Jungheinrich TFG 660, DFG660, DFG S80, DFG 670, DFG690 Service Manual

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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

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Declaration of Conformity

Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg Manufacturer or agent acting in the European Union

Additional information

On behalf of

Date

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.

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

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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

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Jungheinrich Aktiengesellschaft

Am Stadtrand 35 22047 Hamburg - Germany

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

www.jungheinrich.com

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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 optional equipment ...................................... 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.................................................................................................. 33

3.6 Engine Data ............................................................................................. 35

3.7 EN norms................................................................................................. 36

3.8 Conditions of use ..................................................................................... 37

3.9 Electrical requirements ............................................................................ 37

4 Identification points and data plates ........................................................ 38

4.1 Data plate ................................................................................................ 40

4.2 Truck capacity plate................................................................................. 41

4.3 Attachment capacity plate ....................................................................... 42

4.4 Jack attachment point.............................................................................. 42

5 Stability .................................................................................................... 42

C Transport and Commissioning ................................................ 43

1 Transport ................................................................................................. 43

2 Truck laden.............................................................................................. 43

2.1 Centre of gravity of the truck ................................................................... 43

2.2 Lifting the truck by crane ......................................................................... 44

2.3 Loading with another industrial truck ....................................................... 45

3 Securing the truck during transport ......................................................... 46

4 Using the Truck for the First Time ........................................................... 47

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D Fuelling the Truck.................................................................... 49

1 General.................................................................................................... 49

1.1 Safety regulations for handling diesel fuel and LPG................................ 49

1.2 LPG system relief valve ........................................................................... 51

2 Adding diesel ........................................................................................... 52

2.1 Fuelling .................................................................................................... 52

2.2 Fuelling with fuel containers .................................................................... 53

3 LPG containers........................................................................................ 54

3.1 LPG bottles .............................................................................................. 54

3.2 Liquid gas tank ........................................................................................ 57

4 Fuel level indicator................................................................................... 58

4.1 Display unit .............................................................................................. 58

E Operation ................................................................................ 59

1 Safety Regulations for the Operation of the Forklift Truck....................... 59

2 Displays and Controls.............................................................................. 61

2.1 Multi-task switch ...................................................................................... 61

2.2 SOLO-PILOT ........................................................................................... 63

2.3 MULTI-PILOT .......................................................................................... 64

2.4 Controls ................................................................................................... 65

2.5 Multifunction display ................................................................................ 67

2.6 Operation of the multifunction display ..................................................... 70

3 Dashboard ............................................................................................... 80

3.1 Without air conditioning system ............................................................... 80

3.2 With air conditioning system .................................................................... 80

3.3 With 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 performed before starting daily operation . 86

5.2 Entry and exit........................................................................................... 88

5.3 Setting up the operator position............................................................... 89

5.4 Seat Belt .................................................................................................. 95

6 Industrial Truck Operation ....................................................................... 96

6.1 Safety regulations for truck operation ...................................................... 96

6.2 Preparing the truck for operation ............................................................. 99

6.3 Operational Checks ................................................................................. 102

6.4 Parking the truck securely ....................................................................... 103

6.5 Emergency Disconnect............................................................................ 105

6.6 Travel....................................................................................................... 106

6.7 Steering ................................................................................................... 108

6.8 Brakes ..................................................................................................... 109

6.9 Adjusting the forks ................................................................................... 111

6.10 Replacing the forks.................................................................................. 112

6.11 Lifting, transporting and depositing loads ................................................ 113

6.12 Operating the lift mechanism and integrated attachments ...................... 115

6.13 Safety instructions for operating additional attachments ......................... 121

6.14 Operating additional attachments for the SOLO-PILOT .......................... 124

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6.15 Operating additional attachments for the Multi Pilot ................................ 125

6.16 Fitting additional attachments .................................................................. 126

7 Towing trailers ......................................................................................... 128

8 Optional equipment ................................................................................. 130

8.1 Rotating Driver's Seat.............................................................................. 131

8.2 Sliding windows ....................................................................................... 140

8.3 Emergency Exit ....................................................................................... 140

8.4 Driver'S Seat Heater................................................................................ 140

8.5 Fire Extinguisher...................................................................................... 141

8.6 Rockinger Coupling with Hand Lever ...................................................... 141

9 Troubleshooting....................................................................................... 143

9.1 Automatic Emergency Brake ................................................................... 143

9.2 Troubleshooting ....................................................................................... 145

9.3 Operating the truck without its own drive system .................................... 146

F Industrial Truck Maintenance .................................................. 151

1 Operational Safety and Environmental Protection................................... 151

2 Maintenance Safety Regulations............................................................. 152

2.1 Working on the electrical system ............................................................. 153

2.2 Consumables and used parts .................................................................. 153

2.3 Wheels..................................................................................................... 153

2.4 Lift Chains................................................................................................ 154

2.5 Hydraulic system ..................................................................................... 154

2.6 Working in the vicinity 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 repairs ......................................................................... 162

4.1 Preparing the truck for maintenance and repairs .................................... 162

4.2 Lifting and jacking up the truck safely...................................................... 163

4.3 Replacing wheels .................................................................................... 164

4.4 Checking the wheel attachments............................................................. 166

4.5 Opening the Service Panel ...................................................................... 166

4.6 Tilting the Cab ......................................................................................... 167

4.7 Replacing wheels .................................................................................... 171

4.8 Checking the wheel attachments............................................................. 173

4.9 Hydraulic system ..................................................................................... 174

4.10 Engine maintenance................................................................................ 177

4.11 Check the transmission oil level .............................................................. 183

4.12 Performing Other Maintenance Work ...................................................... 183

4.13 Closing the Motor Compartment.............................................................. 183

4.14 Checking electrical fuses......................................................................... 184

4.15 Cleaning .................................................................................................. 189

4.16 Starter battery.......................................................................................... 191

4.17 Exhaust system ....................................................................................... 192

4.18 Restoring the truck to service after maintenance and repairs ................. 193

5 Decommissioning the industrial truck ...................................................... 194

5.1 Prior to decommissioning ........................................................................ 195

5.2 During decommissioning ......................................................................... 195

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5.3 Restoring the truck to service after decommissioning ............................. 196

6 Safety tests to be performed at intervals 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

10.2 Customer Service .................................................................................... 203

11 Maintenance checklist TFG ..................................................................... 212

11.1 Operating Company ................................................................................ 212

11.2 Customer Service .................................................................................... 215

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A Correct Use and Application

1 General

The truck must be used, operated and serviced in accordance with the present instructions. All other types of use are beyond its scope of application and may result in damage to personnel, the industrial truck or property.

2 Correct application

NOTE

The maximum load and load distance are indicated on the capacity plate 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 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 lowered loads over short distances. – Occasional towing of trailer loads. – When towing trailers the load must be secured on the trailer. – The permissible trailer load must not be exceeded.

The following operations are prohibited: – Travelling with a raised load (>30 cm). – Carrying and lifting passengers. – Pushing or pulling loads. – Transporting hanging loads. If the truck is to be operated with hanging loads, proof

of sufficient safety distance under local operating conditions must be obtained from a specialist assessor.

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3 Approved application conditions

DANGER!

Do not exceed the permissible surface and point loading on the travel lanes. At blind spots get a second person to assist. The driver must ensure that the loading dock /dock leveller cannot be removed or come loose during loading/unloading.

– Operation in industrial and commercial environments. – Permissible temperature range -20 to 40°C. – Operation only on secure, level surfaces with sufficient capacity. – Do not exceed the permissible surface and spot load limits on the travel routes. – Operation only on routes that are visible and approved by the operating company. – Negotiating inclines up to a maximum of 15 %. – Do not travel across or at an angle on inclines. Travel with the 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

substances.

WARNING!

Operating an LPG truck under ground level areas could result in explosions.

LPG is heavier than air. An explosive LPG/air mixture could therefore form under ground level areas without sufficient ventilation.

XDo not use LPG trucks under ground level areas.

WARNING!

Use under extreme conditions

Using the truck under extreme conditions can result in malfunctions and accidents. 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 cannot be used 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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4 Proprietor responsibilities

For the purposes of the present operating instructions the “operating company” is defined as any natural or legal person who either uses the industrial truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting) the proprietor is considered the person who, in accordance with existing contractual agreements between the owner and user of the industrial truck, is charged with operational duties. The proprietor must ensure that the industrial truck is used only for the purpose it is intended for and that danger to life and limb of the user and third parties 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 read and understood these operating instructions.

NOTE

Failure to comply with the operating instructions invalidates 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 optional equipment

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

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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 name.

The rated capacity is not generally the same as the permissible capacity. The capacity can be found on the capacity plate attached to the truck.

DFG660

DFG Model name

6Series

60 Rated capacity x 100 kg

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2 Assemblies and Functional Description

2.1 Assembly Overview

14 13 12 910

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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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. A 3-way catalytic converter ensures very low exhaust levels.

Electrical System

12-volt system with 3-phase alternator. A repeat 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 start and stop the engine.

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Drive System

A power shift gear with radiator and torque converter is flanged directly to the engine. This transfers the force to the drive axle (12). The travel direction lever, either on the steering column or optionally on the multi-task handle, controls forward/reverse travel and the neutral position.

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.

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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 The technical specifications comply with the German "Industrial Truck Data Sheet"

Guidelines. Technical modifications and additions reserved.

3.1 Performance data

DFG 660-690

for vertical mast.

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%.

Component 660 670 680 690

QCapacity

6000 7000 8000 9000 kg

C Load centre distance 600 600 600 600 mm

Travel speed * with /

without load

22.4/22.5 22.4/22.6 22.4/22.5 22.4/22.6 km/h

Lift speed with / without

load

0.50/0.60 0.40/0.60 0.40/0.60 0.40/0.60 m/s

Lowering speed with /

without load

0.60/0.36 0.60/0.36 0.60/0.36 0.60/0.36 m/s

Gradeability

with / without load

30.3/32.0 28.7/31.0 27.1/31.0 24.6/28.0 %

Tow force

with/without load

49.5/49.5 49.5/49.5 49.5/49.5 49.5/49.5 kN

Acceleration* with /

without load to 15 m

6.0/5.0 6.0/5.0 6.0/5.0 7.0/6.0 sec

Available working

pressure

for attachments

160 160 160 160 bar

Oil flow

for attachments

80 80 80 80 l/min

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DFG S80-S90

for vertical mast.

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%.

Component S80 S90

Q Capacity

8000 9000 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 0.60/0.36 m/s

Gradeability

with / without load

21.5/25.0 20.9/24.0 %

Tow force with / without load 49.5/49.5 52.9/52.9 kN

Acceleration time *

with / without load to 15 m

7.0/6.0 7.0/6.0 sec

Available working pressure

for attachments

160 160 bar

Oil flow for attachments 80 80 l/min

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TFG 660-690

for vertical mast.

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%.

Component 660 670 680 690

QCapacity

6000 7000 8000 9000 kg

C Load centre distance 600 600 600 600 mm

Travel 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 0.60/0.36 m/s

Gradeability

with / without load

27.5/30.0 27.5/30.0 26.5/30.0 23.0/27.0 %

Tow f o r ce

with / without load

45.6/45.6 45.6/45.6 45.6/45.6 45.6/45.6 kN

Acceleration * with /

without load to 15 m

6.0/5.0 6.0/5.0 6.0/5.0 7.0/6.0 sec

Available working

pressure

for attachments

160 160 160 160 bar

Oil flow

for attachments

80 80 80 80 l/min

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TFG S80-S90

for vertical mast.

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%.

Component S80 S90

Q Capacity 8000 9000 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 0.60/0.36 m/s

Gradeability*

with / without load

20.2/23.0 17.6/20.0 %

Tow f or ce

with / without load

45.6/45.6 45.6/45.6 kN

Acceleration time *

with / without load to 15 m

7.0/6.0 7.0/6.0 sec

Available working

pressure

for attachments

160 160 bar

Oil flow

for attachments

80 80 l/min

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3.2 Dimensions

DFG 660-690

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

Model 660 670 680 690

a/2 Safety distance 100 100 100 100 mm

Collapsed height* 2710 2710 3010 3160 mm

Lift* 3600 3600 3600 3600 mm

Extended height* 4510 4510 4810 4960 mm

Overhead guard height*

2705 2705 2705 2705 mm

h7Seat height* 1600 1600 1600 1600 mm

Coupling height 500 500 500 500 mm

Mast tilt, fwd.* 6 6 6 6 °

Mast tilt, back* 9 9 9 9 °

l1Length, including

forks*

4760 4770 4880 5035 mm

Length, including fork shank*

3560 3570 3680 3835 mm

b1Overall width* 1820 2002 2002 2100 mm

s/e/l Fork dimensions* 60/150/

1200

60/150/

1200

70/150/

1200

70/150/

1200

Ground clearance, laden, below mast*

230 230 230 230 mm

m2Ground clearance

centre wheelbase*

250 250 250 250 mm

Fork carriage ISO 2328 class / type A, B

4 A4 A4 A4 Amm

Fork carriage width 1800 1800 2000 2100 mm

Ast Working aisle width for

pallets 800 x 1200 lengthways

5320 5330 5440 5745 mm

Ast Working aisle width for

pallets 1000 x 1200 traverse

5120 5130 5240 5545 mm

Wa Turning radius 3250 3250 3350 3650 mm b

Smallest turning radius

1270 1270 1320 1390 mm

x Load distance* 680 680 700 700 mm c Load centre of gravity 600 600 600 600 mm y Wheelbase 2295 2295 2395 2545 mm

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DFG S80-S90

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

TFG 660-690

Model S80 S90

a/2 Safety distance 100 100 mm

Collapsed height* 3160 3310 mm

Lift* 3600 3600 mm h4Extended height* 4960 5110 mm h

Overhead guard

height*

2705 2705 mm

h7Seat height* 1600 1600 mm

h10Coupling height 500 500 mm

Mast tilt, fwd.* 6 6 °

Mast tilt, back* 9 9 °

Length, including

forks*

5640 5840 mm

l2Length, including fork

shank*

3840 4040 mm

Overall width* 2150 2150 mm

s/e/l Fork dimensions* 70/180/

1800

70/180/

1800

m1Ground clearance,

laden, below mast*

230 230 mm

Ground clearance

centre wheelbase*

250 250 mm

Fork carriage ISO

2328 class / type A, B

4 A 4 A mm

Fork carriage width 2100 2100 mm

Ast Working aisle width for

pallets 800 x 1200

lengthways

5745 5995 mm

Ast Working aisle width for

pallets 1000 x 1200

traverse

5545 5795 mm

Wa Turning radius 3900 3900 mm b

Smallest turning

radius

1490 1490 mm

x Load distance* 700 700 mm c Load centre of gravity 900 900 mm y Wheelbase 2545 2745 mm

Type 660 670 680 690

a/2 Safety distance 100 100 100 100 mm

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

TFG S80-S90

Collapsed height* 2710 2710 3010 3160 mm h

Lift* 3600 3600 3600 3600 mm h

Extended height* 4510 4510 4810 4960 mm h

Overhead guard

height*

2705 2705 2705 2705 mm

Seat height* 1600 1600 1600 1600 mm

Coupling height 500 500 500 500 mm

Mast tilt, fwd.* 6 6 6 6 °

Mast tilt, back* 9 9 9 9 °

l1Length, including

forks*

4860 4870 4980 5135 mm

Length, including fork

shank*

3660 3670 3780 3935 mm

b1Overall width* 1820 2002 2002 2150 mm

s/e/l Fork dimensions* 60/150/

1200

60/150/

1200

70/150/

1200

70/150/

1200

Ground clearance,

laden, below mast*

230 230 230 230 mm

m2Ground clearance

centre wheelbase*

235 250 250 250 mm

Fork carriage ISO

2328 class / type A, B

4 A4 A4 A4 Amm

Fork carriage width 1800 1800 2000 2100 mm

Ast Working aisle width for

pallets 800 x 1200

lengthways

5420 5430 5640 5895 mm

Ast Working aisle width for

pallets 1000 x 1200

traverse

5220 5230 5440 5695 mm

Wa Turning radius 3350 3350 3550 3800 mm b

Smallest turning

radius

1320 1320 1370 1440 mm

x Load distance* 680 680 700 700 mm c Load centre of gravity 600 600 600 600 mm y Wheelbase 2395 2395 2495 2645 mm

Component S80 S90

a/2 Safety distance 100 100 mm

Mast height retracted* 3160 3310 mm h

Lift* 3600 3600 mm h

Mast height extended* 4960 5110 mm

Type 660 670 680 690

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

Overhead guard

height*

2705 2720 mm

Seat height* 1600 1600 mm

Coupling height 500 500 mm

Mast tilt, fwd.* 6 6 °

Mast tilt, back* 9 9 °

Length, including

forks*

5740 5740 mm

l2Length, including fork

shank*

3940 3940 mm

b1Overall width* 2150 2150 mm

s/e/l Fork dimensions* 70/180/

1800

70/180/

1800

Ground clearance,

laden, below mast*

240 240 mm

Ground clearance

centre wheelbase*

240 240 mm

Fork carriage ISO

2328 class / type A, B

4 A 4 A mm

b3Fork carriage width 2100 2100 mm

Ast Aisle width for pallets

800 x 1200

lengthways

5895 5895 mm

Ast Working aisle width for

pallets 1000 x 1200

traverse

5695 5695 mm

Wa Turning radius 3800 3800 mm b

Smallest turning

radius

1440 1440 mm

x Load distance* 700 700 mm c Load centre of gravity 900 900 mm y Wheelbase 2645 2645 mm

Component S80 S90

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3.3 Weights

Z All dimensions in kg.

DFG 660-690

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

DFG S80-S90

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

TFG 660-690

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

TFG S80-S90

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

660 670 680 690

Net weight* 10500 11400 12400 14000 Axle loading, 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 / rear*

7200/7200 7800/7700

Axle loading, laden front / rear*

20400/2000 22500/2000

660 670 680 690

Net weight* 10970 11570 12700 14200 Axle loading, unladen

load front / rear*

5360/5610 5660/5910 5800/6100 6900/7300

Axle loading, laden front / rear*

14810/2160 16670/1900 18600/2100 20700/2500

S80 S90

Net weight* 14600 15200 Axle loading, unladen

load front / rear*

7300/7300 7500/7700

Axle loading, laden front / rear*

20100/2500 22100/2100

Page 28

11.14 E N

3.4 Mast versions

Z All dimensions in mm.

Mast chart

V D I 3 5 9 6

Description

Lift h

Free lift

Retracted

height h

Extended

height h

Weight (kg)

660/670 660/670

3600 0 2710 4510 2080 4000 0 2910 4910 2140 4500 0 3160 5410 2240 5000 0 3410 5910 2335 5500 0 3660 6410 2460 6000 0 3910 6910 2585 6500 0 4160 7410 2735

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 6000 3000 4075 7075 2772 6500 3300 4325 7575 2892

4500 1500 2585 5585 2671 5000 1667 2752 6086 2754 5500 1833 2918 6586 2837 6000 2000 3085 7086 2920 6500 2167 3252 7586 3045 7000 2333 3418 8086 3191 7500 2500 3585 8586 3295 8000 2667 3752 9086 3397

Page 29

11.14 E N

Special trucks are not included in this overview.

Mast chart

V D I 3 5 9 6

Description

Lift h

Free lift

Retracted

height h

Extended

height h

Weight (kg)

680 680

3600 0 3010 4810 2180 4000 0 3210 5210 2261 4500 0 3460 5710 2360 5000 0 3710 6210 2485 5500 0 3960 6710 2610 6000 0 4210 7210 2757 6500 0 4460 7710 2910

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 6000 3000 4225 7225 2847 6500 3300 4475 7725 2964

4500 1500 2735 5736 2733 5000 1667 2902 6236 2816 5500 1833 3068 6736 2900 6000 2000 3235 7236 3024 6500 2167 3402 7736 3170 7000 2333 3568 8236 3274 7500 2500 3735 8736 3377 8000 2667 3902 9236 3459

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DFG/TFG 690-S90

Mast chart

V D I 3 5 9 6

Description

Lift h

Free lift

Collapsed

height h

Extended

height h

Weight (kg)

690/S80 690/S80

3600 0 3160 4960 2240 4000 0 3360 5360 2310 4500 0 3610 5860 2435 5000 0 3860 6360 2560 5500 0 4110 6860 2710 6000 0 4360 7360 2860 6500 0 4610 7860 2985

3600 1800 3175 4975 2374 4000 2000 3375 5375 2446 4500 2250 3625 5875 2556 5000 2500 3875 6375 2676 5500 2750 4125 6875 2796 6000 3000 4375 7375 2916 6500 3300 4625 7875 3036

4500 1500 2885 5886 2796 5000 1667 3052 6386 2879 5500 1833 3218 6886 3004 6000 2000 3385 7386 3149 6500 2167 3552 7886 3253 7000 2333 3718 8386 3357 7500 2500 3885 8886 3439 8000 2667 4052 9386 3522

Mast chart

V D I 3 5 9 6

Description

Lift h

Free lift

Collapsed

height h

Extended

height h

Weight (kg)

S90 S90

3600 0 3310 5110 2285 4000 0 3510 5510 2385 4500 0 3760 6010 2510 5000 0 4010 6510 2635 5500 0 4260 7010 2810 6000 0 4510 7510 2935 6500 0 4760 8010 3060

Page 31

11.14 E N

Special trucks are not included in this overview.

3600 1800 3325 5125 2422 4000 2000 3525 5525 2518 4500 2250 3775 6025 2628 5000 2500 4025 6525 2748 5500 2750 4275 7025 2868 6000 3000 4525 7525 2988 6500 3300 4775 8025 3108

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 2333 3868 8536 3418 7500 2500 4035 9036 3501 8000 2667 4202 9536 3574

Mast chart

V D I 3 5 9 6

Description

Lift h

Free lift

Collapsed

height h

Extended

height h

Weight (kg)

S90 S90

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3.5 Tyre type

WARNING!

The use of tyres that do not match the manufacturer's specifications can result in accidents.

The quality of tyres affects the stability and performance of the truck. Uneven wear affects the truck's stability and increases the stopping distance.

When replacing tyres make sure the truck is not skewed.

Always 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. If you have any queries contact the manufacturer's customer service department.

DFG/TFG 660-690

Model DFG/TFG

660 670 680 690

Front

tyres

SE* 355/65 - 15 8.25 - 15 8.25 - 15 300 - 15

Pneumatic*

355/65 - 15

18 PR

8.25 - 15 18 PR

300 - 15

18 PR

Tyre pressure bar 10 10 10 10

Torque Nm 650 650 650 650

Rear tyres

SE* 8.25 - 15 8.25 - 15 8.25 - 15 300 - 15

Pneumatic*

8.25 - 15 18 PR

300 - 15 18

Tyre pressure bar 10 10 10 10

Torque Nm 450 450 450 450

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11.14 E N

DFG/TFG S80-S90

*) The models listed in the table correspond to the standard version. 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

SE* 300 - 15 300 - 15

Pneumatic*

300 - 15

18 PR

300 - 15

18 PR

Tyre pressure bar 10 10

Torque Nm 450 450

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3.6 Engine Data

DFG 660-680

DFG 690-S90

TFG 660-680

TFG 690-S90

Model 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 Engine output 91 91 91 kW Fuel consumption

60 VDI duty cycles/h

7.7 8.1 8.5 l/h [kg/h]

Model DFG 690 DFG S80 DFG S90

Cylinders/cubic capacity 4/4400 4/4400 6/6600 cm³ Rated speed (without 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 8/5700 8/5700 cm³ Rated speed (without load) 2200 2200 2200 rpm Idle speed 850 850 850 rpm Engine output 85 85 85 kW Fuel consumption

60 VDI duty cycles/h

8 8.5 8.9 l/h [kg/h]

Model TFG 690 TFG S80 TFG S90

Cylinders/cubic capacity 8/5700 8/5700 8/5700 cm³ Rated speed (without load) 2200 2200 2200 rpm Idle speed 850 850 850 rpm Engine output 85 85 85 kW Fuel consumption

60 VDI duty cycles/h

10.2 10.2 10.7 l/h [kg/h]

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3.7 EN norms

Noise emission level

– DFG 660-690, S80: 73 dB (A)* – DFG S90: 70 dB (A)* – TFG: 71 dB(A)*

*+/- 4 dB(A) depending on the truck's equipment

in accordance with EN 12053 as harmonised with ISO 4871.

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 thresholds at constant speed (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 special service to measure these human vibrations, see "Human vibration measurement" on page 198.

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.

Whole-body vibration Motor type Vibration Uncertainty

TFG 1.0 m/s

0.2 m/s

DFG S90 0.9 m/s

0.2 m/s

DFG 660-690, S80 1.3 m/s

0.2 m/s

Hand/arm vibration

Vibration <2.5 m/s

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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.

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 used

continually in conditions of extreme temperature or condensing 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.

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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.

XXXXXX

xxx xxxxxx

16 17 1918

39 40 42

4137

Page 38

11.14 E N

Item Component

15 Attachment points for loading by crane (o) 16 Read operating instructions 17 Wear seat belt 18 Test plaque (o) 19 Hot surface warning 20 Trailer coupling 21 Capacity plate 22 Tipover hazard 23 No passengers 24 Do not drive or tilt the mast 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 Hydraulic oil 29 Jack contact points 30 Emergency exit 31 Battery main switch 32 Warning 33 Coolant notice 34 Noise level 35 Truck data plate 36 Fuel 37 Lift load cushioning (o) 38 Fire extinguisher (o) 39 Add engine oil 40 Windscreen fluid 41 Coolant 42 Check engine oil

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4.1 Data plate

Z For queries regarding the truck or ordering spare parts always quote the truck serial

number (44).

43 44 4645

Item Component Item Component

43 Type 48 Year of manufacture 44 Serial number 49 Load centre distance (mm) 45 Rated capacity (kg) 50 Net weight in kg 46 Output 51 Manufacturer 47 Option 52 Manufacturer's logo

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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.

When replacing the forks you must attach an additional capacity plate to the truck.

Trucks supplied without forks are given a capacity plate for standard forks (length: 1150 mm).

The capacity plate (21) 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 (21) 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 h

of 5000 mm.

the max. capacity Q is 6940 kg.

Lift height restriction

The arrow shaped markings (53 and

54) on the inner and outer masts show the operator when the prescribed lift limits have been reached.

6960 7470 8340

6460 6940 7740

5660 6080 6770

6000

5000

4000

600 700 900

53 54

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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.

4.4 Jack attachment 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 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.

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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!

An altered centre of gravity can result in tipovers when cornering.

The overall centre of gravity can vary depending on the truck's equipment (especially the mast version).

For trucks without a mast the centre of gravity will move significantly in the direction of the counterweight.

XDrive carefully and with modified speed to avoid tipping over.

The picture shows the approximate centre of gravity location.

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2.2 Lifting the truck by crane

CAUTION!

The mast can get damaged

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

Loading must be carried out by specially trained staff in accordance with recommendations contained in Guidelines VDI 2700 and VDI 2703

DANGER!

Crane slings can tear, resulting in accidents

Only use crane lifting gear with sufficient capacity.

Loading weight = Net weight of truck (+ battery weight for electric trucks).

The mast must be tilted back fully.

The crane lifting gear on the mast must have a minimum clear length of 2 m.

Crane 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. XThe truck should only be handled by people who are trained in using lifting slings

and tools.

XWear safety shoes when lifting the truck by crane. XDo not walk into or stand in a hazardous area. XAlways attach the crane lifting gear to the prescribed strap points and prevent them

from slipping.

Z Truck net weight: see "Data plate" on page 40.

Lifting the truck by crane

Requirements

– Park the truck securely, see "Parking the

truck securely" on page 103.

Procedure

• Secure the crane slings to the attachment points (55) and (56.

• Raise and load the truck.

• Lower and deposit the truck carefully (see "Parking the truck securely" on page 103).

• Secure the truck with wedges to prevent it from rolling away.

This concludes the loading by crane.

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2.3 Loading with another industrial truck

DANGER!

Slipping can cause accidents

Do not use another Industrial truck to load the truck!

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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.

Loading must be carried out by specially trained staff in accordance with recommendations contained in Guidelines VDI 2700 and VDI 2703 In each case correct measurements must be made and appropriate safety measures adopted.

The truck must be securely fastened when transported on a lorry or a trailer.

The loading area must have clamp rings and a wooden floor to secure the retaining wedges.

Use wedges to prevent the truck from moving.

Use only tensioning belts or tie-down straps or with sufficient strength.

Securing with a mast Securing without a mast

Securing the industrial truck for transport

Requirements

– Position the industrial truck securely on a lorry or trailer, see "Parking the truck

securely" on page 103.

Tools and Material Required

– 2 fastening belts with a tensioner – Retaining wedges

Procedure

• Secure the truck with the fastening belt (58) at the top cross member of the mast (55) and the trailer coupling (56) or over the front axle cross member (57) and the trailer coupling (56).

• Tighten the fastening belts (58) with the tensioner.

The truck is now secured for transport.

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4 Using the Truck for the First Time

Safety Instructions for Assembly and Commissioning

WARNING!

Incorrect assembly can result in accidents

The assembly of the truck at the application site, commissioning and operator training must only be performed by the manufacturer's customer service representatives who have been specially trained for these tasks.

The hydraulic lines may only be connected to the basic truck / mast interface when the mast has been properly assembled.

Only then can the truck be started.

If 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.

• Check the brake fluid level.

• 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 86.

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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.

Switch off the truck securely before filling up or replacing the LPG bottle, see "Parking the truck securely" on page 103.

WARNING!

Accident risk from ignition

Fuels and liquefied petroleum gas can ignite.

Smoking, 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.

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NOTE

Fuel can cause environmental damage

Bind any spilled diesel fuel with suitable methods.

Then dispose of the diesel and fuel filter in accordance with environmental regulations.

Fuel filling and LPG bottle replacement personnel

Personnel filling the trucks or replacing LPG bottles must have sufficient knowledge of the nature of fuels to ensure safe operation.

CAUTION!

Liquid gas can cause frostbite

Liquid gas produces frostbite when it comes into contact with bare skin.

Avoid direct contact with the skin.

Wear 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 operator 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.

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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 (59).

– When the valve is activated the plastic

cover comes off, thereby clearly indicating a fault in the gas system.

– In this case the truck must not be

operated.

– The gas system must be check by

suitably qualified and trained personnel.

– The operator must check that the plastic cover is in place each time he uses the

truck.

– Models with a liquid gas tank have the

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 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.

– 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.

6061

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2 Adding diesel

CAUTION!

Air in the fuel system will result in malfunctions.

Never allow the fuel tank to run dry.

2.1 Fuelling

WARNING!

Diesel fuel can be hazardous

Diesel fuel can cause irritation if it comes into contact with the skin. Rinse any affected areas thoroughly.

If it comes into contact with the eyes rinse them immediately with flowing water and call for a doctor.

Wear 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 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 103.

• Unscrew the tank cap (62).

• Insert the pump nozzle into the open tank filler neck.

• Add the fuel.

• Do not overfill the tank.

• Tighten the cap (62) back on after fuelling.

Fuelling is now complete.

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The fuel gauge (63) indicates the fuel level.

NOTE

Never allow the fuel tank to run dry. Air in the fuel system will result in malfunctions.

2.2 Fuelling with fuel containers

Procedure

• 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 tightly to each other.

• Raise the fuel container carefully and slowly add the diesel.

• Do not overfill the tank.

• Screw the cap (62) back on tightly after fuelling.

Fuelling is now complete.

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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

The LPG bottle must only be replaced at designated areas by trained and authorised personnel.

CAUTION!

Using unsuitable LPG bottles can cause accidents.

Use only approved LPG bottles.

The 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 103

• Close the shut-off valves (64) securely.

• Start the motor and allow the LPG system to run empty in neutral.

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Remove the LPG bottle

CAUTION!

The connection has a left thread

Procedure

• The LPG bottle console is released with the finger screw (65).

• Unfold the console (66) as far as the stop.

• Unscrew the union nut (68).

• Remove the hose (60) and immediately screw the valve cap onto the empty LPG bottle.

• Loosen the 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 the hose connection downwards.

• Clamp the toggle-type fastener with the handle (67).

• Unscrew the valve cap.

• Fit the hose (60) in accordance with instructions.

• Carefully open the shut-off valve (64).

• Check the hose connection for leaks using a foam-forming agent.

The replacement is now complete.

6864606864

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3.1.2 Operating the Twin Bottle System and Liquid Gas Tank

Changing the LPG Supply

Procedure

Z The (71) switch controls the release of the LPG bottle

or tank.

• Open the shut-off valves (64) of both LPG bottles by turning anticlockwise.

• 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 lower

switch position.

• Close the LPG bottles and open the LPG tank by

applying the top switch position.

LPG supply changed.

S7 S8 S24

S12 S13 S15

S20 S26 S30

69 70

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3.2 Liquid gas tank

The filling valve (72) is located on the left side of the truck.

Filling refillable liquid gas tanks

DANGER!

Risk of explosion

Fuelling must always be performed in designated areas by trained and authorised personnel.

Requirements

– Park the truck securely (see "Parking the

truck securely" on 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 filling valve (72).

• 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 (72).

• Screw on the tank cap (62).

Z The level of the tank is shown by the fuel indicator.

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4 Fuel level indicator

4.1 Display unit

The level indicator (63) shows the capacity of the tank.

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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.

Operator’s rights, responsibilities and rules of conduct

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. 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 prevent unauthorised persons from driving or operating the truck. Do not carry passengers or lift other people.

Damage and faults

The supervisor must be informed immediately 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 operator must not carry out any repairs or alterations to the truck without authorisation and the necessary training to do so. The operator must never disable or adjust safety mechanisms or switches.

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Hazardous area

WARNING!

Risk of accidents/injury in the hazardous area of the truck

A hazardous area is defined as the area in which people are at risk due to travel or lifting operations of the truck, its load handler or the load. This also includes the area within reach of falling loads or lowering/falling operating equipment.

Instruct unauthorised persons to leave the hazardous area.

In case of danger to third parties, give a warning signal in good time.

If unauthorised persons are still within the hazardous area, stop the truck immediately.

WARNING!

Falling objects can cause accidents

Falling objects can injure the operator while the truck is being operated.

The operator must remain within the protected area of the overhead guard while the truck is being operated.

Safety devices, warning signs and warning instructions

Safety devices, warning signs (see "Identification points and data plates" on page 38) and warning instructions in the present operating instructions must be strictly observed.

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2 Displays and Controls

2.1 Multi-task switch

Item Control /

Display

Function

73 Multi-task switch t

– Travel function switch – Sets automatic gear shifting – Travel direction

switch

– Selects travel direction / neutral position

= Standard equipment

= Optional equipment

Einzelpedalsteuerung

76 75

Page 61

11.14 E N

74 Multi-task switch

– Travel direction

indicator

– Switches the travel direction indicator on

and off

– Dipped lights/main

beam

– Switch spot lights from dipped lights to

main beam

– Windscreen 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 pedal

When activated, causes the truck to brake to a halt immediately.

75 Accelerator pedal

Infinite travel speed control.

Item Control /

Display

Function

= Standard equipment

= Optional equipment

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2.2 SOLO-PILOT

77 78 79 80 81

Item Control /

Display

Function

77 Lever t Load handler raise / lower 78 Lever t Mast forward / reverse tilt

79 Auxiliary hydraulics lever

o 1. Activate 1st attachment

80 Auxiliary hydraulics lever

o 2. Activate 2nd attachment

81 Auxiliary hydraulics lever

o 3. Activate 3rd attachment

82 Auxiliary hydraulics

acknowledgement key

t = Standard equipment o = Optional equipment

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2.3 MULTI-PILOT

Item Control /

Display

Function

77 MULTI-PILOT (F+B)

MULTI-PILOT (L+R)

t Load handler raise / lower

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 attachment

81 ZH2 / ZH3

acknowledgement key switch

o 3. Activate attachment / acknowledgement

key for ZH2

t = Standard equipment o = Optional equipment

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2.4 Controls

Item Control /

Display

Function

85 Battery indicator lamp t Lights up to indicate errors in the power

supply

84 Main beam indicator

lamp

t Lit when the main beam is 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 supply on and off

Starts and stops the engine

89 Emergency Disconnect

switch

t Switches control current on and off in

emergencies.

t = Standard equipment o = Optional equipment

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2.4.1 Switch variants

Symbol Switch/display Function

Switch Rear work lights

Switches the rear work lights on and off

Switch Front work lights

Switches the front work lights on and off.

Switch Rear window wiper

Switches the rear window wiper on and off

Air conditioning system switch

Switches the air conditioning system on and off

Fan 1 switch t Switches the cab fan on and off

Switch Beacon

o Switches the beacon on and off

Switch Warning indicator

t Switches warning indicator lights on

and off

t = Standard equipment o = Optional equipment

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2.5 Multifunction display

Item Control /

Display

Function

63 Level indicator t Remaining fuel quantity 90 Engine speed t Current speed of the engine 91 Speed 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 configuration menu 96 Gear lever display t Current travel stage 97 Clock t Shows the time and date t = Standard equipment o = Optional equipment

90 91 92 93 63

9697

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2.5.1 Warnings

This field (98) shows information related to operation.

Symbol Display

Engine cuts out automatically

Engine is preheated

Switch all travel direction switches to neutral position immediately

No driver in the truck

Service interval expired Contact Customer Services.

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

Information from transmission controller: Faulty travel pattern recorded

Emergency mode activated, see "Automatic Emergency Brake" on page 143

Swivel seat (o)

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2.5.2 Warning indicators

Symbol Display Function

Hydraulic oil

Hydraulic oil level too low.

Transmission flashing

Transmission oil temperature too low Stop the truck immediately.

Engine oil flashing with "Stop"

Engine oil pressure too low Engine cuts out.

Exhaust gas pressure

Exhaust pressure too high Clean particle filter

Brake pressure

No brake pressure present

Air filter

Clean air filter

Main control unit

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 (above +85° C) Stop the truck immediately

Engine t Engine error

Pilot valve t Pilot valve error

Preheat display t Engine preheated

“Stop“ t Engine is switched off automatically

Intake temperature flashing

t Air filter must be cleaned immediately

Park the truck immediately

Multi-Pilot t Multi-Pilot has an error

Engine temperature flashing with "Stop"

t Engine temperature too high

Engine cuts out.

t = Standard equipment o = Optional equipment

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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 (99). 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.

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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

11.14 E N

Optionally, 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

Diagn

ostic

Setup

Disp

setting

SPD

Level

Disp

setting

SPD

Level

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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).

Datum Uhr

Kontrast Tastenbeleuchtung Hintergrundbeleuchtung

Mo, 05.11.12

14:45:54 Deutsch 16

Sprache

Page 73

11.14 E N

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

90 Engine speed (t)

91 Speed display (t) 102 Transmission status (t) 103 Weigher system (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 operating hours (t) 110 Tilt angle (o)

t = Standard equipment o = Optional equipment

102

106

107

109

103

104

105

108

110

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2.6.2 Diagnostics

Press the "F5" button to open the diagnostics area (101).

All default values of the truck can be seen here.

111 Serial number 117 Date of the engine software

version 112 Truck type (A or C) 118 Engine software version 113 CVC firmware version 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-

SETUP

nose

101

Stabler ID no: 7702 CVC SW. ver: 2,06

Disp. SW. ver: 1,08 Motor ID No: LPG GM 5,7L Motor SW ver: 00710***

Getriebe SW Ver: v2.3PP 4216375.A15 Ventil: R900000000 HW: SW:

Bremse

Joystick

Ventil

Kühler

Fahren

Type : A A V :4

112

116

115 117

119 121

111 113

114

118

120

Page 76

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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 (122), pedal position (124) and the valve (123) can be seen here.

122

124

123

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"F2" key - hydraulic controller.

– Activated ranges are identified by a checkmark (127). – Range (125) indicates the position of the control lever(s):

• Minus = forward

• Plus = back – Range (126) indicates the current temperature of the control module: – Range (128) 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

127

128

125 126

127

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11.14 E N

"F3" button - cooling

– Pressing this button provides information about the coolant temperature in "°C" and

the air speed as a "%" for the engine (129), transmission (131) and charge air cooler (132) an.

– The speed of the cooler fan (130) is shown as a "%".

"F4" button - travel switch

– Indicates the current state of the travel direction (133), control lever(s) (134) and

accelerator pedal (135).

•(t) activated

•(o) not activated

129

131

132

130

135

133 134

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3 Dashboard

3.1 Without air conditioning system

3.2 With air conditioning system

S4 S5 S 6

S7 S8 S 24

S1 2 S 13 S 15

S2 0 S 26

X28

XR 9

S3 0

136 137 86 138 139 140 141

142 143

14414514614771148149

S4 S 5 S6

S7 S 8 S 24

S1 2 S 13 S 15

SS2200SS226

XX228

XXRR9

SS330

136 137 86 138 139 140 141 142 143

14414514614771148149

150

S4 S5 S6

S7 S8 S24

S12 S13 S15

S20 S26

X28

XR9

S30

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3.3 With automatic air conditioning

Item Component

71 LPG bottle switch (LPG only)

86 Hazard warning lights switch 136 Socket 137 Beacon 138 Work lights 139 Windscreen wiper / windscreen washing system (rear

windscreen)

140 Windscreen wiper / windscreen 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) 148 Load damping 149 Rear window heating 150 Air conditioning system switch 151 Heater + air conditioning controller (o) (automatic)

S4 S5 S6

S7 S8 S 24

S1 2 S 13 S 15

S2 0 S 26

X28

XR 9

S3 0

136 137 86 138 139 140 141 151 143

14414514614771148149

S4 S5 S6

S7 S8 S24

S12 S13 S15

S20 S26

X28

XR9

S30

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4 Heater, fan, air conditioning system

4.1 Heater

Cab heating is controlled by the temperature selector (153).

Procedure

• Turn to the right - higher temperature

• Turn to the left - lower temperature

Fan

Z The fan speed is controlled with the (154) 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.

XWhen using the air conditioning system make sure the temperature is no higher

than 6°C more than the outside air temperature.

XKeep the doors and windows closed when the air conditioning system is switched

on.

XDo not direct discharge jets at other people. XThere should be no draft effect.

4.2.1 Air Conditioning Mode

CAUTION!

Never aim the nozzles directly at other people.

XThe discharge should always be

directed to prevent any draft effect.

Starting the truck

Procedure

• The fan switch (154) and rocker switch (150) turn the air conditioning system on and off (green indicator lamp in the rocker switch (150) is lit during operation).

152153150154

155

156

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• The air flow of the air conditioning system is controlled by discharge jets (155) and an intake nozzle (156) in the legroom (recirculated air) and by drawing in outside air.

CAUTION!

The intake nozzle (156) must always be unobstructed

The air flow in the cab is set via the discharge jets.

4.2.2 Function of the controls

Procedure

• Switch (152) to the left: Recirculated air

• Switch (152) to the right: Outside air

• Centre position of the switch (152): Combination of recirculated air / outside air

• Switch (153) provides additional temperature control.

• The air flow is controlled by switch (154).

Z Switch off the entire system before parking the truck. To switch off the entire

system, turn the fan switch (154) 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 (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 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 (154) 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 "Servicing and Inspection" on page 199.

152153150154

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4.2.4 Automatic air conditioning

Z When the setting for completely recirculated air is selected, the supply of outside

air is shut off.

Item Description Description

157 Internal temperature setpoint Setting for the desired internal temperature.

The adjustment range is between 16°C (60°F) and 28°C (82°F). The setting should be no more than 5° - 6°C below the current outside temperature.

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 and off. 160 Air mix control Setting of the outside and inside air. The setting

can range from outside air to completely

recirculated air. 161 Mode Setting for the work mode of automatic air

conditioning (automatic, heating, cooling,

defrosting, fuel preheating (o)). 162 Display Display of inside or outside temperature.

157 158

159

160161162

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4.2.5 Displays

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 "Servicing and Inspection" on page 199

163 Display of inside or outside temperature 164 Current operating mode 165 Current air supply (Fresh = fresh air, Rec = recirculated air) 166 Current fan output

163 164

165166

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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 (optional equipment) defects can result in accidents.

If damage or other truck or attachment (optional equipment) defects are discovered during the following checks, the truck must be taken out of service until it has been repaired.

Report any defects immediately to your supervisor.

Mark defective truck and take out of service.

Do not return the industrial truck to service until you have identified and rectified the fault.

CAUTION!

Checking the accelerator pedal

XThe accelerator pedal should only be

checked when the parking brake is applied and the engine is idle.

Checks before daily operation

Procedure

• Visually inspect the entire truck (in particular the wheels, wheel bolts 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 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.

• Check the accelerator pedal can move freely by pressing it several times.

• 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 182.

168

167

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11.14 E N

• Check the LPG system is working correctly, see "LPG containers" on page 54

• Attachment: Visually inspect bearing points, guides and stops for wear and damage

and lubricate these components.

• Visually inspect battery and battery components.

• Check that the battery cable is positioned securely.

• 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

Procedure

• Check the gas system is working correctly, see "LPG containers" on page 54

• 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 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 provided for the driver position extension (

169

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5.3 Setting up the operator position

WARNING!

Accidents can occur if the driver's seat, steering column and armrest are not engaged

The driver's seat, steering column and armrest can accidentally adjust during travel and therefore cannot be operated safely.

Do not adjust the driver’s seat, steering column or armrest while travelling.

Procedure

• 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 up the truck. XHold the weight setting lever only by the recess, do not reach through underneath

the lever.

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Adjusting the driver's weight

NOTE

To achieve optimal seat cushioning the driver’s seat must be set to the driver’s weight. Set the driver's weight when the seat is occupied.

Procedure

• Fold out the weight adjustment lever (171)

as far as it will go in the arrow direction

• Move the weight adjustment lever (171)

up and down to set the seat to a higher weight.

• Move the weight adjustment lever (171) 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

(170). 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 (171) back in full.

The driver’s weight is now set.

Adjusting the backrest

Procedure

• Sit on the driver’s seat.

• Pull the lever (172) to adjust the backrest.

• Adjust the backrest tilt.

• Release the lever (172) again. The backrest is locked.

The backrest is now set.

Z Hold the weight setting lever (171) only by the recess, never reach through

underneath the lever.

171

172

173

170

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Adjusting the seat position

CAUTION!

An unsecured driver's seat can cause injury

An unsecured driver's seat can slide out of its guide during travel, resulting in accidents.

The driver's seat must be locked in position.

Do not adjust the driver’s seat while travelling.

Procedure

• Sit on the driver’s seat.

• Pull up the driver’s seat locking lever173 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 (173) in position.

The seat position is now correctly set.

171

172173

170

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5.3.2 Adjusting the steering wheel / steering column

CAUTION!

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.

Adjusting the Tilt

Procedure

• Pull up on the adjusting lever (174).

• Tilt the steering wheel (175) forward or

backward as required.

• 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 required height.

• Pull the adjusting lever (174) into the centre position.

The steering column height is adjusted.

5.3.3 Adjusting the arm rest

The height and angle of the armrest can be adjusted with the screw (176).

Procedure

• Turn the screw clockwise - the armrest is

raised.

• Turn the screw anti-clockwise - the armrest

is lowered.

The armrest is adjusted.

174

175

176

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5.3.4 Adjusting the Control Panel

The height and tilt of the control panel (177) can be changed. This makes it possible to adjust the armrest (178) and control panel optimally to each other.

Procedure

• Release the lever (179).

• Move the control panel to the required

position.

• Pull the lever tight again.

The control panel is adjusted.

177

178

179

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5.3.5 Adjusting the Multifunction Display

To ensure an optimum view of the multifunction display, it can be individually adjusted.

Procedure

• Sit on the driver's seat.

• Adjust the seat to its optimum position.

• Loosen the central wing screw (180) of the

display holder just enough so that the two ball joints (181) can be moved freely in the holder.

• Move the display to the desired position and

retighten the central wing screw (180).

181

180

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5.4 Seat Belt

WARNING!

Travelling without a seat belt increases the risk of injury.

Accidents or personal injury can result if the seat belt is not worn or is modified.

Always put the seat belt on before starting the industrial truck.

Do not modify the seat belt.

Damaged or non-operational seat belts must be replaced by trained personnel.

Seat belts must always be replaced after an accident.

Only original spare parts must be used for retrofits or repairs.

Report any defects immediately to your supervisor.

Remove the truck from service until a functional seat belt has been fitted.

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.

Checking the seat belt

Procedure

• Check the attachment points for wear and damage.

• Check the cover for damage.

• Pull the belt out fully from the retractor and check for damage (loose seams, fraying

and nicks).

• Test the belt buckle and make sure the belt returns correctly into the retractor.

Check the automatic locking system

Procedure

• Park the truck on a level surface.

• Jerk the seat belt out suddenly.

Z The locking system should prevent the belt from coming out.

The seat belt has now been checked.

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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!

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 operator 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 operator 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.

Do not use a mobile phone or walkie-talkie without a handsfree device while operating the truck.

Hazardous situations

If the truck is about to tip over, do not loosen the seat belt. The operator must not jump off the truck. The operator 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 operator must look in the direction of travel and must always have a clear view of the route ahead. If the truck is carrying loads that affect visibility, the truck must travel against the load direction. 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 operator. 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 and inclines up to 15% is only permitted if they are specifically designed as travel routes, are clean and have a non-slip surface and providing they can be safely travelled along in accordance with the truck's technical specifications. The truck must always be driven with the load facing uphill. The industrial truck must not be turned, operated at an angle or parked on inclines and 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, loading ramps and docks

Lifts may only be negotiated 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. Persons riding in the lift with the forklift truck must only enter the lift after the truck has come to a rest and must leave the lift before the truck. The driver must ensure that the loading ramp / dock 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 the manufacturer's customer service department.

Z For safety instructions on the nature of loads to be carried with attachments,see

"Lifting, transporting and depositing loads" on page 113.

Towing trailers

The truck may only be used occasionally to tow trailers, see "Towing trailers" on page 128

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11.14 E N

DANGER!

Exhaust emissions can be fatal

The truck must only be operated in well ventilated areas. If the truck is operated in enclosed areas, this can lead to a build-up of harmful exhaust emissions, resulting in dizziness, tiredness and even death.

The operator must comply with legal requirements, technical standards and health and safety regulations when operating an IC motor powered lift truck in closed rooms.

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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 86.

Switching On the Truck

Procedure

• Turn the battery isolator (182) to position "1".

• Unlock the Emergency Disconnect (89),

• Turn the rotary button until the switch unlocks.

• Set the travel direction switch to neutral position

• Parking brake is activated.

• Carry out the appropriate starting procedure for

the engine type; see 6.2.1 "Starting procedure for the DFG" or 6.2.2 "Starting procedure for the TFG".

182

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100

6.2.1 Starting procedure for the DFG

Procedure

•

• Insert the key in the key switch (88) and turn it to the “2”

position.

• The pre-heat indicator lamp lights up and goes out

automatically as soon as the required pre-heat time (approx. 4 seconds) has been reached.

• 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 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 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 is operational.

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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 49)

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 bottles, see "LPG

bottles" on page 54.

• Insert the key in the key switch (88) and turn it to the “2”

position.

•

• 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 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, see "Operating the Twin Bottle System and Liquid Gas Tank" on page 56.

• Turn the key to position "3".

Z Apply the starter for no more than 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 is operational.

S4 S5 S6

S7 S8 S24

S12 S13 S15

S20 S26

X28

XR9

S30

S20 S26 S30

Jungheinrich TFG 660, DFG660, DFG S80, DFG 670, DFG690 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual