RX50 Operator Manual 04.05

Electric Fork Lift Trucks
RX 50
Operator's Manual
166552 04.05
LINDE LIFT TRUCK CORP.

A MEMBER OF THE LINDE GROUP
RX50 Operating instructions
Foreword
Foreword
General
Linde fork lift trucks comply with safety Operating and maintenance instructions
regulations. If your truck is used on public accompany each truck. This manual must be
roadways, it must be equipped as required by stored carefully and kept within easy reach of
local regulations. The driving permit must be the driver and operator.
obtained at the appropriate office.
If the operating instructions are lost, the
Linde fork lift trucks are equipped with the operator must immediately order a replacement
latest technology. It is now important to from Linde.
operate your truck safely and to maintain its
operability. The operating and maintenance instructions are
included in the spare parts list and can be
To achieve this, Linde provides you with the ordered like a spare part.
necessary information in this manual. Read and
follow the instructions before commissioning The staff concerned with the operation and
your truck! In this way you will avoid accidents, maintenance of the equipment must be made
save yourself trouble, and not void your cognizant of these operating and maintenance
©
guarantee. instructions.
163 453-05.04
The operator must ensure that all users have

Scope of documentation access to, have read and understood these
instructions.
- Operating and maintenance instructions
- Operating and maintenance instructions for We thank you for reading and following these
attachments and battery (optional) instructions. Please contact our Service if you
- Recommended fuels and lubricants have any questions, want to submit
- Spare parts list improvement suggestions or have discovered
- VDMA Guidelines an error.
- Test manual for power-driven industrial trucks
These operating and maintenance instructions

Date of issue and version of
contain all the measures required for the safe manual
operation and proper maintenance of your fork
truck in all the variants available at the time of May 2004
printing. The customised options are
documented in the operating and maintenance Linde is constantly developing and improving
instructions supplied with them. If you have their fork lift trucks. Therefore, the
any questions, please contact your Linde Ser- manufacturer reserves the right to make
vice. modifications and he will not accept any liability
Please enter the serial no. and year from the claims based on the information and illustrations
manufacturer’s plate (see section “Location of contained in these operating and maintenance
plates”) below: instructions.
If you need technical assistance for your truck,
Serial no. ............................................... please contact the competent Linde service
(see next page).
Year ......................................................
Your partner
For all technical questions, please state this
serial number.
BA I
Operating instructions RX50
163 453-05.04
©
II BA
Foreword
Table of contents
Page
Foreword ............................................... I
Lift truck information ............................... 1
Information on operation .......................... 5
Safety .................................................. 7
Description .......................................... 12
Starting up .......................................... 35
Operation ............................................ 51
Operating the lifting device .................... 69
Other activities .................................... 95

©
Ending operation ................................. 109

163 453-05.04
Trailers, Towing .................................. 113
Transport, Hoisting, Towing .................. 117
Indications, settings,
operation of the control unit ............. 121
Malfunctions, cause, remedy ................ 125
Index ................................................ 127
BA III
R5051-R5055 Operating instructions R 50
Lift truck information
Approved applications Unapproved applications
The fork lift truck is suitable for lifting, The manufacturer is not liable
transporting and stacking loads in a way for any hazards arising from
described and shown in this manual. unapproved applications.
If the truck is to be used in a way other than Use for other purposes is
established in the operating instructions, the prohibited. Riders are not
written approval of Linde and, if necessary, of allowed on the truck.
the responsible authorities must be obtained
beforehand to prevent any potential dangers. Do not operate the truck in
zones posing a fire or
The maximum load that can be lifted is specified explosion risk or in areas
on the load capacity plate (load diagram). Do causing corrosion or in a very
not exceed the maximum load capacity. dusty environment.
Site of operation
©
The lift truck can be used in enclosed spaces

163 453-05.04
and in the open. Road operation is only

permitted if the road lighting option is installed.
Obey the national regulations governing driving

lift trucks on public roads.
The floors must have a sufficient load capacity

(concrete, asphalt) and should have a rough
surface.
The aisles and work areas must meet the

specifications in this manual.
Slopes and inclines can be driven on as specified

in the technical data and in section „Dimensions
of roadways and aisles“.
The truck can be used inside and outdoors in

countries ranging from tropical to northern
(temperature range -20 °C to +40 °C).
BA 1
Special risks when using the truck
and attachments
Any exceptional use where the driver is not

sure if it can be carried out in an approved and
safe way must first be approved by Linde. In
particularly difficult cases, like the simultaneous
use of two trucks to transport heavy or bulky
loads, the supervisor must be present and
assume responsibility for and supervise the
transport.
163 453-05.04
©
2 BA
Modifications and retrofits Warning against using non-
genuine parts
If your truck is to be operated, for example, in Genuine Linde parts, attach-

a cold store or in an environment with an ments and accessories are
explosion hazard, the truck must be equipped designed especially for Linde
and approved for this application. vehicles.
We expressly point out that
If your fork lift truck is to be used for work not any parts, attachments and
specified in the guidelines and has to be accessories not supplied by
converted or re-equipped for such use, us have also not been tested
remember that any alteration to the structural and released by us. The in-
state can affect the driving behaviour and stallation and/or the use of
stability of the truck and lead to accidents. such products can therefore
You should therefore contact your Linde negatively change the speci-
distributor beforehand. No modifications fied design characteristics of
affecting the stability of the truck negatively your truck and therefore re-
may be performed without our approval. duce its active and/or pas-
sive driving safety. We rec-
Retrofits are only allowed with our written ommend obtaining our ap-
©
approval. proval before the installation

of such parts. The manufac-
163 453-05.04
We warn against the installation and utilisation turer does not assume any liabil-
of retaining systems not approved by us. ity for damages caused by
the use of non-genuine parts
If your truck is equipped with a retaining system and accessories without our
approved by Linde, we nevertheless advise you approval.
to use the seat belt.
For reasons of safety it is not allowed to weld

or drill holes on the overhead guard. Before
doing welding on other parts of the truck,
disconnect the battery and all cables to the
electronic control cards.
Please contact your Linde Service for this
service.
BA 3
Fuels and lubricants CAUTION: All persons stand-
ing in the vicinity of the truck
Please refer to "Recommended Fuels and Lu- must be advised of the haz-
bricants“ for the required materials. ards arising with the opera-
tion of the truck. We also re-
CAUTION: Fuels and lubricants can be haz- fer to additional safety rules
ardous. Please follow the safety instructions in these operating instruc-
when handling these materials. tions.
Definition of directions
The references front, rear, forward, backward,
etc. when describing location are made rela-
tive to the driver when seated in the normal These hazards can be:
driving position. The load is at the front.
- Egress of fuels and lubri-
cants due to leaks, break-
Definition of used terms: ing of pipes and contain-
ers, etc.
DANGER: For work proce- - Risk of driving accidents
dures which must be followed
163 453-05.04
due to unfavourable ground
exactly to prevent danger to conditions such slope, ice,
the life and limb of persons.
roughness or poor visibility,
etc.
WARNING: Indicates procedures which must
- Falling off or down, etc.
be followed exactly to prevent personal in-
when moving on the truck,
jury.
©
particularly when wet.
CAUTION: Indicates procedures which must
be followed exactly to prevent damage to and/ - The stability of the truck
or destruction of the equipment. has been tested according
NOTE: Indicates points of technical interest to the state of the art. Only
requiring special attention. the dynamic and static tip-
ping forces occurring dur-
Residual hazards and risks ing the determined regular
operating conditions and
approved operations were
Despite working carefully and
taken into consideration.
according to the standards
The risk of exceeding the
and regulations, residual risks
tipping moment during un-
cannot be excluded when
approved or incorrect op-
operating the lift truck.
eration cannot entirely be
excluded for difficult sta-
The truck and all other sys-
tem components conform to bility conditions.
current safety regulations.
Nevertheless, even for ap- - Loss of stability due to dis-
proved applications and with placed or unstable load,
the observance of all safety etc.
notices, a residual risk can-
not be excluded. - Fire and explosion hazard
A residual risk cannot be ex- due to the battery and
cluded even beyond the im- electric power.
mediate danger area of the
truck, so that any persons - Human error: non-observ-
standing in this area must pay ance of safety rules.
particular attention to the
truck in order to be able to
react fast in case of an inci-
dent, failure, etc.
4 BA
Information on operation
Rights, obligations and
Operator behavioural rules for drivers
The operator is the natural or legal person using Drivers must be informed of
the truck or on whose order the truck is used. their rights and obligations.
The operator must ensure that the truck is They must be accorded the
only used for approved applications. He is rights to which they are en-
responsible for the observance of the accident titled. The driver must wear
prevention rules and the safety rules in these safety gear according to the
operating instructions. The operator must conditions of his activities
ensure that all users understand the safety (protective clothing, safety
information. shoes, helmet, safety glasses,
protective gloves and other)
as required by his task and
Experts the load to be handled.
The driver must be acquainted
with the operating instruc-
Experts are specially skilled persons who have
tions and they must be avail-
thorough knowledge and experience in servicing
able to him at all times.
and testing industrial trucks and being
©
furthermore sufficiently familiar with the na-

tional industrial safety and accident prevention
163 453-05.04
regulations and all further general technical Prohibition of use by unauthorized

rules and guidelines (DIN and ISO standards, persons
technical rules arising from EC directives or EEA
agreements), so that they can give a qualified During the shift the driver is responsible for
judgement upon the safe operating conditions the truck. He must ensure that it is not driven
of the truck. or operated by unauthorized persons. When
leaving the truck unattended, he must secure
the truck against unauthorized use.
Driver
The lift truck may only be driven by qualified Damages, deficiencies, misuse of
persons at least 18 years of age, trained in its safety devices
operation, and who have demonstrated to the
operator or his representative their driving and
The driver must immediately notify the
load-handling ability and have expressly been
supervisors of any damage to the truck or of
entrusted with driving the truck.
any faults. Inoperative and unsafe trucks and
attachments must not be operated until they
The training requirements are fulfilled if the
have been properly repaired.
driver is instructed according to the rules of
the trade association. Observe your national
Safety devices and switches must not be
rules and regulations.
removed or disabled. Fixed settings may only
be changed with the approval of STILL.
Any interventions in the electrical installation
(eg the connection of a radio, supplementary
lights, etc) are only allowed with the approval
of the manufacturer.
BA 5
Packaging
The truck packaging material must be disposed

of in accordance with laws and regulations.
Disposal
Your truck consists of different materials. Each

material must be disposed of /treated /
recycled according to different regional and /
or national regulations. We recommend
cooperation with a disposal specialist.
EC conformity certificate,
EC conformity sign
With the EC conformity cer-

tificate, STILL certifies that
163 453-05.04
the truck conforms to the
valid standards and require-
ments at the time of market-
ing.
The EC conformity sign is lo-
cated on the truck identifi-
cation plate and it indicates
©
that the above-mentioned
requirements are met.
If the truck is modified or ret-

rofitted without the approval
of the manufacturer, the
safety of the truck may be
reduced so that the EC con-
formity certificate is invali-
dated.
Keep the CE certificate in a

safe place and show it, if
requested, to the responsible
authorities.
Copyright and property rights
These operating instructions - even excerpts

thereof- may not be reproduced, translated or
made available to third parties without the
written permission of STILL.
6 BA
Safety
Safety
Safety inspection according to

interval and extraordinary events
(in Germany UVV inspection;
please observe your national
jährliche Prüfung
gem. UVV
regulations) Mängel siehe Prüfbuch
letzte Prüfung
The industrial truck must be inspected at least
once annually or after special incidents by a
person especially qualified for this task. This
person must present his expert opinion and
assessment uninfluenced by any economical
and business circumstances and only from the
standpoint of safety. He must have sufficient
knowledge and experience to be able to as-
sess the condition of an industrial truck and
the effectiveness of the protective features
according to the rules of the art and the prin-
©
ciples applying for the inspection of industrial

trucks.
163 453-05.04
nächste Prüfung
The truck must be inspected completely in re-
spect to its safe technical condition. The truck
must also be thoroughly checked for possible
damages due to improper use. An inspection
record must be prepared. The results of the
inspection must be filed at least until the in-
spection after the next one.
The next inspection is indicated by a sticker
on the truck.
The booklet "Test manual for power-driven in-
dustrial trucks“ should be used. (STILL Part.
No. 135745)
Refer to the guidelines for the inspection of
STILL trucks according to the accident
prevention guidelines for industrial trucks.
BA 7
Safety
Personal liability in the plant area
NOTE
Many plant areas are so-

called limited public traffic
areas.
We advise you to check if
your company liability insur-
ance covers any damages
„limited” public traffic areas
for your material handling
truck against third parties.
Safety precautions for handling

lubricants
Gear oil
163 453-05.04
Do not eat, drink or smoke
when working with the prod-
uct. Prolonged intensive con-
tact may cause degreasing
and irritation of the skin.
Wash skin with soap and wa-
ter, use skin care products.
©
If required, wear protective
gear. Change soaked clothes
and shoes immediately. If
vapor or mist was inhaled,
breath fresh air, if trouble per-
sists, consult a doctor.
After contact with eyes rinse
thoroughly with water (at
least 10 minutes) then con-
sult an eye doctor. When
swallowed do not force to
vomit, but consult doctor.
Danger of slipping by spilled
product, especially in connec-
tion with water.
Oils can contaminate water.
Always keep them in approved
containers. Avoid spilling oils.
Remove spilled fluids at once
with an oil binding agent and
dispose of in accordance with
laws and regulations. Dispose
of drained fluids in accordance
with regulations. The appli-
cable laws and regulations
must be followed. The oils are
inflammable. Do not let them
come in contact with hot en-
gine parts. Fire hazard!
8 BA
Safety
Hydraulic fluid, brake fluid Hazards for personnel
Hydraulic fluids are hazardous
The owner (operator) of the truck must deter-
to health and under pressure
mine and assess the hazards in his works. He
during operation. Do not spill
must establish the worker’s protection meas-
these fluids! Remove spilled
ures for his personnel. The owner must there-
fluids at once with oil binding
fore make public the work instructions for his
agents and dispose as
plant and make the driver cognizant thereof. A
specified. Dispose of old fluids
safety officer must be appointed.
as specified and follow the
The construction and equipment of the truck
applicable laws and
conform to machine directive 89/37/EEC and
regulations. Do not allow to
they therefore carry the CE symbol. They are
come in contact with hot
therfore not included in the hazard assess-
engine parts. Fire hazard!
ment, and attachments likewise on account of
their own CE marking. The owner, however,
Do not allow these fluids to
must select the design and equipment of the
contact skin. Avoid the
truck so that they conform to local operating
inhalation of spray fog. The
regulations.
ingress of pressure fluids into
The result must be documented. Truck opera-
the skin is particularly
tions posing a similar hazard can the results
hazardous if these emerge
can be bundled. With the following chart we
©
under high pressure through

provide an aid to help you to fulfill these legal
leaks in the hydraulic system.
163 453-05.04
requirements.
Seek medical aid at once if
The chart lists important hazards which most
such injuries occur.
often lead to accidents if not observed. If fur-
If injuries cannot be excluded,
ther important operational hazards exist, they
use suitable protectors (for
must also be taken into consideration.
example, protective gloves,
In many work places the operating conditions
glasses and skin protection
of the trucks will be so similar that the hazards
and care creams).
can be summarized in a chart.
Also please note the information of your trade
Battery acid association on this subject.
Battery acid contains dis-

solved sulphuric acid. This
acid is poisonous and caus-
tic. When working with bat-
tery acid, wear protective
clothing and eye protection.
Do not allow acid to contact
clothing, skin or eyes. In case
of contact, wash directly with
ample clean water. If personal
injuries exist, visit a doctor
at once. Flush spilled battery
acid with a large amount of
water.
Dispose of drained fluids in ac-
cordance with regulations.
The applicable laws and regu-
lations must to be observed.
BA 9
Safety
Overview of hazards and preventive measures
Hazard Action Check Status

9 done
Remarks
- not
appplicable
Truck equipment not in

accordance with local
Inspection
O Contact appropriate
authorities in case of
regulations doubt
Too little knowledge Operator training

and operator unsuitable (walkie and stand-on
O UVV-BGV 27, BGG 925
driver's license to VDI
truck) 3313
Unauthorised use Access with key only

for proper staff
O
Truck not in safe
condition
Recurring inspection
and eliminate
O UVV-BGV 27 - §§ 9,
37, BGG 918
163 453-05.04
deficencies
Visibility reduced by
load
Truck job planning
O UVV-BGV 27 - § 12
Exhaust emissions Assessment of diesel

exhaust gases
O TRGS 554
©
Assessment of LPG
exhaust gases
O MAK-List
Unauthorised Post the operating

application (unapproved instructions
O UVV-BGV 27 - § 5
use)
Written job order for

operator
O UVV-BGV 27 - § 7
Observe safety
regulations,
O
operating instructions
and VDMA rules
10 BA
Safety
Hazard Action Check Status

9 done
Remarks
- not
appplicable
When refuelling
O
a) Diesel Observe safety
regulations,
O
and VDMA rules
b) LP gas Observe safety

regulations,
O
and VDMA rules
©
When charging traction

batteries
Observe safety
regulations,
O VDE 0510: especially
- ensure proper
163 453-05.04
operating instructions ventilation

and VDMA rules - insulation value in
admissible range
BA 11
Description
Description
l
h4
Sitz
60 verstellbar
h3
± 90 mm
Q
h1
h6
h5
163 453-05.04
S
h7
h10
h2
m1
m2
s
©
x y
l2
l1
5051-Ba-072
Technical data
(standard version)
Dimensions
Centre of gravity S (distance from front axle)

RX 50-10 ...................................... 536 mm
RX 50-13 ...................................... 631 mm
RX 50-15 ...................................... 685 mm
RX 50-16 ...................................... 690 mm
12 BA
Description
Technical data
(standard version)
Identification
Manufacturer STILL STILL
GmbH GmbH
Model designation RX 50-10 RX 50-13
Manufacturer’s model designation 5051 5053
Drive: Battery, Diesel, petrol, LP gas, mains Battery Battery
Operation: Manual, walkie, driver standing, driver driver seated
driver seated, order picker seated
Load capacity/hoisted load Q (kg) 1000 1250
Load centre c (mm) 500 500
Load distance x (mm) 298 325
Wheel base y (mm) 1030 1112
Weights
Dead weight kg 2210 2520
Axle load with load, front kg 2805 3265
Axle load with load, rear kg 405 505
©
Axle load without load, front kg 1060 1090

Axle load without load, rear kg 1150 1430
163 453-05.04
Wheels, chassis
Tyres, solid rubber (V), superelastic (SE), V SE
pneumatic (L), polyurethane (P)
Tyre dimensions, front 16x6-8 SE 18x7-8/16 PR
Tyre dimensions, rear 16x6-8 SE 18x7-8/16 PR
Wheels, number front (x = driven) 2 2
Wheels, number rear (x = driven) 1x 1x
Track width, front b 10 (mm) 865 842
Track width, rear b 11 (mm) - -
Overall dimensions*
Mast/fork carriage tilt, forward degr. 3 3
Mast/fork carriage tilt, backward degr. 6 6
Mast height, retracted h 1 (mm) 2260 2260
Free lift h 2 (mm) 150 150
Lift h 3 (mm) 3430 3430
Mast height, extended h 4 (mm) 4080 4080
Height, including overhead guard (cab) h 6 (mm) 1965 1980
Height, driver seat/driver stand h 7 (mm) 920 935
Height of trailer coupling h 10 (mm) 420 435
Overall length l 1 (mm) 2423 2527
Length including fork heel l 2 (mm) 1623 1727
Overall width b 1 (mm) 1006 996
Fork thickness s (mm) 35 35
Fork width e (mm) 80 80
Fork length l (mm) 800 800
Fork carriage acc. to DIN 15173, class/form A,B FEM II B FEM II B
Fork carriage width b 3 (mm) 980 980
Ground clearance with load under lift mast m 1 (mm) 90 90
Ground clearance, centre wheel base m 2 (mm) 100 100
Aisle width with pallets 1000 x 1200 across Ast (mm) 2954 3057
Aisle width with pallets 800 x 1200 long Ast (mm) 3075 3179
Turning radius Wa (mm) 1325 1403
Smallest pivoting point b 13 (mm) - -
* See the data sheet for your truck
BA 13
Description
Performances
Driving with load km/h 11.5 12
Driving without load km/h 12 12.5
Lifting with load m/s 0.32 0.31
Lifting without load m/s 0.52 0.52
Lowering with load m/s 0.54 0.54
Lowering without load m/s 0.6 0.6
Rated tractive force with load N 1650 1400
Rated tractive force without load N 1950 1700
Maximum tractive force with load N 2480 3500
Maximum tractive force without load N 8200 7500
Climbing capacity with load % 6 5
Climbing capacity without load % 10 8.5
Max. climbing capacity with load % 18 17
Max. climbing capacity without load % 25 25
Acceleration for driving with load s 5.3 5.4
Acceleration for driving without load s 4.7 4.8
Service brake hydraulic hydraulic
Electric motors
163 453-05.04
Drive motor performance (60 min. interm. rating) kW 4.5 4.5
Lift motor performance (15 % interm. duty) kW 7.8 7.8
Battery acc. to DIN 43531/35/36 A, B, C, no DIN 43535 DIN 43535 A
A
Battery voltage U (V) 24 24
Battery capacity K 5 (Ah) 550 770
Battery weight kg 445 600
©
Energy consumption acc. to VDI cycle kWh/h -
Other specifications
Speed control type Stilltronic Stilltronic
Operating pressure for attachments bar 190 190
Oil quantity for attachments l/min - -
Noise level at driver’s ear dB (A) - -
Trailer coupling, type/model DIN Tow pin Tow pin
14 BA
Description
Technical data
(standard version)
Identification
Manufacturer STILL STILL
GmbH GmbH
Drive: Battery, Diesel, petrol, LP gas, mains Battery Battery
Operation: Manual, walkie, driver standing, driver driver
driver seated, order picker seated seated
Load capacity/hoisted load Q (kg) 1500 1600
Load centre c (mm) 500 500
Load distance x (mm) 325 330
Wheel base y (mm) 1162 1162
Weights
Dead weight kg 2730 2780
Axle load with load, front kg 3685 3875
Axle load with load, rear kg 545 505
Axle load without load, front kg 1120 1130
©
Axle load without load, rear kg 1610 1650

163 453-05.04
Wheels, chassis
Tyres, solid rubber (V), superelastic (SE), SE SE
pneumatic (L), polyurethane (P)
Tyre dimensions, front 18x7-8/16 18x7-8/16
Tyre dimensions, rear 18x7-8/16 18x7-8/16
Wheels, number front (x = driven) 2 3
Wheels, number rear (x = driven) 1x 1x
Track width, front b 10 (mm) 842 842
Track width, rear b 11 (mm) 0 0
Overall dimensions*
Mast/fork carriage tilt, forward degr. 3 3
Mast/fork carriage tilt, backward degr. 6 6
Mast height, retracted h 1 (mm) 2260 2260
Free lift h 2 (mm) 150 150
Lift h 3 (mm) 3430 3430
Mast height, extended h 4 (mm) 4080 4080
Height, including overhead guard (cab) h 6 (mm) 1980 1980
Height, driver seat/driver stand h 7 (mm) 935 935
Height of trailer coupling h 10 (mm) 435 435
Overall length l 1 (mm) 2577 2582
Length including fork heel l 2 (mm) 1777 1782
Overall width b 1 (mm) 996 996
Fork thickness s (mm) 35 40
Fork width e (mm) 80 80
Fork length l (mm) 800 800
Fork carriage acc. to DIN 15173, class/form A,B FEM II B FEM II B
Fork carriage width b 3 (mm) 980 980
Ground clearance with load under lift mast m 1 (mm) 90 90
Ground clearance, centre wheel base m 2 (mm) 100 100
Aisle width with pallets 1000 x 1200 across Ast (mm) 3107 3112
Aisle width with pallets 800 x 1200 long Ast (mm) 3229 3239
Turning radius Wa (mm) 1453 1458
Smallest pivoting point b 13 (mm) - -
* See the data sheet for your truck
BA 15
Description
Performances
Driving with load km/h 12 12
Driving without load km/h 12.5 12.5
Lifting with load m/s 0.3 0.3
Lifting without load m/s 0.52 0.52
Lowering with load m/s 0.54 0.54
Lowering without load m/s 0.6 0.6
Rated tractive force with load N 1250 1250
Rated tractive force without load N 1670 1670
Maximum tractive force with load N 3770 3470
Maximum tractive force without load N 7500 7500
Climbing capacity with load % 4.5 4
Climbing capacity without load % 8 7.5
Max. climbing capacity with load % 16 15
Max. climbing capacity without load % 25 25
Acceleration for driving with load s 5.5 5.6
Acceleration for driving without load s 4.9 5
Service brake hydraulic hydraulic
Electric motors
163 453-05.04
Drive motor performance (60 min. interm. rating) kW 4.5 4.5
Lift motor performance (15 % interm. duty) kW 7.8 7.8
Battery acc. to DIN 43531/35/36 A, B, C, no DIN DIN
443535 A 443535 A
Battery voltage U (V) 24 24
Battery capacity K 5 (Ah) 880 880
Battery weight kg 676 676
©
Energy consumption acc. to VDI cycle kWh/h -
Other specifications
Speed control type Stilltronic Stilltronic
Operating pressure for attachments bar 190 191
Oil quantity for attachments l/min - -
Noise level at driver’s ear dB (A) - -
Trailer coupling, type/model DIN Tow pin Tow pin
16 BA
Description
Technical data
Noise emissions Frequency characteristics
The values were determined in a test cycle in The machine frequencies were determined on
accordance with EN 12053 (noise measurement an identical machine in accordance with EN
on industrial trucks on the basis of EN 12001 13059 of CEN “Vibration Tests on Industrial
and EN ISO 3744 and EN ISO 4871 Trucks”.
requirements).
This machine emits the following noise pressure: Weighted effective value of acceleration on
the human body
Noise level at driver’s station (feet or seat) ......................... < 1.6 m/s2
Uncertainty K ............................ 0.5 m/s2
LpAz ........................................................................ 64 dB (A)
Uncertainty KpA .............................................. 4 dB (A)
Studies have shown that the frequency of hand
and arm vibrations at fork truck steering wheels
These values were determined during a test
or controls is under 2.5 m/s². For this reason
cycle on an identical machine from weighted
no test specifications are available for these
values in the operating modes driving, lifting
measurements.
and idling.
The personal vibration load on the driver for
©
one work day must be determined, if necessary,

Time weighting:
at the site of operation in order to take all
- Lifting 18%
163 453-05.04
other influencing factors such as road stretch,

- Idling 58%
intensity of operation, etc., into consideration.
- Driving 24%
According to directive 86/188/EC, however,

the specified truck noise levels cannot be used Emissions
for determining the noise emission at the
workplace (daily personal noise allowance). If During charging, the drive battery emits a
required, these must be determined directly at mixture of oxygen and hydrogen (detonating
the workplace under actually existing influences gas). This gas mixture is explosive and it must
(further sources of noise, special operating not be ignited. The risk of explosion can be
conditions, sound reflections). avoided through sufficient ventilation and by
avoiding naked flames. Follow the safety
precautions for handling the drive battery.
BA 17
Operating instructions R5051-R5055
Description
Wheels and tyres
Approved types of tyres
Only the specified types of tyres may be installed. Inflate the pneumatic tyres to the pressure
specified on the tyre inflation pressure labels. We recommend contacting our Service before
carrying out a conversion.
RX 50-10
Tyre inflation Width of

Tyre type Tyres Track
(bar) axle
front rear front rear front
16x6-8 / 16x6-8 /
SIT 876 848
150/75-8 150/75-8
16x6-8 / 16x6-8 /
SIT 888 912
150/75-8 150/75-8
16x6-8 / 16x6-8 /
SITn 876 848
150/75-8 150/75-8
163 453-05.04
16x6-8 / 16x6-8 /
SITn 888 912
150/75-8 150/75-8
16x6x10½ 16x6x10½
VG 876 848
KS15/6 KS15/6
16x6x10½ 16x6x10½
VG 888 940
KS15/6 KS15/6
©
16x6x10½ 16x6x10½
VGn 876 848
KS15/6 KS15/6
16x6x10½ 16x6x10½
VGn 888 940
KS15/6 KS15/6
Mast types
Tyre type Truck width Triplex
Telescopic mast NiHo mast
mast
from to from to from to
SIT 998 1860 3260 1860 2510
SIT 1062 1860 2510
SITn 998 1860 3260 1860 2510
SITn 1062 1860 2510
VG 1006 1860 3260 1860 2510

VG 1098 1860 2510
VGn 1006 1860 3260 1860 2510
VGn 1098 1860 1860 2510
L = Pneumatic tyres VGn = Cushion tyres, natural colour

VG = Cushion tyre SIT C= Superelastic SIT CONTI tyres
SIT = Superelastic SIT tyres SIT a = Superelastic SIT antistatic tyres
SITn = Superelastic SIT tyres, natural colour DIN = Superelastic tyres System DIN
18 BA
Description
RX 50-13
Tyre inflation
Tyre type Tyres Width of axle Track
(bar)
SIT 18x7-8 18x7-8 883 842
SIT 18x7-8 18x7-8 895 919
SIT 18x7-8 18x7-8 1060 1032
SITn 18x7-8 18x7-8 883 842
SITn 18x7-8 18x7-8 895 919
SITn 18x7-8 18x7-8 1060 1032
SITa 18x7-8 18x7-8 883 842
SITa 18x7-8 18x7-8 895 919
SITa 18x7-8 18x7-8 1060 1032
SITC 18x7-8 18x7-8 883 842
SITC 18x7-8 18x7-8 895 919
SITC 18x7-8 18x7-8 1060 1032
©
Mast types
163 453-05.04

mast
SIT 996 1860 3260 1860 2510
SIT 1075 1860 2760
SIT 1188 1860 2760
SITn 996 1860 3260 1860 2510
SITn 1075 1860 2760
SITn 1188 1860 2760
SITa 996 1860 3260 1860 2510
SITa 1075 1860 2760
SITa 1188 1860 2760
SITC 996 1860 3260 1860 2510
SITC 1075 1860 2760
SITC 1188 1860 2760

BA 19
Description
RX 50-13
Tyre inflation
Tyre type Tyres Width of axle Track
(bar)
DIN 18x7-8 18x7-8 883 842
DIN 18x7-8 18x7-8 895 919
DIN 18x7-8 18x7-8 1060 1032
L 10 10 18x7-8 18x7-8 870 870

L 10 10 18x7-8 18x7-8 1060 1032
16x6x10½ 16x6x10½
VG 883 835
KS15/6 KS15/6
16x6x10½ 16x6x10½
VG 895 847
KS15/6 KS15/6
16x6x10½ 16x6x10½
VG 895 969
KS15/6 KS15/6
16x6x10½ 16x6x10½
163 453-05.04
VGn 883 835
KS15/6 KS15/6
16x6x10½ 16x6x10½
VGn 895 847
KS15/6 KS15/6
16x6x10½ 16x6x10½
VGn 895 969
KS15/6 KS15/6
©
Mast types
mast
DIN 996 1860 3260 1860 2510
DIN 1075 1860 2760
DIN 1188 1860 2760
L 1043 1860 2760 1860 2510

L 1205 1860 2760
VG 996 1860 3260 1860 2510

VG 1005 1860 2760
VG 1127 1860 2760
VGn 996 1860 3260 1860 2510
VGn 1005 1860 2760
VGn 1127 1860 2760

20 BA
Description
RX 50-15, RX 50-16
Tyre type Tyre inflation (bar) Tyres Width of axle Track

18x7-8 / 18x7-8 /
SIT 883 842
180/70-8 180/70-8
18x7-8 / 18x7-8 /
SIT 895 919
180/70-8 180/70-8
18x7-8 / 18x7-8 /
SIT 1060 1032
180/70-8 180/70-8
18x7-8 / 18x7-8 /
SITn 883 842
180/70-8 180/70-8
18x7-8 / 18x7-8 /
SITn 895 919
180/70-8 180/70-8
18x7-8 / 18x7-8 /
SITn 1060 1032
180/70-8 180/70-8
18x7-8 / 18x7-8 /
SITa 883 842
180/70-8 180/70-8
©
18x7-8 / 18x7-8 /
SITa 895 919
180/70-8 180/70-8
163 453-05.04
18x7-8 / 18x7-8 /
SITa 1060 1032
180/70-8 180/70-8
18x7-8 / 18x7-8 /
SIT 883 842
180/70-8 180/70-8
18x7-8 / 18x7-8 /
SIT 895 919
180/70-8 180/70-8
18x7-8 / 18x7-8 /
SIT 1060 1032
180/70-8 180/70-8
Mast types
Tyre type Truck width
Telescopic mast NiHo mast Triplex mast
front rear front rear front rear
SIT 996 1860 3260 1860 2510
SIT 1073 1860 2760
SIT 1186 1860 2760
SITn 996 1860 3260 1860 2510
SITn 1073 1860 2760
SITn 1186 1860 2760
SITa 996 1860 3260 1860 2510
SITa 1073 1860 2760
SITa 1186 1860 2760
SIT 996 1860 3260 1860 2510
SIT 1073 1860 2760
SIT 1186 1860 2760

BA 21
Description
RX 50-15, RX 50-16
Tyre type Tyre inflation (bar) Tyres Width of axle Track

18x7-8 / 18x7-8 /
DIN 883 842
180/70-8 180/70-8
18x7-8 / 18x7-8 /
DIN 895 919
180/70-8 180/70-8
18x7-8 / 18x7-8 /
DIN 1060 1032
180/70-8 180/70-8
18x7-8 / 18x7-8 /
L 10 10 870 870
180/70-8 180/70-8
18x7-8 / 18x7-8 /
L 10 10 1060 1032
180/70-8 180/70-8
16x7x10½ 16x7x10½
VG 883 853
KS15/6 KS15/6
163 453-05.04
16x7x10½ 16x7x10½
VG 895 865
KS15/6 KS15/6
16x7x10½ 16x7x10½
VG 895 955
KS15/6 KS15/6
16x7x10½ 16x7x10½
VGn 883 853
KS15/6 KS15/6
16x7x10½ 16x7x10½
©
VGn 895 865
KS15/6 KS15/6
16x7x10½ 16x7x10½
VGn 895 955
KS15/6 KS15/6
Mast types
Tyre type Truck width
Telescopic mast NiHo mast Triplex mast
front rear front rear front rear
DIN 996 1860 3260 1860 2510
DIN 1073 1860 2760
DIN 1186 1860 2760
L 1043 1860 2760 1860 2510

L 1205 2810 3260 1860 2760
VG 1037 1860 3260 1860 2510

VG 1049 1860 2760
VG 1139 1860 2760
VGn 1037 1860 2560 1860 2510
VGn 1049 1860 2760
VGn 1139 2810 2760

22 BA
Description
Battery specifications* (acc. to DIN 43536 A)
CAUTION: Only use batteries conforming to DIN. The battery tray must be closed. Do not
change the location of additional weights.
Max. battery
compartment size in mm
Battery type Capacity En- Weight Height* Width Length Added
in Ah hanced in kg weight in
power ±5% kg
RX 50-10
5 PZS 550 L 550 x 445 628 830 327 -
5 PZW 500/WF200 500 445 628 830 327 -
5 PZS 550L/CSM600 550 x 445 628 830 327 -
5 PZS 550L/600 550 x 445 628 830 327 -
5 PZV 500 GEL 500 445 628 830 327 -
5 PZS 550L/CSM625DP 550 x 445 628 830 327 -
RX 50-13
©
6 PZS 660L 660 x 524 628 830 381 70

163 453-05.04
6 PZW 660/WF 200 660 524 628 830 381 70

6 PZV 600/GEL 600 524 628 830 381 70
6 PZS 660L/CSM 720 660 x 524 628 830 381 70
6 PZS 660L/720 660 x 524 628 830 381 70
6 PZS 660L/CSM 720 DP 660 x 524 628 830 381 70
7 PZS 770L 770 x 600 628 830 435 -
7 PZW 700/WF 200 700 600 628 830 435 -
7 PZS 770L/CSM 840 770 x 600 628 830 435 -
7 PZS 770L/840 770 x 600 628 830 435 -
7 PZS 770L/CSM 875 DP 770 x 600 628 830 435 -
5 PZS 550L-A 550 x 445 628 830 327 219
5 PZW 500-A 500 445 628 830 327 219
5 PZV 500-A/GEL 500 445 628 830 327 219
5 PZS 550L-A/CSM 600 550 x 445 628 830 327 219
5 PZS 550L-A/600 550 x 445 628 830 327 219
5 PZS 550L-A/CSM 625 550 x 445 628 830 327 219
* less 8 mm with roller frame
* Temporary values
BA 23
Description
Max. battery
compartment size in mm
Battery type Capacity En- Weight Height* Width Length Added
in Ah hanced in kg weight in
power ± 5 % kg
RX 50-15
7 PZS 770L 770 x 600 628 830 435 70
7 PZW 700/WF 200 700 600 628 830 435 70
7 PZV 700/GEL 700 600 628 830 435 70
7 PZS 770L/CSM 840 770 x 600 628 830 435 70
7 PZS 770L/840 770 x 600 628 830 435 70
7 PZS 770L/CSM 875 DP 770 x 600 628 830 435 70
8 PZS 880L 880 x 676 628 830 489 -
8 PZW 800/WF 200 800 676 628 830 489 -
8 PZV 800/GEL 800 676 628 830 489 -
8 PZS 880L/CSM 960 880 x 676 628 830 489 -
8 PZS 880L/960 880 x 676 628 830 489 -
163 453-05.04
8 PZS 880L/CSM 1000 DP 880 x 676 628 830 489 -
5 PZS 550L 550 x 445 628 830 327 219
5 PZW 500/WF 200 500 445 628 830 327 219
5 PZV 500/GEL 500 445 628 830 327 219
5 PZS 550L/CSM 600 550 x 445 628 830 327 219
5 PZS 550L/600 550 x 445 628 830 327 219
©
5 PZS 550L/CSM 625 DP 550 x 445 628 830 327 219
RX 50-16
7 PZS 770L 770 x 600 628 830 435 70
7 PZW 700/WF 200 700 600 628 830 435 70
7 PZV 700/GEL 700 600 628 830 435 70
7 PZS 770L/CSM 840 770 x 600 628 830 435 70
7 PZS 770L/840 770 x 600 628 830 435 70
7 PZS 770L/CSM 875 DP 770 x 600 628 830 435 70
8 PZS 880L 880 x 676 628 830 489 -
8 PZW 800/WF 200 800 676 628 830 489 -
8 PZV 800/GEL 800 676 628 830 489 -
8 PZS 880L/CSM 960 880 x 676 628 830 489 -
8 PZS 880L/960 880 x 676 628 830 489 -
8 PZS 880L/CSM 1000 DP 880 x 676 628 830 489 -
* less 8 mm with roller frame
24 BA
Description
1 2 3
21
4
20
6
19
©
7
163 453-05.04
18
8
17 16 15 14 13 12 11 10 5051-Ba-004
Overviews
Truck
1 Mast 11 Gearbox
2 Overhead guard 12 Steering motor
3 Control and display panel 13 Pump controller with fuses
4 Levers for operating the lifting device and 14 Battery
attachments* 15 Hydraulic oil filter
5 Parking brake lever 16 Tilt cylinder
6 Driver’s seat 17 Axle
7 Converter 18 Forks
8 Tow coupling 19 Pump motor and hydraulic pump
9 Traction motors 20 Brake fluid reservoir
10 Drive wheel 21 Lift cylinder
* Option
BA 25
Description
1 2 3 4 5 6
21
20
7
19 8
9
18 10
163 453-05.04
11
12
13
©
14
17
15
16
Driver’s station 5051-Ba-166
1 Steering wheel 11 Load capacity plate

2 Switch key 12 Load capacity plate for attachment*
3 Brake pedal 13 Parking brake lever
4 Paper pocket 14 Emergency isolator button
5 Accelerator pedal 15 Knob for unlocking battery cover
6 Control and display panel 16 Tray
7 „Lift/lower“ control lever 17 Operator’s seat
8 „Tilt“ control lever 18 Battery plug
9 Control lever for attachment* 19 Horn push
10 Directional switch 20 Button panel
21 Beverage holder
* Option
26 BA
Description
1 2 3 4 5 6
21
20
7
19
8
F
8
9
18
©
10
163 453-05.04
11
12
13
17
14
15
16
5051-Ba-167
Driver’s station
1 Steering wheel 11 Load capacity plate for attachment*
2 Switch key 12 Parking brake lever
3 Brake pedal 13 Adjustable armrest
4 Paper pocket 14 Armrest handwheel
5 Accelerator pedal 15 Knob for unlocking battery cover
6 Control and display panel 16 Tray
7 Joystick 17 Operator’s seat
8 Emergency stop button 18 Battery plug
9 Operating notice label on valve cover 19 Horn push
10 Load capacity plate 20 Button panel
21 Beverage holder
* Option
BA 27
Description
1 2 3
163 453-05.04
©
12 11 10 9 8 7 6 5 4
5051-Ba-002
Control and display panel
1 Forward travel indicator 7 Functional switch for scrolling down

2 Display 8 Functional switch for top right display field
3 Escape key 9 Function button for bottom right display
4 Enter key field
5 Field for FleetManager* 10 Function button display field lower left
6 Functional switch for scrolling up 11 Function button for upper left display field
12 Reverse travel indicator
* Option
28 BA
Description
Mini console* 2
1 Directional switch 3 4 5 6
2 Turn signal switch
3 Turn signal indicator
4 Headlight switch/side marker light switch
5 Forward travel indicator
6 Wash/wiper switch 1 7
7 Rear working light switch
8 Front flood light button
9 Reverse travel indicator
10 Rotating beacon 8
11 Seat heating button
5051-Ba-003 11 10
©
163 453-05.04
Button panel
1
1 Driving program button
2 Front flood lights*
3 Rear flood lights*
3 2 5051-Ba-086
* Option
BA 29
Description
1 2 3 4 5
F
6
9 8
11
163 453-05.04
10 12
©
5051-Ba-201
Joystick*
1 Mast tilt control 7 Joystick
- Tilt load 8 To lift carriage – pull joystick back
- Functions of attachments* 9 To lower carriage – push joystick forward
2 Horn button (red) 10 Auxiliary hydraulic circuit* joystick to the
3 Directional switch, forward (yellow) left (eg sideshift* to the left)
4 Fine control (dark grey) 11 Auxiliary hydraulic circuit* joystick to the
(not for auxiliary hydraulic piping circuit*) right (eg sideshift* to the right)
5 Control button for attachments* (light grey) 12 Emergency stop button
6 Directional switch, reverse (yellow)
Display 1 2 3 4
1 Selected driving program
2 Number ranging from 1 to 5
3 Time and day in hours and minutes
4 Battery charge
* Option 5051-Ba-168
30 BA
Description
5051-Ba-156
1 27 14
4 20
1
6
10
7 24
STOP 2 25
4 17
8 6
3 10
STOP
7
9 22 13
4 1
1
16 16
5
6 7 8
26 23
DANGER DANGER DANGER
11
28 2
18 3
9 10 11 1 12
21 16 STILL GmbH Hamburg
jährliche Prüfung
8
©
gem. UVV
DANGER DANGER Mängel siehe Prüfbuch
9 letzte Prüfung
19
163 453-05.04
10 bar Hydraulikoel 19..
(fuer Lebensmittelindustrie) UVV

16 USDA H1 / 46
19..
nächste Prüfung
12 13 18
17
24
22
14
21 DANGER
20 Berzeliusstr. 10 D-22113 Hamburg

23 25
646202
Typ
Fabrik-Nr. XX XXXX X XXXXX Baujahr
Leergewicht kg
Nenntragfähigkeit kg
zul. Gesamtgewicht kg
28
zul. Achslasten: v. kg h. kg
Nenn-Antriebsleistung *
Zusatzgewicht *
kW
kg
27
Batterie Gewicht/Spannung *
min. kg max. kg V
* siehe Betriebsanleitung
ACHTUNG - ATTENTION !
+F
26 Zum Öffnen der Haube Armlehne in
unterste Stellung bringen und den

Fahrersitz ganz nach hinten schieben
To open the batteryhood the armrest

Im Falle des Kippens
has to be placed in the lowest position
and the driverseat must be moved
Befolgen Sie diese Keinesfalls
GEFAHR Verhaltensmaßnahmen Gurt öffnen Nicht abspringen Festhalten Füße abstützen Gegenlehnen completely back 617547
Location of plates and labels

1 Hook symbol 15 n/a.
2 “Single-pedal operation” label 16 Tyre inflation pressure label*
3 Label “Driving with double-pedal model”* 17 Notice label*
4 Manufacturer’s logo 18 Hydraulic oil label (food industry)*
5 Manufacturer’s logo 19 Safety inspection label
6 Warning sign 20 Load capacity plate
7 Warning label 21 Identification plate
8 Warning label 22 Notice label
9 Warning label 23 Notice label
10 Warning label 24 Warning label
11 Notice label 25 Warning label
12 Notice label 26 Warning label
13 Warning label 27 Warning label*
14 Notice label 28 “Joystick operation” label*
* Option
Warning signs
The warning signs and notices must always be obeyed.
BA 31
Description
Manufacturer’s identification plate GB
1 Type
2 Year of manufacture
3
4
Load capacity in kg
Admissible total load in kg
1 2
5 Admissible rear axle load in kg 15
646203
Type
6 Ballast
7 Battery voltage in Volt 14 weight kg 3
8 Maximum battery weight
9 See technical data for detailed information 13 e
front kg rear
kg
kg
4
10 Minimum battery weight * kW
11 CE symbol 12 Additional weight *

*
kg 5
12 Rated power kg max. kg V
13 Admissible front axle load in kg
14 Dead weight in kg
15 Serial number
6
11
NOTE:Please indicate this serial number for all 10 9 8 7
technical questions.
163 453-05.04
Serial number
xx xxxx x xxxxx
The serial number contains the following
information:
©
1 Plant 1
2 Type
3 Variant
4 Sequence number 2
4 70Ba-001
32 BA
Description
Overview of options and models
Frame and superstructure Overview of attachments
Driver’s seat - Fork extension

- Standard seat - Warning beam
- Standard seat with textile cover - Guard
Rolling frame for battery - Ram
Lifting gear for batteries - Crane boom
Chocks - Snow plough
Tray - Bucket
- Sideshift (SS)
Overhead guard and cabin - Clamp forks without SS
- Bale clamp without SS
Overhead guard - Clamp forks with SS
Weather protection - Bale clamp with SS
Tarpaulin cabin - Fork spreader
Front windscreen
Roof with hatch
Defroster system
Heater
©
Wiper
163 453-05.04
Washer system
Closed canopy
Special overhead guard for drive-in racking
Braking system
Regenerative brake
Hydraulic equipment
Multi-lever control
Single-lever control
Auxiliary hydraulics
Pressure relief valve
Proportional valves with joystick operation
Cold storage version
Lifting mast
(Mast height and lifting height, see data sheet)

Telescopic
NiHo
Triplex
Larger forward tilt (over 3°)
Electrical equipment
Standard lighting system

Road lighting system
Spotlight, LH, RH, front, rear
Revolving light
Back-up light
Travel control with two pedals
Joystick
FleetManager
Accident recorder
Antistatic ribbon
Comfort package
BA 33
Description
Overview of accessories
- Key for switch lock (2 items)
Installation of attachments
If attachments are mounted

in the field, the information
in the operating instructions
for the attachment must be
followed. Before
commissioning, an expert
must check the operation of
the attachment.
If an attachment is supplied
with the truck by Linde, the
instructions from Linde and
the operating instructions of
163 453-05.04
the attachment manufacturer
must be observed.
Please observe your national
rules and regulations. Attach-
ments must be CE certified.
©
Hydraulic coupling
Before mounting attachments, the pressure in

the quick-disconnect couplings (arrows) must
be released.
WARNING: If a clamp with integrated sideshift

is installed, be sure that the clamp does not
open when the sideshift is operated. Danger
of accident through falling load!
Please contact our Service before installation. 5051-Ba-123
Mounting of attachments Load capacity with attachment
The mounting of attachments and the The admissible load capacity of the attachment
connection of the energy supply for driven and the admissible capacity (load capacity and
attachments must be according to the load moment) of the truck must not be
instructions supplied by Linde and the supplier exceeded. The specifications given by Linde
of the attachment. The operation of the and the supplier of the attachment must be
attachment must be checked before initial adhered to.
operation after every mounting.
Mounting working platforms
Please observe the appropriate passage in the

section “Operating the lifting device”.
34 BA
Starting up
Starting up
Daily pre-operational checks and

services
CAUTION: Do not operate the truck until it is

repaired if any damage or faults are detected 1
on the truck or attachment* during the
following inspections.
Safety features and switches must not be
removed or disabled. Fixed settings must not
be altered.
2
- Report any faults to the supervisors.
Connecting the battery plug

5051-Ba-126
- Disconnect the battery plug (1) from the

charging station and insert into the socket
©
on the truck.
0 I
163 453-05.04
- Pull the emergency stop button (2).
NOTE: If the truck was parked at temperatures

under 0 °C, the hydraulic functions can be
sluggish. 3
Turning on the key switch
- Insert the key (3) into the key switch and

turn it clockwise to position (I).
- The message “PLEASE WAIT” appears briefly

in the display, then “SEAT BELT !” is displayed.
Apply the seat belt (See section: Applying
the seat belt).
5051-Ba-124
Then the following information (factory settings)

is displayed: 4 5 6
- The selected driving program PROG (4)
followed by a number ranging from 1 to 5
(5). The driving program can be changed,
refer to the section on "Driving".
- Time (6). The time can be set, see the

section “Indications, settings, operation of
the control unit”.
* Option 7 5051-Ba-125
BA 35
Starting up
- Battery charge (7).
The dark fields show the remaining battery
4 5 6
capacity. Each field corresponds to 10 per
cent battery capacity, i.e. in the example
the remaining capacity is 80 per cent. You
can continue to work with the truck until
the black field is no longer visible. For furt-
her information, see the section “Displays,
settings, operation of the control unit".
NOTE: If a pressure regulator* is installed, the

hydraulic pressure is indicated here. In this
case, the battery charge is shown in %.
Checking the battery charge
NOTE: The correct state of charge is only

indicated after the first load - either by driving 7 5051-Ba-125
or lifting – is put on the truck.
163 453-05.04
- Further information can appear in the display.
Refer to the section "Malfunctions, cause
and remedy“.
* Option
36 BA
Starting up
Adjusting the driver's seat
WARNING: Do not adjust the

seat while the truck is
moving. Risk of accident!
- Adjust the seat so that all controls can be

reached and operated safely.
3
CAUTION: Make sure that
there are no objects in the
swivelling range of the seat
to prevent injuries.
2
The head clearance can be limited on certain
truck versions*. Check the data sheet of your 1 6036Ba-031
truck.
©
NOTE: If separate operating instructions for

163 453-05.04
the seat are supplied with your truck, follow

these instructions.
Adjusting the seat
- Pull up the lever (2) and adjust the seat.
- Release the lever and engage the seat.
WARNING: The seat must engage fully.
Adjusting the backrest
- Pull up the lever (1) and adjust the backrest

tilt with your weight.
WARNING: The backrest must engage fully.
Adjusting the seat cushioning
NOTE: Perform the adjustment only with the

driver unseated.
CAUTION: To prevent back problems, set the

weight adjuster to your own weight.
- Pull up the lever (3) and turn it to the right

or left according to the driver’s weight.
NOTE: The number on the scale must

correspond to the driver’s weight.
* Option
BA 37
Starting up
Adjusting the driver's seat*
DANGER: Do not adjust the

seat while the truck is
moving. Risk of accident!
1
Horizontal adjustment
- Fully pull up lever (3).

- Slide the seat either forward or back.
- Allow the lever (3) to re-engage.
2
WARNING: The lever must engage securely.
Adjusting the backrest

4 3 JoBa-002
- Pull the grip (4) up.
163 453-05.04
JoBa-003
- Put the backrest (1) to the desired position.

- Allow the grip (4) to re-engage.
WARNING: The grip must engage securely.
©
Adjusting the driver’s weight
- Move the adjustment grip (2) only from the

top down to set the desired weight on the 5
scale (5).
- The adjustment range has 9 stages ranging

from 50 kg to 130 kg.
2
Adjusting the armrest
7
- Loosen the armrest adjustment handwheel
(6).
- Move the armrest (7) to the desired position.
- Tighten the handwheel (6) again.
WARNING: The handwheel must be tight.
6
* Option R2015Ba-002
38 BA
Starting up
Seat belt 1 2 3
DANGER: Driving without the
seat belt applied is dangerous
and not allowed!
DANGER
- Only the full cabin with

closed, solid doors or body
guards constitute an
operator restraint system.
PVC doors are not a
restraint system.
- Another driver restraint

system must be used (eg 5051-Ba-043
the seat belt) if the truck

is operated with the doors
©
open or removed.
163 453-05.04
Applying the seat belt
WARNING: Apply the seat belt before moving

the truck. The seat belt must not be twisted
when applied. The seat belt may only be used
to secure only one person!
Have the seat belt repaired if you notice
malfunctions when applying the belt.
- Pull the seat belt (3) out of the retractor

and place it over the upper thighs close to
the body.
NOTE: Sit back as far as possible so that the

back contacts the backrest. The automatic
lock will allow enough freedom of movement
on the seat.
- Engage the tongue (2) in the buckle (1).
- Check the tension of the seat belt. It should

be snug on the body.
BA 39
Starting up
Applying seat belt on a steep slope
The automatic lock will block the seat belt when

the truck is on a steep slope. The seat belt
can no longer be pulled out of the retractor.
- Drive out of the slope cautiously.
- Apply the seat belt.
Opening the seat belt
- Press the red button (4) on the belt buckle

(1).
- Move the tongue (2) back to the retractor

slowly with the hand.
5051-Ba-042
NOTE: Do not let the seat belt retract too

fast. The tongue hitting the retractor can
163 453-05.04
trigger the automatic lock. The seat belt can
then not be pulled out with the usual force.
- Pull the seat belt with increased force about

10 - 15 mm out of the retractor to disengage
the lock.
1
©
- Allow the seat belt to retract slowly.
- Protect the seat belt against dirt (by covering

it, for example).
Malfunction due to cold
- Thaw a frozen seat belt buckle or retractor 4

and dry to prevent a renewed freezing.
CAUTION: Do not use air over 60°C for 5051-Ba-028
thawing.
40 BA
Starting up
Driving behaviour in case of
unused or incorrectly used belt SICHERHEITSGURT !
with belt lock switch present*

and not allowed!
NOTE: This feature ensures that the truck only

drives slowly or (optionally) not at all if the
seat belt is not or improperly applied. Depend-
ing upon the model, the working hydraulics
functions (lifting, tilting) are available as usual
or can only be operated slowly or not at all.
This function is triggered by the following con-
ditions: 5051-Ba-094
©
Seat belt not applied, operator seated

163 453-05.04
SICHERHEITSGURT !
- Turn on the key switch.
The message “SICHERHEITSGURT !” (SAFETY
BELT) is shown in the display as long as a
control lever, steering wheel or accelerator
pedal is being operated.
The truck drives only slowly or not at all;
depending upon the model, the working func-
tions are available as usual or can only be
operated slowly or not at all.
- Apply the seat belt as specified and insert

it.
The truck can be operated again without
any restrictions.
Seat belt constantly inserted, operator 5051-Ba-095
only seated afterwards

The message “SICHERHEITSGURT !”
(SAFETY BELT) is shown in the display as
long as a control lever or accelerator pedal
is being operated.
depending upon the model, the working
functions are available as usual or can only
be operated slowly or not at all.
- Pull the seat belt out of the latch, apply the

belt as specified and insert it again.
any restrictions.
* Option
BA 41
Starting up
Seat belt only applied after key switch is
turned on
SICHERHEITSGURT !
BELT) is shown in the display as long as a
control lever or accelerator pedal is oper-
ated.
depending upon the model, the working func-
tions are available as usual or can only be
operated slowly or not at all.
- Pull the seat belt out of the latch, apply the

belt as specified and insert it again.
any restrictions.
5051-Ba-095
163 453-05.04
©
42 BA
Operating instructions
Starting up
Adjusting the steering column
1
NOTE: Trucks with a front windscreen* have 2
two tilt ranges for the steering column:
• Tilt range (1) is required for opening the

battery cover and may not be used for
driving.
• Tilt range (2) is the adjustment range for
driving.
5051-Ba-127
- Loosen the steering column hand wheel (4).

©
3
- Set the angle of the steering column (5) so
163 453-05.04
that you have enough free space to operate

the steering wheel. Retighten the handwheel.
WARNING: Make sure that steering column is
secure. 4
Checking the steering system for

proper operation
NOTE: Steering play is measured at the

circumference of the steering wheel.
- Turn the steering wheel (3).

The steering play may not be more than 2
fingers wide.
5 5051-Ba-128
WARNING: Steering is difficult when the hy-

draulics have failed.
3
DANGER: Do not operate the
truck with a defective
steering system.
NOTE: If you have restarted the truck, the

maximum driving speed is limited.
- With the truck stationary, turn the steering
wheel (3) about half a turn.
This will remove the speed limitation and the
truck can be driven at maximum speed again.
- When the steering wheel is turned for a curve
while driving, the truck speed will be reduced
while driving in the curve.
BA 43
Starting up
Speed reduction when steering
(Curve Speed Control)
Functional description
This feature reduces the speed of the truck as

the steering lock increases, thus supporting
the driver in the handling of the truck.
DANGER: Before using this

feature, familiarize yourself
with this changed driving and
steering behaviour of the
truck.
The physically-given stability
limits still remain in force
despite this feature (curve
speed control).
6026ba-002
This applies in particular in the following
163 453-05.04
situations:
- driving too fast in curves on uneven or sloping

lanes
- spinning the steering wheel while driving
- driving in curves with an insufficiently secured
load
- driving too fast in curves on a slippery or
©
wet lane
In these cases, the truck can tip over in an

extreme situation!
DANGER: Do not turn off the

key switch while driving. This
turns off the controller and
the speed is no longer
reduced when steering.
The same situation arises if
you press the emergency
isolator button or if the
control unit has failed.
Therefore, always adapt your
driving style to the driving
situation and do not allow
yourself to be induced to put
your safety at risk.
44 BA
Starting up
Speed limitation* with a lifted load
NOTE: This feature ensures that the truck only HUBHOEHE !
drives slowly when the load is raised.
DANGER: Before using this

truck. The truck can either
have a different acceleration
and/or braking behaviour.
DANGER: Never drive with a

load raised as the truck can
tip over due to the high
centre of gravity.
As the physically-given
stability limits still remain in 5051-Ba-100
force, do not misuse this

safety-enhancing feature to
©
put your safety at risk.

163 453-05.04
In case the forks are raised

above a certain height, the HUBHOEHE !
following will occur:
Raising the load at a standstill
The key switch is turned on.
You are seated with the seat belt applied.
- Lift the load.

The message “HUBHOEHE !“ (HOIST HEIGHT)
flashes briefly in the display.
The truck will only drive at reduced speed.
- Lower the forks (load) to just above the floor. 5051-Ba-101
The truck can now drive without speed

limitation again.
* Option
BA 45
Starting up
Lifting the load while driving*
DANGER: Before using this HUBHOEHE !

truck. The truck can either
have a different acceleration
and/or braking behaviour.
DANGER: Driving with a lifted

load is dangerous and not
allowed as the truck can tip
over!
This feature cannot prevent
a wilful tip-over of the truck.
This feature does not protect
you against serious driving
mistakes. 5051-Ba-100
As the physically-given sta-

bility limits still remain in
163 453-05.04
force, do not misuse this
safety-enhancing feature to
put your safety at risk. HUBHOEHE !
The feature does not release

you from the obligation to
adapt the speed of the truck
to the driving situation.
©
- If you are driving with a load when handling
materials and lifting it while driving:
The indication ”HOIST HEIGHT !” will flash
briefly in the display.
The truck will be braked or held at slow
driving speed.
- Lower the forks (load) to just above the

ground.
The truck can be driven again without any 5051-Ba-101
speed limitation.
* Option
46 BA
Starting up
Checking the braking system for
proper operation
WARNING: Do not operate the truck with

faulty brakes.
Checking the service brake

3
- Accelerate the unloaded truck in a free area. 4
- Depress the brake pedal (3) with force

(approx. 60 kg).
- Measure the braking distance required for

the truck to stop.
The braking distance must be:
5051-Ba-009
12 km/h ........................ approx. 1.9 m
©
Checking the parking brake

163 453-05.04
- Drive the unloaded truck on a suitable slope

(e.g. ramp).
Gradient
RX 50-10 ........................ approx. 25 %
RX 50-13 ........................ approx. 25 %
RX 50-15 ........................ approx. 25 %
RX 50-16 ........................ approx. 25 %
DANGER: Never park the

truck on a gradient. In an
emergency, secure the truck
with chocks.
- Engage the parking brake firmly (4). 5051-Ba-042
The truck should not roll back.
BA 47
Starting up
Filling wiper-washer system*
WARNING: Before topping

up, tilt the mast forward. Do
not tilt the mast back during
this servicing, danger of being
squeezed in!
- Remove the cap (1).

2
- Fill the windscreen washer reservoir (2) with
cleaning fluid mixed with antifreeze (eg
approx. 1 litre of Caramba XL).
1
CAUTION: If there is no an-
tifreeze in the system, the
washer system can be dam-
aged.
5051-Ba-196
- Top up the washer reservoir with clear water.
163 453-05.04
Total filling quantity ..... approx. 2.5 litres
- Refit the cap.
- Operate the washer system until washing

water emerges from the nozzles.
* Option
48 BA
Starting up
Checking the wheels for condition
and tyre inflation pressure*
The tyres (1) must not be damaged or worn

and they must have the required inflation
pressure (if pneumatic tyres are fitted*). Tyre
wear must be equal on both sides.
- The tyres must be inflated to the pressure

specified on the labels.
- Please note the information on tyres in the

section „Description“.
WARNING: The stability of the truck is reduced

if tyre wear is uneven or the inflation pressure
is incorrect.
1 5051-Ba-070
WARNING: Renew worn or damaged left and
right tyres without delay. There is a higher
©
risk of accidents as the braking distance is

longer.
163 453-05.04
Use only the types of tyres specified in the

section "Technical Data“.
Checking the emergency stop 3

function
- Drive the truck slowly forward.
- Pull out the battery plug (3) or depress the

emergency stop button (4).
The truck will roll to a stop.
- Pull the emergency stop button up.

This releases the button and lets it pop up. 5051-Ba-011
The truck is operational again.
Emergency stop procedure
In an emergency all the functions of the truck 4

can be cut off.
- For the cut-off, pull out the battery plug (3)

or depress the emergency stop button (4).
F
ATTENTION: These safety features may only

be used in an emergency or to shut down the
truck.
BA 49
Starting up
Checks before driving
1
Before starting up, make sure that the truck is
in a safe condition: 2
- The fork removal and shifting safeties (1)
must not be defective.
- No visible damage (e.g. deformation, cracks,
heavy wear) forks and other load lifting
devices.
- No damage to the chains, sufficient and equal
chain tension.
- Warning devices (e.g. horn) are functioning
properly.
- Lighting* and stop lights* are functioning
properly.
- No damage to and secure mounting of load R2015i BA-018.eps
guard* (if equipped) and overhead guard.
- Proper mounting and operation of
163 453-05.04
attachments* according to operating
instructions.
- Check that all notice labels are present and
legible.
- Replace any damaged or missing labels
according to the overview of the location of
©
plates and labels.
- The roller guide channels (2) must be coated
with a visible film of grease.
- Check the visible parts of hydraulic hoses
and tank for damage and leaks. Replace
damaged hoses.
- Close the battery cut-out cover* (overhead
guard).
Persons in the danger area Danger zone
Before starting up, the driver must ensure that The danger zone is the area in which persons
no person is standing in the danger area of the are endangered through the movement of the
truck. He must also keep unauthorized persons truck, working devices, load-lifting devices (e.g.
out of this area. It is prohibited, in particular, attachment) or the load. This also includes the
to stand in the area of moving parts. A warning area within the range of falling loads or a
signal must be given in the event of an descending working device.
impending danger to persons. If these persons
refuse to leave the danger area despite the
warning, the driver must stop work with the
vehicle immediately.
* Option
50 BA
Operation
Operation
b12
Before driving 100
Dimensions of roadways and aisles

l6
The following dimensions and aisle widths apply
R
under established conditions to ensure safe
driving. Check, when necessary, if a wider aisle x
Ast
is required when the load dimensions differ.
Wa
Obey the national regulations.
The required aisle widths (Ast) depend on the

dimensions of the load.
The dimension stated hereafter apply for 100

standard trucks, please observe your data
sheet. 5051-Ba-071
For pallets the dimensions are:

©
Aisle width With pallet With pallet

163 453-05.04
(Standard) 1000x1200 800x1200

across long
RX 50-10 2954 3075

RX 50-13 3057 3179
RX 50-15 3107 3229 2 3
RX 50-16 3112 3239
The truck may only be used on roadways not

having too tight curves, too large gradients
and too narrow and too low passages.
Driving with special overhead

guard* for drive-in racking
1
NOTE: To be able to access drive-in racking,

the trucks can be equipped with a special
overhead guard.
Observe the following during operation:
- Use the hand grip (1) for safe mounting and
dismounting.
- Activate the restraint system (eg apply the
seat belt).
- During driving, do not let the body or arms
and legs project into area (2 or 3).
DANGER: Danger of pinching 5051-Ba-171

and shearing in these areas.
NOTE: The installation of accessories is only
allowed with the approval of the manufacturer.
Their installation must be supervised by the
manufacturer. All the relevant standards,
ATTENTION: The overall height of the truck directives and safety regulations must be
for drive-in racking is different. Please observe observed.
this in order to avoid collisions and follow-up
damages.
* Option
BA 51
Operation
Driving on gradients
The following inclines or slopes may be driven

on with the truck:
Examples
(dry, rough concrete lane = 0.8, SE tyres)

admissible driving range each hour in metres.
without load
Gradient RX50-10 RX50-13
20% 730 m 570 m

15% 1800 m 820 m
10% 6010 m 2730 m
5% 8400 m 7980 m
without load
5051-Ba-155
163 453-05.04
20% 400 m 380 m
15% 740 m 700 m
10% 2240 m 2100 m
5% 7800 m 7500 m
©
with load
13% 710 m 420 m

10% 1490 m 970 m*
5% 6930 m 3900 m
with load
Gradient RX50-15 RX50-16 5051-Ba-131
13% 270 m 250 m

10% 570 m 510 m
5% 2600 m 2360 m
* For example RX50-13 (with a load and SE

tyres) gradient 10%, 10 m long.
This gradient can be driven 97 times per hour.
The inclines and slopes must not exceed the

above gradients and they should possess a
rough surface.
Smooth passages at the top and lower end

should prevent the load from touching the
ground or damage to the truck.
52 BA
Operation
Checking for condition of roadways Driving safety rules
Roadways must be solid enough, free of debris
and dropped objects. Drainage ducts, railway
Behaviour when driving
crossings and the like must be level and, if
necessary, provided with ramps so that they The driver must drive within the plant according
can be crossed without jolts, if possible. to the traffic rules for public roads. The speed
of the truck must be consistent with the local
There must be sufficient clearance between conditions. Speed must be reduced, for
the highest parts of the truck or load and fixed example, in bends, narrow passages, when
parts of the surroundings. The height depends driving through swing doors, in areas where
on the height of the mast and the dimensions visibility is obstructed and on uneven ground.
of the load. Check the data sheet for your A safe braking distance must always be
truck. maintained to the vehicle ahead and to persons.
Sudden braking, fast turns, overtaking in
hazardous or areas with poor visibility must be
Rules for roadways and work area avoided. First practice driving in a clear area
or on a free roadway.
Only the roads released for traffic by the
operator or his representative may be driven While driving, it is forbidden:
on. The roadways must be free of obstacles. - to dangle arms and legs out of the truck,
©
The load may only be stacked and stored at - to lean out of the truck,
the appropriate places. The operator and his - to climb from one vehicle to another or to
163 453-05.04
representative must ensure that unauthorized fixed objects,

persons keep away from the work area. - to release the seat belt,
- to adjust the driver’s seat,
- to take the restraint system out of operation.
Hazards
Hazards on roadways must be marked with the Visibility when driving

usual traffic signs or, if necessary, by additio-
nal warning signs. The driver must look in the direction of travel
and have a clear view of the route travelled
on. He must always ensure that the way is
clear, particularly when reversing. When
transporting goods that obstruct visibility, the
lift truck must be driven with the load trailing.
If this is not possible, a guide must walk ahead
of the truck. In this case, the truck may only
be driven at walking pace and with the utmost
caution. The truck must be stopped immediately
when eye contact wit the guide is lost. Do not
drive with the load raised.
Rear-view mirrors are only fitted for monitoring

the traffic to the rear; they should not be used
for reversing. If rear-view mirrors are necessary
for sufficient visibility, carefully practice driving
with their help.
BA 53
Operation
Seat belt is removed while driving*
SICHERHEITSGURT !

and not allowed!
- In case the belt is removed while driving:

BELT) is shown in the display.
The truck speed is reduced to slow speed.
DANGER: This feature does
not relieve you of the duty to
adapt the speed of the truck
to the driving situation. The
enhanced safety given by this
feature should not be misused
to put your safety at risk.
5051-Ba-096
- Apply the seat belt as specified and insert
it. The truck can be operated again without
163 453-05.04
any restrictions.
Behaviour in an emergency
Do not jump off!
DANGER: If the truck is
©
about to tip over, do not
attempt to jump off. The risk
of personal injury increases
when jumping off. R6046-Ba-R-006
Never open the seat belt!
R6046-Ba-R-013
Correct behaviour in case of tip-overs:
- Bend over the steering wheel with the top

part of the body.
R6046-Ba-R-007
- Hold the steering wheel with both hands and

brace yourself with the feet.
R6046-Ba-R-008
- Tilt the body against the direction of tipping.
* Option R6046-Ba-R-009
54 BA
Operation
Selecting the driving program
1
The driving and braking characteristics of the
truck can be set on the button panel.
- Press the button (1) with the hare symbol

until the desired driving program (2) appears
in the display.
NOTE: The program numbers appear in ascend-

ing order. The number 1 appears after 5 again.
The program numbers have the following mean-
ing:
1-2: ● gentle and slow acceleration and de-

celeration (e.g. for fragile goods).
3-5: ● fast acceleration and deceleration.

5051-Ba-076
NOTE: Observe the following schematic for the

selection of the driving program.
©
2
163 453-05.04
The following settings (Standard setting*) are

possible:
Driving program 1 2 3 4 5
PROG
Truck speed 12.5 12.5 12.5 12.5 12.5
(km/h)
Acceleration 50% 60% 70% 80% 90%

(forw./rev.)
Deceleration 50% 60% 70% 70% 70%

(forw./rev.)
Reversimg 50% 60% 70% 80% 90%

(forw./rev.)
5051-Ba-078
electric 60% 70% 80% 90% 100%

deceleration
(brake booster)
* Settings may vary
BA 55
Operation
Directional switch
1
The directional switch can be installed in either
of two versions:
As switch (1) on the lift control lever or as

switch on the mini console*.
- Depress the switch at the top for forward

travel.
- Press the switch at the bottom for reverse

travel.
- The symbol (2) shows the direction of travel

when the switch is operated. 2
5051-Ba-172
- The arrow for the selected direction of travel
163 453-05.04
comes on for forward (3) or reverse (4)
3
travel.
NOTE: To shift into neutral, shift briefly in the

opposite direction. In the neutral position no
directional arrow is illuminated.
If the drive is cut out (eg due to emergency
©
stop or application of parking brake), the
selected direction of travel is indicated as long
as the accelerator is not operated.
4 5051-Ba-173
Driving
WARNING: The truck may only be operated

with the driver seated.
1
- Elevate the fork carriage until the required
ground clearance is obtained by pulling back 2
the lift lever (1).
- Tilt the mast back by pulling back the tilt

lever (2).
- Do not pick up the load yet!
5051-Ba-132
56 BA
Operation
Directional switch with mini console*
- Switch (1) on the mini console*.
- Push the switch forward to select forward

travel.
- Pull the switch back to select reverse travel. 1
5051-Ba-033
- The arrow for the selected direction of travel

©
for forward (2) or reverse (3) travel.

163 453-05.04
NOTE: To shift into neutral, shift briefly in the 2

opposite direction. In the neutral position no
directional arrow is illuminated.
If the drive is cut out (eg due to emergency
stop or application of parking brake), the
selected direction of travel is indicated as long
as the accelerator is not operated.
5051-Ba-079 3
* Option
BA 57
Operation
Accelerating 1 2
- Release the parking brake by depressing

button (3) and push the lever fully down.
- Set the directional switch (4) to the desired
direction of travel.
- Gently depress the accelerator pedal (2) until
the desired driving speed is reached.
When the accelerator pedal is released, the

truck is braked electrically, and if fully released, 3
the truck will come to a full stop. The truck
stays braked - even on gradients.
4
Forward travel
5051-Ba-014
- Depress the directional switch (4) at the top.
- The arrow for forward travel (5) comes on.
163 453-05.04
- Depress the accelerator pedal (2). The truck 5
drives forward. The driving speed depends
on how far the accelerator pedal is depressed.
truck is braked. It will also remain stationary
on slopes.
©
NOTE: The truck can be stopped briefly on
upslopes or downslopes without operating the
parking brake (electric braking). It is possible
that the truck creeps slowly.
CAUTION: This electric braking only remains

in proper operation as long as the key switch
is turned on, the emergency stop was not
actuated and the parking brake is not engaged.
6 5051-Ba-015
Reverse travel Changing the direction of travel
- Depress the directional switch (4) at the - Release the accelerator pedal (2).
bottom. - Operate the directional switch (4) in the
- The arrow for reversing (6) is illuminated. opposite direction of travel.
- Depress the accelerator pedal (2) to drive in - Depress the accelerator pedal again.
reverse. The other functions are the same
as for forward travel. The reversing light will NOTE: It is also possible to change the direction
light up (only with lighting* acc. to road of travel while driving. The foot can even remain
traffic regulations). on the accelerator. The truck is then braked
and accelerated in the opposite direction of
travel (reversing).
* Option
58 BA
Operation
Starting with the mini console* 1 2
- Release the parking brake by depressing

button (3) and push the lever fully down.
- Set the directional switch (4) to the desired
direction of travel.
- Gently depress the accelerator pedal (2) until
the desired driving speed is reached.

truck is braked electrically, and if fully released, 3
the truck will come to a full stop. The truck
stays braked - even on gradients.
Forward travel
5051-Ba-081
- Set the directional switch (4) forward.
- The arrow for forward travel (5) comes on.
©
- Depress the accelerator pedal (2). The truck

163 453-05.04
drives forward. The driving speed depends 4

on how far the accelerator pedal is depressed. 5
truck is braked. It will also remain stationary
on slopes.
NOTE: The truck can be stopped briefly on

upslopes or downslopes without operating the
parking brake (electric braking). It is possible
that the truck creeps slowly.
CAUTION: This electric braking only remains

in proper operation as long as the key switch
is turned on, the emergency stop was not
actuated and the parking brake is not engaged.
5051-Ba-034 6
Reverse travel Changing the direction of travel
- Depress the directional switch (4) at the - Release the accelerator pedal (2).
bottom.
- Operate the directional switch (4) in the
- The arrow for reversing (6) is illuminated. opposite direction of travel.
- Depress the accelerator pedal (2) to drive in - Depress the accelerator pedal again.
reverse. The other functions are the same
as for forward travel. The reversing light will NOTE: It is also possible to change the direction
light up (only with lighting* acc. to road of travel while driving. The foot can even remain
traffic regulations). on the accelerator. The truck is then braked
and accelerated in the opposite direction of
travel (reversing).
* Option
BA 59
Operation
Driving (joystick*) 2
WARNING: Operate the truck only from the
driver’s seat.
Please refer to the section "Safety precautions

for driving“.
- Pull the joystick* (2) back to raise the fork

carriage until the required ground clearance
is obtained.
- Push the tilt control (1) up to tilt the mast 1

back.
- Do not pick up a load yet!
NOTE: The information on the driving and JoBa-005

braking characteristics when driving with the
directional switch also applies.
163 453-05.04
3
Setting the driving program
F
- See note on page 55. 4
©
Forward travel
- Push the travel direction switch (3) forward.

The arrow for forward travel (5) will illuminate
on the console.
60BA-016
Reverse travel 5
- Push the travel direction switch (4) back.
The arrow for reverse travel (6) will illuminate
on the console.
- Depress the accelerator pedal. The truck will

reverse. The other functions are as described
for forward travel.
NOTE: An acoustic signal* sounds at the same

time as an alert.
* Option 6 5051-Ba-015
60 BA
Operation
Service brake
CAUTION: Always drive at a speed for which

the braking distance is long enough. In this
respect it should be noted that the braking
distance itself increases at about the square
of the speed and that the front wheels can
slip and the truck tip over in case of abrupt
braking.
The braking distance of the truck is affected
by the characteristics of the floor surface.
The braking distance increases on a wet
roadway. The driver must take this into
consideration in the way he drives and brakes.
- Always use the foot brake (1) to brake the

truck when driving. In the first part of the
pedal stroke, only the electric brake is in
1
action; when the pedal is depressed further,
5051-Ba-040
the hydraulic brake is activated and acts on

the front wheels.
©
163 453-05.04
Electric regenerative braking
When braking electrically, energy is fed back

into the battery so that the operating time
3
between battery charging intervals is exten-
ded and the brake lining wear is reduced.
Parking brake
- To park the truck, pull the parking brake lever

(3) fully up and let it engage.
5051-Ba-041
NOTE: When the accelerator pedal is depressed

with the parking brake applied,
„FESTSTELLBREMSE” (PARKING BRAKE) appears
on the display.
WARNING: If the parking brake is applied only

lightly, the truck can roll.
- Driving is disabled.
- The travel directional indicator is

extinguished.
BA 61
Operation
DANGER: If the truck is
stopped on a gradient, the
bonnet may only be opened 2
if the truck is secured against
rolling with chocks.
- To release the parking brake, press the button

(2) and push the parking brake lever 3
completely down.
- After releasing the parking brake, the

previously selected direction of travel is still
selected.
Steering
- Steer the truck by turning the steering wheel

(4) as required.
5051-Ba-041
Steering radii: see technical data.
163 453-05.04
WARNING: When the hydraulics have failed,
4
steering is difficult.
©
5051-Ba-017
62 BA
Operation
Double-pedal model*
Driving
1
Please refer to the section "Safety precautions
for driving“.
2
WARNING: Always remain seated when
operating the lift truck.
- Elevate the fork carriage with the lift lever

(1) until the required ground clearance is
obtained.
- Tilt the mast back with the tilt lever (2).
- Do not pick up the load yet!
Accelerating
5051-Ba-133
©
Forward travel 3
163 453-05.04
- Release the parking brake.

- Depress the right accelerator pedal (4).
The fork truck will drive forward. The speed of
the truck depends upon how far the accelerator 4
pedal is depressed.
Reversing the travel direction
- Release the depressed accelerator pedal.

- Depress the accelerator pedal for the
opposite direction of travel.
The truck will be braked to a stop electrically
and then accelerate in the new direction.
5 5051-Ba-075
Reverse travel
- Depress the left accelerator pedal (3). The

truck will reverse. The speed of the truck
depends upon how far the accelerator pedal
is depressed. The reversing light will light up
(only with lighting* acc. to road traffic
regulations).
Foot brake
- Releasing the accelerator pedal brakes the

truck automatically. Also use the foot brake
(5).
* Option
BA 63
Operation
Driving behaviour with seat switch
not operated S I T Z S C H A LT E R
NOTE: This device ensures that the truck only

drives slowly or (optionally) not at all if the
seat switch is not operated. Depending upon
the model, the working hydraulics functions (eg
lifting, tilting) are available as usual or can be
operated only slowly or (optionally) not at all.
This function is triggered by the following
conditions:
Seat switch not operated
- You are not seated on the seat and operate

the accelerator or steering wheel.
5051-Ba-117
The message “SITZSCHALTER” (SEAT
163 453-05.04
SWITCH) is shown in the display.
The truck will not drive. S I T Z S C H A LT E R
- Sit down on the operator’s seat and apply

the seat belt.
The truck can now be driven without any
restrictions.
©
Seat switch not operated
- You are not seated on the seat and are

operating a control lever.
The message “SITZSCHALTER” (SEAT
SWITCH) is shown in the display.
Depending upon the model, the working
functions are available as usual or can only 5051-Ba-118
be operated slowly or not at all.
- Sit down on the operator’s seat and apply

the seat belt.
The work functions can either be carried out
without any restrictions.
64 BA
Operation
Driving behaviour when seat
switch is operated too long S I T Z S C H A LT E R !
Exceeding the shift time
NOTE: This device ensures that the truck only

drives slowly if the seat switch is operated too
long. Depending upon the model, the working
hydraulics functions (eg lifting, tilting) can only
be operated slowly or (optionally) not at all.
This function is triggered by the following
conditions:
NOTE: The work shift time can be set.
- The message “SITZSCHALTER !” (SEAT

SWITCH) is shown in the display after the
preset time if the seat has not been vacated
beforehand. This is also the case if a control
5051-Ba-099
lever or the accelerator pedal is operated.

©
The truck drives only slowly; depending upon

the model, the working functions are available S I T Z S C H A LT E R !
163 453-05.04
as usual or can only be operated slowly or

not at all.
- Stand up for a short time and sit down again.

any restrictions.
Exceeding the operating time
NOTE: The operating time can be set.
- If you sit longer than the preset operating

time with the key switch turned on and the
parking brake released, the message “SITZ-
SCHALTER !” (SEAT SWITCH) is shown in the
display if neither a control lever or the 5051-Ba-099
accelerator pedal is operated during this

time.
The truck drives only slowly; depending upon
the model, the working functions are available
as usual or can only be operated slowly or
not at all.

any restrictions.
BA 65
Operation
Use in cold storage warehouses*
Your truck can be used for cold storage appli-

cations with the proper optional equipment. It
can be employed for two types of applications
and is identified with the cold storage symbol.
Description
The cold storage equipment consists of a heater

in the console and the use of oils suitable for
cold storage areas (for the hydraulics and gear-
box) and greases (for moving parts such as
toothing and chains).
A further option for the truck is a cabin with
heater.
Proper use
163 453-05.04
Application 1: Continuous duty in the –5 °C
temperature range and brief
operation down to –10 °C;
parking outside the cold stor-
age area.
Application 2: Duty alternating between inside
©
and outside in temperatures
ranging from –32°C to +40° C;
parking outside the cold stor-
age area.
For this duty, use the recom-
mended cold store hydraulic oil.
Use
General
The change from a cold temperature inside to

a warm temperature outside causes conden-
sation. The condensate water can freeze when
re-entering the cold storage area, blocking
moving parts of the truck. That is why it is
important to pay attention to how long you
work in the different temperature zones.
The traction batteries should never be cooled
to the temperature of the cold storage ware-
house (down to –32 °C), otherwise they will
be become inoperative.
* Option
66 BA
Operation
Before operation
CAUTION: The truck must be dry and at op-

erating temperature before it is used in the
cold storage area.
- Drive the truck about 5 minutes and operate

the brake several times to ensure safe op-
eration.
- Operate all mast lift functions several times.

This warm-up phase is necessary for the oil
to reach its operating temperature.
Operation
Application 1
Continuous duty in the –5 °C temperature range

©
and brief operation down to –10 °C.

163 453-05.04
Application 2
Duty alternating between inside and outside in

temperatures ranging from –32 °C to +25 °C,
brief operation up to +40 °C. The truck should
not leave the cold storage warehouse area for
longer than 10 minutes to prevent the forma-
tion of condensate water.
If the truck remains outside for over 10 min-
utes, it must stay there at least until the con-
densate water has run off. This usually takes
at least 30 minutes.
CAUTION: If the condensate water freezes in

the cold storage warehouse, do not loosen
frozen parts with your hands.
Parking
- Always park the truck outside the cold stor-

age area.
CAUTION: The batteries should not remain

overnight in the cold storage area if not used
or recharged.
- Recharge the battery outside the cold stor-

age area and operate the truck with a re-
placement battery.
BA 67
Operating the lifting device
Safety rules for handling loads
The following sections contain the safety rules

for handling loads.
The most important safety precautions are:
WARNING: The working

hydraulics may only be
operated from the operator
compartment.
Do not step or stand under a
raised load. Danger of loss of
life!
Do not exceed the maximum
loads given in the capacity
plate. Otherwise truck
stability will not be ensured!
©
Danger of loss of life!

Do not step on the forks.
163 453-05.04
Danger of personal injury!
Never put your hands in

moving parts of the mast.
Mast versions
Your truck can be equipped with one of the

following masts. Their method of operation is
as follows:
Telescopic mast
When the lift control lever is pulled back, the

mast is raised by the two outer cylinders and
the fork carriage is lifted via the chains (fork
carriage is raised at twice the speed of the
inner mast). 1
ATTENTION: In case of low ceilings, remem-

ber that the inner mast (1) can be raised higher
than the fork carriage.
BA 69
NiHo mast*
2
When the lift lever is pulled back, the inner
cylinder extends as far as the free lift (3). The
outer cylinders then raise the inner mast to
the maximum height (2).
3
NOTE: When a load is raised beyond the free
lift, the fork carriage always remains at the
top edge of the extending mast end.
CAUTION: If the ceiling is low, note that the

picked up load can be higher than the fork
carriage.
5051-Ba-051
Triplex mast*
163 453-05.04
Operation as for NiHo mast, but increased lifting
height for the same mast height.
CAUTION: If the ceiling is low, note that the

picked up load can be higher than the fork
carriage.
©
WARNING: Before picking up the load, carefully
follow the instructions starting on page 83. Do
not reach or climb into moving truck parts
(e.g. mast, sideshifts, working devices, load
lifting devices, etc.).
5051-Ba-052
Tilting the mast 2

To tilt the mast forward:
- Push the tilt lever (1) forward.
To tilt the mast back:

1
- Pull the tilt lever (1) back.
NOTE: The symbol (2) on the control lever

shows the direction of mast movement when
pulling or pushing the control lever.
70 BA
Raising, lowering the fork carriage
To raise the fork carriage:

- Pull the lift lever (1) back. 1
CAUTION: On HiLo* and triplex masts* the
mast can extend in the wrong sequence, ie
the inner channel extends before the fork
carriage reaches the end of lift 1.
This results in the mast height being exceeded
so that damages can occur when driving
through gates/doors or under low ceilings.
This can happen, for example, due to:
- Low oil temperature
NOTE: The oil temperature can be raised by 5051-Ba-175

slowly operating the mast functions several
times.
©
- Blocking of the fork carriage in the inner mast

163 453-05.04
- Blocking of lift jack 1 2

- Blocking of the lift 1 chain pulley.
In these cases have the cause of the blocking
eliminated before continuing work.
- Contact your Service.
- Have the service ”Check chain tension”
carried out according to the maintenance
instructions.
To lower the fork carriage:

- Push the lift lever forward.
DANGER: When lowering the

mast, take care that the
chain(s) do(es) not become
loose. There is a risk of the
load dropping suddenly. 5051-Ba-176
This can happen, for example, due to:

- The fork carriage or the load resting on the NOTE: Raise the fork carriage until the chains
racking. are taut again. Remove the dirt before
continuing work.
NOTE: Raise the fork carriage until the chains
are taut again and lower the load at another NOTE: The symbol (2) on the control lever
suitable spot. shows the direction of fork carriage movement
when the control lever is pulled or pushed.
- Blocking of the fork carriage rollers in the
mast due to the accumulation of dirt.
* Option
BA 71
Operating the attachments*
WARNING: Attachments may only be used

for the applications they were designed as
described in the relevant operating
instructions. The driver must be instructed in
the handling of the attachments. 3
Picking up loads with attachments
WARNING: Loads may only be picked up and

transported with attachments if they can be
seized and held properly. If necessary, the
loads must also be secured against sliding,
rolling, falling over, swinging or falling off. When 5051-Ba-134
the load centre of gravity changes, note that
the stability of the truck also changes. Please
163 453-05.04
refer to the attachment load capacity plates.
- Control lever (3) for hydraulically-operated

attachments (eg sideshift).
©
Follow the operating instructions supplied by
the manufacturer.
NOTE: Other options and functions are

possible. The attachment functions are
indicated on the control lever symbols.
* Option
72 BA
Symbols for movements of the lifting device and attachments*
NOTE: The upper symbol shows the movement when the control lever is pushed forward. The
lower symbol shows the movement when the control lever is pulled back.
1 Lowering/lifting forks or mast 7 Releasing / actuating load

holder
2 Tilting mast or forks forwards 8 Pulling load on to forks /

/ back pushing load off forks
©
163 453-05.04
3 Advancing / retracting reach 9 Opening / closing clamp

frame or forks
4 Sideshifting to the left / right 10 Rotating
5 Increasing / reducing fork 11 Dumping / scooping with

spread bucket
6 Rotating mast or forks to

the left / right
* Option
BA 73
Transporting swinging loads
Observe the national safety rules and

regulations.
DANGER: The following

dangers can result from
swinging loads:
- reduced braking and steering ability,
- tipping over the running or traction wheels,
- tipping of the truck to the side,
- risk of squeezing for accompanying persons,
- reduced visibility.
163 453-05.04
DANGER: Loss of stability
due to displaced, unstable
and, in particular,
suspended loads.
Observe the following instructions for the
©
transport of swinging loads:
- Always avoid the swinging of loads by

selecting the proper truck speed and style
of driving (by steering and braking cautiously).
- Suspended loads must always be attached

to the truck so that the means of attachment
can not slide or become loose accidentally
and not become damaged.
- Make sure that no persons are in the driving

lane in the direction of travel.
- Make sure that no persons are endangered

by swinging loads.
- When transporting suspended loads, suitable

aids (eg holding ropes or bars) must be
available to and used by guides.
WARNING: Always perform or terminate

driving and load movements smoothly when
transporting loads. Do not drive on gradients
with a suspended load. Do not transport
containers with liquids as a suspended load.
74 BA
Adjusting the auxiliary hydraulics*
1
NOTE: If a joystick* is fitted, the pressure for
the operation of an attachment must be set % 123 bar
at the attachment itself.
The pressure of the auxiliary hydraulic system

is infinitely variable.
- Read the set pressure (1) in the second line

of the display.
Check the data on the attachment type plate

when changing the setting.
- Operate the clamp control lever (close the 2

clamp), for example.
- Set the knob (2) to the desired pressure:
Turn clockwise to increase pressure, 5051-Ba-135
Turn anti-clockwise to decrease pressure

(can be read on the display).
©
- Press button Enter again. 3

163 453-05.04
WARNING: Do not remove any limiting shims.
Fork extension*
- Slide the extension (3) onto the forks and

secure with the pin (4).
CAUTION: The fork extension reduces the

stability of the truck. The maximum capacity
given on the load capacity diagram must be
reduced in relation to the actual load distance.
4 R60BA-38
Load capacity plate for

attachments*
2
- Please check the maximum values for:
• the load capacity Q (kg) (1)

• the lifting height (mm) (2) 1
• the load centre distance C (mm) (3)
3
* Option R2015i BA-026.eps
BA 75
Single-lever* operation of the 5
lifting device
6
- Push the control lever (5) forward.
- Pull the control lever back.
- Move the control lever (5) to the right.
- Move the control lever to the left. 5051-Ba-136
NOTE: The direction of fork carriage motion is
163 453-05.04
indicated on the inserted label. 7 8
This label can exist in 2 versions:
(7) Single-lever control with directional

switch (6)
©
(8) Single-lever control with horn push (6)
(version with twin-pedal model*)
5051-Ba-137
* Option
76 BA
Operating the lifting device with
the joystick*
NOTE: The lifting device can only be operated

when the seat is occupied.
WARNING: Before picking up a load, observe

the instructions beginning on page 83. Do not
put your hand or step into moving truck parts
(e.g. mast, sideshift, implements, load lifting
device, etc.).
Tilting the mast

©
1
163 453-05.04
- Push the mast tilt control (1) down.
- Push the mast tilt control up.
JoBa-010
Raising, lowering the fork carriage
- Pull the lift/lower joystick (2) back.
- Push the lift/lower joystick forward. 2

NOTE: The symbols on the valve cover indicate
the directions of movement.
* Option JoBa-009
BA 77
Operating attachments*
WARNING: Attachments may only be used

for the applications they were designed as
described in the relevant operating
instructions. The driver must be instructed in
the handling of the attachments.
Picking up loads with attachments
WARNING: Loads may only be picked up and

transported with attachments if they can be
seized and held properly. If necessary, the
loads must also be secured against sliding,
rolling, falling over, swinging or falling off. When
the load centre of gravity changes, note that
the stability of the truck also changes. Please
refer to the attachment load capacity plates.
163 453-05.04
NOTE: Further options and functions are
possible. The directions of movement are shown
on the notice labels on the valve cover.
To sideshift* left F
©
- Move the joystick (3) to the left.
3
To sideshift* right
- Move the joystick (3) to the right.
JoBa-011
To advance the forks* 3 4

- Push button (4) and simultaneously push the
joystick (3) forward.
To retract the forks*
- Push button (4) and simultaneously pull the

joystick (3) back.
78 BA
Fork spreader* 3 4
To increase fork spread
- Push button (4) and simultaneously move

the joystick (3) to the left.
To reduce fork spread F

the joystick (3) to the right.
R2015Ba-007
To rotate the head* clockwise

©
3
163 453-05.04
- Move the joystick (3) to the right.
To rotate the head* anticlockwise
- Move the joystick to the left. F
JoBa-014
To close the roll clamp* 3 4

the joystick (3) to the right.
To open the roll clamp*
- Push button (4) and simultaneously move F

the joystick to the left.
BA 79
To lower the bucket* 3 4
- Push button (4) and simultaneously push the
joystick (3) forward.
To raise the bucket*
- Push button (4) and simultaneously pull the

joystick (3) back.
R2015Ba-009
Emergency lowering (Joystick*)
163 453-05.04
2
In case the load can not be lowered due to a
failure of the control, follow the emergency 1
lowering procedure below.
- Pull the knob (1).
©
- Open the valve cover (2).
DANGER: Do not step under

the raised load!
5051-Ba-177
- Using a screwdriver, loosen the emergency

lowering screw (3) at the control block (4)
by a maximum of 1½ turns.
CAUTION: The load will be lowered. The

lowering speed can be controlled by loosening
the screw more or less.
- Loosening the screw a little

lets the load lower slowly.
- Loosening the screw a lot
lets the load lower fast.
- Retighten the emergency lowering screw (3) 4
after the load has been lowered.
3
Tightening torque ................ max. 2.5 Nm
80 BA
Overriding the lifting height
limitation* 1 2
NOTE: The lifting function is cut out at a preset
lifting height. The fork carriage stops at a
certain height.
If the truck is equipped with the lifting height

limitation feature, it can be overridden as
follows:
- Lift the fork carriage as far as the cut-out

point for the lifting height limitation.
- Move joystick (1) to the neutral position.
- Press the function button (2) while

simultaneously pulling the joystick back. R2015Ba-018
The fork carriage can now be lifted as far as
the mechanical stop.
©
Beibl_1
WARNING: If the forks are lifted below the

163 453-05.04
lifting height limitation while the function button

(2) is simultaneously pressed, the fork carriage
is raised as far as the mechanical stop without
being stopped by the lifting height limitation.
Operation with reversible forks*
Normal operation
- Reversible forks can be raised and tilted with

the mast like normal forks.
Operation with reversible forks 5051-Ba-179
CAUTION: Because the load backrest is mis-

sing, it is not allowed to carry a load on the
forks (1).
When driving, the load centre of gravity (2)
should not be more than 600 mm over the
floor. Do not use the fork extension*.
1
NOTE: Inspect the fork bend exterior annually
for cracks.
Max.
2 600 mm
* Option
BA 81
Hydraulic coupling 6036Ba-047.eps
Before mounting attachments, the pressure in

the quick-disconnect couplings (arrows) must
be released.
Relieving pressure with control

lever*
- Turn off the key switch.
- Operate the „attachment“ control lever sev-

eral times.
Relieving pressure with the joy-
163 453-05.04
stick*
12 3
F
- Switch on the key switch.
4
- Depress buttons (1, 2, 3, 4) at the same
time.
©
60BA-009
* Option
82 BA
Before picking up the load
Load capacity
Do not exceed the load capacity of the truck.

It is influenced by the load centre of gravity of
the lifting height and possibly by the tyres.
kg
2
Refer to the load capacity plate to the right of
the driver’s seat. Do not mount additional 1080 640 780 880 5230
weights to increase the load capacity. 1310 660 800 910 5030
1500 680 1230 930 4830
DANGER: Do not exceed the
maximum load capacities in-
3
1500 690 1260 950 4630
1500 710 860 970 4230
dicated there. These apply for
1500 730 880 1000 3830
compact and homogeneous
loads.
The stability and the stiffness of forks and
1 500 800 600 500
mast are not ensured otherwise.

The improper or wrong operation or taking on
10-16-Ba038
passengers to increase the load capacity is

not allowed.
©
3
163 453-05.04
1 Distance "C“, load centre from the fork heel

(in mm)
2 Lift height "h“ (in mm)
3 Maximum loads "Q“ (in kg)
2
Example:
Load to be lifted: 880 kg (3) 88

Distance of load centre 0 5230
from heel of forks: 500 mm (1) K
g
Admissible lifting height: 5230 mm (2)
WARNING: The illustrations are only examples.

Only the data on the load capacity labels on
the truck are applicable!
WARNING if attachments are fitted*: The

admissible load of attachments and the reduced
load capacity of the truck and attachment
combined should not be exceeded. Check the
special load capacity notices on the truck and
attachments.
WARNING: When small goods are transported,

a protective guard* must be installed to
prevent the goods from falling on to the driver.
A closed canopy* should also be used.
Observe the load capacity plate for
attachments. The data on the plate are
explained in the above example.
500
1
10-16-BA-022
* Option
BA 83
Adjusting the forks
- Raise the fork quick-release (1) and shift

the forks to the desired position. 1
- Let the quick-release engage again. The load

centre should be located in the centre
between the forks.
- Do not operate the fork spreader* with a

load on the forks.
Picking up the load
Danger zone
The danger zone is the area 5051-Ba-138

in which persons are
endangered through the
163 453-05.04
movement of the truck,
working devices, load-lifting
devices (e.g. attachment) or Picking up unit loads
the load. This also includes
the area within the range of
To ensure that the load is carried safely, the
falling loads or a descending
driver must make sure that the forks are spread
working device.
wide enough apart and also inserted as far as
©
possible under the load. The load should not
Do not step on the forks.
protrude substantially over the tips of the forks.
Transporting pallets
Under normal circumstances, unit loads (e.g.

pallets) should be transported individually.
WARNING: No person, except the driver in Simultaneous transport of more than one unit
his normal operating position, may stand in load is only permitted
the danger zone of the truck. If persons refuse
to leave the danger zone despite warnings, - on instruction of the supervisor and
stop working with the truck immediately and
secure it against use by unauthorized persons. - if the technical requirements are met.
DANGER: Do not step or The driver must satisfy himself that the load is
stand under a raised load. in proper condition. Only properly and securely
Danger of loss of life! positioned loads may be moved.
* Option
84 BA
Load handling
Only stack pallets not exceeding the specified

maximum dimensions.
Do not stack damaged transport aids and
improperly formed load units.
Place and secure the load on the lifting device

in such a way that it cannot move or fall off.
Stack the load unit so that the specified aisle

width is not reduced by protruding parts.
R60BA-44
- Approach the racking carefully, brake gently

©
and stop just before the racking.

163 453-05.04
- Position the forks.
- Set the mast to the vertical position.
DANGER: When tilting the

mast forwards, take care
that the truck does not tip
forwards or the load slide off.
If your truck has a larger
angle of tilt* (over 3°), a
large risk of sliding during
lifting or lowering of the load
can be assumed.
- Elevate the fork carriage to stack height.

R60BA-45
- Drive slowly forward.
- Do not damage the racking or the load when

inserting the forks.
- Insert the forks as far as possible under the

load. Stop the truck when the load rests
squarely against the face of the forks. The
load centre must be in the centre between
the forks.
- Raise the fork carriage until the load is clear.
* Option R60BA-46
BA 85
- Back off the truck.
- Make sure that the way to the rear is clear.

Reverse slowly and cautiously until the load
is clear of the racking. Brake gently.
R60BA-47
Picking up and depositing the load
163 453-05.04
- Tilt the mast back.
©
R60BA-48
- Lower the load. Maintain enough floor

clearance.
Now you can start driving. Drive carefully and

slowly in sharp corners! Always accelerate and
brake gently!
R60BA-49
86 BA
Carrying the load
WARNING: Always travel with the load as low

as possible. Carrying the load high reduces
the stability of the truck. Raise or lower the
load until ground clearance is obtained. The
load should only be so high that the driver’s
view to the front is not obstructed, otherwise
drive with the load trailing. If this is not
possible, work with a guide walking beside the
truck. In this case, drive the truck only at
walking pace and with the utmost caution.
Stop the truck immediately when losing contact
with the guide.
R60BA-50
- Always travel with the mast tilted back.

©
163 453-05.04
DANGER: Do not drive the

truck with the mast tilted
forwards. The truck can tip
over or the load fall off.
R60BA-51
WARNING: Always accelerate and brake

gently! Avoid fast starts and sudden stops!
R60BA-52
BA 87
WARNING: Never drive the truck with the load
reached out laterally (e.g. sideshift or
sideloading forks).
R60BA-53
Driving on gradients
163 453-05.04
WARNING:When driving on gradients, the load
must be positioned on the uphill side. It is only
permitted to drive on gradients which are
identified as suitable for traffic and which can
be safely negotiated. The driver must satisfy
©
himself that the ground is clean and provides
good grip. It is not allowed to turn or parking
on gradients or to approach them at an ang-
le. Danger of loss of life!
Drive at reduced speed on slopes.
Entering lifts
R60BA-54
With this truck, the driver may only enter lifts
having a sufficient load capacity and with the
permission of the operator. Drive the truck with
the load first into the lift and do not touch the
shaft walls. In the lift, the truck must be
secured so that no parts touch the shaft walls.
The standoff to the shaft wall must at least
100 mm.
The maximum weight of the truck (dead weight
with maximum load) is:
RX 50-10 ....................... approx. 3210 kg

RX 50-13 ....................... approx. 3626 kg
RX 50-15 ....................... approx. 4230 kg
RX 50-16 ....................... approx. 4380 kg
Persons travelling with the lift at the same time

may enter the lift only after the truck is
standing securely and they must leave the lift
first. R60BA-76
88 BA
Driving on loading ramps
Before crossing a loading ramp, the driver must

satisfy himself that it is properly attached and
secured and has a sufficient load capacity.
Cross the ramp slowly and carefully. The driver
must be sure that the vehicle to be entered is
secured sufficiently against moving and that it
can bear the load of the lift truck.
The lorry driver and fork truck operator must
communicate on the departure time of the lorry.
R60BA-77
Depositing the load

©
163 453-05.04
Stacking and removing load units
Always use the following procedure:
- Slowly approach the stack with the load

lowered as specified.
- Set the mast vertical.
WARNING: If your truck has a larger angle of

tilt* (over 3°), a large risk of sliding during
lifting or lowering of the load can be assumed.
- Raise the load to stacking height.
- Carefully drive the truck into the racking. R60BA-55

- Deposit the load on the racking
- Look to the rear.
- Reverse the truck until the forks can be

lowered without touching the racking.
- Lower the forks until ground clearance is

reached, tilt the mast back and drive off.
* Option
BA 89
THIS PAGE INTENTIONAL LEFT BLANK.
5051-Ba-165
163 453-05.04
©
90 BA
BLANK
163 453-05.04
©
BA 91
BLANK
163 453-05.04
©
5051-Ba-163
92 BA
BLANK
5051-Ba-164
©
163 453-05.04
BA 93
BLANK
AB-004
163 453-05.04
©
AB-004
94 BA
Other activities
Other activities
Changing the battery
Maintenance staff
Batteries may only be changed

by specially trained personnel
and in accordance with the
instructions of the manufacturer
of the battery, charger and lift
truck. Follow the battery
handling instructions.
Fire precautions
WARNING: Smoking and naked flames are not
permitted when handling batteries. No
inflammable or spark-producing materials may
be located within at least 2 metres of the
©
truck to be charged and the charger. The room

must be well ventilated. Fire extinguishers 1
163 453-05.04
must be kept ready.

2
Safe parking
When the battery is being worked on, the truck
must be properly parked and it may only be
started when the battery cover is closed and
the battery plug connected.
- Park the truck, engage the parking brake.
Adjusting the steering column for

battery change
NOTE: Trucks with a front windscreen* have

two settings for the steering column tilt: 5051-Ba-127
• Tilt range (1) is required for opening the

battery cover and may not be used for 3
driving.
• Tilt range (2) is the adjustment range for
driving.
ATTENTION: Do not loosen the handwheel (4)

more than 8 turns.
- Loosen the handwheel (4) anticlockwise

approx. 4 full turns.
- Move the steering wheel (3) from range (2)
to range (1) towards the front windscreen 4
as far as the stop.
- Tighten the handwheel.
NOTE: The battery cover now has enough room

and can be opened.
BA 95
Other activities
Opening the battery cover
1 2 3
NOTE: The battery cover can be put into two
different positions for charging and changing
the battery. 4
1 Valve cover
2 Battery removal position
3 Battery charging position
4 Cover closed position
5 Unlock knob
5 5051-Ba-111
Battery charging position
163 453-05.04
3
NOTE: The battery cover must be half open
when charging the battery.

6
- Open the valve cover (1) fully forward.
- Raise the battery cover (6) into the charging
5
©
position.
- Put the valve cover back to the battery
charging position (3).
The knob engages.
NOTE: There is a support (7) for the battery

cover on the valve cover.
- Lower the battery cover back into place.

7 5051-BA-140
Battery removal position

6
To change the battery, the cover must be fully
open. 2
- The knob engages in battery removal position

(2).
ATTENTION: Before opening the cover, make

sure there is enough free space (8) beside
5
the truck. The free space should be at least 8
700 mm and depends on your version.
- Open the battery cover (6) fully.

5051-BA-141
96 BA
Other activities
- Pull the battery socket (1).
5051-Ba-142
- Unlock the cover at the button (2) and open

©
it to the side.
163 453-05.04
2 5051-Ba-143
- Lift the side panel (3) up and out of the

frame.
CAUTION: Do not damage any parts.
* Option 3 5051-Ba-144
BA 97
Other activities
Opening the battery cover (with joy-
stick*) 2 3
- Pull the knob (5). 1
- The knob engages in battery removal position

(1).
ATTENTION: Before opening the cover, make

sure there is enough free space (4) beside
the truck. The free space should be at least
700 mm and depends on your version.
5
4
5051-BA-180
- Unlock the cover at the button (6) and open
163 453-05.04
it to the side. F
- Open the battery cover (3) fully.
©
6
5051-Ba-182
- Pull the battery socket (7).
NOTE: Any further activities must be carried

out as for trucks with control lever(s) for the
lifting device.
98 BA
Other activities
- Open the battery lid* (overhead guard):
z Turn the latch handle (4) to the side.
z Open the battery lid upwards with the
handle.
CAUTION: Close the battery lid* (overhead
guard) after use.
4
Battery replacement
To avoid short circuits, cover batteries with

unprotected terminals or connectors with a
rubber mat.
5051-Ba-146
- Attach the battery (5) to suitable lifting

©
device (eg STILL lifting gear).

163 453-05.04
- The lifting tackle should exercise a vertical

pull so that the battery tray is not squeezed
together. Hooks must be attached in such a
way that they cannot fall onto the battery
cells when the lifting tackle is slack.
- Carefully lift the battery out of the truck.
CAUTION: Do not step or 5

stand under a raised load.
Battery weight and dimensions 5051-BA-089
The weight and size of the battery influence

the stability of the truck. When changing the
battery, the weight conditions must not be
changed. Additional weights may be neither
removed nor their position changed.
Please note the description of installable
batteries in the section „Battery
specifications“.
Notes on the charging the

battery are included in the
workshop maintenance in-
structions in section "Battery
maintenance“.
- Installation and connection of the charged

battery is the reverse of removal.
* Option
BA 99
Other activities
Battery change with roller frame*
1
NOTE: On trucks equipped with a roller frame*
the battery can be removed and installed
laterally with a suitable pallet truck.
This pallet truck must be equipped with a roller
platform*. The roller platform must be bolted
to the pallet truck. The pallet truck must have
a service and parking brake. Please follow the
operating instructions for the pallet truck.
2
- Open the battery cover as far as the
charging position or fully.
3
- Lift the side panel up and out of the frame.
- Disconnect the battery plug.
- Position the pallet truck (2) with roller 5051-Ba-198
platform* beside the battery (1).
163 453-05.04
- Turn the pallet truck steer wheels to the
side and apply the parking brake. 4
- Raise the roller platform to the same height
as the roller frame with the battery.
- Raise the battery retaining lever (3) on the
©
pallet truck to allow the battery to be rolled
onto the roller platform.
- Push the battery catch (4) down 90°. The

battery can now be slid laterally onto the
pallet truck.
CAUTION: Do not step on the

pallet truck or between the
rollers when pulling the
battery out. 5051-Ba-183
Danger of injury and being
pinned in by the heavy
battery!
- Holding the tiller with the right hand and

pulling the battery with the left hand, pull
the battery (1) over the first roller.
100 BA
Other activities
- Now raise the battery slightly by pumping
the roller platform up.
- Pull the battery completely onto the roller

platform.
1
- Lower the battery retaining lever (3) behind
the battery (1).
DANGER: If the battery

retaining lever does not
engage behind the battery,
the battery can roll off the
pallet truck when moved.
Danger of injury and being
pinched in by the heavy
battery!
3
- Turn the tiller of the pallet truck in the 5051-Ba-197
direction of travel and release the parking

brake.
©
- Pick up a new or charged battery and install 4

163 453-05.04
it in reverse order of removal.
- Turn the battery latch (4) straight up.
DANGER: The battery latch

must be in a vertical position
after the installation of the
battery so that the battery
is secured against lateral
displacement.
NOTE: A contact switch prevents driving if the

battery latch is open.
5051-Ba-199
BA 101
Other activities
Closing the battery cover
ATTENTION: When removing and replacing the 1

battery, care must be taken that the battery
cables are not damaged.
The battery cable for operation with a rolling
frame* is provided with a protective hose. This
protective hose must be present and
undamaged.
CAUTION: When closing the bonnet, be sure

that there is nothing between the bonnet and
chassis edge. Danger of squeezing the part.
- Fit the side wall.
- Close the battery cover (2). 2

- The button (3) must engage. 3 5051-Ba-147
- Close the valve cover (1) and engage it
163 453-05.04
securely.
DANGER: Only drive with the

bonnet locked! Always fasten
the side wall.
4
©
- Reconnect the female battery connector (4).
5051-Ba-148
Setting the steering column* in

operating position 5
- Loosen the steering column handwheel (7) 6
slightly.
- Set the steering column from range (5) to

range (6) for normal driving.
- Retighten the handwheel firmly.
CAUTION: Make sure the steering column is

clamped tight.
7
102 BA
Other activities
Turning on the lights* 5051-Ba-083
1 2 3
- Depress light switch (2) to turn on the
parking lights.
- Depress light switch (2) to turn on the 4

headlights.
5
Turning on the seat heater*
- Press switch (8) for seat heater*:
Seat heater is on. 6
- Press switch again:
seat heater is off.
Turning on the directional

indicators* 8 7
- Turning on the left or right directional indicator
as required with the directional indicator
©
9
switch (9). Turn signal indicators (1 and 4)
163 453-05.04
blink.
- To activate the left directional indicator:

Switch to the left.
- To activate the right directional indicator:

Switch to the right.
5051-Ba-084
NOTE: To deselect a direction, return the

switch to the neutral position in the centre.
* Option
BA 103
Other activities
Turning on the front spotlight* 5051-Ba-083
1 2 3
- Turn on the spotlight by actuating the
spotlight switch (5).
4
Turning on the rear spotlight*
- Turn on the spotlight by actuating the
spotlight switch (6).
5
Turning on the windscreen was- 6

her/wipers*
- Turn on the windscreen wiper switch (3).
- Press once with long duration to turn on the

windscreen washer.
8 7
- Press once briefly to turn on the intermittent
wiper.
163 453-05.04
9
- Press twice for continuous wiper operation.
- Press three times to turn off.
Turning on the revolving light*
©
- Turn on the revolving light with switch (7). 5051-Ba-084
Turning on the hazard warning

light*
- Depress the hazard warning flasher switch
(10). Turn signal indicators (1 and 4) blink. 3 7
Selecting auxiliary functions*

- Turn on auxiliary function F* (11).
3 6
6 7
11 10
104 BA
Other activities
Turning on the road lighting* 1 2
- Press the headlight switch (2).
The position lights (5,9) are turned on.
3
- Press the headlight switch (2) again.
The headlights (5,9) are turned on.
5051-Ba-186
Turning on the turn signal light*

4
- Turn on the right or left turn signal light with
the turn signal switch (4). The appropriate
turn signal indicator (1 or 3) comes on.
- Left turn signal:

Move the switch to the left to operate the
left turn signal lights (6 and 7). 5051-Ba-185
- Right turn signal:

©
Move the switch to the right to operate the 5

right turn signal light (6 and 7).
163 453-05.04
6
NOTE: To deselect a direction, return the
switch to the neutral position in the centre.
5
5051-Ba-184
Reversing
- The reversing lights* (8) come on.
Braking
- The stop lights* (9) come on.
7 8 9
5051-Ba-187
BA 105
Other activities
Operating the horn
- Depress the foot switch (1).

The horn sounds.
5051-Ba-023
NOTE: Option with double pedal model.*
163 453-05.04
2
- Depress the horn button* (2) in the lift
control lever.
The horn sounds.
©
5051-Ba-202
NOTE: Optional on joystick model.*
- Press the horn button* (3). 3

The horn sounds.
F
106 BA
Other activities
Heater and ventilation
Electric heater*
(Trucks with electric heater)
Authorized application
The heater is to be used for heating battery-

powered fork trucks provided with a cabin.
DANGER: Do not cover

heater. Risk of fire!
Do not touch the housing
during operation. Risk of
burning!
Operation 5051-Ba-189
Ventilation
©
1 2 3 4 5
NOTE:
163 453-05.04
The fan can also be operated without the

heater.
- Depress the fan switch (2). The fan will run

at the speed selected with the fan stage
switch.
Open fresh air inlet (6).

- Direct it upwards.
Selecting the fan stage
To select the low stage:

- Set the fan stage switch (3) to stage I. The
fan will run at low speed. 5051-Ba-203
6
To select the high stage:
- Set the fan stage switch (3) to stage II.
The fan will run at high speed.
* Option
BA 107
Other activities
Heating
1 2 3 4 5
DANGER: The heater may not be used near
stock-rooms or similar facilities where fuel
vapours or carbon and wood dust or flour dust
can form.
Spray cans or gas cartridges must not be
exposed to the hot air jet.
DANGER: Risk of explosion!
- Depress the heater switch (4). The electric

heater is in operation. The air will be heated
by the heating stage turned on with the 7
heating stage switch (5). 5051-Ba-204
6
DANGER: Do not cover
163 453-05.04
heater. Risk of fire!
Do not touch the housing
during operation. Risk of
burning!
- Adjust fresh air inlet (6) as required.
©
● down
fresh air inlet closed.
● up
fresh air inlet open.
- Depress the fan switch (2). The fan will run

at the speed selected with the fan stage
switch.
Selecting the heating stage
To set the heating on low:

- Set the heating stage switch (5) to stage I.
To set the heating on high:

- Set the heating stage switch (5) to stage
II.
Regulating the cabin temperature
- Set the temperature control knob (1) to the

desired value between 1 and 10.
With position 1 the cabin temperature is held
constant at the lowest level, with position
10 the highest temperature can be achieved.
CAUTION: Replace fuses (7) only with original

fuses.
Please observe the information in the
maintenance instructions.
108 BA
Ending operation
Ending operation
Leaving the truck unattended
WARNING: Do not park the truck on gradients.

In an emergency, secure the truck with
chocks.
1
- Apply the parking brake (2). 2
- Tilt the mast so that the fork tips rest on

the ground.
- Depress the emergency stop button (3).
WARNING: Do not leave the truck with the

load elevated.
5051-Ba-153 3
Using the chock*
©
The chock is used, among other things, to 4

163 453-05.04
secure the truck against rolling on gradients.
- Raise the handle (4) on the mounting.

- Take the chock (5) from the mounting.
- Place the chock behind a front axle wheel
on the downhill end.
NOTE: After use, put the chock back in its

mounting again and lower the handle (4) again. 5
- Turn the switch key (1) to the left and remove
it.
NOTE: After turning off the switch lock, the

display remains on for about 10 seconds.
When the switch lock is turned off, the display 5 5051-Ba-190
(6) of the driving program, clock and battery

charge can be turned on by pressing the
warning hazard switch.
6
- Do not give the switch key, FleetManager

card* or other equipment to other persons
without express instruction.
NOTE: Avoid parking the truck at temperature

under 0 °C as the hydraulic fluid becomes very
viscous and the hydraulic functions sluggish
as a result.
BA 109
Ending operation
NOTE: If the truck is to be parked for a longer
period, eg over night, please observe the
following instructions.
- Disconnect the battery plug (7).
ATTENTION: If the battery connector is not

disconnected, the functions described below
may be active.
Messages in case of improper

truck shutoff* 7
NOTE: This feature ensures that an

improperly shut-off truck displays messages
(and, optionally, acoustic alarms). These 5051-Ba-200
functions are triggered in the following shutoff
situations:
163 453-05.04
Parking the truck with parking
brake not or insufficiently applied
Parking brake not applied*
©
DANGER: Parking the truck
without the parking brake
firmly applied is dangerous
and not allowed as a rule. The
greater safety provided by
this feature should not be
misused to put your safety
at risk. BREMSE ANZIEHEN !
- You have not disconnected the battery 5051-Ba-102

connector.
- If you park the truck without engaging the

parking brake and leave the seat:
The message “BREMSE ANZIEHEN !“ (APPLY
BRAKE !) appears in the display; if a buzzer is
fitted, it will sound.
- Engage the parking brake. The message

“APPLY BRAKE!” will disappear.
* Option
110 BA
Ending operation
Truck rolling slowly despite parking brake 5051-Ba-103
applied* BREMSE ANZIEHEN !
DANGER: Parking the truck

without the parking brake
firmly applied is dangerous
and not allowed as a rule. The
greater safety provided by
this feature should not be
misused to put your safety
at risk.
- You have not disconnected the battery

connector.
- If the truck is parked without the parking

brake being engaged firmly enough, the truck
rolls slowly.
The message “BREMSE ANZIEHEN !“ (APPLY
BRAKE !) appears in the display; if a buzzer is
fitted, it will sound.
©
- Engage the parking brake so firmly that the GABELN ABSENKEN !

163 453-05.04
truck no longer rolls. The message “APPLY

BRAKE !” disappears.
Truck shutoff with a lifted load*
DANGER: Shutting the truck

off with a raised load is
dangerous and not allowed!
Do not misuse the enhanced
safety provided by this
feature to put your safety at
risk!
5051-Ba-104
Forks are not lowered*
- The forks are positioned over the height

sensor.

connector.
- Turn off the key switch and leave the seat.

The message “GABELN ABSENKEN !” (LOWER
FORKS!) appears in the display or a buzzer
(if fitted) sounds.
- Lower the forks on to the ground with the

lift control lever. The message in the display
will be cleared.
* Option
BA 111
Ending operation
Referential lift
REFERENZHUB !
NOTE: If the controller was switched off and
the load was lowered with the lift control lever,
proceed as follows to restart the truck:

The message “REFERENZHUB !” (REFERENCE
CYCLE) is shown in the display or none at
all.
The truck only drives at reduced speed.
Carry out a test lifting (reference cycle) with
the lifting device:
- Raise the forks until the message disappears

or, if not visible previously, appears and dis-
appears again.
- Lower the forks again. 5051-Ba-106
The truck can be driven without any speed

limitation.
163 453-05.04
5051-Ba-107
S I T Z S C H A LT E R !
Exceeding the post-shutoff time*
NOTE: The time after the truck shutdown can

be set as desired by the customer.
©
connector.
- If the truck is shut down and the driver

remains seated longer than the preset time:
The message “SITZSCHALTER!” (SEAT
SWITCH !) appears in the display. The truck
will shut down automatically.
- If you have not left the seat and turn the

key switch on again, the following will
happen:
The truck drives either slowly or not at all;
the work functions can only be carried out
slowly or not at all.

any restrictions.
* Option
112 BA
Towing, trailers
Trailers, Towing
Approved towing applications
The fork truck can also be used to tow trailers

occasionally. For this purpose it is provided with
a tow coupling. Occasional towing should not
exceed 2 % of the daily operating time.
If you want to use the truck for towing more
often, it is necessary to contact the
manufacturer.
Maximum towed weight
CAUTION: A supporting weight is not allowed.
For occasional towing, the maximum trailer load 5051-Ba-060
is the capacity indicated on the fork load

capacity plate (to the right of the seat). Do
©
not exceed the maximum load.

163 453-05.04
The maximum trailer load only applies for the

tow coupling.
If the maximum load is being towed, do not

carry a load on the forks.
However, it is possible to carry part of the load

on the forks and to tow the remainder.
CAUTION: The maximum load

applies only for the towing of
trailers without brakes on
level ground (maximum
difference +/- 1%) and on a
solid surface.
When towing uphill or down-
hill, reduce the maximum
load capacity.
Please advise the manufac-
turer of your operating con-
ditions. He will then supply
the appropriate information.
CAUTION:
Maximum towing speed ............... 5 km/h
- Do not attach the truck in front of

railmounted vehicles.
- Do not push trailers (any type).
WARNING: Operate the towing vehicles in such

a way that the trailer train can be moved and
braked safely during all driving manoeuvres.
BA 113
Towing, trailers
Connecting trailers 5051-Ba-192
- Secure parked trailers against inadvertent

movement (1). Do not release the parking
brake until the trailer has been connected.
DANGER: When dismounting

from the truck briefly to hook
up a trailer:
- Engage the parking brake.
- Press the emergency stop
button.
- Turn off the key switch
and remove the key.
1
Using the chock*
163 453-05.04
The chock is an accessory on the truck. It is
3
used, among other things, to secure the trailer
against rolling when hooking up.
2
- Raise the handle (3) on the mounting.
©
- Take the chock (2) from the mounting.
- Place the chock on the downhill end behind

a rear axle wheel.
NOTE: After use, put the chock back in its

mounting again and lower the handle (3) again.
5051-Ba-194
- Pull out the drawbar pin (4). 4

- Insert the towing fork in the eye.
DANGER: Only use a genuine

drawbar pin!
- Insert the drawbar pin.
CAUTION: Be sure that the drawbar pin is

properly engaged.
5051-Ba-193
114 BA
Towing, trailers
Towing trailers
- Make enough test drives before starting

trailer operation.
- When driving through narrow passages, bear

the dimensions of the trailer and its load in
mind.
- If several trailers are connected in a train,

keep sufficient clearance from fixed building
parts when making a turn or in corners.
The admissible length of the train will depend

on the route to be travelled and it may have
to be established empirically.
The driver should be given instructions in regard
to the maximum number of trailers and - if
necessary - the speed limit for specific sections
of the route.
©
163 453-05.04
BA 115
Transport, hoisting, towing
Transport, Hoisting, Towing
Transporting the truck

When driving the truck on the means of
transport, please observe the following:
- The load capacity of the transport means

must be higher than the weight of the truck.
- Observe the safety distance to edges,

loading bridges, ramps, work platforms, etc.
- Watch out for the rear end moving out.
- Note that by turning the steering wheel when

driving the rear will swing out from the loading
ramp in the direction of the edge. This can
cause the truck to fall off. 5051-Ba-063
DANGER:
©
- Always disconnect the

163 453-05.04
battery plug before

transporting the truck.
- Apply the parking brake

remove the key.
1
Chocking the truck
- Secure the front and rear wheels against

rolling by means of two chocks each and
against lateral sliding with blocks of wood
on the side.
CAUTION: Fasten wooden blocks (eg with

nails).
5051-Ba-026
Lashing down the truck
- Attach the lashing ropes at the front of the

frame (1) and at the trailer coupling (2) at
the rear.
5051-Ba-054
BA 117
Towing procedure
If the brake of the towed truck is inoperative,

the truck may only be towed with a rigid
connection (tow bar).
For towing the fork truck you need a pulling
vehicle with sufficient tractive and braking
power for the unbraked trailing load. 1
- Deposit the load and lower the forks near to
the ground.
CAUTION: If procedures stated below are not

followed, the drive may be damaged.
- Move directional switch to neutral position.
- Disconnect battery plug (1).

5051-Ba-074
CAUTION: The truck may only be towed at

walking pace. Steering is difficult! No power-
163 453-05.04
assisted steering if the hydraulics have failed!
- After towing, secure the lift truck against

rolling (with chocks, for example).
- Apply the parking brake.
©
5051-Ba-061
118 BA
Hoisting the truck GB-2
A hoisting of the truck for transport is only
allowed before commissioning of the complete
truck including the mast. If the conditions of
use require frequent loading of the truck or
646203
are not shown here, contact the manufacturer Type
about special optional equipment.
Only persons having sufficient experience with
Serial number
Dead weight
XX XXXX XXXXX
Year of
construction
kg
1
suitable means of attachment and lifting gear Pay load kg
may hoist the fork truck. Permissible total weight kg
t kg rear kg
kW
Determining the hoisting weight * kg
*
- Park the truck safely.
- Determine the hoisting weight of the truck:
min. kg max.
* see Operating Instructions
kg V 2
- by reading on the manufacturer’s plate:
Dead weight (1) 3

+ Battery weight (3)
+ Additional weight (2)
©
If an attachment is fitted, read the dead weight

163 453-05.04
on its identification plate:
+ Dead weight of attachment

= Hoisting weight
1
Attaching the hoist
CAUTION: Only use a lifting gear and means
of attachment with sufficient lifting capacity
for the determined hoisting weight. Use texti-
le means of attachment and edge protectors,
if needed, or other protective devices to
prevent damage to the truck. The means of
attachment must be attached so that they
do not come in contact with any attaching
parts or parts of the overhead guard or the 5051-Ba-026
cabin. If attaching parts are in the way (eg

lighting, etc.), they should be dismantled
before hoisting.
- Attach the crane lifting bands with shackles

to the lifting eyes (1) at the front frame.
NOTE: The attachment points are identified

with a hook symbol.
DANGER: Only use the

marked attachment points on
your truck! Be sure to use
the means of attachment
such as hooks, shackles,
slings etc. only in the
specified direction of stress.
Do not allow the means of
attachment to be damaged
by parts of the truck.
BA 119
- Attach the crane sling around the tow pin
(2) in the tow coupling. Secure the tow pin.
- Determine the centre of gravity of the truck.

The centre of gravity is marked with an “S”
in the “Technical Data and Dimensions” part
of the operating instructions.
- Adjust the length of the means of attach-

ment so that the crane hook (4) is plumb
over the centre of gravity of the truck. This
ensures that the truck will hang horizontally
when lifted.
2
- Hook the slings into the crane hook and close
the safety (5).
Hoisting the truck

5051-Ba-064
163 453-05.04
- Carefully raise the truck and the deposit it
at the intended place. 5 4
DANGER: Do not step or

stand under a raised load.
©
DANGER: When lifting the
truck, do not allow it to hit
anything or come in an
uncontrollable movement. If
necessary, hold the truck
with guiding ropes.
5051-Ba-062
Attachment points*
The truck can have different points of

attachment*:
- Eyebolts (1) in the rear ballast weight.
- Only attach hooks of size 1 (UNI 9469/1 DIN

15401) to the lifting eyes or eyebolts.
120 BA
Indications, settings, operation of the control unit
Indications, settings, 1 2 3
operation of the control unit
NOTE: All computer adjust-

ments can only be performed
when the truck is stationary
and the parking brake applied.
Normal information
The following information (factory settings) is

normally shown on the display:
(1) The selected driving program PROG followed
by a number ranging from 1 to 5 (2).
The driving program can be changed, refer to
the section on "Driving“. 4 5051-Ba-027
(3) Time and day in hours and minutes. The

©
time can be set, refer to the following sec-

tions.
163 453-05.04
(4) Battery charge. The dark fields show the

useful battery capacity. Each field corresponds
to 10%.
- If only two black fields are visible, the dis- % 123 bar
play starts flashing. Only 20% battery ca-
pacity are at your disposal. The battery
should be charged soon.
- If no black field is visible, deep discharging

begins. The display keeps on flashing. Stop
work with the truck immediately and recharge
the battery.
NOTE: If a pressure regulator* is installed, the

hydraulic pressure (5) is indicated here. In this 4 5 5051-Ba-110
case, the battery charge (4) is shown in %.
To prevent a deep discharge, certain limita-

tions* (eg slow lifting) can be activated. Please
contact your STILL Service.
* Option
BA 121
Additional information
6 7 8
NOTE: The operation of the keys is only ac-
cepted if the truck is stationary and the park-
ing brake applied.
- Stop the truck.

- Apply the parking brake. WARTUNG IN 346 h
- Turn on the key switch. 01654,0 h
Pressing button enter (8) displays the following

additional information:
(6) WARTUNG IN (SERVICE IN) display shows

the remaining time in hours
(7) until the performance of the next servicing

according to the maintenance schedule in the
maintenance instructions. The services must 9 5051-Ba-109
be carried every 1000 hours or as required.
(9) Hour meter. The hour meter displays the
163 453-05.04
1
elapsed service hours of the truck. It runs as
soon as the switch key is in the "on“ position. FleetManager
FleetManager*
The Smart Card (1) can be used for
©
FleetManager functions.
Please contact your Service.
5051-Ba-047
Accident recorder*
2
The accident recorder is a supplement to the
FleetManager. An acceleration sensor (2) is
installed in the truck. The acceleration sensor
can register data, which result with an
accident, for later evaluation.
122 BA
Additional information (options) 1 2
The following information can be shown on the
display. A maximum of eight displays are ,
possible. Please contact your Service.
(1) Date as day, month year.

,
(2) Truck speed in km/h. 4

3
(3) Trip mileage in km.
(4) Daily mileage in km per trip.
5051-Ba-048
(5) Daily driving time in hours.

©
5
163 453-05.04
Setting and adjusting the displays
NOTE: The operation of the keys is only ac-

cepted if the truck is stationary and the park-
ing brake applied.
5051-Ba-065
Adjusting the date and time
- Stop the truck. 6

- Apply the parking brake.
For this adjustment proceed as follows:
- Press buttons (6) and enter (7) at the same

time. 13
- Push button (8) once to set the time.
- Push button (8) twice to set the date.
- Select the field in which, for example, the
time is located with buttons (10) to (13). 7
The displayed time flashes.
- Press buttons (9) or (8) to change the time.
- When the time is set correctly, press enter
(7) to store the setting.
- Press buttons (7) and (6) simultaneously to
restore the normal display. 12 11 10 9 8 5051-Ba-067
BA 123
Resetting daily mileage and daily
1
driving time
The displayed daily mileage and daily driving

time can reset to zero. ,
- Press buttons (1) and enter (2) at the same ,
time. 8
- Press button (3) three times.
- Select the field in which, for example, the 2

daily mileage is displayed with buttons (5)
to (8). The display flashes.
- Press the buttons (4) or (3) until the dis-

played value is zero.
- Press enter (2) to store the setting. 7 6 5 4 3 5051-Ba-205
163 453-05.04
restore the normal display.
Selecting the language
The malfunctions can also be displayed in other
©
languages.
- Press buttons (1) and enter (2) at the same

time.
- Select the field in which LANGUAGE is dis-

played with buttons (5) to (8). The display
flashes.
- Press the buttons (4) or (3) until the Eng-

lish, French or special language is displayed.
- Press button enter (2) to store the selec-

tion. All information will now be displayed in
the selected language.

restore the normal display.
Other settings
By entering a password, it is possible to enter

other values. Please contact your Service.
124 BA
Malfunctions, cause, remedy
Malfunctions, cause, remedy 1
Indicated malfunction
The following malfunctions can be indicated

on the display (1):
A message describing the malfunction, a letter
and a number.
Depending on the fault, the malfunctions are

always displayed in cycles for a few seconds.
If several faults exist, they are displayed one
after the other. There follows a pause whose
length also depends on the type of fault.
During the pause, the ready indication of the
truck is shown.
SERVICE REQUIRED 5051-Ba-069

(Indication appears for 5 s after power-
up)
©
- Service interval exceeded. Have the required

163 453-05.04
maintenance carried out.
OVERHEATING A 5044
(Indication blinks every 10 s)
- Traction motor overheated, traction power

reduced.
OVERHEATING A 5034
- Pump motor overheated, lifting performance

is reduced.
- Interrupt your work, allow motor to cool. Do
not turn off the key switch.
OVERHEATING X 2004
- Pump control overheated, lifting performance

is reduced.
- Interrupt your work, allow motor to cool. Do
not turn off the key switch.
MOTOR BRUSHES A 5002

(No emergency operation, message every
2 min)
- The truck can still be operated for up to 10

service hours.
- Renew/check the motor brushes as described
in the maintenance instructions.
* Option
BA 125
Malfunctions, cause, remedy
MOTOR BRUSHES A 5004
(Emergency operation, indication blinks
every 10 s)
- Lifting performance is reduced.
- Renew the pump motor brushes as described
in the maintenance instructions.
ADJUST A 3504
- Calibration for 2-pedal control incorrect*.
ACCELERATOR PEDAL ASSY. A 3505

- Calculation for accelerator settings for 2-
pedal control* in progress.
SERVICE BRAKE A 3035

(Indication blinks every 10 s) 5051-Ba-116
- The truck speed is reduced to approx. 5 km/h.

- Brake fluid fault
163 453-05.04
- Check the brake fluid level as described in
the maintenance instructions
VOLTAGE A 2237
- Short 10 V ext.
©
- Have the electrical system checked.
SEAT SWITCH A 3027

- The seat switch has not been operated for
6 hours. The truck only drives at reduced
speed and with reduced lifting performance.
- Stand up briefly and sit down again.
CONFIGURATION A 3801
- Invalid truck type.
- Please contact your Service.
CONFIGURATION A 2111
- Invalid hardware version.
STEERING A 3202
- Plausibility of steering angle sensor*.
- The speed reduction function during steer-
ing is faulty. The truck speed is reduced.
Other malfunctions can be indicated. Please
inform your Service.
* Option
126 BA
Index
Index
Page Page
A C
Accelerating ................................... 58, 63 Carrying the load .................................. 87
ACCELERATOR PEDAL ASSY. A 3505 Changing the battery ............................ 95
(Indication blinks every 30 s) ........... 126 Changing the direction of travel ......... 58, 59
Accident recorder ................................ 122 Checking for condition of roadways ......... 53
Additional information ........................... 122 Checking the battery charge .................. 36
Additional information (options) .............. 123 Checking the braking system
ADJUST A 3504 for proper operation ......................... 47
(Indication blinks every 30 s) ........... 126 Checking the emergency stop function ..... 49
Adjusting the armrest ............................ 38 Checking the parking brake .................... 47
Adjusting the auxiliary hydraulics ............. 75 Checking the service brake .................... 47
Adjusting the backrest ..................... 37, 38 Checking the steering system
Adjusting the date and time .................. 123 for proper operation ......................... 43
Adjusting the driver's seat ................ 37, 38 Checking the wheels for condition
Adjusting the driver’s weight .................. 38 and tyre inflation pressure ................ 49
Adjusting the forks ................................ 84 Checks before driving ............................ 50
©
Adjusting the seat ................................ 37 Chocking the truck ............................... 117

Adjusting the seat cushioning ................. 37 Closing the battery cover ..................... 102
163 453-05.04
Adjusting the steering column ................. 43 CONFIGURATION A 2111

Adjusting the steering column (Indication blinks every 30 s) ........... 126
for battery change .......................... 95 CONFIGURATION A 3801
Application 1 ........................................ 67 (Indication blinks every 30 s) ........... 126
Application 2 ........................................ 67 Connecting the battery plug ................... 35
Applying seat belt on a steep slope ......... 40 Connecting trailers ............................... 114
Applying the seat belt ........................... 39 Control and display panel ....................... 28
Approved applications ............................. 1 Copyright and property rights ................... 6
Approved towing applications ................ 113
Approved types of tyres ........................ 18 D
Attaching the hoist .............................. 119
Attachment points ............................... 120 Daily pre-operational checks and services . 35
Authorized application .......................... 107 Damages, deficiencies,
misuse of safety devices .................... 5
B Danger zone ................................... 50, 84
Date of issue and version of manual ............ I
Battery acid ........................................... 9 Definition of directions ............................. 4
Battery change with roller frame ............ 100 Definition of used terms ........................... 4
Battery charging position ....................... 96 Depositing the load ............................... 89
Battery removal position ........................ 96 Description ..................................... 12, 66
Battery replacement ............................. 99 Determining the hoisting weight ............. 119
Battery specifications Dimensions .......................................... 12
(acc. to DIN 43536 A) ...................... 23 Dimensions of roadways and aisles .......... 51
Battery weight and dimensions................ 99 Directional switch ................................. 56
Before beginning work ........................... 91 Directional switch with mini console ......... 57
Before driving ....................................... 51 Display ................................................ 30
Before operation ................................... 67 Disposal ................................................ 6
Before picking up the load ...................... 83 Double-pedal model ............................... 63
Behaviour in an emergency ..................... 54 Driver ................................................... 5
Behaviour when driving .......................... 53 Driver’s station ................................ 26, 27
Braking ............................................... 105 Driving ........................................... 56, 63
Braking system ..................................... 33 Driving (joystick) .................................. 60
Button panel ........................................ 29 Driving behaviour in case of unused or
incorrectly used belt with belt lock
switch present ................................ 41
BA 127
Index
Page Page
Driving behaviour when seat switch is Hoisting the truck ........................ 119, 120
operated too long ........................... 65 Horizontal adjustment ............................ 38
Driving behaviour with seat switch not Hydraulic coupling ............................ 34, 82
operated ........................................ 64 Hydraulic equipment .............................. 33
Driving on gradients ......................... 52, 88 Hydraulic fluid, brake fluid ........................ 9
Driving on loading ramps ........................ 89
Driving safety rules ............................... 53 I
During work ......................................... 92
Indicated malfunction ........................... 125
E Indications, settings,
operation of the control unit ............ 121
EC conformity certificate, Information for the driver ....................... 92
EC conformity sign ............................ 6 Information for the person(s)
Electric heater .................................... 107 in the working platform ..................... 94
Electric regenerative braking .................. 61 Information on operation .......................... 5
163 453-05.04
Electrical equipment .............................. 33 Installation of attachments .................... 34
Emergency lowering (Joystick) ................ 80
Emergency stop procedure ..................... 49 J
Emissions ............................................ 17
Ending operation .................................. 109 Joystick .............................................. 30
Entering lifts ........................................ 88
Exceeding the operating time .................. 65 L
©
Exceeding the post-shutoff time ............ 112
Lashing down the truck ........................ 117
Exceeding the shift time ........................ 65
Leaving the truck unattended ................ 109
Experts ................................................. 5
Lift truck information ............................... 1
F Lifting mast ......................................... 33
Lifting the load while driving ................... 46
Filling wiper-washer system .................... 48 Load capacity ...................................... 83
Fire precautions ................................... 95 Load capacity plate for attachments ....... 75
FleetManager ...................................... 122 Load capacity with attachment .............. 34
Foot brake ........................................... 63 Load handling ....................................... 85
Foreword ................................................ I Location of plates and labels .................. 31
Fork extension ..................................... 75
Fork spreader ....................................... 79 M
Forks are not lowered ........................... 111
Maintenance staff ................................. 95
Forward travel .................... 58, 59, 60, 63
Malfunction due to cold ......................... 40
Frame and superstructure ...................... 33
Malfunctions, cause, remedy ................. 125
Frequency characteristics ...................... 17
Manufacturer’s identification plate ........... 32
Fuels and lubricants ................................ 4
Mast versions ....................................... 69
G Maximum towed weight ......................... 113
Messages in case of improper
Gear oil ................................................. 8 truck shutoff ................................. 110
General ............................................ I, 66 Mini console ......................................... 29
Modifications and retrofits ........................ 3
H MOTOR BRUSHES A 5002 (No emergency
operation, message every 2 min) .......... 125
Hazards ............................................... 53 MOTOR BRUSHES A 5004 (Emergency
Hazards for personnel .............................. 9 operation, indication blinks every 10 s) 126
Heater and ventilation .......................... 107 Mounting of attachments ....................... 34
Heating .............................................. 108 Mounting working platforms .................... 34
128 BA
Index
Page Page
N R
NiHo mast ............................................ 70 Raising, lowering the fork carriage ...... 71, 77
Noise emissions .................................... 17 Raising the load at a standstill ................ 45
Noise level at driver’s station .................. 17 Referential lift ..................................... 112
Normal information ............................... 121 Regulating the cabin temperature ........... 108
Normal operation .................................. 81 Relieving pressure with control lever ........ 82
Relieving pressure with the joystick ......... 82
O Requirements for the mounting
of working platforms ........................ 91
Opening the battery cover ..................... 96 Resetting daily mileage
Opening the battery cover (with joystick) 98 and daily driving time ...................... 124
Opening the seat belt ............................ 40 Residual hazards and risks ........................ 4
Operating attachments .......................... 78 Reverse travel ..................... 58, 59, 60, 63
Operating the attachments .................... 72 Reversing ........................................... 105
Operating the horn ............................... 106 Reversing the travel direction ................. 63
Operating the lifting device .................... 69 Rights, obligations and behavioural rules
©
Operating the lifting device for drivers ........................................ 5

with the joystick ............................. 77
163 453-05.04
Rules for roadways and work area ........... 53

Operation ............................... 51, 67, 107 RX 50-10 ............................................. 18
Operation with reversible forks ................ 81 RX 50-13 ........................................ 19, 20
Operator ............................................... 5 RX 50-15, RX 50-16 ......................... 21, 22
Other activities .................................... 95
Other settings ..................................... 124
Overhead guard and cabin ..................... 33
S
OVERHEATING A 5034 Safe parking ........................................ 95
(Indication blinks every 10 s) ........... 125 Safety .................................................. 7
OVERHEATING A 5044 Safety inspection according to interval
(Indication blinks every 10 s) ........... 125 and extraordinary events (in Germany
OVERHEATING X 2004 UVV inspection; please observe your
(Indication blinks every 30 s) ........... 125 national regulations) .......................... 7
Overriding the lifting height limitation ....... 81 Safety precautions for handling lubricants .. 8
Overview of accessories ........................ 34 Safety rules for handling loads ................ 69
Overview of attachments ....................... 33 Scope of documentation ........................... I
Overview of hazards and preventive Seat belt ............................................. 39
measures ....................................... 10 Seat belt constantly inserted,
Overview of options and models .............. 33 operator only seated afterwards ........ 41
Overviews ........................................... 25 Seat belt is removed while driving ........... 54
Seat belt not applied, operator seated ..... 41
P Seat belt only applied after key switch is
turned on ....................................... 42
Packaging .............................................. 6 SEAT SWITCH A 3027
Parking ................................................ 67 (Indication blinks every 30 s) ........... 126
Parking brake ....................................... 61 Seat switch not operated ...................... 64
Parking brake not applied ...................... 110 Selecting auxiliary functions .................. 104
Parking the truck with parking brake not Selecting the driving program ................. 55
or insufficiently applied .................... 110 Selecting the fan stage ........................ 107
Personal liability in the plant area .............. 8 Selecting the heating stage .................. 108
Persons in the danger area ..................... 50 Selecting the language ......................... 124
Picking up and depositing the load ........... 86 Serial number ....................................... 32
Picking up loads with attachments ...... 72, 78 Service brake ....................................... 61
Picking up the load ................................ 84 SERVICE BRAKE A 3035
Picking up unit loads ............................. 84 (Indication blinks every 10 s) ........... 126
Prohibition of use by unauthorized persons . 5 SERVICE REQUIRED
Proper use ........................................... 66 (Indication appears for 5 s
after power-up) ............................. 125
BA 129
Index
Page Page
Setting and adjusting the displays .......... 123 Turning on the directional indicators ....... 103
Setting the driving program .................... 60 Turning on the front spotlight ................ 104
Setting the steering column in operating Turning on the hazard warning light ........ 104
position ........................................ 102 Turning on the key switch ...................... 35
Single-lever operation Turning on the lights ............................ 103
of the lifting device ......................... 76 Turning on the rear spotlight ................. 104
Site of operation .................................... 1 Turning on the revolving light ................. 104
Special risks when using the truck Turning on the road lighting ................... 105
and attachments ............................... 2 Turning on the seat heater .................... 103
Speed limitation with a lifted load ............ 45 Turning on the turn signal light............... 105
Speed reduction when steering Turning on the turn signal lights ............. 105
(Curve Speed Control) ..................... 44 Turning on the windscreen
Stacking and removing load units ............ 89 washer/wipers ............................... 104
Starting up .......................................... 35
U
163 453-05.04
Starting with the mini console ................. 59
Steering .............................................. 62
STEERING A 3202 Unapproved applications .......................... 1
(Indication blinks every 10 s) ........... 126 Use .................................................... 66
Symbols for movements of Use in cold storage warehouses .............. 66
the lifting device and attachments ..... 73 Using the chock .......................... 109, 114
T V
©
Table of contents .................................. III Ventilation .......................................... 107
Technical data ..................................... 17 Visibility when driving ............................ 53
Technical data VOLTAGE A 2237
(standard version) ................ 12, 13, 15 (Indication blinks every 30 s) ........... 126
Telescopic mast ................................... 69
Tilting the mast ............................... 70, 77 W
To advance the forks ............................ 78
Warning against using non-genuine parts .... 3
To close the roll clamp ........................... 79
Warning signs ....................................... 31
To increase fork spread ......................... 79
Wheels and tyres .................................. 18
To lower the bucket .............................. 80
To open the roll clamp ........................... 79
To raise the bucket ............................... 80
To reduce fork spread ........................... 79
To retract the forks .............................. 78
To rotate the head anticlockwise ............ 79
To rotate the head clockwise ................. 79
To sideshift left .................................... 78
To sideshift right .................................. 78
Towing procedure ................................ 118
Towing trailers .................................... 115
Trailers, Towing ................................... 113
Transport, Hoisting, Towing ................... 117
Transporting pallets ............................... 84
Transporting swinging loads .................... 74
Transporting the truck .......................... 117
Triplex mast ......................................... 70
Truck .................................................. 25
Truck rolling slowly despite parking brake
applied ......................................... 111
Truck shutoff with a lifted load .............. 111
130 BA
RX 50
MAINTENANCE INSTRUCTIONS
RX50 Maintenance instructions
Foreword
Foreword
General
These instructions contain all the information

required to perform the routine maintenance
on your fork truck. Carry out the maintenance WARTUNG IN 346 h
at the correct interval according to the 01654,0 h
maintenance chart to keep your truck ready
for operation, maintain its efficiency and prolong
its service life and to benefit from the warranty.
Maintenance chart
The maintenance on the truck must be

performed according to the hour meter. Refer
to the maintenance chart for the services 5051-Wa-057
required at a particular interval.

©
The instructions describing the maintenance

procedures are located after the maintenance
163 453-05.04
chart.
In a dusty environment and with fluctuating

temperatures, reduce all lubrication and
maintenance intervals as required.
Quality and quantity of required

lubricants
Only use the lubricants specified in the

maintenance instructions.
The lubricants required for maintenance are

listed in the table „Recommended Fuels and
Lubricants“ for Linde vehicles.
Oils and greases of different grades may not

be mixed, as this affects lubricity. If changing
from one brand to another is unavoidable, drain
the previous oil particularly thoroughly.
Carefully clean the area surrounding a

component prior to lubrication, filter renewal
or working on the hydraulic system.
Use only clean containers when replenishing

lubricants and other fluids.
WA I
Maintenance instructions RX50
Foreword
Ordering spare parts
Spare parts are supplied by our Service. Refer

to the Linde Parts List for the required order-
ing information.
Only use spare parts as specified by Linde.

Due to insufficient quality or incorrect assign-
ment, the use of parts not approved bY Linde
can increase the risk of accidents. The use of
unapproved parts places full responsibility for
any damage and liability on the part of the
user.
Staff training and qualifications for

maintenance and repairs
Only qualified and authorized staff may carry
163 453-05.04
out the maintenance. The annual inspection
must be performed by an expert. The expert
must provide his opinion and safety assess-
ment irrespective of operating and financial cir-
cumstances. He must have adequate knowl-
edge and experience to assess the state of
the vehicle and the effectiveness of the pro-
tective devices in accordance with the rules
©
of technology and the basic principles of fork
trucks.
Maintenance personnel for

batteries
Batteries may only be

charged, serviced and re-
placed by specially trained
personnel and in accordance
with the instructions of the
battery charger. Observe the
battery handling and charger
operating instructions.
II WA
Foreword
Services not requiring special
qualifications
Simple maintenance services such as checking

the hydraulic oil level or the electrolyte level
of the battery may be performed by unquali-
fied staff. A qualification such as for the previ-
ously mentioned work is not necessary. Refer
to these maintenance instructions for further
information hereto.
Definition of used terms:
DANGER: For work

procedures which must be
followed exactly to prevent
danger to the life and limb of
persons.
WARNING: Indicates procedures which must

©
be followed exactly to prevent personal in-

jury.
163 453-05.04
CAUTION: Indicates procedures which must

be followed exactly to prevent damage to and/
or destruction of the equipment.
NOTE: Indicates points of technical interest

requiring special attention.
We thank you for reading and following these

instructions. Please contact our Service if you
have any questions, want to submit improve-
ment suggestions or have discovered an error.
Your partner
STILL GmbH
Berzeliusstr. 4
D-22113 Hamburg
hopes you will be driving safely.
WA III
Foreword
Table of contents
Page
Foreword ............................................... I
Safety precautions for maintenance .......... 1
Maintenance chart .................................. 8
Maintenance as required ........................ 11
1000-hour maintenance ......................... 25
Annual maintenance .............................. 45
2-year maintenance .............................. 47

©
Taking out of service ............................. 49

163 453-05.04
Maintenance data ................................. 51
Diagrams ............................................. 53
Index .................................................. 63
WA V
Safety precautions for maintenance
Safety precautions for
maintenance
Safety inspection according to jährliche Prüfung

interval and extraordinary events gem. UVV
Mängel siehe Prüfbuch
(in Germany UVV inspection; letzte Prüfung
please observe your national
regulations)
The industrial truck must be inspected at least

once annually or after special incidents by a
person especially qualified for this task. This
person must present his expert opinion and
assessment uninfluenced by any economical
and business circumstances and only from the
standpoint of safety. He must have sufficient nächste Prüfung
knowledge and experience to be able to assess

the condition of an industrial truck and the
effectiveness of the protective features
©
according to the rules of the art and the

principles applying for the inspection of industrial
163 453-05.04
trucks.
The truck must be inspected completely in
respect to its safe technical condition. The
truck must also be thoroughly checked for
possible damages due to improper use. An
inspection record must be prepared. The results
of the inspection must be filed at least until
the inspection after the next one.
The next inspection is indicated by a sticker
on the truck.
The booklet "Test manual for power-driven
industrial trucks“ should be used. (STILL Part.
No. 135745)
Refer to the guidelines for the inspection of
STILL trucks according to the accident
prevention guidelines for industrial trucks.
WA 1
Safety precautions for handling
fuels and oils
Hydraulic oil, brake fluid Gear oil
Hydraulic oil are hazardous to Do not eat, drink or smoke

health and are under pressure when working with the prod-
during operation. Do not spill uct. Prolonged intensive con-
these fluids. Do not allow the tact may cause degreasing
fluids to come in contact with and irritation of the skin.
hot motor parts. Fire hazard! Wash skin with soap and wa-
ter, use skin care products.
Do not allow the fluids to If required, wear protective
contact skin. Avoid the gear. Change soaked clothes
inhalation of sprays. The and shoes immediately. If
ingress of pressure fluids into vapor or mist was inhaled,
the skin is particularly breath fresh air, if trouble per-
hazardous if these emerge sists, consult a doctor. After
under high pressure through contact with eyes rinse thor-
leaks in the hydraulic system. oughly with water (at least
163 453-05.04
Seek medical aid at once if 10 minutes) then consult an
such injuries occur. eye doctor. When swallowed
If injuries cannot be excluded, do not force to vomit, but
use suitable protectors (for consult doctor. Danger of slip-
example, protective gloves, ping by spilled product, es-
glasses and skin protection pecially in connection with
and skin care creams). water.
©
Oils can contaminate water.
Battery electrolyte Always keep them in approved
containers.
Battery electrolyte contains Avoid spilling oils.
dissolved sulphuric acid. This
acid is poisonous and caustic. The oils are inflammable. Do
When working with battery not allow them to come in
electrolyte, wear protective contact with hot motor parts.
clothing and eye protectors. Fire hazard!
Do not allow electrolyte to
contact clothing, skin or
eyes. In case of contact,
wash directly with ample
clean water. If personal
injuries occur, visit a doctor
at once. Flush with a lot of
water or neutralise it.
2 WA
Disposal of greases, oils and Work on the electrical equipment
batteries
The materials used for repair, Work on the electrical equip-

maintenance and cleaning ment of the truck is only al-
must be collected as specified lowed with the electrical sys-
and disposed of in accordance tem dead. Function checks,
with national laws and inspections and adjustments
regulations. The services may on live parts may only be car-
only be performed at places ried out by trained and au-
provided for this work. Take thorized staff under observ-
care to avoid polluting the ance of suitable precautions.
environment as much as Rings, metal bracelets, etc.
possible. must be removed before
working on electric compo-
- Remove spilled fluids such as hydraulic oil, nents.
brake fluid or gear oil at once with an oil
binding agent. Dispose of in accordance with To prevent damage to elec-
the regulations for the disposal of used oil. trical equipment with elec-
tronic components such as an
electronic travel control or lift
©
- Neutralize leaked battery electrolyte

immediately. control, remove them from
163 453-05.04
the vehicle before doing any

electric welding.
Accident hazards
Safety devices
Safety measures for maintenance and
repair
Refit and check all safety devices for proper
To prevent accidents during maintenance and operation
repair, perform all necessary safety measures after maintenance and servicing.
such as:
- Ensure that the truck is secured against Settings

inadvertent movement or starting
(disconnect the battery plug, engage the Retain the vehicle-specific settings when
parking brake). repairing and replacing hydraulic and electric
components. They are specified in the
- When working under an elevated load lifting appropriate sections.
member, secure it against inadvertent
lowering.
- Secure the lift mast against inadvertent

tilting.
WA 3
Lifting and jacking up the truck
When jacking up the truck, components and

attachments, the lifting tackle may only be
attached at the designated points. When
jacking up the equipment, secure it against
sliding or tipping with suitable means (wedges,
wooden blocks).
Jacking up the truck
The truck must be jacked up for various

services. Always be sure that:
- the load capacity of the jack is sufficient,
- the truck is only jacked up on level ground
and that it is secured against rolling and
lowering. 5051-Wa-002
WARNING: When jacking up the truck, apply
163 453-05.04
the handbrake and disconnect the battery
plug.
Jacking up at the counterweight
CAUTION: Jack up the truck only at the points
©
shown.
- Hold blocks of wood ready.

- Position the jack at the cut-out at the left-
hand side of the counterweight.
- Jack up the truck until the wheels are clear
of the ground.
- After jacking the truck up, place blocks of
wood under the counterweight at the left-
and right-hand side and lower the truck on
the blocks. 5051-Wa-003
Jacking up on the mast
CAUTION: Jack up the truck only at the points

shown.
- Raise the fork carriage and secure it against

inadvertent lowering.
WARNING: Follow the safety precautions for

working on the mast.
- Place the jack at the indicated points on

the mast.
- Jack up the truck until the wheels are clear
of the ground.
- Secure the truck.
10-16-Wa-003
4 WA
Working on the front part of the
truck
2
ATTENTION: When the mast or forks are 1
raised, do not work on the mast or the front
part of the truck without first following the
safety procedures below!
Lift mast removal
ATTENTION: Attach the lifting sling to the outer

ends of the upper cross member (2).
This procedure may only be carried out by your

STILL Service.
5051-Wa-004
Working on the lift mast

©
5051-Wa-005
Securing the mast against tilting back

3
163 453-05.04
To prevent the lift mast from tilting back

inadvertently, insert a suitable 120 x 120 x
800 mm long hardwood beam (1) between the
chassis and mast.
Securing the raised telescopic

mast
ATTENTION: When securing the mast, use a

chain suitable for the particular lift mast. Do
not exceed the maximum height of lift.
- Raise the mast.

- Fasten the chain around the cross member 4
of the outer upright (3) and the cross member
of the inner mast (4).
- Lower the inner mast until it is held by the
chain. 5
Securing the raised NiHo mast

suitable chain for the particular lift mast. Do
not exceed the maximum height of lift.
- Raise the mast.

- Fasten the chain around the cross member
of the outer upright (5) and the cross member
of the inner mast (6).
- Lower the inner mast until it is held by the
chain.
- Lower the fork carriage as far as possible.
5051-Wa-006
6
WA 5
Securing the raised triplex mast
7
suitable chain for the particular lift mast. Do
not exceed the maximum lift height.
- Raise the mast.
- Fasten the chain around the cross member

of the outer mast (7) and the intermediate
mast (8).
- Lower the mast until it is held by the chain
- Lower the fork carriage as far as possible.
8
Servicing the battery
5051-Wa-007
Observe the applicable natio-
163 453-05.04
nal regulations for the
installation and operation of
battery charging units. Obey
the operating instructions for
the charging unit or charger
and the battery. The following
safety regulations must be
©
observed when servicing,
charging and replacing
batteries:
Fire precautions
Smoking and naked flames are

prohibited in the vicinity of
batteries. No inflammable
materials or spark-producing
materials may be located
within at least 2 metres of
the truck to be charged and
the charger. The room must
be well ventilated. Keep fire
extinguishers ready.
6 WA
Safe parking
When the battery is being worked on, the truck

must be properly parked and it may only be
started when the battery cover is closed and
the battery plug connected.
Battery servicing
Keep the battery cell lid dry

and clean. Neutralize spilled
electrolyte immediately. Ter-
minals and cable lugs should
be clean, slightly greased and
secure.
Battery charging
©
Switch off the truck and

charger before removing the
163 453-05.04
plug from the socket. During

charging, keep the surface of
the battery cells exposed in
order to provide sufficient
ventilation. Do not place any
metallic objects on the bat-
teries.
WA 7
Maintenance chart
Maintenance chart
1 2
163 453-05.04
13
3
12
©
11
4
10 9 8 7 6 5051-Wa-008
8 WA
Maintenance chart
Inspection and maintenance intervals
The services must be performed according to the following maintenance intervals.
h Item Maintenance work
as required - Cleaning the truck

6, 10 Servicing the wheels and tyres
3 Servicing the battery
- Oiling joints and controls
- Servicing the attachments
- Maintenance of cold storage warehouse truck
5, 12 Servicing the electric motors
- Replacing fuses
13 Servicing the braking system
- Servicing the seat belt
©
- Servicing the restraint system

- Check the driver’s seat
163 453-05.04
7 Servicing the gearbox

8 Servicing the steering system
4 Servicing the electrical system
1000 5, 12 Servicing the electric motors
9 Servicing the hydraulic system
1 Servicing the mast
11 Checking the forks
1 Servicing the mast
2000 - Safety inspection

7 Servicing the gearbox
3000 10 Service the carrying axle
9 Servicing the hydraulic system
annually - Insulation inspection (earthing)
- Safety inspection
11 Checking the forks
Every 2 years 9 Renewing the hydraulic oil
WA 9
Maintenance as required
Cleaning the truck
Washing instructions
- Always park the truck as specified.

- Apply the parking brake (3).
- Press the emergency stop button (2).
- Turn off the key switch (1) and remove the
key.
- Disconnect the battery plug (4).
ATTENTION: Before washing, turn the key

switch off, remove the key, press the
emergency stop button and disconnect the
battery connector.
5051-Wa-009
Washing the exterior of the truck

161 958-06.02 ©
1
WARNING: Do not use
inflammable fluids for
cleaning. Observe the above
safety precautions for
preventing sparks through
shorts (disconnecting the
battery plug).
WARNING: When the truck

is cleaned with hot-water
appliances, carefully cover all 3
sensitive components,
particularly electric
components. Follow the
manufacturer’s instructions
for handling the cleaners.
2 5051-Wa-058
- Clean the truck exterior with water and

cleaning agents soluble in water (using water
jet, sponge, rags).
- Especially clean the oil filler openings and
the surrounding area, and the lubricating
nipples before lubrication.
Please note: Lubricate more frequently if the

truck is cleaned often. 4
NOTE: Steam jets may be used at max. 50 bar

and 85 °C and at a distance of min. 20 cm.
WARNING: Do not spray directly onto the

electric motors and other electric components.
Do not point the cleaning jet directly on
adhesive labels and notice plates.
5051-Wa-011
WA 11
Cleaning the lift chains
CAUTION: Lift chains are safety components.

The use of cold cleaners, chemical cleaning
agents and caustic or acidic and chlorinated
fluids can cause damage to the chains.
- Place a container under the mast.

- Clean the chain using paraffin derivatives
such as washing petrol (observe the
manufacturer’s notes on safety).
- When using a steam jet, clean without addi-
tives.
- After cleaning, blow dry the chain at once
to remove any water in the chain links and
on the surface. The chain should be moved
several times during this procedure.
6033Wa-10
- Spray STILL chain spray S on the chain at
once, while moving the chain when spraying.
163 453-05.04
Cleaning the electrical system
ATTENTION: The cleaning of

the pump regulator or the
converter with water is not
allowed and can lead to
©
damage to the electrical
system.
NOTE: Only use dry cleaning agents as cleaners

and according to the manufacturer’s
instructions. Do not remove protective covers,
etc.
- Clean and blow dry electrical components

using a non-metallic brush and a weak jet of 5051-Wa-012
air.
After washing the truck
- Dry the truck thoroughly (e.g. with

compressed air).
- Sit down on the driver’s seat and start the
truck as described.
CAUTION: If moisture penetrated the motors

despite the precautionary measures, first dry
them to prevent a short! Then operate the
truck to prevent damage due to corrosion.
WARNING: Reduced braking action due to

wetness. Brake the truck briefly to dry the
brakes.
5051-Wa-013
12 WA
Servicing the wheels and tyres
1
Tyres
The quality of the tyres affects the stability

and driving characteristics of the truck.
Modifications may only be made with the
approval of STILL. When changing wheels or
tyres, do not tilt the truck sideways (always
change the left and right wheels at the same
time, for example).
When using wheels with split disks, carry out

the special measures for changing these tyres.
Checking the tyres for inflation

pressure*, wear and condition
5051-Wa-014
The tyre inflation pressure depends on the type

of tyre fitted.
161 958-06.02 ©
Check the data given on the labels on your

truck.
2
The minimum tread depth (1) of pneumatic
tyres* on the entire rolling surface should be
1.6 mm minimum.
Remove any foreign objects which may have

penetrated the tyres.
The wear on the wheels of the same axle must

be approximately equal.
WARNING: Uneven tyre wear reduces the

stability of the truck.
Superelastic tyres* can be driven until the wear

limit (2) is reached. 10-16-Wa-015
WARNING: Worn or damaged tyres on both

sides must be replaced without delay. The risk
of accidents is greater as the stopping distance
3
is longer.
Tighten wheel nuts / bolts
- Check wheel nuts (3) and bolts for security

and tighten, if necessary.
Torque ........................................ 195 Nm
NOTE for solid rubber tyres*:
- Replace the hex head screws fastening rim

parts when changing tyres.
* Depending on the version 5051-Wa-015
WA 13
Servicing the battery
NOTE: The battery must be serviced according

to the operating instructions of the battery
manufacturer!
Also observe the operating instructions of the
battery charger. Only the instructions supplied
with the battery charger apply.
If one of these is missing, please request it
from your dealer.
Checking the battery state of

charge

- Press the emergency isolator button.
- Read the battery state of charge on the
163 453-05.04
display on the console.
- Charge a discharged battery immediately if
no black field (1) is visible. Never allow a
battery to stay in a discharged condition,
recharge immediately. This also applies for
partially discharged batteries. The discharge P R OG 1 1 2 : 23
should not drop below an acid density of
©
BA T T :
1.14 kg/l.
ATTENTION: Discharges under 20% of the

rated capacity are deep discharges, which
shorten the service life of the battery.
Charging the battery
ATTENTION: Shut the truck down properly! 1

5051-Wa-016
- Lower the fork carriage.

- Press the emergency isolator button.
- Turn the key switch off, remove the switch 2
key.
- Disconnect the battery plug (2) from the
truck.
DANGER: Explosive gases

are released during charging.
Make sure that the rooms are
well ventilated.
Truck with cabin: Keep all
cabin doors (also tarp cabins)
open during the charging
procedure.
3
* Option R20WA-19
14 WA
- Open the battery cover fully or at least as
far as the charging position (see operating
instructions). 2
DANGER: Do not place any
metallic objects or tools on
the battery. No naked lights,
no smoking permitted. Risk of
damage, shorting and
explosion.
CAUTION: The electrolyte

(diluted sulphuric acid) is
poisonous and caustic! Follow
the safety rules for handling
battery acid! Flush off any
spilled battery acid
immediately with plenty of 3
water! R20WA-19
Do not top up battery acid

before charging!
161 958-06.02 ©
- Before charging, inspect the battery leads

and charging cables for damage and replace
them, if required.
- Connect the battery plug (2) with the

battery charger plug.
- Turn the battery charger on.
NOTE: Observe the information in the operating

instructions for your battery and the battery
charger (equalising charge).
DANGER: During the charging process, the

surfaces of the battery cells must be exposed
to ensure sufficient ventilation.
After charging is completed:

- Turn the battery charger off.
- Disconnect the battery plug from the battery
charger.
CAUTION: Separate the plug and socket only

with the truck and battery charger switched
off.
- Reconnect the battery plug (2) to the

connector on the truck.
CAUTION: Never squeeze battery cables (3).
WA 15
Check the battery condition,
electrolyte level and acid density 4
Also observe the information in the operating

instructions for your battery.
- Examine the battery for cracks in the casing,

raised plates and leaked acid.
CAUTION: Spilled battery acid must be

neutralised immediately with plenty of water.
- Have a faulty battery repaired.
- Open the caps (4) and check the electrolyte

level.
- On batteries with level inserts, the fluid must 5

reach as far as the base of the insert, in
5051-Wa-065
batteries without level inserts approx. 10 to
163 453-05.04
15 mm over the lead plates.
- Only add distilled water when topping up the

electrolyte.
- The cell caps must be kept clean and dry.
- Remove any oxidation residues on the battery
©
terminals and grease them subsequently with
acid-free grease.
- Tighten the terminal clamps (5) firmly.
- Check the acid density with a hydrometer.

After charging, the reading must be between
1.24 and 1.28 (specific gravity).
Check the roller platform catch*

1
- Lift the side panel up and out of the frame.
- Turn the battery catch (1) down.
- Attempt to drive with the truck:

The truck should not move.
- Return the battery catch to the vertical

position.
Driving should be possible again.
* Option 5051-Wa-066
16 WA
Oiling joints and controls
- Oil or grease all other pivots and joints with

oil OG or grease F according to
"Recommended Fuels and Lubricants“.
❍ Seat channels
❍ Cabin door hinges*
❍ Battery lid hinges
❍ Valve control linkage
Servicing the attachments*

161 958-06.02 ©
1
- Lubricate the attachments such as sideshift
or clamp, slide rails with grease F according
to the table of lubricants.
NOTE: Follow the

manufacturer’s maintenance
instructions.
5051-Wa-017
Maintenance of cold storage

warehouse truck*
- Check all mast rollers and chains for ease of

movement on a weekly basis.
* Option
WA 17
Servicing the electric motors 1
Renewing the motor brushes
- If the brush wear warning (1) appears, the

pump motor brushes must be renewed. KOHLEBUERSTEN
A5004
KOHLEBUERSTEN (MOTOR BRUSHES)

A 5002
- Text appears every 2 min.
NOTE: The truck can still be operated for up

to 10 service hours.
KOHLEBUERSTEN (MOTOR BRUSHES)

A 5004 5051-Wa-018
- Text appears every 10 s.
163 453-05.04
CAUTION: Emergency operation, as brushes
are worn. The power of the hydraulic system
is noticeably reduced.
- Renew the brushes as described in these

maintenance instructions on page 28.
©
- If the brush monitor text appears, all motor
brushes must be renewed.
NOTE: Replacement brushes can be found in

the Spare Parts List.
18 WA
Replacing fuses 1 2
DANGER: Always disconnect

the battery connector before
servicing the electrical
system.
ATTENTION: Only use genuine fuses as

replacements.
NOTE: Depending on the options, not all fuses

are installed in your truck.
The fuses are located on the pump regulator

(1) and the converter (2) in the rear of the
truck.
5051-Ba-150
- Open the battery cover.

161 958-06.02 ©
- Remove the pump regulator cover. 3

9
Fuses on the pump regulator
3 Line fuse 2F1 400A, hydraulic pump motor 4

4 Fuses F20 5A, additional p.c. board
8
5 Fuse F20 5A, distributor board, relay board
5
6 Fuse F15 5A, switch key
7 Fuse F5 5A, horn
8 Fuse 9F20, 75 A, 58 V, for heater*
9 Fuse F8, 15 A, hydraulic control* 7 6 5051-Wa-067
ATTENTION: To protect the 10

electrical system against
water, refit the cover after
replacing a fuse.
Fuses on the converter
10 Line fuse 1F2 355A, converter
WA 19
Maintenance instructions
Fuses* on front distributor board
11 12
11 Fuse F6, 10 A, 24 V
Auxiliary load
12 Fuse F7, 10 A, 24 V
Auxiliary load
5051-Wa-068
Fuses for heater*
163 453-05.04
CAUTION: Replace damaged fuses only with
OEM fuses.
1 Fuse 4 A, 32 V
Fan
©
2 Fuse 30 A, 32 V
Heating element
3 Fuse 30 A, 32 V
Heating element 1
2
3
5051-Wa-069
* Option
20 WA
Servicing the braking system 1
Checking the brake fluid level, topping up
if necessary
Check the brake fluid level if the text BETRIEBS- BETRIEBSBREMSE

BREMSE (SERVICE BRAKE) (1) appears in the A3035
display.
NOTE: The message appears every 10 s. The

truck only drives at walking pace.
5051-Wa-043
- Remove the front panel (3).

161 958-06.02 ©
3
WARNING: Brake fluid is hazardous to health.
Follow the safety precautions for handling
brake fluid.
- Check the brake fluid level in the reservoir

(4). The brake fluid level should be between
the MAX and MIN marks.
NOTE: If the brake fluid level is low, there are

leaks in the braking system. Remedy the cause 7
before topping up brake fluid.
- Add brake fluid BF according to "Recom-

mended Fuels and Lubricants" to the MAX
mark after removing the cap.
Filling capacity ..................... ca. 0.25 L
5051-Wa-044
Checking float switch and the brake fluid

level function 5
4
- Operate the switch in the cover (5) through 6

the hole (7) in the trim. The message
BETRIEBSBREMSE (SERVICE BRAKE) (1) must
flash on the display.
- Remove the cap (6) before filling.
5051-Wa-045
WA 21
Service the seat belt
Check the seat belt
Carry out the following inspection regularly

(monthly). In case of heavy stress, the 2
inspection is required daily.
1
- Pull the belt (3) out fully and inspect it for
fraying. The belt should not show any sign 3
of frays or cuts. The seams should not be
loose.
- Check the belt for dirt.
- Check for worn or damaged parts, including
the fastening points.
- Check that the buckle (1) engages properly.
When the tongue (2) is inserted, the belt
R6046-WA-004
must be held firmly. The tongue (2) of the
belt should be released when the red
pushbutton (4) is depressed.
163 453-05.04
- Checking the automatic anti-blocking system:
● Park the fork truck on level ground.

● Pull the belt out suddenly.
The automatic anti-blocking system
should prevent the belt from reeling out.
©
● Open the battery cover or motor bonnet
or tilt the seat at least 30°.
● Pull the belt out slowly.
The automatic anti-blocking system 4
should prevent the belt from reeling out.
DANGER: Do not operate a truck with a

defective seat belt. Have the defective belt
renewed immediately by your Service. Only
use genuine replacement parts for repairs.
Do not carry out any modifications on the belt.
This will increase the risk of malfunctions. 1 R6046-BA-R-005
Clean the seat belt
- Clean the belt if required (brush suffices).
Renewal after an accident
The seat belt must always be replaced after

an accident.
22 WA
Service the restraint system*
NOTE: Your truck can be equipped with a

restraint system.
Please follow the

maintenance instructions of
the manufacturer.
Check the driver’s seat

161 958-06.02 ©
DANGER: After an accident,

have the driver’s seat
checked along with the seat
belt and the fastening
elements.
- Check the controls for proper working order

as described in the operating manual.
- Check the condition of the seat (eg wear

and tear of the upholstery) and its security
on the cover.
CAUTION: Have the seat repaired by your

Service if damage is detected during the
inspection.
5051-Wa-059
WA 23
1000-hour maintenance
1
Servicing the gear box
Checking the oil level in the drive axle
CAUTION: Follow the safety precautions for

handling gear oil.
NOTE: Truck must be parked on level ground.
- Screw out the oil fill plug (1).
- The oil level must reach the base of the

bore; if not, add oil OG.
Checking the gearbox for leaks 5051-Wa-039
- Inspect the gearbox (arrowed) for leaks

©
(traces of oil). 2
163 453-05.04
Servicing the steering system
Check condition and tension of the

steering chain, lubricate
- Check the sprockets and chain links for wear.
- Lubricate the steering chain (2) with chain

spray S acc. to the lubricant chart.
- Check chain tension. If the chain is too tight,

steering will be hard and chain wear will
increase.
5051-Wa-019
WA 25
Tighten the steering chain 2
- Remove the cover (2) to gain access to the
service port (3).
5051-Wa-046
- Pull out the roll pin (5).
163 453-05.04
4
- Torque the hexagonal nut (4) to 10 Nm.
5
- Hit the chain at the centre of the free end 5
times with a plastic hammer.
- Retorque the hexagonal nut (4) to 10 Nm.
©
- Secure with a roll pin (5) against becoming
loose.
If necessary, turn the hexagonal nut until
the roll pin can be installed.
- Secure the setscrew (6) with liquid glue

(Loctite 243).
6 5051-Wa-050
26 WA
Servicing the brake system
Check service brake for function and

leaks
- Apply the service brake.
If the pedal feels spongy:

- Bleed the system.
- Inspect the pipes, brake cylinders and hoses

for condition and leaks.
If pedal reserve drops to below 20% of total

pedal travel:
- Adjust the brake shoes manually.
10-16-Wa-027
Adjust brake shoes

©
163 453-05.04
- Jack up the front section of the truck,

release the parking brake.
- Remove the plug from the brake adjustment

opening (1).
1
- Rotate the brake shoe adjusters evenly until
the brake shoes make contact with the brake
drum.
- Back off the adjusters evenly until the brake

drum rotates freely.
CAUTION: After the adjustment of the brake,

recalibrate the neutral position of the brake
sensor.
10-16-Wa-026
Please contact your Service for this work.
Check thickness of brake linings
- Remove the wheels and brake drums.
- Check the brake linings for wear.
Minimum lining thickness ............... 2 mm
Renew all brake linings if one should have less

than the minimum thickness.
10-16-Wa-028
WA 27
Check parking brake cables, adjust if
necessary
- Adjust the brake cables only to take up cable 2

stretch and after adjusting the foot brake.
- Adjust the position of the cable adjusting

nut (2).
- Parking brake engaged in 1st notch:

Handbrake switch activated.
Parking brake engaged in 2nd notch of
quadrant: Brake drags.
- Parking brake engaged in 3rd notch:

Brake fully applied, the wheels cannot be
turned by hand or foot.
- Parking brake engaged in 4th to 5th notch: 5051-Wa-037
Full braking action.
163 453-05.04
Lubricate parking brake lever pivot and
ratchet
- Sparingly grease parking brake lever pivot

(arrowed), ratchet and joints with grease F.
©
Check brake fluid level, top up if
necessary
WARNING: Brake fluid is poisonous. Do not

allow brake fluid to contact skin.
- Check brake the fluid level in the brake fluid

reservoir (1).
The brake fluid should reach the „MAX.“ mark.
NOTE: If the brake fluid level is low, there are

5051-Wa-038
leaks in the braking system. Remedy the cause

before topping up brake fluid. Subsequently
bleed the system.
2
1
Topping up
If necesary, top up commercial brake fluid BF

to the „MAX.“ mark.
Filling capacity .................. approx. 0.25 L
- Check the float switch for proper operation

as described on page 21.
5051-Wa-021
28 WA
Adjust parking brake lever switch
- The driving current is cut off when the parking

brake lever is operated beyond the first
detent.
- To adjust the switch, slacken the retaining

screws (2) and slide the switch (3) on the
mounting plate.
Servicing the electrical system
Checking and cleaning the battery
WARNING: No smoking, no
naked light and do not put
any metal objects on the 3 2 5051-Wa-047
battery. Explosion or short

can occur!
©
163 453-05.04
Servicing the battery according to the

manufacturer’s instructions
DANGER: Do not exchange

the battery poles or cause a
short: Risk of personal injury
due to arcing!
Battery insulation inspection
NOTE: Have the battery insulation resistance

checked at least every year. The resistance is
sufficient if at least 1000 Ohm.
10-16-Wa-032
Contact your Service for this inspection.
5 1
Checking the cable connections
DANGER: Before beginning

the following services, stop
the truck, press the 2
emergency stop button and
disconnect the battery
connector. 4
- Check the main fuse (1) for condition

(ceramic body undamaged) and tightness.
Tighten retaining bolts, if required.
- Check fuses (2-5) for condition, cable

connections for tightness and oxidation
residues. Clean if required.
3 5051-Wa-067
WA 29
Servicing the electric motors
1
Replace the pump motor brushes
- Stop the truck, disconnect the battery plug.

Raise and secure the fork carriage.
WARNING: Observe the safety precautions

for securing the mast.
- Remove the floor plate.
- Remove the cover band from the pump motor

(1).
5051-Wa-023
- Lift up the brush springs (4) and pull out
163 453-05.04
the motor brushes (3). 3 4
- The brushes may only be worn down to a
Minimum
length of ................................... 15 mm
- If the minimum brush length is reached on
©
one brush, renew all brushes as a set.
5051-Wa-024
NOTE: Always replace brushes below the wear

limit in kits. Check the armature before installing
new brushes. New brushes must be ground in.
If refitting the existing brushes, do not
interchange or turn them.
- Refit the cover band (clip below the motor

in the centre).
- Refit the removed parts.
15 mm
10-16-Wa-038
30 WA
Check drive motor power cables for
condition and secureness
- Check drive motor power cable for condition

and tight seating in the clamp.
5051-Wa-054
Check commutator and bearings of drive

©
motor and pump motor for wear

163 453-05.04
- Check motor bearings for noise, excessive

play and easy armature movement.
NOTE: The bearings are maintenance-free,

sealed and lubricated for life.
- Check the pump motor commutator for

excessive wear and scoring.
10-16-Wa-025
WA 31
Servicing the hydraulic system
Checking the hydraulic oil level and the

hydraulic system for leaks
- Park the truck on level ground.
- Tilt the mast forward.
- Lower the forks, retract the service cylinder

of any attachments* fitted.
- Disconnect the battery plug and open the

battery bonnet.
- Remove the floor plate.
WARNING: Hydraulic oil is hazardous to health

and it is under pressure during truck operation. 5051-Wa-026

hydraulic oil.
163 453-05.04
1
- Unscrew the breather filter (1).
©
5051-Wa-027
- Measure the dimension X between the top

edge of the filler neck (2) and the surface of 1
the hydraulic oil.
Dimension X ...................... 65 mm (±15)
- The oil level must be between the markings (3). 2

3
- If the oil level has reached dimension X, add
hydraulic oil OZ according to the
recommended lubricants through the filler
neck until the dimension is reached.
X
- Screw in the breather filter.
- Check the pipe and hose unions for leaks (oil

traces).
32 WA
Check hydraulic hoses and pipes
CAUTION: Hydraulic oil under

pressure can escape from
hydraulic lines and cause skin
and eye injuries. Wear suit-
able protective gloves, gog-
gles, etc.
The hoses must be replaced in case of:

- damage to or embrittlement of outer layer
with cracks,
- leaks
- unnatural deformations (eg bulges or kinks)
- fitting detached from hose
- heavy damage to or corrosion of the fitting.

©
163 453-05.04
Pipes must be replaced in case of:

- chafing with removal of material,
- unnatural deformations and visible signs of

bending stress
- leaks.
WA 33
Servicing the mast
- Raise the fork carriage and secure it against

inadvertent lowering.
WARNING: Follow the safety precautions for

servicing the mast.
Checking the lift cylinders and

connections for leaks
- Check the hydraulic connections and lift

cylinders for leaks (visual inspection).
- Tighten leaky unions, repair leaking hydraulic

cylinders.
6033Wa-10_n
Check chain tension
163 453-05.04
NOTE: This inspection is required for HiLo* and 1
various triplex masts*.
- Tilt the mast back.

- Lower the fork carriage completely.
NOTE: Support rollers with different diameters X
©
are fitted in the masts for different load
capacities.
- Measure which support roller is fitted on your

mast.
- Measure the dimension x between the 2

support roller (2) and the bottom of the mast
(1).
5051-Wa-062
Table of support roller dimensions
Mast Support roller Dimension x

Load capacity Diameter (mm)
(tons) (mm) Max.
-2.0 76 28
2.0 - 3.0 90 35
3.5 - 5.5 106 38
The dimension x should not be exceeded.

If the dimension x is larger, chain tension must
be adjusted.
* Option
34 WA
Checking the clearance between the fork
carriage and run-out stop
3
NOTE: This check is required after every chain

adjustment.
- Fully elevate the fork carriage as far as the

snubber in the lift cylinder.
- Measure the clearance between the carriage

and run-out stop roller (3) with a feeler
gauge.
Minimum clearance is ......... min. 2 mm
5051-Wa-063
Checking the lift chains for condition and

©
wear, lubricating
163 453-05.04
- Spray the lift chains with chain spray S.
Adjusting the lift chains

1
NOTE: Never compensate tyre wear by
adjusting lift chain tension!
Adjust the lift chains only if elongation - 3

percent maximum - is due to wear.
ATTENTION: If lift chains can no longer be

retightened, replace them together with all
related connecting parts.
10-16-Wa-043
Telescopic mast
- With the lift cylinders fully extended, turn

the adjusting nuts (1) until the centre point
of the central fork carriage roller remains 35
mm below the upper edge of the inner mast.
The stop must always be between cylinder
and piston.
NiHo mast
- With lift cylinder fully extended, turn the

adjusting nut (2) until the centre point of
the middle fork carriage roller remains 35 mm
below the upper edge of the inner mast. The
stop must always be between the lift cylinder
and piston.
2
10-16-Wa-044
WA 35
Maintenance instructions
Triplex mast
- Fully lower the fork carriage. The upper edges

of the mast sections must be flush.
If not:
- Tighten the chains with the tensioning nuts

(3) at the outer uprights.
- Extend the lift cylinder and tighten the centre

3
chain at the tensioning nut (4) until the
centre of the central fork carriage roller
remains 35 mm (with solid rubber tyres* 10
mm) below the upper edge of the inner mast.
The stop must always be between the lift
cylinder and piston.
4
10-16-Wa-045
Greasing the mast channels
163 453-05.04
- Remove any dirt and grease on the channels.
- Lubricate the outer, intermediate and inner

mast channels (1) with high pressure grease
S to reduce wear.
©
NOTE: Spray the channels evenly while holding
the can approx. 15 - 20 cm from the surface.
Wait for approx. 15 minutes before operating
the truck again.
1
5051-Wa-028
Servicing the mast pivots
Checking the torque of the mast pivot

bolts
- Check the torque of the mast pivot bolts (1)

with a dynamometer (torque wrench).
Torque .......................................... 73 Nm
36 WA
Checking the forks
Checking the forks for condition and for

function of quick-releases
- Check the forks (1) for visible distortion. The

fork wear must not exceed 10 % of the ori-
ginal thickness. 3
2
CAUTION: Worn forks must always be renewed
in pairs.
- Check the function of the fork quick-releases

(3).
- The fork stop bolt (2) must be present.

1
5051-Wa-030
©
163 453-05.04
WA 37
Servicing the mast
- Check the bearings for wear and play.
- Check the chain pulley bearings, support

roller bearings at the mast and fork carriage
for play, condition and tightness.
- The bearings are lubricated for life and need

no servicing. Replace them if they are
damaged, have too much play or stick.
WARNING: Do not change the angle of tilt

arbitrarily. This can affect the stability of the
truck.
5051-Wa-031
After repairs or cylinder replacement, the tilt

cylinder must only be adjusted by your Ser-
©
vice!
"x"
163 453-05.04
Checking lateral clearance (Y)
- Cant the fork carriage in the mast channel.
- Measure the clearance between the mast

channel and the roller with a feeler gauge.
Admissible
lateral clearance (Y) ........... min. 0.3 mm
"y"
18Wa-91
Checking bearing clearance (X)
NOTE: Prior to this check, make sure that la-

teral clearance (Y) is within the specified
tolerances.
- Park the truck on level ground and raise the

fork carriage.
- Place a parallel support under the fork tips.
- Lower the fork carriage onto the support.
- Measure the clearance between the fork

carriage roller and the mast channel with a
feeler gauge.
Clearance (X) ..................... max.1.4 mm

18Wa-92
WA 39
Safety inspection according to
interval and extraordinary events
(in Germany UVV inspection;
please observe your national jährliche Prüfung
regulations) gem. UVV
Mängel siehe Prüfbuch
(at least once a year) letzte Prüfung
Have the fork truck inspected by an expert.

nächste Prüfung
163 453-05.04
©
40 WA
Servicing the steering system
Checking the steering axle
Check swivelling bolster bearing for wear
- Inspect the four-point swivelling bolster

bearing for condition, wear and play.
Check steering lock
- Turn the steering wheel from full lock to full

lock.
5051-Wa-054
Servicing the gearbox

©
Renewing the gear oil

1
163 453-05.04
Draining the gear oil
CAUTION: Follow the safety precautions for

handling gear oil.
- Park the truck on level ground.

- Remove the oil drain plug (2) and filler plug
(1).
- Fully drain the oil into a dish.
CAUTION: Dispose of the

drained oil as specified in en-
vironmental regulations.
2 5051-Wa-040
- Using a new seal, install the oil plugs and
tighten.
Filling the gear oil
- Fill transmission oil OG according to the

lubrication chart up to the filler opening.
Capacity ............................... approx. 2 L
Checking the drive wheel bearing play
- Jack up the truck at the rear.

- Inspect the drive wheel bearing for axial play,
loud rolling noise, damage and wear.
- Check the wheel shaft seal for leaks and
condition.
5051-Wa-041
WA 41
Servicing the carrying axle
Check wheel bearing play
- Jack up the truck at the front.
- Check wheel bearings for excessive play, loud

rolling noise, damage and wear.
Check the grease filling
- Fill new or re-used bearings with new grease.
5051-Wa-032
163 453-05.04
Change brake fluid
NOTE: Renew the brake fluid at least once a

year.
©
For change, use normal retail brake fluid BF.

Bleed the brake lines after filling.
CAUTION: Dispose of old

brake fluid as required by 5051-Wa-033
regulation.
42 WA
Servicing the hydraulic system
Renewing the hydraulic oil and hydraulic

oil filter
(every 3000 hours, but at least every two
years)
WARNING: Hydraulic oil is hazardous to health.

hydraulic oil.
- Park the truck on a level surface.
- Tilt the mast forward.
- Lower the forks and retract the service

cylinder of the attachments.
1
- Disconnect the battery plug and remove the 5051-Wa-051
floor plate.
©
CAUTION: Disconnect the travel drive

2
163 453-05.04
connector.
- Remove the hydraulic oil filter cover (3).

3
- Unscrew the hydraulic oil drain plug (1) under
the oil reservoir and catch the hydraulic oil
in a container.
CAUTION: Dispose of the

drained oil in accordance with
laws and regulations.
- Refit the drain plug (1) and tighten the plug.
Torque .......................................... 70 Nm
5051-Wa-034
- Remove and discard the old hydraulic oil filter

element (5) in the filter cover (3).
- Install a new seal (6) on the conducting pipe 4

(7).
3
- Install a new hydraulic oil filter element and
refasten the filter cover with the nuts (4).
- Unscrew the dipstick (2).
7
5051-Wa-055
WA 43
- Fill fresh hydraulic oil OZ according to the
recommended lubricants into the opening.
2
Filling quantity .................... approx. 20 L
- Check the oil level.

Dimension X ................... 65 mm (+15)
Renewing the breather filter
- Remove the breather filter (2) and discard

it.
- Screw in a new breather filter.

X
5051-Wa-056
Bleeding the hydraulic system
163 453-05.04
Bleeding the steering system
- Operate the steering wheel several times from

lock to lock to bleed the steering system.
Bleeding the telescopic mast
©
- Loosen the hexagonal head screw (1) at the
head of the lift cylinder by 1/2 to 1 turn (do
not screw out too far!). 1
10-16-Wa-056
Bleeding the triplex and NiHo mast
- Loosen the hexagonal head screw located

on the head of the centre cylinder (2) and
one hexagon head screw each at the heads
of the externally arranged cylinders (1) by
1/2 to 1 turn (not more!).
- Put a load on the forks and gently pull the

lift lever back until air bubbles no longer 2
appear in the fluid emerging at the screws.
Tighten the bleed screws.
Bleeding the tilt cylinders
- Tilt the mast fully back and forward several

times. This will bleed the tilt cylinders
automatically. 6033Wa-10
44 WA
Annual maintenance
Annual maintenance
Checking the insulation resistance
The insulation of industrial trucks should have

sufficient insulation resistance. Test the truck
and battery separately.
Battery insulation inspection
NOTE: Have the battery insulation resistance

checked at least every year. The resistance is
sufficient if at least 1000 Ohm.
Testing the insulation resistance of the

electrical system 10-16-Wa-032
Have the insulation resistance of all active

©
electrical components checked in accordance

with DIN 57117 and DIN 43539, VDE 0117 and
163 453-05.04
VDE 0510.
Measuring voltage > rated voltage < 500 V.
The insulation resistance of all live parts of
the truck is sufficient provided it amounts to
at least 1000 ohms per volt of rated voltage
against body.
Please contact your Service for this test.
Recurring inspections
Safety inspection according to interval

and extraordinary events (in Germany
UVV inspection; please observe your
national regulations)
The vehicle must be tested (at least once a

year) by an expert.
This annual test by an expert must cover the
condition of the assemblies and equipment and
the completeness and efficacy of the safety
features.
The truck must also be examined thoroughly
for damage which may have occurred through
improper operation. An inspection report must
be prepared. The results must be kept on file
until the next inspection.
The operator must ensure that any defects
are remedied without delay.
WA 45
Annual maintenance
Change brake fluid
NOTE: Renew the brake fluid at least once a

year.
For change, use normal retail brake fluid BF.

- Check the float switch for proper operation

(see page 15).
Bleed the brake lines after filling.

5051-Wa-033
CAUTION: Dispose of old

brake fluid as required by
163 453-05.04
5051-Wa-061
regulation.
1
Service the steering system
©
Visual inspection of the perforated disc
- Remove the battery.
- Make a visual inspection of the perforated

disc (1) for accumulation of dirt, blooming
oxidation.
There should be no chafed metal on the
perforated disc. If there is dirt on the disc,
clean it carefully.
ATTENTION: Do not clean the perforated disc

mechanically, clean it only with compressed 5051-Wa-064
air. Do not bend or bring the perforated disc
out of adjustment.
Check the forks 1

NOTE: This inspection is only for required re-
versible forks*.
- Have the exterior of the fork bend (1)

examined for cracks.
Please inform your Service.
* Option
46 WA
2-year maintenance
2-year maintenance
Renewing the hydraulic oil
NOTE: The hydraulic oil must be renewed at

least every two years; see section „Renewing
the hydraulic oil“.
5051-Wa-035
©
163 453-05.04
WA 47
Taking out of service
Taking out of service
Measures when storing, taking the Recommissioning after taking out of

truck out of service for a long service
period
If the truck has been out of service for over
six months, it must be inspected carefully before
If the truck is stored for a long period, carry recommissioning. The inspection, similarly to
out the following corrosion protection measures. the safety inspection or the annual inspection,
When taking the truck out of service for over should also include safety-related points on
two months, park it in a clean and dry enclosed the truck.
space which is also well ventilated and frost-
free. Also perform the following measures: - Thoroughly clean the truck.
- Oil joints and actuators.

Measures before taking out of service
- Check the condition and specific gravity of
- Thoroughly clean the truck. the battery, charge the battery if necessary.
- Raise and lower the carriage several times - Check the hydraulic oil for condensate and
as far as possible. renew the oil, if necessary.
©
- Tilt the mast forward and back a few times - Perform the services as before initial
163 453-05.04
and also move the attachment several times, operation.

if fitted.
- Renew the brake fluid.
- Lower the forks on to a suitable object, eg
on a pallet, to relieve the chains. - Take the truck into service.
- Check the hydraulic oil level and add oil, if

necessary. During commissioning check the following points
in particular:
- Cover all blank moving parts lightly with oil
or grease. - Drive, control, steering
- Oil joints and actuators. - Brake, (service brake, parking brake)
- Check the condition and specific gravity of - Lifting device (load lifting member, lift chain,
the battery. Service the battery according mounting)
to the instructions of the manufacturer.
(Follow the manufacturer’s instructions.)
- Spray all open electric contacts with a

suitable contact spray.
CAUTION: Jack up the truck so that all wheels

are clear of the ground. This measure will
prevent a permanent deformation of the tyres.
- Cover the truck with a cotton cover and

protect against dust.
CAUTION: We do not recommend using a

plastic foil as this enhances the formation of
condensate.
If the truck is to be taken out of service for a

yet longer period, contact your Service.
WA 49
Maintenance data
Maintenance data
Table of maintenance data
No. Assembly Aids/ Symbol Dimension

Lubricants
1 General lubrication Lithium-based FL as required
points grease
2 Battery Distilled water - as required
- Insulation resistance - min. 1000 Ohm against body
3 Controls/joints Grease, oil F/OG as required
4 Brakes Linings - min. 2 mm
Brake fluid BF approx. 0.25 l
5 Hydraulic system Hydraulic oil OZ max. 20 l
Hydraulic oil for the USDA max. 20 l
foodstuff industry* H1/46
Hydraulic oil for max. 20 l
cold storage HVLP 46
warehouse duty* DIN
51524-T3
©
6 Tyres
163 453-05.04
- Pneumatic inflation pressure see data on truck
min. tread min. 1.6 mm

- Superelastic wear limit to wear mark
7 Wheel nuts/bolts
- Drive wheel Dynamometer - 195 Nm
- Carrying wheel Dynamometer - 195 Nm
8 Gearbox Gear oil OG approx. 2 l
SAE 80 W
API GL 4
9 Mast Extreme pressure S as required
adhesive grease
- Stop clearance min. 2 mm
- Mast pivot screws Dynamometer - 73 Nm
10 Lift chains chain spray S as required

- Adjustment roller clearance - 35 mm below top edge
of inner mast
11 Motor brushes - - min. rest length 15 mm
* Option
Checklist Truck: .................................................

Model, Serial No. ..................................
Maintenance and lubrication 1000 2000 3000
1. following work hour meter (numbers printed 1000 1000 3000
in bold) 2000 1000
4000 5000 6000
After 3000 hours of operation for instance: 2000 1000 3000
any maintenance and lubrication work due
1000 2000
"every 1000 and 3000 hours" must be done.
1000
After 9000 hours of operation continue as 7000 8000 9000
shown above - but instead of 1000 hours, 1000 2000 3000
10000 operating hours etc.
1000 1000
WA 51
Diagrams
Diagrams Wiring Diagram (1/5)
©
163 453-05.04
Wirkschaltplan 656807 Index d 03/2004
WA 53
Diagrams
Wiring Diagram (2/5)
163 453-05.04
©
54 WA
Diagrams
©
163 453-05.04
WA 55
Diagrams
163 453-05.04
©
56 WA
Diagrams
©
163 453-05.04
WA 57
Diagrams
Legend for the wiring diagrams 2Y2 Lowering
2Y3 Tilting back
Shown switching state: 2Y4 Tilting forward
Truck parked as specified 2Y5 Auxiliary hydraulics 3
2Y6 Auxiliary hydraulics 3
- Parking brake applied 2Y7 Auxiliary hydraulics 4
- Key switch „OFF“ 2Y8 Auxiliary hydraulics 4
- Directional switch „NEUTRAL“ 2Y9 Enable
- Other controls not operated 2Y10 Auxiliary function
- Operator not seated
- Emergency stop button operated Auxiliary drives
- Cross section of unmarked cables 0.75 3B28 Zero sensor for steering
mm² 3B29 Steering switch
General electrical parts Signalling devices
A09 Control computer 4H1 Horn
2A7 Control unit 4S1 Horn push
2F1 Fuse (line fuse)
F2 Fuse (control fuse) Lighting
F4 Fuse (control fuse)
F5 Fuse (control fuse) 5E1 Spotlight, right
163 453-05.04
F6 Fuse (control fuse) 5E2 Spotlight, left
F7 Fuse (control fuse) 5E3 Taillight, right
G1 Battery 5E4 Taillight left
K1 Relay 5E5 Position light, right
K2 Relay 5E6 Position light left
S1 Key switch 5E7 Stoplight, right
X1 Female battery connector 5E8 Stoplight, left
©
5E10 Turn signal light, front left
Traction drives 5E11 Turn signal light, front right
5E12 Turn signal light, rear left
1B1 Accelerator transmitter 5E13 Turn signal light, rear right
1B2 Brake transmitter 5E17 Spotlight, right
1F2 Fuse for 1M2 5E18 Spotlight, left
1K1 Main line contactor 5E23 Rotating beacon
1M2 Traction motor 5E24 Reversing light, left
1R17 Temperature sensor 5E25 Reversing light, right
1S1 Directional switch 5E28 Reversing spotlight, right
1S3 Parking brake switch 5E29 Reversing spotlight, left
1S14 Step switch 5S2 Hazard warning switch
1S16 Switch for accelerator transmitter
1U06 Converter Instruments and gauges
Hydraulic drives for moving the load 6B17 Speed sensor for 1M1
6B22 Speed sensor
2A13 Pump controller 6S3 Oil pressure switch
2B1 Lift transmitter 6S4 Brake fluid switch
2B2 Tilt transmitter
2B3 Aux. hydraulics transmitter1 Special functions
2B4 Aux. hydraulics transmitter 2
2B5 Aux. hydraulics transmitter 3 7B43 Mast double sensor
2F1 Fuse for 2M1 7S1 Seat contact switch
2F11 Fuse 7S2 Emergency stop button
2M1 Pump motor 7S17 Seat belt lock switch
2M1S Motor brush monitor
2R17 Temperature sensor Miscellaneous
2Y1 Lifting 9E12 Seat heater
9M2 Wiper motor
9M5 Fan motor
58 WA
Diagrams
2-Pedal-Bodenplatte 2-pedal floor plate
5. Funktion 5th aux. function
abnehmbares Dach Removable overhead guard
Ausgangsparameter Initial parameters
bei Joystick at joystick
belegt Not free
Danfoss-Kammerbelegung Danfoss terminal assignment
GND-Geber GND transmitter
Heizung Heater
Hubbegrenzung Lift limiting
Hupenansteuerung bei 2-Pedalsteuerung mit Horn control with 2-pedal control with horn
Hupenschalter statt Fahrtrichtungsschalter switch instead of directional switch in lift
in „Heben“-Hebel lever
Hupenansteuerung Horn driver
Hupenschalter in Bodenplatte Horn switch active in floor plate
und im Joystick aktiv and in joystick
Kanalbelegung Channel assignment
+20h ohne Antaktung +20h without clock signal
+00h mit Antaktung +00h with clock signal
Dargestellt Ausführung C1 Version C1 is shown
Kennzeichenleuchte License plate light
©
Mag. Ventil Anbau Solenoid valve for attachment

Mag. Ventil Hubbegrenzung Solenoid valve for lift limiting
163 453-05.04
Rahmen Frame
Relaisbox vorn Relay box, front
Relaisplatte Relay plate
Signalgeber Signal transmitter
Sitzheizung Seat heater
Steuerrechner Control computer
STILL-Kammerbelegung STILL terminal assignment
Sucher als Scheinwerfer Spotlight
Tastenfeld Vorderaufbau Button panel for front part of truck
Totmannschalter Dead man’s switch
Umrichter Converter
Verteilerplatte Distributor plate
Verteilerplatte auf Pumpensteller Distributor plate on pump controller
Warnblinker Hazard warning flasher
Wascher Washer
Wischer Wiper
Zweipedalsteuerung Two-pedal control
WA 59
Diagrams
Wiring diagram for heater*
* Changes reserved
163 453-05.04
Schaltplan Nr.1/951212 Stand 06/2004
Legend
1 Connector 8 Relay
2 Fuse 30 A 9 Diode
3 Switch 10 Coil
4 Switch 11 Thermal fuse
5 Thermal switch 12 Fan
6 Thermostat 13 Heating element
7 Fuse 4 A 14 Flow filter
60 WA
©
163 453-05.04 Diagrams
Hydraulic diagram Hydraulikschaltplan 652 446 Stand 04/2003

Standard equipment (modifications reserved)
Legend
1 Pump unit 11 cc/rev 10c Pressure-relief valve

2 Priority valve 11 Suction filter
3 Steering unit 12 Hydraulic oil reservoir
4 Steering motor 125 cc/rev 13 Pipe check valve
5 Way valve block 14 Breather filter
6 Check valve
7 Check valve for mast height over 5000
8 Tilt cylinder
9 Lift cylinder Mast Version
10a Way valve block
(single auxiliary hydraulics)* Mast height (mm) Tele Niho Triplex
10b Way valve block ≤ 2760 A - -
(double auxiliary hydraulics)*
≥ 2810 B - -
≤ 2510 - C -
≤ 2760 - - D
* Option
WA 61
Diagrams
163 453-05.04
©
Hydraulikschaltplan 634 288 Stand 03/2004
Hydraulic diagram
Provided with Joystick (modifications reserved)
Legend
1 Hydraulic pump 11 cm³/rev 13 High pressure filter
2 Priority valve 14 Variant (4-fold)*
3 Steering unit 15 Hydraulic accumulator
4 Steering motor 125 cm³/rev 16 Load holding valve (variant)*
5 Way valve block 17 Emergency lowering screw
6 Load holding valve 18 Pressure-relief valve
7 Tilt cylinder
8 Lift cylinder
9 Suction filter
10 Hydraulic oil reservoir Mast Version
11 Pipe check valve
12 Breather filter Mast height (mm) Tele Niho Triplex
≤ 2760 A - -
≥ 2810 B - -
≤ 2510 - C -
≤ 2760 - - D
* Option
62 WA
Index
Index
Page Page
1000-hour maintenance ...................................... 25 Checking the gearbox for leaks ........................... 25

2-year maintenance ........................................... 47 Checking the hydraulic oil level and
2000-hour maintenance ...................................... 39 the hydraulic system for leaks ...................... 32
3000-hour maintenance ...................................... 41 Checking the insulation resistance ....................... 45
Checking the lift chains for condition and wear,
A lubricating ...................................................
Checking the lift cylinders and connections
35
for leaks ..................................................... 34

Accident hazards .................................................. 3
Checking the oil level in the drive axle ................ 25
Adjust brake shoes ............................................. 27
Checking the steering axle .................................. 41
Adjust parking brake lever switch ....................... 29
Checking the torque of the mast pivot bolts ......... 36
Adjusting the lift chains ....................................... 35
Checking the tyres for inflation pressure,
After washing the truck ....................................... 12
wear and condition ...................................... 13
Annual maintenance ........................................... 45
Checklist ............................................................ 51
Auxiliary drives .................................................. 58
Clean the seat belt ............................................. 22
B Cleaning the electrical system .............................

Cleaning the lift chains ........................................
12
12
Cleaning the truck .............................................. 11
Battery charging ................................................... 7
Battery electrolyte ................................................ 2
D
©
Battery insulation inspection .......................... 29, 45

Battery servicing .................................................. 7
Definition of used terms ...................................... III
Bleeding the hydraulic system ............................. 44
163 453-05.04
Diagrams ........................................................... 53
Bleeding the steering system .............................. 44
Disposal of greases, oils and batteries ................... 3
Bleeding the telescopic mast ............................... 44
Draining the gear oil ........................................... 41
Bleeding the tilt cylinders .................................... 44
F
Bleeding the triplex and NiHo mast ...................... 44
C Filling the gear oil ............................................... 41

Fire precautions .................................................... 6
Change brake fluid ....................................... 42, 46
Foreword .............................................................. I
Charging the battery .......................................... 14
Fuses for heater ................................................. 20
Check brake fluid level, top up if necessary ......... 28
Fuses on the converter ....................................... 19
Check chain tension ........................................... 34
Fuses on the pump regulator ............................... 19
Check commutator and bearings of drive motor
Fuses on front distributor board ........................... 20
and pump motor for wear ............................ 31
G
Check condition and tension of
the steering chain, lubricate ......................... 25
Check drive motor power cables for condition
and secureness ........................................... 31 Gear oil ................................................................ 2
Check hydraulic hoses and pipes ......................... 33 General ................................................................. I
Check parking brake cables, adjust if necessary .. 28 General electrical parts ....................................... 58
Check service brake for function and leaks .......... 27 Greasing the mast channels ................................ 36
Check steering lock ............................................ 41
Check swivelling bolster bearing for wear ............
Check the battery condition, electrolyte level
41 H
and acid density .......................................... 16
Hydraulic diagram ........................................ 61, 62
Check the driver’s seat ....................................... 23
Hydraulic drives for moving the load ................... 58
Check the forks .................................................. 46
Hydraulic oil, brake fluid ....................................... 2
Check the grease filling ...................................... 42
Check the roller platform catch ...........................
Check the seat belt ............................................
16
22 I
Check thickness of brake linings ......................... 27
Check wheel bearing play ................................... 42 Inspection and maintenance intervals .................... 9
Checking and cleaning the battery ...................... 29 Instruments and gauges ..................................... 58
Checking bearing clearance (X) .......................... 39
Checking float switch and the brake fluid level
function ....................................................... 21
J
Checking lateral clearance (Y) ............................ 39 Jacking up at the counterweight ............................ 4
Checking the battery state of charge ................... 14 Jacking up on the mast ......................................... 4
Checking the brake fluid level, Jacking up the truck ............................................. 4
topping up if necessary ................................ 21
Checking the cable connections ...........................
Checking the clearance between the fork
29
K
carriage and run-out stop ............................ 35
Checking the drive wheel bearing play ................ 41 KOHLEBUERSTEN (MOTOR BRUSHES) A 5002 ...... 18
Checking the forks ............................................. 37 KOHLEBUERSTEN (MOTOR BRUSHES) A 5004 ...... 18
Checking the forks for condition and for function .. 37
WA 63
Index
Page Page
L
Legend for the wiring diagrams ........................... 58 Services not requiring special qualifications ......... III
Lift mast removal ................................................. 5 Servicing the attachments ................................... 17
Lifting and jacking up the truck ............................. 4 Servicing the battery ...................................... 6, 14
Lighting .............................................................. 58 Servicing the battery according to the
Lubricate parking brake lever pivot and ratchet ... 28 manufacturer’s instructions .......................... 29
Servicing the brake system ..................... 27, 42, 46
M Servicing the braking system .............................. 21
Servicing the carrying axle ................................. 42
Maintenance and lubrication ................................ 51 Servicing the electric motors ......................... 18, 30
Maintenance as required ..................................... 11 Servicing the electrical system ............................ 29
Maintenance chart ............................................ I, 8 Servicing the gear box ........................................ 25
Maintenance data ............................................... 51 Servicing the gearbox ......................................... 41
Maintenance of cold storage warehouse truck ...... 17 Servicing the hydraulic system ...................... 32, 43
Maintenance personnel for batteries ..................... II Servicing the mast ....................................... 34, 39
Measures before taking out of service ................. 49 Servicing the mast pivots .................................... 36
Measures when storing, taking the truck out of Servicing the steering system ....................... 25, 41
service for a long period .............................. 49 Servicing the wheels and tyres ............................ 13
163 453-05.04
Miscellaneous ..................................................... 58 Settings ............................................................... 3
Signalling devices ............................................... 58
N Special functions ................................................ 58

Staff training and qualifications for maintenance ... II
NiHo mast .......................................................... 35

T
O Table of contents .................................................. V
Table of maintenance data .................................. 51
©
Oiling joints and controls ..................................... 17 Table of support roller dimensions ....................... 34
Ordering spare parts ........................................... II Taking out of service .......................................... 49
Telescopic mast .................................................. 35
Q Testing the insulation resistance of the electrical
system ........................................................ 45
Quality and quantity of required lubricants .............. I Tighten the steering chain ................................... 26
Tighten wheel nuts / bolts ................................... 13
R Topping up ......................................................... 28
Traction drives ................................................... 58
Triplex mast ....................................................... 36
Recommissioning after taking out of service ........ 49 Tyres ................................................................. 13
Recurring inspections .......................................... 45
Renewal after an accident ...................................
Renewing the breather filter ................................
22
44 V
Renewing the gear oil ......................................... 41
Renewing the hydraulic oil .................................. 47 Visual inspection of the perforated disc ................ 46
Renewing the hydraulic oil and hydraulic oil filter . 43
Renewing the motor brushes ...............................
Replace the pump motor brushes ........................
18
30
W
Replacing fuses .................................................. 19 Washing instructions ........................................... 11
Washing the exterior of the truck ......................... 11
S Wiring Diagram (1/5) .......................................... 53
Wiring Diagram (2/5) .......................................... 54
Safe parking ........................................................ 7 Wiring Diagram (3/5) .......................................... 55
Safety devices ..................................................... 3 Wiring Diagram (4/5) .......................................... 56
Safety inspection according to interval and Wiring Diagram (5/5) .......................................... 57
extraordinary events (in Germany UVV Wiring diagram for heater ................................... 60
inspection; please observe your national Wiring diagram for heater ................................... 60
regulations) ....................................... 1, 40, 45 Work on the electrical equipment ........................... 3
Safety measures for maintenance and repair ......... 3 Working on the front part of the truck .................... 5
Safety precautions for handling fuels and oils ........ 2 Working on the lift mast ........................................ 5
Safety precautions for maintenance ...................... 1
Securing the mast against tilting back .................... 5
Securing the raised NiHo mast .............................. 5
Securing the raised telescopic mast ....................... 5
Securing the raised triplex mast ............................ 6
Service the restraint system ............................... 23
Service the seat belt ........................................... 22
Service the steering system ................................ 46
64 WA
Register 10 : MISCELLANEOUS
10/01 00-02 FINISH AND MARKING (U.S.)
RX50 166610 04.05

FINISH AND MARKING
1, 2
3, 4 8, 9, 10, 11
12, 13
5
14
6, 7
15
1 166610
FINISH AND MARKING
17, 18, 19
16
20, 21
22, 23
24
25, 27
22
166610 2
FINISH AND MARKING
1 - Capacity Plate- Contact Factory 1

2 - OHG Plate-Contact Factory 1
3 149569 Decal, Crushed Fingers Warning 1
4 149579 Decal, No Step Warning 1
5 149963 Decal, Operator’s Manual/tip Over/Seat Belt Warning 1
6 648139* Note Plate 1
7 131884 Decal, 24 Volt Only 1
8 136257 Decal, Trained Operators Warning 1
9 142526 Decal, Personnel Warning 1
10 118029 Decal, Park Brake Warning 1
11 650628* Note Plate (Park Brake Operation Decal) 1
12 142774 Decal, Test/Service Warning 1
13 645095* Note Plate 1
14 161971 Manual, Safety Tips- Sit-Down Rider 1
15 7011387* Note Plate, Safety Belt 1
16 - Data Plate- Contact factory 1
17 149570 Decal, Don’t Stand On or Under Forks 2
18 646136* Decal, Pinch Point 1
19 646135* Decal, Fluid Under Pressure 1
20 139950 Decal, Operator’s Warning 1
21 153603 Decal, Back Up Alarm (if equipped) 1
22 L0009380623 Linde Logo 2
23 658013* Decal, 3-postion Instructions 1
24 L0009380622 Linde Logo 1
25 128324 Decal, Control Pedal Direction
(Dual Pedal trucks only) 1
26 342889* Note Plate, Stop/Directional Arrows Single Pedal 1
342880* Note Plate, Stop/Directional Arrow- Dual Pedal 1
27 L0009381385 Tag, Lug Nut 1
136214 Tywrap 1
28 653163* Symbol 1
29 653170* Symbol 1
30 -* Symbol 1
* From STILL
3 166610

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RX50 Operator Manual 04.05

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Electric Fork Lift Trucks

LINDE LIFT TRUCK CORP.

The operator must ensure that all users have

These operating and maintenance instructions

Lift truck information ............................... 1

Information on operation .......................... 5

Operating the lifting device .................... 69

Other activities .................................... 95

Ending operation ................................. 109

Trailers, Towing .................................. 113

Transport, Hoisting, Towing .................. 117

Malfunctions, cause, remedy ................ 125

Index ................................................ 127

Approved applications Unapproved applications

The lift truck can be used in enclosed spaces

and in the open. Road operation is only

Obey the national regulations governing driving

The floors must have a sufficient load capacity

The aisles and work areas must meet the

Slopes and inclines can be driven on as specified

The truck can be used inside and outdoors in

Any exceptional use where the driver is not

If your truck is to be operated, for example, in Genuine Linde parts, attach-

approval. proval before the installation

For reasons of safety it is not allowed to weld

furthermore sufficiently familiar with the na-

regulations and all further general technical Prohibition of use by unauthorized

The truck packaging material must be disposed

Your truck consists of different materials. Each

With the EC conformity cer-

If the truck is modified or ret-

Keep the CE certificate in a

Copyright and property rights

These operating instructions - even excerpts

Safety inspection according to

ciples applying for the inspection of industrial

Many plant areas are so-

Safety precautions for handling

under high pressure through

Battery acid contains dis-

Hazard Action Check Status

Truck equipment not in

Too little knowledge Operator training

Unauthorised use Access with key only

Exhaust emissions Assessment of diesel

Unauthorised Post the operating

Written job order for

Hazard Action Check Status

b) LP gas Observe safety

When charging traction

operating instructions ventilation

Centre of gravity S (distance from front axle)

Axle load without load, front kg 1060 1090

* See the data sheet for your truck

Axle load without load, rear kg 1610 1650

* See the data sheet for your truck

Noise emissions Frequency characteristics

one work day must be determined, if necessary,

other influencing factors such as road stretch,

According to directive 86/188/EC, however,

Approved types of tyres

Tyre inflation Width of

VG 1006 1860 3260 1860 2510