Jungheinrich TFG 660 User manual

12.12 -
11.14
51289390
DFG/TFG 660-690
Operating instructions G
TFG 680
DFG 670
DFG 680
DFG 690
DFG S80
DFG S90
TFG 660
TFG 670
TFG 690
TFG S80
TFG S90
DFG 660

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11.14 EN
Declaration of Conformity
Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg
Manufacturer or agent acting in the European Union
Additional information
On behalf of
Date
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.
Type Option Serial no. Year of
manufacture
DFG 660
DFG 670
DFG 680
DFG 690
DFG S80
DFG S90
TFG 660
TFG 670
TFG 680
TFG 690
TFG S80
TFG S90
G

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Foreword
Notes on the operating instructions
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide
sufficient instruction for the safe operation of the industrial truck. The information is
provided clearly and concisely. The chapters are arranged by letter and the pages are
numbered continuously.
The operator manual details different industrial truck models. When operating and
servicing the industrial truck, make sure that the particular section applies to your
truck model.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to
alter the design, equipment and technical features of the system. No guarantee of
particular features of the truck should therefore be assumed from the present
operating instructions.
Safety notices and text mark-ups
Safety instructions and important explanations are indicated by the following
graphics:
DANGER!
Indicates an extremely hazardous situation. Failure to comply with this instruction will
result in severe irreparable injury and even death.
WARNING!
Indicates an extremely hazardous situation. Failure to comply with this instruction
may result in severe irreparable injury and even death.
CAUTION!
Indicates a hazardous situation. Failure to comply with this instruction may result in
slight to medium injury.
NOTE
Indicates a material hazard. Failure to comply with this instruction may result in
material damage.
ZUsed before notices and explanations.
tIndicates standard equipment
oIndicates optional equipment

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Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Am Stadtrand 35
22047 Hamburg - Germany
Tel: [phone]
www.jungheinrich.com

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Contents
A Correct Use and Application ................................................... 11
1 General.................................................................................................... 11
2 Correct application................................................................................... 11
3 Approved application conditions.............................................................. 12
4 Proprietor responsibilities ........................................................................ 13
5 Adding attachments and/or optional equipment ...................................... 13
B Truck Description .................................................................... 15
1 Application ............................................................................................... 15
1.1 Truck models and rated capacity............................................................. 15
2 Assemblies and Functional Description................................................... 16
2.1 Assembly Overview ................................................................................. 16
2.2 Functional Description ............................................................................. 17
3 Technical Specifications .......................................................................... 19
3.1 Performance data .................................................................................... 19
3.2 Dimensions.............................................................................................. 23
3.3 Weights.................................................................................................... 28
3.4 Mast versions .......................................................................................... 29
3.5 Tyre type.................................................................................................. 33
3.6 Engine Data............................................................................................. 35
3.7 EN norms................................................................................................. 36
3.8 Conditions of use..................................................................................... 37
3.9 Electrical requirements ............................................................................ 37
4 Identification points and data plates ........................................................ 38
4.1 Data plate ................................................................................................ 40
4.2 Truck capacity plate................................................................................. 41
4.3 Attachment capacity plate ....................................................................... 42
4.4 Jack attachment point.............................................................................. 42
5 Stability .................................................................................................... 42
C Transport and Commissioning ................................................ 43
1 Transport ................................................................................................. 43
2 Truck laden.............................................................................................. 43
2.1 Centre of gravity of the truck ................................................................... 43
2.2 Lifting the truck by crane ......................................................................... 44
2.3 Loading with another industrial truck ....................................................... 45
3 Securing the truck during transport ......................................................... 46
4 Using the Truck for the First Time ........................................................... 47

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D Fuelling the Truck.................................................................... 49
1 General.................................................................................................... 49
1.1 Safety regulations for handling diesel fuel and LPG................................ 49
1.2 LPG system relief valve........................................................................... 51
2 Adding diesel ........................................................................................... 52
2.1 Fuelling .................................................................................................... 52
2.2 Fuelling with fuel containers .................................................................... 53
3 LPG containers........................................................................................ 54
3.1 LPG bottles.............................................................................................. 54
3.2 Liquid gas tank ........................................................................................ 57
4 Fuel level indicator................................................................................... 58
4.1 Display unit .............................................................................................. 58
E Operation ................................................................................ 59
1 Safety Regulations for the Operation of the Forklift Truck....................... 59
2 Displays and Controls.............................................................................. 61
2.1 Multi-task switch ...................................................................................... 61
2.2 SOLO-PILOT ........................................................................................... 63
2.3 MULTI-PILOT .......................................................................................... 64
2.4 Controls ................................................................................................... 65
2.5 Multifunction display ................................................................................ 67
2.6 Operation of the multifunction display ..................................................... 70
3 Dashboard ............................................................................................... 80
3.1 Without air conditioning system............................................................... 80
3.2 With air conditioning system.................................................................... 80
3.3 With automatic air conditioning................................................................ 81
4 Heater, fan, air conditioning system ........................................................ 82
4.1 Heater...................................................................................................... 82
4.2 Air conditioning system (o) ..................................................................... 82
5 Preparing the Truck for Operation ........................................................... 86
5.1 Checks and operations to be performed before starting daily operation . 86
5.2 Entry and exit........................................................................................... 88
5.3 Setting up the operator position............................................................... 89
5.4 Seat Belt .................................................................................................. 95
6 Industrial Truck Operation ....................................................................... 96
6.1 Safety regulations for truck operation...................................................... 96
6.2 Preparing the truck for operation ............................................................. 99
6.3 Operational Checks ................................................................................. 102
6.4 Parking the truck securely ....................................................................... 103
6.5 Emergency Disconnect............................................................................ 105
6.6 Travel....................................................................................................... 106
6.7 Steering ................................................................................................... 108
6.8 Brakes ..................................................................................................... 109
6.9 Adjusting the forks ................................................................................... 111
6.10 Replacing the forks.................................................................................. 112
6.11 Lifting, transporting and depositing loads ................................................ 113
6.12 Operating the lift mechanism and integrated attachments ...................... 115
6.13 Safety instructions for operating additional attachments ......................... 121
6.14 Operating additional attachments for the SOLO-PILOT .......................... 124

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6.15 Operating additional attachments for the Multi Pilot ................................ 125
6.16 Fitting additional attachments.................................................................. 126
7 Towing trailers ......................................................................................... 128
8 Optional equipment ................................................................................. 130
8.1 Rotating Driver's Seat.............................................................................. 131
8.2 Sliding windows ....................................................................................... 140
8.3 Emergency Exit ....................................................................................... 140
8.4 Driver'S Seat Heater................................................................................ 140
8.5 Fire Extinguisher...................................................................................... 141
8.6 Rockinger Coupling with Hand Lever ...................................................... 141
9 Troubleshooting....................................................................................... 143
9.1 Automatic Emergency Brake ................................................................... 143
9.2 Troubleshooting....................................................................................... 145
9.3 Operating the truck without its own drive system .................................... 146
F Industrial Truck Maintenance .................................................. 151
1 Operational Safety and Environmental Protection................................... 151
2 Maintenance Safety Regulations............................................................. 152
2.1 Working on the electrical system............................................................. 153
2.2 Consumables and used parts.................................................................. 153
2.3 Wheels..................................................................................................... 153
2.4 Lift Chains................................................................................................ 154
2.5 Hydraulic system ..................................................................................... 154
2.6 Working in the vicinity of the engine ........................................................ 155
3 Lubricants and Lubrication Schedule ...................................................... 156
3.1 Handling consumables safely.................................................................. 156
3.2 Lubrication Schedule ............................................................................... 158
3.3 Consumables........................................................................................... 160
3.4 Coolant specification ............................................................................... 161
4 Maintenance and repairs ......................................................................... 162
4.1 Preparing the truck for maintenance and repairs .................................... 162
4.2 Lifting and jacking up the truck safely...................................................... 163
4.3 Replacing wheels .................................................................................... 164
4.4 Checking the wheel attachments............................................................. 166
4.5 Opening the Service Panel...................................................................... 166
4.6 Tilting the Cab ......................................................................................... 167
4.7 Replacing wheels .................................................................................... 171
4.8 Checking the wheel attachments............................................................. 173
4.9 Hydraulic system ..................................................................................... 174
4.10 Engine maintenance................................................................................ 177
4.11 Check the transmission oil level .............................................................. 183
4.12 Performing Other Maintenance Work ...................................................... 183
4.13 Closing the Motor Compartment.............................................................. 183
4.14 Checking electrical fuses......................................................................... 184
4.15 Cleaning .................................................................................................. 189
4.16 Starter battery.......................................................................................... 191
4.17 Exhaust system ....................................................................................... 192
4.18 Restoring the truck to service after maintenance and repairs ................. 193
5 Decommissioning the industrial truck ...................................................... 194
5.1 Prior to decommissioning ........................................................................ 195
5.2 During decommissioning ......................................................................... 195

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5.3 Restoring the truck to service after decommissioning ............................. 196
6 Safety tests to be performed at intervals and after unusual incidents ..... 197
7 Final de-commissioning, disposal............................................................ 198
8 Human vibration measurement ............................................................... 198
9 Servicing and Inspection ......................................................................... 199
10 Maintenance checklist DFG..................................................................... 200
10.1 Operating Company ................................................................................ 200
10.2 Customer Service .................................................................................... 203
11 Maintenance checklist TFG ..................................................................... 212
11.1 Operating Company ................................................................................ 212
11.2 Customer Service .................................................................................... 215

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A Correct Use and Application
1 General
The truck must be used, operated and serviced in accordance with the present
instructions. All other types of use are beyond its scope of application and may result
in damage to personnel, the industrial truck or property.
2 Correct application
NOTE
The maximum load and load distance are indicated on the capacity plate and must
not be exceeded.
The load must rest on the load handler or be lifted by an attachment approved by the
manufacturer.
The load must be fully raised,see "Lifting, transporting and depositing loads" on
page 113.
The following operations are in accordance with regulations and are permitted:
– Lifting and lowering loads.
– Transporting lowered loads over short distances.
– Occasional towing of trailer loads.
– When towing trailers the load must be secured on the trailer.
– The permissible trailer load must not be exceeded.
The following operations are prohibited:
– Travelling with a raised load (>30 cm).
– Carrying and lifting passengers.
– Pushing or pulling loads.
– Transporting hanging loads. If the truck is to be operated with hanging loads, proof
of sufficient safety distance under local operating conditions must be obtained from
a specialist assessor.

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3 Approved application conditions
DANGER!
Do not exceed the permissible surface and point loading on the travel lanes.
At blind spots get a second person to assist.
The driver must ensure that the loading dock /dock leveller cannot be removed or
come loose during loading/unloading.
– Operation in industrial and commercial environments.
– Permissible temperature range -20 to 40°C.
– Operation only on secure, level surfaces with sufficient capacity.
– Do not exceed the permissible surface and spot load limits on the travel routes.
– Operation only on routes that are visible and approved by the operating company.
– Negotiating inclines up to a maximum of 15 %.
– Do not travel across or at an angle on inclines. Travel with the load facing uphill.
– Operation in partially public traffic.
– Do not operate LPG trucks under ground level areas.
– The truck may only be operated in areas that are clean and free of oil and similar
substances.
WARNING!
Operating an LPG truck under ground level areas could result in explosions.
LPG is heavier than air. An explosive LPG/air mixture could therefore form under
ground level areas without sufficient ventilation.
XDo not use LPG trucks under ground level areas.
WARNING!
Use under extreme conditions
Using the truck under extreme conditions can result in malfunctions and accidents.
XSpecial equipment and authorisation are required if the truck is to be constantly
used in extreme conditions, especially in dusty or corrosive atmospheres.
XThe truck cannot be used in areas at risk of explosion.
XIn adverse weather conditions (thunder, lightning) the industrial truck must not be
operated outside or in endangered areas.

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4 Proprietor responsibilities
For the purposes of the present operating instructions the “operating company” is
defined as any natural or legal person who either uses the industrial truck himself, or
on whose behalf it is used. In special cases (e.g. leasing or renting) the proprietor is
considered the person who, in accordance with existing contractual agreements
between the owner and user of the industrial truck, is charged with operational duties.
The proprietor must ensure that the industrial truck is used only for the purpose it is
intended for and that danger to life and limb of the user and third parties are excluded.
Furthermore, accident prevention regulations, safety regulations and operating,
servicing and repair guidelines must be followed. The operating company must
ensure that all users have read and understood these operating instructions.
NOTE
Failure to comply with the operating instructions invalidates the warranty. The same
applies if improper work is carried out on the truck by the customer or third parties
without the permission of the manufacturer.
5 Adding attachments and/or optional equipment
The mounting or installation of additional equipment which affects or enhances the
performance of the industrial truck requires the written permission of the
manufacturer. Local authority approval may also need to be obtained.
Local authority approval however does not constitute the manufacturer’s approval.

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B Truck Description
1 Application
The DFG/TFG 660-690 is a four-wheel IC engine sit-down forklift truck. The DFG
series are diesel engine trucks, while the TFG series are fitted with a petrol engine for
LPG operation.
The DFG/TFG 660-690 is a cantilever counterbalanced truck which can lift, transport
and deposit loads using the load handler attached in front.
Closed bottom pallets can also be lifted.
The DFG/TFG 660-690 is equipped with a hydrodynamic drive.
1.1 Truck models and rated capacity
The rated capacity depends on the model. The rated capacity can be derived from
the model name.
The rated capacity is not generally the same as the permissible capacity. The
capacity can be found on the capacity plate attached to the truck.
DFG660
DFG Model name
6Series
60 Rated capacity x 100 kg

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2 Assemblies and Functional Description
2.1 Assembly Overview
6
3
14 13 12 910
12 4578
11
Item Description Item Description
1oFork adjustment 8 tExhaust pipe
2tLoad chains 9 tSteer axle
3tMast 10 tCounterweight
4tSteering column 11 tIllumination
5tCab 12 tDrive
6tDriver's seat 13 tFork carriage
7oBeacon 14 tFork tines
t= Standard equipment o= Optional equipment

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2.2 Functional Description
Chassis and superstructure
A rigid chassis which protects the units and controls, provides the truck with
maximum static safety. A wide opening cab (5) facilitates service and maintenance
work. The hydraulic oil reservoir is integrated on the right-hand side and the fuel tank
on the opposite side of the chassis. The vertical, free standing front exhaust pipe (8)
is positioned much higher than is common. It prevents vibrations and sound saves
from being transferred and exhaust gases from penetrating into the operator position.
Operator position
The operator position is articulating, which cushions vibrations and noise. Non-slip
steps and a handle on the cab post ensure easy entry and exit. The driver is protected
by the cab (5). To adapt the seat position, the driver can adjust the seat and steering
head both vertically and horizontally. The accelerator pedal and brake pedal are of
"automotive" design.
Steering
The steer cylinder of the hydrostatic steering is integrated in the steer axle (9) and is
controlled by the power steering. The steer axle is fully floating in the chassis to
ensure excellent grip even on non-level surfaces.
Wheels
All wheels are located within the truck geometry. A choice of pneumatic or
superelastic tyres are available.
Diesel engine
Quiet-running, water-cooled diesel engines featuring high performance and low
consumption with very clean fuel combustion under all operating conditions ensure
soot values are below the limit of visibility. An additional particle filter (o) ensures
very low exhaust levels.
LPG engine
Quiet running, water-cooled four-stroke engines featuring high performance and low
consumption. Petrol engines with very low residual exhaust levels are used. A 3-way
catalytic converter ensures very low exhaust levels.
Electrical System
12-volt system with 3-phase alternator. A repeat start block prevents malfunctions
when the truck is powered up. For diesel engines, a rapid pre-heat system is installed;
LPG motors have an electronic ignition system for rapid and trouble-free engine
starting. The key switch is used to start and stop the engine.

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Drive System
A power shift gear with radiator and torque converter is flanged directly to the engine.
This transfers the force to the drive axle (12).
The travel direction lever, either on the steering column or optionally on the multi-task
handle, controls forward/reverse travel and the neutral position.
Brakes
The brake pedal activates the laminated brakes hydraulically. The parking brake is
switched on and off by pressing the parking brake button in the multifunction display.
It acts mechanically on the brake disc of the cardan shaft.
Hydraulic System
All operations can be performed sensitively, proportionally and simultaneously.
Hydraulic functions are controlled by a servo hydraulic controller. Control is possible
via single lever (SOLO-PILOT) or multi-task lever (MULTI-PILOT).
Mast
Two or three-stage masts, optionally with free lift function; narrow mast sections
ensure excellent visibility of the fork tines and attachments. Fork carriages and lift
frames run on lubricating support rollers.
Attachments
The trucks can be optionally fitted with mechanical and hydraulic attachments.

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3 Technical Specifications
All technical details refer to standard trucks.
Values indicated with *) may vary, depending on the
types of equipment used (e.g. mast, cabin, tyres etc.).
ZThe technical specifications comply with the German "Industrial Truck Data Sheet"
Guidelines.
Technical modifications and additions reserved.
3.1 Performance data
DFG 660-690
1) for vertical mast.
2) The values shown represent the maximum gradeability to overcome short
differences in height and surface unevenness (surface edges). The truck must not
operate on inclines of more than 15%.
Component 660 670 680 690
QCapacity
1) 6000 7000 8000 9000 kg
C Load centre distance 600 600 600 600 mm
Travel speed * with /
without load 22.4/22.5 22.4/22.6 22.4/22.5 22.4/22.6 km/h
Lift speed with / without
load 0.50/0.60 0.40/0.60 0.40/0.60 0.40/0.60 m/s
Lowering speed with /
without load 0.60/0.36 0.60/0.36 0.60/0.36 0.60/0.36 m/s
Gradeability 2)
with / without load 30.3/32.0 28.7/31.0 27.1/31.0 24.6/28.0 %
Tow force
with/without load 49.5/49.5 49.5/49.5 49.5/49.5 49.5/49.5 kN
Acceleration* with /
without load to 15 m 6.0/5.0 6.0/5.0 6.0/5.0 7.0/6.0 sec
Available working
pressure
for attachments
160 160 160 160 bar
Oil flow
for attachments 80 80 80 80 l/min

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DFG S80-S90
1) for vertical mast.
2) The values shown represent the maximum gradeability to overcome short
differences in height and surface unevenness (surface edges). The truck must not
operate on inclines of more than 15%.
Component S80 S90
Q Capacity 1) 8000 9000 kg
C Load centre distance 900 900 mm
Travel speed *
with / without load 22.3/22.6 22.3/22.6 km/h
Lift speed
with / without load 0.40/0.60 0.40/0.60 m/s
Lowering speed
with / without load 0.60/0.36 0.60/0.36 m/s
Gradeability 2
with / without load 21.5/25.0 20.9/24.0 %
Tow force with / without load 49.5/49.5 52.9/52.9 kN
Acceleration time *
with / without load to 15 m 7.0/6.0 7.0/6.0 sec
Available working pressure
for attachments 160 160 bar
Oil flow for attachments 80 80 l/min

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TFG 660-690
1) for vertical mast.
2) The values shown represent the maximum gradeability to overcome short
differences in height and surface unevenness (surface edges). The truck must not
operate on inclines of more than 15%.
Component 660 670 680 690
QCapacity
(1 6000 7000 8000 9000 kg
C Load centre distance 600 600 600 600 mm
Travel speed * with /
without load 22.4/22.6 22.4/22.6 22.4/22.6 22.4/22.6 km/h
Lift speed
with / without load 0.40/0.48 0.40/0.48 0.40/0.48 0.40/0.48 m/s
Lowering speed
w / w.o. load 0.60/0.48 0.60/0.36 0.60/0.36 0.60/0.36 m/s
Gradeability (2
with / without load 27.5/30.0 27.5/30.0 26.5/30.0 23.0/27.0 %
Tow f or ce
with / without load 45.6/45.6 45.6/45.6 45.6/45.6 45.6/45.6 kN
Acceleration * with /
without load to 15 m 6.0/5.0 6.0/5.0 6.0/5.0 7.0/6.0 sec
Available working
pressure
for attachments
160 160 160 160 bar
Oil flow
for attachments 80 80 80 80 l/min