Jungheinrich Forklift TFG 425-435df Operating instructions Manual 51554812 – PDF DOWNLOAD by www.heydownloads.com

TFG 425-435df

Operating instructions 51554812 07.18 08.16 TFG 425df TFG 430df TFG 435df 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 :

,& 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.

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............................................................................................. 28 3.7 EN norms................................................................................................. 30 3.8 Conditions of use..................................................................................... 30 3.9 Electrical Requirements........................................................................... 31 4 Identification Points and Data Plates....................................................... 32 4.1 Data plate 34 4.2 Truck capacity plate................................................................................. 35 4.3 Attachment capacity plate 37 5 Stability.................................................................................................... 39 5.1 Wind loads............................................................................................... 39 C Transport and Commissioning .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. ... .. .. .. . .. .. . 41 1 Transport .. ......... .. .. ............. .. . ............ .. .. ......... .. .. ........ .... .. . ........ .. .. .. . ....... 41 2 Truck laden.............................................................................................. 41 2.1 Centre of gravity of the truck 41 2.2 Lifting the truck by crane ......................................................................... 42 2.3 Loading with another industrial truck....................................................... 44 3 Securing the truck during transport 45 4 Using the Truck for the First Time........................................................... 47 D Fuelling the Truck.................................................................... 49 1 General.................................................................................................... 49 1.1 Safety Regulations for Handling Petrol and LPG 49 1.2 LPG system relief valve........................................................................... 51 z 2 UJ Filling with Petrol ................. ...... ................ ............ ........ ....... ......... ....... ... 52 Cl0 2.1 .... Fuelling.................................................................................................... 52 r....: 0 7

o o o o 2.2 Fuelling with fuel containers 53 2.3 Fuel Level Indicator 53 3 LPG containers ....................................................................................... . 54 3.1 LPG bottles 54 3.2 LPG tank ( ) 56 E Operation ............................................................................... . 57 1 Safety Regulations for the Operation of Forklift Trucks 57 2 Displays and Controls 59 2.1 Control panel with display unit ................................................................ . 61 3 Description of the Display and Controls on the Armrest ( ) 65 3.1 Pilots 67 3.2 Function symbols for the Pilots 68 3.3 Control panel with display unit 70 4 Preparing the Truck for Operation .......................................................... . 74 4.1 Checks and Operations to Be Performed Before Starting Daily Work 74 4.2 Entry and exit. 76 4.3 Trucks with reduced headroom ( ) 77 4.4 Setting up the operator position 77 4.5 Seat Belt 89 5 Industrial Truck Operation 91 5.1 Safety regulations for truck operation 91 5.2 Preparing the truck for operation ............................................................ . 95 5.3 Starting the Truck 96 5.4 Switching the Fuel Supply 98 5.5 Parking the truck securely ...................................................................... . 99 5.6 Battery Isolator 100 5.7 Travel 101 5.8 Steering .................................................................................................. . 103 5.9 Brakes 104 5.10 Adjusting the forks .................................................................................. . 106 5.11 Replacing the forks 107 5.12 Lifting, transporting and depositing loads 108 5.13 Operating the Lift Mechanism and Integrated Attachments .................. .. 111 5.14 Safety instructions for operating additional attachments 128 5.15 Operating additional attachments for the SOLO-PILOT 132 5.16 Operating Additional Attachments for SOLO-PILOT on the Armrest.. .... . 134 5.17 Operating Additional Attachments for MULTI-PILOT on the Armrest.. 137 5.18 Operating Additional Attachments for DUO-PILOT on the Armrest.. ...... . 140 5.19 Fitting additional attachments 143 6 Towing trailers 146 7 Optional equipment ................................................................................. 148 7.1 Steel cab ................................................................................................. . 148 7.2 Sliding windows 149 7.3 Heating .................................................................................................... 149 7.4 Removable load backrest 149 7.5 Adding window washer system fluid 150 7.6 CanCode Keypad ( ) ............................................................................ .. 151 7.7 Control Layout "N" on the Armrest. 166 7.8 USB charger module in armrest ............................................................ .. 168 7.9 7.10 Camera system ...................................................................................... . Floor-Spot 169 z 171 w CIC) 7.11 Horn Button on Overhead Guard ............................................................ . 173 ..... r-..: 0 8

o z UJ Cl0 .... 0 7.12 StVZO road traffic regulations equipment 174 8 Troubleshooting....................................................................................... 175 8.1 Troubleshooting....................................................................................... 175 8.2 Starting aid 178 8.3 Operating the truck without its own drive system 179 F Industrial Truck Maintenance .................................................. 185 1 Operational Safety and Environmental Protection................................... 185 2 Maintenance Safety Regulations............................................................. 186 2.1 Working on the electrical system............................................................. 186 2.2 Consumables and used parts.................................................................. 186 2.3 Wheels..................................................................................................... 187 2.4 Lift Chains................................................................................................ 187 2.5 Hydraulic system 188 2.6 Working in the vicinity of the engine........................................................ 189 3 Lubricants and Lubrication Schedule 190 3.1 Handling consumables safely.................................................................. 190 3.2 Lubrication Schedule............................................................................... 192 3.3 Consumables........................................................................................... 193 4 Maintenance and repairs......................................................................... 195 4.1 Preparing the truck for maintenance and repairs 195 4.2 Lifting and jacking up the truck safely...................................................... 196 4.3 Opening the Engine Cover...................................................................... 197 4.4 Opening the Engine Cover with Comfort Seat ( ) 198 4.5 Removing the Covers.............................................................................. 202 4.6 Removing the Floor Plate........................................................................ 202 4. 7 Replacing wheels 203 4.8 Checking the Wheel Mounting................................................................. 205 4.9 Hydraulic system ................. ...... ............... ............. ........ ....... ......... ..... ..... 206 4.10 Cooling system........................................................................................ 209 4.11 Engine maintenance................................................................................ 211 4.12 Checking electrical fuses......................................................................... 217 4.13 Cleaning.................................................................................................. 221 4.14 Starter battery.......................................................................................... 223 4.15 Exhaust system 224 4.16 Transmission and Drive Axle................................................................... 225 4.17 Brake ....... .. .. ... ........ .. .... ........ .. .... .......... .. .. ........ .. .. .. ........ .. .. .. ........ .. .. .. ..... 226 4.18 Restoring the truck to service after maintenance and repairs 226 5 Decommissioning the Industrial Truck..................................................... 227 5.1 Prior to decommissioning 228 5.2 During decommissioning 228 5.3 Restoring the truck to service after decommissioning .. .............. ............. 228 6 Safety tests to be performed at intervals and after unusual incidents 229 7 Final de-commissioning, disposal............................................................ 229 8 Human vibration measurement............................................................... 229 G Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement. 231 1 Maintenance Contents TFG 425-435df................................................... 232 1.1 Owner 232 1.2 Customer Service .. .. .. ..... ....... .. .. ........... .. .. ....... ... .. .. ....... .. .. .. .. ........ ... .. ..... 236 9

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