Page 1 DFG/TFG 660-690 12.12 - Operating instructions 51289390 DFG 660 11.14 DFG 670 DFG 680 DFG 690 DFG S80 DFG S90 TFG 660 TFG 670 TFG 680 TFG 690 TFG S80 TFG S90...
Page 2 Declaration of Conformity Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg Manufacturer or agent acting in the European Union Type Option Serial no. Year of manufacture DFG 660 DFG 670 DFG 680 DFG 690 DFG S80 DFG S90 TFG 660 TFG 670...
Page 4 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 particular features of the truck should therefore be assumed from the present operating instructions.
Page 5 Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG. Jungheinrich Aktiengesellschaft Am Stadtrand 35 22047 Hamburg - Germany Tel: +49 (0) 40/6948-0 www.jungheinrich.com...
Page 6: Table Of Contents
Contents Correct Use and Application ........... General....................Correct application................... Approved application conditions.............. Proprietor responsibilities ................ Adding attachments and/or optional equipment ........Truck Description ..............Application ....................Truck models and rated capacity............. Assemblies and Functional Description........... Assembly Overview ................. Functional Description ................Technical Specifications ................
Page 7 Fuelling the Truck..............General....................Safety regulations for handling diesel fuel and LPG........ LPG system relief valve................Adding diesel ................... Fuelling ....................Fuelling with fuel containers ..............LPG containers..................LPG bottles....................Liquid gas tank ..................Fuel level indicator................... Display unit ....................Operation ................
Page 8 6.15 Operating additional attachments for the Multi Pilot ........ 125 6.16 Fitting additional attachments..............126 Towing trailers ..................128 Optional equipment ................. 130 Rotating Driver's Seat................131 Sliding windows ..................140 Emergency Exit ..................140 Driver'S Seat Heater................140 Fire Extinguisher..................141 Rockinger Coupling with Hand Lever ............
Page 9 Restoring the truck to service after decommissioning ......196 Safety tests to be performed at intervals and after unusual incidents ..197 Final de-commissioning, disposal............198 Human vibration measurement ............... 198 Servicing and Inspection ................. 199 Maintenance checklist DFG..............200 10.1 Operating Company ................
Page 10: A Correct Use And Application
A Correct Use and Application General The truck must be used, operated and serviced in accordance with the present instructions. All other types of use are beyond its scope of application and may result in damage to personnel, the industrial truck or property. Correct application NOTE The maximum load and load distance are indicated on the capacity plate and must...
Page 11: Approved Application Conditions
Approved application conditions DANGER! Do not exceed the permissible surface and point loading on the travel lanes. At blind spots get a second person to assist. The driver must ensure that the loading dock /dock leveller cannot be removed or come loose during loading/unloading.
Page 12: Proprietor Responsibilities
Proprietor responsibilities For the purposes of the present operating instructions the “operating company” is defined as any natural or legal person who either uses the industrial truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting) the proprietor is considered the person who, in accordance with existing contractual agreements between the owner and user of the industrial truck, is charged with operational duties.
Page 14: B Truck Description
B Truck Description Application The DFG/TFG 660-690 is a four-wheel IC engine sit-down forklift truck. The DFG series are diesel engine trucks, while the TFG series are fitted with a petrol engine for LPG operation. The DFG/TFG 660-690 is a cantilever counterbalanced truck which can lift, transport and deposit loads using the load handler attached in front.
Page 15: Assemblies And Functional Description
Assemblies and Functional Description Assembly Overview Item Description Item Description 1 o Fork adjustment 8 t Exhaust pipe 2 t Load chains 9 t Steer axle 3 t Mast 10 t Counterweight 4 t Steering column 11 t Illumination 5 t Cab 12 t Drive 6 t Driver's seat 13 t Fork carriage...
Page 16: Functional Description
Functional Description Chassis and superstructure A rigid chassis which protects the units and controls, provides the truck with maximum static safety. A wide opening cab (5) facilitates service and maintenance work. The hydraulic oil reservoir is integrated on the right-hand side and the fuel tank on the opposite side of the chassis.
Page 17 Drive System A power shift gear with radiator and torque converter is flanged directly to the engine. This transfers the force to the drive axle (12). The travel direction lever, either on the steering column or optionally on the multi-task handle, controls forward/reverse travel and the neutral position.
Page 18: Technical Specifications
Technical Specifications All technical details refer to standard trucks. Values indicated with *) may vary, depending on the types of equipment used (e.g. mast, cabin, tyres etc.). The technical specifications comply with the German "Industrial Truck Data Sheet" Guidelines. Technical modifications and additions reserved. Performance data DFG 660-690 Component...
Page 19 DFG S80-S90 Component Capacity 8000 9000 Load centre distance Travel speed * 22.3/22.6 22.3/22.6 km/h with / without load Lift speed 0.40/0.60 0.40/0.60 with / without load Lowering speed 0.60/0.36 0.60/0.36 with / without load Gradeability 21.5/25.0 20.9/24.0 with / without load Tow force with / without load 49.5/49.5 52.9/52.9...
Page 20 TFG 660-690 Component Capacity 6000 7000 8000 9000 Load centre distance Travel speed * with / 22.4/22.6 22.4/22.6 22.4/22.6 22.4/22.6 km/h without load Lift speed 0.40/0.48 0.40/0.48 0.40/0.48 0.40/0.48 with / without load Lowering speed 0.60/0.48 0.60/0.36 0.60/0.36 0.60/0.36 w / w.o. load Gradeability 27.5/30.0 27.5/30.0...
Page 21 TFG S80-S90 Component Capacity 8000 9000 Load centre distance Travel speed * 22.4/22.6 22.4/22.6 km/h with / without load Lift speed 0.40/0.48 0.40/0.48 with / without load Lowering speed 0.60/0.36 0.60/0.36 with / without load Gradeability* 20.2/23.0 17.6/20.0 with / without load Tow force 45.6/45.6 45.6/45.6...
Page 22: Dimensions
Dimensions DFG 660-690 Model a/2 Safety distance Collapsed height* 2710 2710 3010 3160 Lift* 3600 3600 3600 3600 Extended height* 4510 4510 4810 4960 Overhead guard 2705 2705 2705 2705 height* Seat height* 1600 1600 1600 1600 Coupling height Mast tilt, fwd.* °...
Page 23 DFG S80-S90 Model a/2 Safety distance Collapsed height* 3160 3310 Lift* 3600 3600 Extended height* 4960 5110 Overhead guard 2705 2705 height* Seat height* 1600 1600 Coupling height Mast tilt, fwd.* ° Mast tilt, back* ° Length, including 5640 5840 forks* Length, including fork 3840...
Page 24 Type Collapsed height* 2710 2710 3010 3160 Lift* 3600 3600 3600 3600 Extended height* 4510 4510 4810 4960 Overhead guard 2705 2705 2705 2705 height* Seat height* 1600 1600 1600 1600 Coupling height Mast tilt, fwd.* ° Mast tilt, back* °...
Page 25 Component Overhead guard 2705 2720 height* Seat height* 1600 1600 Coupling height Mast tilt, fwd.* ° Mast tilt, back* ° Length, including 5740 5740 forks* Length, including fork 3940 3940 shank* Overall width* 2150 2150 s/e/l Fork dimensions* 70/180/ 70/180/ 1800 1800 Ground clearance,...
Page 27: Weights
Weights All dimensions in kg. DFG 660-690 Net weight* 10500 11400 12400 14000 Axle loading, unladen 5000/5500 5500/5900 6000/6400 6800/7200 load front / rear* Axle loading, laden front / 14900/1600 16400/2000 18100/2300 20500/2500 rear* *) The data listed in the table corresponds to the standard version. DFG S80-S90 Net weight* 14400...
Page 28: Mast Versions
Mast versions All dimensions in mm. Mast chart VDI 3596 Lift h Free lift Retracted Extended Weight Description height h height h (kg) 660/670 660/670 3600 2710 4510 2080 4000 2910 4910 2140 4500 3160 5410 2240 5000 3410 5910 2335 5500 3660...
Page 29 Mast chart VDI 3596 Lift h Free lift Retracted Extended Weight Description height h height h (kg) 3600 3010 4810 2180 4000 3210 5210 2261 4500 3460 5710 2360 5000 3710 6210 2485 5500 3960 6710 2610 6000 4210 7210 2757 6500 4460...
Page 30 DFG/TFG 690-S90 Mast chart VDI 3596 Lift h Free lift Collapsed Extended Weight Description height h height h (kg) 690/S80 690/S80 3600 3160 4960 2240 4000 3360 5360 2310 4500 3610 5860 2435 5000 3860 6360 2560 5500 4110 6860 2710 6000 4360...
Page 31 Mast chart VDI 3596 Lift h Free lift Collapsed Extended Weight Description height h height h (kg) 3600 1800 3325 5125 2422 4000 2000 3525 5525 2518 4500 2250 3775 6025 2628 5000 2500 4025 6525 2748 5500 2750 4275 7025 2868 6000...
Page 32: Tyre Type
Tyre type WARNING! The use of tyres that do not match the manufacturer's specifications can result in accidents. The quality of tyres affects the stability and performance of the truck. Uneven wear affects the truck's stability and increases the stopping distance. When replacing tyres make sure the truck is not skewed.
Page 33 DFG/TFG S80-S90 Model DFG/TFG 300 - 15 300 - 15 300 - 15 300 - 15 Pneumatic* Front 18 PR 18 PR tyres Tyre pressure bar Torque Nm 300 - 15 300 - 15 300 - 15 300 - 15 Pneumatic* Rear 18 PR...
Page 34: Engine Data
Engine Data DFG 660-680 Model DFG 660 DFG 670 DFG 680 Cylinders/cubic capacity 4/4400 4/4400 4/4400 cm³ Rated speed (without load) 2200 2200 2200 Idle speed Engine output Fuel consumption l/h [kg/h] 60 VDI duty cycles/h DFG 690-S90 Model DFG 690...
Page 35: En Norms
EN norms Noise emission level – DFG 660-690, S80: 73 dB (A)* – DFG S90: 70 dB (A)* – TFG: 71 dB(A)* *+/- 4 dB(A) depending on the truck's equipment in accordance with EN 12053 as harmonised with ISO 4871. The noise emission level is calculated in accordance with standard procedures and takes into account the noise level when travelling, lifting and when idle.
Page 36: Conditions Of Use
Electromagnetic compatibility (EMC) The manufacturer confirms that the truck adheres to the limits for electromagnetic emissions and resistance as well as the static electricity discharge test in accordance with EN 12895 as well as the standardised instructions contained therein. No changes to electric or electronic components or their arrangement may be made without the written agreement of the manufacturer.
Page 37: Identification Points And Data Plates
Identification points and data plates Warnings and notices such as capacity charts, strap points and data plates must be legible at all times. Replace if necessary. XXXXXX xxx xxxxxx 39 40...
Page 38 Item Component Attachment points for loading by crane (o) Read operating instructions Wear seat belt Test plaque (o) Hot surface warning Trailer coupling Capacity plate Tipover hazard No passengers Do not drive or tilt the mast forward with a load raised Turn the exhaust pipe back before tilting the cab Air pressure Do not stand on load handler / Do not stand under load handler / Risk of...
Page 39: Data Plate
Data plate Item Component Item Component Type Year of manufacture Serial number Load centre distance (mm) Rated capacity (kg) Net weight in kg Output Manufacturer Option Manufacturer's logo For queries regarding the truck or ordering spare parts always quote the truck serial number (44).
Page 40: Truck Capacity Plate
Truck capacity plate CAUTION! Accident risk from fork replacement If you replace the forks with ones that differ from the originals, the capacity will change. When replacing the forks you must attach an additional capacity plate to the truck. Trucks supplied without forks are given a capacity plate for standard forks (length: 1150 mm).
Page 41: Attachment Capacity Plate
Attachment capacity plate 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. The serial number for the attachment indicated on the capacity plate must match the data plate of the attachment.
Page 42: C Transport And Commissioning
C Transport and Commissioning Transport Transport can be carried out in two different ways, depending on the height of the mast and the local conditions. – Vertically, with the mast assembled (for low heights) – Vertically, with the mast dismantled (for large heights), all mechanical connections and hydraulic lines between the basic truck and the mast separated.
Page 43: Lifting The Truck By Crane
Lifting the truck by crane CAUTION! The mast can get damaged Loading by crane is only intended for the initial transport before the truck is used for the first time. Loading must be carried out by specially trained staff in accordance with recommendations contained in Guidelines VDI 2700 and VDI 2703 DANGER! Crane slings can tear, resulting in accidents...
Page 44: Loading With Another Industrial Truck
Loading with another industrial truck DANGER! Slipping can cause accidents Do not use another Industrial truck to load the truck!
Page 45: Securing The Truck During Transport
Securing the truck during transport WARNING! Accidental movement during transport Improper fastening of the truck and mast during transport can result in serious accidents. Loading must be carried out by specially trained staff in accordance with recommendations contained in Guidelines VDI 2700 and VDI 2703 In each case correct measurements must be made and appropriate safety measures adopted.
Page 46: Using The Truck For The First Time
Using the Truck for the First Time Safety Instructions for Assembly and Commissioning WARNING! Incorrect assembly can result in accidents The assembly of the truck at the application site, commissioning and operator training must only be performed by the manufacturer's customer service representatives who have been specially trained for these tasks.
Page 48: D Fuelling The Truck
D Fuelling the Truck General Safety regulations for handling diesel fuel and LPG WARNING! An unsecured industrial truck can cause accidents The truck can suddenly start to move. Switch off the truck securely before filling up or replacing the LPG bottle, see "Parking the truck securely"...
Page 49 NOTE Fuel can cause environmental damage Bind any spilled diesel fuel with suitable methods. Then dispose of the diesel and fuel filter in accordance with environmental regulations. Fuel filling and LPG bottle replacement personnel Personnel filling the trucks or replacing LPG bottles must have sufficient knowledge of the nature of fuels to ensure safe operation.
Page 50: Lpg System Relief Valve
LPG system relief valve LPG powered trucks are fitted with a relief valve. This is located on the rear cover next to the gas bottle. – In the event of a fault the pressure in the gas system is restricted to a maximum level.
Page 51: Adding Diesel
Adding diesel CAUTION! Air in the fuel system will result in malfunctions. Never allow the fuel tank to run dry. Fuelling WARNING! Diesel fuel can be hazardous Diesel fuel can cause irritation if it comes into contact with the skin. Rinse any affected areas thoroughly.
Page 52: Fuelling With Fuel Containers
The fuel gauge (63) indicates the fuel level. NOTE Never allow the fuel tank to run dry. Air in the fuel system will result in malfunctions. Fuelling with fuel containers Procedure • Unscrew the filler cap (62) and open the fuel container.
Page 53: Lpg Containers
LPG containers Only use liquid gas that complies with DIN 51622 or comparable national regulations. LPG bottles DANGER! Risk of explosion The LPG bottle must only be replaced at designated areas by trained and authorised personnel. CAUTION! Using unsuitable LPG bottles can cause accidents. Use only approved LPG bottles.
Page 54 Remove the LPG bottle CAUTION! The connection has a left thread Procedure • The LPG bottle console is released with the finger screw (65). • Unfold the console (66) as far as the stop. • Unscrew the union nut (68). •...
Page 55 3.1.2 Operating the Twin Bottle System and Liquid Gas Tank Changing the LPG Supply Procedure The (71) switch controls the release of the LPG bottle or tank. • Open the shut-off valves (64) of both LPG bottles by turning anticlockwise. •...
Page 56: Liquid Gas Tank
Liquid gas tank The filling valve (72) is located on the left side of the truck. Filling refillable liquid gas tanks DANGER! Risk of explosion Fuelling must always be performed in designated areas trained authorised personnel. Requirements – Park the truck securely (see "Parking the truck securely"...
Page 57: Fuel Level Indicator
Fuel level indicator Display unit The level indicator (63) shows the capacity of the tank.
Page 58: E Operation
E Operation Safety Regulations for the Operation of the Forklift Truck Driver authorisation The truck may only be used by suitably trained personnel, who have demonstrated to the proprietor or his representative that they can drive and handle loads and have been authorised to operate the truck by the proprietor or his representative.
Page 59 Hazardous area WARNING! Risk of accidents/injury in the hazardous area of the truck A hazardous area is defined as the area in which people are at risk due to travel or lifting operations of the truck, its load handler or the load. This also includes the area within reach of falling loads or lowering/falling operating equipment.
Page 60: Displays And Controls
Displays and Controls Multi-task switch Einzelpedalsteuerung Item Control / Function Display Multi-task switch – Travel function switch – Sets automatic gear shifting – Travel direction – Selects travel direction / neutral position switch t = Standard equipment o = Optional equipment...
Page 61 Item Control / Function Display Multi-task switch – Travel direction – Switches the travel direction indicator on indicator and off – Dipped lights/main – Switch spot lights from dipped lights to beam main beam – Windscreen wiper – Switches the windscreen wiper on and off –...
Page 62: Solo-Pilot
SOLO-PILOT 80 81 Item Control / Function Display Lever Load handler raise / lower Lever Mast forward / reverse tilt Auxiliary hydraulics lever 1. Activate 1st attachment Auxiliary hydraulics lever 2. Activate 2nd attachment Auxiliary hydraulics lever 3. Activate 3rd attachment Auxiliary hydraulics acknowledgement key t = Standard equipment...
Page 63: Multi-Pilot
MULTI-PILOT Item Control / Function Display MULTI-PILOT (F+B) Load handler raise / lower MULTI-PILOT (L+R) Mast forward / reverse tilt Travel direction switch Selects travel direction / neutral position Auxiliary hydraulics 1 1. Activate attachment switch Auxiliary hydraulics 2 2. Activate attachment switch ZH2 / ZH3 3.
Page 64: Controls
Controls Item Control / Function Display Battery indicator lamp Lights up to indicate errors in the power supply Main beam indicator Lit when the main beam is switched on lamp Hazard warning lights Flashes when the hazard warning lights are indicator lamp activated Dipped lights...
Page 65 2.4.1 Switch variants Symbol Switch/display Function t Switches the rear work lights on and Switch Rear work lights t Switches the front work lights on and off. Switch Front work lights t Switches the rear window wiper on and off Switch Rear window wiper o Switches the air conditioning system...
Page 66: Multifunction Display
Multifunction display Item Control / Function Display Level indicator Remaining fuel quantity Engine speed Current speed of the engine Speed Current speed Warning indicator Current warnings (variable) Temperature display Current engine temperature Parking brake display Position of the parking brake Menu Access to the configuration menu Gear lever display...
Page 67 2.5.1 Warnings This field (98) shows information related to operation. Symbol Display Engine cuts out automatically Engine cuts out automatically Engine is preheated Switch all travel direction switches to neutral position immediately No driver in the truck Service interval expired Contact Customer Services.
Page 68 2.5.2 Warning indicators Symbol Display Function o Hydraulic oil level too low. Hydraulic oil t Transmission oil temperature too low Transmission flashing Stop the truck immediately. t Engine oil pressure too low Engine oil flashing with "Stop" Engine cuts out. t Exhaust pressure too high Exhaust gas pressure...
Page 69: Operation Of The Multifunction Display
Operation of the multifunction display Procedure • Turn the key switch to stage "2" with the key. Operating data as well as Errors and information are shown in the multifunction display. Pictograms in the top section of the display act as warning indicators (99). The function keys (lower row) are lit.
Page 70 Press the "F4" key to go to the "SETUP" (100) and "Diagnostics" (101) areas. Diag- SETUP nose Press the "F4" key (SETUP) to open the adjustment range for the display. Einstell Displays...
Page 71 Optionally, the travel stages can also be adjusted here (single pedal drive) Setup Setup Setup Setup Disp Diagn Diagn Level setting ostic ostic Press the "F1" key to open the adjustment range for the standard values of the truck.
Page 72 2.6.1 Setting Default Values After the adjustment range is opened, you can set default values by pressing the "F1" and "F2" keys plus the "Enter" key. Example 1: Procedure • Select a range with the "F1" or "F2" key. • Confirm the selected range with the "Enter" key. •...
Page 73 Example 2: The display can be adapted to individual needs in this adjustment range. The arrow (3) designates the range in the display to be changed. Procedure • Make the settings with the "F1" and "F2" keys. • Press the "F3" button to change to another range. •...
Page 74 Adjustment options Engine speed (t) Speed display (t) Transmission status (t) Weigher system (o) Hydraulic oil reservoir capacity (o) Hydraulic oil temperature (measurement in the tank) (o) Engine operating hours (t) Time until next service (t) Lift height (o) Hydraulic system operating hours (t) Tilt angle (o) t = Standard equipment o = Optional equipment...
Page 75 2.6.2 Diagnostics Press the "F5" button to open the diagnostics area (101). Diag- SETUP nose All default values of the truck can be seen here. Serial number Date of the engine software version Truck type (A or C) Engine software version CVC firmware version Transmission parameter no.
Page 76 Reading Current Values The "F1" to "F4" buttons open the lower level menu ranges. "F1" button - brake system: The current values for the brake pressure (122), pedal position (124) and the valve (123) can be seen here.
Page 77 "F2" key - hydraulic controller. – Activated ranges are identified by a checkmark (127). – Range (125) indicates the position of the control lever(s): • Minus = forward • Plus = back – Range (126) indicates the current temperature of the control module: –...
Page 78 "F3" button - cooling – Pressing this button provides information about the coolant temperature in "°C" and the air speed as a "%" for the engine (129), transmission (131) and charge air cooler (132) an. – The speed of the cooler fan (130) is shown as a "%". "F4"...
Page 79: Dashboard
Dashboard Without air conditioning system 139 140 141 S 12 S 13 S 15 S 24 S 20 S 26 S 30 XR 9 With air conditioning system 139 140 141 S 12 S 13 S 15 S 24 X X 2 2 8 8 S S 2 2 0 0 S S 2 2 6 6 S S 3 3 0 0...
Page 80: With Automatic Air Conditioning
With automatic air conditioning 139 140 141 S 12 S 13 S 15 S 24 S 20 S 26 S 30 XR 9 Item Component LPG bottle switch (LPG only) Hazard warning lights switch Socket Beacon Work lights Windscreen wiper / windscreen washing system (rear windscreen) Windscreen wiper / windscreen washing system (roof window) (o)
Page 81: Heater, Fan, Air Conditioning System
Heater, fan, air conditioning system Heater heating controlled temperature selector (153). Procedure • Turn to the right - higher temperature • Turn to the left - lower temperature The fan speed is controlled with the (154) switch. Air conditioning system (o) Keep doors and windows closed when the air conditioning system is on –...
Page 82 • The air flow of the air conditioning system is controlled by discharge jets (155) and an intake nozzle (156) in the legroom (recirculated air) and by drawing in outside air. CAUTION! The intake nozzle (156) must always be unobstructed The air flow in the cab is set via the discharge jets.
Page 83 4.2.4 Automatic air conditioning Item Description Description 157 Internal temperature setpoint Setting for the desired internal temperature. The adjustment range is between 16°C (60°F) and 28°C (82°F). The setting should be no more than 5° - 6°C below the current outside temperature.
Page 84 4.2.5 Displays Display of inside or outside temperature Current operating mode Current air supply (Fresh = fresh air, Rec = recirculated air) Current fan output 4.2.6 Notes on automatic air conditioning operation – Automatic mode: The set internal temperature is maintained automatically. –...
Page 85: Preparing The Truck For Operation
Preparing the Truck for Operation Checks and operations to be performed before starting daily operation WARNING! Damage and other truck or attachment (optional equipment) defects can result in accidents. If damage or other truck or attachment (optional equipment) defects are discovered during the following checks, the truck must be taken out of service until it has been repaired.
Page 86 • Check the LPG system is working correctly, see "LPG containers" on page 54 • Attachment: Visually inspect bearing points, guides and stops for wear and damage and lubricate these components. • Visually inspect battery and battery components. • Check that the battery cable is positioned securely. •...
Page 87: Entry And Exit
Entry and exit Procedure • Open the cab door (o). • To enter and exit the cab, hold onto the handle (169). Always face the truck when entering and exiting. Always use the entry aid (169) provided to climb onto the truck. An additional step is provided for the driver position extension (o).
Page 88: Setting Up The Operator Position
Setting up the operator position WARNING! Accidents can occur if the driver's seat, steering column and armrest are not engaged The driver's seat, steering column and armrest can accidentally adjust during travel and therefore cannot be operated safely. Do not adjust the driver’s seat, steering column or armrest while travelling. Procedure •...
Page 89 Adjusting the driver's weight NOTE To achieve optimal seat cushioning the driver’s seat must be set to the driver’s weight. Set the driver's weight when the seat is occupied. Procedure • Fold out the weight adjustment lever (171) as far as it will go in the arrow direction •...
Page 90 Adjusting the seat position CAUTION! An unsecured driver's seat can cause injury An unsecured driver's seat can slide out of its guide during travel, resulting in accidents. The driver's seat must be locked in position. Do not adjust the driver’s seat while travelling.
Page 91 5.3.2 Adjusting the steering wheel / steering column CAUTION! Do not adjust the steering wheel while travelling Individual steering wheel position The steering wheel can be height- and tilt-adjusted to suit the operator. Adjusting the Tilt Procedure • Pull up on the adjusting lever (174). •...
Page 92 5.3.4 Adjusting the Control Panel The height and tilt of the control panel (177) can be changed. This makes it possible to adjust the armrest (178) and control panel optimally to each other. Procedure • Release the lever (179). • Move the control panel to the required position.
Page 93 5.3.5 Adjusting the Multifunction Display ensure optimum view multifunction display, it can be individually adjusted. Procedure • Sit on the driver's seat. • Adjust the seat to its optimum position. • Loosen the central wing screw (180) of the display holder just enough so that the two ball joints (181) can be moved freely in the holder.
Page 94: Seat Belt
Seat Belt WARNING! Travelling without a seat belt increases the risk of injury. Accidents or personal injury can result if the seat belt is not worn or is modified. Always put the seat belt on before starting the industrial truck. Do not modify the seat belt.
Page 95: Industrial Truck Operation
Industrial Truck Operation Safety regulations for truck operation Travel routes and work areas Only use lanes and routes specifically designated for truck traffic. Unauthorised third parties must stay away from work areas. Loads must only be stored in places specially designated for this purpose. The truck must only be operated in work areas with sufficient lighting to avoid danger to personnel and materials.
Page 96 Negotiating slopes and inclines Negotiating slopes and inclines up to 15% is only permitted if they are specifically designed as travel routes, are clean and have a non-slip surface and providing they can be safely travelled along in accordance with the truck's technical specifications. The truck must always be driven with the load facing uphill.
Page 97 DANGER! Exhaust emissions can be fatal The truck must only be operated in well ventilated areas. If the truck is operated in enclosed areas, this can lead to a build-up of harmful exhaust emissions, resulting in dizziness, tiredness and even death. The operator must comply with legal requirements, technical standards and health and safety regulations when operating an IC motor powered lift truck in closed rooms.
Page 98: Preparing The Truck For Operation
Preparing the truck for operation Before starting the truck The truck should only be operated from the driver’s seat. Do not run up the engine in idle. The engine soon reaches operating temperature at a moderate charge and when the speed alternates. Only fully charge the engine once it has reached operating temperature.
Page 99 6.2.1 Starting procedure for the DFG Procedure • • Insert the key in the key switch (88) and turn it to the “2” position. • The pre-heat indicator lamp lights up and goes out automatically as soon as the required pre-heat time (approx. 4 seconds) has been reached.
Page 100 6.2.2 Starting procedure for the TFG DANGER! Risk of escaping liquid gas if the truck does not start Note the safety regulations governing the handling of liquid gas (see "Safety regulations for handling diesel fuel and LPG" on page 49) Close the gas bottle shut-off valve.
Page 101: Operational Checks
Operational Checks WARNING! After starting the engine, perform the following operational checks: Procedure • Check whether the parking brake is locked in place. • Turn the steering wheel as far as it will go in both directions and test the steering. •...
Page 102: Parking The Truck Securely
Parking the truck securely WARNING! Switching off an LPG truck under ground level areas could result in explosions. LPG is heavier than air. An explosive LPG/air mixture could therefore form under ground level areas without sufficient ventilation. LPG trucks may only be switched off in ground level rooms or higher and providing they are adequately ventilated.
Page 103 Parking the Truck Securely (TFG) Procedure • Turn the travel direction switch to idle (centre position). • Press the "F5" button in the display. The brake shoe that appears in the "parking brake" icon (94) changes its position to the right. •...
Page 104: Emergency Disconnect
Emergency Disconnect CAUTION! Applying maximum braking can result in accidents Applying the Emergency Disconnect switch during travel will cause the truck to decelerate to a halt at maximum force. This may cause the load to slide off the load handler. There is a higher risk of accidents and injury. Do not use the Emergency Disconnect switch as a service brake.
Page 105: Travel
Travel WARNING! Improper travel can result in accidents Do not get up from the driver’s seat during travel. Do not drive the truck unless your are wearing a seat belt and the panels and doors are properly locked. Do not lean out of the truck while travelling. Make sure that the travel area is clear.
Page 106 Adjust the automatic gearshift with the rotary button on the lever (73). – Stage "1": transmission does not switch into 2nd gear. – Stage "2": the truck starts in 1st gear and automatically switches to 2nd gear as soon as the truck reaches a speed of 7-8 km/h. As soon as the speed is more than 3 - 4 km/h, the travel direction can no longer be changed.
Page 107: Steering
Steering Steering Procedure Very little steering effort is required; you should therefore turn the steering wheel (175) sensitively. • To negotiate a right-hand bend: Turn the steering wheel clockwise according to the required steering radius. • To negotiate a left-hand bend: Turn the steering wheel anti-clockwise according to the required steering radius.
Page 108: Brakes
Brakes WARNING! Accident risk The brake pattern of the truck depends largely on the ground conditions. The driver must be aware of travel route conditions and them into account when braking. Brake with care to prevent the load from slipping. Allow for increased braking distance when travelling with an attached load.
Page 109 6.8.2 Parking brake DANGER! Accident risk The parking brake will hold the truck with maximum load on a clean ground surface, on inclines of up to 15%. Do not park and abandon the truck on an incline. Applying the parking brake during travel will cause the truck to brake to a standstill. This may cause the load to slide off the fork tines.
Page 110: Adjusting The Forks
Adjusting the forks WARNING! Trapping hazard There is a trapping hazard when you perform this operation. Wear work gloves and safety shoes. WARNING! Unsecured and incorrectly adjusted fork tines can cause accidents Adjust the two fork tines so that they are equidistant from the outside edge of the fork carriage.
Page 111: Replacing The Forks
6.10 Replacing the forks WARNING! Unsecured fork tines can cause injury You can injure your legs when replacing the fork tines. Never pull the fork tines towards your body. Always push the fork tines away from your body. Secure heavy fork tines with lifting slings and a crane before pushing them down from the fork carriage.
Page 112: Lifting, Transporting And Depositing Loads
6.11 Lifting, transporting and depositing loads WARNING! Unsecured and incorrectly positioned loads can cause accidents. Before lifting a load the operator must make sure that it has been correctly palletised and does not exceed the truck’s capacity. Instruct other people to move out of the hazardous area of the truck. Stop working with the truck if people do not leave the hazardous area.
Page 113 NOTE 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. Transporting loads Requirements – Load raised correctly. – Load handler lowered for transport (approx. 150 - 200 mm above the ground). –...
Page 114: Operating The Lift Mechanism And Integrated Attachments
6.12 Operating the lift mechanism and integrated attachments WARNING! Operating the lifting device and integrated attachments can be hazardous Other people can be injured in the truck's hazardous area. The hazardous area is defined as the area in which people are at risk from the truck movement, the load handler, attachments etc.
Page 115 Tilting the mast forward / backward Requirements – Truck prepared operation, "Preparing the truck for operation" on page 99. Procedure • Pull back on the lever (78). The mast tilts back. • Push forward on the lever (78). The mast tilts forward.
Page 116 Fork Adjustment (SOLO-PILOT) Procedure • • To adjust the fork to the width of the load: • Wider fork spread: Press the handle (80) in direction (A) while simultaneously pressing the acknowledgement key (82). • Narrower fork spread: Press the handle (80) in direction (B) while simultaneously pressing the acknowledgement key (82).
Page 117 6.12.2 Operating the lift mechanism with the Multi Pilot Lifting and lowering Requirements – Truck prepared operation, "Preparing the truck for operation" on page 99. Procedure • Pull back on MULTI-PILOT (77). The load is raised. • Push MULTI-PILOT (77) forward. The load is lowered.
Page 118 Twin operation Requirements – To prepare the truck for operation, see "Preparing the truck for operation" on page 99 Procedure • To lower the load handler and tilt the mast forward at the same time, push the Multi Pilot forward and to the right. •...
Page 119 Fork Adjustment (MULTI-PILOT) Procedure • Adjusting the fork makes it possible to set the fork to the width of the load. Wider fork spread: Press the control button (80) in direction (F) while simultaneously pressing the acknowledgement key (81). Narrower fork spread: Press the control button (80) in direction (B) while simultaneously pressing the acknowledgement key (81).
Page 120: Safety Instructions For Operating Additional Attachments
6.13 Safety instructions for operating additional attachments Optionally, trucks can be fitted with one or more auxiliary hydraulic functions to operate attachments. The auxiliary hydraulics are referenced ZH1, ZH2 and ZH3. Auxiliary hydraulic functions for exchangeable equipment are fitted with replacement couplings on the fork carriage.
Page 121 Safety instructions for sideshifter and fork positioner attachments WARNING! Restricted visibility and reduced tilt resistance can cause accidents When using sideshifters and fork positioners, the change in centre of gravity can result in reduced lateral tilt resistance and accidents. Note that this affects visibility as well.
Page 122 Safety instructions for attachments when transporting suspended loads WARNING! Swinging loads and a reduced residual capacity can result in accidents. Transporting hanging loads can reduce the stability of the truck. Adapt the travel speed to the load, less than walking pace. Secure swinging loads for example with lifting slings.
Page 123: Operating Additional Attachments For The Solo-Pilot
6.14 Operating additional attachments for the SOLO-PILOT WARNING! Incorrect symbols can cause accidents Symbols on controls that do not depict the function of the attachments can cause accidents. Mark the controls with symbols that indicate their function. Specify the attachments’ direction of movement in accordance with ISO 3691-1 so that they match the controls’...
Page 124: Operating Additional Attachments For The Multi Pilot
6.15 Operating additional attachments for the Multi Pilot WARNING! Incorrect symbols can cause accidents Symbols on controls that do not depict the function of the attachments can cause accidents. Mark the controls with symbols that indicate their function. Specify the attachments’ direction of movement in accordance with ISO 3691-1 so that they match the controls’...
Page 125: Fitting Additional Attachments
6.16 Fitting additional attachments WARNING! Incorrectly connected attachments can cause accidents. Attachments with incorrectly connected hydraulic attachments can result in accidents. Attachments must only be assembled and commissioned by trained, specialist personnel. Observe the manufacturer’s operating instructions. Before starting, check the fasteners are positioned correctly and securely and make sure they are complete.
Page 126 Spilled hydraulic oil must be set using a suitable agent and disposed of in accordance with environmental regulations. If hydraulic oil comes into contact with the skin, wash it off immediately with soap and water. If it comes into contact with the eyes rinse them immediately with flowing water and call for a doctor.
Page 127: Towing Trailers
Towing trailers DANGER! 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 pull apart when cornering and braking. The truck should only be used occasionally to tow trailers. The overall weight of the trailer should not exceed the capacity indicated on the capacity plate, see "Identification points and data plates"...
Page 128 Attaching the trailer CAUTION! Trapping hazard There is a trapping risk when you attach a trailer. Follow the instructions of the coupling manufacturer if using special trailer couplings. Secure the trailer to prevent it from rolling away before coupling it. Do not get caught between the truck and the tiller when coupling the trailer.
Page 129: Optional Equipment
Optional equipment...
Page 130: Rotating Driver's Seat
Rotating Driver's Seat 8.1.1 Functional Description The driver's seat is turned via an electric motor. The electric motor is located under the cab. Travel is activated for the following seat positions: – 0° seat position: Seat facing the load handler. –...
Page 131 8.1.2 Emergency Disconnect CAUTION! Applying maximum braking can result in accidents Applying the Emergency Disconnect switch during travel will cause the truck to decelerate to a halt at maximum force. This may cause the load to slide off the load handler.
Page 132 8.1.4 Panoramic mirror An additional panoramic mirror (191) is included for the rotary seat option.
Page 133 8.1.5 Steering direction reversal notice sign An additional notice sign (192) is included for the steering direction reversal option.
Page 134 8.1.6 Rotating the driver's seat WARNING! Rotary movement can result in trapping When the driver's seat rotates parts of your body can be trapped between the cab and the driver's seat. The operator must remain seated on driver's seat during the rotary movement with both feet placed on the rotating panel.
Page 135 Item Travel direction Left Reverse Forward Right Selects the travel direction. Procedure • Set the travel direction switch (73) to direction truck travels forward (195). • Set the travel direction switch (73) to direction R: The truck reverses (194). The truck travels in the direction selected. Steers the truck Procedure •...
Page 136 8.1.8 Travelling in the 90° seat position with steering direction reversal (o) Forward travel direction • To negotiate a right-hand bend: Travel direction switch in V, turn the steering wheel clockwise to match the desired steering radius. • To negotiate a left-hand bend: Travel direction switch in V, turn the steering wheel anti-clockwise to match the desired steering radius.
Page 137 8.1.9 Travelling in the 180° seat position Item Travel direction Left Forward Reverse Right Selects the travel direction. Procedure • Travel direction switch (73) in direction V: The truck travels forward (194). • Travel direction switch (73) in direction R: The truck reverses (195). The truck travels in the direction selected.
Page 138 8.1.10 Troubleshooting Fault Possible cause Remedy Truck operational, – Travel speed too high – Decelerate until the truck driver's seat does not comes to rest – Operator not on the rotate driver's seat – Operator on the driver's seat – Faulty fuse –...
Page 139: Sliding Windows
Sliding windows CAUTION! An unlocked sliding window can cause accidents The sliding windows must be locked at all times. Opening and closing the windows Procedure • Push the lock (197) up. • Move the window forward or back. • Insert the lock in the stop (198). Emergency Exit If a locking pin in the closing mechanism is removed, the right side window can be used as an emergency exit.
Page 140: Fire Extinguisher
Switching the seat heating on and off (optional equipment) Procedure • Press the seat heating switch (199). Switch setting 1 = Seat heating on. Switch setting 0 = Seat heating off. Fire Extinguisher Procedure • Open the fasteners (200) • Pull the fire extinguish out of its bracket To operate, refer to the illustrations on the fire extinguisher Rockinger Coupling with Hand Lever...
Page 141 • Drive the truck forward. • Press down on the hand lever (202).
Page 142: Troubleshooting
Troubleshooting Automatic Emergency Brake The automatic emergency brake is activated if an error occurs in one of the following components during operation: – Brake pedal – Pressure sensor in the brake system – Magnetic coil in the service brake or parking brake Emergency braking initiates the following sequence: –...
Page 143 R N D 1 LIMP Disg- SETUP Nostic HOME Procedure • Press the "ESC" key to exit the current menu area and return to the travel mask. LIMP HOME flashes on the multifunction display. 14.04.08 MENU R N D 1 07:43 Procedure •...
Page 144: Troubleshooting
Troubleshooting This chapter enables the operator to localize and rectify basic faults or the results of incorrect operation himself. When trying to locate a fault, proceed in the order shown in the remedy table. If, after carrying out the following remedial action, the truck cannot be restored to operation or if a fault in the electronics system is displayed with a corresponding error code, contact the manufacturer’s service department.
Page 145: Operating The Truck Without Its Own Drive System
Operating the truck without its own drive system 9.3.1 Towing the truck WARNING! Accident risk Other people can be injured if the truck is towed incorrectly. Only use vehicles to tow the truck which have sufficient tow and brake forces for the trailer load without its own braking system.
Page 146 DANGER! The parking brake is non-operational in this condition. Use other methods to prevent the truck from rolling away. Adjust the parking brake before starting up the truck again. The brake must be set to default after emergency release, repair work, fitting new brake lining support or brake disk, and if there is insufficient brake force.
Page 147 9.3.2 Emergency lowering The mast can be lowered manually if a fault occurs in the hydraulic system. WARNING! Lowering the mast can result in injuries Instruct other people to move out of the hazardous area of the truck during emergency lowering. Never stand underneath a raised load handler.
Page 148 9.3.3 Starting aid WARNING! Danger from overheating Only use an ISO 6722 battery jump lead with fully insulated terminal pliers and a lead diameter of at least 50 mm². Procedure • Open the right side window completely. • see "Tilting the Cab" on page 167Tilt the cab of the truck until the retaining device (210) is locked in position, •...
Page 150: F Industrial Truck Maintenance
F Industrial Truck Maintenance Operational Safety and Environmental Protection The checks and servicing operations contained in this chapter must be performed in accordance with the maintenance checklist service intervals. WARNING! Risk of accidents and damage to components Any modification to the truck, in particular the safety mechanisms, is prohibited. Do not alter the truck's operating speeds under any circumstances.
Page 151: Maintenance Safety Regulations
Maintenance Safety Regulations Maintenance and repair personnel The manufacturer has a service department specially trained for these tasks. A maintenance contract with the manufacturer will ensure trouble-free operation. Truck maintenance and repair work must only be carried out by specially trained personnel.
Page 152: Working On The Electrical System
Working on the electrical system CAUTION! Accident risk from Working on the electrical system: Make sure the electrical system is voltage-free before starting work on it. Remove any rings or metal bracelets etc. before working on electrical components. Only trained personnel may work on the electrical system. Switch off the truck securely (see "Parking the truck securely"...
Page 153: Lift Chains
Lift Chains WARNING! Non-lubricated and incorrectly cleaned lift chains can cause accidents Lift chains are safety-critical parts. They must not contain any serious contamination. Lift chains and pivot pins must always be clean and well lubricated. Lift chains should only be cleaned with paraffin derivatives e.g. petroleum or diesel fuels.
Page 154: Working In The Vicinity Of The Engine
WARNING! Faulty hydraulic hoses can result in injury and infection Pressurised hydraulic oil can escape from fine holes or hairline cracks in the hydraulic hoses. Brittle hydraulic hoses can burst during operation. People standing near the truck can be injured by the hydraulic oil. Call for a doctor immediately in the event of an injury.
Page 155: Lubricants And Lubrication Schedule
Lubricants and Lubrication Schedule Handling consumables safely Handling consumables Consumables must always be handled correctly. Follow the manufacturer’s instructions. WARNING! Improper handling is hazardous to health, life and the environment Consumables can be flammable. Keep consumables away from hot components and naked flames. Always keep consumables in prescribed containers.
Page 156 WARNING! Improper handling of oils can be hazardous Oils (chain spray / hydraulic oil) are flammable and poisonous. Dispose of used oils in accordance with regulations. Store used oil safely until it can be disposed of in accordance with regulations. Do not spill oil.
Page 157: Lubrication Schedule
Lubrication Schedule Grease nipple Number Chain sprocket Mast, suspension Tilt cylinder front bearing Mast rollers 8/10/12 Tilt cylinder rear bearing Cardan shaft Stub axle pins Track rod Dipstick and filling points Hydraulic oil filler plug (in the motor compartment) Fuel filler neck Battery (in the motor compartment) Engine oil filler neck...
Page 158 Dipstick and filling points Coolant tank Engine oil dipstick Filler neck for window washer system Lowering points Wheel hub, right Hydraulic oil (right tank) Fuel (left tank) Wheel hub, left...
Page 159: Consumables
51332291 16 l Fricofin V Mix coolant with water 1:1 51132716 4 cylinders 150 Jungheinrich hydraulic oil Hydraulics 6 cylinders 190 8 cylinders 170 52017727 4 cylinders 7 l Titan UNIMAX PLUS MC Engine 6 cylinders 15 l SAE 10W40 8 cylinders 4.8 l...
Page 160: Coolant Specification
Coolant specification Coolant specification The quality of the coolant used can have a major impact on the efficiency and service life of the cooling circuit. The recommendations listed below are useful for servicing a good cooling circuit with anti-freeze and/or anti-corrosion. Always use clean, soft water.
Page 161: Maintenance And Repairs
Maintenance and repairs Preparing the truck for maintenance and repairs All necessary safety measures must be taken to avoid accidents when carrying out maintenance and repairs. The following preparations must be made: Procedure • Park the truck securely, see "Transport and Commissioning"...
Page 162: Lifting And Jacking Up The Truck Safely
Lifting and jacking up the truck safely WARNING! A truck tipover can cause accidents In order to raise the truck, use only suitable lifting gear at the points specially provided for this purpose. Note the weight of the truck on the data plate. Always use a jack with a minimum capacity of 10000 kg kg.
Page 163: Replacing Wheels
Replacing wheels WARNING! A truck tipover can cause accidents In order to raise the truck, use only suitable lifting gear at the points specially provided for this purpose. Note the weight of the truck on the data plate. Always use a jack with a minimum capacity of 10000 kg kg. Raise the unladen truck on a level surface.
Page 164 Fitting the wheels Procedure • Assemble the wheel, using a suitable mounting lever if necessary. • Fit the wheel attachment. • Remove the hard wooden blocks. • Lower the truck. • Torque the wheel attachment (233) crosswise with a torque wrench, for torques see "Tyre type" on page 33.
Page 165: Checking The Wheel Attachments
Checking the wheel attachments. WARNING! Using different tyres can cause accidents The quality of tyres affects the stability and performance of the truck. The diameter of the wheels must differ by no more than 15 mm. Always replace tyres in pairs. After replacing the tyres check the wheel nuts are secure after 10 service hours.
Page 166: Tilting The Cab
Tilting the Cab DANGER! Before tilting the cab, allow the motor and muffler to cool off. Unlock the muffler and tilt it back. Procedure • To do this release the lever (236) and unlock the button (235). The muffler can be carefully turned back as far as the stop.
Page 167 Lifting Procedure • To lift the cab, insert the short side of the pump rod (239) through the infeed (237) onto the pump drive and activate. Tilt the cab back manually until the cab locking device engages engine compartment. Cab is now raised.
Page 168 4.6.2 Lowering the Cab The cab cannot be lowered electrically. Procedure • To lower the cab, use the lever (240) to release the locking device (210) and lower the cab. • • To lower the cab, insert the long side of the pump rod (239) through the infeed (238) onto the hexagon of the lowering valve and carefully turn the lowering valve...
Page 169 4.6.3 Raising the Cab Electrically (o) DANGER! Before tilting the cab, allow the motor and muffler to cool off. Unlock the muffler and tilt it back. Procedure • To do this release the lever (236) and unlock the button (235). The exhaust purifier can be carefully turned back as far as the stop.
Page 170: Replacing Wheels
Replacing wheels WARNING! A truck tipover can cause accidents In order to raise the truck, use only suitable lifting gear at the points specially provided for this purpose. Note the weight of the truck on the data plate. Always use a jack with a minimum capacity of 10000 kg kg. Raise the unladen truck on a level surface.
Page 171 Fitting the wheels Procedure • Assemble the wheel, using a suitable mounting lever if necessary. • Fit the wheel attachment. • Remove the hard wooden blocks. • Lower the truck. • Torque the wheel attachment (233) crosswise with a torque wrench, for torques see "Tyre type" on page 33.
Page 172: Checking The Wheel Attachments
Checking the wheel attachments. WARNING! Using different tyres can cause accidents The quality of tyres affects the stability and performance of the truck. The diameter of the wheels must differ by no more than 15 mm. Always replace tyres in pairs. After replacing the tyres check the wheel nuts are secure after 10 service hours.
Page 173: Hydraulic System
Hydraulic system CAUTION! The hydraulic oil is pressurised during operation and is a hazard to health and to the environment. Do not touch pressurised hydraulic lines. Dispose of used oil in accordance with regulations. Store used oil safely until it can be disposed of in accordance with regulations.
Page 174 4.9.1 Checking the hydraulic oil level Requirements – Park the truck on a level surface. – Start the engine and fully raise and lower the mast once. – Switch off the engine. Procedure • Remove the hydraulic oil dipstick (242) from the hole, wipe it with a clean cloth and insert it fully again.
Page 175 4.9.2 Adding hydraulic oil Procedure • Unscrew the lid (243) of the hydraulic filter • Add hydraulic oil to the MAX mark on the hydraulic oil dipstick (244). Use only approved hydraulic oil (see consumables table). • Check the hydraulic oil level with the dipstick and top up as required.
Page 176: Engine Maintenance
4.10 Engine maintenance WARNING! Turning and hot components can cause trapping and burning hazards when the engine is running. When the cover is open turning and hot components are freely accessible and can cause injury if touched. Before starting work make sure that the Emergency Disconnect switch can be reached to switch off the engine.
Page 177 4.10.1 DFG engine maintenance NOTE Used oil contaminates the environment Dispose of used oil and used engine oil filters in accordance with environmental regulations. CAUTION! Risk of scalding through hot oil. Wear appropriate safety gloves when replacing the oil and oil filter. NOTE When the engine is cold the engine oil can be viscous.
Page 178 4.10.2 Cooling System NOTE Lack of coolant can cause malfunctions The coolant level should be between the “MIN” and “MAX” markings on the expansion vessel. If the coolant is below the MIN marking, this indicates possible leakage in the radiator system. Do not continue using the truck.
Page 179 Check the coolant concentrate Tools and Material Required – Anti-freeze tester for coolants Procedure • Slowly unscrew the filler cap (246) from the expansion vessel (247). • Check the anti-freeze content of the coolant with an anti-freeze tester. NOTE Incorrect coolant concentration can cause malfunctions If there is insufficient anti-freeze content arrange for trained personnel to restore the correct mix ratio.
Page 180 Replace air filter cartridge Procedure • Undo the end cap (248) and remove the dust collector pot. • Carefully remove the air filter cartridge from the filter housing. Cleaning the filter housing Procedure NOTE A faulty motor can cause malfunctions Do not clean the air filter housing with compressed air.
Page 181 4.10.4 Adding Window Washer System Fluid Procedure • Open the service panel. • Unscrew the cover (230) and add window washing fluid. • If necessary top up with anti-freeze. The capacity of the tank is 5 litres.
Page 182: Check The Transmission Oil Level
4.11 Check the transmission oil level Procedure • Prepare the truck for maintenance and repairs. • Check the oil level with the dipstick (249). Slowly insert the dipstick into the transmission to prevent false measurements. Check the oil level for the transmission while the motor is at idle.
Page 183: Checking Electrical Fuses
4.14 Checking electrical fuses 4.14.1 Standard Fuse Strip Checking electrical fuses Requirements – Prepare the truck for maintenance and repairs (4.14.2). Procedure The main fuse box is located in the dashboard to the right of the driver's seat in the cab.
Page 184 Type Electric circuit Rating (A) Reading light Display Travel direction switch Radio +30 radio, cab lighting Ignition switch 15 Ignition switch 50 Swivel seat Front work lights Cigarette lighter Air conditioning system Load damping Brake pedal LPG supply (TFG only) t = Standard equipment o = Optional equipment Type...
Page 185 4.14.2 Fuse ratings in motor compartment for 4 + 6 cylinder diesel All fuses (section 4.14.3 + see "Identification points and data plates" on page 38) are located on the right side of the motor compartment as seen in travel direction behind a Plexiglas window above the hydraulic reservoir.
Page 186 4.14.3 Fuse strip in motor compartment for LPG motor Type Electric circuit Rating (A) Front work lights on mast Transmission controller terminal 30 Truck controller terminal 15 Option terminal 15 (X27:4) Option terminal 15 (X27:1) Valve block Option terminal 15 (X26:7) Transmission controller terminal 15 Option terminal 15 Fan motor for LPG tank...
Page 187 4.14.4 Cab lift fuse Description Power circuit Rating (A) Electric cab lift main fuse 4.14.5 Checking the Electric Relays (DFG) The main fuse box with the relays is located in the dashboard to the right of the driver's seat in the cab. Work lights / rear Indicator relay Main beam...
Page 188: Cleaning
4.15 Cleaning CAUTION! Fire hazard The truck must not be cleaned with flammable fluids. If flammable materials are not removed from the engine compartment, they can come into contact with hot components and cause a fire. Carry out all necessary safety measures to prevent sparking before cleaning (e.g. by short-circuiting).
Page 189 CAUTION! Risk of electrical system damage Cleaning the assemblies (controllers, sensors, motors etc.) of the electronic system with water can damage the electrical system. Do not clean the electrical system with water. Clean the electrical system with weak suction or compressed air (use a compressor with a water trap) and not a conductive, anti-static brush.
Page 190: Starter Battery
4.16 Starter battery Checking the battery condition, acid level* and acid density* *not for maintenance-free batteries WARNING! Batteries can be hazardous Batteries contain an acid solution which is poisonous and corrosive. Avoid contact with battery acid at all times. Dispose of used battery acid in accordance with regulations. Always wear protective clothing and goggles when working with batteries.
Page 191: Exhaust System
4.17 Exhaust system NOTE Check emissions at regular intervals Check the combustion engine exhaust emissions at regular intervals in accordance with national regulations. Black or blue exhaust smoke is an indicator of high emission levels resulting from combustion engine damage or wear. In this case the truck must be examined by specialist personnel.
Page 192: Restoring The Truck To Service After Maintenance And Repairs
4.18 Restoring the truck to service after maintenance and repairs Procedure • Thoroughly clean the truck, see "Lubrication Schedule" on page 158. • Lubricate the truck according to the lubrication schedule, see "Preparing the Truck for Operation" on page 86. •...
Page 193: Decommissioning The Industrial Truck
Decommissioning the industrial truck If the truck is to be out of service for more than a month, it must be stored in a frost- free and dry room. All necessary measures must be taken before, during and after decommissioning as described hereafter. When the truck is out of service it must be jacked up so that all the wheels are clear of the ground.
Page 194: Prior To Decommissioning
Prior to decommissioning Procedure • Thoroughly clean the truck, see "Checking the hydraulic oil level" on page 175. • Prevent the truck from rolling away. • Check the hydraulic oil level and replenish if necessary, see "Lubrication Schedule" on page 158. •...
Page 195: Restoring The Truck To Service After Decommissioning
Restoring the truck to service after decommissioning Procedure • Thoroughly clean the truck. • Lubricate the truck according to the lubrication schedule, see "Starter battery" on page 191. • Clean the battery, grease the terminals and connect the battery. • Charge the battery, see "Preparing the Truck for Operation" on page 86. •...
Page 196: Safety Tests To Be Performed At Intervals And After Unusual Incidents
Safety tests to be performed at intervals and after unusual incidents Perform a safety check in accordance with national regulations. The manufacturer recommends the truck be checked to FEM guideline 4.004. The manufacturer has a service department specially trained for these tasks. The truck must be inspected at least annually (refer to national regulations) or after any unusual event by a qualified inspector.
Page 197: Final De-Commissioning, Disposal
Final de-commissioning, disposal Final de-commissioning or disposal of the truck in must be performed in accordance with the regulations of the country of use. In particular, regulations governing the disposal of batteries, consumables and electronic and electrical systems must be observed. The truck must only be disassembled by trained personnel in accordance with the procedures as specified by the manufacturer.
Page 198: Servicing And Inspection
Servicing and Inspection WARNING! Risk of accident due to neglected maintenance Failure to perform regular servicing can lead to truck failure and poses a potential hazard to personnel and equipment. Thorough and expert servicing is one of the most important requirements for the safe operation of the industrial truck.
Page 199: Maintenance Checklist Dfg
Maintenance checklist DFG 10.1 Operating Company 10.1.1 Standard Equipment Brakes W A B C Test brakes. Electrical System W A B C Test warning and safety devices in accordance with operating instructions. Test displays and controls. Test Emergency Disconnect switch. Power Supply W A B C Check battery cable connections are secure, grease terminals if...
Page 200 10.1.2 Optional Equipment Work lights Electrical System W A B C Test lighting. Strobe light / beacon Electrical System W A B C Test strobe light / beacon and check for damage. Heating Chassis and Superstructure W A B C Test the heating.
Page 201 Optional equipment Chassis and Superstructure W A B C Check that optional equipment such as mirrors, storage compartments, grips, windscreen wipers and washing systems etc. are working correctly and check for damage.
Page 202: Customer Service
10.2 Customer Service 10.2.1 Standard Equipment Brakes W A B C Test brakes. Check the brake lining on the parking brake. Check connections and lines for leaks. Electrical System W A B C Test warning and safety devices in accordance with operating instructions.
Page 203 Travel W A B C Check wheels for wear and damage. Check wheel suspension and attachment. Test starter and generator, check wires and attachment. Replace the engine discharge filter. Replace fuel filter. Replace the fuel pre-filter. Replace engine oil filter. Check V belt / multi-V belt is tensioned and check for damage.
Page 204 Hydraulic operations W A B C Test "hydraulic" controls and make sure the labels are present, legible and complete. Test hydraulic controls and check they are assigned to the correct functions. Check cylinders and piston rods for damage and leaks, and make sure they are secure.
Page 205 Steering W A B C Test hydraulic steering and its components. Test the hydraulic steering for leaks. Check steering axle and steering knuckle for wear and damage. Check steering-knuckle bearing and adjust if necessary. Grease the steering axle. Check mechanical parts of steering column. 10.2.2 Optional Equipment Discharge strap Electrical System...
Page 206 Data recorder Electrical System W A B C Check data recorder is secure and check for damage. 90° / 180° rotary seat Chassis and Superstructure W A B C Check drive chain of rotary seat and adjust if necessary. Lubricate drive chain of rotary seat. Test rotary seat and check for damage.
Page 207 Clamping device Hydraulic operations W A B C Test the acknowledgement key. Test the hose reel and check for leaks and damage. Check axial play of the front and rear rollers and adjust if necessary. Check attachment is properly secured to the truck and the supporting elements.
Page 208 Particle filter Travel W A B C Note: Any work carried out on the particle filter system must only be performed by specialist personnel. Particle filter: Clean filter in accordance with the manufacturer's instructions. Test the particle filter system. Check its setting and check for contamination, clean if necessary.
Page 209 Road traffic approval (StVZO) Electrical System W A B C Test lighting. Boom Hydraulic operations W A B C Check attachment is properly secured to the truck and the supporting elements. Weigher sensors / switches Electrical System W A B C Test weigher system and check for damage.
Page 210 Optional equipment Chassis and Superstructure W A B C Check that optional equipment such as mirrors, storage compartments, grips, windscreen wipers and washing systems etc. are working correctly and check for damage. Issued on: 15/11/2013 10:00:24...
Page 211: Maintenance Checklist Tfg
Maintenance checklist TFG 11.1 Operating Company 11.1.1 Standard Equipment Brakes W A B C Test brakes. Electrical System W A B C Test warning and safety devices in accordance with operating instructions. Test displays and controls. Test Emergency Disconnect switch. Power Supply W A B C Check battery cable connections are secure, grease terminals if...
Page 212 11.1.2 Optional Equipment Work lights Electrical System W A B C Test lighting. Strobe light / beacon Electrical System W A B C Test strobe light / beacon and check for damage. Heating Chassis and Superstructure W A B C Test the heating.
Page 213 Optional equipment Chassis and Superstructure W A B C Check that optional equipment such as mirrors, storage compartments, grips, windscreen wipers and washing systems etc. are working correctly and check for damage.
Page 214: Customer Service
11.2 Customer Service 11.2.1 Standard Equipment Brakes W A B C Test brakes. Check the brake lining on the parking brake. Check connections and lines for leaks. Electrical System W A B C Test warning and safety devices in accordance with operating instructions.
Page 215 Travel W A B C Clean the engine oil cooler. Check and clean radiator. Check transmission for noise and leakage. Replace transmission oil. Check tyre air pressure and top up if necessary. Check wheels for wear and damage. Check wheel suspension and attachment. Test starter and generator, Check wires and attachment.
Page 216 Hydraulic operations W A B C Test "hydraulic" controls and make sure the labels are present, legible and complete. Test hydraulic controls and check they are assigned to the correct functions. Check cylinders and piston rods for damage and leaks, and make sure they are secure.
Page 217 Steering W A B C Test hydraulic steering and its components. Test the hydraulic steering for leaks. Check steering axle and steering knuckle for wear and damage. Check steering-knuckle bearing and adjust if necessary. Grease the steering axle. Check mechanical parts of steering column. 11.2.2 Optional Equipment Discharge strap Electrical System...
Page 218 Data recorder Electrical System W A B C Check data recorder is secure and check for damage. 90° / 180° rotary seat Chassis and Superstructure W A B C Check drive chain of rotary seat and adjust if necessary. Lubricate drive chain of rotary seat. Test rotary seat and check for damage.
Page 219 Clamping device Hydraulic operations W A B C Test the acknowledgement key. Test the hose reel and check for leaks and damage. Check axial play of the front and rear rollers and adjust if necessary. Check attachment is properly secured to the truck and the supporting elements.
Page 220 Impact sensor Electrical System W A B C Check impact sensor is secure and check for damage. Sideshifter Hydraulic operations W A B C Test the hose reel and check for leaks and damage. Check axial play of the front and rear rollers and adjust if necessary. Check attachment is properly secured to the truck and the supporting elements.
Page 221 Wiper/washer system Chassis and Superstructure W A B C Check wiper water container for leaks and check volume, top up if necessary. Test windscreen wipers and check for damage, replace if necessary. Fork positioner Hydraulic operations W A B C Test the hose reel and check for leaks and damage.

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Jungheinrich DFG 670 Operating Instructions Manual

A Correct Use and Application

B Truck Description

C Transport and Commissioning

D Fuelling the Truck

E Operation

F Industrial Truck Maintenance

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Troubleshooting

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