R6046-49 Operator & Maintenance Manual

Electric Fork Lift Trucks
R 60-35 R 60-40
R 60-45 R 60-50
Operation Manual
! WARNING
Read and observe all warnings on this unit before operating it. DO NOT operate this
equipment unless all factory installed guards and shields are properly secured in place.
Contract#C2824 R 6046-49 SERIES
LINDE LIFT TRUCK CORP.

BA Ident-No. 164 456 - 05.04 A MEMBER OF THE LINDE GROUP
Operation Manual R6046-49
Foreword
Foreword
General Date of issue and version of manual
LINDE fork lift trucks comply with safety October 2003

regulations. If your truck is used on public including change 05.04
roadways, it must be equipped as required by
local regulations. The driving permit must be LINDE is constantly developing and improving their
obtained at the appropriate office. fork lift trucks. Therefore, the manufacturer
reserves the right to make modifications and he
LINDE fork lift trucks are equipped with the latest
will not accept any liability claims based on the
technology. It is now important to operate your
information and illustrations contained in these
truck safely and to maintain its operability.
operating and maintenance instructions.
To achieve this, LINDE provides you with the If you need technical assistance for your truck,
necessary information in this manual. Read and please contact the competent LINDE service.
follow the instructions before commissioning your
The information and specifications contained
truck! In this way you will avoid accidents, save
herein were accurate at the time of publication,
yourself trouble, and not void your guarantee.
but may change without notice as required for
product improvements. Neither Linde Lift Truck
Scope of documentation Corporation, nor its parent company nor any of
its subsidiaries will be held responsible for dam-
- Operation and Maintenance Manual ages due to misuse or inappropriate use of its
©
products.
- Operating and maintenance instructions for at-
164 456-05.04
tachments and battery (optional)

Requests for information, comments and other
- Chart of recommended fuels and lubricants inquiries should be sent to:
- Spare parts list Linde Lift Truck Corporation

2450 West 5th North Street
These operating and maintenance instructions Summerville, S.C. 29484
contain all the measures required for the safe Phone (843) 875-80000 FAX (843) 875-8329
operation and proper maintenance of your fork
truck in all the variants available at the time of
printing. The customised options are documented
in the operating and maintenance instructions
supplied with them. If you have any questions,
please contact your LINDE Service.
Operation and maintenance manuals accompany
each truck. These manuals must be stored
carefully and kept within easy reach of the driver
and operator. The manuals should be kept in the
document pocket on the truck.
If the operation and maintenance manuals are
lost, the operator must immediately order a
replacement from LINDE.
The operation and maintenance manuals are
included in the spare parts list and can be ordered
like a spare part.
The staff concerned with the operation and
maintenance of the equipment must be made
cognizant of these operation and maintenance
manuals.
The operator must ensure that all users have
access to, have read and understood these
instructions.
© Copyright 2003, Linde Lift Truck Corporation.
We thank you for reading and following these All rights reserved. No part of this document may
instructions. Please contact our Service if you have be photocopied or reproduced in any way without
any questions, want to submit improvement prior written consent of LINDE Lift Truck Corpora-
suggestions or have discovered an error. tion.
BA I
R6046-49 Operation Manual
Foreword
This instruction manual describes the fork lift trucks of the table below.
MODEL LINDE LIFT TRUCK

SERIAL NUMBER
DESIGNATION MODEL
R60-35 6046 51 6046 0 _ _ _ _ _
R60-40 6047 51 6047 0 _ _ _ _ _
R60-45 6048 51 6048 0 _ _ _ _ _
R60-50 6049 51 6049 0 _ _ _ _ _
164 456-10.03
Linde Lift Truck Corp.
700014
©
- Please transfer the SERIAL NUMBER from the
manufacturers identification plate to the above
table.
- NOTE: Please indicate this SERIAL NUMBER for

all technical enquiries.
Manufacturers Identification Plate on the truck.
II BA
Foreword
Table of contents
Page
Foreword ..................................................... I
Lift truck information .................................... 2
Information on operation .............................. 8
Safety ....................................................... 10
Description ................................................ 42
Starting up ................................................ 58
Operation .................................................. 76
Operating the lifting device ......................... 96
Other activities ........................................ 122
Ending operation ..................................... 136

©
Trailers, Towing ........................................ 142

164 456-10.03
Transport, Hoisting, Towing ....................... 146
Display, Setting, Operation ....................... 152
Malfunctions, cause, remedy ..................... 158
Index ...................................................... 162
BA III
Lift truck information
LIFT TRUCK
INFORMATION
©
164 456-10.03
WARNING
READ AND FOLLOW ALL SAFETY

PRECAUTIONS. FAILURE TO DO SO MAY
RESULT IN SERIOUS INJURY OR DEATH.
BA 1
Approved applications
The fork lift truck is suitable for lifting, transporting

and stacking loads in a way described and shown Linde Lift Truck Corp.
in this manual.
700014
If the truck is to be used in a way other than
established in this operation manual, the written
approval of LINDE and, if necessary, of the
responsible authorities must be obtained
beforehand to prevent any potential dangers.
The maximum load that can be lifted is specified

on the manufacturers identification plate. Do not
exceed the maximum load capacity.
LINDE cannot predict every circumstance that

might involve a potential hazard in operation and
maintenance. Therefore, the safety messages in
this manual and on the lift truck may not include
164 456-10.03
all possible safety precautions.
If any procedures or actions not specifically

recommended or allowed in this manual are used,
it is your responsibily to be sure that you and
others can do such procedures and actions safely
and without damaging the lift truck. If you are
unsure about the safety of some procedures,
©
contact your LINDE distributor/dealer.
The procedures and precautions given in this

manual apply only to intended uses of the lift
truck. If you use your lift truck for any unintended
use that is not specifically prohibited, you must
be sure that it is safe for you and others. In no
event should you or others engage in prohibited
uses or actions as described in this manual.
Standards and regulations
This truck meets the requirements of:
- Safety Standards for Low Lift & High Lift Trucks

ASME B 56.1 as of 2000 Industrial Trucks
UL 583, Type E as of 1999
- Evaluation of Visibility
ASME B 56.11.6 as of 1992 UL conformity
- Measurement of Sound Emitted by Low Lift, High
With the UL conformity label,
Lift and Rough Terrain Powered Industrial Trucks
LINDE certifies that the truck
ASME B 56.11.5 as of 1992
SIFI conforms to the valid standards
The noise level at the drivers ear is below 70 AS and requirements at the time
dB (A).
ED
CL
- Product Safety Signs & Labels C

U® L US
of production.
ANSI Z 535.4 as of 2002

If the truck is modified or retrofitted without
- Safety Standards for Electric Battery Powered
the approval of the manufacturer, the safety of
the truck may be reduced so that the UL
conformity is invalidated.
2 BA
Site of operation Unapproved applications
The lift truck can be used in enclosed spaces and The manufacturer is not liable
in the open. Road operation is only permitted if for any hazards arising from
the road lighting option is installed. unapproved applications.
Obey the national regulations governing driving Use for other purposes is
lift trucks on public roads. prohibited. Riders are not
allowed on the truck.
The floors must have a sufficient load capacity
(concrete, asphalt) and should have a rough Do not operate the truck in
surface. zones posing a fire or
explosion risk or in areas
The aisles and work areas must meet the causing corrosion or in a very
specifications in this manual. dusty environment.
The use of work platforms is not
Slopes and inclines can be driven on as specified permitted on your lift truck.
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 -4°F to 104°F (-20 °C to
©
+40 °C)).
164 456-10.03
WARNING
Improper operation and maintenance of this lift truck can be hazardous and could result in
serious injury or death.
Operators and maintenance personnel should read this manual thoroughly before beginning
operation or maintenance.
Keep this manual handy and have all personnel read it periodically.
Do not use this lift truck unless you are sure that you understand the contents completely.
If this manual has been lost, or has become dirty or worn and cannot be read, request a
replacement manual from your LINDE distributor/dealer.
LINDE delivers lift trucks that comply with (to the best of our knowledge at the time of delivery)
all applicable regulations and standards of the country to which they have been shipped. If this
lift truck has been purchased in another country or purchased from someone in another country,
it may lack certain safety devices and specifications that are necessary for use in your country.
If there is any question about whether your product complies with the applicable standards
and regulations of your country, consult your LINDE distributor/dealer before operating the
lift truck.
Continuing improvements in the design of this lift truck may not be reflected in this manual.
Consult LINDE or your LINDE distributor/dealer for the latest available information on your lift
truck or for questions regarding information in this manual.
Information on safety is given in Chapters LIFT TRUCK INFORMATION, SAFETY and the
OPERATION and MAINTENANCE sections of this manual.
BA 3
Special risks when using the truck
and attachments WARNING
We warn against the installation and utilisation
Each application not within the scope of the usual of retaining systems not approved by us.
operations and about which the driver is uncer-
tain whether it can be performed in an approved If your truck is equipped with a retaining
and safe manner requires the approval of LINDE system approved by LINDE, we nevertheless
and, if necessary, of the responsible authorities. advise you to use the seat belt.
In particularly difficult cases requiring the simul-
For reasons of safety it is not allowed to weld
taneous use of two trucks for the transport of
or drill holes on the overhead guard. Before
heavy or bulky loads, the supervising officer must
doing welding on other parts of the truck,
be on the site and assume the responsibility and
disconnect the battery and all cables to the
supervision for this transport.
electronic control cards.
Please contact your LINDE Service for this
Modifications and retrofits service.
If your truck is to be operated, for example, in a

cold store or in an environment with an explosion
hazard, the truck must be equipped and approved Warning against using non-genuine
for this application.
parts
If your fork lift truck is to be used for work not
164 456-10.03
Genuine LINDE parts and accessories are
specified in the guidelines and has to be con-
specifically designed for LINDE vehicles.
verted or re-equipped for such use, remember
that any alteration to the structural state can af-
LINDE genuine parts are manufactured from the
fect the driving behaviour and stability of the truck
same materials, and by the same methods, as
and lead to accidents. You should therefore con-
the parts built in the new lift truck.
tact your LINDE distributor beforehand. No modi-
fications affecting the stability of the truck nega-
tively may be performed without our approval.
©
Retrofits are only allowed with our written ap- WARNING
proval. The approval of the responsible authori-
ties must also be obtained, if required. In the event that the customer uses imitation
parts, LINDE will not be held accountable for
any faults which result from the use of such
imitation parts, and LINDE warranty will not be
applicable. Always use genuine LINDE parts
when replacing parts.
4 BA
Fuels and lubricants
CAUTION
Please refer to "Recommended Fuels and This word is used on safety messages and safety
Lubricants for the required materials. labels for hazards which could result in injury
or damage to the lift truck or surrounding
property if the hazard is not avoided.
CAUTION
Fuels and lubricants can be hazardous. Please
follow the safety instructions when handling
these materials. NOTICE
This word is used for precautions that may not
lead to damage or failure, but which must be
Definition of directions taken to avoid actions that could shorten the life
of the lift truck.
The references front, rear, forward, backward, etc.
when describing location are made relative to the
driver when seated in the normal driving position.
The load is at the front.
©
Definition of used terms:

164 456-10.03
Most accidents are caused by a failure to follow

fundamental safety rules for the operation and
maintenance of lift trucks.
To avoid accidents, read, understand and follow
all precautions and warnings in this manual and
on the lift truck before operating and performing
maintenance. Do not operate or carry out
maintenance of this lift truck unless you are sure
that you understand the explanations and
procedures completely.
To identify safety messages in this manual and
on lift truck labels, the following signal words are
used.
DANGER
These safety messages or labels describe
precautions that must be taken to avoid a hazard
which carries a serious risk of serious injury or
death.
WARNING
These safety messages or labels usually
describe precautions that must be taken to avoid
a hazard which may lead to serious injury or
death.
BA 5
Information on operation
INFORMATION
ON OPERATION
©
164 456-10.03
WARNING

BA 7
Operator Prohibition of use by unauthorized

persons
The operator is the natural or legal person using
the truck or on whose order the truck is used. During the shift the driver is responsible for the
The operator must ensure that the truck is only truck. He must ensure that it is not driven or op-
used for approved applications. He is responsible erated by unauthorized persons. When leaving
for the observance of the accident prevention the truck unattended, he must secure the truck
rules and the safety rules in these operating against unauthorized use.
instructions. The operator must ensure that all
users understand the safety information.
Damage, deficiencies
Experts
The driver must immediately notify the supervisors
of any damage to the truck or of any faults.
Experts are specially skilled persons who have Inoperative and unsafe trucks and attachments
thorough knowledge and experience in servicing must not be operated until they have been
and testing industrial trucks and being furthermore properly repaired.
sufficiently familiar with the national industrial
safety and accident prevention regulations and all
further general technical rules and guidelines (Stan-
dards and engineering guidelines), so that they WARNING
164 456-10.03
can give a qualified judgement upon the safe
operating conditions of the truck. Safety devices and switches must not be
removed or disabled. Fixed settings may only
Driver be changed with the approval of LINDE.
Any interventions in the electrical installation
The lift truck may only be driven by qualified (eg the connection of a radio, supplementary
persons at least 18 years of age, trained in its lights, etc) are only allowed with the approval
©
operation, and who have demonstrated to the of the manufacturer.
operator or his representative their driving and
load-handling ability and have expressly been
entrusted with driving the truck. Packaging
The training requirements are fulfilled if the driver
is instructed according to the rules of the trade
The truck packaging material must be disposed
association. Observe your national rules and
of in accordance with laws and regulations.
regulations.
Disposal
Rights, obligations and behavioural
rules for drivers
Your truck consists of different materials. Each ma-
terial must be disposed of /treated / recycled
Drivers must be informed of their rights and according to different regional and / or national
obligations. They must be accorded the rights to regulations. We recommend cooperation with a
which they are entitled. The driver must wear safety disposal specialist.
gear according to the conditions of his activities
(protective clothing, safety shoes, helmet, safety Copyright and property rights
glasses, protective gloves and other) as required
by his task and the load to be handled.
These operating instructions - even excerpts
thereof- may not be reproduced, translated or
made available to third parties without the written
permission of LINDE.
9JMO1089.eps
The driver must be acquainted with the operating

instructions and they must be available to him at
all times.
8 BA
Safety
SAFETY
©
164 456-10.03
WARNING

BA 9
Safety
Safety These hazards can be:
Egress of fuels and lubricants

Safety Management due to leaks, breaking of pipes
and containers, etc.
Operation manual and safety labels
WARNING
Read the instructions in this Manual and the Risk of driving accidents due to unfavourable
Safety Labels attached to the various parts ground conditions such slope, ice, roughness or
of the lift truck, and make sure that you poor visibility, etc.
understand and follow them. If you do not
understand or do not follow the instructions, Falling off or down, etc. when
this will lead to improper operation, which moving on the truck, particularly
may lead to damage, personal injury or when wet.
death.
Be sure that you understand the proper
method of using the lift truck and the
procedure for carrying out an inspection,
and ensure that they are carried out safely. The stability of the truck has been tested
according to the state of the art. Only the dynamic
Read this Manual and the Safety Labels
164 456-10.03
and static tipping forces occurring during the
again from time to time. If the Operation determined regular operating conditions and
and Maintenance Manual or Safety Labels approved operations were taken into
have been lost or become dirty and cannot consideration. The risk of exceeding the tipping
be read, obtain replacements from your moment during unapproved or incorrect operation
LINDE distributor/dealer and attach the cannot entirely be excluded for difficult stability
Safety Labels in the specified positions. conditions.
©
Loss of stability due to
displaced or unstable load, etc.
Hazards and risks
DANGER
Despite working carefully and according to the
standards and regulations, risks cannot be Fire and explosion hazard due to the battery and
excluded when operating the lift truck. electric power.
The truck and all other system components Human error: non-observance of safety rules.
conform to current safety regulations.
Nevertheless, even for approved applications
and with the observance of all safety notices, a
risk cannot be excluded. Operating qualifications
A risk cannot be excluded even beyond the
immediate danger area of the truck, so that any WARNING
persons standing in this area must pay
particular attention to the truck in order to be Only qualified personnel should operate this lift
able to react fast in case of an incident, failure, truck. Be sure you have proper qualifications
etc. before operating the lift truck.
When operating this lift truck, even if you have
experience in operating other lift trucks, obtain
CAUTION instructions from an authorized person who has
experience in operating this lift truck or the
All persons standing near the truck must be same type of lift truck.
advised of the hazards arising with the
operation of the truck. Please also note the ad-
ditional safety rules in these operating
instructions.
10 BA
Safety
Clothing and personal protective Exhaust gas
items
WARNING
WARNING
Do not leave the diesel-operated heater
Avoid loose clothing, jewelry, and loose long running inside closed rooms and where there
hair. They can catch on controls or in moving is poor ventilation. The exhaust gas contains
parts and cause serious injury or death. carbon monoxide. There is a danger that this
Always wear a hard hat and safety boots. will cause gas poisoning, which may result in
serious injury or death.
Depending on the working conditions, wear
other safety equipment in addition to the hard
hat and safety boots.
A0055060.eps
©
164 456-10.03
9JMO1089.eps
Fire extinguisher and first aid kit
WARNING
Overhead guard, load backrest
If any abnormality in the lift truck occurs, stop
operation immediately, park the lift truck in a
WARNING safe place and safe condition, then contact the
person in charge.
Do not use this lift truck unless it is equipped
with the overhead guard and load backrest Be sure that fire extinguishers have been
shipped with the lift truck from the factory by provided and that you read the labels to ensure
LINDE. that you know how to use them.
Unauthorized modification
A0055070.tif
WARNING Know what to do in the event of a fire.
Any modification made without authorization Be sure that you know the phone numbers of
from LINDE can create hazards. persons you should contact in case of an
emergency.
Before making any modification whatsoever,
consult your LINDE distributor/dealer. LINDE Provide a first aid kit at the storage point.
will not be responsible for any damage, injury Do not use the lift truck if it is leaking fuel.
or death caused by any unauthorized Inform the person on charge of the nature of
modification. the abnormality, and repair the leakage before
Do not install any equipment or parts, which using the lift truck.
obstruct or limit the operators view. Do not leave the lift truck switched on. Always
apply the parking brake securely, lower the
forks to the ground, switch off and remove the
key before leaving the lift truck.
BA 11
Safety
Safety rules Safety equipment
WARNING WARNING
Do not operate the lift truck if you are fatigued, The overhead guard is installed to protect the
or when you have been drinking, or you have operator from failing objects. It is designed to
taken any medication which can make you withstand the force of light boxes or small
drowsy or sleepy. packages. It is not designed to withstand every
possible impact. Always be careful to prevent
When carrying out operation, inspection, or
damage or injury from falling objects.
maintenance of the lift truck, always follow all
workshop rules, safety regulations and
precautions.
During operation, always pay attention to safety
and be careful of pedestrians, traffic and other Tire fenders
surrounding conditions.
WARNING
The tire fenders prevent objects from being
Check when traveling in reverse thrown up by the tires. When changing from a
single tire to a double tire arrangement on your
164 456-10.03
forklift truck, always extend the tire fenders to
WARNING cover the additional tires. If the fenders are not
extended, small stones and other objects will
When reversing, depending on the situation, an be thrown up and may injure the operator or
optional alarm, reversing lamp or rotary lamp other people in the surrounding area.
should be used. In all cases, be sure to face the
rear and check around before traveling in
reverse.
©
Incorrect Correct
fenders fenders
Traveling regulations on public roads
WARNING
Always observe all traffic regulations when
operating the lift truck.
Do not drive on public roads with the lift truck
loaded.
Do not tow other machines on public roads.
(Tow other machines only by following the
rules in chapter Approved towing applications
when not on public roads).
R6046-49_Ba-054
Always carry your drivers license when
traveling on public roads.
12 BA
Safety
Safe working area Reduce load for lift trucks with
attachment
WARNING
WARNING
Always work on level surfaces and wipe up all
oil or grease from the ground. The permissible load for any lift trucks equipped
When working on quays, platforms, docks or with an attachment is lower than the
other places where there is a danger of falling, permissible load for the standard lift truck.
set up blocks to prevent the lift truck from going Reason:
over the edge.
1) The permissible load must be reduced by
Put warning signs up in dangerous places to an amount equivalent to the weight of the
warn the operator not to approach. attachment itself.
Mark the travel areas clearly and maintain the 2) Because of the thickness of the attachment,
road surfaces in good condition. the load center moves forward.
Put up signs to prevent unauthorized machines Always observe the permissible load capacity
from entering areas where trucks are being chart strictly (this chart is stuck to the lift truck
operated. for the attachment). Never exceed the
Ensure that there is adequate lighting to enable permissible load.
operations to be carried out safely.
©
164 456-10.03
Fire Prevention for fuel (Diesel-

operated heater only)
Clean operators compartment
WARNING WARNING
Keep the operators compartment clean and FUEL IS EXTREMELY FLAMMABLE AND CAN
tidy. Be sure to clean up all oil or mud. If the CAUSE FIRES AND EXPLOSIONS.
operators hand or foot slips, this may lead to a
serious accident.
Do not leave tools or spare parts lying around
in the operators compartment. They may
damage or obstruct the control levers or pedals.
Always keep them in the toolbox when not being
used.
Do not smoke or allow any flame.
Carry out refueling away from flames or sparks.
Safe operating plan
WARNING
Before operation, establish an operating plan
and hold a meeting to discuss operating safety. Switch off the truck when refueling.
In confined areas, position a signal person and
carry out operations in accordance with his/
her instructions.
When carrying out operations on roads, put up
fences around the working area and carry out
operations in accordance with instructions from
the signal person.
After refueling, tighten the gas cap securely and

wipe up any spilled fuel.
BA 13
Safety
Fuel system safety
WARNING
Accidents involving fuel systems are always
dangerous and can cause fire and explosion,
serious injury, death and property damage,
Keep the following points in mind when working
with fuel systems.
Read, understand and remember relevant
information in the NATIONAL FIRE
PROTECTION AGENCY (NFPA) standard for
fuel in use. Do this BEFORE working on any fuel
system.
Ensure you are wearing proper personal
protective equipment.
Check for fuel leaks before you begin work on
any fuel system.
AB801120
Ensure there are NO SOURCES OF IGNITION
nearby before beginning work.
With large-sized lift trucks, get off the lift truck
164 456-10.03
Be sure your work area is adequately
and walk around it to check that no one is near
ventilated.
the mast, tires or counterweight, then get on
Disconnect the battery before working on the the lift truck, sit in the operators seat, and start
fuel system. the truck.
©
Precautions when operating
Safe travel directional levers
Precautions when starting the truck WARNING

When switching between FORWARD and
WARNING REVERSE, always slow down or stop the lift
truck. It is dangerous to change the direction
Before starting the truck, always check that the of travel suddenly.
parking brake is applied and that the directional
levers are in neutral.
Adjust the operators seat and the steering
wheel before starting the truck. Always lock
them in position after adjusting. Adjusting the
seat or steering wheel during operation is
dangerous and it may cause you to lose your
balance or to operate the lift truck improperly.
Before starting the truck, check that the
surrounding area is safe.
ALWAYS SIT IN THE OPERATORS SEAT when
starting the truck.
Before starting the truck, sound the horn to
warn people in the area.
14 BA
Safety
Tipping Travel on slopes
WARNING WARNING
If the load-engaging means or load is raised, Do not turn, or travel across or at an angle on
the center of gravity of the lift truck will also slopes. There is danger that the lift truck will
rise and increase the danger of the lift truck tip.
tipping. Do not turn the lift truck when the forks
are raised high.
Do not suddenly raise the forks or tilt the mast
to the front or rear when the forks are loaded.
There is danger that the lift truck will tip.
Reduce speed before turning the lift truck. In
particular, when traveling unloaded, the rear
of the lift truck is heavy.
If the lift truck is turned at high speed, there is
a greater chance of tipping than with the forks
loaded.
©
164 456-10.03
AB801140
Before starting to drive up a slope, stop the lift

truck and adjust the clearance between the
ground surface and the bottom of the forks so
that the bottom of the forks or pallet do not
contact the ground surface or the tip of the fork
does not stick into the ground when traveling.
AB801130
Always ensure that the hood is properly latched.
6046US-BA-037
For safe travel on slopes:

When loaded:
Travel FORWARD up the slope and in REVERSE
down the slope with the load upgrade.
BA 15
Safety
When unloaded:
Travel in REVERSE up the slope and FORWARD
down the slope with the load engaging means
downgrade.
6046US-BA-038
When traveling down slopes, use the braking

force of the electric drive together with the foot
brake, and travel slowly down the slope.
Do not jump off lift truck even if it
164 456-10.03
tips
WARNING
NEVER JUMP OFF the lift truck even if it seems
that it will tip. Always do as follows:
©
- Hold the steering wheel securely.
- Stay in the operators seat.
- Brace your legs.
- If you jump off the lift truck when it turns

over, there is danger that you will be fatally
crushed under the lift truck.
- Always stay in the operators compartment

if the lift truck turns over, and then escape
from the lift truck after it has stopped.
- Always wear the seat belt correctly.

AB801680
16 BA
Safety
Road shoulder Before starting operations, check the load limit
for the gangplanks (dock boards), and do not
use them if they do not have ample strength to
WARNING take the weight of the lift truck when loaded.
Apply the brakes on the highway truck and block
There is danger that soft road shoulders may
the wheels.
collapse, so do not go near them with the lift
truck. With trailers, use jacks and take steps to
prevent the trailer from sinking when the
Always maintain a safe distance from the edge
forklift truck travels on it.
of road shoulders and platforms.
When driving the forklift inside trucks, reduce
speed when backing out and be sure to check
that the gangplanks are safe.
Be careful of pedestrians.
Tell the truck driver not to move the truck until
the operation is completed.
If there is some system to secure the truck to
the dock, always use this system. Secure the
gangplanks so that they do not slip and fall.
©
164 456-10.03
R6046-49_Ba-053
Loading Highway trucks or railroad

cars
WARNING
Do not travel on the edge of docks. There is
danger that the lift truck may fall, which may R6046-49_Ba-063
result in serious injury or death.
Escaping from a railroad crossing
WARNING
If drive trouble occurs on a railroad crossing
and the lift truck cannot move, leave the truck
immediately.
In such an emergency, light a flare or smoke
candle, to warn approaching trains, vehicles
and persons in the area that there is a broken
down truck on the tracks.
It is critically important to remove the lift truck
from the tracks as soon as possible.
R6046-49_Ba-062
BA 17
Safety
No riders Driving in reverse
WARNING WARNING
FORKLIFT TRUCKS ARE ONE-PERSON MACH- When driving in REVERSE, turn to face the rear
INES. and check the area directly behind the lift truck.
Do not allow any other
person to ride on the truck
under any circumstances.
Never allow anyone to act as an extra

counterweight.
164 456-10.03
6046US-BA-047
©
When front view is poor
WARNING
If the load obstructs the view to the front, turn
R6046-49_Ba-049
to the rear and drive the forklift truck in reverse.
6046US-BA-028
When driving in reverse with a high load, use a

signal person to ensure the safety of the load
and the safety in the surrounding area.
18 BA
Safety
Check before starting If there is any oil, grease or mud on the
handrails or steps, wipe it off immediately.
Always keep these parts clean. Repair any
WARNING damage.
When checking the lift truck before starting,

follow the procedure given in this Manual, and
do not start the lift truck until all the checks
have been completed. Always sit in operators seat
If anything abnormal is found, inform the person
in charge and carry out the necessary repairs.
WARNING
Never operate the lift truck from outside the
operators compartment.
Lamps Always keep your body under the overhead

guard.
Do not extend your arms and legs outside the
WARNING operators compartment.
Check that the lamps light up correctly. Replace
any broken or inoperative bulbs.
©
164 456-10.03
Keep hands free from oil and water
WARNING
Do not drive the lift truck if your hands are wet
or covered with oil. Your hands will slip on the
work equipment control levers or directional
lever, and this may cause a serious accident.
Mounting and dismounting

AB801240
WARNING
NEVER jump on or off the lift truck.
When getting on or off the lift truck, always stop
the lift truck and use the handrails and steps to
ensure that you support yourself.
R6046-49_Ba-068
Never hold any control levers or the steering

wheel when getting on or off the lift truck.
BA 19
Safety
Seat belt Braking when traveling
WARNING WARNING
Always wear your seat belt Do not switch off the truck when traveling. If
correctly when on the the truck is switched off, the power steering
operators seat. and electric brake (for trucks with electric
The seat belt will reduce the brakes) will not work.
risk of injury.
Do not use the brake excessively. Do not rest
your foot on the brake pedal unless you are
operating it.
If you do, the brake will overheat and the
braking effect will be lost.
Always check the seat belt mounts and check

for any damage to the seat belt itself. If any
abnormality is found, repair or replace the seat
belt immediately. Safety during travel
WARNING
164 456-10.03
Safety when starting Keep a clear view of the path of travel and
observe for other traffic, personnel and safe
clearances.
WARNING Yield the right of way to pedestrians.
Before starting and moving the lift truck, check When passing oncoming vehicles, reduce speed
that the surrounding area is safe. and keep a safe distance from the other vehicle.
©
Before moving the lift truck, raise the forks In places where there are speed limits, observe
(approx. 8 in. (20 cm) from the ground surface), the speed limit and maintain a safe distance from
and tilt the mast back. other vehicles.
8 in. (15 ~ 20 cm)
6046US-BA-032
Before moving the lift truck, release the parking

brake.
20 BA
Safety
Confirming safety Safety during travel
WARNING WARNING
When traveling, always pay careful attention Avoid traveling in places which are flooded or
to the area around your lift truck, particularly where there are holes.
in the direction of travel or when turning.
Do not pass other vehicles on narrow roads or
at crossings or other places where the view is
poor.
When traveling through crossings or other
places where the view is poor, or when entering
or leaving narrow roads, stop and sound the
horn to confirm safety before driving on.
Even if you sound the horn, not everyone in the
surrounding area will necessarily hear it.
Always pay careful attention to the movements
of people in the surrounding area.
When crossing roads or turning corners, stop
and confirm safety before continuing.
©
164 456-10.03
R6046-49_Ba-061
Do not try to drive the lift truck on soft ground.

Avoid curbs, rails, ditches or other obstacles,
and do not travel directly over them.
Do not travel on slippery road surfaces.
When entering buildings, check the weight limit
of the floor and be careful not to exceed the
limit.
Give priority to loaded lift trucks

R6046-49_Ba-060
Always pay careful attention to the movements

WARNING
of people in the surrounding area, and take steps
When traveling on slopes or in confined areas,
to prevent people from entering the working
unloaded lift trucks should always give the right
area.
of way to loaded trucks.
BA 21
Safety
Height or width limits Precautions when turning
WARNING WARNING
When going in or out of places with height or When turning while traveling forward, the
width limits: counterweight will swing far out. Keep an ample
clearance from walls and other objects to
Ensure that there is ample height and width for
ensure safety.
the lift truck to pass.
164 456-10.03
©
R6046-49_Ba-059 R6046-49_Ba-058
Do not extend your hands or legs outside the When turning, travel slowly and be careful that
lift truck. the front or rear wheels do not come off the
ground. When turning on soft road shoulders,
Check that the surrounding area is safe.
there is danger that the rear wheels may come
Be careful of electric wires and other obstacles off the road shoulder and cause the lift truck to
inside and outside the building. tip.
Stopping distance
WARNING
When traveling downhill, it requires a longer
distance for the lift truck to stop then when
traveling on level ground.
When traveling downhill, reduce the speed and
make sure that you have ample room at the
bottom of the slope to stop.
When traveling on wet surfaces, it requires a
longer distance to stop then when traveling on
normal road surfaces. Always have ample room
to stop.
22 BA
Safety
Towing Dont go under forks
WARNING WARNING
If there is any problem with the brakes or Never allow anyone to go
steering system of your lift truck, only use under the load-engaging
another vehicle with sufficient brake power to means or load when it is
tow it. raised.
The area under the forks is a
There is danger that the lift truck may run away.
danger area. If the forks
come down, the person under
the forks may be crushed, or
seriously injured or killed.
Never allow anyone to go under the load-
engaging means or load even if it is elevated or
Loading operations stuck. It may fall down suddenly at any moment.
No overloading
WARNING Do not lift people on forks

©
Do not load the lift truck over the capacity set

WARNING
164 456-10.03
forth in the load capacity chart.

If the rear wheels come off the ground because Do not use the forks to lift
of overloading, the lift truck cannot travel or people. If the person falls
turn. There is also danger that it may tip. from the forks he/she may be
seriously injured.
Be careful not to get caught or fall
WARNING
Never put your hands or feet
or head into the mast
structure. There is danger
that you will get caught in
moving parts and be seriously
injured.
R6046-49_Ba-051
Always check the load capacity chart to confirm

the loading capacity.
Do not use the mast as a
ladder. If you slip, there is
danger that you will fall.
BA 23
Safety
Operate from operators Do not load above height of load
compartment backrest
WARNING WARNING
Always operate the mast and forks from the Keep the height of the load within the height of
operators compartment. the load backrest.
Do not carry any load that is higher than the
load backrest. If the load is higher than the load
backrest, there is danger that it will fall back
on top of the operator. This may lead to serious
No unstable loads injury or death.
WARNING
Make sure that the center of gravity of the load
is in line with the center of the lift truck.
Do not carry loads off-center. There is danger
that unbalanced loads may cause the lift truck
to tip.
164 456-10.03
Place the load so that it contacts the load
backrest.
Do not handle unstable loads. If there is danger
that the load may fall off, secure it in position
and take steps to prevent the load from
collapsing or falling.
©
R6046-49_Ba-043
AB801340
When carrying stacked loads, tie with rope to

prevent the load from falling.
24 BA
Safety
Do not tilt mast forward when Use only for intended purposes
loaded
WARNING
WARNING
Do not use the lift truck for anything other than
Do not tilt the mast forward when the forks are the intended use (loading operations using the
loaded and raised. There is danger that the load forks).
may fall and that the lift truck may tip.
©
164 456-10.03
R6046-49_Ba-052
6046US-BA-031
Do not use the forks to open or close the doors
Do not travel with the mast tilted forward. of railroad cars or warehouses. Do not push any
other vehicle.
Do not load and unload on slopes
Do not hook ropes or cables on the forks and
use the forks to lift loads. Use the drawbar pin
only for approved towing operations.
Keep tension on chain
WARNING Lever operation
If there is any slack in the chain, the mast rail

or forks may catch in the load or a shelf, and WARNING
there is danger that the load may fall and the
lift truck tip. Be careful not to operate the lever by mistake.
There is danger that the forks or work equipment
may cause serious injury.
Do not operate the levers when getting off the
lift truck.
AB801370.eps
Always be careful that there is no slack in the

chain when pulling the forks out from a pallet
or shelf.
BA 25
Safety
Using drawbar pin
WARNING
Use the drawbar pin only for approved towing After adjusting, check that the forks are held
applications as described in chapter Approved securely in position by the fork stopper. If the
towing applications. forks are not held in position, there is a danger
that the forks may move when the lift truck is
traveling and the load may fall off.
FREE
LOCK
164 456-10.03
R6046-49_Ba-069
©
R6046-49_Ba-070.eps
Fit forks securely in position
WARNING Caution
When adjusting the position (width) of the
forks, be careful not to get your hands caught. Adjust chain
WARNING
Be sure the tension of the left and right chains
is the same. (See CHECK BEFORE OPERATI-
ON). If the tension is not the same, the load
will be unbalanced even if it is loaded correctly
in the center, and there is danger that the lift
truck may tip.
AB801400
26 BA
Safety
Be careful of fork tips Handling long or wide loads
WARNING WARNING
Do not allow the tips of the forks to get close to Be extremely careful when carrying long or
people. The tips of the forks are pointed, so wide loads.
there is a risk that they may cause injury.
Raise the load slowly and be careful not to touch
Do not hook the tips of the forks under objects. anything in the surrounding area.
If the forks slip out, there is danger that the lift
truck or object may move unexpectedly.
©
164 456-10.03
6046US-BA-054
R6046-49_Ba-038
Keep the load as low as possible and be sure to
maintain the balance.
When turning, operate slowly and be careful
not to let the load move.
People in working area
WARNING
Do not allow anyone except the signal person
in the working area.
Do not let any person or another lift truck come
close during operation. When working with a
signal person, always follow their instructions.
Use strong pallets and skids
WARNING
Always be sure that the pallets and skids have
ample strength.
If broken or damaged pallets or skids are used,
there is a risk that the load may fall.
BA 27
Safety
Overhead objects Precautions when loading/unloading
WARNING WARNING
Be careful not to let the mast, overhead guard Do not let anyone place a load on the forks.
or load contact electrical wiring, pipes,
Do not let anyone remove a load directly from
sprinklers or roof beams. If the truck hits such
the forks.
objects, there is a risk that the load will fall or
the lift truck will tip. Standing on the forks is dangerous because the
When the forks are raised, the mast height forks are slippery and the load may move.
increases, so be particularly careful when the
Do not use anyone to keep the load stable. The
forks are raised.
lift truck may move unexpectedly, causing the
load to fall and crush the person.
Stopping and parking
Precautions when stopping or

parking
164 456-10.03
WARNING
Observe the following procedure when stopping
or parking the lift truck:
1) Stop the lift truck on level ground.
2) Apply the parking brake securely to make
sure that the lift truck cannot move.
©
R6046-49_Ba-056
No pushing
650628
WARNING 3) Set the directional lever to neutral.

4) Lower the forks to the ground.
Do not use the forks to push or pull loads. There
is a risk that the load will be damaged or fall.
6046US-BA-029
R6046-49_Ba-045
5) Turn the key switch OFF to stop the truck.
6) Remove the key from the key switch. Then
get off the lift truck.
28 BA
Safety
Parking Remove the key from the faulty lift truck and
hang signs in the operators compartment to
prevent its use.
WARNING
Park the lift truck in the specified place.
Park the lift truck on a firm surface.
Abrupt lowering of stuck fork
Do not park near any emergency exit, stairway,
fire extinguisher or other safety equipment.
Park the lift truck in a place where it will not
WARNING
obstruct pedestrians or other vehicles.
Because a stuck fork may drop down
Never park the lift truck near any flammable unexpectedly, do not go under the fork when it
object. is in this condition. Be very careful when
dealing with this problem to prevent damage
When parking the lift truck on a slope, park as
or injury, and warn those in the work area.
specified above (PRECAUTIONS WHEN
STOPPING OR PARKING), then put blocks under
the tires to prevent the lift truck from moving.
©
Parking machine after failure

164 456-10.03
WARNING
If the lift truck has suffered a failure and the
lift truck must be parked without lowering the
forks, put markers on the tips of the forks and
take steps to prevent pedestrians or other
vehicles from hitting the forks.
Danger
use
Never
6046US-BA-039
Select a parking place where people or vehicles

do not pass, and stop the lift truck so that it is
difficult for anyone to go under the forks. (The
area under the forks is a DANGER zone).
Place a stand or something similar under the
inner mast rail or forks to prevent unexpected
drop of the forks.
BA 29
Safety
Safety precautions for handling
lubricants
Gear oil, Diesel fuel Hydraulic fluid
WARNING WARNING
Do not eat, drink or smoke when working with Hydraulic fluids are hazardous to health and
the product. Prolonged intensive contact may under pressure during operation. Do not spill
cause degreasing and irritation of the skin. these fluids! Remove spilled fluids at once with
Wash skin with soap and water, use skin care oil binding agents and dispose as specified. Dis-
products. If required, wear protective gear. pose of old fluids as specified and follow the
Change soaked clothes and shoes immediately. applicable laws and regulations. Do not allow
If vapor or mist was inhaled, breath fresh air, to come in contact with hot engine parts. Fire
if trouble persists, consult a doctor. After contact hazard!
with eyes rinse thoroughly with water (at least
Do not allow these fluids to contact skin. Avoid
10 minutes) then consult an eye doctor. When
the inhalation of spray fog. The ingress of
swallowed do not force to vomit, but consult
pressure fluids into the skin is particularly
doctor.
hazardous if these emerge under high pressure
Danger of slipping by spilled product, especially through leaks in the hydraulic system. Seek
164 456-10.03
in connection with water. medical aid at once if such injuries occur.
If injuries cannot be excluded, use suitable
Oils can contaminate water. Always keep them
protectors (for example, protective gloves,
in approved containers. Avoid spilling oils.
glasses and skin protection and care creams).
©
WARNING
NEVER put your hands or feet
9JM00848.eps
into the mast structure. There
is danger that you will get
Remove spilled or drained fluids at once with caught in moving parts and be
an oil binding agent and dispose of in seriously injured.
accordance with laws and regulations. The
applicable laws and regulations must be
followed. The oils are inflammable. Do not let
them come in contact with hot engine parts. Fire
hazard!
30 BA
Safety
Checking and inflating tires
DANGER
If the tire inflation pressure is low, it will affect Battery electrolyte can cause blindness if
truck stability. splashed into the eyes. If electrolyte gets into
your eyes, flush them immediately with large
However, do not inflate the tires immediately.
quantities of water and consult a doctor at once.
The inflation pressure may have gone down
because of damage to the rim. If the rim is If you accidentally drink electrolyte, drink a
damaged or cracked and the tires are inflated, large quantity of water or milk mixed with
there is danger that the rim will break when beaten egg white or vegetable oil. Call a doctor
the tire is under high pressure, and this may or poison control center immediately.
cause personal injury or death.
Dispose of drained fluids in accordance with
For safety, when checking tire pressure, place regulations. The applicable laws and
your body in front of the tread face of the tire. regulations must to be observed.
Do not check from the side face of the tire.
©
164 456-10.03
9JM00848.eps
9JL00164.eps
Suitable qualifications are needed for tire When working with batteries, ALWAYS wear
inflation work. Always have the work carried safety glasses or goggles. Batteries generate
out by properly qualified personnel. hydrogen gas. Hydrogen gas is highly EXPLO-
SIVE, and is easily ignited with a small spark
The tire inflation pressure on a forklift truck is or flame.
several times higher than the pressure on an
automobile. When the tires are being inflated, Do not smoke or create any spark near a
there is danger that dirt or dust may be thrown battery. Before working with batteries, switch
up by the compressed air and enter your eyes. off the truck.
Always wear safety glasses to protect your When removing the battery, remove the battery
eyes. plug first.
Avoid short-circuiting the battery terminals
through accidental contact with tools or other
metal objects across the terminals. Tighten the
Battery hazard prevention battery terminals securely. Loose terminals can
generate sparks and lead to an explosion.
WARNING Tighten the battery caps securely.

When cleaning the battery, leave the battery
caps tightened.
Do not put metal objects on top of

battery
9JM00787.eps
WARNING
Battery electrolyte contains sulfuric acid and Never place any metal objects on top of the
can quickly burn the skin and eat holes in battery. There is danger that they will cause a
clothing. If you spill electrolyte on yourself, short circuit and start a fire.
immediately flush the area with a large quantity
of water.
BA 31
Safety
Precautions when charging Structure of lift truck
WARNING CAUTION
Observe all warnings and procedures given by A forklift truck consists basically of the lifting
the manufacturer of the battery. When the mechanism (the forks and mast) at the front
battery is charged, hydrogen gas is generated and the lift truck itself (with tires) at the rear.
and the battery is heated by the chemical
The front wheels of the lift truck act as the
change. To prevent the danger of gas explosion,
fulcrum, and the center of gravity of the lift truck
always do as follows: Carry out the charging
and center of gravity of the load are kept in
operation in a well-ventilated place. Do not
balance.
smoke or allow any flame. Start the charging
operation when the temperature of the battery
electrolyte is below 95°F (35°C). If the
electrolyte temperature goes above 122°F
(50°C) during the charging operation, wait for
it to go down below 95°F (35°C) before starting
charging operation again.
When using a battery charger station to charge
the battery, take the battery caps off.
164 456-10.03
Waste materials
CAUTION
©
Obey appropriate laws and regulations when
disposing of harmful items and materials such
as oil, fuel, solvent, filters and batteries.
6046US-BA-030
INCORRECT The relationship between the position of the

center of gravity of the lift truck and the center
of gravity of the load is extremely important
for maintaining the safety of the lift truck.
9JM00848.eps
Center of gravity of load
CAUTION
The loads carried by forklift trucks come in
various shapes (and weights) from boxes to
planks and long objects. To judge the stability
Structure and stability of the lift of the lift truck, it is important to distinguish
truck (to prevent lift truck from the position of the center of gravity for loads of
tipping) various shapes.
To operate the lift truck safely, it is important to
understand the structure and stability of the lift
truck.
AB801580.eps
32 BA
Safety
Center of gravity and stability Stable range of center of gravity
CAUTION CAUTION
The stability of the lift truck is determined by For the lift truck to be stable, the position of
the position of the combined center of gravity the combined center of gravity must be inside
resulting from the combination of the centers the triangle (stable range of center of gravity)
of gravity of the lift truck and the load. formed by the ground contact points of the left
and right front tires and the center of the rear
axle.
Center of Combined Center of
gravity of center of gravity of Stable range
lift truck gravity load
A380161A.eps
AB80159B
If the position of the overall center of gravity is

When the lift truck is carrying no load, the center in front of the front axle, the front tires will form
©
of gravity remains as it is, but when the lift truck the fulcrum and the lift truck will tip to the front.
is loaded, the combined center of gravity If the position of the combined center of gravity
164 456-10.03
becomes the combination of the centers of moves outside the triangle forming the stable
gravity of both the lift truck and the load. area for the center of gravity, the lift truck will
tip in the direction where the combined center
The position of the center of gravity of the load of gravity moves outside of the triangle.
changes according to whether the mast is tilted
forward or back or whether the mast is raised
or lowered.
Center of Maximum load (weight and center of

gravity
of load Combined
gravity of load)
center of Center of
gravity gravity of
lift truck CAUTION
The horizontal distance between the center of
gravity of the load on the forks and the load
backrest of the forks, or the front face of the
forks (whichever is shorter), is called the load
center.
It is assumed that the lift truck body is constant
R6046-49_Ba-047
The position of the combined center of gravity AB801620.eps

of the lift truck is governed by the following
factors: The maximum load is the maximum weight of
the load that can be loaded at the standard load
- Size, weight, shape of load center. The relationship between the maximum
- Lifting height load and the load center is given in the load
- Tilting angle of mast capacity charts on the nameplate on the lift
- Inflation pressure of tires truck. If the load center moves to the front of
- Acceleration, deceleration, turning radius the forks, the overall center of gravity also
Condition of road surface, angle of road moves to the front, so this means that the load
- Type of attachments must be reduced.
BA 33
Safety
Allowable load Speed and acceleration
CAUTION WARNING
The allowable load is stamped on the If a stationary object is not subjected to
manufacturers identification plate to show the external force, it will remain stationary. In the
relationship regarding the position of the load same way, if a moving object is not subjected
center, the height of the fork and the maximum to external force, it will continue to move at
load. Before loading the forks, check that the the same speed. This is called inertia.
load and load center are within the permitted
Because of inertia, a force is applied towards
range on the stamped allowable load.
the rear when the lift truck starts to move, and
If the shape of the load is complex, set it so is applied towards the front when the lift truck
that the heaviest part of the load is at the center stops- If the brakes are applied suddenly, there
of the forks and set the load close to the load is danger of a large force being applied towards
backrest. the front which may make the lift truck tip or
the load come off the forks.
If the forks are loaded more than the allowable
value, the drive wheels will float during travel When the lift truck is turned, a centrifugal force
and the steering system will not work. This is is applied to the outside from the center of the
very dangerous. Furthermore, the lift truck will turn. This force pushes the lift truck to the
tip over easily under this condition. Therefore, outside and makes it tip. The range of stability
be sure to keep the load below the allowable to the left and right is particularly small, so it is
164 456-10.03
value and properly centered. necessary to reduce speed when turning, in
order to prevent the lift truck from tipping. If
the lift truck is traveling with a raised load, the
Linde Lift Truck Corp. position of the overall center of gravity is high,
so the danger of tipping to the front, left or right
700014
becomes greater.
34 BA
Safety
Safety label sticking positions 1 Buckle up for safety!
Operator should
Keep these labels clean. If a label (decal) comes
always wear safety
off, stick it on again in the same location or replace
belt when driving the
it with a new one. Treat all labels (decals) in the
truck.
same way whether they are safety related or not.
5, 6 4
2 Never stand on the

forks!
No one is permitted to
stand or ride on the
forks or to lift and
4 lower a person.
3
2 3 Never enter the area
under the forks!
©
enter or stand under
164 456-10.03
1 the forks or a load.

This is a dangerous
2 3 6046US-BA-001 area because the
forks or load may
come down and crush
a person.
4 No passengers
allowed!
ride on the lift truck
together with the
operator.
5 Do not touch mast!

put his/her hand on
the mast. There is a
risk of hand or other
part of body getting
crushed between
moving part of mast.
6 Do not touch hydraulic

hoses!
If hydraulic oil is
leaking out under
pressure it is
dangerous if oil jet
hits skin or eyes.
BA 35
Safety
9 Warning from limited overhead guard
9 protection
10,11
8
13
10 Caution when cleaning electrical components
12
6046US-BA-002
8 Notice to read instructions in this manual 11 Warning from electrical shock
164 456-10.03
©
12 Warning
for operation
13 What to do in case of tip-over
36 BA
Safety
16 Warning for handling battery
18 14, 15
16
50 ˚C
C (122F)
17
17 Warning for operation of battery lock latch
6046US-BA-003
©
14 Battery specification label for model 6046

164 456-10.03
775 h h
600 h h
1957 4315
1770 3903
855 33.7
658021
15 Battery specification label for models 6047- 18 Warning for operation of valve cover lock bolt
49
930 h h
720 h h
2286 5040
2069 4562
999 39.3
658022
BA 37
Safety
22 Parking brake operation
22 26
32
29
25
19
31
23, 24
20 650628
33 28 23 Brake pedal and accelerator pedal operation

label for single pedal operation
27
342889
30
STOP
6049US-BA-002
164 456-10.03
19 Nameplate

700014
24 Brake pedal and forward/reverse pedal

operation label for double pedal operation
©
342890
STOP
25/26 Hook symbol for identification of truck
slinging points
20 Made in Germany label
655186
27 Front tire pressure label (for pneumatic tires

only)
145 psi 661246_GB
38 BA
Safety
28 Rear tire pressure label (for pneumatic tires 31 Manufacturers logo
only)
130 psi 661245_GB
29 Handling instructions for drive program 32 Manufacturers logo

setting
33 Manufacturers logo
©
164 456-10.03
30 Hydraulic oil filler point identification

648139
BA 39
Description
DESCRIPTION
©
164 456-10.03
WARNING

BA 41
Description
Description
6046US-BA-044
Battery to be removed
upwards
Seat adjustable
± 2.95 in (75 mm)
164 456-10.03
S
©
Distance between forks can be fixed
Technical data
(standard version)
Dimensions
Centre of gravity S (distance from front axle)
R60-35 ............................... 35.47 in (901 mm)
R60-40 .............................. 37.46 in (1002 mm)
R60-45 .............................. 38.44 in (1028 mm)
R60-50 .............................. 40.76 in (1090 mm)
42 BA
Description
Technical data
(standard version)
Identification
Manufacturer LINDE LINDE
Model designation R60-35 R60-40
Type
Manufacturers model designation 6046 6047
Drive: Battery, Diesel, petrol, LP gas, mains Battery Battery
Operation: Manual, walkie, driver standing, driver seated driver seated
driver seated, order picker
Load capacity/hoisted load Q lb (kg) 6880 (3120) 7894 (3580)
Load centre c in (mm) 23.62 (600) 23.62 (600)
Load distance x in (mm) 19.36 (484) 19.36 (484)
Wheel base y in (mm) 72.20 (1843) 78.23 (1987)
Weights
Dead weight lb (kg) 12 502 (5671) 13 177 (5977)
Axle load with load, front lb (kg) 18 226 (8267) 19 767 (8966)
Axle load with load, rear lb (kg) 1993 (904) 2229 (1011)
Axle load without load, front lb (kg) 6391 (2899) 6535 (2964)
©
Axle load without load, rear lb (kg) 6111 (2772) 6643 (3013)
164 456-10.03
Wheels, chassis
Tires, solid rubber (V), superelastic (SE), SE/L SE/L
pneumatic (L), polyurethane (P)
Tire dimensions, front 250-15 250-15
Tire dimensions, rear 21x8-9 21x8-9
Wheels, number front (x = driven) 2x 2x
Wheels, number rear (x = driven) 2 2
Track width, front b 10 in (mm) 38.27 (972) 38.27 (972)
Track width, rear b 11 in (mm) 36.22 (920) 36.22 (920)
Overall dimensions*
Mast/fork carriage tilt, forward degr. 3 3
Mast/fork carriage tilt, backward degr. 8 8
Mast height, retracted h 1 in (mm) 93.50 (2375) 93.50 (2375)
Free lift h 2 in (mm) 6.30 (160) 6.30 (160)
Lift h 3 in (mm) 130.71 (3320) 130.71 (3320)
Mast height, extended h 4 in (mm) 162.60 (4130) 162.60 (4130)
Height, including overhead guard (cab) h 6 in (mm) 91.22 (2317) 91.22 (2317)
Height, driver seat/driver stand h 7 in (mm) 46.66 (1248) 46.66 (1248)
Height of trailer coupling h 10 in (mm) 16.4/20.6 16.4/20.6
(438/550) (438/550)
Overall length l 1 in (mm) 144.49 (3670) 150.16 (3814)
Length including fork heel l 2 in (mm) 105.12 (2670) 110.79 (2814)
Overall width b 1 in (mm) 47.09 (1196) 47.09 (1196)
Fork thickness s in (mm) 1.97 (50) 1.97 (50)
Fork width e in (mm) 4.72 (120) 4.72 (120)
Fork length l in (mm) 39.37 (1000) 39.37 (1000)
Fork carriage acc. to ISO 2038, class/form A,B FEM III A FEM III A
Fork carriage width b 3 in (mm) 43.31 (1100) 43.31 (1100)
Ground clearance with load under lift mast m 1 in (mm) 3.78 (96) 3.78 (96)
Ground clearance, centre wheel base m 2 in (mm) 6.30 (160) 6.30 (160)
Aisle width with pallets 3 Ast in (mm) 156.14 (3996) 162.83 (4136)
9.37 x 47.24 (1000 x 1200) across
Aisle width with pallets 3 Ast in (mm) 165.20 (4196) 170.71 (4336)
1.50 x 47.24 (800 x 1200) long
Turning radius Wa in (mm) 91.02 (2312) 96.54 (2452)
Smallest pivoting point b 13 in (mm) 23.78 (604) 24.57 (624)
* See the data sheet for your truck
BA 43
Description
Technical data
(standard version)
Ide ntification
Ma nufa ct ure r LINDE LINDE
Mo de l de s igna tio n R 60-35 R 60-40
Type
Ma nufa ct ure rs mo del de s igna tio n 6046 6047
Drive : Ba tt e ry, Die s el, pe t ro l, LP gas , mains Bat te ry Bat te ry
O pe rat io n: Ma nua l, wa lkie , driver s ta nding, drive r s e a te d drive r s e a te d
drive r s e a te d, o rde r picke r
Pe rformance s
Driving with lo a d mph (km/h) 8.70 (14) 8.70 (14)
Driving witho ut lo a d mph (km/h) 10 (16) 10 (16)
Lift ing with lo a d ft/s (m/s ) 1.08 (0.33) 1.08 (0.33)
Lift ing witho ut lo a d ft/s (m/s ) 1.51 (0.46) 1.51 (0.46)
Lo we ring w it h lo ad ft/s (m/s ) 1.97 (0.6) 1.97 (0.6)
Lo we ring w it ho ut lo ad ft/s (m/s ) 1.48 (0.45) 1.48 (0.45)
Rat e d t ra ct ive force with lo a d N 3395 3230
Rat e d t ra ct ive force witho ut lo a d N 4115 4055
Ma ximum t ract ive fo rce with loa d N 13700 13630
Ma ximum t ract ive fo rce witho ut loa d N 14500 14450
164 456-10.03
Climbing ca pa cit y with lo a d % 5.5 5
Climbing ca pa cit y witho ut lo a d % 10 9
Ma x. climbing capa city with loa d % 14 13
Ma x. climbing capa city witho ut lo a d % 25 23
Accele rat ion for driving w it h lo a d s 5.1 5.5
Accele rat ion for driving w it ho ut lo a d s 4.6 4.8
Se rvice bra ke e lect r./hydr. e lect r./hydr.
Ele ctric motors

Drive mo to r pe rfo rma nce kW 15 15
©
(60 min. inte rm. rat ing)
Lift mo to r pe rformance (15 % inte rm. duty) kW 20 20
Bat te ry acc. t o DIN 43531/35/36 A, B, C, no
Bat te ry vo lt age U (V) 80 80
Bat te ry capa city K 5 (Ah) 700 840
Bat te ry we ight lb (kg) 4107 (1863) 4802 (2178)
Energy co ns umptio n a cc. to VDI cycle kW h/h
O the r spe cifications

Spee d co nt rol type SCR SCR
O pe rat ing pre s s ure fo r at ta chme nts ps i (ba r) 3625 (250) 3625 (250)
O il qua ntity fo r a tt a chme nt s U.S. gpm
(l/min)
No is e le ve l a t drivers e a r dB (A) 71 74
Tra ile r co upling, t ype/mo de l DIN To w pin To w pin
44 BA
Description
Technical data
(standard version)
Identification
Manufacturer LINDE LINDE
Model designation R60-45 R60-50
Type
Manufacturers model designation 6048 6049
Drive: Battery, Diesel, petrol, LP gas, mains Battery Battery
Operation: Manual, walkie, driver standing, driver seated driver seated
driver seated, order picker
Load capacity/hoisted load Q lb (kg) 8886 (4030) 9900(4490)
Load centre c in (mm) 23.62 (600) 23.62 (600)
Load distance x in (mm) 19.36 (484) 19. 45 (494)
Wheel base y in (mm) 78.23 (1987) 80.59 (2047)
Weights
Dead weight lb (kg) 13 808 (6263) 14 339 (6504)
Axle load with load, front lb (kg) 21 506 (9755) 23 043 (10452)
Axle load with load, rear lb (kg) 2233 (1013) 2297 (1042)
Axle load without load, front lb (kg) 6671 (3026) 6700 (3039)
©
Axle load without load, rear lb (kg) 7147 (3242) 7639 (3465)
164 456-10.03
Wheels, chassis
Tires, solid rubber (V), superelastic (SE), SE SE
pneumatic (L), polyurethane (P)
Tire dimensions, front 250-15 28x12,5-15
Tire dimensions, rear 21x8-9 21x8-9
Wheels, number front (x = driven) 2x 2x
Wheels, number rear (x = driven) 2 2
Track width, front b 10 in (mm) 38.27 (972) 43.46 (1104)
Track width, rear b 11 in (mm) 36.22 (920) 36.22 (920)
Overall dimensions*
Mast/fork carriage tilt, forward degr. 3 3
Mast/fork carriage tilt, backward degr. 8 8
Mast height, retracted h 1 in (mm) 93.50 (2375) 93.50 (2375)
Free lift h 2 in (mm) 6.30 (160) 6.30 (160)
Lift h 3 in (mm) 130.71 (3320) 125.20 (3180)
Mast height, extended h 4 in (mm) 163.90 (4163) 161.14 (4093)
Height, including overhead guard (cab) h 6 in (mm) 91.22 (2317) 91.22 (2317)
Height, driver seat/driver stand h 7 in (mm) 46.66 (1248) 46.66 (1248)
Height of trailer coupling h 10 in (mm) 16.4/20.6 16.4/20.6
(498/550) (498/550)
Overall length l 1 in (mm) 150.16 (3814) 152.52 (3874)
Length including fork heel l 2 in (mm) 110.79 (2814) 113.15 (2874)
Overall width b 1 in (mm) 47.09 (1196) 54.88 (1394)
Fork thickness s in (mm) 1.97 (50) 2.36 (60)
Fork width e in (mm) 4.72 (120) 5.12 (130)
Fork length l in (mm) 39.37 (1000) 39.37 (1000)
Fork carriage acc. to ISO 2038, class/form A,B FEM III A FEM III A
Fork carriage width b 3 in (mm) 43.31 (1100) 51.57 (1310)
Ground clearance with load under lift mast m 1 in (mm) 3.78 (96) 3.78 (96)
Ground clearance, centre wheel base m 2 in (mm) 6.30 (160) 6.30 (160)
Aisle width with pallets Ast in (mm) 162.83 (4136) 165.55 (4205)
39.37 x 47.24 (1000 x 1200) across
Aisle width with pallets Ast in (mm) 170.71 (4336) 173.42 (4405)
31.50 x 47.24 (800 x 1200) long
Turning radius Wa in (mm) 96.54 (2452) 98.86 (2511)
Smallest pivoting point b 13 in (mm) 24.57 (624) 24.92 (633)
* See the data sheet for your truck
BA 45
Description
Technical data
(standard version)
Identification
Manufact urer LINDE LINDE
Model de s ignation R 60-45 R 60-50
Type
Manufacturers model de s ignation 6048 6049
Drive: Batte ry, Die s el, petrol, LP gas , mains Batte ry Batte ry
O pe ration: Manual, walkie, drive r s tanding, drive r s e at ed drive r s e at ed
drive r s e at ed, order picke r
Performance s
Driving wit h load mph (km/h) 8.10 (13) 8.10 (13)
Driving wit hout load mph (km/h) 9.30 (15) 9.30 (15)
Lifting wit h load ft /s (m/s ) 0.92 (0.28) 0.85 (0.26)
Lifting wit hout load ft /s (m/s ) 1.51 (0.46) 1.28 (0.39)
Lowering with load ft/s (m/s ) 1.97 (0.6) 1.97 (0.6)
Lowering without load ft /s (m/s ) 1.48 (0.45) 1.48 (0.45)
Rated tractive force with load N 3055 2849
Rat ed tractive force without load N 3980 3877
Maximum tract ive force with load N 13455 13249
Maximum tractive force without load N 14380 14277
Climbing capacity with load % 4.5 4
164 456-10.03
Climbing capacity without load % 9 8
Max. climbing capacit y with load % 11 11
Max. climbing capacit y without load % 21 21
Accelerat ion for driving with load s 5.7 6
Accelerat ion for driving without load s 5.0 5.2
Se rvice brake electr./hydr. electr./hydr.
Electric motors
Drive motor pe rformance kW 15 15
©
(60 min. interm. rating)
Lift motor performance (15 % inte rm. duty) kW 20 20
Batte ry acc. to DIN 43531/35/36 A, B, C, no 43536 A
Bat te ry voltage U (V) 80 80
Batte ry capacity K 5 (Ah) 840 840
Bat te ry weight lb (kg) 4802 (2178) 4802 (2178)
Energy cons umption acc. to VDI cycle kW h/h
O ther specifications
Spee d control type SCR SCR
O pe ra ting pres s ure for attachme nts ps i (bar) 3625 (250) 3625 (250)
O il quantity for attachme nts U.S. gpm
(l/min)
Nois e le vel at drivers ear dB (A) 71 71
Trailer coupling, type/model DIN Tow pin Tow pin
Emissions
During charging, the drive battery emits a mixture of oxygen and hydrogen (detonating gas). This gas
mixture is explosive and it must not be ignited. The risk of explosion can be avoided through sufficient
ventilation and by avoiding naked flames. Follow the safety precautions for handling the drive battery.
46 BA
Description
Wheels and tires
Approved types of tires
Only the specified types of tires may be installed. Inflate the pneumatic tires to the pressure specified
on the tire inflation pressure labels. We strongly advise contacting our Service before carrying out a
conversion.
WARNING
If a wrong type of tire is used the load bearing capacity of your lift truck may be reduced. It may
also be necessary to install extended fenders.
R60-35 / R60-40
Truck Mast types in. (mm)

Tire Tire inflation Track width
Tires Telescopic
type psi (bar) in. (mm) in. NiHo mast Triplexmast
©
(mm) mast
front rear front rear front rear from to from to from to
164 456-10.03
38.27 36.22 47.64 109.25 109.25

SIT 250-15 21x8-9
(972) (920) (1210) (2775) (2775)
41.81 36.22 51.18 109.25 126.97 109.25 126.97 126.97
SIT 250-15 21x8-9
(1062) (920) (1300) (2775) (3225) (2775) (3225) (3225)
44.02 36.22 59.84 126.97 126.97
SIT 7.00-15 21x8-9
(1118) (920) (1520) (3225) (3225)
48.86 36.22 64.17 126.97
SIT 7.00-15 21x8-9
(1241) (920) (1630) (3225)
145 130 250-15 21x8-9 38.27 36.22 47.64 109.25 109.25
L
(10.0) (9.0) 18PR 16PR (972) (920) (1210) (2775) (2775)
145 130 250-15 21x8-9 41.81 36.22 51.18 109.25 126.97 109.25 126.97 126.97
L
(10.0) (9.0) 18PR 16PR (1062) (920) (1300) (2775) (3225) (2775) (3225) (3225)
125 130 7.00-15 21x8-9 48.86 36.22 64.96 126.97 126.97 126.97
L
(8.5) (9.0) 12PR 16PR (1241) (920) (1650) (3225) (3225) (3225)
145 145 250/70 200/75 38.27 36.22 47.64 95.47 91.54
L
(10.0) (10.0) R15 R9 (972) (920) (1210) (2425) (2325)
145 145 250/70 200/75 41.81 36.22 51.18 81.69
L
(10.0) (10.0) R15 R9 (1062) (920) (1300) (2075)
645/300- 18x7x12 40.71 36.22 52.76 125.98 125.98
VG
410z 1/8 (1034) (920) (1340) (3200) (3200)
645/300- 18x7x12 42.52 36.22 54.72 125.98
VG
410z 1/8 (1080) (920) (1390) (3200)
38.27 36.22 47.64 109.25 109.25
SITn 250-15 21x8-9
(972) (920) (1210) (2775) (2775)
41.81 36.22 51.18 109.25 126.97 109.25 126.97 126.97
SITn 250-15 21x8-9
(1062) (920) (1300) (2775) (3225) (2775) (3225) (3225)
645/300- 18x7x12 40.71 36.22 52.76 125.98 125.98
VGn
410z 1/8 (1034) (920) (1340) (3200) (3200)
645/300- 18x7x12 42.52 36.22 54.72 125.98
VGn
410z 1/8 (1080) (920) (1390) (3200)
L = Pneumatic tires VGn = Cushion tires, natural colour

VG = Cushion tire SIT C = Superelastic SIT CONTI tires
SIT = Superelastic SIT tires SIT a = Superelastic SIT antistatic tires
SITn = Superelastic SIT tires, natural colour DIN = Superelastic tires System DIN
BA 47
Description
R60-45

Tire
Tire Track width
inflation Tires Telescopic
type in. (mm) in. NiHo mast Triplexmast
psi (bar) mast
(mm)
38.27 36.22 47.64 109.25 109.25
SIT 250-15 21x8-9
(972) (920) (1210) (2775) (2775)
28x12.5- 43.46 36.22 54.88 109.25 126.97 109.25 126.97 126.97
SIT 21x8-9
15 (1104) (920) (1394) (2775) (3225) (2775) (3225) (3225)
44.02 36.22 59.84 126.97 126.97
SIT 7.00-15 21x8-9
(1118) (920) (1520) (3225) (3225)
48.86 36.22 64.17 126.97
SIT 7.00-15 21x8-9
(1241) (920) (1630) (3225)
125 130 7.00-15 21x8-9 48.86 36.22 64.96 126.97 126.97 126.97
L
(8.5) (9.0) 12PR 16PR (1241) (920) (1650) (3225) (3225) (3225)
645/300- 18x7x12 40.71 36.22 52.76 125.98 125.98
VG
410z 1/8 (1034) (920) (1340) (3200) (3200)
645/300- 18x7x12 42.52 36.22 54.72 125.98
VG
410z 1/8 (1080) (920) (1390) (3200)
38.27 36.22 47.64 109.25 109.25
SITn 250-15 21x8-9
(972) (920) (1210) (2775) (2775)
164 456-10.03
28x15.5- 43.46 36.22 54.88 109.25 109.25 126.97 126.97
SITn 21x8-9 3225
15 (1104) (920) (1394) (2775) (2775) (3225) (3225)
645/300- 18x7x12 40.71 36.22 52.76 125.98 125.98
VGn
410z 1/8 (1034) (920) (1340) (3200) (3200)
645/300- 18x7x12 42.52 36.22 54.72 125.98
VGn
410z 1/8 (1080) (920) (1390) (3200)
©
R60-50

Tire Tire inflation Track width
Tires Telescopic
type psi (bar) in. (mm) in. NiHo mast Triplexmast
(mm) mast
43.46 36.22 54.88 126.97 126.97 126.97
SIT 28x12.5-15 21x8-9
(1104) (920) (1394) (3225) (3225) (3225)
44.02 36.22 59.84 126.97 126.97
SIT 7.00-15 21x8-9
(1118) (920) (1520) (3225) (3225)
48.86 36.22 64.17 126.97
SIT 7.00-15 21x8-9
(1241) (920) (1630) (3225)
43.46 36.22 54.88 126.97 126.97 126.97
SITn 28x12.5-15 21x8-9
(1104) (920) (1394) (3225) (3225) (3225)
L = Pneumatic tires VGn = Cushion tires, natural colour

VG = Cushion tire SIT C = Superelastic SIT CONTI tires
SIT = Superelastic SIT tires SIT a = Superelastic SIT antistatic tires
SITn = Superelastic SIT tires, natural colour DIN = Superelastic tires System DIN
48 BA
Description
Battery specifications
CAUTION
Only use batteries as described below. The battery tray must be closed. Do not change the location
of ballast weights.
For model:
R60-35
775 h h
600 h h
1957 4315
1770 3903
855 33.7
©
164 456-10.03
658021
For models:
R60-40
R60-45 930 h h
R60-50
720 h h
2286 5040
2069 4562
999 39.3
658022
* Option
BA 49
Description
1 2
3
18
17
4
16
5
164 456-10.03
15
©
14
7
13
12 11 10 9 8 6049US-BA-009
Overviews
Truck
1 Mast 10 Battery
2 Overhead guard 11 Fan
3 Levers for operating the lifting device and 12 Drive motor
attachments* 13 Drive axle
4 Parking brake lever 14 Tilt cylinder
5 Drivers seat 15 Forks
6 Voltage converter* 16 Hydraulic pump
7 Drawbar pin 17 Lift cylinder
8 Steer cylinder 18 Document pocket for operation manual
9 Steer axle
* Option
50 BA
Description
9 6049US-BA-007
10
11
20
12
13
©
164 456-10.03
14
15
19 18 17 16
Operator position
1 Directional switch 11 Tilt lever

2 Steering wheel 12 Attachment lever*
3 Horn button* 13 Attachment lever*
4 Directional indicator switch* 14 Parking brake lever
5 Directional switch 15 Emergency stop button
6 Switch key 16 Accelerator pedal
7 Steering column lock knob 17 Brake pedal
8 Display 18 Drivers seat
9 Document pocket 19 Horn button*
10 Lift lever 20 Beverage holder
* Option
BA 51
Description
1 2 3 4 5 6 7
18
17
164 456-10.03
10
©
11
16 15 14 13 12 6049US-BA-008
Operator position with joystick*
1 Steering wheel 10 Operating notice label on valve cover

2 Horn button 11 Parking brake lever
3 Directional indicator switch* 12 Armrest handwheel
4 Switch key 13 Adjustable armrest
5 Steering column lock knob 14 Accelerator pedal
6 Display 15 Brake pedal
7 Document pocket 16 Drivers seat
8 Joystick 17 Horn button*
9 Emergency stop button 18 Beverage holder
* Option
52 BA
Description
1 2 3 4 5
F
6
9 8
11
©
164 456-10.03
10
6030Ba-03
Joystick*
1 Mast tilt control 6 Directional switch, reverse (yellow)
- Tilt load 7 Joystick
- Functions of attachments* 8 To lift carriage pull joystick back
2 Horn button (red) 9 To lower carriage push joystick forward
3 Directional switch, forward (yellow) 10 Auxiliary hydraulic circuit* joystick to the left
4 Fine control (dark grey) (eg sideshift* to the left)
(not for auxiliary hydraulic piping circuit*) 11 Auxiliary hydraulic circuit* joystick to the left
5 Control button for attachments* (light grey) (eg sideshift* to the left)
Display
1 2 3
1 Selected driving program
2 Number ranging from 1 to 5
3 Time in hours and minutes

P R OG 1 12: 23
4 Battery charge BA T T :
* Option 4 R20BA-79
BA 53
Description
Manufacturers identification plate
1
1 Type Linde Lift Truck Corp.
2 Serial number
2 3
700014
4
NOTICE
Please indicate this serial number for all technical
5
questions.
6
3 Year of production 8
4 Truck weight without battery
7
5 Without or integral attachment 9
6 First Attachment
7 Second Attachment
A: Centre of load (distance)
B: Lift 11
C: Centre of load (distance) R6049US-Ba-003 10
Capacity of truck
Truck weight
8 Battery voltage
164 456-10.03
9 Battery type
10 Battery weight min.
11 Battery weight max.
xx xxxx x xxxxx
Serial number
©
The serial number contains the following
information:
1
1 Plant
2 Type 2
3 Variant
4 Sequence number
3
4 70Ba-001
54 BA
Description
Overview of options and models
Frame and superstructure Overview of attachments
Drivers seat - Fork extension

- Standard seat - Warning beam
- Standard seat with textile cover - Guard
- Seat with armrest and joystick - Ram
- Tow coupling - Crane boom
Snow plough
Overhead guard and cabin - Bucket
- Sideshift (SS)
Overhead guard - Clamp forks without SS
Weather protection - Bale clamp without SS
Tarpaulin cabin - Clamp forks with SS
Cabin - Bale clamp with SS
Electric heater - Fork spreader
Diesel heater
Defroster system
Washer system
Closed canopy
Braking system
©
Regenerative brake
164 456-10.03
Zero braking
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
Emergency stop switch
Joystick
FleetManager
Accident recorder
BA 55
Description
Overview of accessories
- Key for switch lock (2 items)
- Cabin key*
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 in-
structions from LINDE and the
operating instructions of the
attachment manufacturer must
be observed.
164 456-10.03
The work platforms must be installed and secured
as specified in the operating instructions.
Please observe your national rules and
regulations.
Attachments and work platforms must be safe.
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! 5051-Ba-123
Please contact our Service before installation.
Mounting of attachments
The mounting of attachments and the connection

of the energy supply for driven attachments must
be according to the instructions supplied by LIN-
DE and the supplier of the attachment. The
operation of the attachment must be checked
before initial operation after every mounting.
Load capacity with attachment
The admissible load capacity of the attachment

and the admissible capacity (load capacity and
load moment) of the truck must not be exceeded.
The specifications given by LINDE and the supplier
of the attachment must be adhered to.
* Option
56 BA
Starting up
STARTING UP
©
164 456-10.03
WARNING

BA 57
Starting up
Starting up
Daily pre-operational checks and

services
Check before starting
WARNING
When checking the lift truck before starting,
follow the procedure given in this Manual, and
do not start the lift truck until all the checks
have been completed.
If anything abnormal is found, inform the person
in charge and carry out the necessary repairs.
CAUTION
Do not operate the truck until it is repaired if
164 456-10.03
any damage or faults are detected 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.
©
- Report any faults to the supervisors.
WARNING
1
If there is any oil, grease or mud on the
damage.
Connecting the battery plug
- Disconnect the battery plug (1) from the

charging station and insert into the socket on
the truck.
* Option R6042-BA-003
58 BA
Starting up
NOTICE
If the truck was parked at temperatures below
0 °C, the hydraulic functions can be sluggish.
Turning on the key switch
Precautions when starting truck
WARNING
Before starting the truck, always check that the
parking brake is applied and that the directional
levers are in neutral.
Adjust the operators seat and the steering
wheel before starting the truck. Always lock
them in position after adjusting. Adjusting the
seat or steering wheel during operation is
dangerous and it may cause you to lose your
©
balance or to operate the lift truck improperly.

Before starting the truck, check that the
164 456-10.03
surrounding area is safe.

ALWAYS SIT IN THE OPERATORS SEAT when
starting the truck.
Before starting the truck, sound the horn to
warn people in the area.
With large-sized lift trucks, get off the lift truck
and walk around it to check that no one is near
the mast, tires or counterweight, then get on
the lift truck, sit in the operators seat, and start
the truck.
- Insert the key (2) into the key switch and turn
it clockwise to position (I). 0 I
- The message "PLEASE WAIT" appears briefly
in the display.
R60BA-7
BA 59
Starting up
Then the following information (factory settings)
is displayed: 3 4 5
- The selected driving program PROG (3) followed
by a number ranging from 1 to 5 (4). The driving
program can be changed, refer to the section
on "Driving.
P R OG 1 12: 23
- Time of day (5). The time can be set, refer to
the section "Display, setting, operation. BA T T :
- Battery charge (6).

The dark fields show the remaining battery
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 further information,
see the section Displays, settings, operation
of the console.
6 R6042-BA-050
NOTICE
164 456-10.03
If a pressure regulator* is installed, the hydraulic
pressure is indicated here. In this case, the bat-
tery charge is shown in %.
©
Checking the battery charge
NOTICE
The correct state of charge is only indicated after
the first load - either by driving or lifting is put
on the truck.
- Further information can appear in the display.

Refer to the section "Malfunctions, cause and
remedy.
* Option
60 BA
Starting up
Adjusting the driver's seat Adjusting the seat cushioning to driver's
weight
Always sit on operators seat
NOTICE
WARNING Perform the adjustment only with the driver
unseated.
Never operate the lift truck from outside the
Always keep your body under the overhead - Rotate the handwheel (3) until the indicator
guard. shows your weight in kgs.
Do not extend your arms and legs outside the Adjusting the seat inclination
- Push the lever (2), tilt the seat back and release
the lever.
WARNING
WARNING
Do not adjust the seat while the truck is moving.
Risk of accident! The lever must engage fully.
©
- Adjust the seat so that all controls can be

reached and operated safely.
164 456-10.03
The head clearance can be limited on certain truck

versions*. Check the data sheet of your truck.
NOTICE
If separate operating instructions for the seat are
supplied with your truck, follow these instructions.
Adjusting the seat
- Pull the lever (4) up and slide the seat

horizontally.
- Release the lever and engage the seat.
WARNING
The seat must engage fully.
Adjusting the backrest
- Pull lever (1) back and simultaneously adjust

the backrest inclination. 1
- Release the lever and let engage.
4
WARNING 2 3 6046US-BA-100.eps
The backrest must engage fully.
* Option
BA 61
Starting up
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.
3
- Pull up the lever (1) and adjust the backrest

tilt with your weight.
2
WARNING 1 6036Ba-031
The backrest must engage fully.
164 456-10.03
Adjusting the seat cushioning
NOTICE
©
Perform the adjustment only with the driver
unseated.
- Pull up the lever (3) and turn it to the right or

left according to the drivers weight.
NOTICE
The number on the scale must correspond to the
drivers weight.
* Option
62 BA
Starting up
Adjusting the driver's seat*
WARNING
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. 2
- Allow the lever (3) to re-engage.
CAUTION 4 3 JoBa-002
The lever must engage securely.

©
JoBa-003
164 456-10.03
- Pull the grip (4) up.

- Put the backrest (1) to the desired position.
- Allow the grip (4) to re-engage.
CAUTION 5
The grip must engage securely.
Adjusting the drivers weight 2

- Move the adjustment grip (2) only from the top
down to set the desired weight on the scale (5).
- The adjustment range has 9 stages ranging from

7
110 lbs to 287 lbs (50 kg to 130 kg).
Adjusting the armrest
- Loosen the armrest adjustment handwheel (6).
- Move the armrest (7) to the desired position.
- Tighten the handwheel (6) again.
CAUTION
The handwheel must be tight.
6
R2015Ba-002
* Option
BA 63
Starting up
Seat belt
WARNING
Always wear your seat belt correctly when on
the operators seat.
The seat belt will reduce the risk of injury.
Always check the seat belt mounts and check
for any damage to the seat belt itself. If any
abnormality is found, repair or replace the seat
belt immediately.
Driving without the seat belt applied is
dangerous and not allowed!
WARNING
- Only the full cabin with closed, solid doors
or body guards constitute an operator
164 456-10.03
restraint system. PVC doors are not a
restraint system.
- Another driver restraint system must be
used (eg the seat belt) if the truck is
operated with the doors open or removed.
©
Applying the seat belt
CAUTION
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.
NOTICE
2
Sit back as far as possible so that the back
contacts the backrest. The automatic lock will 1
allow enough freedom of movement on the seat.
3
- Engage the tongue (2) in the buckle (1).
- Check the tension of the seat belt. It should

be snug on the body.
6036Ba-035
64 BA
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.
6046US-BA-015
Opening the seat belt

©
- Press the red button (4) on the belt buckle (1).

164 456-10.03
- Move the tongue (2) back to the retractor slowly

with the hand.
NOTICE
Do not let the seat belt retract too fast. The
tongue hitting the retractor can trigger the
automatic lock. The seat belt can then not be
pulled out with the usual force. 4
- Pull the seat belt with increased force about 4

to 6 in. (10 - 15 mm) out of the retractor to
disengage the lock.
- Allow the seat belt to retract slowly. 1 R6046-Ba-035
- Protect the seat belt against dirt (by covering

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

dry to prevent a renewed freezing.
NOTICE
Do not use air over 95-113°F (R6046-49°C) for
thawing.
BA 65
Starting up
Driving behaviour in case of unused
or incorrectly used belt with belt lock
switch present*
DANGER
NOTICE
This feature ensures that the truck only drives
slowly or (optionally) not at all if the seat belt is
not or improperly applied. Depending upon the
model, the working hydraulics functions (lifting,
tilting) are available as usual or can only be oper-
ated slowly or not at all. This function is triggered
by the following conditions:
164 456-10.03
S A F E T Y B E LT !
Seat belt not applied, operator seated
- Turn on the key switch.

The message 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; de-
pending upon the model, the working functions
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.
6046US-BA-007
Seat belt constantly inserted, operator only

seated afterwards
display as long as a control lever or accelerator
pedal is being operated.
The truck drives only slowly or not at all;
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.
restrictions.
* Option 6046US-BA-008
66 BA
Starting up
Seat belt only applied after key switch is
turned on
display as long as a control lever or accelera-
tor pedal is operated.
The truck drives only slowly or not at all; de-
pending 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.
restrictions.
6046US-BA-008
Adjusting the steering column

©
164 456-10.03
WARNING
Always stop the lift truck completely before
adjusting the position of the steering wheel.
After adjusting, move the steering wheel
backward and forward to check that it is locked
2
securely in position.
- Loosen the steering column locking knob (2).

1
- Position the steering column (1) and tighten
the knob again.
WARNING
Make sure that steering column is secure.
6046US-BA-010
3
Checking the steering system for
proper operation
- Turn the steering wheel (3).

The steering play may not be more than 2
fingers wide.
NOTICE
Steering is difficult when the hydraulics have failed.
BA 67
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 situations:
- driving too fast in curves on uneven or sloping
164 456-10.03
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 extre-
me 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 danger arises if the emergency stop
button is operated or the controller is defective.
Therefore, always adapt your driving style to
the driving situation and do not allow yourself
to be induced to put your safety at risk.
Speed limitation* with a lifted load
NOTICE
This feature ensures that the truck only drives
slowly when the load is raised.
DANGER
behaviour of the truck. The truck can either
have a different acceleration and/or braking
behaviour.
* Option
** Option not available
68 BA
Starting up
DANGER
Never drive with a load raised as the truck can HOIST HEIGHT !
tip over due to the high centre of gravity.

As the physically-given stability limits still
remain in force, do not misuse this safety-
enhancing feature to put your safety at risk.
In case the forks are raised above a certain
height, the 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 HOIST HEIGHT ! flashes briefly
in the display.
The truck will only drive at reduced speed. 6026ba-001_GB
- Lower the forks (load) to just above the floor.
The truck can now drive without speed limitation
©
again.
164 456-10.03
Lifting the load while driving*
DANGER HOIST HEIGHT !

behaviour of the 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. 6026ba-005_GB
As the physically-given stability limits still

remain in force, do not misuse this safety-
enhancing feature to put your safety at risk.
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 speed
limitation.
* Option
BA 69
Starting up
Checking the braking system for 3
proper operation
Checking the service brake
- Accelerate the unloaded truck in a free area.
- Depress the brake pedal (3) with force (approx.

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

truck to stop.
The braking distance must be at:
9.30 mph (15 km/h) ... approx. 11.5 ft (3.5 m)

10 mph (16 km/h) ......... approx. 13 ft (4 m)
4 6046US-BA-062
Checking the parking brake
164 456-10.03
- Drive the unloaded truck on a suitable slope
(e.g. ramp).
R60-35 ................................. approx. 25 %

R60-40 ................................. approx. 23 %
R60-45 ................................. approx. 21 %
©
R60-50 ................................. approx. 21 %
DANGER
Never park the truck on a gradient. In an
emergency, secure the truck with chocks.
- The parking brake must engage firmly (4).

The truck should not roll back.
6046US-BA-015
DANGER
Do not operate the truck with faulty brakes.
70 BA
Starting up
Checking the wheels for condition
and tire inflation pressure*
The tires (1) must not be damaged or worn and

they must have the required inflation pressure (if
pneumatic tires are fitted*). Tire wear must be
equal on both sides.
WARNING
If the tire inflation pressure is low, it will affect
truck stability.
because of damage to the rim. If the rim is
1
damaged or cracked and the tires are inflated,
there is danger that the rim will break when
R60BA-15 2
the tire is under high pressure, and this may
©

For safety, when checking tire pressure, place
164 456-10.03
your body in front of the tread face of the tire.

Suitable qualifications are needed for tire
inflation work. Always have the work carried
out by properly qualified personnel.
The tire inflation pressure on a forklift truck is
several times higher than the pressure on an
automobile. When the tires are being inflated,
there is danger that dirt or dust may be thrown
up by the compressed air and enter your eyes.
Always wear safety glasses to protect your
eyes.
- The tires must be inflated to the pressure

specified on the labels (2).
- Please note the information on tires in the

section Description.
WARNING
The stability of the truck is reduced if tire wear
is uneven or the inflation pressure is incorrect.
Renew worn or damaged left and right tires
without delay. There is a higher risk of
accidents as the braking distance is longer.
Use only the types of tires specified in the section

Technical Data.
* Option
BA 71
Starting up
Tire fenders
WARNING
The tire fenders prevent objects from being
thrown up by the tires. When changing from a
single tire to a double tire arrangement on your
forklift truck, always extend the tire fenders to
cover the additional tires. If the fenders are not
extended, small stones and other objects will
be thrown up and may injure the operator or
other people in the surrounding area.
Checking the emergency stop
164 456-10.03
function
- Drive the truck slowly forward.
- Depress the emergency stop button (3 or 4).

The truck will roll to a stop.
©
- Pull the emergency stop button (3) up to unlock
and release the button.
The truck is operational again.
Pull the emergency stop button (4) up.

This releases the button and lets it pop up.
The truck is operational again.
3 R6042-BA-011
Emergency stop procedure
In an emergency all the functions of the truck can

be cut off. 4
- For the cut-off, depress the emergency stop
button (3 or 4).
CAUTION
These safety features may only be used in an
emergency.
6030Ba-08
72 BA
Starting up
Checks before driving - No damage to and secure mounting of load
guard* (if equipped) and overhead guard.
Before starting up, make sure that the truck is in
- Check if the battery hook is locked, the battery
a safe condition:
cover closed and locked with the latch.
- The fork removal and shifting stoppers (1) must
not be defective.
1
©
164 456-10.03
- Check if the valve cover is closed and locked

R6042-BA-036 with the bolt.
- 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.
Lamps
WARNING
Check that the lamps light up correctly. Replace
any broken or inoperative bulbs. - Proper mounting and operation of
attachments* according to operating
instructions.
- Lighting* and stop lights* are functioning - Check that all safety and notice labels are
properly. present and legible.
Overhead guard, load backrest - Replace any damaged or missing labels
according to the section SAFETY LABEL
WARNING STICKING POSITIONS.
Do not use this lift truck unless it is equipped - The roller guide channels (2) must be coated
with the overhead guard and load backrest with a visible film of grease.
shipped with the lift truck from the factory by
LINDE. - Check the visible parts of hydraulic hoses and
reservoir for damage and leaks. Replace
damaged hoses.
- Close the battery cut-out cover* (overhead

guard).
* Option
BA 73
Starting up
Clean operators compartment
WARNING
Keep the operators compartment clean and
tidy. Be sure to clean up all oil or mud. If the
operators hand or foot slips, this may lead to a
serious accident.
Do not leave tools or spare parts lying around
in the operators compartment. They may
damage or obstruct the control levers or pedals.
Always keep them in the toolbox when not being
used.
Persons in the danger area
Safety when starting
164 456-10.03
WARNING
Before starting and moving the lift truck, check
that the surrounding area is safe.
Before moving the lift truck, raise the forks
(approx. 8 in. (20 cm) from the ground surface),
and tilt the mast back.
©
Before moving the lift truck, release the parking
brake.
Before starting up, the driver must ensure that

no person is standing in the danger area of the
truck. He must also keep unauthorized persons
out of this area. It is prohibited, in particular, to
stand in the area of moving parts. A warning
signal must be given in the event of an 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.
Danger zone
The danger zone is the area in which persons

are endangered through the movement of the
truck, working devices, load-lifting devices (e.g.
attachment) or the load. This also includes the
area within the range of falling loads or a
descending working device.
74 BA
Operation
OPERATION
©
164 456-10.03
WARNING

BA 75
Operation
Operation
Traveling regulations on public roads
WARNING
Always observe all traffic regulations when
operating the lift truck.
Do not drive on public roads with the lift truck
loaded.
Do not tow other machines on public roads.
(Tow other machines only by following the
rules in chapter Approved towing applications
when not on public roads).
Always carry your drivers license when
traveling on public roads.
Before driving
164 456-10.03
Dimensions of roadways and aisles
The following dimensions and aisle widths apply

under established conditions to ensure safe
driving. Check, when necessary, if a wider aisle is
required when the load dimensions differ.
Obey the national regulations.
©
The required aisle widths (Ast) depend on the
dimensions of the load.
The dimension stated hereafter apply for standard
trucks, please observe your data sheet.
For pallets the dimensions are:
Aisle width With pallet With pallet

(Standard) 39.37x47.24 in 31.50x47.24 in
(1000x1200 mm) (800x1200 mm)
across long
Model (in) (mm) (in) (mm)

R60-35 156.14 3996 165.20 4196
R60-40 162.83 4136 170.71 4336 1200
1000
X
R60-45 162.83 4136 170.71 4336

R60-50 165.55 4205 173.42 4405
b13 1200
800
The truck may only be used on roadways not

having too tight curves, too large gradients and
too narrow and too low passages.
W
a
100 100
AST
R6046-BA-003
76 BA
Operation
Travel on slopes
WARNING
Do not turn, or travel across or at an angle on
slopes. There is danger that the lift truck will
tip.
that the bottom of the forks or pallet do not

When loaded:
6046US-BA-016
When unloaded:
©

164 456-10.03
downgrade.
The following inclines or slopes may be driven on

with the truck: WARNING
Max. gradient With load Without load There must be sufficient clearance between the
in % highest parts of the truck or load and fixed parts
of the surroundings. The height depends on the
R60-35 14 25 height of the mast and the dimensions of the
R60-40 13 23 load. Check the data sheet for your truck.
R60-45 11 21
R60-50 11 21
The inclines and slopes must not exceed the above

gradients and they should possess a rough Rules for roadways and work area
surface.
Smooth passages at the top and lower end should

prevent the load from touching the ground or
WARNING
damage to the truck.
Only the roads released for traffic by the
operator or his representative may be driven
WARNING on. The roadways must be free of obstacles.
The load may only be stacked and stored at the
Please observe specific warnings regarding appropriate places. The operator and his
Safe working area in the Safety section. representative must ensure that unauthorized
persons keep away from the work area.
Checking for condition of roadways
Roadways must be solid enough, free of debris Hazards

and dropped objects. Drainage ducts, railway
crossings and the like must be level and, if Hazards on roadways must be marked with the
necessary, provided with ramps so that they can usual traffic signs or, if necessary, by additional
be crossed without jolts, if possible. warning signs.
BA 77
Operation
Driving safety rules
Behaviour when driving

The driver must drive within the plant according
to the traffic rules for public roads. The speed of
the truck must be consistent with the local
conditions. Speed must be reduced, for example,
in bends, narrow passages, when driving through
swing doors, in areas where visibility is obstructed
and on uneven ground. A safe braking distance
must always be maintained to the vehicle ahead
and to persons. Sudden braking, fast turns,
overtaking in hazardous or areas with poor
visibility must be avoided. First practice driving in
a clear area or on a free roadway.
WARNING
While driving, it is forbidden:
- to dangle arms and legs out of the truck,
- to lean out of the truck,
164 456-10.03
- to climb from one vehicle to another or to
fixed objects,
- to adjust the drivers seat.
- to release the seat belt
Visibility when driving
©
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.
* Option
78 BA
Operation
Seat belt is removed while driving*
DANGER
- In case the belt is removed while driving:

display.
The truck speed is reduced to slow speed.
- Apply the seat belt as specified and insert it.

restrictions.
Behaviour in an emergency
5051-Ba-096_GB
Do not jump off

©
DANGER
164 456-10.03
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!
Correct behaviour in case of tip-overs: R6046-Ba-R-013
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
BA 79
Operation
Driving 1 2
WARNING
The truck may only be operated with the driver
seated. Check that the operating area is safe
before operating the lever.
- Elevate the fork carriage until the required

ground clearance is obtained by pulling back
the lift lever (1).
- Tilt the mast back by pulling back the tilt

lever (2).
- Do not pick up the load yet!
6046US-BA-072
Selecting the driving program
164 456-10.03
The driving and braking characteristics of the truck
can be set on the display.
To reduce acceleration:
- Press the button with the tortoise symbol (4):
● gentle and slow acceleration and P R OG 1 12: 23
©
deceleration (e.g. for fragile goods). BA T T :
To increase acceleration:
- Press the button with the hare symbol (3):
● fast acceleration and deceleration.
3 4 R20BA-22
The following settings are standard.
The settings may be adapted by your service.
Driving program 1 2 3 4 5
PROG
Truck speed
mph 5 10 10 10 10
(km/h) (8) (16) (16) (16) (16)
Acceleration (%) 67 67 82 100 100
Deceleration (%) 67 67 82 82 100
80 BA
Operation
Zero braking*
5 6
Trucks with zero braking do not have electric
brakes.
The truck also decelerates only minimally when
the accelerator pedal is released.
Directional switch
Precautions when operating directional levers
WARNING
When switching between FORWARD and
REVERSE, always slow down or stop the lift
truck. It is dangerous to change the direction
of travel suddenly.
The directional switch is a lever type switch. Two 6046US-BA-051
switches are installed, one on the left (5) and right

(6) side.
©
2
- The switches return to the centre position after
164 456-10.03
actuation.
Accelerating
- Release the parking brake (1) by pressing the

button and push the parking brake lever fully
down.
- Select the desired direction of travel with the

directional lever (5 or 6).
- Gently push down on the accelerator pedal (2)

until the desired speed is reached.
1 6046US-BA-068
* Option
BA 81
Operation
Forward travel
3 4 5 6
- Set either directional lever (3) or (6) forward.
- The arrow for forward travel (5) is illuminated.
- Depress the accelerator pedal (7) to drive the

truck in the forward direction. The truck speed
depends on how far the accelerator pedal is
depressed. When the accelerator pedal is
released, the truck is braked to a stop. It will
also remain stationary on gradients.
WARNING
Trucks with zero braking* do not have electric
brakes.
6046US-BA-049
NOTICE
164 456-10.03
The truck can be stopped briefly on inclines and 7
slopes without application of the parking brake
(electric brake). The truck may creep slowly in this
case.
©
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.
Reverse travel
Check when traveling in reverse
8 R6042-BA-054
WARNING
When reversing, depending on the situation, an
optional alarm, reversing lamp or rotary lamp
reverse.
Set the directional switch (3 or 6) to reserve.
The arrow for reversing (4) is illuminated.
- Depress the accelerator pedal (7) to drive in

reverse. The other functions are the same as
for forward travel. The reversing light will light
up (only with lighting* acc. to road traffic
regulations).
* Option
82 BA
Operation
Driving in reverse
3 4 5 6
WARNING
When driving in REVERSE, turn to face the rear
and check the area directly behind the lift truck.
Changing the direction of travel
- Release the accelerator pedal (7).
CAUTION
Trucks with zero braking* are not braked
electrically. The truck is braked only when the 6046US-BA-049
brake pedal (8) is depressed.

©
7
- Put either directional lever (3) or (6) to the
164 456-10.03
opposite direction of travel.
- Depress the accelerator pedal again.
NOTICE
The direction of travel can also be reversed while
driving. The foot can remain on the accelerator
pedal. The truck will be braked and accelerated
in the opposite direction (reversing).
8 R6042-BA-054
* Option
BA 83
Operation
Driving (joystick*)
2
WARNING
- 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 back.

1
- Do not pick up a load yet!
JoBa-005
Setting the driving program
164 456-10.03
3
- See instructions on page 80.
F
Forward travel 4
- Push the travel direction switch (3) forward.
©
60BA-016
The arrow for forward travel (5) will illuminate

on the console. 5
84 BA
Operation
- Depress the accelerator pedal (6). The truck
will move forward. Truck speed is controlled with 6
the accelerator pedal. When the accelerator is
released, the truck will be braked to a stop. It
will also stand still on a slope.
CAUTION
Except trucks with zero braking*.
WARNING
brakes.
R6042-BA-016
NOTICE
©
7 8
The truck can be stopped briefly on inclines and
164 456-10.03
slopes without application of the parking brake

(electric brake). The truck may creep slowly in this
case.
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.
6046US-BA-023
* Option
BA 85
Operation
Reverse travel
6
WARNING
rear and check around before traveling in reverse.
- Push the travel direction switch (4) back. The

arrow for reverse travel (8) will illuminate on
the console.
- Depress the accelerator pedal (6). The truck
will reverse. The other functions are as
described for forward travel.
Driving in reverse R6042-BA-016
WARNING
164 456-10.03
7 8
Steering
©
Precautions when turning
WARNING
When turning while traveling forward, the
counterweight will swing far out. Keep an ample
clearance from walls and other objects to
ensure safety.
When turning, travel slowly and be careful that 6046US-BA-023
the front or rear wheels do not come off the
ground. When turning on soft road shoulders,
there is danger that the rear wheels may come
off the road shoulder and cause the lift truck to
tip.
- Steer the truck by turning the steering wheel

(7) as required.
Steering radii: see technical data.
WARNING
When the hydraulics have failed, steering is
difficult.
86 BA
Operation
Service brake
Safety during travel
WARNING
Avoid traveling in places which are flooded or
where there are holes. Do not try to drive the
lift truck on soft ground. Avoid curbs, rails,
ditches or other obstacles, and do not travel
directly over them. Do not travel on slippery
road surfaces. When entering buildings, check
the weight limit of the floor and be careful not
to exceed the limit.
WARNING
Always select the speed allowing a sufficient
braking distance. You should take into
©
consideration that the braking distance alone

increases with the square of the speed and that
164 456-10.03
when braking suddenly, the drive wheels can

skid and the truck tip over.
The braking distance of the truck is influenced
by the characteristics of the floor surface. On a
wet surface the braking distance increases. The
driver must take this into consideration when
driving and braking.
- The truck should be braked with the accelerator

pedal. The footbrake (1) should only be used
in an emergency. Only the electric brake will be
actuated in the first part of the pedal stroke;
depressing the brake further will also activate
the hydraulic brake acting on the drive wheels.
WARNING 1
brakes.
Electric regenerative braking
When braking electrically, energy is fed back into

the battery so that the operating time between 6046US-BA-074
battery charging intervals is extended and the
brake lining wear is reduced.
* Option
BA 87
Operation
Parking brake
- To park the truck, pull the parking brake lever

(2) fully up and let it engage.
2
6046US-BA-075
164 456-10.03
NOTICE 3
When the accelerator pedal is depressed with the
parking brake applied, APPLY HANDBRAKE ap-
pears on the display.
©
WARNING
If the parking brake is applied only lightly, the
truck can roll.
A P P LY H A N D B R A K E !
R6046-49_Ba-071.eps
- Driving is disabled.
5
- The travel directional indicator is (5)
extinguished.
DANGER
If the truck is parked on a gradient, the battery
cover may only be opened if the truck is secured
against rolling with chocks.
- To release the parking brake, press the button

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

selected direction of travel is still selected.
6046US-BA-009
88 BA
Operation
Double-pedal operation* 1 2
Driving
Please refer to the section "Safety precautions

for driving.
WARNING
- 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! 6046US-BA-072
Accelerating
©
4
164 456-10.03
Forward travel
- 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 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.
6046US-BA-077
* Option
BA 89
Operation
Reverse travel
3
WARNING
reverse.
- 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).
5
6046US-BA-076
Driving in reverse
164 456-10.03
WARNING
©
Foot brake
- Releasing the accelerator pedal brakes the truck

automatically. The footbrake (5) should only be
used in an emergency.
WARNING
brakes.
90 BA
Operation
Driving behaviour with seat switch
not operated
S E AT S W I T C H
NOTICE
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 (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

6046US-BA-006_GB
- You are not seated on the seat and operate

the accelerator or steering wheel.
©
The message SEAT SWITCH is shown in the

display.
164 456-10.03
S E AT S W I T C H
The truck will not drive.
- Sit down on the operators 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 SEAT SWITCH is shown in the
display.
Depending upon the model, the working
functions are available as usual or can only be
6026ba-004_GB
operated slowly or not at all.
- Sit down on the operators seat and apply the

seat belt.
The work functions can either be carried out
without any restrictions.
BA 91
Operation
Driving behaviour when seat switch
is operated too long S E AT S W I T C H !
Exceeding the shift time
NOTICE
The shift time can be set.
NOTICE
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 (lifting, tilting) can only be
operated normally or slowly or (optionally) not at
all. This function is triggered by the following 6026ba-007_GB
conditions:
164 456-10.03
- The message 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 lever or the accelerator pedal
is operated.
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.
- Stand up for a short time and sit down again.

restrictions.
Exceeding the operating time
S E AT S W I T C H !
NOTICE
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 SEAT SWITCH !
is shown in the display if neither a control lever
or the 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.

restrictions. 6026ba-007_GB
92 BA
Operation
Use in cold storage warehouses*
Your truck can be used for cold storage

applications 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 gearbox)
and greases (for moving parts such as toothing
and chains).
A further option for the truck is a cabin with heater.
Proper use
Application 1: Continuous duty in the 23 °F

(-5 °C) temperature range and
brief operation down to 14 °F
(10 °C); parking outside the cold
©
storage area.
Application 2: Duty alternating between inside
164 456-10.03
and outside in temperatures ran-

ging from -25.6 °F to 104 °F
(-32°C to +40° C); parking out-
side the cold storage area.
Use
General
The change from a cold temperature inside to a

warm temperature outside causes condensation.
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 diffe-
rent temperature zones.
The traction batteries should never be cooled to
the temperature of the cold storage warehouse
(down to -25.6 °F (-32 °C)), otherwise they will
be become inoperative.
Before operation
CAUTION
The truck must be dry and at operating tem-
perature before it is used in the cold storage
area.
- Drive the truck about 5 minutes and operate

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

This warm-up phase is necessary for the oil to
reach its operating temperature.
* Option
BA 93
Operation
Operation
Application 1
Continuous duty in the 23 °F (-5 °C) temperature

range and brief operation down to 14 °F (-10 °C).
Application 2
Duty alternating between inside and outside in

temperatures ranging from -25.6 °F to 77 °F
(-32 °C to +25 °C), brief operation up to 113 °F
(+45 °C). The truck should not leave the cold
storage warehouse area for longer than 10
minutes to prevent the formation of condensate
water.
If the truck remains outside for over 10 minutes,
it must stay there at least until the condensate
water has run off. This usually takes at least 30
minutes.
164 456-10.03
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 storage
area.
CAUTION
The batteries should not remain overnight in the
cold storage area if not used or recharged.
- Recharge the battery outside the cold storage

area and operate the truck with a replacement
battery.
94 BA
Operating the lifting device
OPERATING THE
LIFTING DEVICE
©
164 456-10.03
WARNING

BA 95
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. Dan-
ger 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. Danger of personal
injury!
164 456-10.03
Never put your hands in
moving parts of the mast.
Mast versions
Your truck can be equipped with one of the 6046US-BA-017
following masts. Their method of operation is as

follows:
1
Telescopic mast
When the lift lever is pulled back, the two outer

cylinders raise the mast and so lift the fork carriage
via the chains (fork carriage is lifted at twice the
speed of the inner mast).
CAUTION
If the ceiling is low, note that the inner mast
(1) can be raised higher than the fork carriage.
96 BA
NiHo mast* 6046US-BA-018
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).
NOTICE
3
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.
©
6046US-BA-019
Triplex mast*
164 456-10.03
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.
* Option
BA 97
Mast operation
WARNING
Before picking up the load, carefully follow the
instructions starting on page 110. Do not reach
or climb into moving truck parts (e.g. mast,
sideshifts, working devices, load lifting devices,
etc.).
Lever operation
WARNING
Be careful not to operate the lever by mistake.
There is danger that the forks or work equipment
may cause serious injury.
Do not operate the levers when getting off the
lift truck.
164 456-10.03
1 2
Tilting the mast
To tilt the mast forward:

- Push the tilt lever (2) forward.
To tilt the mast back:
©
- Pull the tilt lever back.
Raising, lowering the fork carriage
To raise the fork carriage:

- Pull the lift lever (1) back.
To lower the fork carriage:

- Push the lift lever forward.
6046US-BA-072
NOTICE
The symbols on the control levers indicate the
direction of movements of the fork carriage or
mast when the levers are operated.
* Option
98 BA
Operating the attachments*
Reduce load for lift trucks with attachment
WARNING
The permissible load for any lift trucks equipped
with an attachment is lower than the
permissible load for the standard lift truck.
Reason:
an amount equivalent to the weight of the
attachment itself.
2) Because of the thickness of the attachment,
the load center moves forward.
Always observe the permissible load capacity
chart strictly (this chart is stuck to the lift truck
for the attachment). Never exceed the
permissible load.
©
164 456-10.03
Picking up loads with attachments 3
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 attach-
ment load capacity plates.
- Control lever (3) for hydraulically-operated

attachments (eg sideshift).
Follow the operating instructions supplied by the
manufacturer.
6046US-BA-069
NOTICE
Other options and functions are possible. The
attachment functions are indicated on the control
lever symbols.
* Option
BA 99
Symbols indicating the movement of attachments*
NOTICE
The upper symbol indicates the movement of the attachment if the control lever is pushed forwards.
The lower symbol indicates the movement of the attachment if the control lever is pulled back.
1 Lowering/lifting forks or 6 Rotating mast or forks

mast to the left / right
2 Tilting mast or forks for- 7 Releasing / actuating

wards / back load holder
164 456-10.03
3 Advancing / retracting 8 Pulling load on to forks
reach frame or forks / pushing load off forks
©
4 Sideshifting to the 9 Opening / closing
left / right clamp
5 Increasing / reducing 10 Rotating

fork spread
11 Dumping / scooping
with bucket
100 BA
Transporting swinging loads
Observe the national safety rules and regulations.

DANGER
No unstable loads 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

164 456-10.03
swinging loads.
- When transporting suspended loads, suitable

R6046-49_Ba-052
aids (eg holding ropes or bars) must be
available to and used by guides.
WARNING
Make sure that the center of gravity of the load WARNING
is in line with the center of the lift truck.
Always perform or terminate driving and load
Do not carry loads off-center. There is danger movements smoothly when transporting loads.
that unbalanced loads may cause the lift truck Do not drive on gradients with a suspended
to tip. load. Do not transport containers with liquids
Place the load so that it contacts the load as a suspended load.
backrest.
Do not handle unstable loads. If there is danger
that the load may fall off, secure it in position
and take steps to prevent the load from
collapsing or falling.
When carrying stacked loads, tie with rope to
prevent the load from falling.
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.
BA 101
Adjusting the auxiliary hydraulics*
1
The pressure of the auxiliary hydraulic system is
infinitely variable.
- Press button PRG (Enter). The pressure setting
can be read on the display.
Check the data on the attachment type plate

when changing the setting.
- Loosen the locking lever (2).

- Operate the clamp control lever (close the
clamp), for example.
- Set the knob (1) to the desired pressure:
Turn clockwise to increase pressure,
Turn anti-clockwise to decrease pressure
(can be read on the display).
- Tighten the locking lever again.
- Press button PRG (Enter) again.
2 6030Ba-11
CAUTION
164 456-10.03
Do not remove any limiting shims in the valve 3
block.
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*
700014
- Please check the maximum values for:
1. the load capacity (lbs/kg)

2. the lifting height (in/mm)
3. the load centre distance A (in/mm)
4. the load centre distance C (in/mm)
* Option 6049US-BA-004.eps
3 2 4 1
102 BA
Single-lever* operation of the lifting
device 5
WARNING
- Push the control lever (5) forward.
- Pull the control lever back.
To raise the fork carriage: 6030Ba-12
- Move the control lever (5) to the right.

©

164 456-10.03
- Move the control lever to the left.
NOTICE
The symbols inserted to the control levers show
the direction of fork carriage movement.
R60BA-40
* Option
BA 103
Operating the lifting device with the
joystick*
NOTICE
The lifting device can only be operated when the
seat is occupied.
WARNING
Before picking up a load, observe the
instructions beginning on page 114. Do not put
your hand or step into moving truck parts (e.g.
mast, sideshift, implements, load lifting device,
etc.).
WARNING
164 456-10.03
The truck may only be operated with the driver 1
Tilting the mast
©
- Push the mast tilt control (1) down.
- Push the mast tilt control up.
JoBa-010
Raising, lowering the fork carriage
To raise the fork carriage:
- Pull the lift/lower joystick (2) back.
- Push the lift/lower joystick forward.

2
NOTICE
The symbols on the valve cover indicate the
directions of movement.
* Option JoBa-009
104 BA
Operating attachments*
Reduce load for lift trucks with attachment
WARNING
The permissible load for any lift trucks equipped
with an attachment is lower than the
permissible load for the standard lift truck.
Reason:
an amount equivalent to the weight of the
attachment itself.
2) Because of the thickness of the attachment,
the load center moves forward.
Always observe the permissible load capacity
chart strictly (this chart is stuck to the lift truck
for the attachment). Never exceed the
permissible load.
©
164 456-10.03
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.
NOTICE
Further options and functions are possible. The
directions of movement are shown on the notice
labels on the valve cover.
* Option
BA 105
To sideshift* left
- Move the joystick (3) to the left.
To sideshift* right
F
- Move the joystick (3) to the right.
JoBa-011
To advance the forks*
164 456-10.03
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.
R2015Ba-006
* Option
106 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

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

©
3
164 456-10.03
- 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

joystick (3) to the right.
To open the roll clamp*

joystick to the left. F
* Option R2015Ba-008
BA 107
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*)
164 456-10.03
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).
JoBa-017
- Using a screwdriver (4) or similar tool, push in

the top valve (3) at the rubber cap. 3 4
CAUTION
The load will lower at a speed that can be
controlled with the change in pressure.
- Depressing much
❍ lowers the load fast.
- Depressing little
❍ lowers the load slowly.
- Close the valve cover (2) again.
* Option JoBa-018
108 BA
Overriding the lifting height
limitation*
1 2
NOTICE
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.
©
JoBa-020
164 456-10.03
WARNING
If the forks are lifted below the 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.
Hydraulic coupling
Before mounting attachments, the pressure in the

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

stick* 12 3
- Switch on the key switch. F
- Depress buttons (1, 2, 3, 4) at the same time.

4
Relieving pressure with control

lever*
- Turn off the key switch.
- Operate the attachment control lever several

times.
* Option 60BA-009
BA 109
Before picking up the load
Load capacity Linde Lift Truck Corp.
700014
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. Refer to
the load capacity plate to the right of the drivers
seat. Do not mount additional weights to increase
the load capacity.
No overloading
WARNING
Do not load the lift truck over the capacity set
forth in the load capacity chart.
If the rear wheels come off the ground because
of overloading, the lift truck cannot travel or 1 2 4 3
turn. There is also danger that it may tip. Always R6049US-BA-005
check the load capacity chart to confirm the
loading capacity.
164 456-10.03
Unapproved or incorrect operation of the truck
or let persons ride on the truck to increase the
load capacity is prohibited. 3
2
Example:
©
Capacity
(Load to be lifted): 6724 lbs (3050 kg) (3) Ca B
pa
A Distance of load center ci
from heel of forks: 23.6 in (600 mm) (1) ty
B Admissible
lifting height: 237.4 in (6030 mm) (2)
C Distance of load center
from fork: 23.6 in (600 mm) (4)
WARNING C
The illustrations are only examples. Only the

data on the load capacity labels on the truck
are applicable!
4
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.
When small parts are transported, a protective
guard* must be attached to prevent goods from
falling onto the driver.
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. A
Observe the load capacity plate for
attachments. The data on the plate are explained
1
in the above example.
6046US-BA-079
* Option
110 BA
Picking up unit loads
To ensure that the load is carried safely, the driver

must make sure that the forks are spread wide
enough apart and also inserted as far as possible
under the load. The load should not protrude
substantially over the tips of the forks.
Do not load above height of load backrest
WARNING
Keep the height of the load within the height of
the load backrest.
Do not carry any load that is higher than the
load backrest. If the load is higher than the load
backrest, there is danger that it will fall back
on top of the operator. This may lead to serious
injury or death.
©
Adjusting the forks

164 456-10.03
Fit forks securely in position
WARNING
When adjusting the position (width) of the
forks, be careful not to get your hands caught.
After adjusting, check that the forks are held
securely in position by the fork stopper. If the
forks are not held in position, there is a danger
that the forks may move when the lift truck is
traveling and the load may fall off.
AB801400
- Move the lift truck in front of the load, and stop.
- Position the mast vertically and lift the forks 4

in. (10 cm) above the ground.
- Tilt the mast forward.

FREE
- Move up the fork stopper knob (1) to the free
LOCK
position. (The forks are movable to left and right
at this position.)
1
- Adjust the fork spread corresponding to the
load size so that the load center of gravity
coincides with the center of the lift truck.
- Set the mast vertically, lower the knob and

insert the fork stopper to lock the forks. (The
forks are fixed.)
- Do not operate the fork spreader* with a load

on the forks.
* Option R6046-49_Ba-072.eps
BA 111
Picking up the load
Danger zone Be careful not to get caught or fall
Do not lift people on forks

WARNING
WARNING Never put your hands or feet or head into the
mast structure. There is danger that you will
Do not use the forks to lift people. It the person get caught in moving parts and be seriously
falls from the forks he/she may be seriously injured.
injured.
Do not use the mast as a ladder. If you slip,
there is danger that you will fall.
The danger zone is the area in No person, except the driver in his normal
which persons are endangered operating position, may stand in the danger zone
through the movement of the of the truck. If persons refuse to leave the
truck, working devices, load- danger zone despite warnings, stop working
lifting devices (e.g. attachment) with the truck immediately and secure it against
or the load. This also includes use by unauthorized persons.
the area within the range of
falling loads or a descending
working device.
164 456-10.03
DANGER
Precautions when loading/unloading
WARNING
Do not let anyone place a load on the forks.
©
Do not let anyone remove a load directly from
Use only for intended purposes
the forks.
Standing on the forks is dangerous because the
forks are slippery and the load may move. WARNING
Do not use anyone to keep the load stable. The Do not use the lift truck for anything other than
lift truck may move unexpectedly, causing the the intended use (loading operations using the
load to fall and crush the person. forks).
Do not use the forks to open or close the doors
of railroad cars or warehouses. Do not push any
Dont go under forks other vehicle.
Do not hook ropes or cables on the forks and
use the forks to lift loads. Use the drawbar pin
WARNING only for approved towing operations.
Never allow anyone to go
under the load-engaging
means or load when it is
raised. The area under the
forks is a danger area. If the
forks come down, the person
under the forks may be
crushed, or seriously injured
or killed.
Never allow anyone to go
under the load-engaging
means or load even if it is
elevated or stuck. It may fall
down suddenly at any
moment.
* Option
112 BA
Transporting pallets
Use strong pallets and skids
WARNING
Always be sure that the pallets and skids have
ample strength.
If broken or damaged pallets or skids are used,
there is a risk that the load may fall.
Under normal circumstances, unit loads (e.g.

pallets) should be transported individually. Simul-
taneous transport of more than one unit load is
only permitted
- on instruction of the supervisor and
- if the technical requirements are met.
The driver must satisfy himself that the load is in

©
proper condition. Only properly and securely

positioned loads may be moved.
164 456-10.03
Handling long or wide loads
WARNING
Be extremely careful when carrying long or
wide loads.
Raise the load slowly and be careful not to touch
anything in the surrounding area.
Keep the load as low as possible and be sure to
maintain the balance.
When turning, operate slowly and be careful
not to let the load move.
No pushing
WARNING
Do not use the forks to push or pull loads. There
is a risk that the load will be damaged or fall.
BA 113
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.
- Approach the racking carefully, brake gently and R60BA-44

stop just before the racking.
164 456-10.03
- Position the forks.
- Set the mast to the vertical position.
Do not tilt mast forward when loaded
WARNING
©
Do not tilt the mast forward when the forks are
loaded and raised. There is danger that the load
may fall and that the lift truck may tip. Do not
travel with the mast tilted forward. Do not load
and unload on slopes.
DANGER
When tilting the mast forwards, take care that
R60BA-45
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.
- 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
114 BA
- 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

©
164 456-10.03
- 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
BA 115
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 drivers 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.
164 456-10.03
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
116 BA
WARNING
Never drive the truck with the load reached out
laterally (e.g. sideshift or sideloading forks).
Travel on slopes
WARNING
Do not turn, or travel across or at an angle on
slopes. There is danger that the lift truck will
tip.
that the bottom of the forks or pallet do not R60BA-53
©

164 456-10.03
When loaded:
When unloaded:
downgrade.
DANGER R60BA-54
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 angle. Danger of loss
of life!
Drive at reduced speed on slopes.
BA 117
Stopping distance
WARNING
When traveling downhill, it requires a longer
distance for the lift truck to stop then when
traveling on level ground.
When traveling downhill, reduce the speed and
make sure that you have ample room at the
bottom of the slope to stop.
When traveling on wet surfaces, it requires a
longer distance to stop then when traveling on
normal road surfaces. Always have ample room
to stop.
Entering lifts
164 456-10.03
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 maximum weight of the truck (dead weight
with maximum load) is:
R60-35 ............................ approx. 20217 lbs

(9171 kg)
R60-40 ............................ approx. 21997 lbs
(9977 kg)
R60-45 ............................ approx. 23728 lbs
(10763 kg)
R60-50 ............................ approx. 25340 lbs
(11494 kg) R60BA-76
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.
118 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 weight of the lift truck.
The truck driver and fork truck operator must
communicate on the departure time of the truck.
Loading highway trucks or railroad cars
WARNING
Do not travel on the edge of docks. There is
danger that the lift truck may fall, which may
result in serious injury or death. R60BA-77
Before starting operations, check the load limit
for the gangplanks (dock boards), and do not
©
use them if they do not have ample strength to

take the weight of the lift truck when loaded.
164 456-10.03
Apply the brakes on the highway truck and block

the wheels.
With trailers, use jacks and take steps to
prevent the trailer from sinking when the
forklift truck travels on it.
When driving the forklift inside trucks, reduce
speed when backing out and be sure to check
that the gangplanks are safe.
Be careful of pedestrians.
Tell the truck driver not to move the truck until
the operation is completed.
If there is some system to secure the truck to
the dock, always use this system. Secure the
gangplanks so that they do not slip and fall.
R60BA-55
Depositing the load
Stacking and removing load units
Always use the following procedure:
- Slowly approach the stack with the load - Raise the load to stacking height.
lowered as specified.
- Carefully drive the truck into the racking.
- Set the mast vertical.
- Deposit the load on the racking
WARNING - Look to the rear.
If your truck has a larger angle of tilt* (over
- Reverse the truck until the forks can be lowered
3°), a large risk of sliding during lifting or
without touching the racking.
lowering of the load can be assumed.
- Lower the forks until ground clearance is
reached, tilt the mast back and drive off.
* Option
BA 119
Other activities
OTHER ACTIVITIES
©
164 456-10.03
WARNING

BA 121
Other activities
Other activities
Changing the battery

1
Maintenance staff
WARNING
Batteries may only be changed by specially 2
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
Do not put metal objects on top of battery

R6050-55-Ba-027
WARNING
164 456-10.03
Never place any metal objects on top of the
battery. There is danger that they will cause a
short circuit and start a fire.
WARNING
©
Smoking and naked flames are not permitted
when handling batteries. No inflammable or
spark-producing materials may be located
within at least 7 ft (2 metres) of the truck to be
charged and the charger. The room must be well
ventilated. Fire extinguishers must be kept
ready.
Safe parking 3
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 4 R6046-BA-030
battery plug connected.
- Park the truck, engage the parking brake.

- Tilt the steering column forward and lock it.
- Open the doors (cabin*).
- Open the rear windscreen (cabin*).
- Pull out the lock bolt (2) and push the control
lever forward. ACHTUNG - ATTENTION !
- Open the battery cover lock (4). Zum Öffnen der Haube Armlehne in
unterste Stellung bringen und den
- Joystick* Fahrersitz ganz nach hinten schieben
Slide the seat so that the support for the
To open the batteryhood the armrest
lighting fixture* and the joystick are not has to be placed in the lowest position
damaged. and the driverseat must be moved
completely back
CAUTION
Do not damage any parts!
* Option R2015i BA-027.eps
122 BA
Other activities
- Unlock the battery hook (3).
- Open the battery cover all the way to the rear 5
at the grip (1).
WARNING
Be sure to open the battery cover completely.

If the cover is not fully back it may fall down
and injure you!
- Disconnect the battery plug (5).
- Open the battery cut-out cover* (overhead

guard).
R6046-BA-031
Battery replacement
©
To avoid short circuits, cover batteries with

164 456-10.03
unprotected terminals or connectors with a rubber 6

mat.
Attach the battery (6) to a suitable lifting device

(eg LINDE lifting gear). Observe the operating
instructions supplied with your lifting gear.
- 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.
WARNING R6042-BA-055

* Option
BA 123
Other activities
Battery weight and dimensions
The weight and size of the battery influence the

stability of the truck. When changing the battery,
the weight conditions must not be changed. Ad-
ditional 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 bat- 1

tery are included in the work-
shop maintenance instructions
in section "Battery mainte-
nance.
- Installation and connection of the charged

battery is the reverse of removal. R2015i BA-032.eps
164 456-10.03
WARNING
Close the battery cut-out cover* (overhead
guard) after use.
Damage to cables
2
©
CAUTION
When removing and replacing the battery, care
must be taken that the battery cables are not
damaged. 3
When closing the battery cover, be sure that
there is nothing between the cover and chassis
edge. Danger of squeezing the part.
- Reconnect the battery plug. 6046US-BA-080.eps
- Lock battery in place by folding down lock hook

(2).
- Close the battery cover.
- Lock battery cover latch (3).
WARNING
If defective, repair before operating it.
- Fold valve cover back and lock bolt (4).

4
WARNING
If defective, repair before operating it.
124 BA
Other activities
Turning on the lights*
1 2
- Depress light switch (1) to turn on the parking
lights. P R OG 1 12: 23
- Depress light switch (2) to turn on the BA T T :
headlights.
R20BA-63
Turning on the hazard warning light*

©
3 4 5
164 456-10.03
- Depress the hazard warning flasher switch (3).

The indicator light besides the switch will flash
alternately with the directional indicator
light (4).
Turning on the directional indicators*
- Turning on the left or right directional indicator

as required with the directional indicator switch
(5). The directional indicator repeater lights (4)
on the instrument panel will illuminate.
- To activate the left directional indicator:

Push the switch forward.
- To activate the right directional indicator:

Pull the switch back. 6046US-BA-050
BA 125
Other activities
Turning on the front spotlight*
6 7
- Turn on the spotlight by actuating the spotlight
switch (6).
12: 23
Turning on the rear spotlight*

8
- Turn on the spotlight by actuating the spotlight
switch (11).
Turning on the windscreen washer/

wipers*
- Actuate the windscreen wiper switch (8) for the

front and switch (9) for the rear windscreen
wiper separately. 9
- Press once with long duration to turn on the
11 10 R20BA-65
windscreen washer.
164 456-10.03
- Press once briefly to turn on the intermittent 1
wiper.
- Press twice for continuous wiper operation.
- Press three times to turn off.
©
Turning on the seat heater*
- Press switch (7) for seat heater*:

Seat heater is on.
- Press switch again:

seat heater is off.
Turning on the revolving light*

2 6046US-BA-052
- Turn on the revolving light with switch (10).
Operating the horn 3

- Push down the horn button* (1).
- Depress the foot switch (2).
- Press the horn button* (3) to sound the horn.
* Option R2015Ba-012
126 BA
Other activities
Electric heater*
(Trucks with electric heater) 1
Authorized application
The heater is to be used for heating and ventilating

battery-powered fork trucks provided with a cabin.
Description
The heater draws in air through a suction filter

(2) or from inside the cabin through a nozzle (4).
The air drawn in is heated electrically and blown
through distribution nozzles and outlets (1, 5) into
the cabin interior by a fan.
Heed the following notice on the maintenance
label (3):
2
NOTICE
The intake filter should be cleaned at least every
half year, in dusty operating conditions more often.
©
5 4 3
164 456-10.03
R6050-55-BA-023
DANGER
Do not cover the heater while in operation. Fire
hazard! Do not touch housing while in operation.
Risk of burning!
1 2 3
The following operating controls are provided:

1 Temperature control knob
2 Fan switch
3 Heater switch
4 Scale
Operation
Ventilation
NOTICE
The fan can also be operated without the heater.
4
- Depress the fan switch (2). The fan will run at R6050-55-BA-024
the speed selected with the fan stage switch.
- Set the heater switch (3) to position 0.
Selecting the fan stage Switching the fan off
To select the low stage: - Set the fan switch (2) to position 0.
- Set the fan switch (2) to position I. The fan will
run at low speed.
To select the high stage:

- Set the fan switch (2) to position II. The fan
will run at high speed.
* Option
BA 127
Other activities
Turning the heater on
- Depress the heater switch (3). The electric

1 2 3
heater is in operation.
Selecting the heating stage
To set the heating on low:

- Set the heating stage switch (3) to stage I.
To set the heating on high:

- Set the heating stage switch (3) to stage II.
Regulating the cabin temperature
- Turn the temperature control knob (1) to the

desired value on the scale (4).
With stage 1 the cabin temperature is held con-
stant at the lowest level, whilst the highest
temperature can be achieved at the full-right 4
position. R6050-55-BA-024
164 456-10.03
Switching the heater off
- Set the heater switch (3) to position 0.
Maintenance
©
NOTICE
The intake filter should be cleaned at least every
6 months, more often in dusty working conditions.
Follow the maintenance notice (5) on the heater.
Cleaning the intake filter
- Remove the intake filter (4) and clean by

tapping or washing.
4
CAUTION
Dry a wet intake filter before installation e.g.
with compressed air.
- Refit the filter.

5
R6050-55-BA-025
128 BA
Other activities
Heater*
(Trucks with diesel fuel heater) 1
Authorized application
2
The air heater is intended for heating and
ventilating the operators station when the truck
is used outside (outdoor use).
3
Description
The heater is installed in a housing at the front right-

hand side of the cabin. It is operated with diesel
fuel stored in a reservoir. The fuel reservoir is
integrated in the front end of the truck. The heater
draws in air through a suction filter (3) or from inside 6
the cabin through a nozzle (5). The heated air is
conducted into the cabin through distribution
4
nozzles and outlets (1, 6). 5 R6050-55-BA-016
A heater control (2) is provided for controlling the
heater functions. Important information that must be
©
heeded is provided on the manufacturers plate (4).

164 456-10.03
NOTICE
The intake filter should be cleaned every 6 months
and more often in a dusty environment.
The heating system in the cabin roof and the hot

water hoses and their connections must be
inspected regularly and at least once a year.
Heater control
5 1 2
The control has the following functions:
1 Temperature button
2 Setting mark
3 Ventilation button
4 Off button (with red or blue LED ON indicator)
5 Heating button
* Option 3 6050-55-Ba-015
BA 129
Other activities
Legal requirements 6046US-BA-095.eps
- The heater must be installed according to the

instructions of the manufacturer.
1
NOTICE
If the heater is retrofitted (not in the factory), the
owner must apply for a new operating permit (e.g.
from inspection agency).
- The official test certificate (1) must be given on

the manufacturers plate.
- The year of commissioning (2) must be
permanently entered on the manufacturers
plate.
- The heat exchanger must be replaced by a 03 04 05
genuine replacement after 10 years. The 2
installation must be permanently noted on the
heater on a label with the words Genuine
replacement and the date of sale of the heat
164 456-10.03
exchanger.
- Repairs may only be performed by an
authorized workshop using genuine
replacement parts.
Unauthorized use
©
The heater may not be operated in enclosed
spaces (e.g. garages, storehouses, etc.).
DANGER
Risk of carbon monoxide poisoning by exhaust
gases!
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!
130 BA
Other activities
Before starting operation
Filling fuel
1
DANGER
Turn the heater off. Do not smoke or eat.
2
- The fuel reservoir (3) is integrated in the front

end of the truck.
WARNING
When adding fuel, never let the fuel overflow. 3
This may cause a fire. If you spill fuel, clean up
any spillage.
R6046US-BA-073
- Open the cap (1) on the fuel reservoir. Fill clean

©
diesel fuel to the upper edge (2) of the filler neck.

164 456-10.03
Capacity ................ approx. .55 U.S. gal (2 L)
NOTICE
Regular diesel fuel can be used above 32 °F
(0 °C), below 0 °C use winter diesel fuel. If no
winter fuel is available, additives can be used ac-
cording to the table below:
Temperature Winter Diesel Additive*

32°F down to -13°F 100 % -
(0°C down to -25°C)
-13°F down to -40°F 50 % 50 %
(-25°C down to -40°C)
* Kerosene, petrol or special diesel fuel for low

temperatures.
- Allow the heater to run about 15 minutes after

changing to cold-resisting fuel so that all pipes
can be filled.
- Refit the cap.
* Option
BA 131
Other activities
Operation
Ventilation
NOTICE
The heater can also be used for ventilation with-
out heating. The air is drawn in from inside the
cabin through nozzle (8).
5
- Depress the ventilation button (4).
NOTICE
The rotating knob has no function in the
ventilation mode.
4 6050-55-Ba-017
- The blue LED in the button (5) is illuminated,
164 456-10.03
the fan is turned on.
6
- The air flow can be regulated with the outlets
(6 and 7).
Turning the ventilation off
©
- Press the OFF button (5) to turn off the fan.
The blue LED in the button goes off.
7
8 R6050-55-BA-018
132 BA
Other activities
Heating 3 1
Turning the heater on
DANGER
Operate the heater only in the open air. Risk of
carbon monoxide poisoning by exhaust gases!
2
- Press the heating button (3) to start the heater.
- Preselect the desired temperature with rotating
knob (1):
Left stop approx. 46.4 °F (8 °C)
low temperature
Right stop approx. 93.2 °F (34 °C)
high temperature
6050-55-Ba-019
NOTICE
©
When the heater is in the heating mode, the red

LED in the button (2) is illuminated. 4
164 456-10.03
- The heated air stream can be controlled with

the outlets (4 and 5).
NOTICE
The heater can be turned off if any malfunctions
occur during the start-up or during operation.
Refer to the section Malfunctions, cause,
remedy.
If the heater fails to start, do not attempt to start
it more than two times. Contact your after-sales
service. 5
R6050-55-BA-020
Turning the heater off
- Depress the OFF button (2). The heater is

turned off, the red LED in the button will
extinguish.
The heater will continue to run for a little while.
During this time the battery must not be
disconnected from the heater.
Malfunction, cause, remedy
If the heater fails to start or goes out during - Battery voltage too low or too high:
operation, the following causes may be Charge the battery as required.
responsible: Fault in the electrical system (voltage converter
defective).
- No fuel:
Refill the fuel reservoir. - Faulty fan, glow plug, burner motor, fuel pump
or controller:
- Heater overheated: Have heater repaired by your authorized
Remedy cause of overheating (e.g. restriction workshop.
of heating ducts, outlets).
BA 133
Ending operation
ENDING OPERATION
©
164 456-10.03
WARNING

BA 135
Ending operation
Ending operation 1
Leaving the truck unattended
Parking
WARNING
Park the lift truck in the specified place.
Park the lift truck on a firm surface.
2
Do not park near any emergency exit, stairway,
fire extinguisher or other safety equipment.
Park the lift truck in a place where it will not
obstruct pedestrians or other vehicles.
Never park the lift truck near any flammable
object.
When parking the lift truck on a slope, park as 6046US-BA-070
specified above then put blocks under the tires

to prevent the lift truck from moving.
164 456-10.03
- Apply the parking brake (2).
Tilt the mast so that the fork tips rest on the

ground.
©
WARNING
Do not leave the truck with the load elevated.
- Turn the switch key (1) to the left and remove

it.
NOTICE
After turning off the switch lock, the display 6046US-BA-020
remains on for about 10 seconds.
3 4
When the switch lock is turned off, the display (4)
of the driving program and battery charge can be
turned on by pressing the warning hazard
switch (3).
Do not give the switch key, FleetManager card*

or other equipment to other persons without
express instruction.
NOTICE
Avoid parking the truck at temperature under
32 °F (0 °C) as the hydraulic fluid becomes very
viscous and the hydraulic functions sluggish as a
result.
6046US-BA-053
136 BA
Ending operation
- Depress the emergency stop button (5). 6046US-BA-082
- Depress the emergency stop button* (6).
WARNING
5
5
If there is any oil, grease or mud on the
damage. 6
©
164 456-10.03
* Option
BA 137
Ending operation
CAUTION
If the battery connector is not disconnected, the
functions described below may be active.
Messages in case of improper truck

shutoff*
NOTICE
This feature ensures that an improperly shut-off
truck displays messages (and, optionally, acoustic
alarms). These functions are triggered in the
following shutoff situations:
Parking the truck with parking brake

not or insufficiently applied
164 456-10.03
Parking brake not applied*
DANGER
A truck parked 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 you park the truck without engaging the
parking brake and leave the seat:
The message APPLY HANDBRAKE ! appears in
the display; if a buzzer is fitted, it will sound.
- Engage the parking brake. The message APPLY
HANDBRAKE! will disappear. A P P LY H A N D B R A K E !
Truck rolling slowly despite parking brake 6046US-BA-089.eps
applied*
DANGER 6046US-BA-090.eps
A P P LY H A N D B R A K E !
A truck parked 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.

connector.
- If the truck is parked without the parking brake
being engaged firmly enough, the truck rolls slowly.
The message APPLY HANDBRAKE ! appears in
the display; if a buzzer is fitted, it will sound.
- Engage the parking brake so firmly that the
truck no longer rolls. The message APPLY
BRAKE ! disappears.
* Option
138 BA
Ending operation
Truck shutoff with a lifted load*
LOWER FORKS !
DANGER
Shutting the truck off with a raised load is
Do not misuse the enhanced safety provided by
this feature to put your safety at risk!
Forks are not lowered*
- The forks are positioned over the height sensor.

connector.
- Turn off the key switch and leave the seat. 6046US-BA-091.eps
The message LOWER FORKS ! appears in the

display or a buzzer (if fitted) sounds.
©
- Lower the forks on to the ground with the lift LOWER FORKS !
164 456-10.03
control lever. The message in the display will

be cleared.
Referential lift
NOTICE
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 REFERENCE CYCLE ! is shown
in the display or none at all. 6046US-BA-092.eps
The truck only drives at reduced speed.

Carry out a test lifting (referential cycle) with
the lifting device:
REFERENCE CYCLE !
- Raise the forks until the message disappears
or, if not visible previously, appears and disap-
pears again.
- Lower the forks again.

The truck can be driven without any speed limi-
tation.
BA 139
Ending operation
Exceeding the post-shutoff time* 6046US-BA-094.eps
S E AT S W I T C H !
NOTICE
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 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.
164 456-10.03
restrictions.
Parking machine after failure
©
WARNING
If the lift truck has suffered a failure and the
lift truck must be parked without lowering the
forks, put markers on the tips of the forks and
take steps to prevent pedestrians or other
Danger
vehicles from hitting the forks.

use
Never
Select a parking place where people or vehicles

do not pass, and stop the lift truck so that it is
difficult for anyone to go under the forks. (The
area under the forks is a DANGER zone).
Place a stand or something similar under the
inner mast rail or forks to prevent unexpected
drop of the forks.
Remove the key from the faulty lift truck and
hang signs in the operators compartment to
prevent its use. 6046US-BA-039
* Option
140 BA
Trailers, Towing
TRAILERS, TOWING
©
164 456-10.03
WARNING

BA 141
Trailers, Towing
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.
6046US-BA-021
For occasional towing, the maximum trailer load
164 456-10.03
is the capacity indicated on the fork load capacity
plate (to the right of the seat). Do not exceed the
maximum load.
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 up hill or downhill, reduce the
maximum load capacity.
Please advise the manufacturer of your
operating conditions. He will then supply the
appropriate information.
Maximum towing speed ................................
approx. 3 mph (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.
142 BA
Trailers, Towing
Coupling a trailer
(automatic coupling)*
- Apply the handbrake. 1

- Lift the lever (1) on the coupling device.
- Release the handbrake and position the trailer
towing hitch into the open coupling. The
coupling closes on contact and the lever (1) will
snap down.
- Apply the handbrake and check that the trailer
is coupled securely.
- Remove any chocks and if fitted release the
trailer braking.
Connecting trailers
- Secure parked trailers against inadvertent

movement (1). Do not release the parking brake R6042-BA-044
until the trailer has been connected.
- Push the drawbar pin (2) down, turn through
©
Allg-001
90° and pull it out.
164 456-10.03
- Insert the drawbar bar into the appropriate

eye.
DANGER
Always use the original drawbar pin.
- Insert the drawbar pin, press down against

spring pressure and turn through 90° (tow pin
is locked in this position).
CAUTION
Be sure that the drawbar pin is properly
engaged.
1
Towing trailers 2
- 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.
* Option R6042-BA-045
BA 143
Transport, hoisting, towing
TRANSPORT, HOISTING,
TOWING
©
164 456-10.03
WARNING

BA 145
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 when turning the steering wheel

while driving forward the rear end can move
out from the loading bridge towards the edge.
This can cause the truck to fall off.
R6046-49_Ba-062
DANGER
164 456-10.03
- Always disconnect the battery plug before
transporting the truck.
- Apply the parking brake and remove the
key.
©
Chocking the truck
- Secure the front and rear wheels against rolling

by means of two chocks each and against late-
ral sliding with blocks of wood on the side.
CAUTION
Fasten wooden blocks (eg with nails).
R60BA-68
Lashing down the truck
- Attach the lashing ropes at the front to the mast

and rear to the tow coupling.
6046US-BA-024
146 BA
Towing procedure
Towing
WARNING
If there is any problem with the brakes or
steering system of your lift truck, only use
another vehicle with sufficient brake power to
tow it.
There is danger that the lift truck may run away.
If the brake of the towed truck is inoperative, the

truck may only be towed with a rigid connection
(tow bar).
- Deposit the load and lower the forks near to

the ground.
CAUTION
©
If procedures stated below are not followed,

1
164 456-10.03
the drive may be damaged.
- Move directional switch to neutral position.
- Disconnect battery plug (1).
R6042-BA-003
CAUTION
The truck may only be towed at walking pace.
Steering is difficult! No power-assisted steering
if the hydraulics have failed!
- After towing, secure the lift truck against rolling

(with chocks, for example).
- Apply the parking brake.
6036Ba-026
6046US-BA-025
BA 147
Hoisting the truck
A hoisting of the truck for transport is only allowed Linde Lift Truck Corp.
700014
before commissioning of the complete truck
including the mast. If the conditions of use require
frequent loading of the truck or are not shown
here, contact the manufacturer about special op-
tional equipment.
Only persons having sufficient experience with
suitable means of attachment and lifting gear may
hoist the fork truck.
Determining the hoisting weight
- Park the truck safely.

- Determine the hoisting weight of the truck: 1
- by reading on the manufacturers plate:
Truck weight (1) R6049US-BA-006
If an attachment is fitted, read the weight in the
164 456-10.03
respective line. Doku-Bild4.eps
= Hoisting weight
Attaching the hoist
DANGER
©
2
Unload truck before lifting!
CAUTION
Only use a lifting gear and means of attachment
with sufficient lifting capacity for the
determined hoisting weight. Use textile 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 cabin. If attaching parts are in the
way (eg lighting, etc.), they should be
dismantled before hoisting.
- Put the crane slings around the top cross

DANGER
member (2) of the outer upright.
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
NOTICE specified direction of stress. Do not allow the
means of attachment to be damaged by parts
The attachment points are identified with a hook of the truck.
symbol.
* if fitted later
148 BA
- Attach the crane sling around the drawbar pin
(2) in the tow coupling. Secure the drawbar pin.
6046US-BA-083
- 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 5 4
164 456-10.03
operating instructions.
- Adjust the length of the means of attachment

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.
- Hook the slings into the crane hook and close

the safety (5).
Hoisting the truck
- Carefully raise the truck and the deposit it at

the intended place.
6046US-BA-026
DANGER
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.
BA 149
The truck can have different points of attachment*:
- welded lifting eyes on the mast (1).
R6046 BA-018.eps
- eyebolts (2) in the counterweight
164 456-10.03
2
©
6046US-BA-066
- lifting eyes (3) bolted on to the counterweight.
- Only attach hooks of size 1 (UNI 9469/1 DIN

15401) to the lifting eyes or eyebolts.
150 BA
Display, Setting, Operation
DISPLAY, SETTING,
OPERATION
©
164 456-10.03
WARNING

BA 151
1 2 3
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). P R OG 1 12: 23
The driving program can be changed, refer to the BA T T :
section on "Driving.
(3) Time and day in hours and minutes. The time

can be set, refer to the following sections.
(4) Battery charge. The dark fields show the useful

battery capacity. Each field corresponds to 10%.
- If only two black fields are visible, the display

starts flashing. Only 20% battery capacity are
at your disposal. The battery should be
charged soon. 4 R20BA-79
- If no black field is visible, deep discharging
164 456-10.03
begins. The display keeps on flashing. Stop work
with the truck immediately and recharge the
battery.
NOTICE
If a pressure regulator* is installed, the hydraulic
©
pressure is indicated here. In this case, the bat-
tery charge is shown in %.
To prevent a deep discharge, certain limitations*

(eg slow lifting) can be activated. Please contact
your LINDE Service.
Additional information
Pressing button PRG (enter) (7) displays the

following additional information:
(5) SERVICE IN display shows the remaining time

in hours 5 6 7
(6) until the next servicing according to the
maintenance chart in the workshop maintenance
instructions. The services should be performed
every 1000 hours or as necessary. Please contact
your LINDE Service or your workshop. S E RV I C E I N 346 h
01 654 , 0 h 12 3psi
(8) Pressure in auxiliary hydraulics* in psi (bar).
(9) Hour meter. The hour meter displays the

elapsed service hours of the truck. It runs as soon
as the switch key is in the "on position.
* Option 9 8 6046US-BA-084.eps
152 BA
FleetManager*
The Smart Card (1) can be used for FleetManager

1
functions. FleetManager
Please contact your LINDE Service.
Accident recorder*
The accident recorder is a supplement to the

FleetManager. An acceleration sensor is installed
in the truck. The acceleration sensor can register
data, which result with an accident, for later
evaluation.
6033Ba-004
©
164 456-10.03
* Option
BA 153
Additional information (options)
1 2
The following information can be shown on the
display. A maximum of eight displays are possible.
(1) Date as day, month, year.
(2) Truck speed in miles/hour.

2 1 . 0 8 . 0 3 1 3 , 5 mph
(3) Trip mileage in miles.
2 4 5 6 miles 4 5, 6 miles/day
(4) Daily mileage in miles per day.
3 4 6046US-BA-085.eps
(5) Daily driving time in hours.
164 456-10.03
5
6 , 4 H / Day
©
6046US-BA-086.eps
Setting and adjusting the displays R20BA-83

6
Adjusting the date and time
For this adjustment proceed as follows:
- Press buttons PRG 0 (6) and PRG (enter) (7) at

the same time. 1 2: 23
- Select the field in which, for example, the time

is located with buttons (10) to (13). The
displayed time flashes.
- Press buttons (9) or (8) to change the time.
- When the time is set correctly, press PRG (enter)

(7) to store the setting. 7
- Press buttons (7) and (6) simultaneously to
restore the normal display.
13 12 11 10 9 8
154 BA
Resetting daily mileage and daily
driving time
6046US-BA-088.eps
1
The displayed daily mileage and daily driving time
can reset to zero.

the same time.
4 5 ,6 miles/day
- Press button (4) three times.
- Select the field in which, for example, the daily

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

value is zero. 2
- Press PRG (enter) (2) to store the setting.
- Press buttons (1) and (2) simultaneously to 8 7 6 5 4 3

©
Selecting the language

164 456-10.03
The malfunctions can also be displayed in other

languages.

the same time.
- Select the field in which LANGUAGE is displayed

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

or other language is displayed.
- Press button PRG (enter) (2) to store the

selection. All information will now be displayed
in the selected language.
- Press buttons (1) and (2) simultaneously to

Other settings
By entering a password, it is possible to enter

other values. Please contact your LINDE Service.
BA 155
Malfunctions, cause, remedy
MALFUNCTIONS, CAUSE,
REMEDY
©
164 456-10.03
WARNING

BA 157
1 2
Indicated malfunction
The following malfunctions can be indicated on

the display (1):
"Error, a number and a text describing the OVERHEATING
malfunction.
ERROR X XX
- After eliminating the failure, press button PRG
O (2) to clear the display.
Servicing required
Service interval exceeded. Have the required

maintenance carried out.
Let then the service adjust the interval up to
the next maintenance due.
OVERHEATING ERROR 197 6046US-BA-087.eps

(display flashes)
164 456-10.03
- Traction motor(s) overheated, traction power
reduced.
- If necessary, clean the vent filter.
OVERHEATING ERROR 198

(display flashes)
- Pump motor overheated, lifting power reduced.
©
- Stop work and allow motor to cool. Do not turn
the switch lock off.
- If necessary, clean the vent filter.
- SCR control overheated, traction and lifting

power reduced.
- Stop work and allow to cool. Do not turn the
switch lock off.
SEAT SWITCH ERROR 13
- The seat switch has not been operated for 6

hours. Truck speed and lifting capacity are now
reduced.
- Stand up for a moment and sit down again.
MOTOR BRUSHES ERROR 195

(Warning)
- Renew/check the traction motor brushes as

described in the maintenance instructions. You
can continue driving for about 10 hours.

(flashes, emergency mode)
- Traction power reduced, driving up slopes is

limited.
- Renew the traction motor brushes as described
in the maintenance instructions.
158 BA
(Warning)
- Renew/check the pump motor brushes as

described in the maintenance instructions. You
can continue working for about 8 hours.

(flashes, emergency mode)
- Lifting power reduced.

- Renew the pump motor brushes as described
in the maintenance instructions.
SERVICE BRAKE ERROR 71
- The truck speed is reduced to approx. 5 km/h.

- Brake fluid fault
- Check the brake fluid level as described in the
maintenance instructions
©
BRAKE SENSOR ERROR 69 or 70

164 456-10.03
- Technical malfunction of the electric braking

system. You can continue driving cautiously.
- Inform the service.
Other malfunctions can be indicated. Please inform

your LINDE Service.
BA 159
Index
INDEX
©
164 456-10.03
BA 161
Index
Index
Page Page
A
Abrupt lowering of stuck fork ....................... 29 Check before starting ............................ 19, 58
Accelerating .......................................... 81, 89 Check when traveling
Accident recorder ...................................... 153 in reverse .......................... 12, 82, 86, 90
Additional information ................................ 152 Checking and inflating tires .................... 31, 71
Additional information (options) ................. 154 Checking for condition of roadways .............. 77
Adjust chain ............................................... 26 Checking the braking system
Adjusting the armrest .................................. 63 for proper operation ............................. 70
Adjusting the auxiliary hydraulics ............... 102 Checking the emergency stop function .......... 72
Adjusting the backrest ................................ 62 Checking the parking brake ......................... 70
Adjusting the backrest ................................ 61 Checking the service brake .......................... 70
Adjusting the date and time ....................... 154 Checking the steering system
Adjusting the driver's seat ..................... 61, 63 for proper operation ............................. 67
Adjusting the drivers weight ....................... 63 Checking the wheels for condition
Adjusting the forks .................................... 111 and tire inflatition pressure .................... 71
Adjusting the seat ...................................... 61 Checks before driving .................................. 73
Chocking the truck .................................... 146
Adjusting the seat cushioning ...................... 62
Clean operators compartment ............... 13, 74
Adjusting the seat cushioning
Cleaning the intake filter ........................... 128
164 456-10.03
to driver's weight .................................. 61
Clothing and personal protective items ......... 11
Adjusting the seat inclination ....................... 61
Confirming safety ........................................ 21
Adjusting the steering column ...................... 67
Connecting the battery plug ........................ 58
Allowable load ............................................ 34 Connecting trailers .................................... 143
Always sit in operators seat ........................ 19 Copyright and property rights ........................ 8
Always sit on operators seat ....................... 61 Correct behaviour in case of tip-overs .......... 79
Application 1 ............................................... 94 Coupling a trailer (automatic coupling) ........ 143
Application 2 ............................................... 94
©
Applying seat belt on a steep slope .............. 65
Applying the seat belt ................................. 64
D
Approved applications ................................... 2 Daily pre-operational checks and services ..... 58
Approved towing applications .................... 142 Damage, deficiencies ..................................... 8
Approved types of tires ............................... 47 Damage to cables ..................................... 124
Attaching the hoist .................................... 148 Danger zone ...................................... 74, 112
Authorized application ....................... 127, 129 Date of issue and version of manual ............... I
Definition of directions ................................... 5
B Definition of used terms ................................. 5
Depositing the load ................................... 119
Battery hazard prevention ........................... 31 Description ........................... 42, 93, 127, 129
Battery replacement .................................. 123 Determining the hoisting weight ................. 148
Battery specifications .................................. 49 Dimensions ................................................. 42
Battery weight and dimensions .................. 124 Dimensions of roadways and aisles .............. 76
Be careful not to get caught Directional switch ........................................ 81
or fall ..................................... 23, 30, 112 Display ....................................................... 53
Be careful of fork tips .................................. 27 Display, Setting, Operation ........................ 152
Before driving ............................................. 76 Disposal ....................................................... 8
Before operation ......................................... 93 Do not jump off ........................................... 79
Before picking up the load ......................... 110 Do not jump off lift truck even if it tips ........... 16
Before starting operation .......................... 131 Do not lift people on forks .................... 23, 112
Behaviour in an emergency .......................... 79 Do not load above height
Behaviour when driving ............................... 78 of load backrest ............................ 24, 111
BRAKE SENSOR ERROR 69 or 70 ................. 159 Do not put metal objects on
Braking system ........................................... 55 top of battery ............................... 31, 122
Braking when traveling ................................ 20 Do not tilt mast forward when loaded ........... 25
Dont go under forks ........................... 23, 112
C Double-pedal operation ............................... 89
Driver ........................................................... 8
Driving ................................................. 80, 89
Carrying the load ...................................... 116
Driving (joystick) ......................................... 84
Caution ...................................................... 26
Driving behaviour in case of unused or
Center of gravity and stability ...................... 33
incorrectly used belt with belt lock
Center of gravity of load .............................. 32
switch present ...................................... 66
Changing the battery ................................ 122
Driving behaviour when seat switch
Changing the direction of travel ................... 83
is operated too long ............................. 92
162 BA
Index
Page Page
Driving behaviour with seat switch Hydraulic coupling ............................... 56, 109
not operated ........................................ 91 Hydraulic equipment .................................... 55
Driving in reverse ...................... 18, 83, 86, 90 Hydraulic fluid ............................................. 30
Driving on loading ramps ........................... 119
Driving safety rules ..................................... 78 I
E Indicated malfunction ................................ 158
Information on operation ............................... 8
Electric heater .......................................... 127 Installation of attachments .......................... 56
Electric regenerative braking ........................ 87
Electrical equipment .................................... 55
Emergency lowering (Joystick) .................... 108
J
Emergency stop procedure .......................... 72 Joystick ...................................................... 53
Emissions ................................................... 46
Ending operation ...................................... 136
Entering lifts ............................................. 118
K
Escaping from a railroad crossing ................. 17 Keep hands free from oil and water .............. 19
©
Exceeding the operating time ...................... 92 Keep tension on chain ................................. 25

Exceeding the post-shutoff time ................. 140
L
164 456-10.03
Exceeding the shift time .............................. 92

Exhaust gas ............................................... 11
Experts ........................................................ 8 Lamps .................................................. 19, 73
Lashing down the truck ............................. 146
F Leaving the truck unattended .................... 136
Legal requirements ................................... 130
Filling fuel ................................................. 131 Lever operation .................................... 25, 98
Fire extinguisher and first aid kit .................. 11 Lift truck information ..................................... 2
Fire precautions ........................................ 122 Lifting mast ................................................ 55
Fire Prevention for fuel Lifting the load while driving ........................ 69
(Diesel-operated heater only) ................ 13 Load capacity ........................................... 110
Fit forks securely in position ................. 26, 111 Load capacity plate for attachments ........... 102
FleetManager ........................................... 153 Load capacity with attachment ..................... 56
Foot brake ................................................. 90 Load handling ........................................... 114
Foreword ..................................................... I Loading highway trucks or
Fork extension .......................................... 102 railroad cars ................................. 17, 119
Fork spreader ........................................... 107 Loading operations ..................................... 23
Forks are not lowered ............................... 139
Forward travel ................................ 82, 84, 89 M
Frame and superstructure ........................... 55
Fuel system safety ...................................... 14 Maintenance ............................................. 128
Fuels and lubricants ...................................... 5 Maintenance staff ..................................... 122
Functional description .................................. 68 Malfunction, cause, remedy ........................ 133
Malfunction due to cold ................................ 65
G Malfunctions, cause, remedy ...................... 158
Manufacturers identification plate ................ 54
Gear oil, Diesel fuel ..................................... 30 Mast operation ........................................... 98
Mast versions ............................................. 96
General .................................................. I, 93
Maximum load
Give priority to loaded lift trucks ................... 21
(weight and center of gravity of load) ..... 33
H Maximum towed weight ............................. 142

Messages in case of improper
truck shutoff ....................................... 138
Handling long or wide loads ................. 27, 113 Modifications and retrofits .............................. 4
Hazards ..................................................... 77 MOTOR BRUSHES ERROR 195 (Warning) ...... 158
Hazards and risks ....................................... 10 MOTOR BRUSHES ERROR 196 (Warning) ...... 159
Heater ..................................................... 129 MOTOR BRUSHES ERROR 203
Heater control .......................................... 129 (flashes, emergency mode) .................. 158
Heating .................................................... 133 MOTOR BRUSHES ERROR 204
Height or width limits .................................. 22 (flashes, emergency mode) .................. 159
Hoisting the truck ...................................... 148 Mounting and dismounting ............. 19, 58, 137
Horizontal adjustment ................................. 63 Mounting of attachments ............................. 56
BA 163
Index
Page Page
N R
NiHo mast .................................................. 97 Raising, lowering the fork carriage ........ 98, 104
No overloading ................................... 23, 110 Raising the load at a standstill ..................... 69
No pushing ......................................... 28, 113 Reduce load for lift trucks
No riders .................................................... 18 with attachment ..................... 13, 99, 105
No unstable loads ............................... 24, 101 Referential lift ........................................... 139
Normal information .................................... 152 Regulating the cabin temperature .............. 128
Relieving pressure with control lever .......... 109
O Relieving pressure with the joystick ............ 109
Resetting daily mileage and
Opening the seat belt ................................. 65 daily driving time ................................. 155
Operate from operators compartment .......... 24 Reverse travel ................................ 82, 86, 90
Operating attachments ............................. 105 Reversing the travel direction ...................... 89
Operating qualifications ............................... 10 Rights, obligations and behavioural
Operating the attachments .......................... 99 rules for drivers ...................................... 8
Operating the horn ................................... 126
Road shoulder ............................................ 17
Operating the lifting device .......................... 96
Operating the lifting device Rules for roadways and work area ............... 77
with the joystick ................................. 104
S
164 456-10.03
Operation ............................. 76, 94, 127, 132
Operation manual and safety labels ............. 10
Operator ...................................................... 8 Safe operating plan ..................................... 13
Operator position ........................................ 51 Safe parking ............................................. 122
Operator position with joystick ..................... 52 Safe travel ................................................. 14
Other activities ......................................... 122 Safe working area ....................................... 13
Other settings .......................................... 155 Safety ........................................................ 10
Overhead guard and cabin .......................... 55 Safety during travel ......................... 20, 21, 87
©
Overhead guard, load backrest .............. 11, 73 Safety equipment ........................................ 12
Overhead objects ....................................... 28
Safety label sticking positions ...................... 35
(display flashes) ................................. 158 Safety Management .................................... 10
OVERHEATING ERROR 198 Safety precautions for handling lubricants ..... 30
(display flashes) ................................. 158 Safety rules ................................................ 12
OVERHEATING ERROR 53 ............................ 158 Safety rules for handling loads ..................... 96
Overriding the lifting height limitation ......... 109 Safety when starting ................................... 20
Overview of accessories .............................. 56 Scope of documentation ................................ I
Overview of attachments ............................. 55 Seat belt .............................................. 20, 64
Overview of options and models .................. 55 Seat belt constantly inserted,
Overviews .................................................. 50 operator only seated afterwards ........... 66
Seat belt is removed while driving ................ 79
P Seat belt not applied, operator seated ......... 66
Seat belt only applied after
Packaging .................................................... 8 key switch is turned on ......................... 67
Parking ........................................ 29, 94, 136 SEAT SWITCH ERROR 13 ............................ 158
Parking brake ............................................. 88 Seat switch not operated ............................ 91
Parking brake not applied .......................... 138 Selecting the driving program ...................... 80
Parking machine after failure ................ 29, 140 Selecting the fan stage ............................. 127
Parking the truck with parking brake Selecting the heating stage ....................... 128
not or insufficiently area ...................... 138 Selecting the language .............................. 155
People in working area ................................ 27 Serial number ............................................. 54
Persons in the danger area ......................... 74
Service brake .............................................. 87
Picking up and depositing the load ............. 115
SERVICE BRAKE ERROR 71 ......................... 159
Picking up loads with attachments ........ 99, 105
Picking up the load .................................... 112 Servicing required ..................................... 158
Picking up unit loads ................................. 111 Setting and adjusting the displays ............. 154
Precautions when charging .......................... 32 Setting the driving program ......................... 84
Precautions when loading/unloading .... 28, 112 Single-lever operation of the lifting device ... 103
Precautions when operating Site of operation ........................................... 3
directional levers .................................. 14 Special risks when using the truck and
Precautions when starting the truck ............. 14 attachments ........................................... 4
Precautions when starting truck ................... 59 Speed and acceleration ............................... 34
Precautions when stopping or parking .......... 28 Speed limitation with a lifted load ................. 68
Precautions when turning ...................... 22, 86 Speed reduction when steering
Prohibition of use by unauthorized persons .... 8 (Curve Speed Control) .......................... 68
Proper use ................................................. 93
164 BA
Index
Page Page
U
Stable range of center of gravity .................. 33 Unapproved applications ............................... 3
Stacking and removing load units ............... 119 Unauthorized modification ........................... 11
Standards and regulations ............................ 2 Unauthorized use ..................................... 130
Starting up ................................................. 58 Use ............................................................ 93
Steering ..................................................... 86 Use in cold storage warehouses .................. 93
Stopping and parking .................................. 28 Use of work platforms ................................... 4
Stopping distance ............................... 22, 118 Use only for intended purposes ........... 25, 112
Structure and stability of the lift truck Use strong pallets and skids ................ 27, 113
(to prevent lift truck from tipping) ........... 32 Using drawbar pin ....................................... 26
Structure of lift truck .................................... 32
Switching the fan off ................................. 127
Switching the heater off ............................ 128
V
Symbols indicating the movement of Ventilation ........................................ 127, 132
attachments ....................................... 100 Visibility when driving .................................. 78
T W
©
Table of contents ........................................ III Warning against using non-genuine parts ....... 4
Technical data (standard version) ................. 42 Waste materials .......................................... 32
164 456-10.03
Telescopic mast ........................................... 96 Wheels and tires ........................................ 47

Tilting the mast ................................... 98, 104 When front view is poor .............................. 18
Tipping ....................................................... 15
Tire fenders .......................................... 12, 72
To advance the forks ................................. 106
Z
To close the roll clamp ............................... 107 Zero braking ............................................... 81
To increase fork spread ............................. 107
To lower the bucket ................................... 108
To open the roll clamp ............................... 107
To raise the bucket ................................... 108
To reduce fork spread ................................ 107
To retract the forks ................................... 106
To rotate the head anticlockwise ................ 107
To rotate the head clockwise ..................... 107
To sideshift left ......................................... 106
To sideshift right ....................................... 106
Towing ............................................... 23, 147
Towing procedure ..................................... 147
Towing trailers .......................................... 143
Trailers, Towing ......................................... 142
Transport, Hoisting, Towing ........................ 146
Transporting pallets .................................. 113
Transporting swinging loads ...................... 101
Transporting the truck ............................... 146
Travel on slopes ............................ 15, 77, 117
Traveling regulations on public roads ...... 12, 76
Triplex mast ................................................ 97
Truck .......................................................... 50
Truck rolling slowly despite
parking brake applied ......................... 138
Truck shutoff with a lifted load .................... 139
Turning on the directional indicators ........... 125
Turning on the front spotlight ..................... 126
Turning on the hazard warning light ........... 125
Turning on the key switch ............................ 59
Turning on the lights ................................. 125
Turning on the rear spotlight ...................... 126
Turning on the revolving light ..................... 126
Turning on the seat heater ........................ 126
Turning on the windscreen washer/wipers .. 126
Turning the heater off ................................ 133
Turning the heater on ........................ 128, 133
Turning the ventilation off .......................... 132
BA 165
Electric Fork Lift Trucks
R 60-35 R 60-40
R 60-45 R 60-50
Maintenance Manual
! WARNING
Read and observe all warnings on this unit before operating it. DO NOT operate this
equipment unless all factory installed guards and shields are properly secured in place.
Contract#C2824 R 6046-49 SERIES

WA Ident-No. 164 456 - 05.04 A MEMBER OF THE LINDE GROUP
Maintenance manual R6046-49
Foreword
Foreword
General
These instructions contain all the information

required to perform the routine maintenance on
your fork truck. Carry out the maintenance at the
SERVI CE I N 346 h
correct interval according to the maintenance
chart to keep your truck ready for operation, 01 654 , 0 h
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 required at a
particular interval. 6046US-WA-009
The instructions describing the maintenance

procedures are located after the maintenance
©
chart.
164 456-10.03
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 booklet 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
R6046-49 Maintenance manual
Foreword
Ordering spare parts
Spare parts are supplied by our Service. Refer to
the LINDE Parts List for the required ordering
information.
Only use spare parts as specified by LINDE. Due
to insufficient quality or incorrect assignment, the
use of parts not approved by LINDE can increase Electric Fork Lift Trucks
the risk of accidents. The use of unapproved parts R 60-35 R 60-40
places full responsibility for any damage and R 60-45 R 60-50
liability on the part of the user.
Staff training and qualifications for

maintenance and repairs
Use qualified personnel for inspection and

maintenance
WARNING
Only persons authorized by the owner or
164 456-10.03
Spare Parts List
operator of the equipment and having proper
certification (local or national) may carry out
inspection, maintenance and repairs of the lift Contract#C2824 R 6046-49 SERIES
truck. If inspection, maintenance or repair work

ETL: Ident-No. 164 510 - 10.03 A MEMBER OF THE LINDE GROUP
is carried out incorrectly, it is very dangerous.
Only qualified and authorized staff may carry out
©
the maintenance. The annual inspection must be
performed by an expert. The expert must provide
his opinion and safety assessment irrespective
of operating and financial circumstances. He must
have adequate knowledge and experience to
assess the state of the vehicle and the
effectiveness of the protective devices in
accordance with the rules of technology and the
basic principles of fork trucks.
Maintenance location
WARNING
When carrying out inspection and maintenance,
use a level, dry, dust-free area. If the work is
carried out inside a building, make sure that
there is ample ventilation.
Maintenance personnel for batteries
WARNING
Batteries may only be charged, serviced and
replaced 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
Definition of used terms:
Most accidents are caused by a failure to follow

fundamental safety rules for the operation and
maintenance of lift trucks.
To avoid accidents, read, understand and follow
all precautions and warnings in this manual and
on the lift truck before operating and performing
maintenance. Do not operate or carry out
maintenance of this lift truck unless you are sure
that you understand the explanations and
procedures completely.
To identify safety messages in this manual and
on lift truck labels, the following signal words are
used.
DANGER
These safety messages or labels describe
precautions that must be taken to avoid a hazard
which carries a serious risk of serious injury or
death.
©
164 456-10.03
WARNING
These safety messages or labels usually
describe precautions that must be taken to avoid
a hazard which may lead to serious injury or
death.
CAUTION
This word is used on safety messages and
safety labels for hazards which could result in
injury or damage to the lift truck or surrounding
property if the hazard is not avoided.
NOTICE
This word is used for precautions that may not
lead to damage or failure, but which must be
taken to avoid actions that could shorten the life
of the lift truck.
We thank you for reading and following these

instructions. Please contact our Service if you have
any questions, want to submit improvement
suggestions or have discovered an error.
Your partner
Linde Lift Truck Corporation
2450 West 5th North Street
Summerville, S.C. 29484
Phone (843) 875-80000 FAX (843) 875-8329
hopes you will be driving safely.
WA III
Foreword
Table of contents
Page
Foreword ..................................................... I
Safety precautions for maintenance .............. 2
Maintenance chart ..................................... 12
Maintenance as required ............................ 20
1000-hour maintenance ............................. 34
Annual maintenance ................................... 56
2-year maintenance ................................... 58
Taking out of service .................................. 60
Maintenance data ...................................... 62
164 456-10.03
Diagrams ................................................... 64
Index ........................................................ 70
IV WA
Safety precautions for maintenance
SAFETY PRECAUTIONS
FOR MAINTENANCE
164 456-10.03 ©
WARNING

WA 1
Safety inspection according to

interval and extraordinary events
(please observe US regulations)
The industrial truck must be inspected at least once Wear suitable clothes for the job.
annually or after special incidents by a person
Use suitable safety and protective equipment
especially qualified for this task. This person must
(hard hat, safety boots, safety glasses, gloves)
present his expert opinion and assessment
for the job.
uninfluenced by any economical and business
circumstances and only from the standpoint of When working on top of the lift truck, be
safety. He must have sufficient knowledge and careful not to fall. Do not put your feet under
experience to be able to assess the condition of an the forks.
industrial truck and the effectiveness of the When opening or closing the floor plate or
protective features according to the rules of the art battery hood, be careful not to get your hands
and the principles applying for the inspection of or body caught.
industrial trucks.
When carrying out inspection with the forks
The truck must be inspected completely in respect raised, insert a stand under the inner mast to
to its safe technical condition. The truck must also prevent the forks and mast from dropping.
be thoroughly checked for possible damages due When carrying out the job with another
164 456-10.03 ©
to improper use. An inspection record must be worker, decide who is the leader and carry out
prepared. The results of the inspection must be filed the job in accordance with instructions from
at least until the inspection after the next one. that person.
The next inspection is indicated by a sticker on the
truck. After repairing, make sure that the trouble has
been corrected by performing a trial run.
During the trial run, start and operate the lift
Precautions for inspection and maintenance truck carefully because it is possible that the
trouble has not been fully corrected or that
defective parts have not been removed.
WARNING
To be prepared in the event of a fire, have a
fire extinguisher nearby and make sure that
you know how to use it.
Before carrying out inspection, lower the forks
to the ground and switch off the truck. Do not
switch on unless it is necessary.
Place the directional levers and work
equipment control levers in neutral.
Precautions when carrying out inspection

and maintenance
WARNING
Wipe off any oil or grease. Immediately wipe
up any oil that has leaked. If the lift truck is
dirty, it becomes difficult or impossible to find
cracks or other problems.
Always clean the lift truck before starting
inspection.
Do not smoke or allow any flame to exist under
any circumstances.
Do not use any cloth, which is soaked in fuel,
flammable solvent, oil or grease. There is
danger that it may catch fire.
2 WA
Use suitable tools
If oil is leaking under high pressure from holes,

WARNING it is dangerous if the jet of high-pressure oil
hits your skin or eyes.
Always use tools that are suited for inspection Always wear safety glasses and thick gloves,
and maintenance. It is extremely dangerous and use a piece of cardboard or a sheet of
to use broken tools or tools designed for plywood to check for oil leakage.
another purpose.
CORRECT
A0055190
A0055050
If a jet of high-pressure oil hits you, consult a

Replace safety critical parts periodically doctor immediately.
WARNING
164 456-10.03 ©

Even if no abnormality is found, always replace
safety critical parts periodically. As time
passes, these parts deteriorate and may cause WARNING
fire or failure in the work equipment system.
However, if these parts show any abnormality NEVER put your hands or feet
before the replacement interval has passed, into the mast structure.
they should be repaired or replaced There is danger that you will
immediately. get caught in moving parts
and be seriously injured.
Precautions with high pressure, high

temperature oil
Do not use the mast as a
ladder. If you slip, there is
WARNING danger that you will fall.
Immediately after using the lift truck, the oil
is at high temperature. Do not drain the oil or
replace the filter when the oil is hot. Hot oil
may spurt out and cause burns.
INCORRECT
A0055180
When carrying out inspection and

maintenance, wait for the oil temperature to
go down, and carry out the operation in the
order given in this manual.
Do not forget that the work equipment circuits
are always under pressure. Do not add oil,
drain oil or carry out maintenance or
inspection before completely releasing the
internal pressure.
WA 3
When the tires have been replaced, carry out

WARNING a test drive and check again for any loose
mounting bolts. If the tightening torque is low,
If the tire inflation pressure is low, it will affect tighten to the specified torque.
truck stability.
164 456-10.03 ©
9JL00164.eps

The tire inflation pressure on a forklift truck
is several times higher than the pressure on
an automobile. When the tires are being
inflated, there is danger that dirt or dust may
be thrown up by the compressed air and enter
your eyes.
eyes.
Handling tires
WARNING
A tire dealer should carry out disassembly and
assembly of tires.
The tire pressure is extremely high, so caution
is needed when handling tires.
The wheel is fitted with mounting (lug) nuts.
It also has rim nuts and bolts used to join the
rim halves.
When removing the tire from the lift truck, do
not loosen the rim nuts and bolts. The tire is
under high pressure, and there is a significant
risk that the rim nuts and bolts may fly off.
Relieve tire inflation pressure before
removing.
4 WA
Disposal of greases, oils and Work on the electrical equipment
batteries
WARNING
Waste materials
Work on the electrical equipment of the truck
WARNING is only allowed with the electrical system dead.
Function checks, inspections and adjustments
Obey appropriate laws and regulations when on live parts may only be carried out by trained
disposing of harmful items and materials such and authorized staff under observance of
as oil, fuel, solvent, filters and batteries. suitable precautions. Rings, metal bracelets,
etc. must be removed before working on
electric components.
The materials used for repair,

maintenance and cleaning must
be collected as specified and
disposed of in accordance with CAUTION
national laws and regulations.
The services may only be To prevent damage to electrical equipment
performed at places provided for with electronic components such as an
this work. Take care to avoid electronic travel control or lift control, remove
polluting the environment as them from the vehicle before doing any electric
164 456-10.03 ©
much as possible. welding.

- Remove spilled fluids such as hydraulic oil, brake
fluid or gear oil at once with an oil binding agent.
Dispose of in accordance with the regulations for
the disposal of used oil.
Safety devices
- Neutralize leaked battery electrolyte immediately. Refit and check all safety devices for proper
operation after maintenance and servicing.
Accident hazards
Settings
Safety measures for maintenance and repair
Retain the vehicle-specific settings when repairing
To prevent accidents during maintenance and repair, and replacing hydraulic and electric components.
perform all necessary safety measures such as: They are specified in the appropriate sections.
WARNING
- Ensure that the truck is secured against
inadvertent movement or starting
(disconnect the battery plug, engage the
parking brake and jack up the truck).
- When working under an elevated load lifting

member, secure it against inadvertent
lowering.
- Secure the lift mast against inadvertent

tilting.
WA 5
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
Jacking up lift truck (when checking or

replacing tires)
WARNING
Do not go under the forklift truck when it is
jacked up.
Check the following before jacking up the lift
truck. R60WA/059
1) Check that there is no one on the lift truck.
2) Check that there is no load on the forks.
When jacking up, stop when the tires come
164 456-10.03 ©
off the ground surface.
Put blocks under both sides of the frame to
prevent the lift truck from coming down.
Put blocks under any tires contacting the
ground to prevent the lift truck from moving.
R60WA/060
- Jack up the truck until the wheels are clear of
the ground.
- Secure the truck.
Jacking up on the mast

- Raise the fork carriage and secure it against
R6046-49_Ba-039
inadvertent lowering.
The truck must be jacked up for various services.
Always be sure that: WARNING
- the load capacity of the jack is sufficient,
Follow the safety precautions for working on
- the truck is only jacked up on level ground and
the mast.
that it is secured against rolling and lowering.
WARNING - Place the jack at the indicated points on the mast.

- Jack up the truck until the wheels are clear of
the ground.
When jacking up the truck, apply the
- Secure the truck.
handbrake and disconnect the battery plug.
WARNING
Jacking up on the frame
- Place the jack at the indicated points on the side Do not jack up the truck at the counterweight.
of the frame.
6 WA
Working on the front part of the
truck
1 2
WARNING
When the mast or forks are raised, do not work
on the mast or the front part of the truck
without first following the safety procedures
below!
Lift mast removal
CAUTION
Attach the lifting sling to the outer ends of the
upper cross member (2).
6046US-WA-004
This procedure may only be carried out by your
Service.
164 456-10.03 ©
Working on the lift mast 3

Securing the mast against tilting back
To prevent the lift mast from tilting back

inadvertently, insert a suitable 4.75 x 4.75 x
31.50 in (120 x 120 x 800 mm) long hardwood
beam (1) between the chassis and mast.
Securing the raised telescopic mast
CAUTION
When securing the mast, use a chain suitable
for the particular lift mast. Do not exceed the
maximum height of lift.
4
- Raise the mast. R60WA/004
- Fasten the chain around the cross member 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
CAUTION
When securing the mast, use a suitable chain
maximum height of lift.
- Raise the mast.

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.
6
R60WA/002
WA 7
Securing the raised triplex mast
7
CAUTION
When securing the mast, use a suitable chain
maximum lift height.
- Raise the mast.

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
R60WA/003
Servicing the battery
164 456-10.03 ©
Observe the applicable national
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
DANGER
Smoking and naked flames
are prohibited in the vicinity
of batteries. No inflammable
materials or spark-producing
materials may be located
within at least 7 ft (2 metres)
of the truck to be charged
and the charger. The room
must be well ventilated. Keep
fire extinguishers ready.
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.
8 WA
Battery hazard prevention
Tighten the battery caps securely.

WARNING
caps tightened.
Do not put metal objects on top of battery
WARNING
Never place any metal objects on top of the
battery. There is danger that they will cause a
9JM00787.eps short circuit and start a fire.
Battery electrolyte contains sulfuric acid and

can quickly burn the skin and eat holes in
clothing. If you spill electrolyte on yourself, Precautions when charging
immediately flush the area with a large
quantity of water. Battery electrolyte can
cause blindness if splashed into the eyes. If WARNING
164 456-10.03 ©
electrolyte gets into your eyes, flush them

immediately with large quantities of water and Observe all warnings and procedures given by
consult a doctor at once. the manufacturer of the battery. When the
battery is charged, hydrogen gas is generated
If you accidentally drink electrolyte, drink a and the battery is heated by the chemical
large quantity of water or milk mixed with change. To prevent the danger of gas
beaten egg white or vegetable oil. Call a doctor explosion, always do as follows: Carry out the
or poison control center immediately. charging operation in a well-ventilated place.
Dispose of drained fluids in accordance with Do not smoke or allow any flame. Start the
regulations. The applicable laws and charging operation when the temperature of
regulations must to be observed. the battery electrolyte is below 95°F (35°C).
If the electrolyte temperature goes above
122°F (50°C) during the charging operation,
wait for it to go down below 95°F (35°C)
before starting charging operation again.
9JM00848.eps
When working with batteries, ALWAYS wear

safety glasses or goggles. Batteries generate
hydrogen gas. Hydrogen gas is highly EXPLO-
or flame.
Do not smoke or create any spark near a
battery. Before working with batteries, switch
off the truck.
When removing the battery, remove the
battery plug first.
through accidental contact with tools or other
battery terminals securely. Loose terminals
can generate sparks and lead to an explosion.
WA 9
Maintenance chart
MAINTENANCE CHART
164 456-10.03 ©
WARNING

WA 11
Maintenance chart
Maintenance chart
1 2
14
164 456-10.03 ©
13
3
12
11 4
10
9 8 7 6 5 6049US-WA-001
12 WA
Maintenance chart
Inspection and maintenance intervals
The services must be performed according to the following maintenance intervals.
h Item Maintenance work
As required
2 Cleaning the truck

- Washing instructions
- Washing the exterior of the truck
1 - Cleaning the lift chains
- Cleaning the electrical system
- After washing the truck
6, 10 Servicing the wheels and tyres

- Tires
- Checking the tires for inflation pressure, wear and
condition
164 456-10.03 ©
3 Servicing the braking system

14 - Checking the brake fluid level, topping up, if
necessary
14 - Checking float switch and the brake fluid level
function
7 Servicing the battery

- Charging the battery
- Oiling the joints and controls
6, 10 Servicing the wheels

- Tighten wheel nuts / bolts
5 Servicing the steering axle
11, 13 Servicing the electric motors

- Renewing the motor brushes
8 - Clean the fan filter and replace, if necessary
- Servicing the heater

- Cleaning the intake filter
- Renewing the fuel filter
- Servicing the mast pivots
- Servicing the attachments
- Maintenance of cold storage warehouse truck
- Servicing the seat belt

- Checking the seat belt
- Clean the seat belt
- Renewal after an accident
- Servicing the driver restraint system
WA 13
Maintenance chart
Maintenance chart
1 2
14
164 456-10.03 ©
13
3
12
11 4
10
9 8 7 6 5 6049US-WA-001
14 WA
Maintenance chart
As required 9 Servicing the drive axle

(continued) - Checking the oil level in the drive axle
- Checking the drive axle for leaks

- Checking the steering axle
- Lubricating the steering axle
- Checking the steering system pipes and hoses for leaks
- Checking the steering axle nuts for proper torque
3 Servicing the braking system

14 - Renewing the brake fluid
- Checking the brake for proper operation and leaks
3 - Checking the parking brake cable for condition,
tension and wear, and adjusting if necessary
164 456-10.03 ©
3 - Adjusting the parking brake switch

3 - Lubricating the parking brake lever and ratchet
Servicing the electrical system

7 - Checking and cleaning the battery
7 - Servicing the battery according to the battery
manufacturer's instructions
7 - Battery insulation inspection
11, 13 Servicing the electric motors

- Checking the cable connections
- Checking the contactors
- Renewing the drive motor and pump motor brushes
- Servicing the hydraulic system

- Checking the hydraulic oil level and the hydraulic system for
leaks
- Check hydraulic hoses and pipes
1 Servicing the mast

- Checking the lift cylinders and connections for leaks
1000 - Checking the lift chains for condition and wear, lubricating
- Adjusting the lift chains
- Greasing the mast channels
- Checking the clearance between the fork carriage
and run-out stop
12 Checking the forks

- Checking the forks for condition and for function of
- stoppers
Servicing the mast pivots

- Checking for proper torque of the mast pivot bolts
- Lubricating the mast pivots
1 Servicing the mast

- Checking the lateral clearance (Y)
2000 - Checking bearing clearance (X)
- Safety inspection
WA 15
Maintenance chart
Maintenance chart
1 2
14
164 456-10.03 ©
13
3
12
11 4
10
9 8 7 6 5 6049US-WA-001
16 WA
Maintenance chart
continued
9 Servicing the drive axle

- Renewing the gear oil
- Checking the drive wheel bearing play

3000 - Checking the steering axle
- Servicing the hydraulic system

- Renewing the hydraulic oil and hydraulic filter
- Bleeding the hydraulic system
- Bleeding the steering system
164 456-10.03 ©
Annual
Maintenance
- - Checking the insulation resistance
7 - Battery insulation inspection
- - Testing the insulation resistance of the electrical system
- Recurring inspections
- Safety inspection
14 Servicing the brake system

- Renewing the brake fluid
2-Year
maintenance
- Renewing the hydraulic oil
Maintenance
after 10 years
- - Renewing the heat exchanger, heater
WA 17
Maintenance as required
MAINTENANCE AS
REQUIRED
164 456-10.03 ©
WARNING

WA 19
Cleaning the truck
Washing instructions
- Always park the truck as described below.

- Apply the parking brake (2).
- Turn off the key switch (1) and remove the key.
- Disconnect the battery plug (3).
CAUTION
When washing the truck, turn off the key
switch, remove the key and disconnect the
battery plug.
Washing the exterior of the truck 6046US-WA-003
WARNING
164 456-10.03 ©
1
Do not use inflammable fluids for cleaning.
Observe the above safety precautions for
preventing sparks through shorts
(disconnecting the battery plug). When the
truck is cleaned with hot-water appliances,
carefully cover all sensitive components,
particularly electric components.
Follow the manufacturers

instructions for handling the
cleaners. 2
- 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. 6046US-WA-008
Please note: Lubricate more frequently if the truck

is cleaned often. 3
NOTICE
Steam jets may be used at max. 725 psi (50 bar)
and 185 °F (85 °C) and at a distance of min. 8 in
(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.
R6042-WA-003
20 WA
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 manufacturers
notes on safety).
- When using a steam jet, clean without additi-
ves.
- 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.
R6042-WA-004
- Spray LINDE chain spray S on the chain at once,
while moving the chain when spraying.
164 456-10.03 ©
Cleaning the electrical system
NOTICE
Only use dry cleaning agents as
cleaners and according to the
manufacturers instructions. Do
not remove protective covers,
etc.
- Clean and blow dry electrical components using

a non-metallic brush and a weak jet of air.
R6042-WA-005
After washing the truck
- Dry the truck thoroughly (e.g. with compressed

air).
- Sit down on the drivers 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.
6046US-WA-005
WA 21
Servicing the wheels and tires
Tires
The quality of the tires affects the stability and

driving characteristics of the truck. Modifications
may only be made with the approval of LINDE. When
changing wheels or tires, 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 tires.
Checking the tires for inflation pressure*,

wear and condition

1
WARNING 2 R6042-WA-007
If the tire inflation pressure is low, it will affect
164 456-10.03 ©
truck stability.
The tire inflation pressure on a forklift truck
is several times higher than the pressure on
an automobile. When the tires are being
inflated, there is danger that dirt or dust may
be thrown up by the compressed air and enter
your eyes.
eyes.
The tire inflation pressure depends on the type of

tire fitted.
Check the data given on the labels (2) on your truck.
The minimum tread depth (1) of pneumatic tires*
on the entire rolling surface should be .006 in.
(1.6 mm) minimum.
Remove any foreign objects which may have
penetrated the tires.
The wear on the wheels of the same axle must be
approximately equal.
* Depending on the version
22 WA
WARNING 3
Uneven tire wear reduces the stability of the
truck.
Superelastic tires* can be driven until the wear limit

(3) is reached.
WARNING
Worn or damaged tires on both sides must be
replaced without delay. The risk of accidents
is greater as the stopping distance is longer.
Handling tires
WARNING R60WA-11
A tire dealer should carry out disassembly and
164 456-10.03 ©
assembly of tires.
The tire pressure is extremely high, so caution
is needed when handling tires.
The wheel is fitted with mounting (lug) nuts.
It also has rim nuts and bolts used to join the
rim halves.
When removing the tire from the lift truck, do
not loosen the rim nuts and bolts. The tire is
under high pressure, and there is a significant
risk that the rim nuts and bolts may fly off.
Relieve tire inflation pressure before
removing.
When the tires have been replaced, carry out
a test drive and check again for any loose
mounting bolts. If the tightening torque is low,
tighten to the specified torque.
* Depending on the version
WA 23
Servicing the braking system
Checking the brake fluid level, topping up if 1 2

necessary
Check the brake fluid level if the text SERVICE

BRAKE (1) appears in the display.
SERVICE BRAKE
NOTICE ERROR 71
The message appears every 60 s. The truck only
drives at walking pace.
6046US-WA-010
- Remove the front panel.
164 456-10.03 ©
3
CAUTION
Follow the safety precautions for handling
4
gear oil.
- Check the brake fluid level in the reservoir (5).

The brake fluid level should be between the MAX
and MIN marks.
CAUTION
5
If the brake fluid level is low, there are leaks
in the braking system. Remedy the cause
before topping up brake fluid.
R6046-WA-002
- Add brake fluid HGS according to "Recommended
Fuels and Lubricants" to the MAX mark after
removing the cap.
Filling capacity ............... approx. .55 pt (0.25 L)
Checking float switch and the brake fluid

level function
- Press switch (3). The message SERVICE BRAKE

must flash on the display.
- Remove the cap (4) before filling.
- After having checked/replenished the brake fluid,

press button PRG O (2) to clear the display.
24 WA
Servicing the battery

NOTICE through accidental contact with tools or other
The battery is serviced according to the operating battery terminals securely. Loose terminals
instructions of the battery manufacturer. can generate sparks and lead to an explosion.
Tighten the battery caps securely.
Battery hazard prevention
caps tightened.
WARNING
Charging the battery
WARNING
Do not place any metallic objects or tools on
the battery. No naked lights, no smoking
permitted! The battery could be damaged,
164 456-10.03 ©
shorted or an explosion could occur.

9JM00787.eps
Battery electrolyte contains sulfuric acid and

can quickly burn the skin and eat holes in Precautions when charging
clothing. If you spill electrolyte on yourself,
immediately flush the area with a large
quantity of water. Battery electrolyte can WARNING
cause blindness if splashed into the eyes. If
electrolyte gets into your eyes, flush them Observe all warnings and procedures given by
immediately with large quantities of water and the manufacturer of the battery. When the
consult a doctor at once. battery is charged, hydrogen gas is generated
and the battery is heated by the chemical
If you accidentally drink electrolyte, drink a change. To prevent the danger of gas
large quantity of water or milk mixed with explosion, always do as follows: Carry out the
beaten egg white or vegetable oil. Call a doctor charging operation in a well-ventilated place.
or poison control center immediately. Do not smoke or allow any flame. Start the
charging operation when the temperature of
Dispose of drained fluids in accordance with
the battery electrolyte is below 95°F (35°C).
regulations. The applicable laws and
If the electrolyte temperature goes above
regulations must to be observed.
122°F (50°C) during the charging operation,
wait for it to go down below 95°F (35°C)
before starting charging operation again.
WARNING
9JM00848.eps
The electrolyte (diluted sulphuric acid) is

When working with batteries, ALWAYS wear
poisonous and caustic! Follow the safety
safety glasses or goggles. Batteries generate
precautions for handling battery electrolyte.
hydrogen gas. Hydrogen gas is highly EXPLO-
or flame.
Do not smoke or create any spark near a
battery. Before working with batteries, switch
off the truck.
When removing the battery, remove the
battery plug first.
WA 25
- Charge a discharged battery immediately when
no black field (1) is visible. 1
- Before charging, inspect the battery and charging
cables for damage; replace them, if necessary.
WARNING
P R OG 1 1 2 : 23
Disconnect the battery plug only when the BA T T :
truck and charger are switched off.
- Connect the battery plug (2) to the connector of

the charger unit.
NOTICE
Please follow the information in
the operating instructions for the
R20WA-18
battery and the charging station
(equalizing charge).
164 456-10.03 ©
2
DANGER
The gases released during charging are ex-
plosive. Ensure that the room is well
ventilated.
Trucks with cab*: Keep all doors open while
charging!
CAUTION
Never squeeze the battery cables (3).
3 R20WA-19
Battery maintenance precautions
Keep the battery cell lid dry and

lean. Neutralize spilled
electrolyte immediately. Termi-
nals and cable lugs should be
clean, slightly greased and
secure.
Battery charging
During charging, keep the surface of the battery

cells exposed in order to provide sufficient
ventilation.
* Option 10-16-Wa-032
26 WA
Fuse replacement
1
WARNING
Work on the electrical equipment of the truck
is only allowed with the electrical system dead.
- Turn off the keyswitch

- Pull out the battery plug.
Rings, metal bracelets, etc. must be removed

before working on electric components.
The fuses are located on the SCR control unit and

in the rear of the truck:
- Remove the rear cover of the electrical system:

R6042-BA-051
1 Main fuse 1F2 300 A
Fuses on fuse panel

164 456-10.03 ©
2 Fuse F1 5A, 80 V via key switch

- Horn
- Variant via emergency isolator button to the
main line contactor
- Motor brush monitor
5 Fuse F4 20A, 80 V continuous
- Electric heater
6 Fuse F5 5A, power supply
7 Fuse F6 15A, 80 V continuous
- Voltage converter
8 Fuse F7 5A, hydraulic controller
9 Fuse F8 5A, 80 V continuous 10 9 8 7 6 5 4 3 2 R6046-BA-033
- Fan motor 9F5

10 Fuse F9 10A, key switch
1 2 3
Fuses on the relay box*
NOTICE
There is one relay box left in the front* and one
other relay box in the rear* of the truck.
1 Fuse F1 5A
2 Fuse F2 5A
3 Fuse F3 15A
* Option R20BA-68
WA 27
Oiling joints and controls
- Oil or grease all other pivots and joints with oil

OG or grease F according to "Recommended Fuels
and Lubricants.
m Seat channels
m Cabin door hinges*
m Battery lid hinges
m Valve control linkage
m Hinges for body restraint systems*
Servicing the wheels
164 456-05.04 ©
Tighten wheel nuts / bolts
Check wheel nuts (1) and bolts for security and

tighten, if necessary.
Drive axle
Torque for nuts / bolts ... 440 lb.ft. (600 Nm)
Steer axle
Torque for nuts / bolts ... 155 lb.ft. (210 Nm)

1
Tighten the intermediate ring mounting nuts if twin
tires* are fitted.
NOTICE
R6042-WA-008
NOTE for solid rubber tires*:
- Replace the hex head screws fastening rim parts

when changing tires.
Servicing the steering axle
- Lubricate the nipples (arrowed) at the steering

knuckles and tie rods with lithium-based grease
FL (according to "Recommended Fuels and
Lubricants). Operate the steering while
lubricating.
Please note: Lubricate more frequently if the truck

is cleaned often.
* Depending on the version R60WA/056
28 WA
Servicing the electric motors
Renewing the motor brushes 1

- The motor brush wear text appears on the display
(1) when the wear limit of the brushes is reached.

MOTOR BRUSHES
- Text appears every 15 min. ERROR 195
NOTICE
The truck can still be operated for up to 10 service
hours.
MOTOR BRUSHES ERROR 203 6046US-WA-011
- Text appears every 10 s.

164 456-10.03 ©
1 2
CAUTION
Emergency operation, as brushes are worn.
The power of the hydraulic system is
noticeably reduced.
- Replace the brushes as described on page 39 of

these maintenance instructions.
- When the motor brush monitor text is displayed,

renew all brushes in a motor.
NOTICE
Replacement brushes can be found in the Spare

Parts List.
3 R60WA_064
Clean the fan filter and replace, if necessary

2
- Remove the floor plate.
- Disconnect plug (3).
- Release lateral locks (arrowed).
- Pull fan (1) forward and remove to the top.
- Remove the filter mats (2) and clean them.

Replace the mats, if necessary.
- Re-install the parts.
R60WA_063
WA 29
Servicing the heater*
Cleaning the intake filter
NOTICE
1
The intake filter should be cleaned every 6 months
and more often in a dusty environment.
- Remove the intake filter (1) and clean by tapping

or washing.
CAUTION
Dry a wet intake filter before installation e.g.
with compressed air.
2 6030Ba-24
- Refit the filter.
164 456-10.03 ©
Renewing the fuel filter
- Remove the cover (2).
- Loosen the clamps (3) on the fuel filter (4)

between the reservoir and metering pump and
remove the fuel filter.
3
- Discard the removed fuel filter.
4
- Install a new fuel filter with the clamps in the
fuel line.
NOTICE
3
Be sure the direction of flow is as indicated on the
filter. The arrow must point towards the metering
pump. 6030Ba-25
- Install and screw on the cover.
* Option
30 WA

WARNING
Follow the safety precautions for servicing the
mast.
- Grease the mast pivots at the lubricating nipples

(1) on the left- and right-hand side with grease
F according to "Recommended Fuels and
Lubricants.
1
R60WA/040
Servicing the attachments*

164 456-10.03 ©
- Lubricate the attachments such as sideshift or

clamp, slide rails with grease F according to the
table of lubricants.
The illustration shows a clamp.
NOTICE
Follow the manufacturers main-

tenance instructions.
R60WA/041
Maintenance of cold storage

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

movement on a weekly basis.
* Option
WA 31
Service the seat belt
Check the seat belt
Carry out the following inspection regularly

(monthly). In case of heavy stress, the inspection
is required daily. 2
Pull the belt (3) out fully and inspect it for fraying.
1
The belt should not show any sign of frays or
cuts. The seams should not be loose.
3
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 must
be held firmly. The tongue (2) of the belt should
be released when the red pushbutton (4) is
depressed.
R6046-WA-004
Checking the automatic anti-blocking system:
164 456-10.03 ©
● 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 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-Wa-017
Clean the seat belt
- Clean the belt if required (brush suffices).
- Use only cleaning agents approved by the seat

belt manufacturer.
Renewal after an accident Service the restraint system*
The seat belt must always be replaced after an NOTICE

accident.
Your truck can be equipped with a restraint system.
Please follow the maintenance

instructions of the manufacturer.
* Option
32 WA
1000-hour maintenance
1000-HOUR
MAINTENANCE
164 456-10.03 ©
WARNING

WA 33
1
Servicing the drive axle
Checking the oil level in the drive axle
CAUTION
gear oil.
NOTICE
Truck must be parked on level ground.
- Remove front wheels. 2 R60WA/018

- Screw out the oil check plug (2) on each side of
164 456-10.03 ©
the drive axle.
- Oil must flow out of the plug bores.

If this is not the case:
- Remove the oil filler plugs (1) at the top of the

drive axle on each side.
- Fill oil HGS according to"Recommended Fuels and

Lubricants" into the filler opening until it flows
out of the bores.
- Refit the check plugs (2) and oil filler plugs (1).
Checking the drive axle for leaks
- Inspect the drive axle (arrowed) for leaks (traces

of oil).
34 WA
1 2
Checking the steering axle
- Inspect the axle pivot rubber mounts for condition

and wear.
- Examine the steering knuckle bearings (1) and

tie rod (2) for wear.
- Check the steering cylinder (4) for leaks (traces

of oil).
R60WA/055
Lubricating the steering axle

164 456-10.03 ©
- Lubricate the nipples (arrowed) at the steering

knuckles and tie rods with lithium-based grease
FL (according to "Recommended Fuels and
Lubricants). Operate the steering while
lubricating.
Checking the steering system pipes and

hoses for leaks
- Tighten loose unions and replace faulty pipes and

hoses.
- After repairs, eliminate any air by turning the

steering wheel several times from full lock to full
lock until the air is removed.
R60WA/056
Checking the steering axle nuts for proper

torque 3
- Turn the steering wheels to full lock.
- Check the torque of the steering knuckle (3) with

a torque key.
Torque of steering
knuckle nuts .................. 230 lb.ft. (310 Nm)
(all parts oiled)
R60WA/057 4
WA 35
Servicing the braking system
Renewing the brake fluid
CAUTION
gear oil.
Capacity of brake fluid

reservoir (1) ........................ .55 pt. (0.25 L)
CAUTION
1
Do not fill commercial brake fluid but gear oil
HGS.
The fluid HGS must be renewed at least R60WA/045
annually.
164 456-10.03 ©
The brake fluid renewal and bleeding the braking
system should be left to your Service.
Checking the brake for proper operation and

leaks
- Accelerate the truck.
- Depress the brake pedal with force until the truck

has come to a full stop.
If the pedal stroke is spongy:

- Have the braking system bled by your Service.
Please contact your Service.

- Inspect the pipes and hoses for condition and
leaks.
18Wa-72
Checking the parking brake cable for

condition, tension and wear, and adjusting if
necessary
NOTICE
Adjust the parking brake cable only if the cable has
stretched.
- Open the battery cover.

- Put the parking brake lever into the neutral
position.
- Turn the cable adjusting nut (1) until:
- Brake engaged in first notch of ratchet: Brake
drags.
- Brake engaged in 8th notch of ratchet: Full 1
braking action. 72Wa-019
36 WA
Adjusting the parking brake switch
- Adjust the parking brake switch (2) so that the

traction drive is cut out when the parking brake
lever is operated. 2
Lubricating the parking brake lever and
ratchet
- Lightly grease the parking brake pivot and ratchet

with grease F.
18Wa-18
Servicing the electrical system

164 456-10.03 ©
Checking and cleaning the battery
WARNING
No smoking, no naked light and do not put any
metal objects on the battery. Explosion or
short can occur!
Servicing the battery according to the

manufacturers instructions
10-16-Wa-032
WARNING
Do not exchange the battery poles or cause a
short: Risk of personal injury due to arcing!
Battery insulation inspection
NOTICE
Have the battery insulation resistance checked at
least every year. The resistance is sufficient if at
least 1000 Ohm.
Contact your Service for this inspection.
WA 37
Servicing the electric motors
Checking the cable connections 2
CAUTION
Before starting the following work, park the
truck and disconnect the battery plug.
1
- Remove the floor plate.
- Check the drive - (1) and pump motor (2) cable

for secure connection, condition and insulation.
NOTICE
Corroded connections and broken cables lead to R6042-WA-011
drops in voltage, leading to malfunctions.
164 456-10.03 ©
- Eliminate any corrosion and replace broken
cables.
- Remove the three screws on the rear cover (3).
- Open the battery lid a little. 3

- Lift out the rear cover.
- Check all battery connections for tightness.
- Tighten all clamping screws.
6046US-WA-006
Checking the contactors

4 5
- Pull off the two red (4) and blue (5) blow
magnets.
- Inspect the contactors for pitting and have them

replaced if necessary.
- Install the blow magnets.
- Refit and secure the cover.
R60WA-66
38 WA
Renewing the drive motor and 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. 1
- Remove the floor plate (1).
R6042-WA-013
- Dismantle fan (2) by removing bracket (3).

164 456-10.03 ©
2
- Remove the cover bands (5) on the drive motor
(6) and pump motor (4).
The drive motor brushes can be accessed from
the drivers station from the front and from the
bottom.
- Lift the holding springs and take out the brushes.
- The brushes may only be worn down to a

Minimum length ............. .59 in. to .67 in.
(15 mm to 17 mm)
- If the minimum brush length is reached on one

brush, renew all brushes as a set.
3 R60WA-67
6046US-WA-012
NOTICE 4
Always replace brushes below the wear limit in kits.
Check the armature for pitting before installing new
brushes. New brushes must be ground in. If refitting
5
the existing brushes, do not interchange or turn
them.
- Refit the cover band (clip below the motor in the

centre).
- Refit the removed parts.
.67 in.
1.26 in.
6
WA 39
Servicing the hydraulic system ;;;;;;;;;;;;;
;;;;;;;;;;;;;
;;;;;;;;;;;;;
;;;;;;;;;;;;;
;;;;;;;;;;;;;
;;;;;;;;;;;;;
;;;;;;;;;;;;;
Checking the hydraulic oil level and the ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
hydraulic system for leaks ;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;
- Park the truck on level ground. ;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;
- Tilt the mast back. ;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;
- Lower the forks, retract the service cylinder of ;;;;;;;;;;;;;;;;;;;;;;;;;;
any attachments* fitted. ;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;
- Disconnect the battery plug and remove the floor
plate.
WARNING
Hydraulic oil is hazardous to health and it is
under pressure during truck operation. Follow R60Wa-62
the safety precautions for handling hydraulic
oil.
164 456-10.03 ©
- Pull out the dipstick (1).
- The distance to the oil level must reach at least

the dimension X:
Dimension X .............. 2.6- .4 in. (66 - 10 mm)
R6046-Wa-010
Marks on dipstick
- If the oil level does not reach this value X, fill 1

hydraulic oil OZ according to Recommended
Fuels and Lubricants through the dipstick
opening until the necessary oil level is reached.
- Reinsert the dipstick.
- Check the pipe and hose unions for leaks (oil

traces). X
* Option R6046-WA-009
40 WA
Check hydraulic hoses and pipes
Precautions with high pressure, high

temperature oil
WARNING
Immediately after using the lift truck, the oil
is at high temperature. Do not drain the oil or
replace the filter when the oil is hot. Hot oil
may spurt out and cause burns.
When carrying out inspection and
maintenance, wait for the oil temperature to
go down, and carry out the operation in the
order given in this manual. Do not forget that
the work equipment circuits are always under
pressure. Do not add oil, drain oil or carry out
maintenance or inspection before completely
releasing the internal pressure.
A0055180
If oil is leaking under high pressure from holes,
it is dangerous if the jet of high-pressure oil
hits your skin or eyes.
164 456-10.03 ©
Always wear safety glasses and thick gloves,

and use a piece of cardboard or a sheet of
plywood to check for oil leakage. If a jet of
high-pressure oil hits you, consult a doctor
immediately.
The hoses must be replaced in case of:

- damage to or embrittlement of outer layer with A0055190
cracks,
- leaks
- unnatural deformations (eg bulges or kinks)
- fitting detached from hose
- heavy damage to or corrosion of the fitting.
Pipes must be replaced in case of:

- chafing with removal of material,
- unnatural deformations and visible signs of
bending stress
- leaks.
WA 41
Servicing the mast

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 R60WA/033

cylinders.
164 456-10.03 ©
Checking the lift chains for condition and
wear, lubricating
- Spray the lift chains with chain spray S.
Adjusting the lift chains
NOTICE
Never compensate tire wear by adjusting lift chain
tension!
Adjust the lift chains only if elongation - 3 percent
maximum - is due to wear.
CAUTION
If lift chains can no longer be retightened,
replace them together with all related
connecting parts.
Adjust chain
CAUTION
Be sure the tension of the left and right chains
is the same. If the tension is not the same,
the load will be unbalanced even if it is loaded
correctly in the center, and there is danger
that the lift truck may tip.
42 WA
Telescopic mast 6033Wa-06n
- With the lift cylinders fully extended, turn the

adjusting nuts (1) until the centre point of the
central fork carriage roller remains .395 in.
(10 mm) below the upper edge of the inner mast.
The stop must always be between cylinder and
piston.
NiHo mast
164 456-10.03 ©
- With lift cylinder fully extended, turn the adjusting

nut (2) until the centre point of the middle fork
carriage roller remains .395 in. (10 mm) below
the upper edge of the inner mast. The stop must
always be between the lift cylinder and piston.
R6042-WA-020
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) 3

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

chain at the tensioning nut (4) until the centre
of the central fork carriage roller remains .395
in. (10 mm) below the upper edge of the inner
mast.
The stop must always be between the lift cylinder
and piston.
R6042-WA-021
WA 43
Greasing the mast channels
- Remove any dirt and grease on the channels.

1 2
- Lubricate the outer, intermediate and inner mast
channels (1, 2) with high pressure grease S to
reduce wear.
NOTICE
Spray the channels evenly while holding the can
approx. 6 to 8 in. (15 to 20 cm) from the surface.
Wait for approx. 15 minutes before operating the
truck again.
R60WA/037
Checking the clearance between the fork
164 456-10.03 ©
carriage and run-out stop 3
NOTICE
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. .080 in. (2 mm).
R60WA/038
44 WA
Checking the forks
4 5 6
Checking the forks for condition and for
function of fork stoppers
- Check the forks (4) for visible distortion. The fork

wear must not exceed 10 % of the original
thickness.
CAUTION
Worn forks must always be renewed in pairs.
- Check the function of the fork stoppers (6).
- The fork stop bolt (5) must be present.
R60WA_05

164 456-10.03 ©
Checking the torque of the mast pivot bolts

WARNING
Follow the safety precautions for servicing the 1
mast.
- Check the torque of the mast pivot bolts (1) with

a dynamometer (torque wrench).
Torque for mast pivot bolts 2

M20 ................................ 285 lb.ft. (385 Nm)
R6042-WA-025
Lubricating the mast pivots
- Grease the mast pivots at the lubricating nipples

(2) on the left- and right-hand side with grease
F according to "Recommended Fuels and
Lubricants.
WA 45
2000-HOUR
MAINTENANCE
164 456-10.03 ©
WARNING

WA 47
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. This can affect
the stability of the truck.
After repairs or cylinder replacement, the tilt R6042-WA-017
cylinder must only be adjusted by your Service!
164 456-10.03 ©
Checking lateral clearance (Y)
"x"
- 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. .004 in. (0.1 mm)
max. .012 in. (0.3 mm) (at closest point)
max. .043 in. (1.1 mm) (at other points)
Lateral clearance (Y) between inner mast, centre

mast and outer mast:
Top roller:
min. .004 in. (0.1 mm)
max. .043 in. (1.1 mm) (at other points) "y"
18Wa-91
Bottom roller:
min. .004 in. (0.1 mm)
max. .043 in. (1.1 mm) (at other points)
Checking bearing clearance (X)
NOTICE
Prior to this check, make sure that lateral clearance
(Y) is within the above 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..055 in. (1.4 mm)
18Wa-92
48 WA
Safety inspection according to
interval and extraordinary events
(please observe US regulations)
(at least once a year)
Have the fork truck inspected by an expert. Please

contact your LINDE Service.
Observe also the regulations of your country.
164 456-10.03 ©
WA 49
3000-HOUR
MAINTENANCE
164 456-10.03 ©
WARNING

WA 51
Servicing the drive axle
Renewing the gear oil
Draining the gear oil
CAUTION
gear oil.
- Park the truck on level ground.

- Remove the oil drain plugs (1) and oil filler plugs
(2) on each side and allow the oil to drain
completely.
R60WA/046 1
CAUTION
164 456-10.03 ©
Dispose of the drained oil as specified in envi-
ronmental regulations. 2 2
- Using a new seal, install the oil drain plugs and
tighten.
Filling the gear oil
- Fill fresh oil HGS according to the list of

recommended lubricants through the oil filler
hole.
Capacity per side ......... approx. 3 pts (1.4 L)
- Install the plugs (1 and 2) and tighten.
Checking the drive wheel bearing play

R6042-WA-018
- Check the wheel bearing for wear and play.
In case of excessive play, have the bearing replaced

by your Service.
Checking the steering axle

3
- Check the rubber mounts at the axle pivots for
wear.
- Check the steering knuckle bearing (3) and tie
rod (5) for play and wear.
- Check the wheel bearings for excessive play, free
movement, damage and wear.
- Check the torque of the steering cylinder bolts
(4) with a torque wrench.
Torque ........................... 155 lb.ft. (210 Nm)
In case of excessive play, have your Service replace
the parts.
R60WA/048 5 4
52 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. Follow the
safety precautions for handling hydraulic oil.
- Park the truck on a level surface.

1
- Tilt the mast back.
- Lower the forks and retract the service cylinder

of the attachments.
- Disconnect the battery plug and remove the floor R60WA/049

plate.
164 456-10.03 ©
- Remove the hydraulic oil filter cover (3). 2

- Unscrew the hydraulic oil drain plug (1) under 3
the oil reservoir and catch the hydraulic oil in a
container.
CAUTION
Dispose of the drained oil in accordance with 4
laws and regulations.
- Screw in the oil drain plug (1) and tighten it.
Torque: ........................... 41.3 lb.ft. (56 Nm)
R6046-Wa-011
- Remove and discard the old hydraulic oil filter

element (6) in the filter cover (3). 2
- Fit a new seal (5) on the filter cover (3).
- Install a new hydraulic oil filter element (6) on

3
the filter cover.
- Secure the filter cover with a new sealing nut 5

(2).
Torque: ................................ 9 lb.ft. (12 Nm)
R6046-Wa-015
WA 53
- Pull out the breather filter with the dipstick (4)
and discard it.
4
- Fill fresh hydraulic oil OZ according to the
recommended lubricants through the opening.
Filling quantity .................. approx. 9 U.S. gal

(34 litres)
- Install a new breather filter (4).

X
- Check the oil level X.
- The distance to the oil level must reach at least

the dimension X:
Dimension X ............... 2.6- .4 in. (66 - 10 mm)
R6046-WA-012
Bleeding the hydraulic system
164 456-10.03 ©
Bleeding the steering system
- Operate the steering wheel several times from

lock to lock to bleeed 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
R72Wa-053
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 appear in
the fluid emerging at the screws. Tighten the
bleed screws.
2
Bleeding the tilt cylinders
- Tilt the mast fully back and forward several times.

This will bleed the tilt cylinders automatically.
R60WA/053
54 WA
Annual maintenance
ANNUAL
MAINTENANCE
164 456-10.03 ©
WARNING

WA 55
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
NOTICE
Have the battery insulation resistance checked at
least every year. The resistance is sufficient if at
least 1000 Ohm.
10-16-Wa-032
Testing the insulation resistance of the
electrical system
164 456-10.03 ©
Have the insulation resistance of all active electrical
components checked in accordance with
regulations.
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 multiplied by rated voltage against
body.
Please contact your Service for this test.
Recurring inspections
Safety inspection according to interval and

extraordinary events (please observe your
national regulations)
The vehicle must be tested (at least once a year)

5051-Wa-033
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. CAUTION
The truck must also be examined thoroughly for
damage which may have occurred through improper Do not fill commercial brake fluid but gear oil
operation. An inspection report must be prepared. HGS.
The results must be kept on file until the next
inspection.
The operator must ensure that any defects are Filling capacity .......... approx. .55 pt (0.25 L)
remedied without delay.
Please contact your Service. - Check the float switch for proper operation (see
page 26).
Bleed the brake lines after filling.

Servicing the brake system
Change brake fluid CAUTION
Have the fluid HGS renewed at least every year if Dispose of old brake fluid as required by
the fluid is not renewed during the 1000-hour regulation.
inspection.
56 WA
2-year maintenance
2-YEAR
MAINTENANCE
164 456-10.03 ©
WARNING

WA 57
2-year maintenance
2-year maintenance
Renewing the hydraulic oil
NOTICE
The hydraulic oil must be renewed at least every
two years; see page 53.
R6046-Wa-014
Maintenance after 10 years
164 456-10.03 ©
6046US-WA-013.eps
Renewing the heat exchanger, heater*
The heat exchanger must be replaced by a genuine

Original-
replacement after 10 years.
replacement
NOTICE
Contact your Service for the replacement of the

Date of sale:
heat exchanger or an authorized workshop.
............................................
- The installation must be permanently noted on
the heater on a label (1) with the words Genuine
replacement and the date of sale of the heat
exchanger.
1
* Option
58 WA
Taking out of service
TAKING OUT
OF SERVICE
164 456-10.03 ©
WARNING

WA 59
Measures when storing, taking the Recommissioning after taking out of service
truck out of service for a long 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 out recommissioning. The inspection, similarly to the
the following corrosion protection measures. safety inspection or the annual inspection, should
When taking the truck out of service for over two also include safety-related points on the truck.
months, park it in a clean and dry enclosed space
which is also well ventilated and frost-free. Also - Thoroughly clean the truck.
perform the following measures:
- Lubricate the mast pivots and steering axle.
Measures before taking out of service - Oil joints and actuators.
- Thoroughly clean the truck. - Check the condition and specific gravity of the
battery, charge the battery if necessary.
- Raise and lower the carriage several times as far
as possible. - Check the hydraulic oil for condensate and renew
the oil, if necessary.
- Tilt the mast forward and back a few times and
also move the attachment several times, if fitted. - Perform the services as before initial operation.
164 456-10.03 ©
Lower the forks on to a suitable object, eg on a - Renew the brake fluid.
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
- Cover all blank moving parts lightly with oil or in particular:
grease.
- Drive, control, steering
- Lubricate the mast pivots and steering axle.
- Brake, (service brake, parking brake)
- Check the condition and acid density of the
battery. Charge and service the battery as - Lifting device (load lifting member, lift chain,
specified by the battery manufacturer. mounting)
- Spray all open electric contacts with a suitable If the truck is to be taken out of service for a yet
contact spray. longer period, contact your Service.
CAUTION
Jack up the truck so that all wheels are clear
of the ground. This measure will prevent a per-
manent deformation of the tires.
- 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.
60 WA
Maintenance data
MAINTENANCE DATA
164 456-10.03 ©
WA 61
Maintenance data
Maintenance data
Table of maintenance data
No. Assembly Aids/ Symbol Dimension/Qty

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 Lithium-based FL/OG as required
grease, oil
4 Braking system Gear oil HGS approx. 0.55 pt (0.25 l)
5 Hydraulic system Hydraulic oil OZ approx. 9 U.S. gal (34 l)
Hydraulic oil for the USDA
foodstuff industry* H1/46
Hydraulic oil for cold
storage warehouse HVLP 46
duty* DIN
51524-T3
164 456-05.04 ©
6 Motor brushes - - max. rest .590 in. to .670 in.
length (15 mm to 17 mm)
7 Tires
Pneumatic inflation pressure see data on truck
min. tread min. .006 in. (1.6 mm)

Superelastic wear limit to wear mark
8 Wheel nuts/bolts
- Steer axle Dynamometer - 155 lb. ft. (210 Nm)
- Drive axle Dynamometer - 440 lb. ft. (600 Nm)
9 Steer axle
Steering knuckle Dynamometer 230 lb. ft. (310 Nm)
nuts
10 Drive axle Gear oil HGS per side approx. 3 pts (1.4 l)
11 Mast Extreme pressure S as required
adhesive grease
Stop clearance min. .080 in. (2 mm)
Mast pivot bolts Dynamometer 285 lb. ft. (385 Nm)
12 Lift chains LINDE-chain spray S as required
Adjustment roller clearance - .395 in. (10 mm)
below top edge of inner mast
* Option
Truck: ........................................................
Model, Serial No. .........................................
Checklist
Maintenance and lubrication 1000 2000 3000

1. following work hour meter (numbers printed in 1000 1000 3000
bold) 2000 1000
4000 5000 6000
After 3000 hours of operation for instance: any 2000 1000 3000
maintenance and lubrication work due "every 3000
1000 2000
and 1000 hours" must be done.
1000
After 9000 hours of operation continue as shown 7000 8000 9000
above but instead of 1000 hours, 10000 operat- 1000 2000 3000
ing hours etc. 1000 1000
62 WA
Diagrams
DIAGRAMS
164 456-10.03 ©
WA 63
Diagrams
Diagrams
Wiring Diagram
Functional Wiring Diagram 652545 Hydraulic drives for moving the load
2A7 Control unit
2B1 Lift transmitter
NOTICE 2B2 Tilt transmitter
2B3 Aux. hydraulics transmitter 1
The wiring diagram is enclosed or can be requested 2B4 Aux. hydraulics transmitter 2
if needed. 2B5 Aux. hydraulics transmitter 3
2M1 Pump motor
2Y1 Lifting
2Y2 Lowering
Legend to the wiring diagram 2Y3 Tilting back
2Y4 Tilting forward
2Y5 Auxiliary hydraulics 1
NOTICE 2Y6 Auxiliary hydraulics 1
2Y7 Auxiliary hydraulics 2
The components listed in the legend are not installed 2Y8 Auxiliary hydraulics 2
in each truck. 2Y9 Enable
2Y10 Additional function
164 456-10.03 ©
Switch state shown: Auxiliary drives
3B28 Zero sensor for steering
Truck parked as specified 3B29 Steering switch
- Parking brake applied
- Key switch OFF Signalling devices
- Directional switch NEUTRAL 4H1 Horn
- Other controls not operated 4H2 Buzzer
- Operator not seated 4S1 Horn push button
- Emergency stop button operated 4Z1 Circuitry
- Cross section of unmarked cables 0.75 mm²
Lighting
General electrical parts 5E1 Spotlight, right
F1 Fuse 5 A, horn 5E2 Spotlight, left
F2 Fuse 5 A, emergency isolator contactor 5E3 Tail light, right
F3 Fuse 5 A/15 A, brushes 5E4 Tail light left
F4 Fuse 20 A, electric heating 5E5 Position light, right
F5 Fuse 5 A, power supply 5E6 Position light left
F6 Fuse 15 A, voltage converter 5E7 Stop light, right
F7 Fuse 5 A, hydraulic control unit 5E8 Stop light, left
F8 Fuse 5 A, fan motor 5E10 Turn signal light, front left
F9 Fuse 10 A, key switch 5E11 Turn signal light, front right
G1 Battery 5E12 Turn signal light, rear left
K1 Relay 5E13 Turn signal light, rear right
K2 Relay 5E17 Spotlight, right
S1 Key switch 5E18 Spotlight, left
X1 Female battery connector 5E19 Internal light
X2 Male battery connector 5E21 Rotating beacon, rear right
5E23 Rotating beacon
Traction drives 5E24 Reversing light, left
1B1 Accelerator pedal transmitter 5E25 Reversing light, right
1B2 Brake transmitter 5E28 Reversing spotlight, right
1B3 Voltage at outlet (X16:2) decreases with 5E29 Reversing spotlight, left
actuation of forwards pedal 5E39 3rd Stop light
1B4 Voltage at outlet (X16:3) increases with 5S2 Hazard warning switch
actuation of forwards pedal
1F2 Fuse Instruments and gauges
1K1 Main line contactor 6B17 Speed sensor
1M2 Traction motor 6B22 Speed sensor
1R17 Temperature sensor 6S3 Oil pressure switch
1S1 Directional switch 6S4 Brake fluid switch
1S3 Parking brake switch
1S14 Step switch
1S16 Switch for accelerator transmitter
64 WA
Diagrams
Special functions
7B1 Sensor for lift limiting
7K2 Emergency isolator
7S1 Seat contact switch
7S2 Emergency stop button
7S13 Dead mans switch
7S15 Switch for 5th hydraulic function (with valve
levers)
7S17 Seat belt lock switch
Miscellaneous
9E10 Heater
9E12 Seat heater
9M2 Wiper, front
9M3 Wiper, rear
9M5 Fan motor
9M10 Wiper motor, front windscreen
9M11 Wiper motor, rear window
9R3 Heating resistance
9R16 Rear window heating
U1 Converter 24 V
U2 Converter 12 V
U3 Converter 24 V
164 456-10.03 ©
X Connector
A9 Control unit
XK Nodal point in wiring harness

N3 Ground at the frame (right)
N4 Ground at the overhead guard
N6 Ground at front body (left)
N7 Ground at the converter fastening screw
N8 Nodal point in the wiring harness
N9 Ground at the converter fastening screw
WA 65
Diagrams
+80V nach Schlüsselschalter +80V after key switch
+80V vor Schlüsselschalter +80V before key switch
2-Pedal-Bodenplatte 2-pedal floor plate
5. Funktion 5th function
Ausgangsparameter Initial parameters
BASF und Mercedes BASF and Mercedes
bei Joystick with joystick
bei Variante Elektroheizung hier gesteckt Installed here with electric heater variant
belegt Not free
Beleuchtung Lighting
Beleuchtung normal mit dritter Bremsleuchte Standard lighting with third stop light
Beleuchtung StVZO mit Kennzeichenhalter Road lighting with license plate holder
Busleitungsverkabelung Bus wiring
Busversorgung Bus power supply
Diagnose Diagnostics
Gebläse Fan
Heizung Heater
Hubbegrenzung Lift limiting
Kabine Cabin
Kanalbelegung Channel layout
Kennzeichenleuchte License plate light
Konsole Display
Lenksäule Steering column
164 456-10.03 ©
Mag. Ventil Anbau Solenoid valve attachment
Mag. Ventil Hubbegrenzung Lift limiting solenoid valve
Magnetventil am Anbaugerät mit Beschaltung Solenoid valve at attachment with circuitry
nur für Signalgeber For signal transmitter only
Optional Optional
Pilotkontakt Pilot contact
Radio Radio
Relaisbox vorn Relay box, front
Relaiskarte hinten Relay card, rear
Relaiskarte vorn Relay card, front
Relaisplatte Relay plate
Schutzdach Overhead guard
Serie Standard
Sicherungsplatte Fuse panel
Signalgeber Signal transmitter
Sitzheizung Seat heater
Steckverbindung siehe zusätzliche STU For connector see additional STU
Sucher als Scheinwerfer Spotlight
Temperaturgeber Temperature transmitter
Totmannschalter Dead mans switch
Variante Zweipedalsteuerung Two-pedal control model
Verteilerkarte Haltewinkel vorne Distributor card front bracket
Warnblinker Hazard warning flasher
Wascher Washer
Wischer Wiper
66 WA
164 456-10.03 © Diagrams
Hydraulic schematic as of 10/1996
Hydraulic diagram
Standard equipment (modifications reserved)
Legend
1 Steering cylinder 10 Tilt cylinder

2 Steering unit 11 Slow-down valve
3 Hydraulic oil reservoir 12 Pipe check valve
4 Suction filter 13 Lift cylinder
5 Pump unit 14 Transmitter (electric pressure pick-up for
6 Way valve block (*Pressure relief valve displaying pressure)
adjusted to 3626 psi (250bar)) 15 Pressure relief valve
7 Way valve block (double auxiliary hydraulics) 16 Breather filter
8 Way valve block (single auxiliary hydraulics) 17 Priority valve
9 Pressurizing valve 18 Pressure switch (electric breaker)
19 Hydraulic accumulator*
* Option
WA 67
Diagrams
164 456-10.03 ©
Hydraulic diagram
Provided with Joystick
(modifications reserved)
Legend
1 Steering cylinder 13 Lift cylinder

2 Steering unit 14 Transmitter (electric pressure pick-up for
3 Hydraulic oil reservoir displaying pressure)
4 Suction filter 15 Pressure-relief valve
5 Pump unit 16 Breather filter
6 Way valve block (lift/tilt) 17 Priority valve
7 Way valve block (double auxiliary hydraulics)* 18 Pressure switch (electric breaker)
8 Way valve block (single auxiliary hydraulics)* 19 Hydraulic accumulator*
9 Pressurizing valve 20 Pressure regulator (double auxiliary
10 Tilt cylinder hydraulics)*
11 Slow-down valve 21 Pressure regulator (single auxiliary hydraulics)*
12 Pipe check valve
* Option
68 WA
Index
INDEX
164 456-10.03 ©
WA 69
Index
Index
Page Page
1000-hour maintenance ............................... 34
2-year maintenance ..................................... 58
A
Accident hazards ............................................ 5 Checking the parking brake cable
Adjust chain ................................................ 42 for condition, tension and wear,
Adjusting the lift chains ................................ 42 and adjusting if necessary ...................... 36
Adjusting the parking brake switch ................. 37 Checking the steering axle ...................... 35, 52
After washing the truck ................................ 21 Checking the steering axle nuts
Annual maintenance ..................................... 56 for proper torque ................................... 35
Auxiliary drives ............................................ 64 Checking the steering system pipes and
hoses for leaks ...................................... 35
B Checking the tires for inflation pressure,
wear and condition ................................ 22
Battery charging .......................................... 26 Checking the torque of the mast pivot bolts .... 45
Battery hazard prevention ......................... 9, 25 Checklist ..................................................... 62
Battery insulation inspection ................... 37, 56 Clean the fan filter and replace, if necessary ... 29
164 456-10.03 ©
Battery maintenance precautions ................... 26 Clean the seat belt ....................................... 32
Be careful not to get caught or fall ................... 3 Cleaning the electrical system ....................... 21
Bleeding the hydraulic system ....................... 54 Cleaning the intake filter ............................... 30
Bleeding the steering system ......................... 54 Cleaning the lift chains ................................. 21
Bleeding the telescopic mast ......................... 54 Cleaning the truck ....................................... 20
Bleeding the tilt cylinders .............................. 54
Bleeding the triplex and NiHo mast ................ 54 D
C Definition of used terms ................................ III
Diagrams .................................................... 64
Change brake fluid ....................................... 56 Disposal of greases, oils and batteries .............. 5
Charging the battery .................................... 25 Do not put metal objects on top of battery ........ 9
Check hydraulic hoses and pipes .................... 41 Draining the gear oil ..................................... 52
Check the seat belt ...................................... 32 Drive axle ................................................... 28
Checking and cleaning the battery ................. 37
Checking and inflating tires ....................... 4, 22 F
Checking bearing clearance (X) ..................... 48
Checking float switch and the Filling the gear oil ........................................ 52
brake fluid level function ......................... 24 Fire precautions ............................................. 8
Checking lateral clearance (Y) ....................... 48 Foreword ...................................................... I
Checking the brake fluid level, Functional Wiring Diagram 652545 ................ 64
topping up if necessary .......................... 24 Fuse replacement ........................................ 27
Checking the brake for proper operation Fuses on fuse panel ..................................... 27
and leaks .............................................. 36 Fuses on the relay box ................................. 27
Checking the cable connections ..................... 38
Checking the clearance between
the fork carriage and run-out stop ........... 44
G
Checking the contactors ............................... 38 General ........................................................ I
Checking the drive axle for leaks ................... 34 General electrical parts ................................. 64
Checking the drive wheel bearing play ............ 52 Greasing the mast channels .......................... 44
Checking the forks ....................................... 45
Checking the forks for condition and
for function of fork stoppers .................... 45
H
Checking the hydraulic oil level and the Handling tires .......................................... 4, 23
hydraulic system for leaks ...................... 40 Hydraulic diagram ........................................ 67
Checking the insulation resistance ................. 56 Hydraulic drives for moving the load .............. 64
Checking the lift chains for condition
and wear, lubricating .............................. 42
Checking the lift cylinders and connections
I
for leaks ............................................... 42 Inspection and maintenance
Checking the oil level in the drive axle ............ 34 intervals ................................... 13, 15, 17
Instruments and gauges ............................... 64
70 WA
Index
Page Page
J Q
Jacking up lift truck (when checking or replacing tires) ... 6 Quality and quantity of required lubricants ........ I
Jacking up on the frame ................................. 6
Jacking up on the mast ................................... 6
Jacking up the truck ....................................... 6
R
Recommissioning after taking out of service .... 60
L Recurring inspections ................................... 56
Renewal after an accident ............................. 32
Lift mast removal ........................................... 7 Renewing the brake fluid ............................... 36
Lifting and jacking up the truck ....................... 6 Renewing the drive motor and
Lighting ...................................................... 64 pump motor brushes .............................. 39
Lubricating the mast pivots ........................... 45 Renewing the fuel filter ................................. 30
Lubricating the parking brake lever Renewing the gear oil ................................... 52
164 456-10.03 ©
and ratchet ........................................... 37 Renewing the heat exchanger, heater ............. 58

Lubricating the steering axle ......................... 35 Renewing the hydraulic oil ............................ 58
Renewing the hydraulic oil and
M hydraulic oil filter ................................... 53
Renewing the motor brushes ......................... 29
Maintenance after 10 years ........................... 58 Replace safety critical parts periodically ............ 3
Maintenance and lubrication .......................... 62
Maintenance as required ............................... 20 S
Maintenance chart ....................... I, 12, 14, 16
Maintenance data ........................................ 62 Safe parking ................................................. 8
Maintenance location ..................................... II Safety devices ............................................... 5
Maintenance of cold storage Safety inspection according to interval
warehouse trucks .................................. 31 and extraordinary events .............. 2, 49, 56
Maintenance personnel for batteries ................ II Safety measures for maintenance and repair ..... 5
Marks on dipstick ......................................... 40 Safety precautions for maintenance ................. 2
Measures before taking out of service ............. 60 Securing the mast against tilting back .............. 7
Measures when storing, taking the truck out Securing the raised NiHo mast ......................... 7
of service for a long period ..................... 60 Securing the raised telescopic mast .................. 7
Miscellaneous .............................................. 65 Securing the raised triplex mast ...................... 8
MOTOR BRUSHES ERROR 195 ....................... 29 Service the restraint system .......................... 32
MOTOR BRUSHES ERROR 203 ....................... 29 Service the seat belt .................................... 32
Servicing the attachments ............................ 31
N Servicing the battery ................................ 8, 25
Servicing the battery according to the
NiHo mast ................................................... 43 manufacturers instructions ..................... 37
Servicing the brake system ........................... 56
O Servicing the braking system .................. 24, 36
Servicing the drive axle .......................... 34, 52
Oiling joints and controls .............................. 28 Servicing the electric motors ................... 29, 38
Ordering spare parts ..................................... II Servicing the electrical system ...................... 37
Servicing the heater ..................................... 30
P Servicing the hydraulic system ................ 40, 53
Servicing the mast ................................. 42, 48
Precautions for inspection and maintenance ...... 2 Servicing the mast pivots ........................ 31, 45
Precautions when carrying out inspection Servicing the steering axle ................ 28, 35, 52
and maintenance ..................................... 2 Servicing the wheels .................................... 28
Precautions when charging ........................ 9, 25 Servicing the wheels and tires ....................... 22
Precautions with high pressure, Settings ........................................................ 5
high temperature oil .......................... 3, 41 Signalling devices ........................................ 64
Special functions .......................................... 65
Staff training and qualifications for
maintenance and repairs ......................... II
WA 71
Index
Page
T
Table of contents ......................................... IV
Table of maintenance data ............................ 62
Taking out of service .................................... 60
Telescopic mast ........................................... 43
Testing the insulation resistance
of the electrical system .......................... 56
Tighten wheel nuts / bolts ............................. 28
Tires .......................................................... 22
Traction drives ............................................. 64
Triplex mast ................................................ 43
Truck parked as specified .............................. 64
164 456-10.03 ©
Use qualified personnel for inspection
and maintenance .................................... II
Use suitable tools ........................................... 3
W
Washing instructions .................................... 20
Washing the exterior of the truck ................... 20
Waste materials ............................................. 5
Wiring Diagram ........................................... 64
Work on the electrical equipment ..................... 5
Working on the front part of the truck .............. 7
Working on the lift mast ................................. 7
72 WA

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Electric Fork Lift Trucks

Contract#C2824 R 6046-49 SERIES

LINDE LIFT TRUCK CORP.

General Date of issue and version of manual

LINDE fork lift trucks comply with safety October 2003

tachments and battery (optional)

- Spare parts list Linde Lift Truck Corporation

MODEL LINDE LIFT TRUCK

R60-35 6046 51 6046 0 _ _ _ _ _

R60-40 6047 51 6047 0 _ _ _ _ _

R60-45 6048 51 6048 0 _ _ _ _ _

R60-50 6049 51 6049 0 _ _ _ _ _

- NOTE: Please indicate this SERIAL NUMBER for

Manufacturers Identification Plate on the truck.

Lift truck information .................................... 2

Information on operation .............................. 8

Operating the lifting device ......................... 96

Other activities ........................................ 122

Ending operation ..................................... 136

Trailers, Towing ........................................ 142

Transport, Hoisting, Towing ....................... 146

Display, Setting, Operation ....................... 152

Malfunctions, cause, remedy ..................... 158

Index ...................................................... 162

READ AND FOLLOW ALL SAFETY

The fork lift truck is suitable for lifting, transporting

The maximum load that can be lifted is specified

LINDE cannot predict every circumstance that

If any procedures or actions not specifically

The procedures and precautions given in this

Standards and regulations

This truck meets the requirements of:

- Safety Standards for Low Lift & High Lift Trucks

- Product Safety Signs & Labels C

ANSI Z 535.4 as of 2002

The truck can be used inside and outdoors in

If your truck is to be operated, for example, in a

Definition of used terms:

Most accidents are caused by a failure to follow

READ AND FOLLOW ALL SAFETY

Operator Prohibition of use by unauthorized

The driver must be acquainted with the operating

READ AND FOLLOW ALL SAFETY

Egress of fuels and lubricants

WARNING Know what to do in the event of a fire.

Fire Prevention for fuel (Diesel-

Safe operating plan

After refueling, tighten the gas cap securely and

Precautions when starting the truck WARNING

Before starting to drive up a slope, stop the lift

Always ensure that the hood is properly latched.

For safe travel on slopes:

When traveling down slopes, use the braking

Do not jump off lift truck even if it

- Stay in the operators seat.

- Brace your legs.

- If you jump off the lift truck when it turns

- Always stay in the operators compartment

Manufacturers Identification Plate on the truck.

- Stay in the operators seat.

- Always stay in the operators compartment

29 Handling instructions for drive program 32 Manufacturers logo