Linde UM - 392 - 01 - T - EN - 0806

Operating Instructions
LPG truck
H20T, H25T
392 807 1051 EN – 06/2008
Preface
g
Linde − Your Partner
With over 100,000 fork lift trucks and ware- ranging from expert advice on all aspects
house machines sold annually, Linde is one of of sales and service through, of course, to
the world’s leading manufacturers of material appropriate finance options. Our leasing, hire
handling equipment. There are many reasons or lease-purchase agreements provide you
for this success: Linde products are renowned with the flexibility to tailor decision-making to
not only for their innovative, cutting-edge tech- your individual business requirements.
nology, but also for their low energy and oper-
Linde Material Handling GmbH
ating costs, which are up to 40 per cent lower
Carl-von-Linde-Platz
than those of their competitors.
63743 Aschaffenburg
The high quality of Linde products is also Telephone +49 (0) 6021 99-0
matched by the quality of our service. With ten Fax +49 (0) 6021 99-1570
production plants worldwide and an extensive Mail: [email protected]
network of sales partners, we are at your Web: http://www.linde-mh.com
service round the clock and around the world.
Your local Linde partner can offer you a
complete package from a single source;
Operating Instructions – 392 807 1051 EN – 06/2008 I

Table of contents
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1 Introduction
Your forklift truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Proper usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Closing the LPG console without an LPG bottle in place . . . . . . . . . . . . . . . . . . . . . . . . . 3
Symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Reception of forklift truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Service plan before initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Safety
Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
In the case of tip-over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Handling consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Specialist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Operation of industrial trucks in plant area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety information on the LPG system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Safety guidelines for LPG (extract) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Safety measures when working on ignition systems . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Determination and assessment of hazards from use of industrial trucks . . . . . . . . . . . . 17
Instructions before fitting attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3 Overview
Identification plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Truck overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Indicator unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Switch panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4 Operation
Running-in instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Checks before starting work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Standard equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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Adjusting the driver’s seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Adjusting the steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Setting the clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Open gas shut-off valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Drive engine (two-pedal operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Close gas shut-off valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Driving (two-pedal operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Drive engine (single-pedal operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Close gas shut-off valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Driving (single-pedal operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Brake system (H 20 T/H 25 T) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Brake system (H 25 TCT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Lifting system and attachments (central lever operation) . . . . . . . . . . . . . . . . . . . . . . . 62
Lifting system and attachments (single lever operation) . . . . . . . . . . . . . . . . . . . . . . . . 66
Special equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Lifting system and attachments (single lever operation with toggle-switch-controlled
third auxiliary hydraulics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Lifting system and attachments with 3rd auxiliary hydraulics without toggle switch . . . . 74
Adjust driver’s seat with swivel device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Adjust the driver’s air-sprung seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Driving speed reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Lift mast positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Lift height reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Windscreen wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Window heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Driver’s cabin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Heater, air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Linde Forklift Data Management (LFM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Working under load . . . . . . . . ............... ............... . . . . . . . . . . . . 96
Before taking up a load . . . . . . ............... ............... . . . . . . . . . . . . 96
Adjusting the fork spread . . . . ............... ............... . . . . . . . . . . . . 97
Taking up load . . . . . . . . . . . . ............... ............... . . . . . . . . . . . . 98
Travelling with load . . . . . . . . ............... ............... . . . . . . . . . . . . 99
Setting down loads . . . . . . . . . ............... ............... . . . . . . . . . . . . 100
Tow coupling . . . . . . . . . . . . . ............... ............... . . . . . . . . . . . . 101
Loading / Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Securing the hose pulley against rolling up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
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Dismantling of lift mast . . . . . . . . . . . . . . . . ............... . . . . . . . . . . . . . . . . . 102

Driving without lift mast . . . . . . . . . . . . . . . . ............... . . . . . . . . . . . . . . . . . 103
Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... . . . . . . . . . . . . . . . . . 104
Transport with lorry or low-bed trailer . . . . . ............... . . . . . . . . . . . . . . . . . 106
Before leaving the truck . . . . . . . . . . . . . . . ............... . . . . . . . . . . . . . . . . . 106
5 Maintenance
General points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Working on the Linde lift mast and at the front of the truck . . . . . . . . . . . . . . . . . . . . . . . 109
Inspection and maintenance data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Consumables recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Inspection and maintenance overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
50 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Service plan as required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
1000 h service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
3000 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
6000 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
9000 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Checking the engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Changing the engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Change motor oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
LPG system: Checking the fuel level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Changing an LPG single cylinder (H 20 T / H 25 T) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Changing an LPG double cylinder (H 20 T / H 25 T) (special equipment) . . . . . . . . . . . . 138
Changing an LPG single cylinder (H 25 TCT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Filling the LPG tank (special equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Change the LP gas filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Check the setting of the LPG mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Cleaning the evaporator / pressure regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
LPG system visual inspection, odour inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Checking the LPG system for damage and leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Checking the coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Changing coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Check coolant concentration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Cleaning the water cooler and hydraulic oil cooler, and checking them for leaks . . . . . . 155
Change the water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Check the condition of the engine mountings and engine suspension; check that they
are attached securely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Check condition of ribbed V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
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Change ribbed V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Checking the condition and tension of toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Changing the toothed belt and tensioner pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Changing the air filter cartridge, checking the vacuum-operated switch . . . . . . . . . . . . 161
Exchange air filter safety cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Check the dust discharge valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Cleaning the prefilter (special equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Cleaning the oil bath air filter (special equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Change the oil in the oil bath air cleaner (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Check the basic setting of closed-loop catalytic converter for gas installation (op-
tion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Check the CO content in the exhaust gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Check the air intake and exhaust lines for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Changing the spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Change the high-pressure gas hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Checking the fastenings of the axle clamps and wheel motors . . . . . . . . . . . . . . . . . . . 169
Checking and adjusting the side stops on the drive axle . . . . . . . . . . . . . . . . . . . . . . . . 169
Checking the drive axle bearings for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Checking the hydraulic pump’s attachment to the engine . . . . . . . . . . . . . . . . . . . . . . . 170
Chassis, bodywork and fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Cleaning the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Floorplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Servicing the air conditioning (special equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Check the lap seat belt for condition and proper operation . . . . . . . . . . . . . . . . . . . . . . 176
Checking fastening of frame, tilt cylinders and steering axle . . . . . . . . . . . . . . . . . . . . . 177
Check and oil other pivots and joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Chassis frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Wheel change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Tighten the wheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Check the tyres for damage and foreign objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Checking solid rubber tyres for wear (H 25 TCT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Checking the tyre pressure and tyre sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Cleaning and greasing the steering axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Check the steering cylinder and king pin for security . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Check the parking brake for correct operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Checking the pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Checking the bellows at the actuating lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
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Electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Checking the condition and secure positioning of electric cables, cable connectors and
cable connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Battery: check condition, acid level and acid density . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Change hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Hydraulic system: Check oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Hydraulic system: changing the filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Check correct operation of breather valve on the hydraulic oil tank . . . . . . . . . . . . . . . . 195
Check the hydraulic system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Check tilt cylinder bearings for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Check the tension of double hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Checking the function and safety system of the third auxiliary hydraulics (special equip-
ment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Load lift system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Cleaning the lift mast chain and applying chain spray . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Mast, lift chains, lift cylinders and end stops: Check for security, condition and proper
operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Adjust lift mast chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Check the forks and fork quick-releases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Clean sideshift (special equipment) and grease, check fastening . . . . . . . . . . . . . . . . . 203
Checking the slide guides on the sideshift (special equipment) for wear . . . . . . . . . . . . 204
Cleaning and lubricating the fork positioner (special equipment), checking the fasten-
ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Check fork arm adjustment device (special equipment) for wear and tear . . . . . . . . . . . 206
Special equipment, accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Filling up the washer system water tank (special equipment) . . . . . . . . . . . . . . . . . . . . 206
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Opening the cover to the electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Fuses for basic and special equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Main fuses in engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Diagnostic connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Jump start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Fork carriage emergency lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Emergency exit for trucks with rear screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Towing regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Placing the forklift truck into storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Disposal of old vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Malfunctions during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Malfunctions, Causes and Remedy (LPG engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Malfunctions, Causes, Remedies (ultrasonic sensor) . . . . . . . . . . . . . . . . . . . . . . . . . 222
Operating Instructions – 392 807 1051 EN – 06/2008 VII

Table of contents
g
Malfunctions, causes, remedies (hydraulic equipment) . . . . . . . . . . . . . . . . . . . . . . . . 223
6 Technical data
Type sheet H 20 T, as at 06/2007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Type sheet H 25 T, as at 06/2007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Type sheet H 25 TCT, as at 04/2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Load diagrams and lift mast data as at 06/2007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Noise emission values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Vibration characteristic values for bodily vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Annex
7 Circuit diagrams
Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
LPG basic equipment sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Basic equipment for LPG sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Basic equipment for LPG sheet 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Special equipment sheet 1 — working headlights, lighting, direction indicator system,
brake light, interior lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Special equipment sheet 2 − Windscreen wiper, seat heater, radio . . . . . . . . . . . . . . . . 260
Special equipment sheet 3 − Heater, air conditioning, rotating beacon, reversing sig-
nal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Special equipment sheet 4 − Hazard warning system for reversing, higher lighting . . . . 264
Special equipment sheet 5 − Lift mast positioning, hydraulic oil microfilter indicator,
vehicle deactivation, Forklift Data Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Special equipment sheet 6 − Particulate filter, diesel filter water trap warning . . . . . . . . 268
Special equipment sheet 7 − LPG volume display, 12 V socket, working headlights
pos. 5 and 6, coolant and engine oil level monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Special equipment sheet 8 − Battery main switch with indicator unit voltage supply,
exchangeable particulate filter, rear window heater, camera system . . . . . . . . . . . . . . . 272
Special equipment sheet 9− Third auxiliary hydraulics with third joystick, centre rear
brake/tail light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Hydraulic circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Traction, working and steering hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
VIII Operating Instructions – 392 807 1051 EN – 06/2008

1
Introduction
1 Introduction
Your forklift truck
Your forklift truck

offers optimum efficiency, safety, reliability Forklift truck model:
and comfort. It is now up to you to maintain
Production number /
these characteristics for as long as possible
Year of manufacture
and to take advantage of the resulting benefits.
Handover date:
During manufacture:
• all safety requirements of the relevant EC The production number should also be spec-
directives were observed ified for parts from the following units: en-
• all conformity assessment procedures gine, lift mast, hydraulic variable displacement
stipulated in the applicable directives were pump, drive axle and steering axle.
carried out.
Engine number:
This is attested by the CE mark shown on the
Lift mast number:
nameplate.
Lift mast stroke:
This operating manual contains everything
you need to know about commissioning, Hydraulic variable
driving and maintenance. displacement pump
number:
A number of special equipment items have
their own operating manuals, which are sup- Drive axle number:
plied along with this equipment. Please ob- Steering axle
serve the information for operation depend- number:
ing on the version of your forklift truck and
carry out the specified work regularly, at the When taking over the forklift truck, this data
due times and using the working materials should be copied from the rating plates of the
envisaged for this purpose according to the units into this operating manual.
inspection and maintenance overview pro-
gram. Please make sure you record the work NOTE
performed in the registration document for the
industrial truck; only in this manner will you In the event of repairs, only use genuine Linde
comply with the warranty conditions. spare parts. This is the only way to guarantee
that your forklift truck remains in the same
The designations used in the text: front - rear technical state as at the time of takeover.
- left - right - always refer to the installation
position of the parts described with forwards Please address all queries and orders for
as the direction of travel (fork arms forwards) spare parts relating to your forklift truck only to
for the forklift truck. your authorised dealer , stating your mailing
address.
In the case of servicing work not described
here, specialist knowledge, measuring instru- Linde is constantly engaged in the further
ments and frequently also special tools are development of its products . We ask for
required. Please ask your authorised dealer your understanding that figures/diagrams
to carry out this work. and technical data are subject to technical
modification in terms of form, equipment and
Servicing should only be carried out by qual- know-how in the interest of progress.
ified personnel approved by Linde (special-
ists). For this reason no claims can be asserted
on the basis of the following data, figures/di-
With orders for parts, please specify the agrams and descriptions in this operating
following along with the parts numbers: manual .
2 Operating Instructions – 392 807 1051 EN – 06/2008

Introduction 1
Closing the LPG console without an LPG bottle in place
This operating manual must not be repro- parties - including as excerpts - except with the
duced, translated or made accessible to third express written approval of the manufacturer .
Proper usage
The forklift truck is intended for transporting • The special measures for driving on public
and stacking the loads indicated in the load roads within the scope of the StVZO (Road
capacity diagram. We expressly draw your Traffic Licensing Regulations)
attention to: • Other specific national regulations.
• The VDMA brochure on "Rules for proper Regulations for proper use of industrial trucks
use of industrial trucks" supplied with these must be observed without fail by the personnel
operating instructions responsible, particularly by operating and
• Extracts from the safety guidelines regard- maintenance personnel.
ing the use of LPG (described in the chapter
Before your truck is used for work not listed
"Safety")
in the guidelines, and which require it to be
• Safety measures when dealing with ignition converted or retrofitted, please contact your
systems (described in the chapter "Safety") authorised dealer.
• The accident prevention regulations of your
employer’s liability insurance association No modifications, in particular attachment or
conversion, should be made to your forklift
truck without the manufacturer’s approval.
The user, and not the manufacturer, is liable
for any hazards caused by improper use.
Closing the LPG console with-

out an LPG bottle in place
CAUTION
On vehicles with an ultrasonic sensor the ultrasonic
sensor may be damaged if the console (5) is closed
without an LPG bottle in place.
Therefore, never close the console without subse-
quently locking the clamping plate (3).
Operating Instructions – 392 807 1051 EN – 06/2008 3

1 Introduction
Technical description
¾ Attach the catches (1) of tightening straps

(4) to bracket (2).
¾ Pull the tightening straps until they are taut.
¾ Close the console until the locking device
engages.
Symbols used
The terms DANGER, WARNING, CAUTION,
NOTE
NOTE and ENVIRONMENT NOTE are used
in these operating instructions for notes on Means that particular attention is drawn to
particular hazards or for unusual information combinations of technical factors which may
that needs to be highlighted: not be evident even to a specialist.
DANGER
ENVIRONMENT NOTE
Means that failure to comply can cause risk to life
and/or major damage to property. The instructions listed here must be complied
with as otherwise environmental damage may
result.
WARNING
CAUTION
Means that failure to comply can cause risk of
serious injury and/or major damage to property. This label is found on the truck in
the areas where particular care and
attention are required.
CAUTION You should refer to the appropriate
section in these operating instruc-
Means that failure to comply can cause risk of tions.
material damage or destruction.
For your safety, additional symbols are also

used. Please heed the various symbols.
Forklift trucks in the 392 series are designed for loads of up to 2 t with the H 20 and 2.5 t with
to handle loading and palletising operations the H 25.

Introduction 1
Details on the exact lift-height-specific maxi- Operation

mum loads are available in the load diagram.
One accelerator pedal each for forward travel
The trucks are eco-friendly and their quiet and reversing (two-pedal operation) is used to
operation and low level of emissions benefit simultaneously regulate the hydraulic variable
both the driver and the environment. They displacement pump and the engine speed.
excel on account of their compact design The hydrostatic drive enables the speed to be
and a small turning radius, and they are fully continuously varied in both directions, ranging
container compatible. For this reason, the from standstill up to maximum speed. The
forklift trucks are particularly well-suited for dual-pedal control means that operation of the
narrow aisles and operational areas where forklift truck is simple, safe, non-fatiguing and
space is at a premium. efficient.
The driver always has both hands free for
Engine steering and controlling the operational
The drive engine is a 4-cylinder, four-stroke movements. This results in fast reversing
spark-ignition engine. It powers the truck’s hy- and efficient stacking.
draulic pumps and varies its speed depending An optional version is also available whereby
on the load. The engine is cooled by means the speed is regulated by an accelerator pedal
of a closed coolant circuit with an expansion (single-pedal operation) and the direction of
tank. travel controlled by means of a travel direction
Forced circulation lubrication with an oil pump switch.
in the oil sump is used to lubricate the engine. To control the operational movements lifting,
The combustion air is cleaned by means of a lowering and tilting, there is only one actuating
dry air filter with a paper insert. lever (joystick). Another joystick is fitted to
Internal combustion engines with ultra-mod- operate additional attachments. Operational
ern engine technology are used for: movements can also be controlled using
two or four joysticks (single-lever operation
• High torque version).
• Low fuel consumption
• Low exhaust emissions Linde Load Control
• Low noise levels The truck’s Linde Load Control (LLC) system
enables:
Hydraulic system
• Millimetre-perfect and secure mast han-
The traction drive consists of a hydraulic dling
variable displacement pump, two hydraulic • Effortless finger-tip control of all lift mast
fixed-displacement wheel motors (assembled functions
as a drive axle unit) and a hydraulic pump
• Drive and lifting functions are entirely
(fixed displacement pump) for the working
separate.
and steering hydraulics. Direction of travel
and speed are regulated by means of two
accelerator pedals via the hydraulic variable Linde Truck Control
displacement pump. The truck’s Linde Truck Control system (LTC)
The hydraulic fixed-displacement wheel provides for:
motors in the drive axle are supplied by the • Sensitive, smooth driving and reversing
hydraulic variable-displacement pump and
• Automatic regulation of the engine speed to
they power the drive wheels.
match the respective power required by the
hydraulics

1 Introduction
Reception of forklift truck
• Fast service by means of self-diagnosis If the power applied to the steering wheel is
• Optimum operational reliability. increased, the steering system can also be
operated when the engine has been switched
off.
Brakes
The hydrostatic drive is used as a service Lift mast
brake. This means that the service brake is
maintenance-free. There are two multi-disc The free-view lift mast enables:
brakes integrated into the wheel motors, • Ideal visibility through slim mast profiles
which are used as a parking brake. The
• Full load capacity up to maximum lift heights
multi-disc brakes are engaged when the
engine is switched off. This gives the truck an • Enormous residual lifting capacity
automatic braking function.The parking brake • Maintenance-free bearings for lift mast and
must always be activated when the truck is tilt cylinders via rubber-cushioned linkage
switched off. points
The type H 25 TCT truck has different braking • Electric tilt angle limitation.
behaviour. Please pay special attention to the
section entitled "Service brake H 25 TCT". Electrical system
The electrical system is supplied with 12 V DC
Steering by the alternator. A 12 V battery with 88 Ah is
The steering is a hydrostatic steering system, installed to start the engine. It is located under
under which the steering wheel acts on the the driver’s seat in the engine compartment.
steering cylinder to actuate the rear wheels.
Reception of forklift truck

Before the truck leaves our factory, it is (one-pedal operation. This screw must be
subjected to a careful inspection to ensure removed after attaching the mast by loosening
that it is in perfect condition and is received the screw and removing it along with the aid of
by you complete with all equipment according a hexagonal nut (see also Driving without lift
to your order. Your authorised dealer is also mast).
obliged to perform another inspection and
Each forklift truck comes with the following
proper handover.
technical documents:
To avoid subsequent complaints, please be
• operating manual for forklift truck
so kind as to carefully check the condition
of the truck and the completeness of the • EC Declaration of Conformity (manufac-
equipment yourself and to confirm proper turer confirms that industrial truck complies
handover/takeover vis-à-vis your dealer. with requirements of EC Machinery Direc-
tive).
NOTE • Safety rules for the use of industrial trucks
(VDMA)
For forklift trucks which leave our works • Registration document for the industrial
without a lift mast, an additional stop screw truck, provided on handover by your autho-
for speed restriction can be found under rised dealer.
the forwards/reversing accelerator pedal
(two-pedal operation) or accelerator pedal

Introduction 1
Service plan before initial start-up

Carried
out
9 8
Engine
Checking the engine oil level
Check the coolant level
LPG system: check fuel level
Check the LPG system for damage and leaks
Chassis frame
Tighten the wheel fastenings
Check the tyre pressure
Check the brake system
Check steering system
Electrics / Electronics
Battery: check the condition, acid level and acid density
Hydraulics
Hydraulic system: Check the oil level.
Check lifting system and attachments.
Check function and safety system of third auxiliary hydraulics

1 Introduction

2
Safety
2 Safety
Safety regulations
Safety regulations
The "Rules for proper use of industrial trucks" Safety instructions
enclosed with these operating instructions
must be brought to the attention of the persons DANGER
responsible, in particular to those persons The truck must not be used by unauthorised per-
concerned with operating and maintaining the sons.
trucks, before working with or on the trucks. As the operator, you must ensure that access to the
truck is only possible for authorised personnel.
The operating company must ensure that the
driver understands all the safety information.
Please comply with the regulations and DANGER
guidelines, e.g. Safety devices (e.g. the seat switch) are there for
your safety.
• Operation of industrial trucks,
Safety devices—of whatever kind—must never be
• Driving licence, disabled.
• Rules for driveways and the area of opera-
tion,
DANGER
• Rights, duties and rules of behaviour for the
driver, When retrofitting a 3rd auxiliary hydraulic system,
using solutions other than those recommended by
• Special operating areas the truck manufacturer will render CE conformity
• Information regarding setting off, driving null and void and is therefore expressly forbidden.
and braking, Trucks may only be retrofitted with a 3rd auxiliary
hydraulic system with the approval of the truck
• Information for maintenance and repair,
manufacturer.
• Periodic checks,
• Disposal of greases, oils and battery,
DANGER
• Residual risks.
It is prohibited to connect any safety critical func-
As the operating company or responsible tions such as a bale clamp or the swivel device for
person, ensure that all regulations and safety a fluid container to any third auxiliary hydraulic sys-
guidelines that are applicable to your industrial tem that may be fitted.
trucks are complied with. To prevent the clamp or swivel opening inadver-
tently, the additional function should be connected
When training a forklift truck driver who has to the first auxiliary hydraulic system.
already been trained to BGV D27 standard,
the following must be practised sufficiently by
training, driving, switching and steering, so DANGER
that they are fully mastered. Any additional drilled holes or welding to the over-
head guard will compromise its secure positioning.
• the special features of the Linde forklift truck
(dual-pedal control, central joystick, stop It is therefore strictly forbidden to drill holes in the
overhead guard or to weld to it.
pedal),
• any special equipment for attachments,
• peculiarities of the operation and working CAUTION
area Welding operations on other parts of the vehicle
can cause damage to the electronics.
Only then should training exercises in the
Therefore, before performing any welding, always
racking commence.
disconnect the battery and all connections to the
electronic control units.

Safety 2
In the case of tip-over
CAUTION WARNING
For ease of operation, various functions on your Depending on the duration of
truck are gas-spring assisted. Gas springs are operation and use, components
complex components which contain high internal carrying exhaust gases and exhaust
pressures (up to 300 bar). air can become hot.
They may under no circumstance be opened unless Therefore wear protective clothing.
so directed, and may be removed only when not
under compression. Any damage, lateral forces,
buckling, temperatures in excess of 80°C and WARNING
heavy soiling must generally be avoided. Damaged
or defective gas springs must be changed immedi- The forklift truck working area must be adequately
ately. Please contact your authorised dealer. He lit.
will, if necessary, depressurise the gas spring in
accordance with regulations before dismantling it. If it is insufficiently lit, work lights must be installed
Gas springs must be depressurised before recyc- to ensure that the driver can see properly
ling.
CAUTION
WARNING Various items of special equipment fitted to your
The following issues must be observed when an truck have the "speed reduction" special function
accumulator is fitted. Improper handling of the . It is purely an assistance function. This means
accumulator can lead to serious injuries. that the driver must not rely solely on the "speed
reduction" function during operation.
Before working on the accumulator, it must be
depressurised. Please contact your authorised The driver is always responsible for safe operation.
dealer.
CAUTION
The functioning of medical equipment, e.g. pace
makers or hearing aids, may be impaired when
driving.
Check with a doctor or the medical equipment
manufacturer whether the equipment is sufficiently
protected against electromagnetic interference.
In the case of tip-over
• Stay buckled up The stability of your truck is ensured if used

• Don’t jump properly and as intended. Should the truck
tip over during an unapproved application or
• Hold on tight
due to incorrect operation, always follow the
• Brace feet instructions depicted below.
• Lean away

2 Safety
Operation of industrial trucks in plant area
Handling consumables
ENVIRONMENT NOTE DANGER
LPG becomes gaseous as soon
Consumables must be handled properly as it escapes; this means that a
and in accordance with the manufacturer’s hazardous explosive atmosphere
instructions. will occur immediately.
Ensure adequate ventilation.
• Consumables should only be stored in
containers complying with applicable
regulations and at the locations stipulated.
CAUTION
• Do not bring flammable consumables into
LPG will cause frostbite on bare skin!
contact with hot objects or a naked flame.
Protective equipment must be worn
• When topping up consumables, use only without fail.
clean containers.
• Observe the manufacturer’s instructions
relating to safety and disposal. WARNING
• Avoid spilling. The penetration of pressurised hydraulic fluid into
• Spilt liquids should be taken up with binding the skin , e. g. due to leakage is hazardous. If an
agents at once and disposed of according injury of this type occurs, always consult a doctor.
to the regulations. Protective equipment must be worn.
• Old and contaminated consumables should
be disposed of according to applicable WARNING
regulations.
The improper handling of coolant and coolant addi-
• Comply with the statutory provisions.
tives presents a risk to health and the environment.
• Before performing greasing, filter changes Observe the manufacturer’s instructions without
or any work on the hydraulic system, fail.
carefully clean the area around the part
involved.
• Dispose of used spare parts in an environ-
mentally friendly manner.
Specialist
A specialist is considered to be someone prevention regulations, directives and gen-
whose technical training, experience and re- erally recognised technical conventions (DIN
cent professional activities have enabled them standards, VDE regulations, technical reg-
to develop a sufficient depth of knowledge re- ulations of other EU member states or other
garding industrial trucks and who is sufficiently countries that are signatories to the treaty es-
familiar with the applicable national occupa- tablishing the European Economic Area) in
tional health and safety regulations, accident order to be able to assess the condition of in-
dustrial trucks in terms of health and safety.
Operation of industrial trucks in plant area

Many plant areas are so-called limited public insurance coverage, to ensure that possible
traffic areas. In this sense, we would like to claims for damages caused by your truck
advise you to check your company liability in limited public traffic areas in relation to

Safety 2
Regulations
third parties are included in the insurance

coverage.
Regulations
Periodic safety inspection
Periodic safety inspections are essential in
order to keep your forklift truck/industrial truck
safe and in good working order.
Comply with the national regulations for your
country.
Europe: National laws based on the Directives
95/63/EC, 99/92/EC and 2001/45/EC require
that the forklift truck/industrial truck is checked
regularly by a competent person to ensure it is
in good condition.
Germany: Ordinance on Industrial Safety and
Health (BetrSichV).
There is a recommendation setting out the
scope of the inspection, FEM 4.004 of the Eu-
ropean Industrial Truck Association, which
defines an inspection log to document the cur-
rent inspection and an inspection sticker for
the next inspection. The next inspection is
shown by the year number (3) on a sticker (2),
the colour of which changes each year, on the
label (1). The scope of the inspection is exten-
ded by Linde in accordance with the specific
truck type. Please ask your authorised dealer
to carry out this work.

2 Safety
Safety guidelines for LPG (extract)
Safety information on the LPG system
DANGER
When liquefied petroleum gas
escapes, there is an immediate
danger of explosion and thus also
the risk of burns. This is especially
the case with leaks in the LPG
system and with the engine either
starting not at all or starting poorly.
It is therefore absolutely forbidden
to manipulate the LPG system or to
continue to operate the truck if any
malfunctions occur.

Always observe the accident prevention systems of trucks may only be operated if they
regulations Use of LPG (BGV D34) published are in perfect condition.
by the main trade association, or the national
The owner must draw up operating instruc-
guidelines.
tions for industrial trucks in an understandable
LPG includes the flammable gases form and language, containing all information
PROPANE, BUTANE and mixtures of required for safe operation. The operating in-
these substances. They are stored in LPG structions must be made known to operators
cylinders or LPG tanks for use as fuel in and maintenance staff.
internal combustion engines. The pressure
They must be accessible to operators and
of these gases in the container depends on
maintenance staff at the site of operation at all
the external temperature and may reach up to
times and be observed by such persons.
25 bar or more.
DANGER A. In operation
LPG becomes gaseous as soon 1. Before releasing pipe or hose connections,
as it escapes; this means that a
hazardous explosive atmosphere the cylinder and main shut-off valves should
will occur immediately. be closed. The connecting nuts on cylinders
No open flames (stoves, storm should only be released slowly and very little
lanterns, spark-forming activities at first as the gas still in the pipe will squirt out.
etc.); do not smoke in storage rooms
and when working on the LPG CAUTION
system!
LPG will cause frostbite on bare skin!
Use personal protective equipment.
Obligations of the owner and employees

Pipework and its accessories for gas in liquid
The owner must ensure that industrial trucks phase and LPG containers must not be
are only operated or maintained by persons exposed to an impermissible level of heat.
trained in the operation or maintenance
of such industrial trucks and who can be 2. Removable LPG containers (LPG cylin-
expected to perform their duties reliably. LPG ders) must be positioned on the vehicle so

Safety 2
that they are horizontal and the collar open- be observed. The cylinder and main shut-off
ing faces downwards. Upon installation and valves should be closed when doing so.
removal, the gas outlet connection of the cylin-
9. The condition of the electrical system of
der valve must be sealed off by a lock nut
industrial trucks running on LPG must be kept
securely tightened with a wrench.
under constant surveillance. Sparks may
Before LPG cylinders are connected, their cause explosions if system parts containing
pipe connections must be checked for perfect gas are leaking. After an industrial truck
condition. running on LPG has been shut down for a
lengthy period, the storage room must be
After removal, the cap of the cylinder must be
ventilated thoroughly before starting up the
immediately screwed onto cylinders provided
truck or its electrical system.
with a lock nut.
10. Explosions involving gas cylinders or LPG
3. Valves should be opened slowly! Impact
systems must be immediately reported to the
tools should not be used to open/close valves.
employers’ liability insurance association and
Risk of explosion from spark discharge.
the industrial inspectorate responsible, even
where no injuries result (applies to Germany).
NOTE Damaged parts must be kept until conclusion
If a fire occurs involving LPG, use only carbon of the investigation.
dioxide dry fire extinguishers or carbon dioxide 11. It must be ensured that trucks with LPG
gas extinguishers. systems are only operated in rooms that are
4. Leaking gas cylinders should no longer be entirely or partially enclosed if no hazardous
used. They must be emptied immediately by concentrations of exhaust constituents harm-
being released outside, taking all precautions ful to health can be produced in the room air.
into account, and marked as leaking. If
damaged gas cylinders are supplied, the B. In storage rooms and maintenance
provider or his representative (gas attendant workshops
etc.) must be immediately notified of the
damage present, where possible in writing. 1. The cylinder and main shut-off valves
should be closed as soon as trucks are put
5. The condition of the entire LPG system away.
must be kept under constant surveillance to
ensure safety of operation, in particular in 2. Industrial trucks fuelled by LPG should only
terms of leakage. It is not permitted to use be left in rooms if they are above ground level
a vehicle if the LPG system leaks. When and have adequate ventilation. They must not
checking for leaks, soapy water, a solution be left near openings to rooms below ground
of Nekal or other foaming products should be level. Sufficient space must be left around
used. Never inspect the gas system using a vehicles that have been put away; such areas
naked flame. must not include cellar openings or access
points, pits or similar cavities, drains without
6. Make sure that the LPG system is adjusted liquid traps, ventilation shafts and light wells or
so that the levels of harmful substances in the combustible material.
exhaust gases are as low as possible.
3. Removable LPG containers may only
7. Frozen-up system parts should only be be changed in storage rooms when there
thawed out with hot water, hot sandbags or the is no possibility of a hazardous explosive
like. Naked flames, red-hot objects etc. may atmosphere being produced.
cause explosions.
4. The special regulations governing the
8. When replacing individual system parts, the storage of pressurised-gas containers must
manufacturers’ installation instructions must be observed without fail, as well as state-

2 Safety
Safety measures when working on ignition systems
specific regulations where appropriate. For be closed and the LPG cylinders protected
example, pressurised-gas containers must from heat. Before pauses in operation and
not be stored: finishing operation, the person responsible
should check whether all valves, in particular
• in rooms below ground level
cylinder valves, are closed. Work involving
• on stairwells fire, specifically welding and cutting, should
• in hallways/landings not be carried out in the vicinity of LPG
• in confined yards or passageways/thor- cylinders. LPG cylinders, even when empty,
oughfares or in their immediate vicinity must not be stored in workshops.
• on steps of outdoor installations 7. Storage rooms and maintenance work-
• on specially marked escape routes shops must be well ventilated. Here it should
• in garages be borne in mind that LPG is heavier than air.
It collects at floor level, in work pits and other
• in workrooms.
depressions in the ground where hazardous
Please also take into account the section explosive mixtures of gas and air may be pro-
"General requirements for pressurised-gas duced.
containers; Using pressurised-gas contain-
ers" in the technical regulations applicable to DANGER
pressurised-gas containers TRG 380 and 404, The exhaust gases are poisonous.
as well as applicable national regulations. Ensure adequate ventilation of
storage rooms!
5. Electric hand lamps used in these rooms
must be provided with an enclosed sealed
cover and a strong basket guard.
6. When working in maintenance workshops,
the cylinder and main shut-off valves should
Safety measures when working on ignition systems

To prevent personal injury and/or destruction ¾ Use of a quick charger to jump start the
of the ignition system, please comply with the engine is only permitted for up to 1 minute
following when working on ignition system at a maximum of 16.5 volts.
units:
¾ The engine should only be washed with the
¾ Ignition system lines — including high- ignition switched off.
voltage cables and test equipment leads —
¾ Before carrying out any electric or spot
should only be connected and disconnected
welding, the battery and connections
with the ignition system switched off.
to the control units must be completely
¾ If the system is supposed to crank at starting disconnected. The earth electrode must be
speed but not actually start (e.g. for a as close as possible to the welding point.
compression pressure test), disconnect
the high-voltage cable (terminal 4) from the
ignition distributor and connect it to earth.

Safety 2
Determination and assessment of hazards from use of industrial trucks
Determination and assessment of hazards from use of industrial

trucks
Check note
X = actioned
Hazard Action Notes
- = not
concerned
If in doubt, consult
Industrial truck
competent factory
equipment does not
Check inspectorate or
comply with local
employers’ liability
provisions
insurance association
Driver training (sit-on UVV-BGV D 27 - § 7,
Lack of skills and
and stand-on industrial BGG 925 driver permit
qualification of driver
trucks) VDI 3313
Lack of skills and Instruction for pedestrian-
qualification of driver controlled trucks
Usage by unauthorised Access with key only for
persons appointed staff
Industrial truck not in a Recurrent testing and UVV-BGV D 27 - §§ 9,
safe condition rectification of defects 37, BGG 918
Impaired visibility
Deployment planning UVV-BGV D 27 - § 12
through load
Contamination of Assessment of diesel
TRGS 554
respiratory air exhaust gases
Contamination of Assessment of fuel gas MAK list (maximum work-
respiratory air exhaust gases place concentrations list)
Impermissible usage Issue of operating
UVV-BGV D 27 - § 5
(improper usage) instructions
Impermissible usage Written notice of
UVV-BGV D 27 - §7
(improper usage) instruction to driver
UVV-BGV D 27, observe
Impermissible usage
operating manual and
(improper usage)
VDMA leaflet
When filling up with a)
diesel
VDMA leaflet
When filling up with b)
fuel gas
VDMA leaflet
UVV-BGV D 27, observe VDE 0510: In particular
When charging traction
operating manual, VDMA a) ventilation b) insulation
batteries
leaflet and VDE 0510 value

2 Safety
Instructions before fitting attachments
In the Federal Republic of Germany the Ger- In order to ensure the safe usage of industrial
man Law on Health and Safety at Work (Arb- trucks we not only supply every industrial
SchG) states that it is up to the Employer to truck with a copy of the operating manual but
assess which hazards are associated with also with the leaflet of the VDMA (German
the work of employees and which Health and Engineering Federation) specifying the rules
Safety measures are required (§ 5 ArbSchG). for the proper usage of industrial trucks "Rules
The result must be documented (§ 6 Arb- for the Proper Use of Industrial Trucks".
SchG). In the case of industrial truck deploy-
The list specifies key hazards which are most
ments involving similar hazard situations it is
frequently the cause of accidents in the event
permitted to summarise the results . In coun-
of non-compliance. If other major hazards are
tries outside the Federal Republic of Germany
involved at a specific plant , they must be listed
the country-specific regulations must be ob-
additionally.
served. With the list we are helping you to
comply with these regulations. The construc- In many plants the conditions of use for
tion and equipment of industrial trucks comply industrial trucks are by and large similar so
with the Machinery Directive 98/37/EC and that the hazards can be summarised in one
are identified by the CE mark accordingly. list. The pronouncements of the employers’
This means that they do not fall under the liability insurance association competent in
scope involved in the assessment of hazards, each case as regards this topic should also be
and nor do attachments due to their own CE taken into account.
marking . The operator must however select
the type and equipment of industrial trucks so
as to comply with the local provisions for de-
ployment.
Instructions before fitting attachments

To depressurise the oil in the pipes before WARNING
fitting an additional hydraulic attachment to
Improper handling of the accumulator can lead to
the hydraulic system, an accumulator (special serious injuries.
equipment) can be used. .
Before starting work on the accumulator it must
For this consult the section "Operate attach- be depressurised. Please contact your authorised
dealer.
ments".

3
Overview
3 Overview
Identification plates
1 Nameplate
9 Lift mast number (stick-on label)
10 Chassis number (stamped into the rear wall
of the overhead guard/chassis)
11 Drive axle identification plate
12 Engine identification plate

Overview 3
NOTE
The CE mark confirms compliance with the EC
machinery directive and with all regulations
applicable to forklift trucks.
1 Nameplate
2 Manufacturer
3 Model / Production no. / Year of manufac-
ture
4 Tare weight
5 CE mark
6 Nominal driving power
7 Nominal load capacity
13 Steering axle identification plate

3 Overview
Truck overview
Truck overview
1 Lift mast 15 Maintenance covers

2 Lift cylinder 16 Chassis with overhead guard
3 Indicator unit 17 Bonnet
4 Tilt cylinders 18 Fuses (in the engine compartment)
5 Toggle switch for additional functions 19 Step for entering and exiting the truck
(special equipment) 20 Left-hand wheel motor
6 Steering wheel / hydrostatic steering 21 Clamping screw for adjusting the steering
7 Actuating levers (joystick) column
8 Driver’s seat 22 Fork carriage
9 Cover for electrical system 23 Fork arm safety devices
10 Fuses (behind the cover) 24 Fork arms
11 LPG cylinder 25 Fork arm catch
12 Counterweight 26 Lift mast chain (only with duplex or triplex lift
13 Diagnostic connector masts)
14 Steering axle

Overview 3
Controls
Controls
1 Parking brake handle (version 1) 11 Icon sticker for additional hydraulics (attach-
2 Clamping screw for adjusting the steering ments) (special equipment)
column 12 Icon sticker for operating hydraulics
3 Combi-lever for wiper/washer system and 13 Armrest on driver’s seat
flasher (special equipment) 14 Driver’s seat
4 Steering wheel / hydrostatic steering 15 Forward travel accelerator pedal
5 Signal button 16 Stop pedal
6 Starting switch with switch key 17 Reverse travel accelerator pedal
7 Parking brake lever (version 2) 18 Lumbar support adjustment (special equip-
8 Storage compartment ment)
9 Operating lever (joystick) for operating 19 Plate: "Guaranteed sound power level"
hydraulics
10 Actuating lever (joystick) for auxiliary hy-
draulics (attachments) (special equipment)

3 Overview
Indicator unit
Indicator unit
1 Indicator unit 14 Operating hours display

2 Hydraulic oil temperature indicator 15 Operating hours symbol
3 Battery charge indicator 16 Time display
4 Engine oil pressure indicator/engine oil level 17 Service interval exceeded symbol
indicator 18 Function button
5 Electrical control system fault 19 Reset button
6 Engine temperature indicator 20 Symbol for Parking brake applied
7 Load/overload indicator (special equipment) 21 "Do not start the engine" symbol
8 Particulate filter alarm (fitted only to diesel 22 Symbol for Operating hours until the next
trucks) service (shown for only 4 sec on display
9 Level display (special equipment) (14))
10 Hydraulic oil microfilter indicator (special 23 Symbol for Lift mast position sensing
equipment) 24 Text field
11 LPG tank / replacement cylinders contents 25 Gas system error light
indicator 26 Air filter vacuum indicator
12 Display 27 Radiator water level indicator
13 Particulate filter symbol (fitted only to diesel 28 Warning light - gas system
trucks)
(2) Hydraulic oil temperature indicator (red) • Oil cooler clogged

Lights up when the specified temperature limit • Switch off the buzzer with the reset button
is reached. A buzzer also sounds when the (19).
permissible temperature limit is reached. If the (3) Battery charge indicator (red)
"engine protection"* function is activated, the
truck only moves at crawling speed (approx. Lights up when there are malfunctions in the
2 km/h). Error code X205 is displayed in text electrical system.
field (24). • V-ribbed belt split or V-ribbed belt tension
• Insufficient oil in the hydraulic circuit too slack
• Incorrect oil used • V-ribbed belt tensioner defective
• Oil filter clogged • Cable defective

Overview 3
Indicator unit
• Alternator defective • Coolant level too low

• Charge controller or cut-out relay defective. • Switch off the buzzer with the reset button
(19).
(4) Engine oil pressure indicator/engine oil
level indicator (red) (7) Load/overload indicator (special equip-
ment)
If the oil pressure of the engine lubricating
system is too low, this indicator lights up and Symbol lights up yellow when load is normal.
a buzzer sounds. If, in addition, the text field
(24) shows the text Oil with a double arrow DANGER
pointing downwards, the engine oil level is too Symbol lights up red when overloaded.
low. Set down load immediately.
• Insufficient oil in the crankcase
• Engine too hot • Consult load diagram.
• Incorrect oil used (8) Particulate filter alarm
• Internal leakage in the lubricating oil circuit fitted only to diesel trucks.
• Topping up with engine oil
(9) Level display (yellow) (special equipment)
• Switch off the buzzer with the reset button
(19). Lights up when the radiator water level is
below the minimum.
If the "engine protection"* function is activated
and the oil pressure or engine oil level con- • Top up the coolant.
tinues to fall, the truck only moves at crawling Please contact your authorised dealer.
speed (approx. 2 km/h) and text field (24) dis-
plays: (10) Hydraulic oil microfilter indicator (yellow)
(special equipment)
• Oil with a double arrow pointing down-
wards and error code X201 for low oil level, Lights up when the microfilter requires main-
• Error code X202 for low oil pressure. tenance.
(5) Electrical control system fault (red) • Microfilter clogged, change it.
Lights up when an electrical control system (11) Fuel tank level display (green or red
fault is present, and displays an error code in depending on level)
text field (24). Indicates current filling level of LPG cylinder or
(6) Engine temperature indicator (red) LPG tank .
Lights up when the specified temperature limit • If the fuel pump field lights up red, a cylinder
is reached. A buzzer also sounds when the change must be carried out or the LPG tank
permissible temperature limit is reached. If the filled in the next 5 to 25 minutes depending
"engine protection"* function is activated, the on the manner of driving and ambient
truck only moves at crawling speed (approx. temperature.
2 km/h). Error code X204 is displayed in text (13) Symbol for Particulate filter
field (24).
fitted only to diesel trucks.
• Fan motor defective
(14) Operating hours display
• Thermal switch defective
• Water cooler clogged Shows the operating hours of the forklift truck.
• Leakage in the coolant circuit This indicator is evidence of the forklift truck’s
operating time and of the inspection and
maintenance work to be performed.

3 Overview
Indicator unit
NOTE depending on oil temperature). Then try to

restart.
If a defective indicator unit is changed, the
(22) Symbol for Operating hours until the next
operating hours up to that point must be
service
recorded. Affix the data on an embossed
strip near the indicator unit. There is also the After the ignition has been switched on,
option of updating the new indicator unit at a display field (14) shows the operating hours
later time. Contact your authorised dealer. until the next service (counting backwards).
(15) Operating hours symbol Symbol (22) lights up. After 5 seconds symbol
(22) goes out, display (14) automatically
Flashes when operating hours are being
switches to the operating hours of the truck,
counted (only when the ignition is on and the
and the operating hours symbol (15) flashes.
engine speed exceeds 500 rpm)
(23) Lift mast position sensing symbol (special
(16) Time display
equipment)
24-hour clock display.
Lights up if lift mast position identification is
Adjustable using the (18) and (19) buttons. activated.
Resetting to 12-hour clock display is possible (24) Text field
using a diagnostic device. Please contact your
Serves as display field. Please contact your
authorised dealer.
authorised dealer to read out the error codes.
(17) Service interval exceeded symbol
(25) Gas system error light (yellow)
If the number of operating hours until the next
Lights up if a fault is discovered in the gas
service is less than or equal to 0, the symbol
system. Fault can be identified using the
flashes for 10 sec every time the vehicle is
diagnostic device. Please contact your
started, and then lights up continuously.
authorised dealer.
The intervals can only be adjusted and reset
(26) Air filter vacuum indicator (yellow)
using the diagnostic device provided for this
purpose. Please contact your authorised Lights up when the air filter is excessively
dealer. clogged.
(18) Function button • Air filter clogged, change it.
Assignment depending on version. (27) Radiator water level indicator (yellow)
(19) Reset button Lights up when the radiator water level is
below the minimum. If the "engine protection"*
To adjust the time, to switch off the warning
function is activated, the truck only moves at
sound and other functions depending on the
crawling speed (approx. 2 km/h) and text field
version.
(24) displays error code X203.
(20) Symbol for Parking brake
• Top up the coolant.
Lights up when the parking brake is applied.
(28) Warning light - gas system (red)
(21)"Do not start the engine" symbol
• Lights up along with error light (25) if the
Lights up when the engine has stalled. engine runs on for more than 20 seconds
after it has been switched off (an error in the
NOTE system for shut-down due to lack of gas).
Please contact your authorised dealer.
Always leave ignition switched on until symbol
extinguishes (between 15 und 50 seconds

Overview 3
Indicator unit
* The "engine protection" function can be

disabled using the diagnostic device. Please
contact your authorised dealer.

3 Overview
Switch panel
Switch panel
1 Switch panel at the top right in the driver’s 8 Rear windscreen wiper - interval / on /
cab with: wipe-wash
2 Interior lighting 9 Roof windscreen wiper - interval / on /
3 Standard or higher lighting or (4) wipe-wash
4 Working headlight positions 1 / 2 without 10 Hazard warning light
higher lighting 11 Particulate filter starting switch
5 Working headlight positions 3 / 4 and/or 12 Particulate filter emergency stop switch
positions 5 / 6 or working headlight positions 13 Rotating beacon or (14) and/or (15)
1 / 2 with higher lighting 14 Gas system error light (yellow only in the US
6 Working headlight position 8 version)
7 Front windscreen wiper - interval / on / 15 Window heater or other special switch
wipe-wash
NOTE depending on the version. Please note the

switch symbols.
The assignment of the switch panel and
arrangement of individual switches may vary

4
Operation
4 Operation
Standard equipment
Running-in instructions
The lift truck can be operated at full speed Tighten opposite wheel fasteners to a torque
directly. Avoid sustained high loads on the of
working hydraulic system and the travel
drive in the first 50 hours of operation. The front: 170 Nm
wheel fasteners must be tightened before the rear: 460 Nm
commissioning and after each wheel change.
Thereafter at least every 100 operating hours.
Checks before starting work

Carried
out
9 8
Engine
Check the LPG level
LPG system: visual and odour inspection
Check the engine oil level
Check the coolant level
Chassis frame
Check the tyre pressure
Hydraulics
Standard equipment
Adjusting the driver’s seat
WARNING
An incorrect adjustment of the seat can cause back
injury. Do not operate the seat adjusting devices
while operating the truck.
Before each start-up of the truck and with each
change in driver, set the weight setting to the indivi-
dual weight of the driver and check if all settings are
correctly engaged. Do not place any objects in the
vicinity of the controls.

Operation 4
Standard equipment
Horizontal adjustment
¾ Lift lever (2) up and pull it.
¾ Move the driver’s seat on the slide rails
backwards or forwards to give the driver
the best position in relation to the steering
wheel and the accelerator pedals.
¾ Re-engage the lever.
Backrest adjustment
¾ Push up and hold the backrest adjuster (1). 1
¾ Move the backrest forward and back until a
comfortable sitting position for the driver is
found.
¾ Release the backrest adjuster (1).
d3921352 2
Adjusting the lumbar support (option)

¾ Turn knob (3) until a comfortable sitting
3
position is achieved.
Turning the knob anticlockwise makes the
backrest arch outwards.
Turning the knob clockwise returns the back- 6
rest to its original position.
Adjusting for the operator’s weight

¾ Turn the adjusting handwheel (5) to set the
cushioning to the weight of the driver.
The adjustment range from 50 kg to 130 kg is
visible at the weight range indicator (4).
To reduce the weight, turn the handwheel 5
anticlockwise. 4 d3921353
To increase the weight, turn the handwheel

clockwise.

4 Operation
Standard equipment
Adjusting the seat angle of tilt (option)

¾ Lift the handle (6).
7
The seat is tilted to the desired position by
applying or taking off one’s weight simultane-
ously.
9
Adjusting the seat position (option) 8
¾ Lift the handle (9).
The desired position is reached by simultane-
ously sliding the seat forward or back.
Adjusting the backrest extension (option)

¾ Push the backrest extension (7) up or down
for an individual adjustment.
d3921354
Turning the seat heating on/off (option)

¾ Toggle the switch (8) on or off.
NOTE
Long sitting puts excessive strain on the spi-
nal column. Prevent strain with regular, light
exercising.
Adjusting the armrest on the operator’s

seat
NOTE
The armrest on the operator’s seat is raised
automatically by spring pressure after the
handwheel (1) is loosened.

Operation 4
Standard equipment
¾ Sit down on the operator’s seat and loosen 4

the handwheel (1).
3
¾ Push the armrest (3) down against the force
of the spring until a comfortable position for
the arm is reached.
¾ Tighten the handwheel (1). 2
¾ Loosen the handwheel (2) and slide the
armrest (3) back and forth until the control
lever (4) is easily accessible.
¾ Tighten the handwheel (2).
1
d3921416
Adjusting the steering column
DANGER
Safe driving is not guaranteed with the clamping
screw open.
Only adjust the steering column when the vehicle is
stationary.
Angle adjustment
¾ Undo the clamping screw (2) anticlockwise.
¾ Move the steering wheel (1) into the re- 1
quired position.
¾ Tighten the clamping screw (2) clockwise.
Height adjustment
¾ Undo the clamping screw (2) anticlockwise.
¾ Move the steering wheel (1) into the re-
quired position by pulling it up or pushing it
down.
¾ Tighten the clamping screw (2) clockwise.
2 t3921369

4 Operation
Standard equipment
Setting the clock
NOTE
The time is shown in the 24 hour mode.
Change to 12 hour mode with diagnostic unit.
Please contact your authorised dealer for this
service.
¾ Depress both buttons (2) and (3) simultane-
ously for 3 seconds.
The hour readout in the time display (1)blinks.
NOTE
The setting of the hours or minutes can be
adjusted slowly with button (2) by tipping it or
fast by holding it.
¾ Depress button (2) to set the hours.
¾ Depress button (3) to confirm the hour set-
ting.
Now the minute readout blinks.
¾ Depress button (2) to set the minutes
¾ Depress button (3) to confirm the setting of
the minutes.
Open gas shut-off valve

Open shut-off valve on LPG cylinder
(single cylinder)
DANGER
After a forklift truck has been left
standing in an enclosed room for
a lengthy period, there is a risk of
explosion.
Before switching on the electrical
system, first ventilate the room
sufficiently.

Operation 4
Standard equipment
¾ Slowly and carefully open shut-off valve (1)

of LPG cylinder or LPG tank.
Open shut-off valve on LPG cylinder

(double cylinder)
DANGER
explosion.
sufficiently.
DANGER
Operating the truck with only one LPG cylinder may
allow gas to escape from the loose hose.
The vehicle should only be operated when both
LPG cylinders have been fitted and connected.
WARNING
During operation there is the risk of LPG overflo-
wing from one cylinder to the other.
Gas should only ever be taken from one cylinder at
a time.
¾ Open shut-off valve (1) of an LPG cylinder

slowly and carefully.

4 Operation
Standard equipment
¾ Open cylinder selector valve (2) of appro-

priate cylinder. 2
Once the LPG cylinder has been run empty,
it is necessary to switch over to the second
cylinder.
¾ Close selector valve of emptied cylinder.
¾ Open selector valve of full cylinder.
NOTE
We recommend that as soon as a cylinder is
empty, it should be refilled at the first opportu-
nity, to avoid a breakdown due to lack of gas (if
the second LPG cylinder runs out).
t3921003
Open shut-off valve on gas fuel tank

(special equipment)
DANGER
explosion.
sufficiently.
¾ Open the shut-off valve (3) of the gas fuel

tank (4) slowly and carefully. 3 4
t3941379

Operation 4
Standard equipment
Seat belt
Affix seat belt
DANGER
There is a risk to life if the driver
leaves the vehicle in an uncontrolled
manner.
For this reason the seat belt must
always be worn when operating the
truck! The seat belt should only be
worn by one person.
WARNING
Perfect functioning of the seat belt must be ensu-
red.
For this reason the belt should not become twisted,
trapped or tangled up. The lock and belt retractor
should be protected from foreign bodies, damage
and dirt.
NOTE
Driver’s cabs with fixed closed doors or bra-
cket doors satisfy the safety requirements for
driver restraint systems. The seat belt can be
used in addition. It must, however, be affixed
when driving with doors that are open or have
been removed. PVC doors do not constitute
an operator restraint system. For trucks with
the "speed reduction" special function, the
seat belt must be worn even at the reduced
speed.
The automatic blocking mechanism prevents
the belt from being extended whenever the in-
dustrial truck is on a steep slope. It is then not
possible to pull the belt any further out of the
retractor. To release the automatic blocking
mechanism carefully move the truck so that it
is no longer positioned at an angle.
While using the truck (e.g. driving, operat-
ing lift mast etc.), adopt a sitting position as
far back as possible so that the driver’s back
rests against the seat backrest. The automatic
blocking mechanism of the belt retractor offers
sufficient freedom of movement on the seat for
normal use of the fork-lift truck.

4 Operation
Standard equipment
¾ Draw seat belt (1) smoothly from the retrac-

tor on the left.
5 1
¾ Position belt over lap, not over stomach.

¾ Allow buckle (2) to snap into place in catch
lock of belt (4).
¾ Check seat belt tension.
Belt must fit close to the body. 4
Open seat belt 2

¾ Press the red button (5) on the buckle (4).
¾ Feed the buckle (2) manually back into the
retractor (3). 3
d3921415
NOTE
The automatic blocking mechanism may be
triggered if the belt runs in too quickly when the
buckle strikes the housing. The belt cannot be
pulled out with normal force.
Drive engine (two-pedal operation)

Starting the engine
DANGER
Risk of poisoning!
Do not allow engine to run in
unventilated rooms.
NOTE
Where possible, avoid frequently starting and
stopping the engine over short periods of time,
since this prevents the internal combustion
engine reaching operating temperature. Fre-
quent cold starts increase wear.
NOTE
When outside temperatures are low (below
10°C), allow the engine to run for at least
1-2 minutes between starting up and switching
off to prevent the LPG system from malfunc-
tioning.

Operation 4
Standard equipment
¾ The actuating lever (joystick) must be in

neutral.
¾ Sit down on the driver’s seat.
¾ Fasten the seat belt.
¾ Place both feet on the accelerator pedals
(4).
¾ Parking brake actuated (it is only possible
to start the engine with the parking brake
actuated).
• Version 1: Parking brake handle (1) en-
gaged.
• Version 2: Parking brake lever (15) turned
clockwise until it snaps into place.
¾ Insert ignition key (2) into the ignition and
starting switch and turn from the zero posi-
tion to position "I".
The electrical system is switched on.
¾ Look at the indicator unit (3).
NOTE
After the ignition has been switched on, the
indicator unit will perform a self-test. The dis-
plays all light up for approx. 2 seconds and
the operating hours until the next service are
displayed for 5 seconds in the display field
(11) on the indicator unit (3). During this time,
symbol (12) remains lit. After 5 seconds the
display reverts automatically to the operating
hours. If symbol (8) flashes or lights up, the
set service interval has been exceeded. The
service that is due must be performed. Please

4 Operation
Standard equipment
On trucks for the USA with three-way catalytic

converters, a yellow error light (16) that indi-
cates a fault in the engine/exhaust system is
located at the upper right of the switch panel.
The following indicators light up:
• Parking brake applied symbol (9)
• Engine oil pressure indicator (6)
• Battery charge indicator (5)
• After a few seconds, the filling level of the
LPG cylinder or LPG tank (special equip-
ment) can be read off on the luminous bar
(13) in the indicator unit.
• Error light (14) or (16).
¾ Turn ignition key to position "II".
As soon as the engine starts:
¾ Release the ignition key.
Symbol (7) will flash on and off.
If the engine fails to start:
¾ stop trying to start the engine, wait for a
while and then repeat.
If the engine stalls, the "Do not start the en-
gine" symbol (10) will appear.
¾ Always leave ignition switched on until sym-
bol extinguishes (between 15 und 50 sec-
onds depending on oil temperature).
¾ Then try to restart.
When trying to start the engine, wait each time
for at least 1 minute to protect the battery. If the
engine still does not start at the third attempt,
see: Malfunctions, Causes and Remedies.
DANGER
There is a risk of explosion if LPG
leaks out in an uncontrolled manner.
If your truck experiences any
malfunctions or starting problems,
the LPG system should be checked
over by a qualified person with
special knowledge of this system.
The battery charge and engine oil pressure

indicators and the fault light must go out as
soon as the engine is running smoothly.

Operation 4
Standard equipment
The engine speed is controlled automatically,

depending on the load on the engine.
NOTE
Do not allow the engine to warm up at idling
speed. Drive the truck, under load, at a brisk
speed. The engine will quickly reach its ope-
rating temperature.
Switching off the engine
NOTE
Do not switch off the engine when under full
load.
¾ Take your feet off the accelerator pedals
(4).
¾ Turn the ignition key (2) to the zero position.
NOTE
The truck is equipped with a system to shut
down if there is a lack of LPG. This causes the
engine to run on for up to 8 seconds. While
the engine is running on, control units (pedals,
joystick) should not be operated. The driver
must remain with the truck until the engine is
switched off. If the engine runs on for more
than 20 seconds, there is a fault in the system
to shut down if there is a lack of LPG. In this
case, the driver should close the gas shut-off
valve on the LPG cylinder immediately and
wait until the engine stops. After the ignition
has been switched on, error lights (5) and (6)

4 Operation
Standard equipment
light up. If only error light (6) lights up, there

is a fault in the LPG system . Contact your
authorised dealer to correct the fault.
In the US version, error lights (5) and (6) il-
luminate instead of (5) and (16). If only error
light (16) is illuminated, there is an error in the
engine exhaust system.
NOTE
The brake is applied when the engine is swit-
ched off.
¾ Apply the parking brake.
• Version 1: Pull up the parking brake handle
(1).
• Version 2: Turn the parking brake lever (15)
¾ Remove the ignition key (2) when leaving
the truck.
DANGER
It should be borne in mind that LPG
is heavier than air. It collects at
floor level, in work pits and other
depressions in the ground where it
may produce hazardous explosive
mixtures of gas and air (see German
accident prevention regulations for
LPG BGV D34 and German accident
prevention regulations for industrial
trucks BGV D27).
Storage rooms and maintenance
workshops must be well ventilated.

Operation 4
Standard equipment
Close gas shut-off valve.

Close shut-off valve on LPG cylinder or
LPG tank
¾ Firmly close the shut-off valve (1) of the LPG
cylinder or LPG tank (special equipment) as
soon as the engine is switched off.
1
¾ Remove the ignition key when leaving the

truck.
¾ In frosty conditions leave the truck in an
enclosed room if possible, since LPG re-
quires temperatures above -5°C (propane)
or +5°C (propane/butane) to evaporate suf-
ficiently to start the engine.
DANGER
If there is a high level of heat
radiation, there is a risk of fire or
explosion.
Do not leave trucks in halls or
t3921355
garages in the immediate vicinity

of heaters or equipment radiating
heat.
Driving (two-pedal operation)
WARNING
It is generally not permitted to drive on long gradi-
ents over 15% due to specified minimum braking
and stability values. Please contact your authori-
sed dealer before driving on larger gradients. The
climbing capability values given in the type sheet
have been determined from the pulling force and
only apply when overcoming obstacles on the carri-
ageway and to short differences in level.
You should always adapt your driving to the conditi-
ons of the route used (unevenness etc.), especially
hazardous work areas and your load.
WARNING
When using mirrors, ensure that the rear-view mir-
ror is only designed for monitoring the traffic behind
the vehicle.
Reversing is therefore only permitted when looking
backwards directly.

4 Operation
Standard equipment
CAUTION
Any side doors attached must be protected from
damage when driving.
Please therefore ensure that both side doors are
closed and locked before setting off.
NOTE
The forklift truck can only be driven with the
driver’s seat under load.
¾ Start the engine.
¾ Slightly raise fork arms and tilt lift mast back.
¾ Release the parking brake(1), as appropri-
ate to the version.
Forwards travel
¾ Carefully operate the right accelerator pedal
(2).
The driving speed of the truck increases the
further the pedal is pressed down.
NOTE
Pressing down the accelerator pedal hard is
to no advantage as the maximum acceleration
rate is controlled automatically.
Reverse travel
¾ Carefully operate the left accelerator pedal
(4).
The truck will reverse slowly or quickly de-
pending on the position of the accelerator
pedal.
Changing direction of travel

¾ Release accelerator pedal pressed.
The hydrostatic drive will act as a service
brake.
¾ Press the accelerator pedal for the opposite
direction of travel.
The forklift truck will now accelerate in the
specified direction.

Operation 4
Standard equipment
¾ Both feet should be left on the accelerator

pedals so that the truck is easily controlled
in every driving movement.
The accelerator pedals can be switched over
directly. The hydrostatic drive brakes the truck
until it comes to a standstill and then acceler-
ates in the opposite direction.
Approaching gradients
¾ Press the stop pedal (3) all the way down.
ate to the version.
¾ Take your foot half way off the stop pedal.
¾ Actuate accelerator pedal (2) or (4).
¾ Slowly take your foot completely off the stop
pedal.
The brake has been released and the truck will
now move without rolling backwards.
Stopping
¾ Slowly release the accelerator pedal after
pressing it.
brake.
¾ When stopping on inclines, leave both feet
on the pedals and press the pedal in the
"uphill" direction of travel down slightly to
counterbalance the slip of the drive. This
slip is caused by technical factors.

4 Operation
Standard equipment
¾ If stopping for an extended period of time,

press the stop pedal (3).
¾ When getting out of the truck with the engine
running, for example to perform short oper-
ations in the immediate vicinity of the truck
(opening the door, uncoupling the trailer
etc.), it is imperative that you apply the park-
ing brake (1) and open the seat belt. If you
are leaving the truck for a longer period of
time, switch off the engine and activate the
parking brake (1).
¾ When leaving the truck, remove the ignition
key.
Drive engine (single-pedal opera-

tion)
Starting the engine
DANGER
Risk of poisoning!
Do not allow engine to run in
unventilated rooms.
NOTE
Where possible, avoid frequently starting and
stopping the engine over short periods of time,
since this prevents the internal combustion
engine reaching operating temperature. Fre-
quent cold starts increase wear.
NOTE
When outside temperatures are low (below
10°C), allow the engine to run for at least
1-2 minutes between starting up and switching
off to prevent the LPG system from malfunc-
tioning.
¾ Sit down on the driver’s seat.
¾ Fasten the seat belt.

Operation 4
Standard equipment
¾ Move the actuating lever (hydraulics and

direction of travel (5)) into neutral.
5
d3921361
¾ Place your foot on accelerator pedal (4).

¾ Parking brake actuated (it is only possible
to start the engine with the parking brake
actuated).
• Version 1: Parking brake handle (1) en-
gaged.
• Version 2: Parking brake lever (16) turned
¾ Insert ignition key (2) into the ignition and
starting switch and turn from the zero posi-
tion to position "I".
The electrical system is switched on.

4 Operation
Standard equipment
NOTE
After the ignition has been switched on, the
indicator unit will perform a self-test. The dis-
plays all light up for approx. 2 seconds and
the operating hours until the next service are
displayed for 5 seconds in the display field
(12) on the indicator unit (3). During this time,
symbol (13) remains lit. After 5 seconds the
display reverts automatically to the operating
hours. If symbol (9) flashes or lights up, the
set service interval has been exceeded. The
service that is due must be performed. Please
On trucks for the USA with three-way catalytic

converters, a yellow error light (17) that indi-
cates a fault in the engine/exhaust system is
located at the upper right of the switch panel.
The following indicators light up:
• Parking brake applied symbol (10)
• Engine oil pressure indicator (7)
• Battery charge indicator (6)
• After a few seconds, the filling level of the
LPG cylinder or LPG tank (special equip-
ment) can be read off on the luminous bar
(14) in the indicator unit.
• Error light (15) or (17).
¾ Turn ignition key to position "II".
As soon as the engine starts:
¾ Release the ignition key.
Symbol (8) will flash on and off.
If the engine fails to start:
¾ stop trying to start the engine, wait for a
while and then repeat.
If the engine stalls, the "Do not start the en-
gine" symbol (11) will appear.
¾ Always leave ignition switched on until sym-
bol extinguishes (between 15 und 50 sec-
onds depending on oil temperature).
¾ Then try to restart.

Operation 4
Standard equipment
When trying to start the engine, wait each time

for at least 1 minute to protect the battery. If the
engine still does not start at the third attempt,
see: Malfunctions, Causes and Remedies.
DANGER
leaks out in an uncontrolled manner.
If malfunctions occur or there are
problems starting the truck, the LPG
system should be checked by a
competent technician with special
knowledge of the system.
The battery charge and engine oil pressure

indicators and the fault light must go out as
soon as the engine is running smoothly.
The engine speed is controlled automatically,
depending on the load on the engine.
NOTE
Do not allow the engine to warm up at idling
speed. Drive the truck, under load, at a brisk
speed. The engine will quickly reach normal
operating temperature.
Switching off the engine
NOTE
Do not switch off the engine when under full
load.

4 Operation
Standard equipment
¾ Remove foot from accelerator pedal (3).
¾ Move the direction of travel lever (4) into the

neutral position.
¾ Turn the ignition key (2) to the zero position. 4
d3921362

Operation 4
Standard equipment
¾ Look at the indicator unit.
NOTE
The truck is equipped with a system to shut
down if there is a lack of LPG. This causes the
motor to run on for up to 8 seconds. While the
engine is running on, control units (pedals,
joystick) should not be operated. The driver
must remain with the truck until the engine is
switched off. If the engine runs on for more
than 20 seconds, there is a fault in the system
to shut it down if there is a lack of LPG. In this
case, the driver should close the gas shut-off
valve on the LPG cylinder immediately and
wait until the engine stops. After the ignition
has been switched on, error lights (6) and (7)
light up. If only the warning light (7) lights up,
there is a fault in the LPG system . Contact
your authorised dealer to correct the fault.
In the US version, error lights (6) and (17) light
up instead of (6) and (7). If only the error light
(17) lights up, there is an error in the engine
exhaust system.
NOTE
The brake is applied when the engine is swit-
ched off.
• Version 1: Pull up the parking brake handle
(1).
• Version 2: Turn the parking brake lever (16)
¾ Remove the ignition key (2) when leaving
the truck.

4 Operation
Standard equipment
DANGER
It should be borne in mind that LPG
is heavier than air. It collects at
floor level, in work pits and other
depressions in the ground where it
may produce hazardous explosive
mixtures of gas and air (see German
accident prevention regulations for
LPG BGV D34 and German accident
prevention regulations for industrial
trucks BGV D27).
Storage rooms and maintenance
workshops must be well ventilated.
Close gas shut-off valve.

Close shut-off valve on LPG cylinder or
LPG tank
¾ Firmly close the shut-off valve (1) of the LPG
cylinder or LPG tank (special equipment) as
soon as the engine is switched off.
1
¾ Remove the ignition key when leaving the

truck.
¾ In frosty conditions leave the truck in an
enclosed room if possible, since LPG re-
quires temperatures above -5°C (propane)
or +5°C (propane/butane) to evaporate suf-
ficiently to start the engine.
DANGER
If there is a high level of heat
radiation, there is a risk of fire or
explosion.
Do not leave trucks in halls or
t3921355
garages in the immediate vicinity

of heaters or equipment radiating
heat.

Operation 4
Standard equipment
Driving (single-pedal operation)
WARNING
It is generally not permitted to drive on long gradi-
ents over 15% due to specified minimum braking
and stability values. Please contact your authori-
sed dealer before driving on larger gradients. The
climbing capability values given in the type sheet
have been determined from the pulling force and
only apply when overcoming obstacles on the carri-
ageway and to short differences in level.
You should always adapt your driving to the conditi-
ons of the route used (unevenness etc.), especially
hazardous work areas and your load.
WARNING
When using mirrors, ensure that the rear-view mir-
ror is only designed for monitoring the traffic behind
the vehicle.
Reversing is therefore only permitted when looking
backwards directly.
CAUTION
Any side doors attached must be protected from
damage when driving.
Please therefore ensure that both side doors are
closed and locked before setting off.
NOTE
The forklift truck can only be driven with the
driver’s seat under load.
¾ Slightly raise fork arms and tilt lift mast back.

4 Operation
Standard equipment

ate to the version.
Forwards travel
¾ Move the direction of travel lever (4) for-
wards.
¾ Press the accelerator pedal (3) carefully.
The driving speed of the truck increases the
further the pedal is pressed down.
NOTE
Pressing down the accelerator pedal hard is
to no advantage as the maximum acceleration
rate is controlled automatically.
Reverse travel
¾ Move the direction of travel lever (4) back-
wards.
¾ Press the accelerator pedal (3) carefully.
The truck will reverse slowly or quickly de-
pending on the position of the accelerator
pedal.
Changing direction of travel

¾ Release accelerator pedal.
brake.
¾ Operate the direction of travel lever (4) for
the opposite direction of travel.
The forklift truck will now accelerate in the 4
specified direction.
The direction of travel lever can be switched
over directly. The hydrostatic drive brakes
the truck until it comes to a standstill and then
accelerates in the opposite direction.
d3921362

Operation 4
Standard equipment
Approaching gradients
¾ Press the stop pedal (2) all the way down.
ate to the version.
¾ Take your foot half way off the stop pedal.
¾ Press accelerator pedal (3).
¾ Slowly take your foot completely off the stop
pedal.
The brake has been released and the truck will
now move without rolling backwards.
Stopping
¾ Slowly release the accelerator pedal.
brake.
¾ When stopping on inclines, leave your foot
on the accelerator pedal, switch the direc-
tion of travel lever (4) to "uphill" direction
and press the pedal down slightly to coun-
terbalance the slip of the drive. This slip is
caused by technical factors.
¾ If stopping for an extended period of time,
press the stop pedal (2).
¾ When getting out of the truck with the engine
running, for example to perform short oper-
ations in the immediate vicinity of the truck
(opening the door, uncoupling the trailer
etc.), it is imperative that you apply the park-
ing brake (1) and open the seat belt. If you
are leaving the truck for a longer period of
time, switch off the engine and activate the
parking brake (1).
¾ When leaving the truck, remove the ignition
key.

4 Operation
Standard equipment
Steering system
Steering
The hydrostatic steering system allows the
level of effort required to turn the steering
wheel to be very low. This is particularly ad-
vantageous when palletising in narrow aisles.
¾ Start the engine and drive.
¾ Turn the steering wheel to the left and right
to the end stop.
The steering wheel can be moved beyond
the stop if sufficient force is applied without
the position of the wheels changing on the
steering axle.
DANGER
d3921423
The forklift truck must not be driven if the steering
system is defective.
If the steering is stiff or has too much clearance,
contact your local authorised dealer.
Turning radius
H 20 T 2382 mm
H 25 T 2420 mm
H 25 TCT 2235 mm

Operation 4
Standard equipment
Brake system (H 20 T/H 25 T)

Service brake (H 25 T/H 30 T)
¾ Allow the accelerator pedals (1) to move to
the neutral position.
brake. Slow or quick release of the acceler-
ator pedals to the neutral position allows the
braking action to be sensitively controlled,
from gentle to hard braking.
NOTE
For emergency braking, apply the stop pedal
(2) located between the accelerator pedals.
This causes full application of the brake.
Stop pedal (H 20 T/H 25 T)

d3921424 1 2 1
NOTE
The stop pedal (2) is not a sensitive service
brake but a sharply applied parking brake. Its
use whilst driving should be avoided, because
this can cause the driving wheels to lock and
in certain circumstances can cause the load
to slip from the fork arms. In unfavourable si-
tuations the engine can also stall. The driver
should then wait approx. 30 seconds before
restarting (until the variable displacement
pump of the traction drive is in neutral). It is re-
commended that drivers familiarise themsel-
ves with the function and action of this brake
without any load on the forklift truck. For this
purpose they should choose a route without
any other traffic, and drive at low speed.
Parking brake (H 20 T/H 25 T) version 1

The multi-disc brakes are used as the parking
brake of the truck.

4 Operation
Standard equipment
Operating the parking brake

(H 20 T/H 25 T)
¾ Pull the parking brake handle (3) upwards.
3
Symbol in indicator unit will light up.
Releasing the parking brake

(H 20 T/H 25 T)
NOTE
The multi-disc brake will release only if the
engine is running.
¾ Press down the parking brake handle (3).
The symbol on the indicator unit goes out.
DANGER
d3921425
The forklift truck must not be driven if the brake
Should there be any defects or wear apparent in
the brake system, please contact your authorised
dealer at once.
Parking brake (H 20 T/H 25 T) version 2

brake of the truck.

¾ Turn the parking brake lever (2) in a clock-
wise direction to the stop.
The lock (1) engages and the icon in the indi-
cator unit lights up.
NOTE
engine is running.

Operation 4
Standard equipment
¾ Press button (1).

The parking brake is unlocked.
¾ Move the parking brake lever (2) down as
far as the stop.
DANGER
dealer at once.
Brake system (H 25 TCT)

Service brake (H 25 TCT)
NOTE
With the single-pedal version the truck is
equipped with a footbrake. This is shown
by the red rubber cover fitted to the stop pedal
(2).To prevent the truck rolling further after re-
lease the truck has to be braked with the stop
pedal.
¾ Take your foot off the accelerator pedal (1).
The truck will roll on.
¾ To prevent this, press the stop pedal (2).
The braking can be regulated in a carefully
controlled manner from gentle to hard braking
right up to the noticeable pressure point of the
pedal. If this pressure point is exceeded, the
multi-disc brake will engage. This will result in
full application of the brake.
NOTE
It is recommended that drivers familiarise
themselves with the function and action of this
brake without any load on the forklift truck. For
this purpose they should chose a route wit-
hout any other traffic. The braking action and
braking deceleration of the hydrostatic brake

4 Operation
Standard equipment
can be adjusted using the diagnostic device.

NOTE
For emergency braking, fully depress the stop
pedal (2).
Parking brake (H 25 TCT) version 1

brake of the truck.
Operating the parking brake (H 25 TCT)

Symbol in indicator unit will light up.
Releasing the parking brake (H 25 TCT)
NOTE
engine is running.
¾ Press down the parking brake handle (3).
DANGER
dealer at once.
Parking brake (H 25 TCT) version 2

brake of the truck.

Operation 4
Standard equipment

¾ Turn the parking brake lever (2) in a clock-
wise direction to the stop.
The lock (1) engages and the icon in the indi-
cator unit lights up.
NOTE
engine is running.

The parking brake is unlocked.
¾ Move the parking brake lever (2) down as
far as the stop.
DANGER
dealer at once.
Horn
Operating the horn
When operating at blind corners and junctions,
a horn serves as warning signal.

4 Operation
Standard equipment
¾ Press the horn button ((1)) on the steering

wheel to sound the horn.
Lifting system and attachments (cen-

tral lever operation)
WARNING
With the moving lift mast or any
attachment there is a risk of the driver
getting caught in between.
Therefore never reach or step into
the lift mast or the space between
the lift mast and the vehicle. The
lifting system and attachments
should only ever be used for their
proper purpose. Drivers must be
instructed in the handling of the lifting
system and attachments. Bear the
maximum lift height in mind.
NOTE
With the central lever version, use of the actu-
ating lever in an intermediate position (approx.
45°) will activate both functions at the same
time (e.g. lifting and tilting).

Operation 4
Standard equipment
¾ Take note of the switching symbols with

arrows.
The actuating lever should always be operated
carefully, never jerkily. Moving the actuating
lever determines the lifting, lowering and tilt
speed. After the actuating lever is released, it
automatically returns to its initial position.
NOTE
The lifting system and attachments only func-
tion with the engine running and the driver’s
seat occupied.
d3931329
Tilting the lift mast forwards

¾ Push actuating lever (1) forwards.
1 2
Tilting the lift mast backwards.
¾ Pull actuating lever (1) backwards.
Lifting the fork carriage

DANGER
When lifting the lift mast there is an increased risk
of falling and crushing.
For this reason it is not permitted to step onto the
fork arms when lifted without a protective cage.
¾ Push actuating lever (1) to the right.

d3921370
Lowering the fork carriage
¾ Push actuating lever (1) to the left.
Operating attachments
Attachments can be fitted to the truck as spe-
cial equipment (e.g. sideshift, clamps etc.).
Take note of the operating pressure and oper-
ating manual for the attachment. An additional
actuating lever (4-way lever) is attached for
operation.

4 Operation
Standard equipment
WARNING
For attachments that perform a clamping operation
(e.g. bale clamp), a lockable lever (4-way lever or
joystick) must be used.
If your truck is not fitted with this equipment, please
NOTE
Before fitting an attachment, a depressurisa-
tion circuit (special equipment) can be used to
depressurise the hydraulic system for the au-
xiliary hydraulics so that the connection on the
attachment can be affixed to the connection
on the fork carriage.
¾ Switch off the engine.
¾ Switch on the ignition.
¾ Operate the actuating lever for the respec-
tive auxiliary hydraulics several times.
¾ Unscrew the union nuts on the fork carriage.
¾ Screw on hoses for attachment or connect
plug connectors.
CAUTION
Attachments affect the load capacity and stability of
the forklift truck.
Attachments which are not supplied with the forklift
truck should only be used when the authorised dea-
ler has checked that safe operation is ensured by
the allocation in terms of load capacity and stability.

Operation 4
Standard equipment

arrows.
NOTE
For every attachment, a label stating the load
capacity of the forklift truck with attachment
must be affixed above the switch console on
the top right of the overhead guard, and a sym-
bol sticker for the relevant attachment must be
affixed behind the actuating lever.
Operating the sideshift
NOTE
In order to prevent damage, do not activate
the sideshift when the fork arms are on the
ground.
Sideshift moves to the left.
Sideshift moves to the right.
Operating the clamp

¾ Release the actuating lever (2) by pressing
1 2
down on the button.
Clamp opens.
Clamp closes.
Operating the fork positioner
NOTE
In order to prevent damage, do not activate the
fork positioner with a load, or with the fork arms
on the ground. Do not use the fork positioner d3921370
as a clamp.

4 Operation
Standard equipment

Fork arms move outwards.
Fork arms move inwards.
Lifting system and attachments (sin-

gle lever operation)
WARNING
getting trapped between parts.

Operation 4
Standard equipment

arrows.
NOTE
seat occupied.

DANGER



Attachments can be fitted to the truck as spe-
cial equipment (e.g. sideshift, clamps etc.).
Take note of the operating pressure and oper-
ating manual for the attachment. One or two
additional actuating levers are fitted for oper-
ating the attachments.

4 Operation
Standard equipment
WARNING
(e.g. bale clamp), a lockable lever must be used.
NOTE
plug connectors.
CAUTION
the forklift truck.
truck should only be used if the authorised dealer
has checked that safe operation is ensured by the
arrangement in terms of load capacity and stability.

Operation 4
Standard equipment

arrows.
NOTE
capacity of the forklift truck plus attachment
must be affixed above the switch console on
the top right of the overhead guard, and a sym-
bol sticker for the relevant attachment must be
affixed behind the actuating lever.
NOTE
ground.
Operating the clamp

down on the button.
Clamp opens.
Clamp closes.
Operating the fork positioner
NOTE
In order to prevent damage, do not activate the
fork positioner with a load, or with the fork arms
on the ground. Do not use the fork positioner
as a clamp.

4 Operation
Special equipment

Special equipment
Lifting system and attachments
(single lever operation with tog-
gle-switch-controlled third auxiliary
hydraulics)
WARNING
getting caught in between.

Operation 4
Special equipment

arrows.
NOTE
seat occupied.

DANGER



The forklift truck is equipped with three addi-
tional functions (e.g. fork adjustment, rotating
unit, sideshift etc.). Take note of the oper-
ating pressure and operating manual for the
attachment. Two other actuating levers are
then attached for operating the attachments.
The actuating lever (5) is used to operate two
attachments which are controlled via a toggle
switch (4).

4 Operation
Special equipment
WARNING
NOTE
plug connectors.
CAUTION
the forklift truck.
truck should only be used when the authorised dea-
ler has checked that safe operation is ensured by
the allocation in terms of load capacity and stability.

arrows.
NOTE
capacity of the truck plus attachment must
be affixed above the switch console on the
top right in the driver’s overhead guard and
a symbol sticker for the relevant attachment
affixed behind the actuating lever or on the left
and right next to the toggle switch (4).

Operation 4
Special equipment
Operating fork adjustment

Operating the rotating unit

¾ Press left-hand side (2) of toggle switch (3).
Green switch illumination lit up.
Unit moves anticlockwise.
Unit moves clockwise.

¾ Press right-hand side (4) of toggle switch
(3).
Orange switch illumination lit up.

4 Operation
Special equipment
Lifting system and attachments with

3rd auxiliary hydraulics without tog-
gle switch
WARNING
getting trapped between parts.

arrows.
NOTE
seat occupied.
d3931329

Operation 4
Special equipment



DANGER

The forklift truck is equipped with three addi-
tional functions (e.g. fork adjustment, rotating
unit, sideshift etc.). Take note of the operating
pressure and operating manual for the attach-
ment. Additional actuating levers are fitted for
operation (4-way lever, joystick).
WARNING
NOTE

4 Operation
Special equipment

plug connectors.
CAUTION
the forklift truck.
truck should only be used if the authorised dealer
has checked that safe operation is ensured by the
arrangement in terms of load capacity and stability.

arrows.
NOTE
capacity of the truck plus attachment must
be affixed above the switch console on the
top right in the driver’s overhead guard and
a symbol sticker for the relevant attachment
affixed behind the actuating lever or on the left
and right next to the toggle switch (4).
NOTE
ground.

Operation 4
Special equipment

Operating the clamp

down on the button.
Clamp opens.
Clamp closes.
Operating fork adjustment

Adjust driver’s seat with swivel de-

vice
CAUTION
The driver’s seat must not swivel while the forklift
truck is in use.
It should therefore be ensured that the swivel de-
vice is locked.
The driver’s seat with swivel device offers

better rear visibility when reversing over long

4 Operation
Special equipment
distances. When driving forwards for long

distances, it is recommended that you return
the seat to the straight position. The swivel is
maintenance free.
¾ Lift locking lever (1).
The swivel device is released and allows the
seat to be swivelled 17° to the right. It can be
locked at 0° and at 17°.
¾ Let the locking bolts engage audibly.
Adjust the driver’s air-sprung seat
WARNING
Incorrect seat adjustment may cause injury to the
driver’s back. The adjustment controls for the dri-
ver’s seat should not be used during operation.
On each occasion, before starting up the vehicle
and changing drivers adjust for the individual weight
of the driver. Adjust the driver’s seat only when the
vehicle is stationary.
Adjust for the driver’s weight

¾ Sit on the driver’s seat.

Operation 4
Special equipment
¾ Check the weight adjustment in viewing

window (3).
The correct selection of the driver’s weight has
been made when the arrow (4) is within the
centre clear area of the viewing window.
¾ Adjust as necessary for the driver’s weight
• Lift lever (2) upwards (5) = increase weight
setting
• Push lever (2) downwards (6) = decrease
weight setting
Longitudinal adjustment
¾ Lift lever (1) upwards.
¾ Move the driver’s seat on the slide rails
backwards or forwards to give the driver
the best position in relation to the steering
wheel and the accelerator pedals.
¾ Allow lever to click back into place.
Adjust the seat angle

¾ Lift lever 2 and hold it there.
Whilst holding the lever, press on the seat
or release it to move the seat to the desired
position.
Adjust the seat height

¾ Lift lever 1 and hold it there.
Whilst holding the lever, slide the seat for-
wards or backwards to move the seat to the
desired position.
Seat heater
NOTE
The maximum temperature is pre-set.

4 Operation
Special equipment
¾ Switch (1) turns the seat heater ON and

OFF.
• 0 = seat heater OFF
• I = seat heater ON
Adjust lumbar support

The lumbar support enables optimum config-
uration of the seat back contour to the driver’s
body.
¾ Turn the handwheel (2) upwards.
The convexity of the upper lumbar support can
be adjusted individually.
¾ Turn the handwheel (2) downwards.
The convexity of the lower lumbar support can
be adjusted individually.
Adjust the seat back

¾ Lift lever (2) and hold it there.
¾ Move the seat back backwards and for-
wards until a comfortable sitting position for
the driver is found.
¾ Release lever (2).
Adjust the headrest

¾ Push in or pull out the headrest (1) and
adjust it individually.
Driving speed reduction
NOTE
In the case of forklift trucks with driving speed
reduction via a switch, the driving speed re-
duction function is designed to aid the driver
and is purely a comfort feature. The responsi-
bility and control for maintaining the required
speed always lie with the driver.

Operation 4
Special equipment
The driving speed reduction function makes

it possible to switch between two adjustable
speeds.
Driving speed reduction via a switch

¾ Activate the switch with the tortoise symbol
(1) in the switch panel at the top right in the
driver’s cab.
The truck drives at a reduced speed.
Driving speed reduction via a sensor

Another option for driving speed reduction
can be activated at a certain lift height, when a
sensor fitted on the lift mast is passed.
Lift mast positioning

Programming
The tilt angle sensor system enables a specific
lift mast tilt angle to be programmed. When
this function is active, the symbol (1) lights up
in the indicator unit.
¾ Tilt lift mast to required angle.

4 Operation
Special equipment
¾ Press the button (2) in the front-left position

of the armrest for longer than 2 seconds.
2
The tilt angle is now permanently stored. As

confirmation, a double acoustic signal sounds
from the indicator unit and the light in the but-
ton (2) flashes briefly several times.
The lift mast tilt angle is saved in relation to
the truck. The lift mast tilt angle in relation to
the ground depends on a variety of influencing
variables such as the tyre wear, tyre pressure
of pneumatic tyres and load, as well as the
unevenness and gradient of the ground.
Operation
t3921358
NOTE
The lift mast positioning function is designed to
aid the driver and is purely a comfort feature.
The responsibility and control for activating
the required mast position always lie with the
driver.
¾ Press the button (2) in the front-left posi-
tion of the armrest briefly. The lamp in the
2
button lights up and the lift mast positioning
detection is switched on.
¾ Operate joystick and activate stored tilt an-
gle. (For safety reasons, tilting is permitted
only in the direction of the stored tilt angle,
and must be reactivated with each lift mast
positioning).
When the stored lift mast position has been
reached, the lift mast remains stationary and
an acoustic signal is sounded in the indicator
unit.
¾ Release the joystick or press the button (2)
again briefly. The light in the button goes t3921358
out, and the lift mast positioning is switched
off.
¾ The lift mast can now be operated normally
using the joystick.
¾ Briefly press the button (2) again. Lift mast
position detection is switched on again.

Operation 4
Special equipment
Lift height reduction
NOTE
In the case of forklift trucks with lift height re-
duction, the lift height reduction function is
designed to aid the driver and is purely a com-
fort feature. The responsibility and control for
maintaining the required lift height always lie
with the driver.
The lift height reduction function enables the
lift to be stopped at a particular lift height. The
required lift height is identified by means of a
sensor fitted on the lift mast.
¾ Activate switch (1) at the front left of the
armrest.
When lifting, the lift mast will switch off at the
required height.
If lift mast positioning is fitted, the switch is
located at the front right (3) of the armrest.
Observe the sticker (2).
Lighting
NOTE
The arrangement of the individual switches
on the right hand overhead console may vary
depending on the version. Please take note of
the symbols for the switches.

4 Operation
Special equipment
Switch on interior lighting

¾ Press toggle switch (1).
Switch on lighting
¾ Move toggle switch (2) to centre position.
Side lights and licence plate light are
switched on.
¾ Switch toggle switch (2) as far as it will go.
Dipped beam, side lights and licence plate
lights are switched on.
Switch on working headlights

¾ Press toggle switch (3) or (4) (depending on 1 2 3 4 5 6 7 8 9
the version) .
d3921516
Switch on hazard warning lights

Switch on rotating flashing light

Depending on the equipment there are two
different versions.
Version 1 (single stage switch):
The rotating flashing light is always switched
on.
Version 2 (two stage switch):
The rotating flashing light is switched on only
when reversing.
The rotating flashing light is always switched
on.

Operation 4
Special equipment
Switch on turn indicator lights

¾ Move operating lever (10 ) on steering
wheel forwards.
The flashing lights flash on the right. Indicator
lamp (11) flashes.
¾ Move operating lever (10 ) on steering
wheel backwards.
The flashing lights flash on the left. Indicator
lamp (11) flashes.
Attach additional consumers

DANGER
The driver’s protective roof is a safety part.
It is therefore not permitted to perform drilling or
welding on the driver’s protective roof .
CAUTION
Any additional electrical consumers to be retrofit-
ted (lights, seat heaters etc.) should be installed
using the unoccupied connections of the harness
provided for this purpose . Other connections going
beyond the scope envisaged are only permitted
after consultation with your authorised dealer.
Such work should only be carried out by trained
competent staff using functional and appropriate
materials subject to compliance with the applicable
rules and regulations .

4 Operation
Special equipment
Windscreen wiper
Switch on the front windscreen wiper
¾ Move operating lever (10) on steering wheel
from centre position upwards.
The front windscreen wiper will run as long as
the lever is in this position.
from centre position downwards.
The front windscreen wiper will run in intermit-
tent mode.

The front windscreen wiper will run in continu-
ous mode.
Switch on the rear windscreen wiper

The rear windscreen wiper will run as long as 1 2 3 4 5 6 7 8 9
¾ Move toggle switch (6) to centre position. d3921516

The rear windscreen wiper will run in intermit-
tent mode.
The rear windscreen wiper will run in continu-
ous mode. The front windscreen wiper will run
in intermittent mode.

Operation 4
Special equipment
Switch on the roof windscreen wiper

The roof windscreen wiper will run as long as
The roof and front windscreen wipers are in
intermittent mode.
The roof windscreen wiper is in continuous
mode. The front windscreen wiper is in inter-
mittent mode.
Switch on the wiper/washer system

¾ Switch on relevant windscreen wiper.
¾ In addition, push the operating lever (10) in
as far as it will go.
The pre-selected wiper/washer system will
run as long as the lever is in this position.

4 Operation
Special equipment
Window heater
Switching on the rear window heater
¾ Press the toggle switch (1).
Rear window heater is in operation.
Driver’s cabin
Opening the cab door
¾ Pull the lever (3) backwards.
¾ Open driver’s door outwards.
Closing the cab door

¾ Pull cab door by handle (4) until latch en-
gages.
Opening/closing the front side window

¾ Squeeze both handles together on the lever
(2).
¾ Keep the handles pressed and push the
side window into the desired position.
Follow a similar procedure to close the side
window.
Opening/closing the rear side window

¾ Squeeze both handles together on the lever
(1).
¾ Keep the handles pressed and push the
side window into the desired position.

Operation 4
Special equipment
Follow a similar procedure to close the side

window.
Heater, air conditioning

Switching on the heater
Controls
• Temperature control knob (1)
• Rotary switch (2) for setting blower
• Knob (3) for setting the vent positions for
windscreen defrosting / footwell ventilation
• Cab air vents (4)
¾ Turn switch (2).
The blower is switched on and there are three
air flow settings.
Windscreen defrosting
¾ For maximum windscreen defrosting, set:
• Knob (1) in the far right position
• Knob (3) in the windscreen defrosting posi-
tion (far left position)
• Rotary switch (2) to level 3
• Cab air vents (4) to open, fins forwards.
For standard heating mode, the following rules
apply:
• Select the temperature using knob (1) (far
left → cold / far right → hot)
• Use the blower switch (2) (level 1 to 3), air
distribution vent (knob (3)) and cab air vents
(4) to select the most comfortable tempera-
ture and temperature distribution
Switching on the air conditioning

CAUTION
The moving parts must be lubricated and the com-
pressor prevented from seizing.
Therefore switch on the air conditioning briefly
every 3 months. In addition, the air conditioning
must be serviced once a year by your authorised
dealer, preferably before the season starts, and a
record must be kept of the servicing. Otherwise, the
warranty will be void.

4 Operation
Special equipment
NOTE
It is normal for condensation to build up in
the hoses and under the truck when the air
conditioning is in use.
Controls
• Temperature control knob (5)
• Rotary switch (6) for setting blower
• Knob (7) for setting the vent positions for
windscreen defrosting / footwell ventilation
• Push button (9) for switching the air condi-
tioning on
• Cab air vents (8)
¾ Turn switch (6).
The blower is switched on and there are three
air flow settings.
NOTE
The air conditioning only works when the en-
gine is running and the blower switch is swit-
ched to setting 1, 2 or 3. The fan in the roof
switches on when necessary. It can come to a
standstill from time to time.
¾ Press the push button (9).
The air conditioning is switched on and the
indicator light (10) is green.
Raising the temperature in the vehicle interior
¾ Turn knob (5) clockwise and reduce the
blower speed using switch (6).
Lowering the temperature in the vehicle inte-
rior
¾ Close windows and doors, turn knob (5)
anti-clockwise and increase the blower
speed using switch (6).
NOTE
To achieve maximum cooling in the vehicle
interior:
• the air conditioning must be switched on,
• knob (5) must be fully turned to the left stop,
• the blower must be set to its highest setting,
• the windows and doors must be closed.

Operation 4
Special equipment
NOTE
On cool, humid days, the heater and air con-
ditioning can be used to dehumidify the air
in the cab (operate the heater and air condi-
tioning simultaneously). The vehicle heater
counteracts the cooling effect. This ensures a
pleasant temperature inside the cab and pre-
vents the windows misting up.
Linde Forklift Data Management

(LFM)
Forklift Data Acquisition
The input device (1) for Forklift Data Acquisi-
tion (FDE) is mounted on the front left-hand
post of the overhead guard
The input device has a 12-digit keypad (3).
In the standard setting the issue of 5-digit PIN
numbers to the respective drivers ensures that
only authorised personnel can operate the
fork-lift truck. The vehicle can only be started
after inputting this PIN number and possibly a
state code (depending on the setting).
NOTE
The PIN number can be extended from 5 to 8
digits. Before inputting the PIN number please
check with your fleet manager about the num-
ber of digits for the PIN number and setting of
the vehicle.
Status code
NOTE
The code indicates the state of the vehicle.
The following codes are available:
0 = Truck OK
1 = Request service (truck will not start)
2 = Request maintenance (truck starts)
3 = Problem with driving
4 = Problem with lifting

4 Operation
Special equipment
5 = Problem with steering

6 = Accident damage
7 = User-defined
8 = User-defined
9 = User-defined
The status messages 7 , 8 and 9 can be in-
dividually defined by the user. Please contact
your fleet manager to discover the definition of
these state messages.
NOTE
If you notice one of these states (such as a
problem with driving) only after you have input
the state code 0 (vehicle OK), you have to log
off.
¾ Turn the rotary button 2 anticlockwise as far
as it will go.
¾ Log in again with the status message 3
(problem with driving)
Forklift Data Acquisition - standard set-

ting (PIN number and state code)
Log on and start vehicle:

Operation 4
Special equipment
¾ Press any key to start input device.

The green LED (2) flashes.
¾ Enter personal PIN number (factory setting
= 0 0 0 0 0 ) and status code.
Therefore, for a properly set-up truck, the PIN
number should be as follows: 0 0 0 0 0 0 .
NOTE
If the PIN was input incorrectly, press the *
button (4) and enter the correct PIN number.
¾ Confirm the input with the # button (3).
The green LED (2) lights up continuously.
NOTE
If the red LED (1) lights up, an incorrect PIN
number was input. Press the * button (4) and
enter it again. If more than three incorrect in-
puts are made (factory setting), the red LED
(1) lights up and the green LED (2) flashes.
The input of a valid PIN is blocked for 10 minu-
tes. The blocking time can be interrupted by
inputting a special PIN number. Please con-
tact your fleet manager.
¾ Turn the rotary knob (5) in a clockwise direc-
tion against the stop and start the vehicle.
NOTE
If the vehicle does not start properly the first
time, the start procedure can be repeated (5)
until the rotary button is returned to the zero
position and the PIN number is discarded after
expiry of the delay time.
NOTE
If the green (2) and red (1) LED both light up
continuously, the data must be read out. Ple-
ase inform your fleet manager at once.
Switch the vehicle off and log off:
¾ Turn the rotary button (5) anticlockwise as
far as it will go.
The engine is turned off.

4 Operation
Special equipment
NOTE
After a delay time (factory setting = 10 se-
conds) the red LED (1) lights up briefly, and
the green (2) and red (1) LEDs then flash for
approx. 3 seconds. During this period the ve-
hicle can be started at any time. The LEDs
then go out, and the PIN number is discarded.
The delay time can be set to between 10 se-
conds and 10 minutes using the diagnostic
device. Please contact your authorised dea-
ler.
Pressing the # button (3) after switching off
the engine terminates the delay time immedi-
ately and the PIN number is deleted.
Forklift Data Acquisition - Special setting

(PIN number)
Log on and start vehicle:
¾ Press any key to start input device.
The green LED (2) flashes.
¾ Enter personal PIN number (factory setting
= 0 0 0 0 0 ).
NOTE
If the PIN was input incorrectly, press the *
button (4) and enter the correct PIN number.
¾ Confirm the input with the # button (3).
The green LED (2) lights up continuously.
NOTE
If the red LED (1) lights up, an incorrect PIN
number was input. Press the * button (4) and
enter it again. If more than three incorrect in-
puts are made (factory setting), the red LED
(1) lights up and the green LED (2) flashes.
The input of a valid PIN is blocked for 10 minu-
tes. The blocking time can be interrupted by
inputting a special PIN number. Please con-
tact your fleet manager.

Operation 4
Special equipment
¾ Turn the rotary knob (5) in a clockwise direc-

tion against the stop and start the vehicle.
NOTE
If the vehicle does not start properly the first
time, the start procedure can be repeated (5)
until the rotary button is returned to the zero
position and the PIN number is discarded after
expiry of the delay time.
NOTE
If the green (2) and red (1) LED both light up
continuously, the data must be read out. Ple-
ase inform your fleet manager at once.
Switch the vehicle off and log off:
¾ Turn the rotary button (5) anticlockwise as
far as it will go.
The engine is turned off.
NOTE
After a delay time (factory setting = 10 se-
conds) the red LED (1) lights up briefly, and
the green (2) and red (1) LEDs then flash for
approx. 3 seconds. During this period the ve-
hicle can be started at any time. The LEDs
then go out, and the PIN number is discarded.
The delay time can be set to between 10 se-
conds and 10 minutes using the diagnostic
device. Please contact your authorised dea-
ler.
Pressing the # button (3) after switching off
the engine terminates the delay time immedi-
ately and the PIN number is deleted.

4 Operation
Working under load
Working under load

Before taking up a load
Before taking up a load, check the load capac-
ity diagram above the switch console on the
top right in the driver’s protective roof.
The max. permissible load is determined by
the distance of the centre of gravity of the load
from the fork back of the fork arms and the lift
height.
DANGER
The values specified in the lifting capacity diagram
or plate apply to compact homogeneous loads and
must not be exceeded as this will impair the stability
of the forklift truck and the strength of the fork arms
and lift mast.
When using attachments take note of the lifting
t3921383
capacity plate for each attachment device.
NOTE
Take the load restriction into account and con-
sult your authorised dealer
• before transporting off-centre or swinging
loads
• before transporting loads with the lift mast
tilted forward or the load not close to the
floor
• loads involving a large centre of gravity
distance
• before using attachments and additional
equipment
• before transporting loads in a wind force of
6 and upwards. 1 Max. weight of permissible loads in kg
2 Lift height in mm
Example 3 Series designation of the forklift truck by
Centre of gravity distance for load: 700 mm max. load capacity and lift mast series
4 Distance between centre of gravity of load
Load height to be lifted: 6000 mm and fork back in mm
¾ Trace a vertical line from a load distance of

700 mm to its point of intersection with the
line for a lift height of 6000 mm.
¾ At the point of intersection with the horizon-
tal line read off the max. permissible load to
the left .
The maximum load in this example is 1500 kg.

Operation 4
Working under load
The same procedure should be followed for

other lift heights und centre of gravity dis-
tances. The values calculated refer to both
fork arms and a uniformly distributed load.
Wheel-slide protection chains

CAUTION
Putting on wheel-slide protection chains alters the
wheel freedom and load capacity of the forklift truck
Before wheel-slide protection chains are put on,
the standard fork carriage must be replaced with
a special fork carriage, which is 40 mm further for-
ward. All other load capacity data on the basic load
capacity diagram and on the additional load capa-
city plate must be reduced by 100 kg. This load
capacity reduction then remains necessary even if
wheel-slide protection chains are not fitted.
¾ In addition attach plate (5) alongside the

basic load capacity diagram.
Adjusting the fork spread
NOTE
The load centre should be in the centre bet-
ween the forks.

4 Operation
Working under load
¾ Raise the fork quick-release levers(1).

¾ Move the forks further apart or closer to-
gether depending to the size of the load to
be lifted.
Make sure that both forks are equally distant
from the truck centre.
¾ Allow the quick-release levers to engage in
a notch on the fork carriage.
d3921429
Taking up load
DANGER
When stepping onto the forks when lifted there is an
increased risk of falling and crushing.
DANGER
Loads should be arranged so that they do not pro-
ject beyond the edge of the truck loading surface
and cannot slip, topple over or fall off.
If necessary, use a load guard (special equipment).
DANGER
When a load is raised, it is not permitted to stand
beneath the suspended cargo.
Forklift trucks should only be driven with the load
lowered and the lift mast tilted back.
¾ Approach the load to be taken up carefully

and as accurately as possible.

Operation 4
Working under load
¾ Position the lift mast so it is vertical.

¾ Lift or lower the fork carriage to the neces-
sary height.
¾ Carefully centre the fork carriage and move
into the load to be taken up, where possible
so the load touches the fork back, taking
account of adjacent loads.
¾ Lift fork carriage until the load is no longer in
contact with the supporting surface.
d3921430
¾ Check load/overload indicators (special

equipment) (2) on indicator unit.
DANGER
If the load/overload indicator lights up red on lifting
¾ set down load immediately.
¾ Check permissible weight of load according to
load diagram.
¾ Reverse the truck until the load is free.

¾ Tilt the lift mast backwards.
Travelling with load
NOTE
When transporting cargo, the sender must
ensure that the goods are safely loaded for
transportation and secured if necessary. Ple-
ase therefore make sure that goods are pro-
perly stacked and there is no damage to pa-
ckaging, pallets etc. The carrier must ensure
safe loading.

4 Operation
Working under load
¾ Do not transport loads if they are shifted to

the side (e.g. with sideshift).
¾ Transport loads close to the floor.
¾ On ascending/descending routes, always
travel with the load facing uphill; never travel
diagonally or turn around.
¾ If visibility is poor, instructions should be
provided by a second person.
¾ If the load to be transported is stacked so
high as to obstruct visibility in the direction
of travel, the truck must only be driven in
reverse.
d3921431
Setting down loads
DANGER
Never stop and leave the vehicle with the load still
raised.
Let down the fork carriage until the fork arms touch
the ground.
¾ Carefully move the forklift truck to the load /

storage area.
¾ Lift the fork carriage to the necessary height.
¾ Position the lift mast so it is vertical (load
horizontal).
¾ Observe the lift mast position identification
symbol (1) on the indicator unit if your forklift
truck is equipped with automatic lift mast
position identification.
¾ Carefully move the load over the load / stor-
age area.
¾ Carefully lower the load until the fork arms
are clear.
¾ Back the forklift truck away.

Operation 4
Loading / Transporting
Tow coupling
NOTE
The tow coupling is used only for towing light
trailers inside the plant. (Observe the applica-
ble safety guidelines and VDI.)
¾ Turn the handle ((1)) of the tow pin 90° to
the rear and then lift it up.
¾ Place the drawbar eye into the coupling
sleeve (2).
¾ Press down the tow pin against spring pres-
sure, turn 90° degrees and let engage in the
retainer.
1
2 d3921373
Securing the hose pulley against
rolling up
When fitting single auxiliary hydraulics, a hose
pulley (1) is located beneath the floorplate
(with double auxiliary hydraulics, a second
hose pulley (5) is fitted in mirror image).
WARNING
The hose pulleys are spring-biased.
This is why they should always be secured against
rolling up:
• Before disconnecting the screw joints of the

hose lines at the connection point to the lift
mast (e.g. to remove the lift mast or remove
the hose pulley itself).
• For all other work on the hose pulleys in the
truck.

4 Operation
WARNING
The roll-up protection on the removed hose pulley
must not be opened.
If this cannot be avoided, reduce the spring tension
to 0 beforehand. Please contact your authorised
dealer.
¾ Open the bonnet.

¾ Open floor plate and secure it.
¾ Turn the hexagon head screw (3) on the
hose pulley (1) in the direction of travel
(right) with a wrench (SW 10) to the stop in
the secure position (6).
The safety catch (2) points against the direc-
tion of travel and the slotted spring pin (8) is
visible; the hose pulley is secured against 5 1
rolling up.
4 2
3
d3921468
¾ For double auxiliary hydraulics, turn the

safety catch (4) of the second hose pulley 2
(5) to the secure position (6) as well.
¾ Disconnect the hoses when removing the
lift mast.
6 7
CAUTION
If the lift mast is extended with the roll-up protection
closed, the hose lines cannot be damaged (ratchet
effect). However, when the mast is then retrac- 8
ted, the hose lines are no longer rolled up and may
therefore be damaged.
Only once the lift mast has been refitted (hoses
connected again), should the roll-up protection be 3
released. To do so, return the safety catch(es) to
the free-wheel setting (7) (safety catch visible).
d3921481
Dismantling of lift mast

This work should only be performed by spe-
cialist staff working for your authorised dealer.

Operation 4
DANGER
The spring elements on the drive axle are pretensi-
oned.
Before dismantling the tilt cylinders, the lift mast
must be tilted back 2 °.
DANGER
The lift mast may fall off during
transportation.
Do not walk under suspended loads!
¾ Fasten the lifting gear to the bridge piece on

the outer mast of the lift mast at the top.
¾ When dismantling the lift mast, place the tilt
cylinders on a suitable square timber and
secure with a steel strap.
CAUTION
After dismantling the lift mast or tilt cylinders, the
tilt-angle potentiometer is misaligned.
The tilt-angle potentiometer therefore has to be
readjusted after reinstalling the lift mast. When
doing so, the parking brake should be applied for
safety reasons, and any restriction in the tilt angle
should be taken into account. Please contact your
authorised dealer.
t3921317
Driving without lift mast
CAUTION
When driving without the lift mast, the speed of the
truck must be reduced for safety reasons.
Therefore, before removing the lift mast, an addi-
tional stop screw must be fitted under the reverse
travel accelerator pedal (two-pedal operation) or
accelerator pedal (single-pedal operation) to rest-
rict the speed.

4 Operation
¾ Screw the hexagon head screw M8 x 20 (3)

half-way into hexagon nut M8 (2) (DIN 6330,
6331, 6334).
¾ Screw the hexagon nut (2) onto the ex-
isting hexagon head screw M8 (1) until
one hexagon head screw (3) hits the other
hexagon head screw (1). 3
¾ Lock them into the hexagonal nut (2).
¾ Remove lift mast.
2
After refitting the lift mast the additional stop

should be removed.
1
d3921520
Loading
Crane lifting
DANGER
When using a crane to load the truck,
be particularly careful to ensure
that no-one is in the working area of
the crane! Observe loading weight
according to nameplate.
Do not walk under suspended loads!
Only use round slings and a loading
crane with a sufficient lifting capacity.
WARNING
Loading by crane may cause damage to the tilt
cylinder and the cover sheet on the counterweight.
Retract the lift mast, retract the tilt cylinder as far as
the stop and lift the truck in such a way that it hangs
to the front.
¾ Attach round slings to the suspension

points.
The suspension positions on the truck are not
specially marked.

Operation 4
¾ Place the round sling (2)(min. lifting ca-

pacity: 3000 kg) around the bottom of the
counterweight.
¾ Use edge protectors as a safeguard from
sharp edges on the bridge piece.
¾ Insert round sling (3) (min. lifting capacity:
3000 kg) around bridge piece on outer mast
of lift mast.
¾ Insert all ends into crane hook (1) .
¾ Make sure that the safety lock (4) is closed.
NOTE
During lifting, the lifting gear should not touch
the overhead guard, the cover sheet on the
counterweight and any additional equipment
attached.
Crane lifting with crane eyes

CAUTION
If the sling is at an angle to the crane eye, the crane
eye may break off.
Crane lifting with crane eyes should only be carried
out with the appropriate lifting gear (3), whereby the
chains (2, 6) lead up vertically from the crane eyes
(1, 7).
¾ Attach chains (6) (min. lifting capacity:

3000 kg) to the crane eyes (7) on the coun-
terweight.
¾ Attach chains (2) (min. lifting capacity:
3000 kg) to the crane eyes (1) on the lift
mast.
¾ Make sure that the safety lock (5) is closed.
NOTE
During lifting, the lifting gear should not touch
the overhead guard, the cover sheet on the
counterweight and any additional equipment
attached.

4 Operation
Transport with lorry or low-bed trailer

¾ Lower the mast.
¾ Engage the parking brake.
¾ Place chocks behind the wheels.
¾ Lash down the truck.
t3921315
Before leaving the truck

¾ Set down load / lower fork carriage.
¾ Tilt mast forwards slightly.
The fork arms must touch the ground.
¾ Actuate the parking brake (1), as appropri-
ate to the version.
¾ Remove the ignition key (2).
¾ Close the LPG shut-off valve.

5
Maintenance
5 Maintenance
General points
General points
Your forklift truck will only remain in a state No modifications, in particular attachment or
ready for use at all times if you perform a small conversion, should be made to your forklift
number of maintenance and inspection tasks truck without the manufacturer’s approval.
according to the information in the registration
All servicing work should be followed by a
document for the industrial truck and the
functional check and a trial run performed on
data or instructions in the operating manual
the forklift truck.
at regular intervals . Servicing should only
be carried out by qualified staff authorised WARNING
by Linde. You can agree performance of this
Any side doors attached could fall shut during
work on the basis of a maintenance agreement
maintenance and trap staff.
concluded with your authorised dealer.
For this reason, both doors should be opened and
If you wish to perform this work yourself, we secured in place during servicing.
recommend having at least the first 3 customer
service checks carried out by the dealer’s
CAUTION
service technician in the presence of your
workshop representative so that your own The truck must always be properly labelled.
workshop staff can be instructed accordingly. Missing or damaged identification plates and/or
adhesive labels must be replaced. Warehouse or
DANGER order No. see spare parts list.
systems are not handled properly ENVIRONMENT NOTE
Maintenance, inspection and
servicing of the LPG system should Observe information regarding working with
only be carried out by competent consumables.
staff familiar with the testing and
setting data of this system. Special
test devices and tools are required. NOTE
Contact local authorised dealer. The
performance of testing, inspection When using forklift trucks under extreme
and maintenance on the LPG system conditions (e.g. extreme heat or cold, high
must be documented by a test levels of dust etc.), the time periods given in
report (e.g. BGG 936). Use only the maintenance overview programme should
original spare parts when carrying be reduced accordingly.
out repairs. This is the only way to
ensure the safety of the system.
Maintenance intervals
Whenever performing maintenance, the Under certain conditions there is the option of
forklift truck should be parked on a flat surface changing the intervals for some of the mainte-
and secured so that it cannot roll away. The nance work listed in the maintenance overview
engine should be switched off and the ignition program. Please make sure you use the con-
key removed. sumables, engine oil and coolant specified for
this purpose . The qualities required in this
For work performed with the fork carriage regard are described in the section Recom-
and/or lift mast lifted they must be secured to mendations for consumables. The inspection
prevent them from accidentally sinking down. and maintenance intervals depend on the op-
Whenever work is carried out at the front of the erating and service conditions of the forklift
forklift truck, the lift mast must be secured to truck. For heavy-duty conditions we recom-
prevent tilting back. mend shorter intervals . Please contact your
authorised dealer.

Maintenance 5
Working on the Linde lift mast and at the front of the truck
Working on the Linde lift mast

and at the front of the truck
DANGER
When working on the lift mast there is the risk of
staff becoming trapped and/or accidental sinking of
the lift mast.
When the lift mast or fork carriage is raised, no
work should be performed on the lift mast and at the
front of the forklift truck without the following safety
measures! These safety precautions are only suf-
ficient for general maintenance to the forklift truck
(inspection and greasing). With repairs (e.g. chan-
ging chains, dismantling lift cylinders), additional
safety precautions must be taken. Please contact
your authorised dealer.
Securing against tilting back

The lift mast must be secured from tilting back
accidentally.
¾ Tilt lift mast right back.
¾ Remove the ignition key.
Standard lift mast

FUNCTION: When lifting the inner mast, the
chain rollers are moved up with the chains so
that the fork carriage is lifted with a transmis-
sion ratio of 2:1, due to the chain deflection .
Securing the raised standard lift mast

DANGER
Check chain load! t3921320
Select safety chain with sufficient load bearing ca-

pacity for the lift mast. Take maximum lift height
into account.
¾ Extend lift mast.

5 Maintenance
¾ Connect the chain over the cross traverse

of the outer mast (1) and under the cross 1
traverse of the inner mast (2).
¾ Lower the inner mast until it reaches the
chain.
Duplex lift mast
NOTE
The benefit of this equipment version is that
full advantage is taken of the special free lift
height, even in very low rooms (cellars, wa-
gons, ships). 2
FUNCTION: The fork carriage is lifted to the
d3921482
special free lift height via the chain guide pul-
ley of the centre cylinder. Here it moves twice
as fast as the centre cylinder. The inner mast
is then lifted via the two outer cylinders, taking
the fork carriage with it. The centre cylinder is
positioned on the extendable inner mast.
Securing the raised duplex lift mast

DANGER
Check chain load!
into account.

Maintenance 5

of the outer mast (1) and under the cross
traverse of the inner mast (2). 1
¾ Lower the lift mast until it reaches the chain.

¾ Lower fork carriage as far as it will go.
Triplex lift mast

FUNCTION: The fork carriage is lifted to the
special free lift height via the chain guide pul-
ley of the centre cylinder. Two lift cylinders
then lift the inner mast. Once the inner mast is
fully extended, two additional lift cylinders lift
the centre mast, which is lifted together with
the inner mast and the fork carriage . The cen- 2
tre cylinder is positioned on the extendable d3921483
inner mast.
Securing the raised triplex lift mast

DANGER
Check chain load!
into account.

of the outer mast (1) and under the cross 1
traverse of the centre mast (2).
¾ Lower the lift mast until it reaches the chain.
¾ Lower fork carriage as far as it will go.
2
d3921484

5 Maintenance
Consumables recommendations
Inspection and maintenance data

No. Unit Devices / Consumables Filling quantity / Set values
1 Engine Engine oil Approx. 4.0 l
2 Cooling system Coolant additive / Drinking With heater / air conditioning:
water Approx. 9.5 l
Without heater / air
conditioning: Approx. 7.5 l
3 Spark plugs NGK BKUR 6 ET–10 Gap between electrodes:
1.0±0.1 mm
Tightening torque 30-5 Nm
4 Hydraulic system Hydraulic oil Lift height up to 5000 mm:
Approx. 24.0 l
Lift height from 5000 mm to
6900 mm: Approx. 25.5 l
Lift height from 6900 mm to
8000 mm: Approx. 28.0 l
5 Battery Distilled water As required
6 Tyres Pneumatic See information on sticker
on right-hand side of truck
7 Wheel fastenings Tighten Front: 170 Nm
Rear: 460 Nm
Load chains / Lift mast Linde chain spray As required
8
channels
9 Air conditioning Refrigerant 1500 grams
10 LPG cylinder LPG Approx. 11 kg
Refillable LPG tank (special LPG Approx. 55.0 l
equipment)
LPG NOTE
Approved for the VW engine:
The use of domestic gas bottles is absolutely
LPG of 95% propane with the remaining 5% prohibited.
other gas up to 80% butane with 20% propane
and other gas, fed through a suitable ignition
and mixture formation system.
Use only LPG cylinders filled with LPG to DIN
51622 or LPG to EN 589 (automotive gas);
gas withdrawal in the liquid phase.

Maintenance 5
Hydraulic oil above. If they are mixed with other hydraulic

fluids or other hydraulic fluids are used, highly
NOTE expensive damage may result.
The working temperature is the critical factor

to be considered in selecting the correct oil for Lubricating grease
hydrostatic traction drives. The recommenda- Linde heavy-duty grease, lithium-saponified
tions for oils given below can only be taken as with EP active ingredients and MOS2. Des-
guide values. ignation as per DIN 51825-KPF 2N-20 (order
no. see spare parts catalogue).
Hydraulic oil recommendations for normal
use: Mixing with lubricating grease types with a
Hydraulic oil ISO - L - HM 68 to ISO 6743 - 4 or soap basis other than lithium is not permitted.
HLP ISO VG 68 to DIN 51524, T.2 (factory
filling) average sustained oil temperature Coolant
60°C–80°C.
CAUTION
Hydraulic oil recommendations for heavy-duty
Refer to the coolant specifications!
use:
Use only coolant G012 A8D to VW specification
Hydraulic oil ISO - L - HM 100 to ISO 6743 - TL-VW 774D (factory filling) or G012 A8F to VW
4 or HLP ISO VG 100 to DIN 51524, T.2 for specification TL-VW 774F.
heavy-duty and multi-shift use, operation in
hot climates or at high ambient temperatures,
Coolant Drinking
average sustained oil temperature over 80 °C. Temperature
additive water
Hydraulic oil recommendations for normal and -25°C 40% 60%
heavy-duty use:
-30°C 45% 55%
Hydraulic oil ISO - L - HV 68 to ISO 6743
- 4 or HVLP ISO VG 68 to DIN 51524, T.3 -35°C 50% 50%
(multi-grade oil)
-40°C 60% 40%
Bio-hydraulic oil
Refrigerant for air conditioning
Highly biodegradable hydraulic fluid
R 134a
Aral Forbex SE 46
CAUTION Battery grease
Bio-oils must not be mixed with mineral-based oils. Acid-free lubricating grease (terminal grease).
No recommendations for other fluids from other
manufacturers can be made at the present time.
Chain spray
NOTE Linde chain spray (order no.: see spare parts
catalogue).
If in doubt, we recommend obtaining the ad-
vice of your authorised dealer. Recommen-
dations made by representatives from the
Engine oil
mineral oil industry should also be agreed with Specification and viscosity of engine oil for oil
your authorised dealer. Manufacturer’s ap- change every 1000 operating hours
proval has been granted only for the oils listed

5 Maintenance
"Longlife" engine oils to VW standard 503 00 Since a good engine oil is a pre-requisite for
or 503 01. These oils are available exclusively problem-free operation and a long service life
in viscosity SAE 0W-30 for the engine, use only good quality engine
oil even when topping up and also during oil
or "Longlife 3" engine oils to VW standard
change. Due to their limited viscosity range,
504 00 in viscosity SAE 5W-30.
single-grade oils should generally not be used
Oil change every 1000 operating hours or all-year-round. These oils should be used only
every 12 months. in extreme climatic zones.
A high-quality engine oil for 1000 operating
NOTE
hours to VW standard 504 00 is factory-filled.
No additional lubricants of any sort should be
Engine oil for oil change every 500 operating
mixed in with the lubricating oils.
hours
¾ Refer to the viscosity table.
Engine oils to VW standard 500 00, 501 01
or 502 00 are also approved. See table for
viscosity.
This engine oil must be changed every 500 op-
erating hours.
Engine oil for oil change every 300 operating
hours
Engine oils to API SF/SG or ACEA A2/A3 and They apply only to oils which must be changed
higher quality API-S or ACEA-A classes are every 500 or 300 operating hours.
also approved. See table for viscosity. When the engine is running, not only is some
This engine oil must be changed every 300 op- of the engine oil for piston lubrication burnt
erating hours. off ("consumed"), but the temperature stress
and the fuel combustion products that enter
¾ When topping up, the various oils may be the oil lead to "wear," affecting especially the
mixed with each other, however the oil chemical additives"" in the oil. For this reason,
change interval is then determined by the the entire filling of engine oil must be renewed
oil of the lowest quality. at specified intervals.
Since this "oil wear" depends on the operating
conditions, the fuel and the oil quality (the
performance characteristics of the oil), the
long oil change intervals vary.
The longest time a filling of lubricating oil
may remain in the engine is 12 months.
Irrespective of the change intervals, the
lubricating oil must be changed at intervals
no less than every 12 months.
ENVIRONMENT NOTE
Used oil must be kept away from children
until disposed of according to the regulations.
Under no circumstances should oil be allowed
to get into the mains drainage or the ground.

Maintenance 5
Because of the problems of disposal and engine oil and filter changing should only be
the special tools and knowledge required, performed by your authorised dealer.

5 Maintenance
Inspection and maintenance overview

50 h Service plan
Carried
At operating hours
out
50 9 8
Preparations
Clean the truck if necessary
Read out error log and delete
Calibrate the drive potentiometer and joysticks
Enter the next maintenance interval
Engine
Check LPG mixer settings
Three-way catalytic converter: Check LPG system default setting
Chassis frame
Tighten wheel fastenings
Check the parking brake for correct operation
Electrics
Check the condition and secure positioning of electric cables, cable connectors and
cable connections
Hydraulics
Check the hydraulic system, drive axle, hydraulic pumps and lines for leaks (visual
inspection)
Load lift system
Lift mast, lift mast chain, lift cylinder and end stops: Check condition, secure faste-
ning and function
Adjust lift mast chain and spray with chain spray
Subsequent tasks
Carry out functional test and test drive
Attach maintenance sticker

Maintenance 5
Service plan as required

Carried
out
9 8
Engine
Change the air filter cartridge (after no longer than 1000 operating hours)
Change the safety cartridge in the air filter (after no longer than 3000 operating
hours)
Check the dust discharge valve
Change the oil bath air filter oil
Clean the prefilter
Clean the water cooler and hydraulic oil cooler, and check them for leaks
Chassis, bodywork and fittings
Clean the truck
Service the air conditioning
Check condition and correct operation of the seat belt
Chassis frame
Wheel change
Clean and grease the steering axle (after no longer than 1000 operating hours)
Check tyres for damage and foreign bodies
Check solid rubber tyres for wear (H 25 TCT)
Tighten wheel fastenings (after each maintenance or repair, no longer than every
100 operating hours)
Hydraulics
Check function and safety system of third auxiliary hydraulics
Load lift system
Clean the lift mast chain, adjust and apply chain spray
Special equipment
Washer system: Top up the water tank

5 Maintenance
1000 h service plan

At operating hours
1000 2000 4000 5000 7000
Carried
8000 10000 11000 13000 14000 out
16000 17000 19000 20000 9 8
Information on service plan
Dependent on the consumables used, driving style and operating conditions, but
at least after 1, 5, 7, 11, 13, 17 and 19 years of service. Refer also to consumable
recommendations.
Preparations
Engine
Change engine oil
Change engine oil filter
Change the spark plugs
Change the LPG filter
Clean evaporator / pressure regulator and refit using a new repair kit
Check condition and secure positioning of engine cradle and engine mounting
Check condition of V-ribbed belt
Check condition and tension of toothed belt
Clean water and hydraulic oil coolers
Check the coolant concentration
Change air filter cartridge, check vacuum-operated switch
Clean the oil bath air filter
Check suction and exhaust pipes for leaks
Check CO level in the exhaust gas
Gearbox

Maintenance 5
At operating hours
1000 2000 4000 5000 7000
Carried
8000 10000 11000 13000 14000 out
16000 17000 19000 20000 9 8
Axle clamps and wheel motors: Check fastening
Drive axle: Check the side stops
Chassis, tilt cylinders and steering axle: Check fastening
Check and grease other bearings and joints
Chassis frame
Clean and grease steering axle
Steering cylinder and steering pivot pin: Check fastening
Controls
Check and oil the pedals
Electrics
cable connections
Battery: check condition, acid level and acid density (even for maintenance-free
battery)
Hydraulics
Check the bleeder valve on the hydraulic oil tank for correct operation
Check the hydraulic system for leaks
Double hoses: Check the pre-tension
Load lift system
ning and function
Check fork arms and arm safety devices
Clean and grease the sideshift, check fastening
Clean and grease fork positioner, check fastening
Subsequent tasks

5 Maintenance
At operating hours
1000 2000 4000 5000 7000
Carried
8000 10000 11000 13000 14000 out
16000 17000 19000 20000 9 8

Maintenance 5
3000 h Service plan

Carried
At operating hours
out
3000 15000 9 8
Dependent on the consumables used, driving style and operating conditions, but at
least after 2, 10 and 14 years of service. Refer also to consumables recommendati-
ons.
Preparations
Engine
Change engine oil
Change high-pressure gas hoses
Change V-ribbed belt
Change toothed belt and tensioner pulley (at latest after 5 years)
Change the safety cartridge in the air filter

5 Maintenance
Carried
At operating hours
out
3000 15000 9 8
Gearbox
Drive axle: Check bearing for wear
Hydraulic pump on engine: Check fastening
Chassis frame
Controls
Check the bellows at the actuating lever
Electrics
cable connections
battery)
Hydraulics
Change feed/pressure/suction filter and breather of the hydraulic system
Check tilt cylinder bearing for wear
Load lift system
ning and function

Maintenance 5
Carried
At operating hours
out
3000 15000 9 8
Check slide guides on sideshift for wear
Check fork positioner for wear
Subsequent tasks

5 Maintenance
6000 h Service plan

Carried
At operating hours
out
6000 12000 9 8
least after 3, 6, 9, 15 and 18 years of service. Refer also to consumables recommen-
dations.
Preparations
Engine
Change engine oil

Maintenance 5
Carried
At operating hours
out
6000 12000 9 8
Gearbox
Chassis frame
Controls
Electrics
cable connections
battery)
Hydraulics
Change hydraulic oil
Load lift system
ning and function

5 Maintenance
Carried
At operating hours
out
6000 12000 9 8
Subsequent tasks

Maintenance 5
9000 h Service plan

Carried
At operating hours
out
9000 18000 9 8
least after 4, 8, 12, 16 and 20 years of service. Refer also to consumables recom-
mendations.
Preparations
Engine
Change engine oil
Change the water pump
Change the coolant

5 Maintenance
Carried
At operating hours
out
9000 18000 9 8
Gearbox
Chassis frame
Controls
Electrics
cable connections
battery)
Hydraulics
Change the hydraulic oil (omitted for 9000 operating hours)
Load lift system

Maintenance 5
Carried
At operating hours
out
9000 18000 9 8
ning and function
Subsequent tasks

5 Maintenance
Engine
Engine
Checking the engine oil level
ENVIRONMENT NOTE
Observe information regarding working with
consumables
WARNING
When topping up the oil, no oil should
drip on to hot engine parts — Risk of
fire!
Fill carefully.
CAUTION
Different oil specifications.
Observe the recommendations for consumables.
CAUTION
The oil level should never be above the upper mark.
Drain engine oil if necessary.
¾ Park the forklift truck on level ground.

¾ Open the bonnet.
¾ Take the oil dipstick (2) out of the engine.
¾ Wipe the oil dipstick with a clean cloth.
¾ Push the oil dipstick fully back in and re- 1
move it again.
Oil level should be between the marks.
¾ If necessary, pour in engine oil through the
filler opening until it reaches the upper dip-
stick mark.
¾ To do so, remove filler cap (1) from the filler
opening.
Difference in quantity between min. and max.
marking: 1.0 l
2
¾ Fit filler cap and turn to tighten. t3921327
¾ Close the bonnet.

Maintenance 5
Engine
Changing the engine oil

(at the latest after 12 months)
CAUTION
Different oil grades result in different maintenance
intervals.
Recommendations for consumables must always
be observed.
Draining the engine oil
WARNING
Risk of scalding when draining hot
engine oil!
Protective equipment must be worn.
ENVIRONMENT NOTE
consumables.
NOTE
Only change engine oil when the engine is at
operating temperature.
¾ Drive truck over pit.
¾ Close the gas shut-off valve on the LPG
cylinder.
¾ Place a collection vessel under the truck
chassis.
¾ Open the bonnet.

5 Maintenance
Engine
¾ Remove the filler cap (1) from the filling

opening.
¾ Remove cover on floor of chassis.
1
t3921335
¾ Unscrew the engine oil drain plug (2) under-

neath from the oil sump.
¾ Allow all of the oil to drain off into the collec-
tion vessel.
¾ Fit the drain plug (2) with a new sealing ring.
Tightening torque: 30 Nm
¾ Refit cover on floor of frame.
¾ Refit the cover (1).
Topping up with engine oil

2
¾ Switch off ignition.
t3921336

Maintenance 5
Engine
¾ Open the filler cap (1) of the filling opening.

¾ Top up with new engine oil to filling opening
according to the recommendations for con-
sumables.
Filling quantity with filter change: max. 4.0 l
¾ Using the dipstick (2), check the engine 1
oil level after adding oil and top up to max.
mark.
¾ Fit filler cap (1) and turn to tighten.
2 t3921350
¾ Check the indicator unit (4).

The Oil display (5) (special equipment) in the
indicator unit must go out. The oil level will not
be displayed reliably in the indicator unit until
approx. 10 minutes after adding oil.
NOTE
After changing the oil and the filter, run the
engine, checking the oil pressure indicator and
the tightness of the oil drain plug and oil filter.
For an accurate oil-level check, especially
after changing the oil filter, it is necessary to
switch off the engine again and then carry out
an oil-level check after approx. one minute.
Change motor oil filter
WARNING
Risk of scalding with hot motor oil!
Wear protective equipment.
ENVIRONMENT NOTE
Take note of information about working mate-
rials.
¾ Open motor hood.

5 Maintenance
Engine
¾ Place a collection vessel under filter car-

tridge (2).
¾ Release motor oil filter with an oil filter
wrench and unscrew by hand.
¾ Collect oil escaping from oil filter and dis-
pose of it with oil filter in an environmentally
friendly manner.
¾ Clean filter top.
¾ Slowly fill new oil filter cartridge (2) with
motor oil.
¾ Lightly oil filter seal (1) with motor oil.
¾ Screw in filter cartridge by hand until seal
touches, then tighten half a turn with oil filter
wrench.
¾ Close motor hood.
NOTE
After changing the filter check the oil pressure
indicator and that there is no leaking of the oil
filter during a trial run of the motor. To make
an accurate oil level check it is necessary to
switch off the motor again and inspect the oil
level after approx. one minute.
LPG system: Checking the fuel level

With the attachment of a single cylinder the
truck is equipped with a sensor which monitors
the filling level of the LPG cylinder.
The fuel level is displayed in the indicator unit
(4) by illuminated fields.
The contents indicator system is designed to
be used with full LPG cylinders.
It is not suitable for measuring the different
filling levels of partially filled LPG cylinders. In
this case, the filling level may not be shown
correctly.

Maintenance 5
Engine

The fuel level is displayed after a few seconds.
The cylinder is full when all 6 LEDs (2) and the
"fuel pump" illuminated field (1) light up green.
As the cylinder empties, the LEDs extinguish,
starting from the right. If only the "fuel pump"
illuminated field (1) is lit up red, the LPG cylin-
der must be changed in the next 5–25 minutes
depending on the driving style and ambient
temperature.
Changing an LPG single cylinder

(H 20 T / H 25 T)
NOTE
The sensor for monitoring the fill level is loca-
ted under the LPG cylinder and is calibrated
for LPG cylinders with a full weight of 11 kg to
DIN 4661 and a gas mixture to DIN 51622. If
the cylinder diameter or gas mixture is diffe-
rent to this (with a propane level below 90%),
the sensor will have to be recalibrated. Ple-
ase contact your authorised dealer. If partially
filled LPG cylinders are used, the fill level may
not be shown correctly.
DANGER
Check that the LPG cylinders are approved. LPG
cylinders with an expired inspection date should not
be used.
The inspection intervals for pressure vessels speci-
fied in EC directive 97/23 must be strictly observed.
The last inspection date marked on the LPG cylin-
der is the applicable date.
Observe safety guidelines for vehicles pow-

ered by LPG! Cylinders may only be changed
by trained personnel.

5 Maintenance
Engine
DANGER
escapes.
Do not smoke or use a naked
flame/fire when changing cylinders.
LPG cylinders should only be
changed in well-ventilated rooms
and not near openings in the ground.
Switch off the truck engine and
combustion heater, and allow them
to cool down.
WARNING
A small amount of LPG will escape
when the LPG hose is disconnected.
This can cause frostbite on the skin.
Therefore, protective gloves should
always be worn.
¾ Firmly close the shut-off valve (2) on the

LPG cylinder.
2
¾ Securely grip the connection nipple with the 1
handhold (1) and carefully undo the union
nut, initially only a little (pressure reduction).
NOTE
The union nut has a left-hand thread. − The
US version of the union nut has a right-hand
thread.
¾ Completely unscrew the union nut.
¾ Remove the hose.
¾ Screw a plastic sealing nut onto the pipe
union. t3921389

Maintenance 5
Engine

¾ Pull the locking bolt (5) and swing the con-
sole (4) to the rear using the handle, until
the latch (5) audibly engages. 3
t3921390
¾ Push the securing hook locks (8) upwards

and pull the securing hook lever (6) back
until the belt straps (7) are slack .
¾ Detach the securing hooks.
¾ Fold the cover plate (9) up.
¾ Remove LPG cylinder.
If necessary, clean the contact surface of the
sensor (18) carefully with water or soapy water
and a soft cloth.
CAUTION
When closing the console with no LPG cylinder
fitted the ultrasonic sensor may be damaged.
Never close the console without locking the clam-
ping plate. Refer to the section entitled "Closing the
LPG console when there is no LPG cylinder fitted".
¾ Gently place a new LPG cylinder in position,

taking care not to damage the sensor.
In order to avoid sensor wear or malfunctions,
do not rotate or drag the LPG cylinder over the
contact surface of the sensor.
Replacement cylinders to DIN 4661 p. 6, ca-
pacity 11 kg, should be used
The recess of the new LPG cylinder must be
positioned above the stop pin. If there is no
stop pin, insert the cylinder as described on
the adhesive label on the cover.

5 Maintenance
Engine
¾ Close the cover plate (9) and connect the

securing hooks.
¾ Tension the belts and tighten securely with
ratchet levers.
When doing so, check for correct positioning
of the cylinder on the contact surface of the
sensor (pretension approx. 9 mm).
¾ Pull the locking bolt (5) and hold it.
¾ Swing the console forward until the latch
audibly engages.
¾ Reattach the hose connection to the LPG
cylinder according to applicable regula-
tions.
¾ Check for leaks with leak spray and a gas
detector in accordance with the inspection
and maintenance guidelines.
Changing an LPG double cylinder

(H 20 T / H 25 T) (special equipment)
DANGER
be used.
The last inspection date marked on the LPG cylin-
der is the applicable date.

DANGER
escapes.
to cool down.

Maintenance 5
Engine
WARNING
always be worn.
¾ Close both cylinder selector valves (2).

1 5
¾ Firmly close the shut-off valves (1) on both
LPG cylinders.
¾ Securely grip the connection nipple with the
handhold (3) on the rear LPG cylinder (5)
and carefully undo the union nut (4), initially
only a little (pressure reduction).
NOTE
The union nut has a left-hand thread. − The 3
2 4
thread.
¾ Completely unscrew the union nut and re-
move the hose. t3921013

union.
and pull the securing hook lever (6) back 6
until the belt straps (8) are slack.
8
t3921004

5 Maintenance
Engine
¾ Hold the LPG cylinder and move the cover-

ing (9) upwards until latch (10) engages.
WARNING
The LPG cylinder is now no longer fixed in the sup-
port mounting and may therefore fall off.
Hold the LPG cylinder.

¾ Remove the LPG hose from the front LPG
cylinder.
union.
¾ Pull the locking bolt (13) and swing the con-

sole (12) to the rear using the handle, until
the latch (13) audibly engages.

Maintenance 5
Engine

and pull the securing hook lever (15) back
until the belt straps (17) are slack.
¾ Fold the cover plate (16) up.
¾ Change the LPG cylinder.
pacity 11 kg, should be used.
The recess of the new LPG cylinder must be
positioned above the stop pin. If there is no
stop pin, insert the cylinder as described on
the adhesive label on the cover.
¾ Close the cover plate (16) and connect the
securing hooks.
ratchet levers.
¾ Pull the locking bolt (13) and hold it.
¾ Swing the LPG console (12) forward until
the latch audibly engages.
tions.
¾ Insert a new rear LPG cylinder in the sup-
port mounting and hold it.
pacity 11 kg, should be used.
NOTE
Place the LPG cylinder in the support so that
the connection thread of the shut-off valve is
facing vertically downwards.
¾ Push the latch (10) forwards and close the
covering (9).
¾ Reattach belts.
ratchet levers.
tions.

5 Maintenance
Engine

Changing an LPG single cylinder

(H 25 TCT)
NOTE
The sensor for monitoring the fill level is loca-
ted under the LPG cylinder and is calibrated
for LPG cylinders with a full weight of 11 kg to
DIN 4661 and a gas mixture to DIN 51622. If
the cylinder diameter or gas mixture is diffe-
rent to this (with a propane level below 90%),
the sensor will have to be recalibrated. Ple-
ase contact your authorised dealer. If partially
filled LPG cylinders are used, the fill level may
not be shown correctly.
DANGER
be used.
The inspection intervals specified in EC directive
97/23 on pressure vessels must be strictly obser-
ved. The last inspection date marked on the LPG
cylinder is the applicable date.

DANGER
escapes.
to cool down.

Maintenance 5
Engine
WARNING
always be worn.
¾ Release LPG cylinder panelling (3) up-

wards by pulling evenly on both handles (4).
¾ Detach LPG cylinder panelling from the
centring pins and remove.
¾ Firmly close the shut-off valve (2) on the

LPG cylinder.
2
¾ Securely grip the connection nipple with the 1
handhold (1) and carefully undo the union
nut, initially only a little (pressure reduction).
NOTE
The union nut has a left-hand thread. − The
thread.
¾ Completely unscrew the union nut.
¾ Remove the hose.
union. t3921389
¾ Press latch (5) downward and flip up the

fastener (6).

5 Maintenance
Engine
¾ Also open the second fastener (7).

¾ Detach both cylinder holders (8) from join-
ing plate and swing up.
If necessary, clean contact surface of sensor
carefully with water or soapy water and a soft
cloth.
¾ Gently place a new LPG cylinder in position,
taking care not to damage the sensor.
In order to avoid sensor wear or malfunctions,
do not rotate or drag the LPG cylinder over the
contact surface of the sensor.
NOTE
Insert LPG cylinder in holder until screwed
connection of shut-off valve points down verti-
cally.
When doing so, check for correct positioning
of the cylinder on the contact surface of the
sensor (pretension approx. 9 mm).
¾ Re-insert both cylinder holders in joining
plate and close locks until locking device
audibly catches.
tions.
¾ Re-insert LPG cylinder panelling in both
centring pins and press down evenly until
locking device audibly catches.

Maintenance 5
Engine
Filling the LPG tank (special equip-

ment)
DANGER
The most recent inspection date marked on the
container is the applicable date. Containers with an
expired inspection date should not be used. They
may not be filled if major defects are observed or if
the inspection interval has been exceeded.
Before connecting the pistol-type nozzle, check
whether the LPG tank or fittings show any defects
and that the inspection interval given on the contai-
ner has not expired.
DANGER
escapes.
When filling the LPG tank, do not
smoke or use a naked flame/fire.
Observe the safety guidelines for the use of

LPG and the safety information for the filling
station. The LPG tank may only be filled by
trained personnel.
WARNING
when the pistol-type nozzle is
removed. This may cause frostbite
on the skin.
always be worn.
NOTE
It is recommended that refuelling is carried
out before the start of work, when the engine
is still cold. If there is a major difference in
temperature between the storage tank outside
and the tank on the truck, the delivery pressure
of the pump may not be sufficient for proper
filling.
¾ Switch off truck engine and combustion
heater.
¾ Put on protective gloves.

5 Maintenance
Engine
¾ Close the (1) shut-off valve.

1 2 3
¾ Unscrew the locking cap from the filling
valve (3).
¾ Check that connecting thread of the pistol-
type nozzle is clean.
¾ Securely connect the pistol-type nozzle to
the filling valve (3).
¾ Open main shut-off valve of LPG fuelling
station and activate pump motor/pistol-type
nozzle until the built-in valve in the tank
stops the filling process.
Fill quantity: approx. 55.0 l
¾ After the tank valve has stopped the fuelling, t3921368
immediately release the actuating lever
of the pistol-type nozzle to end the filling
process.
¾ Switch off the pump motor and close the
main shut-off valve of the LPG fuelling sta-
tion.
CAUTION
Do not overfill the LPG tank.
The LPG tank should only be filled up until the tank
valve switches off and not as shown on the display
of the contents indicator (2).
¾ Carefully unscrew the pistol-type nozzle

from the filling valve (3).
¾ Screw the locking cap onto the filling valve.
CAUTION
Carefully observe the entire filling process.
If irregularities or special incidents are noted during
filling, immediately notify the departments respon-
sible and arrange for the defects to be corrected.

Change the LP gas filter

¾ Close the shut-off valve the LPG bottle.
¾ Let the engine run until the gas in the instal-
lation is consumed.

Maintenance 5
Engine
¾ Loosen the screw (2) and remove it with the

filter housing (1).
¾ Take out the old filter.
1
¾ Clean the housing.
¾ Insert a new filter and fit the housing.
¾ Perform a leak test.
t3921329
Check the setting of the LPG mixer

¾ Check the setting of the LPG mixer (1) and
correct the setting, if necessary.
WARNING
Special knowledge is required for this service.
Cleaning the evaporator / pressure

regulator
(mount it with a new repair kit, after 12 months
at the latest)

5 Maintenance
Engine
¾ Dismantle, clean and check the evaporator

/ pressure regulator and mount with a new
repair kit.
¾ Measure the CO content and check the
output by means of the pressure speed.
t3921385
LPG system visual inspection, odour

inspection
A high-pressure relief valve (1) in front of the
gas cylinder protects the gas pipe against
1
excess pressure.
NOTE
The driver must perform a visual and odour
inspection of the LPG system each day before
beginning work. If problems occur, the truck
must not enter operation. Report problem to a
qualified person immediately.
t3921365
Checking the LPG system for dam-

age and leaks
NOTE
The LPG system must be checked for leaks
at least once a year by a trained technician
(specialist).
¾ Open shut-off valve of the LPG cylinder.

Maintenance 5
Engine
¾ Check the shut-off valve of the LPG cylin-

der or LPG tank (special equipment), hose
screw joints and hoses for leaks and dam-
age.
t3921322
¾ Check the hose and line screw joints, LPG

filter with shut-off valve, evaporator pres-
sure regulator and LPG mixer with gas
detector; applyleak spray and see if any
bubbles form.
NOTE
Icing and yellow foam deposits on the LPG
system indicate the presence of leaks.
In models with an LPG tank (special equip-
ment)
NOTE
Regular inspection of the LPG tank is gover-
ned by the Ordinance on Industrial Safety and t3921384
Health (BetrSichV), § 15. The owner of the

forklift truck is responsible for ensuring that
checks are performed and that the inspection
intervals are correct. The maximum inspec-
tion intervals specified in the Ordinance on In-
dustrial Safety and Health must not be excee-
ded. Different regulations apply in countries
other than Germany. The applicable national
regulations must be complied with.

5 Maintenance
Engine
¾ Check the extraction valve, contents indica-

tor and filling valve for leaks.
¾ Re-tighten leaking screw joints, change
damaged hoses and check for leaks again.
¾ Leaks on the LPG filter, evaporator pres-
sure regulator, shut-off valve and LPG
mixer must only be rectified by an autho-
rised dealer.
Checking the coolant level
ENVIRONMENT NOTE
consumables.
NOTE
If the display lights up (depending on the mo-
del) (special equipment) (1) the coolant level
is too low and more coolant must be added.
If the coolant continues to fall below the min.
mark, the truck only moves at crawling speed.
NOTE
For models without a display (1) the coolant
level can be checked at the viewing window
(2).
CAUTION
Only use an approved coolant.
Observe the recommendations for consumables.

Maintenance 5
Engine
¾ Open the bonnet.

2
The coolant level in the viewing window (2)
should not be below the mark.
¾ Top up the coolant when necessary; to do
this the LPG cylinder cover must first be
opened.
Refer to the information in the chapter entitled
"Changing the LPG cylinder".
WARNING
The expansion tank is under
pressure! Risk of scalding due to
hot coolant.
Unscrew the filler cap slowly (3) and
only if the expansion tank is not hot. t3921328
¾ Open the filler cap (3) of the expansion tank

and top up with coolant.
The coolant must be visible between the
marks on the filler neck.
¾ Twist the filler cap into position.
t3921303
Changing coolant
The cooling system must be filled all-year-
round with a mixture of water and phosphate-
free, glycol-based coolant additive with anti-
corrosion additives to prevent the deposit of
lime scale and damage caused by frost and
corrosion, and to raise the boiling tempera-
ture.

5 Maintenance
Engine
WARNING
Never open the filler cap (2) when
the engine is hot. Risk of scalding!
Wait until the coolant has cooled
down.
ENVIRONMENT NOTE
Observe information about working with con-
sumables.
¾ Open the bonnet.
¾ Place a collection vessel under the coolant
hose (3).
¾ Disconnect coolant hose at cylinder.
¾ Drain off all coolant. Dispose of coolant in
an environmentally friendly manner.
¾ Refit the coolant hose (3).
3
t3921347
¾ Add new coolant at filler neck (1).

Coolant level must be between min. and max.
marks on the filler neck. 1 2
AU
F
1,2
GE ES
RM T-
W
AN
Y
ZU
d3921339

Maintenance 5
Engine
¾ Read off the filling level in filler neck.

• Min. marking is the edge (4) of the lower 4
step.
• Max. marking is the edge (5) of the upper
step.
5
Difference in quantity between min. and max.:
approx. 0.75 l 5
Filling quantity in cooling system
Without heater and air conditioning: 7.5 l
With heater and air conditioning: 9.5 l
The frost protection should be sufficient for
temperatures down to -25°C. The mixture 4
ratio required here is 40% coolant additive and t3921378
60% drinking water.
Mixture ratio for lower temperatures:
Coolant Drinking
Temperature
additive water
-30°C 45% 55%
-35°C 50% 50%
-40°C 60% 40%
¾ Run engine until cooling system has been

drained.
¾ Check coolant level.
¾ Fit filler cap (2) and turn to tighten.
Check coolant concentration

The cooling system has to be filled all year
round with a mixture of water and phosphate-
free glycol-based coolant additive with anti-
corrosion additives to prevent the deposit of
limescale and damage caused by frost and
corrosion and to raise the boiling temperature.
WARNING
Never open the lid (2) when the
motor is hot. Risk of scalding!
Wait until the coolant has cooled
down.

5 Maintenance
Engine
ENVIRONMENT NOTE
Take note of information about working mate-
rials.
¾ Check coolant concentration in filling port
(1).
The frost protection should be sufficient for 1 2
temperatures down to -25 °C. The mixing ratio
required here is 40% coolant additive and 60%
drinking water. AU
F
1,2
Mixing ratio for lower temperatures:
GE ES
RM T-
W
AN
Y
ZU
Coolant Drinking
Temperature
additive water
-30°C 45% 55%
-35°C 50% 50%
-40°C 60% 40%
d3921339
If coolant additive level is too low:
¾ Open motor hood.
¾ Place a collection vessel under the coolant
hose (3).
¾ Release hose clip from coolant hose at
cylinder block. 4
¾ Remove hose from stub and allow some
coolant to drain off.
¾ Push coolant hose back onto stub and fas-
ten with hose clip.
¾ Dispose of removed coolant in an environ-
mentally friendly manner.
¾ Add coolant additive to filling port (1) until
right mixing ratio is achieved.
¾ Check coolant level at view window (4). 3
t3921339
¾ Fit lid (2) and turn to fix in place.

¾ Close motor hood.

Maintenance 5
Engine
Cleaning the water cooler and hy-

draulic oil cooler, and checking them
for leaks
NOTE
Only clean the water cooler and hydraulic oil
cooler when the engine is switched off and has
cooled down.
¾ Open the bonnet.
¾ Release the 4 screws (2).
¾ Remove the cover sheet (1) from the rear.
1
1,2
GER
MAN
WES
ZU
T-
2
2
d3921387
Cleaning with compressed air

¾ Ventilate the cooler (3) of the engine with
compressed air.
¾ Rinse out the released dirt using a water jet.
Cleaning with cleaner solvent 3

CAUTION
No humidity must penetrate the three-phase gene-
rator.
Therefore, protect it from direct contact with the
water jet.
¾ Spray the cooler (3) with a conventional

cleaner solvent and leave it to work for ap-
prox 10 minutes.
t3921349
¾ Spray the cooler in the engine with a direct
jet of water until it is clean.

5 Maintenance
Engine
¾ Warm up the engine.

Vaporise the water residue to prevent the for-
mation of rust.
¾ Check the connection screw joints, cooling
hoses and the pipes on the water cooler and
hydraulic cooler for leaks.
¾ Replace porous hoses. Re-tighten hose
clips if necessary.
¾ Refit the cover sheet (1).
Change the water pump
NOTE
Changing the water pump requires specialist
knowledge and special tools. Please contact
d3921410
Check the condition of the engine

mountings and engine suspension;
check that they are attached se-
curely
The resilient mountings used for the engine
suspension are subjected to high loads. Their
service life is limited by the operating condi-
tions.

Maintenance 5
Engine
¾ Check rubber elements for cracks and se-

vere deformation; if necessary, exchange
them.
¾ Check all screws and nuts in the engine
mount and engine suspension for damage.
Check that they are securely attached.
Tightening torques of the fixing screws and
nuts:
Pump side:
2 SKS M 12 (spring element) 80 Nm

1 SKM M 12 (bottom) 110 Nm
d3931380
Engine side:
3 SKS M 8 23 Nm
1 SKS M 10 46 Nm
top centre:

Spherical collar nut A14
110 Nm
(rod)
Check condition of ribbed V-belt
WARNING
Do not touch rotating parts!
Switch off the engine and remove
ignition key.
NOTE
A defective or loose ribbed V-belt will affect
the vehicle electrical system voltage.
¾ Open the bonnet.
¾ Remove the maintenance cover on the
right-hand side.

5 Maintenance
Engine
¾ Check the ribbed V-belt (1) for excessive

wear, frayed edges, cracks across the belt
and traces of oil.
¾ Replace the ribbed V-belt if it is damaged.
¾ Refit the side maintenance cover.
t3921340
Change ribbed V-belt
WARNING
Do not touch rotating parts.
ignition key.
NOTE
On trucks without air conditioning, first discon-
nect the ribbed V-belt from the alternator and
when reassembling, replace it last. On trucks
with air conditioning, first disconnect the rib-
bed V-belt from the deflection pulley and when
reassembling, replace it last. Note the running
direction of the ribbed V-belt.
¾ Open the bonnet.
¾ Remove the access cover on the right-hand
side.

Maintenance 5
Engine
¾ Mark the running direction of the ribbed

1
V-belt (3). 2
¾ Swing away (2) the tensioner pulley, (1)
using a flat 16 AF ring spanner at the ten-
sioning lever.
NOTE
Observe the running direction of the ribbed
V-belt (3).
¾ Replace the ribbed V-belt.
3
t3921345
Checking the condition and tension

of toothed belt
WARNING
Do not touch rotating parts!
ignition key.
¾ Remove the maintenance cover on the

right-hand side.
¾ Take off the engine cover
¾ Check the toothed belt (4) for excessive
wear, frayed edges, damaged teeth, cracks
across the belt and traces of oil.
¾ If the toothed belt is damaged, get your
authorised dealer to exchange it.

5 Maintenance
Engine
¾ Check that the holding bracket (1) engages

in the recess.
¾ Put the toothed belt (4) under pressure by
firmly pushing down with the thumb.
The pointer (2) must move.
¾ Release the toothed belt again.
¾ Turn the crankshaft a further two turns in the
running direction of the engine.
The tensioner pulley must return to its initial
position (notch (3) and pointer (2) opposite
each other). If this does not happen, please
¾ Check the water pump gear (6) for wear.

¾ Place a knife edge (5) on the tooth (8) and
use a feeler gauge to establish the thinning
(7) over the length of the tooth.
If the thinning is more than 0.3 mm, the water
pump must be changed, together with the
crankshaft pinion gear and the toothed belt.
¾ Refit the engine cover.

Maintenance 5
Engine
Changing the toothed belt and ten-

sioner pulley
NOTE
Changing the toothed belt and tensioner pul-
ley requires specialist knowledge and special
tools. Please contact your authorised dealer.
Changing the air filter cartridge,

checking the vacuum-operated
switch
(After 1000 operating hours at the latest)
NOTE
The air filter cartridge must not be cleaned.
The air filter cartridge must be changed when
the vacuum display (1) lights up in the indicator
unit.
¾ Open the bonnet.
¾ Open the 3 fasteners (2) and remove the air
filter cover (3).
2
¾ Pull out the air filter cartridge.
CAUTION
Clean the inside of the air filter housing thoroughly.
Do not blow it out with compressed air. 1
Wipe the housing clean with a clean cloth.
¾ Insert the new air filter cartridge back into

the housing.
When installing, ensure that the filter cartridge
3
is not damaged and that the seal on the filter
housing is securely in place.
¾ Fit the air filter cover. t3921372

5 Maintenance
Engine
¾ Release the upper clips (4) at the suction

hose (5) and remove the hose.
¾ With the engine running, slowly close the
air filter intake port by covering it (e.g. with 4
a board or a plate) until the vacuum display
(1) lights up in the indicator unit.
In order to avoid damage, the intake port must
not be closed further after the vacuum display
has illuminated. If the vacuum display does
not light up contact your authorised dealer.
¾ Reattach the hose (5).
5
t3921381
Exchange air filter safety cartridge
NOTE
Read the information on the label on the air
filter housing. It indicates whether a safety
cartridge is installed in the air filter.
¾ Exchanging the safety cartridge:
• Two years after it has entered operation at
the latest.
• If the air filter vacuum display lights up again
immediately after the filter cartridge has
been serviced.
• If the filter cartridge is faulty.
CAUTION
Safety cartridges must not be cleaned or reused.
Do not start the engine without an air filter cartridge.
The function of the safety cartridge is to prevent
ingress of dust while the main cartridge is being
exchanged or inadvertent use of a damaged main
cartridge.

¾ Open the bonnet.

Maintenance 5
Engine
¾ Take off the air filter cover and remove the

filter cartridge (2).
¾ Pull out the safety cartridge (1).
¾ Insert the new safety cartridge.
¾ Fit the filter cartridge and attach the air filter
cover.
2 1
t3921373
Check the dust discharge valve

The dust discharge valve (1) is largely mainte-
nance-free.
¾ Open the bonnet.
¾ Compress the valve (1) and remove the
remaining dust.
¾ If the value is damaged, exchange it.
1 d3931387

5 Maintenance
Engine
Cleaning the prefilter (special equip-

ment)
NOTE
The dust collecting tank must never be more
than half full with dust. If there is a heavy ac-
cumulation of dust, the tank must be emptied
every day.
¾ Unscrew the wing nut (1).
¾ Remove the cover (2).
¾ Remove and empty the dust collecting tank
(3).
¾ Refit dust collecting tank and secure with
wing nut.
Cleaning the oil bath air filter (special

equipment)
ENVIRONMENT NOTE
consumables.

Maintenance 5
Engine
¾ Open fasteners (4) on oil tank (3).

¾ Remove oil tank (downwards), then empty
and clean.
¾ Clean and check seals (2) and change if
damaged.
¾ Loosen the air hose clip on the clean air
connection (1) and remove the hose.
¾ Detach and clean dust collecting tank (8).
¾ Detach upper part of filter (7) on overhead
guard.
¾ Wash out upper part of filter and filter insert
with diesel fuel.
The filter and knotted steel inserts can be
cleaned with a steam jet.
¾ Thoroughly dry the cleaned filter.
¾ Fit upper part of filter and secure air hose
with hose clip.
¾ Fit the dust collecting tank (8).
¾ Fill the oil tank (3) with engine oil as far as
mark (5).
¾ Fit oil tank (3) to upper part of filter (7) , en-
suring that it is correctly positioned, then
secure with fasteners (4).
Change the oil in the oil bath air

cleaner (Optional)
NOTE
An oil change is necessary when the dirt sedi-
ments have reached half of the oil filling, and
at least whenever the filter element is rene-
wed. Do not add oil between the oil change
intervals.
ENVIRONMENT NOTE
Follow the precautions for handling fluids and
lubricants.
¾ Shut the engine off.

5 Maintenance
Engine
¾ Open the clamps (3) on the oil bowl (2).

¾ Remove the oil bowl downwards, empty
and clean it.
¾ Clean and check ((1)) the seals, renew if
damaged.
¾ Check the filter element ((5)) and clean if
dirty. Fill the oil bowl (2) with engine oil up to
the mark(4).
¾ Place the oil bowl (2) on the filter head (6),
check for correct seating and fasten with the
clamps (3).
Check the basic setting of closed-

loop catalytic converter for gas in-
stallation (option)
Prerequisite for the adjustment with a lambda
viewer is a proper basic adjustment of the
engine and truck.
¾ Check the throttle plate angle.
¾ Check the lower and upper idle speed
(specified by the governor).
¾ Check the ignition point (specified by the
ignition control unit; note dependence on
ignition point of different gas qualities).
¾ Check the setting of the pressure relief
valve.
Special skills are required for this work, please
Check the CO content in the exhaust

gas
NOTE
In Germany, laws require the CO content in the
exhaust gas to be checked every 500 hours
or after 6 months maximum. Special skills
and special tools are required for the inspec-
tion. Please contact your authorised dealer.

Maintenance 5
Engine
Outside of Germany, observe your national

regulations.
Check the air intake and exhaust

lines for leaks
¾ Inspect the air intake hoses on air filter for
condition and leaks.
If necessary, retighten hose clamps and re-
place any porous hoses.
¾ Check the air intake and exhaust manifolds
at the cylinder head for leaks.
If they prove not to be tight, retighten the fas-
tening bolts or replace the gaskets.
¾ Check the exhaust pipe for leaks at the
manifold and tighten the fastening bolts or
renew the gasket if necessary.
t3921343
¾ Remove the cover at the counterweight.

¾ Check the mounting, connections and air
tightness of the exhaust pipe in the coun-
terweight, tightening the fastening bolts if
necessary.
1,2
GER
MAN
WES
ZU
Y
T-
¾ Refit the cover at the counterweight.
d3921388
Changing the spark plugs
NOTE
Use the following spark plugs: NGK BKUR 6
ET-10

5 Maintenance
Engine
¾ Open the bonnet.

¾ Clean the area around the spark plugs on
the cylinder head thoroughly.
¾ Disconnect the spark plug connectors.
¾ Unscrew the spark plugs.
¾ Check the gap between the electrodes in
the new spark plug with a feeler gauge.
Setpoint value: 1.0 ±0.1 mm
¾ Screw in the spark plugs manually and
tighten them to a torque of 30-5 Nm.
¾ Reattach the spark plug connectors.
CAUTION
Do not start the engine, the ignition system will be t3921396
broken.
Do not attempt to start the engine without spark
plugs.
Change the high-pressure gas hoses
DANGER
The high-pressure gas hoses age in the course of
time and become brittle.
The high-pressure gas hoses of the LPG system
must therefore be replaced every 3000 hours or
2 years. Please contact your authorised dealer.

Maintenance 5
Gearbox
Gearbox
Checking the fastenings of the axle
clamps and wheel motors
¾ Check that the 4 fixing screws (M16) (1) of
the axle clamps have a tightening torque of 1
1
275 Nm.
¾ Check that the fixing screws (M10) (arrows)
of the wheel motors have a tightening torque
of 64 Nm.
To do so, the drive wheels must be removed
beforehand.
1 1
d3921397
Checking and adjusting the side

stops on the drive axle
¾ Check the air gap (1) between the stop (2)
and chassis (3).
The air gap should not be larger than 1 mm.
Check the air gap on the left and right of the
axle.
If the air gap is larger, adjust the stop.
¾ Slacken the hexagonal nut (4).
¾ Adjust the stop with the hexagonal nut (5)
until the air gap is 1 mm.
When it is no longer possible to adjust the
air gap, the axle spring element is worn. The
spring element must be changed. Please ad-
vise your authorised dealer.
¾ Tighten the hexagonal nut (4).

5 Maintenance
Gearbox
Checking the drive axle bearings for

wear
NOTE
The drive axle is installed in the chassis with
rubber spring elements on both sides.
¾ Remove the drive wheels.
¾ Using a lamp, check the state of the rubber
spring elements (1) between the axle, chas-
sis and plastic stops.
The rubber spring elements must be checked
on both the left and right of the axle. If the axle
spring elements or the plastic stops are worn,
these must be changed. Please contact your
authorised dealer.
¾ Attach the drive wheels.
1 1
d3921498
Checking the hydraulic pump’s at-

tachment to the engine
¾ Open the bonnet.
¾ Tighten the 4 hexagon head screws to the
prescribed tightening torque of 80 Nm.

Maintenance 5

Cleaning the truck
The need for cleaning depends on use of the
truck. If highly aggressive media are involved,
e.g. salt water, fertiliser, chemicals, cement
etc., thorough cleaning is required after finish-
ing the task.
Hot steam or cleaning materials with a power-
ful degreasing effect should only be used with
great caution as this will affect the grease filling
of bearings with lifetime lubrication, causing it
to escape. As relubrication is not possible, the
bearings will be irreparably damaged.
Switch off the engine and wait for it to cool
down before cleaning the vehicle.
t3921320
Deposits/accumulations of combustible ma-
terials, especially on or in the vicinity of parts
with high temperatures (e.g. exhaust pipes)
must be removed regularly.
CAUTION
When cleaning with a water jet (high-pressure or
steam cleaner etc.), it should not be applied directly
to the electric and electronic components, plug
connectors, air duct plastic pipes or the area with
hose clips. Water should not be used for cleaning in
the area of the central electrical system and switch
console.
If this cannot be avoided, the affected parts must
be covered in advance or only cleaned using a dry
cloth or clean compressed air.
When using high-pressure cleaners, the mini-

mum distance between the steel pipe and the
truck should be approx. 300 mm.
When using compressed air for cleaning, re-
move stubborn soiling with a cleaner solvent.
During cleaning pay special attention to the oil
filler openings and the surrounding areas as
well as the lubricating nipples prior to greas-
ing.

5 Maintenance
Bonnet
Opening the bonnet.
WARNING
Always observe the following when opening the
bonnet with the engine running: The hydraulic drive
and a temperature-dependant circuit may cause
the fan to suddenly switch on automatically.
Allow engine to cool down.
WARNING
Remember that parts of the engine
and exhaust will be hot.
¾ Move steering column all the way forward

and clamp in place.
For luxury driver seat only
¾ Pull the lever (2) outwards and slide the
driver’s seat all the way forwards. 4 1
¾ Release lever and allow it to engage.
3 d3921405

Maintenance 5
¾ Push the lever (1) fully upwards, hold it

4
there, push the seat back (4) fully forwards 5
and release the lever (1). (Only where rear
window fitted)
¾ Insert ignition key into the hole (3) and push
to release the bonnet catch; whilst so doing,
release the pressure on the bonnet catch by
pressing the bonnet in the direction of the
arrow.
¾ Open the bonnet (5) to the rear up to the
stop.
7
NOTE
The bonnet can be opened further for specific
maintenance work. Before opening the bon- 6 d3921489
net in this way, the armrest must be moved all

the way down.
¾ Undo the clamping screw (10) in the armrest
(8), push the armrest fully downwards.
8
¾ Retighten clamping screw.
¾ Release the mounting support (7). Push
mounting support to rear.
If a rear window is installed, the armrest 9
fore/aft adjustment must also be pushed
all the way forwards. To do so release the
clamping screw (9), and push the armrest (8)
all the way forwards. Tighten clamping screw
again.
10
¾ Open bonnet all the way.
NOTE d3921400
The bonnet is held in both open positions by

gas springs.

5 Maintenance
Closing the bonnet

¾ Release the mounting support (7) by push-
4
ing it to the rear. 5
¾ Close the bonnet, then press on it until the
locking lever (6) engages.
6 d3921489
Floorplate
Opening the floorplate
Some maintenance operations require that
the floorplate is lifted.
¾ Open the bonnet.
¾ Unscrew the fixing screws (2) from the floor-
plate.
¾ Remove plates (5) and (6)
¾ Remove the rubber covering from the floor-
plate (1).
¾ Swing the floorplate up.

Maintenance 5
¾ Feed a restraint strap (3) around the steer-

ing wheel and hang it onto the bolt (4).
3
1
Closing the floorplate 4
¾ Lift up the floorplate.
¾ Detach the restraint strap.
¾ Close the floorplate.
¾ Install plates (5) and (6).
¾ Secure the floorplate with the fixing screws
(2).
¾ Replace the rubber covering on the floor-
plate.
d3921504
Servicing the air conditioning (spe-

cial equipment)
The following maintenance work must be car-
ried out at the beginning, middle and end of a
season:
¾ Check the belt tension at the compressor.
¾ Check the refrigerant level and moisture
content in the system.
The refrigerant must flow, bubble-free,
through the sight glass of the dryer (1) when
the engine is running.
When changing a component in the cooling
circuit, the dryer must be changed before re-
filling.
¾ Clean the condenser.
When cleaning the condenser fins, do not
press hard, otherwise they will be damaged
and air will no longer flow properly across
them.
When performing maintenance work, please
consult your authorised dealer.

5 Maintenance
Check the lap seat belt for condition

and proper operation
NOTE
For safety reasons, the condition and proper
operation of the restraint system should be
inspected regularly (once a month). Under
extreme operating conditions this check is
required daily before taking the truck into ope-
ration.
¾ Pull the belt (1) out fully and inspect for fray-
ing. 1
¾ Check the buckle (3) for correct operation

and the retractor for proper return of the belt.
¾ Check the trims for damage.
Check the automatic lock.
¾ Park the truck on level ground. 3
¾ Jerk out the belt.
The automatic lock should prevent the belt
from unrolling from the retractor (2).
¾ Slide the seat fully forward.
2
¾ Tilt the backrest fully forward. d3921441
NOTE
When opening the bonnet, watch out for a
possibly installed rear windscreen.

Maintenance 5
¾ Unlock the bonnet and open it with the seat

(4) about 30°.
The automatic lock should prevent the belt
from unrolling from the retractor (2). 4
WARNING
Do not operate a truck with a defective seat belt.
The seat belt must be renewed after an accident.
In the case of seat belts attached to the operator’s
seat, the seat and mounting of the seat must also
be inspected by qualified personnel. Nuts and bolts 30˚
should be checked regularly for tightness. A wobb-

ling of the seat can indicate loose bolts or other
faults. In case of non-observance, you will put your
health at risk and increase the risk of accidents.
If malfunctions in the operation of the seat are de-
tected (eg springy seat), contact your authorised t3921323
dealer immediately to eliminate the cause.
Checking fastening of frame, tilt

cylinders and steering axle
¾ Check 6 fastening screws (M 24) (1) of the-
frame with a tightening torque of 660 Nm.
2
¾ Check the security of the 4 fastening bolts
(M16) (2) of the tilt cylinders with a torque of
2 1
275 Nm.
¾ Check the security of the fastening bolts
(M16) of the steering axle with a torque of
195 Nm.
t3921324
Check and oil other pivots and joints
ENVIRONMENT NOTE
Follow the precautions for handling fluids and
lubricants.

5 Maintenance
¾ Check the following bearings and fasteners

for security and oil:
• Driver’s seat guide.
• Bonnet pivot pin.
• Wiper mounting (option).
• Door locks and hinges of the cabin (option).
• Mounting of the LPG bottle mount.
• Grease the bonnet latch.
• Lock of the LPG bottle mount.
d3921450

Maintenance 5
Chassis frame
Chassis frame
Wheel change
WARNING
Note truck tare weight.
Only use jacks with a load capacity of at least
3600 kg.
¾ Position the jack at the front edge of the

chassis (2) on the left or right or beneath the
counterweight (1).
The truck should only be raised at these sus-
pension points on the left and right.
¾ Release the wheel fastenings on the wheel
in question.
¾ Raise truck with jack until wheels are off the
ground.
1
¾ Prop up securely using square timber sup- 2
ports at the chassis or counterweight.
¾ Unscrew the wheel fastenings.
¾ Change the wheel. d3921491
¾ Position wheel fastenings and tighten them

manually.
¾ Lower truck.
¾ Tighten wheel fastenings
Front 170 Nm
Rear 460 Nm
NOTE
If new wheel screws are used or a new rim is
fitted, the front tightening torque on the first
occasion should be 195 Nm.

5 Maintenance
Chassis frame
Tighten the wheel bolts

The wheel fastenings should be tightened
before initial commissioning and whenever
wheels are changed or repairs are made.
After this tightening should be performed after
100 operating hours at the latest.
The wheel fastenings should be tightened
crosswise with a torque of:
front 170 Nm
rear 460 Nm
NOTE
If new wheel bolts are used or a new wheel is
fitted the tightening torque on the first occasion
only should be 195 Nm
Check the tyres for damage and

foreign objects
¾ Secure the truck against rolling (apply park-
ing brake).
¾ Chock a wheel that is not to be jacked up.
¾ Raise the truck with a jack until the wheels
are clear of the ground.
¾ Secure the truck with wood blocks.
¾ Check the wheels for ease of rotation and
remove anything hindering their free move-
ment.
¾ Replace worn or damaged tyres.
t3921321

Maintenance 5
Chassis frame
Checking solid rubber tyres for wear

(H 25 TCT)
WARNING
Reductions in the tyre diameter cause changes to
the braking characteristics of the truck.
Therefore the solid rubber tyres must be regularly
checked for wear.
Tyre size (2) of new tyres:

Drive axle
22x8-16 22 inches = 559 mm
Steering axle
16x6x10½ 16 inches = 406 mm
Cross-section height (3) of new tyres:

Drive axle 3.01 inches = 76.5 mm
Steering
2.74 inches = 69.5 mm
axle
NOTE
Permissible wear: 30% of the cross-section
height maximum
Minimum diameter (1) of the tyres:

Drive axle 20.20 inches= 513 mm
Steering
14.33 inches= 364 mm
axle

5 Maintenance
Chassis frame
Checking the tyre pressure and tyre

sizes
CAUTION
If tyre pressures are too low, tyre life will be reduced
and the stability of the forklift truck will be affected.
Therefore, regularly check tyre pressures.
¾ Check that the tyres are at the correct pres-

sure.
d3921385
¾ If necessary, adjust the tyre pressures in ac-

cordance with the information on the sticker
(1) on the right-hand side of the truck next to
the drive wheel:
Drive axle
Single fitment
H 20, 23x9-10/14 PR 10.0 bar
H 25
225/75 R 10 10.0 bar
23x9-10/16 PR 10.0 bar
23x9-10/20 PR 10.0 bar
23x9-10 SE -- 1
23x10-12 SE -- d3921515
6.50-10 SE --
Dual fitment
H 20, 6.50-10/10 PR 8.5 bar
H 25
6.50-10/14 PR 8.5 bar
6.50 R 10 8.5 bar
6.50-10 SE --
Steering axle

Maintenance 5
Chassis frame
Single fitment
H 20, 6.50-10/14 PR 7.0 bar
H 25
6.50 R 10 7.0 bar
23x9-10/14 PR 7.0 bar
23x9 R 10 7.0 bar
23x9-10/20 PR 7.0 bar
6.50-10 SE --
200/50-10 SE --
23x9-10 SE --
Example
Tyre pressure sticker (1)
Drive axle
Single fitment 10.0 bar
Dual fitment 8.5 bar
Steering axle
Single fitment 7.0 bar
Cleaning and greasing the steering

axle
ENVIRONMENT NOTE
consumables.
When used indoors in clean, dry conditions, it
is generally sufficient to perform maintenance
every 1000 operating hours. It is advisable to
halve these lubrication intervals if the vehicle
is used both indoors and outdoors.

5 Maintenance
Chassis frame
If used in areas with constant exposure to dust,

dirt, water, road salt or chemicals, weekly lu-
brication will considerably lengthen the ser-
vice life of the spherical bearings.
NOTE
It is better to apply a little grease to the be-
arings frequently than a lot of grease infre-
quently.
¾ Clean steering axle with water or cleaner
solvent.
NOTE
Lubricating grease should be used for gre-
asing in accordance with consumables re-
commendations. First grease the axle stub
bearings on top, then underneath.
¾ Grease the tie rod and axle stubs at the
lubricating nipples (see arrows) using lubri-
cating grease.
¾ Grease with grease gun until fresh lubricat-
ing grease escapes at bearings.
d3921344
Check the steering cylinder and king

pin for security
¾ Check the 4 fastening screws (1) for tight-
ness. 2
Torque: 210 Nm
¾ Check the nut (2) on the king pin for tight-
ness.
Torque: 250 Nm 1
d3921345

Maintenance 5
Chassis frame
Check the parking brake for correct

operation
¾ Drive the fork lift truck, carrying its maximum
load, up a gradient of 15 %.
The vehicle must remain stationary.
Version 1:
¾ Release the parking brake handle (1).
Version 2:
1 d3921457
¾ Place the parking brake lever (2) in a hori-

zontal position.
¾ Press the button (1) and unlock the parking
brake lever (2).
¾ Move the parking brake 90° downwards.
NOTE
If the parking brake fails this test, contact your
authorised dealer.

5 Maintenance
Controls
Controls
Checking the pedals
ENVIRONMENT NOTE
consumables.
¾ Lift up the floorplate and secure in place.
¾ Unscrew the 4 nuts of the pedal box.
¾ Check pedals for smooth action.
¾ If necessary, grease the bearings slightly.
¾ Re-attach the pedal box.
d3921378
Checking the bellows at the actuat-

ing lever
¾ Check that the bellows (1), (2) and (3) (de-
pending on the version) are securely po-
sitioned and show no signs of damage.
Change if necessary.

Maintenance 5
Electrics
Electrics
Checking the condition and secure
positioning of electric cables, cable
connectors and cable connections
NOTE
Oxidised connections and brittle cables lead
to voltage drops and thus to difficulties during
start-up and operation.
¾ Check cable connections for secure attach-
ment and oxidation residues.
¾ Check earth wire for secure attachment.
¾ Check electric wiring for scuffing and secure
attachment.
¾ Remove oxidation residues and replace
brittle cables.
t3921341
Battery: check condition, acid level

and acid density
When handling starter batteries, the following
should be complied with:
¾ Wear industrial goggles and a protection
suit.
¾ Before touching the battery, first grasp con-
ductive parts of the frame to discharge any
static charge.
¾ Avoid producing sparks when connect-
ing/disconnecting.
¾ When recharging new batteries, ensure
good degassing (unscrew any plugs
present).

5 Maintenance
Electrics
¾ After charging the battery, leave it standing

for at least 8 hours before reconnecting, if
possible.
¾ When filling up or recharging, remove any
packaging film beforehand to ensure gas
venting.
¾ Do not use plastic adhesive tape, in par-
ticular on the battery lid and the ventilation
openings of the plugs.
¾ Before recharging, first check battery with-
out electric load to make sure that only intact
batteries undergo charging.
¾ During electrical charging, batteries pro-
duce hydrogen and oxygen gas which
under certain conditions may result in an
explosive mixture. Battery should only be
filled and charged in well ventilated rooms.
¾ Avoid rubbing textiles against the battery.
¾ The electrolyte level must always be main-
tained between max. and min. markers (to
avoid large gas volumes).
¾ Due to the possibility of static charges, do
not rub batteries with dry cloths. Use damp
cloths instead.
WARNING
Battery acid is highly corrosive.
Contact with battery acid should
therefore always be avoided. If the
clothing, skin or eyes have come
into contact with battery acid, the
affected areas should be rinsed with
water immediately. In the event of
contact with the eyes, please consult
a doctor at once! Any spilt battery
acid should be neutralised straight
away!
NOTE
Even in the case of maintenance-free batte-
ries, it is necessary to check the condition and
acid density/level.
¾ Open the bonnet.

Maintenance 5
Electrics
¾ Inspect battery (1) for cracked housing,

1
raised plates and acid leaks.
¾ Unscrew sealing plugs (2) and check acid
level.
In the case of batteries with level checking
inserts, the fluid must reach the bottom of the 2
insert, and for batteries without level checking
inserts, it must lie 10–15 mm above the lead
plates.
¾ Any lack of fluid should only be made up
with distilled water.
¾ Remove any oxidation residues on the
battery terminals and then apply acid-free
grease. t3921387
¾ Retighten battery-terminal clips firmly.

¾ Check acid density with an acid siphon. The
density value must be 1.24-1.28 kg/l.
¾ Screw sealing plugs (2) back in.

5 Maintenance
Hydraulics
Hydraulics
Change hydraulic oil
Drain hydraulic oil
ENVIRONMENT NOTE
consumables.
¾ Drive truck over pit.
¾ Fully lower fork carriage and lift mast.
¾ Place a collection vessel under the left side
of the truck floor.
¾ Open the bonnet. Unscrew breather filter
with oil dipstick (2).
¾ Unscrew hydraulic oil drain plug (1) on hy-

draulic oil tank.
¾ Allow all oil to drain off. Clean area around
oil drainage location thoroughly.
¾ Refit drain plug.
Tightening torque: 25 Nm
Refill/top up hydraulic oil
NOTE
The oil dipstick has markings that apply to the 1
various lift heights.
d3921335

Maintenance 5
Hydraulics
¾ Add hydraulic oil to filling port.

Total fill quantity:
• for lift heights up to 5000 mm marking po-
tentiometer (5): approx. 24.0 l
• for lift heights 5000 mm - 6900 mm between
marking 3 and 5 (4): approx. 25.5 l
• for lift heights 6900 mm - 8000 mm marking
(3): approx. 28.0 l
¾ Check oil level with dipstick (2) and top up
until upper marking on dipstick for relevant
lift height is reached.
¾ Allow engine to idle for 3 minutes in upper
range (parking brake applied and accelera-
tor pedal depressed).
¾ Check oil level again (do not drive).
Only then should the suction filter be changed.
NOTE
The hydraulic system will bleed itself when the
engine is running.
Hydraulic system: Check oil level
ENVIRONMENT NOTE
sumables.
NOTE
Oil specifications: see Recommendations for
working materials
¾ Fully lower the fork carriage.

5 Maintenance
Hydraulics
¾ Unscrew the breather filter (1) with oil dip-

stick on the left side of the vehicle.
NOTE
Tank under low pressure. A small amount of
air will escape.
¾ Wipe the oil dipstick with a clean cloth.
NOTE
There are 2 markings on the oil dipstick (2)
that are used according to the height of the lift
mast. The various lift heights are stamped into
the dipstick
¾ Only check the marking which applies to

your truck.
• Marking (3) for lift heights of 6900 to 8000
mm.
• Marking (5) for lift heights up to 5000 mm.
• Between marking 3 and 5 (4) for lift heights
from 5000 mm to 6900 mm.
¾ Screw the breather filter with oil dipstick in
completely and then unscrew it again.
The oil level shown on the dipstick should be
between the two markings for the relevant lift
height.
¾ If necessary, add more hydraulic oil until it
reaches the marking for your truck.
The difference in quantity between the max.
and min. mark
for all lift heights is approx. 2 l
Hydraulic system: changing the filter

Feed and pressure filter
ENVIRONMENT NOTE
consumables.
¾ Unscrew the side maintenance cover on the
left.

Maintenance 5
Hydraulics
¾ Lower lift mast. Slacken the lower fixing

screw (2) and the upper fixing screw (1) on
the filter carrier.
4
¾ Swing out the filter carrier.
¾ Place a collection vessel underneath.
3
¾ Slacken the pressure filter housing (3) and
the feed filter housing (4) at the hexagon
section. 1
¾ Unscrew the filter housing manually and
remove the filter cartridges from its base.
ENVIRONMENT NOTE 2
Dispose of the filter cartridges in an environ-

mentally friendly manner. d3921369
¾ Apply oil to the seals on the new filter car-

tridges.
¾ Attach the filter cartridges to the base on the
filter head.
¾ Screw on the filter housing and tighten it
hand-tight.
Tightening torque: 10+5 Nm; then slack it back
¼ turn.
¾ Check the filter flange for leaks during a test
run.
Suction filter
CAUTION
The oil must have an optimal purity level at all times.
When servicing the device after 6,000 operating
hours, it is therefore absolutely essential to change
the hydraulic oil before changing the suction filter.

5 Maintenance
Hydraulics
¾ Open the bonnet.

¾ Open the breather (1).
This allows the air to escape so that the oil
will not overflow when the filter cartridge is
inserted.
¾ Turn the filter cover (2) in an anti-clockwise
direction and unscrew it.
¾ Slowly remove the filter cartridge.
This will allow the oil to flow back into the reser-
voir.
¾ Pull filter cartridge out entirely.
¾ Carefully insert new filter cartridge in hy-
draulic tank.
Ensure that it is correctly centred in the filter
bottom.
¾ Clean seal of filter cover and wet with oil.
¾ Replace the filter cover (2) and turn it in the
clockwise direction.
¾ Tighten the filter cover to 25 Nm.
The hydraulic system will vent itself automati-
cally when the motor is running.
¾ Screw breather filter on.
¾ Perform a trial run to check the filter cover
for leakage.
Breather
NOTE
If there are high levels of dust, it may be ne-
cessary to change the filter earlier.

Maintenance 5
Hydraulics
¾ Open the bonnet.

¾ Unscrew the filter (1) for the hydraulic oil
tank from the filler neck.
¾ Remove the dipstick (2) from the breather
and attach it to the new filter.
¾ Screw in the filter and tighten it.
¾ Mount the side maintenance cover.
Check correct operation of breather

valve on the hydraulic oil tank
NOTE
The breather filter on the hydraulic oil tank is
fitted with a breather valve, which causes the
tank to be at a slight positive pressure.
ENVIRONMENT NOTE
sumables.
¾ Close the breather filter (1) and check
whether the breather filter is seated cor-
rectly.
¾ Extend lift mast several times to the stop
and let it return.
¾ Switch off the engine. Open the breather
filter (1) on the hydraulic oil tank.
Air must be heard to escape from the tank. If
no noise of air escaping is audible, replace the
breather filter.

5 Maintenance
Hydraulics

¾ Raise and secure the floor plate.
¾ Check all unions between oil reservoir, drive
motors, pumps and control valves for leaks.
¾ Tighten connections if necessary.
¾ Check the lift, tilt and steering cylinders for
leaks.
¾ Replace any porous hoses.
¾ Inspect the lines for chafing and replace, if
necessary.
¾ Close the floor plate.
t3921344
Check tilt cylinder bearings for wear
NOTE
The tilt cylinders are mounted in rubber bea-
rings at both ends.
¾ Remove the screw (1) at the disc (2).
1 2
¾ Make a visual inspection of the rubber bear-
ings for cracks.
The rubber should not have any cracks.
¾ Check the rubber bearing at the front and
rear of each tilt cylinder.
When a rubber bearing is worn or damaged,
renew it. Please contact your authorised
dealer.
d3921471

Maintenance 5
Hydraulics
Check the tension of double hoses

The tension of the double hoses should be
5-10 mm per metre, depending upon the origi-
nal length.
¾ Adjust the tension of the hoses to the
specified dimension by sliding them in the
clamps.
d3921519
Checking the function and safety

system of the third auxiliary hy-
draulics (special equipment)
NOTE
If a toggle-switch-controlled third auxiliary hy-
draulics system is fitted, a functional test and
safety check must be carried out when perfor-
ming the initial start-up and after carrying out
repairs to the third auxiliary hydraulics system.
Functional test:
¾ Activate all three additional functions one
after the other.
The functions performed by the attachment
must comply with the signs on the operating
console.
Safety check:
¾ Remove a cable connector from the sole-
noid valve on the fork carriage.

5 Maintenance
Hydraulics
¾ Operate the pre-selector (1) from the sec-

ond to the third auxiliary hydraulic function.
The following safety precautions / warning
messages are activated:
• Switchable auxiliary hydraulic function
blocked.
• Truck switched to creep mode.
• Error code displayed in text field of indicator
unit.
• Buzzer sounds.
If there are any malfunctions, please contact

Maintenance 5
Load lift system
Load lift system

Cleaning the lift mast chain and ap-
plying chain spray
DANGER
Lift mast chains are safety elements. Incorrect clea-
ning materials may cause direct damage to chains.
Do not use cold / chemical cleaners or fluids that
are corrosive or contain acid or chlorine.
If the lift mast chain is so dusty that penetration

of the lubricating oil is not ensured, the chain
must be cleaned.
¾ Place a collection vessel under the lift mast.
¾ Clean lift mast chain with paraffin deriva-
d3921398
tives such as petroleum ether.
Take note of the manufacturer’s safety infor-
mation. When cleaning with a steam jet, do
not use additives.
¾ After cleaning, immediately use com-
pressed air to remove any water remaining
on the surface of the chain and in the chain
joints.
The chain should be moved several times
during this process.
¾ Immediately apply Linde chain spray to
chain, also moving chain while doing so.

5 Maintenance
Load lift system
Mast, lift chains, lift cylinders and end

stops: Check for security, condition
and proper operation
¾ Clean the mast channels and chains.
¾ Inspect the chains for condition and wear,
especially in the area of the pulleys.
¾ Check that the chain is attached securely to
the chain anchor.
¾ Replace damaged chains.
NOTE
Single damaged and missing plastic links do
not impair the operation and service life of the
chain.
¾ Check mast, channels and rollers for condi-
tion and security.
¾ Check stops for condition, mounting and
proper operation.
¾ Check the lift cylinders for security.
¾ Check the circlip of the piston rod fastener
on the top of the lift mast for security.
Adjust lift mast chain

Standard lift mast
NOTE
The lift mast chain stretches over time during
operation and therefore has to be readjusted
on the right and left.
¾ Lower the lift mast completely.

Maintenance 5
Load lift system
¾ Loosen locknut (1).

¾ Adjust chain at adjustment nut (2) of chain
anchor.
The lower guide roller of the fork carriage
should only protrude max. 25 mm from the
guide rail of the inner lift mast.
¾ Tighten the locknut (1).
¾ Also adjust second chain.
CAUTION
When extended, the lift mast should not touch the
end stops.
Fully extend lift mast and check clearance to end
stops.
Apply chain spray.
NOTE
In the case of trucks that are used in the food
production sector, chain spray should not be
used. Instead, use a low-viscosity oil licensed
for use in the food industry.
¾ Apply Linde chain spray to guide surfaces
and chain.
Duplex or triplex lift mast
NOTE
The lift mast chain stretches over time during
operation and therefore has to be readjusted.
¾ Lower the lift mast and fork carriage com-
pletely.

5 Maintenance
Load lift system
¾ Loosen locknut (4). Adjust chain at adjust-

ment nut (3) of chain anchor.
The lower guide roller of the fork carriage
should only protrude max. 25 mm from the
guide rail of the inner lift mast.
¾ Tighten the locknut (4).
CAUTION
When extended, the lift mast should not touch the
end stops.
Fully extend lift mast and check clearance to end
stops.
3
Apply chain spray.
4 d3921486
NOTE
In the case of trucks that are used in the food
production sector, chain spray should not be
used. Instead, use a low-viscosity oil licensed
for use in the food industry.
¾ Apply Linde chain spray to guide surfaces
and chain.
Check the forks and fork quick-

releases
¾ Check the forks for visible deformations,
wear and damages.
¾ Check the bolts of the fork stops and fork
quick-releases for correct seating and dam-
age.
¾ Replace any defective parts.
d3921451

Maintenance 5
Load lift system
Clean sideshift (special equipment)

and grease, check fastening
ENVIRONMENT NOTE
Observe information about working materials.
NOTE
The sideshift should be greased whenever the
truck is washed. Use lubricating grease com-
plying with the recommendations for working
materials.
¾ Clean sideshift with steam jet.
¾ Check hydraulic lines for scuffing and re-
place if necessary.
¾ Check hydraulic connections and fastening
elements for secure positioning and wear
and tighten/replace if necessary.
¾ Check cylinders for leaks.
¾ Check piston rods for damage.
¾ Adjust the fork arms so that the 4 lubricating
nipples (1) are accessible.
¾ Let down sideshift until fork arms touch the
ground.
¾ Apply lubricating grease to lubricating nip-
ples (1) of support rollers on fork carriage
until grease escapes at the side.
ples (2) of wear strips on fork carriage at top
until grease escapes at the side.

5 Maintenance
Load lift system
Checking the slide guides on the

sideshift (special equipment) for
wear
¾ Dismantle sideshift.
¾ Clean sideshift.
¾ Remove the slide guides from the upper
guide (1).
¾ Measure the wall thickness of the slide
guide (3).
If wall thickness is less than 2.5 mm, change
the slide guides.
¾ Lubricate slide guides.
¾ Reassemble sideshift.
¾ Tilt lift mast forwards and lower fork arms
until they touch the ground, so that sideshift
frame is relieved of the weight of forks.
¾ Lubricate the sideshift at lubricating nipples
(2) and (4).
Cleaning and lubricating the fork po-

sitioner (special equipment), check-
ing the fastening
¾ Clean the fork positioner using a steam-jet
cleaner.
¾ Check condition of fork positioner device
and look for leaks.
¾ Check hydraulic lines for chafing and re-
place if necessary.
¾ Check hydraulic connections for tightness,
replace if necessary.
¾ Check cylinders for leaks.
¾ Check piston rods for damage.

Maintenance 5
Load lift system
¾ Tighten fixing screws (1) to 85 Nm.


¾ Lubricate slide guides (4) with lubricating
grease.
ples (5) of guide shoes until grease escapes
at the side.
ples (6) of guide rollers until grease escapes
at the side.

5 Maintenance
Special equipment, accessories
Check fork arm adjustment device

(special equipment) for wear and
tear
The fork arm adjustment device must only be
dismantled by a specialist using special tools.
Special equipment, accessories

Filling up the washer system water
tank (special equipment)
¾ Open the bonnet.
¾ Remove cap (1) from water tank (2) on the
frame wall, right hand side.
¾ Fill up with water until it is visible in the filling
neck.
¾ Refit the cap.

Maintenance 5
Troubleshooting
Troubleshooting
Opening the cover to the electrical
system
Depending on the set-up, up to 40 fuses may
be installed in the electrical system in order to
protect it. The fuse box can be accessed after
removing the cover of the electrical system.
¾ Unscrew both handles(2).
¾ Take off the cover (1).
¾ Take off the fuse box cover.

5 Maintenance
Troubleshooting
Fuses for basic and special equipment

Checking and changing fuses
1 12 V socket (9F10)*, 15 A 21 Blower toothed belt seal (0F1)*, 10 A or

2 Heater/air conditioning (9F9)*, 20 A Time-delayed lighting off (F17)*, 2 A
3 Seat heater (9F6)*, 15 A 22 Not assigned
4 Warning light and rotating beacon (4F3)*, 23 Not assigned
7.5 A 24 Not assigned
5 Working headlight positions 3, 4 (5F2)*, 15 A 25 Vehicle Data Management (6F1)*, 5 A
6 Working headlight positions 5, 6 (5F3)*, 15 A 26 Reverse travel (4F1)*, 10 A
(with attachment of one 7.5 A headlight) 27 Radio terminal 58 (9F8)*, 10 A
7 Working headlight positions 7, 8 (5F4)*, 15 A 28 Radio terminal 30 (9F7)*, 5 A
(with attachment of one 7.5 A headlight) 29 Washer pumps (9F4)*, 10 A
8 Rear window heater (9F5)*, 20 A 30 Windscreen wiper rear and roof (9F3)*, 10 A
9 Indicator unit (terminal 30) (F5), 2 A 31 Front windscreen wiper (9F2)*, 10 A
10 Indicator unit (terminal 15) (F6), 2 A 32 Windscreen wiper (9F1)*, 2 A
11 Signal horn (F7), 15 A 33 Interior light (5F12)*, 5 A
12 Traction-lift control (terminal 15) (F8), 2 A 34 Brake light (5F7)*, 5 A
13 Engine control unit (F12), 10 A 35 Warning lights (5F6/5F13)*, 10 A
14 Engine control unit (F11), 7.5 A 36 Lighting / working headlight positions 1, 2
15 Ignition coil supply (F10), 20 A (5F5/5F1)*, 15 A
16 Traction-lift control (terminal 30) (F9), 15 A 37 Right sidelights (5F11)*, 5 A
17 3. Auxiliary hydraulics (F16)* 7.5 A 38 Left sidelights (5F10)*, 5 A
18 Terminal 15 (F15), 10 A 39 Right headlight (5F9)*, 7.5 A
19 Terminal 58 (F14), 2 A 40 Left headlight (5F8)*, 7.5 A
20 Terminal 30 (F13), max. 15 A
* Special equipment
Main fuses in engine compartment

Checking and changing fuses
¾ Open the bonnet.

Maintenance 5
Troubleshooting
¾ Open the covering of the fuse box.

1
In the engine compartment, MTA fuses protect
the following circuits: 3
• Main fuse (F2) (2) for complete electrical 2
system, 30 A
• Main fuse (F3) (1) for complete special
equipment, 70 A
• Fuse (F4) (3) for air conditioning, 30 A
t3921394
Diagnostic connector
The diagnostic connector can be found under
the cladding on the left behind the driver’s
seat.
¾ When troubleshooting, connect the diag-
nostic device to the diagnostic plug, using
the appropriate diagnostic software . In ad-
dition, truck data can be read in and out,
adjustments made and maintenance inter-
vals reset or amended.
d3921428
Jump start
NOTE
When the truck battery is discharged, a jump-
start battery can be used with a jumper cable

5 Maintenance
Troubleshooting
to start the truck. The following must be taken

into consideration when doing this:
• Both batteries must have the same nominal
voltage.
• The capacity (Ah) of the current-giving bat-
tery must not be significantly lower than the
capacity of the discharged battery.
• Use a jumper cable with a sufficient cross-
section and insulated pole clips.
WARNING
A discharged battery can freeze at temperatures
below 0°C. There is then a risk of explosion.
Before connecting the jumper cable, it is essential
that a frozen battery is thawed.
¾ Switch off all current consumers (heater, air

conditioning, lighting).
¾ Open the engine bonnet.
¾ Connect one end of the positive cable (1) to
the positive terminal (+) of the discharged
truck battery (2).
¾ Connect the other end of the positive cable
(1) to the positive terminal (+) of the current-
giving battery (5).
¾ Connect one end of the negative cable (4)
to the negative terminal (-) of the current-
giving battery (5).
¾ Connect the other end of the negative cable
(4) as far away as possible from the dis-
charged truck battery (2) to a massive metal
component securely connected to the en-
gine block or to the engine block itself (3).
NOTE
If the jump-start battery is housed in another
vehicle, start the vehicle’s engine and allow to
idle.
If the engine does not start straightaway, stop
the starting process after 10 seconds and try
again after around 30 seconds.
¾ Once the engine is running, first disconnect
the negative cable (4) from the engine block

Maintenance 5
Troubleshooting
(3), and then from the current-giving battery

(5).
¾ First disconnect the positive cable (1) from
the current-giving battery (5), then from the
discharged battery (2).
Fork carriage emergency lowering

If there is a malfunction, the fork carriage can
be lowered manually.
¾ Remove floormat.
DANGER
People are not allowed to stand in
the vicinity of the fork arms when
they are being lowered.
During lowering, leave the socket
wrench on the screw (1) on the valve
block (3) to enable lowering to be
interrupted at any time.
¾ Insert the 8 mm WAF socket wrench

through the opening in the floor plate.
¾ Slowly rotate the screw (1) using the socket
wrench approx. 1.5 turns in an anti-clock-
wise direction until the fork carriage has
been completely lowered.
¾ Open the bonnet.
¾ Open floor plate and secure it.
¾ Undo the self-locking nut (2) about 2 turns.

5 Maintenance
Troubleshooting
¾ Turn screw (1) back in again, in a clockwise

direction, (tightening torque 2.5 Nm), oth-
erwise the fork carriage cannot be raised
using the joystick.
¾ Tighten the self-locking nut (2) again (tight-
ening torque: 9.5 Nm).
¾ Close floor plate and bonnet.
¾ Insert the floormat. 1
3 2 d3941386
Emergency exit for trucks with rear

screen
If the truck is fitted with a front and rear wind-
screen, it may not be possible to dismount at
the side if the truck breaks down in a narrow
aisle. In the case of a dangerous situation the
operator can exit the vehicle at the rear wind-
screen. For this purpose, the emergency exit
hammer must be used to destroy the wind-
screen.
¾ Bend up the cotter pin (1) on the mounting
(2) underneath the rear wiper motor.
WARNING
Danger of personal injury from glass splinters.
Carefully remove the glass splinter.
¾ Remove the emergency exit hammer (3)

from the mounting and carefully break the
windscreen.
¾ Carefully dismount to the rear.
3
2 1
t3921371

Maintenance 5
Troubleshooting
Towing regulations
Towing
If the truck needs to be towed away in an emer-
gency, the towing unit can:
• Short-circuit the hydraulic oil circuit
• Release the multi-disc brakes in the drive
axle via the brake valve and stop pedal.
WARNING
Braking the truck is no longer possible. The parking
brake does not operate either.
To tow the forklift truck, a towing vehicle with suf-
ficient tractive power and braking force for the un-
braked towed load is required. It is only permitted to
tow the truck using a fixed connection (towing bar).
CAUTION
The H 25 TCT truck is not equipped with towing
jaws and a towing pin for towing.
The truck may be towed only in the raised position.
Towing procedure
¾ Lower the load to height where the fork
arms will not scrape along the ground during
towing.
¾ Remove the load.
¾ Attach towing vehicle (ensure sufficient
tractive power and braking force) to towing
pin of truck using towing bar.
Opening the choke plunger of the hy-

draulics
¾ Open the bonnet.

5 Maintenance
Troubleshooting
¾ Release self-locking nut (1) (AF 19 mm) on

left of variable pump with socket at housing.
¾ Unscrew threaded stud (2) (AF 8 mm)
2 turns with socket.
¾ Lock the threaded stud with the self-locking
nut (1), tighten to 80 Nm.
2
Releasing the multi-disc brake
The brake valve is located under the floorplate
on the left-hand side of the truck frame. 1
¾ Remove floormat.
t3921370
¾ Insert hexagon socket head screw

(AF 5 mm) through hole in the floorplate
and unscrew socket head screw (3)
about 8 turns.
¾ Occupy the driver’s seat.
¾ Press down the parking brake handle.
3
¾ Move the stop pedal back and forth several
times in easy-movement range until resis-
tance is felt (pump max. 10 strokes) and
until the brake is released.
After towing
¾ Secure with chocks on downhill side. d3921511
¾ Open the bonnet.

¾ Loosen self-locking nut (1) on the variable
pump.
¾ Screw in threaded stud (2) (AF 8 mm);
tighten to 20+5 Nm.
¾ Lock threaded stud with self-locking nut (1).
¾ Tighten nut to 80 Nm.
Restoring braking
¾ Insert the socket head screw (3) into the
valve block up to the stop.
¾ Replace floormat and close bonnet.

Maintenance 5
Troubleshooting
DANGER
After repairs to the brake system, check for correct
operation. If defects occur in the brake system,
Placing the forklift truck into storage

Actions prior to placing the forklift truck ¾ Apply a suitable contact spray to all exposed
into storage electrical contacts.
If the truck is to be placed into storage for more ¾ Jack up the truck so all wheels are off the
than 2 months e. g. for operational reasons, it ground.
should be stored only in a well ventilated, clean This will prevent permanent deformation of the
and dry room free of frost, and the following tyres.
measures undertaken beforehand.
¾ Clean forklift truck thoroughly. NOTE
¾ Raise the fork carriage several times to the Do not cover with plastic foil or this will en-
end stop. courage the formation and collection of con-
¾ Tilt the lift mast several times back and for- densed water.
wards and operate any special attachments
NOTE
that may be fitted .
¾ Lower the fork carriage to a supporting If the truck is to be shut down for more than 6
surface until the chains are relieved of load. months, further measures should be agreed
with your authorised dealer.
¾ Check the hydraulic oil level and top up if
necessary.
Bringing back into service after storage
¾ Tightly close the shut-off valve for the gas
¾ Clean forklift truck thoroughly.
bottle or gas tank.
¾ Lubricate the forklift truck.
¾ Empty the gas hoses by starting the engine.
¾ Connect the battery.
¾ Remove the gas bottle.
¾ Clean the battery and lubricate battery
¾ All unpainted mechanical components
terminals with acid-free grease
should be coated with a thin film of oil or
grease. ¾ Check battery condition and specific gravity
of acid and recharge if necessary.
¾ Grease truck.
¾ Check engine oil for condensed water,
¾ Disconnect the battery.
change if necessary.
¾ Check battery condition and density of acid.
¾ Check hydraulic oil for condensed water,
¾ Lubricate battery terminals with acid-free change if necessary.
grease. (Follow instructions of battery
¾ Perform maintenance as before initial
manufacturer .)
commissioning.

5 Maintenance
Troubleshooting
¾ Fit the gas bottle and connect it in accor- ¾ Put forklift truck into service.
dance with instructions.
Disposal of old vehicles

The disposal of old vehicles is regulated partially smeared with oil as well as for tyres,
in directive 2000/53/EC of the European including fire protection measures. Suitable
Parliament and Council. storage tanks for fluids such as fuel, engine
oil, hydraulic oil, coolant and fluids from air
We recommend having this work carried out
conditioners must also be available.
by an authorised salvager. If you want to do
this yourself, you must, according to Articles • For the disposal of harmful substances from
9, 10 and 11 the directive 75/442/EEC, obtain the old vehicles, the batteries and LPG bot-
a permit from the responsible authorities. tle/tanks must be removed. The following
must also be removed, collected and stored
The following minimum requirements must separately: fuel, engine oil, coolant, hy-
also be observed: draulic oil, fluids from air conditioners.
• The storage locations for old vehicles • The following parts can be collected and
before their processing must be suitable recycled separately: catalytic converters,
areas with an impermeable surface. They metal parts containing copper and alu-
must be provided with collecting facilities minium, tyres, big plastic parts (console,
and separators for fluids running out and fluid reservoirs), glass.
grease-cutting cleaning agents.
• The processing locations must be suitable NOTE
areas with an impermeable surface. They
The owner is responsible for the compliance
must be provided with collecting facilities
with the directives and further national regula-
and separators for fluids running out and
tions.
grease-cutting cleaning agents. Suitable
storerooms for removed parts and parts
Malfunctions during operation
CAUTION
If one of the following indicator lights illuminates
in the indicator unit and the buzzer sounds during
operation, a malfunction has occurred.
The engine must be shut down immediately and the
malfunction dealt with. (See: Malfunctions, Causes
and Remedies)
• Hydraulic oil temperature indicator (1) and

buzzer
• (2) Battery charge indicator
• Engine oil pressure indicator (3) and buzzer
• Indicator light: error in electrical control
system (4)

Maintenance 5
Troubleshooting
• Engine temperature indicator (5) and

buzzer
• Level display (6) (special equipment)
• Coolant level indicator (11) (special equip-
ment)
• Hydraulic oil microfilter (7) (special equip-
ment)
• Gas system error light (9)
The following should also be kept in mind:
NOTE
• If the indicator light (4) flashes, there is an
error in the electrical control system. De-
pending on the setting and error, it may only
be possible to drive the forklift truck at low
speed or not at all. Each error is indicated
by a numerical code or symbols in the text
field (8). Please contact your authorised
dealer.
• If the warning light (12) illuminates together
with the error light (9) there is a fault in the
system for shut-down due to lack of gas.
• Only on forklift trucks with a three-way cata-
lytic converter for the USA: If the yellow er-
ror light (13) at the upper right in the switch
panel lights up, there is a fault in the en-
gine/exhaust system. The engine/exhaust
system must be inspected without delay.
• If the warning light (9) illuminates, there is
a fault in the LPG system. Please contact
• If error light (9) or (13) flashes after starting
the engine, a fault has been logged in the
gas system that must be cleared by your
authorised dealer.
• If the air filter vacuum indicator (10) lights
up on the indicator unit, maintenance must
be performed on the air filter.
• Only when the 3rd auxiliary hydraulics are
fitted: If the switchable additional function
is blocked or the forklift truck can travel only
at crawler speed or the text field (8) shows
error code L247 and the buzzer sounds,
there is a malfunction in the safety system.

5 Maintenance
Troubleshooting
Malfunctions, Causes and Remedy (LPG engine)
Engine fails to start

Possible cause Remedy
Shut-off valve for LPG cylinder or LPG tank
Open shut-off valve.
closed.
Gas cylinder or LPG tank empty. Change gas cylinder, fill LPG tank.
Warm the gas system and lines with hot water.
Temperature of LPG in tank too low.
Do not use naked flame or hot air.
Use test lamp to check whether power is
Electromagnetic gas shut-off valve does not available; if not, check line and eliminate fault.
open. Change shut-off valve if necessary. Fuse F11
may be defective, change fuse.
LPG filter clogged. Change LPG filter.
Break in ignition circuit. Check circuit, starting with battery.
Spark plugs damp (condensed water). Dry spark plugs thoroughly.
Spark plugs oily due to defective piston rings or Change spark plugs or have engine checked
worn pistons. by your authorised dealer.
Spark plugs defective, spark plug gap too Correct gap between electrodes or change
great. spark plugs.
Immobiliser active. Contact your authorised dealer
Tighten connecting terminals on battery, check
The indicator unit does not light up.
line connections.
Engine starts but does not idle smoothly.

Tighten fastenings. Change flange gasket,
Intake manifold connections not tight.
check intake manifold for cracks.
Electric speed control badly adjusted. Contact your authorised dealer.
No valve clearance or valves worn. Contact your authorised dealer.
Pressure drop between piston and cylinder. Contact your authorised dealer.
Engine oil level too high. Drain oil until oil level is at upper dipstick mark.

Maintenance 5
Troubleshooting
Engine overheats, coolant temperature indicator lights up in the indicator unit. Switch off engine
immediately.
Check the cooling system for leaks, seal them
Insufficient coolant in cooling system.
as required. Top up the coolant fluid.
Water cooler radiator fins partially clogged by
Clean water and hydraulic oil coolers.
dirt or foreign bodies.
Gas/air mixture too lean. Contact your authorised dealer.
Engine oil pressure too low. Switch off engine immediately.

Leaks in the lubricating system. Contact your authorised dealer.
Oil level too low Top up with engine oil
Charging current indicator lamp lights up during operation.

Three-phase alternator speed too low. Check V-ribbed belt tension.
Battery not being charged by alternator,
Contact your authorised dealer
alternator or cut-out relay defective.
Engine not firing on all 4 cylinders.

Loose cable connections at ignition coils. Check cable connections and tighten.
Check connector, change defective parts as
Connector defective (insulation breakdown).
necessary.
Clean spark plugs, check gap between elec-
Spark plugs dirty or defective.
trodes, change spark plugs if necessary.
Leaking or seized valve. Contact your authorised dealer.
Engine does not run smoothly or misfires.

Check spark plugs and clean them, adjust gap
Spark plugs failing to fire. between electrodes, change spark plugs if
necessary.
Change defective connectors (generally
Spark plug connectors defective.
shown by burnt areas).
Gas supply insufficient or blocked. Check gas system.

5 Maintenance
Troubleshooting
Once warm, engine does not idle smoothly; sooty exhaust.

Idling speed not set correctly. Contact your authorised dealer.
Engine pinks under load.

Ignition timing too advanced. Contact your authorised dealer.
Engine overheating. See: Engine overheating.
Heavy coking in combustion chamber. Contact your authorised dealer.
Use type of spark plug specified. Check spark
Heat range of spark plugs too low.
plug sealing ring.
Unsuitable LPG. Use LPG specified.
Error light comes on when engine is running.

Switch off the forklift truck immediately. Defect
Fault in LPG system or shut-down due to lack
can be determined using the diagnostics
of gas function.
device. Please contact your authorised dealer.
Fault in the exhaust system (applies only to the US version)

The yellow indicator light in the switch panel, Have the engine exhaust system checked
top right in the driver’s cab, lights up. without delay. Contact your authorised dealer.
Truck only moves in crawling speed, the buzzer sounds and error code X201 is displayed in the
text field of the indicator unit.
Engine oil level too low. Top up engine oil.
Top up engine oil, if the error persists, contact
Engine oil pressure too low.

Maintenance 5
Troubleshooting
Radiator water level too low. Top up radiator water.
The truck only moves at crawling speed and the level display lights up in the indicator unit.
Radiator water level too low. Top up radiator water.
Truck only moves at crawling speed, the buzzer sounds and error code X204 is displayed in the
Top up radiator water. Water pump defective.
Engine temperature too high. Clean the water cooler. Adjust the fuel injection
system.

5 Maintenance
Troubleshooting
Malfunctions, Causes, Remedies (ultrasonic sensor)
No display possible.
Supporting surface dirty. Carefully clean the supporting surface.
Position the gas bottle correctly or check
whether the gas bottle is positioned with a weld
No display at the fuel gauge.
seam or label over the sensor, remove label if
so.
Incorrect value displayed.

Drive the forklift truck away from the sloping
Maximum forklift truck tilt exceeded.
ground. Switch the ignition on and off.
Partially filled gas bottle fitted. Fit a full gas bottle.
Either use the correct bottle or recalibrate the
Different bottle diameter or gas mixture used.
sensor.
Engine cuts out although the fuel gauge shows there is still fuel.
Place the gas bottle in the correct position and
Gas bottle mounted crookedly.
secure it
Partially filled gas bottle fitted. Fit a full gas bottle.

Maintenance 5
Troubleshooting
Malfunctions, causes, remedies (hydraulic equipment)
Abnormal noises.
Possible cause Correction
Clogged suction filter. Replace the filter.
Seal the pipe line. Check the hydraulic oil level,
Leaks in the suction pipe line, oil foaming.
top up as necessary.
Hydraulic pump or motor damage, defective Have the hydraulic power unit checked by your
seals, causing air to be drawn in. authorised dealer.
Incorrect oil viscosity, insufficient oil in the tank Change the hydraulic oil; ensure the oil has the
or hydraulic pump. specified viscosity. Top up hydraulic oil.
No pressure or insufficient pressure in the system.

Change the hydraulic oil, top up the hydraulic
Suction line damaged, noisy.
oil.
Defective pump, loss of pressure, pressure
Contact your authorised dealer.
valves fail to close, valve seat damaged.
Pipe line broken or leaking. Replace pipe line or seal it.
Change the hydraulic oil; ensure the oil has the
Oil too thin, causing excessive leakage losses.
specified viscosity.
Check hydraulic oil level, clean hydraulic oil
Oil temperature indicator lights up.
cooler.
Oil pressure fluctuations.

Causes as for abnormal noises. See under abnormal noises.
Pressure relief valve or feed pressure valves
jamming.
Lift and tilt cylinders exhibit chafe points. Please contact your authorised dealer.
Lift mast does not extend fully, or leans back
Top up hydraulic oil. Bleed the cylinders.
somewhat.
No flow or insufficient flow.

Clogged filters (if noises also occur at the same
Clean the filter or replace it.
time).
Defective pump, loss of pressure, pressure
Contact your authorised dealer.
valves fail to close, valve seat damaged.
Pipe line broken or leaking. Replace pipe line or seal it.

5 Maintenance
Troubleshooting
No flow or insufficient flow.

Valves clogged. Contact your authorised dealer.
Check the hydraulic oil level, use the specified
Hydraulic system overheats.
hydraulic oil, clean the hydraulic oil cooler.
Hydraulic oil temperature too high.

Pump damage, valves leaking. Contact your authorised dealer.
Check the hydraulic oil level, top up with
hydraulic oil if necessary. Clean the hydraulic
Insufficient oil in the tank or oil cooler clogged.
oil cooler and check for leaks, if defective
Truck is still running only at crawling speed, the buzzer sounds and error code X205 is displayed
in the text field of the indicator unit
Check the hydraulic oil level Clean the hy-
Hydraulic oil temperature too high.
draulic oil cooler.
Malfunction in the third auxiliary hydraulic system (special equipment).

Truck running in crawler mode.
Solenoid valve slider jamming.
Error code L 247 is displayed in the indicator
Wiring damaged.
unit and the buzzer sounds.
Short circuit.
Switchable auxiliary hydraulic functions are
blocked.

6
Technical data
6 Technical data
Type sheet H 20 T, as at 06/2007

1 Identification
1.1 Manufacturer Linde
1.2 Manufacturer’s model designation H 20 T
1.3 Drive LPG
1.4 Operation Seated
1.5 Load capacity / Load Q [kg] 2000
1.6 Load centre of gravity c [mm] 500
1.8 Load distance x [mm] 390
1.9 Wheelbase y [mm] 1865
2 Weight
2.1 Tare weight kg 3255
2.2 Axle weight with front/rear load kg 4599/656
2.3 Axle weight without front/rear load kg 1645/1610
3 Wheels, chassis frame

3.1 Front/rear tyres: polyurethane, rubber SE
3.2 Front tyre size 23 x 9 - 101
3.3 Rear tyre size 6.50 - 102
3.5 Number of wheels, front/rear (x = driven) 2 (4) x / 23
3.6 Front track width b10 [mm] 972 (1140)4,5
3.7 Rear track width b11 [mm] 9426
4 Basic dimensions
4.1 Forward/backward fork tilt α/β (°) 5/8
4.2 Lowered mast height h1 [mm] 22277
4.3 Free lift h2 [mm] 150
1 Alternatively 6.50-10 dual fitment (pneumatic/SE). Single fitment 23x9-10/14PR and SE 23x10-12.
2 Alternatively 6.50-10/10PR, 23x9-10 (pneumatic and SE).
3 Bracketed value for dual fitment.
4 1024 mm with tyre size SE 23x10-12.
6 Track width 932 mm with tyre size 23x9–10 pneumatic/SE.
7 With 150 mm free lift on standard lift mast.

Technical data 6
4 Basic dimensions
4.4 Lift h3 [mm] 3150
4.5 Raised mast height h4 [mm] 3793
4.7 Overhead guard height (cab) h6 [mm] 2170
4.8 Sitting height (min/max) h7 [mm] 1065
4.12 Coupling height h10 [mm] 655
4.19 Overall length l1 [mm] 3635
4.20 Length including fork back l2 [mm] 2635
4.21 Overall width b1/b2 [mm] 11808
4.22 Fork arm dimensions s/e/l [mm] 45 x 100 x 1000
4.23 Fork carriage DIN 15173, class/form A, B 2A
4.24 Fork carriage width b3 [mm] 10809
4.31 Ground clearance at mast m1 [mm] 111
4.32 Ground clearance, centre of wheelbase m2 [mm] 131
4.33 Aisle width for pallet 1000x1200 crosswise Ast [mm] 3972
4.34 Aisle width for pallet 800x1200 longitudinal Ast [mm] 4172
4.35 Turning radius Wa [mm] 2382
4.36 Smallest pivot point distance b13 [mm] 580
5 Performance data
5.1 Driving speed with/without load km/h 22/22
5.2 Lifting speed with/without load m/s 0.55/0.56
5.3 Lowering speed with/without load m/s 0.56/0.56
5.5 Pulling force with/without load N 15,020/12,910
5.7 Climbing capability with/without load % 10
28/33
5.9 Acceleration with/without load s 5.3/4.5
5.10 Service brake Hydrostatic
8 1189 mm with tyre size 23x9-10/14 PR, 1273 mm with tyre size 23x10-12, 1506 mm
with dual fitment SE 6.50-10/10, 1550 mm with dual fitment 6.50-10/10PR.
9 With dual fitment 1510 mm.
10 On short slopes, driving over obstacles (see section: Driving)

6 Technical data
7 Drive / Engine
7.1 Engine manufacturer / Type VW/BEF
7.2 Engine output as per ISO 1585 kW 36
7.3 Nominal speed rpm 2600
3
7.4 Number of cylinders / Displacement cm 4/1984
7.5 Fuel consumption according to VDI cycle kg/h 2.5
8 Miscellaneous
hydrostatic
8.1 Traction controller type
Gearbox
8.2 Working pressure for attachments bar 175 (190)11
8.3 Oil volume for attachments l/min 32
8.4 Noise level at the driver’s ear dB (A) 79
8.5 Towing hook, type/model DIN 15170-H
11 Bracketed values for triplex lift mast.

Technical data 6

1 Identification
1.2 Manufacturer’s model designation H 25 T
1.3 Drive LPG
2 Weight

3.1 Front/rear tyres: polyurethane, rubber SE
3.2 Front tyre size 23 x 9 - 1012
3.3 Rear tyre size 6.50 - 1013
3.5 Number of wheels, front/rear (x = driven) 2 (4) x / 214
3.6 Front track width b10 [mm] 972 (1140)15,16
4 Basic dimensions
4.1 Forward/backward fork tilt α/β (°) 5/8
12 Alternatively 6.50–10 dual fitment (pneumatic/SE). Single fitment 23x9-10/14PR and SE 23x10-12.
13 Alternatively 6.50-10/10PR, 23x9-10 (pneumatic and SE).
15 1024 mm with tyre size SE 23x10-12.
17 Track width 932 mm with tyre size 23x9–10 pneumatic/SE.
18 With 150 mm free lift on standard lift mast.

6 Technical data
4 Basic dimensions
4.4 Lift h3 [mm] 3150
5 Performance data
5.7 Climbing capability with/without load % 21
24/31
19 1189 mm with tyre size 23x9-10/14PR, 1273 mm with tyre size 23x10-12, 1506 mm
with dual fitment SE 6.50-10/10, 1550 mm with dual fitment 6.50-10/10PR.
20 With dual fitment 1510 mm.

Technical data 6
7 Drive / Engine
3
7.4 Number of cylinders / Displacement cm 4/1984
7.5 Fuel consumption according to VDI cycle kg/h 2.7
8 Miscellaneous
hydrostatic
Gearbox
8.2 Working pressure for attachments bar 205 (220)22
8.5 Towing hook, type/model DIN 15170-H
22 Bracketed values for triplex lift mast.

6 Technical data
Type sheet H 25 TCT, as at 04/2004

1 Identification
1.2 Manufacturer’s model designation H 25 TCT
1.3 Drive LPG
2 Weight

3.1 Front/rear tyres: polyurethane, rubber Cushion
3.2 Front tyre size 22x8-16
3.3 Rear tyre size 16x6x10½
3.5 Number of wheels, front/rear (x = driven) 2x/2
3.6 Front track width b10 [mm] 972
4 Basic dimensions
4.1 Forward/backward fork tilt α/β (°) 5.0/8.0
4.4 Lift h3 [mm] 3150

Technical data 6
4 Basic dimensions
5 Performance data
5.7 Climbing capability with/without load %23 23/27
7 Drive / Engine
7.4 Number of cylinders / Displacement cm3 4/1984
7.5 Fuel consumption according to VDI cycle kg / h 2.9

6 Technical data
8 Miscellaneous
hydrostatic
Gearbox
8.2 Working pressure for attachments bar 205
8.5 Towing hook, type/model --

Technical data 6
Load diagrams and lift mast data as at 06/2007
Load diagrams and lift mast

data as at 06/2007
Main dimensions

6 Technical data
Load diagrams and lift mast data as at 06/2007
Load diagrams
Load diagrams apply to standard and duplex

masts with SE tyres.
Lift mast data

Standard lift mast (in mm)
Lift h3 H 20/25 3150 3450 3750 4050 4550
Overall heights when
retracted with specified free h1 H 20/25 2227 2377 2527 2677 2927
lift
Overall height when extended h4 H 20 3703 4103 4303 4603 5103
H 25 3793 4193 4393 4693 5193
Free lift h2 H 20/25 150 150 150 150 150
Duplex lift mast (in mm)

Lift h3 H 20/25 3170 3770 4070
Overall heights when retracted with
h1 H 20/25 2154 2454 2604
specified free lift

Technical data 6
Noise emission values
Duplex lift mast (in mm)

Overall height when extended h4 H 20 3700 4300 4600
H 25 3813 4413 4713
Free lift h2 H 20 1624 1924 2074
H 25 1511 1811 1961
Triplex lift mast (in mm)

Lift h3 H 20/25 4715 5515 5965 6465
Overall heights when retracted
h1 H 20/25 2154 2454 2604 2804
with specified free lift
H 20 5245 6045 6495 6995
Overall height when extended h4
H 25 5258 6158 6608 7108
H 20 1624 1924 2074 2274
Free lift h2
H 25 1511 1811 1961 2161
Noise emission values

Calculated in the test cycle in accordance with Sound power level
EN 12053 from the weighted values for the
In the IDLING
DRIVE, LIFT and IDLING operating states. LWb = 73 dB (A)
operating state
Sound-pressure level in the driver’s com- In the DRIVE
partment LWc = 99 dB (A)
operating state
H 20 T, H 25 T,
LPAZ = 79 dB (A)
H 25 TCT Uncertainty KWA = 2 dB (A)
In the LIFT
LPa = 80 dB (A)
operating state
Guaranteed sound power level
In the IDLING
LPb = 63 dB (A) In accordance
operating state
with 2000/14/EC LWA = 100 dB (A)
In the DRIVE Directive
LPc = 84 dB (A)
operating state
Uncertainty KPA = 4 dB (A) Under the terms of the directive, it is a statu-
tory requirement to provide this information.
The value is calculated from the sound power
Sound power level levels of the "Lift" and "Drive" operating sta-
H 20 T, H 25 T, tuses. It can only be used as a comparative
LWAZ = 94 dB (A)
H 25 TCT value for different forklift trucks. The value is
In the LIFT less suitable for determining real environmen-
LWA = 93 dB (A) tal impact levels, as it is not representative
operating state
for normal truck operation, which includes the
"Idling" operating status.

6 Technical data
NOTE
Lower or higher noise values may occur when
using industrial trucks, for instance, due to the
method of operation, environmental factors
and other sources of noise.
Vibration characteristic values for bodily vibrations

The values were determined according to EN Specified vibration characteristic for hand-
13059 using trucks with standard equipment arm vibrations
according to the data sheet (driving over test Vibration characteristic < 2.5 m/s2
course with humps).
Specified vibration characteristic as per EN NOTE

12096
The vibration characteristic for bodily vibra-
Measured
tions cannot be used to determine the actual
vibration aW.ZS = 0.9 m/s2
load level of vibrations during operation. This
characteristic
depends on the operating conditions (state
Uncertainty K = 0.3 m/s2 of pathway, method of operation etc.) and
should therefore be determined on site, where
appropriate. It is mandatory to specify the
hand-arm vibrations even where the values do
not indicate any hazard, as in this case.

Index
g
A Before taking up a load . . . . . . . . . . . . . . 96

Bio-hydraulic oil . . . . . . . . . . . . . . . . . . 113
Actions prior to placing the forklift truck
into storage . . . . . . . . . . . . . . . . 215 Bonnet
Adjust driver’s seat with swivel device . . . 77 closing . . . . . . . . . . . . . . . . . . . . . . 174
Adjust for the driver’s weight . . . . . . . . . . 78 opening . . . . . . . . . . . . . . . . . . . . . 172
Adjust lift mast chain Bringing back into service after storage . 215
Duplex or triplex lift mast . . . . . . . . . 201
C
Standard lift mast . . . . . . . . . . . . . . 200
Adjust lumbar support . . . . . . . . . . . . . . 80 Cab door
Adjust the driver’s air-sprung seat . . . . . . 78 closing . . . . . . . . . . . . . . . . . . . . . . . 88
Adjust the headrest . . . . . . . . . . . . . . . . 80 opening . . . . . . . . . . . . . . . . . . . . . . 88
Adjust the seat angle . . . . . . . . . . . . . . . 79 Chain spray . . . . . . . . . . . . . . . . . . . . . 113
Adjust the seat back . . . . . . . . . . . . . . . . 80 Change breather . . . . . . . . . . . . . . . . . 194
Adjust the seat height . . . . . . . . . . . . . . . 79 Change the high-pressure gas hoses . . 168
Adjusting for the operator’s weight . . . . . 31 Change the LP gas filter . . . . . . . . . . . . 146
Adjusting the armrest on the operator’s Change the water pump . . . . . . . . . . . . 156
seat . . . . . . . . . . . . . . . . . . . . . . . 32 Changing coolant . . . . . . . . . . . . . . . . . 151
Adjusting the driver’s seat . . . . . . . . . . . . 30 Changing direction of travel . . . . . . . 44, 54
Adjusting the fork spread . . . . . . . . . . . . 97 Changing the feed filter . . . . . . . . . . . . 192
Adjusting the lumber support . . . . . . . . . 31 Changing the pressure filter . . . . . . . . . 192
Adjusting the seat angle of tilt . . . . . . . . . 32 Changing the spark plugs . . . . . . . . . . . 167
Adjusting the steering column . . . . . . . . . 33 Changing the suction filter . . . . . . . . . . 193
After towing . . . . . . . . . . . . . . . . . . . . . 214 Changing the tensioner pulley . . . . . . . 161
Air conditioning . . . . . . . . . . . . . . . . . . . 89 Check and oil other pivots and joints . . . 177
Servicing . . . . . . . . . . . . . . . . . . . . 175 Check basic setting of gas installation . . 166
Switch on . . . . . . . . . . . . . . . . . . . . . 89 Check coolant concentration . . . . . . . . 153
Air filter Check correct operation of breather
Changing the cartridge . . . . . . . . . . 161 valve on the hydraulic oil tank . . . 195
Checking the vacuum-operated Check the air intake lines for leaks . . . . 167
switch . . . . . . . . . . . . . . . . . . . . 161 Check the CO content in the exhaust
an accumulator . . . . . . . . . . . . . . . . . . . 18 gas . . . . . . . . . . . . . . . . . . . . . . 166
Approaching gradients . . . . . . . . . . . 45, 55 Check the condition of the engine
mountings, check that they are
Attach additional consumers . . . . . . . . . . 85
attached securely . . . . . . . . . . . . 156
Attachments
Check the condition of the engine
Instructions before fitting . . . . . . . . . . 18 suspension, check that it is
attached securely . . . . . . . . . . . . 156
B
Check the dust discharge valve . . . . . . 163
Backrest adjustment . . . . . . . . . . . . . . . 31 Check the exhaust pipes for leaks . . . . . 167
Backrest extension adjustment . . . . . . . . 32 Check the fork quick-releases . . . . . . . . 202
Battery grease . . . . . . . . . . . . . . . . . . . 113 Check the forks . . . . . . . . . . . . . . . . . . 202
Battery: check condition, acid level and Check the king pin for security . . . . . . . 184
acid density . . . . . . . . . . . . . . . . 187 Check the steering cylinder for security . 184

Index
g
Check the tension of double hoses . . . . 197 Cleaning

Check the tyres for damage and foreign Evaporator / pressure regulator . . . . 147
objects . . . . . . . . . . . . . . . . . . . . 180 Fork positioner . . . . . . . . . . . . . . . . 204
Check tilt cylinder bearings for wear . . . 196 Lift mast chain . . . . . . . . . . . . . . . . . 199
Checking Oil bath air filter . . . . . . . . . . . . . . . . 164
steering axle fastenings . . . . . . . . . . 177 Prefilter . . . . . . . . . . . . . . . . . . . . . . 164
Checking frame fastenings . . . . . . . . . . 177 Sideshift . . . . . . . . . . . . . . . . . . . . . 204
Checking slide guides on sideshift for Steeringaxle . . . . . . . . . . . . . . . . . . 183
wear . . . . . . . . . . . . . . . . . . . . . 204
Truck . . . . . . . . . . . . . . . . . . . . . . . 171
Checking solid rubber tyres for wear (H
Water cooler and hydraulic oil
25 TCT) . . . . . . . . . . . . . . . . . . . 181
cooler . . . . . . . . . . . . . . . . . . . . 155
Checking the bellows at the actuating Cleaning the evaporator . . . . . . . . . . . . 147
lever . . . . . . . . . . . . . . . . . . . . . 186
Cleaning the lift mast chain and
applying chain spray . . . . . . . . . . 199
positioning of electric cables . . . . 187
Cleaning the prefilter . . . . . . . . . . . . . . 164
positioning of the cable connec- Cleaning the pressure regulator . . . . . . 147
tions . . . . . . . . . . . . . . . . . . . . . 187 Cleaning the truck . . . . . . . . . . . . . . . . 171
Checking the condition and secure po- Clock
sitioning of the cable connectors . 187 setting . . . . . . . . . . . . . . . . . . . . . . . 34
Checking the coolant level . . . . . . . . . . 150 Close shut-off valve
Checking the fastenings of the axle on LPG cylinder . . . . . . . . . . . . . 43, 52
clamps . . . . . . . . . . . . . . . . . . . . 169 on LPG tank . . . . . . . . . . . . . . . . 43, 52
Checking the fastenings of the wheel Open gas fuel tank . . . . . . . . . . . . . . 36
motors . . . . . . . . . . . . . . . . . . . . 169
Open LPG cylinder (double cylinder) . 35
Checking the function and safety
Open LPG cylinder (single cylinder) . . 34
system of the third auxiliary
hydraulics . . . . . . . . . . . . . . . . . 197 Closed-loop catalytic converter
Checking the hydraulic pump’s check basic setting of gas installa-
attachment to the engine . . . . . . 170 tion . . . . . . . . . . . . . . . . . . . . . . 166
Checking the pedals . . . . . . . . . . . . . . . 186 Closing the LPG console without an
LPG bottle in place . . . . . . . . . . . . . 3
Checking the tyre pressure . . . . . . . . . . 182
Consumables . . . . . . . . . . . . . . . . . . . . 12
Checking the vacuum-operated switch . 161
Consumables recommendations . . . . . 112
Checking tilt cylinder fastenings . . . . . . 177
Controls . . . . . . . . . . . . . . . . . . . . . . . . . 23
Checks
Coolant . . . . . . . . . . . . . . . . . . . . . . . . 113
before starting work . . . . . . . . . . . . . . 30
Crane lifting . . . . . . . . . . . . . . . . . . . . . 104
Clean sideshift and
Crane lifting with crane eyes . . . . . . . . . 105
grease . . . . . . . . . . . . . . . . . . . . . . 203
D
Depressurisation . . . . . . . . . . . . . . . . . . 18
Determination and assessment of
hazards from use of industrial
trucks . . . . . . . . . . . . . . . . . . . . . 17
Diagnostic connector . . . . . . . . . . . . . . 209

Index
g
Dismantling of lift mast . . . . . . . . . . . . . 102 Fork positioner

Disposal of old vehicles . . . . . . . . . . . . 216 Cleaning and lubricating, checking
Drive axle the fastening . . . . . . . . . . . . . . . 204
Adjusting the side stops . . . . . . . . . . 169 Forklift Data Acquisition . . . . . . . . . . . . . 91
Checking the bearings for wear . . . . 170 Forklift Data Acquisition - special
setting
Checking the side stops . . . . . . . . . . 169
PIN number . . . . . . . . . . . . . . . . . . . 94
Driver’s cabin . . . . . . . . . . . . . . . . . . . . . 88
Forklift Data Acquisition - standard
Driving speed reduction . . . . . . . . . . . . . 80
setting
via a sensor . . . . . . . . . . . . . . . . . . . 81
PIN number and state code . . . . . . . . 92
via a switch . . . . . . . . . . . . . . . . . . . . 81
Forklift Data Management . . . . . . . . . . . 91
Duplex lift mast . . . . . . . . . . . . . . . . . . 110
Forwards travel . . . . . . . . . . . . . . . . 44, 54
Securing the raised mast . . . . . . . . . 110
Front side window
E closing . . . . . . . . . . . . . . . . . . . . . . . 88
opening . . . . . . . . . . . . . . . . . . . . . . 88
Emergency exit for trucks with rear
screen . . . . . . . . . . . . . . . . . . . . 212 Fuel tank level display . . . . . . . . . . . . . . 25
Emergency lowering . . . . . . . . . . . . . . 211 Function button . . . . . . . . . . . . . . . . . . . 26
Engine Fuses
Starting (single-pedal operation) . . . . 46 Changing . . . . . . . . . . . . . . . . . . . . 208
Starting (two-pedal operation) . . . . . . 38 Checking . . . . . . . . . . . . . . . . . . . . 208
Switching off (single-pedal opera- Engine compartment . . . . . . . . . . . . 208
tion) . . . . . . . . . . . . . . . . . . . . . . . 49 Fuses for basic and special equipment . 208
Switching off (two-pedal operation) . . 41
G
Engine oil . . . . . . . . . . . . . . . . . . . . . . . 113
Changing . . . . . . . . . . . . . . . . . . . . 131 Gas shut-off valve
Checking the level . . . . . . . . . . . . . . 130 closing . . . . . . . . . . . . . . . . . . . . 43, 52
draining . . . . . . . . . . . . . . . . . . . . . 131 opening . . . . . . . . . . . . . . . . . . . . . . 34
Topping up . . . . . . . . . . . . . . . . . . . 132 Gas system
Engine temperature indicator . . . . . . . . . 25 Error light . . . . . . . . . . . . . . . . . . . . . 26
Exchanging the safety cartridge . . . . . . 162 General points . . . . . . . . . . . . . . . . . . . 108
F H
Filling the LPG tank . . . . . . . . . . . . . . . 145 Handling consumables . . . . . . . . . . . . . . 12
Filling up the washer system water tank . 206 Heater . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Filling up washer system water tank . . . 206 Switch on . . . . . . . . . . . . . . . . . . . . . 89
Floorplate Hydraulic circuit diagram
closing . . . . . . . . . . . . . . . . . . . . . . 175 Accumulator . . . . . . . . . . . . . . . . . . 278
opening . . . . . . . . . . . . . . . . . . . . . 174 Traction, working and steering
Fork arm adjustment device hydraulics . . . . . . . . . . . . . . . . . 276
Hydraulic equipment
Check wear and tear . . . . . . . . . . . . 206
Filter change . . . . . . . . . . . . . . . . . . 192
Fork carriage emergency lowering . . . . 211

Index
g
Hydraulic oil . . . . . . . . . . . . . . . . . . ... 113 Inspection data . . . . . . . . . . . . . . . . . . 112

Changing . . . . . . . . . . . . . . . . . ... 190
draining . . . . . . . . . . . . . . . . . . ... 190
J
Temperature indicator . . . . . . . . ... . 24 Jump start . . . . . . . . . . . . . . . . . . . . . . 209
top up . . . . . . . . . . . . . . . . . . . . ... 190
Hydraulic oil cooler
L
Checking for leaks . . . . . . . . . . . . . . 155 Lap seat belt
Cleaning . . . . . . . . . . . . . . . . . . . . . 155 check for condition and proper
Hydraulic system operation . . . . . . . . . . . . . . . . . . 176
check for leaks . . . . . . . . . . . . . . . . 196 Leaving the truck . . . . . . . . . . . . . . . . . 106
Check oil level . . . . . . . . . . . . . . . . . 191 Level display . . . . . . . . . . . . . . . . . . . . . 25
Level indicator
I Engine oil . . . . . . . . . . . . . . . . . . . . . 25
Identification plates . . . . . . . . . . . . . . . . 20 Lift height reduction . . . . . . . . . . . . . . . . 83
Indicator unit . . . . . . . . . . . . . . . . . . . . . 24 Lift mast data . . . . . . . . . . . . . . . . . . . . 235
Air filter vacuum indicator . . . . . . . . . . 26 Lift mast position identification . . . . . . . . 26
Battery charge indicator . . . . . . . . . . . 24 Lift mast positioning . . . . . . . . . . . . . . . . 81
Do not start the engine symbol . . . . . . 26 Lifting system and attachments
Electrical control system fault Central lever operation . . . . . . . . . . . 62
indicator . . . . . . . . . . . . . . . . . . . . 25 Single lever operation . . . . . . . . . . . . 66
Engine oil level indicator . . . . . . . . . . 25 Single lever operation with toggle-
Engine oil pressure indicator . . . . . . . 25 switch-controlled third auxiliary
hydraulics . . . . . . . . . . . . . . . . . . 70
Engine temperature indicator . . . . . . . 25
With 3rd auxiliary hydraulics without
Fuel tank level display . . . . . . . . . . . . 25
toggle switch . . . . . . . . . . . . . . . . 74
Function button . . . . . . . . . . . . . . . . . 26
Gas system error light . . . . . . . . . . . . 26
Central lever operation . . . . . . . . . . . 63
Hydraulic oil . . . . . . . . . . . . . . . . . . . 24
Single lever operation . . . . . . . . . . . . 67
Hydraulic oil microfilter indicator . . . . . 25
Single lever operation with 3rd
Level display . . . . . . . . . . . . . . . . . . . 25 auxiliary hydraulics . . . . . . . . . . . . 71
Load indicator / Overload indicator . . . 25 with 3rd auxiliary hydraulics . . . . . . . . 75
Operating hours display . . . . . . . . . . . 25 Lighting
Operating hours symbol . . . . . . . . . . 26 switch on . . . . . . . . . . . . . . . . . . . . . 84
Parking brake symbol . . . . . . . . . . . . 26 Load diagrams . . . . . . . . . . . . . . . . . . . 235
Radiator water level indicator . . . . . . . 26 Load indicator . . . . . . . . . . . . . . . . . . . . 25
Reset button . . . . . . . . . . . . . . . . . . . 26 Lowering the fork carriage
Service interval exceeded symbol . . . 26 Central lever operation . . . . . . . . . . . 63
Symbol for Lift mast position Single lever operation . . . . . . . . . . . . 67
identification . . . . . . . . . . . . . . . . 26
Single lever operation with 3rd
Symbol for operating hours until auxiliary hydraulics . . . . . . . . . . . . 71
next service . . . . . . . . . . . . . . . . . 26
with 3rd auxiliary hydraulics . . . . . . . . 75
Text field . . . . . . . . . . . . . . . . . . . . . . 26
LPG . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Time display . . . . . . . . . . . . . . . . . . . 26

Index
g
LPG cylinder Oil bath air filter

Changing a single cylinder (H 25 Cleaning . . . . . . . . . . . . . . . . . . . . . 164
TCT) . . . . . . . . . . . . . . . . . . . . . 142 Opening the choke plunger of the
Changing an LPG double cylinder hydraulics . . . . . . . . . . . . . . . . . 213
(H 20 T / H 25 T) . . . . . . . . . . . . . 138 Opening the cover to the electrical
Changing an LPG single cylinder (H system . . . . . . . . . . . . . . . . . . . . 207
20 T / H 25 T) . . . . . . . . . . . . . . . 135 Operating attachments
LPG mixer Central lever operation . . . . . . . . . . . 63
check setting . . . . . . . . . . . . . . . . . . 147 Single lever operation . . . . . . . . . . . . 67
LPG system Single lever operation with 3rd
Checking for damage . . . . . . . . . . . 148 auxiliary hydraulics . . . . . . . . . . . . 71
Checking for leaks . . . . . . . . . . . . . . 148 with 3rd auxiliary hydraulics . . . . . . . . 75
Checking the fuel level . . . . . . . . . . . 134 Operating fork adjustment
Odour inspection . . . . . . . . . . . . . . . 148 Single lever operation with 3rd
Visual inspection . . . . . . . . . . . . . . . 148 auxiliary hydraulics . . . . . . . . . . . . 73
Lubricating grease . . . . . . . . . . . . . . . . 113 with 3rd auxiliary hydraulics . . . . . . . . 77
Operating hours display . . . . . . . . . . . . . 25
M Operating hours symbol . . . . . . . . . . . . . 26
Main fuses in engine compartment . . . . 208 Operating the clamp
Maintenance data . . . . . . . . . . . . . . . . 112 Central lever operation . . . . . . . . . . . 65
Maintenance intervals . . . . . . . . . . . . . 108 Single lever operation . . . . . . . . . . . . 69
Malfunctions during operation . . . . . . . . 216 with 3rd auxiliary hydraulics . . . . . . . . 77
Malfunctions, Causes and Remedies Operating the fork positioner
LPG engine . . . . . . . . . . . . . . . . . . . 218 Central lever operation . . . . . . . . . . . 65
Malfunctions, Causes and Remedy Single lever operation . . . . . . . . . . . . 69
Ultrasonic sensor . . . . . . . . . . . . . . 222 Operating the horn . . . . . . . . . . . . . . . . . 61
Malfunctions, causes, remedies Operating the rotating unit
Hydraulic equipment . . . . . . . . . . . . 223 Single lever operation with 3rd
Mast, lift chains, lift cylinders and auxiliary hydraulics . . . . . . . . . . . . 73
end stops: Check for security, Operating the sideshift
condition and proper operation . . 200 Central lever operation . . . . . . . . . . . 65
Microfilter indicator Single lever operation . . . . . . . . . . . . 69
Hydraulic oil . . . . . . . . . . . . . . . . . . . 25 Single lever operation with 3rd
Motor oil auxiliary hydraulics . . . . . . . . . . . . 73
Change filter . . . . . . . . . . . . . . . . . . 133 With 3rd auxiliary hydraulics . . . . . . . 76
Operation of industrial trucks in plant
N area . . . . . . . . . . . . . . . . . . . . . . . 12
Noise emission values . . . . . . . . . . . . . 237 Overload indicator . . . . . . . . . . . . . . . . . 25
O
Oil bath air cleaner
Change the oil . . . . . . . . . . . . . . . . . 165

Index
g
P Safety instructions . . . . . . . . . . . . . . . . . 10
3rd auxiliary hydraulic system . . . . . . 10
Parking brake
Checking for correct operation . . . . . 185 active medical equipment . . . . . . . . . 11
Driver sight . . . . . . . . . . . . . . . . . . . . 11
Operating version 1 (H 25 TCT) . . . . . 60
Gas springs . . . . . . . . . . . . . . . . . . . 11
Operating version 2 (H 25 TCT) . . . . . 61
Operating, version 1 (H 20 T/H 25 T) . 58 Speed reduction . . . . . . . . . . . . . . . . 11
Welding operations . . . . . . . . . . . . . . 10
Operating, version 2 (H 20 T/H 25 T) . 58
Safety measures when working on
Releasing version 1 (H 25 TCT) . . . . . 60
ignition systems . . . . . . . . . . . . . . 16
Releasing version 2 (H 25 TCT) . . . . . 61
Safety regulations . . . . . . . . . . . . . . . . . 10
Releasing, version 1 (H 20 T/H 25 T) . 58
Seat belt
Releasing, version 2 (H 20 T/H 25 T) . 58
Fastening . . . . . . . . . . . . . . . . . . . . . 37
Symbol . . . . . . . . . . . . . . . . . . . . . . . 26
opening . . . . . . . . . . . . . . . . . . . . . . 38
Periodic safety inspection . . . . . . . . . . . . 13
Seat heater . . . . . . . . . . . . . . . . . . . . . . 79
Placing the forklift truck into storage . . . 215
Seat heating, turning on/off . . . . . . . . . . . 32
Pressure indicator
Seat position adjustment . . . . . . . . . . . . 32
Engine oil . . . . . . . . . . . . . . . . . . . . . 25
Securing the hose pulley against rolling
Proper usage . . . . . . . . . . . . . . . . . . . . . . 3 up . . . . . . . . . . . . . . . . . . . . . . . 101
R Securing the lift mast from tilting back . . 109
Service brake
Rear side window H 20 T/H 25 T . . . . . . . . . . . . . . . . . . 57
closing . . . . . . . . . . . . . . . . . . . . . . . 88 Service brake H 25 TCT . . . . . . . . . . . . . 59
opening . . . . . . . . . . . . . . . . . . . . . . 88 Service plan
Reception of forklift truck . . . . . . . . . . . . . 6 1000 h . . . . . . . . . . . . . . . . . . . . . . 118
Refrigerant for air conditioning . . . . . . . 113 3000-hour . . . . . . . . . . . . . . . . . . . . 121
Regulations . . . . . . . . . . . . . . . . . . . . . . 13 50-hour . . . . . . . . . . . . . . . . . . . . . . 116
Releasing the multi-disc brake . . . . . . . 214 6000 h . . . . . . . . . . . . . . . . . . . . . . 124
Reset button . . . . . . . . . . . . . . . . . . . . . 26 9000-hour . . . . . . . . . . . . . . . . . . . . 127
Restoring braking . . . . . . . . . . . . . . . . . 214 As required . . . . . . . . . . . . . . . . . . . 117
Reverse travel . . . . . . . . . . . . . . . . . 44, 54 before initial start-up . . . . . . . . . . . . . . 7
Ribbed V-belt, before starting work . . . . . . . . . . . . . . 30
changing . . . . . . . . . . . . . . . . . . . . 158 Setting down loads . . . . . . . . . . . . . . . . 100
Testing the condition . . . . . . . . . . . . 157 Sideshift
Running-in instructions . . . . . . . . . . . . . . 30 Check fastening . . . . . . . . . . . . . . . 203
S Special equipment wiring diagram
Sheet 1 Working headlights,
Safety guidelines for LPG (extract) . . . . . 14 lighting, direction indicator
Safety information on the LPG system . . . 14

Index
g
system, brake light, interior Switch on the wiper/washer system . . . . . 87

lighting . . . . . . . . . . . . . . . . . . . . 258 Switch on turn indicator lights . . . . . . . . . 85
Sheet 2 − Windscreen wiper, seat Switch on working headlights . . . . . . . . . 84
heater, radio . . . . . . . . . . . . . . . 260
Switch panel . . . . . . . . . . . . . . . . . . . . . 28
Sheet 3 − Heater, air conditioning, Switching on the rear window heater . . . . 88
rotating beacon, reversing
signal . . . . . . . . . . . . . . . . . . . . . 262 Symbol for Do not start engine . . . . . . . . 26
Sheet 4 − Hazard warning system Symbols . . . . . . . . . . . . . . . . . . . . . . . . . 4
for reversing, higher lighting . . . . 264
T
Sheet 6 − Particulate filter, diesel
filter water trap warning . . . . . . . 268 Takeover of forklift truck . . . . . . . . . . . . . . 6
Sheet 7 − LPG volume display, 12 V Taking up load . . . . . . . . . . . . . . . . . . . . 98
socket, working headlights pos. Technical description . . . . . . . . . . . . . . . . 4
5 and 6, coolant and engine oil
Brakes . . . . . . . . . . . . . . . . . . . . . . . . 6
level monitoring . . . . . . . . . . . . . 270
Electrical system . . . . . . . . . . . . . . . . . 6
Sheet 8 − Battery main switch with
indicator unit voltage supply, Engine . . . . . . . . . . . . . . . . . . . . . . . . 5
exchangeable particulate filter, Hydraulic system . . . . . . . . . . . . . . . . 5
rear window heater, camera Lift mast . . . . . . . . . . . . . . . . . . . . . . . 6
system . . . . . . . . . . . . . . . . . . . . 272 Linde Load Control . . . . . . . . . . . . . . . 5
Sheet 9− Third auxiliary hydraulics Linde Truck Control . . . . . . . . . . . . . . . 5
with third joystick, centre rear
Operation . . . . . . . . . . . . . . . . . . . . . . 5
brake/tail light . . . . . . . . . . . . . . . 274
Steering . . . . . . . . . . . . . . . . . . . . . . . 6
Special equipment sheet 5 − Lift
mast positioning, hydraulic oil Text field in indicator unit . . . . . . . . . . . . 26
microfilter indicator, vehicle Tighten the wheel bolts . . . . . . . . . . . . . 180
deactivation, Forklift Data Tilting the lift mast backwards.
Management . . . . . . . . . . . . . . . 266 Central lever operation . . . . . . . . . . . 63
Specialist . . . . . . . . . . . . . . . . . . . . . . . . 12 Single lever operation . . . . . . . . . . . . 67
Standard lift mast . . . . . . . . . . . . . . . . . 109 Single lever operation with 3rd
Securing the raised mast . . . . . . . . . 109 auxiliary hydraulics . . . . . . . . . . . . 71
Status code . . . . . . . . . . . . . . . . . . . . . . 91 with 3rd auxiliary hydraulics . . . . . . . . 75
Steering . . . . . . . . . . . . . . . . . . . . . . . . . 56 Tilting the lift mast forwards
Steering axle Central lever operation . . . . . . . . . . . 63
Cleaning . . . . . . . . . . . . . . . . . . . . . 183 Single lever operation . . . . . . . . . . . . 67
greasing . . . . . . . . . . . . . . . . . . . . . 183 Single lever operation with 3rd
Steering system . . . . . . . . . . . . . . . . . . . 56 auxiliary hydraulics . . . . . . . . . . . . 71
Stop pedal (H 20 T/H 25 T) . . . . . . . . . . . 57 With 3rd auxiliary hydraulics . . . . . . . 75
Stopping . . . . . . . . . . . . . . . . . . . . . 45, 55 Time
Switch on hazard warning lights . . . . . . . 84 Display . . . . . . . . . . . . . . . . . . . . . . . 26
Switch on interior lighting . . . . . . . . . . . . 84 Tip-over of the truck . . . . . . . . . . . . . . . . 11
Switch on rotating flashing light . . . . . . . . 84 Toothed belt
Switch on the front windscreen wiper . . . 86 Changing . . . . . . . . . . . . . . . . . . . . 161
Switch on the rear windscreen wiper . . . . 86 Checking condition . . . . . . . . . . . . . 159
Switch on the roof windscreen wiper . . . . 87 Checking tension . . . . . . . . . . . . . . 159

Index
g
Tow coupling . . . . . . . . . . . . . . . . . . . . 101 Vibration characteristic values for

Towing . . . . . . . . . . . . . . . . . . . . . . . . 213 bodily vibrations . . . . . . . . . . . . . 238
Towing procedure . . . . . . . . . . . . . . . . 213
W
Towing regulations . . . . . . . . . . . . . . . . 213
Traction Warnings . . . . . . . . . . . . . . . . . . . . . . . .. 4
Single-pedal operation . . . . . . . . . . . 53 Water cooler
Two-pedal operation . . . . . . . . . . . . . 43 Checking for leaks . . . . . . . . . . . . . . 155
With load . . . . . . . . . . . . . . . . . . . . . 99 Cleaning . . . . . . . . . . . . . . . . . . . . . 155
without lift mast . . . . . . . . . . . . . . . . 103 Wheel change . . . . . . . . . . . . . . . . . . . 179
Transport with lorry or low-bed trailer . . 106 Wheel-slide protection chains . . . . . . . . . 97
Triplex lift mast . . . . . . . . . . . . . . . . . . . 111 Windscreen defrosting . . . . . . . . . . . . . . 89
Securing the raised mast . . . . . . . . . 111 Windscreen wiper . . . . . . . . . . . . . . . . . 86
Truck overview . . . . . . . . . . . . . . . . . . . 22 Wiring diagram
Type sheet H 20 T . . . . . . . . . . . . . . . . 226 Basic equipment for LPG . . . . . . . . . 252
Type sheet H 25 T . . . . . . . . . . . . . . . . 229 Working on the Linde lift mast and at
the front of the truck . . . . . . . . . . 109
Type sheet H 25 TCT . . . . . . . . . . . . . . 232
Tyre sizes . . . . . . . . . . . . . . . . . . . . . . 182
V
Vacuum indicator
Air filter . . . . . . . . . . . . . . . . . . . . . . . 26

392 807 1051 EN – 06/2008

Operating Instructions
LPG truck
H20T, H25T
Annex 392 807 1051 EN – 06/2008
7
Circuit diagrams
7 Circuit diagrams
Wiring diagram
Wiring diagram
LPG basic equipment sheet 1

Circuit diagrams 7
Wiring diagram
Legend :2 − Terminal 15 6X1 10-pin plug connector (6P1), 26–39 The number in front of the wire colour refers
F2 30 A MTA fuse, 4 :6 − Earth 6X2 7-pin plug connector (diagnostics), 48 to the wire cross-section.
F5 2 A fuse, 26 S1 Ignition and starting switch, 9–17 :3 − Terminal 15 Wires with unspecified cross-section =
F6 2 A fuse, 28 S2 Brake pedal switch 2 (start-up prevention), :4 − Earth 0.75 mm2.
F7 15 A fuse, 73 12–14
F13 Fuse (max. 15 A), 61 S3 Suction filter vacuum-operated switch, 31 Wire colours Notes
F14 2 A fuse, 64 0S1 Oil pressure switch, 28 BK Black (a) Wires twisted together
F15 10 A fuse, 67 4S1 Horn activation, 73 BN Brown (b) Special equipment wiring diagram
G1 660 W three-phase alternator with regulator, X1 10-pin plug connector (S1), 9–16, 73 BU Blue *) Gold-plated contacts
1–5 X2 3-pin plug connector (S2), 12, 13 GN Green
G2 88 Ah battery, 7 X6 5-pin plug connector, 33, 36 GY Grey
4H1 60 W signal horn, 73 X10 18-pin plug connector (central electrical OG Orange
K2 Start relay, 10–13 system), 21, 64–69 RD Red
M1 1.7 kW starter motor, 9–11 X11 9-pin plug connector (central electrical VT Violet
6P1 Indicator unit, 25–40 system), 23, 65–67 WH White
:1 − Terminal 30 X15 2-pin plug connector (CAN), 42 YE Yellow

7 Circuit diagrams
Wiring diagram
Basic equipment for LPG sheet 2

Circuit diagrams 7
Wiring diagram
Legend :37 − Forwards :106 − 0V lift/lower 2Y7 Auxiliary valve 2B, 150
1B1 Speed actual-value transmitter, 85–86 :38 − Seat switch :107 − 0V tilt forwards/backwards 2Y8 Auxiliary valve 2A, 152
1B2 Dual potentiometer for accelerator, 85-90 :39 − ISO L-drive :109 − 0V safety valve 2Y9 Release valve, 156
1B4 Hydraulic oil temperature sensor, 85 :40 − Mast vertical indicator :111 − Safety valve
1B9 Brake potentiometer, 92–97 :44 − Auxiliary 2/B (B4) :112 − 0V (1/A)/(1/B) Wire colours
2B1 Joystick basic functions, 118–124 :45 − Auxiliary 2/A (A4) :113 − 0V (2/A)/(2/B) BK Black
:1 − 5V :46 − Release valve 1Y4 :114 − Earth BN Brown
:2 − Lift/lower :47 − Coding :116 − 5V lift sensor BU Blue
:3 − Tilt forwards/back :49 − Drive potentiometer :118 − 5V lift sensor GN Green
:4 − Lift/lower reference :52 − Coding :119 − Earth GY Grey
:5 − Tilt forwards/back reference :53 − Terminal 15 :120 − Terminal 30 OG Orange
:6 − 0V :54 − Brake potentiometer reference :121 − Terminal 30 RD Red
2B2 Joystick additional functions, 126–132 :56 − Code S4 Seat switch, 149-150 VT Violet
:1 − 5V :58 − Brake 1 1S1 Brake pedal switch 1, 103-104 WH White
:2 − Auxiliary 1 :59 − Brake 3 1S2 Travel direction switch, single-pedal, 108- YE Yellow
:3 − Auxiliary 2 :60 − Brake potentiometer 114 The number in front of the wire colour refers
:4 − Auxiliary 1 reference :61 − Drive earth sensor X4 3-pin plug connector (seat heater)149, 150 to the wire cross-section.
:5 − Auxiliary 2 reference :62 − Fan valve 1Y5 X10 18-pin plug connector (central electrical Wires with unspecified cross-section =
:6 − 0V :68 − GND system), 99–107 0.75 mm2.
2B3 Dual potentiometer for lift mast tilt angle, :69 − GND X11 9-pin plug connector (central electrical Notes
139-143 :70 − GND system), 112–114 (a) Potentiometer 1B9 only with automatic
F8 2A fuse, 81 :71 − GND 1X1 3-pin plug connector (1B1), 84 operation (H 25 TCT)
F9 15A fuse, 83 :72 − Reverse 1X2 3-pin plug connector (1S1), 103, 104 (b) Speed restriction
N1 LHC electronic traction controller, 81–158 :73 − Brake 2 1X3 6-pin plug connector (single-pedal), 109- (c) Brake lights
:1 − 5V drive sensor :74 − Engine temperature 114 (d) Programmable reversing signal
:6 − Forwards hydraulic pump 1Y2 :80 − Drive earth sensor 2X1 2-pin plug connector (microfilter), 127, 128 (e) Not assigned
:7 − Reverse hydraulic pump 1Y3 :81 − Drive earth sensor 2X3 6-pin plug connector (2B1), 120–124 (f) Shovel insert
:8 − Microfilter pressure switch :82 − Auxiliary 1/A (A3) 2X4 6-pin plug connector (2B2), 127–131 (g) Radiator water level
:10 − Coding :85 − ISO K-lift 2X5 10-pin plug connector (valve block), (h) Door locking switch
:13 − Hydraulic oil temperature sensor :88 − Lift earth sensor 136–156 (j) Air conditioning
:15 − 0V forwards hydraulic pump :89 − Lift earth sensor 1Y2 Forwards solenoid valve "y", 92 (k) Engine switch-off
:16 − 0V reverse hydraulic pump :90 − Auxiliary 1/B (B3) 1Y3 Backwards solenoid valve "z", 94 (l) Air conditioning switch-off
:17 − 0V fan valve :91 − Tilt forwards (A2) 1Y4 Release valve, 97 (m) Engine temperature sensor
:19 − 0V release valve :92 − Tilt backwards (B2) 1Y5 Fan valve, 99 (n) Brake pedal switch 2
:21 − ISO K-drive :93 − Lift 2Y1 Lowering valve, 134 (o) Coding plug for double-pedal identification
:28 − Coding :94 − ISO K-lift 2Y2 Lifting valve, 136 (p) Travel direction switch for single-pedal
:30 − Tilt angle :96 − Lift earth sensor 2Y3 Tilt forwards valve, 139 (r) Wires twisted together
:32 − Drive potentiometer reference :98 − Lower 2Y4 Tilt backwards valve, 141
:33 − Seat switch reference :103 − Tilt angle reference 2Y5 Auxiliary valve 1B, 145
:36 − Middle :105 − Mast vertical 2Y6 Auxiliary valve 1A, 147

7 Circuit diagrams
Wiring diagram
Basic equipment for LPG sheet 3

Circuit diagrams 7
Wiring diagram
Legend 0M1 Butterfly valve servo motor with potentiome- 0X7 3-pin plug connector (engine speed), VT Violet
0B1 Coolant temperature transmitter, 195-198 ter, 208-213 165–168 WH White
0B2 Engine speed transmitter, 165–168 0N1 LPG system control unit, 164–237 0X11 2-pin plug connector (pulse valve), 201 YE Yellow
0B6 Intake air pressure/temperature sensor, :8 − LPG shut-off valve 0X12 4-pin plug connector (lambda sensor), 184, The number in front of the wire colour refers
171–173 :19 − Earth 186 to the wire cross-section.
0B10 Phase sensor, 177–179 :20 − Earth 0X24 4-pin plug connector (lambda sensor), 190, Wires with unspecified cross-section =
0B11 Lambda sensor, 184-186 :21 − Terminal 15 192 0.75 mm2.
0B21 2. Lambda sensor, 190-192 :22 − Terminal 30 0Y3 Pulse valve, 201
0E1 Spark plug 1st cylinder, 219 :23 − Terminal 30 1Y6 LPG shut-off valve, 182 Notes
0E2 Spark plug 2nd cylinder, 222 :26 − Fault light (a) Special equipment wiring diagram
0E3 Spark plug 3rd cylinder, 225 :36 − Not controlled Wire colours (b) Wires twisted together
0E4 Spark plug 4th cylinder, 228 :49 − Electronics earth BK Black (c) Screened wires
F10 20A fuse, 161 :50 − 5V reference BN Brown (d) 0B11, 0X11, 0X12 and 0Y3 only if a three-
F11 7.5A fuse, 179 0T1 4-way ignition module, 217–230 BU Blue way catalytic converter is fitted
F12 10A fuse, 171 X6 5-pin plug connector, 184 GN Green (e) 0X24 and 0B21 only present on trucks with a
0H1 Fault light, 175 X10 18-pin plug connector (central electrical GY Grey three-way catalytic converter for the USA
0K3 Supply relay, 161–164 system), 175 OG Orange (f) Engine block earthing point
RD Red (g) Wire for two-way catalytic converter only
*) Gold-plated contacts

7 Circuit diagrams
Wiring diagram
Special equipment sheet 1 — working headlights, lighting, direction indicator system, brake light, interior lighting

Circuit diagrams 7
Wiring diagram
Legend 5F5 15A fuse (lighting terminal 15), 55 X10 18-pin plug connector (for basic equipment), The number in front of the wire colour refers
5E1 Lower front left working headlight 55 W 5F6 10A fuse (lighting terminal 30), 58 1, 32, 67 to the wire cross-section.
(position 1), 7, 13 5F7 5A fuse (brake light), 69 5X1 12-pin plug connector (overhead guard Wires with unspecified cross-section = 0.75
5E2 Lower front right working headlight 55 W 5F8 7.5A fuse (left headlight), 39 lighting), 13, 15, 39-69 mm2
(position 2), 9, 15 5F9 7.5A fuse (right headlight), 41 5X2 6-pin plug connector (rear lighting), 44–69
5E3 Upper front left working headlight 55 W 5F10 5A fuse (left sidelight), 43 5X4 12-pin plug connector (working headlight Notes
(position 3), 19 5F11 5A fuse (right sidelight), 46 positions 1, 2), 7, 9 (I) Working headlights (positions 1, 2)
5E4 Upper front right working headlight 55 W 5F12 5A fuse (interior lighting), 74 5X5 2-pin plug connector (working headlight (II) Working headlights (positions 1, 2 with
(position 4), 21 5H1 21W left front direction indicator, 56 positions 3, 4), 15, 21 higher lighting)
5E7 Upper rear right working headlight 55 W 5H2 21W right front direction indicator, 59 5X6 2-pin plug connector (working headlight (III) Working headlights (positions 3, 4)
(position 8), 29 5H3 21W left rear direction indicator, 55 positions 7, 8), 29 (IV) Working headlights (positions 7, 8)
5E8 6W interior light, 74 5H4 21W right rear direction indicator, 61 5X7 6-pin plug connector (left headlight), 39, 43, (a) For electronic controller N1:23
5E9 10W left number plate light, 50 5H10 2W direction indicator control lamp, 64 59 (V) Lighting
5E10 10W right number plate light, 52 5H20 21W right brake light, 69 5X8 6-pin plug connector (right headlight), 41, (VI Direction indicator and hazard warning
5E11 55W left dipped beam, 39 5H21 21W left brake light, 71 46, 59 system
5E12 55W right dipped beam, 41 K1 Terminal 58 auxiliary relay, 1-3 5X10 2-pin plug connector (number plate lighting), (VII Brake lights
5E13 5W left front sidelight, 43 5K1 Flasher unit, 59–62 50 (b) For electronic controller N1:41
5E14 5W right front sidelight, 46 5K2 Brake light relay, 67–69 5X16 2-pin plug connector (number plate light), 50 (VIII) Interior lighting
5E15 10W left rear sidelight, 44 5K4 Working headlight relay (positions 7, 8),
5E16 10W right rear sidelight, 47 32–36 Wire colours
5E19 Upper rear left working headlight 55 W 5S1 Working headlight switch (positions 1, 2), BK Black
(position 7), 31 9–11 BN Brown
F3 70A MTA fuse (terminal 58), 3 5S2 Working headlight switch (positions 3, 4), BU Blue
F14 2A fuse (terminal 58), 1 15–23 GN Green
5F1 15A fuse (working headlight positions 1, 2), 5S3 Working headlight switch (positions 7, 8), GY Grey
9 27–35 OG Orange
5F2 15A fuse (working headlight positions 3, 4), 5S4 Interior lighting switch, 74–76 RD Red
15, 21 5S11 Light switch, 39–45 VT Violet
5F4 15A fuse (working headlight positions 7, 8), 5S12 Warning light switch, 55–61 WH White
30 5S13 Direction indicator switch, 57–59 YE Yellow

7 Circuit diagrams
Wiring diagram
Special equipment sheet 2 − Windscreen wiper, seat heater, radio

Circuit diagrams 7
Wiring diagram
Legend 9K2 Rear windscreen wiper relay, 106–111 9X1 9-pin plug connector (windscreen wipers), RD Red
9E3 Radio, 148-156 9K3 Roof windscreen wiper relay, 125–132 83–94 VT Violet
:4 − Terminal 15 9M1 Front windscreen wiper motor 55 W, 91–95 9X2 3-pin plug connector (radio), 149-156 WH White
:7 − Terminal 30 9M2 Rear windscreen wiper motor 36 W, 9X5 6-pin plug connector (wash pumps), 98, 116, YE Yellow
:8 − Earth 110–113 137 The number in front of the wire colour refers
9E4 Left loudspeaker, 147 9M3 Roof windscreen wiper motor 36 W, 9X7 3-pin plug connector (seat heater), 144 to the wire cross-section.
9E5 Right loudspeaker, 154 130–134 9X8 3-pin plug connector (radio), 149-156 Wires with unspecified cross-section = 0.75
9F1 2A fuse (windscreen wipers, general), 83 9M4 Front wash pump, 98 9X14 2-pin plug connector (seat heater), 144 mm2
9F2 10A fuse (front windscreen wiper), 96 9M5 Rear wash pump, 116
9F3 10A fuse (rear and roof windscreen wipers), 9M6 Roof wash pump, 137 Wire colours Notes
114 9R2 80W seat heater, 144 BK Black (I) Windscreen wipers
9F4 10A fuse (wash pumps), 86 9S1 Windscreen wiper switch, 82–87 BN Brown (II) Front windscreen wiper
9F6 15A fuse (seat heater), 144 9S2 Front windscreen wiper switch, 82–89 BU Blue (III) Rear windscreen wiper
9F7 5A fuse (radio terminal 30), 149 9S3 Rear windscreen wiper switch, 101–109 GN Green (IV) Roof windscreen wiper
9F8 10A fuse (radio terminal 15), 152 9S4 Roof windscreen wiper switch, 121–128 GY Grey (V) Seat heater
9K1 Front windscreen wiper relay, 85–93 9W1 Antenna, 154-155 OG Orange (VI) Radio

7 Circuit diagrams
Wiring diagram
Special equipment sheet 3 − Heater, air conditioning, rotating beacon, reversing signal

Circuit diagrams 7
Wiring diagram
Legend X10 18-pin plug connector (for basic equipment), 9X13 4-pin plug connector (air-conditioning Notes
4B1 2W buzzer, 224 213 pressure switch), 178-180 (I) Heater
9E1 Heater, 161–167 X11 9-pin plug connector (for basic equipment), 9Y1 Electric clutch for air conditioning, 174 (II) Heater with air conditioning
9E2 Heater with air conditioning, 170–194 182–184 (a) LHC controller N1:22
F4 30A fuse (air conditioning), 182 4X1 2-pin plug connector (warning flashing light / Wire colours (b) Alternator G1:L
4F1 10A fuse (reversing signal), 217 rotating beacon), 229 BK Black (c) LHC controller N1:35
4F3 7.5A fuse (warning flashing light / rotating 4X2 6-pin plug connector (buzzer), 220-226 BN Brown (III) Flashing beacon / rotating beacon via
beacon), 200, 206 4X3 2-pin plug connector (warning flashing light / BU Blue terminal 58
9F9 20A fuse (heater), 164, 172 rotating beacon), 200 GN Green (IV) Warning flashing light / rotating beacon via
4H4 Warning flashing light, 200, 206, 217, 229 4X4 2-pin plug connector (warning flashing light / GY Grey switch
4H5 Rotating beacon, 200, 206, 217, 229 rotating beacon), 206, 217 OG Orange (V) Constant and switchable reversing signal,
4K1 Reversing signal relay, 213-217 4X5 2-pin plug connector (buzzer), 224 RD Red reversing OFF / reversing ON
9M7 Fan motor 1 for air conditioning, 188 5X11 12-pin plug connector (higher lighting), 232 VT Violet (d) For electronic controller N1:23
9M8 Fan motor 2 for air conditioning, 191 9X9 2-pin plug connector (heater, air condition- WH White (e) For higher reversing light special equipment
9M9 Fan motor 3 for air conditioning, 194 ing), 164, 170, 172 YE Yellow wiring diagram
4S3 Switch for warning flashing light / rotating 9X10 1-pin plug connector (air conditioning), 182 The number in front of the wire colour refers
beacon, 205-208, 215-222 9X11 6-pin plug connector (air conditioning), to the wire cross-section.
9S6 Air conditioning pressure switch, 177–179 178–194 Wires with unspecified cross-section = 0.75
9V1 Free-wheeling diode (electric clutch), 172 9X12 2-pin plug connector (heater), 164, 170, 172 mm2

7 Circuit diagrams
Wiring diagram
Special equipment sheet 4 − Hazard warning system for reversing, higher lighting

Circuit diagrams 7
Wiring diagram
Legend 5H21 21W left brake light, 254, 310 5X8 6-pin plug connector (right headlight), 278, The number in front of the wire colour refers
5E11 55W left dipped beam, 276 5K1 Flasher unit, 243-245, 297-300 285, 296 to the wire cross-section.
5E12 55W right dipped beam, 278 5K2 Brake light relay, 250-252, 306-308 5X9 6-pin plug connector (warning light), 244, Wires with unspecified cross-section = 0.75
5E13 5W left front side light, 280 5K3 Hazard warning system relay for reversing, 248, 252 mm2
5E14 5W right front side light, 285 270-272 5X11 12-pin plug connector (higher lighting),
5E15 10W left rear side light, 282 5S11 Light switch, 276-282 276-313 Notes
5E16 10W right rear side light, 287 5S12 Warning light switch, 291-300 5X12 5-pin plug connector (right rear light), 287, (I) Warning light when reversing with brake
5E17 10W left reversing light, 313 5S13 Direction indicator switch, 294-296 299, 308, 315 light (without lighting)
5E18 10W right reversing light, 315 5V1 Decoupling diode, 258 5X13 5-pin plug connector (left rear light), 282, (a) For electronic controller N1:23
5F5 15A fuse (lighting terminal 15), 291 5V2 Decoupling diode, 264 290, 310, 313 (b) For electronic controller N1:41
5F6 10A fuse (lighting terminal 30), 295 5V3 Decoupling diode, 269 (II) Hazard warning system when reversing
5F7 5A fuse (brake light), 252, 308 5V4 Decoupling diode, 269 Wire colours (with lights)
5F8 7.5A fuse (left headlight), 276 X10 18-pin plug connector (for basic equipment), BK Black (c) For electronic controller N1:23
5F9 7.5A fuse (right headlight), 278 241, 250, 272, 306 BN Brown (III) Higher lighting
5F10 5A fuse (left side light), 280 5X1 12-pin plug connector (overhead guard BU Blue (IV) Higher direction indicator and hazard
5F11 5A fuse (right side light), 285 lighting), 292-303 GN Green warning system
5F13 10A fuse (warning light), 244 5X2 6-pin plug connector (rear lighting), 244–252 GY Grey (V) Higher brake light
5H1 21W left front direction indicator, 293 5X2.1 6-pin plug connector (rear lighting), 258, 264 OG Orange (d) For electronic controller N1:41
5H2 21W right front direction indicator, 296 5X2.2 6-pin plug connector (rear lighting), 258, 264 RD Red (VI) Higher reversing light
5H3 21W left rear direction indicator, 244, 291 5X3 3-pin plug connector (reversing signal VT Violet (e) For reversing signal special equipment
5H4 21W right rear direction indicator, 246, 299 transfer), 270 WH White wiring diagram
5H10 2W direction indicator control lamp, 248, 303 5X7 6-pin plug connector (left headlight), 276, YE Yellow
5H20 21W right brake light, 252, 308 280, 293

7 Circuit diagrams
Wiring diagram
Special equipment sheet 5 − Lift mast positioning, hydraulic oil microfilter indicator, vehicle deactivation, Forklift Data Management

Circuit diagrams 7
Wiring diagram
Legend K2 Start relay, 363-366 2X6 2-pin plug connector (pressure switch), 329 The number in front of the wire colour refers
6A1 Data logger with keypad (Linde Forklift Data K3 Engine shutoff relay, 353-356 2X7 2-pin plug connector (pressure switch), 332 to the wire cross-section.
Management), 369-383 N1 LHC electronic control system, 321-325, 6X4 14-pin plug connector (data logger), 369- Wires with unspecified cross-section = 0.75
:1 − Terminal 30 329-333 383 mm2
:2 − Terminal 15 S1 Ignition and starting switch, 342-349 6X5 3-pin plug connector (data logger transfer),
:3 − Earth 2S1 Lift mast position preselection switch, 378, 380 Notes
:4 − Free input 322-324 6X7 5-pin plug connector (data transfer), 376- (I) Lift mast positioning
:5 − Load sensor 2S2 Feed-pressure filter pressure switch, 329 380 (II) Hydraulic oil microfilter indicator
:6 − Free output 2S3 High-pressure filter pressure switch, 332 6X9 4-pin plug connector (Linde Forklift Data (III) Vehicle deactivation via seat switch
:7 − Terminal 50 V1 Decoupling diode, 359 Management online module), 386-388 (a) For horn activation 4S1 (basic equipment
:8 − Starter relay 6W1 Antenna (Linde Forklift Data Management wiring diagram)
6A2 Linde Forklift Data Management online online module), 390 Wire colours (b) For electronic controller N1:42
module, 386-391 X1 10-pin plug connector, 342-348, 354, 365 BK Black (IV) Linde Forklift Data Management (LFM)
:3 − Terminal 15 X1.1 10-pin plug connector, 342-348, 354 BN Brown (c) For generator G1:B+
:4 − Earth X10 18-pin plug connector (for basic equipment), BU Blue (d) For ignition and starting switch S1:50
6B2 Load sensor, 393-397 380 GN Green (e) For starter motor M1:50a
:1 − Terminal 15 X11 9-pin plug connector (for basic equipment), GY Grey (f) For brake pedal switch X2:3
:2 − Signal 359, 382 OG Orange
:3 − Earth X15 2-pin plug connector (CAN connection), RD Red
F15 5A fuse, 380 370, 376 VT Violet
6F1 5A fuse, 378 2X1 2-pin plug connector (microfilter), 329, 333 WH White
2H1 1.2W lift mast position preselection warning 2X2 4-pin plug connector (lift mast position), 322, YE Yellow
light, 324 324

7 Circuit diagrams
Wiring diagram
Special equipment sheet 6 − Particulate filter, diesel filter water trap warning

Circuit diagrams 7
Wiring diagram
Legend 0B15 Water trap buzzer, 462 7X1 9-pin plug connector (central electrical The number in front of the wire colour refers
7A1 Particulate filter control unit, 408-455 7B2 Flame sensor, 437-438 system transfer), 423-430 to the wire cross-section.
:5 − Terminal 50 F15 5A fuse, 428, 454 7X2 4-pin plug connector (blower shut-off valve), Wires with unspecified cross-section = 0.75
:6 − Thermocouple (negative) 7F1 5A fuse (particulate filter), 414 412, 415 mm2
:10 − Regeneration indicator 7F2 20A fuse (particulate filter), 420 7X3 2-pin plug connector (flame sensor), 437,
:12 − Signal input terminal 15 7F3 30A fuse (glow plug), 447 438 Notes
:13 − Electronics voltage supply 0H2 Water trap warning light, 458 7X4 2-pin plug connector (glow plug), 447 (I) Particulate filter (only in diesel version)
:14 − Consumers voltage supply 7H1 1.2W regeneration warning light, 424 7X5 2-pin plug connector (metering pump), 419 (a) For generator G1:B+ (only in diesel version)
:17 − Regeneration start K2 Start relay, 403-405 7Y1 Shut-off valve, 415 (b) For ignition and starting switch S1:50 (only
:18 − Glow plug controller voltage supply 7K1 Glow plug relay, 445-447 in diesel version)
:19 − Glow plug indicator 7K2 Starting aid relay, 405-408 Wire colours (c) For starter motor M1:50a (only in diesel
:20 − Thermocouple (positive) 7M1 60W blower, 412 BK Black version)
:24 − Shut-off valve 7M2 24W metering pump, 419 BN Brown (d) For brake pedal switch X2:3 (only in diesel
:26 − Metering pump 7R1 200W glow plug, 447 BU Blue version)
:29 − Relay for glow plug 7S1 Starting switch, 422-424 GN Green (II) Diesel filter water trap warning (diesel
:30 − Emergency stop switch 7S2 Emergency stop switch, 428-430 GY Grey version only)
:31 − Emergency stop switch 7V1 Decoupling diode, 416 OG Orange
:37 − Starter relay X8 2-pin plug connector, 454 RD Red
:39 − Earth X10 18-pin plug connector (for main harness), VT Violet
:40 − Earth 428, 454 WH White
:41 − Consumers voltage supply X11 9-pin plug connector (for main harness), YE Yellow
:42 − Combustion air blower 405, 434
0B14 Water trap transmitter, 454-455 X15 2-pin plug connector (CAN), 436, 439

7 Circuit diagrams
Wiring diagram
Special equipment sheet 7 − LPG volume display, 12 V socket, working headlights pos. 5 and 6, coolant and engine oil level monitoring

Circuit diagrams 7
Wiring diagram
Legend 0N3 Evaluation electronics, 541-545 9X15 3-pin plug connector (12 V socket), 483 (III) LPG volume display for volumetric filling
B1 Tank transmitter (volumetric filling), 500, :1 − Terminal 15 9X16 2-pin plug connector (12 V socket), 483 (only with LPG version)
512-514 :2 − Earth 9X30 5-pin plug connector (oil and coolant con- (b) Basic equipment wiring diagram (only with
:1 − Terminal 15 :3 − Signal nection), 337-541 LPG version)
:2 − Earth S6 LPG residual volume switch, 507 1Y12 Natural gas tank shutoff valve, 518 (IV) LPG residual volume display (only with LPG
:3 − Signal 0S3 Coolant level switch, 537 version)
B2 Tank transmitter (replacement cylinder), 5S2 Working headlights switch (positions 3, 4, 5, Wire colours (c) Basic equipment wiring diagram (only with
490-492 6), 523-530 BK Black LPG version)
:1 − Terminal 15 X6 5-pin plug connector (for main harness), BN Brown (V) Natural gas volume display and tank shutoff
:2 − Calibration 490-518 BU Blue valve (with natural gas version only)
:3 − Signal X7 4-pin plug connector (tank transmitter), 490, GN Green (d) Basic equipment wiring diagram (with
:4 − Earth 492 GY Grey natural gas version only)
0B16 Oil level sensor, 540-541 X10 18-pin plug connector (for basic equipment), OG Orange (VI) Working headlights position 5 and 6
5E3 Upper front left working headlight 55 W 537, 541 RD Red (VII) Coolant and engine oil level monitoring
(position 3), 526 X11 9-pin plug connector (for basic equipment), VT Violet (e) LHC controller (N1:27)
5E4 Upper front right working headlight 55 W 544 WH White (f) Switch shown in "Coolant level OK" position
(position 4), 528 X14 1-pin plug connector (calibration), 490 YE Yellow
5E5 Lift mast left working headlight 55 W (posi- X15 2-pin plug connector (CAN), 543, 548 The number in front of the wire colour refers
tion 5), 522 0X19 6-pin plug connector (evaluation electron- to the wire cross-section.
5E6 Lift mast right working headlight 55 W ics), 541-545 Wires with unspecified cross-section = 0.75
(position 6), 524 0X20 3-pin plug connector, 537-541 mm2
F15 10A fuse, 541 5X5 2-pin plug connector (working headlight Notes
5F2 15A fuse (working headlight positions 3, 4), positions 3, 4), 528 (I) 12V socket
528 5X14 3-pin plug connector (working headlight (II) LPG volume display for replacement cylin-
5F3 15A fuse (working headlight positions 5, 6), positions 5, 6), 524 der (only with LPG version)
524 5X15 2-pin plug connector (working headlight (a) Wiring diagram basic equipment (only with
9F10 15A fuse (12V socket), 483 position 5), 524 LPG version)

7 Circuit diagrams
Wiring diagram
Special equipment sheet 8 − Battery main switch with indicator unit voltage supply, exchangeable particulate filter, rear window heater, camera system

Circuit diagrams 7
Wiring diagram
Legend S5 Battery main switch, 567 9X28 5-pin plug connector (camera system), The number in front of the wire colour refers
7A2 Exchangeable particulate filter controller, 7S3 Exchangeable particulate filter switch, 625-627 to the wire cross-section.
597-609 596-597 9X29 3-pinplug connector (camera system), Wires with unspecified cross-section = 0.75
9A5 Monitor, 625-635 7S4 Exchangeable particulate filter pressure 625-634 mm2
7B3 Exchangeable particulate filter buzzer, 610 switch, 601-602
9E6 Camera 1, 625-627 9S5 Rear window heater switch, 614-620 Wire colours Notes
9E7 Camera 2, 630-632 X10 18-pin plug connector (for basic equipment), BK Black (I) Battery main switch with indicator unit
F2 30A fuse, 567 597, 601, 625, 632 BN Brown voltage supply
F15 10A fuse, 601, 625 6X1 10-pin plug connector, 577-590 BU Blue (a) to wiring diagram for basic equipment
6F2 2A fuse, 574 7X6 9-pin plug connector (exchangeable partic- GN Green (II) Exchangeable particulate filter (fitted only to
7F4 2A fuse, 607 ulate filter), 597-601 GY Grey the diesel version)
9F5 20A fuse, 617 7X7 3-pin plug connector (reset switch), 596, 597 OG Orange (b) Switch opens when the exchangeable
G1 660W three-phase alternator with regulator, 7X8 2-pin plug connector (pressure switch), 601, RD Red particulate filter is fitted and the cover is
562-565 602 VT Violet closed (fitted only to the diesel version)
G2 88Ah battery, 567 9X26 5-pin plug connector (camera system), WH White (c) Switch is shown in the pressure differential
7H4 Indicator light (orange), 607 625-627 YE Yellow OK position (fitted only to the diesel version)
M1 1.7 kW starter motor, 569-571 9X27 5-pin plug connector (camera system), (III) Rear window heater
9R1 Rear window heater, 617 630-632 (IV) Camera system
(d) To electronic control N1:22

7 Circuit diagrams
Wiring diagram
Special equipment sheet 9− Third auxiliary hydraulics with third joystick, centre rear brake/tail light

Circuit diagrams 7
Wiring diagram
Legend :20 − 0V third auxiliary hydraulics X10 18-pin plug connector, 693 GY Grey
2B6 Third auxiliary hydraulics joystick, 646-648 changeover relay 2X9 6-pin plug connector, 658-674 OG Orange
:3 − Auxiliary 3 :25 − 12V third auxiliary hydraulics 2X10 6-pin plug connector, 658-674 RD Red
:4 − Auxiliary 3 reference changeover relay 2X11 10-pin plug connector, 658-674 VT Violet
2B11 End position sensor 1, 658-661 :64 − Auxiliary 3 reference 2X13 6-pin plug connector, 646-648 WH White
2B12 End position sensor 2, 672-674 :84 − end position 1 5X20 4-pin plug connector (brake/tail light), 688, YE Yellow
5E20 10W centre rear sidelight, 688 :96 − Lift earth sensor 691 The number in front of the wire colour refers
F16 7.5A fuse (terminal 15), 666 :99 − end position 2 2Y11 Third auxiliary hydraulics valve, 665 to the wire cross-section.
5F7 5A fuse, 691 116 − 5V lift sensor 2Y12 Third auxiliary hydraulics valve, 668 Wires with unspecified cross-section = 0.75
5H22 21W centre rear brake light, 691 5S2 Switch for working headlights positions 3 mm2
2K1 Third auxiliary hydraulics changeover relay, and 4, 682-685 Wire colours
662-666 2V11 Free-wheeling diode for third auxiliary BK Black Notes
5K2 Brake light relay, 691-693 hydraulics valve, 666 BN Brown (I) Third auxiliary hydraulics with third joystick
N1 LHC electronic control system, 643-655 2V12 Free-wheeling diode for third auxiliary BU Blue (II) Centre rear brake/tail light
:9 − auxiliary 3 hydraulics valve, 669 GN Green (a) For electronic controller (N1:41)

7 Circuit diagrams
Hydraulic circuit diagram

Traction, working and steering hydraulics

Circuit diagrams 7
A Auxiliary hydraulics with duplex or triplex C Depressurisation circuit (special equipment) 35 Combined feed maximum valve 435+20 bar 50 3/2 solenoid valve
1 Left hose pulley (double auxiliary hydraulics) 19 Control valve 36 Choke plunger (towing unit) 51 Pump for venting brake
2 Right hose pulley (single auxiliary hy- 20 Non-return valve 37 Shuttle valve 52 Non-return valve
draulics) 21 Accumulator 38 Servo piston Y→forwards Z→backwards 53 Pressure relief valve
39 2/2 solenoid valve 54 2/2 solenoid valve
B Working hydraulics D Linde Truck Control 40 Proportional valve (direction of travel)
3 Tilt cylinders 22 Working hydraulics central lever N Pressure filter (feed pressure) / microfilter
4 Standard lift mast 23 Auxiliary hydraulics central lever 1+2 H Tandem pump
5 Auxiliary hydraulics connection 2 41 3/3 solenoid valve (priority valve) O Fan drive
6 Auxiliary hydraulics connection 1 E Internal combustion engine n = 1000 to 2800 rpm 42 Gear pump 11 cm3 55 Solenoid valve
7 Solenoid valve 43 Gear pump 20 cm3 56 Hydraulic motor 8 cm3
F Engine speed regulator
8 Tilt brake valve P Radiator
9 Load holding valve G Hydraulic variable pump assembly consisting of: I Working hydraulics pressure filter / microfilter
10 Non-return valve 24 Hydraulic variable pump HPV 55-02 K Steering control valve with: R Drive axle AH 25-03 consisting of:
11 Pressure relief valve 1 (for H 20 standard/du- 25 Release valve (traction hydraulics) 44 Suction valve 57 Multi-disc brake (brake air min. 16 bar)
plex/triplex 200+5 bar, for H 25 standard/du- 26 Set piston A→forwards B→reverse 45 Hose safety valve 180+20 bar 58 Hydraulic fixed displacement motor
plex/triplex 230+5 bar) 27 Non-return valve 1 bar 46 Servostat HMF 360R
12 2/2 solenoid valve (pressure governor) 28 Sensor (hydraulic oil temperature) 47 Maximum valve 120+5 bar
29 4/2 solenoid valve S Oil tank consisting of:
13 Release valve (working hydraulics) 59 Breather with suction and counter-balance
14 Solenoid valve - lift/lower 30 Pilot valve L Steering cylinder
31 Feed pressure valve 19+0.5 bar valve 0.35 ±0.15 bar
15 Solenoid valve - tilt M Brake air valve 60 Suction filter with by-pass valve 0.25 bar
16 Pressure relief valve 2 32 Brake valve (main control valve)
33 Brake valve (servo valve) 48 Towing unit
17 Solenoid valve - auxiliary hydraulics 1 49 Pedal group
18 Solenoid valve - auxiliary hydraulics 2 34 Purge valve 13 bar

7 Circuit diagrams
Accumulator

Circuit diagrams 7
1 Left drive axle AH25-03 4 Accumulator H 20 standard/duplex/triplex 133 bar

2 High-pressure relief valve Nitrogen filling pressure of accumulator H 25 standard/duplex/triplex 153 bar
3 Lift/lower junction, (lift mast 185 series)

392 807 1051 EN – 06/2008

Linde UM - 392 - 01 - T - EN - 0806

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Operating Instructions

Linde − Your Partner

Operating Instructions – 392 807 1051 EN – 06/2008 I

Operating Instructions – 392 807 1051 EN – 06/2008 III

Adjusting the driver’s seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

IV Operating Instructions – 392 807 1051 EN – 06/2008

Dismantling of lift mast . . . . . . . . . . . . . . . . ............... . . . . . . . . . . . . . . . . . 102

Operating Instructions – 392 807 1051 EN – 06/2008 V

Change ribbed V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

VI Operating Instructions – 392 807 1051 EN – 06/2008

Operating Instructions – 392 807 1051 EN – 06/2008 VII

Malfunctions, causes, remedies (hydraulic equipment) . . . . . . . . . . . . . . . . . . . . . . . . 223

VIII Operating Instructions – 392 807 1051 EN – 06/2008

Your forklift truck

2 Operating Instructions – 392 807 1051 EN – 06/2008

Closing the LPG console with-

Operating Instructions – 392 807 1051 EN – 06/2008 3

¾ Attach the catches (1) of tightening straps

For your safety, additional symbols are also

4 Operating Instructions – 392 807 1051 EN – 06/2008

Details on the exact lift-height-specific maxi- Operation

Operating Instructions – 392 807 1051 EN – 06/2008 5

Reception of forklift truck

6 Operating Instructions – 392 807 1051 EN – 06/2008

Service plan before initial start-up

Operating Instructions – 392 807 1051 EN – 06/2008 7

8 Operating Instructions – 392 807 1051 EN – 06/2008

10 Operating Instructions – 392 807 1051 EN – 06/2008

In the case of tip-over

• Stay buckled up The stability of your truck is ensured if used

Operating Instructions – 392 807 1051 EN – 06/2008 11

Operation of industrial trucks in plant area

12 Operating Instructions – 392 807 1051 EN – 06/2008

third parties are included in the insurance

Operating Instructions – 392 807 1051 EN – 06/2008 13

Safety information on the LPG system

Safety guidelines for LPG (extract)

Obligations of the owner and employees

14 Operating Instructions – 392 807 1051 EN – 06/2008

Operating Instructions – 392 807 1051 EN – 06/2008 15

Safety measures when working on ignition systems

16 Operating Instructions – 392 807 1051 EN – 06/2008

Determination and assessment of hazards from use of industrial

Operating Instructions – 392 807 1051 EN – 06/2008 17

Instructions before fitting attachments

18 Operating Instructions – 392 807 1051 EN – 06/2008

20 Operating Instructions – 392 807 1051 EN – 06/2008

13 Steering axle identification plate

Operating Instructions – 392 807 1051 EN – 06/2008 21

1 Lift mast 15 Maintenance covers

22 Operating Instructions – 392 807 1051 EN – 06/2008

Operating Instructions – 392 807 1051 EN – 06/2008 23

1 Indicator unit 14 Operating hours display

(2) Hydraulic oil temperature indicator (red) • Oil cooler clogged

24 Operating Instructions – 392 807 1051 EN – 06/2008