Related Manuals for Linde 1102-02 Series
Summary of Contents for Linde 1102-02 Series
- Page 1 1102-02 series Electric Rid- er Pallet Truck Operating Instructions Models ECR 30, ECR 40 1102-02 series ECR – 11028011640 rv03 US - 04/2020...
- 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 - 1102-02 series ECR – 11028011640 rv03 US - 04/2020...
- 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 - 1102-02 series ECR – 11028011640 rv03 US - 04/2020...
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Page 5: Table Of Contents
Decal and Data Plate Location - Manual Steer ......Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... - Page 6 Lubricate Tie Bar Linkage ..........Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020...
- Page 7 Specifications - Electric Steer ......... . . Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020...
- Page 9 Introduction...
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Page 10: Introduction Scope
Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... -
Page 11: Operator Responsibilities
Lifting of loads or trans- designed and rated. port of elevated loads is prohibited on inclines Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... -
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 - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... -
Page 13: Safety
Safety... -
Page 14: Before Operation
Place a “Do Not Operate” tag on the truck, remove the key and alert your supervisor. The Truck may not be placed back into service until necessary repairs are made. F296 05-2013 Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... -
Page 15: Operating Position
To avoid hazards associated with a dock, you should personally check that the trailer brakes Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... -
Page 16: Parking
Remove any metal rings, bracelets, bands, ● or other jewelry before working with or near batteries or electrical components. Never expose batteries to open flame or ● sparks. Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... - Page 17 Shorting of battery terminals can cause ● burns, electrical shock, or explosion. Do not Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020...
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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 - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... - 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 - 1102-02 series ECR – 11028011640 rv03 US - 04/2020...
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Page 20: Operator Warning Decals
DO NOT USE TEST DEVICES OR SYSTEMS ANALYZERS IN PLACE OF CONTROL BOARDS OR CONTROL MODULES TO DRIVE THE TRUCK. ATTEMPTS TO DRIVE WITH TEST DEVICES OR ANALYZERS ARE HIGHLY DANGEROUS. 0009384609 Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... -
Page 21: Voltage Decal
SEE INSTRUCTIONS IN OPERATOR’S MANUAL FAILURE TO FOLLOW INSTRUCTIONS COULD RESULT 11014391000 IN INJURY OR DEATH. SEE INSTRUCTIONS IN OPERATOR’S MANUAL PICK WHEN 11024391000 SYSTEM ACTIVE Manual steer Electric steer Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... - Page 22 Safety Operator Warning Decals Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020...
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Page 23: Overview
Overview... -
Page 24: Technical Description
A ed. The weight of the forks (and any load) Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... - Page 25 Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020...
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Page 26: Truck Components - Manual Steer
Operator manual storage Battery connector Load wheels Dash Forks Operator compartment Floor mat Operator backrest cushion Battery Load backrest Battery retainer (with optional rollers) Accessory tray (optional) Front bumper Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... -
Page 27: Truck Components - Electric Steer
Forks Operator console Floor mat Operator compartment Battery Operator backrest cushion Battery retainer (with optional rollers) Load backrest Front bumper Accessory tray (optional) Storage compartment Operator manual storage Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... -
Page 28: Controls - Manual Steer
Accessory switches (optional) system Indicator unit Lowering button Horn button Lift button Brake button Auxiliary lift button (optional) Order pick system indicator light (optional) Auxiliary lowering button (optional) Travel control Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... -
Page 29: Controls - Electric Steer
Order pick forward jog button (optional) Horn button Order pick reverse jog button (optional) Accessory switches (optional) Auxiliary horn button (optional) Indicator unit Order pick system control switch (optional) Key switch Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... -
Page 30: Display Unit
Temperature icon (8) Appears if the truck The icon will flash when the next service inter- controller temperature exceeds 185 ºF (85C). val is actually reached. Truck performance Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... -
Page 31: Definition Of Directions
Overview Definition of Directions Definition of Directions Forwards Right Reverse Left Directions as seen from the driving position; operator facing forward (1). 1102 04022015-01 Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... -
Page 32: Decal And Data Plate Location - Manual Steer
Warning Decal, Trained Operator Warning Decal, Order Pick System (option- Plate, UL Classification Decal, Operator Manual Location Cold Storage Decal (optional) Warning Decal, Service Work EE Designation Decal (optional) Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... -
Page 33: Decal And Data Plate Location - Electric Steer
Warning Decal, Trained Operator Warning Decal, Order Pick System (option- Plate, UL Classification Decal, Operator Manual Location Cold Storage Decal (optional) Warning Decal, Service Work EE Designation Decal (optional) Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... -
Page 34: 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 - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... -
Page 35: Operation
Operation... -
Page 36: Unloading And Preparing A New Truck For Operation
Ensure that the tilt adjustment lever (1) is completely and firmly tightened clockwise before operating the truck. Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... -
Page 37: 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 - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... -
Page 38: Driving
This can be done while the truck is still moving in the original direction. The truck will be electrically Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... - Page 39 Weight must then be restored to the floor plate and the throttle returned to neutral before trav- el will be restored. Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020...
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Page 40: Steering
Manual steer controls are illustrated in panel A. Electric steer controls are illustrated in pan- el B. 1102-02 11072018-03 Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... -
Page 41: Horn
(2) are provided in the button group on both sides of the load backrest. Ei- ther button will sound the horn. 1102-02 11072018-04 Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... -
Page 42: Braking
The truck will slow to a stop faster than if the travel control is simply released. After stop- ping, the truck will accelerate in the new direc- tion unless the travel control is then released. Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... - Page 43 If necessary, the parking brake may be acti- vated in an emergency by disconnecting the battery or turning the key switch off. Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020...
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Page 44: Raising And Lowering The Forks
To lower the forks, press the lower portion of the rocker button (2). Note the symbols on the buttons. 1102-02 11072018-05 Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... - Page 45 If weight is removed from the floor plate during lifting or lowering, operation will stop. Weight must be restored to the floor plate before hydraulic function will be restored. Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020...
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Page 46: Order Picking System (Optional Equipment) - Manual Steer
This operation allows movement of the truck be- tween pick locations with greater conven- ience than the twist action of the travel Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... - Page 47 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 - 1102-02 series ECR – 11028011640 rv03 US - 04/2020...
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Page 48: Order Picking System (Optional Equipment) - Electric Steer
(up to a programmed time limit). The truck will coast to a stop when the but- ton is released. If the time limit is reached, Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... - Page 49 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 - 1102-02 series ECR – 11028011640 rv03 US - 04/2020...
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Page 50: Connecting And Disconnecting The Battery
Charge batteries only in well ventilated areas. Park the truck safely. Turn off the key switch. Remove the accessory tray if equipped. Open the battery cover. Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... - Page 51 Attach the battery connector on the battery cables to the connector plug of the external battery charger. Charge the battery in accordance with the charger manufacturer's instructions. Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020...
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Page 52: Changing The Battery
(3) all the way to one side or the oth- er to gain clearance over the battery. This step is not necessary if using side extrac- tion equipment. Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... - Page 53 Install only batteries whose weight meets the specifi- cation listed on the truck data plate. Carefully position the replacement battery in the battery box. Disconnect and remove all lifting equipment. Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020...
- Page 54 For electric steer trucks, en- sure the console is securely locked in the vertical position. WARNING Batteries produce explosive gases. Always store batteries in well ventilated areas. Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020...
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Page 55: 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 - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... - Page 56 Operation Towing the Truck Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020...
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Page 57: Maintenance
Maintenance... -
Page 58: 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 - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... -
Page 59: Operator Inspection And Maintenance
Place a “Do Not Operate” tag on the truck, remove the key and alert your supervisor. The Truck may not be placed back into service until necessary repairs are made. F296 05-2013 Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... - Page 60 Inspect the battery This condition must be checked and corrected imme- connector and its cables for damage. diately to avoid damage to the hydraulic pump. Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020...
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Page 61: Routine Lubrication And Inspection
Lubricate the lift cylinder and fork frame pivot pins. 200 hours Lubricate caster swivel bearings. 200 hours Lubricate the teeth of the steering gear (optional electric steer only). 200 hours Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... -
Page 62: 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 - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... -
Page 63: 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 - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... -
Page 64: Lubricate Drive Axle Swivel Bearing
Manual Steer Electric Steer (optional) Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... -
Page 65: 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 - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... -
Page 66: 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 - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... -
Page 67: 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 - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... -
Page 68: 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 - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... -
Page 69: Fluid And Lubricant Specifications
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 - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... -
Page 70: Troubleshooting
Control Fuses Empty Position open; may be used for non-stand- (4A) Options at X9 ard option (4A) Speed sensor B1 (4A) Solenoid driver pin 1X1:4 on drive con- troller Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... -
Page 71: Diagnostic Connector
The procedure is explained in the service manual. Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... - Page 72 Maintenance Troubleshooting Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020...
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Page 73: Specifications
Specifications... -
Page 74: Specifications - Manual Steer
Specifications Specifications - Manual Steer Specifications - Manual Steer Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... - Page 75 (130 mm) / (283 mm) 1.03 in 1.03 in 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) Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020...
- Page 76 Drive motor power rating (60 min) 5.4 hp (4.0 kW) 5.4 hp (4.0 kW) Battery voltage 24 V 24 V Maximum battery capacity (6h) 750 Amp-hr 750 Amp-hr Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020...
- 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 - 1102-02 series ECR – 11028011640 rv03 US - 04/2020...
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Page 78: Specifications - Electric Steer
Specifications Specifications - Electric Steer Specifications - Electric Steer Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020... - Page 79 (130 mm) / (283 mm) 1.03 in 1.03 in 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) Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020...
- Page 80 Drive motor power rating (60 min) 5.4 hp (4.0 kW) 5.4 hp (4.0 kW) Battery voltage 24 V 24 V Maximum battery capacity (6h) 750 Amp-hr 750 Amp-hr Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020...
- Page 81 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 - 1102-02 series ECR – 11028011640 rv03 US - 04/2020...
- Page 82 Specifications Specifications - Electric Steer Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020...
- Page 83 Lubrication, routine intervals... Electric braking..... Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020...
- Page 84 Regenerative braking....34 torque specification....55 Operating Instructions - 1102-02 series ECR – 11028011640 rv03 US - 04/2020...
- Page 88 KION North America Corporation 1102-02 series ECR – 11028011640 rv03 US - 04/2020...
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