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Jungheinrich DFG 316s, Operating Instructions Manual, Page: 146 / 187

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Jungheinrich DFG 316s Operating Instructions Manual Download Page 146

147

05.10 EN

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.

X

Note the safety regulations when handling these materials.

Summary of Contents for DFG 316s

Page 1: ...JUNGHEINRICH 09 09 05 10 51123193 DFG TFG 316s 320s Operating instructions G DFG 320s TFG 316s TFG 320s DFG 316s...

Page 2: ...ries hereby certify that the specified powered industrial truck conforms to the EU Directive 2006 42 EC Machine Directive and 2004 108 EEC Electro Magnetic Compatibility EMC including their amendments...

Page 3: ...05 10 EN 4...

Page 4: ...ruck 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...

Page 5: ...05 10 EN 6 Jungheinrich Aktiengesellschaft Am Stadtrand 35 22047 Hamburg Germany Tel 49 0 40 6948 0 www jungheinrich com...

Page 6: ...pecifications 19 3 1 Performance data 19 3 2 Dimensions 21 3 3 Weights 23 3 4 Mast versions 23 3 5 Tyre type 24 3 6 Engine Data 24 3 7 EN norms 25 3 8 Conditions of use 26 3 9 Electrical requirements...

Page 7: ...duced headroom X o 63 3 4 Setting up the operator position 64 3 5 Seat Belt 69 4 Industrial Truck Operation 70 4 1 Safety regulations for truck operation 70 4 2 Preparing the truck for operation 72 4...

Page 8: ...4 1 DFG Maintenance Checklist 136 4 2 TFG Maintenance Checklist 141 5 Lubricants and Lubrication Schedule 146 5 1 Handling consumables safely 146 5 2 Lubrication Schedule 148 5 3 Consumables 149 6 Mai...

Page 9: ...05 10 EN 10...

Page 10: ...ion 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 T...

Page 11: ...fficient 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 lo...

Page 12: ...ird 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 unders...

Page 13: ...05 10 EN 14...

Page 14: ...in front Closed bottom pallets can also be lifted The DFG TFG 316s 320s is equipped with a hydrostatic drive The combustion engine drives a high pressure pump for the hydraulic functions and two hydra...

Page 15: ...cription 1 t Driver s seat 9 t Drive 2 t Overhead guard 10 t Emergency Disconnect switch 3 t Steering wheel 11 t Engine bonnet 4 t Mast 12 t Steer axle 5 t Fork carriage 13 t Counterweight 6 t Fork ti...

Page 16: ...m to be monitored during operation thereby ensuring a very high level of safety Steering The steer cylinder of the hydrostatic steering is integrated in the steer axle 12 and is controlled by the powe...

Page 17: ...rake is an automatic multi plate brake that can also be applied manually Hydraulic system A multi pilot valve allows for sensitive operation of the functions via the controls A speed controlled hydrau...

Page 18: ...t differences in height and surface unevenness surface edges The truck must not operate on inclines of more than 15 Preglow relay DFG 316s 320s Description DFG 316s DFG 320s Q Capacity where C 500 mm...

Page 19: ...6s 320s Description TFG 316s TFG 320s Q Capacity where C 500 mm 1 1600 2000 kg C Load centre 500 500 mm Travel speed w w o load 19 5 19 5 19 5 19 5 km h Lift speed w w o load 0 60 0 62 0 60 0 62 m s L...

Page 20: ...gth including forks 3453 3473 mm L2 Overall length including fork shank 2303 2323 mm b1 Overall width 1100 1100 mm s e l Fork dimensions 40x100x1150 40x100x1150 mm m1 Ground clearance with load below...

Page 21: ...05 10 EN 22...

Page 22: ...ift h3 Free lift h2 Height retracted h1 Height extended h4 Mast weight kg ZT 2900 150 1985 3520 440 3100 150 2085 3720 450 3300 150 2185 3920 465 3600 150 2335 4220 485 3800 150 2435 4420 500 4000 150...

Page 23: ...6 50 10 6 50 10 Pneumatic 6 50 10 14PR 6 50 10 14PR Tyre pressure bar max 10 0 max 10 0 Torque NM 170 170 Rear tyres SE 18x7 8 18x7 8 Pneumatic 18x7 8 16PR 18x7 8 16PR Tyre pressure bar max 9 0 max 9...

Page 24: ...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 1...

Page 25: ...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 manufact...

Page 26: ...d data plates Z Warnings and notices such as capacity charts strap points and data plates must be legible at all times Replace if necessary 1 2 1 1 1 0 9 8 7 6 5 4 3 2 1 2000 28 16 22 17 27 26 30 31 2...

Page 27: ...passengers warning 21 Fuel 22 Wear seat belt 23 Serial number engraved in chassis below the engine bonnet 24 Jack contact points 25 Do not step onto or beneath the load risk of trapping with moving ma...

Page 28: ...ts always quote the truck serial number 35 34 35 37 36 43 40 42 39 38 41 Item Description Item Description 34 Type 39 Year of manufacture 35 Serial number 40 Load centre mm 36 Rated capacity kg 37 Out...

Page 29: ...he 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 31 of the truck indicates the truck s capacity with the fork...

Page 30: ...ntre of gravity above 500 mm upward the capacities are reduced by the difference of the altered centre of gravity 5 Stability The truck s stability has been tested according to latest technological st...

Page 31: ...05 10 EN 32...

Page 32: ...lic 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...

Page 33: ...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 attach...

Page 34: ...tly long XTransporting over long distances prohibited Loading the truck with a second industrial truck Requirements Park the truck securely Siehe Parking the truck securely auf Seite 76 Procedure Rais...

Page 35: ...d 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 wit...

Page 36: ...roperly 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 tr...

Page 37: ...05 10 EN 38...

Page 38: ...andling 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 with...

Page 39: ...nd 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 s...

Page 40: ...stem In this event the truck must not be operated The gas system must be check by suitably qualified and trained personnel The user must check that the plastic cover is present each time he uses the t...

Page 41: ...ter 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 316s 320s 50...

Page 42: ...nsert the outlet pipe into the open tank filler neck Make sure the fuel container and outlet pipe are connected tightly to each other Carefully raise the fuel container and insert the outlet pipe into...

Page 43: ...les 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 regul...

Page 44: ...and place it down securely Inserting a new LPG bottle Procedure Insert the LPG bottle into the bracket 59 Centre the handle 52 in the hole 58 Align the hose connection upwards Fit the tensioning belt...

Page 45: ...ge between gas supply You can tell which bottle is supplying the gas by the gas hose connection on the valve 56 and the routing towards the LPG bottles e g RH side of toggle valve up LH side of toggle...

Page 46: ...es and regulations concerning the filling of LPG bottles on the LPG pump Procedure Close the dispensing valve 66 Unscrew the cap 67 of the filling stop valve 64 Screw the filling connection of the liq...

Page 47: ...icator for LPG bottles o When the fuel indicator 67 and warning light 69 with additional warning sound light up this indicates that the LPG bottle is empty The remaining travel time will be 8 12 minut...

Page 48: ...ons 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...

Page 49: ...uthorised 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...

Page 50: ...51 05 10 EN 2 Displays and Controls Doppelpedalsteuerung S TAR T S TAR T Solopilot Multipilot Einzelpedalsteuerung 74 75 75 79 79 77 77 73 73 71 72 70 78 78 76 76...

Page 51: ...ion the truck brakes to a halt immediately 74 Steering wheel t Steers the truck 75 SOLO PILOT t Operates the following functions Forward reverse travel direction not with dual pedal operation Load han...

Page 52: ...r t Lever for operating the hydraulic functions 82 Horn t Activates an audible warning 83 Additional hydraulic function release button o Activates the additional hydraulic functions or hydraulics that...

Page 53: ...ata the battery charge the service hours and error details and information Pictograms in the left top section of the control panel act as warning indicators km h R 101 102 103 110 109 108 121 116 111...

Page 54: ...89 t No function 90 Overtemperature indicator t Hydraulic oil temperature too high Coolant temperature too high As the temperature rises the truck s performance is automatically and steadily reduced t...

Page 55: ...FEM test after 12 months display flashes must be set by the manufacturer s customer service department 98 Pre heat indicator lamp t Engine is preheated DFG only Indicator lamp flashing Engine control...

Page 56: ...he parking brake 104 Rear windscreen wiper o Press 1x intermittent Press 2x fast Press 3x off Press for 2 seconds rear windscreen washing system After releasing the previous function is set interval o...

Page 57: ...utton t Crawl speed can only be adjusted by Customer Services 111 P1 function switch o Can be used for auxiliary equipment 112 Parking light o Switches parking light on and off 113 Dipped lights o Swi...

Page 58: ...59 05 10 EN performance for high throughput levels If necessary the operating programs can also be adapted or restricted to suit the customer Please contact the manufacturer s service department...

Page 59: ...error Err or a warning Inf occurs the error or info code is displayed If several errors occur they are displayed alternately at 1 5 second intervals A warning sounds 125 Travel direction and speed dis...

Page 60: ...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 rep...

Page 61: ...the control panel Make sure the load chains are evenly tensioned Test the seat belt The belt should block if extracted suddenly Test the seat switch When the driver s seat is vacated it should not be...

Page 62: ...unsuitable workplace can damage your health Failure to observe the recommended body size can cause stress and endanger the driver and may lead to lasting ill health due to an unhealthy posture and ex...

Page 63: ...ent mirrors camera systems etc so that the working environment can be clearly seen 3 4 1 Adjusting the driver s seat WARNING Risk of accidents and damage to health An incorrectly adjusted driver s sea...

Page 64: ...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 130 The minimum or maximum weight setting is reached when you can fee...

Page 65: ...driver s seat must be locked in position XDo not adjust the driver s seat while travelling Procedure Sit on the driver s seat Pull up the driver s seat locking lever131 in the direction of the arrow P...

Page 66: ...ion using the steering column engine bonnet release lever 138 The individual steering wheel position remains intact Procedure Hold the steering column 135 against the steering wheel 3 Z It will be und...

Page 67: ...n you have reached the required setting tighten the clamping screw 139 again this will lock the armrest in place Vertical adjustment Procedure Depress the locking button 140 and hold it in place The a...

Page 68: ...iginal 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 thaw...

Page 69: ...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...

Page 70: ...y 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...

Page 71: ...nce it has reached operating temperature Switching on the truck Requirements For checks and operations to be performed before starting daily operation see Checks and operations to be performed before...

Page 72: ...rent warning light 91 should go out after a short while If not stop the start up process and rectify the fault Press the start button 78 Z Only apply the starter for a maximum of 15 seconds without in...

Page 73: ...engine oil pressure display 86 parking brake 87 truck operational indicator lamp 95 and charge current indicator lamp 91 should go out after a short while If not stop the start up process and rectify...

Page 74: ...keys simultaneously The set time appears on the display The first digit hour display will flash Us the up 101 and down 102 keys to set the reading Press the Set key 109 to store the reading The next n...

Page 75: ...he 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 and lea...

Page 76: ...to slide off the forks There is a higher risk of accidents and injury The operation of the Emergency Disconnect button must not be affected by any objects placed in its way Applying the Emergency Dis...

Page 77: ...have enough visibility when reversing Travel Requirements Truck prepared for operation see Preparing the truck for operation on page 72 Procedure Release the parking brake to do this press the parkin...

Page 78: ...ion see Preparing the truck for operation on page 72 Procedure Z For trucks with a dual pedal the travel direction is selected via the accelerator pedals 72 70 When the driver leaves the truck the tru...

Page 79: ...steering radius The truck travels in the direction selected 4 8 Brakes WARNING Accident risk The brake pattern of the truck depends largely on the ground conditions XThe driver must be aware of travel...

Page 80: ...soon as the truck comes to a halt Auxiliary brake Apply the brake pedal 73 CAUTION When you apply the auxiliary brake 73 the full brake force is available XThe auxiliary brake must only be used for e...

Page 81: ...s may cause the load to slide off the forks There is an increased risk of accidents and injury Z The parking brake can be used as an emergency brake Procedure Apply the brake button 103 Z The truck br...

Page 82: ...moving accidentally XThe load centre of gravity must be located centrally between the forks Adjusting the forks Requirements Park the truck securely see Parking the truck securely on page 76 Procedur...

Page 83: ...e forks fit the retaining bolts 127 and make sure the bolts are seated correctly Retaining bolt torque 85 Nm WARNING Trapping hazard There is a trapping hazard when you perform this operation XWear wo...

Page 84: ...the truck XMake sure you have enough visibility when reversing XNever exceed the maximum loads specified in the capacity chart XNever stand underneath a raised load handler XDo not stand on the load h...

Page 85: ...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 appr...

Page 86: ...ave 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 XNev...

Page 87: ...ever The lever will revert automatically to neutral Positioning the integrated sideshift option Requirements To prepare the truck for operation see Preparing the truck for operation on page 72 Procedu...

Page 88: ...alignment of the forks with an integrated fork adjuster option Requirements To prepare the truck for operation see Preparing the truck for operation on page 72 The forks are no longer aligned Procedu...

Page 89: ...l be a noise from the pressure relief valve release the lever The lever will revert automatically to neutral Tilting the mast forward backward Requirements Truck prepared for operation see Preparing t...

Page 90: ...push the Multi Pilot forward and to the left The mast is now tilted back forward Positioning the integrated sideshift option Requirements Truck prepared for operation see Preparing the truck for oper...

Page 91: ...ositioned Synchronising the alignment of the forks with an integrated fork adjuster option Requirements To prepare the truck for operation see Preparing the truck for operation on page 72 The forks ar...

Page 92: ...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 fit...

Page 93: ...XWhen connecting the attachment make sure that the hydraulic lines of the attachment are connected to the right ports see Assembly and hydraulic ports of additional attachments on page 100 Safety inst...

Page 94: ...ork 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...

Page 95: ...on of movement in accordance with ISO 3691 1 so that they match the controls direction of movement 4 14 1 Solo Pilot with control of ZH1 hydraulic port Z Depending on the attachments used the lever 14...

Page 96: ...R direction The attachment s function is performed 4 14 3 Solo Pilot with control of ZH1 ZH2 and ZH3 hydraulic ports Z Depending on the attachments used the levers buttons 144 146 147 150 are assigned...

Page 97: ...For connections see Assembly and hydraulic ports of additional attachments on page 100 Procedure Operating the hydraulic port ZH1 Press button 148 or button 149 The attachment s function is performed...

Page 98: ...tions see Assembly and hydraulic ports of additional attachments on page 100 Procedure Operating the hydraulic port ZH1 Press button 148 or button 149 Operating the hydraulic port ZH2 Turn the Multi P...

Page 99: ...ulic ports The exchange ports on the truck are marked ZH2 and ZH3 Attachment directions of movement defined to match the controls direction of movement Procedure Non pressurised hydraulic hoses Switch...

Page 100: ...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...

Page 101: ...eed the capacity indicated on the capacity plate see Identification points and data plates on page 27 If a load is also transported on the forks the trailer load must be reduced by the same amount XDo...

Page 102: ...e 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...

Page 103: ...n 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 ope...

Page 104: ...ns to be performed before starting daily operation on page 61 the driver must carry out the following checks Lift the empty load handler beyond the reference lift height and check if the slow travel d...

Page 105: ...ver from his responsibility to wear a seat belt see Seat Belt on page 69 Opening and closing the door Procedure To unlock the cabin door turn the key anti clockwise To lock the cabin door turn the key...

Page 106: ...mm gap between the gate 157 and the seat to ensure safety 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 lea...

Page 107: ...st lean his upper body over the steering wheel and hold on with both hands Tilt your body in the opposite direction of fall Requirements On trucks with a door monitoring sensor travel is only enabled...

Page 108: ...Pull the filter cassette 160 out in the direction of the arrow Replace the filter Insert the filter cassette 160 into the heating console 159 Turn the twist off knob anti clockwise The filter cassett...

Page 109: ...ntire airflow is directed to the front window defrosting Controller centre The airflow is directed to the front window and the footwell Controller left The airflow is directed to the upper body of the...

Page 110: ...ht will be off The air conditioning system switches off before the truck is parked Using the air conditioning system at high air humidity and temperature levels Procedure Press the toggle switch 169 D...

Page 111: ...ing the backrest extension CAUTION Accident risk when adjusting the backrest during travel XDo not adjust the backrest extension while travelling Procedure The backrest extension height can be adjuste...

Page 112: ...rocedure Attach the load backrest to the top rail of the fork carriage Fit the bolts and tighten them with a torque wrench Z Torque 85 Nm 6 10 Lift cutout override Z A lift cutout device can be factor...

Page 113: ...on on page 61 Check automatic sideshifter centring with the function key 108 Procedure Press and hold down on the function key 108 the sideshifter goes to the centre position Z Releasing the key inter...

Page 114: ...Procedure Prevent the trailer from rolling away Adjusting the trailer pull rod to the height of the coupling Pull the hand lever 174 remote control 173 o up Z The remote control 173 o is located in t...

Page 115: ...ar Using the camera system Press the button 181 on the monitor to switch the camera system on or off Press the button 180 to lighten or darken the screen day night settings Press the button 177 to ope...

Page 116: ...clogged Procedure Tilt the gas bottle holder back TFG only Remove the rear overhead guard cover Turn the quick release lock 182 to open it Pull the lint mesh up by the handle 183 and clean it Fit the...

Page 117: ...Pilot Avoid dropping the load abruptly in order to protect the load and the rack surface Lifting Procedure Push the Multi Pilot to the right direction H to raise the load Push the Multi Pilot to the l...

Page 118: ...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 ser...

Page 119: ...display Graphic illustration of the fuel supply TFG with gas tank 69 WARNING Lights up a single time to indicate that the fuel supply is too low Lights up in conjunction with err xx xxx or inf xx xxx...

Page 120: ...test interrupted The truck performs a self test after the start tests the controllers and motor During this time the truck cannot move or lift 191 Overtemperature Hydraulic oil temperature too high Co...

Page 121: ...m for leaks add coolant if necessary Engine running but truck does not travel Travel direction switch in neutral Parking brake applied Set travel direction switch to required direction Release the par...

Page 122: ...e fuel system fill up the truck and bleed the fuel system Check the fuel tank if necessary replace the fuel filter Park the truck in a warm room and wait until the separation has returned to its origi...

Page 123: ...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 Towing the truck Requirements Park...

Page 124: ...truck from rolling away Open the floor plate 184 by undoing the quick release locks and remove the plug connections 185 Procedure Undo the setscrew on the valve block 186 a maximum of 1 5 turns Fully...

Page 125: ...ort 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 Procedure Set the Emerge...

Page 126: ...el in the engine compartment main fuse box with the red lead Connect the negative terminal of the feeder battery and the earth point of the crane eye on the engine with the black lead To start the ind...

Page 127: ...05 10 EN 128...

Page 128: ...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 mar...

Page 129: ...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 foll...

Page 130: ...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 wate...

Page 131: ...ss 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...

Page 132: ...cidents 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 wi...

Page 133: ...lations 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 caus...

Page 134: ...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 dus...

Page 135: ...ulation damage connections Make sure the wire connections are secure t Option 2 9 Test the electrical auxiliary equipment and check for damage t Maintenance intervals Standard t W A B C Power supply 3...

Page 136: ...and damage t 4 16 Check the wheel motor attachments t 4 17 Test the starter and generator check the wires and attachment t 4 18 Check V belt multi V belt is tensioned and check for damage t 4 19 Repl...

Page 137: ...ab are secure and check for damage t 5 9 Test the driver s seat restraint system and check for damage t Option 5 10 Check that optional equipment such as mirrors storage compartments grips windscreen...

Page 138: ...e of the mast connections and the fork carriage t 6 10 Check the running surfaces of the mast for wear and damage and lubricate if necessary t 6 11 Test the hydraulic system t 6 12 Replace the hydraul...

Page 139: ...Carry out a test run with rated load t 7 2 Demonstration after servicing t 7 3 Lubricate the truck according to the lubrication schedule t Maintenance intervals Standard t W A B C Steering 8 1 Test th...

Page 140: ...the fuse ratings t 2 8 Check the electric wiring for damage insulation damage connections Make sure the wire connections are secure t Option 2 9 Test the electrical auxiliary equipment and check for d...

Page 141: ...eck for leaks t 4 8 Check and clean the radiator t 4 9 Check the wheel suspension and attachment t 4 10 Check the tyres for wear and damage t 4 11 Check the tyre air pressure and top up if necessary t...

Page 142: ...ab are secure and check for damage t 5 9 Test the driver s seat restraint system and check for damage t Option 5 10 Check that optional equipment such as mirrors storage compartments grips windscreen...

Page 143: ...e of the mast connections and the fork carriage t 6 10 Check the running surfaces of the mast for wear and damage and lubricate if necessary t 6 11 Test the hydraulic system t 6 12 Replace the hydraul...

Page 144: ...Carry out a test run with rated load t 7 2 Demonstration after servicing t 7 3 Lubricate the truck according to the lubrication schedule t Maintenance intervals Standard t W A B C Steering 8 1 Test th...

Page 145: ...t 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 r...

Page 146: ...zard 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 hav...

Page 147: ...05 10 EN 148 5 2 Lubrication Schedule g Contact surfaces c Hydraulic oil drain plug s Grease nipple t Coolant filler cap S Hydraulic oil filler neck Engine oil filler neck DFG TFG K K...

Page 148: ...Grease guidelines Code Order no Quantit y Capaci ty Description Used for A 51037495 51037499 1l 5 l 40 l HVI Renolin B46 Hydraulic system E 50055726 400 gr Grease K P 2K Mast roller and sideshifter c...

Page 149: ...so result if poisonous quantities come into contact with the skin for long or repeated periods XNote the manufacturer s safety instructions The quality of the anti freeze must be checked at least annu...

Page 150: ...nd 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 in...

Page 151: ...ackrest forward move the driver s seat forward and lock it in position see Adjusting the driver s seat on page 64 Pull the lever 137 in the arrow direction L until the engine cover is unlocked The eng...

Page 152: ...ne cover up by the handle 194 and engage it in the lock 197 of the gas pressure spring 195 The engine cover opens in the first stage Open the engine cover 11 as far as the 70 stage Requirements The en...

Page 153: ...gine cover as far as the 50 stage Raise the engine cover again slightly From the 50 stage push in the red lock 197 of the left hand gas pressure spring Close the engine cover and make sure it is locke...

Page 154: ...ure after 10 service hours XAlways use tyres of the same make model and profile Checking the wheel attachment Requirements Prepare the truck for maintenance and repairs see Preparing the truck for mai...

Page 155: ...c 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 X...

Page 156: ...For hot oil The hydraulic oil should lie just above the MAX marking Add hydraulic oil if necessary Repeat the test When the oil level is correct fully insert the hydraulic oil dipstick 200 again 6 6...

Page 157: ...back on 6 6 4 Replacing the ventilation discharge filter Procedure Unscrew the ventilation discharge filter 202 Visually inspect the filter If contaminated insert a new filter Screw the ventilation di...

Page 158: ...k 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 6 7 1 Starting the engine with the cover open The engin...

Page 159: ...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 Parkin...

Page 160: ...oil filter housing 208 Collect any oil that emerges Thoroughly clean the raised faces of the oil filter housing and oil filter lid Insert a new oil filter in the oil filter housing Apply a thin layer...

Page 161: ...incorrect amount of oil will damage the engine XAfter replacing the oil and oil filter carry out a test run and check the oil pressure display 86 XCheck that the oil drain plug and oil filter housing...

Page 162: ...off the return lines Slacken the collar screw 211 and take off the fuel filter 212 Fill the new fuel filter entirely with clean diesel and fit it with the collar screw 211 Reconnect the fuel hoses and...

Page 163: ...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 Parkin...

Page 164: ...il drain plug Collect any oil that emerges Screw in the oil drain plug with a new seal torque 30 Nm Replace the engine oil filter Procedure Undo the oil filter 214 with a filter wrench and manually un...

Page 165: ...damage the engine XAfter replacing the oil and oil filter carry out a test run and check the oil pressure display 86 XCheck that the oil drain plug and oil filter housing are tight 6 7 6 Replacing sp...

Page 166: ...belt for damage NOTE A damaged V belt will result in malfunctions XIf the V belt 213 is not in good condition first rectify the damage before using the truck Procedure Check the V belt 213 for cracks...

Page 167: ...when the filler cap is opened Checking the coolant level Procedure Park the truck securely on a level surface Open the rear bonnet locks and lift off the rear bonnet see Opening the rear panel on page...

Page 168: ...nsion vessel 216 Check the anti freeze content of the coolant with an anti freeze tester NOTE The incorrect coolant concentration can cause malfunctions XIf there is insufficient anti freeze content a...

Page 169: ...CAUTION A damaged cooler and fan can be dangerous XCheck the radiator and fan for damage XIf the radiator or fan are damaged only start to use the truck when the damage has been rectified Fan unit as...

Page 170: ...oth 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 cl...

Page 171: ...console 159 Turn the twist off knob anti clockwise The filter cassette has been replaced and locked Z Check the filter after 500 service hours and replace it at the latest after 1000 service hours 6...

Page 172: ...r of the truck see Opening the rear panel on page 151 Remove the electrical system cap Check condition and rating of the fuses in accordance with the table To do this Insert the fuse to be check in th...

Page 173: ...21 6 4F6 o Brake light 10 21 7 5F4 o Tail light RH parking light 7 5 21 8 4F5 1 o Left indicator 5 31 9 4F5 2 o Right indicator 5 31 10 6F5 o Road traffic regulations armrest 5 11 4F9 t E BOX 2 12 3F...

Page 174: ...10 30 9F14 o Rear window wiper 7 5 31 5F1 2 o Rear work lights 10 51 32 9F25 t Air mass meter DFG only 5 Shutoff valve TFG only 33 9F31 t Charge control generator 5 34 4F1 t Horn 10 35 4F11 t ECU ter...

Page 175: ...05 10 EN 176 Z 1 LED optional equipment t Series equipment o Optional equipment...

Page 176: ...any damaged fuses in accordance with the table Close the electrical system cap Close the truck s engine cover The main fuses engine compartment are now checked Relay Item Description To protect Ratin...

Page 177: ...Engine ignition off 100 74 9F20 o External air conditioning system 30 75 F22 t Terminal 30 constant positive 100 76 F19 4 t Starter relay supply wire 40 77 F19 3 t Constant positive for engine term 3...

Page 178: ...he 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 sh...

Page 179: ...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 see Starting t...

Page 180: ...c 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 fa...

Page 181: ...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 severa...

Page 182: ...d 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...

Page 183: ...schedule see Lubrication Schedule on page 148 Disconnect the battery clean it and grease the terminals Z In addition follow the battery manufacturer s instructions Spray all exposed electrical contact...

Page 184: ...c 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 s...

Page 185: ...nomic 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...

Page 186: ...he 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...

Page 187: ...05 10 EN 188...

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