As individual as the needs of the user

With powerful electric counterbalanced forklift trucks, Linde Material Handling is now setting the benchmark for Europe's leading manufacturers. At the CeMAT 2011 trade fair, the manufacturer of industrial trucks with lifting capacity of between two to five tonnes will present a new, trend-setting electric forklift series.

With 19 different standard model versions — some shorter, some longer, some higher, some flatter — you will always find the perfect truck for any conditions. A dozen technical innovations are aimed at economical energy consumption, high productivity, driver safety and convenience. In the lifting capacity class from 2 to 3.5 tonnes, the electric forklift will be available after CeMAT 2011 and from autumn 2011 in the higher lifting capacity classes from 3.5 to 5 tonnes. Upon its launch, the electrical forklift series had already received the “iF product design award 2011”, one of the world's oldest and most renowned design awards, in the "special vehicles/construction/agriculture" category.

At the CeMAT 2011 trade fair, Linde Material Handling will present a new, trendsetting electric forklift series with lifting capacity of between two to five tonnes.

Flat, high, long or compact

Customers are offered an extremely large selection from the numerous different versions and accordingly only pay for what they really need. All eight different load capacities from two to five tonnes are available in a high design with a centre of gravity of 600 mm for improved visibility over the load and a flat design with a centre of gravity of 500 mm for low clearance heights, container use or picking work where the driver has to frequently get in and out of the truck. The customer can also choose from a long or compact design for the high or flat versions. The long models have a larger battery and provide additional energy reserves, but also allow the use of standard pool batteries. The compact models, on the other hand, are recommended for tight, narrow working areas or less demanding use.

With 19 different standard model versions — some shorter, some longer, some higher, some flatter — you will always find the perfect electric truck for any conditions.

High performance through innovative technology

The key to the highest installed performance in this forklift class is the extraordinary two-motor front drive. The two rotary current motors power the truck with 9 and 11.9 kW, as a result of which the machine can reverse quickly and accelerate to a maximum of 20 km/h in the shortest possible time. A further important contribution to the performance is made by the active steering support in conjunction with the top-connected combined steering axle, which gives the four-wheeled forklift the turning radius and manoeuvrability of a three-wheeled forklift. The forklift turns centrally on the front axle. This is achieved by a steering angle sensor which, when the rear wheels are steered beyond a given angle, gives the command to the inside wheel motor to drive the relevant front wheel in the opposite direction. This active control does not power the truck via the rear wheels, rather it turns within the truck contour. The result is high manoeuvrability and high revs, high tip stability when cornering, low tyre wear, less start-up damage to shelves and economical energy consumption.

A dozen technical innovations of the new electric forklift trucks are aimed at economical energy consumption, high productivity, driver safety and convenience.

Safety and support for the driver

The Linde project team, consisting of developers, marketing and sales specialists, service technicians and production and quality officers place a very great focus on forklift functions for improving driver safety and support. For example, the uncoupling of the drive axle has been further improved. Through spring oscillation on the drive axle suspension, for the first time impacts to the forklift are absorbed in the same way as in motorcycles or fully spring loaded bicycles. Impacts from the driving surface or the lift unit are effectively absorbed. The new models also have an air-sprung seat with additional cushioning and wider seating surface, in order to keep human-caused and other vibrations away from the driver as much as possible.

The tilting cylinders connected above the driver protection roof ensure high stability and torsional rigidity for the lift mast. This makes the lift mast profiles slimmer and improves visibility of the load and the path to be driven. In order for the design of the A-pillar profiles to be slimmer and to thus give the driver a wider field of vision on the right and left, the forces working on the lift mast in the new electric forklift series are dissipated via a special tilting cylinder support.

Linde Load Control has become a benchmark for the whole industrial truck sector. The visual appearance of the central control lever for activating the lift mast functions has been copied many times since its introduction in 1998, but the same level of functionality has not yet been achieved. This is because it is only through the perfect coordination of electronic and hydraulic components that prongs, side shifters and accessory equipment can be controlled by the user's fingertips with millimetre accuracy. The armrest in which the Linde Load Control is integrated has also been developed further. It can now be adjusted horizontally and vertically via a single-point adjustment actuator at the front end and also accommodates a spacious storage compartment for personal items such as phones, gloves or wallets. Alternatively, the hardware unit of the Linde truck data management (LFM) system, which regulates access to the truck and gathers truck data for subsequent evaluation for optimising forklift use, can be integrated into this compartment.

To precisely and continuously measure the battery level and prevent damaging depth discharge of the battery, Linde MH has developed a measurement process based on a combination of battery voltage and current measurement. This precise battery charge display has now been developed further into a remaining travel time display, which shows the driver how much longer the forklift can be driven for to the minute, before the battery must be replaced or charged.

For the battery charging procedure in forklifts with full cabs, an electric fan is optionally available in the new series, which sucks the battery gases that occur during the charging procedure out of the counterweight to the rear in a controlled manner. This means that it is no longer necessary to open the doors or battery cover during the charging procedure. The driver now only has to open the rear cover and connect the charging cable of the high-frequency on-board charger with the high-power current socket or an external charger.

Customers are offered an extremely large selection from the numerous different versions of the new electric forklift truck and accordingly only pay for what they really need.

The first series-production traction control for forklift trucks ensures a high degree of safety and reliable wheel grip even in poor weather conditions. It distributes the drive force of the electric motor individually to both wheel motors and thus ensures that there will be tractive force even if one wheel is spinning. The automatic handbrake, which engages quickly and reliably when the driver gets out, ensures a secure hold on ramps and slopes. If the driver wants to start the truck up again, all they have to do is press the driving pedal and the forklift will start moving smoothly, without rolling backwards. In the event of an operating error during driving or a fault, the truck will brake in a controlled manner. In this way, there is no risk of the load falling down due to excessively jerky braking. Additional safety is offered by the Linde Driver Assistant, which automatically reduces the speed if the operator takes a corner too quickly, and by the robust and bright yet economical LED technology. In the new forklift series, this technology is used right through to the optional headlights and has an expected operating life of up to 20,000 hours. The double control processors also ensure uncompromising safety for the electronics. All safety-relevant signals such as for driving and lifting are sent twice, which means that the processors monitor each other. If the electrical signals differ from each other, the function here is also stopped in a controlled manner.

The first series-production traction control for forklift trucks ensures a high degree of safety and reliable wheel grip even in poor weather conditions.

Economical use of resources

How can energy be saved sensibly? To answer this question, Linde MH points to the great diversity of the new forklift series. This is because it is above all the choice of the most appropriate forklift for the application in question that is decisive for optimal energy consumption. The reason: every kilogram of the total weight of the forklift counts in the frequent reversing procedures involving acceleration and deceleration. The lighter the truck, the more economical its use of resources. In addition to the correct choice of forklift model, there is a whole system dedicated to the economical use of energy. Firstly, from a design perspective, this involves the power elements of the forklift control being located in the compact drive axle together with the drive and lifting motors, instead of in the counterweight as in conventional forklifts. Metres of wiring harnesses are replaced by power rails. The short supply lines not only avoid energy loss, but also achieve outstanding electromagnetic compatibility. In addition, the power electronics are equipped with the latest chip generation for the lowest possible power dissipation. Other features include the precisely adjusted engine control and high drive dynamics. Overlapping work can be used to achieve high energy recovery in the lifting motor and battery. In this way, for example, the energy generated during braking can be used in the lifting procedure.

A further advantage of the compact drive axle with integrated power elements is the space that is now made free in the rear of the forklift. The optional high-frequency on-board charger is now located here. On the one hand, this enables the battery to be charged anywhere, independently from fixed chargers and, on the other hand, is an effective way of combating the plug and start-up damage that frequently occurs with external chargers. The automatic, temperature-controlled charging of the battery, the automatic conservation and equalisation charging also ensure exemplary battery maintenance and help extend the lifespan of these cost-intensive components. Operators who have to replace the battery can do so in numerous different ways: vertically by means of an overhead crane, horizontally using a forklift, a lift truck or a battery traverse device, or through hydraulic battery replacement.

In addition to the standard "Efficiency mode" setting, the new forklifts have two further operating settings, which can be activated as required. With the even more economical "Economy mode", power can be reduced in favour of lower energy consumption, when less power is required. Using "Performance mode", on the other hand, the highest possible warehouse turnaround can be achieved. Here, it is reassuring for the operator that, even in "Efficiency mode", the forklifts represent the benchmark in terms of performance amongst all forklifts in this lifting capacity class.

The key to the highest installed performance in this forklift class is the extraordinary two-motor front drive. A further contribution is made by the active steering support in conjunction with the top-connected combined steering axle.

The long service intervals are also favourable in terms of economical use of resources and keeping operating costs low. For example, the service intervals are 1,000 hours, hydraulic oil is to be replaced only every 6,000 hours and the enclosed rotary current motors are maintenance-free in any case. For the daily battery check, the seat with battery cover can also easily be folded back, which ensures good access. In order for everything to proceed quickly during servicing, maintenance flaps provide convenient access to all important components.