Jungheinrich DFG 660 Service Manual

DFG/TFG 660-690 02.
11 -
Operating instructions G
51139143
02.11 DFG 660
DFG 670
DFG 680
DFG 690
DFG S80
DFG S90
TFG 660
TFG 670
TFG 680
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TFG S80
TFG S90
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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
TFG 680
TFG 690
TFG S80
TFG S90
Additional information
On behalf of
Date
G EU Conformity Declaration
The undersigned hereby declare that the powered industrial truck described below in
detail complies with the European Directives 2006/42/EC (Machinery Directive) and
2004/108/EEC (Electromagnetic Compatibility - EMC) including amendments as well
as the legislative decree to incorporate the directives in national law. The signatories
are in each case individually authorized to compile the technical documents.
02.11 EN

02.11 EN

Foreword
Notes on the operating instructions
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide
sufficient instruction for the safe operation of the industrial truck. The information is
provided clearly and concisely. The chapters are arranged by letter and the pages are
numbered continuously.
The operator manual details different industrial truck models. When operating and
servicing the industrial truck, make sure that the particular section applies to your truck
model.
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.
Safety notices and text mark-ups
Safety instructions and important explanations are indicated by the following graphics:
DANGER!
Indicates an extremely hazardous situation. Failure to comply with this instruction will
result in severe irreparable injury and even death.
WARNING!
Indicates an extremely hazardous situation. Failure to comply with this instruction may
result in severe irreparable injury and even death.
CAUTION!
Indicates a hazardous situation. Failure to comply with this instruction may result in
slight to medium injury.
NOTE
Indicates a material hazard. Failure to comply with this instruction may result in
material damage.
Z Used before notices and explanations.
t Indicates standard equipment

o Indicates optional equipment
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
02.11 EN

Jungheinrich Aktiengesellschaft
Am Stadtrand 35
22047 Hamburg - Germany
Tel: +49 (0) 40/6948-0
www.jungheinrich.com
02.11 EN

Table of Contents
A Correct Use and Application .................................................... 11

1 General.................................................................................................... 11
2 Correct application................................................................................... 11
3 Approved application conditions.............................................................. 12
4 Proprietor responsibilities ........................................................................ 13
5 Adding attachments and/or accessories.................................................. 13
B Truck Description ..................................................................... 15

1 Application ............................................................................................... 15
1.1 Truck models and rated capacity............................................................. 15
2 Assemblies and Functional Description................................................... 16
2.1 Assembly Overview ................................................................................. 16
2.2 Functional Description ............................................................................. 17
3 Technical Specifications .......................................................................... 19
3.1 Performance data .................................................................................... 19
3.2 Dimensions.............................................................................................. 23
3.3 Weights ................................................................................................... 28
3.4 Mast versions .......................................................................................... 29
3.5 Tyre type ................................................................................................. 31
3.6 Engine Data............................................................................................. 32
3.7 EN norms................................................................................................. 33
3.8 Conditions of use..................................................................................... 35
3.9 Electrical requirements ............................................................................ 35
4 Identification points and data plates ........................................................ 36
4.1 Data plate ................................................................................................ 38
4.2 Truck capacity plate................................................................................. 39
4.3 Attachment capacity plate ....................................................................... 40
4.4 Jack attachment point.............................................................................. 40
5 Stability .................................................................................................... 40
C Transport and Commissioning ................................................. 41

1 Transport ................................................................................................. 41
2 Truck laden.............................................................................................. 41
2.1 Centre of gravity of the truck ................................................................... 41
2.2 Lifting the truck by crane ......................................................................... 42
2.3 Loading with another industrial truck ....................................................... 42
3 Securing the truck during transport ......................................................... 43
4 Using the Truck for the First Time ........................................................... 44
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D Fuelling the Truck .................................................................... 45
1 General.................................................................................................... 45
1.1 Safety regulations for handling diesel fuel and LPG................................ 45
1.2 LPG system relief valve........................................................................... 47
2 Adding diesel ........................................................................................... 48
2.1 Fuelling .................................................................................................... 48
2.2 Fuelling with fuel containers .................................................................... 49
3 LPG containers........................................................................................ 50
3.1 LPG bottles.............................................................................................. 50
3.2 Liquid gas tank ........................................................................................ 53
4 Fuel level indicator................................................................................... 54
4.1 Display unit .............................................................................................. 54
E Operation ................................................................................. 55
1 Safety Regulations for the Operation of the Forklift Truck....................... 55
2 Displays and Controls.............................................................................. 57
2.1 Multi-task switch ...................................................................................... 57
2.2 SOLO-PILOT ........................................................................................... 59
2.3 MULTI-PILOT .......................................................................................... 60
2.4 Controls ................................................................................................... 61
2.5 Multifunction display ................................................................................ 63
2.6 Operation of the multifunction display ..................................................... 68
3 Dashboard ............................................................................................... 78
3.1 Without air conditioning system............................................................... 78
3.2 With air conditioning system.................................................................... 78
3.3 With automatic air conditioning................................................................ 79
4 Heater, fan, air conditioning system ........................................................ 80
4.1 Heater...................................................................................................... 80
4.2 Air conditioning system (o) ...................................................................... 80
5 Preparing the Truck for Operation ........................................................... 84
5.1 Checks and operations to be performed before starting daily operation . 84
5.2 Entry and exit .......................................................................................... 86
5.3 Setting up the operator position............................................................... 87
5.4 Seat Belt .................................................................................................. 93
6 Industrial Truck Operation ....................................................................... 94
6.1 Safety regulations for truck operation...................................................... 94
6.2 Preparing the truck for operation ............................................................. 96
6.3 Operational Checks ................................................................................. 99
6.4 Parking the truck securely ....................................................................... 100
6.5 Emergency Disconnect............................................................................ 102
6.6 Travel ...................................................................................................... 102
6.7 Steering ................................................................................................... 104
6.8 Brakes ..................................................................................................... 105
6.9 Adjusting the forks ................................................................................... 107
6.10 Replacing the forks.................................................................................. 108
6.11 Lifting, transporting and depositing loads ................................................ 109
6.12 Operating the lift mechanism and integrated attachments ...................... 111
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6.13 Safety instructions for operating additional attachments ......................... 116

6.14 Operating additional attachments for the SOLO-PILOT .......................... 119

6.15 Operating additional attachments for the Multi Pilot ................................ 120
6.16 Fitting additional attachments.................................................................. 122
7 Towing trailers ......................................................................................... 123
8 Optional equipment ................................................................................. 125
8.1 Sliding windows ....................................................................................... 125
8.2 Emergency Exit ....................................................................................... 126
8.3 Driver'S Seat Heater................................................................................ 126
8.4 Adjusting the Multifunction Display.......................................................... 127
8.5 Fire Extinguisher...................................................................................... 127
8.6 Rockinger Coupling with Hand Lever ...................................................... 128
9 Troubleshooting....................................................................................... 129
9.1 Automatic Emergency Brake ................................................................... 129
9.2 Troubleshooting....................................................................................... 131
9.3 Operating the truck without its own drive system .................................... 132
F Industrial Truck Maintenance................................................... 137

1 Operational Safety and Environmental Protection................................... 137
2 Maintenance Safety Regulations............................................................. 138
3 Servicing and Inspection ......................................................................... 143
4 Maintenance checklist ............................................................................. 144
4.1 Maintenance checklist DFG..................................................................... 144
4.2 Maintenance checklist TFG ..................................................................... 147
4.3 DFG/TFG Options Maintenance Checklist .............................................. 151
5 Lubricants and Lubrication Schedule ...................................................... 156
5.1 Handling consumables safely.................................................................. 156
5.2 Lubrication Schedule ............................................................................... 158
5.3 Consumables........................................................................................... 160
5.4 Coolant specification ............................................................................... 161
6 Maintenance and repairs ......................................................................... 162
6.1 Preparing the truck for maintenance and repairs .................................... 162
6.2 Opening the Service Panel...................................................................... 163
6.3 Tilting the Cab ......................................................................................... 163
6.4 Checking the wheel attachments............................................................. 167
6.5 Hydraulic system ..................................................................................... 168
6.6 Engine maintenance................................................................................ 171
6.7 Check the transmission oil level .............................................................. 177
6.8 Performing Other Maintenance Work ...................................................... 177
6.9 Closing the Motor Compartment.............................................................. 177
6.10 Checking electrical fuses......................................................................... 178
6.11 Starter battery.......................................................................................... 183
6.12 Exhaust system ....................................................................................... 184
6.13 Seat belt maintenance............................................................................. 189
6.14 Restoring the truck to service after maintenance and repairs ................. 190
7 Decommissioning the industrial truck ...................................................... 191
7.1 Prior to decommissioning ........................................................................ 192
7.2 During decommissioning ......................................................................... 192
7.3 Restoring the truck to service after decommissioning ............................. 193
8 Safety tests to be performed at intervals and after unusual incidents ..... 194
9 Final de-commissioning, disposal............................................................ 195
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10 Human vibration measurement ............................................................... 195

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10

A Correct Use and Application
1 General
The industrial truck described in the present operating instructions is designed for
lifting, lowering and transporting load units.
It must be used, operated and serviced in accordance with the present instructions.
Any other type of use is beyond the scope of application and can result in damage to
personnel, the industrial truck or property.
2 Correct application
NOTE
The maximum load and load distance are indicated on the load chart and must not be
exceeded.
The load must rest on the load handler or be lifted by an attachment approved by the
manufacturer.
The load must rest on the back of the fork carriage and centrally between the forks.
– Lifting and lowering of loads.

– Transporting lowered loads over short distances.
– Do not travel with a raised load (>30 cm).
– Do not carry or lift passengers.
– Do push or pull load units.
– Occasional towing of trailer loads.
– When towing trailer loads the load must be secured on the trailer.
– The permissible trailer load must not be exceeded.
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11

3 Approved application conditions
DANGER!
Do not exceed the permissible surface and spot load limits on the travel routes.
At blind spots get a second person to assist.
The driver must ensure that the loading dock / ramp cannot move or come loose
during loading / unloading.
– Operation in industrial and commercial environments.

– Permissible temperature range -20 to 40°C.
– Operation only on secure, level surfaces with sufficient capacity.
– Operation only on routes that are visible and approved by the proprietor.
– Negotiating inclines up to a maximum of 15 %.
– Do not negotiate inclines crosswise or at an angle. Transporting loads downhill.
– Operation in partially public traffic.
– The truck may only be operated in areas that are clean and free of oil and similar
substances.
WARNING!
Extreme conditions
XSpecial equipment and authorisation are required if the truck is to be constantly
used in extreme conditions, especially in dusty or corrosive atmospheres.
XThe truck is not authorised for use in areas at risk of explosion.
XIn adverse weather conditions (thunder, lightning) the industrial truck must not be
operated outside or in endangered areas.
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12

4 Proprietor responsibilities
For the purposes of the present operating instructions the “proprietor” 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.
The proprietor must ensure that the industrial truck is used only for the purpose for
which it is intended and that there is no danger to life and limb of the user and third
parties. Furthermore, accident prevention regulations, safety regulations and
operating, servicing and repair guidelines must be followed. The proprietor must
ensure that all users have read and understood these operating instructions.
NOTE
Failure to comply with the operating instructions shall invalidate the warranty. The
same applies if improper work is carried out on the truck by the customer or third
parties without the permission of the manufacturer.
5 Adding attachments and/or accessories

Adding accessories
The mounting or installation of additional equipment which affects or enhances the
performance of the forklift truck requires the written permission of the manufacturer.
Local authority approval may also need to be obtained.
Local authority approval does not however constitute the manufacturer’s approval.
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13

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14

B Truck Description
1 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.
Closed bottom pallets can also be lifted.

The DFG/TFG 660-690 is equipped with a hydrodynamic drive.
1.1 Truck models and rated capacity

The rated capacity depends on the model. The rated capacity can be derived from the
model description.
DFG660
DFG Model name
6 Series
60 Rated capacity x 100 kg
The rated capacity does not generally match the permissible capacity. The capacity
can be found on the load chart attached to the rack.
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15

2 Assemblies and Functional Description
2.1 Assembly Overview
1 2 3 4 5 6 7 8
14 13 12 11 10 9
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
7 o Beacon 14 t Fork tines
t = Standard equipment o = Optional equipment
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16

2.2 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. The vertical, free standing front exhaust pipe (8) is
positioned much higher than is common. It prevents vibrations and sound saves from
being transferred and exhaust gases from penetrating into the operator position.
Operator position
The operator position is articulating, which cushions vibrations and noise. Non-slip
steps and a handle on the cab post ensure easy entry and exit. The driver is protected
by the cab (5). To adapt the seat position, the driver can adjust the seat and steering
head both vertically and horizontally. The accelerator pedal and brake pedal are of
"automotive" design.
Steering
The steer cylinder of the hydrostatic steering is integrated in the steer axle (9) and is
controlled by the power steering. The steer axle is fully floating in the chassis to
ensure excellent grip even on non-level surfaces.
Wheels
All wheels are located within the truck geometry. A choice of pneumatic or
superelastic tyres are available.
Diesel engine
Quiet-running, water-cooled diesel engines featuring high performance and low
consumption with very clean fuel combustion under all operating conditions ensure
soot values are below the limit of visibility. An additional particle filter (o) ensures very
low exhaust levels.
LPG engine
Quiet running, water-cooled four-stroke engines featuring high performance and low
consumption. Petrol engines with very low residual exhaust levels are used. An
additional 3-way catalytic converter (o) ensures very low exhaust levels.
Electrical system
12 volt system with threephase alternator. A start block prevents malfunctions when
the truck is powered up. For diesel engines, a rapid pre-heat system is installed; LPG
motors have an electronic ignition system for rapid and trouble-free engine starting.
The key switch is used to stop the engine.
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17

Drive system
A power shift gear with radiator and torque converter is directly flanged to the engine.
This transfers the force to the drive axle (12).
The travel direction lever on the steering column, on the multi-task lever or on the
pedal controller (o) controls forward/reverse travel and the neutral position.
Brakes
The brake pedal activates the laminated brakes hydraulically. The parking brake is
switched on and off by pressing the parking brake button in the multifunction display.
It acts mechanically on the brake disc of the cardan shaft.
Hydraulic System
All operations can be performed sensitively, proportionally and simultaneously.
Hydraulic functions are controlled by a servo hydraulic controller. Control is possible
via single lever (SOLO-PILOT) or multi-task lever (MULTI-PILOT).
Mast
Two or three-stage masts, optionally with free lift function; narrow mast sections
ensure excellent visibility of the fork tines and attachments. Fork carriages and lift
frames run on lubricating support rollers.
Attachments
The trucks can be optionally fitted with mechanical and hydraulic attachments.
02.11 EN
18

3 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.).
Z Technical data specified in accordance with VDI 2198.

Technical modifications and additions reserved.
3.1 Performance data
DFG 660-690
Description 660 670 680 690
Q Capacity 1) 6000 7000 8000 9000 kg
C Load centre distance 600 600 600 600 mm
Travel speed* with /
22.4/22.5 22.4/22.6 22.4/22.5 22.4/22.6 km/h
without load
Lift speed with / without
0.50/0.60 0.40/0.60 0.40/0.60 0.40/0.60 m/s
load
Lowering speed with /
0.60/0.36 0.60/0.36 0.60/0.36 0.60/0.36 m/s
without load
Gradeability 2)
30.3/32.0 28.7/31.0 27.1/31.0 24.6/28.0 %
with / without load
Tow force
49.5/49.5 49.5/49.5 49.5/49.5 49.5/49.5 kN
with / without load
Acceleration* with /
6.0/5.0 6.0/5.0 6.0/5.0 7.0/6.0 s
without load to 15 m
Working pressure
160 160 160 160 bar
for attachments
Oil volume
80 80 80 80 l/min
for attachments
1) for vertical mast.
2) The values shown represent the maximum gradeability to overcome short
differences in height and surface unevenness (surface edges). The truck must not
operate on inclines of more than 15%.
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DFG S80-S90
Description S80 S90
Q Capacity 1) 8000 9000 kg
C Load centre distance 900 900 mm
22.3/22.6 22.3/22.6 km/h
without load
0.40/0.60 0.40/0.60 m/s
load
0.60/0.36 0.60/0.36 m/s
without load
Gradeability 2)
21.5/25.0 20.9/24.0 %
with / without load
Tow force
49.5/49.5 52.9/52.9 kN
with / without load
7.0/6.0 7.0/6.0 s
Working pressure
160 160 bar
for attachments
Oil volume
80 80 l/min
for attachments
02.11 EN
20

TFG 660-690
Q Capacity (1 6000 7000 8000 9000 kg
C Load centre distance 600 600 600 600 mm
22.4/22.6 22.4/22.6 22.4/22.6 22.4/22.6 km/h
without load
0.40/0.48 0.40/0.48 0.40/0.48 0.40/0.48 m/s
load
0.60/0.48 0.60/0.36 0.60/0.36 0.60/0.36 m/s
without load
Gradeability (2
27.5/30.0 27.5/30.0 26.5/30.0 23.0/27.0 %
with / without load
Tow force
45.6/45.6 45.6/45.6 45.6/45.6 45.6/45.6 kN
with / without load
6.0/5.0 6.0/5.0 6.0/5.0 7.0/6.0 s
Working pressure
160 160 160 160 bar
for attachments
Oil volume
80 80 80 80 l/min
for attachments
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21

TFG S80-S90
Description S80 S90
Q Capacity 8000 9000 kg
C Load centre distance 900 900 mm
22.4/22.6 22.4/22.6 km/h
without load
0.40/0.48 0.40/0.48 m/s
load
0.60/0.36 0.60/0.36 m/s
without load
Gradeability*
20.2/23.0 17.6/20.0 %
with / without load
Tow force
45.6/45.6 45.6/45.6 kN
with / without load
7.0/6.0 7.0/6.0 s
Working pressure
160 160 bar
for attachments
Oil volume
80 80 l/min
for attachments
02.11 EN
22

3.2 Dimensions
DFG 660-690
a/2 Safety distance 100 100 100 100 mm
h1 Mast height retracted* 2710 2710 3010 3160 mm
h3 Lift* 3600 3600 3600 3600 mm
h4 Mast height extended* 4510 4510 4810 4960 mm
h6 Overhead guard 2705 2705 2705 2705 mm
height*
h7 Seat height* 1600 1600 1600 1600 mm
h10 Coupling height 500 500 500 500 mm
Į Mast tilt, forward* 6 6 6 6 °
ȕ Mast tilt, back* 9 9 9 9 °
l1 Length, including 4760 4770 4880 5035 mm
forks*
l2 Length, including fork 3560 3570 3680 3835 mm
shank*
b1 Overall width* 1820 1820 2002 2002 mm
s/e/l Fork dimensions* 50/150/ 60/150/ 60/150/ 65/150/ mm
1200 1200 1200 1200
m1 Floor clearance with 250 250 250 250 mm
load below mast*
m2 Floor clearance centre 250 250 250 250 mm
wheel base*
Fork carriage ISO 4A 4A 4A 4A mm
2328 class / type A, B
b3 Fork carriage width 1800 1800 2000 2000 mm
Ast Working aisle width for 5320 5330 5440 5745 mm
pallets 800 x 1200
longit.
pallets 1000 x 1200
traverse
Wa Turning radius 3250 3250 3350 3650 mm
b13 Smallest turning 1270 1270 1320 1390 mm
radius
x Load distance* 670 680 690 695 mm
c Load centre of gravity 600 600 600 600 mm
y Wheel base 2295 2295 2395 2545 mm
*) The data listed in the table corresponds to the standard version.

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23

DFG S80-S90
Description S80 S90
a/2 Safety distance 100 100 mm
h1 Mast height retracted* 3160 3310 mm
h3 Lift* 3600 3600 mm
h4 Mast height extended* 4960 5110 mm
h6 Overhead guard 2705 2705 mm
height*
h7 Seat height* 1600 1600 mm
h10 Coupling height 500 500 mm
Į Mast tilt, forward* 6 6 °
ȕ Mast tilt, back* 9 9 °
l1 Length, including 5640 5840 mm
forks*
l2 Length, including fork 3840 4040 mm
shank*
b1 Overall width* 2150 2150 mm
s/e/l Fork dimensions* 70/180/ 70/180/ mm
1800 1800
m1 Floor clearance with 250 250 mm
load below mast*
m2 Floor clearance centre 250 250 mm
wheel base*
Fork carriage ISO 4A 4A mm
b3 Fork carriage width 2100 2100 mm
Ast Working aisle width for 5745 5995 mm
pallets 800 x 1200
longit.
pallets 1000 x 1200
traverse
Wa Turning radius 3900 3900 mm
b13 Smallest turning 1490 1490 mm
radius
x Load distance* 700 700 mm
c Load centre of gravity 900 900 mm
y Wheel base 2545 2745 mm
TFG 660-690
02.11 EN
a/2 Safety distance 100 100 100 100 mm

h1 Mast height retracted* 2710 2710 3010 3160 mm
24

TFG 660-690
h3 Lift* 3600 3600 3600 3600 mm
h4 Mast height extended* 4510 4510 4810 4960 mm
h6 Overhead guard 2705 2705 2705 2705 mm
height*
h7 Seat height* 1600 1600 1600 1600 mm
h10 Coupling height 500 500 500 500 mm
Į Mast tilt, forward* 6 6 6 6 °
ȕ Mast tilt, back* 9 9 9 9 °
l1 Length, including 4860 4870 4980 5135 mm
forks*
l2 Length, including fork 3660 3670 3780 3935 mm
shank*
b1 Overall width* 1820 1820 2002 2002 mm
s/e/l Fork dimensions* 50/150/ 60/150/ 60/150/ 65/150/ mm
1200 1200 1200 1200
m1 Floor clearance with 250 250 250 250 mm
load below mast*
m2 Floor clearance centre 250 250 250 250 mm
wheel base*
Fork carriage ISO 4A 4A 4A 4A mm
b3 Fork carriage width 1800 1800 2000 2000 mm
pallets 800 x 1200
longit.
pallets 1000 x 1200
traverse
Wa Turning radius 3350 3350 3550 3800 mm
b13 Smallest turning 1320 1320 1370 1440 mm
radius
x Load distance* 670 680 690 695 mm
c Load centre of gravity 600 600 600 600 mm
y Wheel base 2395 2395 2495 2645 mm
TFG S80-S90
Description S80 S90
a/2 Safety distance 100 100 mm
h1 Mast height retracted* 3160 3310 mm
h3 Lift* 3600 3600 mm
02.11 EN
h4 Mast height extended* 4960 5110 mm
25

TFG S80-S90
Description S80 S90
h6 Overhead guard 2705 2720 mm
height*
h7 Seat height* 1600 1600 mm
h10 Coupling height 500 500 mm
Į Mast tilt, forward* 6 6 °
ȕ Mast tilt, back* 9 9 °
l1 Length, including 5740 5740 mm
forks*
l2 Length, including fork 3940 3940 mm
shank*
b1 Overall width* 2150 2150 mm
s/e/l Fork dimensions* 70/180/ 70/180/ mm
1800 1800
m1 Floor clearance with 250 250 mm
load below mast*
m2 Floor clearance centre 250 250 mm
wheel base*
Fork carriage ISO 4A 4A mm
b3 Fork carriage width 2100 2100 mm
pallets 800 x 1200
longit.
pallets 1000 x 1200
traverse
Wa Turning radius 3800 3800 mm
b13 Smallest turning 1440 1440 mm
radius
x Load distance* 700 700 mm
c Load centre of gravity 900 900 mm
y Wheel base 2645 2645 mm
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26

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27

3.3 Weights
Z All dimensions in kg.
DFG 660-690
660 670 680 690
Net weight* 10500 10800 11700 12500
Axle load w.o. load front / 5500/5000 5500/5300 6000/5700 6000/6500
rear*
Axle load with load front / 14900/1600 16000/1800 17700/2000 19000/2500
rear*
DFG S80-S90
S80 S90
Net weight* 14400 15500
Axle load w.o. load front / 7400/7000 8200/7300
rear*
Axle load with load front / 20400/2000 22500/2000
rear*
TFG 660-690
660 670 680 690
Net weight* 10970 10970 11900 13000
Axle load w.o. load front / 5610/5360 5610/5360 5900/6000 6000/7000
rear*
Axle load with load front / 14810/2160 16350/1620 17900/2000 19500/2500
rear*
TFG S80-S90
S80 S90
Net weight* 14600 15000
Axle load w.o. load front / 7000/7600 7200/7800
rear*
Axle load with load front / 20100/2500 22000/2000
rear*

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28

3.4 Mast versions
Z All dimensions in mm
DFG/TFG 660-680
Mast table
VDI 3596 Lift h3 Free lift Retracted height h1 Extended height h4
Description h2
660/670 680 660/670 680
3600 0 2710 3010 4510 4810
4000 0 2910 3210 4910 5210
4500 0 3160 3460 5410 5710
ZT 5000 0 3410 3710 5910 6210
5500 0 3660 3960 6410 6710
6000 0 3910 4210 6910 7210
6500 0 4160 4460 7410 7710
3600 1800 2875 3025 4675 4825
4000 2000 3075 3225 5075 5225
4500 2250 3325 3475 5675 5725
ZZ 5000 2500 3575 3725 6075 6225
5500 2750 3825 3975 6575 6725
6000 3000 4075 4225 7075 7225
6500 3300 4325 4475 7575 7725
4500 1500 - 2735 - 5736
5000 1667 2752 2902 6086 6236
5500 1833 2918 3068 6586 6736
6000 2000 3085 3235 7086 7236
DZ
6500 2167 3252 3402 7586 7736
7000 2333 3418 3568 8086 8236
7500 2500 3585 3735 8586 8736
8000 2667 3752 3902 9086 9236
Special trucks are not included in this overview.

02.11 EN
29

DFG/TFG 690-S90
Mast table
VDI 3596 Lift h3 Free lift Retracted height h1 Extended height h4
Description h2
690-S80 S90 690-S80 S90
3600 0 3160 3310 4960 5110
4000 0 3360 3510 5360 5510
4500 0 3610 3760 5860 6010
ZT 5000 0 3860 4010 6360 6510
5500 0 4110 4260 6860 7010
6000 0 4360 4510 7360 7510
6500 0 4610 4760 7860 8010
3600 1800 3175 3325 4975 5125
4000 2000 3375 3525 5375 5525
4500 2250 3625 3775 5875 6025
ZZ 5000 2500 3875 4025 6375 6525
5500 2750 4125 4275 6875 7025
6000 3000 4375 4525 7375 7525
6500 3300 4625 4775 7875 8025
4500 1500 2885 3035 5886 6036
5000 1667 3052 3202 6386 6536
5500 1833 3218 3368 6886 7036
6000 2000 3385 3535 7386 7536
DZ
6500 2167 3552 3702 7886 8036
7000 2333 3718 3868 8386 8536
7500 2500 3885 4035 8886 9036
8000 2667 4052 4202 9386 9536
Special trucks are not included in this overview.
02.11 EN
30

3.5 Tyre type
NOTE
When replacing tyres/rims fitted at the factory, always use original spare parts or tyres
approved by the manufacturer. Otherwise the manufacturer's specification cannot be
guaranteed.
If you have any queries please contact the manufacturer's customer service
department.
DFG/TFG 660-690
Description DFG/TFG
660 670 680 690
SE* 355/65 - 15 355/65 - 15 8.25 - 15 8.25 - 15
355/65 - 15 355/65 - 15 8.25 - 15 8.25 - 15
Front Pneumatic*
18 PR 18 PR 18 PR 18 PR
tyres
Tyre pressure bar 10 10 10 10
Torque Nm 450 450 450 450
SE* 8.25 - 15 8.25 - 15 8.25 - 15 300 - 15
8.25 - 15 8.25 - 15 8.25 - 15 300 - 15 18
Rear Pneumatic*
18 PR 18 PR 18 PR PR
tyres
Tyre pressure bar 10 10 10 10
Torque Nm 290 290 290 450
DFG/TFG S80-S90
Description DFG/TFG
S80 S90
SE* 300 - 15 300 - 15
300 - 15 300 - 15
Front Pneumatic*
18 PR 18 PR
tyres
Tyre pressure bar 10 10
Torque Nm 450 450
SE* 300 - 15 300 - 15
300 - 15 300 - 15
Pneumatic*
Rear 18 PR 18 PR
tyres Tyre pressure bar 10 10
290
Torque Nm 450
DFG 450
*) The models listed in the table correspond to the standard version. Other tyres can
be used depending on the truck's equipment.
02.11 EN
31

3.6 Engine Data
DFG 660-680
Description DFG 660 DFG 670 DFG 680
Cylinders/cubic capacity 4/4400 4/4400 4/4400 cm³
Rated speed (without load) 2200 2200 2200 rpm
Idle speed 850 850 850 rpm
Motor output 91 91 91 kW
Fuel consumption 7.9 8.3 8.7 l/h [kg/h]
60 VDI duty cycles/h
DFG 690-S90
Description DFG 690 DFG S80 DFG S90
Fuel consumption 9 9 10.5 l/h [kg/h]
TFG 660-680
Description TFG 660 TFG 670 TFG 680
TFG 690-S90
Description TFG 690 TFG S80 TFG S90
02.11 EN
32

3.7 EN norms
Noise emission level
– DFG 660-690, S80: 78 dB (A)*

– DFG S90: 70 dB (A)*
– TFG: 78 dB(A)*
*+/- 4 dB(A) depending on the truck's equipment
in accordance with EN 12053 as harmonised with ISO 4871.
Z The noise emission level is calculated in accordance with standard procedures and
takes into account the noise level when travelling, lifting and when idle. The noise
level is measured at the level of the driver's ear.
Vibration
in accordance with EN 13059.

Z The vibration acceleration acting on the body in the operating position is, in
accordance with standard procedures, the linearly integrated, weighted
acceleration in the vertical direction. It is calculated when travelling over bumps at
constant speed. These recordings were taken on a single occasion and must not be
confused with the human vibrations of the "2002/44/EC/Vibrations" operator
directive. The manufacturer offers a special service to measure these human
vibrations, (see "Human vibration measurement" on page 195).
Whole-body vibration
Motor type Vibration awz Uncertainty
2
TFG 1.5 m/s 0.2 m/s2
DFG S90 0.9 m/s2 0.1 m/s2
DFG 660-690, S80 0.7 m/s2 0.2 m/s2
Hand/arm vibration
Vibration <2.5 m/s2
Z The vibration that is characteristic for vibrations of the body cannot be used to
determine the actual load caused by vibrations during operation. That depends on
the operating conditions (condition of the travel routes, method of operation, etc.)
and should therefore be determined on site at a suitable location. Hand/arm
vibration must always be determined without exception, even if the values do not
indicate any hazard at all, as in this case.
02.11 EN
33

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.
Z No changes to electric or electronic components or their arrangement may be made

without the written agreement of the manufacturer.
WARNING!
Medical equipment can be damaged by non-ionised radiation
Electrical equipment on the truck emitting non-ionised radiation (e.g. wireless data
transmission) can affect operators' medical equipment (pacemakers, hearing aids
etc.) and result in malfunctions. Consult with a doctor or the medical equipment
manufacturer to clarify whether it can be used near the industrial truck.
02.11 EN
34

3.8 Conditions of use
Ambient temperature
– operating at -20 to 40°C
Z Special equipment and authorisation are required if the truck is to be constantly
used in conditions of extreme temperature or air humidity fluctuations.
3.9 Electrical requirements

The manufacturer certifies compliance with the requirements for the design and
manufacture of electrical equipment, according to EN 1175 "Industrial Truck Safety -
Electrical Requirements", provided the truck is used according to its purpose.
02.11 EN
35

4 Identification points and data plates
Z Warnings and notices such as capacity charts, strap points and data plates must be
legible at all times. Replace if necessary.
15 16 17 18 19 20 21 22
23
H mm L6
Q
XXX
XXX
mm XXX
24
L6
Q kg
25
XXXX XXXX XXXX XXXX
XXXX XXXX XXXX XXXX
XXXX XXXX XXXX XXXX
XXXX XXXX XXXX XXXX
XXXX XXXX XXXX XXXX
26
27
17
02.11 EN
36

Item Description
15 Do not stand on load handler / Do not stand under load handler / Risk of
trapping when mast extended
16 Tipover caution, no passengers
17 Attachment points for loading by crane (o)
18 Read operating instructions
19 Putting on the seat belt
20 Hot surface warning
21 Turn the exhaust pipe back before tilting the cab
22 Do not drive or tilt the mast forward with a load raised
23 Test plaque (o)
24 Jack attachment point
25 Capacity plate
26 Fuel
27 Truck data plate
02.11 EN
37

4.1 Data plate
28 29 30 31
32
33
34
35
36
37
Item Description Item Description

28 Type 33 Year of manufacture
29 Serial number 34 Load centre (mm)
30 Rated capacity (kg) 31 Output
31 Output 36 Manufacturer
35 Net weight in kg 37 Manufacturer’s logo
32 Option
Z For queries regarding the truck or ordering spare parts always quote the truck serial
number (29).
02.11 EN
38

4.2 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.
XWhen replacing the forks you must attach an additional capacity plate to the truck.
XTrucks supplied without forks are given a capacity plate for standard forks (length:
1150 mm).
The capacity plate (25) gives the capacity (Q in kg) of the truck for a vertical mast. The
maximum capacity is shown as a table with a given load centre of gravity D (in mm)
and the required lift height H (in mm).
The capacity plate (25) of the truck indicates the truck's capacity with the forks as
originally supplied.
Example of how to calculate the maximum capacity:
With a load centre distance D of 700 mm and a maximum lift height h3 of 5000 mm.
the max. capacity Q is 6940 kg.
25
6000 6960 6460 5660

5000 7470 6940 6080
4000 8340 7740 6770
600 700 900
Lift height restriction

The arrow shape markings (38 and 39)
38 39
on the inner and outer masts show the
driver when the prescribed lift limits
have been reached.
02.11 EN
39

4.3 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.
Z For loads with a centre of gravity above 600 mm upward, the capacities are reduced
by the difference of the altered centre of gravity.
4.4 Jack attachment point
The "Jack contact point" decal (24) indicates 24

where the truck may be lifted and jacked up.
5 Stability
The truck's stability has been tested according to latest technological standards.
These take into account the dynamic and static tipover forces that can occur if used
correctly.
Stability can also be affected by the following factors:
– Tyre type
– Mast
– Attachment
– Transported load (size, weight and centre of gravity)
WARNING!
Loss of stability can cause accidents

Changing the components can alter the stability.
02.11 EN
40

C Transport and Commissioning
1 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.
2 Truck laden
2.1 Centre of gravity of the truck
WARNING!
Altering the centre of gravity can be hazardous
The overall centre of gravity can vary depending on the truck's equipment (especially
the mast version).
XFor masts with a low height the centre of gravity will move towards the
counterweight.
XFor masts with a greater height the centre of gravity will move towards the centre of
the truck.
The picture shows the approximate centre of

gravity location.
02.11 EN
41

2.2 Lifting the truck by crane
CAUTION!
The mast can get damaged

XLoading by crane is only intended for the initial transport before the truck is used for
the first time.
XLoading 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

XOnly use crane lifting gear with sufficient capacity.
XLoading weight = Net weight of truck (+ battery weight for electric trucks).
XThe mast must be tilted back fully.
XThe crane lifting gear on the mast must have a minimum clear length of 2 m.
XCrane slings should be fastened in such a way that they do not come into contact
with any attachments or the overhead guard when lifting.
XDo not stand under a swaying load.
Z Truck net weight: (see "Data plate" on page 38).
Lifting the truck by crane

40
Requirements
– Park the truck securely, (see "Parking the
truck securely" on page 100).
Procedure
• Secure the crane slings to the attachment
points (40) and (41.
• Raise and load the truck. 41
• Lower and deposit the truck carefully ((see
"Parking the truck securely" on page 100)).
• Secure the truck with wedges to prevent it
from rolling away.
This concludes the loading by crane.
2.3 Loading with another industrial truck
DANGER!
Slipping can cause accidents
XDo not use another Industrial truck to load the truck!
02.11 EN
42

3 Securing the truck during transport
WARNING!
Accidental movement during transport

Improper fastening of the truck and mast during transport can result in serious
accidents.
XLoading 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.
XThe truck must be securely fastened when transported on a lorry or a trailer.
XThe loading area must have clamp rings and a wooden floor to secure the retaining
wedges.
XUse wedges to prevent the truck from moving.
XUse only tensioning belts or tie-down straps or with sufficient strength.
Securing with a mast Securing without a mast
40
41 42
43
43 43 43
Securing the truck for transport

Requirements
– Position the truck securely on a lorry or trailer, (see "Parking the truck securely" on
page 100).
Tools and Material Required

– 2 tensioning belts with tensioner
– Retaining wedges.
Procedure
• Secure the truck with the tensioning belt (43) at the top cross member of the mast
(40) and the trailer coupling (41) or over the front axle cross member (42) and the
trailer coupling (41).
• Tighten the tensioning belts (43) with the tensioner.
The truck is now secured for transport.
02.11 EN
43

4 Using the Truck for the First Time
Safety Instructions for Assembly and Commissioning
WARNING!
Accident risk from incorrect assembly
The assembly of the truck at the application site, commissioning and driver training
must only be performed by the manufacturer's customer service representatives who
have been specially trained for these tasks.
XThe hydraulic lines may only be connected to the basic truck / mast interface when
the mast has been properly assembled.
XOnly then can the truck be started.
XIf several trucks have been delivered, make sure that the serial numbers of the load
handlers, masts and basic trucks always match.
Preparing the truck for operation after delivery or transport

Procedure
• Check the equipment is complete.
• Check the engine oil level.
• Check the hydraulic oil level. Check the transmission oil level (only on trucks with
hydrodynamic drives).
• Check the brake fluid level (only on trucks with hydrodynamic drives).
• Test the battery connections.
• Check the battery acid level (not for maintenance-free batteries).
The truck can now be started, (see "Preparing the Truck for Operation" on page 84).
02.11 EN
44

D Fuelling the Truck
1 General
1.1 Safety regulations for handling diesel fuel and LPG
WARNING!
An unsecured industrial truck can cause accidents

The truck can suddenly start to move.
XBefore filling up or replacing the LPG bottle, park the truck securely, (see "Parking
the truck securely" on page 100)
WARNING!
Accident risk from ignition
XFuels and liquefied petroleum gas can ignite.
XSmoking, naked flames and other ignition sources are strictly prohibited in the
immediate vicinity when handling fuels and LPG.
XLabels indicating the hazard are must be positioned where they are clearly visible.
XDo not store flammable materials in this area.
XPowder fire extinguisher must be provided within easy reach of the filling area.
XUse only category A, B or C type powder fire extinguishers to fight LPG fires.
XBring any unsealed LPG bottles immediately outside, attach visible markings and
notify the supplier.
Storage and Transport

The diesel and LPG storage and transport devices must comply with statutory
requirements.
If there is no filling point available, the fuel must be stored and transported in clean,
approved containers.
The contents must be clearly indicated on the container.

02.11 EN
45

NOTE
Fuel can cause environmental damage

XBind any spilled diesel fuel with suitable methods.
XThen 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.
CAUTION!
Liquid gas can cause frostbite

XLiquid gas produces frostbite when it comes into contact with bare skin.
XAvoid direct contact with the skin.
XWear gloves.
Filling up LPG containers

LPG containers remain attached to the truck and are filled up at LPG stations. Always
follow the instructions of the tank system and LPG container manufacturer as well as
statutory and local regulations when filling up.
NOTE
Instructions for the safe operation of LPG systems
XAll maintenance and repair work on LPG systems and containers should be carried
out by qualified personnel who have been trained to work on LPG systems.
XThe owner must comply with all legal requirements, technical standards and health
and safety regulations applicable to liquid gas.
XBefore starting work, the driver must check that all accessible components of the
LPG system are in good working order, in accordance with the regulations of the
country of use.
XDo not operate the truck if there is any damage, corrosion, wear or degradation to
individual components of the LPG system. 02.11 EN
46

1.2 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. The relief valve is
fitted with a plastic cover (44).
– When the valve is activated the plastic
cover comes off, thereby clearly
indicating a fault in the gas system.
– In this event the truck must not be
operated.
– The gas system must be check by
suitably qualified and trained 44
personnel.
– The user must check that the plastic cover is present each time he uses the truck.
– Models with a liquid gas tank have the

relief valve (46) in the drive
compartment. The relief valve is fitted
with a hose (45) that diverts the LPG if
the relief valve is opened.
– When the valve is activated the plastic
cover comes off, thereby clearly
indicating a fault in the gas system.
– In this event the truck must not be
operated.
– The gas system must be check by
suitably qualified and trained
personnel. 46 45
– The user must check that the plastic
cover is present each time he uses the
truck.
DANGER!
Danger from escaping liquid gas.
Liquid gas can escape from faulty gas hoses.
XUse only gas bottles with an integrated line break safety valve.
XThe gas bottle connection is also fitted with a line break safety valve which prevents
the gas from escaping accidentally during operation.
XWhen replacing, always use a gas bottle connection with an integrated line break
safety valve.
02.11 EN
47

2 Adding diesel
CAUTION!
Air in the fuel system will result in malfunctions.

XNever allow the fuel tank to run dry.
2.1 Fuelling
WARNING!
Diesel fuel can be hazardous

XDiesel fuel can cause irritation if it comes into contact with the skin. Rinse any
affected areas thoroughly.
XIf it comes into contact with the eyes rinse them immediately with flowing water and
call for a doctor.
XWear safety gloves when handling diesel fuels.
NOTE
Fuelling must always be performed in designated areas by trained and authorised

personnel.
NOTE
XCapacity: DFG 660-690 = 125 l.
XUse only diesel in accordance with DIN 590 or DIN 51628 with a cetane rating
above 51.
2.1.1 Fuelling the tank system

Procedure
• Park the truck securely before fuelling,
(see "Parking the truck securely" on
page 100)
• Unscrew the tank cap (47).
• Insert the tap into the open tank filler
neck.
• Add the fuel.
• Do not overfill the tank.
• Tighten the cap (47) back on after
fuelling. 47
Fuelling is now complete.
02.11 EN
48

The fuel gauge (48) indicates the fuel level. 48
NOTE
XNever allow the fuel tank to run dry. Air

in the fuel system will result in
malfunctions.
2.2 Fuelling with fuel containers
Procedure
• Unscrew the tank cap (47) and open the
fuel container.
• Fit the outlet pipe onto the fuel
container.
• Insert the outlet pipe into the open tank
filler neck.
• Make sure the fuel container and outlet
pipe are connected tightly to each other.
• Raise the fuel container carefully and
slowly add the diesel.
• Do not overfill the tank.
• Tighten the cap (47) back on after 47
fuelling.
Fuelling is now complete.
02.11 EN
49

3 LPG containers
Z Only use liquid gas that complies with DIN 51622 or comparable national
regulations.
3.1 LPG bottles
DANGER!
Risk of explosion
XThe LPG bottle must only be replaced at designated areas by trained and
authorised personnel.
CAUTION!
Using unsuitable LPG bottles can cause accidents.
XUse only approved LPG bottles.
XThe LPG bottle must always rest on an engaged bottle holder so that the hose
connection of the shutoff valve is facing vertically down.
XFor bottle types of other countries note the national regulations.
XNote the indications and markings on the LPG bottle.
3.1.1 Using an LPG bottle
Replace the LPG bottle

Procedure
• Park the truck securely before replacing
the LPG bottle, (see "Parking the truck
securely" on page 100)
• Close the shut-off valves (49) securely.
• Start the motor and allow the LPG system
to run empty in neutral.
49
02.11 EN
50

Remove the LPG bottle
50
CAUTION!
The connection has a left thread
Procedure
• The LPG bottle console is released with
the finger screw (50).
• Unfold the console (51) as far as the stop.
• Unscrew the union nut (53).
• Remove the hose (45) and immediately
screw the valve cap onto the empty LPG
bottle.
• Loosen the toggle-type fastener with the
handle (52).
• Carefully remove the LPG bottle from the
bracket and place it down securely.
51
Inserting a new LPG bottle
Procedure
• Insert the LPG bottle into the bracket
• Align the hose connection downwards.
• Clamp the toggle-type fastener with the
handle (52).
• Unscrew the valve cap.
• Fit the hose (45) in accordance with
instructions. 49 53 45 49 53 52
• Carefully open the shut-off valve (49).
• Check the hose connection for leaks using
a foam-forming agent.
The replacement is now complete.
02.11 EN
51

3.1.2 Operating the twin bottle system and liquid gas tank
Tank A Tank B
Note the following when switching the LPG
gas supply:
– The switch (54) controls the release of the

LPG bottle or liquid gas tank.
– Open the shut-off valves (49) of both LPG
bottles by turning anticlockwise.
– Enable LPG bottle A or B with the middle
position (tank A) or the lower position
(tank B) of the switch (54). 49
– The upper position of the switch (54)
disables both LPG bottles and opens the
liquid gas tank.
S12 S13 S15
S7 S8 S24
X28
S20 S26 S30

S4 S5 S6
XR9
S20 S26 S30
54
02.11 EN
52

3.2 Liquid gas tank
The filling valve (55) is located on the left side of the truck.
Filling refillable liquid gas tanks
DANGER!
Risk of explosion 47
XFuelling must always be performed in
designated areas by trained and
authorised personnel.
Requirements
– Park the truck securely ((see "Parking the
truck securely" on page 100)).
– Note all guidelines and regulations
concerning the filling of LPG bottles on the
LPG pump.
Procedure
• Unscrew the tank cap (47). 55
• Lock the filling adapter of the tank system in
place on the filling valve (55).
• Enabling filling on the tank system
Z The integrated filling stop valve prevents the
tank from overfilling.
• When the filling process is complete,
release the filling adapter of the filling system from the filling valve (55).
• Screw on the tank cap (47).
Z The level of the tank is shown by the fuel indicator.
02.11 EN
53

4 Fuel level indicator
4.1 Display unit
The level indicator (48) shows the capacity 48

of the tank.
02.11 EN
54

E Operation
1 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.
Driver’s rights, obligations and responsibilities

The driver must be informed of his duties and responsibilities and be instructed in the
operation of the truck and shall be familiar with the operating instructions. The driver
shall be afforded all due rights. Safety shoes must be worn for pedestrian operated
trucks.
Unauthorised use of truck
The driver is responsible for the truck during the time it is in use. The driver must
prevent unauthorised persons from driving or operating the truck. Do not carry
passengers or lift other people.
Damage and faults
The supervisor must be immediately informed of any damage or faults to the truck or
attachment. Trucks which are unsafe for operation (e.g. wheel or brake problems)
must not be used until they have been rectified.
Repairs
The driver must not carry out any repairs or alterations to the truck without the
necessary training and authorisation to do so. The driver must never disable or adjust
safety mechanisms or switches.
02.11 EN
55

Hazardous area
WARNING!
Risk of accidents / injury in the hazardous area of the 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. forks or attachments) or the load
itself. This also includes areas which can be reached by falling loads or lowering
operating equipment.
XInstruct unauthorised people to leave the hazardous area.
XGive a warning signal with plenty of time for people to leave.
XIf unauthorised personnel are still within the hazardous area stop the truck
immediately.
DANGER!
Accident risk
XThe driver must remain within the protected area of the overhead guard while the
truck is being operated.
Safety devices and warning labels

Safety devices, warning signs ((see "Identification points and data plates" on
page 36)) and warning instructions in the present operating instructions must be
strictly observed.
02.11 EN
56

2 Displays and Controls
2.1 Multi-task switch
56 57
Einzelpedalsteuerung
59 58
Item Control / Function

display
56 Multi-task switch t
– Travel function switch – Adjusts automatic aisle switching
– Travel direction – Selects travel direction / neutral position
switch
02.11 EN
57

display
57 Multi-task switch t
– Travel direction – Switches the travel direction indicator on
display and off
– Dipped lights/main – Switch spot lights from dipped lights to
beam main beam
– Wiper – Switches the window wiper on and off
– Switches interval speed on and off
– Window washer – Switches window washer system on and
system off
– Horn – Activates an audible warning
59 Brake pedal t Upon activation, the truck brakes to a
standstill immediately.
58 Accelerator pedal t Infinitely variable travel speed control.
02.11 EN
58

2.2 SOLO-PILOT
60 61 62 63 64
A
B

display
60 Lever t Raise / lower load lifting
61 Lever t Mast forward / reverse tilt
62 Auxiliary hydraulics lever o Activate 1st attachment
1
63 Auxiliary hydraulics lever o Activate 2nd attachment
2
64 Auxiliary hydraulics lever o Activate 3rd attachment
3
02.11 EN
59

2.3 MULTI-PILOT
F
60
L R
65
62
B
63
64

display
60 MULTI-PILOT (F+B) t Raise / lower load lifting
MULTI-PILOT (L+R) Mast forward / reverse tilt
65 Travel direction switch o Selects travel direction / neutral position
62 Auxiliary hydraulics 1 o Activate 1st attachment
switch
63 Auxiliary hydraulics 2 o Activate 2nd attachment
switch
64 Auxiliary hydraulics 3 o Activate 3rd attachment
switch
02.11 EN
60

2.4 Controls
66 67
68
70 69

display
66 Battery indicator lamp t Lit to indicate errors in the power supply
67 Main beam indicator t Lit when the main beam is switched on
lamp
68 Key switch t Switches the power supply on and off
Starts and stops the engine
69 Interior lighting switch t Switches the interior lighting on and off
70 Hazard warning lights t Flashes when the hazard warning lights are
indicator lamp activated
02.11 EN
61

2.4.1 Switch variants
Symbol Switch/display Function

Switch t Switches the rear work lights on and
Rear work lights off
t Switches the front work lights on and

Switch off.
Front work lights
t Switches the rear window wiper on

Switch and off
Rear window wiper
Air conditioning system o Switches the air conditioning system

switch on and off
Fan 1 switch t Switches the cab fan on and off
Switch o Switches the beacon on and off

Beacon
Switch t Switches warning indicator lights on

Warning indicator and off
02.11 EN
62

2.5 Multifunction display
71 72 73 74 48
75
76
78 77

display
48 Level indicator t Remaining fuel quantity
71 Motor speed t Current speed of the motor
72 Speed t Current speed
73 Warning indicator t Current warnings (variable)
74 Temperature display t Current motor temperature
75 Parking brake display t Position of the parking brake
76 Menu t Access to the configuration menu
77 Gear lever display t Current travel stage
78 Clock t Shows the time and date
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2.5.1 Warnings
This field (79) shows information related to operation.
79
Symbol Display
Motor is switched off automatically
Motor is switched off automatically
Motor is preheated
Switch all travel direction switches to neutral position immediately
No driver in the truck
Service interval has expired

Contact Customer Service
Flashes to indicate an error in the brake system. Park the truck

securely.
Contact the manufacturer's customer service department
Information from the transmission controller:
Incorrect driving behaviour recorded
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Symbol Display
Emergency mode activated
Swivel seat (o)

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2.5.2 Warning indicators

Display o Hydraulic oil level too low
Hydraulic oil
Display t Transmission oil temperature too high

Transmission Park the truck immediately
flashing
Display t Engine oil pressure too low
Engine oil flashing Motor switches off.
Flashing with "Stop"
Display t Exhaust gas pressure too high
Exhaust gas Clean particle filter
pressure
Display t No brake pressure present
Brake pressure
Display t Clean air filter

Air filter
Display t Error in the main control unit (CVC)

Main control unit
Display t Error in the transmission controller

Transmission
Display o Hydraulic oil temperature too low (below

Hydraulic oil flashing +5° C)
Hydraulic oil temperature too high (above
+85° C)
Park the truck immediately
Display t Motor has an error
Motor
Display t Control valve has an error

Pilot valve
Preheat display t Motor is preheated
"Stop" display t Motor is switched off automatically

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Display t Air filter must be cleaned immediately
Intake temperature Park the truck immediately
flashing
Display t MULTI-PILOT has an error
MULTI-PILOT
Display t Motor temperature too high.

Motor temperature Motor switches off
flashing
Flashing with "Stop"
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2.6 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 (80). The
function keys (lower row) are lit. Areas inside borders in the display are directly
assigned to these via function keys. Press the "ESC" key to exit the current menu
item. Press the "Enter" key to go one step back.
80
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Press the "F4" key to go to the "SETUP" (81) and "Diagnostics" (82) areas.
81
82
Setup Diagnostic
Press the "F4" key (SETUP) to open the adjustment range for the display.
Setup
Disp Setup Diagn

setting ostic
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It is also optionally possible to adjust travel stages here (single pedal drive)
Setup
Disp SPD SPD Setup Diagn

setting ON Level
ostic
Press the "F1" key to open the adjustment range for the standard values of the truck.
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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.
• Make the settings.
• Press the "ESC" button to exit the current menu range.
• Press the "F3" button to open further setting options (example 2).
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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.
• Press the "F5" button to change to the next adjustment range.
• Press the "ESC" button to exit the current menu range.
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Adjustment options
83 84
71 85
72 86
87
88 89
90 91
71 Motor speed (t)

72 Speed display (t)
83 Transmission status (t)
84 Weigher system (o)
85 Hydraulic oil reservoir capacity (o)
86 Hydraulic oil temperature (measurement in the tank) (o)
87 Motor operating hours (t)
88 Time until next service (t)
89 Lift height (o)
90 Hydraulic system operating hours (t)
91 Tilt angle (o)

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2.6.2 Diagnostics
Press the "F5" button to open the diagnostics area.
Setup
Setup Diagnostic
Diagnostic
All default values of the truck can be seen here.
92 Serial number 98 Motor software version

93 Truck type (A or C) 99 Date of the motor software
version
94 CVC firmware version 100 Transmission software version
95 Display firmware version 101 Transmission parameter no.
96 Motor variant 102 Information area for optional
components
97 Motor type list number
Diagnostic
92 Truck ID no: 7193 Type C 93
94 CVC SW. ver: 0,4 Disp. SW. ver: 0,4 95
96 Engine ID no: 1104D NJ38665US_1192P 97
98 Engine SW ver: 3304957-00 FEB 08 99
100 Transmission SW ver: V1.7PP 4212534.A17.APT
Di101102
Brake Joystick Cooler Setup
Drive Diagnostic
Valve
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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 (103), pedal position (105) and the valve
(104) can be seen here.
103
104
105
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"F2" key - hydraulic controller.
– Activated ranges are identified by a checkmark (108).
– Range (106) indicates the position of the control lever(s):
• Minus = forward
• Plus = back
– Range (107) indicates the current temperature of the control module:
– Range (109) indicates the current setting of the travel direction:
• (t) activated
• (o) not activated
– Press the "F3" button to switch to another hydraulic range.
– The "F4" and "F5" buttons activate the selected hydraulic range
106 107
108 108
109
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"F3" button - cooling
– Pressing this button provides information about the coolant temperature in "°C" and
the air speed as a "%" for the motor (110), transmission (112) and charge air cooler
(113) an.
– The speed of the cooler fan (111) is shown as a "%".
110
111
112
113
"F4" button - travel switch

– Indicates the current state of the travel direction (114), control lever(s) (115) and
accelerator pedal (116).
• (t) activated
• (o) not activated
114 115
116
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3 Dashboard
3.1 Without air conditioning system
117 118 70 119 120 121 122 123 124
S12 S13 S15
S7 S8 S24
X28
S20 S26 S30

S4 S5 S6
XR9
130 129 54 128 127 126 125
3.2 With air conditioning system
117 118 70 119 120 121 122 123 124
S12 S13 S15
S7 S8 S24
X28
S20 S26 S30

S4 S5 S6
XR9
130 129 54 128 127 126 131 125

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3.3 With automatic air conditioning
117 118 70 119 120 121 122 132 124
S12 S13 S15
S7 S8 S24
X28
S20 S26 S30

S4 S5 S6
XR9
130 129 54 128 127 126 125
Item Description
70 Hazard warning lights switch
117 Socket
118 Beacon
119 Work lights
120 Window wiper / window washer system (rear window) (o)
121 Window wiper / window washer system (roof window) (o)
122 Seat heating (o)
123 Heater + air conditioning controller (o) (manual)
124 Nozzle (heater)
125 Cigarette lighter
126 Spot lights
127 Spot light (rear)
128 Spot light (front)
54 LPG bottle switch (TFG only)
129 Load damping
130 Air conditioning system (o)
131 Air conditioning system switch
132 Heater + air conditioning controller (o) (automatic)
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4 Heater, fan, air conditioning system
4.1 Heater
Cab heating is controlled by the temperature

selector (134).
Procedure
• Turn to the right - higher temperature
• Turn to the left - lower temperature
Fan 135 131 134 133

Z The fan is controlled with the (135) switch.
4.2 Air conditioning system (o)

Z Keep doors and windows closed when the air conditioning system is on – this
ensures the maximum cooling performance when the air circulation flap is fully
opened. The air is continuously filtered both in heating and in air conditioning mode.
CAUTION!
Extreme temperature differences can affect your health.

XThe difference in temperature from the outside air should not exceed 5° - 6° C in air
conditioning mode.
4.2.1 Air Conditioning Mode
CAUTION!
Never aim the nozzles directly at other
people.
XThe discharge should always be 136
directed to prevent any draft effect.
Starting the truck 137

Procedure
• The fan switch (135) and rocker switch
(131) turn the air conditioning system on
and off (green indicator lamp in the rocker
switch (131) is lit during operation).
• The air flow of the air conditioning system
is controlled by discharge jets (136) and an intake nozzle (137) in the legroom
(recirculated air) and by drawing in outside air.
CAUTION!
XThe intake nozzle (137) must always be unobstructed
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The air flow in the cab is set via the discharge jets.
4.2.2 Function of the controls
Procedure
• Switch (133) to the left: Recirculated air
• Switch (133) to the right: Outside air
• Centre position of the switch (133):
Combination of recirculated air / outside
air
• Switch (134) provides additional 135 131 134 133
temperature control.
• The air flow is controlled by switch (135).
Z Switch off the entire system before parking the truck. To switch off the entire system,
turn the fan switch (135) all the way to the left and press the rocker switch (the green
lamp goes out).
4.2.3 Air conditioning operation notes

Z If there is a high level of air humidity in the truck, switch on the air conditioning
system. To distribute air evenly to all the discharge jets, set the fan switch (135) to
the highest level, set the temperature selector (134) as required and open the side
sliding window a notch. When the humidity has been removed from the interior of
the truck close the windows again and set the required air flow.
Z To cool off the interior quickly, turn on the air conditioning system. To distribute air
evenly, open all the discharge jets. Set the fan switch (135) to the highest level and
open the side sliding window a notch. When the desired temperature has been
reached, close the windows again and set the required air flow.
Z To guarantee maximum operation of the air conditioning system it must be switched
on in the cold season at least once a month for about 10 minutes (refrigerant needs
to be recirculated).
Z When the air conditioning system is operating, condensation water may be visible
underneath the truck. This happens during the air dehumidification process, in
particular at high external temperatures and high air humidity.
CAUTION!
Regular servicing of the air conditioning system is required to ensure it can
work at a consistently high level, (see "Maintenance checklist" on page 144).
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4.2.4 Automatic air conditioning
138 139
143 142 141 140
Item Description Description

138 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.
139 Fan The fan speed can be adjusted up and down
with the Up/Down buttons. The display is
shown as a percentage.
140 ON / OFF Turn the system on and off.
141 Air mix control Setting of the outside and inside air. The setting
can range from outside air to completely
recirculated air.
142 Mode Setting for the work mode of automatic air
conditioning (automatic, heating, cooling,
defrosting, fuel preheating (o)).
143 Display Display of inside or outside temperature.
Z When the setting for completely recirculated air is selected, the supply of outside air
is shut off.
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4.2.5 Displays
144 145
147 146
144 Display of inside or outside temperature

145 Current operating mode
146 Current air supply (Fresh = fresh air, Rec = recirculated air)
147 Current fan output
4.2.6 Notes on automatic air conditioning operation

– Automatic mode:
The set internal temperature is maintained automatically.
– Heater mode:
The cab is heated. The air conditioning compressor is switched off.
– Cooling mode:
The cab is cooled. The air conditioning compressor is switched on at an external
temperature 10 °C and switched off at an external temperature of 8 °C. Fan output
is controlled automatically.
– Defrosting mode:
The cab windows are defrosted. All air jets under the windows must be opened. The
heater is activated. Fat output is at the highest stage.
– Fuel preheating (o)
All other functions are deactivated.
CAUTION!
Regular servicing of the air conditioning system is required to ensure it can
work at a consistently high level, (see "Maintenance checklist" on page 144)
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5 Preparing the Truck for Operation
5.1 Checks and operations to be performed before starting daily
operation
WARNING!
Damage and other truck or attachment (special equipment) defects can result
in accidents.
If damage or other truck or attachment (special equipment) defects are discovered
during the following checks, the truck must be taken out of service until it has been
repaired.
XReport any defects immediately to your supervisor.
XTag out and decommission a faulty lift truck.
XOnly return the truck to service when you have identified and rectified the fault.
WARNING!
Before the truck can be started or operated or a load can be lifted, the driver must
ensure that there is nobody within the hazardous area.
CAUTION!
Checking the accelerator pedal
XThe accelerator pedal should only be
checked when the parking brake is
applied and the engine is idle.
148
Checks before daily operation
149
Procedure
• Visually inspect the entire truck (in particular the wheels, wheel bolts and load
handler) for damage.
• Check the fork stop (148) and fork tine retainer (149).
• Visually inspect the hydraulic system in the visible area for damage and leaks.
• Check the driver’s seat has been adjusted to the correct position.
• Test the horn and reversing buzzer (o) where applicable.
• Check that the load chart and warning labels are legible.
• Test the controls and displays.
• Test the steering.
• Make sure the load chains are evenly tensioned.
• Test the seat belt. (The belt should jam if extracted suddenly.)
• Test the seat switch. When the driver’s seat is vacated it should not be possible to
activate the working hydraulics.
• Test the restraint system (o),
• Test the lift/lower, tilt and if applicable the attachment hydraulic control functions.
02.11 EN
• Check the accelerator pedal can move freely by pressing it several times.
84

• Test the service brake and parking brake: Start driving carefully and test the
effectiveness of the brake pedal.
• Check the fuel supply.
• Check the fluid level of the window washer system (o), (see "Adding Window
Washer System Fluid" on page 176).
• Check the LPG system is working correctly, (see "LPG containers" on page 50)
• 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.
• Engine oil check.
• Checking the coolant level.
• Check hydraulic oil level and top up if necessary.
• Check wheels and tyres for damage.
• Test lighting.
• Check radiator and clean if necessary.
TFG only
Procedure
• Check the gas system is working correctly, (see "LPG containers" on page 50)
• Leak test (smell of gas?).
• Leak test after bottle replacement.
• Check gas hoses for damage (visual inspection).
• Check that the gas line connection are secure.
• Test the entire gas system for leaks using a leakage spray.
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5.2 Entry and exit
Procedure
• Open the cab door (o)
• To enter and exit the cab, hold onto the
150
handle (150).
Z An additional step is provided for the driver

position extension (o)
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5.3 Setting up the operator position
WARNING!
Accident risk
XDo not adjust the driver’s seat while travelling.
Procedure
• Before starting to travel, adjust the driver’s seat, steering column and armrest (if
necessary) so that all the controls are within reach and can be applied without
having to strain.
• Adjust the visibility aid equipment (mirrors, camera systems etc.) so that the working
environment can be clearly seen.
5.3.1 Adjusting the driver’s seat
WARNING!
Risk of accidents and damage to health
An incorrectly adjusted driver’s seat can result in accidents and damage to health.
XDo not adjust the driver’s seat while travelling.
XThe driver’s seat should lock in position after adjustment.
XCheck and adjust the individual driver’s seat setting before starting to use the truck.
XHold the weight setting lever (152) only by the recess, do not reach through
underneath the lever.
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Adjusting the driver's weight 151
NOTE
To achieve optimal seat cushioning the

driver’s seat must be adapted to the
driver’s weight.
Set the driver's weight when the seat is
occupied.
152
Procedure
• Move the lever (152) as far as it will go in
the arrow direction
until you reach the required weight on the 154 153
scales.
• Move the weight adjustment lever (152) up
and down to set the seat to a higher weight.
• Move the weight adjustment lever (152) up and down to set the seat to a lower
weight.
Z The driver's weight is correct when the arrow is in the middle of the display window
(151). The minimum or maximum weight setting is reached when you can feel a
return stroke on the lever.
• After setting the weight, move the lever (152) back in full.
The driver’s weight is now set.
Adjusting the backrest
Procedure
• Sit on the driver’s seat.
• Pull the lever (153) to adjust the backrest.
• Adjust the backrest tilt.
• Release the lever (153) again. The backrest is locked.
The backrest is now set.
Z Hold the weight setting lever (152) only by the recess, never reach through
underneath the lever.
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Adjusting the seat position 151
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.
XThe driver's seat must be locked in 152
position.
XDo not adjust the driver’s seat while
travelling.
154 153
Procedure
• Sit on the driver’s seat.
• Pull up the driver’s seat locking lever154 in the direction of the arrow.
• Push the driver’s seat forwards or backwards to the desired position
• Engage the driver’s seat locking lever (154) in position.
The seat position is now correctly set.
5.3.2 Rotating Driver'S Seat
Functional Description
The driver's seat is turned by means of an
electric motor. The motor is located under
the cab.
F
N
R
The truck is equipped with two sets of

driving and reverse lights. The spot lights
can be activated to match the selected
travel direction. After the seat has been
turned, the main controller switches the
steering, travel direction indicator and spot
lights to the opposite direction. The
following rule applies to spot lights on the
mast: If the spot light is set to stage 1, the
spot light is lit if the driver's seat is turned 155
forward, and extinguished if the driver's
seat is turned to the rear. If the spot light is
set to stage 2, the spot light is lit regardless of the direction of the driver's seat.
Z The truck cannot be moved while the direction is being changed.
The (155) button for activating the rotating driver's seat must be pressed and held
down during the entire turning process. As soon as the button is released, the turning
process stops. It is also possible to change the direction of rotation.
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Rotating the Driver'S Seat
DANGER!
XThe driver must be seated on driver's F
seat during the rotation process with N

R
both feet placed on the rotating panel.

XNo other persons are permitted in the
cab.
XThe door must remain closed.
Requirements
– The driver's seat is facing forward.
– The truck starts to move.
155
Procedure
• As soon as the travel speed falls below 1
km/h, button (155) is enabled to rotate the seat. Press and hold button (155).
The seat brake is released.

The driving brake is activated and transfer of force is switched to the neutral position.
This ensures that the truck remains stopped while the driver's seat is being rotated.
The rotation process begins.
When the seat has left the front driver's seat position sensor (default setting), the seat
turns at maximum speed. The "Driver's seat turning process active" icon appears in
the display.
When the seat has almost reached the driver's seat position sensor (90-degree setting
(o)), the turning speed is reduced. The "Driver's seat turning process active" icon
goes out.
When button (155) is released, operation of the truck is permitted. The steering, travel
direction indicator and spot lights have not been switched to the opposite direction.
If the user continues to hold down button (155), the seat continues turning at
maximum speed. The "Driver's seat turning process active" icon is lit again.
When the seat has almost reached the rear driver's seat position sensor (180-degree
setting), the turning speed is reduced. The turning motion ends as soon as the end
position is reached. The "Driver's seat turning process active" icon goes out. The
direction of the spotlights and steering is changed to match the travel direction.
As soon as the seat has reached the rear position (180-degree position) and a travel
direction is set on a travel direction switch, the "N!" icon appears in the display. The
travel direction lever must be moved to the neutral position before another selection
of the travel direction can be made.
The driver's seat is rotated.
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5.3.3 Adjusting the steering wheel / steering column
DANGER!
Do not adjust the steering wheel while travelling
Individual steering wheel position

Z The steering wheel can be height- and tilt-adjusted to suit the operator.
156
Adjusting the Tilt
Procedure
• Pull up on the adjusting lever (157).
• Tilt the steering wheel (156) forward or
backward as required.
157
• Push the adjusting lever into the centre
position.
The steering column tilt is adjusted.
Adjusting the Height

Procedure 4
• Push down on the adjusting lever (157).
• Adjust the steering column (4) to the
required height.
• Pull the adjusting lever (157) into the centre position.
The steering column height is adjusted.
5.3.4 Adjusting the Armrest
The height and angle of the armrest can be

adjusted with the screw (158).
Procedure
• Turn the screw clockwise - the armrest is 158
raised.
• Turn the screw anti-clockwise - the armrest
is lowered.
The armrest is adjusted.
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5.3.5 Adjusting the Control Panel
The height and tilt of the control panel (159)

can be changed. This makes it possible to
159
adjust the armrest (160) and control panel
optimally to each other.
160
Procedure 161
• Release the lever (161).
• Move the control panel to the required
position.
• Pull the lever tight again.
The control panel is adjusted.
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5.4 Seat Belt
DANGER!
Travelling without a seat belt increases the risk of injury.

If the seat belt is not worn or is modified, personal injury can result.
XAlways put on the seat belt before starting the industrial truck.
XDo not modify the seat belt.
XDamaged or non-operational seat belts must be replaced by trained personnel.
XSeat belts must always be replaced after an accident.
XOnly original spare parts must be used for retrofits or repairs.
Z Protect the seat belt from contamination (e.g. cover it when the truck is idle) and
clean it regularly. Frozen belt locks or pulleys must be thawed out and dried to
prevent them from freezing up again.
The temperature of the warm air should not exceed +60 °C!
Starting the industrial truck on steep slopes
The automatic blocking system locks the belt in the retractor when the truck is
positioned on a steep slope. This prevents the belt from being pulled out of the
retractor.
Z Carefully drive the truck off the slope and then put on the belt.
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6 Industrial Truck Operation
6.1 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. Additional equipment is necessary to operate the truck in
areas of insufficient lighting.
DANGER!
Do not exceed the permissible surface and spot load limits on the travel routes.
At blind spots get a second person to assist.
The driver must ensure that the loading dock / ramp cannot move or come loose
during loading / unloading.
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.
Travel conduct
The driver must adapt the travel speed to local conditions. The truck must be driven
at slow speed when negotiating bends or narrow passageways, when passing
through swing doors and at blind spots. The driver must always observe an adequate
braking distance between the forklift truck and the vehicle in front and must be in
control of the truck at all times. Abrupt stopping (except in emergencies), rapid U turns
and overtaking at dangerous or blind spots are not permitted. Do not lean out or reach
beyond the working and operating area.
Hazardous situations
If the truck is about to tip over, do not loosen the seat belt. The driver must not jump
off the truck. The driver must lean his upper body over the steering wheel and hold on
with both hands. Tilt your body in the opposite direction of fall.
Travel visibility
The driver must look in the direction of travel and must always have a clear view of
the route ahead. Loads that affect visibility must be positioned at the rear of the truck.
If this is not possible, a second person must walk alongside the truck as a lookout to
observe the travel route while maintaining eye contact with the driver. Proceed only at
walking pace and with particular care. Stop the truck as soon as you lose eye contact.
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Negotiating slopes and inclines
Negotiating slopes or 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 unit facing uphill. The industrial truck
must not be turned, operated at an angle or parked on inclines or slopes. Inclines must
only be negotiated at slow speed, with the driver ready to brake at any moment.
Particular care is required when travelling near slopes and quay walls.
Negotiating lifts and docks
Lifts may only be entered if they have sufficient capacity, are suitable for driving on
and authorised for truck traffic by the owner. The driver must satisfy himself of the
above before entering these areas. The truck must enter lifts with the load in front and
must take up a position which does not allow it to come into contact with the walls of
the lift shaft. People travelling in the lift with the forklift truck must only enter the lift
after the truck has come to a halt and must exit the lift before the truck. The driver must
ensure that the loading ramp / bridge cannot move or come loose during loading /
unloading.
Type of loads to be carried

The operator must make sure that the load is in a satisfactory condition. Loads must
always be positioned safely and carefully. Use suitable precautions to prevent parts
of the load from tipping or falling down. Prevent liquid loads from sloshing out.
Inflammable liquids (e.g. fused metal etc.) may only be transported with suitable
auxiliary equipment. Contact your authorized Jungheinrich customer adviser.
Z For safety instructions on the nature of loads to be carried with attachments,(see

"Lifting, transporting and depositing loads" on page 109).
Towing trailers
The truck may only be used occasionally to tow trailers, (see "Towing trailers" on
page 123)
DANGER!
Exhaust emissions can be fatal
XThe 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.
XThe user must comply with legal requirements, technical standards and health and
safety regulations when operating an IC motor powered lift truck in closed rooms.
02.11 EN
95

6.2 Preparing the truck for operation
Before starting the truck
Z 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.
Requirements
– Checks and operations to be performed before starting daily operation, (see
"Checks and operations to be performed before starting daily operation" on
page 84).
Switching on the truck
Procedure 162
• Turn the battery isolator (162) to position
"A".
• Set the travel direction switch to neutral
position N.
• Parking brake is activated.
• Perform the appropriate starting procedure
depending on the type of motor; see 6.2.1
"Starting procedure for the DFG" or 6.2.2
"Starting procedure for the TFG".
02.11 EN
96

6.2.1 Starting procedure for the DFG
Procedure
•
• Insert the key in the key switch (68) and

turn it to the “2” position.
• The pre-heat indicator lamp lights up and 68
goes out automatically as soon as the
required pre-heat time (approx. 4
seconds) has been reached. 3
• All the indicators light up briefly to test
operation.
Z All the indicators except for the engine oil
pressure display, parking brake indicator,
indicator lamp for neutral position and
charge current indicator (163) should go
out after a short while. If not, stop the start-
up process and rectify the fault.
•
• Turn the key to position "3".

Z Only apply the starter for a maximum of 15
seconds without interruption. The truck is
equipped with an immobiliser which
prevents it from starting again while the
engine is running.
• Release the key as soon as the engine
starts. The key automatically reverts to the
"2" position.
Z All indicators lights except for neutral
position and parking brake should go out
as soon as the engine starts. If not, stop 163 68
the engine immediately and rectify the
fault.
Truck ready for operation.
02.11 EN
97

6.2.2 Starting procedure for the TFG
DANGER!
Risk of escaping liquid gas if the truck does not start

XNote the safety regulations governing the handling of liquid gas
((see "Safety regulations for handling diesel fuel and LPG" on page 45))
XClose the gas bottle shut-off valve.
XSet the key switch to "O"
XNotify your superior.
Procedure
•
• Slowly open the shut-off valve on the LPG 68

bottles.
• Insert the key in the key switch (68) and
turn it to the “2” position.
3
• All the indicators light up briefly to test
operation.
Z All the indicators except for the engine oil
pressure display, parking brake indicator,
indicator lamp for neutral position and
charge current indicator (163) should go
out after a short while. If not, stop the start-
up process and rectify the fault.
•
• Select LPG bottle 1 or 2. To do this move S12 S13 S15
switch (54) for LPG bottle 1 to the centre X28

S7 S8 S24
position and for LPG bottle 2 to the lowest S20 S26 S30
S4 S5 S6
position.
XR9
Z In the highest position of the switch both

LPG bottles are disabled. S20 S26 S30
• Turn the key to position "3". 54

Z Only apply the starter for a maximum of 15
seconds without interruption. The truck is
equipped with an immobiliser which
prevents it from starting again while the engine is running.
•
• Release the key as soon as the engine

starts. The key automatically reverts to the
"2" position.
Z All indicators lights except for neutral
position and parking brake should go out
as soon as the engine starts. If not, stop
the engine immediately and rectify the
fault.
Truck ready for operation.
163 68
02.11 EN
98

6.3 Operational Checks
DANGER!
After starting the motor, 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.
• Test the lift/lower, tilt and if applicable the
attachment hydraulic control functions.
• Test the horn.
• Test the motor speed with the accelerator 59 58
pedal (58) over a range of speeds while
checking the freedom of movement of the
pedal.
• Release the parking brake. Start driving carefully and press the parking brake (59)
to test it.
• Press the "F5" to lock the parking brake.
Z If all operational checks were carried out with no problems, the truck is ready for
operation.
WARNING!
Do not run up the motor in idle. The engine soon reaches operating temperature at a
moderate charge and when the speed alternates. Do not fully load the engine until it
has reached operating temperature.
02.11 EN
99

6.4 Parking the truck securely
DANGER!
Risk of explosion
XLPG trucks may only be parked in ground level rooms or higher and providing they
are adequately ventilated. They must not be parked near to cellar doors and entry
points, hollows, drains, drain inlets or other recesses below the parked truck.
WARNING!
An unsecured truck can cause accidents

Parking the truck on an incline, without the brakes applied or with a raised load / load
handler is dangerous and is strictly prohibited.
XAlways park the truck on a level surface. In special cases the truck may need to be
secured with wedges.
XAlways fully lower the mast and load handler.
XTilt the mast forward.
XSelect a place to park where no other people are at risk of injury from lowering forks.
XDo not park and abandon the truck on an incline.
Parking the Truck Securely (DFG)

When you exit the truck it must be securely
parked even if you only intend to leave it for a 75
short time.
Procedure
• Turn the travel direction switch to idle
(centre position).
• Press the "F5" button in the display: The 68
brake shoe that appears in the "parking
brake" icon (75) changes its position to the
right.
• Lower the load completely and position it
horizontally.
WARNING!
XDo not switch the engine off from full
charge. Instead, let it run for a short
while to allow the temperature to
compensate.
• Turn the key in the key switch (68) to the "0" position and remove the key.
02.11 EN
100

Parking the Truck Securely (TFG)
Procedure
• Turn the travel direction switch to idle
(centre position). 75
• Press the "F5" button in the display. The
brake shoe that appears in the "parking
brake" icon (75) changes its position to the
right.
• Lower the load completely and position it 68
horizontally.
WARNING!
XDo not switch the engine off from full
charge. Instead, let it run for a short
while to allow the temperature to
compensate.
• Set the travel direction switch to neutral

position.
• Turn the switch (54) to the upper position to S7 S8 S24
S12 S13 S15
close the electrical shut-off valves of the X28
S20 S26 S30

S4 S5 S6
LPG bottles. XR9
• Turn the key in the key switch (68) to the “0”

position. S20 S26 S30
• Wait until the motor stops.

54
• Close the shut-off valves (49) of the LPG
bottle securely.
Z After the motor is turned off, it continues

running briefly for safety reasons. This uses
up the remaining amount of LPG between
the motor and the shut-off valve of the LPG
system.
49
02.11 EN
101

6.5 Emergency Disconnect
Procedure
• Turn the ignition key to position "0" and remove the key.
• Tilt the cab and remove the terminal clip from the battery terminal.
This disconnects the battery from the on-board supply network and switches off all
electrical functions.
6.5.1 Battery Isolator
Procedure
• Move the battery isolator (162) to position
"A". All electrical functions are enabled. 162
• Move the battery isolator (162) to position
"B" and remove it is appropriate: All
electrical functions are deactivated.
6.6 Travel
WARNING!
Improper travel can result in accidents
XDo not get up from the driver’s seat during
travel.
XDo not drive the truck unless your are
wearing a seat belt and the panels and doors are properly locked.
XMake sure that the travel area is clear.
XAdapt the travel speed to the conditions of the route, the work area and the load.
XTilt the mast back and raise the fork carriage approx. 200 mm.
XMake sure you have enough visibility when reversing.
Travel
Requirements
– Truck prepared for operation, (see
"Preparing the truck for operation" on
page 96).
Procedure
• Release the parking brake. To do this press
the parking brake button F5.
• Choose the travel direction with the travel
direction switch (56).
• Raise the fork carriage approx. 200 mm.
• Tilt the mast back.
• Apply the accelerator pedal (58). The travel speed is governed by the accelerator
02.11 EN
(58).
102

The truck travels in the selected travel direction.
56
56
56 59 58
Z Adjust the automatic gearshift with the rotary button on the lever (56).
– 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.
Z As soon as the speed is more than 3 - 4 km/h, the travel direction can no longer be
changed. The reversing disable makes it impossible to change the travel direction
from forward to reverse at high speed.
As soon as the speed is more than 8 km/h, it is not possible to switch from 2nd gear
to first gear.
Changing Travel Direction
Press the pedal (59) to bring the truck to a standstill. Change the travel direction with
the travel direction switch. Resume travel.
Neutral locking
If the driver leaves the truck without taking it out of gear, the truck will automatically
be set to neutral. To resume travel (sitting on the truck) all controls must be
deactivated, the travel direction switch must be set to neutral “N” and then the required
direction selected.
02.11 EN
103

6.7 Steering
Steering 164
Procedure
Z Very little steering effort is required; you
should therefore turn the steering wheel
(164) 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.
The truck travels in the direction selected.
02.11 EN
104

6.8 Brakes
WARNING!
Accident risk
The brake pattern of the truck depends
largely on the ground conditions.
XThe driver must be aware of travel route
conditions and them into account when
braking.
XBrake with care to prevent the load from
slipping.
XAllow for increased braking distance
when travelling with an attached load.
XUse the service brake in emergencies.
59 58
There are two ways of braking:
– Service brake (59)
and for secure parking:
– Parking brake ("F5" button)

The truck has two brake systems that work independently of each other, a service
brake and a parking brake.
6.8.1 Service brake

The drive coupling is deactivated in the first half of the pedal path. The tow force of
the truck is reduced proportionately to how far the brake pedal is depressed (59).
The service brake is activated in the last half of the pedal path. If the pedal is
depressed further, the truck is brought to a stop. The brake force is proportional to the
pedal path.
To allow the truck to move slowly, first step on the brake pedal (59). The press the
accelerator pedal (58). Carefully release the brake pedal (59). The truck begins to
move slowly.
02.11 EN
105

6.8.2 Parking brake
DANGER!
Accident risk
XThe parking brake will hold the truck with maximum load on a clean ground surface,
on inclines of up to 15%.
XDo not park and abandon the truck on an incline.
XApplying 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. There is an increased risk of
accidents and injury!
Z The parking brake can be used as an emergency brake.
Procedure
• To activate the parking brake, press the
"F5" button (165). The arrow that appears
in the "parking brake" icon (75) changes
its position to the right. 75
CAUTION!
The parking brake is automatically
activated when the driver's position is
vacated.
165
DANGER!
If there is reason to suspect an error in
the brake system, it is not possible to
continue driving.
XPlease contact the manufacturer's
service department.
02.11 EN
106

6.9 Adjusting the forks
WARNING! 148
Trapping hazard
There is a trapping hazard when you
perform this operation.
XWear work gloves and safety shoes.
WARNING!
Unsecured and incorrectly adjusted

fork tines can cause accidents
XAdjust the two fork tines so that they are
equidistant from the outside edge of the
fork carriage.
XEngage the locking pin in a groove to
prevent the fork tines from moving
accidentally.
XThe load centre of gravity must be
located centrally between the fork tines.
Adjusting the forks
Requirements
– Park the truck securely, (see "Parking the truck 166
securely" on page 100).
Procedure 167
• Lift up the locking lever (166). 168
• Push the forks (167) into the correct position on
the fork carriage (168).
Z To lift the load securely, the forks (167) must be
spread as far apart as possible and positioned
centrally with respect to the fork carriage. The
load centre of gravity must be centrally aligned between the forks (167).
• Lift the locking lever down (166) and move the forks until the locking pin engages in
a slot.
The forks are now adjusted.
02.11 EN
107

6.10 Replacing the forks
WARNING!
Unsecured fork tines can cause injury

You can injure your legs when replacing the fork tines.
XNever pull the fork tines towards your body.
XAlways push the fork tines away from your body.
XSecure heavy fork tines with lifting slings and a crane before pushing them down
from the fork carriage.
WARNING! 148
Trapping hazard
There is a trapping hazard when you
perform this operation.
XWear work gloves and safety shoes.
Replacing the fork tines

Requirements
– Load handler lowered and fork tines not
touching the ground.
Procedure
• Loosen the fork stop (148).
• Carefully push the fork tines to the centre of the fork carriage and remove them.
The fork tines are now dismantled from the fork carriage and can be replaced.
02.11 EN
108

6.11 Lifting, transporting and depositing loads
WARNING!
Unsecured and incorrectly positioned loads can cause accidents

Before lifting a load unit the driver must make sure that it has been correctly palletised
and does not exceed the truck’s capacity.
XInstruct 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.
XOnly carry loads that have been correctly secured and positioned. Use suitable
precautions to prevent parts of the load from tipping or falling down.
XDo not transport loads other than on the authorised load handler.
XDamaged loads must not be transported.
XIf the stacked load obscures forward visibility, then you must reverse the truck.
XNever exceed the maximum loads specified in the capacity chart.
XNever stand underneath a raised load handler.
XDo not stand on the load handler.
XDo not lift other people on the load handler.
XDo not reach through the mast.
XCheck the fork spread before lifting the load and adjust if necessary.
XInsert the forks as far as possible underneath the load.
Lifting load units

Requirements
– Load unit correctly palletised.
– Fork spread for the pallet checked and adjusted if necessary.
– Load unit weight matches the truck's capacity.
– Forks evenly loaded for heavy loads.
Procedure
• Drive the truck carefully up to the pallet.
• Set the mast vertical.
• Slowly insert the forks into the pallet until the fork shank touches the pallet.
• Raise the load handler.
• Reverse carefully and slowly until the load unit is outside the storage area. Make
sure you have enough clear space to reverse into.
02.11 EN
109

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 load units
Requirements
– Load unit correctly lifted.
– Load handler lowered for transport (approx. 150 - 200 mm above the ground).
– Mast tilted back fully.
Procedure
• Accelerate and decelerate gradually.
• Adapt your travel speed to the conditions of the route and the load you are
transporting.
• Watch out for other traffic at crossings and passageways.
• Always travel with a lookout at blind spots.
• On slopes and inclines always carry the load facing uphill, never approach at an
angle or turn.
Depositing load units

Requirements
– Warehouse location suitable for storing the load.
Procedure
• Set the mast vertical.
• Drive carefully up to the storage location.
• Carefully lower the load handler so that the forks are clear of the load.
Z Avoid depositing the load to avoid damaging the load and the load handler.
• Lower the load handler.
• Carefully remove the forks from the pallet.
The load unit is lowered.
02.11 EN
110

6.12 Operating the lift mechanism and integrated attachments
WARNING!
Accident risk when operating the lifting device and integrated attachments
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. This also includes areas which can be
reached by falling loads or lowering operating equipment.
Apart from the operator (in the normal operating position) there should be no other
people in the truck's hazardous area.
XInstruct 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.
XThe truck must be prevented from being used by unauthorised people if people do
not leave the hazardous area despite the warning.
XOnly carry loads that have been correctly secured and positioned. Use suitable
protection measure to prevent parts of the load from tipping or falling down.
XNever exceed the maximum loads specified in the capacity chart.
XDo not stand on the load handler.
XDo not lift other people on the load handler.
XDo not reach through the mast.
XThe controls should only be operated from the driver’s seat, and never suddenly.
XThe driver must be instructed in how to operate the lifting device and the
attachments.
6.12.1 Operating the lifting device with the SOLO-PILOT
Lifting and lowering 169
Requirements
"Preparing the truck for operation" on A
page 96).
B
Procedure
• Pull back on the lever (169). The load is
raised.
• Press forward on the lever (169). The load
is lowered.
The load is now raised or lowered.
Z When the end stop for the operation has been reached (there will be a noise from
the pressure limitation valve) release the lever. The lever will revert automatically to
the neutral position.
02.11 EN
111

Tilting the mast forward / backward 61
Requirements
"Preparing the truck for operation" on A
page 96).
B
Procedure
• Pull back on the lever (61). The mast tilts
back.
• Push forward on the lever (61). The mast
tilts forward.
The mast is now tilted back or forward.
the pressure limitation valve) release the lever. The lever will revert automatically to
the neutral position.
Depositing a load unit (SOLO-PILOT)
Procedure
• To place the load in a horizontal position: Press the lever (61) in direction (A).
• To position the load at the correct height: Press the lever (169) in direction (A or B).
• To lower the load: Press the lever (169) in direction (A).
Z When you reach the limit position return the control lever to its home position.
Fork adjustment (SOLO-PILOT)

Procedure
•
• To adjust the fork to the width of the load: 62 63

• Wider fork spread: Press the lever (62)
in direction (A).
• Narrower fork spread: Pull the lever
(62) in direction (B). A
• To move both fork tines at the same time:
• Right: Press the lever (63) in direction B
(A)
• Left: Pull the lever (63) in direction (B)
56
02.11 EN
112

Sideshifter (SOLO-PILOT) 169 61
Procedure
• Push the lever (62) in direction (A). The
fork tines are shifted to the right (as seen A
by the driver).
• Pull the lever (62) in direction (B). The fork B
tines are shifted to the left (as seen by the
driver).
56
02.11 EN
113

6.12.2 Operating the lift mechanism with the Multi Pilot
60
Lifting and lowering
Requirements
page 96).
Procedure
• Pull back on MULTI-PILOT (60). The load
is raised.
• Push MULTI-PILOT (60) forward. The
load is lowered.
The load is now raised or lowered.
the pressure limitation valve) release MULTI-PILOT. MULTI-PILOT will revert
automatically to the neutral position.
60
Tilting the mast forward / backward
Requirements
page 96).
Procedure
• Push MULTI-PILOT (60) to the left. The
mast tilts back.
• Push MULTI-PILOT (60) to the right. The
mast tilts forward.
The mast is now tilted back or forward.
the pressure limitation valve) release MULTI-PILOT. MULTI-PILOT will revert
automatically to the neutral position.
02.11 EN
114

Twin operation
Requirements
– To prepare the truck for operation, (see
page 96)
Procedure
• To lower the load handler and tilt the mast
forward at the same time, push the Multi
Pilot forward and to the right.
• To lift the load handler and tilt the mast back
at the same time, push the Multi Pilot back and to the left.
• To lower the load handler and tilt the mast back at the same time, push the Multi
Pilot forward and to the left.
The mast is now tilted back / forward.
CAUTION!
XTo raise the load safely, set the fork tines as far apart from each other as possible
and centrally to the truck. The load centre of gravity must lie centrally between the
fork tines.
Fork adjustment (MULTI-PILOT) 62
Procedure
• Adjusting the fork makes it possible to set
the fork for the width of the load.
Wider fork spread: Press the control button
(62) in direction (2).
Narrower fork spread: Press the control
button (62) in direction (1).
Sideshifter (MULTI-PILOT)
Procedure
Z The references to left and right are based on L
load lifting as viewed from the operator's
position.
• Sideshifter left: Press the control button (63)
in direction (L). 63
• Sideshifter right: Press the control button R
(63) in direction (R).
With MULTI-PILOT control, adjusting and
02.11 EN
reaching are simultaneous
115

6.13 Safety instructions for operating additional attachments
Z 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.
DANGER!
Attaching exchangeable equipment can result in accidents.

Other people can be damaged by attaching exchangeable equipment. Use only
exchangeable equipment which has been deemed safe after a risk analysis carried
out by the owner.
XOnly use attachments with a CE mark.
XOnly use attachments that have been designed by the attachment manufacturer for
use with the respective industrial truck.
XOnly use attachments that have been fitted for the purpose by the owner.
XMake sure the operator has been instructed in the use of the attachment and that
he uses it for its correct purpose.
XRe-assess the residual capacity of the truck and if it has been altered, attach an
additional capacity plate to the truck.
XNote the attachment manufacturer’s operating instructions.
XOnly use attachments that do not restrict visibility in the travel direction.
Z If visibility in the travel direction is impaired, the owner must carry out a risk analysis
to assess whether the truck needs to be fitted with auxiliary equipment such as a
camera system or mirrors. If such equipment is used, spend sufficient time
practicing travelling with them.
02.11 EN
116

Safety instructions for sideshifter and fork adjuster attachments
WARNING!
When using multi fork adjusters (multi pallet clamps), restricted visibility and reduced
lateral tilt resistance can result in accidents.
XAdapt the travel speeds to the visibility and load.
Safety instructions for clamping attachments (e.g. baling clamps, barrel

clamps, grabs etc.)
WARNING!
Falling loads can cause accidents
This can result in malfunctions and the load can fall accidentally.
XClamping attachments may only be added to trucks which have a button to enable
additional hydraulic functions.
XClamping attachments must only be operated on trucks will auxiliary hydraulics HF4
or HF5.
XWhen connecting the attachment make sure that the hydraulic lines of the
attachment are connected to the right ports, (see "Fitting additional attachments" on
page 122).
Safety instructions for rotary attachments
WARNING!
A non-centred centre of gravity can result in accidents
When using rotary devices and non-centred loads, the centre of gravity can be
displaced from the centre with a high risk of accidents.
XAdapt the travel speed to the load.
XLift the load from the centre.
Safety instructions for telescopic attachments
WARNING!
Accident risk from increased tipover hazard and reduced residual capacity
There is a greater tipover risk with extended telescopic attachments (e.g. reach
carriages, telescopic forks, telescopic crane booms).
XOnly use the telescopic function for stacking and retrieving.
XAlways retract the attachment fully during transport.
XAdapt the travel speed to changed load centre of gravity.
02.11 EN
117

Safety instructions for attachments when transporting suspended loads
WARNING!
Swinging loads and a reduced residual capacity can result in accidents

XAdapt the travel speed to the load, less than walking pace.
XSecure swinging loads for example with lifting slings.
XReduce the residual capacity and have it certified by a expert.
Safety instructions for using loading buckets as attachments
WARNING!
Greater mast loading can cause accidents.
XWhen carrying out the daily checks and operations before starting, (see "Checks
and operations to be performed before starting daily operation" on page 84), in
particular attention check the fork carriage, mast rails and mast rollers for damage.
Safety instructions for fork extensions:
WARNING!
Unsecured and excessive fork extensions can cause accidents.
XFor fork extensions with an open cross sectional area, only carry loads that are
resting along the entire length of the fork extension.
XOnly use fork extensions with the same fork cross section and minimum fork length
of the truck and which comply with the details on the fork extension data plate.
XThe basic fork length must be at least 60% of the length of the fork extension.
XLock the fork extensions onto the basic forks.
XWhen carrying out the daily checks and operations before starting, (see "Checks
and operations to be performed before starting daily operation" on page 84), also
check the fork extension lock.
XMark any fork extensions with an incomplete or faulty lock and take them out of
service.
XDo not use trucks with an incomplete or faulty fork extension lock. Replace the fork
extension.
XOnly restore the fork extension to service when the fault has been rectified.
XUse only fork extensions which have no dirt or foreign bodies near the entry opening
point. Clean the fork extensions as required.
02.11 EN
118

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.
XMark the controls with symbols that indicate their function.
XSpecify the attachments’ direction of movement in accordance with ISO 3691-1 so
that they match the controls’ direction of movement.
6.14.1 Solo Pilot with control of ZH1 and ZH2 hydraulic ports
Z Functions are assigned to the levers (62, 63) 62 63

depending on the attachments used. Levers
that are not required are void. For
connections (see "Fitting additional
attachments" on page 122). A
Procedure B
• Operating hydraulic port ZH1:
Move the lever (62) in direction A or B.
The attachment performs its operation.
6.14.2 Solo Pilot with control of ZH1, ZH2 and ZH3 hydraulic ports
Z Functions are assigned to the levers (62, 63, 62 63 64

64) depending on the attachments used.
Levers that are not required are void. For
attachments" on page 122). A
Procedure B
• Operating the hydraulic port ZH3:
02.11 EN
119

6.14.3 SOLO-PILOT with control of hydraulic ports ZH1, ZH2 and ZH3 with an extra
button
Z Functions are assigned to the levers (62, 63, 62 63

attachments" on page 122).
A
Procedure
B
• Operating the hydraulic port ZH3:
170
Press the toggle switch (170) and at the
same time move the lever (63) in direction A
or B.
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.
XMark the controls with symbols that indicate their function.
XSpecify the attachments’ direction of movement in accordance with ISO 3691-1 so
that they match the controls’ direction of movement.
6.15.1 Multi Pilot with control of ZH1 and ZH2 hydraulic ports
Z Functions are assigned to the levers (62, 63) 62

depending on the attachments used. Levers
that are not required are void. For
Procedure
Press the button (62). 63
Press the button (63).
02.11 EN
120

6.15.2 Multi Pilot with control of ZH1, ZH2 and ZH3 hydraulic ports
Z Functions are assigned to the levers (62, 63, 62

Procedure
Press the button (62). 64 63
Press the button (63).
Press button (62) or button (63) and
simultaneously button (64).
02.11 EN
121

6.16 Fitting additional attachments
CAUTION!
Incorrectly connected attachments can cause accidents.

Attachments with incorrectly connected hydraulic attachments can result in accidents.
XAttachments must only be assembled and commissioned by trained, specialist
personnel.
XNote the attachment manufacturer's operating instructions.
XBefore commissioning, check the fasteners are positioned correctly and securely
and make sure they are complete.
XBefore commissioning, make sure the attachment is working correctly.
Hydraulic ports
Requirements
– Non-pressurised hydraulic hoses.
– Attachment directions of movement defined to match the controls’ direction of
movement.
Procedure
• Non-pressurised hydraulic hoses
• Switch off the truck and wait a few minutes.
• Attach the plug connector and engage it in position.
• Mark the controls with symbols that indicate the function of the attachment.
The attachment is hydraulically connected.
Z 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.
02.11 EN
122

7 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.
XThe truck should only be used occasionally to tow trailers.
XThe overall weight of the trailer should not exceed the capacity indicated on the
capacity plate, (see "Identification points and data plates" on page 36). If a load is
also transported on the forks, the trailer load must be reduced by the same amount.
XDo not exceed the maximum speed of 5 km/h km/h.
XA truck must not be continually operated with trailers.
XDo not use supporting loads.
XTowing must only be performed on level, secure travel routes.
XThe owner must test trailer operation with the permissible tow load by means of a
trial run under the applicable operating conditions on site.
02.11 EN
123

Attaching the trailer
CAUTION!
Trapping hazard
There is a trapping risk when you attach a trailer.
XFollow the instructions of the coupling manufacturer if using special trailer
couplings.
XSecure the trailer to prevent it from rolling away before coupling it.
XDo not get caught between the truck and the tiller when coupling the trailer.
XThe tiller must be horizontal, tilted down by no more than 10° and never facing up.
Attaching the trailer
Requirements
– Truck and trailer are on a level surface.
– Trailer prevented from rolling away.
Procedure
• The handle (172) is moved to a horizontal
position and the bolt (171) is raised so that
the coupling fork becomes free. Then
position the handle (172) vertically so that
the bolt (171) remains in place. 172 171
• Insert the trailer tiller into the opening.
• Move the handle (172) to a horizontal position let down the bolt (171), thereby
locking the handle (172) in a vertical position.
The trailer is now attached to the truck.
02.11 EN
124

8 Optional equipment
8.1 Sliding windows
CAUTION!
An unlocked sliding window can cause accidents
XThe sliding windows must be locked at all times.
Opening and closing the windows
Procedure
• Push the lock (173) up.
173
• Move the window forward or back.
• Insert the lock in the stop (174).
174
02.11 EN
125

8.2 Emergency Exit
If a locking pin in the closing mechanism is removed, the right side window can be
used as an emergency exit.
Procedure
• Open the window to its normal open position
• Use the upper ring to pull the locking pin out of the closing mechanism.
• Open the window all the way.
8.3 Driver'S Seat Heater
175
S12 S13 S15
S7 S8 S24
X28
S20 S26 S30

S4 S5 S6
XR9
Switching the seat heating on and off (optional equipment)
Procedure
• Press the seat heating switch (175).
Switch setting 1 = Seat heating on.
Switch setting 0 = Seat heating off.
02.11 EN
126

8.4 Adjusting the Multifunction Display
To ensure an optimum view of the

multifunction display, it can be individually
adjusted.
Procedure 176
• Sit on the driver's seat. 177
• Adjust the seat to its optimum position.
• Loosen the central wing screw (176) of the
display holder just enough so that the two
ball joints (177) can be moved freely in the
holder.
• Move the display to the desired position and
retighten the central wing screw (176).
8.5 Fire Extinguisher
Procedure
• Open the fasteners (178)
• Pull the fire extinguish out of its bracket 178
Z To operate, refer to the illustrations on the fire
extinguisher
02.11 EN
127

8.6 Rockinger Coupling with Hand Lever
Z Refer to the instructions for towing trailers, (see "Towing trailers" on page 123).
179 180
CAUTION!
Incorrectly coupled trailers can cause 181
accidents
XMake sure the coupling is engaged
securely before starting the truck.
XThe contro pin (181) must be flush with
the control sleeve (179).
Rockinger Coupling Operation

Attaching a trailer
Procedure
• Prevent the trailer from rolling away.
• Adjust the trailer pull rod to the height of the
coupling.
• Pull up on the hand lever (180).
• Slowly reverse the truck until the coupling engages.
• Press down on the hand lever (180).
Disconnecting a trailer
Procedure
• Prevent the trailer from rolling away.
• Pull up on the hand lever (180).
• Drive the truck forward.
• Press down on the hand lever (180).
02.11 EN
128

9 Troubleshooting
9.1 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:
– The brakes are activated and the truck decelerates sharply

– STOP flashes on the multifunction display
– An error code appears in the multifunction display
If the emergency brake is activated, the truck can be moved to a safe location by
activating emergency mode (see Activating Emergency Mode on page 124 and
Driving in Emergency Mode on page 125). This not not apply, however, if the error is
in the magnetic coil for the parking brake, in the earth connection for the brake pedal
or in the pressure sensor. If one of these components is faulty, the truck cannot be
driven and must be repaired by a qualified specialist as soon as possible.
!
828
0 0 1/2 1/1
40 80 120
14.04.08
07:43 P RND1 MENU P
ESC F1 F2 F3 F4 F5
Activation of Emergency Mode
Requirements
– The automatic emergency brake is activated due to a serious error (see Automatic
Emergency Brake on page 123).
Z Emergency mode cannot be activated for certain serious errors.
Procedure
• Press the "F4" button until the multifunction display shows LIMP HOME (emergency
mode).
• Activate emergency mode with the "F3" button. When emergency mode is
02.11 EN
activated, the menu disappears over the row of function keys.
129

P RND1 0
0
0 0
LIMP Disg-
SETUP
HOME Nostic
ESC F1 F2 F3 F4 F5
Procedure
• Press the "ESC" key to exit the current menu area and return to the travel mask.
LIMP HOME flashes on the multifunction display.
!
828
0 0 1/2 1/1
40 80 120
14.04.08
07:43 P RND1 MENU P
ESC F1 F2 F3 F4 F5
Procedure
• Choose the travel direction with the travel direction switch.
The parking brake can now be deactivated ((see "Parking brake" on page 106)).
The truck can now travel at max. 1200 rpm. Error messages continue to appear in
the display.
CAUTION!
The braking pattern deteriorates when driving in emergency mode. In some
cases the brakes may not work. There is a higher risk of accidents and injury.
CAUTION!
Emergency mode must only be used to move the truck to a location where it can
be securely parked. Then the truck must be repaired as soon as possible by a
qualified specialist. Never use emergency mode for normal work with the truck!
02.11 EN
130

9.2 Troubleshooting
This chapter enables the user to identify and rectify basic faults and the effects of
incorrect operation. When trying to locate a fault, proceed in the order shown in the
table.
Z 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.
Additional troubleshooting must only be performed by the manufacturer’s specialist
service engineers. The manufacturer's customer service department is specially
trained to carry out these operations.
In order for customer services to react quickly and specifically to the fault, the
following information is essential:
- Truck serial number
- Error number on the display unit (if applicable)
- Error description
- Current location of truck
Fault Possible cause Remedy

Starter motor Battery isolator is not Switch on the battery isolator
is not working switched on
Faulty fuse Check fuses
Battery charge too low Check battery charge, charge battery if
necessary
Battery terminal cable Clean and grease terminals, tighten battery
loose or terminals terminal cable
oxidized
Motor does Air filter contaminated Clean / replace air filter
not start Fuel filter clogged Replace the fuel filter
Gear oil Gear oil too hot Motor speed is automatically reduced
temperature
indicator
flashing
Motor running Travel direction lever in Set travel direction lever to the required
but truck does neutral position travel direction
not travel Parking brake applied Release the parking brake
Lift speed too Hydraulic reservoir oil Check hydraulic oil, top up if necessary
low level too low
Hydraulic reservoir Clean / replace hydraulic reservoir discharge
discharge system system
contaminated or
clogged
Load cannot Hydraulic reservoir oil Check hydraulic oil, top up if necessary
be raised to level too low
max. height
Excessive Air in steering system Check hydraulic oil level and top up if
02.11 EN
steering play necessary, then turn the steering wheel

several times from one end stop to the other.
131

9.3 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.
XOnly use vehicles to tow the truck which have sufficient tow and brake forces for the
trailer load without its own braking system.
XAlways use a pull rod to tow.
XAlways tow the truck at walking pace.
XDo not park the truck with the parking brake released.
XOne person must be seated in the recovery truck to steer it and one person must be
seated on the towed truck.
The brake system is designed so that the parking brake is automatically activated
when the truck comes to rest. It must therefore be released for towing as described
below.
DANGER!
XPrevent the truck from rolling away.
Emergency release of the parking brake
Procedure
• If the pressure supply fails, the parking
brake can be released mechanically as 182
follows:
Park the truck on a level surface and 183
prevent it from rolling away. 184
• Loosen and unscrew the screw cap (184).
• Loosen the retaining nut (182). Manually
turn the adjusting screw (183) anti-
clockwise with the Allen key until the brake
disk is clear.
Z A torque of at least 40 Nm (SW8) / 70 Nm
(SW10) on the adjusting screw is required
for emergency releasing.
• Counter-fix the retaining nut (182) manually. Fit the screw cap to protect against
contamination and insert it by several threads.
DANGER!
XThe parking brake is non-operational in this condition. Use other methods to prevent
the truck from rolling away.
XAdjust the parking brake before starting up the truck again.
Z
02.11 EN
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.
132

DANGER!
XThe default setting must normally be set by the manufacturer's Customer Service.
Towing the Truck

Procedure
• Attach the tow bar to the trailer coupling of the recovery vehicle and the truck to be
recovered.
• Remove the device to prevent the truck from rolling away.
• Tow the truck at max. 2 km/h.
DANGER!
XOne person must be seated in the towed truck to steer it.
Z As the power steering does not work when the truck is being towed, it takes
considerably more effort to steer it.
02.11 EN
133

9.3.2 Emergency lowering
Z The mast can be lowered manually if a fault occurs in the hydraulic system.
WARNING!
Lowering the mast can result in injuries
XInstruct other people to move out of the hazardous area of the truck during
emergency lowering.
XOnly operate the emergency lowering valve when standing next to the truck.
XEmergency lowering of the mast cannot be applied when the load handler is in the
rack.
Procedure
• Turn key switch to "0".
185
• Loosen the red cap (187) on the solenoid
valve on the valve block somewhat. 186
• Carefully loosen the nut (185) on the
emergency lowering valve (186).
• The mast lowers slowly. 187
• Control the lowering speed with the nut
(185).
• When the mast and the load handler have
been lowered, torque the nut (185) to 2.5 -
3.0 Nm. Tighten the red cap (187) finger
tight again.
WARNING!
Only return the truck to service when you
have identified and rectified the fault.
02.11 EN
134

9.3.3 Starting aid
WARNING!
Danger from overheating

XOnly 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.
• Tilt the cab of the truck until the retaining
device (188) is locked in position 188
• First connect the positive terminal of the
feeder battery to the positive terminal of
the truck battery (189) with the red lead.
• Connect the negative terminal of the
feeder battery and the earth point of the 189
crane eye on the engine with the black
lead.
• Use a ladder to change the truck height
and reach through the open side window to
start the truck motor with the ignition key
with the cab fully tilted.
• Start the motor as normal.
• When the motor has started first remove
the negative lead followed by the positive
lead
Z If the starter motor does not switch on the motor after connecting the battery
terminals, check that the battery terminal clips are positioned correctly.
02.11 EN
135

02.11 EN
136

F Industrial Truck Maintenance
1 Operational Safety and Environmental Protection
The checks and servicing operations contained in this chapter must be performed in
accordance with the intervals as indicated in the servicing checklists.
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.
Do not bond the front window with adhesive.
Exception: Owners should only make changes or have changes made to powered
industrial trucks if the truck manufacturer is no longer operating in the field and there
is no successor to the business; owners must however:
– Ensure that the changes to be made are planned, tested and performed by a
specialist engineer in industrial trucks taking safety into account.
– keep permanent graphic records of the plans, tests and completion of the changes
– carry out and have authorised the respective changes to the capacity data plates,
decals and stickers as well as the operator and service manuals.
– attach permanent and clearly visible marking to the truck indicating the types of
changes made, the date of the changes and the name and address of the
organisation responsible for the work.
NOTE
Only original spare parts have been certified by our quality assurance department. To
ensure safe and reliable operation of the truck, use only the manufacturer's spare
parts.
For safety reasons, only components which have been specially agreed by the
manufacturer for this truck may be installed near the computer, controllers and wire
guidance sensors (antennae). These components (computers, controllers, wire
guidance sensors (antennae)) must therefore not be replaced either by similar
components from other trucks of the same series.
Z On completion of inspection and service work, carry out the operations listed in the
“Recommissioning the truck after cleaning or maintenance work” section ((see
"Restoring the truck to service after maintenance and repairs" on page 190)).
02.11 EN
137

2 Maintenance Safety Regulations
Maintenance and repair personnel
Truck maintenance and repair work must only be carried out by specially trained
personnel. A maintenance contract with the manufacturer will ensure trouble-free
operation. The manufacturer’s service department has customer service technicians
specially trained for these tasks.
Lifting and Jacking up
WARNING!
Lifting and jacking up the truck safely

When raising the truck, the lifting gear must only be secured to the points specially
provided for this purpose.
You may only work under a raised load handler / cab if they have been secured with
a sufficiently strong chain or the fastening bolt.
In order to raise and jack up the truck safely, proceed as follows:
XJack up the truck only on a level surface and prevent it from moving accidentally.
XAlways use a jack with sufficient capacity. When jacking up the truck, take
appropriate measures to prevent it from slipping or tipping over (e.g. wedges,
wooden blocks).
XWhen raising the truck, the lifting slings must only be secured to the points specially
provided for this purpose, (see "Identification points and data plates" on page 36).
XWhen jacking up the truck, take appropriate measures to prevent it from slipping or
tipping over (e.g. wedges, wooden blocks).
02.11 EN
138

Cleaning
CAUTION!
Fire hazard
Do not use flammable liquids to clean the industrial truck.
XAlways disconnect the battery before starting cleaning work.
XCarry out all necessary safety measures to prevent sparking before cleaning (e.g.
by short-circuiting).
CAUTION!
Risk of electrical system damage

The electrical system can be damaged if it is cleaning with water. It is prohibited to
clean the electrical system with water.
XDo not clean the electrical system with water.
XClean the electrical system with weak suction or compressed air (use a compressor
with a water trap) and not a conductive, anti-static brush.
CAUTION!
Risk of component damage when cleaning the truck
If the truck is to be cleaned with a water jet or a high-pressure cleaner, all electrical
and electronic components must be carefully covered beforehand as moisture can
cause malfunctions. Do not clean with pressurised water.
Z After cleaning, carry out the operations detailed in “Recommissioning the truck after
cleaning or maintenance work” ((see "Restoring the truck to service after
maintenance and repairs" on page 190)).
02.11 EN
139

Electrical system
CAUTION!
Accident risk from Electrical system:

XOnly trained personnel may work on the electrical system.
XBefore working on the electrical system, all precautionary measures must be taken
to avoid electrical accidents.
XThe connecting leads on the starter battery must be disassembled to disable it.
WARNING!
Electric currents can cause accidents

Make sure the electrical system is voltage-free before starting work on it. Before
starting maintenance on the electrical system:
XPark the truck securely ((see "Parking the truck securely" on page 100)).
XPress the Emergency Disconnect.
X Disconnect the battery.
XRemove any rings or metal bracelets etc. before working on electrical components.
Consumables and used parts
CAUTION!
Consumables and used parts are an environmental hazard
Used parts, oils and fuels must be disposed of in accordance with the relevant
environmental protection regulations. To change the oil contact the manufacturer's
customer service department, who have been specially trained for this task.
XNote the safety regulations when handling these materials.
Welding
Remove electrical and electronic components from the truck before performing
welding operations, to avoid damage.
Settings
When repairing or replacing hydraulic, electric or electronic components or
assemblies, always note the truck-specific settings.
02.11 EN
140

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.
XWhen replacing tyres make sure the truck is not skewed.
XAlways replace tyres in pairs, i.e. left and right at the same time.
Z When replacing rims and tyres fitted at the factory, only use the manufacturer’s
original spare parts. Otherwise the manufacturer’s specifications cannot be
ensured.
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.
XLift chains should only be cleaned with paraffin derivatives e.g. petroleum or diesel
fuels.
XNever clean lift chains with steam jet high pressure cleaners, cold or chemical
cleaning agents.
XImmediately after cleaning, dry the lift chain with compressed air and apply a chain
spray.
XAlways lubricate a lift chain when it is discharged.
XLubricate a lift chain with particular care around the pulleys.
WARNING!
Diesel fuel can be hazardous
XDiesel fuel can cause irritation if it comes into contact with the skin. Rinse any
affected areas thoroughly.
XIf it comes into contact with the eyes rinse them immediately with flowing water and
call for a doctor.
XWear safety gloves when handling diesel fuels.
02.11 EN
141

Hydraulic hoses
WARNING!
Brittle hydraulic hose lines can cause accidents

The hoses must be replaced every six years. The manufacturer's customer service
department is specially trained to carry out these operations.
XComply with the safety regulations for hydraulic hose lines in accordance with BGR
237.
WARNING!
Hydraulic line leaks can cause accidents
Hydraulic oil can escape from leaky and faulty hydraulic lines.
XSpilled fluids must be removed immediately with an appropriate bonding agent. The
bonding agent / consumable mixture must be disposed of in accordance with
regulations.
WARNING!
Hairline cracks in the hydraulic lines can cause injury and infection
Pressurised hydraulic oil can penetrate the skin through fine holes or hairline cracks
in the hydraulic lines, causing severe injury.
XCall for a doctor immediately if you are injured.
XDo not touch pressurised hydraulic lines.
XSpilled fluids must be removed immediately with an appropriate bonding agent. The
bonding agent / consumable mixture must be disposed of in accordance with
regulations.
WARNING!
Danger from hot fluids and components!
XConsumables (hydraulic oil, engine oil, coolant) and power train components
(engine, manifold, exhaust system, turbo charger etc.) get very hot during
operation.
XWhen carrying out maintenance and repairs wear suitable protective clothing
(gloves etc.) to avoid getting burned.
02.11 EN
142

3 Servicing and Inspection
Thorough and expert servicing is one of the most important requirements for the safe
operation of the industrial truck. Failure to perform regular servicing can lead to truck
failure and poses a potential hazard to personnel and equipment.
WARNING!
The application conditions of an industrial truck have a considerable impact on the

wear of the service components.
We recommend that a Jungheinrich customer service adviser carries out an
application analysis on site to work out specific service intervals to prevent damage
due to wear.
The service intervals stated are based on single shift operation under normal
operating conditions. They must be reduced accordingly if the truck is to be used in
conditions of extreme dust, temperature fluctuations or multiple shifts.
The following servicing checklist indicates the operations to be performed and the
respective intervals to be observed. Maintenance intervals are defined as:
W = Every 50 service hours, at least weekly

A = Every 500 service hours
B = Every 1000 service hours, or at least annually
C = Every 2000 service hours, or at least annually
t = Standard maintenance interval
Cold store maintenance interval (in addition to standard maintenance
k =
interval)
Z W maintenance intervals must be performed by the owner.
During the run-in period – after approx. 100 service hours – the owner must check the
wheel nuts / bolts and re-tighten if necessary.
02.11 EN
143

4 Maintenance checklist
4.1 Maintenance checklist DFG
Brakes W A B C
1 Test brakes. t
2 Test brakes. t
3 Check the brake lining on the parking brake. t
4 Check connections and lines for leaks. t
Electrical System W A B C
Test warning and safety devices in accordance with operating
1 t
instructions.
Test warning and safety devices in accordance with operating t
2
instructions.
3 Test displays and controls. t
4 Test the main switch / isolator. t
5 Check contactors and/or relays. t
6 Check fuse ratings. t
Check electric wiring for damage [insulation damage, connections]. t
7
Make sure wire connections are secure.
Power Supply W A B C
1 Check the fuel system, tank and lines for leaks and damage. t
Check the battery cable connections are secure, grease terminals if t
2
necessary.
Check the battery cable connections are secure, grease terminals if
3 t
necessary.
4 Check the battery and battery components. t
6 Check battery voltage. t
Travel W A B C
1 Replace transmission oil filter. t
Check transmission oil level or grease filling of the transmission and t
2
top up if necessary.
3 Replace the axle return filter. t
4 Test exhaust system and check for leaks and damage. t
5 Test anti-freeze, top up if necessary. t
6 Replace radiator fluid and anti-freeze. t
7 Check cooling system for leaks. t
8 Check coolant level and top up if necessary. t
02.11 EN

10 Test hydraulic fans and check for leaks. t
144

Travel W A B C
11 Clean the engine oil cooler. t
12 Check and clean radiator. t
13 Check transmission for noise and leakage. t
14 Replace gear oil. t
15 Check tyre air pressure and top up if necessary. t
17 Check wheels for wear and damage. t
19 Check wheel bearing and attachment. t
20 Test starter motor and generator, check wires and attachment. t
21 Replace the motor discharge filter. t
22 Replace fuel filter. t
23 Replace the fuel pre-filter. t
24 Replace engine oil filter. t
25 Check V belt / multi-V belt is tensioned and check for damage. t
26 Replace air filter. t
27 Check air filter, replace if necessary. t
28 Check motor for noise and leakage. t
29 Replace engine oil. t
30 Check engine oil level, top up if necessary. t
31 Check valve setting and adjust if necessary t
32 Check engine suspension. t
33 Test water pump and the fans. t
34 Check glow plugs. t
35 Check fuel/water separator and discharge if necessary. t
36 Replace drive axle oil. t
Chassis and superstructure W A B C

1 Check chassis and screw connections for damage. t
2 Check the doors and covers. t
4 Check labels are legible and complete. t
6 Check attachment and setting function of the driver's seat. t
7 Check condition of the driver’s seat. t
Check the motor compartment for contamination and clean if t
8
necessary.
9
necessary.
10 Check attachment of the counterweight. t
11 Check mast attachment / mounting. t
02.11 EN
12 Check trailer coupling or tow mechanism stop. t
145

Check the overhead guard and / or cab are secure and check for
13 t
damage.
14 t
damage.
15 Check operator mat and steps are non-slip and damage-free. t
16 Test driver's seat restraint system and check for damage. t
Hydraulic Operation W A B C
Test the "hydraulic" controls and make sure the labels are present,
1 t
legible and complete.
Test hydraulic controls and check they are assigned to the correct t
2
functions.
Check cylinders and piston rods for damage and leaks, and make t
3
sure they are secure.
Check the running surfaces of the integral sideshifter and / or integral
4 t
fork adjuster for wear and damage, and lubricate if necessary.
Check settings and wear levels of sliding pieces and stops and
5 t
adjust the sliding pieces if necessary.
6 Check load chain setting and tension if necessary. t
7 Check load chain lubrication and lubricate if necessary. t
Check lateral clearance of the mast connections and the fork
9 t
carriage.
Visually inspect the mast rollers. Check the wear on the running
10 t
surfaces.
Check the running surfaces of the mast for wear and damage, and
11 t
lubricate if necessary.
12 Test hydraulic system. t
14 Replace hydraulic reservoir discharge paper filter. t
15 Replace hydraulic oil filter. t
Check that hydraulic ports, hose and pipe lines are secure, check for t
16
leaks and damage.
17 Test emergency lowering system. t
18 Check hydraulic oil level and top up if necessary. t
20 Test pressure limitation valve and adjust if necessary. t
21 Replace hydraulic oil. t
22 Check fork tines or load handler for wear and damage. t
02.11 EN
146

24 Check mast tilt. t
Check piston rod screw depth and counter fixing / clamp. Where two t
25 tilt cylinders with the same stroke length are used, check their setting
in respect of each other.
26 Check tilt cylinders and mounting. t
27 Test lift and lowering speeds. t
Agreed performance levels W A B C

Carry out a test run with rated load, if necessary with a customer-
1 t
specific load.
2 Demonstration after servicing. t
3 Lubricate the truck according to the lubrication schedule. t
Steering W A B C
1 Test hydraulic steering and its components. t
2 Test the hydraulic steering for leaks. t
3 Check steer axle and stub axle for wear and damage. t
4 Check the stub axle and adjust if necessary. t
5 Grease the steer axle. t
6 Check mechanical parts of steering column. t
4.2 Maintenance checklist TFG
Brakes W A B C
1 Test brakes. t
2 Test brakes. t
3 Check the brake lining on the parking brake. t
4 Check connections and lines for leaks. t
Electrical System W A B C
Test warning and safety devices in accordance with operating
1 t
instructions.
Test warning and safety devices in accordance with operating t
2
instructions.
3 Test displays and controls. t
4 Test the main switch / isolator. t
5 Check contactors and/or relays. t
6 Check fuse ratings. t
Check electric wiring for damage [insulation damage, connections]. t
7
Make sure wire connections are secure.
02.11 EN
147

Power Supply W A B C
1 Final adjustments to the LPG system. t
2
necessary.
3
necessary.
6 Check battery voltage. t
7 Check the exhaust levels and adjust if necessary. t
Note: The LPG system may only be inspected by LPG system
8
experts.
9 Test the LPG system and check for leaks and damage. t
10 Replace the LPG filter. t
Travel W A B C
1 Replace transmission oil filter. t
Check transmission oil level or grease filling of the transmission and t
2
top up if necessary.
3 Replace the axle return filter. t
4 Test exhaust system and check for leaks and damage. t
5 Test anti-freeze, top up if necessary. t
6 Replace radiator fluid and anti-freeze. t
7 Check cooling system for leaks. t
10 Test hydraulic fans and check for leaks. t
11 Clean the engine oil cooler. t
12 Check and clean radiator. t
13 Check transmission for noise and leakage. t
14 Replace gear oil. t
19 Check wheel bearing and attachment. t
20 Test starter motor and generator, check wires and attachment. t
21 Replace engine oil filter. t
22 Check V belt / multi-V belt is tensioned and check for damage. t
23 Replace air filter. t
24 Check air filter, replace if necessary. t
25 Check motor for noise and leakage. t
02.11 EN
26 Replace engine oil. t
148

Travel W A B C
27 Check engine oil level, top up if necessary. t
28 Check engine suspension. t
29 Test water pump and the fans. t
30 Replace the spark plugs. t
31 Replace drive axle oil. t

1 Check chassis and screw connections for damage. t
6 Check attachment and setting function of the driver's seat. t
7 Check condition of the driver’s seat. t
8
necessary.
9
necessary.
10 Check attachment of the counterweight. t
11 Check mast attachment / mounting. t
12 Check trailer coupling or tow mechanism stop. t
13 t
damage.
14 t
damage.
15 Check operator mat and steps are non-slip and damage-free. t
Test the "hydraulic" controls and make sure the labels are present,
1 t
legible and complete.
Test hydraulic controls and check they are assigned to the correct t
2
functions.
Check cylinders and piston rods for damage and leaks, and make t
3
sure they are secure.
Check the running surfaces of the integral sideshifter and / or integral
4 t
fork adjuster for wear and damage, and lubricate if necessary.
Check settings and wear levels of sliding pieces and stops and
5 t
adjust the sliding pieces if necessary.
6 Check load chain setting and tension if necessary. t
02.11 EN
149

Check lateral clearance of the mast connections and the fork
9 t
carriage.
Visually inspect the mast rollers. Check the wear on the running
10 t
surfaces.
Check the running surfaces of the mast for wear and damage, and
11 t
lubricate if necessary.
14 Replace hydraulic reservoir discharge paper filter. t
15 Replace hydraulic oil filter. t
Check that hydraulic ports, hose and pipe lines are secure, check for t
16
leaks and damage.
17 Test emergency lowering system. t
20 Test pressure limitation valve and adjust if necessary. t
21 Replace hydraulic oil. t
24 Check mast tilt. t
Check piston rod screw depth and counter fixing / clamp. Where two t
25 tilt cylinders with the same stroke length are used, check their setting
in respect of each other.
26 Check tilt cylinders and mounting. t
27 Test lift and lowering speeds. t
Agreed performance levels W A B C

Carry out a test run with rated load, if necessary with a customer-
1 t
specific load.
2 Demonstration after servicing. t
3 Lubricate the truck according to the lubrication schedule. t
Steering W A B C
1 Test hydraulic steering and its components. t
2 Test the hydraulic steering for leaks. t
3 Check steer axle and stub axle for wear and damage. t
4 Check the stub axle and adjust if necessary. t
5 Grease the steer axle. t
6 Check mechanical parts of steering column. t
02.11 EN
150

4.3 DFG/TFG Options Maintenance Checklist
Particle filter (o)
Particle filter W A B C
Measure the soot index according to the manufacturer's
1 t
specifications or national regulations.
Note: All work carried out on the particle filter system must only be
2
performed by specialist personnel.
Particle filter: clean the filter in accordance with the manufacturer's
3
instructions.
Particle filter system: check and clean the components in
4
accordance with the manufacturer's instructions.
Work platform (o)
Work platform W A B C
Check the attachment is properly secured to the truck and the
1 t
supporting elements.
Clamping device (o)
Clamping device W A B C
1 Test the hose reel and check for leaks and damage. t
Attachment: check bearing points, guides and stops for wear and t
2
damage, grease and clean these components.
3 Attachment: clean and lubricate. t
Check the axial play of the front and rear rollers and adjust if t
5
necessary.
Check the attachment is properly secured to the truck and the t
6
Test the operation and setting of the attachment. Check the t
7
attachment for damage.
8 Check the sliding blocks are complete. t
9 Check the hydraulic ports and tighten if necessary. t
10 Check the cylinder seals. t
11 Check the cylinder piston rods and bushings. t
Crane hook (o)
Crane hook W A B C
1 t
02.11 EN
151

Load backrest (o)
Load backrest W A B C
1 t
Sideshifter (o)
Sideshifter W A B C
1 Test the hose guide and check for leaks and damage. t
2
5 Check axial play of the front and rear rollers and adjust if necessary. t
Check attachment is properly secured to the truck and the t
6
Test operation and setting of the attachment. Check the attachment t
7
for damage.
8 Check sliding blocks are complete. t
9 Check hydraulic ports and tighten if necessary. t
10 Test the sideshifter, check settings and check for damage. t
11 Check cylinder seals. t
12 Check cylinder piston rods and bushings. t
Boom (carpet boom) (o)
Boom (carpet boom) W A B C

1 t
Fork adjuster (o)
Fork adjuster W A B C
2
Check the axial play of the front and rear rollers and adjust if t
5
necessary.
Check the attachment is properly secured to the truck and the t
6
Test the operation and setting of the attachment. Check the t
7
attachment for damage.
02.11 EN
152

Fork adjuster W A B C
8 Check the sliding blocks are complete. t
9 Check the hydraulic ports and tighten if necessary. t
10 Test the fork adjuster, check the settings and check for damage. t
11 Check the cylinder seals. t
12 Check the cylinder piston rods and bushings. t
Discharge strap (o)
Discharge strap W A B C
1 Check the anti-static discharge strap is present and not damaged. t
Audible warning device (o)
Audible warning devices W A B C

Test the buzzer / warning alarm, check for damage and make sure it
1 t
is secure.
Strobe light / beacon (o)
Strobe light/beacon W A B C
Test the strobe light/beacon, check for damage and make sure it is
1 t
secure.
Test the strobe light/beacon, check for damage and make sure it is t
2
secure.
Work lights (o)
Work lights W A B C
1 Test the lights. t
Road traffic approval (StVZO) (o)
Road traffic approval (StVZO) W A B C

Hose reel (o)
Hose reel W A B C
02.11 EN
153

Truck Management Information System "ISM" (o)
Truck Management Information System "ISM" W A B C

1 Test access module, check for damage and make sure it is secure. t
2 Check impact sensor is secure and check for damage. t
3 Check data recorder is secure and check for damage. t
Heating (coolant water) (o)
Heating (coolant water) W A B C

1 Test the heating. t
2 Test the heating. t
3 Replace the heating breather t
Check the hoses for leaks and damage and make sure they are
4 t
secure.
Air conditioning system (o)
Air conditioning system W A B C

Note: service the air conditioning system every two years or 2000
1 service hours. The air conditioning system should only be serviced
by specialist personnel.
Air conditioning system: Test the air conditioning system and its
2 t
settings and check its components for damage.
Air conditioning system: Visually inspect the filter and replace if
3 t
necessary.
Air conditioning system: Check temperature reading at the outlet of
4 t
the ventilation nozzles against manufacturer's ratings.
Wiper/washer system (o)
Wiper/washer system W A B C
Check the wiper water container for leaks and check the volume, top
1 t
up if necessary.
Check the wiper water container for leaks and check the volume, top
2 t
up if necessary.
Test the windscreen wipers and check for damage, replace if
3 t
necessary.
Trailer coupling (o)
Trailer coupling W A B C
1 Check the trailer coupling or tow mechanism stop. t
Belt lock control (o)

02.11 EN
Belt lock control W A B C

1 Test the belt lock control and check for damage. t
154

Seat heating (o)
Seat heating W A B C
Check the electric wiring for damage [insulation damage,
1 t
connections]. Make sure the wire connections are secure.
Weigher sensors / switches (o)
Weigher sensors / switches W A B C

1 Test weigher and check for damage. t
Electrical optional equipment (o)
Electrical optional equipment W A B C

1 Test the electrical optional equipment and check for damage. t
Fire extinguisher (o)
Fire extinguisher W A B C
Check the fire extinguisher is present, secure and check the test
1 t
interval.
Optional equipment (reference) (o)
Optional equipment W A B C
Check that optional equipment such as mirrors, storage
1 compartments, grips, windscreen wipers and washing systems etc. t
are working correctly and check for damage.
Check that optional equipment such as mirrors, storage
2 compartments, grips, windscreen wipers and washing systems etc. t
are working correctly and check for damage.
02.11 EN
155

5 Lubricants and Lubrication Schedule
5.1 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.
XKeep consumables away from hot components and naked flames.
XAlways keep consumables in prescribed containers.
XAlways fill consumables in clean containers.
XDo not mix up different grades of consumable. The only exception to this is when
mixing is expressly stipulated in the operating instructions.
CAUTION!
Spilled liquids can cause slipping and endanger the environment
Risk of slipping from spilled liquids. The risk is greater when combined with water.
XDo not spill fluids.
XSpilled fluids must be removed immediately with an appropriate bonding agent.
XThe bonding agent / consumable mixture must be disposed of in accordance with
regulations.
WARNING!
Oils (chain spray / hydraulic oil) are flammable and poisonous.
XDispose of used oils in accordance with regulations. Store used oil safely until it can
be disposed of in accordance with regulations.
XDo not spill oil.
regulations.
XObserve national regulations when handling oils.
XWear safety gloves when handling oils.
XPrevent oil from coming into contact with hot motor parts.
XDo not smoke when handling oil.
XAvoid contact and digestion. If you swallow oil do not induce vomiting but call for a
doctor immediately.
XSeek fresh air after breathing in oil fumes or vapours.
XIf oil has come into contact with your skin, rinse your skin with water.
XIf oil has come into contact with your eyes, rinse them with water and call for a doctor
immediately.
02.11 EN
XReplace oil-soaked clothing and shoes immediately.
156

Consumables and used parts
CAUTION!

02.11 EN
157

5.2 Lubrication Schedule
190 190
191 198 197 196 195 194 193 192
199 198 200 201 202 203 204 204
199 200 208 207 206 205 205
Grease nipple
Number
190 Chain sprocket 2/4
198 Mast, suspension 2
191 Tilt cylinder front bearing 2
199 Mast rollers 8/10/12
200 Tilt cylinder rear bearing 2
201 Cardan shaft 2
204 Stub axle pins 4
205 Track rod 4
Dipstick and filling points

193 Hydraulic oil filler plug (in the motor compartment)
02.11 EN
195 Fuel filler neck
158

Dipstick and filling points
202 Battery (in the motor compartment)
203 Engine oil filler neck
206 Coolant tank
207 Engine oil dipstick
208 Filler neck for window washer system
Lowering points
192 Wheel hub, right
194 Hydraulic oil (right tank)
196 Fuel (left tank)
197 Wheel hub, left
02.11 EN
159

5.3 Consumables
DFG/TFG 660-S90
Item Order no. Quantity Description Used for
199 14038650 Lithium w. MOS NLGI 2 Grease
lubrication
206 51118018 16 l Fricofin G12 Plus Mix coolant with
water 1:1
193 52017728 4 cylinders 150 HVLP 46 Hydraulics
l
6 cylinders 190
l
8 cylinders 170
l
203 51094056 4 cylinders 7 l DHD 1 Motor
6 cylinders 15 l API CH-4, CI 4
8 cylinders 6.5 l SAE 10W40
Item Order no. Quantity Description Used for

51170122 25 l JD 20 C Transmission
Textran TDH Premium
51050011 2 x 0.9 API GL 5 Reducing gear
MIL-L-2105 D
SAE 85W-90
51050011 9l API GL 5 Drive shaft
MIL-L-2105 D Single
51050011 12 l API GL 5 Drive shaft
MIL-L-2105 D Wide/twin
* The coolant consists of a 1:1 mixture ratio of Fricofin S and water

Z The volumes indicated are approximate.
WARNING!
Using incorrect hydraulic oil can be dangerous
XDo not use hydraulic oils with a different specification or viscosity and do not mix
with additives.
02.11 EN
160

5.4 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.
Z Always use clean, soft water. Do not use distilled water.
NOTE
Anti-freeze/water mixture ratio:

X1: 1 (anti-freeze to -35°C)
XNever mix different types of anti-freeze.
NOTE
Corrosion damage
XEven if the coolant cannot freeze up due to the application conditions, you must still
use anti-freeze. The anti-freeze provides protection against corrosion and raises the
boiling point of the coolant.
The quality of the anti-freeze must be checked at least annually, e.g. at the start of the
cold season.
If the correct procedures are not applied, the manufacturer cannot be held liable for
frost or corrosion damage.
DANGER!
Anti-freeze is poisonous
XAnti-freeze contains ethylene glycol and other components which can result in
poisoning if ingested.
XIngression into the human body can also result if poisonous quantities come into
contact with the skin for long or repeated periods.
XNote the manufacturer’s safety instructions.
02.11 EN
161

6 Maintenance and repairs
6.1 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
162
• Park the truck securely, (see "Parking the
truck securely" on page 100).
• Fully lower the load handler.
• Remove the key (209) from the key
switch (68) to prevent the truck from being
switched on accidentally.
• Turn the battery isolator (162) to position A
"B".
WARNING!
B
Risk of accidents when working under
the load handler, driver's cab and lift
truck
XWhen working under a raised load
handler, driver's cab or a raised truck,
secure them to prevent the truck from from
lowering, tipping or sliding away.
XWhen raising the truck, follow the
instructions, (see "Transport and
Commissioning" on page 41). When
working on the parking brake, prevent the
truck from accidentally rolling away (e.g.
with wedges).
68 209
02.11 EN
162

6.2 Opening the Service Panel
There is a service panel between the cab and the

cooler (210). The coolant level and engine oil can be
checked here and coolant engine oil and cleaning
agent for the window washer system can be added.
Opening the Service Panel

Requirements
– Prepare the truck for maintenance and repairs
((see "Preparing the truck for maintenance and
repairs" on page 162)).
Procedure
• Raise the service panel (210).
The rear panel is now open.
210
6.3 Tilting the Cab
DANGER!
XBefore 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 (212) and 211
unlock the button (211). The muffler can 212
be carefully turned back as far as the
stop.
• After the cab is lowered, move the muffler back to its vertical position and lock it in
place.
6.3.1 Raising the Cab Manually
Procedure
• Remove the pump rod (215) from the
holder behind the driver's seat. 213
• The lift pump is fed into the cab through
inlets in the chassis on the right side of the
truck (213 = lift; 214 = lower)
CAUTION!
Before activating the lift pump always
close the lowering valve.
214
02.11 EN
163

•
• To close, insert the long side of the pump

rod through the infeed (214) onto the
hexagon of the lowering valve and turn
clockwise as far as the stop.
215
Lifting
Procedure
• To lift the cab, insert the short side of the
pump rod (215) through the infeed (213)
onto the pump drive and activate. Tilt the
cab back manually until the cab locking
device engages in the motor compartment.
215
02.11 EN
164

6.3.2 Lowering the Cab
Z The cab cannot be lowered electrically.
Procedure
• To lower the cab, use the lever (216) to
release the locking device (188) and lower
the cab.
214
• To lower the cab, insert the long side of the

pump rod (215) through the infeed (214)
onto the hexagon of the lowering valve and
carefully turn the lowering valve anti-
clockwise to open it.
215
DANGER!
No persons are permitted in the area
around the cab while it is being
lowered.
Z After the cab is lowered, return the muffler

to the vertical position.
188
216
02.11 EN
165

6.3.3 Raising the Cab Electrically (o)
DANGER!
XBefore 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 (212) and
211
unlock the button (211). The exhaust 212
purifier can be carefully turned back as
far as the stop.
CAUTION!
XBefore activating the lift pump always close the lowering valve.
• To close, insert the long side of the pump rod through the infeed (214) onto the
hexagon of the lowering valve and turn clockwise as far as the stop.
Lifting
Procedure
•
• Press switch (217) on the service panel.

The cab is tilted back electrically until the
cab locking device (188) engages.
217
•
• After the locking device (188) engages, it

must also be secured in place with the
lever (216).
6.3.4 Lowering the Cab

see section (see "Lowering the Cab" on 188
216
page 165).
DANGER!
No persons are permitted in the area
around the cab while it is being lowered.
02.11 EN
166

6.4 Checking the wheel attachments.
WARNING!
Using different tyres can cause accidents

The quality of tyres affects the stability and performance of the truck.
XThe diameter of the wheels must differ by no more than 15 mm.
XAlways replace tyres in pairs. After replacing the tyres check the wheel nuts are
secure after 10 service hours.
XAlways use tyres of the same make, model and profile.
Checking the wheel attachment 218

Requirements
– Prepare the truck for maintenance and
repairs ((see "Preparing the truck for
– Torque wrench
Procedure
• Torque the wheel nuts (218) crosswise with
a torque wrench, for torques (see "Tyre
type" on page 31).
The wheel attachment is now checked.
Z When using pneumatic tyres check the air pressure, for the air pressure (see "Tyre
type" on page 31)
02.11 EN
167

6.5 Hydraulic system
CAUTION!
The hydraulic oil is pressurised during operation and is a hazard to health and to the
environment.
XDo not touch pressurised hydraulic lines.
XDispose of used oil in accordance with regulations. Store used oil safely until it can
be disposed of in accordance with regulations.
XDo not spill hydraulic oil.
regulations.
XObserve national regulations when handling hydraulic oil.
XWear safety gloves when handling hydraulic oil.
XPrevent hydraulic oil from coming into contact with hot motor parts.
XDo not smoke when handling hydraulic oil.
XAvoid contact and digestion. If you swallow oil do not induce vomiting but call for a
doctor immediately.
XSeek fresh air after breathing in oil fumes or vapours.
XIf oil has come into contact with your skin, rinse your skin with water.
XIf oil has come into contact with your eyes, rinse them with water and call for a doctor
immediately.
XReplace oil-soaked clothing and shoes immediately.
CAUTION!
02.11 EN
168

6.5.1 Checking the hydraulic oil level
Requirements
– Park the truck on a level surface.
– Start the motor and fully raise and lower
the mast once.
– Switch off the motor.
Procedure
• Remove the hydraulic oil dipstick (219)
from the hole, wipe it with a clean cloth
and insert it fully again.
• Remove the hydraulic oil dipstick and
check the level of the hydraulic oil.
Z For cold oil: The oil level should lie 219
between the “Min.” and “Max.” levels.
For hot oil: The hydraulic oil should lie just
above the MAX marking.
• The difference between MIN and MAX is MAX
about 10 litres. MIN
• Add hydraulic oil if necessary.
• Repeat the test.
• When the oil level is correct, fully insert
the hydraulic oil dipstick (219) again.
02.11 EN
169

6.5.2 Adding hydraulic oil
Procedure
• Unscrew the lid (220) of the hydraulic
filter
• Add hydraulic oil to the MAX mark on the
hydraulic oil dipstick (221).
Z Use only approved hydraulic oil (see
consumables table).
• Check the hydraulic oil level with the
dipstick and top up as required.
• Screw the lid back on. 220
• Insert the dipstick back in fully.
221
MAX
MIN
02.11 EN
170

6.6 Engine maintenance
DANGER!
A running engine can be dangerous.

XThere is a high risk of injury when the cover is open and the engine running.
XDo not reach into moving parts (e.g. fan, belt drive).
XTruck maintenance and repair work must only be carried out by specially trained
personnel who have been authorised by the owner.
XThere must be nobody present in the danger zone.
02.11 EN
171

6.6.1 DFG engine maintenance
NOTE
Used oil contaminates the environment

XDispose of used oil and used engine oil filters in accordance with environmental
regulations.
CAUTION!
Risk of scalding through hot oil.
XWear appropriate safety gloves when replacing the oil and oil filter.
NOTE
When the engine is cold the engine oil can be viscous.

XOnly change the engine oil when the engine is at operating temperature and the
industrial truck is horizontal. Always replace the engine oil and engine oil filter
together.
Checking the engine oil level

Requirements
– Park the truck on a level surface (see
222
"Parking the truck securely" on
page 100)
Procedure
• Prepare the truck for maintenance and
repairs. MIN
MAX
• The engine oil dipstick (222) is located

under the service panel behind the cab.
• Remove the oil dipstick.
• Check the oil level with the dipstick.
• Check the oil level while the motor is
cold. If the motor is at operating
temperature, it must stand for at least 2 203
minutes before the oil level can be read
correctly.
• Add the correct grade of engine oil as
required through the filler neck (203)
when the oil level reaches the minimum
range. The difference between minimum
and maximum is about 0.75 litres.
The engine oil level has now been checked.
02.11 EN
172

6.6.2 Cooling System
NOTE
Lack of coolant can cause malfunctions

XThe coolant level should be between the “MIN” and “MAX” markings on the
expansion vessel.
XIf the coolant is below the MIN marking, this indicates possible leakage in the
radiator system.
XDo not continue using the truck.
XThe truck may only be started again once the cause has been removed.
CAUTION!
Hot coolant can cause injury
XAllow the engine to cool down sufficiently to prevent hot gases/liquids from escaping
when the filler cap is opened.
Checking the coolant level

Procedure
Z The cooling system compensation tank is
located on the left side of the truck in travel
direction on the service panel. 210
• Park the truck securely on a level surface.
• Open the service panel cover (210).
• Check the coolant level on the expansion
vessel (224).
• Close the service panel cover.
NOTE
The incorrect coolant can cause
malfunctions 223
XTo prevent the build up of lime as well as
front and corrosion damage in the
radiator system, and to raise the boiling 224
point temperature of the coolant, the
cooling circuit must be filled each year
with a mixture of water and anti-freeze
with anti-corrosion additives.
XCoolant can only be checked and added
by experts.
02.11 EN
173

Check the coolant concentrate

– Anti-freeze tester for coolants
Procedure
• Slowly unscrew the filler cap (223) from the expansion vessel (224).
• Check the anti-freeze content of the coolant with an anti-freeze tester.
NOTE
Incorrect coolant concentration can cause malfunctions
XIf there is insufficient anti-freeze content arrange for trained personnel to restore the
correct mix ratio.
• Screw the filler cap back on.

• Fit the rear bonnet again and snap it back into position.
Check the cooler and fan and clean if necessary

Procedure
Z The cooling unit is located under the service panel (210).
• Open the service panel (210) completely.
• Clean the cooling unit carefully using compressed air without touching the cooling
multi-plates.
• Close the service panel.
CAUTION!
A damaged cooler and fan can be dangerous
XCheck the cooler and fan for damage. If the radiator or fan are damaged, do not
operate the truck until the damage has been rectified.
CAUTION!
A broken fan can be dangerous

XUsing a suitable tool, check and make
sure that the fan can move freely.
XThe fan must not touch the deflector.
XOnly start the motor when the cover is 210
closed.
02.11 EN
174

6.6.3 Cleaning and Replacing the Air Filter Cartridge
DANGER!
A running motor can be dangerous

XCarry out all maintenance work with the motor switched off.
XDo not start the motor if the air filter cartridge is removed.
Replace air filter cartridge
Procedure
• Undo the end cap (225) and remove the
dust collector pot.
• Carefully remove the air filter cartridge from
the filter housing.
Cleaning the filter housing

Procedure
NOTE 225
A faulty motor can cause malfunctions
XDo not clean the air filter housing with compressed air.
XAlways use a clean cloth to clean the air filter housing.
• Remove the air filter cartridge.

• Thoroughly clean the dust collector pot. To do this remove the dust extraction valve.
• Carefully clean the air filter housing with a clean cloth.
Z There must be no residue from the cloth in the air filter housing.
• Insert the air filter cartridges back in the filter housing.
Z Take care not to damage the air filter cartridges when assembling.
• Fit the dust extraction valve back into the dust collector pot.
• Insert the dust collector pot and fasten the end cap (225) in place.
02.11 EN
175

6.6.4 Adding Window Washer System Fluid
Procedure
• Open the service panel.
• Unscrew the cover (208) and add
window washing fluid.
• If necessary top up with anti-freeze.
Z The capacity of the tank is 5 litres.
208
02.11 EN
176

6.7 Check the transmission oil level
Procedure
• Prepare the truck for maintenance and
repairs.
• Check the oil level with the dipstick (226).
Slowly insert the dipstick into the
transmission to prevent false
measurements.
Z Check the oil level for the transmission while
the motor is at idle. The oil must be at
operating temperature.
• Add the correct grade of transmission oil
through the filler neck as required. 226
6.8 Performing Other Maintenance Work
CAUTION!
MAX
XSpecial knowledge and in some cases
special tools are required to perform other MIN
maintenance work (especially changing oil
and filters) according to the maintenance
checklist (section 4 "Maintenance checklist"). These tasks should therefore only be
performed by the manufacturer's customer service department.
Z If service intervals are not observed as specified by the maintenance checklist (see
"Maintenance checklist" on page 144), the manufacturer's warranty will become
void.
6.9 Closing the Motor Compartment

Procedure
• Remove tools and other objects from the motor compartment.
DANGER!
No persons are permitted in the area around the cab while it is being lowered.
02.11 EN
177

6.10 Checking electrical fuses
6.10.1 Standard Fuse Strip
Checking electrical fuses
Requirements
– Prepare the truck for maintenance and repairs ((see "Preparing the truck for
Procedure
Z The main fuse box is located in the dashboard to the right of the driver's seat in the
cab.
• Remove the electrical system cap.
• Check condition and rating of the fuses in accordance with the table.
• Replace any damaged fuses in accordance with the table.
• Close the electrical system cap.
The electrical fuses are now checked.
Description Electric circuit Rating (A)

F1 Parking light t 10
F2 Dipped lights t 15
F3 Main beam t 15
F4 Rear work lights / tail light (roof panel) o 15
F5 Indicator t 10
F6 Hazard warning lights t 10
F7 Beacon t 10
F8 Front window wiper + horn t 7.5
F9 Rear window wiper t 7.5
F10 Roof window wiper t 7.5
F11 Front / top work lights t 15
F12 Option t 10
F13 Fan / air conditioning system t 25
F14 Steering column switch, dipped lights o 15
02.11 EN
F15 Workplace illumination / swivel seat valve t 10
178

Description Electric circuit Rating (A)
F16 Compressor for air-sprung seat o 10
F17 Seat heating o 10
F18 12V + 30 for option o 10
F19 Reading light t 10
F20 Display t 1
F21 Travel direction switch t 1
F22 Radio o 10
F23 +30 radio, cab lighting o 10
F24 Ignition switch 15 t 1
F25 Ignition switch 50 t 1
F26 Swivel seat o
F27 Front work lights o 15
F28 Cigarette lighter t 10
F29 Air conditioning system t 10
F30 Load damping o 15
F31 Brake pedal o 1
F32 TFG only o 5

02.11 EN
179

6.10.2 Fuse ratings in motor compartment for 4 + 6 cylinder diesel
Z All fuses (section 6.10.2 + 6.10.3) are located on the right side of the motor
compartment as seen in travel direction behind a Plexiglas window above the
hydraulic reservoir.
Description Power circuit Rating (A)

F41 Front work lights on mast 15
F42 Transmission controller +30 10
F43 Truck controller 15
F44 Option +15 10
F45 Particle filter alarm 5
F46 Pilot valve 10
F47 Engine controller +30 5
Main fuses in the motor compartment

FH1
FH2
FH3

FH1 Cab 80
FH2 Preheat relay +30 50
FH3 Engine controller +30 30
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6.10.3 Fuse strip in motor compartment for LPG motor

F41 Front work lights on mast 15
F43 Truck controller 15
F44 Option +15 (X27:4) 10
F45 Option +15 (X27:1) 5
F46 Pilot valve 10
F47 Option +15 (X26:7) 5
F49 Option +15 10
F50 Fan motor for LPG tank 15
F51 Engine controller +15 7.5
F52 Option
F53 Option
F54 Option
Main fuses in the motor compartment

FH1 Cab 80
Z The fuses are located on the right side of the motor compartment as seen in travel
direction behind a Plexiglas window.
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181

6.10.4 Cab lift fuse
FH4

FH4 Electric cab lift main fuse o 80
6.10.5 Checking the Electric Relays (DFG)

Z The main fuse box with the relays is located in the dashboard to the right of the
driver's seat in the cab.
K2 Work lights / rear

K3 Beacon / strobe light
K4 Main beam
K5 Dipped lights
K14 Front / top work lights
K15 Front / bottom work lights
K6 Window wiper
WARNING!
To avoid damaging the electrical system, only use fuses with the correct
02.11 EN
ratings.
182

6.11 Starter battery
Checking the battery condition, acid level* and acid density*
Z *not for maintenance-free batteries
CAUTION!
Battery acid can be dangerous
XBattery acid is highly corrosive.
XTherefore it is essential to avoid contact with battery acid.
XIf clothing, skin or eyes have nevertheless come into contact with battery acid,
immediately rinse the affected parts with water.
XIf the eyes have been affected, immediately seek medical attention.
XNeutralise spilled battery acid immediately.
Check battery
Procedure
• Check the battery housing for cracks and any spilled acid. Remove any oxidisation
remains from the battery terminals. Lubricate the battery terminals with an acid-free
grease. Check the acid level.
Z The acid should lie between the top and bottom markings.
Checking the acid density
Procedure
• Clean the area around the inspection plugs. If necessary, add distilled water to the
top mark. Check the acid density.
Z If the battery is charged sufficiently, the acid density should be 1.24 to 1.28 kg/l.
• Recharge the battery if necessary. Fit the drain plug back on.
Battery disposal
Batteries may only be disposed of in accordance with national environmental
protection regulations or disposal laws. The manufacturer’s disposal instructions must
be followed.
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183

6.12 Exhaust system
NOTE
Check emissions at regular intervals

XCheck the combustion engine exhaust emissions at regular intervals in accordance
with national regulations.
XBlack or blue exhaust smoke is an indicator of high emission levels resulting from
combustion engine damage or wear.
XIn this case the truck must be examined by specialist personnel.
Check the exhaust system regularly for leaks.

Procedure
• Open the engine cover.
• Start the engine when the engine cover is open.
• Check for any rising smell of exhaust and altered engine noise level.
• If you detect a rising smell of exhaust and altered engine noise level arrange for the
exhaust system to be inspected by specialist personnel.
The exhaust system has now been checked for leaks.
6.12.1 Particle filter (o)
Item Component 227

227 Control device
228 Particle filter
229 Regeneration unit
228
229
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During travel
Procedure
• Be aware of the ”High counter pressure” 227
display light. The light may flash with high
motor speeds and heavy loads.
• If the display light flashes continuously at a
high motor speed, the filter must be
regenerated as quickly as possible.
• If the filter system is working normally and
the regeneration intervals have been
observed, the display light will not light up
during operation.
Regeneration
Z The filter must be regenerated daily, or at the latest after 8 operating hours (sooner
if the engine is used less frequently).
CAUTION!
XThe regeneration process must not be interrupted!
Procedure
• Connect the electrical wires and air hose to the truck (standard system only).
• Switch the control device on.
• Check with the ammeters whether the system is working, All three instruments must
show an amplitude simultaneously. The regeneration is complete after 40 minutes.
The ammeters show 0 amps and the green lamp is lit.
• Switch off the control device.
• Disconnect the electrical wires and air hose from the truck (standard system only).
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185

6.12.2 Maintenance
Z The diesel engine must be regularly maintained to ensure proper function of the
particle filter. The maximum recommended smoke value without particle filter is 2.5
Bosch units.
At regular intervals
Block the exhaust pipe and check whether the “High counter pressure” display lamp
is lit. If the lamp is not lit, clean the connection pipe to the pressure switch.
As required
Z Clean the residue of fuel and oil from the particle filter at least once a year or after
1500 operating hours.
Procedure
• Regenerate the particle filter.
• Allow the particle filter to cool for 3 to 4 hours.
• Loosen the tensioning belt on the particle filter and remove the middle section.
• Set the particle filter upright and clean it from the output side with warm water (do
not use high pressure!).
• Allow the particle filter to drip off well.
• Install the particle filter with new seals.
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186

6.12.3 Troubleshooting
Procedure
• Connect the electrical wires and air hose to the filter system.
• Turn on the main switch and check the following assemblies.
Electrical radiator
Filter model Current rating

S9 13.0 A (at 400V)
If the current intensity differs on the ammeter, check the following items:
Procedure
• Check the connection according to the circuit diagram. The circuit diagram and
information about the connections can be found in the assembly instructions, which
came with the truck.
• Check fuse ratings and functionality.
Z If these items are in order, the radiator or alternatively the entire input section must
be replaced.
Thermostatic control
Procedure
• Check the thermostat setting (800°C).
Z The set temperature should be reached after 10 minutes.

Air inlet
Procedure
• Check the air supply for leaks.
Air supply with pump

Procedure
• Check whether air is being supplied through the hose. Check the hose for leaks.
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187

Timer Setting
Procedure
• Check the timer setting.
Troubleshooting with counter pressure too high

If the combustion time is too short and/or the counter pressure is too high, check the
following items.
Procedure
• Check the function and setting of the radiators, air supply and timer.
• Check the voltage during regeneration (at least 380V).
• Make certain the input side on the particle filter is free of soot.
• Make certain the motor is maintained and the maximum smoke value without
particle filter is 2.5 Bosch units.
• Make certain the filter is flushed out every 1500 operating hours.
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188

6.13 Seat belt maintenance
Check the safety restraint belt
Procedure
• Pull out the belt completely and check for fraying
• Test the belt buckle and make sure the belt returns correctly into the retractor.
• Check the cover for damage.
Testing the automatic blocking system
Procedure
• Park the truck on a level surface.
• Pull out the seat belt with a jerk
Z The interlock must prevent the belt from coming out.
The seat belt service is now complete.
DANGER!
A faulty seat belt can cause injury
Using a faulty seat belt can result in injury.
XOnly operate the truck with the seat belt intact. A faulty seat belt should be replaced
immediately.
XThe truck must remain decommissioned until a functional seat belt has been fitted.
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189

6.14 Restoring the truck to service after maintenance and repairs
Procedure
• Thoroughly clean the truck.
• Lubricate the truck according to the lubrication schedule, (see "Lubrication
Schedule" on page 158).
• Clean the battery, grease the terminals and connect the battery.
• Check the transmission oil for condensation water and replace if necessary
(hydrostatic trucks only).
• Check the hydraulic oil for condensation water and replace if necessary.
Z The manufacturer's customer service department is specially trained to carry out
these operations.
WARNING!
Faulty brakes can cause accidents
As soon as the truck has been started, test the brakes several times.
• Start up the truck, (see "Preparing the Truck for Operation" on page 84).
Z If there are switching problems in the electrical system, apply contact spray to the
exposed contacts and remove any oxide layers on the contacts of the controls by
applying them repeatedly.
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190

7 Decommissioning the industrial truck
Z If the truck is to be out of service for more than a month, e.g. for commercial
reasons, 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.
WARNING!
Lifting and jacking up the truck safely

In order to raise the truck, the lifting gear must only be secured to the points specially
provided for this purpose.
You may only work under a raised load handler / raised cab if they have been secured
with a sufficiently strong chain or the fastening bolt.
In order to raise and jack up the truck safely, proceed as follows:
XJack up the truck only on a level surface and prevent it from moving accidentally.
XOnly use a jack with sufficient capacity. When jacking up the truck, take appropriate
measures to prevent it from slipping or tipping over (e.g. wedges, wooden blocks).
XIn order to raise the truck, the lifting gear must only be secured to the points
specially provided for this purpose. (see "Transport" on page 41).
XWhen jacking up the truck, take appropriate measures to prevent it from slipping or
tipping over (e.g. wedges, wooden blocks).
When the truck is out of service it must be jacked up so that all the wheels are clear
of the ground. This is the only way of ensuring that the wheels and wheel bearings are
not damaged.
If the truck is to be out of service for more than 6 months, agree further measures with
the manufacturer's customer service department.
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191

7.1 Prior to decommissioning
Procedure
• Test the brakes.
• Check the hydraulic oil level and replenish if necessary,
(see "Checking the hydraulic oil level" on page 169).
• Apply a thin layer of oil or grease to any non-painted mechanical components.
• Disconnect the battery, clean it and grease the terminals.
Z In addition, follow the battery manufacturer’s instructions.
• Spray all exposed electrical contacts with a suitable contact spray.
7.2 During decommissioning
NOTE
Full discharge can damage the battery

Self-discharge can cause the battery to fully discharge. Full discharge shortens the
useful life of the battery.
XCharge the battery at least every 2 months.
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192

7.3 Restoring the truck to service after decommissioning
Procedure
• Clean the battery, grease the terminals and connect the battery.
• Charge the battery, (see "Starter battery" on page 183).
• Check the transmission oil for condensation water and replace if necessary
(hydrostatic trucks only).
• Check the engine oil for condensation water and replace if necessary.
• Check the hydraulic oil for condensation water and replace if necessary.
Z The manufacturer's customer service department is specially trained to carry out
these operations.
WARNING!
Faulty brakes can cause accidents
As soon as the truck has been started, test the brakes several times.
• Start up the truck, (see "Preparing the Truck for Operation" on page 84).
Z If there are switching problems in the electrical system, apply contact spray to the
exposed contacts and remove any oxide layers on the contacts of the controls by
applying them repeatedly.
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193

8 Safety tests to be performed at intervals and after unusual
incidents
Z Perform a safety check in accordance with national regulations. 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.
The truck must be inspected at least annually or after any unusual event by a qualified
inspector (be sure to comply with national regulations). The inspector shall assess the
condition of the truck from purely a safety viewpoint, without regard to operational or
economic circumstances. The inspector shall be sufficiently instructed and
experienced to be able to assess the condition of the truck and the effectiveness of
the safety mechanisms based on the technical regulations and principles governing
the inspection of forklift trucks.
A thorough test of the truck must be undertaken with regard to its technical condition
from a safety aspect. The truck must also be examined for damage caused by
possible improper use. A test report shall be provided. The test results must be kept
for at least the next 2 inspections.
The owner is responsible for ensuring that faults are rectified immediately.
Z A test plate is attached to the truck as proof that it has passed the safety inspection.
This plate indicates the due date for the next inspection.
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194

9 Final de-commissioning, disposal
Z 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, fuels 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. Note the manufacturer’s safety
instructions as specified in the service documentation.
10 Human vibration measurement

Z Vibrations that affect the driver during operation over the course of the day are
known as human vibrations. Excessive human vibrations will cause the driver long
term health problems. The European "2002/44/EC/Vibration" operator directive has
therefore been established to protect drivers.
To help operators to assess the application situation, the manufacturer offers a
service of measuring these human vibrations.
02.11 EN
195

Jungheinrich DFG 660 Service Manual

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DFG/TFG 660-690 02.

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Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg

Type Option Serial no. Year of

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Z Used before notices and explanations.

t Indicates standard equipment

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Tel: +49 (0) 40/6948-0

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A Correct Use and Application .................................................... 11

B Truck Description ..................................................................... 15

C Transport and Commissioning ................................................. 41

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6.13 Safety instructions for operating additional attachments ......................... 116

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F Industrial Truck Maintenance................................................... 137

10 Human vibration measurement ............................................................... 195

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– Lifting and lowering of loads.

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– Operation in industrial and commercial environments.

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5 Adding attachments and/or accessories

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Closed bottom pallets can also be lifted.

1.1 Truck models and rated capacity

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Item Description Item Description

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Z Technical data specified in accordance with VDI 2198.

3.1 Performance data

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*) The data listed in the table corresponds to the standard version.

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*) The data listed in the table corresponds to the standard version.

a/2 Safety distance 100 100 100 100 mm

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h4 Mast height extended* 4960 5110 mm

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*) The data listed in the table corresponds to the standard version.

*) The data listed in the table corresponds to the standard version.

*) The data listed in the table corresponds to the standard version.

*) The data listed in the table corresponds to the standard version.

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Special trucks are not included in this overview.

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Special trucks are not included in this overview.

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