Jungheinrich Forklift DFG 425s DFG 430s DFG 435s TFG 425s TFG 430s TFG 435s Operating instructions M

DFG/TFG 425s - 435s

05.18

Operating instructions

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51694496 08.18

DFG 425s DFG 430s DFG 435s TFG 425s TFG 430s TFG 435s

fiUNGHEINRICH

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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. We reserve 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:

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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.

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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.

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Used before notices and explanations.

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Indicates standard equipment Indicates optional equipment

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Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG. Jungheinrich Aktiengesellschaft Friedrich-Ebert-Damm 129 22047 Hamburg - Germany Tel: +49 (0) 40/6948-0 www.jungheinrich.com

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Contents

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A

Correct Use and Application .. .... .... .... .... .... ... .... .... ..... ....... .... ..

11

1 2 3 4 5

General....................................................................................................

Correct application...................................................................................

Approved application conditions..............................................................

Proprietor responsibilities ............. ................ ............. ............... ...............

Adding attachments and/or optional equipment......................................

11 11 12 13 13

B

Truck Description....................................................................

15

1 1.1 2 2.1 2.2 2.3 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 4 4.1 4.2 4.3 5 5.1

Application .. .......... .. ......... .... .. ......... .... .. .. ........ .. .. ........ .... .. ......... .. .. .. ........

Truck models and rated capacity.............................................................

Assemblies and Functional Description...................................................

Travel direction definition.........................................................................

Assembly Overview.................................................................................

Functional Description .............................................................................

Technical Specifications..........................................................................

Performance data .. .. .. .. ... ....... .. .. ........... .. .. ....... ... .. .. ....... .. .. .. .. ........ ... .. .. ...

Dimensions..............................................................................................

Weights....................................................................................................

Mast versions ........ .. ........ .... .. ......... ... .. .. ....... .... .. ........ .. .. .. ......... .. .. .. .. ......

Tyre type..................................................................................................

Engine Data.............................................................................................

EN norms.................................................................................................

Conditions of use.....................................................................................

Electrical Requirements...........................................................................

Identification Points and Data Plates.......................................................

Data plate .. .. .. ......... .. .. .. ........ .. .... ......... .. .. ......... .. .. ............ .. .. ....... .... .. .. ....

Truck capacity plate.................................................................................

Attachment capacity plate .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .

Stability....................................................................................................

Wind loads...............................................................................................

15 15 16 16 17 18 20 21 22 24 25 28 29 29 30 30 31 33 34 36 38 38

C

Transport and Commissioning .. .. .. .. .. ... .. .. .. .. .. .. .. .. .. .. ... .. .. .. ... .. .

39

1 2 2.1 2.2 2.3 3 4

Transport .. ......... .. .. ............. .. ............. .. .. ......... .. .. ........ .... .. ......... .. .. .. ........

Truck laden..............................................................................................

Centre of gravity of the truck...................................................................

Lifting the truck by crane .........................................................................

Loading with another industrial truck.......................................................

Securing the truck during transport .. ...... .. .. .. .. .. ...... .. .. .. .............. .............

Using the Truck for the First Time .. ...... .. ... .. .. .. ..... .. .. .. .. .............. .............

39 39 39 40 42 43 44

D

Fuelling the Truck....................................................................

45

1 1.1 1.2 2 2.1

General....................................................................................................

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

LPG system relief valve...........................................................................

Adding diesel...........................................................................................

Fuelling....................................................................................................

45 45 47 48 48

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3 3.1 3.2 4 4.1 4.2

LPG containers ....................................................................................... .

LPG bottles ..............................................................................................

LPG tank (o) .......................................................................................... .

Fuel Level Indicator ................................................................................ .

Display unit ..............................................................................................

Level indicator for LPG bottles (o) ......................................................... .

50 50 53 54 54 54

E

Operation ............................................................................... .

55

1 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 3 3.1 3.2 3.3 3.4 3.5 3.6 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16 4.17 4.18 4.19 5 6 6.1 6.2 6.3 6.4

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

Displays and Controls ............................................................................. .

Controls ...................................................................................................

Pilots ........................................................................................................

Function symbols for the Pilots ............................................................... .

Control panel buttons ............................................................................. .

Control panel with display unit ................................................................ .

Symbols in the display ............................................................................ .

Button allocation of the display ............................................................... .

Operating Programs ............................................................................... .

Hourmeter ................................................................................................

Instrument panel switches (o) ............................................................... .

Preparing the Truck for Operation .......................................................... .

Checks and Operations to Be Performed Before Starting Daily Work ... .

Entry and exit. ......................................................................................... .

Trucks with reduced headroom (o) ........................................................ .

Setting up the operator position .............................................................. .

Seat Belt ..................................................................................................

Setting the time ....................................................................................... .

Industrial Truck Operation ...................................................................... .

Safety regulations for truck operation ..................................................... .

Preparing the truck for operation ............................................................ .

Starting procedure for the DFG .............................................................. .

Starting procedure for the TFG ............................................................... .

Parking the truck securely ...................................................................... .

Emergency Disconnect. .......................................................................... .

Travel .......................................................................................................

Steering ...................................................................................................

Brakes .....................................................................................................

Adjusting the forks ...................................................................................

Replacing the forks ................................................................................. .

Lifting, transporting and depositing loads ............................................... .

Operating the Lift Mechanism and Integrated Attachments ................... .

Safety instructions for operating additional attachments ........................ .

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

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

Operating additional Attachments for Duo-Pilot ..................................... .

Fitting additional attachments ................................................................. .

Particle Filter (DFG) .................................................................................

Towing trailers ........................................................................................ .

Optional equipment .................................................................................

Keyless Access System ..........................................................................

General Information on Using the Display Unit ...................................... .

Commissioning the Keypad and the Transponder Reader ..................... .

Keyless access system - display unit ..................................................... .

55 57 57 59 60 62 67 68 71 73 73 74 76 76 79 80 81 88 90 91 91 95 96 97 98 99 100 104 105 109 110 111 114 124 128 130 132 134 137 142 144 144 145 145 148

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6.25 6.26 6.27 6.28 6.29 6.30 6.31 6.32 6.33 6.34 6.35 6.36 7 7.1 7.2 7.3

Keyless access system - keypad.............................................................

Keyless access system - transponder reader..........................................

Assistance systems .......... ... .. ......... .. .. .. .. ........ .. .. ........ .. .. .. .. ........ .. .. .. ...... .

Tilt angle display......................................................................................

Steel cab..................................................................................................

Split Door.................................................................................................

Sliding windows.......................................................................................

Gate.........................................................................................................

Panel door...............................................................................................

Door Monitoring .................. ...... .... ........... ............... ....... ....... ......... ..... .....

Operator position extension.....................................................................

Heating and air conditioning system........................................................

USB charger module in armrest..............................................................

Load Weighing.........................................................................................

Operating hydraulics cutout............. ..... ............... ..................... ............ ...

Lift cutout override .. ......... .. .. .... ........ .. .. .. ......... .. .. ........ .... .. ......... .. .. .. ....... .

Fork Tilt Horizontal ..................................................................................

Sideshifter Centre Position ... .. .. ........ .... .. .. ....... .. .. .. .. ....... .... .. ......... ... .. .....

Control layout "N" ....... ........... ...... ........ ..... ............. ........ ....... ......... ..... .....

Operating the Auxiliary Hydraulics without Pressing the Acknowledgement Key .................................................................................................

Special control layout .. .. ........ .. .. ........... .. .. ......... .. .. ....... ..... .. ......... .... .. .....

Load Damping ......... .. .. ... ....... .. .. ............ .. .. ......... .. ......... .... .. ......... .... .. .....

Removable load backrest........................................................................

Fire extinguisher......................................................................................

Rockinger coupling with hand lever or remote control.............................

Trailer Coupling with Electrical Socket (12V) ..........................................

Camera system ....... .. ............ .. ............. .. ........ ... .. .. ....... ..... .. ......... .... .. .....

Optional equipment for working in dusty environments...........................

Floor-Spot................................................................................................

Horn Button on Overhead Guard.............................................................

StVZO road traffic regulations equipment .. .. .. .. .............. ...... .. .. .... ...... .. .. .

Truck Terminal.........................................................................................

Troubleshooting.......................................................................................

Troubleshooting.......................................................................................

Starting aid..............................................................................................

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

F

Industrial Truck Maintenance .................................................. 219

1 2 2.1 2.2 2.3 2.4 2.5 2.6 3 3.1 3.2 3.3 4 4.1

Operational Safety and Environmental Protection...................................

Maintenance Safety Regulations.............................................................

Working on the electrical system.............................................................

Consumables and used parts..................................................................

Wheels .....................................................................................................

Lift Chains................................................................................................

Hydraulic system ................. ...... ............... ............. ........ ....... ......... ..... .....

Working in the vicinity of the engine........................................................

Lubricants and Lubrication Schedule .. .. .. .. ....... .. .. .. ......... .. .. ........ .... .. ......

Handling consumables safely..................................................................

Lubrication Schedule...............................................................................

Consumables...........................................................................................

Maintenance and repairs.........................................................................

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

6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12 6.13 6.14 6.15 6.16 6.17 6.18 6.19 6.20 6.21 6.22 6.23 6.24

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153 158 163 165 166 167 169 169 171 172 172 173 176 176 176 176 177 178 179 181 185 190 192 193 194 195 196 198 199 201 202 203 207 207 212 213

219 220 220 220 221 221 222 223 224 224 226 227 229 229

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4.2 4.3 4.4 4.5 4.6 4. 7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16 4.17 5 5.1 5.2 5.3 6 7 8

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

Opening the rear panel............................................................................

Unlocking the engine bonnet...................................................................

Opening the Engine Cover......................................................................

Replacing wheels .. ....... .. .................... ........... .. ............ .... ............ .. ..........

Checking the Wheel Mounting.................................................................

Hydraulic system .......... .. .................... ............. ........... ... ............. ... ..........

Cooling system........................................................................................

Engine maintenance................................................................................

Heating and air conditioning system (o) ... ............. .. .......... ......... ............

Adding window washer system fluid........................................................

Checking electrical fuses.........................................................................

Cleaning ..................................................................................................

Starter battery..........................................................................................

Exhaust system .......................................................................................

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

Decommissioning the Industrial Truck.....................................................

Prior to decommissioning ............. .. ............... ............. ...... .. ............ .. .......

During decommissioning ....... ........... ................ ............ .............. .............

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

Safety tests to be performed at intervals and after unusual incidents .....

Final de-commissioning, disposal............................................................

Human vibration measurement...............................................................

230 231 232 233 235 237 238 241 244 253 253 254 259 261 262 262 263 264 264 264 265 265 265

G

Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement........................................................... 267

1 1.1 1.2 2 2.1 2.2

Maintenance Contents DFG 425s-435s ..................................................

Owner......................................................................................................

Customer Service ....................................................................................

Maintenance Contents TFG 425s-435s...................................................

Owner......................................................................................................

Customer Service ....................................................................................

268 268 272 284 284 288

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DOWNLOAD THE COMPLETE MANUAL

• 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.

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DOWNLOAD THE COMPLETE MANUAL