LPG truck, CNG truck

Original instructions

H14T, H16T, H16CNG,

H18T, H18CNG, H20T,
H20CNG
391 807 10 51 EN – 09/2010

Linde − Your Partner
With over 100,000 fork lift trucks and ware-
house machines sold annually, Linde is one of
the world’s leading manufacturers of material
handling equipment. There are many reasons
for this success: Linde products are renowned
not only for their innovative, cutting-edge tech-
nology, but also for their low energy and oper-
ating costs, which are up to 40 per cent lower
than those of their competitors.
The high quality of Linde products is also
matched by the quality of our service. With ten
production plants worldwide and an extensive
network of sales partners, we are at your
service round the clock and around the world.
Operating Instructions – 391 807 10 51 EN – 09/2010
Preface
g
Your local Linde partner can offer you a
complete package from a single source;
ranging from expert advice on all aspects
of sales and service through, of course, to
appropriate finance options. Our leasing, hire
or lease-purchase agreements provide you
with the flexibility to tailor decision-making to
your individual business requirements.
Linde Material Handling GmbH
Carl-von-Linde-Platz
63743 Aschaffenburg
Telephone +49 (0) 6021 99-0
Fax +49 (0) 6021 99-1570
Mail: info@linde-mh.com
Web: http://www.linde-mh.com
I
 Table of contents
g

1 Introduction
Your forklift truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Proper usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Impermissible use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description of use and climatic conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Reception of truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
EC declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Service plan before initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2 Safety
Safety guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
In the case of tip-over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Handling consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Specialist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Operation of industrial trucks in plant area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Safety information on the LPG system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Safety guidelines for LPG (extract) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Safety measures when working on ignition systems . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Determination and assessment of hazards from use of industrial trucks . . . . . . . . . . . . 18
Instructions before fitting attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3 Overview
Identification plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Additional capacity rating plate for attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Truck overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Display unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Switch panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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4 Operation
Instructions for running-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Checks before starting work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Standard equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 36
Adjusting the driver’s seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 36
Entering and exiting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 39
Adjusting the steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 40
Setting the clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 41
Opening the gas shut-off valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 41
Seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 43
Drive engine (dual-pedal operation) . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 45
Closing the gas shut-off valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 49
Driving (two-pedal operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 50
Drive engine (single-pedal operation) . . . . . . . . . . . . . . . . . . . . . . . . . ............ 53
Closing the gas shut-off valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 58
Driving (single-pedal operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 59
Steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 62
Brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 63
horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 64
Lifting system and attachments (central lever operation) . . . . . . . . . . . ............ 65
Lifting system and attachments (single lever operation) . . . . . . . . . . . . ............ 70
Special equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Lifting system and attachments (single lever operation with toggle-switch-controlled
3rd auxiliary hydraulics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Adjust driver’s seat with swivel device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Adjusting the driver’s seat equipped with air suspension . . . . . . . . . . . . . . . . . . . . . . . 78
Lift mast positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Windscreen wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Window heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Driver’s cabin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Heating system, air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Linde Forklift Data Management (LFM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Working under load . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 98
Before taking up load . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 98
Adjusting the fork spread .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 99
Taking up loads . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 100
Travelling with load . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 101
Setting down loads . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 102
Towing device . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 102

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Loading / Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... .. 103

Removing the lift mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... .. 103
Operating the truck without a lift mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... .. 104
Loading the crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... .. 105
Transportation by truck or low loading truck . . . . . . . . . . . . . . . . . . . . . . . . ....... .. 107
Before leaving the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... .. 107

5 Maintenance
General points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Working on the Linde lift mast and in the front part of the truck . . . . . . . . . . . . . . . . . . . 111
Inspection and maintenance data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Recommendations for consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Inspection and maintenance overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. 118
Service plan as required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. 118
1000 h service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. 119
3000 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. 122
6000 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. 125
9000 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. 128
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Checking the engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Changing the engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Change engine oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Gas system: Checking the level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Changing the LPG cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Filling the LPG tank (special equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Filling the CNG tank (special equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Replace the fuel gas filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Check the fuel gas settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Cleaning the evaporator / pressure regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Natural gas system: checking the high-pressure relief valve (special equipment) . . . . . 147
Natural gas system: carrying out a system check (special equipment) . . . . . . . . . . . . . 147
Natural gas system: Carry out system service (special equipment) . . . . . . . . . . . . . . . 148
LPG system visual inspection, odour inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Checking the LPG system for damage and leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Checking the coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Change coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Check coolant concentration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Cleaning the water cooler and hydraulic oil cooler, and checking them for leaks . . . . . . 154
Change the water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

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Check the condition of the engine mount and engine suspension; check that they are
attached securely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Check condition of the ribbed V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Change ribbed V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Checking the condition and tension of toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Changing the toothed belt and tensioner pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Changing the air filter cartridge, checking the vacuum-operated switch . . . . . . . . . . . . 160
Changing the safety cartridge in the air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 suction and exhaust leads for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Changing the spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Change the high-pressure gas hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... ............ 169
Drive axle and wheel motors: Checking mounting . ............... ............ 169
Checking and adjusting side stops on drive axle . . ............... ............ 170
Check the drive axle bearing for wear and tear . . . . ............... ............ 170
Check hydraulic pump attachment to the engine . . ............... ............ 171
Chassis, bodywork and fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 172
Cleaning the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 172
Bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 173
Floorplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 175
Servicing the air conditioning (special equipment) . . . . . . . . . . . . . . . . ............ 176
Checking the condition and correct function of the seat belt . . . . . . . . . ............ 177
Check the attachment points on the frame, tilt cylinder and steering axle ............ 178
Check other bearings and joints and oil them . . . . . . . . . . . . . . . . . . . . ............ 179
Chassis frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 180
Wheel change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 180
Tighten the wheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 181
Check tyres for damage and foreign bodies . . . . . . . . . . . . . . . . . . . . . ............ 181
Checking the tyre pressure, tyre sizes, rim sizes . . . . . . . . . . . . . . . . . ............ 182
Cleaning and greasing the steering axle . . . . . . . . . . . . . . . . . . . . . . . ............ 183
Check the fastening on the steering cylinder and axle stub bolt . . . . . . . ............ 185
Check the operation of the parking brake . . . . . . . . . . . . . . . . . . . . . . ............ 185
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Checking the pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

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Checking the bellows at the actuating lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

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
Changing the hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Hydraulic system: Check oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Hydraulic system: changing the filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Check correct operation of breather valve on the hydraulic oil tank . . . . . . . . . . . . . . . . 195
Check hydraulic system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Check the tilt cylinder bearings for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Checking the hose carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Check the pre-tension of the double tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Checking the function and safety system of the third auxiliary hydraulics (special equip-
ment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Load lift system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Cleaning the lift mast chain and applying chain spray . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Lift mast, lift mast chains, lift cylinder and end stops: Check attachment, condition and
function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Adjust lift mast chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Check the forks and fork quick-releases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Cleaning and lubricating the sideshift (special equipment), checking the fastening . . . . 204
Checking the slide guides on the sideshift (special equipment) for wear . . . . . . . . . . . . 204
Cleaning and lubricating the fork prong positioner (special equipment), checking the
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Check fork arm adjustment device (special equipment) for wear and tear . . . . . . . . . . . 207
Special equipment, accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Topping up the washer system water tank (special equipment) . . . . . . . . . . . . . . . . . . 208
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ .. 209
Open cover of electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ .. 209
Fuses for basic and special equipment . . . . . . . . . . . . . . . . . . . . . . . . . . ........ .. 210
Main fuses in engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ .. 210
Diagnostics connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ .. 211
Jump start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ .. 211
Fork carriage emergency lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ .. 213
Emergency exit with attached rear window . . . . . . . . . . . . . . . . . . . . . . . ........ .. 214
Towing instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ .. 215
Placing the forklift truck into storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ .. 217
Disposal of old vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ .. 217
Malfunctions during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ .. 218

Operating Instructions – 391 807 10 51 EN – 09/2010 VII

Table of contents
g

Malfunctions, Causes and Remedy (LPG engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Malfunctions, Causes, Remedies (ultrasonic sensor) . . . . . . . . . . . . . . . . . . . . . . . . . 224
Malfunctions, causes, remedies (hydraulic equipment) . . . . . . . . . . . . . . . . . . . . . . . . 225

6 Technical data
Type sheet H14T, as at 04/2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Type sheet H16T, as at 04/2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Type sheet H16CNG, as at 02/2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Type sheet H18T, as at 04/2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Type sheet H18CNG, as at 02/2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Type sheet H20T, as at 04/2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Type sheet H20CNG, as at 02/2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
Type sheet H20T-CT/600, as at 05/2007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Type sheet H20CNG-CT/600, as at 09/2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Load capacity diagrams and lift mast data as at 04/2008 . . . . . . . . . . . . . . . . . . . . . . . 255
Noise emission values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Vibration characteristic values for bodily vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

Annex

7 Circuit diagrams
Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
LPG basic equipment sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Basic equipment for LPG sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Basic equipment for LPG sheet 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
CNG basic equipment sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
CNG basic equipment sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
CNG basic equipment sheet 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Special equipment sheet 1 - Working spotlights, interior light . . . . . . . . . . . . . . . . . . . . 284
Special equipment sheet 2 — windscreen wiper, seat heater . . . . . . . . . . . . . . . . . . . . 286
Special equipment sheet 3 − Heating system, air conditioning, flashing beacon / rotat-
ing beacon, reversing signal, 12 V socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Special equipment sheet 4 − hazard warning system for reverse travel, truck deactiva-
tion, lift mast positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Special equipment sheet 5 − particle filter, radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292

VIII Operating Instructions – 391 807 10 51 EN – 09/2010

 Table of contents
g

Special equipment sheet 6 - higher lighting, hydraulic oil microfilter indicator, diesel
filter water trap warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
Special equipment sheet 7 − Forklift Data Management, LPG volume display, oil level
monitoring, coolant level monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
Special equipment sheet 8 − third auxiliary hydraulics, changing particle filter, working
spotlights positions 5, 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
Special equipment sheet 9 - camera system, centre rear brake/tail light, rear window
heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
Special equipment sheet 10 - Single lever locked, third auxiliary hydraulics via
switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
Special equipment sheet 11 - Lighting, direction indicator and hazard warning system,
brake light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
Hydraulic circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
Traction, working and steering hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

Operating Instructions – 391 807 10 51 EN – 09/2010 IX

 1

Introduction
1 Introduction
Your forklift truck
Your forklift truck
offers optimum economic efficiency, safety
and driving comfort. It is primarily down to
you to maintain these characteristics for a
long time and take advantage of the resulting
benefits.
During manufacture:
• all safety requirements of the relevant EC
directives were observed
• all conformity assessment procedures
stipulated in the applicable directives were
carried out
This is attested by the CE mark shown on the
nameplate.
These operating instructions contain every-
thing you need to know about commissioning,
driving and maintenance.
For trucks which are delivered from the factory
with an attachment, the operating instruc-
tions for the attachment are enclosed. Before
starting a truck with an attachment, you must
make sure that loads are handled securely.
Depending on the type of attachment, it may
be necessary to make adjustments, e.g. pres-
sure settings or adjusting stops and operating
speeds. See the attachment operating in-
structions for the corresponding notes. The
notes for operation of the attachment must
also be observed.
Carry out the specified work regularly, at the
due times and using the consumables envis-
aged for this purpose in accordance with the
inspection and maintenance overview. Please
make sure you record the work performed in
the registration document for the industrial
truck; this is essential for any warranty claims.
The designations used in the text (front, back,
left, right) always refer to the installation
position of the parts described, with forwards
as the drive direction for the truck (fork arms
forwards).
Servicing work not described here will require
specialist knowledge, measuring devices and
frequently also special tools. Please ask your
authorised dealer to carry out this work.
2 Operating Instructions – 391 807 10 51 EN – 09/2010
Servicing should only be carried out by qual-
ified personnel approved by Linde (special-
ists).
With orders for parts, please specify the
following along with the parts numbers:
Truck model:
Production number /
Year of manufacture
Handover date:
The production number should also be spec-
ified for parts from the following units: en-
gine, lift mast, hydraulic variable displacement
pump, drive axle and steering axle.
Engine number:
Lift mast number:
Lift mast lift:
Hydraulic variable
displacement pump
number:
Drive axle number:
Steering axle
number:
When taking over the truck, this data should
be copied from the identification plates of the
units into these operating instructions.
NOTE
In the event of repairs, only use genuine Linde
spare parts. This is the only way to guarantee
that your truck remains in the same technical
condition as at the time of reception.
Please address all queries and orders for
spare parts relating to your truck only to
your authorised dealer, stating your mailing
address.
Linde is constantly engaged in the further
development of its products. We ask for your
understanding that figures and technical data
are subject to technical modification in terms of

form, equipment and expertise in the interest
of progress.
For this reason, no claims can be asserted
on the basis of the following data, figures and
descriptions in these operating instructions.
Proper usage
The forklift truck is intended for transporting
and stacking the loads indicated in the load
capacity diagram. We expressly draw your
attention to:
• The VDMA brochure on "Rules for proper
use of industrial trucks" supplied with these
operating instructions
• Extracts from the safety guidelines regard-
ing the use of LPG (described in the chapter
"Safety")
• The gas system manufacturer’s operating
and maintenance instructions which come
with the truck (natural gas version)
• Safety measures when dealing with ignition
systems (described in the chapter "Safety")
• The accident prevention regulations of your
employer’s liability insurance association
Impermissible use
The operating company or driver, and not the
manufacturer, is liable if the truck is used in a
manner that is not permitted.
It is not permitted to use the truck:
• for taking passengers
• in areas where there is a risk of fire of
explosion
Operating Instructions – 391 807 10 51 EN – 09/2010
Introduction 1
Impermissible use
These operating instructions must not be
reproduced, translated or made accessible to
third parties—including as excerpts—except
with the express written approval of the
manufacturer.
• The special measures for driving on public
roads within the scope of the StVZO (Road
Traffic Licensing Regulations)
• Other specific national regulations.
The regulations governing the proper use of
industrial trucks and the gas system manu-
facturer’s operating and maintenance instruc-
tions (natural gas version) must be observed
without fail by the personnel responsible, par-
ticularly by operating and maintenance per-
sonnel.
The user, and not the manufacturer, is liable
for any hazards caused by improper use.
Before your truck is used for work not listed
in the guidelines, and which require it to be
converted or retrofitted, please contact your
authorised dealer.
No modifications, in particular attachment or
conversion, should be made to your forklift
truck without the manufacturer’s approval.
• for stacking/unstacking operations on
slopes
• for stepping onto the fork arms when the lift
mast is raised
• if the maximum load capacity is exceeded.
3
1 Introduction
Technical description
Description of use and climatic conditions
Normal use
• Indoor and outdoor use
• Ambient temperature in tropical and Nordic
regions ranging from -15 °C to 50 °C
• Start capability at -15 °C to 50 °C
• Maximum start time of 20 seconds
• Use at up to 2000 metres above sea level.
Symbols used
The terms DANGER, WARNING, CAUTION,
NOTE and ENVIRONMENT NOTE are used
in these operating instructions for notes on
particular hazards or for unusual information
that needs to be highlighted:
DANGER
Means that failure to comply can cause risk to life
and/or major damage to property.
WARNING
Means that failure to comply can cause risk of
serious injury and/or major damage to property.
CAUTION
Means that failure to comply can cause risk of
material damage or destruction.
Technical description
Forklift trucks in the 391 series are designed to
handle loading and palletising operations for
loads up to 1.4 t for H 14, up to 1.6 t for H 16,
up to 1.8 t for H 18 and up to 2.0 t for H 20 at a
load distance of 500 mm.
The H 20-600 forklift truck supports loading
and palletising of 2.0 t, given a load distance
of 600 mm.
4 Operating Instructions – 391 807 10 51 EN – 09/2010
Special use (partly with special mea-
sures)
• Use, e.g. in the event of abrasive dust (such
as AL203), lint, acid, leach, salt, corundum,
incombustible substances
• Ambient temperature in tropical regions up
to 55 °C
• Start capability to -25 °C
• Use at up to 3500 metres above sea level.
NOTE
Means that particular attention is drawn to
combinations of technical factors which may
not be evident even to a specialist.
ENVIRONMENT NOTE
The instructions listed here must be complied
with as otherwise environmental damage may
result.
CAUTION
This label is found on the truck in
the areas where particular care and
attention are required.
You should refer to the appropriate
section in these operating instructi-
ons.
For your safety, additional symbols are also
used. Please heed the various symbols.
Details on the exact lift-height-specific maxi-
mum loads are available in the load capacity
diagram.
The trucks are eco-friendly and their quiet op-
erational noise and low emission levels benefit
both the driver and the environment. They are
compact in design and have a small turning

radius, and are therefore particularly suitable
for narrow passageways or operational areas.
Engine
The drive engine is a 4-cylinder, four-stroke
engine. It powers the truck’s hydraulic pumps
and varies its speed depending on the load.
The engine is cooled by means of a closed
coolant circuit with expansion tank.
Forced circulation lubrication with an oil pump
in the oil sump is used for engine lubrication.
The combustion air is cleaned by means of
a dry air filter with a paper insert. Internal
combustion engines with ultra-modern engine
technology are used for:
• High torque
• Low fuel consumption
• Low exhaust emissions
• Low noise levels
Hydraulic system
The drive unit consists of a hydraulic variable
displacement pump, two hydraulic constant
wheel motors (assembled as a drive axle
unit), as well as a hydraulic pump (fixed
displacement pump) for the working and
steering hydraulics. Drive direction and
driving speed are regulated by means of two
accelerator pedals via the hydraulic variable
displacement pump.
The hydraulic constant wheel motors in
the drive axle are supplied by the hydraulic
variable displacement pump and they power
the drive wheels.
Operation
One accelerator pedal each for forward and
reverse travel (dual-pedal operation) is used
to simultaneously regulate the hydraulic
variable displacement pump and the engine
speed. The hydrostatic drive enables the
driving speed to be continuously varied in
both directions, ranging from standstill to the
maximum speed. The dual-pedal control
means that operation of the forklift truck is
simple, safe, non-fatiguing and efficient.
Operating Instructions – 391 807 10 51 EN – 09/2010
Introduction 1
Technical description
The driver always has both hands free for
steering and controlling operational move-
ments. This results in fast reversing and effi-
cient stacking.
An optional version is also available whereby
the driving speed is regulated by an acceler-
ator pedal (single-pedal operation) and the
drive direction controlled by means of a drive
direction switch.
To control the operational movements of lift-
ing, lowering and tilting, there is only one actu-
ating lever (joystick). Another joystick is fitted
for actuation of additional attachments. The
work movements can also be controlled using
up to four joysticks (single-lever operation ver-
sion).
Linde Load Control
The truck’s Linde Load Control (LLC) control
electronics system enables:
• Millimetre-precise and secure load handling
• Effortless finger-tip control of all lift mast
functions
• Drive and lifting functions are entirely
separate.
Linde Truck Control
The truck’s Linde Truck Control control
electronics system (LTC) offers:
• Sensitive, smooth driving and reversing
• Automatic regulation of the engine speed to
match the respective power required by the
hydraulics
• Fast service by means of self-diagnosis
• Optimum operational reliability.
Brakes
The hydrostatic drive is used as the service
brake. This means that the service brake is
maintenance-free. Two multi-disc brakes
incorporated in the wheel motors are used
as the parking brake. When the engine is
switched off, the multi-disc brakes engage,
meaning that the forklift truck has an automatic
5
1 Introduction
Reception of truck
brake function. Always apply the parking
brake when parking the truck.
Steering
The steering is a hydrostatic steering system,
under which the steering wheel acts on the
steering cylinder to actuate the rear wheels.
If the power applied to the steering wheel is
increased, the steering can also be operated
when the engine has been switched off.
Lift mast
The free-view lift mast enables:
Reception of truck
Before the truck leaves our factory, it is
subjected to a careful inspection to ensure
that it is in perfect condition and is received by
you complete with all equipment according to
your order.
To avoid subsequent complaints, please be
so kind as to carefully check the condition
of the truck and the completeness of the
equipment yourself and to confirm proper
handover/reception with your dealer.
NOTE
When trucks leave our factory without a lift
mast, the drive axle is secured with a support
on the right side in order to prevent it from
tilting. Before the lift mast is fitted, this support
must be removed by releasing two screws
and removing them together with the support.
6 Operating Instructions – 391 807 10 51 EN – 09/2010
• Ideal visibility through slim mast profiles
• Full load capacity up to maximum lift heights
• Enormous residual load capacity
• Maintenance-free bearings for lift mast and
tilt cylinders via rubber-cushioned linkage
points
• Electric tilt angle limitation.
Electrical system
The electrical system is powered by the
three-phase alternator with 12 V DC voltage. A
12 V battery with 88 Ah is installed for starting
the engine. It is located beneath the bottom
plate in the engine compartment.
(See also "Driving without lift mast"). It is
advisable to keep the support and screws as
you may need them again at a later date.
Each forklift truck comes with the following
technical documents:
• Operating instructions for the truck
• Gas system manufacturer’s operating
and maintenance instructions (natural gas
version)
• EC Declaration of Conformity (manufac-
turer confirms that industrial truck complies
with requirements of EC Machinery Direc-
tive).
• Rules for proper use of industrial trucks
(VDMA)
• Registration document for the industrial
truck, provided on handover by your autho-
rised dealer.
 Introduction 1
EC declaration of conformity

EC declaration of conformity

Declaration

Linde Material Handling GmbH

Carl-von-Linde-Platz
D-63743 Aschaffenburg, Germany

We declare that the machine

Industrial truck according to these operating instructions

Model according to these operating instructions

complies with the most recent version of machinery directive 2006/42/EC.

Personnel authorised to compile the technical documents:

see EC declaration of conformity

Linde Material Handling GmbH

The manufacturer declares that the truck
complies with the requirements of the EC
directives valid at the time of marketing. This is
confirmed by the EC declaration of conformity
and by the CE labelling on the nameplate. See
also the above declaration.
An independent structural change or addition
to the truck can compromise safety, thus
invalidating the EC declaration of conformity.
The EC declaration of conformity must be
carefully stored and made available to the
responsible authorities.

Operating Instructions – 391 807 10 51 EN – 09/2010 7

1 Introduction
Service plan before initial start-up

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

8 Operating Instructions – 391 807 10 51 EN – 09/2010

 2

Safety
2 Safety
Safety guidelines
Safety guidelines
The "Rules for proper use of industrial trucks"
supplied with these operating instructions
must be brought to the attention of the persons
responsible, in particular to those persons
concerned with operating and maintaining the
trucks, before working with or on the trucks.
The operating company must ensure that the
driver understands all the safety information.
Please observe the directives and guidelines
listed, e.g.
• Operation of industrial trucks,
• Driving licence,
• Rules for driveways and the area of opera-
tion,
• Rights, duties and rules of behaviour for the
driver,
• Special operating areas
• Information regarding setting off, driving
and braking,
• Information for maintenance and repair,
• Periodic checks,
• Disposal of greases, oils and battery,
• Residual risks.
As the operating company or responsible
person, ensure that all directives and safety
guidelines that are applicable to your industrial
truck are complied with.
When training a forklift truck driver who has
already been trained to BGV D 27 standard,
the following must be practised sufficiently by
training, driving, switching and steering, so
that they are fully mastered:
• The special features of the Linde truck
(dual-pedal control, central control lever
(joystick), stop pedal),
• Any special equipment for attachments,
• Peculiarities of operation and the working
area
Only then should training exercises in the
racking commence.
10
Safety information
DANGER
The truck must not be used by unauthorised per-
sons.
As the operating company, you must ensure that
access to the truck is only possible for authorised
personnel.
DANGER
Safety systems (e.g. the seat switch) are there for
your safety.
Safety systems - of whatever kind - must never be
disabled.
DANGER
Loads should be arranged so that they do not
project beyond the edge of the truck loading surface
and cannot slip, topple over or fall off.
If necessary, use a load backrest (special equip-
ment).
DANGER
When retrofitting a 3rd auxiliary hydraulic system,
using solutions other than those recommended by
the truck manufacturer will render CE conformity
null and void, and is therefore expressly prohibited.
Trucks may be retrofitted with a 3rd auxiliary hy-
draulic system only with the approval of the truck
manufacturer.
DANGER
It is prohibited for any safety-critical functions such
as a bale clamp or the swivel device for a fluid
container to be connected to any 3rd auxiliary
hydraulic system that may be fitted.
To prevent inadvertent opening of the clamp or
swivel device, the additional function should be
connected to the first auxiliary hydraulic system.
DANGER
Any additional bores or welding to the overhead
guard will compromise its strength.
It is therefore strictly prohibited to drill holes in the
overhead guard or to weld to it.
Operating Instructions – 391 807 10 51 EN – 09/2010

CAUTION
Welding operations on other parts of the truck can
cause damage to the electronics.
Therefore, always disconnect the battery and all
connections to the electronic controls beforehand.
WARNING
For ease of operation, various functions on your
truck are gas-spring assisted. Gas springs are
complex components which contain high internal
pressures (up to 300 bar).
They may under no circumstance be opened un-
less so directed, and may be removed only when
not under compression. Any damage, lateral for-
ces, buckling, temperatures in excess of 80° C and
heavy contamination must generally be avoided.
Damaged or defective gas springs must be chan-
ged immediately. Please contact your authorised
dealer. He will, if necessary, depressurise the gas
spring in accordance with regulations before dis-
mantling it. Gas springs must be depressurised
before recycling.
WARNING
Fan start-up on the radiator depends on the coolant
temperature and can therefore switch on automati-
cally even when the ignition is switched off.
When performing work in the engine compartment,
wait until the engine has cooled down.
WARNING
The following issues must be observed when an
accumulator is fitted. Improper handling of the
accumulator can lead to serious injuries.
Before starting work on the accumulator it must
be depressurised. Please contact your authorised
dealer.
Residual risks
Despite careful working and compliance with
all applicable standards and regulations, the
possibility of other dangers when using the
truck cannot be entirely excluded.
The truck and its possible attachments comply
with current safety regulations. Nevertheless,
even when the truck is used for its proper
Operating Instructions – 391 807 10 51 EN – 09/2010
Safety 2
Residual risks
WARNING
Depending on the duration of use and
operating time, components carrying
exhaust gases and exhaust air may
become hot.
Therefore wear protective equip-
ment.
WARNING
The truck working area must be adequately lit.
If it is insufficiently lit, working spotlights must be
installedto ensure the driver has a good field of
vision.
CAUTION
Various items of special equipment fitted to your
truck have the "speed reduction" special function.
It is purely an assistance function. This means
that the driver must not rely solely on the "speed
reduction" function during operation.
The driver is always responsible for safe operation.
CAUTION
The functioning of active medical equipment, e.g.
pace makers or hearing aids, may be impaired.
Check with a doctor or the medical equipment
manufacturer whether the equipment is sufficiently
protected against electromagnetic interference.
NOTE
If your truck is equipped with a fire extinguis-
her, make sure that you familiarise yourself
with it in case of an emergency. Information
about handling is given on the fire extinguis-
her.
purpose and all instructions are followed,
some residual risk cannot be excluded.
Even beyond the narrow danger areas of the
truck itself, a residual risk cannot be excluded.
Persons in this area around the truck must
exercise a heightened degree of awareness,
11
2 Safety
In the case of tip-over
so that they can react immediately in the event
of any malfunction, incident or breakdown.
DANGER
Persons in the vicinity of the truck must be instruc-
ted regarding these dangers that arise through use
of the truck.
These operating instructions also contain additional
safety regulations.
Residual dangers can include:
• Escape of consumables due to leakages or
the rupture of lines, hoses or containers,
• Risk of accident when driving over difficult
ground such as gradients, smooth or
irregular surfaces, or poor visibility,
Stability
Stability is guaranteed if your truck is used
properly and according to its intended pur-
pose. Common reasons for a loss of truck
stability include:
• cornering at excessive speeds,
• moving with the load raised,
• moving with a load that is protruding to the
side (e.g. sideshift),
In the case of tip-over
• Stay buckled up
• Don’t jump
• Hold on tight
• Brace feet
• Lean away
12
• Risk of falling, tripping, slipping etc. when
moving on the truck, especially in the
wet, with leaking consumables or on icy
surfaces,
• Risk of fire and explosion due to the battery
and electrical voltages,
• Human error,
• Disregarding the safety regulations,
• Risk caused by unrepaired damage,
• Risk caused by insufficient maintenance or
testing,
• Risk caused by using the wrong consum-
ables.
• turning and driving diagonally across
slopes,
• driving on slopes with the load on the
downhill side,
• loads that are too wide,
• swinging loads,
• ramp edges or steps.
The stability of your truck is ensured if used
properly and as intended. Should the truck
tip over during an unapproved application or
due to incorrect operation, always follow the
instructions depicted below.
Operating Instructions – 391 807 10 51 EN – 09/2010

Operation of industrial trucks in plant area
Handling consumables
ENVIRONMENT NOTE
Consumables must be handled properly
and in accordance with the manufacturer’s
instructions.
• Consumables should only be stored in
containers complying with applicable
regulations and at the locations stipulated.
• Do not bring flammable consumables into
contact with hot objects or a naked flame.
• When topping up consumables, use only
clean containers.
• Observe the manufacturer’s instructions
relating to safety and disposal.
• Avoid spilling.
• Spilt liquids should be taken up with binding
agents at once and disposed of according
to the regulations.
• Old and contaminated consumables should
be disposed of according to applicable
regulations.
• Comply with the statutory provisions.
• Before performing greasing, filter changes
or any work on the hydraulic system,
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
whose technical training, experience and re-
cent professional activities have enabled them
to develop a sufficient depth of knowledge re-
garding industrial trucks and who is sufficiently
familiar with the applicable national occupa-
tional health and safety regulations, accident
prevention regulations, directives and gen-
Operation of industrial trucks in plant area
Many plant areas are so-called limited public
traffic areas. In this sense, we would like to
Operating Instructions – 391 807 10 51 EN – 09/2010
Safety 2
DANGER
LPG becomes gaseous as soon
as it escapes; this means that a
hazardous explosive atmosphere
will occur immediately.
Ensure adequate ventilation.
CAUTION
LPG will cause frostbite on bare skin!
Protective equipment must be worn
without fail.
WARNING
The penetration of pressurised hydraulic fluid into
the skin , e. g. due to leakage is hazardous. If an
injury of this type occurs, always consult a doctor.
Protective equipment must be worn.
WARNING
The improper handling of coolant and coolant addi-
tives presents a risk to health and the environment.
Observe the manufacturer’s instructions without
fail.
erally recognised technical conventions (DIN
standards, VDE regulations, technical reg-
ulations of other EU member states or other
countries that are signatories to the treaty es-
tablishing the European Economic Area) in
order to be able to assess the condition of in-
dustrial trucks in terms of health and safety.
advise you to check your company liability
insurance coverage, to ensure that possible
13
2 Safety
Regulations

claims for damages caused by your truck third parties are included in the insurance
in limited public traffic areas in relation to 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
European Industrial Truck Association, which
defines an inspection log to document the
current 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 extended by Linde in accordance with
the specific truck type. Please ask your
authorised dealer to carry out this work.

Natural gas system checks (special

equipment)
The tank module is subject to guideline
97/23/EC governing pressure vessels. It is
a system that requires monitoring, and for
which the nature, scope and deadlines for
regular checks are stipulated in the Ordinance
on Industrial Safety and Health (BetrSichV) .
The operator must ensure that the prescribed
checks are carried out within the specified
deadlines. The checks themselves should be
carried out by an approved supervisory board.

14 Operating Instructions – 391 807 10 51 EN – 09/2010

 Safety 2
Safety guidelines for LPG (extract)

Other national regulations may apply to the

operation of natural gas forklift trucks outside
Germany.

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.

Safety guidelines for LPG (extract)

Always observe the accident prevention reg-
ulations "Use of LPG" (BGV D34) published
by the main trade association, or the national
guidelines.
LPG includes the flammable gases
PROPANE, BUTANE and mixtures of these
substances. LPG is stored in LPG cylinders
or LPG tanks to drive internal combustion
engines. The pressure of these gases in the
container depends on the outside temperature
and may reach up to 25 bar or more.
DANGER
LPG becomes gaseous as soon as
it escapes; this means that a hazar-
dous, potentially-explosive atmo-
sphere will be created immediately.
No open flames (stoves, storm
lanterns, spark-forming activities
etc.); do not smoke in storage rooms
and when working on the LPG
system!
Obligations of the owner and employees
The owner must ensure that industrial trucks
are only operated or maintained by persons
trained in the operation or maintenance
of such industrial trucks and who can be
expected to perform their duties reliably. The
truck LPG systems may only be operated if
they are in perfect condition.
The owner must draw up operating instruc-
tions for industrial trucks in an understandable
form and language, containing all information
required for safe operation. The operating in-
structions must be made known to operators
and maintenance staff.
They must be accessible to operators and
maintenance staff at the site of operation at all
times and be observed by such persons.
A. In operation
1. Before pipe or hose connections are
released, the cylinder and main shut-off valves
should be closed. The connecting nuts on
cylinders should only be released slowly and

Operating Instructions – 391 807 10 51 EN – 09/2010 15

2 Safety
Safety guidelines for LPG (extract)
only very little at first, as the gas still in the line
will squirt out.
CAUTION
LPG will cause frostbite on bare skin!
Use personal protective equipment.
Pipework and its accessories for gas in the
liquid phase and LPG containers must not be
exposed to an impermissible level of heat.
2. Removable LPG containers (LPG cylin-
ders) must be positioned on the truck in such
a way that they are horizontal and the collar
opening faces downwards. Upon installation
and removal, the gas outlet connection of the
cylinder valve must be sealed off by a lock nut
securely tightened with a wrench.
Before LPG cylinders are connected, their
pipe connections must be checked for perfect
condition.
After removal, the cap of the cylinder must be
immediately screwed onto cylinders provided
with a lock nut.
3. The valves must be opened slowly. Striking
tools should not be used for opening/closing.
Risk of explosion from spark discharge.
NOTE
If a fire involving LPG breaks out, use only
carbon dioxide dry fire extinguishers or
carbon dioxide gas extinguishers. In the
United Kingdom, only carbon dioxide dry fire
extinguishers may be used to extinguish fires.
4. Leaking gas cylinders may not be reused.
They must be emptied immediately by being
released outside, taking all precautions into
account, and marked as leaking. If damaged
gas cylinders are supplied, the provider or his
representative (service-station attendant etc.)
must be immediately notified of the damage
present, where possible in writing.
5. The condition of the entire LPG system
must be kept under constant surveillance to
ensure safety of operation, in particular in
terms of leak tightness. It is not permitted to
16
use trucks if the LPG system has leaks. When
checking for leaks, soapy water, a solution of
Nekal or other foaming products should be
used. It is not permitted to inspect the gas
system using a naked flame for illumination.
6. Make sure that the LPG system is adjusted
so that the level of harmful substances in the
exhaust gases is kept as low as possible.
7. Frozen system parts should only be thawed
out with hot water, hot sand bags or the like.
Open flames, red-hot objects etc. may cause
explosions.
8. When individual system parts are changed,
the manufacturers’ installation instructions
must be observed. Cylinder and main shut-off
valves should be closed when doing so.
9. The condition of the electrical system of
industrial trucks running on LPG must be kept
under constant surveillance. Sparks may
cause explosions if system parts containing
gas are leaking. After an industrial truck
running on LPG has been shut down for a
lengthy period, the storage room must be
ventilated thoroughly before the truck or its
electrical system is started up.
10. Explosions involving gas cylinders or LPG
systems must be immediately reported to the
employers’ liability insurance association and
the industrial inspectorate responsible, even
if no injuries occur. Damaged parts must be
kept until conclusion of the investigation.
11. It must be ensured that trucks with LPG
systems are only operated in rooms that are
entirely or partially enclosed if no hazardous
concentrations of exhaust constituents harm-
ful to health can be produced in the room air.
B. In storage rooms and maintenance
workshops
1. The cylinder and main shut-off valves
should be closed as soon as the truck is shut
down.
2. Industrial trucks fuelled by LPG should
only be parked in areas that are above ground
level and have adequate ventilation. They
must not be parked near openings to areas
Operating Instructions – 391 807 10 51 EN – 09/2010

Safety measures when working on ignition systems
below ground level. Sufficient space must
be left around trucks that have been parked;
such areas must not include cellar openings
or access points, pits or similar cavities, drains
without liquid traps, ventilation shafts and light
wells or combustible material.
3. Removable LPG containers may only be
changed in storage rooms if there is no pos-
sibility of a hazardous explosive atmosphere
being produced.
4. The special regulations governing the
storage of pressurised-gas vessels must
be observed without fail, as well as specific
national regulations where appropriate. For
example, pressurised-gas vessels must not
be stored:
• in rooms below ground level
• on stairwells
• in hallways/landings
• in confined yards or passageways/thor-
oughfares or in their immediate vicinity
• on steps of outdoor installations
• on specially marked escape routes
• in garages
• in workrooms.
Please also take into account the section
"General requirements for pressurised-gas
containers; Using pressurised-gas contain-
ers" in the technical regulations applicable to
Safety measures when working on ignition systems
To prevent personal injury and/or destruction
of the ignition system, please comply with the
following when working on ignition system
units:
¾ Ignition system lines — including high-
voltage cables and test equipment leads —
should only be connected and disconnected
with the ignition system switched off.
¾ If the system is supposed to crank at starting
speed but not actually start (e.g. for a
compression pressure test), disconnect
the high-voltage cable (terminal 4) from the
ignition distributor and connect it to earth.
Operating Instructions – 391 807 10 51 EN – 09/2010
Safety 2
pressurised-gas containers TRG 380 and 404,
as well as applicable national regulations.
5. Electric hand lamps used in these areas
must be fitted with an enclosed sealed cover
and a strong basket guard.
6. When work is performed in maintenance
workshops, cylinder and main shut-off valves
should be closed and the LPG cylinders
protected from the impact of heat. Before
breaks in operation and the end of operation,
the person responsible should check whether
all valves, in particular cylinder valves, are
closed. Work involving fire, specifically
welding and cutting, should not be carried
out in the vicinity of LPG cylinders. LPG
cylinders, even when empty, must not be
stored in workshops.
7. Storage rooms and maintenance work-
shops must be well ventilated. It is important
to keep in mind that LPG is heavier than air.
It collects at floor level, in work pits and other
depressions in the ground where hazardous
explosive mixtures of gas and air may be pro-
duced.
DANGER
The exhaust gases are poisonous.
Ensure adequate ventilation of
storage rooms!
¾ Use of a quick charger to jump start the
engine is only permitted for up to 1 minute
at a maximum of 16.5 volts.
¾ The engine should only be washed with the
ignition switched off.
¾ Before carrying out any electric or spot
welding, the battery and connections
to the control units must be completely
disconnected. The earth electrode must be
as close as possible to the welding point.
17
2 Safety
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 Measure Notes
- = not
applicable
If in doubt, consult
Industrial truck
competent factory
equipment does not
Testing inspectorate or
comply with local
employers’ liability
provisions
insurance association
UVV-BGV D 27 - § 7,
Lack of skills and Driver training (sit-on and
BGG 925 driver’s licence
qualification of driver stand-on industrial trucks)
VDI 3313
Instruction for pedestrian-
Lack of skills and
controlled industrial
qualification of driver
trucks
Usage by unauthorised Access with key only for
persons authorised persons
Industrial truck not in a Recurrent testing and UVV-BGV D 27 - §§ 9, 37,
safe condition rectification of defects BGG 918
Impaired visibility due to
Resource planning UVV-BGV D 27 - § 12
load
Contamination of Assessment of diesel
TRGS 554
respiratory air exhaust gases
Contamination of Assessment of LPG 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 instructions and
(improper usage)
VDMA leaflet
UVV-BGV D 27, observe
When filling up with a)
operating instructions and
diesel
VDMA leaflet
UVV-BGV D 27, observe
When filling up with b)
operating instructions and
LPG
VDMA leaflet
UVV-BGV D 27, observe
VDE 0510: In particular
When charging traction operating instructions,
a) ventilation b) insulation
batteries VDMA leaflet and VDE
value
0510

In the Federal Republic of Germany, the Ger- that it is up to the employer to assess which
man labour protection law (ArbSchG) states hazards are associated with the work of em-

18 Operating Instructions – 391 807 10 51 EN – 09/2010


ployees and which health and safety mea-
sures are required (§ 5 ArbSchG). The result
must be documented (§ 6 ArbSchG). In the
case of industrial truck deployments involv-
ing similar hazard situations it is permitted to
summarise the results. In countries outside
the Federal Republic of Germany the coun-
try-specific regulations must be observed.
With the list we are helping you to comply
with these regulations. The construction and
equipment of industrial trucks comply with
the Machinery Directive 2006/42/EC and are
identified by the CE mark accordingly. They
are therefore not included in the hazard as-
sessment, and the attachments likewise on
account of their own CE labelling. The op-
erating company must, however, select the
type and equipment of industrial trucks so as
to comply with the local provisions for deploy-
ment.
Instructions before fitting attachments
To depressurise the oil in the pipes before
fitting an additional hydraulic attachment to
the hydraulic system, an accumulator (special
equipment) can be used. .
For this consult the section "Operate attach-
ments".
Operating Instructions – 391 807 10 51 EN – 09/2010
Safety 2
Instructions before fitting attachments
In order to ensure the safe usage of industrial
trucks, we not only supply every industrial
truck with a copy of the operating instructions
but also with the VDMA leaflet (German
Engineering Federation) specifying the "Rules
for proper use of industrial trucks".
The list specifies key hazards which are most
frequently the cause of accidents in the event
of non-compliance. If other major hazards are
involved at a specific plant, they must be listed
additionally.
At many plants the conditions of use for
industrial trucks are by and large similar so
that the hazards can be summarised in one
list. Also observe the information provided
by the relevant employers’ liability insurance
association on this subject in each case.
WARNING
Improper handling of the accumulator can lead to
serious injuries.
Before starting work on the accumulator it must
be depressurised. Please contact your authorised
dealer.
19
2 Safety
Instructions before fitting attachments

20 Operating Instructions – 391 807 10 51 EN – 09/2010

 3

Overview
3 Overview
Identification plates

Identification plates

1 Nameplate 11 Engine identification plate

9 Lift mast number (stick-on label) 12 Chassis number (stamped into the roofing
10 Drive axle identification plate sheet)

22 Operating Instructions – 391 807 10 51 EN – 09/2010

 Overview 3
Identification plates

NOTE
The CE mark confirms compliance with the EC
machinery directive and with all regulations
applicable to fork lift 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

Operating Instructions – 391 807 10 51 EN – 09/2010 23

3 Overview
Additional capacity rating plate for attachments

Additional capacity rating plate

for attachments
DANGER
The entries in the following capacity rating plates
are examples. The information will vary depending
on the truck series, lift mast series, truck equipment
and attachment. If an attachment is fitted, an
additional capacity rating plate must be attached
to your truck within the driver’s field of vision.
If the plate is missing or the information about
the truck equipment, attachments, load data etc.
is not accurate, please contact your authorised
dealer, who will calculate the data using a program
authorised by Linde.

Additional capacity rating plate for attachments with loads that are not clamped

1 Truck series (year of manufacture, from - to) 7 Reference number and note about person
2 Lift mast type (series) calculating the load capacity
3 Lift heights 8 Front tyres
4 Attachments 9 Maximum permissible centre offset of load
5 Load capacities 10 Maximum permissible load height
6 Load centres of gravity 11 Maximum permissible backward tilt of lift
mast

NOTE
Example for reading the load capacity:
• a = 3930 kg at load centre of gravity b =
900 mm to lift height c = 7200 mm.

24 Operating Instructions – 391 807 10 51 EN – 09/2010


Additional capacity rating plate for attachments
Additional capacity rating plate for attachments with loads that are fixed or clamped
1 Truck series (year of manufacture, from - to)
2 Lift mast type (series)
3 Lift heights
4 Attachments
5 Load capacities
6 Reduced load capacities
7 Load centres of gravity
8 Reference number and note about person
calculating the load capacity
9 Front tyres
10 Note — If there is sufficient visibility for
forwards travel when transporting loads,
we recommend that the calculated residual
load capacity based on the roller height /
load height (value = maximum permissible
load height (13)) is limited to the following in
order to achieve a more dynamic driving
NOTE
Example for reading the load capacity:
• a = 4340 kg at load centre of gravity b =
650 mm to lift height c = 6800 mm.
Operating Instructions – 391 807 10 51 EN – 09/2010
Overview 3
behaviour: at a load centre of gravity
650 mm = 4,560 kg.
11 Specifies in mm how much the load centre
of gravity is offset vertically upwards to the
centre of the attachment (e.g. roller / bale
taken off).
Also applicable for attachments with a rotate
function: The actual centre of gravity of the
load during rotation must not lie outside the
pivot point by more than 100 mm (truck rated
capacity ≤ 6300 kg) or 150 mm (truck rated
capacity > 6300 kg and ≤ 10,000 kg)!
12 Maximum permissible centre offset of load
13 Maximum permissible load height
14 Maximum permissible backward tilt of lift
mast
25
3 Overview
Truck overview

Truck overview

1 Lift mast 16 Chassis with overhead guard

2 Lift cylinder 17 Bonnet
3 Tilt cylinder 18 Step for entering and exiting the truck
4 Display unit 19 Fuses (in the engine compartment)
5 Toggle switch for additional functions 20 Left-hand wheel motor
(special equipment) 21 Fork carriage
6 Driver’s seat 22 Fork arm safety devices
7 Aspiration for combustion air 23 Fork arms
8 Fuses (behind the cover) 24 Fork arm latch
9 Diagnostic connector 25 Clamping screw for adjusting the steering
10 Cover for electrical system column
11 Cover for LPG cylinder 26 Handhold for entering and exiting the truck
12 LPG cylinder (special equipment)
13 Counterweight 27 Lift mast chain (only for standard lift mast)
14 Steering axle 28 Steering wheel / hydrostatic steering
15 Maintenance cover 29 Actuating lever (joystick)

26 Operating Instructions – 391 807 10 51 EN – 09/2010

 Overview 3
Operating elements

Operating elements

1 Combi-lever for wiper/washer system and 10 Icon sticker for operating hydraulics
flasher (special equipment) 11 Armrest on driver’s seat
2 Steering wheel / hydrostatic steering 12 Driver’s seat
3 Signal button 13 Accelerator pedal for forwards motion
4 Parking brake 14 Stop pedal
5 Starting switch with switch key 15 Accelerator pedal for reverse motion
6 Boot 16 Plate: "Guaranteed sound power level"
7 Operating lever (joystick) for operating 17 Locking screw for adjusting the steering
hydraulics column
8 Actuating lever (joystick) for auxiliary hy- 18 Indicator light for turn indicator and hazard
draulics (attachments) (special equipment) warning system (green) (special equipment)
9 Icon sticker for additional hydraulics (attach-
ments) (special equipment)

Operating Instructions – 391 807 10 51 EN – 09/2010 27

3 Overview
Display unit

Display unit

28 Operating Instructions – 391 807 10 51 EN – 09/2010

 Overview 3
Display unit

1 Display unit 20 Symbol without function

2 Hydraulic oil temperature indicator 21 Function key
3 Charging indicator 22 Reset button
4 Engine oil pressure indicator / engine oil 23 Time display
level indicator (special equipment) 24 "Do not start the engine" symbol
5 Electrical controller fault 25 Symbol for "Parking brake applied"
6 Engine coolant temperature indicator 26 Symbol for "Operating hours until the next
7 Lift height restriction (function / warning) service" (shown for only 5 sec in the display
(special equipment) (17))
8 Particle filter warning 27 Symbol for "Seat belt not fastened" (special
9 Vibration absorption (special equipment) equipment)
10 Water in the fuel filter (special equipment) 28 Text field
11 Hydraulic oil microfilter indicator (special 29 "Lift mast position identification" symbol
equipment) active (special equipment)
12 Level display for diesel tank, LPG tank / 30 Display
replacement cylinders or CNG tank 31 Air filter vacuum indicator
13 Symbol for "Particle filter" 32 Coolant level indicator
14 Symbol without function 33 Preheating indicator (function only available
15 Symbol for "Service interval exceeded" on diesel trucks)
16 Operating hours symbol 34 Gas system error light (function only avail-
17 Operating hours display able on LPG trucks)
18 Symbol without function 35 Engine malfunction warning light
19 Symbol for "Clock display (am/pm)"

The display unit (1) is mounted to the top right on the overhead guard. It is positioned within the
driver’s field of vision and provides centralised information about all functions of the truck. After
the key switch has been switched on, a self-test of the display unit is then performed. During the
self-test all indicator lights and the displays are activated.

Display element Function
- Lights up if the maximum
permissible temperature is
reached. A buzzer also sounds
if the temperature limit is
(2) Hydraulic oil temperature exceeded.
indicator With activated function "Engine
(red) protection"*):
- Truck moves at creep speed
(approx. 2 km/h)
Display in the text field (28):
- Error code X205
Possible malfunctions
Remedy
Insufficient oil in the hydraulic
circuit
Incorrect oil used
Oil filter clogged
Oil cooler clogged
Switch off the buzzer with the
reset button (22)

Operating Instructions – 391 807 10 51 EN – 09/2010 29

3 Overview
Display unit

Possible malfunctions
Display element Function
Remedy
V-ribbed belt split or V-ribbed
belt tension too slack
V-ribbed belt tensioner
defective

(3) Charging indicator - Lights up if there are Cable defective

(red) generator malfunctions. Alternator defective
Charging controller or cut-out
relay defective
Short circuit at output D+ of the
display unit
- Lights up and buzzer sounds Insufficient oil in the crankcase
when the oil pressure is too
low. Engine too hot
- If in addition the text field Incorrect oil used
(28) shows Oil with a double
arrow pointing downwards, Internal leakage in the
the engine oil level is too low. lubricating oil circuit
(4) Engine oil pressure (special equipment) Topping up with engine oil
indicator / engine oil level With activated function "Engine
indicator protection"*):
(red) - Truck moves at creep speed
(approx. 2 km/h)
Display in the text field (28): Switch off the buzzer with the
- Error code X202 if the oil reset button (22)
pressure is too low.
- Error code X201 and Oil
with double arrow pointing
down, if the oil level is too low.
- Lights up when an electrical
(5) Electrical controller fault fault is present.
(red) Error code is displayed in the
text field (28).
- Lights up if the maximum Fan motor defective
permissible temperature is
reached. A buzzer also sounds Thermal switch defective
if the temperature limit is Water cooler clogged
(6) Engine coolant tempera- exceeded.
ture indicator With activated function "Engine Leakage in the cooling circuit
(red) protection"*):
Coolant level too low
- Truck moves at creep speed
(approx. 2 km/h) Switch off the buzzer with the
Display in the text field (28): reset button (22)
- Error code X204

30 Operating Instructions – 391 807 10 51 EN – 09/2010


Display element
(7) Lift height restriction
(function / error)
(green / red)
(special equipment)
(8) Particle filter error
(red)
(9) Vibration absorption
(yellow)
(special equipment)
(10) Water in the fuel filter
(yellow)
(special equipment)
(11) Hydraulic oil microfilter
indicator
(yellow)
(special equipment)
(12) Level display for diesel
tank, LPG tank / replacement
cylinders or CNG tank
(green or red depending on
the fuel level)
(13) Symbol for "Particle
filter"
(14) Symbol without function
(15) Symbol for "Service
Interval Exceeded"
(16) Operating hours symbol
Operating Instructions – 391 807 10 51 EN – 09/2010
Overview 3
Display unit
Possible malfunctions
Function
Remedy
- Lights up green when the
specified lift height is reached
Sensor system defective
- Lights up red in the event of
an error in the sensor system
- Lights up with activated Regenerate the particle filter
particle filter control system, immediately
if the load period of the particle
filter exceeds 8.5 h.
- Additionally, a buzzer sounds
and in the text field (28) an error
Error in the particle filter control
code appears in the event of an
error in the particle filter control system
system. The truck moves
only at creep speed (approx.
2 km/h).
- Lights up if vibration
absorption is active for the lift
mast
- Lights up if water has Drain water from the fuel filter
collected in the fuel filter
- Additionally, a buzzer sounds Switch off the buzzer with the
if the warning light is activated reset button (22)
for more than 5 seconds
- Lights up if the pressure filters
Microfilter clogged, change it
require maintenance work.
Shows the current fuel
level in the diesel tank, the
current level in the LPG tank /
replacement cylinders or the
current level in the CNG tank.
- Lights up if the particle filter
control system is active.
If the number of operating
hours until the next service
is less than or equal to 0, the The display can only be reset
symbol flashes for 10 sec every using the diagnostic program.
time the truck is started, and
then lights up continuously.
Flashes when operating hours
are being counted (only when
the ignition is on and the engine
speed exceeds 300 rpm).
31
3 Overview
Display unit
Display element
(17) Operating hours display
(18) Symbol without function
(19) Clock display (am/pm)
(20) Symbol without function
(21) Function key
(22) Reset button
(23) Time display
(24) Symbol for "Do not start
the engine"
(25) Symbol for "Parking
brake"
(26) Symbol for "Operating
hours until the next service"
(27) Symbol for "Seat belt not
- Lights up if seat belt was not
fastened"
fastened
(special equipment)
32
Possible malfunctions
Function
Remedy
If a defective display unit
Indicates the operating hours is changed, the operating
of the truck. This display hours up to that point must be
is evidence of the truck’s recorded. Affix the data on an
operating time and of the embossed strip near the display
inspection and maintenance unit. There is also the option of
work to be performed. updating the new display unit at
a later time.
For 12-hour format: The diagnostic program can be
am = morning used to reset the display to a
pm = afternoon 12-hour clock.
- Adjusting the time
- Scrolling through error
messages
- Adjusting the time
- Scrolling through error
messages
- Turning off the warning sound
24-hour clock display The diagnostic program can be
Adjustable using the (21) and used to reset the display to a
(22) push buttons. 12-hour clock.
- Lights up when the engine Always leave the ignition
has stalled. (A block against switched on until the symbol
repeat starting is active and the goes out.
engine cannot be started). Then repeat the start attempt.
- Lights up if the parking brake
is activated.
After the ignition has been
switched on, display field (17)
shows the operating hours
until the next service (counting
backwards).
Symbol (26) lights up. After
5 seconds, symbol (26) goes
out and display (17) switches
automatically to the truck’s
operating hours; operating
hours symbol (16) flashes.
Fasten the seat belt.
Operating Instructions – 391 807 10 51 EN – 09/2010
 Overview 3
Display unit

Possible malfunctions
Display element Function
Remedy
Charge status display:
Serves as display field for error
- 0 symbols blacked out =>
code display and charge status
(28) Text field particle filter empty
display for particle filter (in
- 11 symbols blacked out =>
line 1).
particle filter full
(29) Symbol for "Lift mast - Lights up when the "Lift mast
position identification" position identification" function
(special equipment) is activated.
Serves as a text display and
(30) Display
symbol display
(31) Air filter vacuum
- Lights up when the air filter is
indicator Air filter clogged, change it.
excessively clogged.
(yellow)
- Lights up when the coolant
level is below the minimum.
With activated function "Engine
(32) Coolant level indicator protection"*):
Top up the coolant.
(yellow) - Truck moves at creep speed
(approx. 2 km/h)
Display in the text field (28):
- Error code X203
Function only available on
diesel trucks:
- Lights up whilst the glow plugs
(33) Glow plug indicator Identify the error using the
are preheating, then goes out.
(yellow) diagnostic program.
- Flashes when a malfunction
exists in the engine or in the
engine control unit.
Function only available on LPG
(34) Gas system error light trucks: Identify the error using the
(red) - Lights up if an error is detected diagnostic program.
in the gas system.
(35) Engine malfunction
- Lights up if an error is detected Identify the error using the
warning light
by the engine control unit. diagnostic program.
(yellow)

*) The "engine protection" function (special equipment) can be disabled using the diagnostic
program. Please contact your authorised dealer.

Operating Instructions – 391 807 10 51 EN – 09/2010 33

3 Overview
Switch panel

Switch panel

1 Switch panel at the top right in the driver’s 8 Rear window wiper - intermittent mode or
cab with: continuous operation on/off (washer system
2 Interior lighting is activated)
3 Standard or higher lighting 9 Roof panel wiper - intermittent mode or
4 Working spotlight position 1/2 continuous operation on/off (washer system
5 Working spotlight position 3/4 or working is activated)
spotlight position 5/6 10 Hazard warning light
6 Working spotlight position 7/8 11 Rotating beacon or flashing beacon
7 Front windscreen wiper - continuous oper- 12 Rear window heating or other special switch
ation on/off (intermittent mode and washer
system always activated)

NOTE
The configuration of the switch panel and
arrangement of individual switches may vary
depending on the version. Please observe the
switch symbols.

34 Operating Instructions – 391 807 10 51 EN – 09/2010

 4

Operation
4 Operation
Standard equipment

Instructions for running-in

The forklift truck can be run at high speeds ating hours at the latest. The wheel fastenings
straight away. However, in the first 50 operat- should be tightened crosswise with a torque of
ing hours avoid subjecting either the operating
hydraulics or the traction drive to high con- front: 210 Nm
tinuous loads. The wheel fastenings should rear: 210 Nm
be tightened before initial commissioning
and whenever wheels are changed. After this
tightening should be performed after 100 oper-

Checks before starting work

Carried
out
9 8
Engine
Check the LPG level
LPG system: visual and odour inspection
Natural gas system: Check high-pressure relief valve
Check the engine oil level
Check the coolant level
Chassis frame
Check the tyre pressure
Hydraulics
Hydraulic system: Check the oil level.

Standard equipment
Adjusting the driver’s seat

WARNING
An incorrect seat adjustment may cause injury to
the driver’s back. The controls for adjusting the
driver’s seat should not be used during operation.
Before starting the truck and whenever changing
drivers, adjust the seat to match the driver’s weight
and make sure that the settings have all engaged
properly. Do not place any objects in the driver’s
rotation range.

36 Operating Instructions – 391 807 10 51 EN – 09/2010

 Operation 4
Standard equipment

Longitudinal adjustment
¾ Pull lever (2) upwards.
¾ Move the driver’s seat backwards or for-
wards on the runners to give the driver the
most comfortable position in relation to the
steering wheel and the accelerator pedals.
¾ Allow lever to click back into place.

Adjusting the seat backrest

¾ Push lever (1) upwards and hold in place. 1
¾ Move the seat backrest forwards or back-
wards until a comfortable seat position for
the driver is found.
¾ Release lever (1).
d3921352 2

Adjusting the lumbar support (special

equipment)
¾ Turn the knob (3) until a comfortable seat
3
position is reached.
Turn in clockwise direction: lumbar support
arches outwards.
Turn in anti-clockwise direction: lumbar 6
support returns to starting position.

Setting the driver’s weight

¾ Turn the adjustment wheel (5) to set the
driver’s weight for the suspension.
The adjustment range between 50 kg and 130
kg can be read off on the adjustment range
display (4).
5 4
Turn in anti-clockwise direction to reduce d3921353

weight.
Turn in clockwise direction to increase weight.

Operating Instructions – 391 807 10 51 EN – 09/2010 37

4 Operation
Standard equipment

Adjusting the seat angle (special

equipment)
¾ Lift the button (6).
The seat surface is moved to the desired
position by applying pressure to the seat
surface or removing pressure from it.

Adjusting the seat depth (special

equipment)
¾ Lift the button (9).
The seat surface can be moved to the desired
position by sliding the seat surface forward or
to the rear.

Adjusting the backrest extension (special

equipment)
¾ Push backrest extension (7) in or pull it out
for individual adjustment.

Activating the seat heater (special

equipment)
¾ Turn the switch (8) on or off.

Adjusting the seat height (special

equipment)
Upwards:

38 Operating Instructions – 391 807 10 51 EN – 09/2010

 Operation 4
Standard equipment

¾ Raise the seat until you hear it engage.

Downwards:
¾ Lift the seat to the stop, then it will sink to its
lowest position.

NOTE
Sitting for lengthy periods places a major
burden on the spine. Try to compensate for
this by performing regular simple gymnastic
movements.

Adjusting the driver’s seat armrest

NOTE
The armrest on the driver’s seat is automati-
cally raised by spring pressure after clamping
screw (1) is released.
¾ Sit down on the driver’s seat and slacken 4
clamping screw (1).
3
¾ Push armrest (3) down against the spring
pressure until a comfortable position for the
arm is found.
¾ Tighten clamping screw (1). 2
¾ Slacken clamping screw (2) and push
armrest (3) forwards or backwards until
actuating levers (4) can easily be reached.
¾ Tighten clamping screw (2).
1

d3921416

Entering and exiting the truck

WARNING
Entering and exiting the truck can result in injuries
to the feet or back.
Always face the truck when you enter or exit the
truck.

Operating Instructions – 391 807 10 51 EN – 09/2010 39

4 Operation
Standard equipment

NOTE
Do not use the steering wheel or the actuating
levers as an aid to get in or out.
¾ Use handle (1) (special equipment) or
longitudinal member (2) and step (3).

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-
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.

40 Operating Instructions – 391 807 10 51 EN – 09/2010

 Operation 4
Standard equipment

Setting the clock

NOTE
The time is displayed in 24-hour format. It is
possible to change to 12-hour format using
the diagnostic device. Please contact your
authorised dealer.
¾ Press both push buttons (2) and (3) simulta-
neously for 3 seconds.
The hour readout in the time display (1)blinks.

NOTE
The hours or minutes can be adjusted gradu-
ally by pressing push button (2) or quickly by
holding down the push button.
¾ Depress button (2) to set the hours.
¾ Depress button (3) to confirm the hour
setting.
Now the minute readout blinks.
¾ Depress button (2) to set the minutes
¾ Depress button (3) to confirm the setting of
the minutes.

Opening the gas shut-off valve

Opening the LPG cylinder shut-off valve
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.

Operating Instructions – 391 807 10 51 EN – 09/2010 41

4 Operation
Standard equipment

¾ Open the shut-off valve (1) for the LPG

cylinder slowly and carefully in an anti-
clockwise direction.

Opening the LPG tank shut-off valve

(special equipment)
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.

¾ Open the LPG tank shut-off valve (1)

(depending on the model) slowly and
carefully in an anti-clockwise direction.

Opening the shut-off valve of the natural

gas version (special equipment)
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.

42 Operating Instructions – 391 807 10 51 EN – 09/2010

 Operation 4
Standard equipment

¾ Open the natural gas system shut-off valve

(1) slowly and carefully in an anti-clockwise
direction.

Seat belt
Fastening the 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
vehicle ! The seat belt should only be
worn by one person.

WARNING
Perfect functioning of the seat belt must be ensured.
For this reason the belt should not become twisted,
trapped or tangled up. The catch lock and belt
retractor should be protected from foreign bodies,
damage and soiling.

NOTE
Driver cabins with fixed closed doors or
bracket doors satisfy the safety requirements
for driver restraint systems. The seat belt
can be used in addition. It must, however,
be fastened 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

Operating Instructions – 391 807 10 51 EN – 09/2010 43

4 Operation
Standard equipment

function, the seat belt must be worn even at

the reduced speed.
The automatic blocking mechanism prevents
the belt from being extended whenever the
industrial 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 industrial truck
so that it is no longer positioned at an angle .
While using the vehicle (e.g. driving, operating
lift mast etc.), a sitting position as far as
possible to the rear should be adopted so
that the driver’s back is against the seat back.
The automatic blocking mechanism of the
belt retractor offers sufficient freedom of
movement on the seat with normal use of
the forklift truck.
¾ Draw seat belt (5) smoothly from the
retractor on the left.
¾ Position belt over lap, not over stomach.
¾ Allow the latch plate (4) to snap into place in
the buckle (1).
¾ Check seat belt tension.
Belt must fit close to the body.

Releasing the seat belt

¾ Press the red button (2) on the buckle (1).
¾ Feed the latch plate (4) manually back into
the retractor (3).

NOTE
The automatic blocking mechanism may be
triggered if the belt runs in too fast when the
buckle strikes the housing. The belt cannot be
pulled out with the normal force .

44 Operating Instructions – 391 807 10 51 EN – 09/2010

 Operation 4
Standard equipment

Drive engine (dual-pedal operation)

Starting the engine
DANGER
Risk of poisoning!
Do not allow the engine to run in
unventilated areas.

NOTE
Where possible, avoid frequently starting and
stopping the engine over short periods of time,
since this prevents the internal combustion
engine from reaching its operating tempera-
ture. Frequent 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 gas system from malfunctio-
ning.
¾ The actuating lever (joystick) must be in the
neutral position.
¾ Sit down on the driver’s seat.
¾ Fasten the seat belt.
¾ Place both feet on the accelerator pedals
(3).
¾ Turn the parking brake lever (1) in a clock-
wise direction until it engages.
The parking brake is actuated (it is only
possible to start the engine with the parking
brake actuated).
¾ Insert the switch key (2) into the ignition
and starting switch and turn from the zero
position to position "I".
The electrical system is switched on.

Operating Instructions – 391 807 10 51 EN – 09/2010 45

4 Operation
Standard equipment

¾ Look at the display unit (4).

NOTE
After the ignition has been switched on, the
display unit will perform a self-test. The
displays all light up for approx. 2 seconds
and the operating hours until the next service
are displayed for 5 seconds in the display
unit (4) display field (9). During this time the
symbol (12) remains lit. After 5 seconds the
display reverts automatically to the operating
hours. If the symbol (8) flashes or lights up,
the set service interval has been exceeded.
The maintenance work that is due must be
performed. Please contact your authorised
dealer.
The following indicators light up:

• Parking brake applied symbol (11)

• Engine oil pressure indicator (6)
• Charging indicator (5)
• Warning light (14),
• Error light (15).
• After a few seconds, the level of the gas
cylinder or gas tank can be read off on the
luminous bar (13) in the display unit.
¾ Turn switch key to position "II".
As soon as the engine starts:
¾ Release the switch key.
Symbol (7) flashes.
If the engine fails to start:
¾ Stop trying to start the engine, wait for a
while and then repeat the starting proce-
dure.
If the engine stalls, the "Do not start the
engine" symbol will appear (10).

NOTE
A block against repeat starting is active and
the engine cannot be started.
¾ Always leave the ignition switched on until
the symbol goes out.
¾ Then try to restart.

46 Operating Instructions – 391 807 10 51 EN – 09/2010

 Operation 4
Standard equipment

Leave a break of at least 1 minute between

each engine starting procedure 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 gas system should be checked
over by a qualified person with
special knowledge of this system.

The charging and engine oil pressure indicator

symbols, the error light and the warning 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 idle
speed. When under load, drive the truck at a
brisk speed. The engine will quickly reach its
operating temperature.

Switching off the engine

NOTE
Do not switch off the engine when under full
load.

Operating Instructions – 391 807 10 51 EN – 09/2010 47

4 Operation
Standard equipment

¾ Take your feet off the accelerator pedals

(3).
¾ Turn the switch key (2) to the zero position.

¾ Look at the display unit (4).

NOTE
The truck is equipped with a gas shortage
shut-down device. 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 gas
shortage shut-down device. In this case, the
driver should close the gas shut-off valve on
the gas cylinder or gas tank immediately and
wait until the engine stops. After the ignition
has been switched on, warning light (14) and
error light (15) light up. If only error light (15)
lights up, there is a fault in the gas system.
Contact your authorised dealer to correct the
fault.

NOTE
The brake is applied when the engine is
switched off.
¾ Turn the parking brake lever (1) in a clock-
wise direction until it engages.
The parking brake is now applied.
¾ Remove the switch key (2) when leaving the
truck.

48 Operating Instructions – 391 807 10 51 EN – 09/2010

 Operation 4
Standard equipment

DANGER
It should be borne in mind that LPG
is heavier than air. It collects at
floor level, in workshop pits and
other cavities 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.

Closing the gas shut-off valve

Closing the LPG cylinder, CNG system
or LPG tank shut-off valve
¾ Close the shut-off valve (1) of the LPG
cylinder or LPG tank (special equipment)
tightly as soon as the engine is switched off.

NOTE
The truck versions with CNG have an electro-
magnetic shut-off valve on the CNG module,
which closes automatically when the engine
comes to a standstill. The shut-off valve on the
gas tank does not therefore have to be closed.
¾ Remove the switch key when leaving the
truck.
¾ In frosty conditions, the truck should be left
in an enclosed room where possible, as
LPG only undergoes sufficient evaporation
at temperatures above -5 °C (propane) and
up to +5 °C (propane/butane) 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
garages in the immediate vicinity
of radiators or equipment radiating
heat.

Operating Instructions – 391 807 10 51 EN – 09/2010 49

4 Operation
Standard equipment

Driving (two-pedal operation)

WARNING
It is not generally permitted to negotiate long gra-
dients exceeding 15% due to the specified mini-
mum braking factors and stability values. Before
negotiating steep gradients please consult your
authorised dealer. The climbing capability values
given in the type sheet have been determined from
the traction force and only apply when overcoming
obstacles on the carriageway and to short differen-
ces 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 rearview mirror
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 Start the engine.
¾ Slightly raise fork arms and tilt lift mast back.

50 Operating Instructions – 391 807 10 51 EN – 09/2010

 Operation 4
Standard equipment

¾ Release the parking brake (unlock the

parking brake (1) and move it downwards
as far as the stop).

Forwards motion
¾ Carefully press right accelerator pedal (2).
The driving speed of the forklift 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 motion
¾ Carefully press left accelerator pedal (4).
The forklift truck will reverse back slowly
or quickly depending on the position of the
accelerator pedal.

Change the direction of travel

¾ Release accelerator pedal pressed.
The hydrostatic drive acts as the service
brake.
¾ Press the accelerator pedal for the opposite
direction of travel.
The forklift truck will now accelerate in the
specified direction.
¾ Both feet should be left on the accelerator
pedals so that the forklift 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
accelerates in the opposite direction.

Operating Instructions – 391 807 10 51 EN – 09/2010 51

4 Operation
Standard equipment

Start up on inclines
¾ Press the stop pedal (3) down completely.
¾ Unlock the parking brake (1) and move it
down as far as the stop.
¾ Take your foot half way off the stop pedal.
¾ Press the 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.

Stop
¾ Slowly release the accelerator pedal after
pressing it.
The hydrostatic drive acts as the service
brake.
¾ When stopping on inclines, leave both feet
on the pedals and press the pedal down
slightly in the "uphill" direction of travel to
counterbalance 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 (3).
¾ If you ever have to leave the truck with the
engine still running, i.e. to do minor jobs
in the direct vicinity of the vehicle (opening
doors, disconnecting trailers, etc.), it is
essential to activate the parking brake (turn
the parking brake lever (1) in a clockwise
direction until it engages), and open the
seat belt. If you are leaving the vehicle for a
longer period of time, switch off the engine
and activate the parking brake.
¾ When leaving the truck, remove the ignition
key.

52 Operating Instructions – 391 807 10 51 EN – 09/2010

 Operation 4
Standard equipment

Drive engine (single-pedal opera-

tion)
Starting the engine
DANGER
Risk of poisoning!
Do not allow the engine to run in
unventilated areas.

NOTE
Where possible, avoid frequently starting and
stopping the engine over short periods of time,
since this prevents the internal combustion
engine from reaching its operating tempera-
ture. Frequent 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 gas system from malfunctio-
ning.
¾ Sit down on the driver’s seat.
¾ Fasten the seat belt.
¾ Move the actuating lever (joystick and drive
direction (16)) into the neutral position.

Operating Instructions – 391 807 10 51 EN – 09/2010 53

4 Operation
Standard equipment

¾ Place your foot on accelerator pedal (3).

¾ Turn the parking brake lever (1) in a clock-
wise direction until it engages.
The parking brake is actuated (it is only
possible to start the engine with the parking
brake actuated).
¾ Insert the switch key (2) into the ignition
and starting switch and turn from the zero
position to position "I".
The electrical system is switched on.

¾ Look at the display unit (4).

NOTE
After the ignition has been switched on, the
display unit will perform a self-test. The
displays all light up for approx. 2 seconds
and the operating hours until the next service
are displayed for 5 seconds in the display
unit (4) display field (9). During this time the
symbol (12) remains lit. After 5 seconds the
display reverts automatically to the operating
hours. If the symbol (8) flashes or lights up,
the set service interval has been exceeded.
The maintenance work that is due must be
performed. Please contact your authorised
dealer.
The following indicators light up:

• Parking brake applied symbol (11)

• Engine oil pressure indicator (6)
• Charging indicator (5)
• Warning light (14),
• Error light (15).
• After a few seconds, the level of the gas
cylinder or gas tank can be read off on the
luminous bar (13) in the display unit.

54 Operating Instructions – 391 807 10 51 EN – 09/2010

 Operation 4
Standard equipment

¾ Turn switch key to position "II".

As soon as the engine starts:
¾ Release the switch key.
Symbol (7) flashes.
If the engine fails to start:
¾ Stop trying to start the engine, wait for a
while and then repeat the starting proce-
dure.
If the engine stalls, the "Do not start the
engine" symbol will appear (10).

NOTE
A block against repeat starting is active and
the engine cannot be started.
¾ Always leave the ignition switched on until
the symbol goes out.
¾ Then try to restart.
Leave a break of at least 1 minute between
each engine starting procedure 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 gas system should be checked
over by a qualified person with
special knowledge of this system.

The charging and engine oil pressure indicator

symbols, the error light and the warning 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 idle
speed. When under load, drive the truck at a

Operating Instructions – 391 807 10 51 EN – 09/2010 55

4 Operation
Standard equipment

brisk speed. The engine will quickly reach its

operating temperature.

Switching off the engine

NOTE
Do not switch off the engine when under full
load.
¾ Remove foot from accelerator pedal (3).

¾ Move the direction selection lever (16) into

the neutral position.
¾ Turn the switch key (2) to the zero position.

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 Operation 4
Standard equipment

¾ Look at the display unit (4).

NOTE
The truck is equipped with a gas shortage
shut-down device. 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 gas
shortage shut-down device. In this case, the
driver should close the gas shut-off valve on
the gas cylinder or gas tank immediately and
wait until the engine stops. After the ignition
has been switched on, warning light (14) and
error light (15) light up. If only error light (15)
lights up, there is a fault in the gas system.
Contact your authorised dealer to correct the
fault.

NOTE
The brake is applied when the engine is
switched off.
¾ Turn the parking brake lever (1) in a clock-
wise direction until it engages.
The parking brake is now applied
¾ Remove the switch 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 workshop pits and
other cavities 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.

Operating Instructions – 391 807 10 51 EN – 09/2010 57

4 Operation
Standard equipment

Closing the gas shut-off valve

Closing the LPG cylinder, CNG system
or LPG tank shut-off valve
¾ Close the shut-off valve (1) of the LPG
cylinder or LPG tank (special equipment)
tightly as soon as the engine is switched off.

NOTE
The truck versions with CNG have an electro-
magnetic shut-off valve on the CNG module,
which closes automatically when the engine
comes to a standstill. The shut-off valve on the
gas tank does not therefore have to be closed.
¾ Remove the switch key when leaving the
truck.
¾ In frosty conditions, the truck should be left
in an enclosed room where possible, as
LPG only undergoes sufficient evaporation
at temperatures above -5 °C (propane) and
up to +5 °C (propane/butane) 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
garages in the immediate vicinity
of radiators or equipment radiating
heat.

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 Operation 4
Standard equipment

Driving (single-pedal operation)

WARNING
It is not generally permitted to negotiate long gra-
dients exceeding 15% due to the specified mini-
mum braking factors and stability values. Before
negotiating steep gradients please consult your
authorised dealer. The climbing capability values
given in the type sheet have been determined from
the traction force and only apply when overcoming
obstacles on the carriageway and to short differen-
ces 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 rearview mirror
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 Start the engine.
¾ Slightly raise fork arms and tilt lift mast back.

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4 Operation
Standard equipment

¾ Release the parking brake (unlock the

parking brake (1) and move it downwards
as far as the stop).

Forwards motion
¾ Move direction of travel lever (4) forwards.
¾ Carefully press accelerator pedal (3).
The driving speed of the forklift 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 motion
¾ Move direction of travel lever (4) backwards.
¾ Carefully press accelerator pedal (3).
The forklift truck will reverse back slowly
or quickly depending on the position of the
accelerator pedal.

Change the direction of travel

¾ Release accelerator pedal.
The hydrostatic drive acts as the service
brake.
¾ Move 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

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 Operation 4
Standard equipment

Start up on inclines
¾ Press the stop pedal (2) down completely.
¾ Unlock the parking brake (1) and move it
down as far as the stop.
¾ Take your foot half way off the stop pedal.
¾ Press the accelerator (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.

Stop
¾ Slowly release the accelerator pedal.
The hydrostatic drive acts as the service
brake.
¾ When stopping on inclines, leave your foot
on the accelerator, switch the direction of
travel lever (4) to "uphill" and press the
pedal down slightly to counterbalance
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 If you ever have to leave the truck with the
engine still running, i.e. to do minor jobs
in the direct vicinity of the vehicle (opening
doors, disconnecting trailers, etc.), it is
essential to activate the parking brake (turn
the parking brake lever (1) in a clockwise
direction until it engages), and open the
seat belt. If you are leaving the vehicle for a
longer period of time, switch off the engine
and activate the parking brake.
¾ When leaving the truck, remove the ignition
key.

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4 Operation
Standard equipment

Steering system
Steering
The hydrostatic steering system allows the
level of effort required for the steering wheel
turning movement to be very low. This is
particularly advantageous when palletising
in narrow aisles.
¾ Start the engine and drive.
¾ Turn the steering wheel to the left and right
to the 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
The truck must not be driven if the steering system
is defective.
If the steering is stiff or has too much play, contact
your authorised dealer.

Turning radius

H 14 T 2005 mm
H 16 T, H16 CNG 2005 mm (2121 mm1)
H 18 T, H18 CNG 2041 mm (2121 mm2)
H 20 T, H20 CNG,
H 20-600 T, 2121 mm
H20-600 CNG

1 When ordering: "Large replacement cylinder" or "CNG system"

2 When ordering: "Large replacement cylinder" or "CNG system"

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 Operation 4
Standard equipment

Brake system
Service brake
¾ Allow accelerator pedals (1) to move to the
neutral position.
The hydrostatic drive will act as a service
brake. Slow or quick release of the accelerator
pedals to the neutral position allows the
braking effect to be sensitively controlled,
from gentle to hard braking.

NOTE
For emergency braking, press the stop pedal
(2) positioned between the accelerator pedals.
This will result in full application of the brake.

Stop pedal
The stop pedal (2) is not a sensitive service
brake but a sharply applied parking brake. Its
use should be avoided whilst driving, because
this can cause the drive wheels to lock and, in
certain circumstances, can cause the load to
slip from the fork arms.
In unfavourable situations, the engine can also
stall; as a result the "Do not start the engine"
symbol (3) appears in the display unit. A block
against repeat starting is active and the engine
cannot be started. Always leave the ignition
switched on until the "Do not start the engine"
symbol (3) goes out. In this time, the variable
displacement pump of the drive unit swivels
to the neutral position. Afterwards, the engine
can be started again.

NOTE
It is recommended that drivers familiarise
themselves with the function and effect of this
brake when there is no load on the truck. For
this purpose they should choose a route with
no other traffic, travelling at a low speed.

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

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4 Operation
Standard equipment

Operating the parking brake

¾ Turn the parking brake lever (2) in a clock-
wise direction to the stop.
The interlock (1) engages and the symbol in
the display unit lights up.

Releasing the parking brake

NOTE
The multi-disc brake will release only if the
engine is running.
¾ Turn the parking brake lever (2) gently in a
clockwise direction to release the interlock.

¾ Press the button (1).

The parking brake is unlocked.
¾ Move the parking brake (2) down as far as
the stop.
The symbol on the indicator unit will go out.

DANGER
The forklift truck must not be driven if the braking
system is defective.
Should there be any defects or wear apparent in
the brake system, please contact your authorised
dealer at once.

horn
Activate horn
The horn is used as a warning signal, e.g. at
blind spots and junctions.

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 Operation 4
Standard equipment

¾ Press horn button (1) on steering wheel;

horn will sound.

Lifting system and attachments

(central lever operation)

WARNING
With the moving lift mast or any
attachment there is a risk of the driver
getting trapped between parts.
Therefore never reach or step into
the lift mast or the space between the
lift mast and the truck. 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
actuating lever in an intermediate position
(approx. 45°) will activate both functions at the
same time (e.g. lifting and tilting).

Operating Instructions – 391 807 10 51 EN – 09/2010 65

4 Operation
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
function with the engine running and the
driver’s seat occupied.

d3931329

Tilting the lift mast forwards

¾ Push actuating lever (1) forwards.

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
raised fork arms.

¾ Push actuating lever (1) to the right.

Lowering the fork carriage

¾ Push actuating lever (1) to the left.

Operating attachments
Attachments can be fitted to the truck as
special equipment (e.g. sideshift, clamps, fork
prong positioner etc.). Refer to the working
pressure and operating instructions for the
attachment. An additional actuating lever
(cross lever) is attached for operation.

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 Operation 4
Standard equipment

WARNING
For attachments that perform a clamping function
(e.g. a bale clamp), a lockable lever (joystick) must
be used. The lever can be identified by its slightly
longer length.
If your truck is not fitted with this equipment, please
contact your authorised dealer.

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 the connecting lines from the
attachment or connect the 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 if the authorised dealer
has checked that safe operation is ensured by the
arrangement in terms of load capacity and stability.

NOTE
This description of how to operate attach-
ments contains examples. The configuration
of the actuating levers may vary depending on
your truck’s equipment.

Operating Instructions – 391 807 10 51 EN – 09/2010 67

4 Operation
Standard equipment

¾ Take note of the switching symbols with

arrows.

NOTE
For every attachment, a label stating the load
capacity of the truck plus attachment (for a
description, see "Additional capacity rating
plate for attachments") must be affixed within
the driver’s range of vision and a symbol label
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.
¾ Push actuating lever (2) to the left.
1 2
Sideshift moves to the left.
¾ Push actuating lever (2) to the right.
Sideshift moves to the right.

Operating the fork prong positioner

NOTE
In order to prevent damage, do not activate
the fork prong positioner with a load, or with
the fork arms on the ground. Do not use the
fork prong positioner as a clamp.
¾ Push actuating lever (2) forwards.
d3921370
Fork arms move outwards.
¾ Pull actuating lever (2) backwards.
Fork arms move inwards.

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 Operation 4
Standard equipment

Operating the clamp

¾ Release actuating lever (3) or (4) depending
on the version by pressing down on the
knob.
¾ Push actuating lever (3) or (4) forwards.
Clamp opens.

¾ Pull actuating lever (3) or (4) backwards.

Clamp closes.
After the actuating lever is released, it is locked
again automatically.

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4 Operation
Standard equipment

Lifting system and attachments

(single lever operation)

WARNING
With the moving lift mast or any
attachment there is a risk of the driver
getting trapped between parts.
Therefore never reach or step into
the lift mast or the space between the
lift mast and the truck. 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.

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
function with the engine running and the
driver’s seat occupied.

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
raised fork arms.

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 Operation 4
Standard equipment

¾ Pull actuating lever (1) backwards.

Lowering the fork carriage

¾ Push actuating lever (1) forwards.

Tilting the lift mast forwards

¾ Push actuating lever (2) forwards.

Tilting the lift mast backwards.

¾ Pull actuating lever (2) backwards.

Operating attachments
Attachments can be fitted to the truck as
special equipment (e.g. sideshift, clamps, fork
prong positioner etc.). Refer to the working
pressure and operating instructions for the
attachment. One or two additional actuating
levers are fitted for operating the attachments.

WARNING
For attachments that perform a clamping function
(e.g. a bale clamp), a lockable lever (joystick) must
be used. The lever can be identified by its slightly
longer length.
If your truck is not fitted with this equipment, please
contact your authorised dealer.

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 the connecting lines from the
attachment or connect the plug connectors.

Operating Instructions – 391 807 10 51 EN – 09/2010 71

4 Operation
Standard equipment

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 if the authorised dealer
has checked that safe operation is ensured by the
arrangement in terms of load capacity and stability.

NOTE
This description of how to operate attach-
ments contains examples. The configuration
of the actuating levers may vary depending on
your truck’s equipment.
¾ Take note of the switching symbols with
arrows.

NOTE
For every attachment, a label stating the load
capacity of the truck plus attachment (for a
description, see "Additional capacity rating
plate for attachments") must be affixed within
the driver’s range of vision and a symbol label
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.

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 Operation 4
Standard equipment

¾ Push actuating lever (3) forwards.

Sideshift moves to the left.
¾ Pull actuating lever (3) backwards.
Sideshift moves to the right.

Operating the fork prong positioner

NOTE
In order to prevent damage, do not activate
the fork prong positioner with a load, or with
the fork arms on the ground. Do not use the
fork prong positioner as a clamp.

¾ Push actuating lever (4) forwards.

Fork arms move outwards.
¾ Pull actuating lever (4) backwards.
Fork arms move inwards.

Operating the clamp

¾ Release actuating lever (3) or (4) depending
on the version by pressing down on the
knob.
¾ Push actuating lever (3) or (4) forwards.
Clamp opens.
¾ Pull actuating lever (3) or (4) backwards.
Clamp closes.
After the actuating lever is released, it is locked
again automatically.

Operating Instructions – 391 807 10 51 EN – 09/2010 73

4 Operation
Special equipment

Special equipment
Lifting system and attachments
(single lever operation with toggle-
switch-controlled 3rd auxiliary
hydraulics)

WARNING
With the moving lift mast or any
attachment there is a danger that
the driver could get trapped between
parts.
Therefore never reach or step into
the lift mast or the space between the
lift mast and the truck. 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
The functions for lifting, lowering, tilting
forwards, tilting backwards can be assigned
by both the central lever and the single lever.
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
function with the engine running and the
driver’s seat occupied.

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
raised fork arms.

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 Operation 4
Special equipment

¾ Pull actuating lever (1) backwards.

Lowering the fork carriage

¾ Push actuating lever (1) forwards.

Tilting the lift mast forwards

¾ Push actuating lever (2) forwards.

Tilting the lift mast backwards.

¾ Pull actuating lever (2) backwards.

Operating attachments
The truck is equipped with three additional
functions (e.g. fork prong positioner, rotator,
clamp, sideshift etc.). Refer to the working
pressure and operating instructions 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).

DANGER
For attachments that perform a clamping function
(e.g. a bale clamp), a locked lever (joystick) must
be used. The lever can be identified by its slightly
longer length.
If your truck is not fitted with this equipment, please
contact your authorised dealer.

DANGER
It is prohibited to activate a load-bearing clamp via
toggle switch (4).
The function and hydraulic connection must always
take place via the first auxiliary hydraulics and be
operated using actuating lever (1).

NOTE
If the toggle switch (4) affects a second locked
actuating lever, this must not be used for
operating clamps.

NOTE
Before fitting an attachment, depressurisation
(special equipment) can be performed to

Operating Instructions – 391 807 10 51 EN – 09/2010 75

4 Operation
Special equipment

depressurise the hydraulic system for the

auxiliary 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 the connecting lines from the
attachment or connect the 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 if the authorised dealer
has checked that safe operation is ensured by the
arrangement in terms of load capacity and stability.

NOTE
This description of how to operate attach-
ments contains examples. The configuration
of the actuating levers may vary depending on
your truck’s equipment.
¾ Take note of the switching symbols with
arrows.

NOTE
For every attachment, a label stating the load
capacity of the truck plus attachment (for a
description, see "Additional capacity rating
plate for attachments") must be affixed within
the driver’s range of vision and a symbol label
for the relevant attachment must be affixed
behind the actuating lever and to the left and
right alongside the toggle switch (4).

Operating the fork prong positioner

NOTE
In order to prevent damage, do not activate
the fork prong positioner with a load, or with
the fork arms on the ground. Do not use the
fork prong positioner as a clamp.

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 Operation 4
Special equipment

¾ Push actuating lever (1) forwards.

Fork arms move outwards.
¾ Pull actuating lever (1) backwards.
Fork arms move inwards.

Operating the rotator

¾ Press left-hand side (2) of toggle switch (4).
Green switch illumination lit up.
¾ Push actuating lever (5) forwards.
Unit moves anticlockwise.
¾ Pull actuating lever (5) backwards.
Unit moves clockwise.

Operating the sideshift

NOTE
In order to prevent damage, do not activate
the sideshift when the fork arms are on the
ground.
¾ Press right-hand side (3) of toggle switch
(4).
Orange switch illumination lit up.
¾ Push actuating lever (5) forwards.
Sideshift moves to the left.
¾ Pull actuating lever (5) backwards.
Sideshift moves to the right.

Operating the clamp

¾ Release the actuating lever (1) by pressing
down on the knob.
¾ Push actuating lever (1) forwards.
Clamp opens.
¾ Pull actuating lever (1) backwards.
Clamp closes.
After the actuating lever is released, it is locked
again automatically.

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4 Operation
Special equipment

Adjust driver’s seat with swivel

device

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

With the swivel device the driver’s seat offers

better visibility to the rear when reversing
over long distances. When moving forwards
for long distances it is recommended putting
the seat straight again. The swivel device is
maintenance-free.
¾ Lift locking lever (1).
1
The swivel device is released and allows the
seat to be swivelled 11° to the right and to be
locked in 0° andthe 11° position.
¾ Let the locking bolts engage audibly.

d3911326

Adjusting the driver’s seat equipped

with air suspension

WARNING
Incorrect seat adjustment may cause injury to the
driver’s back. The setting devices for adjusting the
driver’s seat should not be used during operation.
Before starting up the truck and whenever changing
drivers, adjust the seat for the individual weight of
the driver. Only adjust the driver’s seat when the
truck is stationary.

Setting the driver’s weight

¾ Sit on the driver’s seat.

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 Operation 4
Special equipment

¾ Check the weight adjustment in viewing

window (3).
The correct driver’s weight has been selected
when the arrow (4) is in the centre of the
inspection 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
WARNING
There is a risk of crushing if the lever is grasped
fully.
Only grasp the lever by the trough provided for this
purpose.

¾ Lift lever (1) upwards.

¾ Move the driver’s seat backwards or for-
wards on the runners to give the driver the
most comfortable 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.
The seat surface is moved to the desired
position by applying pressure to the seat
surface or removing pressure from it.

Adjust the seat height

¾ Lift lever 1 and hold it there.
The seat surface can be moved to the desired
position by sliding the seat surface forward or
to the rear.

Seat heater

NOTE
The maximum temperature is pre-set.

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4 Operation
Special equipment

¾ Switch (1) turns the seat heater ON and

OFF.
• 0 = seat heater OFF
• I = seat heater ON

Adjusting the 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 part of the backrest
can be adjusted individually.
¾ Turn the handwheel (2) downwards.
The convexity of the lower part of the backrest
can be adjusted individually.

Adjust the seat back

¾ Lift lever (2) and hold it there.
¾ Move the seat backrest forwards and
backwards to find a comfortable seat
position for the driver.
¾ Release lever (2).

Adjusting the backrest extension

¾ Push backrest extension (1) in or pull it out
for individual adjustment.

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 Operation 4
Special equipment

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 display unit.
¾ Tilt lift mast to required angle.

¾ Press the push button (2) in the front-left

position of the armrest for longer than
2 seconds.
The tilt angle is now permanently stored. As
confirmation, a double acoustic signal sounds
from the display unit and the light in the button
(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

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.

Operating Instructions – 391 807 10 51 EN – 09/2010 81

4 Operation
Special equipment

¾ Press the button (2) in the front-left position

of the armrest briefly. The lamp in the
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 display
unit.
¾ Release the joystick or press the button (2)
again briefly. The light in the push button
goes 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 push button (2) again. Lift
mast position identification is switched on
again.

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.

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 Operation 4
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
the version).

Switch on hazard warning lights

¾ Press toggle switch (5).

Switch on rotating flashing light

Depending on the equipment there are two
different versions.
Version 1 (single-stage switch):
¾ Press toggle switch (6).
The rotating flashing light is always switched
on.
Version 2 (two-stage switch):
¾ Move toggle switch (6) to centre position.
The rotating flashing light is switched on only
when reversing.
¾ Switch toggle switch (6) as far as it will go.
The rotating flashing light is always switched
on.

Operating Instructions – 391 807 10 51 EN – 09/2010 83

4 Operation
Special equipment

Switch on turn indicator lights

¾ Move operating lever (8) on steering wheel
forwards.
The flashing lights flash on the right. Control
light (7) flashes.
¾ Move operating lever (8) on steering wheel
backwards.
The flashing lights flash on the left. Control
light (7) 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 retrofitted
(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.

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 Operation 4
Special equipment

Windscreen wiper
Switch on the front windscreen wiper
¾ Move operating lever (1) on steering wheel
from centre position upwards.
The front windscreen wiper remains in opera-
tion as long as the lever is activated.
¾ Move operating lever (1) on steering wheel
from centre position downwards.
The windscreen wiper at the front is in intermit-
tent mode.

¾ Switch toggle switch (2) as far as it will go.

¾ Move operating lever (1) on steering wheel
from centre position downwards.
The windscreen wiper at the front is in contin-
uous mode.

Switch on the rear windscreen wiper

¾ Move toggle switch (3) to centre position.
¾ Move operating lever (1) on steering wheel
from centre position upwards.
The rear windscreen wiper remains in opera-
tion as long as the lever is activated.
¾ Move toggle switch (3) to centre position.
¾ Move operating lever (1) on steering wheel
from centre position downwards.
The windscreen wiper at the front and rear is
in intermittent mode.
¾ Switch toggle switch (3) as far as it will go.

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4 Operation
Special equipment

¾ Move operating lever (1) on steering wheel

from centre position downwards.
The windscreen wiper at the rear is in continu-
ous mode. The windscreen wiper at the front
is in intermittent mode.

Switch on the roof windscreen wiper

¾ Move toggle switch (4) to centre position.
¾ Move operating lever (1) on steering wheel
from centre position upwards.
The roof windscreen wiper remains in opera-
tion as long as the lever is activated.
¾ Move toggle switch (4) to centre position.
¾ Move operating lever (1) on steering wheel
from centre position downwards.
The roof and front windscreen wiper is in
intermittent mode.
¾ Switch toggle switch (4) as far as it will go.
¾ Move operating lever (1) on steering wheel
from centre position downwards.
The roof windscreen wiper is in continuous
mode. The front windscreen wiper is in
intermittent mode.

Switch on the wiper/washer system

¾ Switch on the appropriate windscreen
wiper.
¾ In addition, push the operating lever (1) in
as far as it will go.
The preselected wiper/washer system is
switched on as long as the lever is pressed.

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 Operation 4
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 (4) backwards.
¾ Open driver’s door outwards.

Closing the cab door

NOTE
To make it easier to close the door, open the
side window slightly.
¾ Pull cab door by handle (5) until latch
engages.

Opening/closing the front side window

¾ Press the interlock (3) upwards.
¾ Keep the interlock pressed, slide the side
window into the desired position until it
engages in one of the grooves (2).
Follow a similar procedure to close the side
window.

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4 Operation
Special equipment

Opening/closing the rear side window

¾ Press the interlock (1) upwards.
¾ Keep the interlock pressed, slide the side
window into the desired position until it
engages in one of the grooves (2).
Follow a similar procedure to close the side
window.

Heating system, air conditioning

Heating system operating devices
• Turning knob (1) for temperature control
• Turning knob (2) for setting the blower
positions
• Rotary switch (3) for setting the vent posi-
tions for windscreen defrosting / footwell
ventilation
• Cab air vents (4)

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 Operation 4
Special equipment

Switching on the heating system

¾ Turn switch (2).
The blower is switched on and there are three
air flow settings.

Defrosting the windows

¾ For maximum defrosting, set the
• Turning knob (1) to the far right position
• Turning knob (3) to the windscreen defrost-
ing position (far left position)
• Rotary switch (2) to level 3
• Cab air vents (4) to open, fins forwards
For normal heating operation, the following
rules apply:
• Select the temperature using turning knob
(1) (far left → cold / far right → hot)
• Use the blower switch (2) (level 1 to 3), air
distribution vent (turning knob (3)) and cab
air vents (4) to select the temperature and
temperature distribution

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4 Operation
Special equipment

Air conditioning operating devices

• Turning knob (5) for temperature control
• Function display (6)
• Push-button (7) for switching the air condi-
tioning on
• Rotary switch (8) for setting the blower
positions
• Turning knob (9) for setting the vent posi-
tions for windscreen defrosting / footwell
ventilation
• Cab air vents (10)

Switching on the air conditioning

CAUTION
The moving parts must be lubricated and the
compressor 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.

NOTE
It is normal for condensation water to build up
in the hoses and under the truck when the air
conditioning is in operation.
¾ Turn switch (8).
The blower is switched on and there are three
air flow settings.

NOTE
The air conditioning only works when the
engine is running and the blower switch is
switched on (setting 1, 2 or 3). The fans in
the roof switch on when necessary. They can
come to a standstill from time to time.
¾ Switch on push-button (7).
The function display (6) lights up green.
To raise the temperature in the cab:
¾ Rotate turning knob (5) clockwise and
reduce the blower speed using switch (8).
To lower the temperature in the cab:

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 Operation 4
Special equipment

¾ Close windows and doors, rotate turning

knob (5) anti-clockwise and increase the
blower speed using switch (8).

NOTE
To achieve maximum cooling in the cab:
• the air conditioning must be switched on,
• the turning knob (5) must be fully turned to
the left stop,
• the blower must be set to its highest blower
position,
• the windows and doors must be closed.

NOTE
On cool, humid days, the heater and air
conditioning can be used to dehumidify the
air in the cab (operate the heating system and
air conditioning simultaneously). The truck
heating system counteracts the cooling effect.
This ensures a pleasant temperature inside
the cab and reduces fogging on the windows.

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4 Operation
Special equipment

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 (2).
With the standard setting, the allocation of a
5-digit PIN number to the respective driver
ensures that the truck can only be operated
by authorised personnel. The truck can only
be started after entering this PIN number and
possibly a status code (depending on the
setting).

NOTE
The PIN number can be extended from 5 to
8 digits. Before entering the PIN number,
please contact your fleet manager to check
the number of digits in the PIN number and
find out about the truck settings.

Status code

NOTE
The code indicates the state of the truck.
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
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
individually defined by the user. Please

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 Operation 4
Special equipment

contact your fleet manager to find out the

definition of these status messages.

NOTE
If you notice one of these states (such as a
problem with driving) only after you have input
the status code 0 (truck OK), you have to log
off.
¾ Rotate the turning knob (5) anticlockwise to
the stop.
¾ Log in again with the status message 3
(problem with driving)

Forklift Data Acquisition - standard

setting (PIN number and status code)
Log on and start the truck:
¾ Apply the parking brake.

¾ Press any button to start the 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
inputs are made (factory setting), the red
LED (1) lights up and the green LED (2)
flashes. The input of a valid PIN is blocked

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4 Operation
Special equipment

for 10 minutes. The blocking time can be

interrupted by inputting a special PIN number.
Please contact your fleet manager.
¾ Rotate the turning knob (5) in a clockwise
direction to the stop and start the truck.

NOTE
If the truck does not start properly the first time,
the starting procedure can be repeated until
the turning knob (5) 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) LEDs both light
up continuously, the data must be read out.
Please inform your fleet manager at once.
Switch off the truck and log off:
¾ Rotate the turning knob (5) anticlockwise to
the stop.
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
truck 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
immediately and the PIN number is deleted.

Forklift Data Acquisition - Special setting

(PIN number)
Log on and start the truck:
¾ Apply the parking brake.

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 Operation 4
Special equipment

¾ Press any button to start the 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
inputs 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 minutes. The blocking time can be
interrupted by inputting a special PIN number.
Please contact your fleet manager.
¾ Rotate the turning knob (5) in a clockwise
direction to the stop and start the truck.

NOTE
If the truck does not start properly the first time,
the starting procedure can be repeated until
the turning knob (5) 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) LEDs both light
up continuously, the data must be read out.
Please inform your fleet manager at once.
Switch off the truck and log off:
¾ Rotate the turning knob (5) anticlockwise to
the stop.
The engine is turned off.

Operating Instructions – 391 807 10 51 EN – 09/2010 95

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
truck 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
immediately and the PIN number is deleted.

Forklift Data Acquisition with a transpon-

der (chip or magnetic strip card)

NOTE
The input device has a field (3) on which the
corresponding transponder (chip or magnetic
strip card) must be placed. Only then can the
truck be started.
Log on and start the truck:
¾ Apply the parking brake.
¾ Rotate the turning knob (5) in a clockwise
direction and switch on the truck’s power
supply.
The green LED (2) flashes.
¾ Place the valid transponder on the field (3).
Data is read in and the green LED (2) lights up
continuously.

NOTE
If the red LED (1) lights up, the transponder is
invalid or there was a reading error. The input
device is reactivated automatically when a
valid transponder is used and read in.

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 Operation 4
Special equipment

¾ Rotate the turning knob (5) in a clockwise

direction to the stop and start the truck.

NOTE
If the truck does not start properly the first time,
the starting procedure can be repeated until
the turning knob (5) is returned to the zero
position.

NOTE
If the green (2) and red (1) LEDs both light
up continuously, the data must be read out.
Please inform your fleet manager at once.
Switch off the truck and log off:
¾ Rotate the turning knob (5) anticlockwise to
the stop.
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
truck 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.

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4 Operation
Working under load

Working under load

Before taking up load
Before taking up a load, check the load
capacity diagram in the top left of the overhead
guard.

DANGER
The residual load capacity of a truck is determined
by the mast type (standard, duplex, triplex), the
lift height of the attached mast, the tyres on the
front axle, the use of attachments or additional
equipment and the backwards tilt restriction. If one
of these parameters is changed, this can have a
considerable effect on the residual load capacity.
For some conversions, the new residual load
capacity of the truck must be determined and the
capacity diagram must be changed as necessary.
Please contact your authorised dealer.

The max. permissible load is determined 1 Max. weight of permissible loads in kg

by the distance between the load centre of 2 Lift height in mm
3 Series designation with truck model and lift
gravity and the back of the fork arms, and the
mast series
lift height. 4 Distance between load centre of gravity and
fork back in mm
DANGER
The values specified in the capacity diagram and
capacity rating plate apply to compact homoge-
neous loads and must not be exceeded, as this will
impair the stability of the truck and the rigidity of the
fork arms and lift mast.
When using attachments, observe the capacity
rating plate for each attachment.

NOTE
Observe the load restriction and consult 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
ground
• loads involving a large centre of gravity
distance
• before transporting loads in a wind force of
6 and upwards.
Example
Load centre of gravity distance: 600 mm

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 Operation 4
Working under load

Load height to be lifted: 6000 mm

¾ Trace a vertical line from a load distance of
600 mm to its point of intersection with the
line for a lift height of 6000 mm.
¾ Read the max. permissible load to the left of
the point of intersection with the horizontal
line.
The maximum load in this example is 600 kg
Use the same procedure for other lift heights
and centre of gravity distances. The deter-
mined values refer to both fork arms and
evenly distributed loads.

Adjusting the fork spread

NOTE
The load centre should be in the centre
between the forks.
¾ Raise the fork quick-release levers(1).
¾ Move the forks further apart or closer
together 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

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4 Operation
Working under load

Taking up loads

DANGER
Danger of a falling load. Standing or
walking in the vicinity of an elevated
mast is extremely dangerous.
During stacking and de-stacking
operations do not allow people to
stand or walk in the working area of
the truck.
Trucks should only be driven with the
load lowered and tilted back. Look
out for people.

DANGER
Risk of falling and crushing.
Never allow people to be lifted on
either the forks, or on a pallet placed
on the forks.
If the truck is to be used for lifting
people then it must be fitted with
a purposely designed working
platform. Ensure that the platform,
platform securing method and
platform interlocks have been
approved for the truck.
Please contact your local distributor.

DANGER
Loads should be arranged so that they do not
project beyond the edge of the truck loading surface
and cannot slip, topple over or fall off.
If necessary, use a load backrest (special equip-
ment).

¾ Approach the load to be taken up carefully

and as accurately as possible.

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 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 steer the truck forks beneath the
centre of 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.
¾ Reverse the truck until the load is free.
¾ Tilt the lift mast backwards.

d3921430

Travelling with load

NOTE
When transporting cargo, the sender must
ensure that the goods are safely loaded for
transportation and secured if necessary.
Please therefore make sure that goods are
properly stacked and there is no damage
to packaging, pallets etc. The carrier must
ensure safe loading.
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

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4 Operation
Working under load

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 display unit if your truck is
equipped with automatic lift mast position-
ing.
¾ Carefully move the load over the load /
storage area.
¾ Carefully lower the load until the fork arms
are clear.
¾ Back the forklift truck away.

Towing device

NOTE
The towing device is used to tow light carria-
ges on the factory premises. (The applicable
guidelines of the accident prevention regula-
tions and German association of engineers
(UVV and VDI 3973) must be observed here.)

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 Operation 4
Loading / Transporting

¾ Move the handle (1) on the towing bolt (2)

90° backwards and lift it until the coupling
sleeve (3) is free.
¾ Insert the towing jaws in the coupling sleeve
(3).
¾ Force down the towing bolt (2) against the
spring pressure, turn the handle (1) 90° to
the right and let it engage in the catch.

Loading / Transporting
Removing the lift mast
This work should only be performed by
specialist staff working for your authorised
dealer.

DANGER
The lift mast may fall off during
transportation.
Secure it firmly in place and do not
stand under suspended loads.

WARNING
The frame is lowered after the lift mast has been
removed.
Therefore prop it up securely in advance.

¾ Prop up the frame on the right and left with

timber.

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4 Operation
Loading / Transporting

¾ Fix the lifting gear to the traverse on the

outer mast of the lift mast at the top.
¾ Unscrew two hexagon-head screws (1) on
the top left and right of the bearing bolt.
¾ Unscrew two hexagon-head screws (2) on
the bottom left and right of the holder.
¾ Unscrew a hexagon-head screw attaching
the tilt cylinder to the lift mast on the left and
right.
¾ When dismantling the lift mast, place the tilt
cylinders on a suitable piece of timber and
secure with a steel strap.
¾ Attach a device (see "Operating the truck
without a lift mast").

CAUTION
After dismantling the lift mast or tilt cylinders, the
potentiometer for the tilt angle is misaligned.
The potentiometer for the tilt angle thus 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 terms of the
tilt angle taken into account. Please contact your
authorised dealer.

Operating the truck without a lift mast

NOTE
Operating the truck without a mast is only
permissible for transfer purposes and the
speed must be adjusted as appropriate.
CAUTION
When operating the truck without a lift mast, the
drive axle must be attached to the frame.
Therefore, a special attachment device for the drive
axle must be mounted after the lift mast has been
removed.

¾ Switch off the engine.

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 Operation 4
Loading / Transporting

¾ Prop up the front right edge of the frame (2)

with timber (1) to keep it secure.
¾ Remove lift mast.

¾ Insert the device (4) into hold (3) in the right

wheel arch, position it against the front lift
mast attachment point and secure it in place
with two cylinderhead screws M 12 (5).
¾ Remove the timber which is propping up the
frame.
Before re-attaching the lift mast
¾ Prop up the vehicle on the left and right so it
is secure.
¾ Remove the device.

Loading the crane

DANGER
When using a crane to load the truck,
ensure that no-one is in the work area
of the crane! Observe loading weight
according to factory nameplate.
Do not move under overhead loads!
Only use round slings and a loading
crane with a sufficient load capacity.

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4 Operation
Loading / Transporting

WARNING
Loading the truck with the crane may cause da-
mage to the tilt cylinder and the cover on the coun-
terweight.
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.
There is no special marking for the suspension
points on the truck.
¾ Place the round sling (2) (min. load ca-
pacity: 2000 kg) around the bottom of the 1 3 4
counterweight.
3
¾ Use edge protectors as a safeguard from
sharp edges on traverse. 1
¾ Insert round sling (3) (load capacity min.
2000 kg) around traverse on outer mast of
lift mast.
¾ Insert all ends into crane hook (1).
¾ Make sure that safety lock (4) is closed.

NOTE
During lifting, the lifting gear should not touch 2
the driver’s protective roof, the cover on the t3911319

counterweight, the cover on the LPG cylinder

and any additional equipment attached.

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 Operation 4
Loading / Transporting

Transportation by truck or low

loading truck
¾ Lower lift mast.
¾ Operate parking brake.
¾ Place chocks underneath.
¾ Lash down forklift truck.

t3911321

Before leaving the truck

¾ Set down load / lower fork carriage.
¾ Tilt mast forwards slightly.
The fork arms must touch the ground.

CAUTION
The truck must be secured against
rolling away.
Apply the parking brake.

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4 Operation
Loading / Transporting

¾ Place the parking brake lever (1) in a

horizontal position.
The parking brake is now applied.
¾ Switch off the engine.
¾ Remove the switch key (2).
¾ Close the LPG shut-off valve.

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 5

Maintenance
5 Maintenance
General points
General points
Your forklift truck will only remain in a state
ready for use at all times if you perform a small
number of maintenance and inspection tasks
according to the information in the registration
document for the industrial truck and the
data or instructions in the operating manual
at regular intervals . Servicing should only
be carried out by qualified staff authorised
by Linde. You can agree performance of this
work on the basis of a maintenance agreement
concluded with your authorised dealer.
If you wish to perform this work yourself, we
recommend having at least the first 3 customer
service checks carried out by the dealer’s
service technician in the presence of your
workshop representative so that your own
workshop staff can be instructed accordingly.
DANGER
There is a risk of explosion if LPG
systems are not handled properly
Maintenance, inspection and
servicing of the LPG system should
only be carried out by competent
staff familiar with the testing and
setting data of this system. Special
test devices and tools are required.
Contact local authorised dealer. The
performance of testing, inspection
and maintenance on the LPG system
must be documented by a test
report (e.g. BGG 936). Use only
original spare parts when carrying
out repairs. This is the only way to
ensure the safety of the system.
Whenever performing maintenance, the
forklift truck should be parked on a flat surface
and secured so that it cannot roll away. The
engine should be switched off and the ignition
key removed.
For work performed with the fork carriage
and/or lift mast lifted they must be secured to
prevent them from accidentally sinking down.
Whenever work is carried out at the front of the
forklift truck, the lift mast must be secured to
prevent tilting back.
110
No modifications, in particular attachment or
conversion, should be made to your forklift
truck without the manufacturer’s approval.
All servicing work should be followed by a
functional check and a trial run performed on
the forklift truck.
WARNING
Any side doors attached could fall shut during
maintenance and trap staff.
For this reason, both doors should be opened and
secured in place during servicing.
CAUTION
The truck must always be properly labelled.
Missing or damaged identification plates and/or
adhesive labels must be replaced. Warehouse or
order No. see spare parts list.
ENVIRONMENT NOTE
Observe information regarding working with
consumables.
NOTE
When using forklift trucks under extreme
conditions (e.g. extreme heat or cold, high
levels of dust etc.), the time periods given in
the maintenance overview programme should
be reduced accordingly.
Maintenance intervals
Under certain conditions there is the option of
changing the intervals for some of the mainte-
nance work listed in the maintenance overview
program. Please make sure you use the con-
sumables, engine oil and coolant specified for
this purpose . The qualities required in this
regard are described in the section Recom-
mendations for consumables. The inspection
and maintenance intervals depend on the op-
erating and service conditions of the forklift
truck. For heavy-duty conditions we recom-
mend shorter intervals . Please contact your
authorised dealer.
Operating Instructions – 391 807 10 51 EN – 09/2010
 Maintenance 5
Working on the Linde lift mast and in the front part of the truck

Working on the Linde lift mast

and in the front part 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 lifted, no work
should be performed on the lift mast and at the front
of the forklift truck without the following safety mea-
sures! These safety precautions are only sufficient
for general maintenance to the forklift truck (inspec-
tion and greasing). With repairs (e.g. changing
chains, dismantling lift cylinders), additional safety
precautions must be taken. Please contact your
authorised dealer.

Secure lift mast from tilting back

The lift mast must be secured from tilting back
accidentally.
¾ Tilt lift mast right back.
¾ Switch off the engine.
¾ Remove the ignition key.
¾ Operate parking brake.

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 transmission ratio of 2:1, due to the chain
deflection.

Secure the lifted standard lift mast

DANGER
Check chain load!
Select safety chain with sufficient load bearing
capacity for the lift mast. Take maximum lift height
into account.

¾ Extend lift mast.

Operating Instructions – 391 807 10 51 EN – 09/2010 111

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

¾ Join chain over cross traverse of outer mast

(1) and under cross traverse of inner mast
(2).
Remember that there are hose lines on the
cross traverse for the outer mast.
¾ Lower inner mast to end of chain.

Duplex lift mast

NOTE
The advantage of this equipment version is
that full advantage is taken of the special free
lift height even in very low rooms (cellars,
wagons, ships).
FUNCTION: The fork carriage is lifted to the
special free lift height via the chain deflection
pulley 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.

Secure the lifted Duplex lift mast

DANGER
Check chain load!
Select safety chain with sufficient load bearing
capacity for the lift mast. Take maximum lift height
into account.

¾ Extend lift mast.

112 Operating Instructions – 391 807 10 51 EN – 09/2010

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

¾ Join chain over cross traverse of outer mast

(1) and under cross traverse of inner mast
(2).
Remember that there are hose lines on the
cross traverse for the outer mast.
¾ Lower lift mast to end of 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 deflection
pulley 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
centre cylinder is positioned on the extendable
inner mast.

Secure the lifted Triplex lift mast

DANGER
Check chain load!
Select safety chain with sufficient load bearing
capacity for the lift mast. Take maximum lift height
into account.

¾ Extend lift mast.

¾ Join chain over cross traverse of outer mast
(1) and under cross traverse of centre mast
(2).
Remember that there are hose lines on the
cross traverse for the outer mast.
¾ Lower lift mast to end of chain.
¾ Lower fork carriage as far as it will go.

Operating Instructions – 391 807 10 51 EN – 09/2010 113

5 Maintenance
Inspection and maintenance data

Inspection and maintenance data

Unit Devices / Consumables Filling quantity / Set values
Engine Engine oil Approx. 4.0 l
Cooling system Coolant additive / drinking with heating system / air
water conditioning: approx. 8.0 l
without heating system / air
conditioning: approx. 6.0 l
Spark plugs NGK BKUR 6 ET–10 Electrode gap: 1.0±0.1 mm
Tightening torque 30-5 Nm
Hydraulic system Hydraulic oil Standard mast: lift height of
5410 mm or less
Duplex mast: all lift heights.
Triplex mast: lift height of
4775 mm or less.
approx. 13.0 l
Standard mast: lift height of
5510 mm or higher
Triplex mast: lift height
between 4925 and 7475 mm
approx. 16.5 l
Battery Distilled water As required
Tyres Pneumatic See information on adhesive
label on right-hand side
of truck
Wheel fastenings Tighten front: 210 Nm
rear: 210 Nm
Load chains / Lift mast Linde chain spray As required
channels
Air conditioning Refrigerant 1520 gram
LPG cylinder LPG Approx. 11 kg
Refillable LPG tank (special LPG Version "1" = approx. 45 l
equipment)
Version "2" = approx. 36 l
Refillable CNG tank (special CNG Filling volume: approx. 50.0 l
equipment)
Max. filling quantity, de-
pending on gas composi-
tion: 7.1 to 8.5 kg

114 Operating Instructions – 391 807 10 51 EN – 09/2010

 Maintenance 5
Recommendations for consumables

Recommendations for consumables

LPG
Approved for the VW engine:
LPG of 95% propane with the remaining 5%
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.
NOTE
The use of domestic gas cylinders is absolu-
tely prohibited.
Hydraulic oil
NOTE
The working temperature is the critical factor
to be considered when selecting the correct
oil for hydrostatic drive units. The recommen-
dations for oils given below can only be guide
values.
Hydraulic oil recommendations for normal
use:
Hydraulic oil ISO - L - HM 68 to ISO 6743 - 4
or HLP ISO VG 68 to DIN 51524, T.2 (factory
filling) average constant oil temperature 60 °C
– 80 °C.

CNG Hydraulic oil recommendations for heavy-duty

use:
NOTE Hydraulic oil ISO - L - HM 100 to ISO 6743 - 4 or
HLP ISO VG 100 to DIN 51524, T.2 for heavy-
The quality of the CNG varies from region to
duty and multi-shift use, operation in hot
region so consult your supplier. The truck is
climate zones or at high outside temperatures,
set to H-gas quality at the time of delivery. If
average constant oil temperature over 80 °C.
L-gas is used, you should arrange adjustment
accordingly. Please contact your authorised Hydraulic oil recommendations for normal and
dealer. heavy-duty use:
Permitted fuels: Hydraulic oil ISO - L - HV 68 to ISO 6743 -
4 or HVLP ISO VG 68 to DIN 51524, T.3
The only fuel permitted is compressed,
(multigrade oil)
odorised CNG (L-gas or H-gas) to the fol-
lowing specification:
Bio-hydraulic oil
Dry CNG
Highly biodegradable hydraulic fluid
Steam content < 32 mg/m3
Aral Forbex SE 46
Dew point -9 °C at 20MPa
CAUTION
Limit values for components: Bio-oils must not be mixed with mineral oils.
Hydrogen sulphide No recommendations for other fluids from other
or other soluble manufacturers can be made at the present time.
sulphides Max. 23 mg/m3
Oxygen Max. 1 Vol-% NOTE

Hydrogen Max. 2 Vol-% If in doubt, we recommend obtaining the ad-

vice of your authorised dealer. Recommen-
dations made by representatives from the
mineral oil industry should also be agreed with
your authorised dealer. Manufacturer’s ap-

Operating Instructions – 391 807 10 51 EN – 09/2010 115

5 Maintenance
Recommendations for consumables

proval only exists for the oils specified above. Chain spray
Mixing with or using other hydraulic fluids may
Linde chain spray (order no.: see spare parts
result in highly expensive damage.
catalogue).

Lubricating grease
Engine oil
Linde heavy-duty grease, lithium-saponified
Specification and viscosity of engine oil for oil
with EP active ingredients and MoS2. Des-
change every 1000 operating hours
ignation according to DIN 51825-KPF 2N-20
(order no.: see spare parts catalogue). "Longlife" engine oils to VW standard 503 00
or 503 01. These oils are available exclusively
Mixing with lubricating grease types with a
in viscosity SAE 0W-30
soap basis other than lithium-saponified is not
permitted. or "Longlife 3" engine oils to VW standard
504 00 in viscosity SAE 5W-30.
Coolant Oil change every 1000 operating hours or
every 12 months.
CAUTION
Refer to the coolant specifications!
A high-quality engine oil for 1000 operating
hours to VW standard 504 00 is factory-filled.
Use only coolant additive to VW standard TL 774-F
(factory filling) or TL 774-D. Engine oil for oil change every 500 operating
hours
This additive must be mixed with water (total
hardness of water must not be more than 20° Engine oils to VW standard 500 00, 501 01
according to German hardness standards). or 502 00 are also approved. See table for
A maximum of 60% coolant additive can be viscosity.
used. This engine oil must be changed every 500 op-
Coolant Drinking erating hours.
Temperature
additive water Engine oil for oil change every 300 operating
-25 °C 40 % 60 % hours

-30 °C 45 % 55 % Engine oils to API SF/SG or ACEA A2/A3 and

higher quality API-S or ACEA-A classes are
-35 °C 50 % 50 % also approved. See table for viscosity.
-40 °C 60 % 40 % This engine oil must be changed every 300 op-
erating hours.
¾ When topping up, the various oils may be
Refrigerant for air conditioning mixed with each other; however the oil
R 134a change interval is then determined by the
oil of the lowest quality.
Battery grease
Acid-free lubricating grease (battery grease).

116 Operating Instructions – 391 807 10 51 EN – 09/2010


Since a good engine oil is a pre-requisite for
problem-free operation and a long service life
for the engine, use only good quality engine
oil even when topping up and also during oil
change. Due to their limited viscosity range,
single-grade oils should generally not be used
all year round. These oils should be used only
in extreme climate zones.
NOTE
No additional lubricants of any sort should be
mixed in with the lubricating oils.
¾ Refer to the viscosity table.
Operating Instructions – 391 807 10 51 EN – 09/2010
Maintenance 5
Recommendations for consumables
They apply only to oils which must be changed
every 500 or 300 operating hours.
When the engine is running, not only is some
of the engine oil for piston lubrication burnt
off ("consumed"), but the temperature stress
and the fuel combustion products that enter
the oil lead to "wear", especially affecting
chemical "additives" in the oil. For this reason,
the entire filling of engine oil must be renewed
at specified intervals.
Since this "oil wear" depends on the operating
conditions, the fuel quality and the oil quality
(the performance characteristics of the oil), 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
not exceeding 12 months.
ENVIRONMENT NOTE
Used oil must be kept away from children
until disposed of according to applicable
regulations. Under no circumstances should
oil be allowed to penetrate the mains drainage
or the ground.
Because of the problems of disposal and the
special tools and knowledge required, engine
oil and filter changes should only be performed
by your authorised dealer.
117
5 Maintenance
Inspection and maintenance overview

Inspection and maintenance overview

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
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

118 Operating Instructions – 391 807 10 51 EN – 09/2010

 Maintenance 5
Inspection and maintenance overview

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 application conditions, but
at least after 1, 2, 4, 5, 7, 8, 10, 11, 13, 14, 16, 17, 19 and 20 years of operating time.
Refer also to the recommendation for consumables.
Preparations
Clean the truck if necessary
Read out error log and delete
Calibrate the drive potentiometer and joysticks
Enter the next maintenance interval
Engine
Change engine oil
Change engine oil filter
Change the spark plugs
Change the LPG filter
Check LPG mixer settings
Clean evaporator / pressure regulator and refit using a new repair kit
Natural gas system: carry out "system check"
CNG system: carry out "system service" (only every 10,000 operating hours or
every 5 years)
Three-way catalytic converter: Check LPG system default setting
Check the LPG system for damage and leaks
Check condition and secure positioning of motor support and motor bearing
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

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5 Maintenance
Inspection and maintenance overview

At operating hours
1000 2000 4000 5000 7000
Carried
8000 10000 11000 13000 14000 out
16000 17000 19000 20000 9 8
Check CO level in the exhaust gas
Gearbox
Drive axle and wheel motors: Check fastening
Drive axle: Check the side stops
Chassis, bodywork and fittings
Chassis, tilt cylinders and steering axle: Check fastening
Check and grease other bearings and joints
Chassis frame
Check the parking brake for correct operation
Clean and grease steering axle
Steering cylinder and steering pivot pin: Check fastening
Controls
Check and oil the pedals
Electrics
Check the condition and secure positioning of electric cables, cable connectors and
connections
Battery: Check condition, acid level and acid density (even for maintenance-free
batteries)
Hydraulics
Hydraulic system: Check the oil level.
Check the bleeder valve on the hydraulic tank for correct operation
Check the hydraulic system for leaks
Check the hose carrier
Double hoses: Check the pre-tension
Load lift system
Lift mast, lift mast chain, lift cylinder and end stops: Check condition, secure moun-
ting and function
Adjust lift mast chain and spray with chain spray
Check fork arms and arm safety devices
Clean and grease the sideshift, check fastening

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 Maintenance 5
Inspection and maintenance overview

At operating hours
1000 2000 4000 5000 7000
Carried
8000 10000 11000 13000 14000 out
16000 17000 19000 20000 9 8
Clean and grease fork positioner, check fastening
Subsequent tasks
Carry out functional test and test drive
Attach maintenance sticker

Operating Instructions – 391 807 10 51 EN – 09/2010 121

5 Maintenance
Inspection and maintenance overview

3000 h Service plan

Carried
At operating hours
out
3000 15000 9 8
Information on service plan
Dependent on the consumables used, driving style and application conditions, but
at least after 3 and 15 years of operating time. Refer also to the recommendation for
consumables.
Preparations
Clean the truck if necessary
Read out error log and delete
Calibrate the drive potentiometer and joysticks
Enter the next maintenance interval
Engine
Change engine oil
Change engine oil filter
Change the spark plugs
Change the LPG filter
Check LPG mixer settings
Clean evaporator / pressure regulator and refit using a new repair kit
Natural gas system: carry out "system check"
Three-way catalytic converter: Check LPG system default setting
Change high-pressure gas hoses
Check the LPG system for damage and leaks
Check condition and secure positioning of engine cradle and engine mounting
Change V-ribbed belt
Change toothed belt and tensioner pulley (at latest after 5 years)
Clean water and hydraulic oil coolers
Check the coolant concentration
Change air filter cartridge, check vacuum-operated switch
Change the safety cartridge in the air filter
Clean the oil bath air filter
Check suction and exhaust pipes for leaks
Check CO level in the exhaust gas

122 Operating Instructions – 391 807 10 51 EN – 09/2010

 Maintenance 5
Inspection and maintenance overview

Carried
At operating hours
out
3000 15000 9 8
Gearbox
Drive axle and wheel motors: Check fastening
Drive axle: Check the side stops
Drive axle: Check bearing for wear
Hydraulic pump on engine: Check fastening
Chassis, bodywork and fittings
Chassis, tilt cylinders and steering axle: Check fastening
Check and grease other bearings and joints
Chassis frame
Check the parking brake for correct operation
Clean and grease steering axle
Steering cylinder and steering pivot pin: Check fastening
Controls
Check and oil the pedals
Check the bellows at the actuating lever
Electrics
Check the condition and secure positioning of electric cables, cable connectors and
connections
Battery: Check condition, acid level and acid density (even for maintenance-free
batteries)
Hydraulics
Hydraulic system: Check the oil level.
Check the bleeder valve on the hydraulic oil tank for correct operation
Change feed/pressure/suction filter and breather of the hydraulic system
Check the hydraulic system for leaks
Check tilt cylinder bearing for wear
Check the hose carrier
Double hoses: Check the pre-tension
Load lift system
Lift mast, lift mast chain, lift cylinder and end stops: Check condition, secure moun-
ting and function
Adjust lift mast chain and spray with chain spray

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5 Maintenance
Inspection and maintenance overview

Carried
At operating hours
out
3000 15000 9 8
Check fork arms and arm safety devices
Clean and grease the sideshift, check fastening
Check slide guides on sideshift for wear
Clean and grease fork positioner, check fastening
Check fork positioner for wear
Subsequent tasks
Carry out functional test and test drive
Attach maintenance sticker

124 Operating Instructions – 391 807 10 51 EN – 09/2010

 Maintenance 5
Inspection and maintenance overview

6000 h Service plan

Carried
At operating hours
out
6000 12000 9 8
Information on service plan
Dependent on the consumables used, driving style and application conditions, but
at least after 6 and 12 years of operating time. Refer also to the recommendation for
consumables.
Preparations
Clean the truck if necessary
Read out error log and delete
Calibrate the drive potentiometer and joysticks
Enter the next maintenance interval
Engine
Change engine oil
Change engine oil filter
Change the spark plugs
Change the LPG filter
Check LPG mixer settings
Clean evaporator / pressure regulator and refit using a new repair kit
Natural gas system: carry out "system check"
Three-way catalytic converter: Check LPG system default setting
Change high-pressure gas hoses
Checking the LPG system for damage and leaks
Check condition and secure positioning of engine cradle and engine mounting
Change V-ribbed belt
Change toothed belt and tensioner pulley (at latest after 5 years)
Clean water and hydraulic oil coolers
Check the coolant concentration
Change air filter cartridge, check vacuum-operated switch
Change the safety cartridge in the air filter
Clean the oil bath air filter
Check suction and exhaust pipes for leaks
Check CO level in the exhaust gas

Operating Instructions – 391 807 10 51 EN – 09/2010 125

5 Maintenance
Inspection and maintenance overview

Carried
At operating hours
out
6000 12000 9 8
Gearbox
Drive axle and wheel motors: Check fastening
Drive axle: Check the side stops
Drive axle: Check bearing for wear
Hydraulic pump on engine: Check fastening
Chassis, bodywork and fittings
Chassis, tilt cylinders and steering axle: Check fastening
Check and grease other bearings and joints
Chassis frame
Check the parking brake for correct operation
Clean and grease steering axle
Steering cylinder and steering pivot pin: Check fastening
Controls
Check and oil the pedals
Check the bellows at the actuating lever
Electrics
Check the condition and secure positioning of electric cables, cable connectors and
connections
Battery: Check condition, acid level and acid density (even for maintenance-free
batteries)
Hydraulics
Change hydraulic oil
Check the bleeder valve on the hydraulic oil tank for correct operation
Change feed/pressure/suction filter and breather of the hydraulic system
Check the hydraulic system for leaks
Check tilt cylinder bearing for wear
Check the hose carrier
Double hoses: Check the pre-tension
Load lift system
Lift mast, lift mast chain, lift cylinder and end stops: Check condition, secure moun-
ting and function
Adjust lift mast chain and spray with chain spray

126 Operating Instructions – 391 807 10 51 EN – 09/2010

 Maintenance 5
Inspection and maintenance overview

Carried
At operating hours
out
6000 12000 9 8
Check fork arms and arm safety devices
Clean and grease the sideshift, check fastening
Check slide guides on sideshift for wear
Clean and grease fork positioner, check fastening
Check fork positioner for wear
Subsequent tasks
Carry out functional test and test drive
Attach maintenance sticker

Operating Instructions – 391 807 10 51 EN – 09/2010 127

5 Maintenance
Inspection and maintenance overview

9000 h Service plan

Carried
At operating hours
out
9000 18000 9 8
Information on service plan
Dependent on the consumables used, driving style and application conditions, but
at least after 9 and 18 years of operating time. Refer also to the recommendation for
consumables.
Preparations
Clean the truck if necessary
Read out error log and delete
Calibrate the drive potentiometer and joysticks
Enter the next maintenance interval
Engine
Change engine oil
Change engine oil filter
Change the spark plugs
Change the LPG filter
Check LPG mixer settings
Clean evaporator / pressure regulator and refit using a new repair kit
Natural gas system: carry out system check
Three-way catalytic converter: Check LPG system default setting
Change high-pressure gas hoses
Check the LPG system for damage and leaks
Checking the condition and secure positioning of engine cradle and engine moun-
ting
Change V-ribbed belt
Change toothed belt and tensioner pulley (at latest after 5 years)
Change the water pump
Clean water and hydraulic oil coolers
Change the coolant
Check the coolant concentration
Change air filter cartridge, check vacuum-operated switch
Change the safety cartridge in the air filter

128 Operating Instructions – 391 807 10 51 EN – 09/2010

 Maintenance 5
Inspection and maintenance overview

Carried
At operating hours
out
9000 18000 9 8
Clean the oil bath air filter
Check suction and exhaust pipes for leaks
Check CO level in the exhaust gas
Gearbox
Drive axle and wheel motors: Check fastening
Drive axle: Check the side stops
Drive axle: Check bearing for wear
Hydraulic pump on engine: Check fastening
Chassis, bodywork and fittings
Chassis, tilt cylinders and steering axle: Check fastening
Check and grease other bearings and joints
Chassis frame
Check the parking brake for correct operation
Clean and grease steering axle
Steering cylinder and steering pivot pin: Check fastening
Controls
Check and oil the pedals
Check the bellows at the actuating lever
Electrics
Check the condition and secure positioning of electric cables, cable connectors and
connections
Battery: Check condition, acid level and acid density (even for maintenance-free
batteries)
Hydraulics
Change the hydraulic oil (omitted for 9000 operating hours)
Hydraulic system: Check the oil level.
Check the bleeder valve on the hydraulic oil tank for correct operation
Change feed/pressure/suction filter and breather of the hydraulic system
Check the hydraulic system for leaks
Check tilt cylinder bearing for wear
Check the hose carrier

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5 Maintenance
Inspection and maintenance overview

Carried
At operating hours
out
9000 18000 9 8
Double hoses: Check the pre-tension
Load lift system
Lift mast, lift mast chain, lift cylinder and end stops: Check condition, secure moun-
ting and function
Adjust lift mast chain and spray with chain spray
Check fork arms and arm safety devices
Clean and grease the sideshift, check fastening
Check slide guides on sideshift for wear
Clean and grease fork positioner, check fastening
Check fork positioner for wear
Subsequent tasks
Carry out functional test and test drive
Attach maintenance sticker

130 Operating Instructions – 391 807 10 51 EN – 09/2010

 Maintenance 5
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
remove 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
dipstick mark.
¾ To do so, remove filler cap (1) from the filler
neck.
Difference in quantity between min. and max.
marking: 1.0 l
¾ Fit filler cap and turn to tighten.
¾ Close the bonnet.

Operating Instructions – 391 807 10 51 EN – 09/2010 131

5 Maintenance
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
Observe information regarding working with
consumables.

NOTE
Only change engine oil when the engine is at
operating temperature.
¾ Drive truck over pit.
¾ Switch off the engine.
¾ Close gas shut-off valve.
¾ Place a collection vessel under the truck
chassis.
¾ Open the bonnet.

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¾ Remove the filler cap (1) from the filling

opening.
¾ Unscrew and remove the cover on the
chassis floor.
¾ Unscrew the engine oil drain plug (2)
underneath from the oil sump.
¾ Allow all of the oil to drain off into the
collection vessel.

¾ Fit the drain plug (2) with a new sealing ring.

Tightening torque: 30 Nm
¾ Attach the cover to the chassis floor.
¾ Refit the cover (1) and turn to tighten.

Topping up with engine oil

¾ Switch off ignition.

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

¾ Pour new engine oil into the filling opening
according to the recommendations for
consumables.
Fill quantity with filter change: max. 4.5 l
¾ Using the dipstick (3), check the engine
oil level after adding oil and top up to max.
mark (2).
¾ Fit filler cap (1) and turn to tighten.

¾ Check the indicator unit (4).

The Oil display (5) (special equipment) in the
display unit must go out. The oil level will not
be displayed reliably in the display unit until
approx. 10 minutes after the oil is added.

NOTE
After changing the oil and the filter, carry out
an engine test run, checking the oil pressure
display 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 engine oil filter

WARNING
Risk of scalding with hot engine oil!
Wear protective equipment.

ENVIRONMENT NOTE
Take note of information about working
materials.
¾ Open the bonnet.

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¾ Place a collection vessel under filter car-

tridge (2).
¾ Release engine oil filter with an oil filter
wrench and unscrew by hand.
¾ Collect oil escapingand dispose of it with oil
filter in an environmentally friendly manner.
¾ Clean filter top.
¾ Slowly fill new oil filter cartridge with engine
oil.
¾ Lightly oil filter seal (1) with engine oil.
¾ Screw in filter cartridge by hand until seal
touches, then tighten half a turn with oil filter
wrench.
¾ Close the bonnet.

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 engine. To make
an accurate oil level check it is necessary to
switch off the engine again and inspect the oil
level after approx. one minute.

Gas system: Checking the level

The truck is equipped with a sensor that
monitors the level of the LPG cylinder, LPG
tank or CNG tank.
The level is shown in the display unit (4) by
illuminated fields.

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¾ Switch on the ignition.

The level is displayed after a few seconds.
The LPG cylinder, the LPG tank or the CNG
tank is full when all 7 LEDs (2) and the "petrol
pump" illuminated field (1) light up green. As
the cylinder or tank empties, the LEDs are
extinguished, starting from the right. If only the
"petrol pump" illuminated field (1) is lit up red,
the cylinder must be changed or the tank must
be filled in the next 5 – 25 minutes depending
on the driving style and ambient temperature.

Changing the LPG cylinder

ENVIRONMENT NOTE
Observe information regarding working with
consumables.

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. Please
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
specified in EC directive 97/23 must be strictly
observed. The last inspection date marked on the
LPG cylinder is the applicable date.

Observe safety guidelines for vehicles pow-

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

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DANGER
There is a risk of explosion if LPG
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.
¾ Securely grip the connection nipple with the
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 the plastic sealing nut (3) onto the
LPG cylinder pipe union.

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¾ Swivel the cover (4) of the LPG cylinder

upwards.
The cover is fitted with friction hinges. They
keep the cover open automatically once it has
opened.

¾ Release the lock (7) on the ratchet (8) and

remove the tightening strap (6) from the
ratchet.
¾ Hook the tightening strap (6) into the holder
(5) on the cover. This will make it easier to
find the strap again once the cylinder has
been changed.
¾ Remove LPG cylinder.

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¾ If necessary, clean the contact surface of

the sensor (9) 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.
Replacement cylinders to DIN 4661 p. 6,
capacity 11 kg, should be used

Secure the LPG cylinder in the holder in such

a way that the hose connection for the LPG
cylinder points vertically downwards. This
ensures that gas is only ever withdrawn
from the liquid phase, thereby avoiding
malfunctioning of the engine.
¾ Insert the tightening strap (6) into the ratchet
(8) and tension it with the ratchet lever.
When doing so, check for correct positioning
of the cylinder on the contact surface of the
sensor (pretension approx. 9 mm).
¾ Swivel the LPG cylinder panelling com-
pletely downwards.
¾ Re-attach the hose to the LPG cylinder
according to regulations.
¾ Check for leaks with leak spray and a gas
detector in accordance with the inspection
and maintenance guidelines.

Filling the LPG tank (special equip-

ment)

ENVIRONMENT NOTE
Observe information regarding working with
consumables.

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DANGER
The inspection intervals for pressure vessels
specified in EC directive 97/23 must be strictly
observed. 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
There is a risk of explosion if LPG
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
A small amount of LPG will escape
when the pistol-type nozzle is
removed. This may cause frostbite
on the skin.
Therefore, protective gloves should
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.

NOTE
The LPG tank fitted can vary depending on the
model (model "1" or model "2").
¾ Switch off truck engine and combustion
heater.

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¾ Put on protective gloves.

¾ Close the (1) shut-off valve.
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.
Filling quantity
Model "1" = approx. 45 l
Model "2" = approx. 36 l
¾ After the tank valve has stopped the fuelling,
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
station.
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).

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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.

CAUTION
For proper operation, it must be ensured that the
fuel is withdrawn only from the liquid phase, thereby
avoiding malfunctioning of the engine.
For this reason, if model "2 "of the LPG tank is ever
removed, ensure that the tank is aligned in the
mounting support (5) such that the wording (4) can
be read horizontally.

¾ Check for leaks with leak spray and a gas

detector in accordance with the inspection
and maintenance guidelines.

Filling the CNG tank (special

equipment)

ENVIRONMENT NOTE
Observe information regarding working with
consumables.
DANGER
Before connecting the filler coupling, check whether
the gas tank and/or fittings are defective, and
that the permitted utilisation period or applicable
inspection intervals as defined by the Ordinance on
Industrial Safety and Health (BetrSichV) have not
been exceeded.
If major defects are observed or the maximum per-
mitted utilisation period and/or applicable inspec-
tion intervals have been exceeded,
¾ the gas tank must not be filled
¾ the truck must no longer be operated
¾ the truck must be switched off safely
¾ the gas system must be checked.
Contact your authorised dealer.

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NOTE
Observe safety guidelines when using CNG,
and the safety instructions for the CNG filling
station. Gas tanks may only be filled by people
who have undergone appropriate training.
For gas quality, see the recommendation for
consumables.

DANGER
There is a danger of explosion when
filling the gas tank
Do not smoke or use a naked
flame/fire

If the "petrol pump" field (1) lights up, the gas

tank is empty and must be filled.
¾ Switch off truck engine and combustion
heater.
¾ Switch off ignition.
¾ Secure the truck against rolling away.

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¾ The shut-off valve (5) must be open ("ON"

position).
¾ Disconnect the locking cap (4) from the
filling nipple.
¾ Check that the O-ring in the filling nipple is
properly seated.
¾ Check that the filling nipple (3) and filler
coupling of the filling station are clean.
¾ Fit the filler coupling to the filling nipple (3)
until the sliding sleeve engages.
¾ Open the filler coupling shut-off valve and
fill the tank until the filling process switches
off automatically.

Filling pressure 200 bar at 15°C

Filling volume 50.0 l
Max. filling quantity,
dependent on gas
composition 7.1–8.5 kg

¾ Terminate filling process immediately after

switching off.

¾ Close the filler coupling shut-off valve.

¾ Push back the sliding sleeve and discon-
nect the filler coupling.

CAUTION
Do not remove the filler coupling until the filling
pressure has dropped! This may take several
seconds, depending on the filling system. Please
observe the instructions for your filling system.
If the coupling is removed under pressure, the filler
connection O-ring may be damaged or blown out.
The O-ring should therefore be checked again
after the filling process to ensure that it is properly
seated.

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¾ Refit the lid (4) on the filling nipple (3).

CAUTION
If irregularities or noteworthy incidents occur during
the filling process,
¾ discontinue filling
¾ the truck must no longer be operated
¾ the truck must be switched off safely
¾ the gas system must be checked.
Please contact your authorised dealer

¾ Check for leaks with leak spray and a gas

detector in accordance with the inspection
and maintenance guidelines (for details see
the gas system manufacturer’s operating
and maintenance instructions).

NOTE
The tank is full when all 7 LEDs (2) and the
"petrol pump" illuminated field (1) in the display
unit light up green when the engine is running.
(The tank content is only displayed correctly
when the engine is running.)

Replace the fuel gas filter

¾ Close shut-off valve to the liquid gas cylin-
der.
¾ Let the engine run until the gas in the system
has been used up.

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¾ Undo screw (2) and remove it together with

filter housing (1).
¾ Take out the old filter.
¾ Clean the housing.
¾ Insert the new filter mount the housing.
¾ Perform a leakage test.
¾ Close the bonnet.

Check the fuel gas settings

¾ Check the fuel gas mixer (1) settings.
Correct them if necessary.

WARNING
Specialised knowledge is required for this work.
Please contact your authorised dealer.

Cleaning the evaporator / pressure

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

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¾ Dismantle, clean and check the evaporator

/ pressure regulator (1) and mount with a
new repair kit.
¾ Measure the CO content and check the
power rating by means of the pressure
speed.

WARNING
Specialised knowledge is required for this work.
Please contact your authorised dealer.

Natural gas system: checking the

high-pressure relief valve (special
equipment)
There must be a plastic cap on the high-
pressure relief valve (1). If there is no cap,
there may be an error in the gas system. In this
case, please contact your authorised dealer.

NOTE
Further information can be found in the
gas system manufacturer’s accompanying
operating and maintenance manual.

Natural gas system: carrying out a

system check (special equipment)
Carry out "system check" in accordance
with the gas manufacturer’s operating and
maintenance guidelines. Please contact your
authorised dealer.

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Natural gas system: Carry out

system service (special equipment)

NOTE
Carry out the "system service" in accordance
with the gas system manufacturer’s operating
and maintenance manual. Please contact
your authorised dealer.

LPG system visual inspection, odour

inspection
A high-pressure relief valve (1) in front of the
gas cylinder protects the gas pipe against
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.

Checking the LPG system for

damage 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.

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¾ Check the shut-off valve of the LPG cylinder

or LPG tank (special equipment), hose
screw joints und hoses for leaks and
damage.

¾ Check the hose and line screw joints,

LPG filter with shut-off valve, evaporator
pressure regulator and LPG mixer with gas
detector; apply leak spray and see if any
bubbles form.

NOTE
Icing and yellow foam deposits on the LPG
system indicate the presence of leaks.
For versions with an LPG tank (special equip-
ment)

NOTE
Regular inspection of the LPG tank is go-
verned by the BetrSichV (Workplace Safety
Ordinance), § 15. The operating company is
responsible for ensuring that checks are per-
formed and that the inspection intervals are
correct. The maximum inspection intervals
specified in the BetrSichV (Workplace Sa-
fety Ordinance) must not be exceeded. Other
regulations apply outside Germany. The ap-
plicable national regulations must be complied
with.

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¾ Check the extraction valve, contents

indicator and filling valve for leaks.
¾ Re-tighten leaking screw joints, change
damaged hoses and check for leaks again.
¾ Leaks in the LPG filter, evaporator pressure
regulator, shut-off valve and LPG mixer can
only be rectified by an authorised dealer.

Checking the coolant level

ENVIRONMENT NOTE
Observe information regarding working with
consumables.

NOTE
If the display (1) lights up (special equipment),
the coolant level is too low and the coolant
must be topped up. If the coolant continues to
fall below the min. mark, the truck only moves
at creep speed.

NOTE
On versions without the display (1), the
coolant level can be checked in the expansion
reservoir (3).
CAUTION
Only use an approved coolant.
Observe the recommendations for consumables.

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¾ Open the bonnet.

The coolant must not fall below the min. mark
(3) in the expansion reservoir (4).
¾ If necessary, top up the coolant. To do this,
twist and remove the filler cap (2).

WARNING
The expansion reservoir is under
pressure! Risk of scalding due to hot
coolant.
Unscrew the filler cap (2) slowly, and
only if the expansion reservoir is not
hot.

¾ Fit filler cap and turn to tighten.

¾ Close the bonnet.

Change coolant
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 (3) when the engine is hot. Risk
of scalding!
Wait until the coolant has cooled down.

ENVIRONMENT NOTE
Take note of information about working
materials.
¾ Open the bonnet.

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¾ Place a collection vessel under the coolant

hose (2).
¾ Release the hose clip (1).
¾ Disconnect the coolant hose from the stub
on the engine.
¾ Drain off all coolant. Dispose of the coolant
in an environmentally friendly manner.
¾ Re-connect the coolant hose (2).
¾ Fasten the hose (2) with a hose clip (1).

¾ Add new coolant to reservoir (4).

The coolant level must be between min. and
max. marking (5) in the reservoir.
Difference in quantity between min. and max.:
approx. 0.75 l
Fill quantity in cooling system
• without heater or air conditioner: 6.0 l (3.6 l
drinking water and 2.4 l frost protection)
• with heater or air conditioner: 8.0 l (4.8 l
drinking water and 3.2 l frost protection)
The frost protection should be sufficient for
temperatures down to -25 °C. The mixing ratio
required here is 40% coolant additive and 60%
drinking water.
Mixing ratio for lower temperatures:
Coolant Drinking
Temperature
additive water
-30 °C 45 % 55 %
-35 °C 50 % 50 %
-40 °C 60 % 40 %

¾ Fit lid (3) and turn to fix in place.

¾ Run the engine until cooling system has
been vented.
¾ Check coolant level.
¾ Close the bonnet.

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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.
¾ Open the bonnet.

WARNING
Never open the lid (1) when the
engine is hot. Risk of scalding!
Wait until the coolant has cooled
down.

ENVIRONMENT NOTE
Take note of information about working
materials.
¾ Check coolant concentration in the brake
fluid reservoir (2).
The frost protection should be sufficient for
temperatures down to -25 °C. The mixing ratio
required here is 40% coolant additive and 60%
drinking water.
Mixing ratio for lower temperatures:
Coolant Drinking
Temperature
additive water
-30° C 45 % 55 %
-35° C 50 % 50 %
-40° C 60 % 40 %

If coolant additive level is too low:

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¾ Place a collection vessel under the coolant

hose (5).
¾ Release the hose clip (5).
¾ Remove the coolant hose from the stub on
the engine and allow some coolant to drain
off.
¾ Re-connect the coolant hose.
¾ Fasten the hose with a hose clip.
¾ Dispose of removed coolant in an environ-
mentally friendly manner.
¾ Add coolant additive to brake fluid reservoir
(2) until right mixing ratio is achieved.
¾ The coolant level must not be above mark-
ing (3).
¾ Fit lid (1) and turn it to fix it in place.
¾ Close the bonnet.

Cleaning the water cooler and

hydraulic 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 engine bonnet.

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Cleaning with compressed air

¾ Ventilate the cooler (1) of the engine with
compressed air.
¾ Rinse out the released dirt using a water jet
through the cooler grill.

Cleaning with cleaner solvent

CAUTION
No humidity must penetrate the three-phase gene-
rator.
Therefore, protect it from direct contact with the
water jet.

¾ Spray the cooler (1) with a conventional

cleaner solvent and leave it to work for
approx 10 minutes.
¾ Spray the cooler in the engine with a direct
jet of water until it is clean.
¾ Warm up the engine.
Vaporise the water residue to prevent the
formation 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.

Change the water pump

NOTE
Changing the water pump requires specialist
knowledge and special tools. Please contact
your authorised dealer.

d3921410

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Check the condition of the engine

mount and engine suspension;
check that they are attached se-
curely
The elastic bearings on the engine suspen-
sions are subject to high loads. Their service
life may be limited depending on how they are
used.
¾ Check rubber elements for cracks and
heavy deformation. If necessary, replace
them.
Please contact your authorised dealer.
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 tightening screws
and nuts:
Engine mount right (1) :

3 SKS M 8 (rear) 23 Nm
1 SKS M 10 (rear) 46 Nm
1 SKM M 12 (bottom) 110 Nm
2 SKS M 12 (spring element) 80 Nm

Engine mount, left:

2 SKS M 12 (spring element) 80 Nm

1 SKM M 12 (bottom) 110 Nm

Engine mount, top centre:

2 SKS M 12 (spring element) 80 Nm

1 SKS M 10 (rod on
46 Nm
connection flange)

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Check condition of the ribbed V-belt

WARNING
Do not touch rotating parts!
Switch off the engine and take the
key out of the ignition switch.

NOTE
A defective or loose ribbed V-belt will cause
the vehicle electrical voltage to be too low.
¾ Remove the maintenance cover on the right
hand side.
¾ Check the ribbed V-belt (1) for excessive
wear, frayed edges, cracks across the belt
and traces of oil.
¾ Exchange the ribbed V-belt if it is damaged.
¾ Refit the engine cover plate.
¾ Refit the side maintenance cover.

Change ribbed V-belt

WARNING
Do not touch rotating parts.
Switch off the engine and remove
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

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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.
¾ Mark the running direction of the ribbed
V-belt (2).
¾ Lift the guide (3) pulley on the tensioning
lever (1) with the combination wrench.

NOTE
Observe the running direction of the ribbed
V-belt (2).
¾ Replace the ribbed V-belt.
¾ Refit the side maintenance cover.
¾ Close the bonnet.

Checking the condition and tension

of toothed belt

WARNING
Do not touch rotating parts!
Switch off the engine and remove
ignition key.

¾ Remove the maintenance cover on the

right-hand side.

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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.

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
contact your authorised dealer.

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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.
Please contact your authorised dealer.
¾ Refit the engine cover.
¾ Refit the side maintenance cover.

Changing the toothed belt and

tensioner pulley

NOTE
Changing the toothed belt and tensioner pulley
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 (4) lights up in the display
unit.

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¾ Open the bonnet.

¾ Open and detach the fastener (3) on the
tightening strap (2).
¾ Raise the filter housing slightly.
¾ Open the 3 fasteners (1) and remove the air
filter cover (5).
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.
Wipe the housing clean with a clean cloth.

¾ Insert the new air filter cartridge back into

the housing.
When installing, ensure that the air filter
cartridge is not damaged and that the seal
on the filter housing is securely in place.
¾ Fit the air filter cover (5).
¾ Hook the fastener (3) into the tightening
strap (2) and close it.
¾ With the engine running, slowly close the air
filter intake opening (6) in the rear left-hand
post of the overhead guard by covering it
(e.g. with a board or plate) until the vacuum
display (4) in the display unit lights up.
In order to avoid damage, the intake open-
ing must not be closed any further once the
indicator light has illuminated. If the vacuum
display does not light up contact your autho-
rised dealer.

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5 Maintenance
Engine

Changing the safety cartridge in the

air filter

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 Change 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
dust penetration while the main cartridge is being
changed or inadvertent use of a damaged main
cartridge.

¾ Switch off the engine.

¾ Open the bonnet.
¾ Open and detach the fastener (4) on the
tightening strap (2).
¾ Open and detach three fasteners (1) on the
air filter cover (5).
¾ Slightly raise the filter housing (3).
¾ Take off the air filter cover (5) and remove
the filter cartridge (6).

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 Maintenance 5
Engine

¾ Pull out the safety cartridge (7).

¾ Insert the new safety cartridge.
¾ Mount the filter cartridge and attach the air
filter cover.
¾ Hook the fastener (4) into the tightening
strap (2) and close it.
¾ Close the bonnet.

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.
¾ Close the bonnet.

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5 Maintenance
Engine

Cleaning the prefilter (special

equipment)

NOTE
The dust collecting tank must never be more
than half full with dust. If there is a heavy
accumulation 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
Observe information regarding working with
consumables.
¾ Switch off the engine.

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 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) ,
ensuring 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
sediments have reached half of the oil filling,
and at least whenever the filter element is
renewed. Do not add oil between the oil
change intervals.

ENVIRONMENT NOTE
Follow the precautions for handling fluids and
lubricants.
¾ Shut the engine off.

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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
installation (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
contact your authorised dealer.

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

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 Maintenance 5
Engine

for the inspection. Please contact your

authorised dealer. Outside of Germany,
observe your national regulations.

Check suction and exhaust leads for

leaks
¾ Check the condition and tightness of the
suction air tubes on the air filter.
If you discover leaks, re-tighten the hose clips
or replace the porous tubes.
¾ Check the inlet and exhaust manifold on the
cylinder head for leaks.
If you discover leaks, re-tighten the fastening
screws or replace the seals.
¾ Check the exhaust lead connection on the
manifold for leaks. If necessary, re-tighten
the fastening screws or replace the gasket.

¾ Remove the cover on the counterweight.

¾ Unscrew 5 fastening screws on the rear
panelling.
¾ Remove the rear panelling.
¾ Check connections and tightness of the ex-
haust lead in the counterweight, and check
how securely fastened it is. Re-tighten the
fastening screws if necessary.
¾ Attach the rear panelling and cover to the
counterweight.

Changing the spark plugs

NOTE
Use the following spark plugs: NGK BKUR 6
ET-10

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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 connector (2).
¾ Unscrew the spark plugs (1).
¾ Check the gap between the electrodes in
the new spark plug with a feeler gauge.
Setpoint value: 1.0 ±0.1 mm

CAUTION
Do not start the engine, the ignition system will be
broken.
Do not attempt to start the engine without spark
plugs.

¾ Screw in the spark plugs manually and

tighten them to a torque of 30-5 Nm.
¾ Re-attach the spark plug connector (2).
¾ Close the bonnet.

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.

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 Maintenance 5
Gearbox

Gearbox
Drive axle and wheel motors:
Checking mounting
¾ Check that each of the 4 mounting screws
(M14x1.5) (4) on the drive axle on the left
and right of the chassis has a tightening
torque of 195 Nm.
¾ Check that each of the 2 collar screws
(M14x1.5) (1) on the bearing halves on the
left and right of the chassis has a tightening
torque of 210 Nm.
¾ Remove the drive wheels.

¾ Prop up the chassis with a square timber (3)

to keep it secure.
¾ Remove the drive wheels.
¾ Check that each of the 24 mounting screws
(M10) (2) of the wheel motors on the left and
right has a tightening torque of 64 Nm.

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5 Maintenance
Gearbox

Checking and adjusting side stops

on drive axle
¾ Check the air gap (3) between the stop (2)
and the drive axle.
The air gap should be max. 3 mm. Check the
air gap on the left and right of the axle.
If the air gap is larger, adjust the stop.
¾ Remove the drive wheels.
¾ Slacken the hexagonal nut (1).
¾ Adjust stop (2) with the Allen key until the air
gap is 3 mm in size.
If the air gap can no longer be adjusted, the
spring element on the axle or the stop is worn.
The spring element or stop must then be
renewed. Please contact your authorised
dealer.
¾ Tighten the hexagonal nut (1).
¾ Attach the drive wheels.

Check the drive axle bearing for wear

and tear

NOTE
The drive axle is supported on both sides of
the frame by elastic spring elements.
¾ Prop up the frame with timber to keep it
secure.
¾ Remove the drive wheels.

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 Maintenance 5
Gearbox

¾ Using a lamp, check the condition of the

spring elements (1) between the drive axle
and frame.
The spring elements must be checked on
both the left and right of the axle. If the spring
elements on the axle are worn or cracked,
replace them. Please contact your authorised
dealer.
¾ Attach the drive wheels.
¾ Remove the timber.

Check hydraulic pump attachment to

the engine
¾ Open the bonnet.
¾ Remove the maintenance cover on the left.
¾ Re-tighten the 4 hexagon-head screws on
the hydraulic pump (1) to the prescribed
tightening torque of 80 Nm.
¾ Re-attach the maintenance cover.
¾ Close the bonnet.

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5 Maintenance
Chassis, bodywork and fittings

Chassis, bodywork and fittings

Cleaning the truck
Cleaning requirements depend on the use of
the truck. For operations with highly abrasive
materials, e.g. salt water, fertiliser, chemicals,
cement etc., thorough cleaning should be
carried out after the task is complete.
Hot steam or cleaning materials with a pow-
erful degreasing effect should only be used
with great caution as they will affect the grease
filling of bearings with lifetime lubrication,
causing it to escape. As relubrication is not
possible, the bearings will be irreparably dam-
aged.
Switch off the engine and wait for it to cool
down before cleaning the truck.
Deposits/accumulations of combustible
materials, 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, any of the
hydraulic and coolant hoses 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

minimum distance between the steel pipe
and the truck should be approx. 300 mm.
When using compressed air for cleaning,
remove stubborn contamination with a cleaner
solvent.
Pay particular attention to cleaning the oil
filling openings, their surroundings and the
lubricating nipples before lubricating.

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 Maintenance 5
Chassis, bodywork and fittings

Bonnet
Opening the bonnet
WARNING
Always observe the following when opening the
bonnet with the engine running: The electric drive
and a temperature-dependent 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.
Wear protective equipment.

¾ Move steering column all the way forward

and clamp in place.
¾ Pull the lever (2) upwards and push the
driver’s seat as far forwards as it will go.
¾ Release the lever and allow the seat to
engage.

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5 Maintenance
Chassis, bodywork and fittings

¾ Unscrew clamping screw (8) on armrest

(9), push the armrest to the very bottom and
retighten the clamping screw (only for single
pedal operation and single lever operation
with 3rd auxiliary hydraulics).

¾ Lift button (10), push the seat surface back

as far as it will go (only for driver’s seats with
an adjustable seat depth).
¾ Push the lever (1) fully upwards, hold it
there, push the seat backrest (4) fully
forwards and release the lever (1). (Only
where rear window fitted)
¾ Push your finger into bore (3) to release the
bonnet catch; whilst doing so, release the
pressure on the bonnet catch by pressing
the bonnet in the direction of the arrow.

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 Maintenance 5
Chassis, bodywork and fittings

¾ Open the bonnet (6) to the rear up to the

stop.

NOTE
The bonnet is kept open by a gas spring (7).

Closing the bonnet

¾ Swing the bonnet down against the pres-
sure of gas spring (7) and push it closed
until locking lever (5) engages.

Floorplate
Opening the floorplate
Some maintenance operations require that
the floorplate is lifted.
¾ Open the bonnet.
¾ Unscrew fixing screws (2) and (5) from the
floorplate (1).
¾ Remove plates (3) and (4)
¾ Remove the rubber covering from the
floorplate.
¾ Fold the floorplate (1) up.

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5 Maintenance
Chassis, bodywork and fittings

¾ Attach the restraint strap (7) to the knob (6)

on the steering wheel.

Closing the floorplate

¾ Lift up the floorplate (1).
¾ Detach the restraint strap.
¾ Close the floorplate.
¾ Place the rubber covering on the floorplate.
¾ Install plates (3) and (4).
¾ Screw the floorplate and plates with fixing
screws (2) and (5).
¾ Close the bonnet.

Servicing the air conditioning

(special equipment)
The following services must be carried out at
the beginning, middle and end of a season:
¾ Check the compressor drive belt tension.
¾ Check the refrigerant level and moisture
content in the system.
The refrigerant must flow, bubble-free,
through the dryer’s (1) inspection glass when
the engine is running.
When changing a component in the cooling
circuit, the dryer must be changed before
refilling.
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.

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 Maintenance 5
Chassis, bodywork and fittings

Checking the condition and correct

function of the seat belt

NOTE
For safety reasons, the condition and correct
function of the restraint system should be
checked regularly (once a month). When
used under extreme conditions, this should be
carried out on a daily basis before starting up
the truck.
¾ Pull belt (3) right out and check for fraying
and torn stitching.
¾ Check that the buckle (1) functions correctly
and that the belt retracts properly.
¾ Check the covers and attachment points for
damage.
Test automatic blocking mechanism.
¾ Park truck in a horizontal position.
¾ Pull out belt with a jerk.
The automatic mechanism should block
extension of the belt from the belt retractor
(2).
¾ Push the driver’s seat all the way forwards.
¾ Fold the seat backrest completely forwards.

NOTE
When opening the bonnet, remember that the
rear window may have been installed.

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5 Maintenance
Chassis, bodywork and fittings

¾ Unlock the bonnet and open approx. 30°

with driver’s seat (4).
The automatic mechanism should block
extension of the belt from the belt retractor
(2).

WARNING
Do not use industrial trucks if the restraining belt
is defective. After an accident, restraining belts
must be changed. In the case of restraining belts
mounted on the driver’s seat, the driver’s seat and
the driver’s seat mounting must also be checked
by a technician following an accident. Screw
connections should be checked regularly to make
sure they are secure. If the seat wobbles, this may
indicate loose screw connections or other defects.
Any failure to do so creates a risk to your health and
an increased risk of accidents.
If you notice any irregularities in the functioning of
the seat (e.g. seat suspension) or the restraining
belt, you should immediately contact your authori-
sed dealer to eliminate the cause.

Check the attachment points on the

frame, tilt cylinder and steering axle
¾ Open the bonnet.
¾ Check the 4 fastening screws (M 20) on the
frame (2 (2) in the engine compartment,
one (2) on the left and one on the right of the
rear wheel arch) with a tightening torque of
385 Nm.
¾ Check the 4 fastening screws (M 16) (1) on
the frames (2 in the engine compartment,
2 behind the cover at the back) with a
tightening torque of 195 Nm.

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 Maintenance 5
Chassis, bodywork and fittings

¾ Check each of the 4 fastening screws (M16)

(3) on the tilt cylinder with a tightening
torque of 275 Nm.
¾ Check the fastening screws (M16) on the
steering axle with a tightening torque of
195 Nm.
¾ Close the bonnet.

Check other bearings and joints and

oil them

ENVIRONMENT NOTE
Take note of information about working
materials.
¾ Check and oil the following bearings and
fastenings:
• driver’s seat guide
• Bearing bolts for the bonnet
• windscreen wiper bearings (special equip-
ment).
• door locks and hinges of weather protection
cab (special equipment).
• Grease the bonnet lock.

NOTE
The bearings on the LPG cylinder cover are
maintenance-free.

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5 Maintenance
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
suspension 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.
¾ Prop up securely using square timber
supports at the chassis or counterweight.
¾ Unscrew the wheel fastenings.
¾ Change the wheel.
¾ Position wheel fastenings and tighten them
manually.
¾ Lower truck.
¾ Tighten wheel fastenings

Front 210 Nm
Rear 210 Nm

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 Maintenance 5
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 210 Nm
rear 210 Nm

Check tyres for damage and foreign

bodies
¾ Secure the truck against rolling away
(activate the parking brake).
¾ Place chock under a wheel not to be lifted.
¾ Raise truck with jack until wheels are off the
ground.
¾ Place pieces of timber underneath.
¾ Check for free movement of wheels and
remove anything hindering their movement.
¾ Replace worn or damaged tyres.

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5 Maintenance
Chassis frame

Checking the tyre pressure, tyre

sizes, rim sizes

CAUTION
If the air pressure is too low, the tyres’ service life
will be reduced and the stability of the forklift truck
will be compromised.
Therefore, regularly check the air pressure.

¾ Check that the tyres have the prescribed air

pressure.

¾ If necessary, adjust the tyre pressures in

accordance with the information on the
adhesive label (1) on the right-hand side of
the truck next to the drive wheel:
Drive axle

Single tyre
H 14, H 16 18x7-8/16 PR 10.0 bar
18x7 R8-XZM 10.0 bar
18x7-8 SE --
18x7x12 1/8 --
180/70 R8 SE --

H 18 18x7-8/16 PR 10.0 bar

17x7 R8-XZM 10.0 bar
18x7-8 SE --
18x7x12 1/8 --
180/70 R8 SE --
200/50-10 SE --

H 20, 18x7x12 1/8 --

H 20-600
200/50-10 SE --

Steering axle

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 Maintenance 5
Chassis frame

Single tyre
H 14, H 16, 18x7-8/16 PR 8.0 bar
H 18
18x7 R8-XZM 8.0 bar
18x7-8 SE --
18x6x12 1/8 --
180/70 R8 SE --

H 20, 18x6x12 1/8 --

H 20-600
180/70 R8 SE --
18x7-8 SE --

Example
Tyre pressure adhesive label (1)

Drive axle
Single tyre 10.0 bar

Steering axle
Single tyre 8.0 bar

Rim sizes
Tyre size Rim size
18x7-8 4.33R-8
18x6x12 1/8 308
18x7x12 1/8 308
180/70R8 4.33R-8
200/50-10 6.50F-10

Cleaning and greasing the steering

axle

ENVIRONMENT NOTE
Observe information regarding working with
consumables.

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5 Maintenance
Chassis frame

When used indoors in clean dry conditions, it

is generally sufficient to perform maintenance
every 1,000 operating hours. It is advisable to
halve these lubrication intervals if the vehicle
is used both indoors and outdoors.
If used in areas with constant exposure to dust,
dirt, water, road salt or chemicals, weekly
lubrication will considerably lengthen the
service life of the spherical bearings.

NOTE
It is better to apply a little grease to the
bearings frequently than a lot of grease
infrequently .
¾ Clean steering axle with water or cleaner
solvent.

NOTE
Lubricating grease should be used for grea-
sing in accordance with consumables recom-
mendations. First grease the axle stub bear-
ings on top, then underneath.
¾ Grease the lubricating nipples (2) on the
tie rod and the lubricating nipples (1) on the
axle stub on the right and left with lubricating
grease.
¾ Grease with grease gun until fresh lubricat-
ing grease escapes at bearings.

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 Maintenance 5
Chassis frame

Check the fastening on the steering

cylinder and axle stub bolt
¾ Check that the 4 fixing screws (1) are
securely seated. 2
Tightening torque: 210 Nm
¾ Check that the nut (2) on the axle stub bolt
is securely seated.
Tightening torque: 290 Nm 1

d3921345

Check the operation of the parking

brake
¾ Drive the fork lift truck, carrying its maximum
load, up a gradient of 15 %.
¾ Place the parking brake (2) in a horizontal
position.
The vehicle must remain stationary.
¾ Switch off the engine.
¾ Press the button (1) and unlock the parking
brake (2).
¾ Move the parking brake 90° downwards.
The vehicle must remain stationary.

NOTE
If the parking brake fails this test, contact your
authorised dealer.

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5 Maintenance
Controls

Controls
Checking the pedals

ENVIRONMENT NOTE
Observe information regarding working with
consumables.
¾ Open the floorplate and secure it in place.
¾ Unscrew the 4 nuts (1) on the pedal box.
¾ Check pedals for smooth action.
¾ If necessary, grease the bearings slightly.
¾ Re-attach the pedal box.

Checking the bellows at the actuat-

ing lever
¾ Check that the bellows (1), (2) and (3)
(depending on the version) are securely
positioned and show no signs of damage.
Change if necessary.

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 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.

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
conductive 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).

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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
without 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!
Wear protective equipment.

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.
¾ Open the floorplate.

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 Maintenance 5
Electrics

¾ Inspect battery (1) for cracked housing,

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
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.
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.
¾ Close the floorplate.
¾ Close the bonnet.

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5 Maintenance
Hydraulics

Hydraulics
Changing the hydraulic oil
Draining the hydraulic oil

ENVIRONMENT NOTE
Observe information regarding working with
consumables.
¾ Drive truck over pit.
¾ Fully lower the lift mast fork carriage.
¾ Open the bonnet. Unscrew the breather (2)
with dipstick (3).
¾ Place a collection vessel under the left side
of the truck floor.

¾ Unscrew hydraulic oil drain plug (1) on

hydraulic oil tank.
¾ Allow all oil to drain off. Clean area around
oil drainage location thoroughly.
¾ Refit drain plug.
Tightening torque: 25 Nm

Refilling/topping up the hydraulic oil

NOTE
There are 2 markings ("1" and "2") on the oil 1
dipstick (3). These apply to the various types
of lift mast and lift heights.
d3921335

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 Maintenance 5
Hydraulics

¾ Add hydraulic oil to filling port.

Mark "1"(5)
• Standard mast with lift height of 5410 mm or
less.
• Duplex mast: all lift heights.
• Triplex mast with lift height of 4775 mm or
less.
Total fill quantity: approx. 13.0 l
Mark "2"(4)
• Standard mast with lift height of 5510 mm or
higher.
• Triplex mast with lift height between
4925 mm and 7475 mm.
Total fill quantity: approx. 16.5 l
¾ Check oil level with dipstick (3) and top up
until upper mark on dipstick for relevant lift
height is reached.
¾ Allow engine to idle for 3 minutes in upper
range (parking brake applied and acceler-
ator pedal depressed). Do not start driving
though.
¾ Check the oil level again.
Only then should the suction filter be changed.
¾ Close the bonnet.

NOTE
The hydraulic system will bleed itself automa-
tically when the engine is running.

Hydraulic system: Check oil level

ENVIRONMENT NOTE
Take note of information about working
materials.

NOTE
Oil specifications: see Recommendations for
working materials
¾ Fully lower fork carriage.

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5 Maintenance
Hydraulics

¾ Unscrew the breather (1) with the oil dipstick

on the left-hand side of the vehicle.

NOTE
Tank under low pressure. A small amount of
air will escape.
¾ Wipe oil dipstick with a clean cloth.

NOTE
There are 2 markings ("1" and "2") on the oil
dipstick (2). These apply to the various types
of lift mast and stroke heights.

¾ Only check the marking which applies to

your truck.
Marking "1"(4)
• Standard mast with stroke height of
5410 mm or less.
• Duplex mast: all stroke heights.
• Triplex mast with stroke height of 4775 mm
or less.
Marking "2"(3)
• Standard mast with stroke height of
5510 mm or higher.
• Triplex mast with stroke height between
4925 and 7475 mm.
¾ Screw the refit breather with oil dipstick
completely in and then unscrew it again.
The oil level should be on the dipstick between
the marking for the stroke height in question.
¾ If necessary, add more hydraulic oil until it
reaches the marking for your truck.
Difference in quantity between min. and max.
for all stroke heights: approx. 0.8 l
Difference in quantity between marking "1"
and marking "2": approx. 3.5 l

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 Maintenance 5
Hydraulics

Hydraulic system: changing the filter

Feed and pressure filter

ENVIRONMENT NOTE
Observe information regarding working with
consumables.
¾ Unscrew the side maintenance cover on the
left.
¾ Lower lift mast. Slacken the lower fixing
screw (3) and the upper fixing screw (2) on
the filter carrier.
¾ Swing out the (1) filter carrier.
¾ Place a collection vessel underneath.
¾ Slacken the pressure filter housing (4) and
the feed filter housing (5) at the hexagonal
section.
¾ Unscrew the filter housing manually and
remove the filter cartridges from the base.

ENVIRONMENT NOTE
Dispose of the filter cartridges in an environ-
mentally friendly manner.
¾ Apply oil to the seals on the new filter
cartridges.
¾ Attach the filter cartridges to the base on the
filter top.
¾ Screw on the filter housing and tighten it
hand-tight.
Tightening torque: 10+5 Nm; then slacken it
back ¼ turn.
¾ Check the filter flange for leakage during
trial 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.

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5 Maintenance
Hydraulics

¾ Open the bonnet.

¾ Open the breather (1).
The air may escape and 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
reservoir.
¾ Pull filter cartridge out entirely.
¾ Carefully insert a new filter cartridge into the
filter cover.
Ensure that it is correctly centred in the filter
bottom.
¾ Clean seal of filter cover and wet with oil.
¾ Refit the filter cover (2) and turn it in a
clockwise direction
¾ Tighten the filter cover to 25 Nm.
The hydraulic system will bleed itself automat-
ically when the engine is running.
¾ Screw the breather on.
¾ Perform a trial run to check the filter cover
for leakage.
¾ Close the bonnet.

Breather

NOTE
If there are high levels of dust, it may be
necessary to change the filter earlier.
¾ Open the bonnet.

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 Maintenance 5
Hydraulics

¾ Unscrew the hydraulic oil tank filter (1) 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.
¾ Close the bonnet.

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
Take note of information about working
materials.
¾ Close the breather filter (1) and check
whether the breather valve is seating
correctly.
¾ Start the engine.
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, renew the
breather filter.

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5 Maintenance
Hydraulics

Check hydraulic system for leaks

¾ Open the base plate and secure it in place.
¾ Check all connections between the oil tank,
drive motors, pumps and control valves for
leaks.
¾ Re-tighten the connections if necessary.
¾ Check the lift, tilt and steering cylinders for
leaks.
¾ Replace porous hoses.
¾ Check lines for scuffing and replace if
necessary.
¾ Close the base plate.

Check the tilt cylinder bearings for

wear

NOTE
The tilt cylinders are attached on both sides in
spring elements.
¾ Undo screw (1) and remove it together with
washer (2).
¾ Visually check the spring elements for
cracks.
The rubber must not exhibit any cracks.
¾ Check the spring elements for each tilt
cylinder at the front and rear.
If the rubber bearings are worn or damaged,
renew them. Please advise your authorised
dealer.
¾ Refit the screw and washer.
¾ Tighten the screw to 275 Nm.

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 Maintenance 5
Hydraulics

Checking the hose carrier

NOTE
For trucks with duplex or triplex lift masts
and auxiliary hydraulics fitted there is a hose
carrier within the lift mast which serves to
tension and guide the double hoses.
Triplex lift mast
¾ Check that the hexagon head screw (2) is
securely attached.
Tightening torque: 49 Nm
¾ Check that the hexagon head screw (3) is
securely attached.
Tightening torque: 23 Nm
¾ Check that the countersunk screw (5) is
securely attached.
Tightening torque: 39 Nm
¾ Check that the tension springs (7) are
properly seated.
¾ Check the tension of the guide rollers (1) by
pressing the lever (6) in the direction of the
arrow.
¾ Check guide rollers (1) and (4) for free
movement.
¾ Oil the bearings of the guide rollers and
lever.
Duplex lift mast

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5 Maintenance
Hydraulics

¾ Check that the hexagon head screws (11)

are securely attached.
Tightening torque: 49 Nm
¾ Check that the hexagon head screw (13) is
securely attached.
Tightening torque: 23 Nm
¾ Check that the tension springs (10) are
properly seated.
¾ Check the tension of the guide rollers (8) by
pressing the lever (12) in the direction of the
arrow.
¾ Check guide rollers (8) and (9) for free
movement.
¾ Oil the bearings of the guide rollers and
lever.

Check the pre-tension of the double

tubes

NOTE
For vehicles with the standard lift mast and
additional hydraulics attached the pretension
of the double hoses must be checked.
Pretensioning of the double hoses should be
5-10 mm per metre, based on the initial length.
¾ Adjust the pretension by sliding the hoses
in the retaining clips to the measurement
specified.

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 Maintenance 5
Hydraulics

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 Switch on the ignition.
¾ Remove a cable connector from the sole-
noid valve on the fork carriage.
¾ Operate the pre-selector (1) from the
second 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
your authorised dealer.

Operating Instructions – 391 807 10 51 EN – 09/2010 199

5 Maintenance
Load lift system

Load lift system

Cleaning the lift mast chain and
applying chain spray

DANGER
Lift mast chains are safety elements. Incorrect
cleaning 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-
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 apply com-
pressed air to chain to remove any water
remaining on the surface 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.

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 Maintenance 5
Load lift system

Lift mast, lift mast chains, lift cylinder

and end stops: Check attachment,
condition and function
¾ Clean lift mast guides and chain.
¾ Check chain for condition and wear, espe-
cially at deflection pulleys.
¾ Check secure fastening of chain to chain
anchor.
¾ Replace damaged chains.

NOTE
Individual plastic links that are damaged or
missing do not impair function or service life.
¾ Check the condition and secure fastening
of the lift mast, guide surfaces and pul-
leys/rollers.
¾ Check the condition, secure fastening and
function of the end stops.
¾ Check the secure fastening of the lift
cylinders.
¾ Check the secure positioning of the lock ring
of the piston rod fastening to the lift mast at
the top.

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.

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5 Maintenance
Load lift system

¾ Release counter nut (2).

¾ Adjust chain at adjusting nut (1) of chain
anchor.
The lower guide roller of the fork carriage
should only protrude max. 25 mm from the
guide rail of the internal lift mast.
¾ Tighten counter nut (2) securely.
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 forklift trucks which are used in
the food production sector chain spray should
not be used but 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.

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 Maintenance 5
Load lift system

¾ Release counter nut (4). Adjust chain at

adjusting 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 internal lift mast.
¾ Tighten counter nut (4) securely.

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 forklift trucks which are used in
the food production sector chain spray should
not be used but 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
damage.
¾ Replace any defective parts.

d3921451

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5 Maintenance
Load lift system

Cleaning and lubricating the sideshift

(special equipment), checking the
fastening

ENVIRONMENT NOTE
Observe information regarding working with
consumables.

NOTE
The sideshift should be greased whenever
the truck is washed. Use lubricating grease
complying with the recommendations for
working materials.
¾ Clean sideshift with steam jet.
¾ Check hydraulic lines for scuffing and
replace 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 Move 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 the lubricating
nipples (1) of the support rollers on the fork
carriage until grease escapes at the side.
¾ Apply lubricating grease to the lubricating
nipples (2) of the slide guides on the fork
carriage until grease escapes at the side.

Checking the slide guides on the

sideshift (special equipment) for
wear
¾ Dismantle sideshift.

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 Maintenance 5
Load lift system

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

prong positioner (special equip-
ment), checking the mounting
¾ Clean the fork prong positioner using a
steam jet.
¾ Check condition of fork prong positioner
and check for leaks.
¾ Check hydraulic lines for chafing and
replace if necessary.
¾ Check hydraulic connections for tightness,
replace if necessary.
¾ Check cylinders for leaks.
¾ Check piston rods for damage.

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5 Maintenance
Load lift system

¾ Tighten mounting screws (1) to 106 Nm.

¾ Screw in the screws (2) to the fork arm stop,
tighten lock nut to 50 Nm.
¾ Tighten mounting screws (3) to 120 Nm.

¾ Tighten mounting screws (7) to 145 Nm.

¾ Lubricate slide guides (4) with lubricating
grease.
¾ Apply lubricating grease to lubricating
nipples (5) of the sliding shoes until grease
escapes at the side.
¾ Apply lubricating grease to lubricating
nipples (6) of the slide rollers until grease
escapes at the side.

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 Maintenance 5
Load lift system

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.
Please contact your authorised dealer.

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5 Maintenance
Special equipment, accessories

Special equipment, accessories

Topping up the washer system water
tank (special equipment)
¾ Fold up part (3) of the floormat.
¾ Remove the filler cap from the water tank
(2) through opening in the floorplate.
¾ Fill up with water until it is visible in the filler
opening (1).
¾ Refit the filler cap.
¾ Fold part (3) of the floormat back down
again.

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 Maintenance 5
Troubleshooting

Troubleshooting
Open cover of 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 two Allen screws (2) from the
cover at the top.
¾ Remove the cover (1).
¾ Remove the lid on the fuse box.

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5 Maintenance
Troubleshooting

Fuses for basic and special equipment

Checking and changing fuses

1 12 V socket (9F10)*, 15 A 20 Terminal 30 (F13), max. 15 A

2 Heating system / air conditioning (9F9)*, 21 Not assigned
20 A 22 Not assigned
3 Seat heater (9F6)*, 15 A 23 Not assigned
4 Hazard warning light and rotating beacon 24 Not assigned
(4F3)*, 7.5 A 25 Forklift Data Management (6F1)*, 5 A
5 Working spotlight positions 3, 4 (5F2)*, 15 A 26 Reverse travel (4F1)*, 10 A
6 Working spotlight positions 5, 6 (5F3)*, 15 A 27 Radio terminal 58 (9F8)*, 10 A
(with attachment of one 7.5 A headlight) 28 Radio terminal 30 (9F7)*, 5 A
7 Working spotlight positions 7, 8 (5F4)*, 15 A 29 Wash pumps (9F4)*, 10 A
(with attachment of one 7.5 A headlight) 30 Windscreen wiper rear and roof (9F3)*, 10 A
8 Rear window heating (9F5)*, 20 A 31 Front windscreen wiper (9F2)*, 10 A
9 Display unit (terminal 30) (F5), 2 A 32 Windscreen wiper (9F1)*, 2 A
10 Display unit (terminal 15) (F6), 2 A 33 Interior light (5F12)*, 5 A
11 Signal horn (F7), 15 A 34 Brake light (5F7)*, 5 A
12 Traction-lift control (terminal 15) (F8), 2 A 35 Hazard warning system (5F6/5F13)*, 10 A
13 Engine control unit (F12), 10 A 36 Lighting / working spotlight positions 1, 2
14 Engine control unit (F11), 7.5 A (5F5/5F1)*, 15 A
15 Ignition coil supply (F10), 20 A 37 Right sidelights (5F11)*, 5 A
16 Traction-lift control (terminal 30) (F9), 15 A 38 Left sidelights (5F10)*, 5 A
17 3rd auxiliary hydraulics (F16)*, 7.5 A 39 Right headlight (5F9)*, 7.5 A
18 Terminal 15 (F15), 10 A 40 Left headlight (5F8)*, 7.5 A
19 Terminal 58 (F14), 2 A

* Special equipment

Main fuses in engine compartment

Checking and changing fuses
¾ Open the bonnet.
210 Operating Instructions – 391 807 10 51 EN – 09/2010
 Maintenance 5
Troubleshooting

¾ Open the fuse box cover (1).

In the engine compartment, MTA fuses protect
the following circuits:
• Main fuse (F3) (2) for complete special
equipment, 70 A
• Fuse (F4) (3) for fan motor, 20 A
• Main fuse (F2) (4) for complete electrical
system, 30 A
When air conditioning (special equipment) is
installed, the fuse box (5) is also installed.
• Fuse (9F11), 30 A

Diagnostics connector
The diagnostic connector can be found on the
left behind the driver’s seat.
¾ For troubleshooting purposes, the diagnos-
tic device including the relevant diagnostic
software is connected to the diagnostic con-
nector. In addition, truck data can be read
in and out, adjustments made and mainte-
nance intervals reset or amended.
Please contact your authorised dealer.

Jump start

NOTE
When the truck battery is discharged, a
jump-start battery can be used with a jumper

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5 Maintenance
Troubleshooting

cable 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
battery 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
discharged truck battery (2) to a massive
metal component securely connected to the
engine 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.
¾ Start the engine.
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

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 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 Unscrew 2 screws from the anti-slip pan-
elling in the left step tread (4).
¾ Remove the panelling.

DANGER
Risk of accident or danger to life
when lowering the fork carriage with
fork arms.
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 threaded stud (1) on
the valve block (3) to enable lowering
to be interrupted at any time.

¾ Slowly turn the threaded stud (1)

about 3 turns anti-clockwise using an 8 AF
socket wrench, then wait until the fork
carriage is fully lowered.
¾ Turn the sealing collar nut (2) approx. 2 rev-
olutions.

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5 Maintenance
Troubleshooting

¾ Screw the threaded stud (1) back in clock-

wise. Otherwise it will not be possible to lift
the fork carriage using the joystick.
Tightening torque 10 Nm.
¾ Retighten the self locking nut (2).
Tightening torque 9.5 Nm.

NOTE
After emergency lowering has been perfor-
med three times, a new threaded stud with self
locking nut must be used.
¾ Secure the anti-slip panelling in the left step
tread with 2 screws.

Emergency exit with attached rear

window
If a vehicle with an attached front and rear
window breaks down in a narrow aisle, the
driver may possibly be unable to exit the
vehicle at the side. In the event of acute
danger the driver can exit the vehicle via
the rear window. For this purpose, the rear
window must be destroyed with an emergency
hammer.
¾ Bend up splint (1) from the holder (2)
beneath the rear wiper motor.

WARNING
Glass splinters may cause injuries.
Remove glass splinters carefully.

¾ Take the emergency hammer (3) carefully

out of the holder and break the rear window
carefully.
¾ Climb out carefully.
3

2 1
t3921371

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 Maintenance 5
Troubleshooting

Towing instructions
Towing
If the truck needs to be towed away, the
following can be brought about by the towing
device:
• short-circuiting of hydraulic oil circuit
• release of multi-disc brakes in drive axle via
brake valve and Stop pedal.

WARNING
Braking of the truck is no longer possible. The
parking brake does not function either.
To tow the truck a towing vehicle with sufficient
tractive power and braking force for the unbraked
towed load is thus required. It is only permitted to
tow the truck using a fixed connection (towing rod).

Towing process
¾ Lower the load so that the fork arms do not
scrape on the ground during towing.
¾ Remove load.
¾ Attach towing vehicle (ensure sufficient
tractive power and braking force) to towing
bolt of truck using towing rod.

Open shorting plunger of hydraulics

¾ Open motor hood.
¾ Release sealing collar nut (2) (size
SW 19 mm) on left on variable pump with
socket at housing.
¾ Unscrew threaded stud (1) (SW 8 mm)
2 turns in an anti-clockwise direction with
socket.
¾ Lock threaded stud with sealing collar nut
(2), tighten to 80 Nm.
¾ Close motor hood.

Release multi-disc brake

The brake valve can be found under the floor
plate on the truck frame on the left.

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5 Maintenance
Troubleshooting

¾ Fold up part (4) of the base plate.

¾ Insert Allen key (SW 5 mm) through the
opening in the floor plate and unscrew
socket head screw (3) about 6 turns in an
anti-clockwise direction.
¾ Sit on driver’s seat.
¾ Move the parking brake (4) downwards.
The symbol on the indicator unit will go out.
¾ Move Stop pedal several times in easy-
movement range until resistance is felt
(pump) until brake is released.

After towing
¾ Place chocks underneath on side facing
downhill.
¾ Open motor hood.
¾ Release sealing collar nut (2) on variable
pump.
¾ Insert threaded stud (1) (SW 8 mm) in
a clockwise direction and tighten it to
20+5 Nm.
¾ Lock threaded stud with sealing collar nut
(1).
¾ Tighten nut to 80 Nm.

Restore braking
¾ Insert socket head screw (3) in a clockwise
direction as far as the stop in valve block.
¾ Close part (4) of the base plate and close
the bonnet.
DANGER
The forklift truck must not be driven if the braking
system is defective.
After repairs to the braking system check function.
If defects in the braking system occur , contact your
authorised dealer.

216 Operating Instructions – 391 807 10 51 EN – 09/2010


Placing the forklift truck into storage
Actions prior to placing the forklift truck
into storage
If the truck is to be placed into storage for more
than 2 months e. g. for operational reasons, it
should be stored only in a well ventilated, clean
and dry room free of frost, and the following
measures undertaken beforehand.
¾ Clean forklift truck thoroughly.
¾ Raise the fork carriage several times to the
end stop.
¾ Tilt the lift mast several times back and for-
wards and operate any special attachments
that may be fitted .
¾ Lower the fork carriage to a supporting
surface until the chains are relieved of load.
¾ Check the hydraulic oil level and top up if
necessary.
¾ Tightly close the shut-off valve for the gas
bottle or gas tank.
¾ Empty the gas hoses by starting the engine.
¾ Remove the gas bottle.
¾ All unpainted mechanical components
should be coated with a thin film of oil or
grease.
¾ Grease truck.
¾ Disconnect the battery.
¾ Check battery condition and density of acid.
¾ Lubricate battery terminals with acid-free
grease. (Follow instructions of battery
manufacturer .)
¾ Apply a suitable contact spray to all exposed
electrical contacts.
Disposal of old vehicles
The disposal of old vehicles is regulated
in directive 2000/53/EC of the European
Parliament and Council.
Operating Instructions – 391 807 10 51 EN – 09/2010
Maintenance 5
Troubleshooting
¾ Jack up the truck so all wheels are off the
ground.
This will prevent permanent deformation of the
tyres.
NOTE
Do not cover with plastic foil or this will encou-
rage the formation and collection of conden-
sed water.
NOTE
If the truck is to be shut down for more than 6
months, further measures should be agreed
with your authorised dealer.
Bringing back into service after storage
¾ Clean forklift truck thoroughly.
¾ Lubricate the forklift truck.
¾ Connect the battery.
¾ Clean the battery and lubricate battery
terminals with acid-free grease
¾ Check battery condition and specific gravity
of acid and recharge if necessary.
¾ Check engine oil for condensed water,
change if necessary.
¾ Check hydraulic oil for condensed water,
change if necessary.
¾ Perform maintenance as before initial
commissioning.
¾ Fit the gas bottle and connect it in accor-
dance with instructions.
¾ Put forklift truck into service.
We recommend having this work carried out
by an authorised salvager. If you want to do
this yourself, you must, according to Articles
9, 10 and 11 the directive 75/442/EEC, obtain
a permit from the responsible authorities.
217
5 Maintenance
Troubleshooting

The following minimum requirements must
also be observed:
• The storage locations for old vehicles
before their processing must be suitable
areas with an impermeable surface. They
must be provided with collecting facilities
and separators for fluids running out and
grease-cutting cleaning agents.
• The processing locations must be suitable
areas with an impermeable surface. They
must be provided with collecting facilities
and separators for fluids running out and
grease-cutting cleaning agents. Suitable
storerooms for removed parts and parts
partially smeared with oil as well as for tyres,
including fire protection measures. Suitable
storage tanks for fluids such as fuel, engine
oil, hydraulic oil, coolant and fluids from air
conditioners must also be available.
• For the disposal of harmful substances from
the old vehicles, the batteries and LPG bot-
tle/tanks must be removed. The following
must also be removed, collected and stored
separately: fuel, engine oil, coolant, hy-
draulic oil, fluids from air conditioners.
• The following parts can be collected and
recycled separately: catalytic converters,
metal parts containing copper and alu-
minium, tyres, big plastic parts (console,
fluid reservoirs), glass.
NOTE
The owner is responsible for the compliance
with the directives and further national regula-
tions.

Malfunctions during operation

CAUTION
If one of the following indicator lights illuminates
in the display 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 Remedy)

• Hydraulic oil temperature indicator (1) and

buzzer
• Battery charge indicator (2)
• Engine oil pressure indicator (3) and/or en-
gine oil level indicator (special equipment)
and buzzer
• Indicator light: error in electrical control
system (4)
• Engine coolant temperature indicator (5)
and buzzer
• Hydraulic oil microfilter indicator (6) (special
equipment)
• Air filter vacuum indicator (8)
• Coolant level indicator (9) (special equip-
ment)

218 Operating Instructions – 391 807 10 51 EN – 09/2010

 Maintenance 5
Troubleshooting

• Gas system error light (10)

• Engine malfunction warning light (11).
The following should also be kept in mind:

NOTE
• If the indicator light (4) flashes, there is an
error in the electrical controller. Depending
on the setting and error, it may only be
possible to drive the truck at low speed
or not at all. Each error is indicated by a
numerical code or symbols in the text field
(7). Please contact your authorised dealer.
• If the error light (10) illuminates together
with the warning light (11), there is a fault in
the gas shortage shut-down device. Please
contact your authorised dealer.
• If the error light (10) illuminates, there is a
fault in the gas system. Please contact your
authorised dealer.
• If the error light (10) flashes after starting
the engine, a fault in the gas system has
been logged that must be cleared by your
authorised dealer.
• If the air filter vacuum indicator (8) lights up
on the display unit, maintenance must be
performed on the air filter.
• Only if the 3rd auxiliary hydraulics are
fitted: If the switchable additional function is
blocked, the truck is only travelling at creep
speed or the text field (7) shows error code
L247 and the buzzer sounds, there is a
malfunction in the safety system. Please
contact your authorised dealer.

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5 Maintenance
Troubleshooting
Malfunctions, Causes and Remedy (LPG engine)
Engine fails to start
Possible cause
Shut-off valve for LPG cylinder or LPG tank
closed.
Gas cylinder or LPG tank empty.
Temperature of LPG in tank too low.
Electromagnetic gas shut-off valve does not
open.
LPG filter clogged.
Break in ignition circuit.
Spark plugs damp (condensed water).
Spark plugs oily due to defective piston rings or Change spark plugs or have engine checked
worn pistons.
Spark plugs defective, spark plug gap too great. Correct spark plug gap or replace spark plugs.
Immobiliser active.
The indicator unit does not light up.
Engine starts but does not idle smoothly.
Possible cause
Intake manifold connections not tight.
Electric speed control badly adjusted.
No valve clearance or valves worn.
Pressure drop between piston and cylinder.
Engine oil level too high.
Engine overheats, radiator water temperature indicator lights up in the indicator unit. Switch off
engine immediately.
Possible cause
Insufficient coolant in cooling system.
Water cooler radiator fins partially clogged by
dirt or foreign bodies.
Gas/air mixture too lean.
220
Remedy
Open shut-off valve.
Change gas cylinder, fill LPG tank.
Heat gas system and lines with hot water. Do
not use naked flame or hot air.
Use test lamp to check whether power is
available; if not, check line and eliminate fault.
Change shut-off valve if necessary. Fuse F11
may be defective, change fuse.
Change LPG filter.
Check circuit, starting with battery.
Dry spark plugs thoroughly.
by your authorised dealer.
Contact your authorised dealer
Tighten connecting terminals on battery, check
line connections.
Remedy
Tighten fastenings. Change flange gasket,
check intake manifold for cracks.
Contact your authorised dealer.
Contact your authorised dealer.
Contact your authorised dealer.
Drain oil until oil level is at upper dipstick mark.
Remedy
Check the cooling system for leaks, seal them
as required. Top up the coolant fluid.
Clean water and hydraulic oil coolers.
Contact your authorised dealer.
Operating Instructions – 391 807 10 51 EN – 09/2010
 Maintenance 5
Troubleshooting

Engine oil pressure too low. Switch off engine immediately.

Possible cause Remedy
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.

Possible cause
Three-phase alternator speed too low.
Battery not being charged by alternator,
alternator or cut-out relay defective.
Remedy
Check V-ribbed belt tension.
Contact your authorised dealer

Engine not firing on all 4 cylinders.

Possible cause
Loose cable connections at ignition coils.
Connector defective (insulation breakdown).
Spark plugs soiled or defective.
Leaking or seized valve.
Remedy
Check cable connections and tighten.
Check connector, change defective parts as
necessary.
Clean spark plugs, check gap between electro-
des, change spark plugs if necessary.
Contact your authorised dealer.

Engine does not run smoothly or misfires.

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

Once warm, engine does not idle smoothly; smoky exhaust.

Possible cause Remedy
Idling speed not set correctly. Contact your authorised dealer.

Engine pinks under load.

Possible cause Remedy
Ignition timing too advanced. Contact your authorised dealer.
Engine overheating. See: Engine overheating.
Heavy coking in combustion chamber. Contact your authorised dealer.

Operating Instructions – 391 807 10 51 EN – 09/2010 221

5 Maintenance
Troubleshooting

Engine pinks under load.

Possible cause Remedy
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 in indicator unit lights up.

Possible cause Remedy
Shut down truck immediately. Defect can
Fault in LPG system. be determined using the diagnostics device.
Please contact your authorised dealer

Error light and warning light in the indicator unit light up.
Possible cause Remedy
Fault in the fuel shortage shut-down device. Please contact your authorised dealer

Yellow indicator light in the switch panel lights up (applies only to US version).
Possible cause Remedy
Have the engine exhaust system checked
Fault in the exhaust system. without delay. Please contact your authorised
dealer.

Truck only moves at crawling speed, the buzzer sounds and error code X201 is displayed in the
text field of the indicator unit.
Possible cause Remedy
Engine oil level too low. Top up engine oil.

Truck only moves at crawling speed, the buzzer sounds and error code X202 is displayed in the
text field of the indicator unit.
Possible cause Remedy
Top up engine oil; if the error persists, contact
Engine oil pressure too low.
your authorised dealer.

Truck only moves at crawling speed, the buzzer sounds and error code X203 is displayed in the
text field of the indicator unit.
Possible cause Remedy
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.
Possible cause Remedy
Radiator water level too low. Top up radiator water.

222 Operating Instructions – 391 807 10 51 EN – 09/2010

 Maintenance 5
Troubleshooting

Truck only moves at crawling speed, the buzzer sounds and error code X204 is displayed in the
text field of the indicator unit.
Possible cause Remedy
Top up radiator water. Water pump defective.
Engine temperature too high. Clean the water cooler. Adjust the fuel injection
system.

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5 Maintenance
Troubleshooting
Malfunctions, Causes, Remedies (ultrasonic sensor)
No display possible.
Possible cause
Supporting surface dirty.
No display at the fuel gauge.
Incorrect value displayed.
Possible cause
Maximum forklift truck tilt exceeded.
Partially filled gas bottle fitted.
Different bottle diameter or gas mixture used.
Engine cuts out although the fuel gauge shows there is still fuel.
Possible cause
Gas bottle mounted crookedly.
Partially filled gas bottle fitted.
224
Remedy
Carefully clean the supporting surface.
Position the gas bottle correctly or check
whether the gas bottle is positioned with a weld
seam or label over the sensor, remove label if
so.
Remedy
Drive the forklift truck away from the sloping
ground. Switch the ignition on and off.
Fit a full gas bottle.
Either use the correct bottle or recalibrate the
sensor.
Remedy
Place the gas bottle in the correct position and
secure it
Fit a full gas bottle.
Operating Instructions – 391 807 10 51 EN – 09/2010
 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.

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

Oil pressure fluctuations.

Possible cause Correction
Causes as for abnormal noises. See under abnormal noises.
Pressure relief valve or feed pressure valves
Please contact your authorised dealer.
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.

Possible cause Correction
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.

Operating Instructions – 391 807 10 51 EN – 09/2010 225

5 Maintenance
Troubleshooting

No flow or insufficient flow.

Possible cause Correction
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.

Possible cause
Pump damage, valves leaking.
Insufficient oil in the tank or oil cooler clogged.
Correction
Contact your authorised dealer.
Check the hydraulic oil level, top up with
hydraulic oil if necessary. Clean the hydraulic
oil cooler and check for leaks, if defective
contact your authorised dealer.

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
Possible cause Correction
Check the hydraulic oil level Clean the hydrau-
Hydraulic oil temperature too high.
lic oil cooler.

Malfunction in the third auxiliary hydraulic system (special equipment).

Possible cause Correction
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
Please contact your authorised dealer.
blocked.

226 Operating Instructions – 391 807 10 51 EN – 09/2010

 6

Technical data
6 Technical data
Type sheet H14T, as at 04/2008

Type sheet H14T, as at 04/2008

1 Identification
1.1 Manufacturer Linde
1.2 Manufacturer’s type designation H14T
1.3 Drive LPG
1.4 Operation Seated
1.5 Load capacity / Load Q [kg] 1400
1.6 Load centre of gravity c [mm] 500
1.8 Load distance x [mm] 365
1.9 Wheelbase y [mm] 1500

2 Weight
2.1 Net weight kg 2565
2.2 Axle load with front/rear load kg 3450 / 515
2.3 Axle load without front/rear load kg 1240 / 1325

3 Wheels, chassis frame

3.1 Front/rear tyres: polyurethane, rubber SE
3.2 Front tyre size 18x7-81
3.3 Rear tyre size 18x7-8
3.5 Number of wheels, front/rear (x = driven) 2x / 2
3.6 Front track width b10 [mm] 930
3.7 Rear track width b11 [mm] 873

4 Basic dimensions
4.1 Forward/backward fork tilt α/β (°) 6.0 / 9.02
4.2 Lowered mast height h1 [mm] 21973
4.3 Free lift h2 [mm] 150
4.4 Lift h3 [mm] 3150
4.5 Raised mast height h4 [mm] 3754
4.7 Overhead guard height (cab) h6 [mm] 2123

1 Alternatively: SE 18x7-8 or 200/50-10 (SE).

2 Lift height and equipment can change the backwards tilt.
3 With 150 mm free lift on standard mast.

228 Operating Instructions – 391 807 10 51 EN – 09/2010

 Technical data 6
Type sheet H14T, as at 04/2008

4 Basic dimensions
4.8 Seat height, min / max h7 [mm] 1067
4.12 Coupling height h10 [mm] 557
4.19 Total length l1 [mm] 3112
4.20 Length including fork back l2 [mm] 2212
4.21 Total width b1 /b2 [mm] 1086
4.22 Fork arm dimensions s/e/l [mm] 40 x 80 x 900
4.23 Fork carriage DIN 15173, class/form A, B 2A
4.24 Fork carriage width b3 [mm] 1040
4.31 Ground clearance at mast m1 [mm] 94
4.32 Ground clearance at centre of wheelbase m2 [mm] 120
4.33 Aisle width for pallet 1000x1200 crosswise Ast [mm] 3570
4.34 Aisle width for pallet 800x1200 longitudinal Ast [mm] 3770
4.35 Turning radius Wa [mm] 2005
4.36 Smallest pivot point distance b13 [mm] 600

5 Performance data
5.1 Driving speed with/without load km/h 20/20
5.2 Lifting speed with/without load m/s 0.60 / 0.63
5.3 Lowering speed with/without load m/s 0.57 / 0.57
5.5 Pulling force with/without load N 12900 / 9500
5.7 Climbing capability with/without load % 4
35.0 / 38.0
5.9 Acceleration with/without load s 4.7 / 4.2
5.10 Service brake Hydrostatic

7 Drive / Engine
7.1 Engine manufacturer / model VW/BEF
7.2 Engine power rating as per ISO 1585 kW 28
7.3 Nominal speed rpm 2100
3
7.4 Number of cylinders / Displacement cm 4/1984
7.5 Fuel consumption according to VDI cycle kg/h 2.0; 1.55

4 On short slopes, driving over obstacles (see section: Driving).

5 Due to a change in the measuring procedure for VDI standard 2198,
the value stated is higher when compared to previous data.

Operating Instructions – 391 807 10 51 EN – 09/2010 229

6 Technical data
Type sheet H14T, as at 04/2008

8 Miscellaneous
hydrostatic /
8.1 Traction controller type continuously
variable
8.2 Working pressure for attachments bar 180
8.3 Oil volume for attachments l/min 38
8.4 Noise level in driver’s ear dB (A) 73
8.5 Towing hook, type/model DIN DIN 15170-H

All data refers to standard equipment with

standard 3110 mm lift mast.

230 Operating Instructions – 391 807 10 51 EN – 09/2010

 Technical data 6
Type sheet H16T, as at 04/2008

Type sheet H16T, as at 04/2008

1 Identification
1.1 Manufacturer Linde
1.2 Manufacturer’s type designation H16T
1.3 Drive LPG
1.4 Operation Seated
1.5 Load capacity / Load Q [kg] 1600
1.6 Load centre of gravity c [mm] 500
1.8 Load distance x [mm] 365
1.9 Wheelbase y [mm] 1500 (1600)6

2 Weight
2.1 Net weight kg 27257
2.2 Axle load with front/rear load kg 3780 / 5458
2.3 Axle load without front/rear load kg 1255 / 14709

3 Wheels, chassis frame

3.1 Front/rear tyres: polyurethane, rubber SE
3.2 Front tyre size 18x7-810
3.3 Rear tyre size 18x7-8
3.5 Number of wheels, front/rear (x = driven) 2x / 2
3.6 Front track width b10 [mm] 930
3.7 Rear track width b11 [mm] 873

4 Basic dimensions
4.1 Forward/backward fork tilt α/β (°) 6.0 / 9.011
4.2 Lowered mast height h1 [mm] 219712
4.3 Free lift h2 [mm] 150

6 When ordering: "large replacement cylinder".

7 When ordering: "large replacement cylinder".
8 When ordering: "large replacement cylinder".
9 When ordering: "large replacement cylinder".
10 Alternatively: SE 18x7-8 or 200/50-10 (SE).
11 Lift height and equipment can change the backwards tilt.
12 With 150 mm free lift on standard mast.

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6 Technical data
Type sheet H16T, as at 04/2008

4 Basic dimensions
4.4 Lift h3 [mm] 3150
4.5 Raised mast height h4 [mm] 3754
4.7 Overhead guard height (cab) h6 [mm] 2123
4.8 Seat height, min / max h7 [mm] 1067
4.12 Coupling height h10 [mm] 557
4.19 Total length l1 [mm] 3112 (3222)13
4.20 Length including fork back l2 [mm] 2212 (2322)14
4.21 Total width b1 /b2 [mm] 1086
4.22 Fork arm dimensions s/e/l [mm] 40 x 80 x 900
4.23 Fork carriage DIN 15173, class/form A, B 2A
4.24 Fork carriage width b3 [mm] 1040
4.31 Ground clearance at mast m1 [mm] 93
4.32 Ground clearance at centre of wheelbase m2 [mm] 119
4.33 Aisle width for pallet 1000x1200 crosswise Ast [mm] 3570 (3686)15
4.34 Aisle width for pallet 800x1200 longitudinal Ast [mm] 3770 (3886)16
4.35 Turning radius Wa [mm] 2005 (2121)17
4.36 Smallest pivot point distance b13 [mm] 600 (638)18

5 Performance data
5.1 Driving speed with/without load km/h 20/20
5.2 Lifting speed with/without load m/s 0.60 / 0.63
5.3 Lowering speed with/without load m/s 0.57 / 0.57
5.5 Pulling force with/without load N 12,900 / 9600
5.7 Climbing capability with/without load %19 32.0 / 36.0
5.9 Acceleration with/without load s 4.9 / 4.3
5.10 Service brake Hydrostatic

13 When ordering: "large replacement cylinder".

14 When ordering: "large replacement cylinder".
15 When ordering: "large replacement cylinder".
16 When ordering: "large replacement cylinder".
17 When ordering: "large replacement cylinder".
18 When ordering: "large replacement cylinder".
19 On short slopes, driving over obstacles (see section: Driving).

232 Operating Instructions – 391 807 10 51 EN – 09/2010

 Technical data 6
Type sheet H16T, as at 04/2008

7 Drive / Engine
7.1 Engine manufacturer / model VW/BEF
7.2 Engine power rating as per ISO 1585 kW 28
7.3 Nominal speed rpm 2100
7.4 Number of cylinders / Displacement cm3 4/1984
7.5 Fuel consumption according to VDI cycle kg/h 2.1; 1.620

8 Miscellaneous
hydrostatic /
8.1 Traction controller type continuously
variable
8.2 Working pressure for attachments bar 170
8.3 Oil volume for attachments l/min 38
8.4 Noise level in driver’s ear dB (A) 73
8.5 Towing hook, type/model DIN DIN 15170-H

All data refers to standard equipment with

standard 3110 mm lift mast.

20 Due to a change in the measuring procedure for VDI standard 2198,

the value stated is higher when compared to previous data.

Operating Instructions – 391 807 10 51 EN – 09/2010 233

6 Technical data
Type sheet H16CNG, as at 02/2008

Type sheet H16CNG, as at 02/2008

1 Identification
1.1 Manufacturer Linde
1.2 Manufacturer’s type designation H16CNG-L
1.3 Drive CNG
1.4 Operation Seated
1.5 Load capacity / Load Q [kg] 1600
1.6 Load centre of gravity c [mm] 500
1.8 Load distance x [mm] 365
1.9 Wheelbase y [mm] 1600

2 Weight
2.1 Net weight kg 2815
2.2 Axle load with front/rear load kg 3720 / 695
2.3 Axle load without front/rear load kg 1255 / 1560

3 Wheels, chassis frame

3.1 Front/rear tyres: polyurethane, rubber SE
3.2 Front tyre size 18x7-8-SC15
3.3 Rear tyre size 18x7-8-SC15
3.5 Number of wheels, front/rear (x = driven) 2x / 2
3.6 Front track width b10 [mm] 930
3.7 Rear track width b11 [mm] 873

4 Basic dimensions
4.1 Forward/backward fork tilt α/β (°) 6.0 / 9.0
4.2 Lowered mast height h1 [mm] 2198
4.3 Free lift h2 [mm] 150
4.4 Lift h3 [mm] 3150
4.5 Raised mast height h4 [mm] 3755
4.7 Overhead guard height (cab) h6 [mm] 2123
4.8 Seat height, min / max h7 [mm] 1067
4.12 Coupling height h10 [mm] 530

234 Operating Instructions – 391 807 10 51 EN – 09/2010

 Technical data 6
Type sheet H16CNG, as at 02/2008

4 Basic dimensions
4.19 Total length l1 [mm] 3222
4.20 Length including fork back l2 [mm] 2322
4.21 Total width b1 /b2 [mm] 1086
4.22 Fork arm dimensions s/e/l [mm] 40 x 80 x 900
4.23 Fork carriage DIN 15173, class/form A, B 2A
4.24 Fork carriage width b3 [mm] 1040
4.31 Ground clearance at mast m1 [mm] 95
4.32 Ground clearance at centre of wheelbase m2 [mm] 121
4.33 Aisle width for pallet 1000x1200 crosswise Ast [mm] 3686
4.34 Aisle width for pallet 800x1200 longitudinal Ast [mm] 3886
4.35 Turning radius Wa [mm] 2121
4.36 Smallest pivot point distance b13 [mm] 638

5 Performance data
5.1 Driving speed with/without load km/h 20/20
5.2 Lifting speed with/without load m/s 0.60 / 0.63
5.3 Lowering speed with/without load m/s 0.57 / 0.57
5.5 Pulling force with/without load N 12,900 / 9600
5.7 Climbing capability with/without load %21 32.0 / 36.0
5.9 Acceleration with/without load s 4.9 / 4.3
5.10 Service brake Hydrostatic

7 Drive / Engine
7.1 Engine manufacturer / model VW / CBS
7.2 Engine power rating as per ISO 1585 kW 30
7.3 Nominal speed rpm 2100
7.4 Number of cylinders / Displacement cm3 4/1984
7.5 Fuel consumption according to VDI cycle m3 / h H-gas 2.9

8 Miscellaneous
hydrostatic /
8.1 Traction controller type continuously
variable

21 On short slopes, driving over obstacles (see section: Driving).

Operating Instructions – 391 807 10 51 EN – 09/2010 235

6 Technical data
Type sheet H16CNG, as at 02/2008

8 Miscellaneous
8.2 Working pressure for attachments bar 170
8.3 Oil volume for attachments l/min 38
8.4 Noise level in driver’s ear dB (A) 73
8.5 Towing hook, type/model DIN DIN 15170-H

All data refers to standard equipment with

standard 3110 mm lift mast.

236 Operating Instructions – 391 807 10 51 EN – 09/2010

 Technical data 6
Type sheet H18T, as at 04/2008

Type sheet H18T, as at 04/2008

1 Identification
1.1 Manufacturer Linde
1.2 Manufacturer’s type designation H18T
1.3 Drive LPG
1.4 Operation Seated
1.5 Load capacity / Load Q [kg] 1800
1.6 Load centre of gravity c [mm] 500
1.8 Load distance x [mm] 370
1.9 Wheelbase y [mm] 1540 (1600)22

2 Weight
2.1 Net weight kg 2935
2.2 Axle load with front/rear load kg 4120 / 57523
2.3 Axle load without front/rear load kg 1300 / 159524

3 Wheels, chassis frame

3.1 Front/rear tyres: polyurethane, rubber SE
3.2 Front tyre size 18x7-825
3.3 Rear tyre size 18x7-8
3.5 Number of wheels, front/rear (x = driven) 2x / 2
3.6 Front track width b10 [mm] 930
3.7 Rear track width b11 [mm] 873

4 Basic dimensions
4.1 Forward/backward fork tilt α/β (°) 6.0 / 9.026
4.2 Lowered mast height h1 [mm] 219727
4.3 Free lift h2 [mm] 150
4.4 Lift h3 [mm] 3150

22 When ordering: "large replacement cylinder".

23 When ordering: "large replacement cylinder".
24 When ordering: "large replacement cylinder".
25 Alternatively: SE 18x7-8 or 200/50-10 (SE).
26 Lift height and equipment can change the backwards tilt.
27 With 150 mm free lift on standard mast.

Operating Instructions – 391 807 10 51 EN – 09/2010 237

6 Technical data
Type sheet H18T, as at 04/2008

4 Basic dimensions
4.5 Raised mast height h4 [mm] 3754
4.7 Overhead guard height (cab) h6 [mm] 2123
4.8 Seat height, min / max h7 [mm] 1067
4.12 Coupling height h10 [mm] 549
4.19 Total length l1 [mm] 3152 (3227)28
4.20 Length including fork back l2 [mm] 2252 (2327)29
4.21 Total width b1 /b2 [mm] 1086
4.22 Fork arm dimensions s/e/l [mm] 45 x 100 x 900
4.23 Fork carriage DIN 15173, class/form A, B 2A
4.24 Fork carriage width b3 [mm] 1040
4.31 Ground clearance at mast m1 [mm] 92
4.32 Ground clearance at centre of wheelbase m2 [mm] 118
4.33 Aisle width for pallet 1000x1200 crosswise Ast [mm] 3611 (3691)30
4.34 Aisle width for pallet 800x1200 longitudinal Ast [mm] 3811 (3891)31
4.35 Turning radius Wa [mm] 2041 (2121)32
4.36 Smallest pivot point distance b13 [mm] 615 (638)33

5 Performance data
5.1 Driving speed with/without load km/h 20/20
5.2 Lifting speed with/without load m/s 0.60 / 0.63
5.3 Lowering speed with/without load m/s 0.57 / 0.57
5.5 Pulling force with/without load N 12,900 / 10,000
5.7 Climbing capability with/without load %34 29.0 / 35.0
5.9 Acceleration with/without load s 5.0 / 4.5
5.10 Service brake Hydrostatic

28 When ordering: "large replacement cylinder".

29 When ordering: "large replacement cylinder".
30 When ordering: "large replacement cylinder".
31 When ordering: "large replacement cylinder".
32 When ordering: "large replacement cylinder".
33 When ordering: "large replacement cylinder".
34 On short slopes, driving over obstacles (see section: Driving).

238 Operating Instructions – 391 807 10 51 EN – 09/2010

 Technical data 6
Type sheet H18T, as at 04/2008

7 Drive / Engine
7.1 Engine manufacturer / model VW/BEF
7.2 Engine power rating as per ISO 1585 kW 28
7.3 Nominal speed rpm 2100
7.4 Number of cylinders / Displacement cm3 4/1984
7.5 Fuel consumption according to VDI cycle kg/h 2.2; 1.735

8 Miscellaneous
hydrostatic /
8.1 Traction controller type continuously
variable
8.2 Working pressure for attachments bar 170
8.3 Oil volume for attachments l/min 38
8.4 Noise level in driver’s ear dB (A) 73
8.5 Towing hook, type/model DIN DIN 15170-H

All data refers to standard equipment with

standard 3110 mm lift mast.

35 Due to a change in the measuring procedure for VDI standard 2198,

the value stated is higher when compared to previous data.

Operating Instructions – 391 807 10 51 EN – 09/2010 239

6 Technical data
Type sheet H18CNG, as at 02/2008

Type sheet H18CNG, as at 02/2008

1 Identification
1.1 Manufacturer Linde
1.2 Manufacturer’s type designation H18CNG-L
1.3 Drive CNG
1.4 Operation Seated
1.5 Load capacity / Load Q [kg] 1800
1.6 Load centre of gravity c [mm] 500
1.8 Load distance x [mm] 370
1.9 Wheelbase y [mm] 1600

2 Weight
2.1 Net weight kg 2930
2.2 Axle load with front/rear load kg 4080 / 650
2.3 Axle load without front/rear load kg 1300 / 1630

3 Wheels, chassis frame

3.1 Front/rear tyres: polyurethane, rubber SE
3.2 Front tyre size 18x7-8-SC15
3.3 Rear tyre size 18x7-8-SC15
3.5 Number of wheels, front/rear (x = driven) 2x / 2
3.6 Front track width b10 [mm] 930
3.7 Rear track width b11 [mm] 873

4 Basic dimensions
4.1 Forward/backward fork tilt α/β (°) 6.0 / 9.0
4.2 Lowered mast height h1 [mm] 2197
4.3 Free lift h2 [mm] 150
4.4 Lift h3 [mm] 3150
4.5 Raised mast height h4 [mm] 3754
4.7 Overhead guard height (cab) h6 [mm] 2123
4.8 Seat height, min / max h7 [mm] 1067
4.12 Coupling height h10 [mm] 530

240 Operating Instructions – 391 807 10 51 EN – 09/2010

 Technical data 6
Type sheet H18CNG, as at 02/2008

4 Basic dimensions
4.19 Total length l1 [mm] 3227
4.20 Length including fork back l2 [mm] 2327
4.21 Total width b1 / b2 [mm] 1086
4.22 Fork arm dimensions s/e/l [mm] 45 x 100 x 900
4.23 Fork carriage DIN 15173, class/form A, B 2A
4.24 Fork carriage width b3 [mm] 1040
4.31 Ground clearance at mast m1 [mm] 95
4.32 Ground clearance at centre of wheelbase m2 [mm] 121
4.33 Aisle width for pallet 1000x1200 crosswise Ast [mm] 3691
4.34 Aisle width for pallet 800x1200 longitudinal Ast [mm] 3891
4.35 Turning radius Wa [mm] 2121
4.36 Smallest pivot point distance b13 [mm] 638

5 Performance data
5.1 Driving speed with/without load km/h 20/20
5.2 Lifting speed with/without load m/s 0.60 / 0.63
5.3 Lowering speed with/without load m/s 0.57 / 0.57
5.5 Pulling force with/without load N 12,900 / 10,000
5.7 Climbing capability with/without load %36 29.0 / 35.0
5.9 Acceleration with/without load s 5.0 / 4.5
5.10 Service brake Hydrostatic

7 Drive / Engine
7.1 Engine manufacturer / model VW / CBS
7.2 Engine power rating as per ISO 1585 kW 30
7.3 Nominal speed rpm 2100
7.4 Number of cylinders / Displacement cm3 4/1984
7.5 Fuel consumption according to VDI cycle m3 / h H-gas 3.05

8 Miscellaneous
hydrostatic /
8.1 Traction controller type continuously
variable

36 On short slopes, driving over obstacles (see section: Driving).

Operating Instructions – 391 807 10 51 EN – 09/2010 241

6 Technical data
Type sheet H18CNG, as at 02/2008

8 Miscellaneous
8.2 Working pressure for attachments bar 170
8.3 Oil volume for attachments l/min 38
8.4 Noise level in driver’s ear dB (A) 73
8.5 Towing hook, type/model DIN DIN 15170-H

All data refers to standard equipment with

standard 3110 mm lift mast.

242 Operating Instructions – 391 807 10 51 EN – 09/2010

 Technical data 6
Type sheet H20T, as at 04/2008

Type sheet H20T, as at 04/2008

1 Identification
1.1 Manufacturer Linde
1.2 Manufacturer’s type designation H20T
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] 374
1.9 Wheelbase y [mm] 1600

2 Weight
2.1 Net weight kg 3085
2.2 Axle load with front/rear load kg 4440 / 645
2.3 Axle load without front/rear load kg 1350 / 1735

3 Wheels, chassis frame

3.1 Front/rear tyres: polyurethane, rubber SE
3.2 Front tyre size 200 / 50-10
3.3 Rear tyre size 18x7-8
3.5 Number of wheels, front/rear (x = driven) 2x / 2
3.6 Front track width b10 [mm] 945
3.7 Rear track width b11 [mm] 873

4 Basic dimensions
4.1 Forward/backward fork tilt α/β (°) 6.0 / 9.037
4.2 Lowered mast height h1 [mm] 219838
4.3 Free lift h2 [mm] 150
4.4 Lift h3 [mm] 3150
4.5 Raised mast height h4 [mm] 3755
4.7 Overhead guard height (cab) h6 [mm] 2123

37 Lift height and equipment can change the backwards tilt.

38 With 150 mm free lift on standard mast.

Operating Instructions – 391 807 10 51 EN – 09/2010 243

6 Technical data
Type sheet H20T, as at 04/2008

4 Basic dimensions
4.8 Seat height, min / max h7 [mm] 1067
4.12 Coupling height h10 [mm] 530
4.19 Total length l1 [mm] 3231
4.20 Length including fork back l2 [mm] 2331
4.21 Total width b1 /b2 [mm] 1152
4.22 Fork arm dimensions s/e/l [mm] 45 x 100 x 900
4.23 Fork carriage DIN 15173, class/form A, B 2A
4.24 Fork carriage width b3 [mm] 1040
4.31 Ground clearance at mast m1 [mm] 95
4.32 Ground clearance at centre of wheelbase m2 [mm] 121
4.33 Aisle width for pallet 1000x1200 crosswise Ast [mm] 3695
4.34 Aisle width for pallet 800x1200 longitudinal Ast [mm] 3895
4.35 Turning radius Wa [mm] 2121
4.36 Smallest pivot point distance b13 [mm] 638

5 Performance data
5.1 Driving speed with/without load km/h 20/20
5.2 Lifting speed with/without load m/s 0.54 / 0.57
5.3 Lowering speed with/without load m/s 0.57 / 0.57
5.5 Pulling force with/without load N 12,900 / 10,400
5.7 Climbing capability with/without load % 39
27.0 / 35.0
5.9 Acceleration with/without load s 5.1 / 4.6
5.10 Service brake Hydrostatic

7 Drive / Engine
7.1 Engine manufacturer / model VW/BEF
7.2 Engine power rating as per ISO 1585 kW 28
7.3 Nominal speed rpm 2100
3
7.4 Number of cylinders / Displacement cm 4/1984
7.5 Fuel consumption according to VDI cycle kg/h 2.3; 1.840

39 On short slopes, driving over obstacles (see section: Driving).

40 Due to a change in the measuring procedure for VDI standard 2198,
the value stated is higher when compared to previous data.

244 Operating Instructions – 391 807 10 51 EN – 09/2010

 Technical data 6
Type sheet H20T, as at 04/2008

8 Miscellaneous
hydrostatic /
8.1 Traction controller type continuously
variable
8.2 Working pressure for attachments bar 170
8.3 Oil volume for attachments l/min 38
8.4 Noise level in driver’s ear dB (A) 73
8.5 Towing hook, type/model DIN DIN 15170-H

All data refers to standard equipment with

standard 3110 mm lift mast.

Operating Instructions – 391 807 10 51 EN – 09/2010 245

6 Technical data
Type sheet H20CNG, as at 02/2008

Type sheet H20CNG, as at 02/2008

1 Identification
1.1 Manufacturer Linde
1.2 Manufacturer’s type designation H20CNG
1.3 Drive CNG
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] 374
1.9 Wheelbase y [mm] 1600

2 Weight
2.1 Net weight kg 3125
2.2 Axle load with front/rear load kg 4440 / 685
2.3 Axle load without front/rear load kg 1350 / 1775

3 Wheels, chassis frame

3.1 Front/rear tyres: polyurethane, rubber SE
3.2 Front tyre size 200 / 50-10-SC15
3.3 Rear tyre size 18x7-8-SC15
3.5 Number of wheels, front/rear (x = driven) 2x / 2
3.6 Front track width b10 [mm] 945
3.7 Rear track width b11 [mm] 873

4 Basic dimensions
4.1 Forward/backward fork tilt α/β (°) 6.0 / 9.0
4.2 Lowered mast height h1 [mm] 2198
4.3 Free lift h2 [mm] 150
4.4 Lift h3 [mm] 3150
4.5 Raised mast height h4 [mm] 3755
4.7 Overhead guard height (cab) h6 [mm] 2123
4.8 Seat height, min / max h7 [mm] 1067
4.12 Coupling height h10 [mm] 530

246 Operating Instructions – 391 807 10 51 EN – 09/2010

 Technical data 6
Type sheet H20CNG, as at 02/2008

4 Basic dimensions
4.19 Total length l1 [mm] 3231
4.20 Length including fork back l2 [mm] 2331
4.21 Total width b1 / b2 [mm] 1152
4.22 Fork arm dimensions s/e/l [mm] 45 x 100 x 900
4.23 Fork carriage DIN 15173, class/form A, B 2A
4.24 Fork carriage width b3 [mm] 1040
4.31 Ground clearance at mast m1 [mm] 95
4.32 Ground clearance at centre of wheelbase m2 [mm] 121
4.33 Aisle width for pallet 1000x1200 crosswise Ast [mm] 3695
4.34 Aisle width for pallet 800x1200 longitudinal Ast [mm] 3895
4.35 Turning radius Wa [mm] 2121
4.36 Smallest pivot point distance b13 [mm] 638

5 Performance data
5.1 Driving speed with/without load km/h 20/20
5.2 Lifting speed with/without load m/s 0.54 / 0.57
5.3 Lowering speed with/without load m/s 0.57 / 0.57
5.5 Pulling force with/without load N 12,900 / 10,400
5.7 Climbing capability with/without load %41 27.0 / 35.0
5.9 Acceleration with/without load s 5.1 / 4.6
5.10 Service brake Hydrostatic

7 Drive / Engine
7.1 Engine manufacturer / model VW / CBS
7.2 Engine power rating as per ISO 1585 kW 30
7.3 Nominal speed rpm 2100
7.4 Number of cylinders / Displacement cm3 4/1984
7.5 Fuel consumption according to VDI cycle m3 / h H-gas 3.2

8 Miscellaneous
hydrostatic /
8.1 Traction controller type continuously
variable

41 On short slopes, driving over obstacles (see section: Driving).

Operating Instructions – 391 807 10 51 EN – 09/2010 247

6 Technical data
Type sheet H20CNG, as at 02/2008

8 Miscellaneous
8.2 Working pressure for attachments bar 170
8.3 Oil volume for attachments l/min 38
8.4 Noise level in driver’s ear dB (A) 73
8.5 Towing hook, type/model DIN DIN 15170-H

All data refers to standard equipment with

standard 3110 mm lift mast.

248 Operating Instructions – 391 807 10 51 EN – 09/2010

 Technical data 6
Type sheet H20T-CT/600, as at 05/2007

Type sheet H20T-CT/600, as at 05/2007

1 Identification
1.1 Manufacturer Linde
1.2 Manufacturer’s model designation H20T-CT/600
1.3 Drive LPG
1.4 Operation Seated
1.5 Load capacity / Load Q [kg] 2000
1.6 Load centre of gravity c [mm] 610
1.8 Load distance x [mm] 374
1.9 Wheelbase y [mm] 1600

2 Weight
2.1 Tare weight kg 3175
2.2 Axle weight with front/rear load kg 4575 / 600
2.3 Axle weight without front/rear load kg 1355 / 1820

3 Wheels, tyres
3.1 Front/rear tyres: polyurethane, rubber Cushion
3.2 Front tyre size 18 x 7 x 12 1/8
3.3 Rear tyre size 18 x 6 x 12 1/8
3.5 Number of wheels, front/rear (x = driven) 2x / 2
3.6 Front track width b10 [mm] 914
3.7 Rear track width b11 [mm] 851

4 Basic dimensions
4.1 Forward/backward fork tilt α/β (°) 6.0 / 9.0
4.2 Lowered mast height h1 [mm] 2200
4.3 Free lift h2 [mm] 150
4.4 Lift h3 [mm] 3110
4.5 Raised mast height h4 [mm] 3757
4.7 Overhead guard height (cab) h6 [mm] 2130
4.8 Sitting height (min/max) h7 [mm] 1067
4.12 Coupling height h10 [mm] 530

Operating Instructions – 391 807 10 51 EN – 09/2010 249

6 Technical data
Type sheet H20T-CT/600, as at 05/2007

4 Basic dimensions
4.19 Overall length l1 [mm] 3231
4.20 Length including fork back l2 [mm] 2331
4.21 Overall width b1 /b2 [mm] 1092
4.22 Fork arm dimensions s/e/l [mm] 45 x 100 x 900
4.23 Fork carriage DIN 15173, class/form A, B 2A
4.24 Fork carriage width b3 [mm] 1040
4.31 Ground clearance at mast m1 [mm] 99
4.32 Ground clearance, centre of wheelbase m2 [mm] 120
4.33 Aisle width for pallet 1000x1200 crosswise Ast [mm] 3695
4.34 Aisle width for pallet 800x1200 longitudinal Ast [mm] 3895
4.35 Turning radius Wa [mm] 2121
4.36 Smallest pivot point distance b13 [mm] 638

5 Performance data
5.1 Driving speed with/without load km/h 20/20
5.2 Lifting speed with/without load m/s 0.60 / 0.63
5.3 Lowering speed with/without load m/s 0.57 / 0.57
5.5 Pulling force with/without load N 12900 / 10400
5.7 Climbing capability with/without load %42 26.0 / 34.0
5.9 Acceleration with/without load s 5.2 / 4.7
5.10 Service brake Hydrostatic

7 Drive / Engine
7.1 Engine manufacturer / Type VW/BEF
7.2 Engine output as per ISO 1585 kW 28
7.3 Nominal speed rpm 2100
7.4 Number of cylinders / Displacement cm3 4/1984
7.5 Fuel consumption according to VDI cycle kg/h 2.4 (1.9)

8 Miscellaneous
hydrostatic /
8.1 Traction controller type continuously
variable

42 On short slopes, driving over obstacles (see section: Driving).

250 Operating Instructions – 391 807 10 51 EN – 09/2010

 Technical data 6
Type sheet H20T-CT/600, as at 05/2007

8 Miscellaneous
8.2 Working pressure for attachments bar 170
8.3 Oil volume for attachments l/min 38
8.4 Noise level at the driver’s ear dB (A) 73
8.5 Towing hook, type/DIN model DIN 15170-H

All data refers to standard equipment with

standard 3110 mm lift mast.

Operating Instructions – 391 807 10 51 EN – 09/2010 251

6 Technical data
Type sheet H20CNG-CT/600, as at 09/2010

Type sheet H20CNG-CT/600, as at 09/2010

1 Identification
1.1 Manufacturer Linde
1.2 Manufacturer’s type designation H20CNG-CT/600
1.3 Drive CNG
1.4 Operation Seated
1.5 Load capacity / Load Q [kg] 2000
1.6 Load centre of gravity c [mm] 610
1.8 Load distance x [mm] 374
1.9 Wheelbase y [mm] 1600

2 Weight
2.1 Net weight kg 3215
2.2 Axle load with front/rear load kg 4575 / 640
2.3 Axle load without front/rear load kg 1355 / 1860

3 Wheels, tyres
3.1 Front/rear tyres: polyurethane, rubber Binding
3.2 Front tyre size 18 x 7 x 12 1/8
3.3 Rear tyre size 18 x 6 x 12 1/8
3.5 Number of wheels, front/rear (x = driven) 2x / 2
3.6 Front track width b10 [mm] 914
3.7 Rear track width b11 [mm] 851

4 Basic dimensions
4.1 Forward/backward fork tilt α/β (°) 6.0 / 9.0
4.2 Lowered mast height h1 [mm] 2200
4.3 Free lift h2 [mm] 150
4.4 Lift h3 [mm] 3150
4.5 Raised mast height h4 [mm] 3757
4.7 Overhead guard height (cab) h6 [mm] 2130
4.8 Seat height, min / max h7 [mm] 1067
4.12 Coupling height h10 [mm] 530

252 Operating Instructions – 391 807 10 51 EN – 09/2010

 Technical data 6
Type sheet H20CNG-CT/600, as at 09/2010

4 Basic dimensions
4.19 Total length l1 [mm] 3231
4.20 Length including fork back l2 [mm] 2331
4.21 Total width b1 /b2 [mm] 1092
4.22 Fork arm dimensions s/e/l [mm] 45 x 100 x 900
4.23 Fork carriage DIN 15173, class/form A, B 2A
4.24 Fork carriage width b3 [mm] 1040
4.31 Ground clearance at mast m1 [mm] 99
4.32 Ground clearance at centre of wheelbase m2 [mm] 120
4.33 Aisle width for pallet 1000x1200 crosswise Ast [mm] 3695
4.34 Aisle width for pallet 800x1200 longitudinal Ast [mm] 3895
4.35 Turning radius Wa [mm] 2121
4.36 Smallest pivot point distance b13 [mm] 638

5 Performance data
5.1 Driving speed with/without load km/h 20/20
5.2 Lifting speed with/without load m/s 0.54 / 0.57
5.3 Lowering speed with/without load m/s 0.57 / 0.57
5.5 Pulling force with/without load N 12,900 / 10,400
5.7 Climbing capability with/without load %43 26.0 / 34.0
5.9 Acceleration with/without load s 5.2 / 4.7
5.10 Service brake Hydrostatic

7 Drive / Engine
7.1 Engine manufacturer / model VW / CBS
7.2 Engine power rating as per ISO 1585 kW 30
7.3 Nominal speed rpm 2100
7.4 Number of cylinders / Displacement cm3 4/1984
7.5 Fuel consumption according to VDI cycle kg / h 2.4 (1.9)

8 Miscellaneous
hydrostatic /
8.1 Traction controller type continuously
variable

43 On short slopes, driving over obstacles (see section: Driving).

Operating Instructions – 391 807 10 51 EN – 09/2010 253

6 Technical data
Type sheet H20CNG-CT/600, as at 09/2010

8 Miscellaneous
8.2 Working pressure for attachments bar 170
8.3 Oil volume for attachments l/min 38
8.4 Noise level in driver’s ear dB (A) 73
8.5 Towing hook, type/model DIN DIN 15170-H

All data refers to standard equipment with

standard 3110 mm lift mast.

254 Operating Instructions – 391 807 10 51 EN – 09/2010

 Technical data 6
Load capacity diagrams and lift mast data as at 04/2008

Load capacity diagrams and lift mast data as at 04/2008

Main dimensions

Operating Instructions – 391 807 10 51 EN – 09/2010 255

6 Technical data
Load capacity diagrams and lift mast data as at 04/2008

Load capacity diagrams

Load capacity diagrams apply to standard and

duplex masts with SE tyres.

Lift mast data

Standard lift mast (in mm)
Lift h3 H 14/16/18/20 3150 3850 4250
Overall heights when retracted with
h1 H 14/16/18/20 2196 2546 2746
specified free lift
Overall height when extended h4 H 14/16/18/20 3713 4413 4813
Free lift h2 H 14/16/18/20 150 150 150

Duplex lift mast (in mm)

Lift h3 H 14/16/18/20 3145 3845 --
Overall heights when retracted with
h1 H 14/16/18/20 2121 2471 --
specified free lift
Overall height when extended h4 H 14/16/18/20 3727 4427 --
Free lift h2 H 14/16/18/20 1518 1868 --

256 Operating Instructions – 391 807 10 51 EN – 09/2010

 Technical data 6
Vibration characteristic values for bodily vibrations

Triplex lift mast (in mm)

Lift h3 H 14/16/18/20 4625 5475 --
Overall heights when retracted with
h1 H 14/16/18/20 2121 2471 --
specified free lift
Overall height when extended h4 H 14/16/18/20 5227 6077 --
Free lift h2 H 14/16/18/20 1518 1781 --

Other lift heights on request

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 = 73.0 dB (A)
operating status
Sound pressure level in the driver’s com- In the DRIVE
LWc = 93.0 dB (A)
partment operating status
H 14 T, H 16 T, Uncertainty KWA = 4 dB (A)
H 16 CNG, H 18 T,
H 18 CNG, H 20 T,
LPAZ = 73.0 dB (A) Guaranteed sound power level
H 20 CNG,
H 20-600 T, In accordance
H 20-600 CNG with 2000/14/EC LWA = 95.3 dB (A)
In the LIFT Directive
LPa = 74.4 dB (A)
operating status
Under the terms of the directive, it is a statu-
In the IDLING tory requirement to provide this information.
LPb = 61.3 dB (A)
operating status The value is calculated from the sound power
In the DRIVE levels of the "Lift" and "Drive" operating sta-
LPc = 77.5 dB (A)
operating status tuses. It can only be used as a comparison
Uncertainty KPA = 4 dB (A) value for different fork lift trucks. The value is
less suitable for determining real environmen-
tal impact levels, as it is not representative
Sound power level for normal truck operation, which includes the
H 14 T, H 16 T, "Idling" operating status.
H 16 CNG, H 18 T,
H 18 CNG, H 20 T, NOTE
LWAZ = 88.1 dB (A)
H 20 CNG,
H 20-600 T, Lower or higher noise values may occur when
H 20-600 CNG using industrial trucks, for instance, due to the
In the LIFT method of operation, environmental factors
LWA = 88.9 dB (A) and other sources of noise.
operating status

Vibration characteristic values for bodily vibrations

The values were determined according to EN according to the data sheet (driving over test
13059 using trucks with standard equipment course with humps).

Operating Instructions – 391 807 10 51 EN – 09/2010 257

6 Technical data

Specified vibration characteristic according

to EN 12096 NOTE
Measured The vibration characteristic for bodily vibrati-
vibration aW.ZS = 0.7 m/s2 ons cannot be used to determine the actual
characteristic load level of vibrations during operation. This
Insecurity K = 0.2 m/s2 depends on the operating conditions (state
of pathway, method of operation etc.) and
Specified vibration characteristic for hand- should therefore be determined on site, where
arm vibrations appropriate. It is mandatory to specify the
hand-arm vibrations even where the values do
Vibration characteristic < 2.5 m/s2 not indicate any hazard, as in this case.

258 Operating Instructions – 391 807 10 51 EN – 09/2010


A B
Actions prior to placing the forklift truck
into storage . . . . . . . . . . . . . . . . 217
Activate horn . . . . . . . . . . . . . . . . . . . . . 64
Activating the seat heater . . . . . . . . . . . . 38
Additional capacity rating plate for
attachments . . . . . . . . . . . . . . . . . 24
with loads that are fixed or clamped . . 25
with loads that are not clamped . . . . . 24
Adjust driver’s seat with swivel device . . . 78
Adjust lift mast chain
Duplex or triplex lift mast . . . . . . . . . 202
Standard lift mast . . . . . . . . . . . . . . 201
Adjust the seat angle . . . . . . . . . . . . . . . 79
Adjust the seat back . . . . . . . . . . . . . . . . 80
Adjust the seat height . . . . . . . . . . . . . . . 79
Adjusting the backrest extension . . . 38, 80
Adjusting the driver’s seat . . . . . . . . . . . . 36
Adjusting the driver’s seat armrest . . . . . 39
Adjusting the driver’s seat equipped
with air suspension . . . . . . . . . . . . 78
Adjusting the fork spread . . . . . . . . . . . . 99
Adjusting the lumbar support . . . . . . 37, 80
Adjusting the seat angle . . . . . . . . . . . . . 38
Adjusting the seat backrest . . . . . . . . . . . 37
Adjusting the seat depth . . . . . . . . . . . . . 38
Adjusting the seat height . . . . . . . . . . . . 38
Adjusting the steering column . . . . . . . . . 40
After towing . . . . . . . . . . . . . . . . . . . . . 216
Air conditioning . . . . . . . . . . . . . . . . . . . 88
Operating devices . . . . . . . . . . . . . . . 90
Servicing . . . . . . . . . . . . . . . . . . . . 176
Switching on . . . . . . . . . . . . . . . . . . . 90
Air filter
Changing the cartridge . . . . . . . . . . 160
an accumulator . . . . . . . . . . . . . . . . . . . 19
Attach additional consumers . . . . . . . . . . 84
Attachments
Instructions before fitting . . . . . . . . . . 19
Axle stub bolt, check fastening . . . . . . . 185
Operating Instructions – 391 807 10 51 EN – 09/2010
Index
g
Basic equipment wiring diagram
CNG . . . . . . . . . . . . . . . . . . . . . . . . 278
LPG . . . . . . . . . . . . . . . . . . . . . . . . 272
Battery grease . . . . . . . . . . . . . . . . . . . 116
Battery: check condition, acid level and
acid density . . . . . . . . . . . . . . . . 187
Before taking up load . . . . . . . . . . . . . . . 98
Bio-hydraulic oil . . . . . . . . . . . . . . . . . . 115
Bonnet
Closing . . . . . . . . . . . . . . . . . . . . . . 175
Opening . . . . . . . . . . . . . . . . . . . . . 173
Brake system . . . . . . . . . . . . . . . . . . . . . 63
Bringing back into service after storage . 217
C
Cab door
closing . . . . . . . . . . . . . . . . . . . . . . . 87
opening . . . . . . . . . . . . . . . . . . . . . . 87
Chain spray . . . . . . . . . . . . . . . . . . . . . 116
Change coolant . . . . . . . . . . . . . . . . . . 151
Change the direction of travel . . . . . . 51, 60
Change the high-pressure gas hoses . . 168
Change the water pump . . . . . . . . . . . . 155
Changing the breather . . . . . . . . . . . . . 194
Changing the feed filter . . . . . . . . . . . . 193
Changing the LPG cylinder . . . . . . . . . . 136
Changing the pressure filter . . . . . . . . . 193
Changing the safety cartridge . . . . . . . . 162
Changing the spark plugs . . . . . . . . . . . 167
Changing the suction filter . . . . . . . . . . 193
Changing the tensioner pulley . . . . . . . 160
Check basic setting of gas installation . . 166
Check coolant concentration . . . . . . . . 153
Check correct operation of breather
valve on the hydraulic oil tank . . . 195
Check exhaust leads for leaks . . . . . . . 167
Check hydraulic pump attachment to
the engine . . . . . . . . . . . . . . . . . 171
Check other bearings and joints and oil
them . . . . . . . . . . . . . . . . . . . . . 179
Check suction leads for leaks . . . . . . . . 167
259
Index
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Check the CO content in the exhaust Cleaning

gas . . . . . . . . . . . . . . . . . . . . . . 166 Evaporator / pressure regulator . . . . 146
Check the condition of the engine Fork prong positioner . . . . . . . . . . . 205
mount; check that it is attached
Lift mast chain . . . . . . . . . . . . . . . . . 200
securely . . . . . . . . . . . . . . . . . . . 156
Oil bath air filter . . . . . . . . . . . . . . . . 164
Check the dust discharge valve . . . . . . 163
Prefilter . . . . . . . . . . . . . . . . . . . . . . 164
Check the fork quick-releases . . . . . . . . 203
Sideshift . . . . . . . . . . . . . . . . . . . . . 204
Check the forks . . . . . . . . . . . . . . . . . . 203
Steering axle . . . . . . . . . . . . . . . . . . 183
Check the operation
Truck . . . . . . . . . . . . . . . . . . . . . . . 172
of the parking brake . . . . . . . . . . . . . 185
Water cooler and hydraulic oil
Check the pre-tension of the double
cooler . . . . . . . . . . . . . . . . . . . . 154
tubes . . . . . . . . . . . . . . . . . . . . . 198
Cleaning and lubricating the sideshift
Check the tilt cylinder bearings for wear . 196
Checking the fastening . . . . . . . . . . 204
Check tyres for damage and foreign
bodies . . . . . . . . . . . . . . . . . . . . 181 Cleaning the evaporator . . . . . . . . . . . . 146
Checking slide guides on sideshift for Cleaning the lift mast chain and
wear . . . . . . . . . . . . . . . . . . . . . 204 applying chain spray . . . . . . . . . . 200
Checking the bellows at the actuating Cleaning the pressure regulator . . . . . . 146
lever . . . . . . . . . . . . . . . . . . . . . 186 Cleaning the truck . . . . . . . . . . . . . . . . 172
Checking the condition and secure Climatic conditions . . . . . . . . . . . . . . . . .. 4
positioning of electric cables . . . . 187 Clock
Checking the condition and secure setting . . . . . . . . . . . . . . . . . . . . . . . 41
positioning of the cable Closed-loop catalytic converter
connections . . . . . . . . . . . . . . . . 187
check basic setting of gas
Checking the condition and secure installation . . . . . . . . . . . . . . . . . 166
positioning of the cable
CNG . . . . . . . . . . . . . . . . . . . . . . . . . . 115
connectors . . . . . . . . . . . . . . . . . 187
Consumables . . . . . . . . . . . . . . . . . . . . 13
Checking the coolant level . . . . . . . . . . 150
Coolant . . . . . . . . . . . . . . . . . . . . . . . . 116
Checking the function and safety
system of the third auxiliary
D
hydraulics . . . . . . . . . . . . . . . . . 199
Checking the hose carrier . . . . . . . . . . . 197 Declaration of conformity . . . . . . . . . . . . . 7
Checking the pedals . . . . . . . . . . . . . . . 186 Defrosting the windows . . . . . . . . . . . . . 89
Checking the tyre pressure . . . . . . . . . . 182 Depressurisation . . . . . . . . . . . . . . . . . . 19
Checking the vacuum-operated switch . 160 Description of use . . . . . . . . . . . . . . . . . . 4
Checks Determination and assessment of
before starting work . . . . . . . . . . . . . . 36 hazards from use of industrial
trucks . . . . . . . . . . . . . . . . . . . . . 18
Clean the prefilter . . . . . . . . . . . . . . . . . 164
Diagnostics connector . . . . . . . . . . . . . 211
Display unit . . . . . . . . . . . . . . . . . . . . . . 28
Disposal of old vehicles . . . . . . . . . . . . 217

260 Operating Instructions – 391 807 10 51 EN – 09/2010

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Drive axle Floorplate

Adjusting the side stops . . . . . . . . . . 170 closing . . . . . . . . . . . . . . . . . . . . . . 176
Check bearing for wear and tear . . . 170 opening . . . . . . . . . . . . . . . . . . . . . 175
Checking mounting . . . . . . . . . . . . . 169 Fork arm adjustment device
Checking the side stops . . . . . . . . . . 170 Check wear and tear . . . . . . . . . . . . 207
Driver’s cabin . . . . . . . . . . . . . . . . . . . . . 87 Fork carriage emergency lowering . . . . 213
Driving Fork prong positioner
single-pedal operation . . . . . . . . . . . . 59 Cleaning and lubricating, checking
two-pedal operation . . . . . . . . . . . . . 50 the mounting . . . . . . . . . . . . . . . 205
With load . . . . . . . . . . . . . . . . . . . . 101 Forklift Data Acquisition . . . . . . . . . . . . . 92
Duplex lift mast Transponder (chip or magnetic strip
card) . . . . . . . . . . . . . . . . . . . . . . 96
Description . . . . . . . . . . . . . . . . . . . 112
Forklift Data Acquisition - special
Secure the lifted mast . . . . . . . . . . . 112
setting
E PIN number . . . . . . . . . . . . . . . . . . . 94
Forklift Data Acquisition - standard
EC declaration of conformity . . . . . . . . . .. 7 setting
Emergency exit with attached rear PIN number and status code . . . . . . . 93
window . . . . . . . . . . . . . . . . . . . 214
Forklift Data Management . . . . . . . . . . . 92
Emergency lowering . . . . . . . . . . . . . . 213
Forwards motion . . . . . . . . . . . . . . . 51, 60
Engine
Frame check attachment points . . . . . . 178
Starting (dual-pedal operation) . . . . . 45
Front side window
Starting (single-pedal operation) . . . . 53
Closing . . . . . . . . . . . . . . . . . . . . . . . 87
Switching off (dual-pedal operation) . . 47
Opening . . . . . . . . . . . . . . . . . . . . . . 87
Switching off (single-pedal
operation) . . . . . . . . . . . . . . . . . . 56 Fuel gas mixer
Engine oil . . . . . . . . . . . . . . . . . . . . . . . 116 Check settings . . . . . . . . . . . . . . . . 146
Change filter . . . . . . . . . . . . . . . . . . 134 Fuses
Changing . . . . . . . . . . . . . . . . . . . . 132 Basic and special equipment . . . . . . 210
Checking the level . . . . . . . . . . . . . . 131 Engine compartment . . . . . . . . . . . . 210
draining . . . . . . . . . . . . . . . . . . . . . 132 G
Topping up . . . . . . . . . . . . . . . . . . . 133
Engine suspension Check its condition; Gas shut-off valve
check that it is attached securely . 156 Closing . . . . . . . . . . . . . . . . . . . . 49, 58
Entering the truck . . . . . . . . . . . . . . . . . . 39 opening . . . . . . . . . . . . . . . . . . . . . . 41
Exiting the truck . . . . . . . . . . . . . . . . . . . 39 General points . . . . . . . . . . . . . . . . . . . 110

F H
Filling the CNG tank . . . . . . . . . . . . . . . 142 Handling consumables . . . . . . . . . . . . . . 13
Filling the LPG tank . . . . . . . . . . . . . . . 139 Heating system . . . . . . . . . . . . . . . . . . . 88
Fire extinguisher . . . . . . . . . . . . . . . . . . 11 Operating devices . . . . . . . . . . . . . . . 88
Switching on . . . . . . . . . . . . . . . . . . . 89

Operating Instructions – 391 807 10 51 EN – 09/2010 261

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Hydraulic circuit diagram Lighting

Depressurisation, accumulator . . . . 306 switch on . . . . . . . . . . . . . . . . . . . . . 83
Traction , working and steering Load backrest . . . . . . . . . . . . . . . . . . . . 10
hydraulics . . . . . . . . . . . . . . . . . 306 Load capacity diagrams . . . . . . . . . . . . 255
Hydraulic oil . . . . . . . . . . . . . . . . . . . . . 115 Loading the crane . . . . . . . . . . . . . . . . 105
Changing . . . . . . . . . . . . . . . . . . . . 190 Lowering the fork carriage
draining . . . . . . . . . . . . . . . . . . . . . 190 Central lever operation . . . . . . . . . . . 66
Topping up . . . . . . . . . . . . . . . . . . . 190 Single lever operation . . . . . . . . . . . . 71
Hydraulic oil cooler Single lever operation with
Check for leaks . . . . . . . . . . . . . . . . 154 3rd auxiliary hydraulics . . . . . . . . . 75
Cleaning . . . . . . . . . . . . . . . . . . . . . 154 LPG . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Hydraulic system LPG system
Changing the filter . . . . . . . . . . . . . . 193 Checking for damage . . . . . . . . . . . 148
Check for leaks . . . . . . . . . . . . . . . . 196 Checking for leaks . . . . . . . . . . . . . . 148
Check oil level . . . . . . . . . . . . . . . . . 191 Checking the level . . . . . . . . . . . . . . 135
Odour inspection . . . . . . . . . . . . . . . 148
I Visual inspection . . . . . . . . . . . . . . . 148
Identification plates . . . . . . . . . . . . . . . . 22 Lubricating grease . . . . . . . . . . . . . . . . 116
Impermissible use . . . . . . . . . . . . . . . . .. 3
Inspection data . . . . . . . . . . . . . . . . . . 114
M
Instructions for running-in . . . . . . . . . . . . 36 Main fuses in engine compartment . . . . 210
Maintenance data . . . . . . . . . . . . . . . . 114
J Maintenance intervals . . . . . . . . . . . . . 110
Jump start . . . . . . . . . . . . . . . . . . . . . . 211 Malfunctions during operation . . . . . . . . 218
Malfunctions, Causes and Remedies
L LPG engine . . . . . . . . . . . . . . . . . . . 220
Leaving the truck . . . . . . . . . . . . . . . . . 107 Malfunctions, Causes and Remedy
Lift mast data . . . . . . . . . . . . . . . . . . . . 255 Ultrasonic sensor . . . . . . . . . . . . . . 224
Lift mast positioning . . . . . . . . . . . . . . . . 81 Malfunctions, causes, remedies
Lift mast, lift mast chains, lift cylinder Hydraulic equipment . . . . . . . . . . . . 225
and end stops: check attach- Medical equipment . . . . . . . . . . . . . . . . . 11
ment, condition and function . . . . 201
Lifting system and attachments N
Central lever operation . . . . . . . . . . . 65
Natural gas system
Single lever operation . . . . . . . . . . . . 70
Carry out system service . . . . . . . . . 148
Single lever operation with
Carrying out a system check . . . . . . 147
toggle-switch-controlled
3rd auxiliary hydraulics . . . . . . . . . 74 Checking high-pressure relief valve . 147
Lifting the fork carriage Checking the level . . . . . . . . . . . . . . 135
Central lever operation . . . . . . . . . . . 66 Natural gas system checks . . . . . . . . . . . 14
Single lever operation . . . . . . . . . . . . 70 Noise emission values . . . . . . . . . . . . . 257
Single lever operation with
3rd auxiliary hydraulics . . . . . . . . . 74

262 Operating Instructions – 391 807 10 51 EN – 09/2010

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O Parking brake
Operating . . . . . . . . . . . . . . . . . . . . . 64
Oil bath air cleaner
Releasing . . . . . . . . . . . . . . . . . . . . . 64
Change the oil . . . . . . . . . . . . . . . . . 165
Periodic safety inspection . . . . . . . . . . . . 14
Oil bath air filter
Placing the forklift truck into storage . . . 217
Cleaning . . . . . . . . . . . . . . . . . . . . . 164
Proper usage . . . . . . . . . . . . . . . . . . . . .. 3
Open cover of electrical system . . . . . . 209
Open shorting plunger of hydraulics . . . 215 R
Operating attachments
Rear side window
Central lever operation . . . . . . . . . . . 66
Closing . . . . . . . . . . . . . . . . . . . . . . . 88
Single lever operation . . . . . . . . . . . . 71
Opening . . . . . . . . . . . . . . . . . . . . . . 88
Single lever operation with
3rd auxiliary hydraulics . . . . . . . . . 75 Reception of truck . . . . . . . . . . . . . . . . . . 6
Operating elements . . . . . . . . . . . . . . . . 27 Recommendations for consumables . . . 115
Operating the clamp Refrigerant for air conditioning . . . . . . . 116
Central lever operation . . . . . . . . . . . 69 Regulations . . . . . . . . . . . . . . . . . . . . . . 14
Single lever operation . . . . . . . . . . . . 73 Release multi-disc brake . . . . . . . . . . . 215
Single lever operation with Removing the lift mast . . . . . . . . . . . . . 103
toggle-switch-controlled Replace the fuel gas filter . . . . . . . . . . . 145
3rd auxiliary hydraulics . . . . . . . . . 77 Residual risks . . . . . . . . . . . . . . . . . . . . 11
Operating the fork prong positioner Restore braking . . . . . . . . . . . . . . . . . . 216
Central lever operation . . . . . . . . . . . 68 Reverse motion . . . . . . . . . . . . . . . . 51, 60
Single lever operation . . . . . . . . . . . . 73 Ribbed V-belt
Single lever operation with check condition . . . . . . . . . . . . . . . . 157
toggle-switch-controlled Ribbed V-belt,
3rd auxiliary hydraulics . . . . . . . . . 76
changing . . . . . . . . . . . . . . . . . . . . 157
Operating the rotator
Rim sizes . . . . . . . . . . . . . . . . . . . 182 – 183
Single lever operation with
toggle-switch-controlled S
3rd auxiliary hydraulics . . . . . . . . . 77
Operating the sideshift Safety guidelines . . . . . . . . . . . . . . . . . . 10
Central lever operation . . . . . . . . . . . 68 Safety guidelines for LPG (extract) . . . . . 15
Single lever operation . . . . . . . . . . . . 72 Safety information . . . . . . . . . . . . . . . . . 10
Single lever operation with 3rd auxiliary hydraulic system . . . . . . 10
toggle-switch-controlled Driver sight . . . . . . . . . . . . . . . . . . . . 11
3rd auxiliary hydraulics . . . . . . . . . 77 Fan . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Operating the truck Gas springs . . . . . . . . . . . . . . . . . . . 11
without a lift mast . . . . . . . . . . . . . . . 104 unauthorised use . . . . . . . . . . . . . . . 10
Operation of industrial trucks in plant Welding operations . . . . . . . . . . . . . . 10
area . . . . . . . . . . . . . . . . . . . . . . . 13
Safety information on the LPG system . . . 15
P Safety measures when working on
ignition systems . . . . . . . . . . . . . . 17
parking brake . . . . . . . . . . . . . . . . . . . . . 63

Operating Instructions – 391 807 10 51 EN – 09/2010 263

Index
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Seat belt
Checking the condition and correct
function . . . . . . . . . . . . . . . . . . . 177
Fastening . . . . . . . . . . . . . . . . . . . . . 43
Releasing . . . . . . . . . . . . . . . . . . . . . 44
Seat heater . . . . . . . . . . . . . . . . . . . . . . 79
Secure lift mast from tilting back . . . . . . 111
Service brake . . . . . . . . . . . . . . . . . . . . . 63
Service plan
1000 h . . . . . . . . . . . . . . . . . . . . . . 119
3000-hour . . . . . . . . . . . . . . . . . . . . 122
6000 h . . . . . . . . . . . . . . . . . . . . . . 125
9000-hour . . . . . . . . . . . . . . . . . . . . 128
As required . . . . . . . . . . . . . . . . . . . 118
before initial start-up . . . . . . . . . . . . . . 8
before starting work . . . . . . . . . . . . . . 36
Setting down loads . . . . . . . . . . . . . . . . 102
Setting the driver’s weight . . . . . . . . . 37, 78
Shut-off valve
Closing the CNG system . . . . . . . 49, 58
Closing the LPG cylinder . . . . . . . 49, 58
Closing the LPG tank . . . . . . . . . . 49, 58
Opening the LPG cylinder . . . . . . . . . 41
Opening the LPG tank . . . . . . . . . . . . 42
Opening the natural gas version . . . . . 42
Special equipment wiring diagram
Sheet 1 - Working spotlights, interior
light . . . . . . . . . . . . . . . . . . . . . . 284
Sheet 10 - Single lever locked, third
auxiliary hydraulics via switch . . . 302
Sheet 11 - Lighting, direction
indicator and hazard warning
system, brake light . . . . . . . . . . . 304
Sheet 2 — windscreen wiper, seat
heater . . . . . . . . . . . . . . . . . . . . 286
Sheet 3 − Heating system, air
conditioning, flashing beacon /
rotating beacon, reversing
signal, 12 V socket . . . . . . . . . . . 288
Sheet 4 − hazard warning
system for reverse travel,
264
truck deactivation, lift mast
positioning . . . . . . . . . . . . . . . . . 290
Sheet 5 - particle filter, radio . . . . . . . 292
Sheet 6 - higher lighting, hydraulic
oil microfilter indicator, diesel
filter water trap warning . . . . . . . 294
Sheet 7 − Forklift Data Manage-
ment, LPG volume display, oil
level monitoring, coolant level
monitoring . . . . . . . . . . . . . . . . . 296
Sheet 8 − third auxiliary hydraulics,
changing particle filter, working
spotlights positions 5, 6 . . . . . . . 298
Sheet 9 - camera system, centre
rear brake/tail light, rear window
heating . . . . . . . . . . . . . . . . . . . 300
Specialist . . . . . . . . . . . . . . . . . . . . . . . . 13
Stability . . . . . . . . . . . . . . . . . . . . . . . . . 12
Standard lift mast
Description . . . . . . . . . . . . . . . . . . . 111
Secure the lifted mast . . . . . . . . . . . 111
Start up on inclines . . . . . . . . . . . . . . 52, 61
Status code . . . . . . . . . . . . . . . . . . . . . . 92
Steering . . . . . . . . . . . . . . . . . . . . . . . . . 62
Steering axle
check attachment points . . . . . . . . . 178
Cleaning . . . . . . . . . . . . . . . . . . . . . 183
greasing . . . . . . . . . . . . . . . . . . . . . 183
Steering cylinder Check fastening . . . . . 185
Steering system . . . . . . . . . . . . . . . . . . . 62
Stop . . . . . . . . . . . . . . . . . . . . . . . . 52, 61
Stop pedal . . . . . . . . . . . . . . . . . . . . . . . 63
Switch on hazard warning lights . . . . . . . 83
Switch on interior lighting . . . . . . . . . . . . 83
Switch on rotating flashing light . . . . . . . . 83
Switch on the front windscreen wiper . . . 85
Switch on the rear windscreen wiper . . . . 85
Switch on the roof windscreen wiper . . . . 86
Switch on the wiper/washer system . . . . . 86
Switch on turn indicator lights . . . . . . . . . 84
Switch on working headlights . . . . . . . . . 83
Switch panel . . . . . . . . . . . . . . . . . . . . . 34
Switching on the rear window heater . . . . 87
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operating Instructions – 391 807 10 51 EN – 09/2010
 Index
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T Towing process . . . . . . . . . . . . . . . . . . 215

Transportation by truck or low loading
Taking up loads . . . . . . . . . . . . . . . . . . 100
truck . . . . . . . . . . . . . . . . . . . . . 107
Technical description . . . . . . . . . . . . . . . . 4
Triplex lift mast
Brakes . . . . . . . . . . . . . . . . . . . . . . . . 5
Description . . . . . . . . . . . . . . . . . . . 113
Electrical system . . . . . . . . . . . . . . . . . 6
Secure the lifted mast . . . . . . . . . . . 113
Engine . . . . . . . . . . . . . . . . . . . . . . . . 5
Truck Control . . . . . . . . . . . . . . . . . . . . .. 5
Hydraulic system . . . . . . . . . . . . . . . . 5
Truck overview . . . . . . . . . . . . . . . . . . . 26
Lift mast . . . . . . . . . . . . . . . . . . . . . . . 6
Type sheet H14T . . . . . . . . . . . . . . . . . 228
Linde Load Control . . . . . . . . . . . . . . . 5
Type sheet H16CNG . . . . . . . . . . . . . . 234
Linde Truck Control . . . . . . . . . . . . . . . 5
Type sheet H16T . . . . . . . . . . . . . . . . . 231
Operation . . . . . . . . . . . . . . . . . . . . . . 5
Type sheet H18CNG . . . . . . . . . . . . . . 240
Steering . . . . . . . . . . . . . . . . . . . . . . . 6
Type sheet H18T . . . . . . . . . . . . . . . . . 237
Tighten the wheel bolts . . . . . . . . . . . . . 181
Type sheet H20CNG . . . . . . . . . . . . . . 246
Tilt cylinder: check attachment points . . 178
Type sheet H20CNG-CT/600 . . . . . . . . 252
Tilting the lift mast backwards.
Type sheet H20T . . . . . . . . . . . . . . . . . 243
Central lever operation . . . . . . . . . . . 66
Type sheet H20T-CT/600 . . . . . . . . . . . 249
Single lever operation . . . . . . . . . . . . 71
Tyre sizes . . . . . . . . . . . . . . . . . . . . . . 182
Single lever operation with
3rd auxiliary hydraulics . . . . . . . . . 75 V
Tilting the lift mast forwards
Vibration characteristic values for
Central lever operation . . . . . . . . . . . 66
bodily vibrations . . . . . . . . . . . . . 257
Single lever operation . . . . . . . . . . . . 71
Single lever operation with W
3rd auxiliary hydraulics . . . . . . . . . 75
Warnings . . . . . . . . . . . . . . . . . . . . ..... 4
Tip-over of the truck . . . . . . . . . . . . . . . . 12
Water cooler
Toothed belt
Check for leaks . . . . . . . . . . . . . . . . 154
Changing . . . . . . . . . . . . . . . . . . . . 160
Cleaning . . . . . . . . . . . . . . . . . . . . . 154
Checking condition . . . . . . . . . . . . . 158
Wheel change . . . . . . . . . . . . . . . . . . . 180
Checking tension . . . . . . . . . . . . . . 158
Wheel motors
Topping up the washer system water
tank . . . . . . . . . . . . . . . . . . . . . . 208 Checking mounting . . . . . . . . . . . . . 169
Towing . . . . . . . . . . . . . . . . . . . . . . . . 215 Windscreen wiper . . . . . . . . . . . . . . . . . 85
Towing device . . . . . . . . . . . . . . . . . . . 102 Working on the Linde lift mast and in
the front part of the truck . . . . . . . 111
Towing instructions . . . . . . . . . . . . . . . 215

Operating Instructions – 391 807 10 51 EN – 09/2010 265

Linde Material Handling GmbH

391 807 10 51 EN – 09/2010

 LPG truck, CNG truck

Original instructions

H14T, H16T, H16CNG,

H18T, H18CNG, H20T,
Annex H20CNG
391 807 10 51 EN – 09/2010
 7

Circuit diagrams
7 Circuit diagrams
Wiring diagram

Wiring diagram
LPG basic equipment sheet 1

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 Circuit diagrams 7
Wiring diagram

Legend :2 − Terminal 15 6X1 10-pin plug connector (6P1), 26–39 Wires with unspecified cross-sec-
F2 30A fuse, 4 :6 − Earth 6X2 7-pin plug connector (diagnostics), 48 tion = 0.75 mm2
F5 2A fuse, 26 S1 Ignition and starting switch, 9–17
F6 2A fuse, 28 S2 Brake pedal switch 2 (start-up prevention), Wire colours Notes
F7 15A fuse, 73 12–14 BK Black (a) Wires twisted together
F13 15A max. fuse, 61 S3 Suction filter vacuum-operated switch, 31 BN Brown (b) Special equipment wiring diagram
F14 2A fuse, 64 OS1 Oil pressure switch, 28 BU Blue *) Gold-plated contacts
F15 10A fuse, 67 4S1 Horn activation, 73 GN Green
G1 660 W three-phase generator with regulator, X1 10-pin plug connector (S1), 9–16, 73 GY Grey
1–5 X2 3-pin plug connector (S2), 12, 13 OG Orange
G2 88 Ah battery, 7 X6 5-pin plug connector, 33, 36 RD Red
4H1 60 W signal horn, 73 X10 18-pin plug connector (central electrical VT Violet
K2 Electronic starter relay, 10-15 system), 20, 64–69 WH White
M1 1.7 kW starter motor, 9–11 X11 9-pin plug connector (central electrical YE Yellow
6P1 Display unit, 25–40 system), 22, 65–67 The number in front of the wire colour refers
:1 − Terminal 30 X15 2-pin plug connector (CAN), 42 to the wire cross-section.

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Wiring diagram

Basic equipment for LPG sheet 2

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Wiring diagram

Legend :31 - Auxiliary 1 :96 − GND sensor, lift 1X1 3-pin plug connector (1B1), 84
1B1 Speed actual value transmitter, 85-86 :32 − Drive potentiometer reference :98 − Lower 1X2 3-pin plug connector (1S1), 101, 102
1B2 Dual potentiometer for accelerator, 85-88 :33 − Seat switch reference :101 − Lift/lower reference 1X3 6-pin plug connector, coded plug for dual
1B4 Hydraulic oil temperature sensor, 85 :36 − Middle :102 − Tilt forwards/back reference pedal identification, 107-111
1B9 Brake potentiometer (only fitted to trucks :37 − Forwards :103 − Tilt angle reference 1X3 + 1S2 6-pin plug connector, drive direction
with automatic function), 91-96 :38 − Seat switch :104 - Auxiliary 1 reference switch for single pedal, 105-111
2B1 Joystick basic functions, 114-118 :39 - ISO L-lift :105 − Mast positioning 1X7 6-pin plug connector (fan motor), 154-157
:1 − 5 V :40 − Mast positioning display :106 − 0 V lift/lower 2X1 2-pin plug connector (microfilter), 122, 123
:2 − Lift/lower :44 − Auxiliary 2/B (B3) :107 − 0 V tilt forwards/backwards 2X3 6-pin plug connector (2B1), 114–118
:3 − Tilt forwards/back :45 − Auxiliary 2/A (A3) :109 − 0 V exhaust valve 2X4 6-pin plug connector (2B2), 121–124
:4 − Lift/lower reference :46 − Exhaust valve 1Y4 :111 − Exhaust valve 2X5 14-pin plug connector (valve block), 127-151
:5 − Tilt forwards/back reference :47 − Coding :112 − 0 V (1/A)/(1/B) 1Y1 Retarder, 90
:6 − 0 V :48 − Tilt forwards/back :113 − 0 V (2/A)/(2/B) 1Y2 Forwards solenoid valve "y", 92
2B2 Joystick additional functions, 121-124 :49 − Drive potentiometer :114 − GND 1Y3 Backwards solenoid valve "z", 95
:1 − 5 V :50 − Fan diagnostics :116 − 5 V lift sensor 1Y4 Exhaust valve, 97
:2 - Auxiliary 1 :52 − Coding :117 - Auxiliary 2 reference 2Y1 Lower valve, 127
:3 - Auxiliary 2 :53 − Terminal 15 :118 − 5 V lift sensor 2Y2 Lift valve, 129
:4 - Auxiliary 1 reference :54 − Brake potentiometer reference :119 − Earth 2Y3 Tilt forwards valve, 132
:5 - Auxiliary 2 reference :56 − Code :120 − Terminal 30 2Y4 Tilt backwards valve, 134
:6 − 0 V :58 − Brake 1 :121 − Terminal 30 2Y5 Auxiliary valve 1B, 138
2B3 Dual potentiometer for lift mast tilt angle, :59 − Brake 3 OB1:3 Engine temperature sensor, 87-88 2Y6 Auxiliary valve 1A, 140
134-138 :60 − Brake potentiometer OB1:4 Engine temperature sensor, 87-88 2Y7 Auxiliary valve 2B, 143
F4 20 A fuse (fan motor), 157 :61 − GND sensor, drive S4 Seat switch, 143–144 2Y8 Auxiliary valve 2A, 145
F8 2 A fuse, 81 :62 − Fan 1S1 Brake pedal switch 1, 101–102 2Y9 Exhaust valve, 149
F9 15 A fuse, 83 :63 − Speed actual-value transmitter 1S2 Single-pedal drive direction switch, 105-111
1M1 Fan motor, 154-157 :68 − GND X2:1 Brake pedal switch 2, 104 Wire colours
N1 LHC electronic control, 81–152 :69 − GND X4 3-pin plug connector (seat switch), 143, 144 BK Black
:1 − 5 V sensor, drive :70 − GND X10 18-pin plug connector (central electrical BN Brown
:6 − Forwards hydraulic pump 1Y2 :71 − GND system), 98-106 BU Blue
:7 − Reverse hydraulic pump 1Y3 :72 − Reverse :4 - Speed limitation GN Green
:8 − Microfilter pressure switch :73 − Brake 2 :6 - Brake light GY Grey
:10 − Coding :74 − Engine temperature :7 - Programmable reversing signal OG Orange
:12 − Lift/lower :80 − GND sensor, drive :8 - Programmable reversing signal RD Red
:13 − Hydraulic oil temperature sensor :81 − GND sensor, drive :9 - Programmable reversing signal VT Violet
:14 − 0 V retarder :82 − Auxiliary 1/A (A1) :10 - Reserve WH White
:15 − 0 V forwards hydraulic pump :85 − ISO K-lift :11 - Shovel insert YE Yellow
:16 − 0 V reverse hydraulic pump :88 − GND sensor, lift :16 - Coolant level The number in front of the wire colour refers
:19 − 0 V exhaust valve :89 − GND sensor, lift :17 - Door lock to the wire cross-section.
:21 - ISO K-lift :90 − Auxiliary 1/B (B1) X11 9-pin plug connector (central electrical Wires with unspecified cross-sec-
:24 − Retarder 1Y1 :91 − Tilt forwards (A2) system), 108-110 tion = 0.75 mm2
:28 − Coding :92 − Tilt backwards (B2) :5 - Air conditioning shut-off Notes
:29 - Auxiliary 2 :93 − Lift :6 - Engine switch-off (a) Wires twisted together
:30 − Tilt angle :94 − ISO L-lift :8 - Air conditioning

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Wiring diagram

Basic equipment for LPG sheet 3

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Wiring diagram

Legend ON1 LPG system control unit, 164–237 1Y6 LPG shut-off valve, 182 Notes
OB1 Coolant temperature transmitter, 196–198 :8 − LPG shut-off valve (a) Special equipment wiring diagram
OB2 Engine speed transmitter, 165–168 :19 − Earth Wire colours (b) Wires twisted together
OB6 Intake air pressure/temperature sensor, :20 − Earth BK Black (c) Screened wires
171–173 :26 − Fault light BN Brown *2) OB11, OX12, OX11, OY3 only present
OB10 Phase sensor, 177–179 :36 − Not controlled BU Blue on trucks fitted with a three-way catalytic
OB11 Lambda sensor, 183–185 :49 − Electronics earth GN Green converter
OB21 2. Lambda sensor, 189-191 :50 − 5V reference GY Grey *3) OX24 and OB21 only present on trucks for
OE1 Spark plug 1st cylinder, 219 OT1 4-way ignition module, 217–230 OG Orange the USA
OE2 Spark plug 2nd cylinder, 222 X6 5-pin plug connector, 184 RD Red *4) Wire only for three-way catalytic converters
OE3 Spark plug 3rd cylinder, 225 X10 18-pin plug connector (central electrical VT Violet *) Gold-plated contacts
OE4 Spark plug 4th cylinder, 228 system), 175 WH White
F10 20A fuse, 161 OX7 3-pin plug connector (engine speed), YE Yellow
F11 7.5A fuse, 179 165–168 The number in front of the wire colour refers
F12 10A fuse, 171 OX11 2-pin plug connector (pulse valve), 201 to the wire cross-section.
OK3 Supply relay, 161–164 OX12 4-pin plug connector (lambda sensor), 183, Wires with unspecified cross-sec-
OM1 Butterfly valve servo motor with potentiome- 185 tion = 0.75 mm2
ter, 208–213 OY3 Pulse valve, 189, 191

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Wiring diagram

CNG basic equipment sheet 1

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Wiring diagram

Legend 6P1 Display unit, 25–40 X11 9-pin plug connector (central electrical WH White
B1 Tank transmitter, 33-35 :1 − Terminal 30 system), 22, 65–67 YE Yellow
F2 30A fuse, 4 :2 − Terminal 15 X15 2-pin plug connector (CAN), 42 The number in front of the wire colour refers
F5 2A fuse, 26 :6 − Earth 6X1 10-pin plug connector (6P1), 26–39 to the wire cross-section.
F6 2A fuse, 28 S1 Ignition and starting switch, 9–17 6X2 7-pin plug connector (diagnostics), 48 Wires with unspecified cross-sec-
F7 15A fuse, 73 S2 Brake pedal switch 2 (start-up prevention), tion = 0.75 mm2
F13 15A max. fuse, 61 12–14 Wire colours
F14 2A fuse, 64 S3 Suction filter vacuum-operated switch, 31 BK Black Notes
F15 10A fuse, 67 OS1 Oil pressure switch, 28 BN Brown (a) Wires twisted together
G1 660 W three-phase generator with regulator, 4S1 Horn activation, 73 BU Blue *) Gold-plated contacts
1–5 X1 10-pin plug connector (S1), 9–16, 73 GN Green
G2 88 Ah battery, 7 X2 3-pin plug connector (S2), 12, 13 GY Grey
4H1 60 W signal horn, 73 X6 5-pin plug connector, 33 OG Orange
K2 Electronic starter relay, 10-15 X10 18-pin plug connector (central electrical RD Red
M1 1.7 kW starter motor, 9–11 system), 20, 64–69 VT Violet

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Wiring diagram

CNG basic equipment sheet 2

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Wiring diagram

Legend :32 − Drive potentiometer reference :102 − Tilt forwards/back reference 1X3 6-pin plug connector, coded plug for dual
1B1 Speed actual value transmitter, 85-86 :33 − Seat switch reference :103 − Tilt angle reference pedal identification, 107-111
1B2 Dual potentiometer for accelerator, 85-88 :36 − Middle :104 - Auxiliary 1 reference 1X3 + 1S2 6-pin plug connector, drive direction
1B4 Hydraulic oil temperature sensor, 85 :37 − Forwards :105 − Mast positioning switch for single pedal, 105-111
2B1 Joystick basic functions, 114-118 :38 − Seat switch :106 − 0 V lift/lower 1X7 6-pin plug connector (fan motor), 154-157
:1 − 5 V :39 − ISO L-drive :107 − 0 V tilt forwards/backwards 2X1 2-pin plug connector (microfilter), 122, 123
:2 − Lift/lower :40 − Mast positioning display :109 − 0 V exhaust valve 2X3 6-pin plug connector (2B1), 114–118
:3 − Tilt forwards/back :44 − Auxiliary 2/B (B3) :111 − Exhaust valve 2X4 6-pin plug connector (2B2), 121–124
:4 − Lift/lower reference :45 − Auxiliary 2/A (A3) :112 − 0 V (1/A)/(1/B) 2X5 14-pin plug connector (valve block), 127-151
:5 − Tilt forwards/back reference :46 − Exhaust valve 1Y4 :113 − 0 V (2/A)/(2/B) 1Y1 Retarder, 90
:6 − 0 V :47 − Coding :114 − GND 1Y2 Forwards solenoid valve "y", 92
2B2 Joystick additional functions, 121-124 :48 − Tilt forwards/back :116 − 5 V lift sensor 1Y3 Backwards solenoid valve "z", 95
:1 − 5 V :49 − Drive potentiometer :117 - Auxiliary 2 reference 1Y4 Exhaust valve, 97
:2 - Auxiliary 1 :50 − Fan diagnostics :118 − 5 V lift sensor 2Y1 Lower valve, 127
:3 - Auxiliary 2 :52 − Coding :119 − Earth 2Y2 Lift valve, 129
:4 - Auxiliary 1 reference :53 − Terminal 15 :120 − Terminal 30 2Y3 Tilt forwards valve, 132
:5 - Auxiliary 2 reference :56 − Code :121 − Terminal 30 2Y4 Tilt backwards valve, 134
:6 − 0 V :58 − Brake 1 OB1:3 Engine temperature sensor, 87-88 2Y5 Auxiliary valve 1B, 138
2B3 Dual potentiometer for lift mast tilt angle, :59 − Brake 3 OB1:4 Engine temperature sensor, 87-88 2Y6 Auxiliary valve 1A, 140
134-138 :61 − GND sensor, drive S4 Seat switch, 143–144 2Y7 Auxiliary valve 2B, 143
F4 20 A fuse (fan motor), 157 :62 − Fan 1S1 Brake pedal switch 1, 101–102 2Y8 Auxiliary valve 2A, 145
F8 2 A fuse, 81 :63 − Speed actual-value transmitter 1S2 Single-pedal drive direction switch, 105-111 2Y9 Exhaust valve, 149
F9 15 A fuse, 83 :68 − GND X2:1 Brake pedal switch 2, 104
1M1 Fan motor, 154-157 :69 − GND X4 3-pin plug connector (seat switch), 143, 144 Wire colours
N1 LHC electronic control, 81–152 :70 − GND X6 5-pin plug connector (CNG display), 93 BK Black
:1 − 5 V sensor, drive :71 − GND X10 18-pin plug connector (central electrical BN Brown
:3 − 5 V sensor, drive :72 − Reverse system), 98-106 BU Blue
:6 − Forwards hydraulic pump 1Y2 :73 − Brake 2 :4 - Speed limitation GN Green
:7 − Reverse hydraulic pump 1Y3 :74 − Engine temperature :6 - Brake light GY Grey
:8 − Microfilter pressure switch :80 − GND sensor, drive :7 - Programmable reversing signal OG Orange
:10 − Coding :81 − GND sensor, drive :8 - Programmable reversing signal RD Red
:12 − Lift/lower :82 − Auxiliary 1/A (A1) :9 - Programmable reversing signal VT Violet
:13 − Hydraulic oil temperature sensor :85 − ISO K-lift :10 - Reserve WH White
:14 − 0 V retarder :88 − GND sensor, lift :11 - Shovel insert YE Yellow
:15 − 0 V forwards hydraulic pump :89 − GND sensor, lift :16 - Coolant level The number in front of the wire colour refers
:16 − 0 V reverse hydraulic pump :90 − Auxiliary 1/B (B1) :17 - Door lock to the wire cross-section.
:19 − 0 V exhaust valve :91 − Tilt forwards (A2) X11 9-pin plug connector (central electrical Wires with unspecified cross-sec-
:21 − ISO K-drive :92 − Tilt backwards (B2) system), 108-110 tion = 0.75 mm2
:24 − Retarder 1Y1 :93 − Lift :5 - Air conditioning shut-off Notes
:28 − Coding :94 − ISO L-lift :6 - Engine switch-off (a) Wires twisted together
:29 - Auxiliary 2 :96 − GND sensor, lift :8 - Air conditioning
:30 − Tilt angle :98 − Lower 1X1 3-pin plug connector (1B1), 84
:31 - Auxiliary 1 :101 − Lift/lower reference 1X2 3-pin plug connector (1S1), 101, 102

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Wiring diagram

CNG basic equipment sheet 3

282 Operating Instructions – 391 807 10 51 EN – 09/2010

 Circuit diagrams 7
Wiring diagram

Legend ON1 LPG system control unit, 164–237 Wire colours Notes
OB1 Coolant temperature transmitter, 196–198 :8 − LPG shut-off valve BK Black (a) Wires twisted together
OB2 Engine speed transmitter, 165–168 :19 − Earth BN Brown (b) Screened wires
OB6 Intake air pressure/temperature sensor, :20 − Earth BU Blue *) Gold-plated contacts
171–173 :36 − Not controlled GN Green
OB10 Phase sensor, 177–179 :49 − Electronics earth GY Grey
OB11 Lambda sensor, 183–185 :50 − 5V reference OG Orange
OE1 Spark plug 1st cylinder, 219 OT1 4-way ignition module, 217–230 RD Red
OE2 Spark plug 2nd cylinder, 222 X6 5-pin plug connector, 184 VT Violet
OE3 Spark plug 3rd cylinder, 225 OX7 3-pin plug connector (engine speed), WH White
OE4 Spark plug 4th cylinder, 228 165–168 YE Yellow
F10 20 A fuse, 161 OX11 2-pin plug connector (pulse valve), 201 The number in front of the wire colour refers
F11 7.5 A fuse, 179 OX12 4-pin plug connector (lambda sensor), 183, to the wire cross-section.
F12 10A fuse, 171 185 Wires with unspecified cross-sec-
OK3 Supply relay, 161–164 OY3 Pulse valve, 189, 191 tion = 0.75 mm2
OM1 Butterfly valve servo motor with potentiome- 1Y6 LPG shut-off valve, 182
ter, 208–213 1Y12 Tank shut-off valve, 184

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7 Circuit diagrams
Wiring diagram

Special equipment sheet 1 - Working spotlights, interior light

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Wiring diagram

Legend 5F2 15 A fuse (working spotlight pos. 3, 4), 17, 5X14 3-pin plug connector (working spotlight (II) Working headlight pos. 1, 2 (with higher
5E1 Left front lower working spotlight 55 W 30 pos. 5, 6), 26 lighting)
(pos. 1), 7, 15 5F3 15 A fuse (working spotlight, pos. 5, 6), 26 5X15 2-pin plug connector (working spotlight (III) Working spotlights, pos. 5, 6
5E2 Right front lower working spotlight 55 W 5F4 15 A fuse (working spotlight pos. 7, 8), 40 pos. 5, 6), 26 (IV) Working headlight pos. 3, 4
(pos. 2), 9, 17 5F4 7.5 A fuse (working spotlight pos. 8), 40 (V) Working headlight pos. 7, 8
5E3 Left front upper working spotlight 55 W 5F12 5 A fuse (interior light), 72 Wire colours (VI) Interior lighting
(pos. 3), 28 K1 Terminal 58 auxiliary relay, 1-3 BK Black (a) to electronic controller N1:23
5E4 Right front upper working spotlight 55 W 5K4 Working spotlight relay (pos. 7, 8) 42–46 BN Brown
(pos. 4), 30 5S1 Working headlight switch (pos. 1, 2) 9–11 BU Blue
5E5 Lift mast left working spotlight 55 W (pos. 5), 5S2 Working spotlight switch (pos. 3, 4), 17-32 GN Green
24 5S3 Working spotlight switch (pos. 7, 8), 38-44 GY Grey
5E6 Lift mast right working spotlight 55 W 5S4 Interior light switch, 72-74 OG Orange
(pos. 6), 26 X10 18-pin plug connector (for basic equipment), RD Red
5E7 Right rear upper working spotlight 55 W 1, 42 VT Violet
(pos. 8), 39 5X1 12-pin plug connector (working spotlight WH White
5E8 6 W interior light, 72 pos. 1, 2), 15, 17 YE Yellow
5E19 Left rear upper working spotlight 55 W 5X4 12-pin plug connector (working spotlight The number in front of the wire colour refers
(pos. 7), 41 pos. 1, 2), 7, 9 to the wire cross-section.
F3 70A fuse (terminal 58), 3 5X5 2-pin plug connector (working spotlight Wires with unspecified cross-sec-
F14 2A fuse (terminal 58), 1 pos. 3, 4), 17, 30 tion = 0.75 mm2.
5F1 15A fuse (working headlight pos. 1, 2), 9 5X6 2-pin plug connector (working spotlight Notes
pos. 7, 8), 39 (I) Working headlight pos. 1, 2

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7 Circuit diagrams
Wiring diagram

Special equipment sheet 2 — windscreen wiper, seat heater

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 Circuit diagrams 7
Wiring diagram

Legend 9M5 Rear wash pump 24 W, 116 BN Brown (II) Front windscreen wiper
9F1 2A fuse (windscreen wipers, general), 83 9M6 Roof wash pump 24 W, 137 BU Blue (III) Rear windscreen wiper
9F2 10A fuse (front windscreen wiper), 96 9R2 80W seat heater, 144 GN Green (IV) Roof windscreen wiper
9F3 10A fuse (rear and roof windscreen wipers), 9S1 Windscreen wiper switch, 82–87 GY Grey (V) Seat heater
114 9S2 Front windscreen wiper switch, 82–89 OG Orange
9F4 10A fuse (wash pumps), 86 9S3 Rear windscreen wiper switch, 101–109 RD Red
9F6 15A fuse (seat heater), 144 9S4 Roof windscreen wiper switch, 121–128 VT Violet
9K1 Front windscreen wiper relay, 85–93 9X1 9-pin plug connector (windscreen wipers), WH White
9K2 Rear windscreen wiper relay, 106–111 83–94 YE Yellow
9K3 Roof windscreen wiper relay, 125–132 9X5 6-pin plug connector (wash pumps), 98, 116, The number in front of the wire colour refers
9M1 Front windscreen wiper motor 55 W, 91–95 137 to the wire cross-section.
9M2 Rear windscreen wiper motor 36 W, 9X7 3-pin plug connector (seat heater), 144 Wires with unspecified cross-sec-
110–113 9X14 2-pin plug connector (seat heater), 144 tion = 0.75 mm2.
9M3 Roof windscreen wiper motor 36 W,
130–134 Wire colours Notes
9M4 Front wash pump 24 W, 98 BK Black (I) Windscreen wipers

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7 Circuit diagrams
Wiring diagram

Special equipment sheet 3 − Heating system, air conditioning, flashing beacon / rotating beacon, reversing signal, 12 V socket

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Wiring diagram

Legend X10 18-pin plug connector (for basic equipment), 9X12 2-pin plug connector (heater), 164, 170, 172 Wires with unspecified cross-sec-
4B1 Buzzer, 222 210 9X13 4-pin plug connector (air conditioning tion = 0.75 mm2.
9E1 Heater, 161–167 X11 9-pin plug connector (for basic equipment), pressure switch), 178–180
9E2 Heater with air conditioning, 170–194 182–184 9X15 3-pin plug connector (12 V socket), 233 Notes
4F1 10A fuse (reversing signal), 214 4X1 2-pin plug connector (warning flashing light / 9X16 2-pin plug connector (12 V socket), 233 (I) Heater
4F3 7.5A fuse (flashing beacon/rotating bea- rotating beacon), 226 9Y1 E-coupling for air conditioner, 174 (II) Heater with air conditioning
con), 201 4X2 6-pin plug connector (buzzer), 216–223 (III) Flashing beacon/rotating beacon via termi-
9F9 20A fuse (heater), 164, 172 4X3 2-pin plug connector (flashing beacon/rotat- Wire colours nal 58
9F10 15A fuse 12 V socket, 233 ing beacon), 201 BK Black (IV) Reversing signal duration and switchable
9F11 30A fuse (air conditioning), 182 4X4 2-pin plug connector (flashing beacon/rotat- BN Brown Off / Reverse travel / On
4H4 Flashing beacon, 204, 214, 226 ing beacon), 214 BU Blue (V) 12V socket
4H5 Rotating beacon, 204, 214, 226 4X5 2-pin plug connector (buzzer), 221 GN Green (a) LHC controller N1:22
4K1 Reversing signal relay, 210–214 5X11 12-pin plug connector (higher lighting), 229 GY Grey (b) Alternator G1:L
9M7 Fan motor 1 for air conditioning, 188 9X4 2-pin plug connector (air-conditioning OG Orange (c) LHC controller N1:35
9M8 Fan motor 2 for air conditioning, 191 compressor), diesel version only, 174 RD Red (d) For electronic control N1:23
9M9 Fan motor 3 for air conditioning, 194 9X9 2-pin plug connector (heating system, air VT Violet (e) For higher reversing light special equipment
4S3 Flashing beacon/rotating beacon switch, conditioning), 164, 170, 172 WH White wiring diagram
212-217 9X10 1-pin plug connector (air conditioning), 182 YE Yellow
9S6 Air conditioning pressure switch, 177–179 9X11 6-pin plug connector (air conditioning), The number in front of the wire colour refers
9V1 Free-wheeling diode (E-coupling), 172 178–194 to the wire cross-section.

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Wiring diagram

Special equipment sheet 4 − hazard warning system for reverse travel, truck deactivation, lift mast positioning

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Wiring diagram

Legend 5N1 Flasher unit (electronic), 244-251 5X12 4-pin plug connector (right rear light), 246, Wires with unspecified cross-sec-
5F7 5 A fuse (brake light), 254 S1 Ignition and starting switch, 289-295 254 tion = 0.75 mm2.
5F13 10 A fuse (hazard warning system), 244 2S1 Lift mast position pre-selection switch, 5X13 4-pin plug connector (left rear light), 244,
2H1 Lift mast position pre-selection warning light, 312-314 257 Notes
314 V1 Decoupling diode, 306 (I) Hazard warning system for reverse travel
5H3 Left rear direction indicator, 3 W, 244 X1 10-pin plug connector, 289-301 Wire colours with brake light (without lighting)
5H4 Right rear direction indicator, 3 W, 246 X1.1 10-pin plug connector, 289-301 BK Black (II) Hazard warning system for reverse travel
5H10 Direction indicator light 2 W, 249 X10 18-pin plug connector (for basic equipment), BN Brown (with lighting)
5H20 Right brake light 3 W, 255 241, 252, 281 BU Blue (III) Truck deactivation via seat switch
5H21 Left brake light 3 W, 257 X11 9-pin plug connector (for basic equipment), GN Green (IV) Lift mast positioning
K2 Start relay, 293-295 305 GY Grey (a) For electronic control N1:23
K3 Engine switch-off relay, 300-303 X23 10-pin plug connector (armrest), 312, 314 OG Orange (b) For electronic control N1:41
5K2 Brake light relay, 252–254 5X2 6-pin plug connector (rear lighting), 244–254 RD Red (c) For electronic control N1:23
5K3 Hazard warning system relay for reverse 5X3 2-pin plug connector (reversing signal VT Violet (d) For horn activation 4S1 (basic equipment
travel, 241-244, 279-281 transfer), 279 WH White wiring diagram)
N1 LHC electronic control, 311-315 5X9 6-pin plug connector (hazard warning YE Yellow (e) For electronic control N1:42
:40 − Lift mast positioning display system), 244-254 The number in front of the wire colour refers
:105 − Lift mast positioning to the wire cross-section.

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Wiring diagram

Special equipment sheet 5 − particle filter, radio

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 Circuit diagrams 7
Wiring diagram

Legend 9E3 Radio, 376-383 X10 18-pin plug connector (to main harness), OG Orange
7A1 Particle filter control unit, 328-365 :4 - Terminal 30 348 RD Red
:5 − Terminal 50 :7 - Terminal 15 X11 9-pin plug connector (to main harness), 325, VT Violet
:6 − Thermocouple (negative) :8 − Earth 354 WH White
:10 − Regeneration indicator 9E4 Left loudspeaker, 375 X15 2-pin plug connector (CAN), 356, 359 YE Yellow
:12 − Signal input terminal 15 9E5 Right loudspeaker, 380 7X1 9-pin plug connector (central electrical The number in front of the wire colour refers
:13 − Electronics power supply F15 5 A fuse, 348 system transfer), 343-350 to the wire cross-section.
:14 − Consumer power supply 7F1 5 A fuse (particle filter), 334 7X2 4-pin plug connector (blower shut-off valve), Wires with unspecified cross-sec-
:17 − Regeneration start 7F2 20 A fuse (particle filter), 340 332, 335 tion = 0.75 mm2.
:18 − Glow plug controller power supply 7F3 30 A fuse (glow plug), 367 7X3 2-pin plug connector (flame sensor), 357,
:19 − Glow plug indicator 9F7 5 A fuse (radio terminal 30), 376 358 Notes
:20 − Thermocouple (positive) 9F8 10 A fuse (radio terminal 15), 379 7X4 2-pin plug connector (glow plug), 367 (I) Particle filter (only with diesel version)
:24 − Shut-off valve 7H1 1.2 W regeneration warning light, 344 7X5 2-pin plug connector (metering pump), 339 (II) Radio
:26 − Metering pump K2 Start relay, 323–325 9X2 3-pin plug connector (radio), 376-383 (a) For generator G1:B+ (only in diesel version)
:29 − Relay for glow plug 7K1 Glow plug current regulator, 365-367 9X8 3-pin plug connector (radio), 376-383 (b) For ignition and starting switch S1:50 (only
:30 - Stop/reset switch 7K2 Starting aid relay, 325–328 7Y1 Shut-off valve, 335 in diesel version)
:31 - Stop/reset switch 7M1 60 W blower, 332 (c) For starter motor M1:50a (only in diesel
:37 − Starter relay 7M2 24 W metering pump, 339 Wire colours version)
:39 − Earth 7R1 200 W glow plug, 367 BK Black (d) For brake pedal switch X2:3 (only in diesel
:40 − Earth 7S1 Starting switch, 342-344 BN Brown version)
:41 − Consumer power supply 7S2 Stop/reset switch, 348-350 BU Blue
:42 − Combustion air blower 7V1 Decoupling diode. 336 GN Green
7B2 Flame sensor, 357-359 9W1 Antenna, 382 GY Grey

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7 Circuit diagrams
Wiring diagram

Special equipment sheet 6 - higher lighting, hydraulic oil microfilter indicator, diesel filter water trap warning

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 Circuit diagrams 7
Wiring diagram

Legend 5H1 Left front direction indicator, 21 W, 423 2X7 2-pin plug connector (pressure switch), 460 RD Red
0B14 Water trap transmitter, 466-467 5H2 Right front direction indicator, 21 W, 426 5X1 12-pin plug connector (overhead guard VT Violet
0B15 Water trap buzzer, 474 5H3 Left rear direction indicator 3 W, 420 lighting), 409-431 WH White
5E11 55 W left dipped beam, 402 5H4 Right rear direction indicator 3 W, 428 5X7 4-pin plug connector (left headlight), 402, YE Yellow
5E12 Right dipped beam, 55 W, 405 5H10 Direction indicator control lamp 2 W, 431 407, 423 The number in front of the wire colour refers
5E13 Left front sidelight, 5 W, 407 5H20 Right brake light 3 W, 442 5X8 4-pin plug connector (right headlight), 404, to the wire cross-section.
5E14 Right front sidelight, 5 W, 412 5H21 Left brake light 3 W, 445 412, 426 Wires with unspecified cross-sec-
5E15 0.5 W left rear sidelight, 409 5K2 Brake light relay, 440-442 5X11 12-pin plug connector (higher lighting), tion = 0.75 mm2.
5E16 0.5 W right rear sidelight, 414 N1 LHC electronic control, 456-461 402-447
5E17 0.5 W left reversing light, 447 5N1 Flasher unit, 420-434 5X12 6-pin plug connector (right rear light), 414, Notes
5E18 0.5 W right reversing light, 450 2S2 Pressure switch for feed filter, 457 428, 442, 450 (I) Higher lighting
F15 10A fuse, 466 2S3 Pressure switch for high pressure filter, 460 5X13 6-pin plug connector (left rear light), 409, (II) Higher direction indicator and hazard
5F5 15 A fuse (lighting terminal 15), 423 5S11 Light switch, 402-408 420, 445, 447 warning system
5F6 10 A fuse (lighting terminal 30), 427 5S12 Warning light switch, 426-431 (III) Higher brake light
5F7 5 A fuse (brake light), 442 5S13 Turn indicator switch, 421-423 Wire colours (IV) Higher reversing light
5F8 7.5 A fuse (left headlight), 402 X8 2-pin plug connector, 466 BK Black (V) Hydraulic oil microfilter indicator
5F9 7.5A fuse (right headlight), 405 X10 18-pin plug connector (for basic equipment), BN Brown (VI) Diesel filter water trap warning (diesel
5F10 5A fuse (left sidelight), 407 440, 466 BU Blue version only)
5F11 5A fuse (right sidelight), 412 2X1 2-pin plug connector (microfilter), 457, 461 GN Green (a) to electronic controller N1:41
0H2 Water trap warning light, 2 W, 470 2X6 2-pin plug connector (pressure switch), 457 GY Grey (b) to reversing signal special equipment wiring
OG Orange diagram

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7 Circuit diagrams
Wiring diagram

Special equipment sheet 7 − Forklift Data Management, LPG volume display, oil level monitoring, coolant level monitoring

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 Circuit diagrams 7
Wiring diagram

Legend :3 − Earth 0X20 4-pin plug connector, 546, 547 (II) LPG volume display for volumetric filling
6A1 Truck Data Acquisition unit (FDE), 488-502 F15 10 A fuse (terminal 15), 499, 547 6X4 14-pin plug connector (FDE), 488-502 (LPG version only)
:1 − Terminal 30 6F1 5 A fuse (Linde Forklift Data Management), 6X5 3-pin plug connector (transfer to FDE), 497, (III) LPG volume display for replacement cylin-
:2 − Terminal 15 497 499 der (LPG version only)
:3 − Earth K2 Start relay, 482–485 6X7 5-pin plug connector (data transfer), (IV) Oil and coolant level monitoring
:4 − Free input 0N3 LOC logic controller, 547–551 495–499 (a) For generator G1:B+
:5 − Load sensor :1 − Terminal 15 6X9 4-pin plug connector (Linde Forklift Data (b) For ignition and starting switch S1:50
:6 − Free output :2 − Earth Management online module), 505-508 (c) For starter motor M1:50a
:7 − Terminal 50 :3 − Signal (d) For brake pedal switch X2:3
:8 − Starter relay 0N4 Level switch for coolant, 540–542 Wire colours (e) Basic equipment wiring diagram
6A2 Linde Forklift Data Management online 6W1 Antenna (Linde Forklift Data Management BK Black (f) Basic equipment wiring diagram
module, 505-510 online module), 510 BN Brown (g) LHC controller N1:27
:3 − Terminal 15 X1 10-pin plug connector, 484 BU Blue
:4 − Earth X6 5-pin plug connector (to main harness), 522, GN Green
B1 Tank transmitter (volumetric filling), 522 530, 532 GY Grey
B2 Tank transmitter (replacement cylinder), X7 4-pin plug connector (tank transmitter), 530, OG Orange
530–532 532 RD Red
:1 − Terminal 15 X10 18-pin plug connector (to basic equipment), VT Violet
:2 − Calibration 499, 540, 547 WH White
:3 − Signal X11 9-pin plug connector (to basic equipment), YE Yellow
:4 − Earth 501, 550 The number in front of the wire colour refers
0B16 Oil level sensor, 546–547 X14 1-pin plug connector (calibration), 530 to the wire cross-section.
0B19 Coolant level sensor, 540 X15 2-pin plug connector (CAN connection), Wires with unspecified cross-sec-
6B2 Load sensor, 512-516 489, 495, 549, 554 tion = 0.75 mm2.
:1 − Terminal 15 0X19 6-pin plug connector (logic controller), Notes
:2 − Signal 547-551 (I) Linde Forklift Data Management (LFM)

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7 Circuit diagrams
Wiring diagram

Special equipment sheet 8 − third auxiliary hydraulics, changing particle filter, working spotlights positions 5, 6

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 Circuit diagrams 7
Wiring diagram

Legend 2H3 3rd auxiliary hydraulics indicator light 2X9 6-pin plug connector, 573-590 GY Grey
7A2 Changing particle filter controller, 600-612 (green), 582 2X10 6-pin plug connector, 573-590 OG Orange
2B11 End position sensor 1, 573-575 7H4 Indicator light (orange), 610 2X11 10-pin plug connector, 573-590 RD Red
2B12 End position sensor 2, 588-590 N1 LHC electronic control, 563-569 5X5 2-pin plug connector (working spotlight VT Violet
7B3 Changing particle filter buzzer, 613 :9 − Auxiliary 3 positions 3, 4), 626 WH White
5E3 Upper front left working spotlight 55 W :64 − auxiliary 3 5X14 3-pin plug connector (working spotlight YE Yellow
(position 3), 624 :84 − End position 1 positions 5, 6), 622 The number in front of the wire colour refers
5E4 Upper front right working spotlight 55 W :99 − End position 2 5X15 2-pin plug connector (working spotlight to the wire cross-section.
(position 4), 626 2S4 3rd auxiliary hydraulics valve switch, 579- position 5), 622 Wires with unspecified cross-sec-
5E5 Lift mast left working spotlight 55 W (position 584 7X6 9-pin plug connector (changing particle tion = 0.75 mm2.
5), 620 5S2 Working spotlight switch (positions 3, 4, 5, filter), 600-605
5E6 Lift mast right working spotlight 55 W 6), 621-628 7X7 3-pin plug connector (reset switch), 599, 600 Notes
(position 6), 622 7S3 Changing particle filter switch, 599-600 7X8 2-pin plug connector (pressure switch), 604, (I) 3rd auxiliary hydraulics
F15 10 A fuse, 604 7S4 Changing particle filter pressure switch, 605 (II) Changing particle filter (diesel version only)
F16 7.5 A fuse (terminal 15), 581 604-605 2Y11 3rd auxiliary hydraulics valve, 580 (III) Working spotlight position 5, 6
5F2 15 A fuse (working spotlight positions 3, 4), 2V11 Free-wheeling diode for 3rd auxiliary hy- 2Y12 3rd auxiliary hydraulics valve, 583 *1) Switch opens when the changing particle
624 draulics valve, 581 filter is fitted and the cover is closed (diesel
5F3 15 A fuse (working spotlight positions 5, 6), 2V12 Free-wheeling diode for 3rd auxiliary hy- Wire colours version only).
622 draulics valve, 584 BK Black *2) Switch is shown in the pressure differential
7F4 2 A fuse, 610 X10 18-pin plug connector (for basic equipment), BN Brown OK position (only with diesel version).
2H2 3rd auxiliary hydraulics indicator light 600, 604 BU Blue
(orange), 584 2X8 4-pin plug connector, 580-584 GN Green

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7 Circuit diagrams
Wiring diagram

Special equipment sheet 9 - camera system, centre rear brake/tail light, rear window heating

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 Circuit diagrams 7
Wiring diagram

Legend 9S5 Rear window heating switch, 678-683 Wire colours Wires with unspecified cross-sec-
9A5 Monitor, 643-655 X10 18-pin plug connector (for basic equipment), BK Black tion = 0.75 mm2.
5E20 10 W centre rear sidelight, 666 644, 651, 671 BN Brown
9E6 Front camera, 644-646 5X20 4-pin plug connector (brake/tail light), 666, BU Blue Notes
9E7 Rear camera, 649-651 669 GN Green (I) Camera system
9F7 5 A fuse, 669 9X26 5-pin plug connector (camera system), GY Grey (II) Centre rear brake/tail light
9F5 20 A fuse (rear window heating), 680 644-646 OG Orange (III) Rear window heating
F15 10 A fuse (camera system), 644 9X27 5-pin plug connector (camera system), RD Red (a) For electronic controller N1:22
5H22 21 W centre rear brake light, 669 649-651 VT Violet (b) For electronic controller N1:41
5K2 Brake light relay, 669-671 9X28 5-pin plug connector (camera system), WH White
9R1 Rear window heating, 680 644-646 YE Yellow
5S2 Working spotlight switch (pos. 3, 4), 660- 9X29 3-pin plug connector (camera system), 644, The number in front of the wire colour refers
663 651, 653 to the wire cross-section.

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7 Circuit diagrams
Wiring diagram

Special equipment sheet 10 - Single lever locked, third auxiliary hydraulics via switch

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 Circuit diagrams 7
Wiring diagram

Legend :64 − Auxiliary 3 reference 2X11 10-pin plug connector, 749-766 YE Yellow
2B2 Additional joystick function, 727-730, 781- :84 − End position 1 2X15 4-pin plug connector, 736-738, 753, 792 The number in front of the wire colour refers
787 :96 − GND sensor, lift 2X15.1 4-pin plug connector (2B6), 736-738, 791- to the wire cross-section.
2B6 Single lever locked for single auxiliary :99 − End position 2 792 Wires with unspecified cross-sec-
hydraulics / double auxiliary hydraulics, :104 - Auxiliary 1 reference 2Y11 3rd auxiliary hydraulics valve, 757 tion = 0.75 mm2.
736-738, 790-793 :116 − 5 V lift sensor 2Y12 3rd auxiliary hydraulics valve, 759
2B11 End position sensor 1, 749-752 :117 - Auxiliary 2 reference Notes
2B12 End position sensor 2, 764-766 2S4 Switch for 3rd auxiliary hydraulics, 756-761 Wire colours (I) Single lever locked for single auxiliary hy-
2H2 3rd auxiliary hydraulics indicator light 2V11 Free-wheeling diode for 3rd auxiliary hy- BK Black draulics, in accordance with ISO 3691
(orange), 760 draulics valve, 757 BN Brown (1st auxiliary hydraulics electrically reversed
2H3 3rd auxiliary hydraulics indicator light 2V12 Free-wheeling diode for 3rd auxiliary hy- BU Blue with 2nd auxiliary hydraulics and 3rd auxil-
(green), 759 draulics valve, 760 GN Green iary hydraulics with 1st auxiliary hydraulics)
F16 7.5 A fuse (terminal 15), 757 X23 10-pin plug connector, 757-761 GY Grey (II) 3rd auxiliary hydraulics via switch
N1 LHC electronic control, 721-746, 775-794 2X4 6-pin plug connector, 726-738, 781-787 OG Orange (III) Single lever locked for double auxiliary
:9 − Auxiliary 3 2X4.1 6-pin plug connector, 726-738, 781-787 RD Red hydraulics, in accordance with ISO 3691
:29 - Auxiliary 2 2X9 6-pin plug connector, 749-766 VT Violet (3rd auxiliary hydraulics electrically reversed
:31 - Auxiliary 1 2X10 6-pin plug connector, 749-766 WH White with 2nd auxiliary hydraulics)

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7 Circuit diagrams
Wiring diagram

Special equipment sheet 11 - Lighting, direction indicator and hazard warning system, brake light

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 Circuit diagrams 7
Wiring diagram

Legend 5H3 Left rear direction indicator, 3 W, 824 5X7 6-pin plug connector (left headlight), 803, GY Grey
5E9 10 W left licence plate lamp, 818 5H4 Right rear direction indicator, 3 W, 832 808, 827 OG Orange
5E10 10 W right licence plate lamp, 820 5H10 Direction indicator light, 2 W, 835 5X8 6-pin plug connector (right headlight), 805, RD Red
5E11 55 W left dipped beam, 803 5H20 Right brake light, 3 W, 845 808, 829 VT Violet
5E12 55 W right dipped beam, 805 5H21 Left brake light, 3 W, 848 5X10 2-pin plug connector (licence plate lighting), WH White
5E13 5 W left front sidelight, 808 5K2 Brake light relay, 843-845 818 YE Yellow
5E14 5 W right front sidelight, 813 5N1 Flasher unit, 824-837 5X12 4-pin plug connector (right rear light), 815, The number in front of the wire colour refers
5E15 0.5 W left rear sidelight, 810 5S11 Light switch, 803-809 832, 845 to the wire cross-section.
5E16 0.5 W right rear sidelight, 815 5S12 Warning light switch, 829-835 5X13 4-pin plug connector (left rear light), 810, Wires with unspecified cross-sec-
5F5 15 A fuse (lighting terminal 15), 826 5S13 Turn indicator switch, 825-827 824, 847 tion = 0.75 mm2.
5F6 10 A fuse (lighting terminal 30), 831 X10 18-pin plug connector (for basic equipment), 5X16 2-pin plug connector (licence plate lamp),
5F7 5 A fuse (brake light), 845 843 818 Notes
5F8 7.5 A fuse (left headlight), 803 5X1 12-pin plug connector (overhead guard (I) Lighting
5F9 7.5 A fuse (right headlight), 805 lighting), 803-835 Wire colours (II) Direction indicator and hazard warning
5F10 5 A fuse (left sidelight), 808 5X2 6-pin plug connector (rear lighting), 810-844 BK Black system
5F11 5 A fuse (right sidelight), 813 5X3 2-pin plug connector (reversing signal BN Brown (III) Brake light
5H1 Left front direction indicator, 21 W, 826 transfer), 837 BU Blue (a) For electronic control N1:41
5H2 Right front direction indicator, 21 W, 829 GN Green

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7 Circuit diagrams
Hydraulic circuit diagram

Hydraulic circuit diagram

Traction, working and steering hydraulics

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 Circuit diagrams 7
Hydraulic circuit diagram

A Working hydraulics 19 Directional control valve - auxiliary hy- E Internal combustion engine 53 Maximum valve 120+10 bar
1 Tilt cylinders draulics 1
2 Standard lift mast lift cylinder 20 Directional control valve - auxiliary hy- F Engine speed regulator L Steering cylinder
3 Line breakage protection draulics 2 G Hydraulic variable pump assembly consisting of: M Brake air valve
4 Auxiliary hydraulics connection 2 34 Hydraulic variable pump HPV 55-02 54 Towing unit
5 Auxiliary hydraulics connection 1 B Depressurisation (special equipment)
21 Connection X control valve 35 Release valve (traction hydraulics) 55 Pedal group
6 Solenoid valve 36 Set piston A→forwards B→reverse 56 3/2 directional control valve
7 Tilt brake valve 22 Accumulator
23 Non-return valve 37 Non-return valve 1 bar 57 Pump for venting brake
8 Load holding valve 38 Sensor (hydraulic oil temperature) 58 Non-return valve
9 Non-return valve 24 Connection E brake valve
39 4/2 directional control valve 59 Pressure relief valve
10 Pressure relief valve 1 C accumulator (special equipment) 40 Pilot valve 60 2/2 directional control valve
for H 14 standard/duplex/triplex 180+5 bar 25 to the oil tank 41 Feed pressure valve 19+0.5 bar
for H 16 standard/duplex/triplex 200+5 bar 26 from HPV 42 Combined feed maximum valve 435+20 bar N Pressure filter (feed pressure) / microfilter
for H 18 standard/duplex/triplex 220+5 bar 27 from connection T control valve 43 Choke plunger (towing unit) O Radiator
for H 20/H 20-600 standard/duplex/triplex 28 Pressure relief valve 44 Servo piston Y→forwards Z→backwards
250+5 bar 29 Accumulator 45 2/2 directional control valve P Drive axle AH 20-03 consisting of:
11 2/2 directional control valve (pressure Accumulator gas charging pressure with 46 Proportional valve (direction of travel) 61 Multi-disc brake (brake vent. min. 16 bar)
governor) nitrogen 62 Hydraulic fixed displacement motor
12 Release valve (working hydraulics) H14 standard/duplex/triplex 114 bar H Gear pump group HMF 240
13 2/2 directional control valve (proportional H16 standard/duplex/triplex 127 bar 47 Solenoid valve (retarder)
48 Gear pump 11 cm3 R Oil tank consisting of:
valve) H18 standard/duplex/triplex 140 bar
49 Gear pump 63 Breather with suction and counter-balance
14 Directional control valve - lift/lower H20/20-600 standard/duplex/triplex 159 bar
H 14DT/16DT/18DT/H20T (20 cm3) valve 0.35±0.15 bar
15 2/2 directional control valve (proportional 30 Connection A1 control valve
H 20D (18 cm3) 64 Suction filter with by-pass valve 0.25 bar
valve) 31 of connection T axle
16 Directional control valve - tilt I Working hydraulics pressure filter / microfilter
17 Pressure relief valve 2 Auxiliary hydraulics D Linde Truck Control
For H 14 — blocked 32 Working hydraulics central lever K Steering control valve with:
For H 16/18/20/20-600 (170+10 bar) 33 Auxiliary hydraulics central lever 1+2 50 Suction valve
18 2/2 directional control valve (proportional 51 Hose safety valve 180+10 bar
valve) 52 Servostat

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Linde Material Handling GmbH

391 807 10 51 EN – 09/2010