04.1103.13 51209061
Operating instructions G DFG 430s DFG 435s TFG 425s TFG 430s TFG 435s DFG 425s
DFG / TFG 425s - 435s
• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
2
Declaration of Conformity
Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg Manufacturer or agent acting in the European Union
TypeOptionSerial no.Year of manufacture
DFG 425s
DFG 430s
DFG 435s
TFG 425s
TFG 430s
TFG 435s
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.
3
4
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.
t Indicates standard equipment
o Indicates optional equipment
Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG.
5
Jungheinrich
Aktiengesellschaft
Am Stadtrand 35 22047 Hamburg - Germany
Tel: +49 (0) 40/6948-0
www.jungheinrich.com
6
7 Contents ACorrect Use and Application....................................................11 1General....................................................................................................11 2Correct application...................................................................................11 3Approved application conditions ..............................................................12 4Proprietor responsibilities........................................................................13 5Adding attachments and/or optional equipment......................................13 BTruck Description.....................................................................15 1Application............... ..............15 1.1Truck models and rated capacity.............. ..............15 2Assemblies and Functional De scription...................................................16 2.1Travel direction definition.........................................................................16 2.2Assembly Overview.................................................................................17 2.3Functional Description.............................................................................18 3Technical Specifications..........................................................................20 3.1Performance data....................................................................................20 3.2Dimensions..............................................................................................22 3.3Weights...................................................................................................24 3.4Mast versions..........................................................................................25 3.5Tyre type.................................................................................................27 3.6Engine Data.............................................................................................27 3.7EN norms.................................................................................................28 3.8Conditions of use.....................................................................................28 3.9Electrical requirements............................................................................29 4Identification points and data plates........................................................30 4.1Data plate.............. 32 4.2Truck capacity plate.................................................................................33 4.3Attachment capacity plate.......................................................................34 5Stability....................................................................................................34 CTransport and Commissioning.................................................35 1Transport................. ..............35 2Loading the Truck....................................................................................35 2.1Centre of gravity of the truck...................................................................35 2.2Lifting the truck by crane.........................................................................36 2.3Loading with another industrial truck........ ..............37 3Securing the truck during transport.........................................................38 4Using the Truck for the First Time............ ..............39
8 DFuelling the Truck....................................................................41 1General....................................................................................................41 1.1Safety regulations for handling diesel fuel and LPG................................41 1.2LPG system relief valve...........................................................................43 2Adding diesel........... ..............44 2.1Fuelling....................................................................................................44 2.2Fuelling with fuel containers ....................................................................46 3LPG containers........................................................................................47 3.1LPG bottles..............................................................................................47 3.2Liquid gas tank........................................................................................50 4Fuel level indicator... ..............51 4.1Display unit..............................................................................................51 4.2Level indicator for LPG bottles (o)..........................................................51 EOperation.................................................................................53 1Safety Regulations for the Operation of the Forklift Truck.......................53 2Displays and Controls..............................................................................55 2.1Control panel with display unit............................. .....................58 2.2Control panel buttons..............................................................................61 2.3Display.....................................................................................................64 3Preparing the Truck for Operation...........................................................65 3.1Checks and operations to be performed before starting daily operation.65 3.2Entry and exit..........................................................................................67 3.3Trucks with reduced headroom (o)........................................................67 3.4Setting up the operator position............. .....................68 3.5Seat Belt..................................................................................................73 4Industrial Truck Operation.......................................................................74 4.1Safety regulations for truck operation......................................................74 4.2Preparing the truck for operation........... .....................76 4.3Starting procedure for the DFG...............................................................77 4.4Starting procedure for the TFG................................................................78 4.5Parking the truck securely.......................................................................79 4.6Emergency Disconnect............................................................................80 4.7Travel...................................................................................................... 81 4.8Steering...................................................................................................83 4.9Brakes.....................................................................................................83 4.10Setting the time....... ..............87 4.11Adjusting the forks...................................................................................88 4.12Replacing the forks..................................................................................89 4.13Lifting, transporting and depositing loads................................................90 4.14Operating the lift mechanism and integrated attachments......................92 4.15Safety instructions for operating additional attachments.........................98 4.16Operating additional attachments for the SOLO-PILOT ..........................101 4.17Operating additional attachments for the MULTI-PILOT.........................103 4.18Fitting additional attachments..................................................................105 5Towing trailers.........................................................................................108 6Optional equipment.................................................................................110 6.1Keypad (CanCode) (o)...........................................................................110 6.2Assistance systems.................................................................................129
9 6.3Steel cab.................................................................................................131 6.4Sliding windows.......................................................................................131 6.5Gate.........................................................................................................132 6.6Panel door...............................................................................................133 6.7Operator position extension.....................................................................133 6.8Heating and air conditioning system........................................................134 6.9Driver’s seat heating / backrest extension................ .......137 6.10Removable load backrest........................................................................138 6.11Lift cutout override...................................................................................138 6.12Sideshifter centre position.......................................................................139 6.13Fire extinguisher......................................................................................139 6.14Tilt angle display......................................................................................139 6.15Rockinger coupling with han d lever or remote control.............................140 6.16Camera system.......................................................................................141 6.17Optional equipment for working in dusty environments.. ..........142 6.18Roof window wiper..................................................................................142 6.19Control layout “N”....................................................................................143 7Troubleshooting............ 144 7.1Troubleshooting.......................................................................................144 7.2Operating the truck without its own drive system....................................149 FIndustrial Truck Maintenance...................................................153 1Operational Safety and Environmental Protection...................................153 2Maintenance Safety Regulations .............................................................154 2.1Working on the electrical system.............................................................155 2.2Consumables and used parts. .................................................................155 2.3Wheels....................................................................................................155 2.4Lift Chains...............................................................................................156 2.5Hydraulic system.....................................................................................156 2.6Working in the vicinity of the engine........................................................157 3Lubricants and Lubrication Schedule......................................................158 3.1Handling consumables safely ..................................................................158 3.2Lubrication Schedule...............................................................................160 3.3Consumables...........................................................................................161 4Maintenance and repairs.........................................................................163 4.1Preparing the truck for maintenance and repairs....................................163 4.2Lifting and jacking up the truck safely......................................................164 4.3Opening the rear panel ............................................................................164 4.4Unlocking the engine bonnet...................................................................165 4.5Opening the engine cover.......................................................................166 4.6Replacing wheels.................................................................................... 168 4.7Checking the wheel attachments.............................................................170 4.8Hydraulic system.....................................................................................171 4.9Engine maintenance................................................................................174 4.10Checking electrical fuses.........................................................................188 4.11Cleaning..................................................................................................194 4.12Starter battery..........................................................................................196 4.13Exhaust system.......................................................................................197 4.14Restoring the truck to service after maintenance and repairs.................198 5Decommissioning the industrial truck......................................................199 5.1Prior to decommissioning........................................................................200
10 5.2During decommissioning.........................................................................200 5.3Restoring the truck to service after decommissioning.......... .......201 6Safety tests to be performed at intervals and after unusual incidents.....202 7Final de-commissioning, disposal............................................................203 8Human vibration measurement...............................................................203 9Servicing and Inspection.........................................................................204 10Maintenance checklist DFG..... .....................205 10.1Operating company.................................................................................205 10.2Customer service.....................................................................................208 11Maintenance checklist TFG..... .....................217 11.1Operating company.................................................................................217 11.2Customer service.....................................................................................220
ACorrect Use and Application
1General
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.
2Correct 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 page90.
–Lifting and lowering loads.
–Transporting lowered loads over short distances.
–Do not travel with a raised load (>30 cm).
–Do not carry or lift passengers.
–Do push or pull load units.
–Occasional towing of trailer loads.
–When towing trailer loads the load must be secured on the trailer.
–The permissible trailer load must not be exceeded.
11
3Approved 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°C 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.
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. Do 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. Special equipment and authorisation are required if the truck is to be constantly used in extreme conditions, especially in dusty or corrosive atmospheres. The truck cannot be used in areas at risk of explosion. In adverse weather conditions (thunder, lightning) the in dustrial truck must not be operated outside or in endangered areas.
12
4Proprietor 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.
5Adding 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.
13
• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
