Jungheinrich DFG 425 Operating Instructions Manual
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Jungheinrich DFG 425 Operating Instructions Manual

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DFG/TFG 425/430/435
07.04-
G
Operating Instructions
52025727
02.08

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Summary of Contents for Jungheinrich DFG 425

  • Page 1 DFG/TFG 425/430/435 07.04- Operating Instructions 52025727 02.08...
  • Page 2 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 which are applied to the drive wheels.
  • Page 4 Used to indicate standard equipment. Used to indicate optional equipment. Our trucks are subject to ongoing development. Jungheinrich reserves the right to alter the design, equipment and technical features of the truck. No guarantee of particular features of the truck should therefore be inferred from the present operating instructions.

  • Page 6: Table Of Contents

    Table of Contents Correct use and application of the truck Truck Description Application ................... B 1 Assemblies and Functional Description ..........B 2 Truck ....................B 3 Standard Version Specifications ............B 5 Performance data ................B 6 Dimensions ..................B 7 Motor data ...................
  • Page 7 Operation Safety Regulations for the Operation of Forklift Trucks ...... E 1 Controls and Displays ................. E 3 Checks and operations to be performed before starting daily work ..E 7 Starting up the truck ................E 12 Checks and operations to be performed before starting daily work ..E 12 Trucks with reduced headroom X (o) ..........
  • Page 8 Maintenance of the forklift truck Operational safety and environmental protection ........ F 1 Maintenance Safety Regulations ............F 1 Servicing and inspection ..............F 3 DFG/TFG maintenance checklist ............F 4 DFG maintenance checklist ..............F 6 TFG maintenance checklist ..............F 7 Coolant specification ................

  • Page 10: A Correct Use And Application Of The Truck

    A Correct use and application of the truck 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 the present operator manual is an industrial truck designed for lifting and transporting load units.

  • Page 12: B Truck Description

    B Truck Description 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 / brake pedal enables rapid lifting while travelling slowly.

  • Page 13: Assemblies And Functional Description

    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...

  • Page 14: Truck

    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 integrated on the right-hand side and the fuel tank for the DFG series on the opposite side in the chassis.
  • Page 15 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 through a multiple control valve.

  • Page 16: Standard Version Specifications

    Standard Version Specifications Technical data specified in accordance with VDI 2198. Technical modifications and additions reserved.

  • Page 17: Performance Data

    Performance data Description DFG 425 DFG 430 DFG 435 Capacity 2500 3000 3500 (where C = 600 mm) C Load centre of gravity distance Travel speed 17/19 18/19 18/19 km/h w / w.o. load Lift speed 0.59/0.60 0.53/0.59 0.49/0.53 w / w.o. load Lowering speed 0.55/0.45 0.55/0.45 0.55/0.42...

  • Page 18: Dimensions

    Dimensions Description DFG 425 DFG 430 DFG 435 a/2 Safety distance Mast height (retracted) 2080 2080 2180 Free lift Lift 2900 2900 3100 Mast height (extended) 3685 3685 3885 Height above overhead guard 2220 2250 2250 Seat height 1068 1068...
  • Page 19 Description TFG 425 TFG 430 TFG 435 a/2 Safety distance Mast height (retracted) 2080 2080 2180 Free lift Lift 2900 2900 3100 Mast height (extended) 3685 3685 3885 Height above overhead guard 2220 2250 2250 Seat height 1068 1068 1068 Length including forks 3690 3810...

  • Page 20: Motor Data

    Motor data Motor - DFG Type S45 four cylinder Ignition order 1 3 4 2 Capacitance 3331 cc 2350 rpm (without load) Control speed 680 rpm (idle) Valve clearance Inlet and outlet 0.25 mm cold Tray capacity 10.0 l Fuel tank capacity 58 l Coolant capacity 5.5 l + system = 15.0 l...

  • Page 21: Mast Versions

    Mast Versions (all dimensions in mm) DFG/TFG 425/430 Mast table VDI 3596 Lift Free lift Retracted height Extended height Description 2900 2080 3510 3100 2180 3710 3300 2280 3910 3500 2380 4110 3700 2480 4310 4000 2630 4610 4300 2830 4910 4500 2930...
  • Page 22 DFG/TFG 435 Mast table VDI 3596 Lift Free lift Retracted height Extended height Description 3100 2180 3870 3500 2380 4270 4000 2630 4770 4500 2930 5270 5000 3180 5770 4700 1417 2180 5463 5000 1517 2280 5763 5500 1717 2480 6263 6000 1917...

  • Page 23: En Norms

    EN norms Noise emission: 78 dB(A) In accordance with EN 12053 as harmonised with ISO 4871. 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 driver’s ear.

  • Page 24: Identification Points And Data Plates

    Identification points and data plates (mm) Q (kg) D (mm) Item Description Attention: Read operator manual. Load fork, Capacity / Load Centre of Gravity / Lift Height diagram “Travel with raised load prohibited” / “Mast forward tilt with raised load prohibited”...

  • Page 25: Truck Load Diagram

    Truck data plate Item Description Item Description Type Manufacturer’s logo Serial no. Net weight Rated capacity (kg) Load centre of gravity (mm) Output (kW) Year of manufacture Manufacturer Option For queries regarding the truck or ordering spare parts please quote the truck serial number (28).

  • Page 26: Fork Load Diagram (Basic Model)

    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. Attachment load diagram The attachment load diagram gives the truck’s capacity Q in combination with the respective attachment in kg.
  • Page 27 B 16...

  • Page 28: C Transport And Commissioning

    C Transport and Commissioning Lifting by crane 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).

  • Page 29: Securing The Truck During Transport

    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 recommendations...

  • Page 30: Commissioning

    Commissioning 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 transport, proceed as follows: –...

  • Page 32: D Filling The Truck With Fuel

    D Filling the Truck with Fuel Safety regulations for handling diesel fuel and LPG Before filling up or replacing the LPG bottle, first park the truck securely (see Chapter Fire protection: When handling fuels and LPG, smoking, naked flames and other ignition sources are strictly prohibited in the immediate vicinity.

  • Page 33: Filling With Diesel

    Filling with diesel 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. Do not overfill the tank. Capacity: 58l Only use DIN 51601 diesel with a cetane rating below 45.

  • Page 34: Replacing The Lpg Bottle

    Replacing the LPG bottle 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.
  • Page 35 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 bottle is full.

  • Page 36: Safety Regulations For The Operation Of Forklift Trucks

    E Operation 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 operate the truck by the proprietor or his representative.
  • Page 37 25 24 23 22...

  • Page 38: Controls And Displays

    Controls and Displays Control / Item Function Display Indicates that the soot filter is Soot filter indicator contaminated. When lit, indicates insufficient motor Motor oil pressure indicator lubricant oil pressure. When lit, indicates that the battery is Charging current indicator not charged.
  • Page 39 25 24 23 22...
  • Page 40 Control / Item Function Display Applies / releases parking brake. To engage, turn switch to position 1. 16 Parking brake lever To release, turn switch to position 0. Pull up lever to engage. Push lever forward to release. t Steers truck in desired direction. 17 Steering wheel Steering column adjusting t Adjusts the steering column tilt.
  • Page 41 Travel direction switch 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. The motor will not start if a travel direction is pre-selected.
  • Page 42 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. Covers may need to be opened for the inspection. Checking the motor oil - TFG –...
  • Page 43 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.
  • Page 44 Gas system drain tap The gas system drain tap must always be closed during operation (it should only be opened by service personnel for maintenance purposes). If the drain is opened gas may escape! Drain closed Drain open...
  • Page 45 Checking the coolant level – Check the coolant level on the reservoir. The coolant should lie between the MIN and MAXmarkings (36). 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.
  • Page 46 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 Testing the windscreen fluid level –...

  • Page 47: Checks And Operations To Be Performed Before Starting Daily Work

    Starting up the truck Before the truck can be commissioned, operated or a load unit lifted, the driver must ensure that there is nobody within the hazardous area. Checks and operations to be performed before starting daily work – The entire truck (in particular wheels and load lifting devices) must be inspected for damage.

  • Page 48: Adjusting The Driver's Seat

    Adjusting the driver’s seat Standard seat MSG 20 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: –...
  • Page 49 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.
  • Page 50 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 above the calibration line.

  • Page 51: Safety Restraint Belt

    Safety restraint belt 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 thawed out and dried to prevent them from freezing up again.

  • Page 52: Starting The Truck

    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.

  • Page 53: Starting Procedure For The Tfg

    Starting procedure for the TFG 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”...

  • Page 54: Starting Procedure For The Dfg

    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 setting (14) and parking brake (5)
  • Page 55 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.

  • Page 56: Operational Fault Displays

    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. The motor should only be started again once the fault has been removed.

  • Page 57: Stopping The Motor 1

    4.10 Stopping the motor 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). –...

  • Page 58: Industrial Truck Operation

    Industrial truck operation 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 purpose. Driving conduct: The driver must adapt the travel speed to local conditions.

  • Page 59: Travel

    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 pulled.
  • Page 60 Reversing 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.

  • Page 61: Steering

    Steering Very little steering force is required for the hydrostatic steering, therefore turn the steering wheel (17) with caution. 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) until you notice the brake pressure.

  • Page 62: Mast And Attachment Operation

    Mast and Attachment Operation 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 carriage.
  • Page 63 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 reached.

  • Page 64: Collecting, Transporting And Depositing Loads

    Collecting, transporting and depositing loads The control levers must only be operated from the driver’s seat. 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 load forks Adjust the load fork in such a way that...
  • Page 65 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.
  • Page 66 It is forbidden to stand underneath a raised load. – Tilt the mast fully backward: – Lower the load as far as is absolutely necessary transport (ground clearance approx. 150...200 mm). The higher the load is transported, the less the operating safety of the truck. E 31...
  • Page 67 Transporting a load 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. –...
  • Page 68 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 row in the opposite direction for extra safety.

  • Page 69: Using The Seat Belt

    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.
  • Page 70 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: –...

  • Page 71: Parking The Truck Securely

    Parking the truck securely 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. In multi-storey buildings, LPG trucks may only be driven on the lowest levels.

  • Page 72: Motor Panel

    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. –...

  • Page 73: Towing

    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).

  • Page 74: Towing Trailers

    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 (trailer without brakes). Net weight Tow force Towed load Truck DFG 425 4290 17300 12.9 DFG 430 4730 17150 14.2 DFG 435...

  • Page 75: Troubleshooting

    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. If the fault cannot be rectified after carrying out the remedial procedures, notify the manufacturer’s service department, as any further troubleshooting can only be performed by specially trained and qualified service personnel.
  • Page 76 Fault Possible cause Action Motor oil – Motor oil level too low – Check motor oil level, top up if indicator lit necessary during operation Motor – Motor oil level too low – Check motor oil level, top up if temperature necessary display in red...
  • Page 77 E 42...

  • Page 78: F Maintenance Of The Forklift Truck

    F Maintenance of the Forklift Truck 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. Any modifications to the forklift truck assemblies, in particular the safety mechanisms, is prohibited.
  • Page 79 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. Welding: To avoid damaging electric or electronic components, remove these from the truck before performing welding operations.

  • Page 80: Servicing And Inspection

    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. The service intervals stated are based on single shift operation under normal operating conditions.

  • Page 81: Dfg/Tfg Maintenance Checklist

    DFG/TFG maintenance checklist Maintenance Intervals = t W A B C Standard Brakes 1.1 Check effectiveness of operating and parking brakes, adjust where necessary and measure braking distance. 1.2 Check brake lining wear and check brake drum diameter 1.3 Check brake fluid level in container and top up if necessary 1.4 Change brake fluid annually, bleed the system if required...
  • Page 82 Maintenance Intervals = t W A B C Standard Hydraulic 5.1 Check mast bearings operation 5.2 Check setting of slide pieces and stops, and adjust if necessary 5.3 Visually inspect the mast rollers and check contact surface wear level 5.4 Check lateral clearance of mast connections and of fork carriage 5.5 Check load chain setting and tighten if necessary 5.6 Check forks and fork carriage for wear and damage...

  • Page 83: Dfg Maintenance Checklist

    DFG maintenance checklist Maintenance Intervals = t W A B C Standard Travel 7.1 Check engine for noise and leaks 7.2 Check engine oil level, top up if necessary 7.3 Replace engine oil 7.4 Replace engine oil filter 7.5 Check valve play, adjust if necessary 7.6 Test glow plugs, electric 7.7 Check V belt for tension and damage 7.8 Check maximum speed (without load), adjust if...

  • Page 84: Tfg Maintenance Checklist

    TFG maintenance checklist Maintenance Intervals = t W A B C Standard Travel 8.1 Check engine for noise and leaks 8.2 Replace spark plugs 8.3 Check ignition system and ignition point 8.4 Check valve play, adjust if necessary 8.5 Check engine oil level, top up if necessary 8.6 Replace engine oil 8.7 Replace engine oil filter 8.8 Check V belt for tension and damage...

  • Page 85: Coolant Specification

    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. If anti-freeze is not necessary, it is still advantageous to use an approved anti-freeze mixture as this offers protection against corrosion and increases the boiling point of the coolant.

  • Page 86: Dfg Fuel Specifications

    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 into the eyes, rinse them immediately. –...

  • Page 87: Lubrication Schedule

    Lubrication schedule Contact surfaces Transmission oil filler neck Grease nipple Transmission oil drain plug Mineral oil filler neck for brake Hydraulic oil filler neck system Hydraulic oil drain plug Oil dipstick F 10...

  • Page 88: Fuels, Coolants And Lubricants

    Fuels, coolants and lubricants Handling consumables: Consumables must always be handled correctly. Follow the manufacturer’s instructions. Improper handling is hazardous to health, life and the environment. Consumables must only be stored in appropriate containers. They may be flammable and must therefore not come into contact with hot components or naked flames.

  • Page 89: Maintenance And Repairs

    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). –...

  • Page 90: Motor Servicing Dfg

    10.2 Motor servicing DFG 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 –...
  • Page 91 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. –...
  • Page 92 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. Dispose of the fuel filter and fuel in accordance with environmental regula- tions. –...

  • Page 93: Motor Servicing Tfg

    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 –...
  • Page 94 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.

  • Page 95: Checking The Coolant Concentration

    10.4 Checking the coolant concentration 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-freeze with anti-corrosion additives.

  • Page 96: Cleaning/Replacing The Air Filter Cartridge

    10.5 Cleaning/replacing the air filter cartridge 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). –...

  • Page 97: Dfg/Tfg Transmission

    10.6 DFG/TFG transmission: 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. Checking the transmission oil level Only use clean, fresh oil from clean containers...

  • Page 98: Brakes

    10.7 Brakes Checking the parking brake The parking brake (26) must be able to keep 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 –...

  • Page 99: Checking The Wheel Attachments

    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 –...

  • Page 100: 10.11 Electrical System

    10.11 Electrical system: Checking the battery condition, the acid level and acid density 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 affected parts with water.
  • Page 101 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.

  • Page 102: Exhaust System

    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. Recommissioning The truck may only be recommissioned after cleaning or repair work, once the following operations have been performed.

  • Page 103: During Decommissioning

    13.2 During decommissioning: Every 2 months: – Charge the battery (see Chapter D). 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 operation after decommissioning –...

This manual is also suitable for:

Dfg 430Dfg 435Tfg 435Tfg 425Tfg 430

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