Operating instructions

51011137

DFG/TFG 316 / 320

G

04.06-

02.07

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Foreword

The present ORIGINAL OPERATING INSTRUCTIONS are designed to providesufficient instruction for the safe operation of the industrial truck. The information isprovided clearly and concisely. The chapters are arranged by letter. Each chapterstarts with page 1. The page identification consists of a chapter letter and a pagenumber.For example: Page B 2 is the second page in chapter B.

The operating instructions detail different truck models. When operating and servicingthe truck, make sure that the instructions apply to your truck model.

Safety instructions and important explanations are indicated by the followinggraphics:

F Used before safety instructions which must be observed to avoid danger topersonnel.

M Used before notices which must be observed to avoid material damage.

Z Used before notices and explanations.

t Used to indicate standard equipment.

o Used to indicate optional equipment.

Our trucks are subject to ongoing development. Jungheinrich reserves the right toalter the design, equipment and technical features of the truck. No guarantee ofparticular features of the truck should therefore be inferred from the present operatinginstructions.

Copyright

Copyright of these operating instructions remains with JUNGHEINRICH AG.

Jungheinrich Aktiengesellschaft

Am Stadtrand 3522047 Hamburg - GERMANY

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

www.jungheinrich.com

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Index

A Correct Application

B Truck Description

1 Application ........................................................................................... B 1

2 Assemblies and Functional Description .............................................. B 2

2.1 Truck ................................................................................................... B 3

3 Standard Version Specifications ......................................................... B 5

3.1 Performance Data DFG ...................................................................... B 5

3.2 Engine data ......................................................................................... B 10

3.3 Tyre Type .......................................................................................... B 10

3.4 Mast Versions ..................................................................................... B 11

3.5 EN norms ............................................................................................ B 12

3.6 Conditions of use ................................................................................ B 12

4 Identification points and data plates .................................................... B 13

4.1 Truck data plate .................................................................................. B 14

4.2 Truck load chart .................................................................................. B 14

4.3 Attachment load chart ......................................................................... B 15

C Transport and Commissioning

1 Lifting by crane .................................................................................... C 1

2 Securing the truck during transport ..................................................... C 2

3 Using the truck for the first time .......................................................... C 3

4 Towing the truck .................................................................................. C 3

D Filling the Truck with Fuel

1 Safety regulations for handling diesel fuel and LPG ........................... D 1

2 Filling with diesel ................................................................................. D 2

3 Replace the LPG bottle ....................................................................... D 3

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E Operation

1 Safety Regulations for the Operation of Forklift Trucks ...................... E 1

2 Controls and Displays ......................................................................... E 3

3 Starting up the truck ............................................................................ E 7

3.1 Checks and operations to be performed before starting daily work .... E 7

3.2 Trucks with reduced headroom X (o) ................................................. E 7

3.3 Adjusting the driver’s seat ................................................................... E 9

3.4 Safety restraint belt ............................................................................. E 10

3.5 Adjusting the steering column ............................................................. E 12

3.6 Starting the truck ................................................................................. E 13

3.7 Starting procedure for the TFG ........................................................... E 14

3.8 Starting procedure for the DFG ........................................................... E 15

3.9 Operational Fault Displays .................................................................. E 17

3.10 Stopping the engine1. ......................................................................... E 18

4 Industrial truck operation ..................................................................... E 19

4.1 Safety regulations for truck operation ................................................. E 19

4.2 Travel .................................................................................................. E 21

4.3 Steering ............................................................................................... E 23

4.4 Braking ................................................................................................ E 23

4.5 Mast and Attachment Operation ......................................................... E 24

4.6 Collecting, transporting and depositing loads ..................................... E 26

4.7 Parking the truck securely ................................................................... E 30

4.8 Towing trailers ..................................................................................... E 32

4.9 Tow loads ............................................................................................ E 32

5 Troubleshooting .................................................................................. E 33

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BF Industrial Truck Maintenance

1 Operational safety and environmental protection ................................ F 1

2 Maintenance Safety Regulations ........................................................ F 1

3 Servicing and inspection ..................................................................... F 3

4 DFG/TFG maintenance checklist ........................................................ F 4

5 DFG maintenance checklist ................................................................ F 6

6 TFG maintenance checklist ................................................................. F 7

7 Coolant specification ........................................................................... F 8

8 DFG fuel specifications ....................................................................... F 9

9 Lubrication schedule ........................................................................... F 10

9.1 Fuels, coolants and lubricants ............................................................. F 11

10 Maintenance and Repairs ................................................................... F 12

10.1 Preparing the truck for maintenance and repairs ................................ F 12

10.2 Engine cover ....................................................................................... F 13

10.3 Servicing the engine DFG ................................................................... F 14

10.4 Engine servicing TFG .......................................................................... F 18

10.5 Check the hydraulic oil level ................................................................ F 21

10.6 Gas system drain tap .......................................................................... F 22

10.7 Checking the coolant level .................................................................. F 23

10.8 Checking the coolant concentration .................................................... F 23

10.9 Filling the cooling circuit ...................................................................... F 24

10.10 Cleaning/replacing the air filter cartridge ............................................. F 25

10.11 DFG/TFG transmission: ...................................................................... F 26

10.12 Brake ................................................................................................... F 27

10.13 Checking the wheel attachments. ....................................................... F 28

10.14 Hydraulic system ................................................................................. F 28

10.15 Clean/replace hydraulic reservoir ........................................................ F 28

10.16 Electrical System ................................................................................. F 29

11 Exhaust system ................................................................................... F 32

12 Restoring the truck to service after cleaning or repairs ....................... F 32

13 Decommissioning the industrial truck .................................................. F 32

13.1 Prior to decommissioning: ................................................................... F 32

13.2 During decommissioning: .................................................................... F 33

13.3 Returning the truck to operation after decommissioning ..................... F 33

14 Safety checks to be performed at regular intervals and following any unusual incidents (D: Accident prevention check according to BGV D27 ......................................................................................... F 34

15 Final de-commissioning, disposal ....................................................... F 34

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A 1

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A Correct Application

Z The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) aresupplied with the truck. The guidelines form part of these operating instructions andmust be observed. National regulations apply in full.

The truck described in the present operating instructions is an industrial truckdesigned for lifting and transporting loads.It must be applied, operated and serviced in accordance with the instructionscontained in the present manual. Any other type of use is beyond the scope ofapplication and can result in damage to personnel, the truck or property. In particular,avoid overloading the truck with loads which are too heavy or placed on one side. Thedata plate attached to the truck or the load diagram are binding for the maximum loadcapacity. The industrial truck must not be used in fire or explosion endangered areas,or areas threatened by corrosion or excessive dust.

Proprietor responsibilities: For the purposes of the present operator manual the“proprietor” is defined as any natural or legal person who either uses the industrialtruck 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 contractualagreements between the owner and user of the industrial truck, is charged withoperational duties.The proprietor must ensure that the industrial truck is used only for the purpose it isintended 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 proprietor must ensure that alltruck users have read and understood this operator manual.

M Failure to comply with the operator manual shall invalidate the warranty. The sameapplies if improper work is carried out on the truck by the customer or third partieswithout the permission of the manufacturer’s customer service department.

Attaching accessories: The mounting or installation of additional equipment whichaffects or enhances the performance of the industrial truck requires the writtenpermission of the manufacturer. In some cases, local authority approval shall berequired.Approval of the local authorities however does not constitute the manufacturer’sapproval.

Trailing and towed loads: The truck may only be used for trailing or towed loads forwhich the truck has been approved.

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B 1

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B Truck Description

1 Application

The DFG/TFG series are IC engine, 4-wheel rider trucks. The DFG series are dieselengine trucks, while the TFG series are fitted with a petrol engine for LPG operation.

The DFG/TFG 316-320 is equipped with a hydrodynamic drive system. The left pedalis a combination of crawl speed and brake pedal, and activates the rapid lift functionduring slow travel. The middle pedal is a standard brake as well as an emergencybrake pedal.

The capacity depends on the model. The type description indicates the maximumload rating. For example, a DFG/TFG 316 can carry loads of up to 1600 kg and aDFG/TFG 320 loads of up to 2,000 kg.

Truck models and maximum capacity:

*) The load diagrams attached to the truck are binding in terms of capacity

Type Max. capacity *) Load centre of gravity

DFG/TFG 316 1,600 kg 500 mm

DFG/TFG 320 2,000 kg 500 mm

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B 2

2 Assemblies and Functional Description

Item Description Item Description

1 t Driver's seat 8 t Load fork

2 t Steering column 9 t Fork carriage

3 t Dashboard 10 t Drive axle

4 t Overhead guard 11 t Engine cover

5 t Mast 12 t Steering axle

6 t Load chain 13 t Trailer coupling

7 t Lift cylinder 14 t Counterweight

7

1

2

3

4

9

10

11

1314 12

8

6

5

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B2.1 Truck

Chassis/Superstructure: A solid, rigid chassis which protects the units andcontrols, provides the truck with maximum static safety.

Maintenance and servicing are made easy through the wide opening cover and thetwo side panels of the engine housing (11). The hydraulic oil reservoir is integratedon the right-hand side and the fuel tank for the DFG series on the opposite side in thechassis. The LPG bottle for the TFG series is secured to a bracket on thecounterbalance weight (14). The exhaust system prevents exhaust from entering thedriver’s position.

Driver’s position: Non-slip steps and a handle on the posts of the overhead guardprovide easy entry and exit. The driver is protected by the overhead guard (4). On thedriver’s seat the seat cushioning and the seat position are adjustable, while thesteering wheel tilt can be set on the steering column (2). Easy operation throughergonomically arranged controls and a practically vibration-proof cab mean that thedriver is subjected to minimum stress. The controls and warning indicators on thedashboard (3) provide system monitoring during operation. This results in a very highlevel of safety.

F Before the truck is started, the overhead guard must be inspected for cracks, and ifdamaged, must be repaired or replaced.

Engine: Silent, water-cooled engines featuring high performance and lowconsumption. In the DFG series diesel engines are used with very clean fuelcombustion under all operating conditions and soot levels below the visibility level.For the TFG series, petrol engines are used with very low residual exhaust levels.

Drive system: A power shift gear with radiator and torque converter is directlyflanged to the engine. This transfers the force to the drive axle (10).

The travel direction switch on the left hydraulic control lever regulates forward/reversetravel and the neutral position.

Steering: Hydrostatic steering consists of a steer cylinder integrated in the steeringaxle (12). The steering axle is fully floating in the chassis to ensure excellent grip evenon non-level surfaces.

Brakes: The slow travel / brake pedal actuates two drum brakes which are appliedto the drive wheels. Worn drum brakes are automatically adjusted. The parking brakeoperates through mechanical actuation of the parking brake lever on the drum brakevia Bowden cables.

Wheels: All wheels are located within the geometry of the truck. A choice of air orsuperelastic tyres is available.

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B 4

Hydraulic system: The gear pump of the hydraulic system is powered by the enginethrough a power take off. The pump speed and hence the supply flow are controlledby the accelerator pedal through the engine speed.

Hydraulic functions are controlled by the control lever through a multiple control valve.

Electrical System: The 12 volt system consists of a starter battery and a threephasegenerator with integrated controller. A repeat start block prevents incorrect operationduring start-up and a safety switch ensures the engine can only start when the traveldirection switch is in neutral. For diesel motors, a rapid pre-heat system is installed,LPG motors have a non-contact electronic ignition system for rapid and trouble-freeengine starting. The ignition / starter switch is used to switch off the engine.

Mast (5): The target has been to maximize visibility. The maximum strength steelsection are narrow, allowing for good fork visibility in particular with the three-stagemast. Equally good results have been achieved for the fork carriage.The mast and the fork carriage run on permanently lubricated and hencemaintenance-free angled backing rollers.

Attachments: The trucks can be optionally fitted with mechanical and hydraulicattachments.

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B3 Standard Version Specifications

Z Technical specification details in accordance with VDI 2198. Technical modificationsand additions reserved.

3.1 Performance Data DFG

TFG performance data

Description DFG 316 DFG 320

Q Capacity 1600 2000 Kg

C Load centre of gravity 500 500 mm

Travel speed w / w.o. load

18/19 18/19 km/h

Lift speedw / w.o. load

0.6/0.62 0.6/0.62 m/s

Lowering speedw / w.o. load

0.55/0.49 0.55/0.49 m/s

Gradeabilityw / w.o. load

23 20 %

Description TFG 316 TFG 320

QCapacity(where C = 600 mm)

1600 2000 Kg

C Load centre of gravity 500 500 mm

Travel speed w / w.o. load

18/19 18/19 km/h

Lift speedw / w.o. load

0.6/0.63 0.6/0.63 m/s

Lowering speedw / w.o. load

0.55/0.49 0.55/0.49 m/s

Gradeabilityw / w.o. load

25 22 %

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B 6

B 7

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BDimensions DFG

Description DFG 316 DFG 320

a/2 Safety distance 100 100 mm

h1 Mast height (retracted) 2185 2185 mm

h2 Free lift 150 150 mm

h3 Lift 3300 3300 mm

h4 Mast height (extended) 3920 3920 mm

h6 Overhead guard height 2145 2145 mm

h7 Seat height (SIP) 1049 1049 mm

L1 Length including forks 3386 3416 mm

L2 Headlength 2236 2266 mm

b1 Overall width 1080 1080 mm

e Fork width 100 100 mm

m1 Ground clearance with load below mast 120 120 mm

m2 Ground clearance from centre of wheelbase 130 130 mm

AstAisle width for pallets 800 x 1200 longit.

3618 3640 mm

AstAisle width 1200 x 800 transverse pallets

3818 3840 mm

Wa Turning radius 2020 2042 mm

x Load distance 398 398 mm

y Wheelbase 1495 1495 mm

Truck weight 2870 3280 Kg

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B 8

B 9

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B TFG dimensions

Description TFG 316 TFG 320

a/2 Safety distance 100 100 mm

h1 Mast height (retracted) 2185 2185 mm

h2 Free lift 150 150 mm

h3 Lift 3300 3300 mm

h4 Mast height (extended) 3920 3920 mm

h6 Overhead Guard Height 2145 2145 mm

h7 Seat height (SIP) 1049 1049 mm

L1 Length including forks 3386 3416 mm

L2 Headlength 2236 2266 mm

b1 Overall width 1080 1080 mm

e Fork width 100 100 mm

m1 Ground clearance with load below mast 120 120 mm

m2 Ground clearance from centre of wheelbase 130 130 mm

AstAisle width for pallets 800 x 1200 longit.

3618 3640 mm

AstAisle width 1200 x 800 transverse pallets

3818 3840 mm

Wa Turning radius 2020 2042 mm

x Load distance 398 398 mm

y Wheelbase 1495 1495 mm

Truck weight 2840 3250 Kg

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3.2 Engine data

Engine - DFG

Engine - TFG

3.3 Tyre Type

Z Permissible tyre type forSolid: Solideal MagnumPneumatic: Solideal ED (Extra Deep)

Type S4Q2 four cylinder

Ignition sequence 1 3 4 2

Capacit. 2505 cc

Control speed2350 RPM (unloaded)680 RPM (idle)

Valve clearance Inlet and outlet 0.25 mm cold

Tray capacity 8.0 l

Fuel tank capacity 48 l

Coolant capacity 5.5 l + system = 14.0 l

Type 2.1 L L4 four cylinder, four stroke, LPG

Ignition sequence 1 3 4 2

Capacit. 2065 cc

Control speed2700 ±50 RPM (unloaded)850 ±50 RPM (idle)

Spark plug type NGH FR2A-D

Spark plug electrode distance 0.8-0.9 mm

Tray capacity 3.8 litres

Coolant capacity 3.5 litre + system = 13 litres

Full rubber SE tyres(=Solid)

DFG/TFG 316 DFG/TFG 320

Drive axle 6.50-10 6.50-10

Steering axle 18x7-8 18x7-8

Pneumatic tyres (diagonal tyres)

DFG/TFG 316 DFG/TFG 320

Drive axle 6-50-10 14PR 6-50-10 14PR

Steering axle 18x7-8 14PR 18x7-8 14PR

Tyre pressure DFG / TFG 316 DFG / TFG 320

Drive axle 10 bar 10 bar

Steering axle 9.0 bar 9.0 bar

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B3.4 Mast Versions

(all dimensions in mm)

DFG/TFG 316/320

Mast table

VDI 3596Description

Lifth3

Free lifth2

Retracted height h1Extended height

h4

ZT

2900 150 1985 3520

3100 150 2085 3720

3300 150 2185 3920

3600 150 2335 4220

3800 150 2435 4420

4000 150 2535 4620

4500 150 2835 5120

5000 150 3085 5620

5500 150 3435 6120

5800 150 3635 6420

ZZ

2900 1290 1940 3550

3100 1390 2040 3750

3300 1490 2140 3950

3600 1640 2290 4250

3800 1740 2390 4450

4000 1840 2490 4650

4500 2140 2790 5150

DZ

4200 1290 1940 4850

4350 1340 1990 5000

4500 1390 2040 5150

4800 1490 2140 5450

5000 1565 2215 5650

5500 1740 2390 6150

6000 1940 2590 6650

6500 2190 2840 7150

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3.5 EN norms

Noise level: 79 dB(A) +/- 3dB (depending on tolerances and features)

in accordance with EN 12053 as harmonized withISO 4871.

Z The noise emission level is calculated in accordance with standard procedures andtakes into account the noise level when travelling, lifting and when idle. The noiselevel is measured at the driver’s ear.

MSG 65

Vibration: 0.50 m/s2

in accordance with EN 13059

Z The vibration acceleration acting on the body in the operating position is, inaccordance with standard procedures, the linearly integrated, weighted accelerationin the vertical direction. It is calculated when travelling over bumps at constant speed.

Electromagnetic Compatibility (

The manufacturer confirms that equipment complies withtolerance levels for electromagnetic emissions andresistance as well as static electricity discharge testing inaccordance with EN 12895 including the normativeprocedures contained therein.

Z No changes to electric or electronic components or their arrangement may be madewithout the written agreement of the manufacturer.

3.6 Conditions of use

Ambient temperature- operating at -20 °C to 40 °C

Z Special equipment and authorisation are required if the truck is to be constantly usedin conditions of extreme temperature or air humidity fluctuations.

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B4 Identification points and data plates

Item Description

15 Warning: Read operator manual.

16 Load fork, Capacity / Load Centre of Gravity / Lift Height Chart

17 “Travel with raised load prohibited” / “Mast forward tilt with raised load prohibited” warning

18 "Attach Safety Restraint Belt" decal

19 Strap points for crane lifting

20 “Procedure when truck in danger of tipover” notice

21 "Do not stand under load lifting device” / “Do not stand under load lifting device” / “Risk of trapping when mast extended” combined notice

22 “Maximum body size” noticeo

23 UVV test sticker (D only)

24 Jack contact points

25 Serial number, on chassis below the engine cover

26 “Do not carry passengers” warning

27 Truck data plate under the engine cover

24

19

D (mm)

(mm) Q (kg)

24

2115

1718

16

27

19

26

20

23

121110

98

76

54 3 2

1

2000

22

25

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4.1 Truck data plate

Z For queries regarding the truck or ordering spare parts always quote the truck serialnumber (29).

4.2 Truck load chart

The load chart (16) gives the capacity (Q) of the truck in kg with a vertical mast. Thediagram will differ, depending on the height of the mast used. The maximum capacityis shown as a table with a given load centre of gravity D (in mm) and the required liftheight H (in mm). The truck load chart shows the truck's capacity with new forks (assupplied). From a fork length of 1300 mm this means a decrease in load. Truckssupplied without fork tines are given a standard data plate.

Example of how to calculate the maximum capacity:

With a load centre of gravity D of 600 mm and a maximum lift height H of 3600 mm.the max. capacity Q is 1105 kg.

Item Description Item Description

28 Type 33 Manufacturer’s logo

29 Serial no. 34 Net weight

30 Rated capacity (kg) 35 Load centre of gravity (mm)

31 Output (kW) 36 Year of manufacture

32 Manufacturer 37 Option

28

29

30

31

32

36

35

33

34

37

4250

3600

29001250 1250 850

500 600 700

1105 1105 850

850 850 600

For example:

16

B 15

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BThe arrow shape markings (38 and 39)on the inner and outer masts show thedriver when the specified lift limits havebeen reached. These arrows areattached to all masts with a height-dependent capacity rating.

4.3 Attachment load chart

The attachment load chart gives the truck’s capacity Q in combination with therespective attachment in kg. The serial number specified in the load chart must matchthe data plate of the attachment, as the capacity for each truck is specifically indicatedby the manufacturer. It is shown in the same way as the truck’s capacity and can bedetermined accordingly.

Z For loads with a centre of gravity above 500mm upward, the capacities are reducedby the difference of the altered centre of gravity.

38 39

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B 16

C 1

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C Transport and Commissioning

1 Lifting by crane

M Only use lifting gear with sufficientcapacity (for transport weight see truckdata plate).

– Park the truck securely (see Chapter E).

– Attach the crane slings to the crossmember of the mast (1) and the trailercoupling (2).

M Only suspend crane belts/chains to thetop eye of the counterbalance weightand the eyes of the upper cross member(mast).The mast must be tilted back fully.The crane belt or the chain on the mastmust be at least 2m long.

M Lifting slings should be fastened to the harness in such a way that they do not comeinto contact with any attachments or the overhead guard when it is being raised.

2

1

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C 2

2 Securing the truck during transport

The truck must be securely fastenedwhen being transported on a lorry or atrailer. The lorry / trailer must havefastening rings and a wooden floor.Loading shall be carried out by staffespecially trained for that purpose inaccordance with recommendationscontained in Guidelines VDI 2700 andVDI 2703.

In each case correct measurementsmust be taken and appropriate safetymeasures adopted.

To secure the truck with the mastassembled, use the eyes on the uppercross member of the mast and the trailerpins. See top picture (fastening withmast assembled) and centre picture(fastening without a mast).

If the truck is to be transported without amast, it must be tied down at the frontover the overhead guard. See centrepicture.

The lower picture shows theapproximate position of the centre ofgravity.

C 3

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B3 Using the truck for the first time

F Commissioning and driver instruction must be performed by trained personnel. Ifseveral trucks have been delivered, make sure that always the serial numbers of theload lifting devices, masts and basic trucks match each other.

To prepare the truck after delivery or after transport, proceed as follows:

– Check the truck for completeness and satisfactory condition of the equipment.

– Check motor oil level.

– Check power shift transmission oil level.

– Check brake fluid level

– Check battery terminals and acid level.

– Commission the truck in accordance with instructions (see Chapter E).

4 Towing the truck

As the gear unit of the forklift motor is powered, it is not lubricated and will overheatif a truck has to be towed with the motor switched off. To avoid this, the truck can onlybe towed at a max. speed of 4 km per hour.

Hitch point

A rigid tow bar must be used for movinga forklift truck.

The tow point of the truck is marked (57).

– Attach the tow bar / rope to the trailer coupling of the recovery vehicle and the truckto be recovered.

– Release the parking brake.

F One person must be seated in the towed truck to steer it. Tow the truck at crawlspeed.

Z As the steering auxiliary unit is not applied, extra effort is required to steer the truck.

56

57

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C 4

D 1

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D Filling the Truck with Fuel

1 Safety regulations for handling diesel fuel and LPG

Before filling up or replacing the LPG bottle, first park the truck securely (seeChapter E).

Fire protection: When handling fuels and LPG, smoking, naked flames and otherignition sources are strictly prohibited in the immediate vicinity. Labels indicating thehazard zone must be positioned where they are clearly visible. It is prohibited to storeflammable materials in this area. Operational fire equipment must be provided withineasy reach of the filling area.

F Only use carbon dioxide dry extinguishers or carbon dioxide gas extinguishers for fireprotection.

Storage and transport: The dieself and LPG storage and transport devices mustcomply with statutory requirements. If there is no filling point available, the fuel mustbe stored and transported in clean, approved containers. The contents must beclearly indicated on the container. Unsealed LPG bottles must be broughtimmediately into the open air, stored in well ventilated areas and the supplier must benotified. Spilled diesel must be set using a suitable agent and disposed of inaccordance with environmental regulations.

Personnel for filling fuel and replacing LPG bottles: Personnel handling LPGmust be have sufficient knowledge of the nature of liquid gases to ensure safeoperation.

Filling up the LPG tank: LPG tanks remain connected to the truck and are filled upat LPG stations. Always follow the instructions of the tank system and LPG tankmanufacturer as well as statutory and local regulations when filling up.

F Liquid gas produces frost damage to naked skin.

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D 2

2 Filling with diesel

F The truck must only be filled at locationsspecifically designed for this purpose.

– Park the truck securely before fillingup (see Chapter E).

– Open the cap (1).

– Fill up with clean diesel.

Z Do not overfill the tank.

Capacity: 48 l

M Only use DIN 51601 diesel with a cetanerating below 45.

The fuel guage (2) indicates the fuellevel. If it points to the red zone, fill thetank.

M Never allow the fuel tank to run dry! Airin the fuel system will result inmalfunctions.

– Tighten the cap back on after fillingwith fuel.

1

D 3

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B3 Replace the LPG bottle

F The LPG bottle must only be replaced at designated areas by trained and authorisedpersonnel.

– Park the truck securely before fillingup (see Chapter E).

– Close the shut-off valve (3) securely.

– Start the motor and allow the LPGsystem to run empty in neutral.

– Unscrew the union nut (4) with anappropriate key while holding againstthe handle (6).

– Remove the hose (5) and immediatelyscrew the valve cap onto the emptyLPG bottle.

– Remove the stop bolt (7) and rotatethe LPG bottle and bracket around thehandle (9).

– Fold back the lever of the toggle-typefastener (8) and unhook thetensioning pivot from the bracket.

– Remove the tensioning belt.

– Carefully remove the LPG bottle fromthe bracket and place it downsecurely.

F Only use 18 kg (29 l) LPG replacementbottles.

– Insert the new LPG bottle in thebracket and turn it so that the neck ofthe shut off valve is facing up.

– Fit the tensioning belt around the LPGbottle.

– Hook in the tensioning pivot andtension the belt with the lever (8).

– Rotate the LPG bottle and the bracketaround the handle (9).

– Press in the stop bolt (7).

– Refit the hose (5) in accordance with regulations.

– Carefully open the shut off valve and check the connection is sealed using a foam-based agent.

3

4

6

5

9

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D 4

o When the reserve indicator for LPGbottle (2) is lit, this indicates that thebottle is empty.

o Reusable LPG bottles with centralfilling device

The bottle is fitted with a filling stopvalve. The discharge valve (10) must besealed. Remove the seal (11). Insert thenozzle of the liquid gas pump into thefiller port. Fill the LPG bottle until you cansee on the fluid gauge that the bottle isfull. Remove the nozzle and refit the seal(11).

F Note all guidelines and regulationsconcerning the filling of LPG bottles onthe LPG pump.

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E Operation

1 Safety Regulations for the Operation of Forklift Trucks

Driver authorisation The forklift truck may only be used by suitably trainedpersonnel, who have demonstrated to the proprietor or his representative that theycan drive and handle loads and have been authorised to operate the truck by theproprietor or his representative.

Driver’s rights, obligations and responsibilities: The driver must be informed ofhis duties and responsibilities and be instructed in the operation of the truck and shallbe familiar with the operator manual. The driver shall be afforded all due rights. Safety shoes must be worn for pedestrian operated trucks.

Unauthorised Use of Truck: The driver is responsible for the truck during the timeit is in use. The drive must prevent unauthorised persons from driving or operating thetruck. Do not carry passengers or lift other people.

Damage and Faults: The supervisor must be immediately informed of any damageor faults to the forklift truck or attachment. Trucks which are unsafe for operation (e.g.wheel or brake problems) must not be used until they have been rectified.

Repairs: The driver must not carry out any repairs or alterations to the forklift truckwithout the necessary training and authorisation to do so. The driver must neverdisable or adjust safety mechanisms or switches.

Hazardous area: A hazardous area is defined as the area in which a person is at riskdue to truck movement, lifting operations, the load handler (e.g. forks or attachments)or the load itself. This also includes areas which can be reached by falling loads orlowering operating equipment.

F Unauthorised persons must be kept away from the hazardous area. Where there isdanger to personnel, a warning must be sounded with sufficient notice. Ifunauthorised personnel are still within the hazardous area the truck shall be broughtto a halt immediately.

Safety Devices and Warning Signs: Safety devices, warning signs and warninginstructions shall be strictly observed.

M Trucks with reduced headroom are equipped with a warning sign within the driver'sline of sight. The max. recommended body size indicated on this sign must beobserved.

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B2 Controls and Displays

ItemControl /Display

Function

1 Soot filter indicator tIndicates that the soot filter is contaminated.

2 Engine oil pressure indicator tWhen lit, indicates insufficient engine lubricant oil pressure.

3 Charging current indicator tWhen lit, indicates that the battery is not charged.

4Transmission oil temperature indicator

t

When lit, indicates that the transmission oil temperature is too high.

5 Parking brake indicator tWhen lit, indicates that the parking brake is applied.

6Fuel supply indicator (DFG)

tWhen lit, indicates the fuel supply is too low.

7 Brake fluid indicator tWhen lit, indicates the brake fluid level is too low.

8 Air filter indicator tWhen lit, indicates that the air filter is contaminated.

9 Diesel filter indicator tWhen lit, indicates that the diesel filter is contaminated.

10 Coolant temperature indicator t Indicates the coolant temperature.

11Time / service hours display

tIndicates the time or number of service hours operated.

12Indicator control light

t Shows the indicator status (right/left).

13 Preheat control light (DFG) tIndicates the operation of the cold start mechanism.

14 Neutral position t

When lit, indicates that the travel direction switch is in neutral (see Neutral Interlock in this chapter)

15 Fuel display (DFG) tIndicates how much fuel is left in the tank.

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ItemControl /Display

Function

16 Parking brake lever t

Applies / releases parking brake.

To engage, turn switch to position 1.

To release, turn switch to position 0.

Pull up lever to engage.

Push lever forward to release.

17 Steering wheel t Steers truck in desired direction.

18Steering column adjusting lever

t Adjusts the steering column tilt.

19 Ignition / starter switch t

Switches power supply on and off.Starts and stops the engine. Removing the ignition key prevents the truck from being switched on by unauthorised personnel.

20 Options switch t Options

21 Brake pedal Standard emergency braking

22 Accelerator pedal tControls engine speed / travel and lift speed.

23 Auxiliary hydraulics (ZH1)

Sideshifto Moves the forks to the right / left.

24 Auxiliary hydraulics (ZH2) o Intended for hydraulic attachments.

25 Mast tilt control lever t

Tilts the mast forward and backward. To tilt the mast forward: push the lever forward.To tilt the mast back: pull the lever back.

26 Lift/lower control lever t

Raises and lowers the fork carriage

To raise the fork carriage: pull the lever back.To lower the fork carriage: push the lever forward.

27 Horn button t Triggers an audible warning.

28 Travel direction switch t Select the travel direction.

29 Slow travel / brake pedal t1st range: controls slow travel.2nd range: applies service brake.

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t Travel direction switch

Z When the travel direction switch (28) isin the central position, the transmissionis in idle.

– To select the forward gear, push theswitch forward.

– To select the reverse gear, push theswitch back.

Z The engine will not start if a traveldirection is pre-selected.

Neutral Interlock

If the truck is abandoned without taking it out of gear, the truck is automatically set toneutal. This is shown by the neutral indicator in the dashboard. When travel isresumed (by sitting on the truck), the travel direction switch must be set to neutral (N).Travel can now resume.

Heating and Fan

– Turn the thermostat control button(31) anti-clockwise to increase thetemperature in the driver’s cab.

– Press the switch (30) to activate thefan.

Horn

– To activate the horn press the warningbutton (27) in the hydraulic lever.

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B3 Starting up the truck

F Before the truck can be commissioned, operated or a load unit lifted, the driver mustensure that there is nobody within the hazardous area.

3.1 Checks and operations to be performed before starting daily work

Truck

– Visually inspect the whole of the truck (especially the wheels and the lifting device)for obvious signs of damage.

– The entire truck (in particular wheels and load lifting devices) must be inspected fordamage.

– Make sure the load chains are evenly tensioned.

– Check the operation of the seat belt buckle and the belt returning to the retractor.For further information see section 3.3.

3.2 Trucks with reduced headroom X (o)

M Failure to comply with the recommendedbody size may result in overload andconstitute a danger to the driver,possibly resulting in permanent damagecaused by an unhealthy posture andexcessive physical exertions on the partof the driver.The owner must ensure that the truckoperator does not exceed the maximumbody size indicated.The owner must also check that thedrivers can sit normally, in an uprightposition without having to exert himself.

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Z Covers may need to be opened for the inspection.

Checking the fuel supply - DFG

– Set the ignition / starter key (19) to the“I” position.

– Read off the fuel supply from the fuelgauge (15).

– If necessary, add diesel (seeChapter D).

o Testing the windscreen fluid level

– The windscreen wiper fluid container(32) is located at the rear right spar(33) of the cabin.

– Make sure there is sufficientwindscreen fluid in the container. Topup if required.

– Use a windscreen fluid with anti-freeze solution.

Wheels and Tyres

– Check wheels and tyres for wear (seeChapter F). Measure the tyre pressure (pneumatic tyres only) (see Chapter B).

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B3.3 Adjusting the driver’s seat

Standard seat MSG 65

To achieve optimal seat damping the driver’s seat must be adjusted according to thedriver’s weight.

Adjusting the seat to the driver's weight:

– Sit on the driver’s seat. When the correct weight adjustment has been made, thearrow of the driver weight display (37) will be above the calibration line. If the arrowis facing too far to the left or right, the seat must be adjusted to the driver's weight.

– To do this, move the weight adjustment lever (36) approx. 90° forward.

– To set the seat to a lesser weight, push the weight adjustment lever (36) down.

– To set the seat to a greater weight, push the weight adjustment lever up.

– After adjusting, return the lever to its original position.

Adjusting the backrest incline:

– Sit on the driver’s seat.

– Lift up the backrest tilt adjuster (34) and adjust the incline of the backrest.

– Release the backrest tilt adjuster (34) to lock the backrest in position.

Adjusting the seat position:

– Pull up the longitudinal adjuster (35) and push the driver’s seat forwards orbackwards to the desired position.

– Engage the longitudinal adjuster (35) in position again.

F The longitudinal adjuster must be securely located in the desired position. Thedriver’s seat setting must not be changed during travel.

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36

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3.4 Safety restraint belt

The driver must check the operation and condition of the seat belt every day beforeusing the industrial truck. Faulty operation can only be detected in good time throughregular inspection.

F Put on the safety restraint belt each time before starting the industrial truck. The belt protects against serious injury.

Protect the belt from contamination (e.g. cover it when the truck is idle) and clean itregularly. Frozen belt locks or pulleys must be thawed out and dried to prevent themfrom freezing up again.

Z The dry temperature of the warm air should not exceed +60 °C.

F Do not alter the belt setting. This will increase the risk of malfunctioning.

– Always replace the safety restraint belt after an accident.

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

F Damaged or non-operational belts must only be replaced by contractual dealers orbranches.

– Withdraw the belt completely and check the belt for possible fraying.

– Check the belt lock and make sure that the belt enters the retractor correctly.

Check the cover for damage

Testing the automatic blocking system:

– Park the truck in a horizontal position.

– Forcibly extract the belt.

M The automatic system should lock the belt in the retractor.

– Open the engine bonnet approx. 30 degrees

M The automatic system should lock the belt in the retractor.

Starting the industrial truck on steep slopes

The automatic blocking system locks the belt in the retractor when the truck ispositioned on a steep slope. This prevents the belt from being pulled out of theretractor.

Z Carefully drive the truck off the slope and then put on the belt.

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BProcedure in unusual situations

F If the truck is about to tip over, neverundo the restraint belt and try to jumpout.Jumping increases the risk of injury.

Correct procedure:

– Lean your upper body over thesteering wheel.

– Grip the steering wheel with bothhands and brace feet.

– Lean your body against the oppositedirection of fall

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3.5 Adjusting the steering column

– Release the steering column adjustinglever (18) in the direction of the arrow(L).

– Tilt the steering column (38) forwardor backward as required.

– Push the steering column adjustinglever in the direction of the arrow (F).

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B3.6 Starting the truck

Before starting the truck

If the engine has not been run for several weeks or if the oil filter has been changed,start the engine (see section 3.7 or 3.8) and leave it to run in idle for a few minutesbefore starting.

Start the engine

F The truck should only be operated from the driver’s seat.

– Apply the parking brake.

Z Set the travel direction switch (28) to neutral N.

Z The engine will only start when the travel direction switch is in neutral.

Z TFG starting procedure (see section 3.7)DFG starting procedure (see section 3.8)

Key operated ignition

Operation:

O - All main circuits are cut outand the key can be removed.

I - Controls and instruments areswitched on. Enginepreheating (diesel only).

II - Starting the engine(automatically returns to the Iposition).

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3.7 Starting procedure for the TFG

F Note the safety regulations forhandling liquid gas (see Chapter D,section 1).

– Slowly open the shutoff valve onthe LPG bottle.

– Put the key in the ignition / starterswitch (19).

– Set the ignition / starter key to the“I” position.

– Press the horn button (27) andtest the horn.

The charging current (3), engine oilpressure (2), neutral setting (14)and parking brake (5) indicatorslight up.

– Gently apply the acceleratorpedal (22).

– Set the ignition / starter key nowto the II position.

M Only apply the starter for amaximum of15 seconds withoutinterruption. Before starting again,wait 30-60 seconds and reset theignition / starter switch to 0.

– Release the key as soon as theengine starts. It automaticallyreturns to the I position.

F When working with LPG trucks it isessential to always observe thefollowing safety regulations.

If a truck will not start:

– Close the gas bottle shutoff valve.

– Turn off the ignition / starter O.

– Call for a trained, authorised customer service engineer.

M All indicators lights except for neutral setting (14) and parking brake (5) should go outas soon as the engine starts. If not, stop the engine immediately and rectify the fault.

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B3.8 Starting procedure for the DFG

– Put the key in the ignition / starterswitch (19).

– Set the ignition / starter key to the“I” position.

– Press the horn button (27) andtest the horn.

– After setting the ignition / starter(19) to the I position, the chargingcurrent (3), engine oil pressure(2), neutral setting (14) andparking brake (5) indicators andthe preheat (13) control light willlight up.

– Apply the accelerator pedal (22)fully and wait until the preheatcontrol light goes out.

Z The preheat time depends on theengine temperature, but normallylasts approx. 4 seconds.

– Set the ignition / starter key nowto the II position.

M Only apply the starter for amaximum of15 seconds withoutinterruption. Before starting again,wait 30-60 seconds and reset theignition / starter switch to 0.

– Release the key as soon as theengine starts. It automaticallyreturns to the I position.

M All indicators lights except forneutral setting (14) and parking brake (5) should go out as soon as the engine starts.If not, stop the engine immediately and rectify the fault.

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F After starting the engine, carryout a test run and check thefollowing functions:

– Test the parking brake (16)and the slow travel /brake pedal (29).

– Test the engine speed withthe accelerator pedal (22)over a range of speedswhile checking the freedomof movement of the pedal.

– Test the operation of theraise/lower (26), tilt (25) andif applicable the attachmenthydraulic control functions.

– Turn the steering wheel(17) as far as it will go inboth directions and test thesteering.

M Do not run up the engine inidle. The engine soon reachesoperating temperature at amoderate charge and whenthe speed alternates.Only fully charge the enginewhen the engine coolanttemperature display (10)shows operating temperature.

The truck is ready foroperation once all thefunctional controls have beensatisfactorily performed andoperating temperature isreached.

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B3.9 Operational Fault Displays

When the following indicators are lit:

– Engine oil pressure (2),

– Charging current (3),

– Coolant temperature (10),

– Transmission oil temperature (4),

the engine must be stoppedimmediately.

M The engine should only be started againonce the fault has been removed.

Z For troubleshooting procedures, seesection 6.

Check the fuel display during operation(15, DFG only).

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3.10 Stopping the engine1.

M Do not stop the engine fromfull charge. Instead, let it runfor a short while to allow thetemperature to compensate.

– Stop the truck.

– Set the travel directionswitch (28) to neutral.

– Apply the parking brake(16).

– Turn the ignition / starterswitch (19) to the 0position.

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B4 Industrial truck operation

4.1 Safety regulations for truck operation

Travel routes and work areas: Only use lanes and routes specifically designated fortruck traffic. Unauthorised third parties must stay away from work areas. Loads mustonly be stored in places specially designated for this purpose.

Travel conduct: The driver must adapt the travel speed to local conditions. The truckmust be driven at slow speed when negotiating bends or narrow passageways, whenpassing through swing doors and at blind spots. The driver must always observe anadequate braking distance between the forklift truck and the vehicle in front and mustbe in control of the truck at all times. Abrupt stopping (except in emergencies), rapidU turns and overtaking at dangerous or blind spots are not permitted. It is forbiddento lean out of or reach beyond the working and operating area.

Travel visibility: The driver must look in the direction of travel and must always havea clear view of the route ahead. Loads which affect visibility must be positioned at therear of the truck, or else the truck must reverse. If this is not possible, a second personmust walk in front of the truck as a lookout.

Negotiating slopes and inclines: Negotiating slopes or inclines is only permitted ifsuch roads are clean and have a non-slip surface and providing such journeys aresafely undertaken in accordance with the technical specifications for the truck inquestion. The truck must always be driven with the load unit facing uphill. Theindustrial truck must not be turned, operated at an angle or parked on inclines orslopes. Inclines must only be negotiated at slow speed, with the driver ready to brakeat any moment.

Negotiating lifts and docks: Lifts and docks must only be used if they have sufficientcapacity, are suitable for driving on and authorised for truck traffic by the owner. Thedriver must satisfy himself of the above before entering these areas. The truck mustenter lifts with the load in front and must take up a position which does not allow it tocome into contact with the walls of the lift shaft. .People travelling in the lift with the forklift truck must only enter the lift after the truckhas come to a halt and must exit the lift before the truck.

Type of loads to be carried: The operator must make sure that the load is in asatisfactory condition. Do not carry loads unless they are positioned safely andcarefully. Use suitable precautions, e.g. a load guard, to prevent parts of the load fromtipping or falling down.

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Towing trailers or the truck itself being towed are only permitted occasionally, onsecure, level routes, with a maximum deviation of +/- 1% and at a max. speed of 5km/h. Do not permanently operate the truck with trailers.While the truck is pulling there must be no load on the forks. Do not exceed the maximum trailer load specified for the forklift truck for trailers withor without brakes. The specified trailer load only applies for the auxiliary coupling inthe counterbalance of the forklift. If a different trailer coupling is used on the truck, theinstructions of the coupling manufacturer must be observed..After coupling and before starting the driver must ensure that the trailer couplingcannot become detached.Trucks pulling a load must be operated in such a manner that the trailing vehicle isdriven safely and can be stopped at all times.

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

Emergency Disconnect with truck electronic system deactivation: All electricalfunctions are deactivated.

Set the keyswitch to the O position. For trucks with a cabin or a canvas top the doorsmust be open. Press the pushbutton in the leg area. The engine cover opens, removeblue quick release lock from the battery pool.

F For gas operated trucks the shutoff valve on the gas tank or gas bottle must betightened to prevent the gas from entering the engine area.

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B4.2 Travel

F Adapt the travel speed to the conditions of the travel lane, the work area and the load

– Set the travel direction switch (28) to neutral.

– Raise the fork carriage approx. 200 mm so that the fork tines are clear of theground.

– Tilt the mast fully backward:

– Release the parking brake.

Forward travel

– Set the travel direction switch (28) forward.

– Slowly apply the accelerator pedal (22) until you reach the required travel speed.

Changing direction

M Only change direction when the truck has stopped.

– Set the travel direction switch (28) via neutral to the required direction.

– Slowly apply the accelerator pedal (22) until you reach the required travel speed.

Reversing

F Make sure you have sufficient space toreverse into.

– Set the travel direction switch (28) tothe rear.

Accelerating

– Slowly apply the accelerator pedal(22) until the truck starts to move.

– Continue to depress the acceleratorpedal.The engine and travel speedsincrease.

Braking

F The braking pattern of the truck dependsto a large extent on the condition of theground. The driver must take this intoconsideration when handling the truck.Carefully brake the truck to prevent the load from slipping.

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Braking

– Take your foot off the accelerator pedal (22).

– Gently depress the slow travel / brake pedal (29).

In the first pedal displacement zone, the flow of force is reduced by the torqueconverter.

– Continue to depress the slow travel / brake pedal (29).

As you continue to depress, the truck automatically comes to a halt.

Slow travel with the slow travel / brake pedal

Sensitive application of the slow travel / brake pedal (29) allows for excellent shuntingin confined areas through slow travel.

M This operating mode can only be used for max. 5 seconds when the engine is runningat high speed.

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B4.3 Steering

F Very little steering force is requiredfor the hydrostatic steering, thereforeturn the steering wheel (17) withcaution.

4.4 Braking

Operating Brake

The slow travel / brake pedalhydraulically actuates the drumbrakes of the front wheels.

– Apply the slow travel / brake pedal(29) until you feel the brakepressure.The flow of force is controlled in thepower shift transmission in the firstpedal displacement zone. As youcontinue to depress the pedal, thefront wheel drum brakes areapplied.

– Alternatively you can use the brakepedal (21); this will actuate thedrum brakes without decouplingthe gear unit.

Parking brake

The parking brake lever mechanicallyactuates the drum brakes of the frontwheels.

– Pull back the parking brake lever(16) beyond the pressure point asfar as the stop. The parking brake is engaged andthe parking brake lever is locked inthis position.

– To release the parking brake, pushthe parking brake lever forwardbeyond the pressure point.

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4.5 Mast and Attachment Operation

F The control levers must only be operated from the driver’s seat.

The lifting device is operated from the control levers on the right-hand side of thedriver's seat.

Lifting/lowering the fork carriage

F Never reach through the mast!

– Pull the control lever (26) back to raisethe fork carriage.

– Push the control lever (26) forward tolower the fork carriage.

Tilting the mast forward / backward

F When tilting the mast back, do notposition any part of your body betweenthe mast and the front wall.

– Pull the control lever (25) back to tiltthe mast back.

– Push the control lever (25) forward totilt the mast forward.

o Operating attachments

Attachments are operated via the controllevers (23, 24) to the right of control lever(25) (mast tilt).

F Also follow the manufacturer’s operatinginstructions when operating anattachment.

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BOperating the integrated sideshift (ISS)

Z The references to left and right are with reference to the load handler as viewed fromthe operator’s position.

Sideshift left (from driver’s position):

– Push the control lever (24) forward.

Sideshift right (from driver’s position):

– Pull the control lever (24) back.

F Note reduced capacity for extending (see Chapter B).

Controlling the speed of thelifting device

Moving the control lever andchanging the engine speed governsthe operating speed of the hydrauliccylinders.

When the control levers arereleased (23, 24) they automaticallyrevert to neutral and the liftingdevice remains in the position it hasreached.

M Always apply the control leversensitively, never with a suddenjerk. Release the control lever assoon as you reach the stop.

– Set the travel direction switch(28) to neutral.

– Increase the engine speed withthe accelerator pedal (22) and

– continue to move the control leverback to increase the speed of thelifting device.

Z The engine speed does not affectthe lowering speed of the forkcarriage.

F Do not lift other people with thelifting device.

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4.6 Collecting, transporting and depositing loads

F The control levers must only be operated from the driver’s seat.

M Before lifting a load, the driver must ensure that it is correctly palletised and that thecapacity of the truck is not exceeded.Note the load chart.

Adjusting the forks

F Adjust the fork tines in such a way thatboth are equally distanced from theouter edge of the fork carriage and theload centre of gravity is in the middle ofthe fork tines.

– Raise the locking lever (39).

– Push the forks (40) to the correctposition on the fork carriage (41).

– Turn the locking lever down and movethe forks until the locking pin engagesin a slot.

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BRaising a load

F Do not lift other people with the liftingdevice.

– Carefully approach the load to beraised.

– Set the travel direction switch (28) toneutral.

– Raise the forks to the correct height forthe load.

– Set the mast vertical.

– Set the travel direction switch toforward travel.

F At least two thirds of their length mustextend into the load.

– Drive the truck with forks spread as farapart as possible underneath the load.

– Set the travel direction switch (28) toneutral.

– Raise the fork carriage until the loadrests freely on the forks.

– Set the travel direction switch toreverse.

– Make sure you have enough space toreverse into.

– Reverse carefully and slowly until theload is outside the storage area.

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F Do not allow anyone to standunderneath a raised load.

– Lower the load as far as is absolutelynecessary for transport (groundclearance approx. 150...200 mm).

– Tilt the mast fully backward:

F The higher the load is transported, theless the operating safety of the truck.

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BTransporting a load

F If the load is stacked up so high that itaffects forward visibility, you mustreverse.

– Gently accelerate with the acceleratorpedal (22) and slowly brake with theslow travel / brake pedal (29). Beready to brake at all times.

– Adapt your travel speed to theconditions of the route and the loadyou are transporting.

– Watch out for other traffic at crossingsand passageways.

– Always travel with a lookout atblindspots.

F On slopes and inclines always carry theload facing uphill, never approach at anangle or turn.

Depositing a load

– Drive the truck carefully up to the rack.

– Set the travel direction switch (28) toneutral.

– Raise the forks to the correct height forthe rack space.

– Set the travel direction switch (28) toforward. Carefully enter the load intothe rack space.

– Slowly lower the load until the forksare free.

– Set the mast vertical.

M Avoid placing the load down suddenly toavoid damaging the load and the loadhandler.

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Handling individually suspended loads

"Travel at max. crawl speed when transporting suspended loads. For operationsinvolving suspended loads, the safety of the truck must be individually assessed by aspecialist.” The capacity reduces by at least 1/3."

4.7 Parking the truck securely

F When you leave the truck it must besecurely parked even if you only intendto leave it for a short time.Never park and leave a truck with araised load.

– Drive the truck onto a level surface.

F LPG powered trucks must not beoperated on ground floors with abasement.Liquid gas is colourless, heavier than airand does not easily dissipate. It tends tosink to the lowest possible level and can collect in pits, drains, basements and otherrecesses.This means that LPG gas can gather in areas far away from the truck and constitutesa hazard for people who are unaware of the potential risks from explosions andfrostbite.

– Fully lower the forks and tilt the mast forward.

– Set the travel direction switch (28) to neutral.

– Apply the parking brake lever (16).

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BStopping the engine DFG

– Set the ignition / starter switch (19) to“0”.

– Remove the key from the ignition /starter switch (19).

Stopping the engine TFG

– Close the shut-off valve (42) of theLPG bottle securely.

– Wait until the engine comes to a stop.

– Turn the ignition / starter switch (19) to“0”.

– Remove the key from the ignition /starter switch (19).

o Steel cabin

For trucks fitted with a steel cabin, bothdoors can be closed.

– To unlock the cabin door turn the keyanti-clockwise.

– To lock the cabin door turn the keyclockwise.

– To open the cabin door, unlock thedoor and remove the handle (43).

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4.8 Towing trailers

F The truck can occasionally be used to tow a light trailer on a dry, level and wellmaintained surface. The truck must not be permanently used with trailers.

To ensure safe transport always observe the following instructions when towingtrailers. Never exceed thepermissible tow load during operation. This informationmust be obtained from the owner in accordance with VDI 3973 and DIN 15172. At anyrate, the maximum tow load specified by the manufacturer must never beexceeded.

Attaching the trailer

– Push the tow pin down and turn it 90 degrees.

– Pull the tow pin up and insert the control handle of the trailer vehicle into theopening.

– Insert the tow pin, push it down, turn it 90 degrees and engage it.

4.9 Tow loads

Before coupling, the driver must ensure the maximum trailer load is not exceeded.

Permissible towed loads for towing without a load on the forks, for +/- 1° inclines andmax. 5 km/h (trailer without brakes).

The maximum tow load as specified by the manufacturer must therefore not beapplied in isolation for local operation, but rather should be considered an absolutemaximum limit for the owner to take into account when determining the permissibletow loads.

Z– The towed load is the sum of the net weight of the trailer and the trailer load.

– The lift truck must not have any load on its forks while towing.

– The specified towed loads only apply to the auxiliary coupling in the counterbalanceweight of the truck. If using other trailer couplings, observe the regulations of thecoupling manufacturer. The maximum tow load remains unaffected.

DFG / TFG

Max. permissible tow loads 8000 Kg

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B5 Troubleshooting

This chapter is designed to help the user identify and rectify basic faults or the resultsof incorrect operation. When locating a fault, proceed in the order shown in the table.

Fault Probable Cause Action

Starter does not turn

– Travel direction switchnot in neutral

– Battery charge too low

– Battery terminal cableloose or terminalsoxidized.

– Starter cable loose orbroken

– Starter magnetic switchjammed

– Turn travel direction switch to neutral(see Neutral Interlock in this chapter)

– Check battery charge, charge battery ifnecessary

– Clean and grease terminals, tightenbattery terminal cable

– Check starter cable, tighten or replaceas required

– Check if the magnetic switch audiblyengages

Engine does not start

– Air filter contaminated

– Bowden cable faulty orhanging

Additional forLPG

– LPG bottle shutoff valveclosed

– LPG bottle empty

– Ignition distributor capdamp

– Spark plugs damp, oilyor loose

– Spark plugs faulty

Additional for diesel

– Fuel tank empty,injection system hassuctioned in air

– Water in fuel system

– Fuel filter contaminated

– Paraffin separation fromthe diesel (flakesforming)

– Clean / replace air filter

– Check Bowden cable

– Shutoff valve open

– Replace the LPG bottle

– Ignition distributor cap dry, ifnecessary apply contact spray

– Dry, clean and tighten spark plugs

– Replace spark plugs

– Fill up with diesel and bleed theinjection system

– Drain the fuel systemFill up the truckBleed the fuel system

– Check the flow of fuel, if necessaryreplace the fuel filter

– Park the truck in a warm room and waituntil the separation has returned to itsoriginal state.Replace the fuel filter if necessaryAdd winter diesel fuel

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Fault Probable Cause Action

Motor oil indicator lit duringoperation

– Motor oil level too low – Check engine oil level, top up ifnecessary

Enginetemperaturedisplay in red zone

– Engine oil level too low

– Radiator contaminated

– Coolant level too low

– Fan V belt slipping

– Check engine oil level, top up ifnecessary

– Clean radiator

– Check engine radiator system forleaks, add coolant if necessary

– Check V belt tension, tighten orreplace as required

Transmissionoil indicator lit duringoperation

– Tranmission oil level toolow

– Radiator contaminated

– Check transmission oil level, top up ifnecessary

– Clean radiator

Engine running but truck does not travel

– Travel direction switchin neutral

– Parking brake applied

– Set travel direction switch to requireddirection

– Release parking brake

Truck does not reach max. speed

– Transmission oil leveltoo low

– Check transmission oil level, top up ifnecessary

Lift speed too low

– Hydraulic reservoir oillevel too low

– Hydraulic reservoirdischarge systemcontaminated orblocked

– Check hydraulic oil, if necessary topup

– Clean / replace hydraulic reservoirdischarge system

Load cannot be raised to max. height.

– Hydraulic reservoir oillevel too low

– Check hydraulic oil, if necessary topup

Steering is sluggish

– Air pressure in steeringaxle tyres too low

– Check tyre air pressure, increase tocorrect pressure if necessary

Excessivesteering play

– Air in steering system – Check hydraulic oil level and top up ifnecessary, then turn the steeringwheel several times from one end tothe other.

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Z If, after carrying out the remedial action, the truck cannot be restored to operation orif a fault in the electronics system is displayed with a corresponding error code,contact the manufacturer’s service department. Additional troubleshooting must only be performed by the manufacturer’s specialistservice engineers. The manufacturer has a customer service department speciallytrained for these tasks. To provide targeted and rapid response to faults, the following details are useful andimportant to provide for the customer service department:-Truck serial number-Display unit error number (if present)-Error description-Current location of truck.

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F 1

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F Industrial Truck Maintenance

1 Operational safety and environmental protection

The servicing and inspection duties contained in this chapter must be performed inaccordance with the intervals indicated in the maintenance checklists.

F Any modification to the forklift truck assemblies, in particular the safety mechanisms,is prohibited. The operational speeds of the truck must not be changed under anycircumstances.

M Only original spare parts have been certified by our quality assurance department. Toensure safe and reliable operation of the forklift truck, use only the manufacturer'sspare parts. Used parts, oils and fuels must be disposed of in accordance with therelevant environmental protection regulations. For oil changes, contact themanufacturer’s specialist department.

Upon completion of inspection and servicing, the tasks contained in the“Recommissioning” section must be performed (see chapter F).

M In the event of irregularites in the truck’s traction and operating qualities, inform themanufacturer’s service department immediately.

2 Maintenance Safety Regulations

Maintenance personnel: Industrial trucks must only be serviced and maintained bythe manufacturer’s trained personnel. The manufacturer’s service department hasfield technicians specially trained for these tasks. We therefore recommend amaintenance contract with the manufacturer’s local service centre.

Lifting and jacking up: When an industrial truck is to be lifted, the lifting gear mustonly be secured to the points specially provided for this purpose. When jacking up thetruck, take appropriate measures to prevent the truck from slipping or tipping over(e.g. wedges, wooden blocks). You may only work underneath a raised load handlerif it is supported by a sufficiently strong chain.

Z Jacking point see chapter B.

Cleaning: Do not use flammable liquids to clean the industrial truck. Prior to cleaning,implement all necessary safety measures to prevent sparking (e.g. through shortcircuits). For battery-operated trucks, the battery connector must be removed. Onlyweak suction or compressed air and non-conductive antistatic brushes may be usedfor cleaning electric or electronic assemblies.

M If the truck is to be cleaned with a water jet or a high-pressure cleaner, all electricaland electronic components must be carefully covered beforehand as moisture cancause malfunctions.Do not clean with pressurised water.

After cleaning the truck, carry out the activities detailed in the “Recommissioning”section.

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F 2

Electrical System: Only suitably trained personnel may operate on the truck’selectrical system. Before working on the electrical system, take all precautionarymeasures to avoid electric shocks.

Welding: To avoid damaging electric or electronic components, remove these fromthe truck before performing welding operations.

Settings: When repairing or replacing hydraulic, electric or electronic components orassemblies, always note the truck-specific settings.

Tyres: The quality of tyres affects the stability and performance of the truck. Whenreplacing tyres fitted at the factory, only use the manufacturer’s original spare parts.Otherwise the data sheet specifications of the truck cannot be guaranteed. Whenchanging wheels and tyres, ensure that the truck does not slew (e.g. when replacingwheels always left and right simultaneously).

Lift chains: Lift chains wear rapidly if not lubricated. The intervals stated in theservice checklist apply to normal duty use. More demanding conditions (dust,temperature) require more regular lubrication. The prescribed chain spray must beused in accordance with the instructions. Applying grease externally will not providesufficient lubrication.

Hydraulic hoses: The hoses must be replaced every six years. When replacinghydraulic components, also replace the hoses in the hydraulic system.

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3 Servicing and inspection

Thorough and expert servicing is one of the most important requirements for the safeoperation of the industrial truck. Failure to perform regular servicing can lead to truckfailure and poses a potential hazard to personnel and equipment.

M The application conditions of an industrial truck considerably affect the wear levels ofthe service components. We recommend an application analysis carried out on site by a Jungheinrichcustomer adviser to establish specific maintenance intervals in order to restrictdamage caused by wear.The service intervals stated are based on single shift operation under normaloperating conditions. They must be reduced accordingly if the truck is to be used inconditions of extreme dust, temperature fluctuations or multiple shifts.

The following maintenance checklist states the tasks and intervals after which theyshould be carried out. Maintenance intervals are defined as:

W = Every 50 service hours, at least weeklyA = Every 500 service hours, or at least every six monthsB = Every 1000 service hours, or at least annually.C = Every 2000 service hours, or at least annually.

Z W service intervals are to be performed by the customer.

During the run-in period – after approx. 100 service hours – the owner must checkthe wheel nuts/bolts and re-tighten if necessary.

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4 DFG/TFG maintenance checklist

Maintenance intervals

Standard = t W A B C

Brakes 1.1 Check effectiveness of operating and parking brakes,adjust where necessary and measure braking distance.

t

1.2 Check brake lining wear and check brake drum diameter t

1.3 Check brake fluid level in container and top up ifnecessary

t

1.4 Change brake fluid annually, bleed the system ifrequired

t

1.5 Check connections and lines for leaks t

1.6 Check brake mechanism, adjust and lubricate ifnecessary

t

Electrics 2.1 Test operation of instruments, displays and controlswitches

t

2.2 Test warning and safety devices t

2.3 Check fuse ratings t

2.4 Make sure wire connections are secure and check fordamage

t

2.5 Test lighting t

2.6 Test micro switch setting t

2.7 Test relay t

Power supply 3.1 Visually inspect battery t

3.2 Check battery connections are secure, grease terminalsif necessary.

t

3.3 Check acid density, acid level and battery voltage t

Truck Design 4.1 Check mast attachment t

4.2 Check chassis for damage. t

4.3 Check the counterweight is secure. t

4.4 Check the overhead guard / cabin for damage. t

4.5 Check driver’s seat and restraint system t

4.6 Check labels t

4.7 Check trailer coupling / tow mechanism t

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Maintenance intervals

Standard = t W A B C

Hydraulicoperation

5.1 Check mast bearings t

5.2 Check setting of slide pieces and stops, and adjust ifnecessary

t

5.3 Visually inspect the mast rollers and check contactsurface wear level

t

5.4 Check lateral clearance of mast connections and of forkcarriage

t

5.5 Check load chain setting and tighten if necessary t

5.6 Check forks and fork carriage for wear and damage t

5.7 Check mast tilt angle t

5.8 Check position of tilt cylinder, check piston head jam nutis secure and tighten if necessary

t

5.9 Test hydraulic system operation t

5.10 Check that hose and pipe lines and their connectionsare secure, check for leaks and damage, and tightenconnections if necessary.

t

5.11 Check cylinders and piston rods for damage and leaks,and make sure they are secure

t

5.12 Check hydraulic oil level and top up if necessary t

5.13 Replace hydraulic oil (this may have to be performed viaa specialist environmental service truck)

t

5.14 Replace the hydraulic oil filter t

5.15 Replace hydraulic reservoir discharge paper filter t

5.16 Check attachments and auxiliary equipment are secure,test operation and check for damage

t

Sign off/Demonstra-tion

6.1 Lubricate truck in accordance with LubricationSchedule.

t

6.2 Test run t

6.3 Demonstration after servicing t

Steeringsystem

7.1 Test steering t

7.2 Check mechanical parts of steering column t

7.3 Check steering axle and steering knuckle for wear anddamage

t

Fitting times 8.1 Enable servicing and inspection by removing/assembling panels and covers.

t

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5 DFG maintenance checklist

Maintenance intervals

Standard = t W A B C

Travel 7.1 Check engine for noise and leaks t

7.2 Check engine oil level, top up if necessary t t

7.3 Replace engine oil t

7.4 Replace engine oil filter t

7.5 Check valve play, adjust if necessary t

7.6 Test glow plugs, electric t

7.7 Check V belt for tension and damage t

7.8 Check maximum speed (without load), adjust ifnecessary

t

7.9 Check coolant level, top up if necessary t t

7.10 Add anti-freeze to coolant t

7.11 Test anti-freeze, top up if necessary t

7.12 Test water pump and fan t

7.13 Check radiator and clean if necessary t t

7.14 Test starter and generator t

7.15 Check exhaust system for leaks and damage t

7.16 Clean the air filter cartridge t

7.17 Replace air filter cartridge t

7.18 Replace fuel filter t

7.19 Check the fuel/water separator, and discharge ifnecessary

t

7.20 Check fuel tank and lines for leaks and damage t

7.21 Check transmission for noise and leakage t

7.22 Check travel mechanism, adjust and lubricate ifnecessary

t

7.23 Check transmission oil level, top up if necessary t

7.24 Replace transmission oil t

7.25 Clean transmission oil suction filter and discharge t

7.26 Replace transmission oil filter t

7.27 Check drive axle for noise and leakage t

7.28 Check drive axle oil level and top up if necessary t

7.29 Replace drive axle oil t

7.30 Check wheels for wear and damage t

7.31 Check wheel bearings and attachments t

7.32 Check tyre air pressure, adjust if necessary t t

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6 TFG maintenance checklist

Maintenance intervals

Standard = t W A B C

Travel 8.1 Check engine for noise and leaks t

8.2 Replace spark plugs t

8.3 Check ignition system and ignition point t

8.4 Check valve play, adjust if necessary t

8.5 Check engine oil level, top up if necessary t t

8.6 Replace engine oil t

8.7 Replace engine oil filter t

8.8 Check V belt for tension and damage t

8.9 Check maximum speed (without load), adjust ifnecessary

t

8.10 Check coolant level, top up if necessary t t

8.11 Add anti-freeze to coolant t

8.12 Test anti-freeze, top up if necessary t

8.13 Test water pump and fan t

8.14 Check radiator and clean if necessary t t

8.15 Test starter and generator t

8.16 Check exhaust system for leaks and damage t

8.17 Check exhaust levels, adjust if necessary t

8.18 Clean the air filter cartridge t

8.19 Replace air filter cartridge t

8.20 Test LPG system, check for leaks and damage (to beperformed by authorised specialist personnel)

t

8.21 Clean LPG filter (to be performed by authorisedspecialist personnel)

t

8.22 Check transmission for noise and leakage t

8.23 Check travel mechanism, adjust and lubricate ifnecessary

t

8.24 Check transmission oil level, top up if necessary t

8.25 Replace transmission oil t

8.26 Clean transmission oil suction filter and discharge t

8.27 Replace transmission oil filter t

8.28 Check drive axle for noise and leakage t

8.29 Check drive axle oil level and top up if necessary t

8.30 Replace drive axle oil t

8.31 Check wheels for wear and damage t

8.32 Check wheel suspension and attachments t

8.33 Check tyre air pressure, adjust if necessary t t

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7 Coolant specification

The quality of the coolant has a considerable effect on the efficiency and useful life ofthe cooling system. The following instructions are designed to provide the bestservicing in terms of frost and corrosion protection.

– Always use clean, soft water.

– To avoid frost and corrosion damage use an ethylene-glycol based anti-freezemixture. Use a standard anti-freeze with a pH value of 7.0 – 8.5.

– Make sure the mixture ratio is correct when using an anit-freeze. The frostprotection level must satisfy the above standard.

The manufacturer cannot be held liable for frost or corrosion damage caused byincorrect procedures.

F The anti-freeze contains ethylene-glycol and other poisonous substances. Ingressioninto the human body can result if large quantities come into contact with the skin forlong or repeated periods.

U.S.A. ASTM D4985 or SAE J1941 Ethylene-glycol based engine coolant

Lowest temperaturerequired for protection

% volume of anti-freeze Volume ratiosanti-freeze :water

-37 °C 50 1:1

F 9

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– NEVER swallow anti-freeze. If anti-freeze is accidentally swallowed, seekIMMEDIATE medical attention.

– Avoid prolonged skin contact with anti-freeze.

– Wipe off spray from the skin immediately.

– If anti-freeze is sprayed into the eyes, rinse them immediately.

– Clothing sprayed with anti-freeze must be removed and washed before being wornagain.

– Wear protective clothing if you are regularly handling anti-freeze (plastic or rubbergloves, boots and non-permeable overalls or aprons).

F Anti-corrosion solutions contain additives which are poisonous if swallowed andwhich can be absorbed in poisonous quantities through persistent, repeated contactwith the skin. Observe the same safety precautions as for anti-freeze.

8 DFG fuel specifications

Only use DIN 51601 compliant diesel.

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9 Lubrication schedule

g Contact surfaces b Transmission oil filler neck

s Grease nipple a Transmission oil drain plug

Hydraulic oil filler neck tMineral oil filler neck for brake system

c Hydraulic oil drain plug K Oil dipstick

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9.1 Fuels, coolants and lubricants

Handling consumables: Consumables must always be handled correctly. Followthe manufacturer’s instructions.

F Improper handling is hazardous to health, life and the environment. Consumablesmust only be stored in appropriate containers. They may be flammable and musttherefore not come into contact with hot components or naked flames.

Only use clean containers when filling up with consumables. Do not mix consumablesof different grades. The only exception to this is when mixing is expressly stipulatedin the Operating Instructions.

Spilled liquids must be removed immediately with suitable bonding agents and thebonding agent / consumable mixture must be disposed of in accordance withregulations..

Grease guidelines

Order no. Quantity Description Used for

A 52017728 55 l HVLP46 Hydraulic system

D 00002832 0.25 lBrake fluidSAE J 1703

Brake system

E 50055726 K-P-2K grease

G 29201280 Chain spray Chains

N 05099205 11 l ATF Dexron II D Transmission

52030273 10 lTitan Supergear 80W-90

Axle

520177278l (DFG)

4l (TFG)

Titan Unic Plus

10W-40Engine oil

Code Saponification Dew point °C

Workedpenetration at 25°

C

NLG1 class Application temperature °C

E Lithium 185 265-295 2 -35/+120

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10 Maintenance and Repairs

10.1 Preparing the truck for maintenance and repairs

All necessary safety measures must be taken to avoid accidents when carrying outmaintenance and repairs. The following preparations must be made:

– Park the truck securely (see Chapter E).

– Pull the key out of the ignition/starterswitch (1) to prevent the truck frombeing switched on accidentally.

– When working under a raised load forkor a raised truck, secure them toprevent them from lowering, tipping orsliding away.

F Note the following when raising theforklift truck:

M Only use lifting gear with sufficient capacity (for transport weight see truck data plate).

– Park the truck securely (see Chapter E).

– Attach crane slings to the mast at the appropriate points.

– Attach the crane slings to the counterweight of the trailer coupling.

M Lifting slings should be fastened to the harness in such a way that they do not comeinto contact with any attachments or the overhead guard when it is being raised.

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10.2 Engine cover

Z Before opening the engine cover thesteering column and the steering columnadjustment lever (2) must be pushedforward fully.Push the driver’s seat forward. The stop bolt on the left hand seat guiderail should engage facing up.

– Press the pushbutton in the legcompartment and raise the enginecover (3) slightly.

– Fully raise the engine cover (3). A gaspressure damper keeps the enginecover in the raised position.

M If a forklift truck is equipped with a steel cabin, both cabin doors and the rear windowmust be opened before raising the engine cover.

When you close the engine cover, pull the stop bolt down and push the driver’s seatback again.

M Make sure the engine cover has engaged correctly before operating the truck again.

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10.3 Servicing the engine DFG

Checking the engine oil - DFG

– Remove the dipstick (4).

– Wipe the dipstick with a lint-free clothand put in back fully into its port.

– Remove the dipstick again and checkwhether the oil level is between theMIN and MAX markings.

– If the oil level is below the centre point,remove the fuel cap (5) and add thecorrect grade of oil to the engine untilthe oil level has reached the MAXmark on the dipstick.

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M Only change the engine oil when theengine is at operating temperature andthe truck is horizontal. Always replacethe engine oil and engine oil filtertogether.

Draining the engine oil

– Unscrew the (6) lid.

– Thoroughly clean the oil drain plug (7)and around the drain hole.

– Unscrew the oil drain plug and drainthe oil into a suitable container.

F Risk of scalding through hot oil.

– Screw in the oil drain plug with a newseal.

F Dispose of used oil in accordance withenvironmental regulations.

Replacing the engine oil filter

– Undo the hose clamp (10) from thehose (9).

– Pull off the hose.

– Undo the air filter attachment (11) andplace the air filter to one side.

– Undo the oil filter (8) with a filterwrench and manually unscrew it.

F Collect any emerging oil and dispose ofthe oil and oil filter in accordance withenvironmental regulations.

– Thoroughly clean the raised faces ofthe oil filter flange.

– Apply a thin layer of fresh engine oil to the seal of the new oil filter.

– Hand-tighten the oil filter.

– Fit the air filter, insert the hoses and tighten with hose clamps.

2

4 3

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Adding engine oil

– Add fresh engine oil through the fillerport (6) in accordance with theconsumables table.

Capacity: 8.0 l

– Check the engine oil level with thedipstick (12) and adjust as necessary.

– Screw the lid (6) back on.

– Insert the dipstick (12) back fully.

M After changing the oil and the oil filter,note the engine oil pressure indicator(13) when you run the engine again andcheck the oil drain plug and oil filter aresealed.

Checking the V belt tension

– Insert the V belt between the fan V beltpulley and the generator V belt pulleyusing a force of 45 N.

It should be possible to insert the V beltafter approx. 10 mm.

Adjusting the V belt tension

– Undo the screw (14) and pull the ACgenerator until the prescribed V belttension has been reached.Tighten thescrews again.

– Check the V belt tension again andrepeat the adjustment if necessary.

9

2

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F 17

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Drain the fuel from the filter into asuitable container.

Undo the fuel filter (17) with a filterwrench and manually unscrew it.

F Dispose of the fuel filter and fuel inaccordance with environmentalregulations.

– Screw the fuel filter with a new O ringinto the new fuel filter.

– Before assembling, apply a thin layerof diesel to the O ring.

– Thoroughly clean the raised faces ofthe filter flange.

– Apply a thin layer of diesel to the sealof the new fuel filter.

– Manually screw in the fuel filter until the seal contacts the filter flange.

– Tighten the fuel filter another third of a turn.

– Bleed the fuel system

Bleeding the fuel system

F Collect any emerging fuel and dispose of it in accordance with environmentalregulations.

– Open the discharge screw (16).

– Apply the manual pump lever on the fuel pump (15) until fuel escapes from thedischarge screw without bubbles.

– Tighten the discharge screw.

– Set the ignition / starter key to the I position for approx. 10 seconds.

– Wait for 10 seconds.

– Repeat the process until the engine starts up.

M While running the engine check the fuel filter, the discharge valve and the union nutsof the injection nozzles for leaks.

Z If the engine does not start up or stops after a short time, repeat the bleedingprocedure.

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10.4 Engine servicing TFG

Checking the engine oil - TFG

– Remove the dipstick (19).

– Wipe the dipstick with a lint-free clothand put in back fully into its port.

– Remove the dipstick again and checkwhether the oil level is between theMIN and MAX markings.

– If the oil level is below the centre point,remove the fuel cap (18) and add thecorrect grade of oil to the engine untilthe oil level has reached the MAXmark on the dipstick.

Replacing the engine oil and engineoil filter

Only change the engine oil when theengine is at operating temperature andthe truck is horizontal. Always replacethe engine oil and engine oil filtertogether.

Draining the engine oil

– Unscrew the (18) lid.

– Thoroughly clean the oil drain plug(21) and around the drain hole.

– Unscrew the oil drain plug and drainthe oil into a suitable container.

F Risk of scalding through hot oil.

– Screw in the oil drain plug with a new seal.

F Dispose of used oil in accordance with environmental regulations.

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20

21

18

F 19

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– Undo the oil filter (20) with a filter wrench and manually unscrew it.

F Collect any emerging oil and dispose of the oil and oil filter in accordance withenvironmental regulations.

– Thoroughly clean the raised faces of the oil filter flange.

– Apply a thin layer of fresh engine oil to the seal of the new oil filter.

– Hand-tighten the oil filter.

Adding engine oil

– Add fresh engine oil through the filler port in accordance with the consumablestable (see Section 9.1).

Capacity: 4.0 l

– Check the engine oil level with thedipstick (19) and adjust as necessary..

– Screw the lid back on.

– Insert the dipstick back fully.

M After changing the oil and the oil filter,note the engine oil pressure indicator(22) when running the engine again andcheck the oil drain plug and oil filter aresealed.

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Replacing spark plugs

– Remove spark plug connector (23) .

– Thoroughly clean around the sparkplugs on the cylinder head.

– Unscrew the spark plugs.

– Check the electrode distance of thenew spark plugs with a feeler gauge,and adjust as required.

Rated value: 1.0 mm

M Only use original spark plugs.

– Manually screw in the spark plugs and then torque them to 20 Nm.

Checking the V belt tension

– Insert the V belt between the fan V belt pulley and the generator V belt pulley usinga force of 45 N.

It should be possible to insert the V belt after approx. 11 mm.

Adjusting the V belt tension

– Undo the screws (24) and pull the ACgenerator until you reach theprescribed V belt tension.

– Re-tighten the screws.

Check the V belt tension again andrepeat the adjustment if necessary.

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10.5 Check the hydraulic oil level

If the oil is cold

– Fully raise and lower the mast in oneoperation.

– Stop the engine.

– Remove the dipstick (25) and clean itwith a clean cloth. Check the hydraulicoil level. It should lie between the MINand MAX markings on the dipstick. Ifnecessary, top up to the MIN markingon the dipstick.

If the oil is hot

– Fully raise and lower the mast in oneoperation.

– Stop the engine.

– Remove the dipstick (25) and clean itwith a clean cloth. Check the hydraulicoil level. It should lie just above theMAX marking on the dipstick. Ifnecessary, top up to just above theMAX marking on the dipstick.

If the engine cuts out or does not run smoothly when the mast is raise, the mast mustbe gently lowered before continuing with this procedure.

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10.6 Gas system drain tap

Z The gas system drain tap must always be closed during operation (it should only beopened by service personnel for maintenance purposes).

F If the drain is opened gas may escape!

Drain open

Drain closed

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10.7 Checking the coolant level

– Open the cover lock and turn it to the right

– Remove the cover

– Check the coolant level on thereservoir.

The coolant should lie between theMIN and MAX markings (26).

M If the coolant is below the MINmarking, this indicates possibleleakage in the radiator system. Thetruck must only be used once thecause has been removed.

F If the engine is hot, the radiatorsystem is pressurised. Only openthe expansion vessel (27) lid whenthe engine has cooled down.

When topping up, add a premixed water and antifreeze solution in equal quantitiesinto the existing solution.

It should be possible to empty the system by opening the drain taps in the radiatorand on the side of the cylinder block. The drain plugs may be made of brass. Whendraining, remove the expansion vessel lid and lay it on the driver's seat as an indicatorthat the engine does not contain any coolant.

For details on recommended concentrations and safety measures, refer to Chapter F.

10.8 Checking the coolant concentration

F Do not open the radiator lid whenthe engine is hot.

To prevent the build up of lime aswell as front and corrosiondamage, and to raise the boilingpoint temperature, the coolingcircuit must be filled each year witha mixture of water and anti-freezewith anti-corrosion additives.

– If there is insufficient anti-freeze,drain the coolant and add anti-freeze to the reservoir (28) untilyou obtain the correct proportionin the mixture.

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F 24

M Use anti-freeze in accordance with the coolant specifications (see section 7).

The water/anti-freeze mixture proportion and the degree of frost protection to beachieved can be taken from the anti-freeze specifications.

Cooling circuit capacity:

DFG/TFG: 14.0 l

10.9 Filling the cooling circuit

F Leave the engine to cool down in order to fill it with coolant. Slowly open the lid;dangerously hot coolant can escape if the coolant circuit is still pressurized. Do notadd too much coolant to the circuit. The lid contains a safety valve which opens to lethot coolant dissipate if the fluid level is too high.

M If coolant is added in the course of servicing, it must meet the specifications of theoriginal fluid (see Section 7). If you add coolant too quickly or if the truck is nothorizontal, air will enter the cooling circuit. Running the engine with air in the coolantcircuit will result in excessive operating temperatures and can damage the engine.

M The truck must be horizontal. Slowly open the reservoir lid. Using a funnel, slowly fillthe coolant circuit to the level indicated in the manufacturer's manual. The funnel willcreate the pressure required to force air out of the coolant circuit. Wait until all the airbubbles have escaped and then refit the lid. Start the engine. Switch off the enginewhen it reaches operating temperature and then let it cool down. Slowly open thereservoir lid and if necessary add coolant in accordance with the manual instructionsuntil you obtain the correct level. Refit the lid.

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10.10 Cleaning/replacing the air filter cartridge

M Carry out all maintenance work with theengine switched off. Do not start theengine if the air filter cartridge isremoved.

– Undo the quick release lock (29) andlift it up.

– Raise the air filter housing.

– Undo the 2 mounting clamps (30) andremove the dust collector pot.

– Carefully remove the internal andexternal air filter cartridges from thefilter housing.

– Apply dry compressed air from theinside of the external cartridge to theoutside until no more dust emerges.

– Carefully wipe the internal cartridgewith a lint-free cloth.

M Do not apply compressed air to the filter housing, instead wipe with a clean cloth.

– Replace any damaged or heavily contaminated air filter cartridges.

– Thoroughly clean the dust collector pot, to do this remove the rubber element.

– Insert the air filter cartridges back in the filter housing and secure them.

M Take care not to damage the air filter cartridges when assembling.

– Insert the dust collector pot and secure it with the 2 mounting clamps (30).

– Fit the air filter housing in the assembly position.

– Close the quick release lock (29).

29

30

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10.11 DFG/TFG transmission:

M It is important to check the oil level correctly. The oil is a lubricant which also acts asa coolant and operates the clutches. A low oil level will result in loss of transmissionand pressure. It also causes overheating and resultant transmission failure.

Checking the transmission oil level

Z Only use clean, fresh oil from cleancontainers to fill or top up thetransmission. Damage will arise fromcontamination or water entering thetransmission.

You access the transmission oil dipstickon the right-hand side of thetransmission (looking in the direction oftravel).

– Start the engine and with the parkingbrake applied, first engage forward gear followed by reverse and wait until thetransmission has reached operating temperature.

– When the engine is running in idle, remove the dipstick (32).

– Wipe the dipstick with a lint-free cloth and put in back fully into its port.

– Remove the dipstick again and check whether the oil level is between the MIN andMAX markings.

– If the level is below the centre point, add the right grade of transmission oil throughthe filler port (31) into the transmission unit, until it reaches the MAX marking on thedipstick.

– Refit the dipstick in the port.

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10.12 Brake

Checking the parking brake

The parking brake (33) must be able tokeep the truck plus maximumpermissible load on an incline of 15%. Ifthis is not the case, the parking brakemust be adjusted.

Checking the brake fluid level

– Undo the screws of the left-hand panel(34).

– Remove the left-handpanel (34).

– Check the brake fluid level in the brakefluid reservoir (35).

The level of the reservoir should liebetween the MIN and MAX markings .

– If necessary, add brake fluid.

Level: 0.25 l

– After adding brake fluid, refit thepanel.

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26

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10.13 Checking the wheel attachments.

– Park the truck securely (see Chapter E).

– Tighten the wheel nuts (36) crosswise with atorque wrench.

Torque

Drive wheels: 200 Nm

Rear wheels: 200 Nm

10.14 Hydraulic system

Replacing the hydraulic oil filter

– Unscrew the lid (37).

– Remove the hydraulic oil filterintegrated in the lid.

– Insert a new hydraulic oil filter andscrew the lid back on.

F Collect any spilled hydraulic oil. Disposeof the hydraulic oil and hydraulic oil filterin accordance with environmentalregulations.

10.15 Clean/replace hydraulic reservoir

– Unscrew the hydraulic reservoir lid (37).

– Lift up the cap (38).

– Remove the filter insert form under the cap.

– Clean the filter insert.

M If the contamination cannot be removed by cleaning, replace the filter insert.

36

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10.16 Electrical System

Checking the battery condition, the acid level and acid density

F Battery acid is highly corrosive. Therefore it is essential to avoid contact with batteryacid. If clothing, skin or eyes have nevertheless come into contact with battery acid,immediately rinse the affected parts with water. If the eyes have been affected,immediately seek medical attention. Neutralise spilled battery acid immediately.

– Check the battery housing for cracks and any spilled acid.

– Remove any oxydation remains from the battery terminals.

– Lubricate the battery terminals with an acid-free grease.

– Check the acid level.

The acid should lie between the top and bottom markings.

– Clean the area around the inspection plugs.

– Unscrew the inspection plugs.

– If necessary, add distilled water to the top mark.

– Check the acid density.

If the battery is charged sufficiently, the acid density should be 1.24 to 1.28 kg/l.

– If necessary, re-charge the battery.

– Screw the inspection plugs back on.

Z It is not necessary to check the acid level or the acid density in batteries with lowmaintenance requirements.

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Checking electrical fuses

– Prepare the truck for maintenance and repair work (see “Preparing the Truck forMaintenance and Repairs” in this chapter)

– for rear mounted fuses, open the rear panel lock and turn it to the right

– Remove the panel

– Check the fuse rating and condition in accordance with the table; replace ifnecessary.

– Fit the panels.

t Standard fuse box (DFG)

t Standard fuse box (TFG)

Item Ref. To protect: Value

39 2F14 Pre-heat relay, diesel valve 5 A

40 4F1 Air filter control, travel direction valves, seat switch, horn 10 A

41 7F5 Diesel filter control, brake fluid control, handbrake control 5 A

42 4F8 Display unit 5 A

43 F19 12 volt system 10 A

44 9F7 Ignition option relay 10 A

Item Ref. To protect: Value

39 2F14 Gas valve, ignition distributor 5 A

40 4F1 Air filter control, travel direction valves, seat switch, horn 10 A

41 7F5 Brake fluid control, handbrake control 5 A

42 4F8 Display unit 5 A

43 F19 12 volt system 10 A

44 9F7 Ignition option relay 10 A

5152

5354

55

5657

5859

60

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TFG main current

o Fuse box for optional equipment (DFG/TFG)

F To avoid damaging the electrical system, only use fuses with the correct ratings.

Item Ref. To protect: Rating

55 9F11 Preheat fuse 70 A

56 9F8 Engine running option relay 50 A

57 9F7 Ignition on options relay 50 A

58 9F16 Key switch 20 A

59 9F17 Pre-fuse for F19 20 A

60 9F1950A-Generator 50 A

80A-Generator 70 A

Item Ref. To protect: Rating

51 9F8 Engine running option relay 50 A

52 9F7 Ignition on options relay 50 A

53 9F16 Key switch 20 A

54 9F17 Pre-fuse for F19 20 A

60 9F1950A-Generator 50 A

80A-Generator 70 A

Item Ref. To protect: Rating

45 4F4 Beacon 7.5 A

46 9F1 Windscreen wiper 7.5 A

47 5F6 Cab 15 A

48 5F1 Searchlights 25 A

49 5F3 Reversing lights 10 A

50 5F5.2 Road traffic regulations parking light 15 A

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11 Exhaust system

The exhaust system must be checked for emissions at regular intervals. Black or blueexhaust is a sign of high emission levels and requires the attention of specialistpersonnel.

Soot filter servicing in accordance with manufacturer’s instructions.

12 Restoring the truck to service after cleaning or repairs

The truck may only be restored to service after cleaning or repair work, once thefollowing operations have been performed.

– Test horn.

– Test main switch operation.

– Test brakes.

– Lubricate the truck in accordance with the lubrication schedule.

13 Decommissioning the industrial truck

If the industrial truck is to be decommissioned for more than two months, e.g. foroperational reasons, it must be parked in a frost-free and dry location and allnecessary measures must be taken before, during and after decommissioning asdescribed.

M On decommissioning the truck must be jacked up so that all the wheels are clear ofthe ground. This is the only way of ensuring that the wheels and wheel bearings arenot damaged.

If the truck is to be out of service for more than 6 months, further measures must betaken in consultation with the manufacturer’s service department.

13.1 Prior to decommissioning:

– Thoroughly clean the truck.

– Check the brakes.

– Check the hydraulic oil level and replenish as necessary (see Chapter F).

– Apply a thin layer of oil or grease to any non-painted mechanical components.

– Lubricate the truck in accordance with the lubrication schedule (see Chapter F).

– Charge the battery.

– Disconnect the battery, clean it and grease the terminals.

Z In addition, follow the battery manufacturer’s instructions.

– Spay all exposed electrical contacts with a suitable contact spray.

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13.2 During decommissioning:

Every 2 months:

– Charge the battery.

13.3 Returning the truck to operation after decommissioning

Z It is advisable to have the truck restored to service after decommissioning by anengineer of the manufacturer.

– Thoroughly clean the truck.

– Lubricate the truck in accordance with the lubrication schedule (see Chapter F).

– Clean the battery, grease the terminals and connect the battery.

– Charge the battery.

– Check transmission oil for condensed water and replace if necessary.

– Check hydraulic oil for condensed water and replace if necessary.

– Start up the truck (see Chapter E).

F Perform several brake tests immediately after re-commissioning the truck.

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14 Safety checks to be performed at regular intervals and following any unusualincidents (D: Accident prevention check according to BGV D27

The truck must be inspected at least annually or after any unusual event by a qualifiedinspector. The inspector shall assess the condition of the truck from purely a safetyviewpoint, without regard to operational or economic circumstances. The inspectorshall be sufficiently instructed and experienced to be able to assess the condition ofthe truck and the effectiveness of the safety mechanisms based on the technicalregulations and principles governing the inspection of forklift trucks.

A thorough test of the truck must be undertaken with regard to its technical conditionfrom a safety aspect. The truck must also be examined for damage caused bypossible improper use. A test report shall be provided. The test results must be keptfor at least the next 2 inspections.

The owner is responsible for ensuring that faults are immediately rectified.

Z The manufacturer has a safety department with trained personnel to carry outinspections. A test plate is attached to the truck as proof that it has passed the safetyinspection. This plate indicates the due date for the next inspection.

15 Final de-commissioning, disposal

Z Final, proper decommissioning or disposal of the truck must be performed inaccordance with the regulations of the country of application. In particular, regulationsgoverning the disposal of batteries, fuels and electronic and electrical systems mustbe observed.