
e th
e key s
wi
tch
(1)
.
-
Check t
he ba
ttery
charge
state
on th
e indi
cator
(2). (
See
chapter on discharge limiter/indicator.)
Opening the battery cover
-
Sto
p th
e ma
chin
e, l
ower
the
fork
s.
-
Sw
it
ch of
f an
d rem
ove t
he ke
y.
-
Rel
ease t
he bat
tery co
ver by pre
ssin
g ligh
tly on it an
d
pulling the flexible tab (3) towards you; then lift the cover.
-
To c
lo
se,
re
pla
ce t
he c
ov
er.
Before operation
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DANGER
Charging and servicing of the battery must be
carried out in conformity with the instructions
supplied with the battery and the charger (if
using an external charger).
The electrolyte contains sulphuric acid, which is a
dangerous substance. During any work on the battery,
wear gloves and goggles. In the event of any splashes on
the skin or into the eyes, rinse immediately in pure water
and consult a doctor if necessary. During charging, batte-
ries emit hydrogen gas, which can create an explosive
mixture. Do not create sparks, smoke, or place any flame
near a battery on charge or one which has been recently
charged. To avoid any accumulation of hydrogen, leave the
battery cover open during charging, which should be
carried out in a well-ventilated area. Do not place any
metallic object on the battery, as this may create a short-
circuit.
Before operation
Daily checks and tasks prior to operation
CAUTION
Never connect or disconnect the connector while
current is flowing through the circuit - this may
cause violent sparking and damage the con-
tacts.
Regularly check the condition of the connector contacts,
and replace them if they show any traces of arcing or of
carbon deposits.
Take care to observe the + and - polarities. Always connect
+ to + and - to -. Do not reverse the connections.
Each half of the connector is fitted with a locating pin to
avoid any risk of connection reversal. Make sure these are
present and in good condition.
Connect / disconnect the battery plug
To disconnect
-
Sto
p the ma
chin
e, swi
tch of
f and re
mov
e the ke
y.
-
The bat
tery pl
ug is
situate
d on t
he righ
t-hand
side of
the
machine (1).
-
Pul
l on
the
han
dle
(2) t
o di
scon
nect
.
To reconnect
-
Positio
n the
guides
of th
e plug
(3) opp
osite
their
housing.
-
Push
the p
lug i
nto t
he soc
ket (
4) on t
he tr
uck.
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4
3
CEE
GB
CH
US-C
1
2
Daily checks and commissioning checks
Charging the battery with the built-in char-
ger ( from 07/2000 )
Every day the truck is used normally, or every two days in
case of non-intensive use, charge the battery at the end of
the shift.
-
Par
k the t
ruck n
ear a so
cket o
utl
et (22
0 V – 10/
16 A)
.
-
Lower t
he for
ks, tur
n off
the ke
y switc
h, rem
ove the
key.
-
Open t
he bat
tery c
ompartm
ent co
ver (1)
for go
od ven
tila-
tion.
-
Rem
ove th
e plug (
2) fro
m its p
ort , pa
y out th
e wire a
nd
connect the plug to the mains.
-
The ch
arge
r start
s auto
mat
ical
ly, th
e gree
n light (
3)
flashes, the red light (4) comes on and then goes off and
the charger fan is switched on.
-
At th
e end o
f the
normal
charge,
the gre
en ligh
t rema
ins
continuously on, and the fan stops.
-
An eq
ualizat
ion c
harge
starts
automa
tically
15 mi
nutes
later; the green light remains on and the fan is switched
on.
-
If th
e char
ger re
mai
ns con
nect
ed to th
e main
s powe
r
supply, it will restart a charge holding cycle every 48
hours, and the green light flashes.
Commissioning
WARNING:
Do not disconnect the battery connector while
charging (green light flashing).
Problems while charging
If a fault occurs while charging, the red light (4) comes on
and the charger stops.
Proceed as follows to resume a charge cycle after detection
of an anomaly:
-
Disc
onne
ct t
he m
ain
s po
wer
supp
ly
-
Unp
lug th
e batt
ery con
nect
or for at l
east 1 mi
nut
e
-
Reconne
ct the
battery
connect
or, an
d then
plug t
he ma
ins
power supply in.
Please call one of our dealers if the problem persists.
Putting the mains power supply cable away
-
Stow
the ca
ble i
n the
compart
ment
between
the b
attery
box and the chassis.
-
Push t
he mai
ns plug
(2) on
the cab
le int
o the
red saf
ety
support in the battery compartment.
-
Cl
os
e t
he
co
ve
r.
IMPORTANT
The truck will operate only if the plug is replaced correc
tly.
Charger electrical specifications
Mains power supply 220 V 50 Hz*Nominal battery voltage
24 V
Maximum output power 720 W Maximum current 30 A
Charging time 12 h (240 Ah)
*Other voltages/frequencies available to suit electrical
mains power supply in different countries
Special case of Gel batteries
Batteries with a gel electrolyte must always be charged
using a special charger.
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6
0
8
0
4
2
5
1
1
-
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4
1
Before operation
Daily checks and tasks prior to operation
Recharging the battery with an external
charger
-
On com
pletio
n of
the sh
ift,
take t
he tru
ck to
the ch
arger.
-
Sto
p the tru
ck, lo
wer th
e fork
s, swi
tch of
f the pow
er,
remove the key (1).
-
Disconne
ct th
e bat
tery
connecto
r (2).
(See
chapter
on
connecting/disconnecting the connector.)
-
Ope
n the co
ver (3
) of the b
att
ery co
mpa
rtm
ent
.
-
Plug
the co
nnector
attach
ed to
the b
attery
into t
he cha
rger
output connector.
-
Activa
te the
charger
in conf
ormity
with t
he spec
ific i
nstruc-
tions for that charger.
-
Whe
n char
gin
g is com
ple
te and t
he cha
rge
r has bee
n
switched off, disconnect the charger connector and
reconnect the battery connector to the truck.
-
Re-close
the co
ver. C
heck th
e batt
ery cha
rge sta
te on
the
truck’s indicator (4) after pulling out the emergency stop
button and turning on the key switch.
The truck is now ready for use.
CAUTION
In order to avoid any sparks, always connect the
battery connector before switching on the char-
ger, and disconnect it after switching off the
charger.
-
Ensure
that
the ch
arger i
s comp
atible
with
the t
ruck
battery in terms of voltage and charging current. (See
charger instructions.)
-
When co
nnectin
g the
battery
to the
charger,
take ca
re to
comply with the + and - polarities (do not reverse the
connections).
-
The con
nectors
are fi
tted
with l
ocating
pins t
o preve
nt any
reversal. Check regularly that these are present and in
good condition.
Checking the condition of battery cables,
terminals and connector.
-
Check t
hat cab
le ins
ulation
is unda
maged,
and th
at the
connections show no sign of overheating.
-
Check
that
the +
and -
batter
y term
inal
pillars
are no
t
sulphated (indicated by the presence of a white salt-like
deposit).
-
Check
the c
onditio
n of
the c
onnecto
r cont
acts,
and t
he
presence of the locating pin.
ATTENTION
Failure to observe the above procedures may
result in serious damage. Please contact your
local representative as quickly as possible to
remedy any such damage.
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