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Jungheinrich DFG 660, Operating Instructions Manual

The Jungheinrich DFG 660 forklift is a powerful and reliable machine designed to make handling heavy loads easy. To ensure safe operation, make sure to download the Operating Instructions Manual for free from manualshive.com. This manual provides detailed information on how to properly use and maintain the forklift.

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11

.1

4

 E

N

186

4.14.2 Fuse ratings in motor compartment for 4 + 6 cylinder diesel

Z

All fuses (section 4.14.3 + see "Identification points and data plates" on page 38)
are located on the right side of the motor compartment as seen in travel direction
behind a Plexiglas window above the hydraulic reservoir.

Main fuses in the motor compartment

Component

Electric circuit

Rating (A)

F41

Front work lights on mast

15

F42

Transmission controller terminal 30

10

F43

Transmission controller terminal 30

15

F44

Option terminal 15 (X27:4)

10

F45

Particle filter alarm

5

F46

Valve block

10

F47

Engine controller terminal 30

5

F48

Transmission controller terminal 15

2

Component

Electric circuit

Rating (A)

FH1

Cab

80

FH2

Pre-glow relay +30 (4 cylinder diesel)

50

FH2

Pre-glow relay +30 (6 cylinder diesel)

80

FH3

Engine cont30

30

FH1

FH2

FH3

Summary of Contents for DFG 660

Page 1: ...12 12 11 14 51289390 DFG TFG 660 690 Operating instructions G TFG 680 DFG 670 DFG 680 DFG 690 DFG S80 DFG S90 TFG 660 TFG 670 TFG 690 TFG S80 TFG S90 DFG 660...

Page 2: ...cribed 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...

Page 3: ...11 14 EN 4...

Page 4: ...uarantee 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 ind...

Page 5: ...1 14 EN 6 Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG Jungheinrich Aktiengesellschaft Am Stadtrand 35 22047 Hamburg Germany Tel 49 0 40 6948 0 www jungheinrich com...

Page 6: ...9 3 1 Performance data 19 3 2 Dimensions 23 3 3 Weights 28 3 4 Mast versions 29 3 5 Tyre type 33 3 6 Engine Data 35 3 7 EN norms 36 3 8 Conditions of use 37 3 9 Electrical requirements 37 4 Identifica...

Page 7: ...ith automatic air conditioning 81 4 Heater fan air conditioning system 82 4 1 Heater 82 4 2 Air conditioning system o 82 5 Preparing the Truck for Operation 86 5 1 Checks and operations to be performe...

Page 8: ...inity of the engine 155 3 Lubricants and Lubrication Schedule 156 3 1 Handling consumables safely 156 3 2 Lubrication Schedule 158 3 3 Consumables 160 3 4 Coolant specification 161 4 Maintenance and r...

Page 9: ...vals and after unusual incidents 197 7 Final de commissioning disposal 198 8 Human vibration measurement 198 9 Servicing and Inspection 199 10 Maintenance checklist DFG 200 10 1 Operating Company 200...

Page 10: ...must be fully raised see Lifting transporting and depositing loads on page 113 The following operations are in accordance with regulations and are permitted Lifting and lowering loads Transporting low...

Page 11: ...load facing uphill Operation in partially public traffic Do not operate LPG trucks under ground level areas The truck may only be operated in areas that are clean and free of oil and similar substance...

Page 12: ...ies are excluded Furthermore accident prevention regulations safety regulations and operating servicing and repair guidelines must be followed The operating company must ensure that all users have rea...

Page 13: ...11 14 EN 14...

Page 14: ...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 capa...

Page 15: ...7 8 11 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 Dr...

Page 16: ...der 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 sur...

Page 17: ...rake 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 Hydra...

Page 18: ...he truck must not operate on inclines of more than 15 Component 660 670 680 690 Q Capacity 1 6000 7000 8000 9000 kg C Load centre distance 600 600 600 600 mm Travel speed with without load 22 4 22 5 2...

Page 19: ...000 kg C Load centre distance 900 900 mm Travel speed with without load 22 3 22 6 22 3 22 6 km h Lift speed with without load 0 40 0 60 0 40 0 60 m s Lowering speed with without load 0 60 0 36 0 60 0...

Page 20: ...l speed with without load 22 4 22 6 22 4 22 6 22 4 22 6 22 4 22 6 km h Lift speed with without load 0 40 0 48 0 40 0 48 0 40 0 48 0 40 0 48 m s Lowering speed w w o load 0 60 0 48 0 60 0 36 0 60 0 36...

Page 21: ...000 kg C Load centre distance 900 900 mm Travel speed with without load 22 4 22 6 22 4 22 6 km h Lift speed with without load 0 40 0 48 0 40 0 48 m s Lowering speed with without load 0 60 0 36 0 60 0...

Page 22: ...shank 3560 3570 3680 3835 mm b1 Overall width 1820 2002 2002 2100 mm s e l Fork dimensions 60 150 1200 60 150 1200 70 150 1200 70 150 1200 mm m1 Ground clearance laden below mast 230 230 230 230 mm m...

Page 23: ...3840 4040 mm b1 Overall width 2150 2150 mm s e l Fork dimensions 70 180 1800 70 180 1800 mm m1 Ground clearance laden below mast 230 230 mm m2 Ground clearance centre wheelbase 250 250 mm Fork carria...

Page 24: ...0 1200 70 150 1200 mm m1 Ground clearance laden below mast 230 230 230 230 mm m2 Ground clearance centre wheelbase 235 250 250 250 mm Fork carriage ISO 2328 class type A B 4 A 4 A 4 A 4 A mm b3 Fork c...

Page 25: ...rk dimensions 70 180 1800 70 180 1800 mm m1 Ground clearance laden below mast 240 240 mm m2 Ground clearance centre wheelbase 240 240 mm Fork carriage ISO 2328 class type A B 4 A 4 A mm b3 Fork carria...

Page 26: ...27 11 14 EN...

Page 27: ...unladen load front rear 5000 5500 5500 5900 6000 6400 6800 7200 Axle loading laden front rear 14900 1600 16400 2000 18100 2300 20500 2500 S80 S90 Net weight 14400 15500 Axle loading unladen load front...

Page 28: ...0 2335 5500 0 3660 6410 2460 6000 0 3910 6910 2585 6500 0 4160 7410 2735 ZZ 3600 1800 2875 4675 2278 4000 2000 3075 5075 2350 4500 2250 3325 5675 2422 5000 2500 3575 6075 2542 5500 2750 3825 6575 2652...

Page 29: ...0 2485 5500 0 3960 6710 2610 6000 0 4210 7210 2757 6500 0 4460 7710 2910 ZZ 3600 1800 3025 4825 2326 4000 2000 3225 5225 2350 4500 2250 3475 5725 2422 5000 2500 3725 6225 2604 5500 2750 3975 6725 2724...

Page 30: ...2556 5000 2500 3875 6375 2676 5500 2750 4125 6875 2796 6000 3000 4375 7375 2916 6500 3300 4625 7875 3036 DZ 4500 1500 2885 5886 2796 5000 1667 3052 6386 2879 5500 1833 3218 6886 3004 6000 2000 3385 7...

Page 31: ...275 7025 2868 6000 3000 4525 7525 2988 6500 3300 4775 8025 3108 DZ 4500 1500 3035 6036 2858 5000 1667 3202 6536 2983 5500 1833 3368 7036 3128 6000 2000 3535 7536 3232 6500 2167 3702 8036 3336 7000 233...

Page 32: ...ing rims and tyres fitted at the factory only use the manufacturer s original spare parts Otherwise the manufacturer s specifications cannot be ensured If you have any queries contact the manufacturer...

Page 33: ...Other tyres can be used depending on the truck s equipment Model DFG TFG S80 S90 Front tyres SE 300 15 300 15 Pneumatic 300 15 18 PR 300 15 18 PR Tyre pressure bar 10 10 Torque Nm 650 650 Rear tyres S...

Page 34: ...load 2200 2200 2200 rpm Idle speed 850 850 850 rpm Engine output 91 91 90 kW Fuel consumption 60 VDI duty cycles h 8 8 8 8 10 3 l h kg h Model TFG 660 TFG 670 TFG 680 Cylinders cubic capacity 8 5700...

Page 35: ...standard truck version 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 spe...

Page 36: ...ation 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 clarif...

Page 37: ...tes Z Warnings and notices such as capacity charts strap points and data plates must be legible at all times Replace if necessary XXXXXX xxx xxxxxx 1 0 21 24 35 27 22 29 15 15 16 17 19 18 36 20 26 28...

Page 38: ...forward with a load raised 25 Turn the exhaust pipe back before tilting the cab 26 Air pressure 27 Do not stand on load handler Do not stand under load handler Risk of trapping when mast extended 28 H...

Page 39: ...arts always quote the truck serial number 44 43 44 46 45 52 49 51 48 47 50 Item Component Item Component 43 Type 48 Year of manufacture 44 Serial number 49 Load centre distance mm 45 Rated capacity kg...

Page 40: ...ast 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 21 of the truck indicates the truck s capacity with the...

Page 41: ...tachment point The Jack contact point decal 29 indicates where the truck may be lifted and jacked up 5 Stability The truck s stability has been tested according to latest technological standards These...

Page 42: ...lines between the basic truck and the mast separated 2 Truck laden 2 1 Centre of gravity of the truck WARNING An altered centre of gravity can result in tipovers when cornering The overall centre of g...

Page 43: ...ay that they do not come into contact with any attachments or the overhead guard when lifting XDo not stand under a swaying load XThe truck should only be handled by people who are trained in using li...

Page 44: ...45 11 14 EN 2 3 Loading with another industrial truck DANGER Slipping can cause accidents XDo not use another Industrial truck to load the truck...

Page 45: ...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...

Page 46: ...ruck 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 an...

Page 47: ...11 14 EN 48...

Page 48: ...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 provid...

Page 49: ...d 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 sa...

Page 50: ...e relief valve 61 in the drive compartment The relief valve is fitted with a hose 60 that diverts the LPG if the relief valve is opened When the valve is activated the plastic cover comes off thereby...

Page 51: ...doctor XWear safety gloves when handling diesel fuels NOTE XFuelling must always be performed in designated areas by trained and authorised personnel NOTE XCapacity DFG 660 690 125 l XUse only diesel...

Page 52: ...cedure Unscrew the filler cap 62 and open the fuel container Fit the spout onto the fuel container Insert the spout into the open tank filler neck Make sure the fuel container and spout are connected...

Page 53: ...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...

Page 54: ...toggle type fastener with the handle 67 Carefully remove the LPG bottle from the bracket and place it down securely Inserting a new LPG bottle Procedure Insert the LPG bottle into the bracket Align th...

Page 55: ...en the shut off valves 64 of both LPG bottles by turning anticlockwise Apply the 71 switch The left LPG bottle 69 is activated by the middle switch position The right LPG bottle 70 is activated by the...

Page 56: ...page 103 Note all guidelines and regulations concerning the filling of LPG bottles on the LPG pump Procedure Unscrew the tank cap 62 Lock the filling adapter of the tank system in place on the fillin...

Page 57: ...11 14 EN 58 4 Fuel level indicator 4 1 Display unit The level indicator 63 shows the capacity of the tank 63...

Page 58: ...he operating instructions Safety shoes must be worn on pedestrian operated trucks Unauthorised use of truck The operator is responsible for the truck during the time it is in use The operator must pre...

Page 59: ...se of danger to third parties give a warning signal in good time XIf unauthorised persons are still within the hazardous area stop the truck immediately WARNING Falling objects can cause accidents Fal...

Page 60: ...witch Item Control Display Function 73 Multi task switch t Travel function switch Sets automatic gear shifting Travel direction switch Selects travel direction neutral position t Standard equipment o...

Page 61: ...en wiper Switches the windscreen wiper on and off Switches interval speed on and off Windscreen washing system Switches windscreen washing system on and off Horn Activates an audible warning 76 Brake...

Page 62: ...ower 78 Lever t Mast forward reverse tilt 79 Auxiliary hydraulics lever 1 o 1 Activate 1st attachment 80 Auxiliary hydraulics lever 2 o 2 Activate 2nd attachment 81 Auxiliary hydraulics lever 3 o 3 Ac...

Page 63: ...Mast forward reverse tilt 83 Travel direction switch o Selects travel direction neutral position 79 Auxiliary hydraulics 1 switch o 1 Activate attachment 80 Auxiliary hydraulics 2 switch o 2 Activate...

Page 64: ...s switched on 86 Hazard warning lights indicator lamp t Flashes when the hazard warning lights are activated 87 Dipped lights t Switches dipped lights on and off 88 Key switch t Switches the power sup...

Page 65: ...ork lights on and off Switch Rear window wiper t Switches the rear window wiper on and off Air conditioning system switch o Switches the air conditioning system on and off Fan 1 switch t Switches the...

Page 66: ...t Current speed 92 Warning indicator t Current warnings variable 93 Temperature display t Current engine temperature 94 Parking brake display t Position of the parking brake 95 Menu t Access to the c...

Page 67: ...travel direction switches to neutral position immediately No driver in the truck Service interval expired Contact Customer Services Flashes to indicate an error in the brake system Park the truck secu...

Page 68: ...it t Error in the main control unit CVC Transmission t Error in the transmission controller Hydraulic oil flashing o Hydraulic oil temperature too low below 5 C Hydraulic oil temperature too high abov...

Page 69: ...and information are shown in the multifunction display Pictograms in the top section of the display act as warning indicators 99 The function keys lower row are lit Areas inside borders in the display...

Page 70: ...71 11 14 EN Press the F4 key to go to the SETUP 100 and Diagnostics 101 areas Press the F4 key SETUP to open the adjustment range for the display Diag SETUP nose 100 101 Einstell Displays...

Page 71: ...the travel stages can also be adjusted here single pedal drive Press the F1 key to open the adjustment range for the standard values of the truck Setup Diagn ostic Setup Setup Diagn ostic Setup Disp s...

Page 72: ...er 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...

Page 73: ...ent 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...

Page 74: ...o 104 Hydraulic oil reservoir capacity o 105 Hydraulic oil temperature measurement in the tank o 106 Engine operating hours t 107 Time until next service t 108 Lift height o 109 Hydraulic system opera...

Page 75: ...ersion 119 Transmission parameter no 114 Engine variant 120 Transmission software version 116 Display firmware version 121 Information area for optional components 115 Engine type list number Diag SET...

Page 76: ...Reading Current Values The F1 to F4 buttons open the lower level menu ranges F1 button brake system The current values for the brake pressure 122 pedal position 124 and the valve 123 can be seen here...

Page 77: ...ntrol lever s Minus forward Plus back Range 126 indicates the current temperature of the control module Range 128 indicates the current setting of the travel direction t activated o not activated Pres...

Page 78: ...the air speed as a for the engine 129 transmission 131 and charge air cooler 132 an The speed of the cooler fan 130 is shown as a F4 button travel switch Indicates the current state of the travel dire...

Page 79: ...tem S 4 S 5 S 6 S 7 S 8 S 24 S 12 S 13 S 15 S 20 S 26 X28 XR 9 S 30 136 137 86 138 139 140 141 142 143 144 145 146 147 71 148 149 S 4 S 5 S 6 S 7 S 8 S 24 S 12 S 13 S 15 S S 2 20 0 S S 2 26 6 X X2 28...

Page 80: ...reen washing system roof window o 141 Seat heating o 142 Heater air conditioning controller o manual 143 Nozzle heater 144 Cigarette lighter 145 Spot lights 146 Spot lights rear 147 Spot lights front...

Page 81: ...g mode CAUTION Extreme temperature differences can affect your health XWhen using the air conditioning system make sure the temperature is no higher than 6 C more than the outside air temperature XKee...

Page 82: ...ets set the fan switch 154 to the highest level set the temperature selector 153 as required and open the side sliding window a notch When the humidity has been removed from the interior of the truck...

Page 83: ...no more than 5 6 C below the current outside temperature 158 Fan The fan speed can be adjusted up and down with the Up Down buttons The display is shown as a percentage 159 ON OFF Turn the system on a...

Page 84: ...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 Fue...

Page 85: ...and load handler for damage Check the fork stop 167 and fork tine retainer 168 Visually inspect the hydraulic system in the visible area for damage and leaks Check the driver s seat has been adjusted...

Page 86: ...ecurely 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 LPG only Pro...

Page 87: ...e cab door o To enter and exit the cab hold onto the handle 169 Always face the truck when entering and exiting Z Always use the entry aid 169 provided to climb onto the truck Z An additional step is...

Page 88: ...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...

Page 89: ...et the seat to a lower weight Z The driver s weight is correct when the arrow is in the middle of the display window 170 The minimum or maximum weight setting is reached when you can feel a return str...

Page 90: ...XThe 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 lever173 in the direction of the ar...

Page 91: ...ed Push the adjusting lever into the centre position The steering column tilt is adjusted Adjusting the Height Procedure Push down on the adjusting lever 174 Adjust the steering column 4 to the requir...

Page 92: ...control panel 177 can be changed This makes it possible to adjust the armrest 178 and control panel optimally to each other Procedure Release the lever 179 Move the control panel to the required posit...

Page 93: ...ndividually adjusted Procedure Sit on the driver s seat Adjust the seat to its optimum position Loosen the central wing screw 180 of the display holder just enough so that the two ball joints 181 can...

Page 94: ...ocks 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 b...

Page 95: ...arrow passageways when passing through swing doors and at blind spots The operator must always observe an adequate braking distance between the forklift truck and the vehicle in front and must be in c...

Page 96: ...ck 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 Persons riding in the lift with the forklift truck...

Page 97: ...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 operator must comply with legal requirements techn...

Page 98: ...Checks and operations to be performed before starting daily operation see Checks and operations to be performed before starting daily operation on page 86 Switching On the Truck Procedure Turn the bat...

Page 99: ...position and battery control light 85 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...

Page 100: ...or lamp for neutral position and battery control light 85 should go out after a short while If not abandon the starting procedure and rectify the fault Select the LPG supply by pressing the 71 switch...

Page 101: ...he lift lower tilt and if applicable the attachment hydraulic control functions Test the horn Test the engine speed with the accelerator pedal 75 over a range of speeds while checking the freedom of m...

Page 102: ...l 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 XAlways apply the parking brake button before parking the t...

Page 103: ...to allow the temperature to compensate Set the travel direction switch to neutral position Turn the switch 71 to the upper position to close the electrical shut off valves of the LPG bottles Turn the...

Page 104: ...connect switch as a service brake XUse the Emergency Disconnect switch during travel only in emergencies Applying the Emergency Disconnect Procedure Press the Emergency Disconnect switch 89 All electr...

Page 105: ...n the work area and the load XTilt the mast back and raise the fork carriage approx 200 mm XMake sure you have sufficient visibility when reversing Travel Requirements Truck prepared for operation see...

Page 106: ...avel 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 76 to b...

Page 107: ...turn the steering wheel 175 sensitively To negotiate a right hand bend Turn the steering wheel clockwise according to the required steering radius To negotiate a left hand bend Turn the steering whee...

Page 108: ...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 pa...

Page 109: ...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 br...

Page 110: ...entre of gravity must be located centrally between the fork tines Adjusting the forks Requirements Park the truck securely see Parking the truck securely on page 103 Procedure Lift up the locking leve...

Page 111: ...s and a crane before pushing them down from the fork carriage WARNING Trapping hazard There is a trapping hazard when you perform this operation XWear work gloves and safety shoes Replacing the fork t...

Page 112: ...ler XDamaged loads must not be transported XIf the stacked load obscures forward visibility then you must reverse the truck XDo not exceed the maximum loads specified on the capacity plate XCheck the...

Page 113: ...ate and decelerate with care 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 look...

Page 114: ...loads that have been correctly secured and positioned Use suitable precautions to prevent parts of the load from tipping or falling down XDo not exceed the maximum loads specified on the capacity plat...

Page 115: ...ll revert automatically to the neutral position Depositing a load unit SOLO PILOT Procedure To place the load in a horizontal position Press the lever 78 in direction A To position the load at the cor...

Page 116: ...0 in direction A while simultaneously pressing the acknowledgement key 82 Narrower fork spread Press the handle 80 in direction B while simultaneously pressing the acknowledgement key 82 To move both...

Page 117: ...from the pressure limitation valve release MULTI PILOT MULTI PILOT will revert automatically to the neutral position Tilting the mast forward backward Requirements Truck prepared for operation see Pre...

Page 118: ...andler 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 e...

Page 119: ...set the fork to the width of the load Wider fork spread Press the control button 80 in direction F while simultaneously pressing the acknowledgement key 81 Narrower fork spread Press the control butto...

Page 120: ...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...

Page 121: ...ly be operated on trucks will auxiliary hydraulics ZH2 or ZH3 XWhen connecting the attachment make sure that the hydraulic lines of the attachment are connected to the right ports see Fitting addition...

Page 122: ...ge Fork extension safety instructions WARNING Unsecured and oversized fork extensions can cause accidents XFor fork extensions with an open cross sectional area carry only loads that are resting along...

Page 123: ...ever 79 in direction A or B Operating hydraulic port ZH2 Move the handle 80 in direction A or B while simultaneously pressing the 82 button The attachment performs its operation 6 14 2 Solo Pilot with...

Page 124: ...Fitting additional attachments on page 126 Procedure Operating hydraulic port ZH1 Press the button 79 Operating hydraulic port ZH2 Press the button 80 The attachment performs its operation 6 15 2 Mul...

Page 125: ...XClamping attachments may only be added to trucks which have a button to enable additional hydraulic functions XOn trucks with auxiliary hydraulics ZH2 the clamping function should only be attached to...

Page 126: ...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 127: ...the capacity indicated on the capacity plate see Identification points and data plates on page 38 If a load is also transported on the load handler the trailer load must be reduced by the same amount...

Page 128: ...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 189 is moved to...

Page 129: ...11 14 EN 130 8 Optional equipment...

Page 130: ...d handler 90 seat position o Seat facing the driver s door 180 seat position Seat facing the counterweight Z Travel is inhibited while the driver s seat rotates Z The travel direction switch must be s...

Page 131: ...the Emergency Disconnect switch as a service brake XUse the Emergency Disconnect switch during travel only in emergencies Z An additional Emergency Disconnect switch 89 is included for the rotary sea...

Page 132: ...133 11 14 EN 8 1 4 Panoramic mirror Z An additional panoramic mirror 191 is included for the rotary seat option 191...

Page 133: ...11 14 EN 134 8 1 5 Steering direction reversal notice sign Z An additional notice sign 192 is included for the steering direction reversal option 192...

Page 134: ...Truck stationary Operator on the driver s seat Brake pedal activated Procedure To rotate the driver s seat Push the button 190 down and hold it down The driver s seat rotates anti clockwise Push the b...

Page 135: ...k travels in the direction selected Steers the truck Procedure To negotiate a right hand bend 196 Turn the steering wheel 174 clockwise to match the desired steering radius To negotiate a left hand be...

Page 136: ...s To negotiate a left hand bend Travel direction switch in V turn the steering wheel anti clockwise to match the desired steering radius Reverse travel direction To negotiate a right hand bend Travel...

Page 137: ...truck travels in the direction selected Steers the truck Procedure To negotiate a right hand bend 196 Turn the steering wheel 174 clockwise to match the desired steering radius To negotiate a left ha...

Page 138: ...iver s seat Check fuse Truck operational driver s seat rotated truck does not travel Driver s seat not in 0 90 o or 180 position Turn the driver s seat exactly to the 0 90 o or 180 position Driver s s...

Page 139: ...he lock in the stop 198 8 3 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 posi...

Page 140: ...ng trailers see Towing trailers on page 128 CAUTION Incorrectly coupled trailers can cause accidents XMake sure the coupling is engaged securely before starting the truck XThe contro pin 203 must be f...

Page 141: ...11 14 EN 142 Drive the truck forward Press down on the hand lever 202...

Page 142: ...avel in Emergency Mode on page 125 This does 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 o...

Page 143: ...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 mo...

Page 144: ...hed on Switch on the battery isolator Faulty fuse Check fuses Battery charge too low Check battery charge charge battery if necessary Battery terminal cable loose or terminals oxidized Clean and greas...

Page 145: ...brakes are released the truck must be parked securely on a level surface since the brakes are no longer effective XDo not release the parking brake on slopes or inclines XApply the parking brake agai...

Page 146: ...d if there is insufficient brake force 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...

Page 147: ...tely 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 Apply the Emergency Disconnect Turn k...

Page 148: ...e terminal of the truck battery 211 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 Use a ladder to change...

Page 149: ...11 14 EN 150...

Page 150: ...lans 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 permane...

Page 151: ...s Customer Services Customer Services are specially trained in the use of the truck and are able to carry out maintenance and repairs independently Customer Services are aware of the relevant standard...

Page 152: ...s must be disposed of in accordance with the applicable environmental protection regulations To change the oil contact the manufacturer s customer service department who have been specially trained fo...

Page 153: ...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...

Page 154: ...s The application conditions of the industrial truck have a considerable impact on the ageing of the hydraulic hoses XCheck the hydraulic hoses at least annually and replace if necessary XIf the opera...

Page 155: ...s 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...

Page 156: ...parts XDo not smoke when handling oil XAvoid contact and digestion If you swallow oil do not induce vomiting but seek medical assistance immediately XSeek fresh air after breathing in oil fumes or va...

Page 157: ...12 222 Tilt cylinder rear bearing 2 223 Cardan shaft 2 226 Stub axle pins 4 227 Track rod 4 Dipstick and filling points 215 Hydraulic oil filler plug in the motor compartment 217 Fuel filler neck 224...

Page 158: ...228 Coolant tank 229 Engine oil dipstick 230 Filler neck for window washer system Lowering points 214 Wheel hub right 216 Hydraulic oil right tank 218 Fuel left tank 219 Wheel hub left Dipstick and fi...

Page 159: ...thium w MOS NLGI 2 Grease lubrication 228 51332291 16 l Fricofin V Mix coolant with water 1 1 215 51132716 4 cylinders 150 l 6 cylinders 190 l 8 cylinders 170 l Jungheinrich hydraulic oil Hydraulics 2...

Page 160: ...dy can also result if poisonous quantities come into contact with the skin for long or repeated periods XNote the manufacturer s safety instructions NOTE Anti freeze water mixture ratio X1 1 anti free...

Page 161: ...truck from being switched on accidentally Press the Emergency Disconnect switch 232 down Turn the battery isolator 182 to position B WARNING Risk of accidents when working under the load handler driv...

Page 162: ...ng the truck take appropriate measures to prevent it from slipping or tipping over e g wedges wooden blocks Raising and jacking up the truck securely Requirements Prepare the truck for maintenance and...

Page 163: ...wheels can cause injury XThe wheels of the truck are very heavy A single wheel can weigh up to 250 kg XAlways replace wheels with a suitable tool and protective equipment Dismantle the wheels Require...

Page 164: ...tachment Remove the hard wooden blocks Lower the truck Torque the wheel attachment 233 crosswise with a torque wrench for torques see Tyre type on page 33 The wheel is now assembled Z When using pneum...

Page 165: ...rial Required Torque wrench Procedure Torque the wheel nuts 233 crosswise with a torque wrench for torques see Tyre type on page 33 The wheel attachment is now checked Z When using pneumatic tyres che...

Page 166: ...fler back to its vertical position and lock it in place 4 6 1 Raising the Cab Manually Procedure Remove the pump rod 239 from the holder behind the driver s seat The lift pump is fed into the cab thro...

Page 167: ...re To lift the cab insert the short side of the pump rod 239 through the infeed 237 onto the pump drive and activate Tilt the cab back manually until the cab locking device engages in the engine compa...

Page 168: ...the cab To lower the cab insert the long side of the pump rod 239 through the infeed 238 onto the hexagon of the lowering valve and carefully turn the lowering valve anti clockwise to open it DANGER...

Page 169: ...close insert the long side of the pump rod through the infeed 238 onto the hexagon of the lowering valve and turn clockwise as far as the stop Lifting Procedure Press switch 241 on the service panel...

Page 170: ...wheels can cause injury XThe wheels of the truck are very heavy A single wheel can weigh up to 250 kg XAlways replace wheels with a suitable tool and protective equipment Dismantle the wheels Require...

Page 171: ...tachment Remove the hard wooden blocks Lower the truck Torque the wheel attachment 233 crosswise with a torque wrench for torques see Tyre type on page 33 The wheel is now assembled Z When using pneum...

Page 172: ...uts are secure 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 Tyre type on pag...

Page 173: ...m 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 seek medical assistance immediately XSee...

Page 174: ...th 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 between the MIN and MAX markings For hot o...

Page 175: ...raulic filter Add hydraulic oil to the MAX mark on the hydraulic oil dipstick 244 Z Use only approved hydraulic oil see consumables table Check the hydraulic oil level with the dipstick and top up as...

Page 176: ...ot components are freely accessible and can cause injury if touched XBefore starting work make sure that the Emergency Disconnect switch can be reached to switch off the engine XDo not touch moving pa...

Page 177: ...gether Checking the engine oil level Requirements Park the truck on a level surface 9 Servicing and Inspection Procedure Prepare the truck for maintenance and repairs The engine oil dipstick 245 is lo...

Page 178: ...ler 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 Park the truck securely...

Page 179: ...ed under the service panel 234 Open the service panel 234 completely Clean the cooling unit carefully using compressed air without touching the cooling multi plates Close the service panel CAUTION A d...

Page 180: ...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...

Page 181: ...182 4 10 4 Adding Window Washer System Fluid Procedure Open the service panel Unscrew the cover 230 and add window washing fluid If necessary top up with anti freeze Z The capacity of the tank is 5 li...

Page 182: ...in some cases special tools are required to perform other maintenance work especially changing oil and filters according to the maintenance checklist section see Servicing and Inspection on page 199...

Page 183: ...5 7 5 15 10 25 15 10 10 F11 F12 F13 F14 F15 F16 F17 F18 10 10 10 1 1 10 10 1 F19 F20 F21 F22 F23 F24 F25 F26 1 15 10 10 15 1 5 F27 F28 F29 F30 F31 F32 10 Type Electric circuit Rating A F1 Parking ligh...

Page 184: ...5 t 1 F25 Ignition switch 50 t 1 F26 Swivel seat o 10 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 LPG supply TF...

Page 185: ...n the motor compartment Component Electric circuit Rating A F41 Front work lights on mast 15 F42 Transmission controller terminal 30 10 F43 Transmission controller terminal 30 15 F44 Option terminal 1...

Page 186: ...15 F42 Transmission controller terminal 30 10 F43 Truck controller terminal 15 15 F44 Option terminal 15 X27 4 10 F45 Option terminal 15 X27 1 5 F46 Valve block 10 F47 Option terminal 15 X26 7 5 F48 T...

Page 187: ...e right of the driver s seat in the cab WARNING To avoid damaging the electrical system only use fuses with the correct ratings Description Power circuit Rating A FH4 Electric cab lift main fuse o 80...

Page 188: ...f the pressure washer by the marked points to avoid damaging them see Preparing the truck for maintenance and repairs on page 162 XDo not clean the truck with pressurised water Cleaning the truck Requ...

Page 189: ...nd repairs see Opening the Service Panel on page 166 Tools and Material Required Compressor with water separator Non conductive antistatic brush Procedure Expose the electrical system see Opening the...

Page 190: ...water XOnly batteries with a sealed battery container may be used XFollow national guidelines and legislation Check battery Procedure Check the battery housing for cracks and any spilled acid Remove a...

Page 191: ...the engine cover Start the engine when the engine cover is open To do this Open the right side window completely Tilt the cab of the truck until the retaining device 210 is locked in position see Clea...

Page 192: ...86 Clean the starter battery grease the terminals and connect the starter battery WARNING Faulty brakes can cause accidents As soon as the truck has been started test the brakes several times XReport...

Page 193: ...d after decommissioning as described hereafter When the truck is out of service it must be jacked up so that all the wheels are clear of the ground This is the only way of ensuring that the wheels and...

Page 194: ...grease to any non painted mechanical components Lubricate the truck according to the lubrication schedule see Lubrication Schedule on page 158 Disconnect the battery clean it and grease the terminals...

Page 195: ...cessary 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 brake...

Page 196: ...es The inspector must 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 p...

Page 197: ...sassembled by trained personnel in accordance with the procedures as specified by the manufacturer 8 Human vibration measurement Z Vibrations that affect the operator over the course of the day are kn...

Page 198: ...ust temperature fluctuations or multiple shifts NOTE To prevent damage due to wear the manufacturer recommends an on site application analysis to agree on appropriate service intervals The following m...

Page 199: ...t 2 Check and clean radiator t 3 Check tyre air pressure and top up if necessary t 4 Check wheels for wear and damage t 5 Check engine oil level top up if necessary t Chassis and Superstructure W A B...

Page 200: ...sis and Superstructure W A B C 1 Test the heating t Hydraulic operations W A B C 1 Check attachment lubrication clean and lubricate if necessary t Hydraulic operations W A B C 1 Check attachment lubri...

Page 201: ...ptional equipment Chassis and Superstructure W A B C 1 Check that optional equipment such as mirrors storage compartments grips windscreen wipers and washing systems etc are working correctly and chec...

Page 202: ...lines for leaks and damage t 2 Check battery cable connections are secure grease terminals if necessary t 3 Check battery and battery components t 4 Check battery voltage t Travel W A B C 1 Replace tr...

Page 203: ...ater separator and discharge if necessary t 32 Check drive axle for noise and leakage t 33 Replace drive axle oil t 34 Clean or replace transmission oil suction filter if necessary t Chassis and Super...

Page 204: ...surface wear level t 10 Check running surfaces of the mast for wear and damage and lubricate if necessary t 11 Test hydraulic system t 12 Replace hydraulic reservoir discharge paper filter t 13 Replac...

Page 205: ...se the steering axle t 6 Check mechanical parts of steering column t Electrical System W A B C 1 Check anti static discharge strap is present and not damaged t Electrical System W A B C 1 Test the buz...

Page 206: ...otary seat and check for damage t 4 Check rotary drive motor attachment t 5 Check rotary drive pinion for wear and damage t Electrical System W A B C 1 Test the electrical optional equipment and check...

Page 207: ...on clean and lubricate if necessary t 9 Check hydraulic ports and tighten if necessary t 10 Check cylinder seals t 11 Check cylinder piston rods and bushings t Chassis and Superstructure W A B C 1 Tes...

Page 208: ...damage t Hydraulic operations W A B C 1 Test the hose reel and check for leaks and damage t 2 Check axial play of the front and rear rollers and adjust if necessary t 3 Check attachment is properly se...

Page 209: ...W A B C 1 Test the hose reel and check for leaks and damage t 2 Check axial play of the front and rear rollers and adjust if necessary t 3 Check attachment is properly secured to the truck and the sup...

Page 210: ...nt Issued on 15 11 2013 10 00 24 Chassis and Superstructure W A B C 1 Check that optional equipment such as mirrors storage compartments grips windscreen wipers and washing systems etc are working cor...

Page 211: ...t 2 Check and clean radiator t 3 Check tyre air pressure and top up if necessary t 4 Check wheels for wear and damage t 5 Check engine oil level top up if necessary t Chassis and Superstructure W A B...

Page 212: ...sis and Superstructure W A B C 1 Test the heating t Hydraulic operations W A B C 1 Check attachment lubrication clean and lubricate if necessary t Hydraulic operations W A B C 1 Check attachment lubri...

Page 213: ...ptional equipment Chassis and Superstructure W A B C 1 Check that optional equipment such as mirrors storage compartments grips windscreen wipers and washing systems etc are working correctly and chec...

Page 214: ...e connections are secure grease terminals if necessary t 3 Check battery and battery components t 4 Check battery voltage t 5 Note check the exhaust levels every six months and adjust if necessary Obs...

Page 215: ...n t 26 Test water pump and the fans t 27 Replace the spark plugs t 28 Check drive axle for noise and leakage t 29 Replace drive axle oil t 30 Clean or replace transmission oil suction filter if necess...

Page 216: ...surface wear level t 10 Check running surfaces of the mast for wear and damage and lubricate if necessary t 11 Test hydraulic system t 12 Replace hydraulic reservoir discharge paper filter t 13 Replac...

Page 217: ...se the steering axle t 6 Check mechanical parts of steering column t Electrical System W A B C 1 Check anti static discharge strap is present and not damaged t Electrical System W A B C 1 Test the buz...

Page 218: ...otary seat and check for damage t 4 Check rotary drive motor attachment t 5 Check rotary drive pinion for wear and damage t Electrical System W A B C 1 Test the electrical optional equipment and check...

Page 219: ...9 Check hydraulic ports and tighten if necessary t 10 Check cylinder seals t 11 Check cylinder piston rods and bushings t Chassis and Superstructure W A B C 1 Test air conditioning system and its set...

Page 220: ...te t 6 Check attachment bearing points guides and stops for wear and damage grease and clean these components t 7 Check attachment lubrication clean and lubricate if necessary t 8 Check hydraulic port...

Page 221: ...t 4 Test attachment check settings and check for damage t 5 Check sliding blocks are complete t 6 Check attachment bearing points guides and stops for wear and damage grease and clean these component...

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