DFG / TFG 540 - 550 11.

09 -

Operating instructions G
51167690
08.12 DFG 540
DFG 545
DFG 550
TFG 540
TFG 545
TFG 550
 Declaration of Conformity Declaration of Conformity

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

Type Option Serial no. Year of Type Option Serial no. Year of
manufacture manufacture
DFG 540 DFG 540
DFG 545 DFG 545
DFG 550 DFG 550
TFG 540 TFG 540
TFG 545 TFG 545
TFG 550 TFG 550

Additional information Additional information

On behalf of On behalf of

Date Date

G EU Conformity Declaration G EU Conformity Declaration

The undersigned hereby declare that the powered industrial truck described below in
detail complies with the European Directives 2006/42/EC (Machinery Directive) and
2004/108/EEC (Electromagnetic Compatibility - EMC) including amendments as well
as the legislative decree to incorporate the directives in national law. The signatories
are in each case individually authorized to compile the technical documents.
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The undersigned hereby declare that the powered industrial truck described below in
detail complies with the European Directives 2006/42/EC (Machinery Directive) and
2004/108/EEC (Electromagnetic Compatibility - EMC) including amendments as well
as the legislative decree to incorporate the directives in national law. The signatories
are in each case individually authorized to compile the technical documents.

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 Foreword Foreword
Notes on the operating instructions Notes on the operating instructions
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide
sufficient instruction for the safe operation of the industrial truck. The information is sufficient instruction for the safe operation of the industrial truck. The information is
provided clearly and concisely. The chapters are arranged by letter and the pages are provided clearly and concisely. The chapters are arranged by letter and the pages are
numbered continuously. numbered continuously.

The operator manual details different industrial truck models. When operating and The operator manual details different industrial truck models. When operating and
servicing the industrial truck, make sure that the particular section applies to your servicing the industrial truck, make sure that the particular section applies to your
truck model. truck model.

Our trucks are subject to ongoing development. Jungheinrich reserves the right to Our trucks are subject to ongoing development. Jungheinrich reserves the right to
alter the design, equipment and technical features of the system. No guarantee of alter the design, equipment and technical features of the system. No guarantee of
particular features of the truck should therefore be assumed from the present particular features of the truck should therefore be assumed from the present
operating instructions. operating instructions.

Safety notices and text mark-ups Safety notices and text mark-ups
Safety instructions and important explanations are indicated by the following Safety instructions and important explanations are indicated by the following
graphics: graphics:

DANGER! DANGER!

Indicates an extremely hazardous situation. Failure to comply with this instruction will Indicates an extremely hazardous situation. Failure to comply with this instruction will
result in severe irreparable injury and even death. result in severe irreparable injury and even death.

WARNING! WARNING!

Indicates an extremely hazardous situation. Failure to comply with this instruction Indicates an extremely hazardous situation. Failure to comply with this instruction
may result in severe irreparable injury and even death. may result in severe irreparable injury and even death.

CAUTION! CAUTION!

Indicates a hazardous situation. Failure to comply with this instruction may result in Indicates a hazardous situation. Failure to comply with this instruction may result in
slight to medium injury. slight to medium injury.

NOTE NOTE
Indicates a material hazard. Failure to comply with this instruction may result in Indicates a material hazard. Failure to comply with this instruction may result in
material damage. material damage.

Z Used before notices and explanations. Z Used before notices and explanations.

t Indicates standard equipment t Indicates standard equipment

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

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 Jungheinrich Aktiengesellschaft Jungheinrich Aktiengesellschaft
Am Stadtrand 35 Am Stadtrand 35
22047 Hamburg - Germany 22047 Hamburg - Germany

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

www.jungheinrich.com www.jungheinrich.com

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 Contents Contents

A Correct Use and Application ................................................... 11 A Correct Use and Application ................................................... 11
1 General.................................................................................................... 11 1 General.................................................................................................... 11
2 Correct application................................................................................... 11 2 Correct application................................................................................... 11
3 Approved application conditions .............................................................. 12 3 Approved application conditions .............................................................. 12
4 Proprietor responsibilities ........................................................................ 13 4 Proprietor responsibilities ........................................................................ 13
5 Adding attachments and/or accessories.................................................. 13 5 Adding attachments and/or accessories.................................................. 13

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

1 Application ............................................................................................... 15 1 Application ............................................................................................... 15
1.1 Truck models and rated capacity............................................................. 15 1.1 Truck models and rated capacity............................................................. 15
2 Assemblies and Functional Description................................................... 16 2 Assemblies and Functional Description................................................... 16
2.1 Assembly Overview ................................................................................. 16 2.1 Assembly Overview ................................................................................. 16
2.2 Functional Description ............................................................................. 17 2.2 Functional Description ............................................................................. 17
3 Technical Specifications .......................................................................... 19 3 Technical Specifications .......................................................................... 19
3.1 Performance data .................................................................................... 19 3.1 Performance data .................................................................................... 19
3.2 Dimensions.............................................................................................. 21 3.2 Dimensions.............................................................................................. 21
3.3 Weights.................................................................................................... 23 3.3 Weights.................................................................................................... 23
3.4 Mast versions .......................................................................................... 24 3.4 Mast versions .......................................................................................... 24
3.5 Tyre type.................................................................................................. 26 3.5 Tyre type.................................................................................................. 26
3.6 Engine Data............................................................................................. 27 3.6 Engine Data............................................................................................. 27
3.7 EN norms................................................................................................. 28 3.7 EN norms................................................................................................. 28
3.8 Conditions of use..................................................................................... 29 3.8 Conditions of use..................................................................................... 29
3.9 Electrical requirements ............................................................................ 29 3.9 Electrical requirements ............................................................................ 29
4 Identification points and data plates ........................................................ 30 4 Identification points and data plates ........................................................ 30
4.1 Data plate ................................................................................................ 32 4.1 Data plate ................................................................................................ 32
4.2 Truck capacity plate................................................................................. 33 4.2 Truck capacity plate................................................................................. 33
4.3 Attachment capacity plate ....................................................................... 34 4.3 Attachment capacity plate ....................................................................... 34
5 Stability .................................................................................................... 34 5 Stability .................................................................................................... 34

C Transport and Commissioning ................................................ 35 C Transport and Commissioning ................................................ 35

1 Transport ................................................................................................. 35 1 Transport ................................................................................................. 35
2 Truck laden.............................................................................................. 35 2 Truck laden.............................................................................................. 35
2.1 Centre of gravity of the truck ................................................................... 35 2.1 Centre of gravity of the truck ................................................................... 35
2.2 Lifting the truck by crane ......................................................................... 36 2.2 Lifting the truck by crane ......................................................................... 36
2.3 Loading with another industrial truck ....................................................... 37 2.3 Loading with another industrial truck ....................................................... 37
3 Securing the truck during transport ......................................................... 38 3 Securing the truck during transport ......................................................... 38
4 Using the Truck for the First Time ........................................................... 39 4 Using the Truck for the First Time ........................................................... 39
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 D Fuelling the Truck.................................................................... 41 D Fuelling the Truck.................................................................... 41
1 General.................................................................................................... 41 1 General.................................................................................................... 41
1.1 Safety regulations for handling diesel fuel and LPG................................ 41 1.1 Safety regulations for handling diesel fuel and LPG................................ 41
1.2 LPG system relief valve........................................................................... 43 1.2 LPG system relief valve........................................................................... 43
2 Adding diesel ........................................................................................... 44 2 Adding diesel ........................................................................................... 44
2.1 Fuelling .................................................................................................... 44 2.1 Fuelling .................................................................................................... 44
2.2 Fuelling with fuel containers .................................................................... 45 2.2 Fuelling with fuel containers .................................................................... 45
3 LPG containers........................................................................................ 46 3 LPG containers........................................................................................ 46
3.1 LPG bottles.............................................................................................. 46 3.1 LPG bottles.............................................................................................. 46
3.2 Liquid gas tank ........................................................................................ 49 3.2 Liquid gas tank ........................................................................................ 49
4 Fuel level indicator................................................................................... 50 4 Fuel level indicator................................................................................... 50
4.1 Display unit .............................................................................................. 50 4.1 Display unit .............................................................................................. 50
4.2 Level indicator for LPG bottles (o).......................................................... 50 4.2 Level indicator for LPG bottles (o).......................................................... 50

E Operation ................................................................................ 51 E Operation ................................................................................ 51

1 Safety Regulations for the Operation of the Forklift Truck....................... 51 1 Safety Regulations for the Operation of the Forklift Truck....................... 51
2 Displays and Controls.............................................................................. 53 2 Displays and Controls.............................................................................. 53
2.1 Display unit .............................................................................................. 55 2.1 Display unit .............................................................................................. 55
2.2 Instrument panel switches (o) ................................................................ 57 2.2 Instrument panel switches (o) ................................................................ 57
2.3 Travel direction switch/gear selector ....................................................... 58 2.3 Travel direction switch/gear selector ....................................................... 58
3 Preparing the Truck for Operation ........................................................... 59 3 Preparing the Truck for Operation ........................................................... 59
3.1 Checks and operations to be performed before starting daily operation . 59 3.1 Checks and operations to be performed before starting daily operation . 59
3.2 Entry and exit........................................................................................... 60 3.2 Entry and exit........................................................................................... 60
3.3 Trucks with reduced headroom X (o) ..................................................... 60 3.3 Trucks with reduced headroom X (o) ..................................................... 60
3.4 Setting up the operator position............................................................... 61 3.4 Setting up the operator position............................................................... 61
3.5 Seat Belt .................................................................................................. 65 3.5 Seat Belt .................................................................................................. 65
4 Industrial Truck Operation ....................................................................... 66 4 Industrial Truck Operation ....................................................................... 66
4.1 Safety regulations for truck operation...................................................... 66 4.1 Safety regulations for truck operation...................................................... 66
4.2 Preparing the truck for operation ............................................................. 68 4.2 Preparing the truck for operation ............................................................. 68
4.3 Parking the truck securely ....................................................................... 71 4.3 Parking the truck securely ....................................................................... 71
4.4 Emergency Disconnect............................................................................ 72 4.4 Emergency Disconnect............................................................................ 72
4.5 Travel....................................................................................................... 73 4.5 Travel....................................................................................................... 73
4.6 Steering ................................................................................................... 74 4.6 Steering ................................................................................................... 74
4.7 Brakes ..................................................................................................... 75 4.7 Brakes ..................................................................................................... 75
4.8 Adjusting the forks ................................................................................... 77 4.8 Adjusting the forks ................................................................................... 77
4.9 Replacing the forks.................................................................................. 78 4.9 Replacing the forks.................................................................................. 78
4.10 Lifting, transporting and depositing loads ................................................ 79 4.10 Lifting, transporting and depositing loads ................................................ 79
4.11 Operating the lift mechanism and integrated attachments ...................... 81 4.11 Operating the lift mechanism and integrated attachments ...................... 81
4.12 Safety instructions for operating additional attachments ......................... 86 4.12 Safety instructions for operating additional attachments ......................... 86
4.13 Operating additional attachments for the SOLO-PILOT .......................... 89 4.13 Operating additional attachments for the SOLO-PILOT .......................... 89
4.14 Fitting additional attachments.................................................................. 91 4.14 Fitting additional attachments.................................................................. 91
5 Towing trailers ......................................................................................... 93 5 Towing trailers ......................................................................................... 93
6 Optional equipment ................................................................................. 95 6 Optional equipment ................................................................................. 95
6.1 Steel cab.................................................................................................. 95 6.1 Steel cab.................................................................................................. 95
6.2 Sliding windows ....................................................................................... 95 6.2 Sliding windows ....................................................................................... 95
6.3 Panel door ............................................................................................... 96 6.3 Panel door ............................................................................................... 96
6.4 Backrest extension .................................................................................. 96 6.4 Backrest extension .................................................................................. 96
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6.5 Heating .................................................................................................... 97 6.5 Heating .................................................................................................... 97
6.6 Removable load backrest ........................................................................ 99 6.6 Removable load backrest ........................................................................ 99

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 6.7 Fire extinguisher ...................................................................................... 99 6.7 Fire extinguisher ...................................................................................... 99
6.8 Rockinger coupling with hand lever or remote control............................. 100 6.8 Rockinger coupling with hand lever or remote control............................. 100
6.9 Camera system ....................................................................................... 101 6.9 Camera system ....................................................................................... 101
6.10 Optional equipment for working in areas with heavy accumulation of dust 102 6.10 Optional equipment for working in areas with heavy accumulation of dust 102
6.11 Tilt angle display...................................................................................... 102 6.11 Tilt angle display...................................................................................... 102
6.12 Speed reduction ...................................................................................... 103 6.12 Speed reduction ...................................................................................... 103
6.13 Transmission block.................................................................................. 103 6.13 Transmission block.................................................................................. 103
6.14 Reversing Block....................................................................................... 103 6.14 Reversing Block....................................................................................... 103
6.15 Direction switch mounted to the steering column .................................... 103 6.15 Direction switch mounted to the steering column .................................... 103
6.16 Temperature control system.................................................................... 104 6.16 Temperature control system.................................................................... 104
6.17 Control layout with Cardan function......................................................... 105 6.17 Control layout with Cardan function......................................................... 105
7 Troubleshooting....................................................................................... 106 7 Troubleshooting....................................................................................... 106
7.1 Troubleshooting....................................................................................... 106 7.1 Troubleshooting....................................................................................... 106
7.2 Operating the truck without its own drive system .................................... 109 7.2 Operating the truck without its own drive system .................................... 109

F Industrial Truck Maintenance .................................................. 113 F Industrial Truck Maintenance .................................................. 113
1 Operational Safety and Environmental Protection................................... 113 1 Operational Safety and Environmental Protection................................... 113
2 Maintenance Safety Regulations............................................................. 114 2 Maintenance Safety Regulations............................................................. 114
3 Servicing and Inspection ......................................................................... 119 3 Servicing and Inspection ......................................................................... 119
4 Maintenance checklist ............................................................................. 120 4 Maintenance checklist ............................................................................. 120
5 Lubricants and Lubrication Schedule ...................................................... 128 5 Lubricants and Lubrication Schedule ...................................................... 128
5.1 Handling consumables safely .................................................................. 128 5.1 Handling consumables safely .................................................................. 128
5.2 Lubrication Schedule ............................................................................... 130 5.2 Lubrication Schedule ............................................................................... 130
5.3 Consumables........................................................................................... 131 5.3 Consumables........................................................................................... 131
6 Maintenance and repairs ......................................................................... 133 6 Maintenance and repairs ......................................................................... 133
6.1 Preparing the truck for maintenance and repairs .................................... 133 6.1 Preparing the truck for maintenance and repairs .................................... 133
6.2 Opening the engine cover ....................................................................... 134 6.2 Opening the engine cover ....................................................................... 134
6.3 Checking the wheel attachments............................................................. 135 6.3 Checking the wheel attachments............................................................. 135
6.4 Hydraulic system ..................................................................................... 136 6.4 Hydraulic system ..................................................................................... 136
6.5 Engine maintenance................................................................................ 139 6.5 Engine maintenance................................................................................ 139
6.6 Checking electrical fuses......................................................................... 151 6.6 Checking electrical fuses......................................................................... 151
6.7 Starter battery.......................................................................................... 156 6.7 Starter battery.......................................................................................... 156
6.8 Exhaust system ....................................................................................... 157 6.8 Exhaust system ....................................................................................... 157
6.9 Seat belt maintenance............................................................................. 158 6.9 Seat belt maintenance............................................................................. 158
6.10 Transmission ........................................................................................... 158 6.10 Transmission ........................................................................................... 158
6.11 Brake ....................................................................................................... 159 6.11 Brake ....................................................................................................... 159
6.12 Restoring the truck to service after maintenance and repairs ................. 160 6.12 Restoring the truck to service after maintenance and repairs ................. 160
7 Decommissioning the industrial truck ...................................................... 161 7 Decommissioning the industrial truck ...................................................... 161
7.1 Prior to decommissioning ........................................................................ 162 7.1 Prior to decommissioning ........................................................................ 162
7.2 During decommissioning ......................................................................... 162 7.2 During decommissioning ......................................................................... 162
7.3 Restoring the truck to service after decommissioning ............................. 163 7.3 Restoring the truck to service after decommissioning ............................. 163
8 Safety tests to be performed at intervals and after unusual incidents ..... 164 8 Safety tests to be performed at intervals and after unusual incidents ..... 164
9 Final de-commissioning, disposal............................................................ 165 9 Final de-commissioning, disposal............................................................ 165
10 Human vibration measurement ............................................................... 165 10 Human vibration measurement ............................................................... 165
11 HUSS FS - MK Series Diesel Particle Filter Operating Instructions (o) . 166 11 HUSS FS - MK Series Diesel Particle Filter Operating Instructions (o) . 166
11.1 Important General Instructions ................................................................ 166 11.1 Important General Instructions ................................................................ 166
11.2 Important safety instructions.................................................................... 166 11.2 Important safety instructions.................................................................... 166
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 11.3 Functional Description ............................................................................. 167 11.3 Functional Description ............................................................................. 167
11.4 HUSS Control Operation ......................................................................... 168 11.4 HUSS Control Operation ......................................................................... 168
11.5 HUSS Control Operating Instructions ...................................................... 169 11.5 HUSS Control Operating Instructions...................................................... 169
11.6 Regeneration ........................................................................................... 170 11.6 Regeneration ........................................................................................... 170
11.7 Maintenance ............................................................................................ 171 11.7 Maintenance ............................................................................................ 171

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 A Correct Use and Application A Correct Use and Application
1 General 1 General
The industrial truck described in the present operating instructions is designed for The industrial truck described in the present operating instructions is designed for
lifting, lowering and transporting load units. lifting, lowering and transporting load units.
It must be used, operated and serviced in accordance with the present instructions. It must be used, operated and serviced in accordance with the present instructions.
Any other type of use is beyond the scope of application and can result in damage to Any other type of use is beyond the scope of application and can result in damage to
personnel, the industrial truck or property. personnel, the industrial truck or property.

2 Correct application 2 Correct application

NOTE NOTE

The maximum load and load distance are indicated on the load chart and must not be
exceeded.
The load must rest on the load handler or be lifted by an attachment approved by the
manufacturer.
The load must rest on the back of the fork carriage and centrally between the forks.
The maximum load and load distance are indicated on the load chart and must not be
exceeded.
The load must rest on the load handler or be lifted by an attachment approved by the
manufacturer.
The load must rest on the back of the fork carriage and centrally between the forks.

– Lifting and lowering loads. – Lifting and lowering loads.

– Transporting lowered loads over short distances. – Transporting lowered loads over short distances.
– Do not travel with a raised load (>30 cm). – Do not travel with a raised load (>30 cm).
– Do not carry or lift passengers. – Do not carry or lift passengers.
– Do push or pull load units. – Do push or pull load units.
– Occasional towing of trailer loads. – Occasional towing of trailer loads.
– When towing trailer loads the load must be secured on the trailer. – When towing trailer loads the load must be secured on the trailer.
– The permissible trailer load must not be exceeded. – The permissible trailer load must not be exceeded.
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3 Approved application conditions 3 Approved application conditions

DANGER! DANGER!

Do not exceed the permissible surface and spot load limits on the travel routes. Do not exceed the permissible surface and spot load limits on the travel routes.
At blind spots get a second person to assist. At blind spots get a second person to assist.
The driver must ensure that the loading dock / ramp cannot move or come loose The driver must ensure that the loading dock / ramp cannot move or come loose
during loading / unloading. during loading / unloading.

– Operation in industrial and commercial environments.
– Permissible temperature range -20 to 40°C.
– Operation only on secure, level surfaces with sufficient capacity.
– Operation only on routes that are visible and approved by the proprietor.
– Negotiating inclines up to a maximum of 15 %.
– Do not negotiate inclines crosswise or at an angle. Transporting loads downhill.
– Operation in partially public traffic.
– Operation in industrial and commercial environments.
– Permissible temperature range -20 to 40°C.
– Operation only on secure, level surfaces with sufficient capacity.
– Operation only on routes that are visible and approved by the proprietor.
– Negotiating inclines up to a maximum of 15 %.
– Do not negotiate inclines crosswise or at an angle. Transporting loads downhill.
– Operation in partially public traffic.

WARNING!
Extreme conditions
XSpecial equipment and authorisation are required if the truck is to be constantly
used in extreme conditions, especially in dusty or corrosive atmospheres.
XThe truck is not authorised for use in areas at risk of explosion.
XIn adverse weather conditions (thunder, lightning) the industrial truck must not be
operated outside or in endangered areas.
WARNING!
Extreme conditions
XSpecial equipment and authorisation are required if the truck is to be constantly
used in extreme conditions, especially in dusty or corrosive atmospheres.
XThe truck is not authorised for use in areas at risk of explosion.
XIn adverse weather conditions (thunder, lightning) the industrial truck must not be
operated outside or in endangered areas.

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 4 Proprietor responsibilities
For the purposes of the present operating instructions the “proprietor” is defined as
any natural or legal person who either uses the industrial truck himself, or on whose
behalf it is used. In special cases (e.g. leasing or renting) the proprietor is considered
the person who, in accordance with existing contractual agreements between the
owner and user of the industrial truck, is charged with operational duties.
The proprietor must ensure that the industrial truck is used only for the purpose for
which it is intended and that there is no danger to life and limb of the user and third
parties. Furthermore, accident prevention regulations, safety regulations and
operating, servicing and repair guidelines must be followed. The proprietor must
ensure that all users have read and understood these operating instructions.
NOTE
Failure to comply with the operating instructions shall invalidate the warranty. The
same applies if improper work is carried out on the truck by the customer or third
parties without the permission of the manufacturer.
5 Adding attachments and/or accessories
Adding accessories
The mounting or installation of additional equipment which affects or enhances the
performance of the forklift truck requires the written permission of the manufacturer.
Local authority approval may also need to be obtained.
Local authority approval does not however constitute the manufacturer’s approval.
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4 Proprietor responsibilities
For the purposes of the present operating instructions the “proprietor” is defined as
any natural or legal person who either uses the industrial truck himself, or on whose
behalf it is used. In special cases (e.g. leasing or renting) the proprietor is considered
the person who, in accordance with existing contractual agreements between the
owner and user of the industrial truck, is charged with operational duties.
The proprietor must ensure that the industrial truck is used only for the purpose for
which it is intended and that there is no danger to life and limb of the user and third
parties. Furthermore, accident prevention regulations, safety regulations and
operating, servicing and repair guidelines must be followed. The proprietor must
ensure that all users have read and understood these operating instructions.
NOTE
Failure to comply with the operating instructions shall invalidate the warranty. The
same applies if improper work is carried out on the truck by the customer or third
parties without the permission of the manufacturer.
5 Adding attachments and/or accessories
Adding accessories
The mounting or installation of additional equipment which affects or enhances the
performance of the forklift truck requires the written permission of the manufacturer.
Local authority approval may also need to be obtained.
Local authority approval does not however constitute the manufacturer’s approval.
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 B Truck Description B Truck Description
1 Application 1 Application
The DFG / TFG 540 - 550 is a four-wheel IC motor sit-down forklift truck. The DFG The DFG / TFG 540 - 550 is a four-wheel IC motor sit-down forklift truck. The DFG
series are diesel engine trucks, while the TFG series are fitted with a petrol engine for series are diesel engine trucks, while the TFG series are fitted with a petrol engine for
LPG operation. LPG operation.

The DFG / TFG 540 - 550 is a cantilever counterbalanced truck which can lift, The DFG / TFG 540 - 550 is a cantilever counterbalanced truck which can lift,
transport and deposit loads using the load handler attached in front. transport and deposit loads using the load handler attached in front.

Closed bottom pallets can also be lifted. Closed bottom pallets can also be lifted.

The DFG / TFG 540 - 550 is equipped with a hydrodynamic drive. The left pedal is a The DFG / TFG 540 - 550 is equipped with a hydrodynamic drive. The left pedal is a
combination of crawl speed and brake pedal, and activates the rapid lift function combination of crawl speed and brake pedal, and activates the rapid lift function
during slow travel. The middle pedal is a standard brake as well as emergency brake during slow travel. The middle pedal is a standard brake as well as emergency brake
pedal. pedal.

1.1 Truck models and rated capacity 1.1 Truck models and rated capacity
The rated capacity depends on the model. The rated capacity can be derived from The rated capacity depends on the model. The rated capacity can be derived from
the model description. the model description.

DFG540 DFG540
DFG Model name DFG Model name
5 Series 5 Series
40 Rated capacity x 100 kg 40 Rated capacity x 100 kg
The rated capacity does not generally match the permissible capacity. The capacity The rated capacity does not generally match the permissible capacity. The capacity
can be found on the load chart attached to the rack. can be found on the load chart attached to the rack.
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2 Assemblies and Functional Description 2 Assemblies and Functional Description
2.1 Assembly Overview 2.1 Assembly Overview

1 2 3 5 4 6 1 2 3 5 4 6

7 7

8 8

9 9

14 13 12 11 10 14 13 12 11 10

Item Description Item Description Item Description Item Description

1 t Overhead guard 8 t Drive 1 t Overhead guard 8 t Drive
2 t Driver's seat 9 t Lifting device control 2 t Driver's seat 9 t Lifting device control
3 t Steering wheel 10 t Engine cover 3 t Steering wheel 10 t Engine cover
4 t Mast 11 t Steer axle 4 t Mast 11 t Steer axle
5 t Control / display unit 12 t Trailer coupling 5 t Control / display unit 12 t Trailer coupling
6 t Fork carriage 13 t Counterweight 6 t Fork carriage 13 t Counterweight
7 t Fork tines 14 t LPG bottle (TFG only) 7 t Fork tines 14 t LPG bottle (TFG only)

t = Standard equipment o = Optional equipment t = Standard equipment o = Optional equipment

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 2.2 Functional Description 2.2 Functional Description
Chassis Chassis
The chassis, in conjunction with the counterweight, forms the supporting base The chassis, in conjunction with the counterweight, forms the supporting base
structure of the truck. It is used to support the main components. structure of the truck. It is used to support the main components.

The hydraulic oil reservoir is integrated on the right-hand side and the fuel tank for the The hydraulic oil reservoir is integrated on the right-hand side and the fuel tank for the
DFG series is on the left side in the chassis. DFG series is on the left side in the chassis.

Operator position and overhead guard Operator position and overhead guard
The overhead guard (1) comes in a range of models and protects the driver from The overhead guard (1) comes in a range of models and protects the driver from
falling objects and other external influences. falling objects and other external influences.

All the controls are ergonomically arranged. The steering column and driver's seat All the controls are ergonomically arranged. The steering column and driver's seat
can be adjusted individually. can be adjusted individually.

The controls and warnings on the display unit (5) enable the system to be monitored
during operation, thereby ensuring a very high level of safety.
Steering
The steer cylinder of the hydrostatic steering is integrated in the steer axle (11) and
is controlled by the power steering. The steer axle is fully floating in the chassis to
ensure excellent grip even on non-level surfaces.
The controls and warnings on the display unit (5) enable the system to be monitored
during operation, thereby ensuring a very high level of safety.
Steering
The steer cylinder of the hydrostatic steering is integrated in the steer axle (11) and
is controlled by the power steering. The steer axle is fully floating in the chassis to
ensure excellent grip even on non-level surfaces.

Wheels Wheels
All wheels are located within the truck geometry. A choice of pneumatic or All wheels are located within the truck geometry. A choice of pneumatic or
superelastic tyres are available. superelastic tyres are available.

Engine Engine
High performance, water-cooled diesel and LPG engines with long useful lives and High performance, water-cooled diesel and LPG engines with long useful lives and
low consumption and emission levels. low consumption and emission levels.

Electrical system Electrical system

12 volt system with threephase alternator. A start block prevents malfunctions when
the truck is powered up. For diesel engines, a rapid pre-heat system is installed; LPG
motors have an electronic ignition system for rapid and trouble-free engine starting.
The key switch is used to stop the engine.
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12 volt system with threephase alternator. A start block prevents malfunctions when
the truck is powered up. For diesel engines, a rapid pre-heat system is installed; LPG
motors have an electronic ignition system for rapid and trouble-free engine starting.
The key switch is used to stop the engine.

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 Drive system
A power shift transmission with radiator and torque converter transfers the force to
the drive axle (8).
The travel direction switch on the engine cover controls forward/reverse travel and
the neutral position. This switch is used to select between the two travel stages for
forward and reverse travel.
Brakes
The brake pedal actuates two drum brakes which are applied to the drive wheels. An
additional slow travel / brake pedal facilitates creep speed applications. The pedal
should not be used for normal braking purposes. Worn drum brakes are automatically
adjusted. The parking brake operates through mechanical actuation of the parking
brake lever on the drum brake via Bowden cables.
Hydraulic system
A multi-pilot valve allows for sensitive operation of the functions via the controls. The
flow rate of the gear pump is regulated by the engine speed.
Mast
Two or three-stage masts, optionally with free lift function; narrow mast sections
ensure excellent visibility of the forks and attachments. Fork carriage and mast run
on permanently lubricated and hence maintenance-free support rollers.
Attachments
The trucks can be optionally fitted with mechanical and hydraulic attachments.
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18
Drive system
A power shift transmission with radiator and torque converter transfers the force to
the drive axle (8).
The travel direction switch on the engine cover controls forward/reverse travel and
the neutral position. This switch is used to select between the two travel stages for
forward and reverse travel.
Brakes
The brake pedal actuates two drum brakes which are applied to the drive wheels. An
additional slow travel / brake pedal facilitates creep speed applications. The pedal
should not be used for normal braking purposes. Worn drum brakes are automatically
adjusted. The parking brake operates through mechanical actuation of the parking
brake lever on the drum brake via Bowden cables.
Hydraulic system
A multi-pilot valve allows for sensitive operation of the functions via the controls. The
flow rate of the gear pump is regulated by the engine speed.
Mast
Two or three-stage masts, optionally with free lift function; narrow mast sections
ensure excellent visibility of the forks and attachments. Fork carriage and mast run
on permanently lubricated and hence maintenance-free support rollers.
Attachments
The trucks can be optionally fitted with mechanical and hydraulic attachments.
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18
 3 Technical Specifications
All technical details refer to standard trucks.
Values indicated with *) may vary, depending on the
types of equipment used (e.g. mast, cabin, tyres etc.).
Z Technical data specified in accordance with VDI 2198.
Technical modifications and additions reserved.
3 Technical Specifications
All technical details refer to standard trucks.
Values indicated with *) may vary, depending on the
types of equipment used (e.g. mast, cabin, tyres etc.).
Z Technical data specified in accordance with VDI 2198.
Technical modifications and additions reserved.

3.1 Performance data 3.1 Performance data

DFG 540/545/550 DFG 540/545/550

Description DFG 540 DFG 545 DFG 550 Description DFG 540 DFG 545 DFG 550
Capacity Capacity
Q 4000 4500 5000 kg Q 4000 4500 5000 kg
(where C = 500 mm)1) (where C = 500 mm)1)
C Load centre distance 500 500 600 mm C Load centre distance 500 500 600 mm
Travel speed* with / Travel speed* with /
24/24.5 23/23.5 22/22.5 km/h 24/24.5 23/23.5 22/22.5 km/h
without load without load
Lift speed, with / without Lift speed, with / without
0.49/0.53 0.49/0.53 0.48/0.53 m/s 0.49/0.53 0.49/0.53 0.48/0.53 m/s
load load
Lowering speed with / Lowering speed with /
0.51/0.49 0.51/0.49 0.51/0.49 m/s 0.51/0.49 0.51/0.49 0.51/0.49 m/s
without load without load
Gradeability 2)* Gradeability 2)*
25/26 24/26 23/26 % 25/26 24/26 23/26 %
with / without load with / without load
Acceleration* with / Acceleration* with /
5/4.5 5/4.5 5.1/4.5 s 5/4.5 5/4.5 5.1/4.5 s
without load to 15 m without load to 15 m
Available working Available working
160 160 160 bar 160 160 160 bar
pressure for attachments pressure for attachments
Oil flow for attachments 30 30 30 l/min Oil flow for attachments 30 30 30 l/min
1) for vertical mast. 1) for vertical mast.
2) 2)
The values shown represent the maximum gradeability to overcome short The values shown represent the maximum gradeability to overcome short
differences in height and surface unevenness (surface edges). The truck must not differences in height and surface unevenness (surface edges). The truck must not
operate on inclines of more than 15%. operate on inclines of more than 15%.
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 TFG 540/545/550 TFG 540/545/550
Description TFG 540 TFG 545 TFG 550 Description TFG 540 TFG 545 TFG 550
Capacity Capacity
Q 4000 4500 5000 Q 4000 4500 5000
(where C = 500 mm)1) (where C = 500 mm)1)
C Load centre distance 500 500 600 C Load centre distance 500 500 600
Travel speed* with / Travel speed* with /
24.4/25.8 23.8/25.8 22.3/25.8 24.4/25.8 23.8/25.8 22.3/25.8
without load without load
Lift speed, with / without Lift speed, with / without
0.49/0.53 0.48/0.53 0.48/0.53 0.49/0.53 0.48/0.53 0.48/0.53
load load
Lowering speed with / Lowering speed with /
0.51/0.49 0.51/0.49 0.51/0.49 0.51/0.49 0.51/0.49 0.51/0.49
without load without load
Gradeability 2)* Gradeability 2)*
25/26 24/26 23/26 25/26 24/26 23/26
with / without load with / without load
Acceleration* with / Acceleration* with /
4.8/4.2 5/4.5 5.5/4.5 4.8/4.2 5/4.5 5.5/4.5
without load to 15 m without load to 15 m
Available working Available working
160 160 160 160 160 160
pressure for attachments pressure for attachments
Oil flow for attachments 30 30 30 Oil flow for attachments 30 30 30
1) 1)
for vertical mast. for vertical mast.
2) 2)
The values shown represent the maximum gradeability to overcome short The values shown represent the maximum gradeability to overcome short
differences in height and surface unevenness (surface edges). The truck must not differences in height and surface unevenness (surface edges). The truck must not
operate on inclines of more than 15%. operate on inclines of more than 15%.

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 3.2 Dimensions 3.2 Dimensions

DFG/TFG 540/545/550 DFG/TFG 540/545/550

Description DFG / TFG Description DFG / TFG
540 545 550 540 545 550
a/2 Safety distance 100 100 100 mm a/2 Safety distance 100 100 100 mm
h1 Mast height retracted* 2540 2540 2540 mm h1 Mast height retracted* 2540 2540 2540 mm
h2 Free lift* 150 150 150 mm h2 Free lift* 150 150 150 mm
h3 Lift* 3500 3500 3500 mm h3 Lift* 3500 3500 3500 mm
h4 Mast height extended* 4215 4215 4363 mm h4 Mast height extended* 4215 4215 4363 mm
h6 Overhead guard height (cabin)* 2375 2375 2375 mm h6 Overhead guard height (cabin)* 2375 2375 2375 mm
h7 Seat height* 1255 1255 1255 mm h7 Seat height* 1255 1255 1255 mm
h10 Coupling height 535/700 535/700 535/700 mm h10 Coupling height 535/700 535/700 535/700 mm
Į Mast tilt, fwd.* 7 7 7 ° Į Mast tilt, fwd.* 7 7 7 °
ß Mast tilt, back* 6 6 6 ° ß Mast tilt, back* 6 6 6 °
l1 Overall length * 4145 4145 4260 mm l1 Overall length * 4145 4145 4260 mm
l2 Headlength* 2995 2995 3110 mm l2 Headlength* 2995 2995 3110 mm
b1 Overall width* 1400/- 1450/- 1450/- mm b1 Overall width* 1400/- 1450/- 1450/- mm
s/e/l Fork dimensions* 50x125 50x150 60x150 mm s/e/l Fork dimensions* 50x125 50x150 60x150 mm
x1150 x1150 x1150 x1150 x1150 x1150
m1 Ground clearance with load below 190 190 190 mm m1 Ground clearance with load below 190 190 190 mm
mast* mast*
m2 Ground clearance centre 230 230 230 mm m2 Ground clearance centre 230 230 230 mm
wheelbase* wheelbase*
Fork carriage ISO 2328 class / 3A 3A 4A Fork carriage ISO 2328 class / 3A 3A 4A
type A, B type A, B
b3 Fork carriage width* 1260 1260 1260 mm b3 Fork carriage width* 1260 1260 1260 mm
Ast Working aisle width for pallets 800 4619 4619 4769 mm Ast Working aisle width for pallets 800 4619 4619 4769 mm
x 1200 longit. x 1200 longit.
Ast Working aisle width for pallets 4419 4419 4569 mm Ast Working aisle width for pallets 4419 4419 4569 mm
1000 x 1200 traverse 1000 x 1200 traverse
Wa Turning radius 2655 2655 2790 mm Wa Turning radius 2655 2655 2790 mm
b13 Smallest turning radius 900 900 900 mm b13 Smallest turning radius 900 900 900 mm
x Load distance* 5641) 5641) 5791) mm x Load distance* 5641) 5641) 5791) mm
c Load centre of gravity 500 500 600 mm c Load centre of gravity 500 500 600 mm
y Wheelbase 1985 1985 1985 mm y Wheelbase 1985 1985 1985 mm

*) The data listed in the table corresponds to the standard version. *) The data listed in the table corresponds to the standard version.
1) 1)
573 mm with DZ mast; with integrated SS: x=596 mm (605 mm with DZ mast); with 573 mm with DZ mast; with integrated SS: x=596 mm (605 mm with DZ mast); with
SS attachment: x=636 mm (645 mm with DZ mast) SS attachment: x=636 mm (645 mm with DZ mast)
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22
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 3.3 Weights 3.3 Weights
Z All dimensions in kg. Z All dimensions in kg.

DFG/TFG 540/545/550 DFG/TFG 540/545/550

DFG/TFG 540 DFG/TFG 545 DFG/TFG 550 DFG/TFG 540 DFG/TFG 545 DFG/TFG 550
Tare weight* 6279 6669 7434 Tare weight* 6279 6669 7434
Axle load, w.o. load front/ 2810/3469 2937/3732 2795/4639 Axle load, w.o. load front/ 2810/3469 2937/3732 2795/4639
rear* rear*
Axle load, w. load front/ 8954/1325 9869/1300 10762/1673 Axle load, w. load front/ 8954/1325 9869/1300 10762/1673
rear* rear*

*) The data listed in the table corresponds to the standard version. *) The data listed in the table corresponds to the standard version.
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23 23
3.4 Mast versions 3.4 Mast versions
Z All dimensions in mm Z All dimensions in mm

DFG/TFG 540/545 DFG/TFG 540/545

Mast table Mast table
VDI 3596 Lift h3 Free lift Retracted Extended Mast VDI 3596 Lift h3 Free lift Retracted Extended Mast
Description h2 height h1 height h4 weight (kg) Description h2 height h1 height h4 weight (kg)
2750 150 2165 3465 1135 2750 150 2165 3465 1135
3000 150 2290 3715 1170 3000 150 2290 3715 1170
3500 150 2540 4215 1240 3500 150 2540 4215 1240
4000 150 2790 4715 1310 4000 150 2790 4715 1310
ZT 4500 150 3040 5215 1430 ZT 4500 150 3040 5215 1430
5000 150 3290 5715 1500 5000 150 3290 5715 1500
5500 150 3540 6215 1570 5500 150 3540 6215 1570
6000 150 3790 6715 1690 6000 150 3790 6715 1690
6500 150 4040 7215 1760 6500 150 4040 7215 1760
2775 1375 2140 3540 1070 2775 1375 2140 3540 1070
3025 1500 2265 3790 1110 3025 1500 2265 3790 1110
3525 1750 2515 4290 1180 3525 1750 2515 4290 1180
ZZ 4025 2000 2765 4790 1250 ZZ 4025 2000 2765 4790 1250
4525 2250 3015 5290 1320 4525 2250 3015 5290 1320
5025 2500 3265 5790 1440 5025 2500 3265 5790 1440
5525 2750 3515 6290 1510 5525 2750 3515 6290 1510
4150 1375 2140 4915 1500 4150 1375 2140 4915 1500
4525 1500 2265 5290 1560 4525 1500 2265 5290 1560
5275 1750 2515 6040 1660 5275 1750 2515 6040 1660
DZ DZ
5650 1875 2640 6415 1720 5650 1875 2640 6415 1720
6025 2000 2765 6790 1770 6025 2000 2765 6790 1770
6775 2250 3015 7540 1920 6775 2250 3015 7540 1920

Special trucks are not included in this overview. Special trucks are not included in this overview.
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24 24
 DFG/TFG 550 DFG/TFG 550
Mast table Mast table
VDI 3596 Lift h3 Free lift Retracted Extended Mast VDI 3596 Lift h3 Free lift Retracted Extended Mast
Description h2 height h1 height h4 weight (kg) Description h2 height h1 height h4 weight (kg)
2750 150 2165 3613 1200 2750 150 2165 3613 1200
3000 150 2290 3863 1240 3000 150 2290 3863 1240
3500 150 2540 4363 1310 3500 150 2540 4363 1310
4000 150 2790 4863 1380 4000 150 2790 4863 1380
ZT 4500 150 3040 5363 1500 ZT 4500 150 3040 5363 1500
5000 150 3290 5863 1570 5000 150 3290 5863 1570
5500 150 3540 6363 1640 5500 150 3540 6363 1640
6000 150 3790 6863 1760 6000 150 3790 6863 1760
6500 150 4040 7363 1820 6500 150 4040 7363 1820
2725 1225 2140 3640 1140 2725 1225 2140 3640 1140
2975 1350 2265 3890 1170 2975 1350 2265 3890 1170
3475 1600 2515 4390 1240 3475 1600 2515 4390 1240
ZZ 3975 1850 2765 4890 1310 ZZ 3975 1850 2765 4890 1310
4475 2100 3015 5390 1385 4475 2100 3015 5390 1385
4975 2350 3265 5890 1500 4975 2350 3265 5890 1500
5475 2600 3515 6390 1580 5475 2600 3515 6390 1580
4050 1225 2140 4965 1570 4050 1225 2140 4965 1570
4425 1350 2265 5340 1620 4425 1350 2265 5340 1620
5175 1600 2515 6090 1730 5175 1600 2515 6090 1730
DZ DZ
5550 1725 2640 6465 1780 5550 1725 2640 6465 1780
5925 1850 2765 6840 1835 5925 1850 2765 6840 1835
6675 2100 3015 7590 1990 6675 2100 3015 7590 1990

Special trucks are not included in this overview. Special trucks are not included in this overview.
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25 25
3.5 Tyre type 3.5 Tyre type

NOTE NOTE

When replacing tyres/rims fitted at the factory, always use original spare parts or tyres
approved by the manufacturer. Otherwise the manufacturer's specification cannot be
guaranteed.
If you have any queries please contact the manufacturer's customer service
department.
When replacing tyres/rims fitted at the factory, always use original spare parts or tyres
approved by the manufacturer. Otherwise the manufacturer's specification cannot be
guaranteed.
If you have any queries please contact the manufacturer's customer service
department.

Description DFG/TFG Description DFG/TFG

540/545 550 540/545 550
SE* 8.25x15 300x15 SE* 8.25x15 300x15
Pneumatic* 8.25x15 16PR 300x15 18PR Pneumatic* 8.25x15 16PR 300x15 18PR
Front tyres Front tyres
Tyre pressure bar 8.5 8.5 Tyre pressure bar 8.5 8.5
Torque Nm 580-620 580-620 Torque Nm 580-620 580-620
SE* 28x9-15 28x9-15 SE* 28x9-15 28x9-15
Pneumatic* 28x9-15 28x9-15 Pneumatic* 28x9-15 28x9-15
Rear tyres Rear tyres
Tyre pressure bar 8.5 8.5 Tyre pressure bar 8.5 8.5
Torque Nm 500-520 500-520 Torque Nm 500-520 500-520

*) The models listed in the table correspond to the standard version. Other tyres can *) The models listed in the table correspond to the standard version. Other tyres can
be used depending on the truck's equipment. be used depending on the truck's equipment.

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26 26
 3.6 Engine Data 3.6 Engine Data

DFG 540/545/550 DFG 540/545/550

Description DFG 540 DFG 545 DFG 550 Description DFG 540 DFG 545 DFG 550
Cylinder/cubic capacity 4/4400 4/4400 4/4400 cm³ Cylinder/cubic capacity 4/4400 4/4400 4/4400 cm³
Rated speed (without load) 2200 2200 2200 rpm Rated speed (without load) 2200 2200 2200 rpm
Engine output 56 56 56 kW Engine output 56 56 56 kW
Fuel consumption 4.7 5.2 5.7 l/h [kg/h] Fuel consumption 4.7 5.2 5.7 l/h [kg/h]
60 VDI duty cycles/h 60 VDI duty cycles/h

TFG 540/545/550 TFG 540/545/550

Description TFG 540 TFG 545 TFG 550 Description TFG 540 TFG 545 TFG 550
Cylinder/cubic capacity 6/4294 6/4294 6/4294 cm³ Cylinder/cubic capacity 6/4294 6/4294 6/4294 cm³
Rated speed (without load) 2200 2200 2200 rpm Rated speed (without load) 2200 2200 2200 rpm
Engine output 67 67 67 kW Engine output 67 67 67 kW
Fuel consumption 6.24 6.5 6.8 l/h [kg/h] Fuel consumption 6.24 6.5 6.8 l/h [kg/h]
60 VDI duty cycles/h 60 VDI duty cycles/h
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27 27
3.7 EN norms
Noise emission level
– DFG 540/545/550: 78 dB (A)*
– TFG 540/545/550: 78 dB(A)*
*+/- 3 dB(A) depending on the truck's equipment
in accordance with EN 12053 as harmonised with ISO 4871.
Z The noise emission level is calculated in accordance with standard procedures and
takes into account the noise level when travelling, lifting and when idle. The noise
level is measured at the level of the driver's ear.
Vibration
– DFG 540/545/550: 0,60 m/s²
– TFG 540/545/550: 0,60 m/s²
in accordance with EN 13059.
Z The vibration acceleration acting on the body in the operating position is, in
accordance with standard procedures, the linearly integrated, weighted
acceleration in the vertical direction. It is calculated when travelling over thresholds
at constant speed (standard truck version). These recordings were taken on a
single occasion and must not be confused with the human vibrations of the "2002/
44/EC/Vibrations" operator directive. The manufacturer offers a special service to
measure these human vibrations, (see "Human vibration measurement" on
page 165).
Electromagnetic compatibility (EMC)
The manufacturer confirms that the truck adheres to the limits for electromagnetic
emissions and resistance as well as the static electricity discharge test in accordance
with EN 12895 as well as the standardised instructions contained therein.
Z No changes to electric or electronic components or their arrangement may be
made without the written agreement of the manufacturer.
WARNING!
Medical equipment can be damaged by non-ionised radiation
Electrical equipment on the truck emitting non-ionised radiation (e.g. wireless data
transmission) can affect operators' medical equipment (pacemakers, hearing aids
etc.) and result in malfunctions. Consult with a doctor or the medical equipment
manufacturer to clarify whether it can be used near the industrial truck.
08.12 EN
28
3.7 EN norms
Noise emission level
– DFG 540/545/550: 78 dB (A)*
– TFG 540/545/550: 78 dB(A)*
*+/- 3 dB(A) depending on the truck's equipment
in accordance with EN 12053 as harmonised with ISO 4871.
Z The noise emission level is calculated in accordance with standard procedures and
takes into account the noise level when travelling, lifting and when idle. The noise
level is measured at the level of the driver's ear.
Vibration
– DFG 540/545/550: 0,60 m/s²
– TFG 540/545/550: 0,60 m/s²
in accordance with EN 13059.
Z The vibration acceleration acting on the body in the operating position is, in
accordance with standard procedures, the linearly integrated, weighted
acceleration in the vertical direction. It is calculated when travelling over thresholds
at constant speed (standard truck version). These recordings were taken on a
single occasion and must not be confused with the human vibrations of the "2002/
44/EC/Vibrations" operator directive. The manufacturer offers a special service to
measure these human vibrations, (see "Human vibration measurement" on
page 165).
Electromagnetic compatibility (EMC)
The manufacturer confirms that the truck adheres to the limits for electromagnetic
emissions and resistance as well as the static electricity discharge test in accordance
with EN 12895 as well as the standardised instructions contained therein.
Z No changes to electric or electronic components or their arrangement may be
made without the written agreement of the manufacturer.
WARNING!
Medical equipment can be damaged by non-ionised radiation
Electrical equipment on the truck emitting non-ionised radiation (e.g. wireless data
transmission) can affect operators' medical equipment (pacemakers, hearing aids
etc.) and result in malfunctions. Consult with a doctor or the medical equipment
manufacturer to clarify whether it can be used near the industrial truck.
08.12 EN
28
 3.8 Conditions of use 3.8 Conditions of use
Ambient temperature Ambient temperature
– operating at -20 to 40°C – operating at -20 to 40°C
Z Special equipment and authorisation are required if the truck is to be constantly Z Special equipment and authorisation are required if the truck is to be constantly
used in conditions of extreme temperature or air humidity fluctuations. used in conditions of extreme temperature or air humidity fluctuations.

3.9 Electrical requirements 3.9 Electrical requirements

The manufacturer certifies compliance with the requirements for the design and The manufacturer certifies compliance with the requirements for the design and
manufacture of electrical equipment, according to EN 1175 "Industrial Truck Safety - manufacture of electrical equipment, according to EN 1175 "Industrial Truck Safety -
Electrical Requirements", provided the truck is used according to its purpose. Electrical Requirements", provided the truck is used according to its purpose.
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29 29
4 Identification points and data plates 4 Identification points and data plates
Z Warnings and notices such as capacity charts, strap points and data plates must Z Warnings and notices such as capacity charts, strap points and data plates must
be legible at all times. Replace if necessary. be legible at all times. Replace if necessary.

15 16 17 15 16 17

18 18

19 19
20 20

21 21

22 22
23 23
24 24

25 25

1 14 1 14

21 21
152 152

2000
26 2000
26
10 3

10 3
6

6
7 7
9

9
2 8 1 2 8 1

27 27
17 17

27 27

31 30 29 28 31 30 29 28
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Item Component Item Component
15 Do not travel with raised load or mast tilted forward with a raised load 15 Do not travel with raised load or mast tilted forward with a raised load

30 30
 Item Component Item Component
16 Wear seat belt 16 Wear seat belt
17 Strap points for crane lifting 17 Strap points for crane lifting
18 Capacity 18 Capacity
19 Capacity with attachment 19 Capacity with attachment
20 Tipover hazard 20 Tipover hazard
21 Fuel 21 Fuel
22 Truck data plate under the engine cover (not shown) 22 Truck data plate under the engine cover (not shown)
23 Read operating instructions 23 Read operating instructions
24 Do not stand on load handler / Do not stand under load handler / Risk of 24 Do not stand on load handler / Do not stand under load handler / Risk of
trapping when mast extended trapping when mast extended
25 Max. body size (o) 25 Max. body size (o)
26 Test plaque (o) 26 Test plaque (o)
27 Jack contact points 27 Jack contact points
28 Hydraulic oil specification 28 Hydraulic oil specification
29 Noise level 29 Noise level
30 Model description 30 Model description
31 Do not carry passengers warning 31 Do not carry passengers warning
Serial number, engraved in chassis below the engine cover Serial number, engraved in chassis below the engine cover
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31 31
4.1 Data plate 4.1 Data plate

32 33 34 35 32 33 34 35

36 36
37 37
38 38

39 39

40 40

41 41

Item Description Item Description Item Description Item Description

32 Type 37 Year of manufacture 32 Type 37 Year of manufacture
33 Serial number 38 Load centre (mm) 33 Serial number 38 Load centre (mm)
34 Rated capacity in kg 39 Net weight in kg 34 Rated capacity in kg 39 Net weight in kg
35 Output in kW 40 Manufacturer 35 Output in kW 40 Manufacturer
36 Option 41 Manufacturer's logo 36 Option 41 Manufacturer's logo

Z For queries regarding the truck or ordering spare parts always quote the truck serial Z For queries regarding the truck or ordering spare parts always quote the truck serial
number (33). number (33).

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32 32
 4.2 Truck capacity plate 4.2 Truck capacity plate

CAUTION! CAUTION!

Accident risk from fork replacement
If you replace the forks with ones that differ from the originals, the capacity will
change.
XWhen replacing the forks you must attach an additional capacity plate to the truck.
XTrucks supplied without forks are given a capacity plate for standard forks (length:
1150 mm).
Accident risk from fork replacement
If you replace the forks with ones that differ from the originals, the capacity will
change.
XWhen replacing the forks you must attach an additional capacity plate to the truck.
XTrucks supplied without forks are given a capacity plate for standard forks (length:
1150 mm).

The capacity plate (18) gives the capacity (Q in kg) of the truck for a vertical mast.
The maximum capacity is shown as a table with a given load centre of gravity D (in
mm) and the required lift height H (in mm).
The capacity plate (18) of the truck indicates the truck's capacity with the forks as
originally supplied.
Example of how to calculate the maximum capacity:
The capacity plate (18) gives the capacity (Q in kg) of the truck for a vertical mast.
The maximum capacity is shown as a table with a given load centre of gravity D (in
mm) and the required lift height H (in mm).
The capacity plate (18) of the truck indicates the truck's capacity with the forks as
originally supplied.
Example of how to calculate the maximum capacity:

h3 (mm) Q (kg) h3 (mm) Q (kg)

4250 850 850 600 4250 850 850 600

3600 1105 1105 850 3600 1105 1105 850
2900 1250 1250 850 2900 1250 1250 850

D (mm) 500 600 700 D (mm) 500 600 700

For a load cente of gravity D of 600 mm and a maximum lift height h3 of 3600 mm the For a load cente of gravity D of 600 mm and a maximum lift height h3 of 3600 mm the
maximum capacity is Q 1105 kg. maximum capacity is Q 1105 kg.

Lift height restriction Lift height restriction

The arrow shape markings (42 and 43) The arrow shape markings (42 and 43)
on the inner and outer masts show the 42 43 on the inner and outer masts show the 42 43
driver when the prescribed lift limits driver when the prescribed lift limits
have been reached. have been reached.
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4.3 Attachment capacity plate
The attachment capacity plate is next to the truck's capacity plate and gives the
truck's capacity Q (in kg) in conjunction with the respective attachment. The serial
number for the attachment indicated on the capacity plate must match the data plate
of the attachment.
4.3 Attachment capacity plate
The attachment capacity plate is next to the truck's capacity plate and gives the
truck's capacity Q (in kg) in conjunction with the respective attachment. The serial
number for the attachment indicated on the capacity plate must match the data plate
of the attachment.

Z For loads with a centre of gravity greater than 500 mm, the capacities are reduced Z For loads with a centre of gravity greater than 500 mm, the capacities are reduced
by the difference of the altered centre of gravity. by the difference of the altered centre of gravity.

5 Stability 5 Stability
The truck's stability has been tested according to latest technological standards. The truck's stability has been tested according to latest technological standards.
These take into account the dynamic and static tipover forces that can occur if used These take into account the dynamic and static tipover forces that can occur if used
correctly. correctly.

Stability can also be affected by the following factors: Stability can also be affected by the following factors:
– Tyre type – Tyre type
– Mast – Mast
– Attachment – Attachment
– Transported load (size, weight and centre of gravity) – Transported load (size, weight and centre of gravity)

WARNING! WARNING!

Loss of stability can cause accidents Loss of stability can cause accidents
Changing the components can alter the stability. Changing the components can alter the stability.

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34 34
 C Transport and Commissioning C Transport and Commissioning
1 Transport 1 Transport
Transport can be carried out in two different ways, depending on the height of the Transport can be carried out in two different ways, depending on the height of the
mast and the local conditions. mast and the local conditions.

– Vertically, with the mast assembled (for low heights) – Vertically, with the mast assembled (for low heights)
– Vertically, with the mast dismantled (for large heights), all mechanical connections – Vertically, with the mast dismantled (for large heights), all mechanical connections
and hydraulic lines between the basic truck and the mast separated. and hydraulic lines between the basic truck and the mast separated.

2 Truck laden 2 Truck laden

2.1 Centre of gravity of the truck 2.1 Centre of gravity of the truck

WARNING! WARNING!

Altering the centre of gravity can be hazardous Altering the centre of gravity can be hazardous
The overall centre of gravity can vary depending on the truck's equipment (especially The overall centre of gravity can vary depending on the truck's equipment (especially
the mast version). the mast version).
XFor masts with a low height the centre of gravity will move towards the XFor masts with a low height the centre of gravity will move towards the
counterweight. counterweight.
XFor masts with a greater height the centre of gravity will move towards the centre XFor masts with a greater height the centre of gravity will move towards the centre
of the truck. of the truck.
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2.2 Lifting the truck by crane 2.2 Lifting the truck by crane

CAUTION! CAUTION!

The mast can get damaged
XLoading by crane is only intended for the initial transport before the truck is used
for the first time.
XLoading must be carried out by specially trained staff in accordance with
recommendations contained in Guidelines VDI 2700 and VDI 2703
The mast can get damaged
XLoading by crane is only intended for the initial transport before the truck is used
for the first time.
XLoading must be carried out by specially trained staff in accordance with
recommendations contained in Guidelines VDI 2700 and VDI 2703

DANGER! DANGER!

Crane slings can tear, resulting in accidents
XOnly use crane lifting gear with sufficient capacity.
XLoading weight = Net weight of truck (+ battery weight for electric trucks).
XThe mast must be tilted back fully.
XThe crane lifting gear on the mast must have a minimum clear length of 2 m.
XCrane slings should be fastened in such a way that they do not come into contact
with any attachments or the overhead guard when lifting.
XDo not stand under a swaying load.
Crane slings can tear, resulting in accidents
XOnly use crane lifting gear with sufficient capacity.
XLoading weight = Net weight of truck (+ battery weight for electric trucks).
XThe mast must be tilted back fully.
XThe crane lifting gear on the mast must have a minimum clear length of 2 m.
XCrane slings should be fastened in such a way that they do not come into contact
with any attachments or the overhead guard when lifting.
XDo not stand under a swaying load.

Z Truck net weight: (see "Weights" on page 23). Z Truck net weight: (see "Weights" on page 23).

Lifting the truck by crane 44 45 Lifting the truck by crane 44 45

Requirements Requirements
– Park the truck securely, (see "Parking the – Park the truck securely, (see "Parking the
truck securely" on page 71). truck securely" on page 71).

Procedure Procedure
• Fasten the crane slings securely to the • Fasten the crane slings securely to the
attachment points (45) and (44). attachment points (45) and (44).
• Raise and load the truck. • Raise and load the truck.
• Lower and deposit the truck carefully ((see • Lower and deposit the truck carefully ((see
"Parking the truck securely" on page 71)). "Parking the truck securely" on page 71)).
• Secure the truck with wedges to prevent it • Secure the truck with wedges to prevent it
from rolling away. from rolling away.
This concludes the loading by crane. This concludes the loading by crane.
08.12 EN

08.12 EN
36 36
 2.3 Loading with another industrial truck 2.3 Loading with another industrial truck

WARNING! WARNING!

The truck can be damaged The truck can be damaged

The truck to be loaded can get damaged when loading with another industrial truck.
XOnly trained specialist personnel should load the truck.
XUse only trucks with sufficient capacity for loading.
XOnly for loading and unloading.
XThe forks of the second industrial truck must be sufficiently long
XTransporting over long distances prohibited.
The truck to be loaded can get damaged when loading with another industrial truck.
XOnly trained specialist personnel should load the truck.
XUse only trucks with sufficient capacity for loading.
XOnly for loading and unloading.
XThe forks of the second industrial truck must be sufficiently long
XTransporting over long distances prohibited.

Loading the truck with a second industrial truck Loading the truck with a second industrial truck
Requirements Requirements
– Park the truck securely, (see "Parking the truck securely" on page 71). – Park the truck securely, (see "Parking the truck securely" on page 71).

Procedure Procedure
• Raise the truck with the forks at the side between the axles. • Raise the truck with the forks at the side between the axles.
• Raise the truck slightly and make sure it is securely positioned on the forks. If • Raise the truck slightly and make sure it is securely positioned on the forks. If
necessary adjust or secure the forks with stops. necessary adjust or secure the forks with stops.
• Carefully load/unload the truck, (see "Lifting, transporting and depositing loads" on • Carefully load/unload the truck, (see "Lifting, transporting and depositing loads" on
page 79). page 79).
• Lower the truck slowly onto the ground and prevent it from rolling away. • Lower the truck slowly onto the ground and prevent it from rolling away.
The truck is now loaded. The truck is now loaded.
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37 37
3 Securing the truck during transport 3 Securing the truck during transport

WARNING! WARNING!

Accidental movement during transport Accidental movement during transport

Improper fastening of the truck and mast during transport can result in serious
accidents.
XLoading must be carried out by specially trained staff in accordance with
recommendations contained in Guidelines VDI 2700 and VDI 2703 In each case
correct measurements must be made and appropriate safety measures adopted.
XThe truck must be securely fastened when transported on a lorry or a trailer.
XThe loading area must have clamp rings and a wooden floor to secure the retaining
wedges.
XUse wedges to prevent the truck from moving.
XUse only tensioning belts or tie-down straps or with sufficient strength.
Improper fastening of the truck and mast during transport can result in serious
accidents.
XLoading must be carried out by specially trained staff in accordance with
recommendations contained in Guidelines VDI 2700 and VDI 2703 In each case
correct measurements must be made and appropriate safety measures adopted.
XThe truck must be securely fastened when transported on a lorry or a trailer.
XThe loading area must have clamp rings and a wooden floor to secure the retaining
wedges.
XUse wedges to prevent the truck from moving.
XUse only tensioning belts or tie-down straps or with sufficient strength.

Securing with a mast Securing without a mast Securing with a mast Securing without a mast

45 45

46 46
46 46

47 47

44 44
46 46 46 46

Securing the industrial truck for transport Securing the industrial truck for transport
Requirements Requirements
– Position the industrial truck securely on a lorry or trailer, (see "Parking the truck – Position the industrial truck securely on a lorry or trailer, (see "Parking the truck
securely" on page 71). securely" on page 71).

Tools and Material Required Tools and Material Required

– 2 tensioning belts with tensioning device – 2 tensioning belts with tensioning device
– Retaining wedges. – Retaining wedges.

Procedure Procedure
• Secure the industrial truck with the tensioning belt (46) at the top cross member of • Secure the industrial truck with the tensioning belt (46) at the top cross member of
the mast (45) and the trailer coupling (44) or over the front mud guards (47) and on the mast (45) and the trailer coupling (44) or over the front mud guards (47) and on
the trailer coupling (44). the trailer coupling (44).
• Tighten the tensioning belts (46) with the tensioning device. • Tighten the tensioning belts (46) with the tensioning device.
The industrial truck is now secured for transport. The industrial truck is now secured for transport.
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38 38
 4 Using the Truck for the First Time 4 Using the Truck for the First Time
Safety Instructions for Assembly and Commissioning Safety Instructions for Assembly and Commissioning

WARNING! WARNING!

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

Preparing the truck for operation after delivery or transport Preparing the truck for operation after delivery or transport
Procedure Procedure
• Check the equipment is complete. • Check the equipment is complete.
• Check the engine oil level. • Check the engine oil level.
• Check the hydraulic oil level. • Check the hydraulic oil level.
• Check the transmission oil level (only on trucks with hydrodynamic drives). • Check the transmission oil level (only on trucks with hydrodynamic drives).
• Check the brake fluid level (only on trucks with hydrodynamic drives). • Check the brake fluid level (only on trucks with hydrodynamic drives).
• Test the battery connections. • Test the battery connections.
• Check the battery acid level (not for maintenance-free batteries). • Check the battery acid level (not for maintenance-free batteries).
The truck can now be started, (see "Preparing the Truck for Operation" on page 59). The truck can now be started, (see "Preparing the Truck for Operation" on page 59).
08.12 EN

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39 39
40
08.12 EN

40

08.12 EN
 D Fuelling the Truck D Fuelling the Truck
1 General 1 General
1.1 Safety regulations for handling diesel fuel and LPG 1.1 Safety regulations for handling diesel fuel and LPG

WARNUNG! WARNUNG!

An unsecured truck can cause accidents An unsecured truck can cause accidents
The truck can suddenly start to move. The truck can suddenly start to move.
XBefore filling up or replacing the LPG bottle, park the truck securely, Siehe “Parking XBefore filling up or replacing the LPG bottle, park the truck securely, Siehe “Parking
the truck securely” auf Seite 71. the truck securely” auf Seite 71.

WARNUNG! WARNUNG!

Accident risk from ignition Accident risk from ignition

XFuels and liquefied petroleum gas can ignite.
XSmoking, naked flames and other ignition sources are strictly prohibited in the
immediate vicinity when handling fuels and LPG.
XLabels indicating the hazard are must be positioned where they are clearly visible.
XDo not store flammable materials in this area.
XPowder fire extinguisher must be provided within easy reach of the filling area.
XUse only category A, B or C type powder fire extinguishers to fight LPG fires.
XBring any unsealed LPG bottles immediately outside, attach visible markings and
notify the supplier.
XFuels and liquefied petroleum gas can ignite.
XSmoking, naked flames and other ignition sources are strictly prohibited in the
immediate vicinity when handling fuels and LPG.
XLabels indicating the hazard are must be positioned where they are clearly visible.
XDo not store flammable materials in this area.
XPowder fire extinguisher must be provided within easy reach of the filling area.
XUse only category A, B or C type powder fire extinguishers to fight LPG fires.
XBring any unsealed LPG bottles immediately outside, attach visible markings and
notify the supplier.

Storage and Transport Storage and Transport

The diesel and LPG storage and transport devices must comply with statutory The diesel and LPG storage and transport devices must comply with statutory
requirements. requirements.

If there is no filling point available, the fuel must be stored and transported in clean, If there is no filling point available, the fuel must be stored and transported in clean,
approved containers. approved containers.

The contents must be clearly indicated on the container. The contents must be clearly indicated on the container.
08.12 EN

08.12 EN

41 41
 HINWEIS HINWEIS
Fuel can cause environmental damage Fuel can cause environmental damage
XBind any spilled diesel fuel with suitable methods. XBind any spilled diesel fuel with suitable methods.
XThen dispose of the diesel and fuel filter in accordance with environmental XThen dispose of the diesel and fuel filter in accordance with environmental
regulations. regulations.

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

VORSICHT! VORSICHT!

Liquid gas can cause frostbite Liquid gas can cause frostbite
XLiquid gas produces frostbite when it comes into contact with bare skin. XLiquid gas produces frostbite when it comes into contact with bare skin.
XAvoid direct contact with the skin. XAvoid direct contact with the skin.
XWear gloves. XWear gloves.

Filling up LPG containers Filling up LPG containers

LPG containers remain attached to the truck and are filled up at LPG stations. Always LPG containers remain attached to the truck and are filled up at LPG stations. Always
follow the instructions of the tank system and LPG container manufacturer as well as follow the instructions of the tank system and LPG container manufacturer as well as
statutory and local regulations when filling up. statutory and local regulations when filling up.

HINWEIS HINWEIS

Instructions for the safe operation of LPG systems
XAll maintenance and repair work on LPG systems and containers should be carried
out by qualified personnel who have been trained to work on LPG systems.
XThe owner must comply with all legal requirements, technical standards and health
and safety regulations applicable to liquid gas.
XBefore starting work, the driver must check that all accessible components of the
LPG system are in good working order, in accordance with the regulations of the
country of use.
XDo not operate the truck if there is any damage, corrosion, wear or degradation to
individual components of the LPG system.
08.12 EN
Instructions for the safe operation of LPG systems
XAll maintenance and repair work on LPG systems and containers should be carried
out by qualified personnel who have been trained to work on LPG systems.
XThe owner must comply with all legal requirements, technical standards and health
and safety regulations applicable to liquid gas.
XBefore starting work, the driver must check that all accessible components of the
LPG system are in good working order, in accordance with the regulations of the
country of use.
XDo not operate the truck if there is any damage, corrosion, wear or degradation to
individual components of the LPG system.

08.12 EN
42 42
 1.2 LPG system relief valve 1.2 LPG system relief valve

LPG powered trucks are fitted with a relief LPG powered trucks are fitted with a relief
valve. This is located on the rear cover next valve. This is located on the rear cover next
to the gas bottle. to the gas bottle.
– In the event of a fault the pressure in the – In the event of a fault the pressure in the
gas system is restricted to a maximum gas system is restricted to a maximum
level. The relief valve is fitted with a level. The relief valve is fitted with a
48 48
plastic cover (45). plastic cover (45).
– When the valve is activated the plastic – When the valve is activated the plastic
cover comes off, thereby clearly cover comes off, thereby clearly
indicating a fault in the gas system. indicating a fault in the gas system.
– In this event the truck must not be operated. – In this event the truck must not be operated.
– The gas system must be check by suitably qualified and trained personnel. – The gas system must be check by suitably qualified and trained personnel.
– The user must check that the plastic cover is present each time he uses the truck. – The user must check that the plastic cover is present each time he uses the truck.

GEFAHR! GEFAHR!

Danger from escaping liquid gas. Danger from escaping liquid gas.
Liquid gas can escape from faulty gas hoses. Liquid gas can escape from faulty gas hoses.
XUse only gas bottles with an integrated line break safety valve. XUse only gas bottles with an integrated line break safety valve.
XThe gas bottle connection is also fitted with a line break safety valve which prevents XThe gas bottle connection is also fitted with a line break safety valve which prevents
the gas from escaping accidentally during operation. the gas from escaping accidentally during operation.
XWhen replacing, always use a gas bottle connection with an integrated line break XWhen replacing, always use a gas bottle connection with an integrated line break
safety valve. safety valve.
08.12 EN

08.12 EN

43 43
2 Adding diesel 2 Adding diesel

VORSICHT! VORSICHT!

Air in the fuel system will result in malfunctions. Air in the fuel system will result in malfunctions.
XNever allow the fuel tank to run dry. XNever allow the fuel tank to run dry.

2.1 Fuelling 2.1 Fuelling

WARNUNG! WARNUNG!
Diesel fuel can be hazardous Diesel fuel can be hazardous
XDiesel fuel can cause irritation if it comes into contact with the skin. Rinse any XDiesel fuel can cause irritation if it comes into contact with the skin. Rinse any
affected areas thoroughly. affected areas thoroughly.
XIf it comes into contact with the eyes rinse them immediately with flowing water and XIf it comes into contact with the eyes rinse them immediately with flowing water and
call for a doctor. call for a doctor.
XWear safety gloves when handling diesel fuels. XWear safety gloves when handling diesel fuels.

HINWEIS HINWEIS

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

HINWEIS
XCapacity: DFG 540 - 550 = 70 l.
XUse only DIN EN 590 diesel with a cetane rating above 51. Use of fuels that do not
comply with this standard may cause increased ware and damage to the engine
and exhaust gas system. Compliance with the required exhaust gas limits might no
longer be provided. The company operating the truck is responsible in this case.
HINWEIS
XCapacity: DFG 540 - 550 = 70 l.
XUse only DIN EN 590 diesel with a cetane rating above 51. Use of fuels that do not
comply with this standard may cause increased ware and damage to the engine
and exhaust gas system. Compliance with the required exhaust gas limits might no
longer be provided. The company operating the truck is responsible in this case.

2.1.1 Fuelling the tank system 2.1.1 Fuelling the tank system
Vorgehensweise Vorgehensweise
• Park the truck securely before fuelling, • Park the truck securely before fuelling,
(see "Parking the truck securely" on (see "Parking the truck securely" on
page 71). page 71).
• Unscrew the tank cap (49). • Unscrew the tank cap (49).
• Insert the pump nozzle into the open • Insert the pump nozzle into the open
tank filler neck. tank filler neck.
• Add the fuel. • Add the fuel.
• Do not overfill the tank. • Do not overfill the tank.
• Tighten the cap (49) back on after • Tighten the cap (49) back on after
fuelling. 49 fuelling. 49
Fuelling is now complete. Fuelling is now complete.
08.12 EN

08.12 EN
44 44
 2.2 Fuelling with fuel containers 2.2 Fuelling with fuel containers

Vorgehensweise
• Unscrew the tank cap (49) and open the
fuel container.
• Fit the outlet pipe onto the fuel
container.
• Insert the outlet pipe into the open tank
filler neck.
• Make sure the fuel container and outlet
pipe are connected tightly to each
other.
• Raise the fuel container carefully and
slowly add the diesel.
• Do not overfill the tank.
• Tighten the cap (49) back on after
fuelling.
Fuelling is now complete.
08.12 EN
Vorgehensweise
• Unscrew the tank cap (49) and open the
fuel container.
• Fit the outlet pipe onto the fuel
container.
• Insert the outlet pipe into the open tank
filler neck.
• Make sure the fuel container and outlet
pipe are connected tightly to each
other.
• Raise the fuel container carefully and
slowly add the diesel.
49 • Do not overfill the tank. 49
• Tighten the cap (49) back on after
fuelling.
Fuelling is now complete.

08.12 EN

45 45
3 LPG containers 3 LPG containers
Z Only use liquid gas that complies with DIN 51622 or comparable national Z Only use liquid gas that complies with DIN 51622 or comparable national
regulations. regulations.

3.1 LPG bottles 3.1 LPG bottles

GEFAHR! GEFAHR!

Risk of explosion Risk of explosion

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

VORSICHT! VORSICHT!

Using unsuitable LPG bottles can cause accidents.
XUse only approved LPG bottles.
XThe LPG bottle must always rest on an engaged bottle holder so that the hose
connection of the shutoff valve is facing vertically down.
XFor bottle types of other countries note the national regulations.
XNote the indications and markings on the LPG bottle.
Using unsuitable LPG bottles can cause accidents.
XUse only approved LPG bottles.
XThe LPG bottle must always rest on an engaged bottle holder so that the hose
connection of the shutoff valve is facing vertically down.
XFor bottle types of other countries note the national regulations.
XNote the indications and markings on the LPG bottle.

3.1.1 Using an LPG bottle 3.1.1 Using an LPG bottle

Replace the LPG bottle Replace the LPG bottle

Vorgehensweise 50 Vorgehensweise 50
• Park the truck securely before replacing the • Park the truck securely before replacing the
LPG bottle, (see "Parking the truck LPG bottle, (see "Parking the truck
securely" on page 71) securely" on page 71)
• Close the shut-off valves (50) securely. • Close the shut-off valves (50) securely.
• Start the motor and allow the LPG system to • Start the motor and allow the LPG system to
run empty in neutral. 08.12 EN run empty in neutral.

08.12 EN
46 46
 14 51 14 51
Remove the LPG bottle Remove the LPG bottle

VORSICHT! VORSICHT!

The connection has a left thread 52 The connection has a left thread 52
Vorgehensweise 53 Vorgehensweise 53
• Unscrew the union nut (54) while holding 54 • Unscrew the union nut (54) while holding 54
against the handle (53). against the handle (53).
• Remove the hose (56) and immediately • Remove the hose (56) and immediately
screw the valve cap onto the empty LPG 55 screw the valve cap onto the empty LPG 55
56 56
bottle. bottle.
• Open the toggle-type fastener (52) and • Open the toggle-type fastener (52) and
fold back the cover (51). fold back the cover (51).
• Carefully remove the LPG bottle (14) from the bracket (55) and place it down • Carefully remove the LPG bottle (14) from the bracket (55) and place it down
securely. securely.

Inserting a new LPG bottle 50 14 51 Inserting a new LPG bottle 50 14 51

Vorgehensweise Vorgehensweise
• Insert the LPG bottle (14) into the bracket • Insert the LPG bottle (14) into the bracket
(55) (55)
• Align the hose connection downwards. 52 • Align the hose connection downwards. 52
• Fold back the cover (51) and secure it with • Fold back the cover (51) and secure it with
tensioning belts. Tighten the toggle-type tensioning belts. Tighten the toggle-type
fasteners (52). fasteners (52).
• Unscrew the valve cap. • Unscrew the valve cap.
• Fit the hose (56) in accordance with 55 • Fit the hose (56) in accordance with 55
56 56
instructions. instructions.
• Carefully open the shut-off valve (50). • Carefully open the shut-off valve (50).
• Check the hose connection for leaks using a foam-forming agent. • Check the hose connection for leaks using a foam-forming agent.
The replacement is now complete. The replacement is now complete.
08.12 EN

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47 47
3.1.2 Operating with two LPG bottles 3.1.2 Operating with two LPG bottles

WARNUNG! WARNUNG!

Visibility is restricted when the truck reverses. Visibility is restricted when the truck reverses.
XExternal mirrors must be fitted on either side of the industrial truck. XExternal mirrors must be fitted on either side of the industrial truck.
XIn addition, a panoramic mirror must be present above the LPG bottles. XIn addition, a panoramic mirror must be present above the LPG bottles.

Operating the twin bottle system Operating the twin bottle system

HINWEIS HINWEIS

Use the additional valve (57) on the Use the additional valve (57) on the
bracket (55) to change the gas supply. bracket (55) to change the gas supply.
You can tell which bottle is supplying You can tell which bottle is supplying
the gas by the gas hose connection on the gas by the gas hose connection on
the shut-off valve (50) and the routing the shut-off valve (50) and the routing
towards the LPG bottles (e.g. RH side towards the LPG bottles (e.g. RH side
of toggle valve = up, LH side of toggle of toggle valve = up, LH side of toggle
valve = down). valve = down).

Vorgehensweise 50 Vorgehensweise 50
55 58 57 55 58 57
• Use the lever (58) to change between • Use the lever (58) to change between
the top and bottom LPG bottles. the top and bottom LPG bottles.

Replacing the LPG bottles Replacing the LPG bottles

Vorgehensweise Vorgehensweise
• (see "Using an LPG bottle" on page 46). • (see "Using an LPG bottle" on page 46).

Z Replace an empty LPG bottle at the earliest opportunity with a full one. Z Replace an empty LPG bottle at the earliest opportunity with a full one.
Switching off the gas supply Switching off the gas supply

Vorgehensweise Vorgehensweise
• Close both shutoff valves (50) on the LPG bottles to interrupt the supply of LPG. • Close both shutoff valves (50) on the LPG bottles to interrupt the supply of LPG.
08.12 EN

08.12 EN
48 48
 3.2 Liquid gas tank 3.2 Liquid gas tank
Refillable liquid gas tanks contain a dispensing valve (63), a filling stop valve (61), a Refillable liquid gas tanks contain a dispensing valve (63), a filling stop valve (61), a
relief valve (62) and a display (59). relief valve (62) and a display (59).

Filling refillable liquid gas tanks (optional Filling refillable liquid gas tanks (optional
equipment). 59 equipment). 59

Voraussetzungen Voraussetzungen
– Note all guidelines and regulations – Note all guidelines and regulations
concerning the filling of LPG bottles on the concerning the filling of LPG bottles on the
LPG pump. LPG pump.

Vorgehensweise
• Close the dispensing valve (63).
• Unscrew the cap (60) of the filling stop valve
(61).
• Screw the filling connection of the liquid gas
pump onto the filling stop valve (61).
Z Fuelling automatically ends when the tank's
capacity has been reached.
• After fuelling, unscrew the filling connection and screw the cap (60) of the filling
stop valve (61) back on.
08.12 EN
Vorgehensweise
• Close the dispensing valve (63).
• Unscrew the cap (60) of the filling stop valve
(61).
63 62 61 60 • Screw the filling connection of the liquid gas 63 62 61 60
pump onto the filling stop valve (61).
Z Fuelling automatically ends when the tank's
capacity has been reached.
• After fuelling, unscrew the filling connection and screw the cap (60) of the filling
stop valve (61) back on.

08.12 EN

49 49
4 Fuel level indicator 4 Fuel level indicator
4.1 Display unit 4.1 Display unit

The level indicator (64) shows the capacity of 64 The level indicator (64) shows the capacity of 64
the tank (only for DFG). the tank (only for DFG).
If the indicator (64) shows the reserve range, If the indicator (64) shows the reserve range,
fill the tank. This is also displayed by the fill the tank. This is also displayed by the
spare indicator (65). R
R R A
spare indicator (65). R
R R A

R R
+ R V R + R V R
A V A V

65 65

4.2 Level indicator for LPG bottles (o) 4.2 Level indicator for LPG bottles (o)
When the level indicator for LPG bottles (o) is lit, this indicates that the LPG bottle is When the level indicator for LPG bottles (o) is lit, this indicates that the LPG bottle is
empty. empty.

The remaining travel time will be 8 - 12 minutes, depending on the application and The remaining travel time will be 8 - 12 minutes, depending on the application and
ambient conditions. ambient conditions.

Z Fluctuations in the liquid gas level caused by the travel mode can cause the level Z Fluctuations in the liquid gas level caused by the travel mode can cause the level
indicator to light up briefly. Only a permanently lit level indicator means that the LPG indicator to light up briefly. Only a permanently lit level indicator means that the LPG
bottle is almost empty. bottle is almost empty.

08.12 EN

08.12 EN
50 50
 E Operation E Operation
1 Safety Regulations for the Operation of the 1 Safety Regulations for the Operation of the
Forklift Truck Forklift Truck
Driver authorisation Driver authorisation
The truck may only be used by suitably trained personnel, who have demonstrated to The truck may only be used by suitably trained personnel, who have demonstrated to
the proprietor or his representative that they can drive and handle loads and have the proprietor or his representative that they can drive and handle loads and have
been authorised to operate the truck by the proprietor or his representative. been authorised to operate the truck by the proprietor or his representative.

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

Unauthorised use of truck Unauthorised use of truck

The driver is responsible for the truck during the time it is in use. The driver must The driver is responsible for the truck during the time it is in use. The driver must
prevent unauthorised persons from driving or operating the truck. Do not carry prevent unauthorised persons from driving or operating the truck. Do not carry
passengers or lift other people. passengers or lift other people.

Damage and faults Damage and faults

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

Repairs Repairs
The driver must not carry out any repairs or alterations to the truck without the The driver must not carry out any repairs or alterations to the truck without the
necessary training and authorisation to do so. The driver must never disable or adjust necessary training and authorisation to do so. The driver must never disable or adjust
safety mechanisms or switches. safety mechanisms or switches.
08.12 EN

08.12 EN

51 51
 Hazardous area Hazardous area

WARNING!
Risk of accidents / injury in the hazardous area of the truck
The hazardous area is defined as the area in which a person is at risk due to truck
movement, lifting operations, the load handler (e.g. forks or attachments) or the load
itself. This also includes areas which can be reached by falling loads or lowering
operating equipment.
XInstruct unauthorised people to leave the hazardous area.
XGive a warning signal with plenty of time for people to leave.
XIf unauthorised personnel are still within the hazardous area stop the truck
immediately.
WARNING!
Risk of accidents / injury in the hazardous area of the truck
The hazardous area is defined as the area in which a person is at risk due to truck
movement, lifting operations, the load handler (e.g. forks or attachments) or the load
itself. This also includes areas which can be reached by falling loads or lowering
operating equipment.
XInstruct unauthorised people to leave the hazardous area.
XGive a warning signal with plenty of time for people to leave.
XIf unauthorised personnel are still within the hazardous area stop the truck
immediately.

DANGER! DANGER!

Accident risk Accident risk

XThe driver must remain within the protected area of the overhead guard while the XThe driver must remain within the protected area of the overhead guard while the
truck is being operated. truck is being operated.

Safety devices and warning labels Safety devices and warning labels
Safety devices, warning signs ((see "Identification points and data plates" on Safety devices, warning signs ((see "Identification points and data plates" on
page 30)) and warning instructions in the present operating instructions must be page 30)) and warning instructions in the present operating instructions must be
strictly observed. strictly observed.

CAUTION! CAUTION!
Reduced headroom can cause injuries Reduced headroom can cause injuries
XTrucks with reduced headroom are equipped with a warning label within the driver's XTrucks with reduced headroom are equipped with a warning label within the driver's
line of sight. The max. recommended body size indicated on this sign must be line of sight. The max. recommended body size indicated on this sign must be
observed. observed.
XThe headroom is also reduced when you wear a protective helmet. XThe headroom is also reduced when you wear a protective helmet.

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 2 Displays and Controls 2 Displays and Controls

66 67 68 69 70 71 72 66 67 68 69 70 71 72

73 73

74 74

75 75

76 76

77 77
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53 53
 Item Control / Function Item Control / Function
Display Display
Emergency Disconnect t Switches control current on and off in Emergency Disconnect t Switches control current on and off in
66 66
switch emergencies switch emergencies
Slow travel / brake pedal t 1st zone: controls slow travel. Slow travel / brake pedal t 1st zone: controls slow travel.
67 67
2nd zone: applies service brake. 2nd zone: applies service brake.
68 Brake pedal t Upon activation, the truck brakes to a halt 68 Brake pedal t Upon activation, the truck brakes to a halt
immediately. immediately.
69 Accelerator pedal t Controls the engine speed and / travel and 69 Accelerator pedal t Controls the engine speed and / travel and
lift speeds. lift speeds.
70 Steering wheel t Steering the industrial truck. 70 Steering wheel t Steering the industrial truck.
71 Travel direction switch/ t – Selects travel direction / neutral position 71 Travel direction switch/ t – Selects travel direction / neutral position
gear selector – Gear selection gear selector – Gear selection
72 Steering column t Adjusts the steering column tilt. 72 Steering column t Adjusts the steering column tilt.
adjusting lever adjusting lever
73 Parking brake lever t To apply / release the parking brake: 73 Parking brake lever t To apply / release the parking brake:

– Pull up lever to engage. – Pull up lever to engage.

– Push lever forward to release. – Push lever forward to release.
74 SOLOPILOT t Operates the following functions: 74 SOLOPILOT t Operates the following functions:

– Load lifting lift/lower – Load lifting lift/lower

– Mast forward / reverse tilt – Mast forward / reverse tilt
– Sideshifter left / right (o) – Sideshifter left / right (o)
– Auxiliary hydraulics (o) – Auxiliary hydraulics (o)
75 Options switch t Options 75 Options switch t Options
76 Horn t Activates an audible warning. 76 Horn t Activates an audible warning.
77 Key switch t Switches power supply on and off. 77 Key switch t Switches power supply on and off.
Starts and stops the engine. Starts and stops the engine.
O - All main circuits are switched off and the O - All main circuits are switched off and the
key can be removed. key can be removed.
I - All consumers off I - All consumers off
II -All consumers on II -All consumers on
pre-heat - Pre-heat pre-heat - Pre-heat
III - Starting the motor (automatically returns III - Starting the motor (automatically returns
to the II position). to the II position).

t= Series equipment o= Optional equipment t= Series equipment o= Optional equipment

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 2.1 Display unit 2.1 Display unit
The control panel display unit shows the operating data, the battery charge, the The control panel display unit shows the operating data, the battery charge, the
service hours and error details and information. Pictograms in the left top section of service hours and error details and information. Pictograms in the left top section of
the control panel act as warning indicators. the control panel act as warning indicators.

2.1.1 Graphical displays 2.1.1 Graphical displays

78 64 79 80 81 82 83 84 78 64 79 80 81 82 83 84

R R
R R A R A R R A R A

R R
+ R V R R R + R V R R R
A V A V

91 90 89 88 65 87 86 85 84 91 90 89 88 65 87 86 85 84

Item Control / Function Item Control / Function

Display Display
64 t Graphic illustration of the fuel supply. 64 t Graphic illustration of the fuel supply.
Fuel display (DFG) Fuel display (DFG)

65 R Fuel supply indicator t When lit, indicates the fuel supply is 65 R Fuel supply indicator t When lit, indicates the fuel supply is
(DFG) too low. (DFG) too low.

78 R
Parking brake t Parking brake activated 78 R
Parking brake t Parking brake activated
warning indicator – Truck operational, parking brake warning indicator – Truck operational, parking brake
active. active.
79 Coolant temperature t Indicates the coolant temperature. 79 Coolant temperature t Indicates the coolant temperature.
display display

t When lit, indicates the brake fluid level t When lit, indicates the brake fluid level
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80 R Brake fluid indicator 80 R Brake fluid indicator

is too low. is too low.

55 55
 Item Control / Function Item Control / Function
Display Display
81 R Not used t 81 R Not used t

82 A Dipped lights t Switches dipped lights on and off. 82 A Dipped lights t Switches dipped lights on and off.

83 R Engine oil pressure t When lit, indicates that the engine oil 83 R Engine oil pressure t When lit, indicates that the engine oil
display pressure is too low. display pressure is too low.

84 Not used o 84 Not used o

85 R Converter
temperature indicator
86 R Seat belt indicator
t When lit, indicates that the oil 85 R Converter t When lit, indicates that the oil
temperature in the power shift temperature indicator temperature in the power shift
transmission is too high. transmission is too high.
o When lit indicates that the seat belt 86 R Seat belt indicator o When lit indicates that the seat belt
has not been properly attached. has not been properly attached.

V Flashing indicator o Right / left indicator lamps activated V Flashing indicator o Right / left indicator lamps activated
87 87

88 V Neutral position t When lit, indicates that the travel 88 V Neutral position t When lit, indicates that the travel
direction switch is in neutral. direction switch is in neutral.

89 Time / service hours t Indicates the time or number of 89 Time / service hours t Indicates the time or number of
display operating hours in service. display operating hours in service.

90 A Pre-heat indicator t Engine is preheated (DFG only). 90 A Pre-heat indicator t Engine is preheated (DFG only).
lamp lamp

91 R Charge current t Battery not charging. 91 R Charge current t Battery not charging.
+ +
indicator indicator

t= Series equipment o= Optional equipment t= Series equipment o= Optional equipment

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 2.2 Instrument panel switches (o) 2.2 Instrument panel switches (o)

Display Function Display Function

Rear windscreen Switches rear windscreen wiper on and Rear windscreen Switches rear windscreen wiper on and
wiper off. wiper off.

Front windscreen Switches the front windscreen washing Front windscreen Switches the front windscreen washing
washing system system on and off. washing system system on and off.
Front windscreen Switches the window wiper on and off. Front windscreen Switches the window wiper on and off.
wiper wiper
Parking light Switches parking light on and off. Parking light Switches parking light on and off.

Rear work lights Switches rear work lights on and off. Rear work lights Switches rear work lights on and off.

Dipped lights Switches dipped lights on and off. Dipped lights Switches dipped lights on and off.

Front work lights Switches front work lights on and off. Front work lights Switches front work lights on and off.

Warning indicator Switches the warning indicator on and off. Warning indicator Switches the warning indicator on and off.

Rear windscreen Switches rear windscreen heating on and Rear windscreen Switches rear windscreen heating on and
heating off. heating off.

Z The arrangement of switches and buttons on the dashboard and engine cover is Z The arrangement of switches and buttons on the dashboard and engine cover is
customised to customer preference. customised to customer preference.
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2.3 Travel direction switch/gear selector 2.3 Travel direction switch/gear selector

2.3.1 Travel direction switch 2.3.1 Travel direction switch

NOTE NOTE

The engine will not start when the travel The engine will not start when the travel
direction switch is in the forward or direction switch is in the forward or
reverse position. reverse position.

Z When the travel direction switch is in the Z When the travel direction switch is in the
middle position, the gear is in neutral. middle position, the gear is in neutral.

Procedure Procedure
• To select the forward gear, push the • To select the forward gear, push the
travel direction switch forward. travel direction switch forward.
• To select the reverse gear, push the • To select the reverse gear, push the
travel direction switch back. travel direction switch back.

2.3.2 Gear selector 2.3.2 Gear selector

Gears are selected manually. When travelling Gears are selected manually. When travelling
on a slope, press ‘I’ to select a lower gear. on a slope, press ‘I’ to select a lower gear.

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58 58
 3 Preparing the Truck for Operation 3 Preparing the Truck for Operation
3.1 Checks and operations to be performed before starting daily 3.1 Checks and operations to be performed before starting daily
operation operation

WARNING! WARNING!

Damage and other truck or attachment (special equipment) defects can result
in accidents.
If damage or other truck or attachment (special equipment) defects are discovered
during the following checks, the truck must be taken out of service until it has been
repaired.
XReport any defects immediately to your supervisor.
XTag out and decommission a faulty lift truck.
XOnly return the truck to service when you have identified and rectified the fault.
Damage and other truck or attachment (special equipment) defects can result
in accidents.
If damage or other truck or attachment (special equipment) defects are discovered
during the following checks, the truck must be taken out of service until it has been
repaired.
XReport any defects immediately to your supervisor.
XTag out and decommission a faulty lift truck.
XOnly return the truck to service when you have identified and rectified the fault.

CAUTION! CAUTION!
Checking the accelerator pedal Checking the accelerator pedal
XThe accelerator pedal should only be XThe accelerator pedal should only be
checked when the parking brake is checked when the parking brake is
applied and the engine is idle. applied and the engine is idle.
92 92
Inspection before starting daily operation Inspection before starting daily operation
93 93
Procedure Procedure
• Visually inspect the entire truck (in particular wheels, wheel bolts and load handler) • Visually inspect the entire truck (in particular wheels, wheel bolts and load handler)
for damage. for damage.
• Check the fork stop (92) and fork tine retainer (93). • Check the fork stop (92) and fork tine retainer (93).
• Visually inspect the hydraulic system in the visible area for damage and leaks. • Visually inspect the hydraulic system in the visible area for damage and leaks.
• Check the driver’s seat has been adjusted to the correct position. • Check the driver’s seat has been adjusted to the correct position.
• Test the horn and reversing buzzer (o) where applicable. • Test the horn and reversing buzzer (o) where applicable.
• Check that the load chart and warning labels are legible. • Check that the load chart and warning labels are legible.
• Test the controls and displays. • Test the controls and displays.
• Test the steering. • Test the steering.
• Make sure the load chains are evenly tensioned. • Make sure the load chains are evenly tensioned.
• Test the seat belt. (The belt should block if extracted suddenly.) • Test the seat belt. (The belt should block if extracted suddenly.)
• Test the seat switch. When the driver’s seat is vacated it should not be possible to • Test the seat switch. When the driver’s seat is vacated it should not be possible to
activate the working hydraulics. activate the working hydraulics.
• Test the restraint system (o), • Test the restraint system (o),
• Test the lift/lower, tilt and if applicable the attachment hydraulic control functions. • Test the lift/lower, tilt and if applicable the attachment hydraulic control functions.
• Check the accelerator pedal can move freely by pressing it several times. • Check the accelerator pedal can move freely by pressing it several times.
• Test the service and parking brakes: Approach carefully and test the effectiveness • Test the service and parking brakes: Approach carefully and test the effectiveness
of the brake pedal. of the brake pedal.
• Check the fuel supply. • Check the fuel supply.
• Check the fluid level of the windscreen washer system (o), (see "Adding window • Check the fluid level of the windscreen washer system (o), (see "Adding window
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washer system fluid" on page 150). washer system fluid" on page 150).
• Check the gas system is working correctly, (see "LPG containers" on page 46) • Check the gas system is working correctly, (see "LPG containers" on page 46)

59 59
3.2 Entry and exit 3.2 Entry and exit

Procedure Procedure
• Open the cab door (o) • Open the cab door (o)
• To enter and exit the cab, hold onto the • To enter and exit the cab, hold onto the
94 94
handle (94). handle (94).

Z An additional step is provided for the driver position extension (o) Z An additional step is provided for the driver position extension (o)

3.3 Trucks with reduced headroom X (o) 3.3 Trucks with reduced headroom X (o)

WARNING! WARNING!
An unsuitable workplace can damage An unsuitable workplace can damage
your health your health
Failure to observe the recommended Failure to observe the recommended
body size can cause stress and endanger body size can cause stress and endanger
the driver and may lead to lasting ill health the driver and may lead to lasting ill health
due to an unhealthy posture and due to an unhealthy posture and
excessive strain on the driver. excessive strain on the driver.
XThe owner must ensure that truck XThe owner must ensure that truck
operators do not exceed the maximum operators do not exceed the maximum
body size indicated. body size indicated.
XThe owner must check that the drivers XThe owner must check that the drivers
can sit in a normal and upright position can sit in a normal and upright position
without having to strain. without having to strain.
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 3.4 Setting up the operator position 3.4 Setting up the operator position

WARNING! WARNING!

Accident risk Accident risk

XDo not adjust the driver’s seat while travelling. XDo not adjust the driver’s seat while travelling.

Procedure
• Before starting to travel, adjust the driver’s seat, steering column and armrest (if
necessary) so that all the controls are within reach and can be applied without
having to strain.
• Adjust the visibility aid equipment (mirrors, camera systems etc.) so that the
working environment can be clearly seen.
Procedure
• Before starting to travel, adjust the driver’s seat, steering column and armrest (if
necessary) so that all the controls are within reach and can be applied without
having to strain.
• Adjust the visibility aid equipment (mirrors, camera systems etc.) so that the
working environment can be clearly seen.

3.4.1 Adjusting the driver’s seat 3.4.1 Adjusting the driver’s seat

WARNING! WARNING!

Risk of accidents and damage to health
An incorrectly adjusted driver’s seat can result in accidents and damage to health.
XDo not adjust the driver’s seat while travelling.
XThe driver’s seat should lock in position after adjustment.
XCheck and adjust the individual driver’s seat setting before starting to use the truck.
XHold the weight setting lever (95) only by the recess, do not reach through
underneath the lever.
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Risk of accidents and damage to health
An incorrectly adjusted driver’s seat can result in accidents and damage to health.
XDo not adjust the driver’s seat while travelling.
XThe driver’s seat should lock in position after adjustment.
XCheck and adjust the individual driver’s seat setting before starting to use the truck.
XHold the weight setting lever (95) only by the recess, do not reach through
underneath the lever.

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61 61
 Adjusting the driver's weight 96 95 Adjusting the driver's weight 96 95

NOTE NOTE

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

Procedure Procedure
• Fold out the weight adjustment lever • Fold out the weight adjustment lever
(95) as far as it will go in the arrow (95) as far as it will go in the arrow
97 98 99 100 97 98 99 100
direction direction
• Move the weight adjustment lever (95) up and down to set the seat to a higher • Move the weight adjustment lever (95) up and down to set the seat to a higher
weight. weight.
• Move the weight adjustment lever (95) up and down to set the seat to a lower • Move the weight adjustment lever (95) up and down to set the seat to a lower
weight. weight.
Z The driver's weight is correct when the arrow is in the middle of the display window Z The driver's weight is correct when the arrow is in the middle of the display window
(96). The minimum or maximum weight setting is reached when you can feel a (96). The minimum or maximum weight setting is reached when you can feel a
return stroke on the lever. return stroke on the lever.
• After setting the weight, move the lever (95) back in full. • After setting the weight, move the lever (95) back in full.
The driver’s weight is now set. The driver’s weight is now set.

Adjusting the backrest Adjusting the backrest

Procedure Procedure
• Sit on the driver’s seat. • Sit on the driver’s seat.
• Pull the lever (98) to adjust the backrest. • Pull the lever (98) to adjust the backrest.
• Adjust the backrest tilt. • Adjust the backrest tilt.
• Release the lever (98) again. The backrest is locked. • Release the lever (98) again. The backrest is locked.
The backrest is now set. The backrest is now set.

Z Hold the weight setting lever (95) only by the recess, never reach through Z Hold the weight setting lever (95) only by the recess, never reach through
underneath the lever. underneath the lever.
Driver’s seat with pneumatic weight adjustment (MSG 75) (o) Driver’s seat with pneumatic weight adjustment (MSG 75) (o)

Procedure Procedure
• Pull the weight adjustment lever (95) up to set the seat to a higher weight. • Pull the weight adjustment lever (95) up to set the seat to a higher weight.
• Push the weight adjustment lever (95) down to set the seat to a lower weight. • Push the weight adjustment lever (95) down to set the seat to a lower weight.
The driver's weight is correct when the arrow is in the middle of the display window The driver's weight is correct when the arrow is in the middle of the display window
(96). (96).
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62 62
 Adjusting the seat position Adjusting the seat position
96 95 96 95
CAUTION! CAUTION!
An unsecured driver's seat can cause An unsecured driver's seat can cause
injury injury
An unsecured driver's seat can slide out of An unsecured driver's seat can slide out of
its guide during travel, resulting in its guide during travel, resulting in
accidents. accidents.
XThe driver's seat must be locked in XThe driver's seat must be locked in
position. position.
XDo not adjust the driver’s seat while XDo not adjust the driver’s seat while
travelling. 97 98 99 100 travelling. 97 98 99 100
Procedure Procedure
• Sit on the driver’s seat. • Sit on the driver’s seat.
• Pull up the driver’s seat locking lever97 in the direction of the arrow. • Pull up the driver’s seat locking lever97 in the direction of the arrow.
• Push the driver’s seat forwards or backwards to the desired position • Push the driver’s seat forwards or backwards to the desired position
• Engage the driver’s seat locking lever (97) in position. • Engage the driver’s seat locking lever (97) in position.
The seat position is now correctly set. The seat position is now correctly set.

Adjusting the lumbar vertebrae 96 95 Adjusting the lumbar vertebrae 96 95

support (o) support (o)

Procedure Procedure
• Turn the hand wheel (100) to the • Turn the hand wheel (100) to the
required position. required position.
Position 0 = no warping in lumbar Position 0 = no warping in lumbar
vertebrae area. vertebrae area.
Position 1 = increasing warping in Position 1 = increasing warping in
upper lumbar vertebrae area. upper lumbar vertebrae area.
Position 2 = increasing warping in lower Position 2 = increasing warping in lower
lumbar vertebrae area. lumbar vertebrae area.
The lumbar vertebrae support is now set. 97 98 100 The lumbar vertebrae support is now set. 97 98 100
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63 63
3.4.2 Adjusting the steering wheel / steering column 3.4.2 Adjusting the steering wheel / steering column

CAUTION! CAUTION!

Do not adjust the steering wheel while travelling Do not adjust the steering wheel while travelling

Individual steering wheel position Individual steering wheel position

Z The tilt of the steering wheel can adjusted to suit the operator. Z The tilt of the steering wheel can adjusted to suit the operator.

Procedure
• Pull the steering wheel adjusting lever
(101) in the direction of the arrow (103).
• Tilt the steering wheel (3) forward or
backward as required.
• Push the steering wheel adjusting lever
(102) in the direction of the arrow.
3 3
Procedure
• Pull the steering wheel adjusting lever
(101) in the direction of the arrow (103).
• Tilt the steering wheel (3) forward or
backward as required.
101 102 • Push the steering wheel adjusting lever 101 102
(102) in the direction of the arrow.

103 103

3.4.3 Adjusting the armrest (o) 3.4.3 Adjusting the armrest (o)

Procedure Procedure
• Loosen the screw (104) and tilt the armrest up • Loosen the screw (104) and tilt the armrest up
or down. or down.
• Re-tighten the screw (104). • Re-tighten the screw (104).
• Loosen the screw (105) and set the armrest • Loosen the screw (105) and set the armrest
vertical. vertical.
• Re-tighten the screw (105). • Re-tighten the screw (105).
• Loosen the screw (106) and set the armrest • Loosen the screw (106) and set the armrest
horizontal. horizontal.
• Re-tighten the screw (106). 104 105 106 • Re-tighten the screw (106). 104 105 106
The armrest is now positioned. The armrest is now positioned.
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64 64
 3.5 Seat Belt
DANGER!
Travelling without a seat belt increases the risk of injury.
If the seat belt is not worn or is modified, personal injury can result.
XAlways put on the seat belt before starting the industrial truck.
XDo not modify the seat belt.
XDamaged or non-operational seat belts must be replaced by trained personnel.
XSeat belts must always be replaced after an accident.
XOnly original spare parts must be used for retrofits or repairs.
Z Protect the seat belt from contamination (e.g. cover it when the truck is idle) and
clean it regularly. Frozen belt locks or pulleys must be thawed out and dried to
prevent them from freezing up again.
The temperature of the warm air should not exceed +60 °C!
Starting the industrial truck on steep slopes
The automatic blocking system locks the belt in the retractor when the truck is
positioned on a steep slope. This prevents the belt from being pulled out of the
retractor.
Z Carefully drive the truck off the slope and then put on the belt.
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65
3.5 Seat Belt
DANGER!
Travelling without a seat belt increases the risk of injury.
If the seat belt is not worn or is modified, personal injury can result.
XAlways put on the seat belt before starting the industrial truck.
XDo not modify the seat belt.
XDamaged or non-operational seat belts must be replaced by trained personnel.
XSeat belts must always be replaced after an accident.
XOnly original spare parts must be used for retrofits or repairs.
Z Protect the seat belt from contamination (e.g. cover it when the truck is idle) and
clean it regularly. Frozen belt locks or pulleys must be thawed out and dried to
prevent them from freezing up again.
The temperature of the warm air should not exceed +60 °C!
Starting the industrial truck on steep slopes
The automatic blocking system locks the belt in the retractor when the truck is
positioned on a steep slope. This prevents the belt from being pulled out of the
retractor.
Z Carefully drive the truck off the slope and then put on the belt.
65
4 Industrial Truck Operation
4.1 Safety regulations for truck operation
Travel routes and work areas
Only use lanes and routes specifically designated for truck traffic. Unauthorised third
parties must stay away from work areas. Loads must only be stored in places
specially designated for this purpose.
The truck must only be operated in work areas with sufficient lighting to avoid danger
to personnel and materials. Additional equipment is necessary to operate the truck in
areas of insufficient lighting.
DANGER!
Do not exceed the permissible surface and spot load limits on the travel routes.
At blind spots get a second person to assist.
The driver must ensure that the loading dock / ramp cannot move or come loose
during loading / unloading.
NOTE
Loads must not be deposited on travel or escape routes, in front of safety
mechanisms or operating equipment that must be accessible at all times.
Travel conduct
The driver must adapt the travel speed to local conditions. The truck must be driven
at slow speed when negotiating bends or narrow passageways, when passing
through swing doors and at blind spots. The driver must always observe an adequate
braking distance between the forklift truck and the vehicle in front and must be in
control of the truck at all times. Abrupt stopping (except in emergencies), rapid U turns
and overtaking at dangerous or blind spots are not permitted. Do not lean out or reach
beyond the working and operating area.
Hazardous situations
If the truck is about to tip over, do not loosen the seat belt. The driver must not jump
off the truck. The driver must lean his upper body over the steering wheel and hold
on with both hands. Tilt your body in the opposite direction of fall.
Travel visibility
The driver must look in the direction of travel and must always have a clear view of
the route ahead. Loads that affect visibility must be positioned at the rear of the truck.
If this is not possible, a second person must walk alongside the truck as a lookout to
observe the travel route while maintaining eye contact with the driver. Proceed only
at walking pace and with particular care. Stop the truck as soon as you lose eye
contact.
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66
4 Industrial Truck Operation
4.1 Safety regulations for truck operation
Travel routes and work areas
Only use lanes and routes specifically designated for truck traffic. Unauthorised third
parties must stay away from work areas. Loads must only be stored in places
specially designated for this purpose.
The truck must only be operated in work areas with sufficient lighting to avoid danger
to personnel and materials. Additional equipment is necessary to operate the truck in
areas of insufficient lighting.
DANGER!
Do not exceed the permissible surface and spot load limits on the travel routes.
At blind spots get a second person to assist.
The driver must ensure that the loading dock / ramp cannot move or come loose
during loading / unloading.
NOTE
Loads must not be deposited on travel or escape routes, in front of safety
mechanisms or operating equipment that must be accessible at all times.
Travel conduct
The driver must adapt the travel speed to local conditions. The truck must be driven
at slow speed when negotiating bends or narrow passageways, when passing
through swing doors and at blind spots. The driver must always observe an adequate
braking distance between the forklift truck and the vehicle in front and must be in
control of the truck at all times. Abrupt stopping (except in emergencies), rapid U turns
and overtaking at dangerous or blind spots are not permitted. Do not lean out or reach
beyond the working and operating area.
Hazardous situations
If the truck is about to tip over, do not loosen the seat belt. The driver must not jump
off the truck. The driver must lean his upper body over the steering wheel and hold
on with both hands. Tilt your body in the opposite direction of fall.
Travel visibility
The driver must look in the direction of travel and must always have a clear view of
the route ahead. Loads that affect visibility must be positioned at the rear of the truck.
If this is not possible, a second person must walk alongside the truck as a lookout to
observe the travel route while maintaining eye contact with the driver. Proceed only
at walking pace and with particular care. Stop the truck as soon as you lose eye
contact.
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66
 Negotiating slopes and inclines
Negotiating slopes or inclines up to 15% is only permitted if they are specifically
designed as travel routes, are clean and have a non-slip surface and providing they
can be safely travelled along in accordance with the truck's technical specifications.
The truck must always be driven with the load unit facing uphill. The industrial truck
must not be turned, operated at an angle or parked on inclines or slopes. Inclines
must only be negotiated at slow speed, with the driver ready to brake at any moment.
Particular care is required when travelling near slopes and quay walls.
Negotiating lifts and docks
Lifts may only be entered if they have sufficient capacity, are suitable for driving on
and authorised for truck traffic by the owner. The driver must satisfy himself of the
above before entering these areas. The truck must enter lifts with the load in front and
must take up a position which does not allow it to come into contact with the walls of
the lift shaft. People travelling in the lift with the forklift truck must only enter the lift
after the truck has come to a halt and must exit the lift before the truck. The driver
must ensure that the loading ramp / bridge cannot move or come loose during loading
/ unloading.
Type of loads to be carried
The operator must make sure that the load is in a satisfactory condition. Loads must
always be positioned safely and carefully. Use suitable precautions to prevent parts
of the load from tipping or falling down. Prevent liquid loads from sloshing out.
Inflammable liquids (e.g. fused metal etc.) may only be transported with suitable
auxiliary equipment. Contact your authorized Jungheinrich customer adviser.
Z For safety instructions on the nature of loads to be carried with attachments,(see
"Lifting, transporting and depositing loads" on page 79).
Towing trailers
The truck may only be used occasionally to tow trailers, (see "Towing trailers" on
page 93)
DANGER!
Exhaust emissions can be fatal
XThe truck must only be operated in well ventilated areas. If the truck is operated in
enclosed areas, this can lead to a build-up of harmful exhaust emissions, resulting
in dizziness, tiredness and even death.
XThe user must comply with legal requirements, technical standards and health and
safety regulations when operating an IC motor powered lift truck in closed rooms.
08.12 EN
08.12 EN
67
Negotiating slopes and inclines
Negotiating slopes or inclines up to 15% is only permitted if they are specifically
designed as travel routes, are clean and have a non-slip surface and providing they
can be safely travelled along in accordance with the truck's technical specifications.
The truck must always be driven with the load unit facing uphill. The industrial truck
must not be turned, operated at an angle or parked on inclines or slopes. Inclines
must only be negotiated at slow speed, with the driver ready to brake at any moment.
Particular care is required when travelling near slopes and quay walls.
Negotiating lifts and docks
Lifts may only be entered if they have sufficient capacity, are suitable for driving on
and authorised for truck traffic by the owner. The driver must satisfy himself of the
above before entering these areas. The truck must enter lifts with the load in front and
must take up a position which does not allow it to come into contact with the walls of
the lift shaft. People travelling in the lift with the forklift truck must only enter the lift
after the truck has come to a halt and must exit the lift before the truck. The driver
must ensure that the loading ramp / bridge cannot move or come loose during loading
/ unloading.
Type of loads to be carried
The operator must make sure that the load is in a satisfactory condition. Loads must
always be positioned safely and carefully. Use suitable precautions to prevent parts
of the load from tipping or falling down. Prevent liquid loads from sloshing out.
Inflammable liquids (e.g. fused metal etc.) may only be transported with suitable
auxiliary equipment. Contact your authorized Jungheinrich customer adviser.
Z For safety instructions on the nature of loads to be carried with attachments,(see
"Lifting, transporting and depositing loads" on page 79).
Towing trailers
The truck may only be used occasionally to tow trailers, (see "Towing trailers" on
page 93)
DANGER!
Exhaust emissions can be fatal
XThe truck must only be operated in well ventilated areas. If the truck is operated in
enclosed areas, this can lead to a build-up of harmful exhaust emissions, resulting
in dizziness, tiredness and even death.
XThe user must comply with legal requirements, technical standards and health and
safety regulations when operating an IC motor powered lift truck in closed rooms.
67
4.2 Preparing the truck for operation 4.2 Preparing the truck for operation

Before starting the truck Before starting the truck

Z The truck should only be operated from Z The truck should only be operated from
the driver’s seat. Do not run up the engine the driver’s seat. Do not run up the engine
in idle. The engine soon reaches operating in idle. The engine soon reaches operating
temperature at a moderate charge and temperature at a moderate charge and
when the speed alternates. Only fully when the speed alternates. Only fully
charge the engine once it has reached charge the engine once it has reached
operating temperature. operating temperature.

Requirements Requirements
– Checks and operations to be performed – Checks and operations to be performed
before starting daily operation, (see 107 108 before starting daily operation, (see 107 108
"Checks and operations to be performed "Checks and operations to be performed
before starting daily operation" on before starting daily operation" on
page 59). page 59).

Switching on the industrial truck Switching on the industrial truck

71 71
Procedure Procedure
• Unlock the Emergency Disconnect switch • Unlock the Emergency Disconnect switch
(107). To do this, raise the flap (108) and (107). To do this, raise the flap (108) and
pull up the Emergency Disconnect switch pull up the Emergency Disconnect switch
• Apply the parking brake. • Apply the parking brake.
• Set the travel direction switch (71) to • Set the travel direction switch (71) to
neutral N. Otherwise the motor cannot be neutral N. Otherwise the motor cannot be
started. started.
• Perform the appropriate starting • Perform the appropriate starting
procedure depending on the type of procedure depending on the type of
motor; see 4.2.1 "Starting procedure for motor; see 4.2.1 "Starting procedure for
the DFG" or 4.2.2 "Starting procedure for the DFG" or 4.2.2 "Starting procedure for
the TFG". the TFG".
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68 68
 4.2.1 Starting procedure for the DFG 4.2.1 Starting procedure for the DFG
Procedure Procedure
• •

• Insert the key in the key switch (77). Set
key switch to “II”.
• All the indicators light up briefly to test
operation.
Z All the indicators except for the engine oil
pressure display (83), parking brake
indicator (78), indicator lamp for neutral
(88) and charge current indicator (110)
should go out after a short while. If not,
stop the start-up process and rectify the
fault.
• Turn the ignition/starter switch further to
the PRE-HEAT setting and hold it there
for about 4 seconds.
• •
• Insert the key in the key switch (77). Set
key switch to “II”.
77 • All the indicators light up briefly to test 77
operation.
Z All the indicators except for the engine oil
pressure display (83), parking brake
indicator (78), indicator lamp for neutral
(88) and charge current indicator (110)
should go out after a short while. If not,
stop the start-up process and rectify the
fault.
• Turn the ignition/starter switch further to
the PRE-HEAT setting and hold it there
for about 4 seconds.

• Now set the ignition / starter key to the 78 83 • Now set the ignition / starter key to the 78 83
"III" position. "III" position.
Z Only apply the starter for a maximum of Z Only apply the starter for a maximum of
15 seconds without interruption. The 15 seconds without interruption. The
truck contains a restart blocking truck contains a restart blocking
mechanism which prevents it from mechanism which prevents it from
starting again while the engine is running. R
R R A R A
starting again while the engine is running. R
R R A R A

R R

• Release the key as soon as the engine • Release the key as soon as the engine
+ R V R R R + R V R R R
A V A V

starts. It automatically reverts to the "II"
setting.
Z All indicators lights except for neutral
setting (88) and parking brake (78), if
activated, should go out as soon as the 110
engine starts. If not, stop the engine
immediately and rectify the fault.
The truck is now ready for operation.
08.12 EN
starts. It automatically reverts to the "II"
setting.
Z All indicators lights except for neutral
setting (88) and parking brake (78), if
109 88 activated, should go out as soon as the 110 109 88
engine starts. If not, stop the engine
immediately and rectify the fault.
The truck is now ready for operation.

08.12 EN

69 69
4.2.2 Starting procedure for the TFG 4.2.2 Starting procedure for the TFG

DANGER! DANGER!

Risk of escaping liquid gas if the truck does not start Risk of escaping liquid gas if the truck does not start
XNote the safety regulations governing the handling of liquid gas XNote the safety regulations governing the handling of liquid gas
((see "Safety regulations for handling diesel fuel and LPG" on page 41)) ((see "Safety regulations for handling diesel fuel and LPG" on page 41))
XClose the gas bottle shut-off valve. XClose the gas bottle shut-off valve.
XSet the key switch to "O" XSet the key switch to "O"
XNotify your superior. XNotify your superior.

Procedure Procedure
• •

• Slowly open the shut-off valve on the
LPG bottle.
• Insert the key in the key switch (77). Set
key switch to “II”.
• All the indicators light up briefly to test
operation.
Z All the indicators except for the engine oil
pressure display (83), parking brake
indicator (78), indicator lamp for neutral
(88) and charge current indicator (110)
should go out after a short while. If not,
stop the start-up process and rectify the
fault.
• Slowly open the shut-off valve on the
LPG bottle.
77 • Insert the key in the key switch (77). Set 77
key switch to “II”.
• All the indicators light up briefly to test
operation.
Z All the indicators except for the engine oil
pressure display (83), parking brake
indicator (78), indicator lamp for neutral
(88) and charge current indicator (110)
should go out after a short while. If not,
stop the start-up process and rectify the
fault.

• •

• Now set the ignition / starter key to the 78 83 • Now set the ignition / starter key to the 78 83
"III" position. "III" position.
Z Only apply the starter for a maximum of Z Only apply the starter for a maximum of
15 seconds without interruption. The 15 seconds without interruption. The
truck contains a restart blocking truck contains a restart blocking
mechanism which prevents it from mechanism which prevents it from
starting again while the engine is running. R
R R A R A
starting again while the engine is running. R
R R A R A

R R

• Release the key as soon as the engine • Release the key as soon as the engine
+ R V R R R + R V R R R
A V A V

starts. It automatically reverts to the "II" starts. It automatically reverts to the "II"
setting. setting.
Z All indicators lights except for neutral Z All indicators lights except for neutral
setting (88) and parking brake (78) setting (88) and parking brake (78)
should go out as soon as the engine 110 88 should go out as soon as the engine 110 88
starts. If not, stop the engine immediately starts. If not, stop the engine immediately
and rectify the fault. and rectify the fault.
The truck is now ready for operation. The truck is now ready for operation.
08.12 EN

08.12 EN
70 70
 4.3 Parking the truck securely 4.3 Parking the truck securely

DANGER! DANGER!

Risk of explosion Risk of explosion

XLPG trucks may only be parked in ground level rooms or higher and providing they XLPG trucks may only be parked in ground level rooms or higher and providing they
are adequately ventilated. They must not be parked near to cellar doors and entry are adequately ventilated. They must not be parked near to cellar doors and entry
points, hollows, drains, drain inlets or other recesses below the parked truck. points, hollows, drains, drain inlets or other recesses below the parked truck.

WARNING! WARNING!

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

Parking and leaving the truck Parking and leaving the truck

Procedure Procedure
• Apply the parking brake, (see "Parking • Apply the parking brake, (see "Parking
brake" on page 76). brake" on page 76).
• Lower the load handler. • Lower the load handler.
• Turn the key in the key switch (77) to the • Turn the key in the key switch (77) to the
“0” position. “0” position.
• Remove the key from the key switch (77). • Remove the key from the key switch (77).
• Press the Emergency Disconnect switch • Press the Emergency Disconnect switch
(107) down. (107) down.
• Close the gas bottle (TFG only). • Close the gas bottle (TFG only).

107 77 107 77

Z TFG only: If the ignition key is set to “0” while the engine is running, the engine will
continue to run for a short time. This ensures that the remaining gas in the lines
between the engine and the automatic shutoff valve of the gas system is used up.
If the engine has accidentally switched off, start up the engine and switch it off again
in the correct manner at the end of the journey.
08.12 EN
Z TFG only: If the ignition key is set to “0” while the engine is running, the engine will
continue to run for a short time. This ensures that the remaining gas in the lines
between the engine and the automatic shutoff valve of the gas system is used up.
If the engine has accidentally switched off, start up the engine and switch it off again
in the correct manner at the end of the journey.

08.12 EN

71 71
4.4 Emergency Disconnect 4.4 Emergency Disconnect

CAUTION! CAUTION!

Accident risk Accident risk

The operation of the Emergency Disconnect switch must not be affected by any The operation of the Emergency Disconnect switch must not be affected by any
objects placed in its way. objects placed in its way.

107 107
Applying the Emergency Disconnect Applying the Emergency Disconnect
Procedure Procedure
• Press the Emergency Disconnect • Press the Emergency Disconnect
switch (107) down. switch (107) down.
All electrical functions are deactivated. The All electrical functions are deactivated. The
truck coasts. truck coasts.

08.12 EN

08.12 EN
72 72
 4.5 Travel 4.5 Travel

WARNING! WARNING!

Improper travel can result in accidents Improper travel can result in accidents
XDo not get up from the driver’s seat during travel. XDo not get up from the driver’s seat during travel.
XDo not drive the truck unless your are wearing a seat belt and the panels and doors XDo not drive the truck unless your are wearing a seat belt and the panels and doors
are properly locked. are properly locked.
XMake sure that the travel area is clear. XMake sure that the travel area is clear.
XAdapt the travel speed to the conditions of the route, the work area and the load. XAdapt the travel speed to the conditions of the route, the work area and the load.
XTilt the mast back and raise the fork carriage approx. 200 mm. XTilt the mast back and raise the fork carriage approx. 200 mm.
XMake sure you have enough visibility when reversing. XMake sure you have enough visibility when reversing.

Travel Travel

Requirements Requirements
– Truck prepared for operation, (see – Truck prepared for operation, (see
"Preparing the truck for operation" on "Preparing the truck for operation" on
page 68). page 68).

Procedure Procedure
• Release the parking brake. • Release the parking brake.
• Choose the travel direction with the travel • Choose the travel direction with the travel
direction switch (71). direction switch (71).

NOTE NOTE
Only change direction when the truck has Only change direction when the truck has
stopped. 71 69 stopped. 71 69

• To select the forward gear, push the • To select the forward gear, push the
switch forward. switch forward.
• To select the reverse gear, pull the switch back. • To select the reverse gear, pull the switch back.
• Raise the fork carriage approx. 200 mm. • Raise the fork carriage approx. 200 mm.
• Tilt the mast back. • Tilt the mast back.
• Apply the accelerator pedal (69). The travel speed is governed by the accelerator • Apply the accelerator pedal (69). The travel speed is governed by the accelerator
(69). (69).
The truck travels in the direction selected. The truck travels in the direction selected.

Neutral locking Neutral locking

If the driver leaves the truck without taking it out of gear, the truck will automatically
be set to neutral. To resume travel (sitting on the truck) all controls must be
deactivated, the travel direction switch must be set to neutral “N” and then the
required direction selected.
08.12 EN
If the driver leaves the truck without taking it out of gear, the truck will automatically
be set to neutral. To resume travel (sitting on the truck) all controls must be
deactivated, the travel direction switch must be set to neutral “N” and then the
required direction selected.

08.12 EN

73 73
 Slow travel / brake pedal
Requirements
– Truck ready for operation, (see "Preparing
the truck for operation" on page 68).
Procedure
• Apply the slow travel / brake pedal (67)
sensitively.
The Industrial truck moves slowly in the
selected travel direction and allows for
excellent shunting in confined areas.
Rapid lifting is possible at a slow travel
speed.
NOTE
The slow travel / brake pedal can also actuate the drum brakes but this is only
intended as a crawl speed aid. The pedal should not be used as a service brake. This
operating mode can only be used for max. 5 seconds when the engine is running at
high speed.
4.6 Steering
Steering
Procedure
Z Very little steering effort is required; you
should therefore turn the steering wheel
(70) sensitively.
• To negotiate a right-hand bend: Turn the
steering wheel clockwise according to the
required steering radius.
• To negotiate a left-hand bend: Turn the
steering wheel anti-clockwise according
to the required steering radius.
The truck travels in the direction selected.
74
67 Slow travel / brake pedal 67
Requirements
– Truck ready for operation, (see "Preparing
the truck for operation" on page 68).
Procedure
• Apply the slow travel / brake pedal (67)
sensitively.
The Industrial truck moves slowly in the
selected travel direction and allows for
excellent shunting in confined areas.
Rapid lifting is possible at a slow travel
speed.
NOTE
The slow travel / brake pedal can also actuate the drum brakes but this is only
intended as a crawl speed aid. The pedal should not be used as a service brake. This
operating mode can only be used for max. 5 seconds when the engine is running at
high speed.
4.6 Steering
70 Steering 70
Procedure
Z Very little steering effort is required; you
should therefore turn the steering wheel
(70) sensitively.
• To negotiate a right-hand bend: Turn the
steering wheel clockwise according to the
required steering radius.
• To negotiate a left-hand bend: Turn the
steering wheel anti-clockwise according
to the required steering radius.
The truck travels in the direction selected.
08.12 EN
08.12 EN
74
 4.7 Brakes 4.7 Brakes

WARNING! WARNING!

Accident risk Accident risk

The brake pattern of the truck depends largely on the ground conditions.
XThe driver must be aware of travel route conditions and them into account when
braking.
XBrake with care to prevent the load from slipping.
XAllow for increased braking distance when travelling with an attached load.
The brake pattern of the truck depends largely on the ground conditions.
XThe driver must be aware of travel route conditions and them into account when
braking.
XBrake with care to prevent the load from slipping.
XAllow for increased braking distance when travelling with an attached load.

4.7.1 Service brake 4.7.1 Service brake

67 67
The brake pedal hydraulically actuates the The brake pedal hydraulically actuates the
drum brakes of the front wheels. drum brakes of the front wheels.

When the brake pedal (68) is applied the When the brake pedal (68) is applied the
drum brakes are applied without drum brakes are applied without
disengaging the transmission. disengaging the transmission.

Applying the slow travel / brake pedal (67) Applying the slow travel / brake pedal (67)
controls the flow of power in the power shift controls the flow of power in the power shift
gear. This pedal can also be used to brake gear. This pedal can also be used to brake
gently during crawl speed operations. gently during crawl speed operations.

68 68
08.12 EN

08.12 EN

75 75
4.7.2 Parking brake 4.7.2 Parking brake

DANGER! DANGER!

Accident risk Accident risk

XThe parking brake will hold the truck with maximum load on a clean ground surface,
on inclines of up to 15%.
XDo not park and abandon the truck on an incline.
XApplying the parking brake during travel will cause the truck to brake to a standstill.
This may cause the load to slide off the forks tines. There is a higher risk of
accidents and injury!
XWhen leaving the industrial truck, always engage the parking brake. An audible
warning will sound if the parking brake is not applied.
XThe parking brake will hold the truck with maximum load on a clean ground surface,
on inclines of up to 15%.
XDo not park and abandon the truck on an incline.
XApplying the parking brake during travel will cause the truck to brake to a standstill.
This may cause the load to slide off the forks tines. There is a higher risk of
accidents and injury!
XWhen leaving the industrial truck, always engage the parking brake. An audible
warning will sound if the parking brake is not applied.

Z The parking brake can be used as an emergency brake. Z The parking brake can be used as an emergency brake.

73 111 73 111
Procedure Procedure
• Pull back the parking brake lever (73) • Pull back the parking brake lever (73)
beyond the pressure point as far as beyond the pressure point as far as
the stop. The parking brake is the stop. The parking brake is
engaged and the parking brake lever engaged and the parking brake lever
is locked in this position. is locked in this position.
• Press the release knob (111) and • Press the release knob (111) and
push the parking brake lever forward push the parking brake lever forward
to release the parking brake. to release the parking brake.

08.12 EN

08.12 EN
76 76
 4.8 Adjusting the forks 4.8 Adjusting the forks

WARNING! WARNING!

Trapping hazard Trapping hazard

There is a trapping hazard when you There is a trapping hazard when you
perform this operation. perform this operation.
XWear work gloves and safety shoes. XWear work gloves and safety shoes.

WARNING! WARNING!

Unsecured and incorrectly adjusted 93 Unsecured and incorrectly adjusted 93

forks can cause accidents forks can cause accidents
Before adjusting the forks make sure the Before adjusting the forks make sure the
retaining bolts (93) are fitted. retaining bolts (93) are fitted.
XAdjust the forks so that both forks are XAdjust the forks so that both forks are
equidistant from the outside edge of the equidistant from the outside edge of the
fork carriage. fork carriage.
XEngage the locking pin in a groove to XEngage the locking pin in a groove to
prevent the forks from moving prevent the forks from moving
accidentally. accidentally.
XThe load centre of gravity must be XThe load centre of gravity must be
located centrally between the forks. located centrally between the forks.

Adjusting the forks Adjusting the forks

Requirements Requirements
– Park the truck securely, (see "Parking the 112 – Park the truck securely, (see "Parking the 112
truck securely" on page 71). truck securely" on page 71).

Procedure 113 Procedure 113

• Lift up the locking lever (112). 114 • Lift up the locking lever (112). 114
• Push the forks (113) into the correct position • Push the forks (113) into the correct position
on the fork carriage (114). on the fork carriage (114).
Z To lift the load securely, the forks (113) must Z To lift the load securely, the forks (113) must
be spread as far apart as possible and be spread as far apart as possible and
positioned centrally with respect to the fork positioned centrally with respect to the fork
carriage. The load centre of gravity must be centrally aligned between the forks carriage. The load centre of gravity must be centrally aligned between the forks
(113). (113).
• Lift the locking lever down (112) and move the forks until the locking pin engages • Lift the locking lever down (112) and move the forks until the locking pin engages
in a slot. in a slot.
The forks are now adjusted. The forks are now adjusted.
08.12 EN

08.12 EN

77 77
4.9 Replacing the forks 4.9 Replacing the forks

WARNING! WARNING!

Unsecured forks can cause injury Unsecured forks can cause injury
You can injure your legs when replacing the forks. You can injure your legs when replacing the forks.
XNever pull the forks towards your body. XNever pull the forks towards your body.
XAlways push the forks away from your body. XAlways push the forks away from your body.
XSecure heavy forks with lifting slings and a crane before pushing them down from XSecure heavy forks with lifting slings and a crane before pushing them down from
the fork carriage. the fork carriage.
XAfter replacing the forks fit the retaining bolts (93) and make sure the bolts are XAfter replacing the forks fit the retaining bolts (93) and make sure the bolts are
seated correctly. Retaining bolt torque: 85 Nm. seated correctly. Retaining bolt torque: 85 Nm.

WARNING! WARNING!
92 92
Trapping hazard Trapping hazard
There is a trapping hazard when you There is a trapping hazard when you
perform this operation. perform this operation.
XWear work gloves and safety shoes. 93 XWear work gloves and safety shoes. 93

Replacing the forks Replacing the forks

Requirements Requirements
– Load handler lowered and forks not touching – Load handler lowered and forks not touching
the ground. the ground.

Procedure Procedure
• Disassemble the retaining bolts (93). • Disassemble the retaining bolts (93).
• Loosen the fork stop (92). • Loosen the fork stop (92).
• Carefully push the forks off the fork carriage. • Carefully push the forks off the fork carriage.
The forks are now dismantled from the fork carriage and can be replaced. The forks are now dismantled from the fork carriage and can be replaced.

08.12 EN

08.12 EN
78 78
 4.10 Lifting, transporting and depositing loads 4.10 Lifting, transporting and depositing loads

WARNING! WARNING!

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

Lifting load units Lifting load units

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

08.12 EN

79 79
 NOTE NOTE
Loads must not be deposited on travel or escape routes, in front of safety Loads must not be deposited on travel or escape routes, in front of safety
mechanisms or operating equipment that must be accessible at all times. mechanisms or operating equipment that must be accessible at all times.

Transporting load units Transporting load units

Requirements Requirements
– Load unit correctly lifted. – Load unit correctly lifted.
– Load handler lowered for transport (approx. 150 - 200 mm above the ground). – Load handler lowered for transport (approx. 150 - 200 mm above the ground).
– Mast tilted back fully. – Mast tilted back fully.

Procedure Procedure
• Accelerate and decelerate gradually. • Accelerate and decelerate gradually.
• Adapt your travel speed to the conditions of the route and the load you are • Adapt your travel speed to the conditions of the route and the load you are
transporting. transporting.
• Watch out for other traffic at crossings and passageways. • Watch out for other traffic at crossings and passageways.
• Always travel with a lookout at blind spots. • Always travel with a lookout at blind spots.
• On slopes and inclines always carry the load facing uphill, never approach at an • On slopes and inclines always carry the load facing uphill, never approach at an
angle or turn. angle or turn.

Depositing load units Depositing load units

Requirements Requirements
– Warehouse location suitable for storing the load. – Warehouse location suitable for storing the load.

Procedure Procedure
• Set the mast vertical. • Set the mast vertical.
• Drive carefully up to the storage location. • Drive carefully up to the storage location.
• Carefully lower the load handler so that the forks are clear of the load. • Carefully lower the load handler so that the forks are clear of the load.
Z Avoid depositing the load to avoid damaging the load and the load handler. Z Avoid depositing the load to avoid damaging the load and the load handler.
• Lower the load handler. • Lower the load handler.
• Carefully remove the forks from the pallet. • Carefully remove the forks from the pallet.
The load unit is lowered. 08.12 EN The load unit is lowered.

08.12 EN
80 80
 4.11 Operating the lift mechanism and integrated attachments
WARNING!
Accident risk when operating the lifting device and integrated attachments
Other people can be injured in the truck's hazardous area.
The hazardous area is defined as the area in which people are at risk from the truck
movement, the load handler, attachments etc. This also includes areas which can be
reached by falling loads or lowering operating equipment.
Apart from the operator (in the normal operating position) there should be no other
people in the truck's hazardous area.
XInstruct other people to move out of the hazardous area of the truck. Stop working
with the truck if people do not leave the hazardous area.
XThe truck must be prevented from being used by unauthorised people if people do
not leave the hazardous area despite the warning.
XOnly carry loads that have been correctly secured and positioned. Use suitable
protection measure to prevent parts of the load from tipping or falling down.
XNever exceed the maximum loads specified in the capacity chart.
XNever stand underneath a raised load handler.
XDo not stand on the load handler.
XDo not lift other people on the load handler.
XDo not reach through the mast.
XThe controls should only be operated from the driver’s seat, and never suddenly.
XThe driver must be instructed in how to operate the lifting device and the
attachments.
NOTE
When the driver's seat is not occupied, the control lever is mechanically locked
in centre position.
If the driver leaves the industrial truck without moving the travel direction switch to the
neutral, the control block will remain locked in the centre position at first when the
driver returns to the driver's seat. The control lever is not released again until the
driver has moved the travel direction switch to the neutral. This safety function also
takes effect if the driver gets up off the seat for longer than 1.5 seconds without
leaving the vehicle. In this case as well the transmission must be switched once to
neutral. If the industrial truck is equipped with belt lock control (o) the belt must also
be closed again to release the control lever.
Z When the controls are released they automatically revert to neutral and the lifting
mechanism remains in the position it has reached.
When the mechanical end stop has been reach for the relevant functions (there will
be a noise from the pressure relief valve) immediately move the control lever back to
its original position.
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81
4.11 Operating the lift mechanism and integrated attachments
WARNING!
Accident risk when operating the lifting device and integrated attachments
Other people can be injured in the truck's hazardous area.
The hazardous area is defined as the area in which people are at risk from the truck
movement, the load handler, attachments etc. This also includes areas which can be
reached by falling loads or lowering operating equipment.
Apart from the operator (in the normal operating position) there should be no other
people in the truck's hazardous area.
XInstruct other people to move out of the hazardous area of the truck. Stop working
with the truck if people do not leave the hazardous area.
XThe truck must be prevented from being used by unauthorised people if people do
not leave the hazardous area despite the warning.
XOnly carry loads that have been correctly secured and positioned. Use suitable
protection measure to prevent parts of the load from tipping or falling down.
XNever exceed the maximum loads specified in the capacity chart.
XNever stand underneath a raised load handler.
XDo not stand on the load handler.
XDo not lift other people on the load handler.
XDo not reach through the mast.
XThe controls should only be operated from the driver’s seat, and never suddenly.
XThe driver must be instructed in how to operate the lifting device and the
attachments.
NOTE
When the driver's seat is not occupied, the control lever is mechanically locked
in centre position.
If the driver leaves the industrial truck without moving the travel direction switch to the
neutral, the control block will remain locked in the centre position at first when the
driver returns to the driver's seat. The control lever is not released again until the
driver has moved the travel direction switch to the neutral. This safety function also
takes effect if the driver gets up off the seat for longer than 1.5 seconds without
leaving the vehicle. In this case as well the transmission must be switched once to
neutral. If the industrial truck is equipped with belt lock control (o) the belt must also
be closed again to release the control lever.
Z When the controls are released they automatically revert to neutral and the lifting
mechanism remains in the position it has reached.
When the mechanical end stop has been reach for the relevant functions (there will
be a noise from the pressure relief valve) immediately move the control lever back to
its original position.
81
 Controlling the speed of the lifting
device
71
Moving the lever and changing the engine
speed governs the operating speed of the
hydraulic cylinders. When the levers (116,
115) are released they automatically revert
to neutral and the lifting device remains in
the position it has reached.
Procedure
• Set the travel direction switch (71) to
neutral.
• Increase the motor speed with the
accelerator pedal (69) and
• Keep moving the lever back to increase
the speed of the lifting device.
Z The engine speed does not affect the
lowering speed of the fork carriage.
82
115 Controlling the speed of the lifting 115
device
71
Moving the lever and changing the engine
speed governs the operating speed of the
hydraulic cylinders. When the levers (116,
115) are released they automatically revert
to neutral and the lifting device remains in
the position it has reached.
Procedure
• Set the travel direction switch (71) to
neutral.
• Increase the motor speed with the
accelerator pedal (69) and
116 69 • Keep moving the lever back to increase 116 69
the speed of the lifting device.
Z The engine speed does not affect the
lowering speed of the fork carriage.
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82
 4.11.1 Operating the lift mechanism with the SOLO PILOT 4.11.1 Operating the lift mechanism with the SOLO PILOT

Lifting and lowering 117 Lifting and lowering 117

S S
Requirements Requirements
– To prepare the truck for operation, (see – To prepare the truck for operation, (see
"Preparing the truck for operation" on "Preparing the truck for operation" on
page 68) H page 68) H
Procedure Procedure
• Pull the Solo-Pilot lever (117) in direction H • Pull the Solo-Pilot lever (117) in direction H
to raise the load. to raise the load.
• Push the Solo-Pilot lever (117)in direction S • Push the Solo-Pilot lever (117)in direction S
to lower the load. to lower the load.
The load is now raised / lowered. The load is now raised / lowered.

Z When the limit position for the operation has been reached (there will be a noise Z When the limit position for the operation has been reached (there will be a noise
from the pressure relief valve) release the lever. The lever will revert automatically from the pressure relief valve) release the lever. The lever will revert automatically
to neutral. to neutral.

Tilting the mast forward / backward Tilting the mast forward / backward
118 118
Requirements V Requirements V
– To prepare the truck for operation, (see – To prepare the truck for operation, (see
"Preparing the truck for operation" on "Preparing the truck for operation" on
page 68) page 68)
R R
Procedure Procedure
• Pull the Solo-Pilot lever (118) in direction R • Pull the Solo-Pilot lever (118) in direction R
to tilt the mast back. to tilt the mast back.
• Push the Solo-Pilot lever (118) in direction V • Push the Solo-Pilot lever (118) in direction V
to tilt the mast forward. to tilt the mast forward.
The mast is now tilted back / forward. The mast is now tilted back / forward.

Z When the limit position for the operation has been reached (there will be a noise Z When the limit position for the operation has been reached (there will be a noise
from the pressure relief valve) release the lever. The lever will revert automatically from the pressure relief valve) release the lever. The lever will revert automatically
to neutral. to neutral.
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83 83
 Positioning the integrated sideshift (option) 119 Positioning the integrated sideshift (option) 119

Requirements Requirements
– Truck prepared for operation, (see V – Truck prepared for operation, (see V
"Preparing the truck for operation" on "Preparing the truck for operation" on
page 68). page 68).

Procedure
• Pull the SOLO-PILOT lever (119) in direction
R to move the load handler to the right (from
the driver’s viewpoint).
• Push the SOLO-PILOT lever (119) in
direction V to move the load handler to the
left (from the driver’s viewpoint).
The sideshifter is now positioned.
R Procedure R
• Pull the SOLO-PILOT lever (119) in direction
R to move the load handler to the right (from
the driver’s viewpoint).
• Push the SOLO-PILOT lever (119) in
direction V to move the load handler to the
left (from the driver’s viewpoint).
The sideshifter is now positioned.

Z When the limit position for the operation has been reached (there will be a noise Z When the limit position for the operation has been reached (there will be a noise
from the pressure relief valve) release the lever. The lever will revert automatically from the pressure relief valve) release the lever. The lever will revert automatically
to neutral. to neutral.

08.12 EN

08.12 EN
84 84
 Positioning the forks with an integrated 120 Positioning the forks with an integrated 120
fork adjuster (option) fork adjuster (option)

CAUTION! CAUTION!
A A
Do not use the fork adjuster to clamp Do not use the fork adjuster to clamp
loads. loads.

Requirements Z Requirements Z
– Truck prepared for operation, (see – Truck prepared for operation, (see
"Preparing the truck for operation" on "Preparing the truck for operation" on
page 68). page 68).

Procedure 121 Procedure 121

• Press the toggle switch (120) and at the • Press the toggle switch (120) and at the
same time pull the Solo Pilot (121) in direction Z: the forks will move towards each same time pull the Solo Pilot (121) in direction Z: the forks will move towards each
other. other.
• Press the toggle switch (120) and at the same time push the Solo Pilot (121) in • Press the toggle switch (120) and at the same time push the Solo Pilot (121) in
direction A: the forks will spread apart. direction A: the forks will spread apart.
The forks are now positioned. The forks are now positioned.

Synchronising the alignment of the fork 120 Synchronising the alignment of the fork 120
tines with an integrated fork adjuster tines with an integrated fork adjuster
(optional equipment) (optional equipment)

Requirements A Requirements A
– Truck ready for operation, (see "Preparing – Truck ready for operation, (see "Preparing
the truck for operation" on page 68). the truck for operation" on page 68).
– The fork tines are no longer aligned. – The fork tines are no longer aligned.
Z Z
Procedure Procedure
• Press the toggle switch (120) and at the • Press the toggle switch (120) and at the
same time push the SOLO-PILOT (121) in same time push the SOLO-PILOT (121) in
direction A and spread the fork tines apart direction A and spread the fork tines apart
as far as they will go. 121 as far as they will go. 121
• Press the toggle switch (120) and at the • Press the toggle switch (120) and at the
same time pull the SOLO-PILOT (121) in direction Z and bring the fork tines as same time pull the SOLO-PILOT (121) in direction Z and bring the fork tines as
close to each other as they will go. close to each other as they will go.
The fork tines are now synchronised. The fork tines are now synchronised.

Z When the limit position for the operation has been reached (there will be a noise Z When the limit position for the operation has been reached (there will be a noise
from the pressure relief valve) release the lever. The lever will revert automatically from the pressure relief valve) release the lever. The lever will revert automatically
to neutral. to neutral.
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85 85
4.12 Safety instructions for operating additional attachments
Z Optionally, trucks can be fitted with one or more auxiliary hydraulic functions to
operate attachments. The auxiliary hydraulics are indicated with HF4 and HF5.
Auxiliary hydraulic functions for exchangeable equipment are fitted with
replacement couplings on the fork carriage. To fit exchangeable equipment (see
"Fitting additional attachments" on page 91).
DANGER!
Attaching exchangeable equipment can result in accidents.
Other people can be damaged by attaching exchangeable equipment. Use only
exchangeable equipment which has been deemed safe after a risk analysis carried
out by the owner.
XOnly use attachments with a CE mark.
XOnly use attachments that have been designed by the attachment manufacturer for
use with the respective industrial truck.
XOnly use attachments that have been fitted for the purpose by the owner.
XMake sure the operator has been instructed in the use of the attachment and that
he uses it for its correct purpose.
XRe-assess the residual capacity of the truck and if it has been altered, attach an
additional capacity plate to the truck.
XNote the attachment manufacturer’s operating instructions.
XOnly use attachments that do not restrict visibility in the travel direction.
Z If visibility in the travel direction is impaired, the owner must carry out a risk analysis
to assess whether the truck needs to be fitted with auxiliary equipment such as a
camera system or mirrors. If such equipment is used, spend sufficient time
practicing travelling with them.
08.12 EN
86
4.12 Safety instructions for operating additional attachments
Z Optionally, trucks can be fitted with one or more auxiliary hydraulic functions to
operate attachments. The auxiliary hydraulics are indicated with HF4 and HF5.
Auxiliary hydraulic functions for exchangeable equipment are fitted with
replacement couplings on the fork carriage. To fit exchangeable equipment (see
"Fitting additional attachments" on page 91).
DANGER!
Attaching exchangeable equipment can result in accidents.
Other people can be damaged by attaching exchangeable equipment. Use only
exchangeable equipment which has been deemed safe after a risk analysis carried
out by the owner.
XOnly use attachments with a CE mark.
XOnly use attachments that have been designed by the attachment manufacturer for
use with the respective industrial truck.
XOnly use attachments that have been fitted for the purpose by the owner.
XMake sure the operator has been instructed in the use of the attachment and that
he uses it for its correct purpose.
XRe-assess the residual capacity of the truck and if it has been altered, attach an
additional capacity plate to the truck.
XNote the attachment manufacturer’s operating instructions.
XOnly use attachments that do not restrict visibility in the travel direction.
Z If visibility in the travel direction is impaired, the owner must carry out a risk analysis
to assess whether the truck needs to be fitted with auxiliary equipment such as a
camera system or mirrors. If such equipment is used, spend sufficient time
practicing travelling with them.
08.12 EN
86
 Safety instructions for sideshifter and fork adjuster attachments
WARNING!
When using multi fork adjusters (multi pallet clamps), restricted visibility and reduced
lateral tilt resistance can result in accidents.
XAdapt the travel speeds to the visibility and load.
XMake sure you have enough visibility when reversing.
Safety instructions for clamping attachments (e.g. baling clamps, barrel
clamps, grabs etc.)
WARNING!
Falling loads can cause accidents
This can result in malfunctions and the load can fall accidentally.
XClamping attachments may only be added to trucks which have a button to enable
additional hydraulic functions.
XClamping attachments must only be operated on trucks will auxiliary hydraulics
HF4 or HF5.
XWhen connecting the attachment make sure that the hydraulic lines of the
attachment are connected to the right ports, (see "Fitting additional attachments"
on page 91).
Safety instructions for rotary attachments
WARNING!
A non-centred centre of gravity can result in accidents
When using rotary devices and non-centred loads, the centre of gravity can be
displaced from the centre with a high risk of accidents.
XAdapt the travel speed to the load.
XLift the load from the centre.
Safety instructions for telescopic attachments
WARNING!
Accident risk from increased tipover hazard and reduced residual capacity
There is a greater tipover risk with extended telescopic attachments (e.g. reach
carriages, telescopic forks, telescopic crane booms).
XOnly use the telescopic function for stacking and retrieving.
XAlways retract the attachment fully during transport.
XAdapt the travel speed to changed load centre of gravity.
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87
Safety instructions for sideshifter and fork adjuster attachments
WARNING!
When using multi fork adjusters (multi pallet clamps), restricted visibility and reduced
lateral tilt resistance can result in accidents.
XAdapt the travel speeds to the visibility and load.
XMake sure you have enough visibility when reversing.
Safety instructions for clamping attachments (e.g. baling clamps, barrel
clamps, grabs etc.)
WARNING!
Falling loads can cause accidents
This can result in malfunctions and the load can fall accidentally.
XClamping attachments may only be added to trucks which have a button to enable
additional hydraulic functions.
XClamping attachments must only be operated on trucks will auxiliary hydraulics
HF4 or HF5.
XWhen connecting the attachment make sure that the hydraulic lines of the
attachment are connected to the right ports, (see "Fitting additional attachments"
on page 91).
Safety instructions for rotary attachments
WARNING!
A non-centred centre of gravity can result in accidents
When using rotary devices and non-centred loads, the centre of gravity can be
displaced from the centre with a high risk of accidents.
XAdapt the travel speed to the load.
XLift the load from the centre.
Safety instructions for telescopic attachments
WARNING!
Accident risk from increased tipover hazard and reduced residual capacity
There is a greater tipover risk with extended telescopic attachments (e.g. reach
carriages, telescopic forks, telescopic crane booms).
XOnly use the telescopic function for stacking and retrieving.
XAlways retract the attachment fully during transport.
XAdapt the travel speed to changed load centre of gravity.
87
 Safety instructions for attachments when transporting suspended loads
WARNING!
Swinging loads and a reduced residual capacity can result in accidents
XAdapt the travel speed to the load, less than walking pace.
XSecure swinging loads for example with lifting slings.
XReduce the residual capacity and have it certified by a expert.
Safety instructions for using loading buckets as attachments
WARNING!
Greater mast loading can cause accidents.
XWhen carrying out the daily checks and operations before starting, (see "Checks
and operations to be performed before starting daily operation" on page 59), in
particular attention check the fork carriage, mast rails and mast rollers for damage.
Safety notices for fork extensions:
WARNING!
Unsecured and excessive fork extensions can cause accidents.
XFor fork extensions with an open cross sectional area, only carry loads that are
resting along the entire length of the fork extension.
XOnly use fork extensions with the same fork cross section and minimum fork length
of the truck and which comply with the details on the fork extension data plate.
XThe basic fork length must be at least 60% of the length of the fork extension.
XLock the fork extensions onto the basic forks.
XWhen carrying out the daily checks and operations before starting, (see "Checks
and operations to be performed before starting daily operation" on page 59), also
check the fork extension lock.
XMark any fork extensions with an incomplete or faulty lock and take them out of
service.
XDo not use trucks with an incomplete or faulty fork extension lock. Replace the fork
extension.
XOnly restore the fork extension to service when the fault has been rectified.
XUse only fork extensions which have no dirt or foreign bodies near the entry
opening point. Clean the fork extensions as required.
08.12 EN
88
Safety instructions for attachments when transporting suspended loads
WARNING!
Swinging loads and a reduced residual capacity can result in accidents
XAdapt the travel speed to the load, less than walking pace.
XSecure swinging loads for example with lifting slings.
XReduce the residual capacity and have it certified by a expert.
Safety instructions for using loading buckets as attachments
WARNING!
Greater mast loading can cause accidents.
XWhen carrying out the daily checks and operations before starting, (see "Checks
and operations to be performed before starting daily operation" on page 59), in
particular attention check the fork carriage, mast rails and mast rollers for damage.
Safety notices for fork extensions:
WARNING!
Unsecured and excessive fork extensions can cause accidents.
XFor fork extensions with an open cross sectional area, only carry loads that are
resting along the entire length of the fork extension.
XOnly use fork extensions with the same fork cross section and minimum fork length
of the truck and which comply with the details on the fork extension data plate.
XThe basic fork length must be at least 60% of the length of the fork extension.
XLock the fork extensions onto the basic forks.
XWhen carrying out the daily checks and operations before starting, (see "Checks
and operations to be performed before starting daily operation" on page 59), also
check the fork extension lock.
XMark any fork extensions with an incomplete or faulty lock and take them out of
service.
XDo not use trucks with an incomplete or faulty fork extension lock. Replace the fork
extension.
XOnly restore the fork extension to service when the fault has been rectified.
XUse only fork extensions which have no dirt or foreign bodies near the entry
opening point. Clean the fork extensions as required.
08.12 EN
88
 4.13 Operating additional attachments for the SOLO-PILOT 4.13 Operating additional attachments for the SOLO-PILOT

WARNING! WARNING!

Incorrect symbols can cause accidents
Symbols on controls that do not depict the function of the attachments can cause
accidents.
XMark the controls with symbols that indicate their function.
XSpecify the attachments’ direction of movement in accordance with ISO 3691-1 so
that they match the controls’ direction of movement.
Incorrect symbols can cause accidents
Symbols on controls that do not depict the function of the attachments can cause
accidents.
XMark the controls with symbols that indicate their function.
XSpecify the attachments’ direction of movement in accordance with ISO 3691-1 so
that they match the controls’ direction of movement.

4.13.1 Solo Pilot with control of ZH1 hydraulic port 4.13.1 Solo Pilot with control of ZH1 hydraulic port

Z Depending on the attachments used the
lever (119) is assigned the function of the
attachment. Levers that are not required are
void. For connections (see "Fitting additional
attachments" on page 91).
119 Z Depending on the attachments used the 119
lever (119) is assigned the function of the
attachment. Levers that are not required are
V void. For connections (see "Fitting additional V
attachments" on page 91).

Procedure
• Operating the hydraulic port ZH1:
Move the lever (119) in direction V or R.
The attachment’s function is performed.
08.12 EN
Procedure
R • Operating the hydraulic port ZH1: R
Move the lever (119) in direction V or R.
The attachment’s function is performed.

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89 89
4.13.2 Solo Pilot with control of ZH1 and ZH2 hydraulic ports
Z Depending on the attachments used the
lever / button (119, 121, 120) is assigned
the function of the attachment. Levers that
are not required are void. For connections
(see "Fitting additional attachments" on
page 91).
Procedure
• Operating the hydraulic port ZH1:
Move the lever (119) in direction V or R.
• Operating the hydraulic port ZH2:
Press the toggle switch (120) and at the
same time move the lever (121) in the V or
R direction.
The attachment’s function is performed.
4.13.3 Solo Pilot with control of ZH1, ZH2 and ZH3 hydraulic ports
Z Functions are assigned to the levers /
buttons (119, 121, 120) depending on the
attachments used. Levers that are not
required are void. For connections (see
"Fitting additional attachments" on
page 91).
Procedure
• Operating the hydraulic port ZH1:
Move the lever (119) in direction V or R.
• Operating the hydraulic port ZH2:
Move the lever (121) in direction V or R.
• Operating the hydraulic port ZH3:
Press the toggle switch (120) and at the
same time move the lever (121) in the V or R direction.
The attachment’s function is performed.
90
4.13.2 Solo Pilot with control of ZH1 and ZH2 hydraulic ports
120
Z Depending on the attachments used the
120
V lever / button (119, 121, 120) is assigned V
the function of the attachment. Levers that
V are not required are void. For connections V
(see "Fitting additional attachments" on
R page 91). R
R Procedure R
121 • Operating the hydraulic port ZH1: 121
Move the lever (119) in direction V or R.
• Operating the hydraulic port ZH2:
Press the toggle switch (120) and at the
119 same time move the lever (121) in the V or 119
R direction.
The attachment’s function is performed.
4.13.3 Solo Pilot with control of ZH1, ZH2 and ZH3 hydraulic ports
120
Z Functions are assigned to the levers /
120
buttons (119, 121, 120) depending on the
attachments used. Levers that are not
required are void. For connections (see
V "Fitting additional attachments" on V
page 91).
Procedure
119 R • Operating the hydraulic port ZH1: 119 R
Move the lever (119) in direction V or R.
• Operating the hydraulic port ZH2:
Move the lever (121) in direction V or R.
121 • Operating the hydraulic port ZH3: 121
Press the toggle switch (120) and at the
same time move the lever (121) in the V or R direction.
The attachment’s function is performed.
08.12 EN
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90
 4.14 Fitting additional attachments 4.14 Fitting additional attachments

WARNING! WARNING!

Incorrectly connected attachments can cause accidents.
Attachments with incorrectly connected hydraulic attachments can result in
accidents.
XAttachments must only be assembled and commissioned by trained, specialist
personnel.
XNote the attachment manufacturer’s operating instructions.
XBefore commissioning, check the fasteners are positioned correctly and securely
and make sure they are complete.
XBefore commissioning, make sure the attachment is working correctly.
Incorrectly connected attachments can cause accidents.
Attachments with incorrectly connected hydraulic attachments can result in
accidents.
XAttachments must only be assembled and commissioned by trained, specialist
personnel.
XNote the attachment manufacturer’s operating instructions.
XBefore commissioning, check the fasteners are positioned correctly and securely
and make sure they are complete.
XBefore commissioning, make sure the attachment is working correctly.

Hydraulic ports Hydraulic ports

Requirements Requirements
– Non-pressurised hydraulic hoses. – Non-pressurised hydraulic hoses.
– The exchange ports on the truck are marked ZH2 and ZH3. – The exchange ports on the truck are marked ZH2 and ZH3.
– Attachment directions of movement defined to match the controls’ direction of – Attachment directions of movement defined to match the controls’ direction of
movement. movement.

Procedure
• Lower the fork carriage to the ground.
• Turn off the ignition (set the ignition / starter switch 0).
• Turn the ignition on again (set the ignition / starter switch I), but do not start the
motor.
• Move all levers as far as they will go in both directions several times. The driver's
seat must be occupied to do this. Otherwise the control lever will remain in neutral
• Attach the plug connector and engage it in position.
• Mark the controls with symbols that indicate their function.
The attachment is now hydraulically connected.
Procedure
• Lower the fork carriage to the ground.
• Turn off the ignition (set the ignition / starter switch 0).
• Turn the ignition on again (set the ignition / starter switch I), but do not start the
motor.
• Move all levers as far as they will go in both directions several times. The driver's
seat must be occupied to do this. Otherwise the control lever will remain in neutral
• Attach the plug connector and engage it in position.
• Mark the controls with symbols that indicate their function.
The attachment is now hydraulically connected.

WARNING! WARNING!
Hydraulic ports for clamping attachments Hydraulic ports for clamping attachments
XClamping attachments may only be added to trucks which have a button to enable XClamping attachments may only be added to trucks which have a button to enable
additional hydraulic functions. additional hydraulic functions.
XOn trucks with auxiliary hydraulics ZH2 the clamping function should only be XOn trucks with auxiliary hydraulics ZH2 the clamping function should only be
attached to the coupling pair marked ZH2. attached to the coupling pair marked ZH2.
XOn trucks with auxiliary hydraulics ZH3 the clamping function should only be XOn trucks with auxiliary hydraulics ZH3 the clamping function should only be
attached to the coupling pair marked ZH3. attached to the coupling pair marked ZH3.
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91 91
 Z Spilled hydraulic oil must be set using a suitable agent and disposed of in
accordance with environmental regulations.
If hydraulic oil comes into contact with the skin, wash it off immediately with soap
and water. If it comes into contact with the eyes rinse them immediately with flowing
water and call for a doctor.
Z Spilled hydraulic oil must be set using a suitable agent and disposed of in
accordance with environmental regulations.
If hydraulic oil comes into contact with the skin, wash it off immediately with soap
and water. If it comes into contact with the eyes rinse them immediately with flowing
water and call for a doctor.

08.12 EN

08.12 EN
92 92
 5 Towing trailers
DANGER!
Inappropriate speeds and excessive trailer loads can be dangerous
If you do not adapt your speed and / or use an excessive trailer load, the truck can
pull apart when cornering and braking.
XThe truck should only be used occasionally to tow trailers.
XThe overall weight of the trailer should not exceed the capacity indicated on the
capacity plate, (see "Identification points and data plates" on page 30). If a load is
also transported on the forks, the trailer load must be reduced by the same amount.
XDo not exceed the maximum speed of 5 km/h km/h.
XA truck must not be continually operated with trailers.
XDo not use supporting loads.
XTowing must only be performed on level, secure travel routes.
XThe owner must test trailer operation with the permissible tow load by means of a
trial run under the applicable operating conditions on site.
08.12 EN
08.12 EN
93
5 Towing trailers
DANGER!
Inappropriate speeds and excessive trailer loads can be dangerous
If you do not adapt your speed and / or use an excessive trailer load, the truck can
pull apart when cornering and braking.
XThe truck should only be used occasionally to tow trailers.
XThe overall weight of the trailer should not exceed the capacity indicated on the
capacity plate, (see "Identification points and data plates" on page 30). If a load is
also transported on the forks, the trailer load must be reduced by the same amount.
XDo not exceed the maximum speed of 5 km/h km/h.
XA truck must not be continually operated with trailers.
XDo not use supporting loads.
XTowing must only be performed on level, secure travel routes.
XThe owner must test trailer operation with the permissible tow load by means of a
trial run under the applicable operating conditions on site.
93
 Attaching the trailer Attaching the trailer

CAUTION!
Trapping hazard
There is a trapping risk when you attach a trailer.
XFollow the instructions of the coupling manufacturer if using special trailer
couplings.
XSecure the trailer to prevent it from rolling away before coupling it.
XDo not get caught between the truck and the tiller when coupling the trailer.
XThe tiller must be horizontal, tilted down by no more than 10° and never facing up.
CAUTION!
Trapping hazard
There is a trapping risk when you attach a trailer.
XFollow the instructions of the coupling manufacturer if using special trailer
couplings.
XSecure the trailer to prevent it from rolling away before coupling it.
XDo not get caught between the truck and the tiller when coupling the trailer.
XThe tiller must be horizontal, tilted down by no more than 10° and never facing up.

Attaching the trailer Attaching the trailer

Requirements Requirements
– Truck and trailer are on a level surface. – Truck and trailer are on a level surface.
– Trailer prevented from rolling away. – Trailer prevented from rolling away.

Procedure Procedure
• Push the tow pin (123) down and turn it • Push the tow pin (123) down and turn it
90°. 90°.
• Pull the tow pin up and insert the tiller of • Pull the tow pin up and insert the tiller of
the trailer into the opening. the trailer into the opening.
• Insert the tow pin, push it down, turn it • Insert the tow pin, push it down, turn it
90 degrees and engage it. 90 degrees and engage it.
The trailer is now attached to the truck. 123 122 The trailer is now attached to the truck. 123 122

Z To additionally ensure safe operation, the truck can be fitted with an electrical Z To additionally ensure safe operation, the truck can be fitted with an electrical
connection for trailers with lighting. connection for trailers with lighting.

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 6 Optional equipment 6 Optional equipment
6.1 Steel cab 6.1 Steel cab
For trucks fitted with a steel cabin, both doors can be closed. For trucks fitted with a steel cabin, both doors can be closed.

CAUTION! CAUTION!

An open door can cause accidents (124) An open door can cause accidents (124)
XDo not travel with an open door (124). When opening the door make sure there is XDo not travel with an open door (124). When opening the door make sure there is
nobody in the door’s swing range. nobody in the door’s swing range.
XAlways close the door tightly and make sure it is locked. XAlways close the door tightly and make sure it is locked.
XClosing the door does not release the driver from his responsibility to wear a seat XClosing the door does not release the driver from his responsibility to wear a seat
belt, (see "Seat Belt" on page 65). belt, (see "Seat Belt" on page 65).

Opening and closing the door 124 Opening and closing the door 124
Procedure Procedure
• To unlock the cabin door turn the key anti- • To unlock the cabin door turn the key anti-
clockwise. clockwise.
• To lock the cabin door turn the key • To lock the cabin door turn the key
clockwise. clockwise.
• To open the cabin door, unlock the door and • To open the cabin door, unlock the door and
pull out the handle (125). pull out the handle (125).

125 125

6.2 Sliding windows 6.2 Sliding windows

CAUTION! CAUTION!

An unlocked sliding window can cause accidents An unlocked sliding window can cause accidents
XThe sliding windows must be locked at all times. XThe sliding windows must be locked at all times.

Opening and closing the windows Opening and closing the windows

Procedure Procedure
• Push the lock (126) up. • Push the lock (126) up.
127 126 127 126
• Move the window forward or back. • Move the window forward or back.
• Insert the lock in the stop (127). • Insert the lock in the stop (127).
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6.3 Panel door 6.3 Panel door

CAUTION! CAUTION!

An open door can cause accidents (124) An open door can cause accidents (124)
XDo not travel with an open door (124). When opening the door make sure there is XDo not travel with an open door (124). When opening the door make sure there is
nobody in the door’s swing range. nobody in the door’s swing range.
XAlways close the door tightly and make sure it is locked. XAlways close the door tightly and make sure it is locked.
XClosing the door does not release the driver from his responsibility to wear a seat XClosing the door does not release the driver from his responsibility to wear a seat
belt, (see "Seat Belt" on page 65). belt, (see "Seat Belt" on page 65).

Hazardous situations Hazardous situations

If the truck is about to tip over, do not loosen the If the truck is about to tip over, do not loosen the
seat belt. The driver must not jump off the truck. seat belt. The driver must not jump off the truck.
The driver must lean his upper body over the The driver must lean his upper body over the
steering wheel and hold on with both hands. Tilt steering wheel and hold on with both hands. Tilt
your body in the opposite direction of fall. your body in the opposite direction of fall.
Requirements Requirements
– On trucks with a door monitoring sensor, travel – On trucks with a door monitoring sensor, travel
is only enabled when the panel door is closed is only enabled when the panel door is closed
(o). (o).

Procedure Procedure
• Pull the handle (128) towards the operator • Pull the handle (128) towards the operator
position, the door swings open. 128 124 position, the door swings open. 128 124
• Pull the door (124) towards the driver; the door • Pull the door (124) towards the driver; the door
closes. closes.

6.4 Backrest extension 6.4 Backrest extension

CAUTION! CAUTION!

Accident risk when adjusting the backrest during travel Accident risk when adjusting the backrest during travel
XThe backrest extension must not be changed during travel! XThe backrest extension must not be changed during travel!

Procedure Procedure
• The backrest extension height can be adjusted by changing the detent. • The backrest extension height can be adjusted by changing the detent.
• To do this push the backrest up or down. • To do this push the backrest up or down.
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 6.5 Heating 6.5 Heating

Replacing the air conditioning filter 129 Replacing the air conditioning filter 129

Procedure Procedure
• Unscrew the cover (129). • Unscrew the cover (129).
• Clean the inside of the filter mat or replace • Clean the inside of the filter mat or replace
it if necessary. it if necessary.

Z Check the filter after 500 operating hours and replace it at the latest after 1000 Z Check the filter after 500 operating hours and replace it at the latest after 1000
operating hours. operating hours.

130 130
130 130

131 131

132 132

133 133

134 134

135 135

Item Name Item Name Item Name Item Name

130 Windscreen jets 133 Recirculating air flap: 130 Windscreen jets 133 Recirculating air flap:
Recycling the air in the cab Recycling the air in the cab
131 Fan settings 134 Heating console 131 Fan settings 134 Heating console
132 Temperature controller 135 Foot compartment jet 132 Temperature controller 135 Foot compartment jet
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 Heating operation Heating operation

Procedure
• Press the switch (131) to switch off the fan.
• Set the nozzles (135 and 130) to the required position.
• Turn the temperature controller (132) to the right to increase the cab temperature.
• Turn the temperature controller (132) to the left to decrease the cab temperature.
• The recirculating air flap (133) on the heating console (134) is used to make cab air
settings and adjust fresh air.
Procedure
• Press the switch (131) to switch off the fan.
• Set the nozzles (135 and 130) to the required position.
• Turn the temperature controller (132) to the right to increase the cab temperature.
• Turn the temperature controller (132) to the left to decrease the cab temperature.
• The recirculating air flap (133) on the heating console (134) is used to make cab air
settings and adjust fresh air.

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 6.6 Removable load backrest 6.6 Removable load backrest

CAUTION! CAUTION!

Trapping hazard and heavy load backrest weight Trapping hazard and heavy load backrest weight
XWear safety gloves and safety shoes when carrying out this operation. XWear safety gloves and safety shoes when carrying out this operation.
XTwo people are required to remove and attach the load backrest. XTwo people are required to remove and attach the load backrest.

Load backrest disassembly Load backrest disassembly

Procedure Procedure
• Loosen the screws (136) 114 • Loosen the screws (136) 114
• Remove the load backrest from the fork • Remove the load backrest from the fork
carriage and put it down securely. 136 carriage and put it down securely. 136

Load backrest assembly Load backrest assembly

Procedure Procedure
• Attach the load backrest to the top rail of the fork carriage. • Attach the load backrest to the top rail of the fork carriage.
• Fit the bolts and tighten them with a torque wrench. • Fit the bolts and tighten them with a torque wrench.
Z Torque = 85 Nm Z Torque = 85 Nm

6.7 Fire extinguisher 6.7 Fire extinguisher

Procedure Procedure
• Open the fasteners (137) • Open the fasteners (137)
• Pull the fire extinguish out of its bracket • Pull the fire extinguish out of its bracket
Z To operate, refer to the illustrations on Z To operate, refer to the illustrations on
the fire extinguisher the fire extinguisher

137 137
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6.8 Rockinger coupling with hand lever or remote control 6.8 Rockinger coupling with hand lever or remote control
Z Refer to the instructions for towing trailers, (see "Towing trailers" on page 93). Z Refer to the instructions for towing trailers, (see "Towing trailers" on page 93).

138 139 138 139

CAUTION! CAUTION!

Incorrectly coupled trailers can cause Incorrectly coupled trailers can cause
accidents accidents
XMake sure the coupling is engaged XMake sure the coupling is engaged
securely before starting the truck. securely before starting the truck.
XThe contro pin (141) must be flush with XThe contro pin (141) must be flush with
the control sleeve (140). the control sleeve (140).

Rockinger coupling operation (attaching Rockinger coupling operation (attaching

trailers) 141 140 trailers) 141 140
Procedure Procedure
• Prevent the trailer from rolling away. • Prevent the trailer from rolling away.
• Adjusting the trailer pull rod to the height of the coupling. • Adjusting the trailer pull rod to the height of the coupling.
• Pull the hand lever (138) / remote control (139) (o) up. • Pull the hand lever (138) / remote control (139) (o) up.
Z The remote control (139) (o) is located in the overhead guard, depending on the Z The remote control (139) (o) is located in the overhead guard, depending on the
truck model. truck model.
• Slowly reverse the truck until the coupling engages. • Slowly reverse the truck until the coupling engages.
• Push the hand lever (138) / remote control (139) (o) down. • Push the hand lever (138) / remote control (139) (o) down.

Rockinger coupling operation (disconnecting trailers) Rockinger coupling operation (disconnecting trailers)

Procedure Procedure
• Prevent the trailer from rolling away. • Prevent the trailer from rolling away.
• Pull the hand lever (138) / remote control (139) (o) up. • Pull the hand lever (138) / remote control (139) (o) up.
• Drive the truck forward. • Drive the truck forward.
• Push the hand lever (138) / remote control (139) (o) down. • Push the hand lever (138) / remote control (139) (o) down.

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 6.9 Camera system 6.9 Camera system

CAUTION! CAUTION!

Accident risk from hidden work areas Accident risk from hidden work areas
XThe camera system acts as an aid to assist safe operation. XThe camera system acts as an aid to assist safe operation.
XPractice travelling and working with the camera system. XPractice travelling and working with the camera system.
XAlign the camera so that the hidden work area can be seen. XAlign the camera so that the hidden work area can be seen.

Z When using the camera to reverse, the monitor automatically switches on when Z When using the camera to reverse, the monitor automatically switches on when
you engage reverse gear. you engage reverse gear.

146 145 144 143 142 146 145 144 143 142

Using the camera system Using the camera system

– Press the button (142) on the monitor to switch the camera system on or off.
– Press the button (143) to lighten or darken the screen (day / night settings).
– Press the button (146) to open the menu.
Z Pressing the button several times changes the menu item (contrast, brightness,
colour saturation, language, video, light reflection) or quits the menu.
Adjusting the menu items
– Press the button (144) to go one step forward.
– Press the button (145) to go one step back.
Z Clean a dirty screen or vent slots with a soft cloth or brush.
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– Press the button (142) on the monitor to switch the camera system on or off.
– Press the button (143) to lighten or darken the screen (day / night settings).
– Press the button (146) to open the menu.
Z Pressing the button several times changes the menu item (contrast, brightness,
colour saturation, language, video, light reflection) or quits the menu.
Adjusting the menu items
– Press the button (144) to go one step forward.
– Press the button (145) to go one step back.
Z Clean a dirty screen or vent slots with a soft cloth or brush.

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6.10 Optional equipment for working in areas with heavy accumulation 6.10 Optional equipment for working in areas with heavy accumulation
of dust of dust
When working in areas with high levels of dust (lint, splinters) the Industrial truck can When working in areas with high levels of dust (lint, splinters) the Industrial truck can
be fitted with an optional lint filter on the cooler. be fitted with an optional lint filter on the cooler.

CAUTION! CAUTION!
Clogged lint filters can cause fires Clogged lint filters can cause fires
XThe lint filter must be cleaned regularly according to how much it is clogged. XThe lint filter must be cleaned regularly according to how much it is clogged.

Procedure Procedure
• Remove the cover (147) after the lock • Remove the cover (147) after the lock
(148) is opened. (148) is opened.
• Remove the (149) lint mesh and clean it. • Remove the (149) lint mesh and clean it.
• Fit the lint mesh back and set the cover in • Fit the lint mesh back and set the cover in
place. place.

147 147
148 148

149 149

6.11 Tilt angle display 6.11 Tilt angle display

NOTE NOTE

The current tilt angle is shown in an The current tilt angle is shown in an
additional display that is attached on the additional display that is attached on the
right of the dashboard. 150 right of the dashboard. 150

– Green LEDs (150) indicate the vertical – Green LEDs (150) indicate the vertical
position to the ground. position to the ground.
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 6.12 Speed reduction
The maximal achievable speed is limited to a preset value. Full motor speed and
power are available while stopped and accelerating. The speed of the motor is not
ramped down until the set maximum speed is reached.
The maximum speed is factory set and can be adjusted by trained and authorised
customer service personnel.
6.12 Speed reduction
The maximal achievable speed is limited to a preset value. Full motor speed and
power are available while stopped and accelerating. The speed of the motor is not
ramped down until the set maximum speed is reached.
The maximum speed is factory set and can be adjusted by trained and authorised
customer service personnel.

6.13 Transmission block 6.13 Transmission block

The gear block is an option which prevents the driver from starting the truck if it is in The gear block is an option which prevents the driver from starting the truck if it is in
gear. The block also prevents the driver from changing the direction of travel when gear. The block also prevents the driver from changing the direction of travel when
the truck is in second gear. the truck is in second gear.

Z Important: although the truck can travel when shifting gear in idle, braking is still Z Important: although the truck can travel when shifting gear in idle, braking is still
enabled. enabled.

6.14 Reversing Block 6.14 Reversing Block

The travel direction can only be changed (reversing) if the industrial truck is travelling
at less than 3 km/h. If the driver attempts to change direction without braking at a
faster speed, the system automatically activates idle speed. The required travel level
can only be applied when the speed is reduced accordingly.
The drive cannot be set from neutral to travel if the engine is more than 300 rpm
above idle speed. Travel is only activated when the speed falls below this limit.
The travel direction can only be changed (reversing) if the industrial truck is travelling
at less than 3 km/h. If the driver attempts to change direction without braking at a
faster speed, the system automatically activates idle speed. The required travel level
can only be applied when the speed is reduced accordingly.
The drive cannot be set from neutral to travel if the engine is more than 300 rpm
above idle speed. Travel is only activated when the speed falls below this limit.

6.15 Direction switch mounted to the steering column 6.15 Direction switch mounted to the steering column

The travel direction switch is attached to the The travel direction switch is attached to the
steering column on the left steering column on the left

When the travel direction switch is in the When the travel direction switch is in the
centre position, the drive is in idle / neutral centre position, the drive is in idle / neutral

Procedure Procedure
• To select forward gear, push the lever • To select forward gear, push the lever
forward. forward.
• To select reverse gear, push the lever • To select reverse gear, push the lever
back. back.

Travel is released in the same way as for the standard version ((see "Travel" in Travel is released in the same way as for the standard version ((see "Travel" in
chapter 4.5)). chapter 4.5)).
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6.16 Temperature control system 6.16 Temperature control system

WARNING! WARNING!

In each case the cause of the overheating must be established and rectified by a In each case the cause of the overheating must be established and rectified by a
trained and authorised customer service engineer. trained and authorised customer service engineer.

79 79
The warning indicator (79) goes on and an The warning indicator (79) goes on and an
audible warning is sounded when the audible warning is sounded when the
permissible coolant temperature is permissible coolant temperature is
exceeded. The truck will only travel for exceeded. The truck will only travel for
another 30 seconds, after which the drive is R
R R A R A another 30 seconds, after which the drive is R
R R A R A

automatically switched to neutral. R

+ A V
R V R R R
automatically switched to neutral. R
+ A V
R V R R R

As soon as the permissible coolant As soon as the permissible coolant

temperature is exceeded, proceed as temperature is exceeded, proceed as
follows: follows:

Procedure
• Remove the truck from the hazardous area if necessary,
• Lower the fork carriage and load securely.
• Switch the drive to neutral and apply the parking brake.
• Run the motor at a slightly higher speed (to improve the cooling effect of the fan)
until the temperature drops back to the normal level.
Z If the temperature does not drop, park the truck securely, switch the motor off and
have the truck examined.
Z In acutely hazardous situations, after the 30 second residual travel period, the truck
can be operated again for a further 30 seconds by switching off the ignition and
starting the engine again.
Procedure
• Remove the truck from the hazardous area if necessary,
• Lower the fork carriage and load securely.
• Switch the drive to neutral and apply the parking brake.
• Run the motor at a slightly higher speed (to improve the cooling effect of the fan)
until the temperature drops back to the normal level.
Z If the temperature does not drop, park the truck securely, switch the motor off and
have the truck examined.
Z In acutely hazardous situations, after the 30 second residual travel period, the truck
can be operated again for a further 30 seconds by switching off the ignition and
starting the engine again.

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 6.17 Control layout with Cardan function 6.17 Control layout with Cardan function

WARNING! WARNING!

Ensure there are no other people standing underneath the raised load and
driver's cab.
XDo not stand on the load handler.
XDo not lift other people on the load handler.
XInstruct other people to move out of the hazardous area of the industrial truck.
XNever stand underneath a raised and unsecured load handler / driver's cab.
Ensure there are no other people standing underneath the raised load and
driver's cab.
XDo not stand on the load handler.
XDo not lift other people on the load handler.
XInstruct other people to move out of the hazardous area of the industrial truck.
XNever stand underneath a raised and unsecured load handler / driver's cab.

Procedure 151 Procedure 151

• Push the main control lever (151) forward to • Push the main control lever (151) forward to
tilt the mast forward. tilt the mast forward.
• Push the main control lever to the right and • Push the main control lever to the right and
forward to tilt the mast forward and raise the forward to tilt the mast forward and raise the
load. load.
• Push the main control lever to the right to • Push the main control lever to the right to
raise the load. raise the load.
• Push the main control lever to the right and • Push the main control lever to the right and
pull back to tilt the mast back and raise the pull back to tilt the mast back and raise the
load. load.
• Pull the main control lever back to tilt the • Pull the main control lever back to tilt the
mast back. mast back.
• Pull the main control lever back and push to the left to tilt the mast back and lower • Pull the main control lever back and push to the left to tilt the mast back and lower
the load. the load.
• Push the main control lever to the left to lower the load. • Push the main control lever to the left to lower the load.
• Push the main control lever to the left and forward to tilt the mast forward and lower • Push the main control lever to the left and forward to tilt the mast forward and lower
the load. the load.
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7 Troubleshooting 7 Troubleshooting
7.1 Troubleshooting 7.1 Troubleshooting
This chapter enables the user to identify and rectify basic faults and the effects of This chapter enables the user to identify and rectify basic faults and the effects of
incorrect operation. When trying to locate a fault, proceed in the order shown in the incorrect operation. When trying to locate a fault, proceed in the order shown in the
table. table.
Z If, after carrying out the following remedial action, the truck cannot be restored to Z If, after carrying out the following remedial action, the truck cannot be restored to
operation or if a fault in the electronics system is displayed with a corresponding operation or if a fault in the electronics system is displayed with a corresponding
error code, contact the manufacturer’s service department. error code, contact the manufacturer’s service department.
Additional troubleshooting must only be performed by the manufacturer’s specialist Additional troubleshooting must only be performed by the manufacturer’s specialist
service engineers. The manufacturer's customer service department is specially service engineers. The manufacturer's customer service department is specially
trained to carry out these operations. trained to carry out these operations.
In order for customer services to react quickly and specifically to the fault, the In order for customer services to react quickly and specifically to the fault, the
following information is essential: following information is essential:
- Truck serial number - Truck serial number
- Error number on the display unit (if applicable) - Error number on the display unit (if applicable)
- Error description - Error description
- Current location of truck - Current location of truck

Operational fault displays Operational fault displays

Faults during operation are indicated by Faults during operation are indicated by
indicators being lit: 64 79 83 indicators being lit: 64 79 83

– Engine oil pressure (83) – Engine oil pressure (83)

– Charge current (91) – Charge current (91)
– Coolant temperature (79) R
R R A R A
– Coolant temperature (79) R
R R A R A

– Transformer temperature (85) R

+ A V
R V R R R
– Transformer temperature (85) R
+ A V
R V R R R

WARNING! WARNING!

Risk from engine damage 91 85 Risk from engine damage 91 85

XThe engine must be switched off XThe engine must be switched off
immediately, and if possible the immediately, and if possible the
industrial truck should be parked industrial truck should be parked
securely. securely.
XContact the manufacturer's service XContact the manufacturer's service
department. department.
XThe engine should only be started again XThe engine should only be started again
once the fault has been removed. once the fault has been removed.

Z Check the fuel display (64) during operation (with TFG option). Z Check the fuel display (64) during operation (with TFG option).
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 Fault Possible Cause Action Fault Possible Cause Action
Starter does Travel direction switch Set the travel direction switch to neutral. Starter does Travel direction switch Set the travel direction switch to neutral.
not turn not in neutral not turn not in neutral
Battery charge too low Check battery charge, charge battery if Battery charge too low Check battery charge, charge battery if
necessary necessary
Battery terminal cable Clean and grease terminals, tighten battery Battery terminal cable Clean and grease terminals, tighten battery
loose or terminals terminal cable loose or terminals terminal cable
oxidized. oxidized.
Starter cable loose or Check the starter motor cable Starter cable loose or Check the starter motor cable
broken broken

Engine does Air filter contaminated Clean / replace air filter Engine does Air filter contaminated Clean / replace air filter
not start not start
Additional for LPG Additional for LPG
LPG bottle shutoff Shutoff valve open LPG bottle shutoff Shutoff valve open
valve closed valve closed
LPG bottle empty Replace the LPG bottle LPG bottle empty Replace the LPG bottle
Ignition distributor cap Ignition distributor cap dry, if necessary apply Ignition distributor cap Ignition distributor cap dry, if necessary apply
damp contact spray damp contact spray
Spark plugs damp, oily Dry, clean and tighten spark plugs Spark plugs damp, oily Dry, clean and tighten spark plugs
or loose or loose
Spark plugs faulty Replacing spark plugs Spark plugs faulty Replacing spark plugs
Additional for diesel Additional for diesel
Fuel tank empty, Fill up with diesel and bleed the injection Fuel tank empty, Fill up with diesel and bleed the injection
injection system has system injection system has system
drawn in air drawn in air
Water in fuel system Discharge the fuel system Water in fuel system Discharge the fuel system
Fill up the truck Fill up the truck
Bleeding the fuel system Bleeding the fuel system
Fuel filter contaminated Check the flow of fuel, if necessary replace Fuel filter contaminated Check the flow of fuel, if necessary replace
the fuel filter the fuel filter
Paraffin separation Park the truck in a warm room and wait until Paraffin separation Park the truck in a warm room and wait until
from the diesel (flakes the separation has returned to its original from the diesel (flakes the separation has returned to its original
forming) state. forming) state.
If necessary replace the fuel filter If necessary replace the fuel filter
Filling with winter diesel Filling with winter diesel
Engine oil Engine oil level too low Check engine oil level, top up if necessary Engine oil Engine oil level too low Check engine oil level, top up if necessary
indicator lit indicator lit
during during
operation operation
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 Fault Possible Cause Action Fault Possible Cause Action
Engine Engine oil level too low Check engine oil level, top up if necessary Engine Engine oil level too low Check engine oil level, top up if necessary
temperature Radiator contaminated Clean radiator temperature Radiator contaminated Clean radiator
display in red display in red
zone Coolant level too low Check engine radiator system for leaks, add zone Coolant level too low Check engine radiator system for leaks, add
coolant if necessary coolant if necessary
Fan V belt slipping Check V belt tension, tighten or replace as Fan V belt slipping Check V belt tension, tighten or replace as
required required
Transmission Transmission oil level Check transmission oil level, top up if Transmission Transmission oil level Check transmission oil level, top up if
oil indicator lit too low necessary oil indicator lit too low necessary
during Radiator contaminated Clean radiator during Radiator contaminated Clean radiator
operation operation
Engine Travel direction switch Set travel direction switch to required Engine Travel direction switch Set travel direction switch to required
running but in neutral direction running but in neutral direction
truck does not Parking brake applied Releasing the parking brake truck does not Parking brake applied Releasing the parking brake
travel travel
Truck does Transmission oil level Check transmission oil level, top up if Truck does Transmission oil level Check transmission oil level, top up if
not reach too low necessary not reach too low necessary
max. speed max. speed
Lift speed too Hydraulic reservoir oil Check hydraulic oil, top up if necessary Lift speed too Hydraulic reservoir oil Check hydraulic oil, top up if necessary
low level too low low level too low
Hydraulic reservoir Clean / replace hydraulic reservoir discharge Hydraulic reservoir Clean / replace hydraulic reservoir discharge
discharge system system discharge system system
contaminated or contaminated or
blocked blocked
Excessive Air in steering system Check hydraulic oil level and top up if Excessive Air in steering system Check hydraulic oil level and top up if
steering play necessary, then turn the steering wheel steering play necessary, then turn the steering wheel
several times from one end to the other. several times from one end to the other.
Malfunction in Faulty fuse Test fuses (see chapter F) Malfunction in Faulty fuse Test fuses (see chapter F)
the electrical the electrical
system system

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 7.2 Operating the truck without its own drive system 7.2 Operating the truck without its own drive system

7.2.1 Towing the truck 7.2.1 Towing the truck

WARNING! WARNING!

Accident risk Accident risk

Other people can be injured if the truck is towed incorrectly.
XOnly use vehicles to tow the truck which have sufficient tow and brake forces for
the trailer load without its own braking system.
XAlways use a pull rod to tow.
XAlways tow the truck at walking pace.
XDo not park the truck with the parking brake released.
XOne person must be seated in the recovery truck to steer it and one person must
be seated on the towed truck.
Other people can be injured if the truck is towed incorrectly.
XOnly use vehicles to tow the truck which have sufficient tow and brake forces for
the trailer load without its own braking system.
XAlways use a pull rod to tow.
XAlways tow the truck at walking pace.
XDo not park the truck with the parking brake released.
XOne person must be seated in the recovery truck to steer it and one person must
be seated on the towed truck.

Towing the truck Towing the truck

Requirements
– Park the truck securely.
Procedure
• Connect the pull rod to the trailer
coupling (44) of the towing truck and attach
it to the truck to be towed.
• Release the parking brake, (see "Parking
brake" on page 76).
• Tow the truck to its destination.
• Apply the parking brake, (see "Parking
brake" on page 76).
• Undo the tow connection.
The truck has now reached its destination.
08.12 EN
Requirements
– Park the truck securely.
Procedure
• Connect the pull rod to the trailer
coupling (44) of the towing truck and attach
it to the truck to be towed.
44 • Release the parking brake, (see "Parking 44
brake" on page 76).
• Tow the truck to its destination.
• Apply the parking brake, (see "Parking
brake" on page 76).
• Undo the tow connection.
The truck has now reached its destination.

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7.2.2 Emergency lowering 7.2.2 Emergency lowering
Z The mast can be lowered manually if a fault occurs in the hydraulic system. Z The mast can be lowered manually if a fault occurs in the hydraulic system.

WARNING! WARNING!
Lowering the mast can result in injuries Lowering the mast can result in injuries
XInstruct other people to move out of the hazardous area of the truck during XInstruct other people to move out of the hazardous area of the truck during
emergency lowering. emergency lowering.
XNever stand underneath a raised load handler. XNever stand underneath a raised load handler.
XOnly operate the emergency lowering valve when standing next to the truck. XOnly operate the emergency lowering valve when standing next to the truck.
XEmergency lowering of the mast cannot be applied when the load handler is in the XEmergency lowering of the mast cannot be applied when the load handler is in the
rack. rack.
XReport any defects immediately to your supervisor. XReport any defects immediately to your supervisor.
XTag out and decommission a faulty lift truck. XTag out and decommission a faulty lift truck.
XOnly return the truck to service when you have identified and rectified the fault. XOnly return the truck to service when you have identified and rectified the fault.

Procedure Procedure
• Press the Emergency Disconnect switch. • Press the Emergency Disconnect switch.
• Turn key switch to "0". • Turn key switch to "0".
• Apply the parking brake. • Apply the parking brake.
• Open the engine cover. • Open the engine cover.
• Pull the protective cover off the left valve. • Pull the protective cover off the left valve.
• Push the locking pin (152) on the valve block • Push the locking pin (152) on the valve block
forward, thereby releasing the control lever. forward, thereby releasing the control lever.
• Lower the mast with the lever. • Lower the mast with the lever.
The mast is now lowered. The mast is now lowered.

152 152

WARNING! WARNING!

Only return the truck to service when you have identified and rectified the fault. Only return the truck to service when you have identified and rectified the fault.
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 7.2.3 Starting aid 7.2.3 Starting aid

WARNING! WARNING!

Danger from overheating Danger from overheating

XOnly use an ISO 6722 battery jump lead XOnly use an ISO 6722 battery jump lead
with fully insulated terminal pliers and a with fully insulated terminal pliers and a
lead diameter of at least 25 mm2. lead diameter of at least 25 mm2.

Procedure Procedure
• First connect the positive terminal of the • First connect the positive terminal of the
feeder battery to the positive terminal with feeder battery to the positive terminal with
the red lead. the red lead.
• Connect the negative terminal of the feeder battery to the negative terminal with the • Connect the negative terminal of the feeder battery to the negative terminal with the
black lead. black lead.
• To start the truck switch on the ignition with the engine cover open. • To start the truck switch on the ignition with the engine cover open.
• Start the engine as normal. • Start the engine as normal.
• When the engine has started first remove the negative lead followed by the positive • When the engine has started first remove the negative lead followed by the positive
lead lead

Z If the starter motor does not switch on the engine after connecting the battery Z If the starter motor does not switch on the engine after connecting the battery
terminals, check that the battery terminal clips are positioned correctly. terminals, check that the battery terminal clips are positioned correctly.
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112
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 F Industrial Truck Maintenance
1 Operational Safety and Environmental Protection
The checks and servicing operations contained in this chapter must be performed in
accordance with the intervals as indicated in the servicing checklists.
WARNING!
Risk of accidents and damage to components
Any modification to the truck, in particular the safety mechanisms, is prohibited. Do
not alter the truck's operating speeds under any circumstances.
Do not bond the front window with adhesive.
Exception: Owners should only make changes or have changes made to powered
industrial trucks if the truck manufacturer is no longer operating in the field and there
is no successor to the business; owners must however:
– Ensure that the changes to be made are planned, tested and performed by a
specialist engineer in industrial trucks taking safety into account.
– keep permanent graphic records of the plans, tests and completion of the changes
– carry out and have authorised the respective changes to the capacity data plates,
decals and stickers as well as the operator and service manuals.
– attach permanent and clearly visible marking to the truck indicating the types of
changes made, the date of the changes and the name and address of the
organisation responsible for the work.
NOTE
Only original spare parts have been certified by our quality assurance department. To
ensure safe and reliable operation of the truck, use only the manufacturer's spare
parts.
For safety reasons, only components which have been specially agreed by the
manufacturer for this truck may be installed near the computer, controllers and wire
guidance sensors (antennae). These components (computers, controllers, wire
guidance sensors (antennae)) must therefore not be replaced either by similar
components from other trucks of the same series.
Z On completion of inspection and service work, carry out the operations listed in the
“Recommissioning the truck after cleaning or maintenance work” section ((see
"Restoring the truck to service after maintenance and repairs" on page 160)).
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F Industrial Truck Maintenance
1 Operational Safety and Environmental Protection
The checks and servicing operations contained in this chapter must be performed in
accordance with the intervals as indicated in the servicing checklists.
WARNING!
Risk of accidents and damage to components
Any modification to the truck, in particular the safety mechanisms, is prohibited. Do
not alter the truck's operating speeds under any circumstances.
Do not bond the front window with adhesive.
Exception: Owners should only make changes or have changes made to powered
industrial trucks if the truck manufacturer is no longer operating in the field and there
is no successor to the business; owners must however:
– Ensure that the changes to be made are planned, tested and performed by a
specialist engineer in industrial trucks taking safety into account.
– keep permanent graphic records of the plans, tests and completion of the changes
– carry out and have authorised the respective changes to the capacity data plates,
decals and stickers as well as the operator and service manuals.
– attach permanent and clearly visible marking to the truck indicating the types of
changes made, the date of the changes and the name and address of the
organisation responsible for the work.
NOTE
Only original spare parts have been certified by our quality assurance department. To
ensure safe and reliable operation of the truck, use only the manufacturer's spare
parts.
For safety reasons, only components which have been specially agreed by the
manufacturer for this truck may be installed near the computer, controllers and wire
guidance sensors (antennae). These components (computers, controllers, wire
guidance sensors (antennae)) must therefore not be replaced either by similar
components from other trucks of the same series.
Z On completion of inspection and service work, carry out the operations listed in the
“Recommissioning the truck after cleaning or maintenance work” section ((see
"Restoring the truck to service after maintenance and repairs" on page 160)).
113
2 Maintenance Safety Regulations
Maintenance and repair personnel
Truck maintenance and repair work must only be carried out by specially trained
personnel. A maintenance contract with the manufacturer will ensure trouble-free
operation. The manufacturer’s service department has customer service technicians
specially trained for these tasks.
Lifting and jacking up
WARNING!
Lifting and jacking up the truck safely
In order to raise the truck, the lifting gear must only be secured to the points specially
provided for this purpose.
You may only work under a raised load handler / raised cab if they have been secured
with a sufficiently strong chain or the fastening bolt.
In order to raise and jack up the truck safely, proceed as follows:
XJack up the truck only on a level surface and prevent it from moving accidentally.
XAlways use a jack with sufficient capacity. When jacking up the truck, take
appropriate measures to prevent it from slipping or tipping over (e.g. wedges,
wooden blocks).
XIn order to raise the truck, the lifting gear must only be secured to the points
specially provided for this purpose, (see "Identification points and data plates" on
page 30).
XWhen jacking up the truck, take appropriate measures to prevent it from slipping or
tipping over (e.g. wedges, wooden blocks).
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2 Maintenance Safety Regulations
Maintenance and repair personnel
Truck maintenance and repair work must only be carried out by specially trained
personnel. A maintenance contract with the manufacturer will ensure trouble-free
operation. The manufacturer’s service department has customer service technicians
specially trained for these tasks.
Lifting and jacking up
WARNING!
Lifting and jacking up the truck safely
In order to raise the truck, the lifting gear must only be secured to the points specially
provided for this purpose.
You may only work under a raised load handler / raised cab if they have been secured
with a sufficiently strong chain or the fastening bolt.
In order to raise and jack up the truck safely, proceed as follows:
XJack up the truck only on a level surface and prevent it from moving accidentally.
XAlways use a jack with sufficient capacity. When jacking up the truck, take
appropriate measures to prevent it from slipping or tipping over (e.g. wedges,
wooden blocks).
XIn order to raise the truck, the lifting gear must only be secured to the points
specially provided for this purpose, (see "Identification points and data plates" on
page 30).
XWhen jacking up the truck, take appropriate measures to prevent it from slipping or
tipping over (e.g. wedges, wooden blocks).
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 Cleaning Cleaning

CAUTION! CAUTION!
Fire hazard Fire hazard
The truck must not be cleaned with flammable fluids. The truck must not be cleaned with flammable fluids.
If flammable materials are not removed from the engine compartment, they can come If flammable materials are not removed from the engine compartment, they can come
into contact with hot components and cause a fire. into contact with hot components and cause a fire.
XCarry out all necessary safety measures to prevent sparking before cleaning (e.g. XCarry out all necessary safety measures to prevent sparking before cleaning (e.g.
by short-circuiting). by short-circuiting).
XRemove all deposits / accumulations of flammable materials from the engine XRemove all deposits / accumulations of flammable materials from the engine
compartment. compartment.

CAUTION! CAUTION!

Risk of electrical system damage Risk of electrical system damage

The electrical system can be damaged if it is cleaning with water. It is prohibited to
clean the electrical system with water.
XDo not clean the electrical system with water.
XClean the electrical system with weak suction or compressed air (use a compressor
with a water trap) and not a conductive, anti-static brush.
The electrical system can be damaged if it is cleaning with water. It is prohibited to
clean the electrical system with water.
XDo not clean the electrical system with water.
XClean the electrical system with weak suction or compressed air (use a compressor
with a water trap) and not a conductive, anti-static brush.

CAUTION! CAUTION!

Risk of component damage when cleaning the truck Risk of component damage when cleaning the truck
If the truck is to be cleaned with a water jet or a high-pressure cleaner, all electrical If the truck is to be cleaned with a water jet or a high-pressure cleaner, all electrical
and electronic components must be carefully covered beforehand as moisture can and electronic components must be carefully covered beforehand as moisture can
cause malfunctions. Do not clean with pressurised water. cause malfunctions. Do not clean with pressurised water.

Z After cleaning, carry out the operations detailed in “Recommissioning the truck after Z After cleaning, carry out the operations detailed in “Recommissioning the truck after
cleaning or maintenance work” ((see "Restoring the truck to service after cleaning or maintenance work” ((see "Restoring the truck to service after
maintenance and repairs" on page 160)). maintenance and repairs" on page 160)).
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 Electrical system Electrical system

CAUTION! CAUTION!
Accident risk from Electrical system: Accident risk from Electrical system:
XOnly trained personnel may work on the electrical system. XOnly trained personnel may work on the electrical system.
XBefore working on the electrical system, all precautionary measures must be taken XBefore working on the electrical system, all precautionary measures must be taken
to avoid electrical accidents. to avoid electrical accidents.
XThe connecting leads on the starter battery must be disassembled to disable it. XThe connecting leads on the starter battery must be disassembled to disable it.

WARNING! WARNING!

Electric currents can cause accidents Electric currents can cause accidents
Make sure the electrical system is voltage-free before starting work on it. Before Make sure the electrical system is voltage-free before starting work on it. Before
starting maintenance on the electrical system: starting maintenance on the electrical system:
XPark the truck securely ((see "Parking the truck securely" on page 71)). XPark the truck securely ((see "Parking the truck securely" on page 71)).
XPress the Emergency Disconnect. XPress the Emergency Disconnect.
X Disconnect the battery. X Disconnect the battery.
XRemove any rings or metal bracelets etc. before working on electrical components. XRemove any rings or metal bracelets etc. before working on electrical components.

Consumables and used parts Consumables and used parts

CAUTION! CAUTION!

Consumables and used parts are an environmental hazard
Used parts, oils and fuels must be disposed of in accordance with the relevant
environmental protection regulations. To change the oil contact the manufacturer's
customer service department, who have been specially trained for this task.
XNote the safety regulations when handling these materials.
Consumables and used parts are an environmental hazard
Used parts, oils and fuels must be disposed of in accordance with the relevant
environmental protection regulations. To change the oil contact the manufacturer's
customer service department, who have been specially trained for this task.
XNote the safety regulations when handling these materials.

Welding Welding
Remove electrical and electronic components from the truck before performing Remove electrical and electronic components from the truck before performing
welding operations, to avoid damage. welding operations, to avoid damage.

Settings Settings
When repairing or replacing hydraulic, electric or electronic components or When repairing or replacing hydraulic, electric or electronic components or
assemblies, always note the truck-specific settings. assemblies, always note the truck-specific settings.
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 Tyre type Tyre type

WARNING!
The use of tyres that do not match the manufacturer's specifications can result
in accidents.
The quality of tyres affects the stability and performance of the truck.
Uneven wear affects the truck's stability and increases the stopping distance.
XWhen replacing tyres make sure the truck is not skewed.
XAlways replace tyres in pairs, i.e. left and right at the same time.
WARNING!
The use of tyres that do not match the manufacturer's specifications can result
in accidents.
The quality of tyres affects the stability and performance of the truck.
Uneven wear affects the truck's stability and increases the stopping distance.
XWhen replacing tyres make sure the truck is not skewed.
XAlways replace tyres in pairs, i.e. left and right at the same time.

Z When replacing rims and tyres fitted at the factory, only use the manufacturer’s Z When replacing rims and tyres fitted at the factory, only use the manufacturer’s
original spare parts. Otherwise the manufacturer’s specifications cannot be original spare parts. Otherwise the manufacturer’s specifications cannot be
ensured. ensured.
Lift chains Lift chains

WARNING! WARNING!

Non-lubricated and incorrectly cleaned lift chains can cause accidents
Lift chains are safety-critical parts. They must not contain any serious contamination.
Lift chains and pivot pins must always be clean and well lubricated.
XLift chains should only be cleaned with paraffin derivatives e.g. petroleum or diesel
fuels.
XNever clean lifting chains with steam jet high pressure cleaners or chemical
cleaning agents.
XImmediately after cleaning, dry the lift chain with compressed air and apply a chain
spray.
XAlways lubricate a chain when it is discharged.
XLubricate a lift chain with particular care around the pulleys.
Non-lubricated and incorrectly cleaned lift chains can cause accidents
Lift chains are safety-critical parts. They must not contain any serious contamination.
Lift chains and pivot pins must always be clean and well lubricated.
XLift chains should only be cleaned with paraffin derivatives e.g. petroleum or diesel
fuels.
XNever clean lifting chains with steam jet high pressure cleaners or chemical
cleaning agents.
XImmediately after cleaning, dry the lift chain with compressed air and apply a chain
spray.
XAlways lubricate a chain when it is discharged.
XLubricate a lift chain with particular care around the pulleys.

WARNING! WARNING!

Diesel fuel can be hazardous Diesel fuel can be hazardous

XDiesel fuel can cause irritation if it comes into contact with the skin. Rinse any XDiesel fuel can cause irritation if it comes into contact with the skin. Rinse any
affected areas thoroughly. affected areas thoroughly.
XIf it comes into contact with the eyes rinse them immediately with flowing water and XIf it comes into contact with the eyes rinse them immediately with flowing water and
call for a doctor. call for a doctor.
XWear safety gloves when handling diesel fuels. XWear safety gloves when handling diesel fuels.
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 Hydraulic hoses Hydraulic hoses

WARNING! WARNING!
Brittle hydraulic hose lines can cause accidents Brittle hydraulic hose lines can cause accidents
The hoses must be replaced every six years. The manufacturer's customer service The hoses must be replaced every six years. The manufacturer's customer service
department is specially trained to carry out these operations. department is specially trained to carry out these operations.

WARNING! WARNING!

Hydraulic line leaks can cause accidents
Hydraulic oil can escape from leaky and faulty hydraulic lines.
XReport any defects immediately to your supervisor.
XTag out and decommission a faulty lift truck.
XOnly return the truck to service when you have identified and rectified the fault.
XSpilled fluids must be removed immediately with an appropriate bonding agent. The
bonding agent / consumable mixture must be disposed of in accordance with
regulations.
Hydraulic line leaks can cause accidents
Hydraulic oil can escape from leaky and faulty hydraulic lines.
XReport any defects immediately to your supervisor.
XTag out and decommission a faulty lift truck.
XOnly return the truck to service when you have identified and rectified the fault.
XSpilled fluids must be removed immediately with an appropriate bonding agent. The
bonding agent / consumable mixture must be disposed of in accordance with
regulations.

WARNING! WARNING!
Hairline cracks in the hydraulic lines can cause injury and infection Hairline cracks in the hydraulic lines can cause injury and infection
Pressurised hydraulic oil can penetrate the skin through fine holes or hairline cracks Pressurised hydraulic oil can penetrate the skin through fine holes or hairline cracks
in the hydraulic lines, causing severe injury. in the hydraulic lines, causing severe injury.
XCall for a doctor immediately if you are injured. XCall for a doctor immediately if you are injured.
XDo not touch pressurised hydraulic lines. XDo not touch pressurised hydraulic lines.
XReport any defects immediately to your supervisor. XReport any defects immediately to your supervisor.
XTag out and decommission a faulty lift truck. XTag out and decommission a faulty lift truck.
XOnly return the truck to service when you have identified and rectified the fault. XOnly return the truck to service when you have identified and rectified the fault.
XSpilled fluids must be removed immediately with an appropriate bonding agent. The XSpilled fluids must be removed immediately with an appropriate bonding agent. The
bonding agent / consumable mixture must be disposed of in accordance with bonding agent / consumable mixture must be disposed of in accordance with
regulations. regulations.

WARNING! WARNING!
Danger from hot fluids and components! Danger from hot fluids and components!
XConsumables (hydraulic oil, engine oil, coolant) and power train components XConsumables (hydraulic oil, engine oil, coolant) and power train components
(engine, manifold, exhaust system, turbo charger etc.) get very hot during (engine, manifold, exhaust system, turbo charger etc.) get very hot during
operation. operation.
XWhen carrying out maintenance and repairs wear suitable protective clothing XWhen carrying out maintenance and repairs wear suitable protective clothing
(gloves etc.) to avoid getting burned. (gloves etc.) to avoid getting burned.
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 3 Servicing and Inspection
Thorough and expert servicing is one of the most important requirements for the safe
operation of the industrial truck. Failure to perform regular servicing can lead to truck
failure and poses a potential hazard to personnel and equipment.
WARNING!
The application conditions of an industrial truck have a considerable impact on the
wear of the service components.
We recommend that a Jungheinrich customer service adviser carries out an
application analysis on site to work out specific service intervals to prevent damage
due to wear.
The service intervals stated are based on single shift operation under normal
operating conditions. They must be reduced accordingly if the truck is to be used in
conditions of extreme dust, temperature fluctuations or multiple shifts.
The following servicing checklist indicates the operations to be performed and the
respective intervals to be observed. Maintenance intervals are defined as:
W = Every 50 service hours, at least weekly
A = Every 500 service hours
B = Every 1000 service hours, or at least annually
C = Every 2000 service hours, or at least annually
t = Standard maintenance interval
Cold store maintenance interval (in addition to standard maintenance
k =
interval)
Z W maintenance intervals must be performed by the owner.
During the run-in period – after approx. 100 service hours – the owner must check the
wheel nuts / bolts and re-tighten if necessary.
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3 Servicing and Inspection
Thorough and expert servicing is one of the most important requirements for the safe
operation of the industrial truck. Failure to perform regular servicing can lead to truck
failure and poses a potential hazard to personnel and equipment.
WARNING!
The application conditions of an industrial truck have a considerable impact on the
wear of the service components.
We recommend that a Jungheinrich customer service adviser carries out an
application analysis on site to work out specific service intervals to prevent damage
due to wear.
The service intervals stated are based on single shift operation under normal
operating conditions. They must be reduced accordingly if the truck is to be used in
conditions of extreme dust, temperature fluctuations or multiple shifts.
The following servicing checklist indicates the operations to be performed and the
respective intervals to be observed. Maintenance intervals are defined as:
W = Every 50 service hours, at least weekly
A = Every 500 service hours
B = Every 1000 service hours, or at least annually
C = Every 2000 service hours, or at least annually
t = Standard maintenance interval
Cold store maintenance interval (in addition to standard maintenance
k =
interval)
Z W maintenance intervals must be performed by the owner.
During the run-in period – after approx. 100 service hours – the owner must check the
wheel nuts / bolts and re-tighten if necessary.
119
4 Maintenance checklist 4 Maintenance checklist
DFG / TFG DFG / TFG

Maintenance intervals Maintenance intervals

Standard = t W A B C Standard = t W A B C
Chassis / Superstructure Chassis / Superstructure
1.1 Check all load bearing components for damage. t 1.1 Check all load bearing components for damage. t
1.2 Check screw connection. t 1.2 Check screw connection. t
1.3 Check overhead guard for damage and make sure it is secure. t 1.3 Check overhead guard for damage and make sure it is secure. t
1.4 Check trailer hitch. t 1.4 Check trailer hitch. t
Check the engine compartment for contamination and clean if Check the engine compartment for contamination and clean if
1.5 t 1.5 t
necessary. necessary.

Service intervals Service intervals

Standard = t W A B C Standard = t W A B C
Drive Drive
2.1 Combustion engine, see separate checklist 2.1 Combustion engine, see separate checklist
2.2 Check the transmission for noise and leakage t 2.2 Check the transmission for noise and leakage t
2.3 Check pedal mechanism, adjust and lubricate if necessary t 2.3 Check pedal mechanism, adjust and lubricate if necessary t
2.4 Check the gear oil level t 2.4 Check the gear oil level t
2.5 Change the gear oil t 2.5 Change the gear oil t
2.6 Clean gear oil suction filter and discharge t 2.6 Clean gear oil suction filter and discharge t
2.7 Changing the gear oil filter t 2.7 Changing the gear oil filter t
2.8 Check drive axle for noise and leakage t 2.8 Check drive axle for noise and leakage t
2.9 Check drive axle oil level (hydrokinetic only) t 2.9 Check drive axle oil level (hydrokinetic only) t
2.10 Replace drive axle oil (hydrokinetic only) t 2.10 Replace drive axle oil (hydrokinetic only) t
Check switching mechanism on control lever for wear and lubricate t Check switching mechanism on control lever for wear and lubricate t
2.11 2.11
the contact surfaces (hydrokinetic only) the contact surfaces (hydrokinetic only)
2.12 Lubricate drive axle / mast swivel axle (hydrokinetic only) t 2.12 Lubricate drive axle / mast swivel axle (hydrokinetic only) t

Service intervals Service intervals

Standard = t W A B C Standard = t W A B C
Brake system Brake system
3.1 Test operation and settings t 3.1 Test operation and settings t
3.2 Check brake lining wear (hydrokinetic only) t 3.2 Check brake lining wear (hydrokinetic only) t
Check brake mechanism, adjust and lubricate if necessary Check brake mechanism, adjust and lubricate if necessary
3.3 t 3.3 t
(hydrokinetic only) (hydrokinetic only)
Check brake lines, connections and brake fluid level (hydrokinetic Check brake lines, connections and brake fluid level (hydrokinetic
3.4 t 3.4 t
only) only)
3.5 Change brake fluid (hydrokinetic only) t 3.5 Change brake fluid (hydrokinetic only) t
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 Service intervals Service intervals
Standard = t W A B C Standard = t W A B C
Wheels Wheels
4.1 Check wheels for wear and damage t 4.1 Check wheels for wear and damage t
4.2 Check suspension and fastening t 4.2 Check suspension and fastening t
4.3 Check air pressure t 4.3 Check air pressure t

Maintenance intervals Maintenance intervals

Standard = t W A B C Standard = t W A B C
Steering Steering
5.1 Check the steering play. t 5.1 Check the steering play. t
Check the mechanical parts of the steering column; grease if Check the mechanical parts of the steering column; grease if
5.2 t 5.2 t
necessary. necessary.
5.3 Check the steer axle, stub axle, stops for wear and deformation. t 5.3 Check the steer axle, stub axle, stops for wear and deformation. t
5.4 Test the operation of the hydraulic components and check for leaks. t 5.4 Test the operation of the hydraulic components and check for leaks. t
5.5 Grease the steering axle. t 5.5 Grease the steering axle. t

Maintenance intervals Maintenance intervals

Standard = t W A B C Standard = t W A B C
Mast Mast
6.1 Check mast attachment. t 6.1 Check mast attachment. t
6.2 Check and lubricate the mast suspension. t 6.2 Check and lubricate the mast suspension. t
6.3 Check operation, wear and setting. t 6.3 Check operation, wear and setting. t
6.4 Visually inspect rollers, slide pieces and stops. t 6.4 Visually inspect rollers, slide pieces and stops. t
6.5 Check lift chains and guides for wear, adjust and lubricate. t 6.5 Check lift chains and guides for wear, adjust and lubricate. t
6.6 Check lateral slack and ensure mast sections are parallel. t 6.6 Check lateral slack and ensure mast sections are parallel. t
6.7 Check fork tines and fork carriage for wear and damage. t 6.7 Check fork tines and fork carriage for wear and damage. t
Check protective mechanisms for damage and make sure they are Check protective mechanisms for damage and make sure they are
6.8 t 6.8 t
secure secure
6.9 Check the tilt cylinder suspension and fastening. t 6.9 Check the tilt cylinder suspension and fastening. t
6.10 Check the mast tilt angle. t 6.10 Check the mast tilt angle. t
Check the running surfaces of the mast for wear and damage, and Check the running surfaces of the mast for wear and damage, and
6.11 t 6.11 t
lubricate if necessary. lubricate if necessary.
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 Service intervals Service intervals
Standard = t W A B C Standard = t W A B C
Hydraulic system Hydraulic system
7.1 Test operation t 7.1 Test operation t
7.2 Check connections and ports for leaks and damage t 7.2 Check connections and ports for leaks and damage t
Check hydraulic cylinder for leaks and damage and make sure it is Check hydraulic cylinder for leaks and damage and make sure it is
7.3 t 7.3 t
secure secure
7.4 Check oil level t 7.4 Check oil level t
7.5 Replace hydraulic oil t 7.5 Replace hydraulic oil t
7.6 Replace filter cartridge t 7.6 Replace filter cartridge t
7.7 Clean hydraulic oil suction filter and discharge t 7.7 Clean hydraulic oil suction filter and discharge t
7.8 Test operation of pressure limitation valves t 7.8 Test operation of pressure limitation valves t
7.9 Test hose guide and check for damage t 7.9 Test hose guide and check for damage t

Service intervals Service intervals

Standard = t W A B C Standard = t W A B C
Electrical system Electrical system
8.1 Test operation t 8.1 Test operation t
8.2 Make sure wire connections are secure and check for damage t 8.2 Make sure wire connections are secure and check for damage t
8.3 Test all warning devices and safety switches. t 8.3 Test all warning devices and safety switches. t
8.4 Test operation of instruments and displays t 8.4 Test operation of instruments and displays t

Service intervals Service intervals

Standard = t W A B C Standard = t W A B C
Battery Battery
9.1 Check acid density, acid level and battery voltage t 9.1 Check acid density, acid level and battery voltage t
Check terminals are securely attached, and apply terminal screw Check terminals are securely attached, and apply terminal screw
9.2 t 9.2 t
grease grease
9.3 Check battery cables for damage, replace if necessary. t 9.3 Check battery cables for damage, replace if necessary. t

Service intervals Service intervals

Standard = t W A B C Standard = t W A B C
Attachment Attachment
10.1 Test operation t 10.1 Test operation t
10.2 Check attachment on truck and load bearing components t 10.2 Check attachment on truck and load bearing components t
Check position of bearings, guides and stops for wear and damage, Check position of bearings, guides and stops for wear and damage,
10.3 t 10.3 t
grease these components. grease these components.

Service intervals Service intervals

Standard = t W A B C Standard = t W A B C
Lubrication Lubrication
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11.1 Lubricate truck in accordance with Lubrication Schedule. t 11.1 Lubricate truck in accordance with Lubrication Schedule. t

122 122
 Service intervals Service intervals
Standard = t W A B C Standard = t W A B C
General measurements General measurements
12.1 Test travel speed and braking distance t 12.1 Test travel speed and braking distance t
12.2 Test lift and lowering speeds t 12.2 Test lift and lowering speeds t
12.3 Test safety devices and cutouts t 12.3 Test safety devices and cutouts t

Service intervals Service intervals

Standard = t W A B C Standard = t W A B C
Demonstration Demonstration
13.1 Test run with rated load t 13.1 Test run with rated load t
13.2 After carrying out maintenance, present the truck to the supervisor. t 13.2 After carrying out maintenance, present the truck to the supervisor. t
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 DFG maintenance DFG maintenance
Service intervals Service intervals
Standard = t W A B C Standard = t W A B C
Engine Engine
1.1 Check engine for noise and leaks t 1.1 Check engine for noise and leaks t
1.2 Check injection pump flow start, adjust if necessary t 1.2 Check injection pump flow start, adjust if necessary t
1.3 Check injector pressure, adjust if necessary t 1.3 Check injector pressure, adjust if necessary t
1.4 Tighten cheese head screws t 1.4 Tighten cheese head screws t
1.5 Check valve play, adjust if necessary t 1.5 Check valve play, adjust if necessary t
1.6 Check engine oil level, top up if necessary t 1.6 Check engine oil level, top up if necessary t
1.7 Replace the engine oil. t 1.7 Replace the engine oil. t
1.8 Replace the engine oil filter t 1.8 Replace the engine oil filter t
1.9 Check V belt for tension and damage t 1.9 Check V belt for tension and damage t
1.10 Check maximum speed (without load), adjust if necessary t 1.10 Check maximum speed (without load), adjust if necessary t

Service intervals Service intervals

Standard = t W A B C Standard = t W A B C
Coolant Coolant
Check the coolant level and top up if required (change coolant Check the coolant level and top up if required (change coolant
2.1 t 2.1 t
annually) annually)
2.2 Check anti-freeze content, top up if necessary t 2.2 Check anti-freeze content, top up if necessary t

Service intervals Service intervals

Standard = t W A B C Standard = t W A B C
Exhaust Exhaust
3.1 Check exhaust system for leaks and damage t 3.1 Check exhaust system for leaks and damage t
3.2 Check exhaust levels, adjust if necessary t 3.2 Check exhaust levels, adjust if necessary t

Service intervals Service intervals

Standard = t W A B C Standard = t W A B C
Air filter Air filter
4.1 Clean air filter cartridge t 4.1 Clean air filter cartridge t
4.2 Replace air filter cartridge t 4.2 Replace air filter cartridge t

Service intervals Service intervals

Standard = t W A B C Standard = t W A B C
Hydraulics Hydraulics
5.1 Check and lubricate the hydraulic pump drive t 5.1 Check and lubricate the hydraulic pump drive t
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 Service intervals Service intervals
Standard = t W A B C Standard = t W A B C
Fuel system Fuel system
6.1 Replacing the fuel filter t 6.1 Replacing the fuel filter t
6.2 Check fuel/water separator, and discharge if necessary t 6.2 Check fuel/water separator, and discharge if necessary t
6.3 Check fuel tank and lines for leaks and damage t 6.3 Check fuel tank and lines for leaks and damage t
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 TFG maintenance TFG maintenance
Service intervals Service intervals
Standard = t W A B C Standard = t W A B C
Engine Engine
1.1 Check engine for noise and leaks t 1.1 Check engine for noise and leaks t
1.2 Check spark plugs, replace if necessary t 1.2 Check spark plugs, replace if necessary t
1.3 Check ignition time, adjust if necessary t 1.3 Check ignition time, adjust if necessary t
1.4 Check ignition distributor, adjust if necessary t 1.4 Check ignition distributor, adjust if necessary t
1.5 Check valve clearance, adjust if necessary t 1.5 Check valve clearance, adjust if necessary t
1.6 Check engine oil level, top up if necessary t 1.6 Check engine oil level, top up if necessary t
1.7 Replace the engine oil t 1.7 Replace the engine oil t
1.8 Replace the engine oil filter t 1.8 Replace the engine oil filter t
1.9 Check V belt for tension and damage t 1.9 Check V belt for tension and damage t
1.10 Check maximum speed (without load), adjust if necessary t 1.10 Check maximum speed (without load), adjust if necessary t

Service intervals Service intervals

Standard = t W A B C Standard = t W A B C
Coolant Coolant
Check the coolant level and top up if required (change coolant Check the coolant level and top up if required (change coolant
2.1 t 2.1 t
annually) annually)
2.2 Check anti-freeze content, top up if necessary t 2.2 Check anti-freeze content, top up if necessary t

Service intervals Service intervals

Standard = t W A B C Standard = t W A B C
Exhaust Exhaust
3.1 Check exhaust system for leaks and damage t 3.1 Check exhaust system for leaks and damage t
3.2 Check exhaust levels, adjust if necessary t 3.2 Check exhaust levels, adjust if necessary t

Service intervals Service intervals

Standard = t W A B C Standard = t W A B C
Air filter Air filter
4.1 Clean air filter cartridge t 4.1 Clean air filter cartridge t
4.2 Replace air filter cartridge t 4.2 Replace air filter cartridge t

Service intervals Service intervals

Standard = t W A B C Standard = t W A B C
Hydraulics Hydraulics
5.1 Check and lubricate the hydraulic pump drive t 5.1 Check and lubricate the hydraulic pump drive t
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 Service intervals Service intervals
Standard = t W A B C Standard = t W A B C
LPG system LPG system
6.1 Check LPG system for leaks and damage t 6.1 Check LPG system for leaks and damage t
6.2 Have LPG filter replaced by specialist t 6.2 Have LPG filter replaced by specialist t
6.3 Have LPG system examined by specialist t 6.3 Have LPG system examined by specialist t
Have the exhaust pollutant levels checked by a specialist and adjust Have the exhaust pollutant levels checked by a specialist and adjust
6.4 t 6.4 t
to the lowest level achievable. to the lowest level achievable.
6.5 Check and service Impco units t 6.5 Check and service Impco units t
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5 Lubricants and Lubrication Schedule 5 Lubricants and Lubrication Schedule
5.1 Handling consumables safely 5.1 Handling consumables safely
Handling consumables Handling consumables
Consumables must always be handled correctly. Follow the manufacturer’s Consumables must always be handled correctly. Follow the manufacturer’s
instructions. instructions.

WARNING! WARNING!

Improper handling is hazardous to health, life and the environment
Consumables can be flammable.
XKeep consumables away from hot components and naked flames.
XAlways keep consumables in prescribed containers.
XAlways fill consumables in clean containers.
XDo not mix up different grades of consumable. The only exception to this is when
mixing is expressly stipulated in the operating instructions.
Improper handling is hazardous to health, life and the environment
Consumables can be flammable.
XKeep consumables away from hot components and naked flames.
XAlways keep consumables in prescribed containers.
XAlways fill consumables in clean containers.
XDo not mix up different grades of consumable. The only exception to this is when
mixing is expressly stipulated in the operating instructions.

CAUTION! CAUTION!

Spilled liquids can cause slipping and endanger the environment
Risk of slipping from spilled liquids. The risk is greater when combined with water.
XDo not spill fluids.
XSpilled fluids must be removed immediately with an appropriate bonding agent.
XThe bonding agent / consumable mixture must be disposed of in accordance with
regulations.
Spilled liquids can cause slipping and endanger the environment
Risk of slipping from spilled liquids. The risk is greater when combined with water.
XDo not spill fluids.
XSpilled fluids must be removed immediately with an appropriate bonding agent.
XThe bonding agent / consumable mixture must be disposed of in accordance with
regulations.

WARNING! WARNING!

Oils (chain spray / hydraulic oil) are flammable and poisonous. Oils (chain spray / hydraulic oil) are flammable and poisonous.
XDispose of used oils in accordance with regulations. Store used oil safely until it can XDispose of used oils in accordance with regulations. Store used oil safely until it can
be disposed of in accordance with regulations. be disposed of in accordance with regulations.
XDo not spill oil. XDo not spill oil.
XSpilled fluids must be removed immediately with an appropriate bonding agent. XSpilled fluids must be removed immediately with an appropriate bonding agent.
XThe bonding agent / consumable mixture must be disposed of in accordance with XThe bonding agent / consumable mixture must be disposed of in accordance with
regulations. regulations.
XObserve national regulations when handling oils. XObserve national regulations when handling oils.
XWear safety gloves when handling oils. XWear safety gloves when handling oils.
XPrevent oil from coming into contact with hot motor parts. XPrevent oil from coming into contact with hot motor parts.
XDo not smoke when handling oil. XDo not smoke when handling oil.
XAvoid contact and digestion. If you swallow oil do not induce vomiting but call for a XAvoid contact and digestion. If you swallow oil do not induce vomiting but call for a
doctor immediately. doctor immediately.
XSeek fresh air after breathing in oil fumes or vapours. XSeek fresh air after breathing in oil fumes or vapours.
XIf oil has come into contact with your skin, rinse your skin with water. XIf oil has come into contact with your skin, rinse your skin with water.
XIf oil has come into contact with your eyes, rinse them with water and call for a XIf oil has come into contact with your eyes, rinse them with water and call for a
doctor immediately. doctor immediately.
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XReplace oil-soaked clothing and shoes immediately. XReplace oil-soaked clothing and shoes immediately.

128 128
 Consumables and used parts Consumables and used parts

CAUTION! CAUTION!

Consumables and used parts are an environmental hazard
Used parts, oils and fuels must be disposed of in accordance with the relevant
environmental protection regulations. To change the oil contact the manufacturer's
customer service department, who have been specially trained for this task.
XNote the safety regulations when handling these materials.
08.12 EN
Consumables and used parts are an environmental hazard
Used parts, oils and fuels must be disposed of in accordance with the relevant
environmental protection regulations. To change the oil contact the manufacturer's
customer service department, who have been specially trained for this task.
XNote the safety regulations when handling these materials.

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5.2 Lubrication Schedule 5.2 Lubrication Schedule

D D

DFG Ö K DFG Ö K

E/P E/P
TFG Ö K TFG Ö K

g Contact surfaces
s Grease nipple
S Hydraulic oil filler neck
c Hydraulic oil drain plug
M Coolant expansion vessel g Contact surfaces
E Steer axle lubrication s Grease nipple
K Engine oil filler neck S Hydraulic oil filler neck
c Hydraulic oil drain plug
08.12 EN
M Coolant expansion vessel
E Steer axle lubrication
K Engine oil filler neck

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 5.3 Consumables 5.3 Consumables

DFG/TFG 540-550 DFG/TFG 540-550

Code Order no. Packag Capacity Description Used for Code Order no. Packag Capacity Description Used for
e e
quantit quantit
y y
A 51132827 5l 80 l Jungheinrich Hydraulic A 51132827 5l 80 l Jungheinrich Hydraulic
hydraulic oil system hydraulic oil system
D 00002832 0.3 l Brake fluid SAE J Brake System D 00002832 0.3 l Brake fluid SAE J Brake System
1703 1703
E 50055726 K-P-2K grease E 50055726 K-P-2K grease
G 29201280 400 ml Chain spray Mast chains G 29201280 400 ml Chain spray Mast chains
N 05099205 7.3 l ATF Dexron II D Transmission N 05099205 7.3 l ATF Dexron II D Transmission
P 51050011 20 l 4.5 l Titan Supergear Axle P 51050011 20 l 4.5 l Titan Supergear Axle
80W-90 80W-90
K 51094056 5l 6.9 l (DFG) Titan UNIC PLUS Engine oil K 51094056 5l 6.9 l (DFG) Titan UNIC PLUS Engine oil
4.7 l (TFG) SAE 10W-40 4.7 l (TFG) SAE 10W-40
M 51115303 1l 16 l Fricofin S Coolant* M 51115303 1l 16 l Fricofin S Coolant*

* The coolant consists of a 1:1 mixture ratio of Fricofin S and water * The coolant consists of a 1:1 mixture ratio of Fricofin S and water

Z The volumes indicated are approximate. Z The volumes indicated are approximate.

WARNING! WARNING!

Using incorrect hydraulic oil can be dangerous Using incorrect hydraulic oil can be dangerous
XDo not use hydraulic oils with a different specification or viscosity and do not mix XDo not use hydraulic oils with a different specification or viscosity and do not mix
with additives. with additives.

Grease guidelines Grease guidelines

Code Saponification Dew point Worked penetr. at NLG1 class Application Code Saponification Dew point Worked penetr. at NLG1 class Application
°C 25°C temperature °C °C 25°C temperature °C
E Lithium 185 265-295 2 -35/+120 E Lithium 185 265-295 2 -35/+120

Coolant specification Coolant specification

The quality of the coolant used can have a major impact on the efficiency and service The quality of the coolant used can have a major impact on the efficiency and service
life of the cooling circuit. The recommendations listed below are useful for servicing life of the cooling circuit. The recommendations listed below are useful for servicing
a good cooling circuit with anti-freeze and/or anti-corrosion. a good cooling circuit with anti-freeze and/or anti-corrosion.

Z Always use clean, soft water. Do not use distilled water. Z Always use clean, soft water. Do not use distilled water.
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 DANGER! DANGER!
Anti-freeze is poisonous Anti-freeze is poisonous
XAnti-freeze contains ethylene glycol and other components which can result in XAnti-freeze contains ethylene glycol and other components which can result in
poisoning if ingested. poisoning if ingested.
XIngression into the human body can also result if poisonous quantities come into XIngression into the human body can also result if poisonous quantities come into
contact with the skin for long or repeated periods. contact with the skin for long or repeated periods.
XNote the manufacturer’s safety instructions. XNote the manufacturer’s safety instructions.

The quality of the anti-freeze must be checked at least annually, e.g. at the start of The quality of the anti-freeze must be checked at least annually, e.g. at the start of
the cold season. the cold season.

If the correct procedures are not applied, the manufacturer cannot be held liable for If the correct procedures are not applied, the manufacturer cannot be held liable for
frost or corrosion damage. frost or corrosion damage.

NOTE NOTE

Corrosion damage Corrosion damage

XEven if the coolant cannot freeze up due to the application conditions, you must still XEven if the coolant cannot freeze up due to the application conditions, you must still
use anti-freeze. The anti-freeze provides protection against corrosion and raises use anti-freeze. The anti-freeze provides protection against corrosion and raises
the boiling point of the coolant. the boiling point of the coolant.

NOTE NOTE

Anti-freeze/water mixture ratio: Anti-freeze/water mixture ratio:

X1: 1 (anti-freeze to -35°C) X1: 1 (anti-freeze to -35°C)
XNever mix different types of anti-freeze. XNever mix different types of anti-freeze.

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132 132
 6 Maintenance and repairs 6 Maintenance and repairs
6.1 Preparing the truck for maintenance and repairs 6.1 Preparing the truck for maintenance and repairs
All necessary safety measures must be taken to avoid accidents when carrying out All necessary safety measures must be taken to avoid accidents when carrying out
maintenance and repairs. The following preparations must be made: maintenance and repairs. The following preparations must be made:

Procedure Procedure
• Park the truck securely, (see "Parking the • Park the truck securely, (see "Parking the
truck securely" on page 71). truck securely" on page 71).
• Fully lower the load handler. • Fully lower the load handler.
• Remove the key from the key switch (77) • Remove the key from the key switch (77)
to prevent the truck from being switched to prevent the truck from being switched
on accidentally. on accidentally.

77 77

WARNING! WARNING!

Risk of accidents when working under the load handler, driver's cab and lift
truck
XWhen working under a raised load handler, driver's cab or a raised truck, secure
them to prevent the truck from from lowering, tipping or sliding away.
XWhen raising the truck, follow the instructions, (see "Lifting the truck by crane" on
page 36). When working on the parking brake, prevent the truck from accidentally
rolling away (e.g. with wedges).
08.12 EN
Risk of accidents when working under the load handler, driver's cab and lift
truck
XWhen working under a raised load handler, driver's cab or a raised truck, secure
them to prevent the truck from from lowering, tipping or sliding away.
XWhen raising the truck, follow the instructions, (see "Lifting the truck by crane" on
page 36). When working on the parking brake, prevent the truck from accidentally
rolling away (e.g. with wedges).

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133 133
6.2 Opening the engine cover
Requirements
– For trucks with a closed cab open both cabin
doors before lifting the engine cover (o).
Procedure
• Before opening the engine compartment
push the steering column as far forward as it
will go and push the seat fully back along its
guide rails.
• To open the engine compartment fit a
suitable instrument (e.g. screwdriver)
through the access hole and push it onto the
locking device (153) of the engine cover.
• Lift up the engine cover fully. A gas pressure
damper keeps the engine cover in the raised
position.
• Make sure the engine cover has engaged
correctly before operating the truck again.
Closing the engine cover
Procedure
• Raise the engine cover slightly and
push the bottom section (154) of the
gas pressure damper in the direction
of the arrow as far as it will go against
the top part of the gas pressure
damper.
• Push the engine cover down and allow
it to lock in place. Push the driver`s
seat back and lock it in place.
• To adjust the seating position and
steering wheel position to your 154
requirements, (see "Adjusting the
driver’s seat" on page 61).
134
6.2 Opening the engine cover
153 Requirements 153
– For trucks with a closed cab open both cabin
doors before lifting the engine cover (o).
Procedure
• Before opening the engine compartment
push the steering column as far forward as it
will go and push the seat fully back along its
guide rails.
• To open the engine compartment fit a
suitable instrument (e.g. screwdriver)
through the access hole and push it onto the
locking device (153) of the engine cover.
• Lift up the engine cover fully. A gas pressure
damper keeps the engine cover in the raised
position.
• Make sure the engine cover has engaged
correctly before operating the truck again.
Closing the engine cover
Procedure
• Raise the engine cover slightly and
push the bottom section (154) of the
gas pressure damper in the direction
of the arrow as far as it will go against
the top part of the gas pressure
damper.
• Push the engine cover down and allow
it to lock in place. Push the driver`s
seat back and lock it in place.
• To adjust the seating position and
steering wheel position to your 154
requirements, (see "Adjusting the
driver’s seat" on page 61).
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 6.3 Checking the wheel attachments. 6.3 Checking the wheel attachments.

WARNING! WARNING!

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

Checking the wheel attachment 155 Checking the wheel attachment 155
Requirements Requirements
– Prepare the truck for maintenance and – Prepare the truck for maintenance and
repairs ((see "Preparing the truck for repairs ((see "Preparing the truck for
maintenance and repairs" on page 133)). maintenance and repairs" on page 133)).
Tools and Material Required Tools and Material Required
– Torque wrench – Torque wrench

Procedure Procedure
• Torque the wheel nuts (155) crosswise with • Torque the wheel nuts (155) crosswise with
a torque wrench, for torques (see "Tyre a torque wrench, for torques (see "Tyre
type" on page 26). type" on page 26).
The wheel attachment is now checked. The wheel attachment is now checked.

Z When using pneumatic tyres check the air pressure, for the air pressure (see "Tyre Z When using pneumatic tyres check the air pressure, for the air pressure (see "Tyre
type" on page 26) type" on page 26)
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135 135
6.4 Hydraulic system
CAUTION!
The hydraulic oil is pressurised during operation and is a hazard to health and to the
environment.
XDo not touch pressurised hydraulic lines.
XDispose of used oil in accordance with regulations. Store used oil safely until it can
be disposed of in accordance with regulations.
XDo not spill hydraulic oil.
XSpilled fluids must be removed immediately with an appropriate bonding agent.
XThe bonding agent / consumable mixture must be disposed of in accordance with
regulations.
XObserve national regulations when handling hydraulic oil.
XWear safety gloves when handling hydraulic oil.
XPrevent hydraulic oil from coming into contact with hot motor parts.
XDo not smoke when handling hydraulic oil.
XAvoid contact and digestion. If you swallow oil do not induce vomiting but call for a
doctor immediately.
XSeek fresh air after breathing in oil fumes or vapours.
XIf oil has come into contact with your skin, rinse your skin with water.
XIf oil has come into contact with your eyes, rinse them with water and call for a
doctor immediately.
XReplace oil-soaked clothing and shoes immediately.
CAUTION!
Consumables and used parts are an environmental hazard
Used parts, oils and fuels must be disposed of in accordance with the relevant
environmental protection regulations. To change the oil contact the manufacturer's
customer service department, who have been specially trained for this task.
XNote the safety regulations when handling these materials.
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136
6.4 Hydraulic system
CAUTION!
The hydraulic oil is pressurised during operation and is a hazard to health and to the
environment.
XDo not touch pressurised hydraulic lines.
XDispose of used oil in accordance with regulations. Store used oil safely until it can
be disposed of in accordance with regulations.
XDo not spill hydraulic oil.
XSpilled fluids must be removed immediately with an appropriate bonding agent.
XThe bonding agent / consumable mixture must be disposed of in accordance with
regulations.
XObserve national regulations when handling hydraulic oil.
XWear safety gloves when handling hydraulic oil.
XPrevent hydraulic oil from coming into contact with hot motor parts.
XDo not smoke when handling hydraulic oil.
XAvoid contact and digestion. If you swallow oil do not induce vomiting but call for a
doctor immediately.
XSeek fresh air after breathing in oil fumes or vapours.
XIf oil has come into contact with your skin, rinse your skin with water.
XIf oil has come into contact with your eyes, rinse them with water and call for a
doctor immediately.
XReplace oil-soaked clothing and shoes immediately.
CAUTION!
Consumables and used parts are an environmental hazard
Used parts, oils and fuels must be disposed of in accordance with the relevant
environmental protection regulations. To change the oil contact the manufacturer's
customer service department, who have been specially trained for this task.
XNote the safety regulations when handling these materials.
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 6.4.1 Checking the hydraulic oil level 6.4.1 Checking the hydraulic oil level

Requirements Requirements
– Park the truck on a level surface. – Park the truck on a level surface.
– Start the engine and fully raise and lower the – Start the engine and fully raise and lower the
mast once. mast once.
– Switch off the engine. – Switch off the engine.
Procedure Procedure
• Remove the hydraulic oil dipstick (156) from • Remove the hydraulic oil dipstick (156) from
the hole wipe it with a clean cloth and insert the hole wipe it with a clean cloth and insert
it fully again. it fully again.
• Remove the hydraulic oil dipstick and check • Remove the hydraulic oil dipstick and check
the level of the hydraulic oil. the level of the hydraulic oil.
Z For cold oil: The oil level should lie between Z For cold oil: The oil level should lie between
the “Min.” and “Max.” levels. 156 the “Min.” and “Max.” levels. 156
For hot oil: The hydraulic oil should lie just For hot oil: The hydraulic oil should lie just
above the MAX marking. above the MAX marking.
• Add hydraulic oil if necessary. • Add hydraulic oil if necessary.
• Repeat the test. • Repeat the test.
• When the oil level is correct, fully insert the hydraulic oil dipstick (156) again. • When the oil level is correct, fully insert the hydraulic oil dipstick (156) again.

6.4.2 Adding hydraulic oil 6.4.2 Adding hydraulic oil

Procedure Procedure
• Unscrew the lid (157) of the hydraulic oil filler • Unscrew the lid (157) of the hydraulic oil filler
neck. neck.
• Add hydraulic oil to the MAX mark on the • Add hydraulic oil to the MAX mark on the
hydraulic oil dipstick. hydraulic oil dipstick.
Z Use only approved hydraulic oil (see Z Use only approved hydraulic oil (see
consumables table). consumables table).
• Check the hydraulic oil level with the dipstick • Check the hydraulic oil level with the dipstick
and top up as required. and top up as required.
• Screw the lid back on. • Screw the lid back on.
• Insert the dipstick back in full. 157 • Insert the dipstick back in full. 157
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6.4.3 Replacing the hydraulic oil filter 6.4.3 Replacing the hydraulic oil filter

CAUTION! CAUTION!

If the pressure indicator (158) on the If the pressure indicator (158) on the
hydraulic oil filter is in the red zone, the hydraulic oil filter is in the red zone, the
filter must be replaced immediately. filter must be replaced immediately.

Procedure Procedure
• Loosen the quick release on the strap • Loosen the quick release on the strap
retainer of the air filter and push the air filter retainer of the air filter and push the air filter
housing to the side. housing to the side.
• Unscrew the lid (159). 158 • Unscrew the lid (159). 158
• Remove the hydraulic oil filter in the lid. • Remove the hydraulic oil filter in the lid.
159 159
• Insert a new hydraulic oil filter and screw the • Insert a new hydraulic oil filter and screw the
lid back on. lid back on.
• Fasten the air filter in place again. • Fasten the air filter in place again.

Z Collect any spilled hydraulic oil. Dispose of the hydraulic oil and hydraulic oil filter Z Collect any spilled hydraulic oil. Dispose of the hydraulic oil and hydraulic oil filter
and fuel in accordance with environmental regulations. and fuel in accordance with environmental regulations.

6.4.4 Replacing the ventilation/discharge filter 6.4.4 Replacing the ventilation/discharge filter

Procedure Procedure
160 160
• Unscrew the ventilation/discharge filter • Unscrew the ventilation/discharge filter
(160). (160).
• Visually inspect the filter. • Visually inspect the filter.
• If contaminated insert a new filter. • If contaminated insert a new filter.
• Screw the ventilation/discharge filter back • Screw the ventilation/discharge filter back
on. on.

Z Collect any spilled hydraulic oil. Dispose of the hydraulic oil and hydraulic oil filter Z Collect any spilled hydraulic oil. Dispose of the hydraulic oil and hydraulic oil filter
and fuel in accordance with environmental regulations. and fuel in accordance with environmental regulations.
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 6.5 Engine maintenance 6.5 Engine maintenance

DANGER! DANGER!

A running engine can be dangerous. A running engine can be dangerous.

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

6.5.1 DFG engine maintenance 6.5.1 DFG engine maintenance

NOTE NOTE

Used oil contaminates the environment Used oil contaminates the environment
XDispose of used oil and used engine oil filters in accordance with environmental XDispose of used oil and used engine oil filters in accordance with environmental
regulations. regulations.

CAUTION! CAUTION!

Risk of scalding through hot oil. Risk of scalding through hot oil.
XWear appropriate safety gloves when replacing the oil and oil filter. XWear appropriate safety gloves when replacing the oil and oil filter.

NOTE NOTE

When the engine is cold the engine oil can be viscous. When the engine is cold the engine oil can be viscous.
XOnly change the engine oil when the engine is at operating temperature and the XOnly change the engine oil when the engine is at operating temperature and the
industrial truck is horizontal. Always replace the engine oil and engine oil filter industrial truck is horizontal. Always replace the engine oil and engine oil filter
together. together.

Checking the engine oil level Checking the engine oil level

Requirements Requirements
– Park the truck on a level surface (see – Park the truck on a level surface (see
"Parking the truck securely" on page 71) "Parking the truck securely" on page 71)
Procedure Procedure
• Remove the dipstick (161). • Remove the dipstick (161).
• Wipe the dipstick with a lint-free cloth and • Wipe the dipstick with a lint-free cloth and
put in back fully into the port. put in back fully into the port.
161 161
• Remove the dipstick again and check that • Remove the dipstick again and check that
the oil level is between the MIN and MAX the oil level is between the MIN and MAX
markings. markings.
• If the engine oil level is below the bottom MIN marking, add engine oil as per the • If the engine oil level is below the bottom MIN marking, add engine oil as per the
consumables list ((see "Consumables" on page 131)). consumables list ((see "Consumables" on page 131)).
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The engine oil has now been checked. The engine oil has now been checked.

139 139
 Draining the engine oil Draining the engine oil

Procedure Procedure
• Unscrew the filler cap. • Unscrew the filler cap.
• Thoroughly clean the oil drain plug (162) • Thoroughly clean the oil drain plug (162)
and around the drain hole. and around the drain hole.
• Unscrew the oil drain plug. • Unscrew the oil drain plug.
• Collect any oil that emerges. • Collect any oil that emerges.
• Screw in the oil drain plug with a new seal. • Screw in the oil drain plug with a new seal.

162 162

Replace the engine oil filter Replace the engine oil filter

Procedure Procedure
• Undo the oil filter (163) with a filter wrench • Undo the oil filter (163) with a filter wrench
and manually unscrew it. and manually unscrew it.
• Thoroughly clean the sealing faces of the oil • Thoroughly clean the sealing faces of the oil
filter flange. filter flange.
• Apply a thin layer of engine oil to the seal of • Apply a thin layer of engine oil to the seal of
the new oil filter. the new oil filter.
• Hand-tighten the oil filter. • Hand-tighten the oil filter.
163 163

164 164
Adding engine oil Adding engine oil

Procedure Procedure
• Add fresh engine oil through the filler port • Add fresh engine oil through the filler port
(164) in accordance with the consumables (164) in accordance with the consumables
table. table.
• Check the engine oil level with the dipstick • Check the engine oil level with the dipstick
(161) and top up if necessary, (see (161) and top up if necessary, (see
"Consumables" on page 131). "Consumables" on page 131).
• Screw the filler cap back on. • Screw the filler cap back on.
161 161
08.12 EN

08.12 EN
140 140
 83 83
NOTE NOTE
The incorrect amount of oil will damage The incorrect amount of oil will damage
the engine. the engine.
R R A R A R R A R A
XAfter replacing the oil and oil filter carry XAfter replacing the oil and oil filter carry
out a test run and check the oil pressure R V R R R
out a test run and check the oil pressure R V R R R

display (83). display (83).

XCheck that the oil drain plug and oil filter XCheck that the oil drain plug and oil filter
housing are tight. housing are tight.

6.5.2 Replacing the fuel filter 6.5.2 Replacing the fuel filter

NOTE NOTE

Fuel can cause environmental damage Fuel can cause environmental damage
XBind any spilled diesel fuel with suitable XBind any spilled diesel fuel with suitable
methods. methods.
XThen dispose of the diesel and fuel filter XThen dispose of the diesel and fuel filter
in accordance with environmental in accordance with environmental
regulations. regulations.

Procedure Procedure
• Drain the fuel from the filter into a suitable • Drain the fuel from the filter into a suitable
container. container.
• Undo the filter housing with a filter wrench • Undo the filter housing with a filter wrench
and manually unscrew it. and manually unscrew it.
• Turn the filter insert anticlockwise to loosen • Turn the filter insert anticlockwise to loosen
165 165
and remove it. and remove it.
• Install a new filter insert and lock it in place. • Install a new filter insert and lock it in place.
• Thoroughly clean the sealing faces of the • Thoroughly clean the sealing faces of the
filter flange. filter flange.
• Apply a thin layer of diesel to the seal of the • Apply a thin layer of diesel to the seal of the
new fuel filter (165). new fuel filter (165).
• Prefill the filter housing with clean diesel. • Prefill the filter housing with clean diesel.
• Screw on the filter housing and hand- • Screw on the filter housing and hand-
tighten. tighten.
• The fuel filter bleeds itself automatically • The fuel filter bleeds itself automatically
after the ignition is turned on. after the ignition is turned on.

Z While running the engine check the fuel filter and the union nuts of the injectors for Z While running the engine check the fuel filter and the union nuts of the injectors for
leaks. leaks.
08.12 EN

08.12 EN

141 141
6.5.3 Check V-belt for damage 6.5.3 Check V-belt for damage
Procedure Procedure
• Check the V-belt for cracks, deformation and wear. • Check the V-belt for cracks, deformation and wear.

NOTE NOTE

A damaged V-belt will result in malfunctions. A damaged V-belt will result in malfunctions.
XIf the V-belt is not in a suitable condition, you must only start to use the truck when XIf the V-belt is not in a suitable condition, you must only start to use the truck when
the damage has been rectified. the damage has been rectified.

6.5.4 Checking the V belt tension 6.5.4 Checking the V belt tension

Procedure Procedure
166 166
• Insert the V belt between the fan V • Insert the V belt between the fan V
belt pulley (166) and the generator belt pulley (166) and the generator
V belt pulley (167) using a force of V belt pulley (167) using a force of
45 N. 45 N.
It should be possible to insert the V It should be possible to insert the V
belt approx. 10 mm. belt approx. 10 mm.
167 167

6.5.5 Adjusting the V belt tension 6.5.5 Adjusting the V belt tension

Procedure
• Undo the screws (169) and pull the
three-phase alternator (168) until
you reach the prescribed V belt
tension.
• Re-tighten the screws.
• Check the V belt tension again and
repeat the adjustment if necessary.
Procedure
• Undo the screws (169) and pull the
three-phase alternator (168) until
you reach the prescribed V belt
168 tension. 168
• Re-tighten the screws.
• Check the V belt tension again and
repeat the adjustment if necessary.

169 169
08.12 EN

08.12 EN
142 142
 6.5.6 TFG engine maintenance 6.5.6 TFG engine maintenance

NOTE NOTE

Used oil contaminates the environment Used oil contaminates the environment
XDispose of used oil and used engine oil filters in accordance with environmental XDispose of used oil and used engine oil filters in accordance with environmental
regulations. regulations.

CAUTION! CAUTION!

Risk of scalding through hot oil. Risk of scalding through hot oil.
XWear appropriate safety gloves when replacing the oil and oil filter. XWear appropriate safety gloves when replacing the oil and oil filter.

NOTE NOTE

When the engine is cold the engine oil can be viscous. When the engine is cold the engine oil can be viscous.
XOnly change the engine oil when the engine is at operating temperature and the XOnly change the engine oil when the engine is at operating temperature and the
industrial truck is horizontal. Always replace the engine oil and engine oil filter industrial truck is horizontal. Always replace the engine oil and engine oil filter
together. together.

Checking the engine oil level Checking the engine oil level

Requirements Requirements
– Park the truck on a level surface (see – Park the truck on a level surface (see
"Parking the truck securely" on page 71) "Parking the truck securely" on page 71)

Procedure
• Remove the dipstick (161).
• Wipe the dipstick with a lint-free cloth and put
in back fully into the port.
• Remove the dipstick again and check that
the oil level is between the MIN and MAX markings.
• If the engine oil level is below the bottom MIN marking, add engine oil as per the
consumables list ((see "Consumables" on page 131)).
The engine oil has now been checked.
08.12 EN
Procedure
• Remove the dipstick (161).
• Wipe the dipstick with a lint-free cloth and put
161 in back fully into the port. 161
• Remove the dipstick again and check that
the oil level is between the MIN and MAX markings.
• If the engine oil level is below the bottom MIN marking, add engine oil as per the
consumables list ((see "Consumables" on page 131)).
The engine oil has now been checked.

08.12 EN

143 143
 Draining the engine oil Draining the engine oil

Procedure Procedure
• Unscrew the filler cap (164). • Unscrew the filler cap (164).
• Thoroughly clean the oil drain plug (162) • Thoroughly clean the oil drain plug (162)
and around the drain hole. and around the drain hole.
• Unscrew the oil drain plug. • Unscrew the oil drain plug.
• Collect any oil that emerges. • Collect any oil that emerges.
• Screw in the oil drain plug with a new seal. • Screw in the oil drain plug with a new seal.

162 162

Replace the engine oil filter Replace the engine oil filter

Procedure Procedure
• Undo the oil filter (163) with a filter wrench • Undo the oil filter (163) with a filter wrench
and manually unscrew it. and manually unscrew it.
• Thoroughly clean the sealing faces of the oil • Thoroughly clean the sealing faces of the oil
filter flange. filter flange.
• Apply a thin layer of engine oil to the seal of • Apply a thin layer of engine oil to the seal of
the new oil filter. the new oil filter.
• Hand-tighten the oil filter. • Hand-tighten the oil filter.
163 163

164 164
Adding engine oil Adding engine oil

Procedure Procedure
• Add fresh engine oil through the filler port • Add fresh engine oil through the filler port
(164) in accordance with the consumables (164) in accordance with the consumables
table. table.
• Check the engine oil level with the dipstick • Check the engine oil level with the dipstick
(161) and top up if necessary, (see (161) and top up if necessary, (see
"Consumables" on page 131). "Consumables" on page 131).
• Screw the filler cap back on. • Screw the filler cap back on.
161 161
08.12 EN

08.12 EN
144 144
 83 83
NOTE NOTE
The incorrect amount of oil will damage The incorrect amount of oil will damage
the engine. the engine.
R R A R A R R A R A
XAfter replacing the oil and oil filter carry XAfter replacing the oil and oil filter carry
out a test run and check the oil pressure R V R R R
out a test run and check the oil pressure R V R R R

display (83). display (83).

XCheck that the oil drain plug and oil filter XCheck that the oil drain plug and oil filter
housing are tight. housing are tight.

6.5.7 Replacing spark plugs 6.5.7 Replacing spark plugs

Procedure Procedure
• Remove spark plug connector (170). • Remove spark plug connector (170).
• Thoroughly clean around the spark plugs • Thoroughly clean around the spark plugs
on the cylinder head. on the cylinder head.
• Unscrew the spark plugs. • Unscrew the spark plugs.
• Check the electrode distance of the new • Check the electrode distance of the new
spark plugs with a feeler gauge. spark plugs with a feeler gauge.
Z It should be 0.8 mm ± 0.1 mm. Z It should be 0.8 mm ± 0.1 mm.
• Screw in the spark plugs by hand and then • Screw in the spark plugs by hand and then
torque them to 20 Nm. torque them to 20 Nm.

170 170
08.12 EN

08.12 EN

145 145
6.5.8 Check V-belt for damage 6.5.8 Check V-belt for damage

NOTE NOTE

A damaged V-belt will result in malfunctions. A damaged V-belt will result in malfunctions.
XIf the V-belt is not in a suitable condition, you must only start to use the truck when XIf the V-belt is not in a suitable condition, you must only start to use the truck when
the damage has been rectified. the damage has been rectified.

Procedure Procedure
• Check the V-belt for cracks, deformation and wear. • Check the V-belt for cracks, deformation and wear.

6.5.9 Checking the V belt tension 6.5.9 Checking the V belt tension

Z The V-belt tension is maintained by an Z The V-belt tension is maintained by an

automatic belt tensioner (171). No manual automatic belt tensioner (171). No manual
adjustment is required. adjustment is required.

Procedure Procedure
• If the attachment indicator (172) is outside • If the attachment indicator (172) is outside
the index marking, this means a new belt the index marking, this means a new belt
must be fitted. must be fitted.

172 171 172 171

CAUTION! CAUTION!

It is essential to route the V-belt correctly. It is essential to route the V-belt correctly.
XBelts must be replaced by qualified and authorised personnel. XBelts must be replaced by qualified and authorised personnel.

08.12 EN

08.12 EN
146 146
 6.5.10 Cooling system 6.5.10 Cooling system

NOTE NOTE

Lack of coolant can cause malfunctions Lack of coolant can cause malfunctions
XThe coolant level should be between the “MIN” and “MAX” markings on the XThe coolant level should be between the “MIN” and “MAX” markings on the
expansion vessel. expansion vessel.
XIf the coolant is below the MIN marking, this indicates possible leakage in the XIf the coolant is below the MIN marking, this indicates possible leakage in the
radiator system. radiator system.
XDo not continue using the truck. XDo not continue using the truck.
XThe truck may only be started again once the cause has been removed. XThe truck may only be started again once the cause has been removed.

CAUTION! CAUTION!

Hot coolant can cause injury Hot coolant can cause injury
XAllow the engine to cool down sufficiently to prevent hot gases/liquids from XAllow the engine to cool down sufficiently to prevent hot gases/liquids from
escaping when the filler cap is opened. escaping when the filler cap is opened.

Checking the coolant level Checking the coolant level

Procedure Procedure
• Park the truck securely on a level surface. • Park the truck securely on a level surface.
• Open the engine cover. • Open the engine cover.
• Check the coolant level on the expansion • Check the coolant level on the expansion
vessel (173). vessel (173).

173 173

NOTE NOTE

The incorrect coolant can cause The incorrect coolant can cause
malfunctions malfunctions
XTo prevent the build up of lime as well XTo prevent the build up of lime as well
as front and corrosion damage in the as front and corrosion damage in the
radiator system, and to raise the boiling radiator system, and to raise the boiling
point temperature of the coolant, the point temperature of the coolant, the
cooling circuit must be filled each year cooling circuit must be filled each year
with a mixture of water and anti-freeze with a mixture of water and anti-freeze
with anti-corrosion additives. with anti-corrosion additives.
XCoolant can only be checked and added XCoolant can only be checked and added
by experts. by experts.
08.12 EN

08.12 EN

147 147
 Check the coolant concentrate 174 Check the coolant concentrate 174
Tools and Material Required Tools and Material Required
– Anti-freeze tester for coolants – Anti-freeze tester for coolants

Procedure Procedure
• Slowly unscrew the filler cap (174) from the • Slowly unscrew the filler cap (174) from the
expansion vessel (173). expansion vessel (173).
• Check the anti-freeze content of the coolant • Check the anti-freeze content of the coolant
with an anti-freeze tester. with an anti-freeze tester.

NOTE NOTE
The incorrect coolant concentration 173 The incorrect coolant concentration 173
can cause malfunctions can cause malfunctions
XIf there is insufficient anti-freeze content XIf there is insufficient anti-freeze content
arrange for trained personnel to restore arrange for trained personnel to restore
the correct mixture ratio. the correct mixture ratio.

• Screw the filler cap back on. • Screw the filler cap back on.
• Close the engine cover. • Close the engine cover.

Check the cooler and fan and clean if necessary Check the cooler and fan and clean if necessary
Z Request customer service for this job. Z Request customer service for this job.

08.12 EN

08.12 EN
148 148
 6.5.11 Replace air filter cartridge 6.5.11 Replace air filter cartridge

DANGER! DANGER!

A running engine can be dangerous A running engine can be dangerous

XCarry out all maintenance work with the engine switched off. XCarry out all maintenance work with the engine switched off.
XDo not start the engine if the air filter cartridge is removed. XDo not start the engine if the air filter cartridge is removed.

Replace air filter cartridge Replace air filter cartridge

Procedure Procedure
• Undo the 2 mounting clamps (176) and • Undo the 2 mounting clamps (176) and
remove the dust collector pot. remove the dust collector pot.
• Carefully remove the air filter cartridge from • Carefully remove the air filter cartridge from
the filter housing. the filter housing.

176 175 176 175

Cleaning the filter housing Cleaning the filter housing

Procedure Procedure

NOTE NOTE
A faulty engine can cause malfunctions A faulty engine can cause malfunctions
XDo not clean the air filter housing with compressed air. XDo not clean the air filter housing with compressed air.
XAlways use a clean cloth to clean the air filter housing. XAlways use a clean cloth to clean the air filter housing.

• Remove the air filter cartridge.
• Thoroughly clean the dust collector pot. To do this remove the dust extraction valve
(175).
• Carefully clean the air filter housing with a clean cloth.
Z There must be no residue from the cloth in the air filter housing.
• Insert the air filter cartridges back in the filter housing.
Z Take care not to damage the air filter cartridges when assembling.
• Fit the rubber element back into the dust collector pot.
• Insert the dust collector pot and secure it with the 2 mounting clamps (176).
08.12 EN
• Remove the air filter cartridge.
• Thoroughly clean the dust collector pot. To do this remove the dust extraction valve
(175).
• Carefully clean the air filter housing with a clean cloth.
Z There must be no residue from the cloth in the air filter housing.
• Insert the air filter cartridges back in the filter housing.
Z Take care not to damage the air filter cartridges when assembling.
• Fit the rubber element back into the dust collector pot.
• Insert the dust collector pot and secure it with the 2 mounting clamps (176).

08.12 EN

149 149
6.5.12 Adding window washer system fluid 6.5.12 Adding window washer system fluid
Procedure Procedure
• Open the engine cover. • Open the engine cover.
• Make sure there is sufficient windscreen fluid in the container. • Make sure there is sufficient windscreen fluid in the container.
• If necessary top up with anti-freeze. • If necessary top up with anti-freeze.

Z Fill with weather-dependent additives. Z Fill with weather-dependent additives.

08.12 EN

08.12 EN
150 150
 6.6 Checking electrical fuses 6.6 Checking electrical fuses
Checking electrical fuses Checking electrical fuses

Requirements Requirements
– Prepare the truck for maintenance and repairs ((see "Preparing the truck for – Prepare the truck for maintenance and repairs ((see "Preparing the truck for
maintenance and repairs" on page 133)). maintenance and repairs" on page 133)).

Procedure Procedure
• Open the engine cover. • Open the engine cover.
• Check condition and rating of the fuses in accordance with the table. • Check condition and rating of the fuses in accordance with the table.
• Replace any damaged fuses in accordance with the table. • Replace any damaged fuses in accordance with the table.
• Close the engine cover. • Close the engine cover.
The electrical fuses are now checked. The electrical fuses are now checked.
08.12 EN

08.12 EN

151 151
6.6.1 Fuse ratings 6.6.1 Fuse ratings

schwarz schwarz

21

21
23

23
22

22
24

24
20

20
19

19
2

2
4

4
5

5
1

1
3

3
6

6
(Grundgerät) (Grundgerät)

schwarz schwarz
(Optionen 1) (Optionen 1)

10

10
12

12
11

11
8

8
7

7
9

9
grün grün

rot rot

14

14
13

13
15

15
16

16
17

17
18

18
schwarz schwarz
(Grundgerät) (Grundgerät)
20

20
24

24
23

23
21

21
22

22
19

19
1

4
3

3
2

2
5

5
6

6
schwarz schwarz
(Optionen 1) (Optionen 1)

10

10
11

11
7

7
12

12
9

9
8

8
grün grün

14

14
15

15
16

16
13

13
17

17
18

18
rot rot

Fuse layout for the basic truck (black fuse box) Fuse layout for the basic truck (black fuse box)
Item Electric circuit Rating (A) Item Electric circuit Rating (A)
1 t Work lights 20 1 t Work lights 20
2 t Travel direction / reversing light / 7.5 2 t Travel direction / reversing light / 7.5
reversing buzzer reversing buzzer
3 t Illumination kit A / brake light 20 3 t Illumination kit A / brake light 20
4 t Neutral relay / display lighting 7.5 4 t Neutral relay / display lighting 7.5
5 t Horn / beacon 10 5 t Horn / beacon 10
6 t Spare 6 t Spare

Fuse layout for cab only (green fuse box) Fuse layout for cab only (green fuse box)
Item Electric circuit Rating (A) Item Electric circuit Rating (A)
7 o Heating 15 7 o Heating 15
8 o Front window wiper 10 8 o Front window wiper 10
9 o Windscreen washer pump 10 9 o Windscreen washer pump 10
10 o Rear window heating 15 10 o Rear window heating 15
11 o Rear window wiper 10 11 o Rear window wiper 10
12 o Radio 10 12 o Radio 10
08.12 EN

08.12 EN
t= Series equipment o= Optional equipment t= Series equipment o= Optional equipment

152 152
 Fuse box for StVZO illumination only (red fuse box) Fuse box for StVZO illumination only (red fuse box)
Item Electric circuit Rating (A) Item Electric circuit Rating (A)
13 o Dipped lights 15 13 o Dipped lights 15
14 o Flasher / parking light 20 14 o Flasher / parking light 20
15 o Indicator 15 15 o Indicator 15
16 o Parking light / right tail light 7.5 16 o Parking light / right tail light 7.5
17 o Parking light / left tail light 7.5 17 o Parking light / left tail light 7.5
18 o Brake light 7.5 18 o Brake light 7.5

Fuse box options 1 (black fuse box) Fuse box options 1 (black fuse box)
Item Electric circuit Rating (A) Item Electric circuit Rating (A)
19 t Spare 19 t Spare
20 t Seat heating 10 20 t Seat heating 10
21 t Spare 21 t Spare
22 t Spare 22 t Spare
23 t Spare 23 t Spare
24 t Spare 24 t Spare
25

26

25

26
TFG fuse box TFG fuse box
Item Electric circuit Rating (A) Item Electric circuit Rating (A)
25 t Gas shutoff valve 5 25 t Gas shutoff valve 5
26 t Gas shutoff valve 5 26 t Gas shutoff valve 5

t= Series equipment o= Optional equipment t= Series equipment o= Optional equipment

08.12 EN

08.12 EN

153 153
 27 27

28 28

DFG fuse box DFG fuse box

Item Electric circuit Rating (A) Item Electric circuit Rating (A)
27 t Pre-heat 100 27 t Pre-heat 100
28 t Fuel pump 15 28 t Fuel pump 15

t= Series equipment o= Optional equipment t= Series equipment o= Optional equipment

08.12 EN

08.12 EN
154 154
 31 31

30 30

29 29

Emergency Disconnect fuse box Emergency Disconnect fuse box

Item Electric circuit Rating (A) Item Electric circuit Rating (A)
29 t Entire truck 50 29 t Entire truck 50
30 t Seat monitoring 7.5 30 t Seat monitoring 7.5
31 o Road traffic regulations lighting 30 31 o Road traffic regulations lighting 30

t= Series equipment o= Optional equipment t= Series equipment o= Optional equipment

WARNING! WARNING!
To avoid damaging the electrical system, only use fuses with the correct To avoid damaging the electrical system, only use fuses with the correct
ratings. ratings.
08.12 EN

08.12 EN

155 155
6.7 Starter battery 6.7 Starter battery
Checking the battery condition, acid level* and acid density* Checking the battery condition, acid level* and acid density*
Z *not for maintenance-free batteries Z *not for maintenance-free batteries

CAUTION! CAUTION!

Battery acid can be dangerous Battery acid can be dangerous

XBattery acid is highly corrosive.
XTherefore it is essential to avoid contact with battery acid.
XIf clothing, skin or eyes have nevertheless come into contact with battery acid,
immediately rinse the affected parts with water.
XIf the eyes have been affected, immediately seek medical attention.
XNeutralise spilled battery acid immediately.
XBattery acid is highly corrosive.
XTherefore it is essential to avoid contact with battery acid.
XIf clothing, skin or eyes have nevertheless come into contact with battery acid,
immediately rinse the affected parts with water.
XIf the eyes have been affected, immediately seek medical attention.
XNeutralise spilled battery acid immediately.

Check battery Check battery

Procedure Procedure
• Check the battery housing for cracks and any spilled acid. Remove any oxidisation • Check the battery housing for cracks and any spilled acid. Remove any oxidisation
remains from the battery terminals. Lubricate the battery terminals with an acid-free remains from the battery terminals. Lubricate the battery terminals with an acid-free
grease. Check the acid level. grease. Check the acid level.

Z The acid should lie between the top and bottom markings. Z The acid should lie between the top and bottom markings.

Checking the acid density Checking the acid density

Procedure
• Clean the area around the inspection plugs. If necessary, add distilled water to the
top mark. Check the acid density.
Z If the battery is charged sufficiently, the acid density should be 1.24 to 1.28 kg/l.
• Recharge the battery if necessary. Fit the drain plug back on.
Procedure
• Clean the area around the inspection plugs. If necessary, add distilled water to the
top mark. Check the acid density.
Z If the battery is charged sufficiently, the acid density should be 1.24 to 1.28 kg/l.
• Recharge the battery if necessary. Fit the drain plug back on.

Battery disposal Battery disposal

Batteries may only be disposed of in accordance with national environmental Batteries may only be disposed of in accordance with national environmental
protection regulations or disposal laws. The manufacturer’s disposal instructions protection regulations or disposal laws. The manufacturer’s disposal instructions
must be followed. 08.12 EN must be followed.

08.12 EN
156 156
 6.8 Exhaust system 6.8 Exhaust system
Check the exhaust system regularly for leaks. Check the exhaust system regularly for leaks.

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

NOTE NOTE

Check emissions at regular intervals Check emissions at regular intervals

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

08.12 EN

157 157
6.9 Seat belt maintenance 6.9 Seat belt maintenance
Check the safety restraint belt Check the safety restraint belt

Procedure Procedure
• Pull out the belt completely and check for fraying • Pull out the belt completely and check for fraying
• Test the belt buckle and make sure the belt returns correctly into the retractor. • Test the belt buckle and make sure the belt returns correctly into the retractor.
• Check the cover for damage. • Check the cover for damage.

Testing the automatic blocking system Testing the automatic blocking system

Procedure Procedure
• Park the truck on a level surface. • Park the truck on a level surface.
• Pull out the seat belt with a jerk • Pull out the seat belt with a jerk
Z The interlock must prevent the belt from coming out. Z The interlock must prevent the belt from coming out.
The seat belt service is now complete. The seat belt service is now complete.

DANGER! DANGER!

A faulty seat belt can cause injury A faulty seat belt can cause injury
Using a faulty seat belt can result in injury. Using a faulty seat belt can result in injury.
XOnly operate the truck with the seat belt intact. A faulty seat belt should be replaced XOnly operate the truck with the seat belt intact. A faulty seat belt should be replaced
immediately. immediately.
XThe truck must remain decommissioned until a functional seat belt has been fitted. XThe truck must remain decommissioned until a functional seat belt has been fitted.

6.10 Transmission 6.10 Transmission

177 177
Check oil level Check oil level

Procedure Procedure
• Open the engine cover. • Open the engine cover.
• Remove the transmission oil dipstick (177) • Remove the transmission oil dipstick (177)
and wipe it off. and wipe it off.
• Reinsert the transmission oil dipstick and • Reinsert the transmission oil dipstick and
pull it out. The oil level must be between the pull it out. The oil level must be between the
marks. marks.
• Reinsert the transmission oil dipstick. Make • Reinsert the transmission oil dipstick. Make
sure it is closed correctly. sure it is closed correctly.
08.12 EN

08.12 EN
158 158
 6.11 Brake 6.11 Brake

6.11.1 Checking the parking brake 6.11.1 Checking the parking brake
The parking brake must be able to hold the truck plus the maximum load on an incline The parking brake must be able to hold the truck plus the maximum load on an incline
of 15%. If it cannot, the parking brake must be adjusted. Please contact Jungheinrich of 15%. If it cannot, the parking brake must be adjusted. Please contact Jungheinrich
customer service in this case. customer service in this case.

6.11.2 Checking the brake fluid level 6.11.2 Checking the brake fluid level
Procedure Procedure
• Undo the screws of the left-hand panel. • Undo the screws of the left-hand panel.
• Remove the panel. • Remove the panel.
• Check the brake fluid level on the brake fluid reservoir. • Check the brake fluid level on the brake fluid reservoir.
• The brake fluid level should lie between the MIN and MAX markings. • The brake fluid level should lie between the MIN and MAX markings.
• If necessary, add brake fluid. • If necessary, add brake fluid.
Capacity: 0.25 l Capacity: 0.25 l
• After adding brake fluid, refit the panel. • After adding brake fluid, refit the panel.
08.12 EN

08.12 EN

159 159
6.12 Restoring the truck to service after maintenance and repairs
Procedure
• Thoroughly clean the truck.
• Lubricate the truck according to the lubrication schedule, (see "Lubrication
Schedule" on page 130).
• Clean the battery, grease the terminals and connect the battery.
• Check the transmission oil for condensation water and replace if necessary
(hydrostatic trucks only).
• Check the hydraulic oil for condensation water and replace if necessary.
Z The manufacturer's customer service department is specially trained to carry out
these operations.
WARNING!
Faulty brakes can cause accidents
As soon as the truck has been started, test the brakes several times.
XReport any defects immediately to your supervisor.
XTag out and decommission the faulty industrial truck.
XOnly return the truck to service when you have identified and rectified the fault.
• Start up the truck, (see "Preparing the Truck for Operation" on page 59).
Z If there are switching problems in the electrical system, apply contact spray to the
exposed contacts and remove any oxide layers on the contacts of the controls by
applying them repeatedly.
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6.12 Restoring the truck to service after maintenance and repairs
Procedure
• Thoroughly clean the truck.
• Lubricate the truck according to the lubrication schedule, (see "Lubrication
Schedule" on page 130).
• Clean the battery, grease the terminals and connect the battery.
• Check the transmission oil for condensation water and replace if necessary
(hydrostatic trucks only).
• Check the hydraulic oil for condensation water and replace if necessary.
Z The manufacturer's customer service department is specially trained to carry out
these operations.
WARNING!
Faulty brakes can cause accidents
As soon as the truck has been started, test the brakes several times.
XReport any defects immediately to your supervisor.
XTag out and decommission the faulty industrial truck.
XOnly return the truck to service when you have identified and rectified the fault.
• Start up the truck, (see "Preparing the Truck for Operation" on page 59).
Z If there are switching problems in the electrical system, apply contact spray to the
exposed contacts and remove any oxide layers on the contacts of the controls by
applying them repeatedly.
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 7 Decommissioning the industrial truck
Z If the truck is to be out of service for more than a month, e.g. for commercial
reasons, it must be stored in a frost-free and dry room. All necessary measures
must be taken before, during and after decommissioning as described hereafter.
WARNING!
Lifting and jacking up the truck safely
In order to raise the truck, the lifting gear must only be secured to the points specially
provided for this purpose.
You may only work under a raised load handler / raised cab if they have been secured
with a sufficiently strong chain or the fastening bolt.
In order to raise and jack up the truck safely, proceed as follows:
XJack up the truck only on a level surface and prevent it from moving accidentally.
XAlways use a jack with sufficient capacity. When jacking up the truck, take
appropriate measures to prevent it from slipping or tipping over (e.g. wedges,
wooden blocks).
XIn order to raise the truck, the lifting gear must only be secured to the points
specially provided for this purpose, (see "Transport" on page 35).
XWhen jacking up the truck, take appropriate measures to prevent it from slipping or
tipping over (e.g. wedges, wooden blocks).
When the truck is out of service it must be jacked up so that all the wheels are clear
of the ground. This is the only way of ensuring that the wheels and wheel bearings
are not damaged.
If the truck is to be out of service for more than 6 months, agree further measures with
the manufacturer's customer service department.
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161
7 Decommissioning the industrial truck
Z If the truck is to be out of service for more than a month, e.g. for commercial
reasons, it must be stored in a frost-free and dry room. All necessary measures
must be taken before, during and after decommissioning as described hereafter.
WARNING!
Lifting and jacking up the truck safely
In order to raise the truck, the lifting gear must only be secured to the points specially
provided for this purpose.
You may only work under a raised load handler / raised cab if they have been secured
with a sufficiently strong chain or the fastening bolt.
In order to raise and jack up the truck safely, proceed as follows:
XJack up the truck only on a level surface and prevent it from moving accidentally.
XAlways use a jack with sufficient capacity. When jacking up the truck, take
appropriate measures to prevent it from slipping or tipping over (e.g. wedges,
wooden blocks).
XIn order to raise the truck, the lifting gear must only be secured to the points
specially provided for this purpose, (see "Transport" on page 35).
XWhen jacking up the truck, take appropriate measures to prevent it from slipping or
tipping over (e.g. wedges, wooden blocks).
When the truck is out of service it must be jacked up so that all the wheels are clear
of the ground. This is the only way of ensuring that the wheels and wheel bearings
are not damaged.
If the truck is to be out of service for more than 6 months, agree further measures with
the manufacturer's customer service department.
161
7.1 Prior to decommissioning
Procedure
• Thoroughly clean the truck.
• Test the brakes.
• Check the hydraulic oil level and replenish if necessary,
(see "Checking the hydraulic oil level" on page 137).
• Apply a thin layer of oil or grease to any non-painted mechanical components.
• Lubricate the truck according to the lubrication schedule, (see "Lubrication
Schedule" on page 130).
• Disconnect the battery, clean it and grease the terminals.
Z In addition, follow the battery manufacturer’s instructions.
• Spray all exposed electrical contacts with a suitable contact spray.
7.1 Prior to decommissioning
Procedure
• Thoroughly clean the truck.
• Test the brakes.
• Check the hydraulic oil level and replenish if necessary,
(see "Checking the hydraulic oil level" on page 137).
• Apply a thin layer of oil or grease to any non-painted mechanical components.
• Lubricate the truck according to the lubrication schedule, (see "Lubrication
Schedule" on page 130).
• Disconnect the battery, clean it and grease the terminals.
Z In addition, follow the battery manufacturer’s instructions.
• Spray all exposed electrical contacts with a suitable contact spray.

7.2 During decommissioning 7.2 During decommissioning

NOTE NOTE

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

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162 162
 7.3 Restoring the truck to service after decommissioning
Procedure
• Thoroughly clean the truck.
• Lubricate the truck according to the lubrication schedule, (see "Lubrication
Schedule" on page 130).
• Clean the battery, grease the terminals and connect the battery.
• Charge the battery, (see "Starter battery" on page 156).
• Check the transmission oil for condensation water and replace if necessary
(hydrostatic trucks only).
• Check the engine oil for condensation water and replace if necessary.
• Check the hydraulic oil for condensation water and replace if necessary.
Z The manufacturer's customer service department is specially trained to carry out
these operations.
WARNING!
Faulty brakes can cause accidents
As soon as the truck has been started, test the brakes several times.
XReport any defects immediately to your supervisor.
XTag out and decommission the faulty industrial truck.
XOnly return the truck to service when you have identified and rectified the fault.
• Start up the truck, (see "Preparing the Truck for Operation" on page 59).
Z If there are switching problems in the electrical system, apply contact spray to the
exposed contacts and remove any oxide layers on the contacts of the controls by
applying them repeatedly.
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163
7.3 Restoring the truck to service after decommissioning
Procedure
• Thoroughly clean the truck.
• Lubricate the truck according to the lubrication schedule, (see "Lubrication
Schedule" on page 130).
• Clean the battery, grease the terminals and connect the battery.
• Charge the battery, (see "Starter battery" on page 156).
• Check the transmission oil for condensation water and replace if necessary
(hydrostatic trucks only).
• Check the engine oil for condensation water and replace if necessary.
• Check the hydraulic oil for condensation water and replace if necessary.
Z The manufacturer's customer service department is specially trained to carry out
these operations.
WARNING!
Faulty brakes can cause accidents
As soon as the truck has been started, test the brakes several times.
XReport any defects immediately to your supervisor.
XTag out and decommission the faulty industrial truck.
XOnly return the truck to service when you have identified and rectified the fault.
• Start up the truck, (see "Preparing the Truck for Operation" on page 59).
Z If there are switching problems in the electrical system, apply contact spray to the
exposed contacts and remove any oxide layers on the contacts of the controls by
applying them repeatedly.
163
8 Safety tests to be performed at intervals and after unusual
incidents
Z Perform a safety check in accordance with national regulations. Jungheinrich
recommends the truck be checked to FEM guideline 4.004. The Jungheinrich
safety department has trained personnel who are able to carry out inspections.
The truck must be inspected at least annually or after any unusual event by a qualified
inspector (be sure to comply with national regulations). The inspector shall assess the
condition of the truck from purely a safety viewpoint, without regard to operational or
economic circumstances. The inspector shall be sufficiently instructed and
experienced to be able to assess the condition of the truck and the effectiveness of
the safety mechanisms based on the technical regulations and principles governing
the inspection of forklift trucks.
A thorough test of the truck must be undertaken with regard to its technical condition
from a safety aspect. The truck must also be examined for damage caused by
possible improper use. A test report shall be provided. The test results must be kept
for at least the next 2 inspections.
The owner is responsible for ensuring that faults are rectified immediately.
Z A test plate is attached to the truck as proof that it has passed the safety inspection.
This plate indicates the due date for the next inspection.
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164
8 Safety tests to be performed at intervals and after unusual
incidents
Z Perform a safety check in accordance with national regulations. Jungheinrich
recommends the truck be checked to FEM guideline 4.004. The Jungheinrich
safety department has trained personnel who are able to carry out inspections.
The truck must be inspected at least annually or after any unusual event by a qualified
inspector (be sure to comply with national regulations). The inspector shall assess the
condition of the truck from purely a safety viewpoint, without regard to operational or
economic circumstances. The inspector shall be sufficiently instructed and
experienced to be able to assess the condition of the truck and the effectiveness of
the safety mechanisms based on the technical regulations and principles governing
the inspection of forklift trucks.
A thorough test of the truck must be undertaken with regard to its technical condition
from a safety aspect. The truck must also be examined for damage caused by
possible improper use. A test report shall be provided. The test results must be kept
for at least the next 2 inspections.
The owner is responsible for ensuring that faults are rectified immediately.
Z A test plate is attached to the truck as proof that it has passed the safety inspection.
This plate indicates the due date for the next inspection.
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164
 9 Final de-commissioning, disposal
Z Final de-commissioning or disposal of the truck in must be performed in
accordance with the regulations of the country of use. In particular, regulations
governing the disposal of batteries, fuels and electronic and electrical systems
must be observed.
The truck must only be disassembled by trained personnel in accordance with the
procedures as specified by the manufacturer. Note the manufacturer’s safety
instructions as specified in the service documentation.
10 Human vibration measurement
Z Vibrations that affect the driver during operation over the course of the day are
known as human vibrations. Excessive human vibrations will cause the driver long
term health problems. The European "2002/44/EC/Vibration" operator directive has
therefore been established to protect drivers.
To help operators to assess the application situation, the manufacturer offers a
service of measuring these human vibrations.
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165
9 Final de-commissioning, disposal
Z Final de-commissioning or disposal of the truck in must be performed in
accordance with the regulations of the country of use. In particular, regulations
governing the disposal of batteries, fuels and electronic and electrical systems
must be observed.
The truck must only be disassembled by trained personnel in accordance with the
procedures as specified by the manufacturer. Note the manufacturer’s safety
instructions as specified in the service documentation.
10 Human vibration measurement
Z Vibrations that affect the driver during operation over the course of the day are
known as human vibrations. Excessive human vibrations will cause the driver long
term health problems. The European "2002/44/EC/Vibration" operator directive has
therefore been established to protect drivers.
To help operators to assess the application situation, the manufacturer offers a
service of measuring these human vibrations.
165
11 HUSS FS - MK Series Diesel Particle Filter Operating 11 HUSS FS - MK Series Diesel Particle Filter Operating
Instructions (o) Instructions (o)
11.1 Important General Instructions 11.1 Important General Instructions
Read the operating instructions carefully before using the soot particle filter. Read the operating instructions carefully before using the soot particle filter.

The general accident prevention and other health and safety regulations must be The general accident prevention and other health and safety regulations must be
observed. observed.

The use of additive-based fuels can have a negative effect on the exhaust and thus The use of additive-based fuels can have a negative effect on the exhaust and thus
the useful life of the diesel particle filter. Therefore use only DIN EN 590 diesel with a the useful life of the diesel particle filter. Therefore use only DIN EN 590 diesel with a
Cetane rating above 50. Cetane rating above 50.

Z The HUSS diesel particle filter complies with TRGS 554, TA Air and VERT Z The HUSS diesel particle filter complies with TRGS 554, TA Air and VERT
(Switzerland). (Switzerland).
Application range of TRGS 554 (Technical Regulations for Hazardous Materials), TA Application range of TRGS 554 (Technical Regulations for Hazardous Materials), TA
Air and VERT: Air and VERT:

– These Technical Regulations apply to work environments where diesel engine – These Technical Regulations apply to work environments where diesel engine
emissions may be contained in the air in the workplace. emissions may be contained in the air in the workplace.
– In Switzerland, VERT specifies in particular the requirements for tunnel building – In Switzerland, VERT specifies in particular the requirements for tunnel building
projects and major construction sites. projects and major construction sites.

11.2 Important safety instructions 11.2 Important safety instructions

CAUTION! CAUTION!
The safe and proper use of the diesel particle filter requires careful operation The safe and proper use of the diesel particle filter requires careful operation
and maintenance. and maintenance.

CAUTION! CAUTION!

Operation and regeneration: Operation and regeneration:

XThe diesel particle filter may only be operated and regenerated by persons who
have been trained in filter regeneration and are aware of the potential hazards.
XOnly trained and authorized personnel may work on the diesel particle filter.
XRemove the diesel particle filter from service immediately if it is clearly damaged or
not working properly. Avoid any build up of flammable materials near the filter.
XThe diesel particle filter may only be operated and regenerated by persons who
have been trained in filter regeneration and are aware of the potential hazards.
XOnly trained and authorized personnel may work on the diesel particle filter.
XRemove the diesel particle filter from service immediately if it is clearly damaged or
not working properly. Avoid any build up of flammable materials near the filter.

DANGER! DANGER!
Risk of burning! Risk of burning!
During regeneration the entire diesel particle filter system heats up and hot During regeneration the entire diesel particle filter system heats up and hot
exhaust emerges from the exhaust pipe. exhaust emerges from the exhaust pipe.

Starting the truck in a hazardous situation (with starter interlock active): Starting the truck in a hazardous situation (with starter interlock active):
Procedure Procedure
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• Depress and hold down both the “M” and “F” buttons on the HUSS control and at • Depress and hold down both the “M” and “F” buttons on the HUSS control and at
the same time start the industrial truck. the same time start the industrial truck.

166 166
 11.3 Functional Description 11.3 Functional Description
As the engine runs the diesel engine exhaust flows through the filter element which As the engine runs the diesel engine exhaust flows through the filter element which
retains virtually all the harmful soot particles. retains virtually all the harmful soot particles.

The longer the diesel engine runs, the more the diesel particle filter fills up and the
greater the backpressure on the exhaust.
The level of the diesel particle filter is shown on the HUSS Control display, enabling
regeneration to be made at the right time.
When a defined maximum backpressure or maximum charge time is reached, the
HUSS Control activates the “Filter Full” alarm.
The longer the diesel engine runs, the more the diesel particle filter fills up and the
greater the backpressure on the exhaust.
The level of the diesel particle filter is shown on the HUSS Control display, enabling
regeneration to be made at the right time.
When a defined maximum backpressure or maximum charge time is reached, the
HUSS Control activates the “Filter Full” alarm.

To burn off the soot particles in the filter element, the HUSS Control system starts To burn off the soot particles in the filter element, the HUSS Control system starts
regeneration when the engine is switched off. regeneration when the engine is switched off.

A starter interlock and engine forced cutout are incorporated in the control system to A starter interlock and engine forced cutout are incorporated in the control system to
protect the engine and diesel particle filter. protect the engine and diesel particle filter.
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167 167
11.4 HUSS Control Operation 11.4 HUSS Control Operation
The diesel particle filter is operated by the HUSS Control unit. The control unit is The diesel particle filter is operated by the HUSS Control unit. The control unit is
mounted within the operator’s field of vision. mounted within the operator’s field of vision.

Z The HUSS control system only works with the ignition is switched on. Z The HUSS control system only works with the ignition is switched on.

Display Display
The top line shows the functional stages; in the bottom line a bar indicates the The top line shows the functional stages; in the bottom line a bar indicates the
condition of the filter (backpressure / regeneration time) condition of the filter (backpressure / regeneration time)

Keys Keys

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168 168
 11.5 HUSS Control Operating Instructions 11.5 HUSS Control Operating Instructions

Normal operation
Switch on the ignition. The
buzzer sounds for min. 1
second and both LEDs light up
at the same time.
If a message is stored it will be
displayed, in conjunction with
the flashing red LED.
Stored message: Before the
last cutout the exhaust
backpressure exceeded the
upper limit for at least 20
seconds or regeneration was
interrupted. The buzzer sounds
continuously.
Note to this message: The
industrial truck cannot be
started, regeneration must be
performed.
If no message is stored the
engine can be started.
Display
Self test
e.g. alarm / filter full
HHHHHHHHHHH
ATTENTION: in a hazardous
situation the industrial truck
can be started by continually
pressing on the “M” and “F”
buttons.
Engine ready
Function LED Normal operation Display Function LED
Green and red Switch on the ignition. The Self test Green and red
LEDs lit buzzer sounds for min. 1 LEDs lit
second and both LEDs light up
at the same time.
Red LED flashing If a message is stored it will be e.g. alarm / filter full Red LED flashing
displayed, in conjunction with HHHHHHHHHHH
the flashing red LED.
Stored message: Before the
last cutout the exhaust
backpressure exceeded the
upper limit for at least 20
seconds or regeneration was
interrupted. The buzzer sounds
continuously.
Note to this message: The ATTENTION: in a hazardous
industrial truck cannot be situation the industrial truck
started, regeneration must be can be started by continually
performed. pressing on the “M” and “F”
buttons.
If no message is stored the Engine ready
engine can be started.

Messages in normal operation that indicate the status of the diesel particle Messages in normal operation that indicate the status of the diesel particle
filter: filter:
with this message>>> Normal Filter condition Green LED with this message>>> Normal Filter condition Green LED
operation possible HHHHHHHH flashing operation possible HHHHHHHH flashing
with this message>>> Regenerate Red LED flashing with this message>>> Regenerate Red LED flashing
Regeneration required HHHHHHHH Regeneration required HHHHHHHH
10 regenerations had to be Call service department / 10 regenerations had to be Call service department /
made within the maximum White ash made within the maximum White ash
charge time. Call the JH charge time. Call the JH
service department service department
Diesel particle filter Maintenance Diesel particle filter Maintenance
maintenance required, the JH maintenance required, the JH
service department must be service department must be
called. called.
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11.6 Regeneration 11.6 Regeneration
Z Regenerate daily even if the filter is not full Z Regenerate daily even if the filter is not full

DANGER! DANGER!

Risk of fire and explosion Risk of fire and explosion

XPay attention when handling fuel. XPay attention when handling fuel.
XAvoid naked flames when handling fuel. XAvoid naked flames when handling fuel.
XDo not smoke. This applies even in areas where the fuel can only be smelled. XDo not smoke. This applies even in areas where the fuel can only be smelled.

DANGER! DANGER!

Risk of fire and poisoning Risk of fire and poisoning

High temperatures and exhaust with poisonous content result every time combustion High temperatures and exhaust with poisonous content result every time combustion
takes place. takes place.
The entire exhaust system becomes very hot during and immediately after operation. The entire exhaust system becomes very hot during and immediately after operation.

Regeneration Display Regeneration Display

Function LED Function LED
Park the truck on a level surface Park the truck on a level surface
Switch off the engine. Switch off the engine.
Ignition ON: HUSS Control is energised. Ignition ON: HUSS Control is energised.
Press the “M” button and hold it down for 5 Start regeneration in 5 sec. Press the “M” button and hold it down for 5 Start regeneration in 5 sec.
seconds. Regeneration starts after 5 seconds. seconds. Regeneration starts after 5 seconds.
>>>>>>>>Green LED >>>>>>>>Green LED
Other displays after the 5 seconds Pre-cooling glow plug Other displays after the 5 seconds Pre-cooling glow plug
The fan is set to pre-cooling. The fan is set to pre-cooling.
The glow plug is switched on. Regeneration The glow plug is switched on. Regeneration
Start glow plug Start glow plug
The fuel-air mixture is ignited. Regeneration The fuel-air mixture is ignited. Regeneration
Start ignition Start ignition
The diesel particle filter is regenerated. The display Regeneration on The diesel particle filter is regenerated. The display Regeneration on
shows the remaining regeneration time. shows the remaining regeneration time.
Regeneration is complete. Regeneration completed Regeneration is complete. Regeneration completed
This display appears for 3 minutes. This display appears for 3 minutes.

Interrupting Regeneration Interrupting Regeneration

Regeneration can be interrupted by switching off “Filter full” alarm >>red LED Regeneration can be interrupted by switching off “Filter full” alarm >>red LED
the ignition with the ignition key or by pressing the flashes the ignition with the ignition key or by pressing the flashes
“F” button on the control system. The display “F” button on the control system. The display
counts down from 5 seconds until the regeneration counts down from 5 seconds until the regeneration
process is switched off. The buzzer sounds process is switched off. The buzzer sounds
continuously. continuously.
IMPORTANT: If you press the “M” and “F” buttons IMPORTANT: If you press the “M” and “F” buttons
simultaneously the engine of the industrial truck simultaneously the engine of the industrial truck
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can be started in hazardous situations even with can be started in hazardous situations even with
“Alarm/Filter full”. “Alarm/Filter full”.

170 170
 Interrupting Regeneration Interrupting Regeneration
Faults Faults
All the hardware and software functions are tested Glow plug fault All the hardware and software functions are tested Glow plug fault
during regeneration. during regeneration.
Fuel pump fault Fuel pump fault
Any faults will cause the regeneration to be Any faults will cause the regeneration to be
cancelled. Faults are displayed on the HUSS Solenoid fault cancelled. Faults are displayed on the HUSS Solenoid fault
control. The battery voltage is also checked. If the Fan fault control. The battery voltage is also checked. If the Fan fault
minimum level is not reached, regeneration is minimum level is not reached, regeneration is
cancelled. If one of the faults indicated here is Temperature gauge fault cancelled. If one of the faults indicated here is Temperature gauge fault
displayed, call the JH service department to rectify displayed, call the JH service department to rectify
the fault. Regeneration fault the fault. Regeneration fault

Regeneration interrupted Regeneration interrupted

Low voltage Low voltage

11.7 Maintenance 11.7 Maintenance

The HUSS control displays the scheduled maintenance times. The HUSS control displays the scheduled maintenance times.

Call the JH service department to carry out maintenance. Call the JH service department to carry out maintenance.

The Huss control system is factory-set for the industrial truck. Only trained JH service The Huss control system is factory-set for the industrial truck. Only trained JH service
engineers are authorised to make changes to these settings. engineers are authorised to make changes to these settings.
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172
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