425s - 435s
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Operating instructions 51343827 08.18 09.14 DFG 425s DFG 430s DFG 435s TFG 425s TFG 430s TFG 435s fiUNGHEINRICH
DFG/TFG
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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 :
,& 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 .
Indicates a material hazard. Failure to comply with this instruction may result in material damage.
Used before notices and explanations.
Indicates standard equipment
Indicates optional equipment
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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 Travel direction definition......................................................................... 16 2.2 Assembly Overview................................................................................. 17 2.3 Functional Description 18 3 Technical Specifications.......................................................................... 20 3.1 Performance data .. .. .. .. ... ....... .. .. ........... .. .. ....... ... .. .. ....... .. .. .. .. ........ ... .. .. ... 21 3.2 Dimensions.............................................................................................. 22 3.3 Weights.................................................................................................... 24 3.4 Mast versions ........ .. . ....... .... .. . ........ ... .. .. ....... .... .. . ....... .. .. .. . ........ .. .. .. .. ...... 25 3.5 Tyre type.................................................................................................. 28 3.6 Engine Data............................................................................................. 29 3.7 EN norms................................................................................................. 29 3.8 Conditions of use..................................................................................... 30 3.9 Electrical Requirements........................................................................... 30 4 Identification Points and Data Plates....................................................... 31 4.1 Data plate 33 4.2 Truck capacity plate................................................................................. 34 4.3 Attachment capacity plate 36 5 Stability.................................................................................................... 38 5.1 Wind loads............................................................................................... 38 C Transport and Commissioning .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. ... .. .. .. . .. .. . 39 1 Transport .. ......... .. .. ............. .. . ............ .. .. ......... .. .. ........ .... .. . ........ .. .. .. . ....... 39 2 Truck laden.............................................................................................. 39 2.1 Centre of gravity of the truck................................................................... 39 2.2 Lifting the truck by crane ......................................................................... 40 2.3 Loading with another industrial truck....................................................... 42 3 Securing the truck during transport 43 4 Using the Truck for the First Time .. ...... .. ... .. .. .. ..... .. .. .. .. .............. ............. 44 D Fuelling the Truck.................................................................... 45 1 General.................................................................................................... 45 1.1 Safety regulations for handling diesel fuel and LPG................................ 45 1.2 LPG system relief valve........................................................................... 4 7 z 2 UJ Adding diesel........................................................................................... 48 Cl0 2.1 .... Fuelling.................................................................................................... 48 00 0 7
o o o o 3 LPG containers 50 3.1 LPG bottles 50 3.2 LPG tank ( ) .......................................................................................... . 53 4 Fuel Level Indicator 54 4.1 Display unit 54 4.2 Level indicator for LPG bottles ( ) ......................................................... . 54 E Operation 55 1 Safety Regulations for the Operation of Forklift Trucks 55 2 Displays and Controls ............................................................................. . 57 2.1 Controls 57 2.2 Pilots 59 2.3 Function symbols for the Pilots 60 2.4 Control panel buttons 62 2.5 Control panel with display unit ................................................................ . 67 2.6 Symbols in the display 68 2.7 Button allocation of the display 71 2.8 Operating Programs ............................................................................... . 73 2.9 Hourmeter 73 2.10 Instrument panel switches ( ) ............................................................... . 74 3 Preparing the Truck for Operation 76 3.1 Checks and Operations to Be Performed Before Starting Daily Work 76 3.2 Entry and exit. ......................................................................................... . 79 3.3 Trucks with reduced headroom ( ) 80 3.4 Setting up the operator position 81 3.5 Seat Belt ................................................................................................. . 88 3.6 Setting the time 90 4 Industrial Truck Operation 91 4.1 Safety regulations for truck operation ..................................................... . 91 4.2 Preparing the truck for operation 95 4.3 Starting procedure for the DFG .............................................................. . 96 4.4 Starting procedure for the TFG 97 4.5 Parking the truck securely 98 4.6 Emergency Disconnect. .......................................................................... . 99 4.7 Travel 100 4.8 Steering 104 4.9 Brakes .................................................................................................... . 105 4.10 Adjusting the forks 109 4.11 Replacing the forks ................................................................................. . 110 4.12 Lifting, transporting and depositing loads 111 4.13 Operating the Lift Mechanism and Integrated Attachments 114 4.14 Safety instructions for operating additional attachments ........................ . 124 4.15 Operating additional attachments for the SOLO-PILOT 128 4.16 Operating additional attachments for the Multi Pilot ............................... 130 4.17 Operating additional Attachments for Duo-Pilot ..................................... . 132 4.18 Fitting additional attachments 134 4.19 Particle Filter (DFG) ................................................................................. 137 5 Towing trailers ........................................................................................ . 142 6 Optional equipment 144 6.1 Keyless Access System ......................................................................... . 144 6.2 6.3 General Information on Using the Display Unit ...................................... . Commissioning the Keypad and the Transponder Reader 145 z 145 w CIC) 6.4 Keyless access system - display unit ..................................................... . 148 ..... CX) 0 8
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 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 F 1 2 2.1 2.2 2.3 2.4 2.5 2.6 3 3.1 3.2 z 3.3 UJ 4 Cl0 .... 4.1 00 0 Keyless access system - keypad............................................................. 153 Keyless access system - transponder reader.......................................... 158 Assistance systems . ......... ... .. . ........ .. .. .. .. ........ .. .. . ....... .. .. .. .. ........ .. .. .. ...... . 163 Tilt angle display...................................................................................... 165 Steel cab.................................................................................................. 166 Split Door................................................................................................. 167 Sliding windows....................................................................................... 169 Gate......................................................................................................... 169 Panel door............................................................................................... 171 Door Monitoring 172 Operator position extension..................................................................... 172 Heating and air conditioning system........................................................ 173 USB charger module in armrest.............................................................. 176 Load Weighing......................................................................................... 176 Operating hydraulics cutout............. ..... ............... ..................... ............ ... 176 Lift cutout override 176 Fork Tilt Horizontal .................................................................................. 177 Sideshifter Centre Position 178 Control layout "N" ....... ........... ...... ........ ..... ............. ........ ....... ......... ..... ..... 179 Operating the Auxiliary Hydraulics without Pressing the Acknowledgement Key 181 Special control layout .. .. . ....... .. .. ........... .. .. ......... .. .. ....... ..... .. . ........ .... .. ..... 185 Load Damping ......... .. .. ... ....... .. .. ............ .. .. ......... .. . ........ .... .. . ........ .... .. ..... 190 Removable load backrest........................................................................ 192 Fire extinguisher...................................................................................... 193 Rockinger coupling with hand lever or remote control............................. 194 Trailer Coupling with Electrical Socket (12V) 195 Camera system ....... .. . ........... .. . ............ .. . ....... ... .. .. ....... ..... .. . ........ .... .. ..... 196 Optional equipment for working in dusty environments........................... 198 Floor-Spot................................................................................................ 199 Horn Button on Overhead Guard............................................................. 201 StVZO road traffic regulations equipment 202 Truck Terminal......................................................................................... 203 Troubleshooting....................................................................................... 207 Troubleshooting....................................................................................... 207 Starting aid.............................................................................................. 212 Operating the truck without its own drive system.................................... 213 Industrial Truck Maintenance .................................................. 219 Operational Safety and Environmental Protection................................... 219 Maintenance Safety Regulations............................................................. 220 Working on the electrical system............................................................. 220 Consumables and used parts.................................................................. 220 Wheels 221 Lift Chains................................................................................................ 221 Hydraulic system 222 Working in the vicinity of the engine........................................................ 223 Lubricants and Lubrication Schedule .. .. .. .. ....... .. .. .. . ........ .. .. ........ .... .. ...... 224 Handling consumables safely.................................................................. 224 Lubrication Schedule............................................................................... 226 Consumables........................................................................................... 227 Maintenance and repairs......................................................................... 229 Preparing the truck for maintenance and repairs ............ ...... .. .. .... ...... .. .. 229 9
o 10 4.2 Lifting and jacking up the truck safely...................................................... 230 4.3 Opening the rear panel............................................................................ 231 4.4 Unlocking the engine bonnet................................................................... 232 4.5 Opening the Engine Cover...................................................................... 233 4.6 Replacing wheels 235 4. 7 Checking the Wheel Mounting................................................................. 237 4.8 Hydraulic system 238 4.9 Cooling system........................................................................................ 241 4.10 Engine maintenance................................................................................ 244 4.11 Heating and air conditioning system ( ) 253 4.12 Adding window washer system fluid........................................................ 253 4.13 Checking electrical fuses......................................................................... 254 4.14 Cleaning 259 4.15 Starter battery.......................................................................................... 261 4.16 Exhaust system ....................................................................................... 262 4.17 Restoring the truck to service after maintenance and repairs 262 5 Decommissioning the Industrial Truck..................................................... 263 5.1 Prior to decommissioning 264 5.2 During decommissioning ....... ........... ................ ............ .............. ............. 264 5.3 Restoring the truck to service after decommissioning ................ ............. 264 6 Safety tests to be performed at intervals and after unusual incidents 265 7 Final de-commissioning, disposal............................................................ 265 8 Human vibration measurement............................................................... 265 G Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement........................................................... 267 1 Maintenance Contents DFG 425s-435s .................................................. 268 1.1 Owner...................................................................................................... 268 1.2 Customer Service 272 2 Maintenance Contents TFG 425s-435s................................................... 284 2.1 Owner...................................................................................................... 284 2.2 Customer Service 288 z w CIC) ..... CIC) 0
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• 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
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