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141 804 30 11 - 02.

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Operating instructions
Type 141

L 16 AS
141 804 30 11

02/00

02/00

Linde - Your Partner

Linde AG

Werksgruppe Flurfrderzeuge und Hydraulik

Linde, an enterprise operating


worldwide in the investment
and service sector, is one of
the large industrial enterprises
in the EC with its four divisions
and over 80 associated
companies.
Fenwick-Linde, Chtellerault

Lansing Linde Ltd., Basingstoke

Werk II, Aschaffenburg-Nilkheim

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.

Werk I, Aschaffenburg

Werk III, Kahl am Main

Lansing Linde (Blackwood) Ltd., Blackwood

YOUR

Accessories must be used in conformity with the directions for use supplied with the equipment. Follow the
instructions applicable to the truck delivered to you, and
carry out regular inspections and services in accordance
with the maintenance schedule, using the specified
materials.
This manual contains everything you need to know
about running in, driving, servicing and maintaining your
truck.
Where they appear in the text, the terms front, rear,
right and left refer to the fitted position of components
in relation to the forward motion of the truck.

Special uses
The LINDE lift-truck is designed for stacking and
transporting the loads indicated in the load capacity
table. Please pay attention to the VDMA booklet Safety
rules governing the use of handling trucks.
The safety rules governing the use of handling trucks
must be observed by service personnel and by the user.
The user must take responsibility for any failure to
observe these rules; in this event, the manufacturer
disclaims all responsibility.
Should you wish to use the truck for operations other
than those indicated in the directions for use, please
contact your local representative.
No modification may be made on your truck, in particular
the fitting of accessories, or any structural changes,
without the manufacturers approval.
Servicing operations must be carried out by qualified
personnel authorised by LINDE. These operations must
be recorded in a service booklet, as both the validity of
the guarantee and the perfect operation of the equipment
depend on their being properly carried out.

Technical notes

Acceptance of the lift-truck

It is expressly prohibited to photocopy, translate or


convey this manual or any part thereof to a third party
without written permission from LINDE.

Before leaving our factory, the truck is subjected to


detailed checks in order to ensure that the equipment
reaches you in perfect operational condition and fully
equipped as ordered. Your local representative will then
conduct a final inspection and, on delivery of the
equipment, will provide you with all necessary information for its operation and servicing.

LINDE is constantly striving to improve its products. For


this reason, we reserve the right to modify designs,
equipment and technical specifications without notice.
Consequently, no claims can be entertained in relation
to the specifications, illustrations or descriptions
appearing in this manual.
If you have any queries about your truck, or any orders
for spare parts, please submit these to your local
representative along with your address.
For repairs, be sure to use only original LINDE parts. Only
by doing so will you be able to maintain your truck to its
technical standard when first delivered.
When ordering spare parts, give the following information in addition to the part numbers:
- Truck type;
- Manufacturers number /
year of manufacture;
- Mast serial number
(for fork-lift trucks).
Upon delivery of your truck, we suggest that you make
a note of its numbers on this page.

In order to avoid any subsequent claims, please make a


careful and personal inspection in order to ensure that
the truck is in perfect order, complete with all fittings, at
the time of delivery.

The truck is supplied with the following documents:


1 - Operating manual.
1 - Spare parts catalogue.
1 - Battery servicing manual
(electric trucks delivered with battery).
1 - Charger instruction manual
(for trucks delivered with separate chargers).
1 - Certificate of conformity (manufacturers certifi
cation that the machine complies with European
standards).
1 - VDMA booklet regarding directives on the use of
Handling Trucks in accordance with specified
applications and regulations.

We wish you good use and complete satisfaction.

141 804 30 11 - 02.00

LINDE truck offers you the best in performance,


safety and driving comfort. It is up to you to ensure
a long life for these qualities, and to learn how to
make the most of their benefits.

PLATES AND LABELS


11

Identification plates
1.
2.
3.

4.
5.
6.
7.
8.
9.
10.

Identification plate
Manufacturer
EC mark
(this plate certifies that the machine
conforms to European regulations
applicable to handling trucks)
Unladen weight
Battery voltage
Minimum battery weight
Maximum battery weight
Nominal load capacity of truck
Serial number / year
Model

12.
13.
14.

Battery safety label


Wear safety shoes label
Mast safety labels

141 804 30 11 - 02.00

11.

12

13

14

15

14

14

Pallet truck slinging label

15.
16.
17.
18.

16

Mast No. (engraved)


Drive safely label
Rating plate
Serial No. (engraved)

17
Inside battery cover

Outside battery cover

10

9
8

Kg

Kg

Kg

Kg

18
6

4
141 804 30 11 - 02.00

Description

Plates and labels ............................................................ 3


Technical characteristics ............................................. 6
Technical description .................................................... 7
Overview L16AS .............................................................. 8
Controls ............................................................................ 9
Indicators ....................................................................... 10
Time counter unit .......................................................... 10
Discharge limiter indicator ......................................... 10

Startup / Daily checks and operations


before startup

141 804 30 11 - 02.00

TABLE OF CONTENTS

Page

Safety rules ................................................................... 11


Definition of safety terms ............................................ 11
Using ingredients .......................................................... 11
Periodic checks on the pallet truck ........................... 12
Recommendations for starting up ............................. 12
Checks before first startup ........................................ 12
Daily checks before use .............................................. 12
Checking forward/reverse and raise/
lower controls ............................................................... 13
Checking the safety braking ....................................... 13
Checking automatic braking ....................................... 13
Checking the driver presence safety device ........... 13
Checking operation of the emergency stop button . 13
Checking the safety inverter switch .......................... 13
Checking the horn ......................................................... 13
Checking the battery charge condition ..................... 13
Opening and closing the battery cover ..................... 15
Connecting the battery connector ............................. 15
Recharging the battery with an external charger ... 16
Checking the state of terminal cables
and battery connector ................................................. 16
Checking the electrolyte level and topping up
with water ...................................................................... 16
Checking the electrolyte density ................................ 16
Removing/Replacing the battery ................................ 18
Replacing the battery using a trolley ......................... 18

Usage
Usage instructions ....................................................... 19
Startup ............................................................................ 19
Safety switch ................................................................. 19
Emergency stop button ................................................ 20
Determining the running direction ............................. 20
Steering ..................................................................... 20-21
Driving ............................................................................. 21
Forward / reverse running ........................................... 21
Reversing the running direction ................................. 21
Using the pallet truck on a slope ............................... 22
Going up slopes ............................................................. 22

Going down slopes ....................................................... 22


Starting on a slope ....................................................... 22
Electromagnetic braking ............................................. 23
Braking by reversing the running direction .............. 23
Parking brake ................................................................ 23
L.B.C. automatic braking ............................................. 23
Horn control ................................................................... 23
Using the mast .............................................................. 24
Raising and lowering the mast using the
control lever on the chassis ....................................... 24
Raising and lowering the master by controlling
the tiller .......................................................................... 24
Controlling auxiliary equipment .................................... 24
Handling loads ............................................................... 25
Reading the rating plate .............................................. 25
Adjusting the spacing between forks .......................... 25
Picking up a load on the ground ................................. 26
Transporting a load ...................................................... 26
Putting a load down on the ground ............................ 26
Stacking a load ............................................................. 27
Picking up a load at a height ....................................... 27
Before leaving the pallet truck ................................... 27
Slinging the pallet truck ............................................... 28
Lifting the pallet truck .................................................. 28
Towing ............................................................................ 28
Taking the mast off ....................................................... 28
Transport and storage of the pallet truck ................ 28

Maintenance
General comments ....................................................... 29
Work on the elevator mast .......................................... 29
Standard elevator mast ............................................... 29
Safety device for standard elevator mast ................ 29
Duplex elevator mast ................................................... 30
Safety device for Duplex elevator mast .................... 30
Triplex elevator mast ................................................... 30
Safety device for Triplex elevator mast .................... 30
Checks and maintenance work after the first
50 hours of service* ..................................................... 31
Calendar for maintenance work ............................ 32-33

Maintenance as required
Cleaning the pallet truck .............................................. 34
Cleaning and greasing chains .................................... 34
Cleaning and greasing the mast ................................ 35
Opening the front cover ............................................... 35
Checking the attachment and condition of
the wheels ...................................................................... 35
Fuses ............................................................................... 35

Checking the electrolyte level and topping up


with water ...................................................................... 36
Checking the electrolyte density ................................ 36
Checking the condition of cables, terminals
and the battery connector ........................................... 37
Cleaning the battery and the battery
compartment ................................................................. 37

Maintenance every 500 hours


Lubrication of the drive unit steering bearing .......... 38
Checking the various hinges ...................................... 38
Checking the leak tightness of the hydraulic
circuit .............................................................................. 38
Checking the hydraulic fluid level .............................. 38
Checking the condition and attachment of
the mast and chains ..................................................... 39
Checking the length of mast chains .......................... 39
Checking the condition and attachment of
cables and electrical connections ............................ 40
Cleaning the electrical panel ...................................... 40
Checking contact wear ................................................ 40
Checking the traction motor brushes, and
replacement if necessary ........................................... 41
Adjusting the electromagnetic brake ........................ 41

Maintenance every 1000 hours


Checking the reduction gear oil level ........................ 42
Removing the motor-pump unit .................................. 42
Checking the pump motor brushes, and
replacement if necessary ........................................... 43
Cleaning the hydraulic filter and cap ......................... 43
Checking the mechanical attachment of devices ... 43

Maintenance every 2000 hours


Replacing the hydraulic fluid ....................................... 44
Replacing reduction gear oil ....................................... 44
Recommended lubricants /
Technical characteristics ........................................... 45
Hydraulic diagrams ...................................................... 47
L 16 AS electrical diagrams ................................... 48-49
Index ........................................................................... 50-51

TECHNICAL SPECIFICATIONS

DESCRIPTION

Drive

Performance

Misc.

1.1

Manufacturer

1.2

Model designation

L 16 AS

1.3

Propulsion mode : battery, diesel, petrol, LP gas, mains power

Battery

1.4

Operation : manual, pedestrian, stand-on, seated, order picker

1.5

Nominal capacity on the mast / support arms / total

Q (kg)

1600

1.6

Load centre

c (mm)

600

1.8

c/c distance between load carrying wheels and load retaining plate

x (mm)

970

1.9

Wheelbase

y (mm)

1218

2.1

Service weight

kg

1130

2.2

Axle load with load, drive side/load side

kg

760/370

2.3

Axle load without load, drive side/load side

kg

3.1

Tyres: rubber, solid tyres, pneumatic polyurethane

3.2

Tyre size, drive wheel

mm

254x102

3.3

Tyre size, load side

mm

85x85

mm

3.4

Auxillary wheels (dimensions)

3.5

Wheels number drive side/load side (x=driven)

3.6

Track width, drive side

pedestrian

810/1920
C+P

1x/4
mm

3.7

Track width, load side

mm

1024/1194/1364

4.2

Height overall mast lowered

h1 (mm)

1790

4.3

Free lift

h2 (mm)

150

4.4

Lift

h3 (mm)

2344
2990

4.5

Height overall mast lifted

h4 (mm)

4.6

Initial lift

h5 (mm)

4.9

Height of tiller arm in operating position, min/max.

h14 (mm)

1088/1400

4.15

Fork height, lowered

h13 (mm)

46

4.19

Overall length

l1 (mm)

1606

4.20

Length to fork face

l2 (mm)

806

4.21

Overall width

b1/b2 (mm)

725/1150

4.22

Fork dimensions

s/e/l (mm)

55/180/1143

4.23

Support arms dimensions

s/e/l (mm)

ISO 2B

4.24

Weight fork support apron

b3 (mm)

800/100/1200

4.25

Fork spread outside, min/max.

b5 (mm)

4.26

Fork spread inside, min/max.

b4 (mm)

900/1070/1240

4.32

Ground clearance, centre of wheelbase

m2 (mm)

50

4.33

Aisle width with pallet 1000 x 1200 through

Ast (mm)

2360

4.34

Aisle width with pallet 800 x 1200 lengthwise

Ast (mm)

2460
1440

4.35

Turning radius

Wa ( mm )

5.1

Travelling speed, with/without load

km/h

5.0/6.0

5.2

Lifting speed with/without load

m/s

0.14/0.22

5.3

Lowering speed with/without load

m/s

0,04/0,035

5.7

Climbing ability, with/without load, 30 minute rating

9/10

5.8

Maximum climbing ability, with/without load, 5 minute rating

9/10

5.10

Service brake

6.1

Drive motor, 60 minute rating

kW

1,5

6.2

Lifting motor, 15% rating

kW

6.3

Battery according to DIN 43 531/35/36 A, B, C, no

6.4

Battery voltage / rated capacity ( discharged in 5 h)

V/Ah

24/240

6.5

Battery weigth ( 5%)

kg

200

kWh

dB(A)

<65

6.6

Power consumption according to standardized VDI cycle

8.1

Speed control

8.4

Noise level at operator's ear

Ast = Wa + r + a
a : safety distance = 200 mm

FENWICK-LINDE

electromagnetic

DIN 43535 B

variator LDC

141 804 30 11 - 02.00

Dimensions

Wheels

Weight

Characteristics

January 2000

Technical data sheet for the electrical


stacker truck with straddle arms

TECHNICAL DESCRIPTION
The L 16 AS series electric stacker truck is ideal for
heavy handling requiring good stability at large
heights. Its stability in turns is excellent due to its
track, low height and low center of gravity.
Its surrounding support arms and ISO apron are
designed to transport and load all types of pallets
and crates, particularly if they are fitted with ducts
or closed entries at the bottom. It is versatile, and
can also be used to work with hydraulic accessories.
It is sufficiently compact to fit into a hoist.
It is easy to handle, and no special training is
necessary to drive it.
Its nominal capacity is 1600 kg.

141 804 30 11 - 02.00

Frame, wheels and elevator mast

DESCRIPTION
Steering:

Driving:

A robust and ergonomical twin-grip tiller steers the


driving wheel directly.

The various controls (forward running, reverse


running, raise and lower the elevator mast and the
horn) are grouped on the tiller.

Lifting:
The hydraulic unit is an assembly including the
motor, tank, pump, solenoid valves, check valves
and filters.
Good visibility industrial type masts made of steel
I-sections. Elevation heights with standard masts
up to 2344 mm. There are three types of elevator
assemblies, namely S for standard, D for duplex
with free lift, T for triplex with free lift.

- The single-piece chassis is supported at three


points, by the driving wheel at the front, and by
four load bearing wheels on the load side.
- The elevator mast is bolted to the frame.

Braking:

Drive:

- Safety/parking braking, provided by an


electromagnetic brake which is actuated when
the electrical power is interrupted. This brake is
automatically engaged when the tiller is released
and allowed to return to its upper position, or
when the safety pedal is released.
- Electronic countercurrent braking, triggered by a
change in the direction of travel and controlled by
the LBC brake unit and the LDC variator.
- Automatic braking obtained on releasing the
accelerator and controlled by the LDC variator.

This stacker truck is driven by 1.5kW traction motor


mounted vertically on the reduction gear. The drive
wheel is driven through two reduction gear stages.
Power is supplied by a 24 volt lead-acid storage
battery with a capacity of 200 to 480 Ah according to
type of chassis.
The motors supply is controlled by the LDC
microprocessor-controlled electronic variator which,
thanks to its parameterization, adapts perfectly to
all requirements.

There is also an elevator mast control lever at the


left side of the chassis, in addition to the controls on
the tiller.
An emergency-stop button completely cuts off the
electrical circuit and actuates the brake when
depressed.

The L 16 AS is equipped with three braking systems:

GENERAL VIEW L 16 AS
Elevator mast
Mast protection screen
Capot batterie
Battery cover
Tiller
Front cover
Contactor plate
LDC (Linde Digital Control) variator
Traction motor
Horn
Driving wheel
Reduction gear
Hydraulic reservoir
Motor-pump unit
Load bearing wheels
Fork arm
Fork support apron
Battery
Distribution
Elevation jacks
Elevation control lever.

1
2
21

3
4

20

5
19
6

18

17

16
15
11

9
10
11
14
13
8

12

141 804 30 11 - 02.00

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.

CONTROLS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Horn control
Raise control on the tiller
Safety inverter switch
Lower control on the tiller
On/Accelerator inverter switch
Raise / lower mast lever
Open battery cover handle
Contact key
Emergency stop button
Time meter / Discharge indicator

1
2
3
4

141 804 30 11 - 02.00

8
9
10

INDICATORS

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 hour meter indicates the trucks hours of
operation.
- The meter is activated whenever the power is
turned on and the tiller is placed in the drive
position.
- During metering, the egg-timer icon (8) flashes
slowly.
- The LCD indicator (5) displays the hours (6) and 1/
10ths of an hour (7). While the truck battery is
connected, it displays the hours stored in memory.

10

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 LED indicator (9) lights as soon as the battery
is connected and the truck is switched on, and
shows the charge state of the battery.
- When the battery is fully charged, the green LED
(4) lights.
- During discharge, the green and orange LED's (3)
light successively (from right to left, one diode at
a time).
- When the red LED's (2) lights and flashes, the
battery is approximately 70% discharged.

- When the red LED's (1) and (2) flash alternately,


the battery is 80% discharged; when this threshold
is reached, the limiter prevents operation of the
lift motor.
- In this event, it will be necessary to recharge 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.
141 804 30 11 - 02.00

Combination hour meter /


Discharge limiter/indicator

DESCRIPTION

SAFETY RULES

BEFORE OPERATION

141 804 30 11 - 02.00

This instruction manual, and the VDMA booklet


Directives governing the use of handling trucks in
conformity with specifications and regulations
supplied with the truck, must be given to the relevant persons, and 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
relation to safety.
Please comply with the enclosed directives and
safety rules, with particular regard to the following:
- Information regarding the use of handling trucks.
- Regulations regarding traffic lanes and working
area.
- Driving conduct, and the drivers rights and obligations.
- Use in special environments.
- Information regarding starting, driving and braking.
- Information regarding maintenance and repair.
- Regular checks and technical inspections.
- Recycling of greases, oils and batteries.
- Residual hazards.
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:
- special characteristics of the truck,
- special accessories,
- special features of the workplace.
The user should be trained in driving and mast
manoeuvres until the truck is fully under control.
Then, and only then, should pallets be moved or
stacked.
The stability of the lift-truck is guaranteed when
used correctly. If, in the event of improper use or
driver error, the truck shows any tendency to
overbalance, it is essential that the instructions
below are followed.

Definition of terms relating to safety

Use of materials

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:

Materials must always be used in conformity with


the instructions supplied by the manufacturer.

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.

follow these
instructions

Do not jump

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 recycled 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
additives is hazardous to health and to the
environment.

In the event of overbalancing

ATTENTION

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.

Hold tight

Bend legs

Countersteer

11

BEFORE OPERATION
Periodic inspection of trucks

Checks prior to initial operation

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.

Trucks with a standing or seated driver shall be


checked every 6 months.
Stacker trucks with pedestrian driver shall be
checked every 12 months.
NOTE
These periodic general inspections shall be made
by an authorized person, and a report shall be
written describing the results.

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 checked for
perfect tightness several days in succession.
NOTE
The torque setting for crosswise tightening of the
wheel nuts is given in the maintenance section.

Tighten wheel nuts!


- before initial operation
- fully, every 10 hours
- then every 100 hours
(torque settings:
see instructions for use)

forward and reverse controls


lift and lower controls
operation of indicators
braking
emergency stop button
horn operation
steering operation
battery electrolyte level and specific gravity
battery cable connections
hydraulic fluid level
oil level from gear box
for oil leaks
tightness of wheels

NOTE:
The last 4 operations above are detailed in the
maintenance section.

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.
-

Check
Check
Check
Check
Check
Check
Check

forward/reverse and raise/lower controls


steering operation
braking
emergency stop button
horn operation
battery charge state.
that the battery cover is locked.

* NOTE
These checks are detailed in the following pages.
CAUTION
In the event of any anomaly, notify the
person in charge immediately. Do not use
the equipment.

12

141 804 30 11 - 02.00

The June 25th 1999, December 2nd 1998 and June


9th 1993 orders define the contents of verifications
and intervals between them.

Check
Check
Check
Check
Check
Check
Check
Check
Check
Check
Check
Check
Check

BEFORE OPERATION

Daily checks and tasks prior to operation


Checking forward/reverse and raise/lower
controls
- For checking the correct operation of these controls,
see the driving chapter.

Checking the safety braking

Checking the automatic braking


- Set the truck in motion.
- Release the accelerator rocker-switch. The
countercurrent braking is triggered automatically
and brings the truck to a halt.

141 804 30 11 - 02.00

- Set the truck in motion, then move the tiller into


zone (1) or (2); the truck should brake.
- In these two zones, the truck is braked by the
electromagnetic brake and the power to the motor
is cut off.

ATTENTION
Do not drive the truck if the brake system is
defective. Please ask your local
representative for advice if you notice any
anomaly concerning the brake system.

Checking
operation

emergency

stop

button

- Press the emergency stop button (3).


- The trucks electrical power will be cut off.
- Power is no longer supplied to the electrical
controls and motors.
- The electromagnetic brake is applied.
- In order to resume work, pull out the emergency
stop button; the truck is under power once again,
and all functions are available.

NOTE
To trigger emergency braking in zone (2), the tiller
must crush the tiller base rubber stop.
When the tiller is released in the operating position,
it returns automatically to the braking position (1).

13

BEFORE OPERATION
Daily checks and tasks prior to operation
Checking horn operation

Checking the battery charge state

- Cause the truck to move tiller forwards.


- Press in the button (1). The truck must stop
immediately and set off again in the opposite
direction for several metres.

Press the horn button (2) on the tiller head.


The horn sounds.

- Before the start of the shift, check that the battery


is correctly charged.
- Plug in the battery connector (3).
- Reset the emergency stop button (6) by pulling it
upwards.
- Activate the key switch (4).
- Check the battery charge state on the indicator( 5).
(See chapter on discharge limiter/indicator.)

141 804 30 11 - 02.00

Checking the safety reverse button

2
3

14

BEFORE OPERATION

Daily checks and tasks prior to operation

141 804 30 11 - 02.00

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, batteries 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.

Opening the battery cover


-

Stop the truck and lower the forks.


Turn off the power and remove the key.
Depress the emergency stop button.
Move towards the left side of the truck
Unlock the battery cover by pulling the handle (1)
Tilt the battery cover beyond the locking position
(2) and then release it. The battery cover is locked
in the open position on the notch (2) by a prop (3).

Connecting/disconnecting the battery


connector
To disconnect

- Stop the truck, turn off the power, and remove the key.
- The battery plug is located behind the steering column.
- Pull the handle (4) to disconnect.

To reconnect

- Check the orientation of the connections.


- Refit the free section of the connector to the fixed section
on the truck.

CAUTION
Never connect or disconnect the connector
when there is a current passing through the
circuit; there is a risk of a severe arcing that
can damage the contacts.

Closing the battery cover


- Pull the battery cover backwards to close it
- Lift the prop (3) to release it from its support (2)
- Fold the cover forwards until it locks in the closed
position.
IMPORTANT
Always check that the battery cover is well closed,
since the cover fixes the battery in place in its
compartment.

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.

2
15

BEFORE OPERATION

Daily checks and tasks prior to operation


CAUTION
In order to avoid any sparks, always connect
the battery connector before switching on
the charger, and disconnect it after
switching off the charger.

Recharging the battery with an external


charger

16

- Ensure that the charger is compatible with the


truck battery in terms of voltage and charging
current. (See charger instructions.)
- When connecting the battery to the charger, take
care to comply with the + and - polarities (do not
reverse the connections).
- The connectors are fitted with locating pins to
prevent any reversal. Check regularly that these
are present and in good condition.

- Check that cable insulation is undamaged, and


that the connections show no sign of overheating.
- Check that the + and - battery terminal pillars are
not sulphated (indicated by the presence of a
white salt-like deposit).
- Check the condition of the connector contacts,
and the 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.
141 804 30 11 - 02.00

- On completion of the shift, take the truck to the


charger.
- Stop the truck, lower the forks, switch off the
power, remove the key (2), and depress the
emergency stop button (4).
- Disconnect the battery connector. (See chapter on
connecting/disconnecting the connector.)
- Open the cover (5) of the battery compartment.
- Plug the connector attached to the battery into the
charger output connector.
- Activate the charger in conformity with the specific
instructions for that charger.
- When charging is complete and the charger has
been switched off, disconnect the charger
connector and reconnect the battery connector to
the truck.
- Re-close the cover. Check the battery charge state
on the trucks indicator (3) after pulling out the
emergency stop button and turning on the key
switch.
The truck is now ready for use.

Checking the condition of battery cables,


terminals and connector.

BEFORE OPERATION

Daily checks and tasks prior to operation


The operations described below apply to lead-acid
batteries with liquid electrolyte.
For maintenance-free batteries with gel
electrolyte, refer to the manufacturers instructions.
CAUTION
Avoid any contact with the acid. Do not
create any short-circuit. Refer to the
recommendations in the daily checks section.

141 804 30 11 - 02.00

Checking electrolyte level and topping up


with water.
- This check, and any necessary topping-up, is to be
carried out once a week, after recharging the
battery.
- Turn off the key-switch, open the cover, and
disconnect the battery connector.
- Check the level. It should be up to the base of the
filler plug, just above the top of the separator.
- Use demineralised water to top up any cells with
a low water level.
- Replace the filler plugs.

ATTENTION
Use only demineralised water for topping
up.
Never add water before charging (risk of
overspill).
Do not overfill the cells.
For more information, refer to the instructions
supplied with the battery.

- We recommend measurement every week or two.


Keep a record of the values measured in the
service booklet for your battery.
- Remove the filler plug for each cell as described
above.
- Using an acid hydrometer, carefully measure the
specific gravity in each cell.
- Replace the filler plugs when finished.

Checking the specific gravity of the


electrolyte

NOTE:
If there are voltage discrepancies between the
various cells, or if any cells show a particularly low
voltage, contact your local representative. Any
discharge below the threshold of 1.14 will be
extremely detrimental to the lifespan of the battery.

- Measuring the specific gravity gives an accurate


indication of the state of charge of each cell in the
battery. This measurement may be carried out
before or after charging.
- Minimum specific gravity, battery 80% discharged:
1.14
- High specific gravity, battery 100% charged: 1.29
to 1.32 (according to make).

For more information, refer to the instructions


supplied with the battery.

17

BEFORE OPERATION

Daily checks and tasks prior to operation


Removing/replacing the battery
ATTENTION
The battery is a heavy and fragile
component which must be handled with
care.

- Position the roller carrier (2) next to the battery


compartment and apply the brake.
- Disconnect the battery plug.
- Open the battery cover (1).
- Pull the battery onto the roller carrier and lock it.
- Replace the battery by carrying out the operations
in reverse order.
- Close the battery cover (1).

WARNING
When lowering the forks, do not place feet
beneath the lifting platform.
WARNING
During the battery locking and locating
manoeuvres, keep fingers clear of the
moving parts in order to avoid any danger
of trapping them.
WARNING
- Before starting to drive the pallet truck,
make sure that the battery cover is
properly locked.

141 804 30 11 - 02.00

When fitting a replacement battery, this must have


specifications identical to the original in the following
respects: weight, compartment dimensions, voltage, capacity, and connectors. Refer to the plate on
the truck for the acceptable minimum and maximum weights.

Changing the battery using a roller carrier

2
18

DRIVING

USE

141 804 30 11 - 02.00

Usage instructions
The L16 AS is designed for use in non-dangerous
atmospheres. The ambient temperature must be
between -10C and +40C, and the relative humidity
of the air must be lower than 95%.
NOTE: For lower temperatures, there is a cold-room
variant.
The ground must be level. Ground clearance at the
lowest point is approx. 19 mm, but the L16 AS can
cope with clearance angles of up to 9 with the lifter
in the upper position.
The resistance of the ground to indentation must be
approx. 26 daN/cm2.
The maximum negotiable gradient recommended
for short distances is 11.5%, for reasons of braking
and stability.
The truck can lift 1600 kg on the fork.Loads must be
uniform, with a maximum recommended height of
2 m. For applications other than the above, please
consult your local representative.

CAUTION
Always keep your hands on the controls,
and never put them near moving parts
without having disconnected the battery.
The truck can only handle pallets up to a maximum
weight of 1.5 tonnes evenly distributed over the full
length of the fork arms. Loads must be uniform, with
a maximum recommended height of 2 m.
For applications other than the above, please consult
your local representative.

- The discharge indicator lights, and the hour meter


(3) is ready to function
- Lift the fork by a few centimeters.

Safety reverse button


In order to protect the driver from being trapped
between an obstacle and the appliance, the end of
the tiller is fitted with a safety flop (5).
When the safety flop is pushed in, the appliance
stops immediately and restarts, forks leading,at
low speed.

Starting
- Connect the battery connector (1)
- Pull the emergency stop button (4) upwards
- Turn the switch key (2) to the right as far as it will
go

CAUTION
Always adapt your driving to the conditions of the surface concerned
(irregularities, etc.), as well as to any
particularly dangerous working areas and
the nature of the load being carried.
ATTENTION
In order to avoid any scraping of the lifting
system against the ground, always raise
the forks to mid-height before setting off.

ATTENTION
Always turn off the power and remove the
key before leaving the truck.
ATTENTION
This machines bumper is designed to
protect the operators feet. This protection
is only fully effective if the operator wears
safety shoes.

19

DRIVING

USE

Emergency stop button

Indication of direction of travel

Steering

- During normal operation, the red button (1) must


be pulled out.
- In the event of any danger, depress the button
(1) to break the electrical circuit and actuate the
electromagnetic brake.

The directional markings conventionally used on


pallet trucks are as follows:

The tiller is centered and the truck is running straight.


- Turn the tiller in the clockwise direction, the
stacker truck turns to the left in reverse running.
- Turn the tiller in the anti-clockwise direction, the
stacker truck turns to the right in reverse running.

- Forward travel >

(2)

- Reverse travel

(3)

<

141 804 30 11 - 02.00

CAUTION
Before negotiating any tight bend, the truck
must be slowed down. Taking a tight bend
too fast may cause the truck to topple over.

20

DRIVING L16AS OPERATOR ALONGSIDE

USE

Driving

Forward travel ( 5 )

Reversing the direction of travel

- Place the tiller in the drive zone (3).

- Using the thumb, press gently and progressively


on the lower part of the control rocker switch (7)
(direction of rotation 9).

- Release the control rocker switch and press it in


the opposite direction.

NOTE
The maximum speed of the L 16 AS is reduced to
6km/h.
In zones (1 and 2), the electromagnetic brake is
activated and the truck cannot be driven.

The stacker truck accelerates in forward motion (5)


in proportion to the pressure exerted on the control
rocker switch.

Reverse travel ( 4 )
- Using the thumb, press gently and progressively
on the upper part of the control rocker switch (6)
(direction of rotation 8).

141 804 30 11 - 02.00

The stacker truck accelerates in reverse motion (4)


in proportion to the pressure exerted on the control
rocker switch.

The direction of travel can be reversed while the


truck is in motion.
In this case, the truck is first braked
electromagnetically until it comes to a halt, and
then moves off in the opposite direction.

Steering
- Set the truck in motion, turn the tiller, and check
that the steering movements are transmitted
correctly and without free travel.
Angle of steering lock: ....................................180
The turning radius (Wa) depends on the length of the
forks. (See technical specifications.)

6
3

7
21

DRIVING

USE

Using the truck on a slope

Going up slopes

NOTE
Abusive use of the pallet truck on a slope is not
recommended. In particular, this can overload the
traction motor, the brakes and the battery.

With a load, you must go up slopes forwards (with


the load in front of you).
However, when the truck does not have a load, you
can also go up reverse.

All slopes must be approached with caution.


- Never go on a slope which is beyond the trucks
possibilities (see data sheet).
- Make sure that the floor is clean and non-slip and
that the way is clear.

Going down slopes

CAUTION
Never park the truck on a slope.
Turning round and taking short cuts on a
slope is not permitted. On a slope, the
operator must drive slowlier.

Starting on a slope

141 804 30 11 - 02.00

With a load, you must go down slopes backwards


(with the load in front of you).
When the truck does not have a load, it must go
down forwards (forks direction).
In this case, travel at very low speed and apply the
brake very progressively.

For starting on a slope, operate the rocker switch in


the desired direction, with the tiller in position 1
(with the trucks brake applied).
Put the tiller in the operating position.

22

BRAKES, HORN

OPERATION

Electromagnetic braking

Braking by reversing the direction of motion

Horn

To release the applied electromagnetic brake, the


tiller must apply pressure on the rubber stop at the
bottom of the tiller in the braking position (2)
or
you can release the tiller. A gas cylinder then
returns the tiller into its braking position (1).

Countercurrent braking can be obtained by reversing


the direction of motion:

The horn must be used in areas of poor visibility and


at junctions.

- Tilt the reverser (3) in the opposite direction until


the truck stops.
- Then release the reverser.

- Press button (4) on the top of the tiller.

Parking brake
- The parking brake is activated automatically when the

driver releases the tiller, which is returned


automatically to the braking position (1).

141 804 30 11 - 02.00

LBC (Linde Brake Control) automatic


braking
- When the accelerator butterfly (3) is released,
counter-current braking is triggered automatically
until the truck stops.

23

USE

USING THE LIFTING DEVICE


ATTENTION
Use the lifting device and the accessories
only for tasks for which they are designed.
The driver must be taught how the lifting
system operates.

Raising and lowering the mast using the


control lever on the chassis
Raising the fork support apron:

- Turn the contact key to the right position


- Tirer the control lever (2) in position (3).

Lowering the fork support apron:

NOTE
Always move the lever smoothly, never pull it
sharply. The speed of mast raising and lowering
movements is proportional to the distance that the
lever is moved.

Raising and lowering the mast using the


tiller controls
Raising the fork support apron:

- Turn the contact key to the right position


- Activate the tiller head control flap (4)

Lowering the fork support apron:

- Activate the tiller head control flap (5)

- Pousser the control lever (2) in direction (1).

2
1
3

5
4

24

Controlling auxiliary equipment


The pallet truck may be equipped with other
equipment for special orders. Respect the working
pressure for this equipment, which is controlled
by additional switches or levers.
NOTE
Refer to the symbols glued next to the controls for
information about how to operate this equipment.
Refer to the rating plate provided with the
equipment for information about the maximum
capacities.
WARNING
Always ask our network to approve any
accessories that are not supplied with
the elevator truck, to make sure that they
are compatible with the truck.

141 804 30 11 - 02.00

Operating the mast

HANDLING LOADS
L 16 AS
ATTENTION

Before picking up a load, be sure that its


weight does not exceed the safe working
load of the truck.

Reading the rating plate

Adjusting the spacing between forks

Example with an L 16 AS equipped with a 2344 standard mast:

- Raise the fork locking bolt (6)


- Adjust the spacing between the forks to suit the
load to be lifted.
- Lower the locking bolt until it click fits into the
notch.

Elevator mast type

Maximum lifted height:

Distance from the back of the forks to

Maximum capacity on the fork: 1600kg

2390mm

the center of gravity of the load:600mm

141 804 30 11 - 02.00

- Note the nominal safe working load indicated on


the plate (1) of the truck.
- Be sure also that the load is stable and
homogeneous to prevent anything falling off the
truck.
- Check that the width of the load is compatible with
the width of the fork
- Place the loads in line with a small space between
each load.

USE

NOTE
The center of gravity of the load must always be at
mid-point between the forks.

180
1600

2390

25

HANDLING LOADS

USE

Picking up a load on the ground ( L16AS )

Transporting a load

Putting the load down on the floor

- Approach the load carefully.


- Lower the fork arms until they can easily enter the
pallet.
- Insert the forks under the load.
- If the load is shorter than the forks, position the
truck so that the far end of the load is a few
centrimetres beyond the end of the fork arms, to
avoid snagging the load in front of the one to be
picked up.
- Raise the support arms to raise the load a few
centimeters above the ground
- Slowly pull the pallet truck out of the pallet rack or
nearby loads without turning.

- It is preferable to transport a load in the forward


direction for reasons of visibility.
- When transporting a load on a steep slope always
ascend or descend with the load on the upstream
side, do not cut across and do not perform U-turns.
- Reverse motion is used only for putting down the
load, at very low speed because of reduced
visibility.

- Move the truck carefully to the required place.


- Manoeuvre the load carefully into the area where
it is to be put down.
- Lower the load until the fork arms are free.
- Slowly pull the pallet truck away, without turning
- Lift the support arms by a few centimeters.

26

WARNING
Take care not to touch nearby loads or
loads behind the truck.
DANGER
No-one should be under or close to the
truck when its load is in the raised position.
141 804 30 11 - 02.00

WARNING
Before lifting the load, make sure that its
width is less than the inside spacing of the
support arms.

DANGER
Never move the truck with the load in the
raised position. The fork must be lowered
before starting to move.

HANDLING LOADS

USE

Stacking a load

Picking up a load at a height

- Carefully bring the pallet truck to the required


location
- Lift the forks well above the level at which the load
is to be placed
- Slowly move the pallet truck forwards into the
stacking area
- Lower the load until the fork arms are released
- Slowly drive the pallet truck out without turning
- Lower the forks again to a few centimeters above
the floor

- Carefully bring the pallet truck to the required


location
- Raise the fork until the pallet is at the right height
- Carefully move the fork under the pallet
- Lift the fork until the pallet lifts off the shelf
- Slowly drive the pallet truck backwards to release
the pallet
- Lower the load to a few centimeters above the
floor

DANGER
No-one shoulb be under or close to the
truck when its load is in the raised position.

Before leaving the truck


ATTENTION
Always stop the truck on level ground and
away from traffic lanes.

141 804 30 11 - 02.00

- Lower the fork arms to their full extent


- Turn off the power and remove the key
- When stopping for prolonged periods, depress the
emergency stop button and disconnect the battery.

27

SLINGING, LIFTING, TOWING AND REMOVING THE MAST


CAUTION
Always check that the capacity of the slings
(1) and the pulley block are sufficient.
Protect all parts that come into contact
with the lifting device. Attach the lifting
device as shown below.
Weight of truck (including battery): see technical
specifications.
DANGER
There must be nobody under or near the
truck when lifting the truck.
Do not lift the truck by the tiller.

Lifting the truck


The forklift truck must be jacked up for some maintenance operations.

- Use a jack of adequate capacity.


- To lift the front part of the truck, put the jack under
the sides of the frame (2) and insert chocks at (2)
(for safety reasons)
- When carrying out maintenance work on the load
bearing wheels, place the jack under the fork
arms at the marked locations (3).
CAUTION
Always immobilise and wedge the truck
carefully after jacking it up.

Removing the mast


CAUTION
Always check that the capacity of the slings
(1) and the pulley block are sufficient.
Protect all parts that come into contact
with the lifting device. Attach the lifting
device as shown below.
This work must be carried out only by our
representatives.

Transporting and storing the truck

Towing
- In the event of an electrical breakdown the truck
cannot be towed because the electromagnetic
brake is applied.
- The truck can only be moved with the front raised,
and then carefully.

If the truck is transported, check that it is correctly


wedged and protected from inclement weather.
If the truck is not to be used for a long time:
- Remove the battery and charge it at least once a
month.
- Place the lifting device in the low position with no
load.
- Raise the truck on blocks to prevent crushing the
tyres.

2
28

141 804 30 11 - 02.00

Slinging the truck

USE

MAINTENANCE
General remarks

141 804 30 11 - 02.00

Your materials handling truck will remain serviceable


only if the small number of maintenance and inspection tasks described in this manual are carried out
regularly.
Maintenance must be carried out only by qualified
and approved personnel.
Maintenance can be handled by the FENWICKLINDE network under a service agreement. If you
wish to carry out this work yourself, we recommend
that you have the first three services carried out by
our representatives in the presence of your maintenance personnel, in order to train them.
CAUTION
For all maintenance work park the truck on
a level floor, in an area set aside for this
purpose, wedge the wheels, remove the
key from the key switch and disconnect the
battery.
After any maintenance work, test the truck to ensure
that it is operating correctly.
Modifying your truck, fitting accessories or structural modifications are prohibited without the prior
agreement of the manufacturer.
NOTE
In the case of difficult working conditions: extreme
ambient temperatures, cold or hot and dusty
environments, maintenance periods are reduced.
Carefully clean the external parts concerned before
carrying out lubrication, replacing the filter or
working on the hydraulic system.
Use appropriate containers for lubricants.

TYPES OF LIFTING MASTS


ATTENTION
Conform to the regulations governing the
use of maintenance products.
ATTENTION
Use only lubricants that conform to the
specifications.
See table of recommended lubricants.

Working on the lifting mast


CAUTION
Work on the front part of the truck with the
mast or the fork-support apron raised must
be carried out only after fitting a safety
device to prevent accidental lowering of
the mast.

Safety device for standard lifting mast


CAUTION
Choose a chain with a SWL very much
greater than the weight of the mast.
- Raise the mast.
- Loop the chain after passing it over the
crossmember of the fixed frame (1) and under the
crossmember of the inner frame (2).
- Lower the inner frame until the safety chain is
taut.

DANGER
Take special care when the mast transparent protection is removed (with your hands,
hair, etc.)

Standard lifting mast

OPERATION
When the inside frame is raised, the jockey wheel of
the chain is also raised and so the fork-support
apron is raised in a ratio of 2 : 1.

29

TYPES OF LIFTING MASTS

MAINTENANCE

NOTE
The advantage of this mast is that it can be used in
places with low ceilings such as cellars, railway
wagons, holds of ships, etc. enabling maximum
exploitation of its free lifting capacity.

CAUTION
Choose a chain whose SWL is very much
greater than the weight of the mast.

OPERATION
The fork-support apron is raised as far as the free lift
position by the jockey wheel of the chain of the
central cylinder. It moves at twice the speed of the
cylinder.
The inner frame is then raised by the two lateral
cylinders and entrains the fork-support apron with it.
The central cylinder is mounted on the mobile inner
frame.

- Raise the mast.


- Remove the plexiglas protection.
- Loop the chain after passing it over the
crossmember of the fixed frame (1) and the
crossmember of the inner frame (2).
- Lower the mast until the safety chain is taut.
- Lower the fork-support apron onto its bottom
abutment (3).

Triplex lifting mast


OPERATION
Raise the fork-support apron as far as the free lift
position by means of the idler wheel of the chain of
the central cylinder.
The two outside cylinders then raise the intermediate
mast. Because of the chain, the inner mast is raised
at the same time.
The central cylinder is disposed inside the mobile
inner mast.

Safety device for triplex lifting mast


DANGER
Choose a chain with a SWL appropriate to
each type of mast. Do not exceed the
authorised maximum lift.
- Raise the mast.
- Remove the plexiglas protection.
- Loop the chain after passing it over the
crossmember of the outer mast (4) and under the
crossmember of the central mast (5).
- Lower the mast until the safety chain is taut.
- Lower the fork-support apron onto its bottom
abutment (6).
DANGER
Take special care when the mast transparent protection is removed (with your hands,
hair, etc.)

4
6

30

141 804 30 11 - 02.00

Safety device for Duplex lifting mast

Duplex lifting mast

MAINTENANCE
Inspection and maintenance tasks after
the first 50 hours service*
-

141 804 30 11 - 02.00

Check braking system


Check the fixing of the wheels
Check the condition of the wheels
Check the hydraulic oil level
Check for leaks in the hydraulic system
Clean the hydraulic filter (strainer) and breather
Check the level and the specific gravity of the
battery electrolyte
Check the condition and the fixing of the cables
and electrical connections
Check the mechanical fixings of the chassis, of the
lifting system and of the platform
Check the condition and the adjustment of the
chains
Grease the mast chains
Lubricate the drive unit steering bearing
Lubricate generally
Change the oil in the reduction gearbox

*NOTE
See below for a description of the above tasks.

31

SCHEDULED MAINTENANCE AND INSPECTION


Before
first
use

Checks before first use (see page 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily
checks

Daily checks before use (see page 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

After
first
50 hours

Braking system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Wheel fixing check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel condition check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic circuit leak check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery electrolyte level and specific gravity check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check on condition and fixing of electrical cables
and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical and chassis fixing check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check on condition of mast and chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grease the mast chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication of drive unit steering bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Change the oil in the reduction gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Truck operation tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

As
required

Truck cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chain cleaning and lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel fixing check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel condition check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrolyte level check and top-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrolyte specific gravity check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check on condition of cables, terminals and battery connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery and battery compartment cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Truck operation tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32

141 804 30 11 - 02.00

Operation / Period

MAINTENANCE

SCHEDULED MAINTENANCE AND INSPECTION


Operation / Period

MAINTENANCE
Every 500 h
or
every 6 months

Every 1000 h
or
one year

Every 2000 h
or
2 years

Hydraulic circuit leak check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Drive unit steering bearing lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Check on condition and fixing of electrical cables

Contact wear check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Traction motor brush check and replacement if necessary . . . . . . . . . . . . . . . . . . .
Electromagnetic brake adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check on condition and fixing of mast and chains . . . . . . . . . . . . . . . . . . . . . . . . . .
Chain length adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grease the mast and chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Truck operation tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

141 804 30 11 - 02.00

Variator panel cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gearbox oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Pump motor brush check and replacement if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical parts check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Truck operation tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic oil replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Gearbox oil replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Truck operation tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33

MAINTENANCE AS REQUIRED

ATTENTION
When using a cleaning device, protect the
electrical circuits, motors and insulating
panels from direct impact by the cleaning
jets before starting cleaning.
When using compressed air, remove stubborn dirt
first by means of a cold detergent.
Before undertaking lubrication tasks, clean the oil
filler orifices and their surroundings and the greasing
nipples. Dry the truck after cleaning.

NOTE
A truck that is cleaned frequently also requires more
frequent lubrication.

Clean and lubricate chains


NOTE
Clean the lifting chain if it is excessively soiled.
- Place a container under the lifting device.
- Use a paraffin-based product (petroleum, gas oil,
etc). Follow the manufacturers safety instructions.
- Do not add additives if using a steam jet.

- Dry the chain and its articulations immediately


with compressed air. During this operation shake
the chain several times.
- Lubricate all the chain immediately using a special
chain lubricant aerosol.
ATTENTION
Chains are safety devices and can severely
be damaged by the use of cold detergents,
chemical products, acid or chlorinated
products.
ATTENTION
To clean the masts transparent protection
screen (U.V.V.), use only a liquid soap
without additives and a soft cloth.
NOTE
The use of cleaning devices employing a pressurised
liquid is not recommended.

34

141 804 30 11 - 02.00

Unplug the battery before cleaning the truck. Use


steam jets or strong degreasing cleaning agents
with great care, as they can dilute the grease in
bearings lubricated for life. Because subsequent
lubrication is impossible, these cleaning methods
damage the bearings.

Should water penetrate into the motor despite all


the above precautions, the truck must be started to
prevent rusting (drying by own heat). The motors
can also be dried using compressed air.

Cleaning

MAINTENANCE

MAINTENANCE

MAINTENANCE AS REQUIRED
Clean and lubricate the mast
- Preferably use a steam jet without any additives to
eliminate dirt on the mast, and dry it with
compressed air.
- Spray the guide surfaces, jockey wheels and
chains with the chain lubricant aerosol.
NOTE
For trucks used in the foodstuffs industry, use a dry
lubricant instead of the aerosol.

- Take out the 2 fastening screws (1).


- Turn the drive wheel perpendicular to the direction of travel so as to make it easier to remove the
cover.
- Lift the top cover (2) and then remove it.
Refitting of the cover is the reverse of the sequence
for removal.

Checking the wheel nuts


- Raise the truck until the wheels are no longer
touching the ground, and chock it up
- Check the tightness of the nuts on the drive wheel
(1). Recommended torque setting: 140Nm

Checking the condition of the wheels


- Raise the truck until the wheels are no longer
touching the ground, and chock it up
- Check the free rotation of the wheels, and remove
any object which might interfere with them.
- Replace any worn or damaged wheels
- Check first in front and after backwards.

Fuses
Remove the variator cover to gain access to the
fuses located on the electrical panel.
-The 225 A fuse protects the traction motor power
circuit.
-The 225 A fuse protects the pump motor power
circuit.
-The 7,5 A fuse protects the control circuits.
WARNING
We recommend that you should always
have this operation performed by a
specialist in our network.

1
2

141 804 30 11 - 02.00

Opening the front cover

ATTENTION
If any wire becomes wrapped around the
wheel hubs or bearings, this must be
removed. Failure to do so may result in
rapid wear to the wheels.

ATTENTION
Before carrying out any operation on the
truck:
- Depress the emergency stop button
- Disconnect the battery connector

35

The operations described below apply to lead-acid


batteries with liquid electrolyte.
For maintenance-free batteries with gel
electrolyte, refer to the manufacturers instructions.
CAUTION
Avoid any contact with the acid. Do not
create any short-circuit. See the
recommendations in the daily checks
section.

Checking electrolyte level and topping up


with water.
- This check, and any necessary topping-up, is to be
carried out once a week, after recharging the
battery.
- Turn off the key-switch, open the cover (1) and
disconnect the battery connector (2).
- Check the level. It should be up to the base of the
filler plug, just above the top of the separator.
- Use demineralised water to top up any cells with
a low water level.
- Replace the filler plugs.

MAINTENANCE
ATTENTION
Use only demineralised water for topping
up.
Never add water before charging (risk of
overspill).
Do not overfill the cells.
For more information, refer to the instructions
supplied with the battery.

Checking the electrolyte specific gravity


- Measuring the specific gravity gives an accurate
indication of the state of charge of each cell in the
battery. This measurement may be carried out
before or after charging.
- Minimum specific gravity, battery 80% discharged:
1.14
- High specific gravity, battery 100% charged: 1.29
to 1.32 (according to make).
- We recommend measurement every week or two.
Keep a record of the values measured in the
service booklet for your battery.

36

- Remove the filler plug for each cell as described


above.
- Using an acid hydrometer, carefully measure the
specific gravity in each cell.
- Replace the filler plugs when finished.
NOTE:
If there are voltage discrepancies between the
various cells, or if any cells show a particularly low
voltage, contact your local representative. Any
discharge below the threshold of 1.14 will be
extremely detrimental to the lifespan of the battery.
For more information, refer to the instructions
supplied with the battery.

141 804 30 11 - 02.00

MAINTENANCE AS REQUIRED

MAINTENANCE AS REQUIRED
Checking the condition of battery cables,
terminals and connector

Cleaning the battery and battery


compartment

- Check that cable insulation is undamaged, and


that the connections show no sign of overheating.
- Check that the + and - battery terminal pillars are
not sulphated (indicated by the presence of a
white salt-like deposit).
- Check the condition of the connector contacts,
and the presence of the locating pin.

CAUTION
This is a delicate operation, and requires
the wearing of gloves, goggles and acidresistant clothing.
Respect the precautions mentioned in the previous
chapters. Do not dispose of acid-polluted washing
water in drains.
For further information, refer to the instructions
supplied with the battery.

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.

141 804 30 11 - 02.00

MAINTENANCE

Battery in unsealed box

Battery in sealed box


- Check that there is no electrolyte in the bottom of
the box by connecting the suction bulb supplied
with the battery to the plastic plunge tube.
- Pump out any electrolyte which may have
overflowed between the cells.
- Clean the upper surface of the cells with a damp
cloth.
ATTENTION
In the event of heavy sulphation or
substantial electrolyte overflow, please
contact your local representative.

- Check for traces of sulphation in the box and on


the chassis.
- If sulphation is mild, it is sufficient to clean the
upper surface of the cells with a damp cloth.
- In the case of heavier sulphation, it is necessary to
remove the battery, pressure-wash it and clean
the chassis.

37

MAINTENANCE EVERY 500 HOURS

NOTE
Use only the type of grease specified in the
lubrication table.
- Open the motor cover to gain access to the grease
nipples
- Clean the two grease nipples (1)
- Inject grease into each nipple while turning the
drive unit, until clean grease emerges from the
bearing race.

Checking miscellaneous joints


Verify and lubricate the various hinge pins on:
- Fork locking levers
- The tiller
- Elements of the battery compartment (hinge, lock,
rollers)

- Ease of movement (stabilizing wheel pivots,


boogies).
Use lithium soap grease for hinges provided with
lubrication nipples, and aerosol lubricant in other
cases.

Checking for leaks in the hydraulic system


- Inspect the hydraulic system: pipes, flexible hoses
and unions between the pump motor and the
pressure cylinders
- Tighten unions if necessary
- Check the two lifting cylinders for leaks
- Check that the flexible hoses are correctly fitted
and not chafed.

Checking the hydraulic fluid level


-

Lower the equipment to the ground.


Open the front cover
Unscrew the breather cap (2) (with the gauge)
Clean the gauge (3) with a clean cloth
Put the plug back into position with its gauge and
unscrew it again
- The oil level must be located between the MIN
and MAX marks on the gauge (3)
- Top up if the level is too low, as far as the max
mark
- Screw the cap back on the end of the operation.
ATTENTION
Use only hydraulic fluid which meets the
relevant specifications (see table of
lubricants).

If any leaks are observed, please contact your local


representative.

141 804 30 11 - 02.00

Lubricating the drive unit slew ring

MAINTENANCE

3
maxi
1

38

mini

MAINTENANCE EVERY 500 HOURS


Check condition and fixing of mast and
chains

141 804 30 11 - 02.00

- Carefully clean the guide rails of the mast and the


chains.
- Check the condition of the friction surfaces and
the rotation of the rollers.
- Check the condition and wear of the chains, in
particular around the jockey wheels.
- Check the fixing of the chain anchors.
- Replace any worn chain or any chain that has
stretched 3%.
- Check the members fixing the mast to the chassis.
- Check the clips fixing the cylinders to the mast.

MAINTENANCE

Adjust length of mast chains


NOTE
The chains stretch during use of the truck and must
be adjusted at regular intervals.
-

Lower the mast completely.


Loosen the lock-nut (2).
Lightly tension the chains by tightening the nut (1).
Tighten the lock nut (2).
ATTENTION
After carrying out the above adjustment,
check that at maximum lift the lift apron
does not abut mechanically against the top
of the mast. If it does, loosen the chains
slightly or replace them.

We recommend that this operation is carried out by


our specialist representative.

39

Electrical system: checking the condition


and fastening of electrical cables and connections
ATTENTION
Before commencing any work on the
electrical equipment, the battery connector
must be disconnected.
- Remove the motor cover.
- Check the tightness of the connections, and ensure
that there are no traces of corrosion.
- Check that cable fastenings are secure.
- Check the cables for any areas of chafing.
Ensure that they are properly insulated and
fastened.
NOTE
Corroded connections and damaged cables may
cause voltage drops and overheating, which can
result in malfunction.

40

MAINTENANCE

Cleaning the electrical panel

Cleaning and checking contacts for wear

- Disconnect the battery connector.


- Remove the pulse control cover.
- Clean the pulse control panel using compressed
air.

- Disconnect the battery connector.


- Clean the contacts using compressed air, and
check their mechanical integrity.
- Any contacts which show advanced wear or
substantial traces of burning must be replaced.

NOTE
Protect the electrical panel against moisture.
Adjustment and repair must be carried out only by
our representatives.
ATTENTION
Before commencing work on any electrical
component, disconnect the battery
connector.

Always replace the contacts as a complete set.


NOTE
We recommend leaving this operation to your local
representative.

141 804 30 11 - 02.00

MAINTENANCE EVERY 500 HOURS

MAINTENANCE EVERY 500 HOURS


Inspection / replacement of the traction
motor brushes
-

141 804 30 11 - 02.00

Disconnect the battery connector.


Open the motor cover.
Remove the retaining spring (1).
Remove the protective grille (2).
Clean the motor using compressed air.
Check that there are no traces of overheating on
the brush connections (3).
Check the tightness of the connections.
Check that the brushes move freely in their
channels by pulling gently on their shunts.
Lift the springs (4), withdraw the brushes from
their guides, and measure their length.
Replace if necessary.
Check that the commutator is not scored, and
shows no signs of sparking.

MAINTENANCE

NOTE
Always replace brushes as a complete set.
We recommend leaving this operation to your local
representative.
Dimensions:
Drive motor: 1.5 kW new length : 32 mm
min. length: 16 mm
ATTENTION
In the event of any anomaly, please contact your local representative.

Adjusting the electromagnetic brake


IMPORTANT
The maximum braking force is set at the factory, and
must not be modified.
- The brake must be checked in the on position,
i.e. with the electrical power turned off.
- Check the brake gap using feeler gauges. The gap
measurement when new is 0.35 mm; the maxi-

mum gap after partial wear of the disc is 0.6 mm.


Any greater gap entails the risk of incomplete
release of the brake, with consequent overheating.
- If the gap is close to the limit of 0.6 mm., it must be
adjusted.
- Disconnect the power to the brake.
- Remove the three securing bolts (5).
- Turn the three hollow bolts (6) to adjust the gap to
its original measurement of 0.35 mm.
- Re-tighten the three securing bolts (5).
- Check the gap again at three points separated by
120.
- Ensure that the gap is uniform all around the
brake.
- Apply power by depressing the safety pedal, and
check that the brake is fully released.
- Energize the pallet truck, and move the tiller into
area 1 or 2. Keep the throttle pressed, move the
tiller in area 3, and the brake should be released
correctly.
We recommend leaving this operation to your local
representative.

2
1

5
0,35 mm
3

41

MAINTENANCE EVERY 1000 HOURS


Checking the reduction gear oil level

WARNING
The battery is a heavy and fragile
component that must be handled with care.
WARNING
Refer to the "Removing/Replacing the
battery" and "Replacing the battery using
a truck with rollers" sections in the "Start
up" chapter, for information on how to
remove and replace the battery.

Removing the pump motor unit


- Remove the motor cover.
- Lower the forks to their fullest extent.
- Remove the two bolts (2) securing the pump motor
to the chassis.
- Disconnect the electrical connections
- Disconnect the hydraulic pipes.
- Remove the pump motor unit.
Refitting of the pump motor unit is the reverse of the
sequence for removal.

141 804 30 11 - 02.00

- Remove the battery.


- Position the wheel so as to allow access to the
filler plug (1).
- Unscrew the plug (1). The oil level should come up
to the base of the orifice.
- If necessary, top up with oil to the correct level.
- Replace the filler plug.
- Check for any signs of leakage.
- Replace the battery.

MAINTENANCE

1
2

42

MAINTENANCE EVERY 1000 HOURS

MAINTENANCE

Inspection / replacement of the pump


motor brushes

Cleaning the reservoir hydraulic filter


(strainer) and the cap

Checking the mechanical fixing of


components

- Access the brushes by removing the cover (9)


- Check the brushes, replace if necessary.
- Check that the commutator is not scored, and
shows no signs of sparking.
- Blow in compressed air and reassemble

- Put the elevator system into the low position


- Clean the strainer on the breather cap (1) with
compressed air
- The filter strainer (3) is mounted with a check
valve (2)
- Unscrew and remove the check valve (2)
- Take the metal strainer (3) out and clean it
WARNING
During disassembly, take care not to lose
the spring (4) and ball (5) on the check
valve provided with the filter.

- Check for secure fitting of the sub-assemblies:


motor / reduction gear, load wheels, driven wheel.
- Check the tightness of the various nuts and bolts.
- Check that the fork arms are in good condition.
- Replace any defective items.
- Retouch paintwork if necessary.

NOTE
The unit must be removed in order to replace the
brushes.
Always replace the brushes as a complete set.
We recommend leaving this operation to your local
representative.

141 804 30 11 - 02.00

DIMENSIONS
Pump motor:

3 kW (S3: 15%)

new: 22,5 mm
min.:
14 mm

- Check that the seal (6) is in good condition


- Put the check valve (2-6) back into position.
- Top up the oil level after carrying out these
operations.
NOTE
We recommend leaving this operation to your local
representative.

1
1

6
43

MAINTENANCE

MAINTENANCE EVERY 2000 HOURS


- Remove the pump-motor unit and place it flat on
the three rubber supports.
- Disconnect the pump-motor unit (1) from the tank
by loosening collar (2).
- Lift the motor-pump assembly, and recover O-ring
(3) from the tank base.
- Drain the oil.
- Clean the intake strainer.

Refilling

- Refit the reservoir (3) to the pump motor unit,


taking care to seat the O-ring properly.
- Refit the pump motor unit to the chassis.
- Reconnect the pipes.
- Unscrew the filler plug (4).
- Refill the reservoir through the opening.
- Replace the filler plug (4).
- Operate the lifting system several times in order to
purge the system.

- Lower the fork arms to their full extent.


- Check the oil level using the gauge on the breather
cap (4)
- Clean the gauge with a clean cloth
- Put the cap back into position with its gauge and
unscrew it again
- The oil level must be located between the two
marks on the gauge
- Top up if the level is too low, as far as the
maximum mark
- Screw the cap on again at the end of the operation.
Hydraulic reservoir capacity. . . . . . . . . . . . . . 7.4 l
Oil quantity between the marks on the gauge. . . . l

Changing the reduction gear oil


NOTE
Before commencing this operation, run the reduction
gear in order to warm the oil.
- Remove the motor cover.
- Raise the truck.
- Use the tiller to turn the reduction gear until the
drain plug (2) and level plug (1) are accessible.
- Place a receptacle beneath the reduction gear.
- Undo the level plug (1).
- Undo the magnetic drain plug (2).
- Clean and replace the magnetic drain plug after
replacing the sealing washer.

Refilling
ATTENTION
Use only hydraulic fluid which meets the
relevant specifications (see table of
lubricants).

- Refill through the upper hole (1) until the level


reaches the bottom of the opening.
- Replace the level plug (1).

4
1

2
1
4
3

MAXI
MINI

44

141 804 30 11 - 02.00

Changing the hydraulic fluid

141 804 30 11 - 02.00

RECOMMENDED LUBRICANTS / TECHNICAL SPECIFICATIONS

MAINTENANCE

Unit

Part / lubricant

Capacity / adjustment value

Hydraulic system
Hydraulic system
Hydraulic system

Hydraulic fluid
Filter element
Max. pressure (start of opening)

7,40 l

Reduction gear

Reduction gear oil

1,8 l

Driven wheel
Load wheels

Wheel nuts
Mounting bolt

Torque setting:
Torque setting:

Traction motor 1,5 kW


Pump motor 3 kW
Control harness

Fuses
Fuses
Fuses

Power
Power
Control

Traction motor 1.5 KW


Pump motor
3 KW ( S3: 15% )

Brushes
Brushes

New
32 mm,
New 22,5 mm,

Battery

Distilled water

As necessary

Joints

Lithium-based grease

As necessary

Efficiency: 150

180 bar

225 A
225 A
7,5 A

140 Nm
50 Nm
Qty : 1
Qty: 1
Qty : 1

min. 16 mm
min. 14 mm

Recommended lubricants
Hydraulic fluid

Multi-purpose grease

ISO VG 46 H-L or H-LP (DIN 51524). Manufacturers


code, 5-litre cans: 8101521.
For cold-room operation: 8101489 (25-litre cans).

Lithium-based grease, high-pressure with antiwear additive: Standard DIN 51825 - KPF 2K - 30, KPF 2K - 20, KPF 2N - 30.
Manufacturers code, cartridge: 7.337.475 140.

Reduction gear oil

Chain aerosol

SAE 80 W 90, API. GL5, MIL.L 21DSC.


Manufacturers code, 5-litre cans: 8100560.

Manufacturers code: 7326300602


For cold-room operation: 7326300615

45

46
141 804 30 11 - 02.00

HYDRAULIC SYSTEM DIAGRAM


1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.

Lifting cylinders
Raise / lower mast distributor
(controlled by the lever)
Motor pump unit
Breather
(built into the filling cap)
Reservoir
Adjustable pressure reducing valve
Suction strainer
Pump
Non-return valve
Pressure filter
Raise solenoid valve (control on tiller)
Lower solenoid valve (control on tiller)
Plug
Flow controller
Pipes
Unions

12

14

13

15

16

2Y2
2Y1

141 804 30 11 - 02.00

11

2
10
9

5
47

L16 AS ELECTRICAL DIAGRAM (LDC variator)


Description

Position

Code

1A1

(LDC) drive variator

15-49

1B1
1B2

Accelerator potentiometer
Motor speed and direction
of rotation detector

40-43
45-44

1F1
1F3
2F1

225 A drive motor fuse


7.5 A control fuse
225A pump motor fuse

G1

Battery

4H1

Horn

1K11
1K12
2K1

Forward drive switch


Reverse drive switch
Pump switch

1M1
2M1

Drive motor
Pump motor

6P2

Hour meter, battery limiter


indicator

R2

1/4W 1K Ohm resistor

47

S1
1S21

Ignition key
(Front) variator
start microswitch
(Rear) variator
start microswitch
Tiller rear safety microswitch
Tiller base safety microswitch
Lower forks control microswitch
Raise forks control microswitch
Raise fork control microcontact
on the lever distributor

11
32

1S22
1S3
1S4
2S6
2S7
2S12

48

5
11
9
1
54
3,6,21
3,6,23
9,61
5
9
61-66

33
37
26
56
58
62

Description

Position

4S1
7S1

Horn control microswitch


Emergency stop mushroom-headed switch

X1
1X1
1X2
1X3
1X4
1X5
1X6
1X9

Battery plug
1
Drive variator control circuit connector
Speed sensor connector
Brake tiller/truck panel circuit connector
Connector for programming unit on LDC
Tiller head-tiller circuit connector
Connector for options
Driver presence connector
(platform)
Encoding circuit connector
Tiller head/truck connector
Platform position connector (panel side)
Handrail and presence connector
Pressure sensor /limit switch
electro. connector (not used)
Charge limiter indicator hour meter connector
Top cut-out/brake release interface connector
(not used)

1X13
1X16
1X17
1X18
2X9
6X1
7X3

54
1

Y1
2Y1
2Y2

Electromagnetic brake
Raise forks solenoid valve
Lower forks solenoid valve

25
59
57

Z1
Z2
Z3
7Z1

Interference suppression circuit


Interference suppression diode
Non-return diode
Brake interference suppression (transit)

24

COLD ROOM OPTION


R1CF
R2CF

Cold room resistor (option)


Cold room resistor (option)

10
11

Code

Colour

Code

Colour

BK

Black

GN

Green

WH

White

VT

Violet

BU

Blue

RD

Red

OG

Orange

YE

Yellow

BN

Brown

GY

Grey

141 804 30 11 - 02.00

Code

141 804 30 11 - 02.00

ELECTRICAL DIAGRAM L16 AS

49

INDEX

Adjusting the electromagnetic brake ........................ 41


Adjusting the spacing between forks ........................ 25

Before leaving the pallet truck ................................... 27


Braking by reversing the running direction .............. 23

Calendar for maintenance work ........................... 32-33


Checking automatic braking ....................................... 13
Checking contact wear ................................................ 40
Checking forward/reverse and raise/lower
controls .......................................................................... 13
Checking operation of the emergency
stop button ..................................................................... 13
Checking the attachment and condition of
the wheels ..................................................................... 35
Checking the battery charge condition ..................... 13
Checking the condition and attachment of
cables and electrical connections ............................ 40
Checking the condition and attachment of the
mast and chains ........................................................... 39
Checking the condition of cables, terminals
and the battery connector ........................................... 37
Checking the driver presence safety device ........... 13
Checking the electrolyte density ................................ 16
Checking the electrolyte density ................................ 36
Checking the electrolyte level and topping up
with water ...................................................................... 16
Checking the electrolyte level and topping up
with water ...................................................................... 36

50

Daily checks before use .............................................. 12


Definition of safety terms ............................................ 11
Determining the running direction ............................. 20
Discharge limiter indicator ......................................... 10
Driving ............................................................................. 21
Duplex elevator mast ................................................... 30

Electromagnetic braking ............................................. 23


Emergency stop button ................................................ 20

Fixing and adjusting stabilizing wheels .................... 35


Forward running ............................................................ 21
Fuses ............................................................................... 35

General comments ....................................................... 29


Going down slopes ....................................................... 22
Going up slopes ............................................................. 22

Handling loads ............................................................... 25


Horn control ................................................................... 23
Hydraulic diagrams ...................................................... 47

Index ......................................................................... 50-51


Indicators ....................................................................... 10

141 804 30 11 - 02.00

Checking the horn ......................................................... 13


Checking the hydraulic fluid level .............................. 38
Checking the leak tightness of the hydraulic
circuit .............................................................................. 38
Checking the length of mast chains .......................... 39
Checking the mechanical attachment of devices ... 43
Checking the pump motor brushes, and
replacement if necessary ........................................... 43
Checking the reduction gear oil level ........................ 42
Checking the safety braking ....................................... 13
Checking the safety inverter switch .......................... 13
Checking the state of terminal cables and
battery connector ......................................................... 16
Checking the traction motor brushes, and
replacement if necessary ........................................... 41
Checking the various hinges ...................................... 38
Checks and maintenance work after the first
50 hours of service* ..................................................... 31
Checks before first startup ........................................ 12
Cleaning and greasing chains .................................... 34
Cleaning and greasing the mast ................................ 35
Cleaning the battery and the battery
compartment ................................................................. 37
Cleaning the electrical panel ...................................... 40
Cleaning the hydraulic filter and cap ......................... 43
Cleaning the pallet truck .............................................. 34
Connecting the battery connector ............................. 15
Controlling auxiliary equipment .................................. 24
Controls ............................................................................ 9

INDEX

L 16 AS electrical diagrams .................................. 48-49


L.B.C. automatic braking ............................................. 23
Lifting the pallet truck .................................................. 28
Lubrication of the drive unit steering bearing .......... 38

O
141 804 30 11 - 02.00

Opening and closing the battery cover ..................... 15


Opening the front cover ............................................... 35
Overview L16AS .............................................................. 8

Parking brake ................................................................ 23


Periodic checks on the pallet truck ........................... 12
Picking up a load at a height ....................................... 27
Picking up a load on the ground ................................. 26
Plates and labels ............................................................ 3
Putting a load down on the ground ............................ 26

Reading the rating plate .............................................. 25


Recharging the battery with an external charger ... 16
Recommendations for starting up ............................. 12
Recommended lubricants / Technical
characteristics ............................................................. 45
Removing the motor-pump unit .................................. 42
Removing/Replacing the battery ................................ 18
Replacing reduction gear oil ....................................... 44
Replacing the battery using a trolley ......................... 18
Replacing the hydraulic fluid ....................................... 44
Reversing the running direction ................................. 21

Safety device for Duplex elevator mast .................... 30


Safety device for standard elevator mast ................ 29
Safety device for Triplex elevator mast .................... 30
Safety rules ................................................................... 11
Safety switch ................................................................. 19
Slinging the pallet truck ............................................... 28
Stacking a load ............................................................. 27
Standard elevator mast ............................................... 29
Starting on a slope ....................................................... 22
Startup ............................................................................ 19
Steering .................................................................... 20-21

Taking the mast off ....................................................... 28


Technical characteristics ............................................. 6
Technical description .................................................... 7
Time counter unit .......................................................... 10
Towing ............................................................................ 28
Transport and storage of the pallet truck ................ 28
Transporting a load ...................................................... 26
Triplex elevator mast ................................................... 30

Usage instructions ....................................................... 19


Using ingredients .......................................................... 11
Using the mast .............................................................. 24
Using the pallet truck on a slope ............................... 22

Raising and lowering the mast using the control


lever on the chassis .................................................... 24
Raising and lowering the master by controlling
the tiller .......................................................................... 24

51