Jungheinrich DFG 540 Operating Instructions Manual

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Operating instructions manual (151 pages)

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DFG / TFG 540 - 550

Operating instructions

51167690

08.12

https://www.besttruckmanuals.com/

11.09 -

DFG 540

DFG 545

DFG 550

TFG 540

TFG 545

TFG 550

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Summary of Contents for Jungheinrich DFG 540

Page 1 DFG / TFG 540 - 550 DFG / TFG 540 - 550 11.09 - 11.09 - Operating instructions Operating instructions 51167690 51167690 DFG 540 DFG 540 08.12 08.12 DFG 545 DFG 545 DFG 550 DFG 550 TFG 540...
Page 2 Declaration of Conformity Declaration of Conformity Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg Manufacturer or agent acting in the European Union Manufacturer or agent acting in the European Union T T y y p p e e O O p p t t i i o o n n S S e e r r i i a a l l n n o o .
Page 3 N N E E 2 2 1 1 . . 8 8 0 0 https://www.besttruckmanuals.com/...
Page 4 Our trucks are subject to ongoing development. Jungheinrich reserves the right to Our trucks are subject to ongoing development. Jungheinrich reserves the right to alter the design, equipment and technical features of the system. No guarantee of ...
Page 5 Jungheinrich Aktiengesellschaft Jungheinrich Aktiengesellschaft Am Stadtrand 35 Am Stadtrand 35 22047 Hamburg - Germany 22047 Hamburg - Germany Tel: +49 (0) 40/6948-0 Tel: +49 (0) 40/6948-0 www.jungheinrich.com www.jungheinrich.com N N E E 2 2 1 1 . .
Page 6 Contents Contents A A Correct Use and App Correct Use and Application lication ...................... Gene neral.. ral........................................Corr rrec ect t ap appli...
Page 7 Fuel elli ling ng th the e Tr Truc uck.. k............................Gene nera ral l ..
Page 8 6. 6.7 7 Fi Fire re ex exti tingu nguis ishe her r .................................... 6.
Page 9 11.3 3 Fun Functi ctiona onal l Des Descri cripti ption on ................................167 11.4 4 HUS HUSS S Con Control Opera...
Page 10 A A Correct Use and Application Correct Use and Application G G e e n n e e r r a a l l The industrial truck described in the present operating instructions is designed for The industrial truck described in the present operating instructions is designed for lifting, lowering and transporting load units.
Page 11 A A p p p p r r o o v v e e d d a a p p p p l l i i c c a a t t i i o o n n c c o o n n d d i i t t i i o o n n s s DANGER! DANGER! Do not exceed the permissible surface and spot load limits on the travel routes.
Page 12 P P r r o o p p r r i i e e t t o o r r r r e e s s p p o o n n s s i i b b i i l l i i t t i i e e s s For the purposes of the present operating instructions the “proprietor”...
Page 13 N N E E 2 2 1 1 . . 8 8 0 0 https://www.besttruckmanuals.com/...
Page 14 B B T T r r u u c c k k D D e e s s c c r r i i p p t t i i o o n n A A p p p p l l i i c c a a t t i i o o n n The DFG / TFG 540 - 550 is a four-wheel IC motor sit-down forklift truck.
Page 15 A A s s s s e e m m b b l l ie ies s a a n n d d F F u u nc nct t io ion n a a l l D D e e s s c c r r i i pt pti i o o n n 2 2 .
Page 16 2 2 . . 2 2 F F u u n n c c t t io ion n a a l De l Des s c c r r i i p p t t i i o o n n Chassis Chassis The chassis, in conjunction with the counterweight, forms the supporting base...
Page 17 Drive system Drive system A power A power shift transmission shift transmission with radiator with radiator and and torque torque converter transfers converter transfers the the force to force to the drive axle (8). the drive axle (8). The travel direction switch on the engine cover controls forward/reverse travel and The travel direction switch on the engine cover controls forward/reverse travel and the neutral position.
Page 18 3 3 . . 1 1 P P e e r r f f o o r r m m a a n n c c e e d d a a t t a a DFG 540/545/550 DFG 540/545/550...
Page 19 TFG 540/545/550 TFG 540/545/550 D D e e s s c c r r i i p p t t i i o o n n T T F F G G 5 5 4 4 0 0 T T F F G G 5 5 4 4 5 5 T T F F G G 5 5 5 5 0 0 Capacity...
Page 20 3 3 . . 2 2 D D i i m m e e n n s s i i o o n n s s DFG/TFG 540/545/550 DFG/TFG 540/545/550 D D e e s s c c r r i i p p t t i i o o n n D D F F G G / / T T F F G G 5 54 4 0 0 5 5 4 4 5 5...
Page 21 N N E E 2 2 1 1 . . 8 8 0 0 https://www.besttruckmanuals.com/...
Page 22 3 3 . . 3 3 W W e e i i g g h h t t s s All dimensions in kg. All dimensions in kg. DFG/TFG 540/545/550 DFG/TFG 540/545/550 D D F F G G / / T T F F G G 5 5 4 4 0 0 D D F F G G / / T T F F G G 5 5 4 4 5 5 D D F F G G / / T T F F G G 5 5 5 5 0 0 T T a a r r e e w w e e i i g g h h t t * *...
Page 23 3 3 . . 4 4 M M a a s s t t v v e e r r s s i i o o n n s s All dimensions in mm All dimensions in mm DFG/TFG 540/545 DFG/TFG 540/545 Mast table...
Page 24 DFG/TFG 550 DFG/TFG 550 Mast table Mast table VDI 3596 VDI 3596 Lift h Lift h Free lift Free lift Retracted Retracted Extended Extended Mast Mast Description Description height h height h height h height h weight (kg) weight (kg) 2 2 7 7 5 5 0 0 1 1 5 5 0 0...
Page 25 3 3 . . 5 5 T T y y r r e e t t y y p p e e NOTE NOTE When replacing tyres/rims fitted at the factory, always use original spare parts or tyres When replacing tyres/rims fitted at the factory, always use original spare parts or tyres approved by the manufacturer.
Page 26 3 3 . . 6 6 E E n n g g i i n n e e D D a a t t a a DFG 540/545/550 DFG 540/545/550 D D e e s s c c r r i i p p t t i i o o n n...
Page 27 E E N N n n o o r r m m s s Noise emission level Noise emission level – – DFG 540/545/550: 78 dB (A)* DFG 540/545/550: 78 dB (A)* – – TFG 540/545/550: 78 dB(A)* TFG 540/545/550: 78 dB(A)*...
Page 28 3 3 . . 8 8 C C o o n n d d i i t t i i o o n n s o s of u f us s e e Ambient temperature Ambient temperature –...
Page 29 I I d d e e n n t t i i f f ic ica a t t i i o o n n p p oi oin n t t s s a a n n d d d d a a t t a a p p l l a a t t e e s s Warnings and notices such as capacity charts, strap points and data plates must Warnings and notices such as capacity charts, strap points and data plates must be legible at all times.
Page 30 I I t t e e m m C C o o m m p p o o n n e e n n t t 1 1 6 6 W W e e a a r r s s e e a a t t b b e e l l t t S S tr trap p ap poi oint nts fo s for cr...
Page 31 4 4 . . 1 1 D D a a t t a a p p l l a a t t e e 3 3 2 2 3 3 3 3 3 3 5 5 I I t t e e m m D D e e s s c c r r i i p p t t i i o o n n I I t t e e m m D D e e s s c c r r i i p p t t i i o o n n 3 3 2 2 T T y y p p e e...
Page 32 4 4 . . 2 2 T T r r u u c c k k c c a a p p a a c c it ity y p p l l a a t t e e CAUTION! CAUTION! Accident risk from fork replacement...
Page 33 4. 4.3 3 Atta tac c hm hmen ent c t ca a pa pac c it ity p y pla late te The attachment capacity plate is next to the truck's capacity plate and gives the The attachment capacity plate is next to the truck's capacity plate and gives the truck's capacity Q (in kg) in conjunction with the respective attachment.
Page 34 C C T T r r a a n n s s p p o o r r t a t an n d C d Co o m m m m i i s s s s i i o o n n i i n n g g T T r r a a n n s s p p o o r r t t Transport can be carried out in two different ways, depending on the height of the Transport can be carried out in two different ways, depending on the height of the...
Page 35 2. 2.2 2 Li Lift ftin ing t g the he tr truc uck k by by c c ra rane CAUTION! CAUTION! The mast can get damaged The mast can get damaged   Loading by crane is only intended for the initial transport before the truck is used Loading by crane is only intended for the initial transport before the truck is used for the first time.
Page 36 2. 2.3 3 Load adin ing wi g with a th ano noth ther i er ind ndus ustr tria ial tr l truc uck k WARNING! WARNING! The truck can be damaged The truck can be damaged The truck to be loaded can The truck to be loaded can get damaged when loading with another get damaged when loading with another industrial truck.
Page 37 S S e e c c u u r r i i n n g t g th h e t e tr r u u c c k d k du u r r i i n n g t g tr r a a n n s s p p o o r r t t WARNING! WARNING!
Page 38 U U s s i i n n g g t t h h e e T T r r u u c c k k f f o o r r t t h h e e F F i i r r s s t t T T i i m m e e Safety Instructions for Assembly and Commissioning Safety Instructions for Assembly and Commissioning WARNING!
Page 39 N N E E 2 2 1 1 . . 8 8 0 0 https://www.besttruckmanuals.com/...
Page 40 D D F F u u e e l l l l i i n n g g t t h h e e T T r r u u c c k k G G e e n n e e r r a a l l 1.
Page 41 HINWEIS HINWEIS Fuel can cause environmental damage Fuel can cause environmental damage   Bind any spilled diesel fuel with suitable methods. Bind any spilled diesel fuel with suitable methods.   Then dispose of the diesel and fuel filter in accordance with environmental Then dispose of the diesel and fuel filter in accordance with environmental regulations.
Page 42 1 1 . . 2 2 L L P P G s G sy y s s t t e e m r m re e l l i i e e f v f va a lv lve e LPG powered trucks are fitted with a relief ...
Page 43 HINWEIS HINWEIS   Capacity: DFG 540 - 550 = 70 l. Capacity: DFG 540 - 550 = 70 l.   Use only DIN EN 590 diesel with a Use only DIN EN 590 diesel with a cetane rating above 51. Use of fuels cetane rating above 51.
Page 44 2. 2.2 2 Fue e ll llin ing w g wit ith f h fue uel c l con onta tain ine e rs Vorgehensweise Vorgehensweise • • Uns Unscre crew the t w the tank c ank cap (4 ap (49) an 9) and ope d open the...
Page 45 L L P P G G c c o o n n t t a a i i n n e e r r s s Only use liquid gas that complies with DIN 51622 or comparable national Only use liquid gas that complies with DIN 51622 or comparable national regulations.
Page 46 Remove the LPG bottle Remove the LPG bottle VORSICHT! VORSICHT! The connection has a left thread The connection has a left thread Vorgehensweise Vorgehensweise • • Uns Unscre crew the uni w the union nut (5 on nut (54) whi 4) while hol le holdin ding g...
Page 47 3. 3.1. 1.2 2 Op Oper erat atin ing wit g with two L h two LPG bo PG bott ttle les s WARNUNG! WARNUNG! Visibility is restricted when the truck reverses. Visibility is restricted when the truck reverses. ...
Page 48 3 3 . . 2 2 L L i i q q u u i i d d g g a a s s t t a a n n k k Refillable liquid gas tanks contain a dispensing valve (63), a filling stop valve (61), a Refillable liquid gas tanks contain a dispensing valve (63), a filling stop valve (61), a relief valve (62) and a display relief valve (62) and a display (59).
Page 49 F F u u e e l l l l e e v v e e l l i i n n d d i i c c a a t t o o r r 4 4 .
Page 50 E E O O p p e e r r a a t t i i o o n n S S a a f f e e t t y R y Re e g g ul ula a t t i i o o n n s f s for or t t h h e O e Op p e e r r a a t t io ion o...
Page 51 Hazardous area Hazardous area WARNING! WARNING! Risk of accidents / injury in the Risk of accidents / injury in the hazardous area of the truck hazardous area of the truck The hazardous area is defined as the area in which a person is at risk due to truck The hazardous area is defined as the area in which a person is at risk due to truck movement, lifting operations, the load handler (e.g.
Page 52 D D i i s s p p l l a a y y s s a a n n d d C C o o n n t t r r o o l l s s 6 6 8 8 6 6 9 9 7 7 1 1...
Page 53 I I t t e e m m C C o o n n t t r r o o l / l / Function Function Display Display Emergency Disconnect Emergency Disconnect Switches control current on and off in Switches control current on and off in switch switch...
Page 54 2 2 . . 1 1 D D i i s s p p l l a a y y u u n n i i t t The control panel display unit shows the operating data, the battery charge, the The control panel display unit shows the operating data, the battery charge, the service hours and error details and information.
Page 55 I I t t e e m m C C o o n n t t r r o o l l / / Function Function Display Display 8 8 1 1 N N o o t t u u s s e e d d ...
Page 56 2. 2.2 2 In Ins s tr trum ume e nt nt pa pane nel s l swi witc tche hes ( D D i i s s p p l l a a y y F F u u n n c c t t i i o o n n Rear windscreen Rear windscreen...
Page 57 2. 2.3 3 Trav avel el di dire rect ctio ion n sw swit itch ch/g /gea ear r se sele lect ctor or 2. 2.3. 3.1 1 Tr Trav avel el di dire rect ctio ion s n swi witc tch h NOTE ...
Page 58 P P r r e e p p a a r r i i n n g g t t h h e e T T r r u u c c k k f f o o r r O O p p e e r r a a t t i i o o n n Checks cks and and ope...
Page 59 3 3 . . 2 2 E E n n t t r r y y a a n n d d e e x x i i t t Procedure Procedure • • Op Open en th the c e cab ab do door or ( (...
Page 60 3. 3.4 4 Sett ttin ing u g up p th the e op oper erat ator or po posi siti tion WARNING! WARNING! Accident risk Accident risk   Do not adjust the driver’s seat while Do not adjust the driver’s seat while travelling. travelling.
Page 61 Adjusting the driver's weight Adjusting the driver's weight NOTE NOTE To achieve optimal seat cushioning the To achieve optimal seat cushioning the driver’s seat must be set to the driver’s driver’s seat must be set to the driver’s weight.
Page 62 Adjusting the seat position Adjusting the seat position CAUTION! CAUTION! An unsecured driver's seat can cause An unsecured driver's seat can cause injury injury An unsecured An unsecured driver's seat driver's seat can slide can slide out of out of ...
Page 63 3.4.2 .2 Adj Adjust usting t ing the st he steer eering wh ing wheel / s eel / stee teerin ring col g column CAUTION! CAUTION! Do not adjust the steering wheel while travelling Do not adjust the steering wheel while travelling Individual steering wheel position Individual steering wheel position The tilt of the steering wheel can...
Page 64 3 3 . . 5 5 S S e e a a t t B B e e l l t t DANGER! DANGER! Travelling without a seat belt increases the risk of injury. Travelling without a seat belt increases the risk of injury. If the seat belt is not If the seat belt is not worn or is modified, personal injury can worn or is modified, personal injury can result.
Page 65 I I n n d d u u s s t t r r i i a a l T l Tr r u u c c k k O O p p e e r r a a t t i i o o n n 4.
Page 66 Inflammable liquids (e.g. fused metal etc.) may only be transported with suitable Inflammable liquids (e.g. fused metal etc.) may only be transported with suitable auxiliary equipment. Contact your authorized Jungheinrich customer adviser. auxiliary equipment. Contact your authorized Jungheinrich customer adviser.
Page 67 4. 4.2 2 Prep epar arin ing t g the he tr truc uck f k for or op oper erat atio ion n Before starting the truck Before starting the truck The truck should only be operated from The truck should only be operated from the driver’s seat.
Page 68 4.2.1 .1 Sta Starti rting ng pro proced cedure ure for for the the DFG Procedure Procedure • • • • Ins Insert th ert the key in t e key in the key s he key swit witch (77 ch (77).
Page 69 4. 4.2. 2.2 2 St Star arti ting p ng pro roce cedu dure fo re for the T r the TFG DANGER! DANGER! Risk of escaping liquid gas if the Risk of escaping liquid gas if the truck does not start truck does not start ...
Page 70 4. 4.3 3 Park rkin ing t g the he tr truc uck s k se e cu cure rely ly DANGER! DANGER! Risk of explosion Risk of explosion   LPG trucks may only be parked in ground level rooms or higher and providing they LPG trucks may only be parked in ground level rooms or higher and providing they are adequately ventilated.
Page 71 4 4 . . 4 4 E E m m e e r r g g e e n n c c y D y Di i s s c c o o n n n n e e c c t t CAUTION! CAUTION! Accident risk...
Page 72 4 4 . . 5 5 T T r r a a v v e e l l WARNING! WARNING! Improper travel can result in accidents Improper travel can result in accidents   Do not get up from the driver’s seat during travel. Do not get up from the driver’s seat during travel.
Page 73 Slow travel / brake pedal Slow travel / brake pedal Requirements Requirements – – Truck Truck ready ready for operation, for operation, (see "Preparing (see "Preparing the truc the truck for operat k for operation" on page ion" on page 68). 68).
Page 74 4 4 . . 7 7 B B r r a a k k e e s s WARNING! WARNING! Accident risk Accident risk The brake pattern of the truck depends largely on the ground conditions. The brake pattern of the truck depends largely on the ground conditions. ...
Page 75 4. 4.7. 7.2 2 Pa Park rki i ng b ng br r ak ake e DANGER! DANGER! Accident risk Accident risk   The parking brake will hold the truck with The parking brake will hold the truck with maximum load on a clean ground surface, maximum load on a clean ground surface, on inclines of up to 15%.
Page 76 4 4 . . 8 8 A A d d j j u u s s t t i i n n g t g th h e f e fo o r r k k s s WARNING! WARNING! Trapping hazard...
Page 77 4 4 . . 9 9 R R e e p p l l a a c c i i n n g t g th h e f e fo o r r k k s s WARNING! WARNING! Unsecured forks can cause injury...
Page 78 4.10 0 Lif Liftin ting, tra g, transp nsport orting a ing and dep nd deposi ositin ting load g loads s WARNING! WARNING! Unsecured and incorrectly positioned loads can cause accidents Unsecured and incorrectly positioned loads can cause accidents Before lifting a load unit the driver Before lifting a load unit the driver must make sure that it has been correctly must make sure that it has been correctly palletised...
Page 79 NOTE NOTE Loads must not be deposited on travel or escape routes, in front of safety Loads must not be deposited on travel or escape routes, in front of safety mechanisms or operating equipment that must be accessible at all times. mechanisms or operating equipment that must be accessible at all times.
Page 80 4.11 4.11 Oper Operating ating the li the lift me ft mechani chanism a sm and inte nd integrate grated att d attachm achments ents WARNING! WARNING! Accident risk when operating the lifting device Accident risk when operating the lifting device and integrated attachments and integrated attachments Other people can be injured in the Other people can be injured in the truck's hazardous area.
Page 81 Controlling the speed of the lifting Controlling the speed of the lifting device device Moving the lever and changing the engine Moving the lever and changing the engine speed governs the operating speed of the speed governs the operating speed of the hydraulic cylinders.
Page 82 4.11.1 4.11.1 Operat Operating the lift mech ing the lift mechanism with the SOL anism with the SOLO PILOT O PILOT Lifting and lowering Lifting and lowering Requirements Requirements – – To To prepare prepare the the truck truck for for operation, operation, (see...
Page 83 Positioning the integrated sideshift (option) Positioning the integrated sideshift (option) Requirements Requirements – – Truck Truck prepared prepared operation, operation, (see (see "Preparing the truck for operation" on "Preparing the truck for operation" on page ge 68 68). ). Procedure Procedure •...
Page 84 Positioning the forks with an integrated Positioning the forks with an integrated fork adjuster (option) fork adjuster (option) CAUTION! CAUTION! Do not use the fork adjuster to clamp Do not use the fork adjuster to clamp loads. loads. Requirements Requirements –...
Page 85 4.12 4.12 Safe Safety ins ty instruct tructions f ions for ope or operatin rating addi g additional tional attac attachment hments s Optionally, trucks can be fitted with one or more auxiliary hydraulic functions to Optionally, trucks can be fitted with one or more auxiliary hydraulic functions to operate attachments.
Page 86 0 0 Safety instructions for sideshifter and fork adjuster attachments Safety instructions for sideshifter and fork adjuster attachments WARNING! WARNING! When using multi fork adjusters (multi When using multi fork adjusters (multi pallet clamps), restricted visibility and reduced pallet clamps), restricted visibility and reduced lateral tilt resistance can result in accidents.
Page 87 0 0 Safety instructions for attachments when transporting suspended loads Safety instructions for attachments when transporting suspended loads WARNING! WARNING! Swinging loads and a reduced residual capacity can result in accidents Swinging loads and a reduced residual capacity can result in accidents ...
Page 88 0 0 4.13 4.13 Opera Operating ting additi additional onal attac attachment hments f s for t or the S he SOLO-P OLO-PILOT ILOT WARNING! WARNING! Incorrect symbols can cause accidents Incorrect symbols can cause accidents Symbols on controls that do not depict the function of the attachments can cause Symbols on controls that do not depict the function of the attachments can cause accidents.
Page 89 0 0 4.13.2 4.13.2 Solo Pilot wit Solo Pilot with control of ZH1 and ZH2 hydra h control of ZH1 and ZH2 hydraulic port ulic ports s Depending on the attachments used the Depending on the attachments used the lever / button (119, 121, 120) is assigned lever / button (119, 121, 120) is assigned the function of the attachment.
Page 90 0 0 4.14 4 Fit Fittin ting a g addit ddition ional al att attach achme ments WARNING! WARNING! Incorrectly connected attachments can cause accidents. Incorrectly connected attachments can cause accidents. Attachments Attachments with with incorrectly incorrectly connected connected hydraulic hydraulic attachments attachments can...
Page 91 0 0 Spilled hydraulic oil must be set using a suitable agent and disposed of in Spilled hydraulic oil must be set using a suitable agent and disposed of in accordance with environmental regulations. accordance with environmental regulations. If hydraulic oil comes into contact with the skin, wash it off immediately with soap If hydraulic oil comes into contact with the skin, wash it off immediately with soap and water.
Page 92 0 0 T T o o w w i i n n g g t t r r a a i i l l e e r r s s DANGER! DANGER! Inappropriate speeds and excessive trailer loads can be dangerous Inappropriate speeds and excessive trailer loads can be dangerous If you do not adapt your speed and / or use an excessive trailer load, the truck can If you do not adapt your speed and / or use an excessive trailer load, the truck can...
Page 93 0 0 Attaching the trailer Attaching the trailer CAUTION! CAUTION! Trapping hazard Trapping hazard There is a trapping risk when you There is a trapping risk when you attach a trailer. attach a trailer.   Follow the instructions of the coupling manufacturer if using special trailer Follow the instructions of the coupling manufacturer if using special trailer ...
Page 94 0 0 O O p p t t i i o o n n a a l l e e q q u u i i p p m m e e n n t t 6 6 .
Page 95 8 8 0 0 6 6 . . 3 3 P P a a n n e e l l d d o o o o r r CAUTION! CAUTION! An open door can cause accidents (124) An open door can cause accidents (124) ...
Page 96 8 8 0 0 6 6 . . 5 5 H H e e a a t t i i n n g g Replacing the air conditioning filter Replacing the air conditioning filter Procedure Procedure • • Uns Unscre crew t w the...
Page 97 8 8 0 0 Heating operation Heating operation Procedure Procedure • • Press Press the sw the switch ( itch (131) t 131) to swit o switch off ch off the fa the fan. n. • • Set th Set the nozzl e nozzles (135 es (135 and 130...
Page 98 8 8 0 0 6. 6.6 6 Rem m ov ova a bl ble e lo loa a d d ba back ckre res s t t CAUTION! CAUTION! Trapping hazard and heavy load backrest weight Trapping hazard and heavy load backrest weight ...
Page 99 8 8 0 0 6. 6.8 8 Rock cking inger c er coup oupli ling w ng wit ith ha h hand le nd leve ver or r r or rem emot ote co e cont ntro rol l Refer to the Refer to the instructions for towing instructions for towing trailers, (see "Towing...
Page 100 8 8 0 0 6 6 . . 9 9 C C a a m m e e r r a a s s y y s s t t e e m m CAUTION! CAUTION! Accident risk from hidden work areas Accident risk from hidden work areas ...
Page 101 8 8 0 0 6.10 6.10 Option Optional equ al equipmen ipment for wo t for working i rking in area n areas with h s with heavy eavy accu accumulat mulation of dust of dust When working in areas with high levels of dust (lint, splinters) the Industrial truck can When working in areas with high levels of dust (lint, splinters) the Industrial truck can be fitted with an optional lint filter on the cooler.
Page 102 8 8 0 0 6. 6.12 12 Sp Spee eed r d red educ ucti tion The maximal achievable speed is limited to a preset value. Full motor speed and The maximal achievable speed is limited to a preset value. Full motor speed and power are available while stopped and accelerating.
Page 103 8 8 0 0 6.16 6 Tem Temper peratu ature re con contro trol l sy syste stem m WARNING! WARNING! In each case the cause of the overheating must be established and rectified by a In each case the cause of the overheating must be established and rectified by a trained and authorised customer service engineer.
Page 104 8 8 0 0 6.17 7 Con Contro trol la l layou yout wi t with C th Card ardan f an func unctio tion n WARNING! WARNING! Ensure there are no other people standing underneath the raised load and Ensure there are no other people standing underneath the raised load and driver's cab.
Page 105 . . 8 8 0 0 T T r r o o u u b b l l e e s s h h o o o o t t i i n n g g 7 7 . . 1 1 T T r r o o u u b b l l e e s s h h o o o o t t i i n n g g This chapter enables the user to identify and rectify basic faults and the effects of ...
Page 106 . . 8 8 0 0 F F a a u u l l t t P P o o s s s s i i b b l l e e C C a a u u s s e e A A c c t t i i o o n n Starter does Starter does...
Page 107 . . 8 8 0 0 F F a a u u l l t t P P o o s s s s i i b b l l e e C C a a u u s s e e A A c c t t i i o o n n Engine Engine...
Page 108 . . 8 8 0 0 7. 7.2 2 Oper erat atin ing th g the t e tru ruck ck wi with thou out it t its ow s own dr n driv ive s e sys yste tem m 7.
Page 109 . . 8 8 0 0 7. 7.2. 2.2 2 Em Emer erge genc ncy low y lower erin ing g The mast can be lowered manually if a fault occurs in the hydraulic system. The mast can be lowered manually if a fault occurs in the hydraulic system. WARNING! WARNING! Lowering the mast can result in injuries...
Page 110 1 1 . . 8 8 0 0 7. 7.2. 2.3 3 S S ta tart rtin ing g ai aid d WARNING! WARNING! Danger from overheating Danger from overheating   Only use an ISO 6722 battery jump lead Only use an ISO 6722 battery jump lead with fully insulated terminal pliers and a with fully insulated terminal pliers and a...
Page 111 1 1 . . 8 8 0 0 https://www.besttruckmanuals.com/ N N E E 2 2...
Page 112 1 1 . . 8 8 0 0 F F I I n n d d u u s s t t r r i i a a l l T T r r u u c c k k M M a a i i n n t t e e n n a a n n c c e e Oper erat atio iona nal S...
Page 113 1 1 . . 8 8 0 0 M M a a i i n n t t e e n n a a n n c c e e S S a a f f e e t t y y R R e e g g u u l l a a t t i i o o n n s s Maintenance and repair personnel Maintenance and repair personnel Truck maintenance and repair work must only be carried out by specially trained...
Page 114 1 1 . . 8 8 0 0 Cleaning Cleaning CAUTION! CAUTION! Fire hazard Fire hazard The truck must not be cleaned The truck must not be cleaned with flammable fluids. with flammable fluids. If flammable materials are not removed from the engine compartment, they can come If flammable materials are not removed from the engine compartment, they can come into contact with hot components and cause a fire.
Page 115 1 1 . . 8 8 0 0 Electrical system Electrical system CAUTION! CAUTION! Accident risk from Electrical system: Accident risk from Electrical system:   Only trained personnel may work on the electrical system. Only trained personnel may work on the electrical system. ...
Page 116 1 1 . . 8 8 0 0 Tyre type Tyre type WARNING! WARNING! The use of tyres that do not match The use of tyres that do not match the manufacturer's specifications can result the manufacturer's specifications can result in accidents.
Page 117 1 1 . . 8 8 0 0 Hydraulic hoses Hydraulic hoses WARNING! WARNING! Brittle hydraulic hose lines can cause accidents Brittle hydraulic hose lines can cause accidents The hoses must be replaced every six years. The manufacturer's customer service The hoses must be replaced every six years.
Page 118 We recommend that a Jungheinrich customer service adviser carries out an We recommend that a Jungheinrich customer service adviser carries out an application analysis on site to work out specific service intervals to prevent damage application analysis on site to work out specific service intervals to prevent damage due to wear.
Page 119 2 2 1 1 . . 8 8 0 0 M M a a i i n n t t e e n n a a n n c c e e c c h h e e c c k k l l i i s s t t DFG / TFG DFG / TFG Maintenance intervals...
Page 120 2 2 1 1 . . 8 8 0 0 Service intervals Service intervals S S t t a a n n d d a a r r d d = = W W A A B B C C Wheels Wheels ...
Page 121 2 2 1 1 . . 8 8 0 0 Service intervals Service intervals S S t t a a n n d d a a r r d d = = W W A A B B C C Hydraulic system Hydraulic system 7.
Page 122 2 2 1 1 1.1 1.1 Lubric Lubricate tr ate truck in uck in accord accordance w ance with Lu ith Lubricat brication Sc ion Schedule hedule. . 1 1 . . 8 8 0 0 Service intervals Service intervals S S t t a a n n d d a a r r d d = =...
Page 123 2 2 1 1 . . 8 8 0 0 DFG maintenance DFG maintenance Service intervals Service intervals S S t t a a n n d d a a r r d d = = W W A A B B C C Engine Engine ...
Page 124 2 2 1 1 . . 8 8 0 0 Service intervals Service intervals S S t t a a n n d d a a r r d d = = W W A A B B C C Fuel system Fuel system ...
Page 125 2 2 1 1 . . 8 8 0 0 TFG maintenance TFG maintenance Service intervals Service intervals S S t t a a n n d d a a r r d d = = W W A A B B C C Engine Engine ...
Page 126 2 2 1 1 . . 8 8 0 0 Service intervals Service intervals S S t t a a n n d d a a r r d d = = W W A A B B C C LPG system LPG system ...
Page 127 2 2 1 1 . . 8 8 0 0 L L u u b b r r i i c c a a n n t t s a s an n d L d Lu u b b r r i i c c a a t t i i o o n S n Sc c h h e e d d u u l l e e 5.
Page 128 2 2 1 1 . . 8 8 0 0 Consumables and used parts Consumables and used parts CAUTION! CAUTION! Consumables and used parts are an environmental hazard Consumables and used parts are an environmental hazard Used parts, oils and fuels must be disposed of in accordance with the relevant Used parts, oils and fuels must be disposed of in accordance with the relevant environmental protection regulations.
Page 129 2 2 1 1 . . 8 8 0 0 5 5 . . 2 2 L L u u b b r r i i c c a a t t i i o o n n S S c c h h e e d d u u le le Ö...
Page 130 U U s s e e d d f f o o r r quantit quantit A A 51132827 132827 80 l 80 l Jungheinrich Jungheinrich Hydraulic Hydraulic hydraulic oil hydraulic oil system system 0 0 0 0 0 0 0 0 2 2 8 8 3 3 2 2 0 0 .
Page 131 2 2 1 1 . . 8 8 0 0 DANGER! DANGER! Anti-freeze is poisonous Anti-freeze is poisonous   Anti-freeze Anti-freeze contains contains ethylene ethylene glycol glycol and and other other components components which which can can result result in in poisoning if ingested.
Page 132 E E 2 2 1 1 . . 8 8 0 0 M M a a i i n n t t e e n n a a n n c c e e a a n n d d r r e e p p a a i i r r s s 6.
Page 133 E E 2 2 1 1 . . 8 8 0 0 6. 6.2 2 O O pe peni ning ng th the e e e ng ngin ine e co cov v e e r r Requirements Requirements –...
Page 134 E E 2 2 1 1 . . 8 8 0 0 6. 6.3 3 Chec ecki king ng th the w e whe heel el at atta tach chme ment nts. s. WARNING! WARNING! Using different tyres can cause accidents Using different tyres can cause accidents The quality of tyres affects the stability and performance of the truck.
Page 135 E E 2 2 1 1 . . 8 8 0 0 6 6 . . 4 4 H H y y d d r r a a u u l l i i c c s s y y s s t t e e m m CAUTION! CAUTION! The hydraulic oil is pressurised during operation and is a hazard to health and to the...
Page 136 E E 2 2 1 1 . . 8 8 0 0 6.4.1 .1 Che Checki cking ng the the hyd hydrau raulic lic oil oil lev level el Requirements Requirements – – Park the truck on a level surface. Park the truck on a level surface.
Page 137 E E 2 2 1 1 . . 8 8 0 0 6.4.3 .3 Rep Replac lacing ing the the hyd hydrau raulic lic oil oil fil filter ter CAUTION! CAUTION! If the pressure indicator (158) on the If the pressure indicator (158) on the hydraulic oil filter is in the red zone, the hydraulic oil filter is in the red zone, the...
Page 138 E E 2 2 1 1 . . 8 8 0 0 6 6 . . 5 5 E E n n g g i i n n e m e ma a i i n n t t e e n n a a n n c c e e DANGER! DANGER! A running engine can be dangerous.
Page 139 The engine oil has now been The engine oil has now been checked. checked. E E 2 2 1 1 . . 8 8 0 0 Draining the engine oil Draining the engine oil Procedure Procedure • • Un Unsc scre rew th w the fi...
Page 140 E E 2 2 1 1 . . 8 8 0 0 NOTE NOTE The incorrect amount of oil will damage The incorrect amount of oil will damage the engine. the engine.   After replacing the After replacing the oil and oil and oil filter carry oil filter carry...
Page 141 E E 2 2 1 1 . . 8 8 0 0 6. 6.5. 5.3 3 Ch Chec eck V k V-b -bel elt f t for or da dama mage Procedure Procedure • • Check Check the V-b the V-belt fo elt for crac r cracks, de...
Page 142 E E 2 2 1 1 . . 8 8 0 0 6. 6.5. 5.6 6 TF TFG G en engi gine ne ma main inte tena nanc nce e NOTE NOTE Used oil contaminates the environment Used oil contaminates the environment ...
Page 143 E E 2 2 1 1 . . 8 8 0 0 Draining the engine oil Draining the engine oil Procedure Procedure • • Uns Unscre crew th w the fi e fille ller ca r cap (1 p (164) 64).
Page 144 N N E E 2 2 1 1 . . 8 8 0 0 NOTE NOTE The incorrect amount of oil will damage The incorrect amount of oil will damage the engine. the engine.   After replacing the After replacing the oil and oil and oil filter carry...
Page 145 N N E E 2 2 1 1 . . 8 8 0 0 6. 6.5. 5.8 8 Ch Chec eck V k V-b -bel elt f t for or da dama mage NOTE NOTE A damaged V-belt will result in malfunctions. A damaged V-belt will result in malfunctions.
Page 146 N N E E 2 2 1 1 . . 8 8 0 0 6.5.10 6.5.10 Cooli Cooling ng system system NOTE NOTE Lack of coolant can cause malfunctions Lack of coolant can cause malfunctions   The coolant level should be between the “MIN” and “MAX” markings on the The coolant level should be between the “MIN”...
Page 147 N N E E 2 2 1 1 . . 8 8 0 0 Check the coolant concentrate Check the coolant concentrate Tool ols s an and d Ma Mate teri rial al Re Requ quir ired ed –...
Page 148 N N E E 2 2 1 1 . . 8 8 0 0 6.5.11 6.5.11 Replac Replace air filter ca e air filter cartrid rtridge DANGER! DANGER! A running engine can be dangerous A running engine can be dangerous ...
Page 149 N N E E 2 2 1 1 . . 8 8 0 0 6.5.12 6.5.12 Addin Adding window was g window washer syste her system fluid m fluid Procedure Procedure • • Op Open t en the e he eng ngin ine co e cove...
Page 150 N N E E 2 2 1 1 . . 8 8 0 0 6. 6.6 6 Che e c c ki king ng e e le lec c tr tric ical al fu fus s e e s s Checking electrical fuses Checking electrical fuses Requirements...
Page 151 N N E E 2 2 1 1 . . 8 8 0 0 6. 6.6. 6.1 1 Fu Fuse se ra rat t in ings schwarz schwarz 0 0 1 1 2 2 3 3 4 4 9 9 2...
Page 152 N N = Series equipment = Series equipment = Optional equipment = Optional equipment E E 2 2 1 1 . . 8 8 0 0 Fuse box for StVZO illumination only (red fuse Fuse box for StVZO illumination only (red fuse box) box) I I t t e e m m E E l l e e c c t t r r i i c c c c i i r r c c u u i i t t...
Page 153 N N E E 2 2 1 1 . . 8 8 0 0 DFG fuse box DFG fuse box I I t t e e m m E E l l e e c c t t r r i i c c c c i i r r c c u u i i t t R R a a t t i i n n g g ( ( A A ) ) ...
Page 154 N N E E 2 2 1 1 . . 8 8 0 0 Emergency Disconnect fuse box Emergency Disconnect fuse box I I t t e e m m E E l l e e c c t t r r i i c c c c i i r r c c u u i i t t R R a a t t i i n n g g ( ( A A ) ) ...
Page 155 N N E E 2 2 1 1 . . 8 8 0 0 6 6 . . 7 7 S S t t a a r r t t e e r r b b a a t t t t e e r r y y Checking the battery condition, acid level* and acid density* Checking the battery condition, acid level* and acid density* *not for maintenance-free batteries...
Page 156 N N E E 2 2 1 1 . . 8 8 0 0 6 6 . . 8 8 E E x x h h a a u u s s t t s s y y s s t t e e m m Check the exhaust system regularly for leaks.
Page 157 N N E E 2 2 1 1 . . 8 8 0 0 6 6 . . 9 9 S S e e a a t b t be e l l t m t ma a i i n n t t e e n n a a n n c c e e Check the safety restraint belt ...
Page 158 The parking brake must be able to hold the truck plus the maximum load on an incline on an incline of 15%. If it cannot, the parking brake must be adjusted. Please contact Jungheinrich of 15%. If it cannot, the parking brake must be adjusted. Please contact Jungheinrich customer service in this case.
Page 159 N N E E 2 2 1 1 . . 8 8 0 0 6.12 6.12 Rest Restoring th oring the truc e truck to se k to service rvice after after maint maintenanc enance and r e and repair epairs s Procedure Procedure...
Page 160 N N E E 2 2 1 1 . . 8 8 0 0 D D e e c c om omm m i i s s s s io ion n in ing g t t h h e e in ind d u u s s t t r r i i a a l l t t r r uc uck k If the truck is to be out of service for more than a month, e.g.
Page 161 N N E E 2 2 1 1 . . 8 8 0 0 7. 7.1 1 Prio ior r to to de dec c om ommi mis s s s io ioni ning Procedure Procedure • • Tho Thorou roughl ghly cl...
Page 162 N N E E 2 2 1 1 . . 8 8 0 0 Restor toring ing the the tru truck ck to to ser servic vice e aft after er dec decomm ommiss ission ioning Procedure Procedure •...
Page 163 Perform a safety check in accordance with national regulations. Jungheinrich Perform a safety check in accordance with national regulations. Jungheinrich recommends the truck be checked to FEM guideline 4.004. The Jungheinrich recommends the truck be checked to FEM guideline 4.004. The Jungheinrich safety department has trained personnel who are able to carry out inspections.
Page 164 N N E E 2 2 1 1 . . 8 8 0 0 F F i i n n a a l l d d e e - - c c o o m m m m i i s s s s i i o o n n i i n n g g , , d d i i s s p p o o s s a a l l Final de-commissioning or disposal of the truck in must be performed in Final de-commissioning or disposal of the truck in must be performed in accordance with the regulations of the country of use.
Page 165 N N E E 2 2 1 1 . . 8 8 0 0 HUSS SS FS - FS - MK MK Se Seri ries es Di Dies esel P el Par arti ticle cle Fi Filte lter Op r Oper erat atin ing g Instructions ( Instructions (...
Page 166 Procedure Procedure N N • • Depre Depress and hol ss and hold down bot d down both the “M” a h the “M” and “F” but nd “F” buttons on th tons on the HUSS co e HUSS control an ntrol and at d at E...
Page 167 N N E E 2 2 1 1 . . 8 8 0 0 11.4 .4 HU HUSS SS Co Cont ntro rol O l Ope pera rati tion The diesel particle filter is operated by the HUSS Control unit. The control unit is The diesel particle filter is operated by the HUSS Control unit.
Page 168 N N E E 2 2 1 1 . . 8 8 0 0 11.5 5 HUS HUSS Con S Contro trol Ope l Operat rating I ing Inst nstruc ructio tions N N o o r r m m a a l l o o p p e e r r a a t t i i o o n n D D i i s s p p l l a a y y F F u u n n c c t t i i o o n n L L E E D D Switch on the ignition.
Page 169 N N E E 2 2 1 1 . . 8 8 0 0 11.6 .6 R R eg ege e ne nera rati tion Regenerate daily even if the filter is not full Regenerate daily even if the filter is not full DANGER! DANGER! Risk of fire and explosion...
Page 170 simultaneously the engine of the industrial truck simultaneously the engine of the industrial truck N N can be started in hazardous situations even with can be started in hazardous situations even with E E “Alarm/Filter full”. “Alarm/Filter full”. 2 2 1 1 .
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