Linde 1101-02 Series Operating Instructions Manual
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Linde 1101-02 Series Operating Instructions Manual

Electric pallet truck
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1101-02 series Electric Pal-
let Truck
Operating Instructions
Models EW 30, EWR 30,
EW 40, EWR 40
1101-02 series EW/EWR –
11018011640 rv02 US - 03/2020

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Summary of Contents for Linde 1101-02 Series

  • Page 1 1101-02 series Electric Pal- let Truck Operating Instructions Models EW 30, EWR 30, EW 40, EWR 40 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...
  • Page 3 With ten production plants worldwide and an extensive network of sales partners, we are at your serv- ice around the clock and around the world. Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...
  • Page 4 This manual - and any excerpts thereof - may not be reproduced, translated or transmitted in any form to third parties without the express written permission of the manufacturer. Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 5: Table Of Contents

    Decal and Data Plate Location ......... . Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...
  • Page 6 Lubricate Tie Bar Linkage ..........Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...
  • Page 7 Specifications EWR ........... Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...
  • Page 9 Introduction...

  • Page 10: Introduction Scope

    Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 11: Operator Responsibilities

    Lifting of loads or trans- designed and rated. port of elevated loads is prohibited on inclines Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 12: Hazard Messages

    NOTE Indicates further information presented to en- sure clarification of a particular item ENVIRONMENT NOTE The information contained herein must be ob- served, otherwise environmental damage may occur. Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 13: Safety

    Safety...

  • Page 14: Before Operation

    Truck may not be placed back into service until necessary repairs are made. F231 05-2013 NOTE Any repairs or maintenance to the truck must be performed only by trained and authorized technicians. Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 15: Operating Position

    The drive end of the truck will limited. swing out if a turn is made while travelling in Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 16: Inclines, Ramps, Docks, Elevators

    Never exceed the rated capacity of a ramp or bridge plate. Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 17: Parking

    Remove any metal rings, bracelets, bands, forklift truck. ● or other jewelry before working with or near batteries or electrical components. Never expose batteries to open flame or ● sparks. Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 18: Safety During Maintenance

    Spilled oil should be removed with oil-bind- ● ing agents at once and disposed of accord- ing to local regulations. If recycling is not possible, dispose of used ● oil according to local regulations. Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...
  • Page 19 Spilled hydraulic oil should be removed with ● oil-binding agents at once and disposed of according to local regulations. If recycling is not possible, dispose of used ● hydraulic oil according to local regulations. Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 20: Operator Warning Decals

    TRAINED AND AUTHORIZED OPERATORS ONLY. MISUSE OF THIS TRUCK COULD CAUSE INJURY TO YOURSELF OR OTHERS WORKING WITH YOU. READ INSTRUCTIONS IN OPERATOR’S MANUAL. 0009384608 Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 21: Test Or Service Warning Decal

    This decal is only present on models designed for riding. Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 22: Order Picking System Decal

    ALLOW THE TRUCK TO COAST. ALWAYS DEACTIVATE THIS SYSTEM BEFORE DISCONNECTING POWER. FAILURE TO FOLLOW INSTRUCTIONS COULD RESULT IN INJURY OR DEATH. SEE INSTRUCTIONS IN OPERATOR’S MANUAL 11014391000 PICK WHEN SYSTEM ACTIVE Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 23: Overview

    Overview...

  • Page 24: Technical Description

    The tains the pump, a manifold block, a lowering Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...
  • Page 25 One fuse for the power circuit is tics or adjustment of certain performance pa- present. A number of control fuses are used rameters. Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...
  • Page 26 Overview Technical Description Model Illustrations Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 27: Truck Components

    Grab bar (EWR only) Battery compartment Auxiliary buttons (EWR only) Battery retainer (optional) Load back rest (optional) Riding platform (EWR only) Accessory tray (optional) Casters (standard on EWR; optional on EW) Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 28: Controls

    High speed travel button (rider trucks only) Travel control Auxiliary horn button (rider trucks only) Order pick activation button (optional) Lever switches for low-speed function (or optional order picking system) Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 29: Display Unit

    The icon will flash when the next service inter- low speed (creep) function is active. val is actually reached. Truck performance may be limited based on preferences set in the truck program. Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 30: Data Plate

    (MAX and MIN) for the battery in center of gravity must be within the pounds and kilograms. corresponding values shown in col- umns A, B, and D. Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 31: Decal And Data Plate Location

    Warning Decal, Platform Surface Warning Decal, Order Pick System (option- 3 (EW) Warning Decal, No Riders Plate, UL Classification Cold Storage Decal (optional) Warning Decal, Service Work EE Designation Decal (optional) Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 32: Definition Of Directions

    Various drive tire types ● Caster wheels (standard on EWR) ● Greasable caster wheel axles ● Order pick system ● Wash-down protection ● Cold storage protection ● Electric steer assist ● Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 33: Operation

    Operation...

  • Page 34: Unloading And Preparing A New Truck For Operation

    Maintenance section. However, during the first 50 operating hours, avoid subjecting the drive motors or hydraulic system to high continuous loads. Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 35: Turning The Truck On And Off

    Switching the truck off To turn the truck off, turn the key switch coun- ter-clockwise to the vertical position. The indi- cator unit display will turn off. Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 36: Driving

    (EWR models only) if riding. Reverse  With the control handle in the working range, press the lower section of the travel control so that it rotates in the direction shown (3). Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...
  • Page 37 Rider models are equipped with a high-speed travel button (6) located on the grab bar. This button will allow the truck to reach a higher speed than that used during walking Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...
  • Page 38 Always ensure a stable riding position and keep one hand on the grab bar while using the high-speed function. Do not use the high-speed function during walking operation. Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 39: Steering

    If the truck is a rider model, additional horn buttons (2) are provided on the grab bar. Ei- ther button will sound the horn. 1101-02 02022018-05 1101-02 02022018-06 Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 40: Braking

    This form of braking will also occur if the con- trol handle moves out of its operating range (A). Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 41: Raising And Lowering The Forks

    On rider models, additional lift and lower but- tons are provided on the grab bar. Their func- tion is identical to the buttons in the control handle. Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 42: Order Picking System (Optional Equipment)

    To stop the truck, release the grey lever switch or travel control and move the handle to the full up or down position. Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...
  • Page 43 Use of the order picking system on an incline can re- sult in longer coasting distances. Do not operate the truck on an incline with the order picking system active. Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 44: Creep-Speed Function

    1101-02 02022018-11 creep-speed icon will no longer appear in the display, Release the travel control to neutral and the truck will now operate normally. Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 45: Connecting And Disconnecting The Battery

    Disconnecting the Battery  Turn the key switch off.  Grasp the battery connector (1) and pull it apart. Place the loose cable on the battery to guard against damage. Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 46: Connecting The Battery To An External Charger

     Charge the battery in accordance with the WARNING charger manufacturer's instructions. Explosive gases are released during battery charg- ing. Charge batteries only in well ventilated areas. Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 47: Changing The Battery

     Remove the optional accessory tray (2) if equipped.  If the truck is equipped with an optional load backrest, pull the tilt release handle (3) and tilt the load backrest towards the forks. Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...
  • Page 48  Carefully position the replacement battery in the battery box. Disconnect and remove all lifting equipment.  If the truck is equipped with battery rollers, replace the battery retainer plate. Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...
  • Page 49  Tilt the load backrest (if equipped) back into position.  Replace the accessory tray if equipped. WARNING Batteries produce explosive gases. Always store batteries in well ventilated areas. Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 50: Towing The Truck

     Lift the front of the truck enough for the drive tire to clear the ground but not so much that the fork tips drag. The truck may then be towed. Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 51: Hoisting The Truck

     Attach lifting equipment to the fork tips to keep the truck approximately horizontal as it is lifted. Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...
  • Page 52 Operation Hoisting the Truck Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 53: Maintenance

    Maintenance...

  • Page 54: Personnel Qualifications

    Run the truck immediately after cleaning to check operation and to aid in drying in case any motors became exposed to moisture. Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 55: Operator Inspection And Maintenance

    The If any problem affecting safety is noted, it must checklist illustrated is intended for a range of be repaired immediately by a trained forklift Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...
  • Page 56 Excessive noise during hydraulic function operation indicates low hydraulic fluid. This condition must be checked and corrected imme- Check Operating Controls diately to avoid damage to the hydraulic pump. Return Spring Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 57: Routine Lubrication And Inspection

    Lubricate the lift cylinder and fork frame pivot pins. 200 hours Lubricate caster swivel bearings (if equipped). 200 hours Lubricate the teeth of the steering gear (optional electric steer only). 200 hours Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 58: Check Casters

    Level should be approximately 3/4 inch (19 mm) be- low the bottom of the filler plug opening. Add hydraulic oil as necessary. See the Fluid and Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 59: Check Drive Wheel And Fasteners

    10 hours thereafter until no further loosening is detected. Drive Wheel Fastener Torque 144 ft-lbs (195 Nm) Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 60: Lubricate Drive Axle Swivel Bearing

     Manual Steer   Electric Steer (optional)  Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 61: Lubricate Tie Bar Linkage

    (1 and 2), each end of the tie bar (3 and 4), and the shackle pivot (5). Access to 1, 2, and 4 is from beneath. Tie Bar Lubrication Points Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 62: Lubricate Lift Cylinder And Fork Frame Pivots

    Always switch the truck off and disconnect the bat- tery before working on or around the drive unit or steer motor unit. Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 63: Scheduled Maintenance

    (based on years in service) listed at the documentation for maintenance requirements. top of each chart. All lubrication and service intervals must be reduced for dusty conditions, large tempera- ture fluctuations or intensive use. Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 64: Maintenance Schedule

    Check lift limit switch by verifying the pump motor stops when forks reach maximum height. Subsequent tasks Carry out functional test and test drive. Attach maintenance sticker. Maintenance every 2000 hours, but at least every 12 months. Preparations Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...
  • Page 65 Read and clear the error memory. Enter the next service interval. Gear unit Change the gear oil. Subsequent tasks Carry out functional test and test drive. Attach maintenance sticker. Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 66: Fluids And Lubricants

    Do not mix non-lithium-based greases with lithium-based greases. Capacities Assembly Fluid or Lubricant Capacity Hydraulic system Hydraulic oil 1.7 qts (1.6 l) Transmission Gear oil 1.9 qts (1.8 l) Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 67: Troubleshooting

    (4A) Options at X9 (4A) Steering input potentiometer A3 (elec- (4A) Speed sensor B1 tric steer only) (4A) Handle angle potentiometer A6 (4A) Electro-magnetic brake Y1 Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 68: Diagnostic Connector

    The procedure is explained in the service manual. Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 69: Technical Data

    Technical Data...

  • Page 70: Specifications Ew

    Technical Data Specifications EW Specifications EW Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...
  • Page 71 Ground clearance, mid-fork (m2) (26.2 mm) (26.2 mm) 2.3 in 2.3 in Fork thickness, mid-fork (s) (57.7 mm) (57.7 mm) Overall length (l1) See fork table See fork table Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...
  • Page 72 (1408/1338 (1663/1593 (724 mm) (1843 mm) 61.5 / 58.7 in 71.5 / 68.7 in 34.5 in 78.6 in 42 in (1067 mm) (1561/1490 (1816/1745 (876 mm) (1996 mm) Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...
  • Page 73 31.5 in (796 mm) 31.5 in (796 mm) Minimum battery weight 900 lbs (408.24 kg) 900 lbs (408.24 kg) Maximum battery weight 1500 lbs (680.4 kg) 1500 lbs (680.4 kg) Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

  • Page 74: Specifications Ewr

    Technical Data Specifications EWR Specifications EWR Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...
  • Page 75 Handle height, maximum (h14) (1507 mm) (1507 mm) 8.6 in 8.6 in Platform height (h7) (218 mm) (218 mm) 1.03 in 1.03 in Ground clearance, mid-fork (m2) (26.2 mm) (26.2 mm) Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...
  • Page 76 (Wa) lowered/ distance (X) (L1) ered/raised raised 55.4 / 52.7 in 65.5 / 62.7 in 28.5 in 80.5 in 36 in (914 mm) (1408/1338 (1663/1593 (724 mm) (2044 mm) Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...
  • Page 77 31.5 in (796 mm) 31.5 in (796 mm) Minimum battery weight 900 lbs (408.24 kg) 900 lbs (408.24 kg) Maximum battery weight 1500 lbs (680.4 kg) 1500 lbs (680.4 kg) Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...
  • Page 78 Technical Data Specifications EWR Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...
  • Page 79 Electric braking..... Lubrication, routine intervals... Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...
  • Page 80 Regenerative braking....32 Scheduled maintenance charts..56 Operating Instructions - 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...
  • Page 82 KION North America Corporation 1101-02 series EW/EWR – 11018011640 rv02 US - 03/2020...

This manual is also suitable for:

Ew 30Ewr 30Ew 40Ewr 40

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