Jungheinrich DFG 425 Operating Instructions Manual Download

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Operating Instructions

52025727

DFG/TFG 425/430/435

07.04-

02.08

Summary of Contents for DFG 425

Page 1: ...Operating Instructions 52025727 DFG TFG 425 430 435 G 07 04 02 08 ...

Page 2: ...uck Further pressing on the pedal allows the truck to brake easily e g during crawl speed operations Supplement Brake System Post 09 2007 Trucks As of 09 2007 DFG TFG 425 435 series trucks have been fitted with a new service brake system In future in addition to the slow travel brake pedal 29 an additional brake pedal 21 will be available The brake pedal 21 hydraulically actuates two drum brakes w...

Page 3: ......

Page 4: ...tiengesellschaft Am Stadtrand 35 22047 Hamburg GERMANY Telephone 49 0 40 6948 0 www jungheinrich com 0108 GB Foreword 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 Each chapter starts with page 1 The page identification co...

Page 5: ...0108 GB 0108 GB ...

Page 6: ...ations for handling diesel fuel and LPG D 1 2 Filling with diesel D 2 3 Replacing the LPG bottle D 3 I 1 0106 GB Table of Contents A Correct use and application of the truck B Truck Description 1 Application B 1 2 Assemblies and Functional Description B 2 2 1 Truck B 3 3 Standard Version Specifications B 5 3 1 Performance data B 6 3 2 Dimensions B 7 3 3 Motor data B 9 3 4 Tyres B 9 3 5 Mast Versio...

Page 7: ...tor panel E 37 5 10 Towing E 38 5 11 Towing trailers E 39 5 12 Tow loads E 39 6 Troubleshooting E 40 0106 GB I 2 E Operation 1 Safety Regulations for the Operation of Forklift Trucks E 1 2 Controls and Displays E 3 3 Checks and operations to be performed before starting daily work E 7 4 Starting up the truck E 12 4 1 Checks and operations to be performed before starting daily work E 12 4 2 Trucks ...

Page 8: ...erformed at intervals and after unusual events D Accident prevention check according to BGV D27 F 26 I 3 0106 GB F Maintenance of the forklift truck 1 Operational safety and environmental protection F 1 2 Maintenance Safety Regulations F 1 3 Servicing and inspection F 3 4 DFG TFG maintenance checklist F 4 5 DFG maintenance checklist F 6 6 TFG maintenance checklist F 7 7 Coolant specification F 8 8...

Page 9: ...0106 GB I 4 0106 GB I 4 ...

Page 10: ...d loads The truck may only be used for trailing or towed loads for which the truck has been approved A 1 0104 GB A Correct use and application of the truck Z The Guidelines for the Correct Use and Application of Industrial Trucks VDMA are supplied with the truck The guidelines form part of these operating instructions and must be observed National regulations apply in full The truck described in t...

Page 11: ...0104 GB A 2 0104 GB A 2 ...

Page 12: ...kg Model Capacity kg Wheel base mm DFG TFG 425 2500 1685 DFG TFG 430 3000 1685 DFG TFG 435 3500 1785 B 1 0207 GB B Truck Description 1 Application The DFG TFG series are IC motor 4 wheel rider trucks The DFG series are diesel motor trucks while the TFG series are fitted with a petrol motor for LPG operation The DFG TFG 425 435 is equipped with a hydrodynamic drive system A combined slow travel bra...

Page 13: ... 13 t Trailer coupling 7 t Lift cylinder 14 t Counterbalance weight 7 1 2 3 4 9 10 11 13 14 12 8 6 5 0207 GB B 2 2 Assemblies and Functional Description Item Description Item Description 1 t Driver s seat 8 t Load fork 2 t Steering column 9 t Fork carriage 3 t Dashboard 10 t Drive axle 4 t Overhead guard 11 t Motor cover 5 t Mast 12 t Steering axle 6 t Load chain 13 t Trailer coupling 7 t Lift cyl...

Page 14: ... are located within the geometry of the truck The trucks offer a choice of air or superelastic tyres B 3 0207 GB 2 1 Truck Chassis Superstructure A rigid chassis which protects the units and controls provides the truck with maximum static safety Maintenance and servicing are made easy through the wide opening cover and the two side panels of the motor housing 11 The hydraulic oil reservoir is inte...

Page 15: ...ed casters Attachments The trucks can be optionally fitted with mechanical and hydraulic attachments 0207 GB B 4 Hydraulic system The gear pump of the hydraulic system is powered by motor through a power take off of the power shift gear The pump speed and hence the supply volume are controlled by the accelerator pedal through the motor speed Hydraulic functions are controlled by the control lever ...

Page 16: ...odifications and additions reserved m1 h3 h1 h2 h7 h6 h4 Wa Ast L2 L1 x d b a 2 a 2 l y m2 s e C Q B B 5 0207 GB 3 Standard Version Specifications Z Technical data specified in accordance with VDI 2198 Technical modifications and additions reserved m1 h3 h1 h2 h7 h6 h4 Wa Ast L2 L1 x d b a 2 a 2 l y m2 s e C Q B ...

Page 17: ... 51 m s Lowering speed w w o load 0 55 0 45 0 55 0 45 0 55 0 42 m s Gradeability w w o load 27 23 19 0207 GB B 6 3 1 Performance data Description DFG 425 DFG 430 DFG 435 Q Capacity where C 600 mm 2500 3000 3500 Kg C Load centre of gravity distance 500 500 500 mm Travel speed w w o load 17 19 18 19 18 19 km h Lift speed w w o load 0 59 0 60 0 53 0 59 0 49 0 53 m s Lowering speed w w o load 0 55 0 4...

Page 18: ...70 2550 mm x Load distance 473 515 515 mm y Wheelbase 1685 1685 1785 mm Net weight 4290 4730 5098 Kg B 7 0207 GB 3 2 Dimensions Description DFG 425 DFG 430 DFG 435 a 2 Safety distance 100 100 100 mm h1 Mast height retracted 2080 2080 2180 mm h2 Free lift 150 150 150 mm h3 Lift 2900 2900 3100 mm h4 Mast height extended 3685 3685 3885 mm h6 Height above overhead guard 2220 2250 2250 mm h7 Seat heigh...

Page 19: ...70 2550 mm x Load distance 473 515 515 mm y Wheelbase 1685 1685 1785 mm Net weight 4190 4630 4998 Kg 0207 GB B 8 Description TFG 425 TFG 430 TFG 435 a 2 Safety distance 100 100 100 mm h1 Mast height retracted 2080 2080 2180 mm h2 Free lift 150 150 150 mm h3 Lift 2900 2900 3100 mm h4 Mast height extended 3685 3685 3885 mm h6 Height above overhead guard 2220 2250 2250 mm h7 Seat height 1068 1068 106...

Page 20: ...FG TFG 430 DFG TFG 435 Drive axle 10 0 bar 9 0 bar 8 25 bar Steering axle 10 0 bar 10 0 bar 10 0 bar B 9 0207 GB 3 3 Motor data Motor DFG Motor TFG 3 4 Tyres Z Permissible tyre type forSolid Solideal Magnum Air Solideal ED Extra Deep Type S45 four cylinder Ignition order 1 3 4 2 Capacitance 3331 cc Control speed 2350 rpm without load 680 rpm idle Valve clearance Inlet and outlet 0 25 mm cold Tray ...

Page 21: ... 5000 1680 2280 5600 5500 1880 2480 6100 6000 2080 2680 6600 6500 2280 2880 7100 7000 2480 3080 7600 0207 GB B 10 3 5 Mast Versions all dimensions in mm DFG TFG 425 430 Mast table VDI 3596 Description Lift h3 Free lift h2 Retracted height h1 Extended height h4 ZT 2900 150 2080 3510 3100 150 2180 3710 3300 150 2280 3910 3500 150 2380 4110 3700 150 2480 4310 4000 150 2630 4610 4300 150 2830 4910 450...

Page 22: ... 4700 1417 2180 5463 5000 1517 2280 5763 5500 1717 2480 6263 6000 1917 2680 6763 6500 2117 2880 7263 B 11 0207 GB DFG TFG 435 Mast table VDI 3596 Description Lift h3 Free lift h2 Retracted height h1 Extended height h4 ZT 3100 150 2180 3870 3500 150 2380 4270 4000 150 2630 4770 4500 150 2930 5270 5000 150 3180 5770 DZ 4700 1417 2180 5463 5000 1517 2280 5763 5500 1717 2480 6263 6000 1917 2680 6763 6...

Page 23: ...the truck is to be constantly used in conditions of extreme temperature or air humidity fluctuations 0207 GB B 12 3 6 EN norms Noise emission 78 dB A In accordance with EN 12053 as harmonised with ISO 4871 Z The noise emission level is calculated in accordance with standard procedures and takes into account the noise level when travelling lifting and when idle The noise level is measured at the dr...

Page 24: ...a plate 24 19 D mm mm Q kg 24 21 15 17 18 16 27 19 26 20 23 1 2 1 1 1 0 9 8 7 6 5 4 3 2 1 2000 22 25 B 13 0207 GB 4 Identification points and data plates Item Description 15 Attention Read operator manual 16 Load fork Capacity Load Centre of Gravity Lift Height diagram 17 Travel with raised load prohibited Mast forward tilt with raised load prohibited warning 18 Attach Safety Restraint Belt decal ...

Page 25: ...9 30 31 35 34 32 33 36 4250 3600 2900 1250 1250 850 500 600 700 1105 1105 850 850 850 600 Example 16 0207 GB B 14 4 1 Truck data plate Z For queries regarding the truck or ordering spare parts please quote the truck serial number 28 4 2 Truck load diagram The load diagram 16 gives the capacity Q of the truck in kg with a vertical mast The diagram will differ depending on the construction of the ma...

Page 26: ...on the inner and outer masts show the driver when the prescribed lift limits have been reached 37 38 B 15 0207 GB 4 3 Fork load diagram basic model The fork load diagram give the truck s capacity Q in kg The maximum capacity for the various load centres of gravity D in mm is shown in diagram form 4 4 Attachment load diagram The attachment load diagram gives the truck s capacity Q in combination wi...

Page 27: ...0207 GB B 16 0207 GB B 16 ...

Page 28: ...they do not come into contact with any attachments or the overhead guard when it is being raised 2 1 C 1 0704 GB C Transport and Commissioning 1 Lifting by crane M Only use lifting gear with sufficient capacity for transport weight see truck data plate Park the truck securely see Chapter E Attach the crane slings to the cross member of the mast 1 and the trailer coupling 2 M Only suspend crane bel...

Page 29: ...d guard See centre picture The lower picture shows the approximate position of the centre of gravity 0704 GB C 2 2 Securing the truck during transport The truck must be securely fastened when being transported on a lorry or a trailer The lorry trailer must have fastening rings and a wooden floor Loading shall be carried out by staff especially trained for that purpose in accordance with recommenda...

Page 30: ...ep speed Z As the steering auxiliary unit is not applied extra effort is required to steer the truck C 3 0704 GB 3 Commissioning F Commissioning and driver instruction must be performed by trained personnel If several trucks have been delivered make sure that always the serial numbers of the load lifting devices masts and basic trucks match each other To prepare the truck after delivery or after t...

Page 31: ...0704 GB C 4 0704 GB C 4 ...

Page 32: ... as statutory and local regulations when filling up F Liquid gas produces frost damage to naked skin D 1 0704 GB D Filling the Truck with Fuel 1 Safety regulations for handling diesel fuel and LPG Before filling up or replacing the LPG bottle first park the truck securely see Chapter E Fire protection When handling fuels and LPG smoking naked flames and other ignition sources are strictly prohibit...

Page 33: ...r in the fuel system will result in malfunctions Tighten the cap back on after filling with fuel 1 2 0704 GB D 2 2 Filling with diesel F The truck must only be filled at locations specifically designed for this purpose Park the truck securely before filling up see Chapter E Open the cap 1 Fill up with clean diesel Z Do not overfill the tank Capacity 58l M Only use DIN 51601 diesel with a cetane ra...

Page 34: ...ly open the shut off valve and check the connection is sealed using a foam based agent 3 4 6 5 7 8 9 D 3 0704 GB 3 Replacing the LPG bottle F The LPG bottle must only be replaced at designated areas by trained and authorised personnel Park the truck securely before filling up see Chapter E Close the shut off valve 3 securely Start the motor and allow the LPG system to run empty in neutral Unscrew ...

Page 35: ...11 F Note all guidelines and regulations concerning the filling of LPG bottles on the LPG pump 11 10 0704 GB D 4 o Reusable LPG bottles with central filling device The bottle is fitted with a filling stop valve The discharge valve 10 must be sealed Remove the seal 11 Insert the nozzle of the liquid gas pump into the filler port Fill the LPG bottle until you can see on the fluid gauge that the bott...

Page 36: ...in the driver s line of sight The max recommended body size indicated on this sign must be obser ved E 1 0106 GB E Operation 1 Safety Regulations for the Operation of Forklift Trucks Driver authorisation The forklift truck may only be used by suitably trained personnel who have demonstrated to the proprietor or his representative that they can drive and handle loads and have been authorised to ope...

Page 37: ... 2 10 16 17 18 19 20 21 25 24 23 22 26 11 12 13 14 15 1 2 5 27 7 8 3 4 6 9 10 11 12 14 3 5 7 1 2 4 6 0106 GB E 2 10 16 17 18 19 20 21 25 24 23 22 26 11 12 13 14 15 1 2 5 27 7 8 3 4 6 9 10 11 12 14 3 5 7 1 2 4 6 ...

Page 38: ...vel direction switch is in neutral 15 Fuel display DFG t Indicates how much fuel is left in the tank E 3 0106 GB 2 Controls and Displays Item Control Display Function 1 Soot filter indicator t Indicates that the soot filter is contaminated 2 Motor oil pressure indicator t When lit indicates insufficient motor lubricant oil pressure 3 Charging current indicator t When lit indicates that the battery...

Page 39: ... 4 10 16 17 18 19 20 21 25 24 23 22 26 11 12 13 14 15 1 2 5 27 7 8 3 4 6 9 10 11 12 14 3 5 7 1 2 4 6 0106 GB E 4 10 16 17 18 19 20 21 25 24 23 22 26 11 12 13 14 15 1 2 5 27 7 8 3 4 6 9 10 11 12 14 3 5 7 1 2 4 6 ...

Page 40: ...rning switch t Triggers an audible warning 27 Travel direction switch t Selects the travel direction E 5 0106 GB Item Control Display Function 16 Parking brake lever t Applies releases parking brake To engage turn switch to position 1 To release turn switch to position 0 Pull up lever to engage Push lever forward to release 17 Steering wheel t Steers truck in desired direction 18 Steering column a...

Page 41: ... fan Horn To activate the horn press the warning signal switch 26 in the hydraulic lever 27 28 29 26 0106 GB E 6 t Travel direction switch Z When the travel direction switch 27 is in the central position the transmission is in idle To select the forward gear push the switch forward To select the reverse gear push the switch back Z The motor will not start if a travel direction is pre selected o He...

Page 42: ...t grade of oil to the motor until the oil level has reached the MAX mark on the dipstick 32 31 34 33 E 7 0106 GB 3 Checks and operations to be performed before starting daily work Truck Visually inspect the whole of the truck especially the wheels and the lifting device for obvious signs of damage Z Covers may need to be opened for the inspection Checking the motor oil TFG Remove the dipstick 32 W...

Page 43: ...thly when the mast is raise the mast must be gently lowered before continuing with this procedure 35 0106 GB E 8 Checking the hydraulic oil level If the oil is cold Fully raise and lower the mast in one operation Stop the motor Remove the dipstick 35 and clean it with a clean cloth Check the hydraulic oil level It should lie between the MIN and MAX markings on the dipstick If necessary top up to t...

Page 44: ...e personnel for maintenance purposes F If the drain is opened gas may escape Drain open Drain closed E 9 0106 GB Gas system drain tap Z The gas system drain tap must always be closed during operation it should only be opened by service personnel for maintenance purposes F If the drain is opened gas may escape Drain open Drain closed ...

Page 45: ...n any coolant For details on recommended concentrations and safety measures refer to Chapter F 37 36 0106 GB E 10 Checking the coolant level Check the coolant level on the reservoir The coolant should lie between the MIN and MAXmarkings 36 M If the coolant is below the MIN marking this indicates possible leakage in the radiator system The truck must only be used once the cause has been removed F I...

Page 46: ...and tyres for wear see Chapter F Measure the tyre pressures air tyres only see Chapter B 15 19 39 38 E 11 0106 GB Checking the fuel supply DFG Set the ignition starter key 19 to the I position Read off the fuel supply from the fuel gauge 15 If necessary add diesel see Chapter D o Testing the windscreen fluid level The windscreen fluid container 38 is located behind the cover 39 at the rear of the ...

Page 47: ...lso check that the dri vers can sit normally in an upright posi tion without having to exert himself 0106 GB E 12 4 Starting up the truck F Before the truck can be commissioned operated or a load unit lifted the driver must ensure that there is nobody within the hazardous area 4 1 Checks and operations to be performed before starting daily work The entire truck in particular wheels and load liftin...

Page 48: ... incline of the backrest 40 Release locking lever 41 to lock the backrest in position 41 42 43 44 40 E 13 0106 GB 4 3 Adjusting the driver s seat Standard seat MSG 20 Z To achieve optimal seat cushioning the driver s seat must be adjusted according to the driver s weight The driver s seat must be adapted to the driver s weight Adjusting the seat to the driver s weight Pull the lever 43 in the dire...

Page 49: ... a deadman switch i e the truck only starts when the driver is positioned on the seat 41 42 43 44 40 0106 GB E 14 Adjusting the seat position Pull up the locking lever 44 of the driver s seat lock in the direction of the arrow and push the seat forwards or backwards to the desired position Engage locking lever 44 in position again F The driver s seat must be securely located in the desired positio...

Page 50: ...ated in the desired position The driver s seat setting must not be changed during travel 45 46 47 48 E 15 0106 GB o MSG 65 seat To achieve optimal seat cushioning the driver s seat must be adjusted according to the driver s weight Adjusting the seat to the driver s weight Sit on the driver s seat When the correct weight adjustment has been made the arrow of the driver weight display 48 will be abo...

Page 51: ...kward as required Push the steering column adjusting lever in the direction of the arrow F F L 18 49 0106 GB E 16 4 4 Safety restraint belt F Put on the safety restraint belt each time before starting the industrial truck The belt protects against serious injury Protect the belt from contamination e g cover it when the truck is idle and clean it regularly Frozen belt locks or pulleys must be thawe...

Page 52: ...r preheating diesel only III Starting the motor automatically returns to the II position 19 21 26 27 E 17 0106 GB 4 6 Starting the truck Before starting the truck If the motor has not run for several weeks or if the oil filter has been changed start the motor see section 4 7 or 4 8 and leave it to run in idle for a few minutes before starting Start the motor F The truck should only be operated fro...

Page 53: ...oon as the motor starts If not stop the motor immediately and rectify the fault 19 21 26 27 14 3 5 2 0106 GB E 18 4 7 Starting procedure for the TFG F Note the safety regulations for handling liquid gas see Chapter D section 1 Slowly open the shutoff valve on the LPG bottle Put the key in the ignition starter switch 19 Set the ignition starter key 19 to the I position Press the warning switch 26 a...

Page 54: ... as the motor starts If not stop the motor immediately and rectify the fault 19 21 13 14 2 5 3 26 27 E 19 0106 GB 4 8 Starting procedure for the DFG Put the key in the ignition starter switch 19 Set the ignition starter key 19 to the I position Press the warning switch 26 and test the horn After setting the ignition starter 19 to the I position the charging current 3 motor oil pressure 2 neutral s...

Page 55: ...ontrols have been satisfactorily performed and operating temperature is reached 21 20 17 16 24 25 10 0106 GB E 20 F After starting the motor carry out a test run and check the following functions Braking of the parking brake 16 and the slow travel brake pedal 20 Test the motor speed with the accelerator pedal 21 over a range of speeds while checking the ease of movement of the pedal Test the opera...

Page 56: ...ng procedures see section 6 Check the fuel display 15 DFG only during operation 10 15 2 3 4 10 3 2 4 E 21 0106 GB 4 9 Operational Fault Displays When the following indicators are lit Motor oil pressure 2 Charging current 3 Coolant temperature 10 Transmission oil temperature 4 the motor must be stopped immediately M The motor should only be started again once the fault has been removed Z For troubl...

Page 57: ... 27 to neutral Apply the parking brake 16 Set the ignition starter key 19 to the 0 position 19 16 27 0106 GB E 22 4 10 Stopping the motor 1 M Do not stop the motor from full charge Instead let it run for a short while to allow the temperature to compensate Stop the truck Set the travel direction switch 27 to neutral Apply the parking brake 16 Set the ignition starter key 19 to the 0 position 19 16...

Page 58: ...cured loads Never transport loads stacked higher than the top of the fork carriage or the load guard E 23 0106 GB 5 Industrial truck operation 5 1 Safety regulations for truck operation Travel routes and work areas Only use lanes and routes specifically designated for truck traffic Unauthorised persons must stay away from work areas Loads must only be stored in places specially designated for this...

Page 59: ...d direction Slowly apply the accelerator pedal 21 until you reach the required travel speed 21 27 20 0106 GB E 24 Towing trailers or the truck itself being towed are only permitted occasionally on secure level routes with a maximum deviation of 1 and at a max speed of 5 km h The truck shall not be permanently used with trailers There must be no load on the load forks when another vehicle is being ...

Page 60: ... operating mode can only be used for max 5 seconds when the engine is running at high speed 21 27 20 E 2 5 0106 GB Reversing F Make sure you have sufficient space to reverse into Set the travel direction switch 27 to the rear Accelerating Slowly apply the accelerator pedal 21 until the truck starts to move Continue to depress the accelerator The motor and travel speedsincrease Slowing down the tru...

Page 61: ...To release the parking brake push the parking brake lever forward beyond the pressure point 20 17 16 0106 GB E 26 5 3 Steering F Very little steering force is required for the hydrostatic steering therefore turn the steering wheel 17 with caution 5 4 Braking Operating Brake The slow travel brake pedal hydrauli cally actuates the drum brakes of the front wheels Apply the slow travel brake pedal 20 ...

Page 62: ...lt F Also follow the manufacturer s operating instructions when operating an attach ment 25 24 23 22 E 27 0106 GB 5 5 Mast and Attachment Operation F The control levers must only be operated from the driver s seat The lifting device is operated from the control levers on the right hand side of the driver s seat Lifting lowering the fork carriage Pull the control lever 25 back to raise the fork car...

Page 63: ...g speed of the fork carriage F It is forbidden to lift people with the lifting device 23 22 21 27 20 0106 GB E 28 Controlling the speed of the lifting device Moving the control lever and changing the motor speed governs the operating speed of the hydraulic cylinders When the control levers are released 22 23 they automatically revert to neutral and the lifting device remains in the position it has...

Page 64: ...e 52 Turn the locking lever down and move the forks until the locking pin engages in a slot 51 50 52 E 29 0106 GB 5 6 Collecting transporting and depositing loads F The control levers must only be operated from the driver s seat M Before picking up a load the driver must ensure that it is correctly palletised and that the capacity of the truck is not exceeded Note the load diagram Adjusting the lo...

Page 65: ... free space to reverse Reverse carefully and slowly until the load is outside the storage area 16 27 0106 GB E 30 Raising a load Carefully approach the load to be raised Set the travel direction switch 27 to neutral Tighten the parking brake lever 16 Raise the load fork to the correct height for the load Set the travel direction switch to forward and release the parking brake Carefully enter the l...

Page 66: ...ce approx 150 200 mm F The higher the load is transported the less the operating safety of the truck E 31 0106 GB F It is forbidden to stand underneath a raised load Tilt the mast fully backward Lower the load as far as is absolutely necessary for transport ground clearance approx 150 200 mm F The higher the load is transported the less the operating safety of the truck ...

Page 67: ...placing the load down suddenly to avoid damaging the load and the load lifting device 21 27 20 16 27 0106 GB E 32 Transporting a load F If the load is stacked up so high that it affects forward visibility then reverse Gently accelerate with the accelerator pedal 21 and slowly brake with the slow travel brake pedal 20 Be ready to brake at all times Adapt your travel speed to the conditions of the r...

Page 68: ...uck do not jump out Hold onto the steering wheel Brace your feet Lean away from the point of contact E 33 0106 GB Stack cylindrical loads close to each other and evenly Place each row on boards and secure each end with wedges Cylindrical objects can also be stacked in pyramids Place wedges on the lowest row of each roller Stack boxed pallets level and at right angles to each other Stack the top ro...

Page 69: ...rklift truck must therfore be moved away from the sharp incline before the seat belt can be attached 0106 GB E 34 5 7 Using the Seat Belt If a seat belt is attached always put it on before starting the truck The belt must be attached as follows Remove the belt smoothly from the retractor Wrap the belt around you and fit the lock into the buckle Make sure the belt is not twisted The operator should...

Page 70: ... seat belt Damaged seat belts that no longer operate correctly must be replaced by trained personnel E 35 0106 GB Daily inspection and servicing of the seat belt The operator must inspect the seat belt each day to ensure it is in a good condition and is operating correctly before starting the truck The following non exhaustive checks should be made Extract the belt in full and make sure it is not ...

Page 71: ...he mast forward Set the travel direction switch 27 to neutral Apply the parking brake lever 16 16 27 0106 GB E 36 5 8 Parking the truck securely F When you leave the truck it must be securely parked even if you only intend to leave it for a short time Never park and abandon a truck with a raised load Drive the truck onto a level surface F In multi storey buildings LPG trucks may only be driven on ...

Page 72: ...again M Make sure the motor panel has engaged correctly before operating the truck again 19 53 18 54 E 37 0106 GB Stopping the motor DFG Set the ignition starter switch 19 to 0 Remove the key from the ignition starter switch 19 Stopping the motor TFG Close the shut off valve 53 of the LPG bottle securely Wait until the motor comes to a stop Set the ignition starter switch 19 to 0 Remove the key fr...

Page 73: ... coupling M Before coupling the driver must ensure the maximum trailer load is not exceeded 55 56 57 0106 GB E 38 o Steel cabin If a truck is fitted with a steel cabin both doors can be closed To unlock the cabin door turn the key anti clockwise To lock the cabin door turn the key clockwise To open the cabin door unlock the door and remove the handle 53 5 10 Towing As the gear unit of the forklift...

Page 74: ...14 2 DFG 435 5028 17000 15 1 TFG 425 4190 17100 12 6 TFG 430 4630 16500 13 9 TFG 435 4928 16000 14 8 E 39 0106 GB 5 11 Towing trailers The hitch point can occasionally be used to tow a light trailer on a dry level and well maintained surface For other towing applications consult the manufacturer or the authorised representative 5 12 Tow loads Permissible towed loads for 1 inclines and max 5 km h t...

Page 75: ...n has returned to its original state If necessary replace the fuel filter Fill up with winter diesel 0106 GB E 40 6 Troubleshooting This chapter is designed to help the user identify and rectify basic faults or the results of incorrect operation When locating a fault proceed in the order shown in the table Z If the fault cannot be rectified after carrying out the remedial procedures notify the man...

Page 76: ...l level and top up if necessary then turn the steering wheel several times from one end to the other E 41 0106 GB Fault Possible cause Action Motor oil indicator lit during operation Motor oil level too low Check motor oil level top up if necessary Motor temperature display in red zone Motor oil level too low Radiator contaminated Coolant level too low Fan V belt slipping Check motor oil level top...

Page 77: ...0106 GB E 42 0106 GB E 42 ...

Page 78: ...ised water After cleaning the truck carry out the activities detailed in the Recommissioning section F 1 02 08 GB F Maintenance of the Forklift Truck 1 Operational Safety and Environmental Protection The servicing and inspection duties contained in this chapter must be performed in accordance with the intervals indicated in the servicing checklists F Any modifications to the forklift truck assembl...

Page 79: ...d every six years When replacing hydraulic components also replace the hoses in the hydraulic system 02 08 GB F 2 Electrical System Only suitably trained personnel may operate on the truck s electrical system Before working on the electrical system take all precautionary measures to avoid electric shocks For battery operated trucks also de energise the truck by removing the battery connector Weldi...

Page 80: ...ice hours or after repair work the owner must check the wheel nuts bolts and re tighten if necessary F 3 02 08 GB 3 Servicing and inspection Thorough and expert servicing is one of the most important requirements for the safe operation of the industrial truck Failure to perform regular servicing can lead to truck failure and poses a potential hazard to personnel and equipment M The service interva...

Page 81: ...k driver s seat and restraint system t 4 6 Check labels t 4 7 Check trailer coupling tow mechanism t 02 08 GB F 4 4 DFG TFG maintenance checklist Maintenance Intervals Standard t W A B C Brakes 1 1 Check effectiveness of operating and parking brakes adjust where necessary and measure braking distance t 1 2 Check brake lining wear and check brake drum diameter t 1 3 Check brake fluid level in conta...

Page 82: ...amage t Fitting times 8 1 Enable servicing and inspection by removing assembling panels and covers t F 5 02 08 GB Maintenance Intervals Standard t W A B C Hydraulic operation 5 1 Check mast bearings t 5 2 Check setting of slide pieces and stops and adjust if necessary t 5 3 Visually inspect the mast rollers and check contact surface wear level t 5 4 Check lateral clearance of mast connections and ...

Page 83: ...e t 7 31 Check wheel bearings and attachments t 7 32 Check tyre air pressure adjust if necessary t t 02 08 GB F 6 5 DFG maintenance checklist Maintenance Intervals Standard t W A B C Travel 7 1 Check engine for noise and leaks t 7 2 Check engine oil level top up if necessary t t 7 3 Replace engine oil t 7 4 Replace engine oil filter t 7 5 Check valve play adjust if necessary t 7 6 Test glow plugs ...

Page 84: ...t 8 32 Check wheel suspension and attachments t 8 33 Check tyre air pressure adjust if necessary t t F 7 02 08 GB 6 TFG maintenance checklist Maintenance Intervals Standard t W A B C Travel 8 1 Check engine for noise and leaks t 8 2 Replace spark plugs t 8 3 Check ignition system and ignition point t 8 4 Check valve play adjust if necessary t 8 5 Check engine oil level top up if necessary t t 8 6 ...

Page 85: ...perature required for protection volume of anti freeze Volume ratio of anti freeze water 37 C 50 1 1 02 08 GB F 8 7 Coolant specification The quality of the coolant used can have a major impact on the efficiency and service life of the cooling circuit The recommendations listed below are useful for servicing a good cooling circuit with anti freeze and or anti corrosion Always use clean soft water ...

Page 86: ... safety precautions as for anti freeze 8 DFG fuel specifications Only use DIN 51601 compliant diesel F 9 02 08 GB When handling anti freeze always observe the following safety measures NEVER swallow anti freeze If anti freeze is accidentally swallowed seek IMMEDIATE medical attention Avoid prolonged skin contact with anti freeze Wipe off spray from the skin immediately If anti freeze is sprayed in...

Page 87: ...eck t Mineral oil filler neck for brake system c Hydraulic oil drain plug K Oil dipstick A D G K E E 02 08 GB F 10 9 Lubrication schedule g Contact surfaces b Transmission oil filler neck s Grease nipple a Transmission oil drain plug Hydraulic oil filler neck t Mineral oil filler neck for brake system c Hydraulic oil drain plug K Oil dipstick A D G K E E ...

Page 88: ...int C Worked penetration at 25 C NLG1 class Applicationtemp erature C E Lithium 185 265 295 2 35 120 F 11 02 08 GB 9 1 Fuels coolants and lubricants Handling consumables Consumables must always be handled correctly Follow the manufacturer s instructions F Improper handling is hazardous to health life and the environment Consumables must only be stored in appropriate containers They may be flammabl...

Page 89: ...t they do not come into contact with any attachments or the overhead guard when it is being raised 1 02 08 GB F 12 10 Maintenance and Repairs 10 1 Prepare the truck for maintenance and repairs All necessary safety measures must be taken to avoid accidents when carrying out maintenance and repairs The following preparations must be made Park the truck securely see Chapter E Remove the key from the ...

Page 90: ... tighten the oil filter Fit the air filter insert the hoses and tighten with hose clamps 2 4 3 6 7 5 F 13 02 08 GB 10 2 Motor servicing DFG Replacing the motor oil and motor oil filter M Only change the motor oil when the motor is at operating temperature and the truck is horizontal Always replace the motor oil and motor oil filter together Draining the motor oil Unscrew the 2 lid Thoroughly clean...

Page 91: ... the screws again Check the V belt tension again and repeat the adjustment if necessary 9 2 8 4 3 10 02 08 GB F 14 Adding motor oil Add fresh motor oil through the filler port 2 in accordance with the consumables table Capacity 8 0 l Check the motor oil level with the dipstick 8 and adjust as necessary see Chapter E Screw the lid 2 back on Insert the dipstick 8 back fully M After changing the oil ...

Page 92: ... Z If the motor does not start up or stops after a short time repeat the bleeding procedure 11 13 12 F 15 02 08 GB Replacing the fuel filter Drain the fuel from the filter into a suitable container Undo the fuel filter 13 with a filter wrench and manually unscrew it F Dispose of the fuel filter and fuel in accordance with environmental regula tions Before assembling apply a thin layer of diesel to...

Page 93: ...8 when running the motor again and check the oil drain plug and oil filter are sealed 15 16 17 14 18 02 08 GB F 16 10 3 Motor servicing TFG Replacing the motor oil and motor oil filter Only change the motor oil when the motor is at operating temperature and the truck is horizontal Always replace the motor oil and motor oil filter together Draining the motor oil Unscrew the 14 lid Thoroughly clean ...

Page 94: ...on Re tighten the screws Check the V belt tension again and repeat the adjustment if necessary 19 20 F 17 02 08 GB Replacing spark plugs Remove spark plug connector 19 Thoroughly clean around the spark plugs on the cylinder head Unscrew the spark plugs Check the electrode distance of the new spark plugs with a feeler gauge and adjust as required Rated value 1 0 mm M Only use original spark plugs M...

Page 95: ...olant in accordance with the manual instructions until you obtain the correct level Refit the lid 21 02 08 GB F 18 10 4 Checking the coolant concentration F Do not open the radiator lid when the motor is hot To prevent the build up of lime as well as front and corrosion damage and to raise the boiling point temperature the cooling circuit must be filled each year with a mixture of water and anti f...

Page 96: ...ter housing in the assembly position Attach the clamp 5 and screw on the clamping screw 22 22 23 7 5 F 19 02 08 GB 10 5 Cleaning replacing the air filter cartridge M Carry out all maintenance work with the motor switched off Do not start the motor when the air filter cartridge is removed Unscrew the clamping screw 22 and lift up the clamp 5 Raise the air filter housing Undo the 2 mounting clamps 2...

Page 97: ...nsmission unit until it reaches the MAX marking on the dipstick Refit the dipstick in the port 25 24 02 08 GB F 20 10 6 DFG TFG transmission M It is important to check the oil level correctly The oil is a lubricant which also acts as a coolant and operates the clutches A low oil level will result in loss of transmission and pressure It also causes overheating and resultant transmission failure Che...

Page 98: ...kings If necessary add brake fluid Capacity 0 25 l After adding brake fluid refit the panel 26 27 28 F 21 02 08 GB 10 7 Brakes Checking the parking brake The parking brake 26 must be able to keep the truck plus maximum permissible load on an incline of 15 If this is not the case the parking brake must be adjusted Checking the brake fluid level Undo the screws of the right hand panel 27 Remove the ...

Page 99: ...ilter insert M If the contamination cannot be removed by cleaning replace the filter insert 29 31 30 02 08 GB F 22 10 8 Checking the wheel attachments Park the truck securely see Chapter E Tighten the wheel nuts 29 crosswise with a torque wrench Torque Drive wheels 380 Nm Rear wheels 200 Nm 10 9 Hydraulic System Replacing the hydraulic oil filter Unscrew the lid 31 Remove the hydraulic oil filter ...

Page 100: ...necessary to check the acid level or the acid density in batteries with low maintenance requirements F 23 02 08 GB 10 11 Electrical system Checking the battery condition the acid level and acid density F Battery acid is highly corrosive Therefore it is essential to avoid contact with battery acid If clothing skin or eyes have nevertheless come into contact with battery acid immediately rinse the a...

Page 101: ...5 A 41 5F1 Searchlights 25 A 42 5F3 Reversing lights 10 A 43 4F6 Brake lights 15 A 32 33 34 35 36 37 02 08 GB F 24 Checking electrical fuses If an error occurs in the electrical system check the fuses located in the overhead guard below the plastic panel Remove the fuse box panels 103 Check the fuse rating and condition in accordance with the table replace if necessary Fit the panels t Standard fu...

Page 102: ...ttery manufacturer s instructions Spay all exposed electrical contacts with a suitable contact spray F 25 02 08 GB 11 Exhaust system The exhaust system must be checked for emissions at regular intervals Black or blue exhaust is a sign of high emission levels and requires the attention of specialist personnel 12 Recommissioning The truck may only be recommissioned after cleaning or repair work once...

Page 103: ...f that it has passed the safety inspection This plate indicates the due date for the next inspection 02 08 GB F 26 13 2 During decommissioning Every 2 months Charge the battery see Chapter D M Battery powered trucks The battery must be charged at regular intervals to avoid depletion of the battery through self discharge The sulfatisation would destroy the battery 13 3 Restoring the truck to operat...

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Jungheinrich DFG 425, Operating Instructions Manual

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