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

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DFG/TFG 425s / 435s
10.07-
G
Operating Instructions
51077936 ► 51209061
► 03.13
01.09

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Summary of Contents for Jungheinrich DFG 425s

  • Page 1 DFG/TFG 425s / 435s 10.07- Operating Instructions 51077936 ► 51209061 ► 03.13 01.09...
  • Page 2 DFG / TFG 425s - 435s 04.11 - Operating instructions 51209061 DFG 425s 03.13 DFG 430s DFG 435s TFG 425s TFG 430s TFG 435s...
  • Page 4 Declaration of Conformity Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg Manufacturer or agent acting in the European Union Type Option Serial no. Year of manufacture DFG 425s DFG 430s DFG 435s TFG 425s TFG 430s TFG 435s Additional information On behalf of...
  • Page 6 Our trucks are subject to ongoing development. Jungheinrich reserves 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.
  • Page 7 Jungheinrich Aktiengesellschaft Am Stadtrand 35 22047 Hamburg - Germany Tel: +49 (0) 40/6948-0 www.jungheinrich.com...

  • Page 8: Table Of Contents

    Contents Correct Use and Application ............ 11 General....................Correct application................... Approved application conditions.............. Proprietor responsibilities ................ Adding attachments and/or optional equipment ........Truck Description ..............15 Application ....................Truck models and rated capacity............. Assemblies and Functional Description........... Travel direction definition................. Assembly Overview .................
  • Page 9 Fuelling the Truck ..............41 General....................Safety regulations for handling diesel fuel and LPG........ LPG system relief valve................Adding diesel ................... Fuelling ....................Fuelling with fuel containers ..............LPG containers..................LPG bottles....................Liquid gas tank ..................Fuel level indicator................... Display unit ....................Level indicator for LPG bottles (o)............
  • Page 10 Steel cab ....................131 Sliding windows ..................131 Gate......................132 Panel door ....................133 Operator position extension..............133 Heating and air conditioning system............134 Driver’s seat heating / backrest extension..........137 6.10 Removable load backrest ................ 138 6.11 Lift cutout override ................... 138 6.12 Sideshifter centre position ...............
  • Page 11 During decommissioning ................. 200 Restoring the truck to service after decommissioning ......201 Safety tests to be performed at intervals and after unusual incidents ..202 Final de-commissioning, disposal............203 Human vibration measurement ............... 203 Servicing and Inspection ................. 204 Maintenance checklist DFG..............

  • Page 12: A Correct Use And Application

    A Correct Use and Application General The truck must be used, operated and serviced in accordance with the present instructions. All other types of use are beyond its scope of application and may result in damage to personnel, the industrial truck or property. Correct application NOTE The maximum load and load distance are indicated on the capacity plate and must not...

  • Page 13: Approved Application Conditions

    Approved application conditions DANGER! Do not exceed the permissible surface and point loading on the travel lanes. At blind spots get a second person to assist. The driver must ensure that the loading dock /dock leveller cannot be removed or come loose during loading/unloading.

  • Page 14: Proprietor Responsibilities

    Proprietor responsibilities For the purposes of the present operating instructions the “operating company” is defined as any natural or legal person who either uses the industrial truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting) the proprietor is considered the person who, in accordance with existing contractual agreements between the owner and user of the industrial truck, is charged with operational duties.

  • Page 16: B Truck Description

    B Truck Description Application The DFG / TFG 425s - 435s is a four-wheel sit-down industrial truck with a combustion engine. The DFG series are diesel engine trucks, while the TFG series are fitted with a petrol engine for LPG operation. The DFG / TFG 425s - 435s is a cantilever counterbalanced truck which can lift, transport and deposit loads using the load handler attached in front.

  • Page 17: Assemblies And Functional Description

    Assemblies and Functional Description Travel direction definition The following conventions have been agreed for travel direction specification: Item Travel direction Left Reverse Forward Right...

  • Page 18: Assembly Overview

    Assembly Overview Item Component Item Component 5 t Driver's seat 13 t Drive system 6 t Overhead guard 14 t Emergency Disconnect switch 7 t Steering wheel 15 t Engine bonnet 8 t Mast 16 t Steer axle 9 t Fork carriage 17 t Counterweight 10 t Fork tines 18 t Trailer coupling...

  • Page 19: Functional Description

    Functional Description Chassis The chassis, in conjunction with the counterweight, forms the supporting base structure of the truck. It is used to support the main components. The hydraulic oil reservoir is integrated on the right-hand side and the fuel tank for the DFG series is on the left side in the chassis.
  • Page 20 Drive system and brakes Both drive wheels are powered by individual hydraulic motors which in turn are driven by a hydraulic pump. Forward/reverse or neutral can be set with the travel direction switch on the control panel (11). The truck brakes to a halt via the hydraulic motors (service brake), keeping energy consumption to a minimum.

  • Page 21: Technical Specifications

    The technical specifications comply with the German "Industrial Truck Data Sheet" Guidelines. Technical modifications and additions reserved. Performance data DFG 425s-435s Description DFG 425s DFG 430s DFG 435s Capacity 2500 3000 3500 (where C = 500 mm) 1) C Load centre distance...
  • Page 22 TFG 425s-435s Description TFG 425s TFG 430s TFG 435s Capacity 2500 3000 3500 (where C = 500 mm) 1) C Load centre distance Travel speed* with / 19.6/19.6 20.8/20.8 20.8/20.8 km/h without load Lift speed, with / without 0.56/0.56 0.56/0.56 0.48/0.48 load Lowering speed with /...

  • Page 23: Dimensions

    Dimensions DFG/TFG 425s-435s Component DFG/TFG DFG/TFG DFG/TFG 425s 430s 435s a/2 Safety distance Collapsed height* 2315 2333 2433 Free lift* Lift* 3300 3300 3300 Extended height* 3910 4070 4083 Overhead guard height* 2220 2238 2238 Seat height* 1058 1076 1076 Coupling height Mast tilt, fwd.* °...

  • Page 25: Weights

    Weights All dimensions in kg. DFG/TFG 425s DFG/TFG 430s DFG/TFG 435s Truck weight* 4080 4376 4821 Axle load w.o. load front / rear* 1943 / 2137 1958 / 2488 2009 / 2812 Axle load with load front / rear* 5833 / 747 6578 / 868 7339 / 982 *) The data listed in the table corresponds to the standard version.

  • Page 26: Mast Versions

    Mast versions All dimensions in mm. DFG/TFG 425s/430s Mast table Component Lift h Free lift h Retracted Extended Mast height h height h weight (kg) 2900 2115 3510/3670 3100 2215 3710/3870 3300 2315 3910/4070 3500 2415 4110/4270 3700 2515 4310/4470 4000 2665 4610/4770...
  • Page 27 DFG/TFG 435s Mast table Component Lift h Free lift h Retracted Extended Mast height h height h weight (kg) 2900 2228 3683 3300 2428 4083 3800 2678 4583 4300 2978 5083 4800 3228 5583 5000 3328 5783 4200 1330 2093 4963 4500 1430...

  • Page 28: Tyre Type

    Torque NM *) The models listed in the table correspond to the standard version. Other tyres can be used depending on the truck's equipment. Engine Data Component DFG 425s DFG 430s DFG 435s Cylinder/cubic capacity 4 / 1968 4 / 1968 4 / 1968 cm³...

  • Page 29: Norms

    EN norms Noise emission level – DFG/TFG 425s/430s: 75 dB(A) – DFG/TFG 435s: 75 dB(A) *+/- 3 dB(A) depending on the truck's equipment 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.

  • Page 30: Electrical Requirements

    Special equipment and authorisation are required if the truck is to be used continually in conditions of extreme temperature or condensing air humidity fluctuations. Electrical requirements The manufacturer certifies compliance with the requirements for the design and manufacture of electrical equipment, according to EN 1175 "Industrial Truck Safety - Electrical Requirements", provided the truck is used according to its purpose.

  • Page 31: Identification Points And Data Plates

    Identification points and data plates Warnings and notices such as capacity charts, strap points and data plates must be legible at all times. Replace if necessary.
  • Page 32 Item Component Do not travel with raised load or mast forward tilt with raised load Strap points for crane lifting Data plate Noise level Do not carry passengers warning Fuel Wear seat belt Serial number, engraved in chassis below the engine cover Jack contact points Do not step onto or beneath the load, risk of trapping with moving mast Max.

  • Page 33: Data Plate

    Data plate The illustration shows the standard version for EU member states. The data plate may differ in other countries. Item Component Item Component Type Year of manufacture Serial number Load centre distance (mm) Rated capacity (kg) Net weight in kg Output Manufacturer Option...

  • Page 34: Truck Capacity Plate

    Truck capacity plate CAUTION! Accident risk from fork replacement If you replace the forks with ones that differ from the originals, the capacity will change. When replacing the forks you must attach an additional capacity plate to the truck. Trucks supplied without forks are given a capacity plate for standard forks (length: 1150 mm).

  • Page 35: Attachment Capacity Plate

    Attachment capacity plate The attachment capacity plate is next to the truck's capacity plate and gives the truck’s capacity Q (in kg) in conjunction with the respective attachment. The serial number for the attachment indicated on the capacity plate must match the data plate of the attachment.

  • Page 36: C Transport And Commissioning

    C Transport and Commissioning Transport Transport can be carried out in two different ways, depending on the height of the mast and the local conditions. – Vertically, with the mast assembled (for low heights) – Vertically, with the mast dismantled (for large heights), all mechanical connections and hydraulic lines between the basic truck and the mast separated.

  • Page 37: Lifting The Truck By Crane

    Lifting the truck by crane CAUTION! The mast can get damaged Loading by crane is only intended for the initial transport before the truck is used for the first time. Loading must be carried out by specially trained staff in accordance with recommendations contained in Guidelines VDI 2700 and VDI 2703 DANGER! Crane slings can tear, resulting in accidents...

  • Page 38: Loading With Another Industrial Truck

    Loading with another industrial truck WARNING! The truck can be damaged The truck to be loaded can be damaged when loading with another industrial truck. Only trained specialist personnel should load the truck. Use only trucks with sufficient capacity for loading. Only for loading and unloading.

  • Page 39: Securing The Truck During Transport

    Securing the truck during transport WARNING! Accidental movement during transport Improper fastening of the truck and mast during transport can result in serious accidents. Loading must be carried out by specially trained staff in accordance with recommendations contained in Guidelines VDI 2700 and VDI 2703 In each case correct measurements must be made and appropriate safety measures adopted.

  • Page 40: Using The Truck For The First Time

    Using the Truck for the First Time Safety Instructions for Assembly and Commissioning WARNING! Accident risk from incorrect assembly The assembly of the truck at the application site, commissioning and driver training must only be performed by the manufacturer's customer service representatives who have been specially trained for these tasks.

  • Page 42: D Fuelling The Truck

    D Fuelling the Truck General Safety regulations for handling diesel fuel and LPG WARNING! An unsecured industrial truck can cause accidents The truck can suddenly start to move. Switch off the truck securely before filling up or replacing the LPG bottle, see "Parking the truck securely"...
  • Page 43 NOTE Fuel can cause environmental damage Bind any spilled diesel fuel with suitable methods. Then dispose of the diesel and fuel filter in accordance with environmental regulations. Fuel filling and LPG bottle replacement personnel Personnel filling the trucks or replacing LPG bottles must have sufficient knowledge of the nature of fuels to ensure safe operation.

  • Page 44: Lpg System Relief Valve

    LPG system relief valve LPG powered trucks are fitted with a relief valve. This is located on the rear cover next to the gas bottle. – In the event of a fault the pressure in the gas system is restricted to a maximum level. The relief valve is fitted with a plastic cover (54).

  • Page 45: Adding Diesel

    Fuel additives (drag reducers), petrol or other substances must not be mixed with diesel fuel. Do not start the engine if non-approved fuels have been added. You must also contact the Jungheinrich Service Department to prevent engine damage. 2.1.1 Fuelling the tank system Procedure •...
  • Page 46 Fuelling is now complete.

  • Page 47: Fuelling With Fuel Containers

    Fuelling with fuel containers Procedure • Unscrew the filler cap (55) and open the fuel container. • Fit the spout onto the fuel container. • Insert the spout into the open tank filler neck. • Make sure the fuel container and spout are connected tightly to each other.

  • Page 48: Lpg Containers

    LPG containers Only use liquid gas that complies with DIN 51622 or comparable national regulations. LPG bottles DANGER! Risk of explosion The LPG bottle must only be replaced at designated areas by trained and authorised personnel. CAUTION! Using unsuitable LPG bottles can cause accidents. Use only approved LPG bottles.
  • Page 49 Remove the LPG bottle CAUTION! The connection has a left thread Procedure • Unscrew the union nut (62) while holding against the handle (63). • Remove the hose (64) and immediately screw the valve cap onto the empty LPG bottle. •...
  • Page 50 3.1.2 Operating with two LPG bottles WARNING! Visibility is restricted when the truck reverses. When using two LPG bottles the truck must be fitted with a functional camera system for reversing. External mirrors must also be fitted on either side of the truck. Operating the twin bottle system NOTE Use the additional valve (65) on the...

  • Page 51: Liquid Gas Tank

    Liquid gas tank Refillable liquid gas tanks contain a dispensing valve (71), a filling stop valve (69), a relief valve (70) and a display (67). Filling refillable liquid gas tanks (optional equipment). Requirements – Note guidelines regulations concerning the filling of LPG bottles on the LPG pump.

  • Page 52: Fuel Level Indicator

    Fuel level indicator Display unit The fuel level indicator (72) shows the fuel level (only on DFG or TFG with gas tank). If “R” appears in the display (72) the tank must be topped up. The warning light (73) will also flash and a warning sounds.

  • Page 54: E Operation

    E Operation Safety Regulations for the Operation of the Forklift Truck Driver authorisation The 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 55 Hazardous area WARNING! Risk of accidents/injury in the hazardous area of the truck A hazardous area is defined as the area in which people are at risk due to travel or lifting operations of the truck, its load handler or the load. This also includes the area within reach of falling loads or lowering/falling operating equipment.

  • Page 56: Displays And Controls

    Displays and Controls SOLO-PILOT MULTI-PILOT...
  • Page 57 Item Control / Function display o The truck reverses when actuated. Provides “Reverse” accelerator twin pedal control infinitely variable travel speed. t Infinite travel speed control. Accelerator pedal o The truck travels forward when actuated. “Forward” accelerator twin pedal control Provides infinitely variable travel speed.
  • Page 58 Item Control / Function display t Selects travel direction / neutral position. Travel direction switch (not available with dual pedal control) t Lever for operating the hydraulic functions. Lever t Activates an audible warning. "Horn" button o Activates the additional hydraulic functions Additional hydraulic function release button or hydraulics that require...

  • Page 59: Control Panel With Display Unit

    Control panel with display unit The control panel display unit shows the operating data, the battery charge, the service hours and error details and information. Pictograms in the left top section of the control panel act as warning indicators. km/h...
  • Page 60 Item Control / Function display – Lights up a single time to indicate that the fuel supply is too low. Lights up in conjunction with err xx xxx or inf WARNING xx xxx to indicate a fault or information. – A warning signal sounds Air filter control –...
  • Page 61 Item Control / Function display Seat switch warning Seat switch not closed indicator – Truck operational, but driver's seat not occupied Time monitoring expired – Restart the truck Seat belt control – Truck is operational indicator – see "Access Control" on page 129 Service display –...

  • Page 62: Control Panel Buttons

    Control panel buttons km/h Item Controls and Function displays t Moves up a level in the travel program* Program selector list. t Moves down a level in the travel Program selector program* list. t Truck switched off and exited securely. LED on parking brake button and The parking brake is applied when the...
  • Page 63 Item Controls and Function displays o – Press 1x > intermittent, Rear windscreen wiper – 2x > fast, – 3x > off – Press approx. 2 sec, rear windscreen washing system is activated. – After releasing, the previous function is set (interval or fast). o Switches the front windscreen washing Front windscreen washing system...
  • Page 64 Item Controls and Function displays o Switches the warning indicator on and Warning indicator off. o Switches the “lift cutout” override “Lift cutout” override button button on and off. o Switches auxiliary equipment on and "P3" function key off. t= Series equipment o= Optional equipment *Five operating programs with different performance levels are available to adapt the travel and operating functions to the application at hand.

  • Page 65: Display

    Display km/h DFG fuel supply display Graphic illustration of the fuel supply. TFG with gas tank 124 Operating program display t Operating program display – Displays the travel program in use. t Shows the time. 125 Time t Hourmeter: Service hours / error display: –...

  • Page 66: Preparing The Truck For Operation

    Preparing the Truck for Operation Checks and operations to be performed before starting daily operation WARNING! Damage and other truck or attachment (optional equipment) defects can result in accidents. If damage or other truck or attachment (optional equipment) defects are discovered during the following checks, the truck must be taken out of service until it has been repaired.
  • Page 67 CAUTION! Checking the accelerator pedal The accelerator pedal should only be checked when the parking brake is applied and the engine is idle. Checks before daily operation Procedure • Visually inspect the entire truck (in particular wheels, wheel bolts and load handler) for damage.

  • Page 68: Entry And Exit

    Entry and exit Procedure • Open the cab door (o). • To enter and exit the cab, hold onto the handle (130). An additional step is provided for the driver position extension (o). Trucks with reduced headroom (o) WARNING! An unsuitable workplace can damage your health Failure to observe the recommended body size can cause stress and endanger the...

  • Page 69: Setting Up The Operator Position

    Setting up the operator position WARNING! Accidents can occur if the driver's seat, steering column and armrest are not engaged The driver's seat, steering column and armrest can accidentally adjust during travel and therefore cannot be operated safely. Do not adjust the driver’s seat, steering column or armrest while travelling. Procedure •...
  • Page 70 Adjusting the driver's weight NOTE To achieve optimal seat cushioning the driver’s seat must be set to the driver’s weight. Set the driver's weight when the seat is occupied. Procedure • Fold out the weight adjustment lever (131) as far as it will go in the arrow direction •...
  • Page 71 Driver’s seat with pneumatic weight adjustment (MSG 75) ( Procedure • Pull the weight adjustment lever (131) up to set the seat to a higher weight. • Push the weight adjustment lever (131) down to set the seat to a lower weight. The driver's weight is correct when the arrow is in the middle of the display window (132).
  • Page 72 3.4.2 Adjusting the steering wheel / steering column Individual steering wheel position The steering wheel can be height- and tilt-adjusted to suit the operator. Procedure • Pull the steering wheel adjusting lever (139) in the direction of the arrow (137). •...
  • Page 73 3.4.3 Adjusting the arm rest Horizontal adjustment: Procedure • Undo the clamping screw (141) a few turns. • The armrest can now be moved forward or back. When you have reached the required setting, tighten the clamping screw (141) again; this will lock the armrest in place. Vertical adjustment: Procedure •...

  • Page 74: Seat Belt

    Seat Belt WARNING! Travelling without a seat belt increases the risk of injury. Accidents or personal injury can result if the seat belt is not worn or is modified. Always put the seat belt on before starting the industrial truck. Do not modify the seat belt.

  • Page 75: 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 third parties must stay away from work areas. Loads must only be stored in places specially designated for this purpose.
  • Page 76 Negotiating slopes and inclines Negotiating slopes and inclines up to 15% is only permitted if they are specifically designed as travel routes, are clean and have a non-slip surface and providing they can be safely travelled along in accordance with the truck's technical specifications. The truck must always be driven with the load facing uphill.

  • Page 77: Preparing The Truck For Operation

    Preparing the truck for operation The truck should only be operated from the driver’s seat. Do not run up the engine in idle. The engine soon reaches operating temperature at a moderate charge and when the speed alternates. Only fully charge the engine once it has reached operating temperature.

  • Page 78: Starting Procedure For The Dfg

    Starting procedure for the DFG Procedure • Insert the key in the key switch (81). Set key switch to “I”. • The pre-heat indicator lamp lights up and goes out automatically as soon as the required pre-heat time (approx. 4 seconds) has been reached.

  • Page 79: Starting Procedure For The Tfg

    Starting procedure for the TFG DANGER! Risk of escaping liquid gas if the truck does not start Note the safety regulations governing the handling of liquid gas (see "Safety regulations for handling diesel fuel and LPG" on page 41) Close the gas bottle shut-off valve. Set the key switch to "O"...

  • Page 80: Parking The Truck Securely

    Parking the truck securely WARNING! Switching off an LPG truck under ground level areas could result in explosions. LPG is heavier than air. An explosive LPG/air mixture could therefore form under ground level areas without sufficient ventilation. LPG trucks may only be switched off in ground level rooms or higher and providing they are adequately ventilated.

  • Page 81: Emergency Disconnect

    Emergency Disconnect CAUTION! Applying maximum braking can result in accidents Applying the Emergency Disconnect switch during travel will cause the truck to decelerate to a halt at maximum force. This may cause the load to slide off the load handler. There is a higher risk of accidents and injury. Do not use the Emergency Disconnect switch as a service brake.

  • Page 82: Travel

    Travel WARNING! Improper travel can result in accidents Do not get up from the driver’s seat during travel. Do not drive the truck unless your are wearing a seat belt and the panels and doors are properly locked. Do not lean out of the truck while travelling. Make sure that the travel area is clear.
  • Page 83 Neutral locking If the driver leaves the truck without taking it out of gear, the truck will automatically be set to neutral. To resume travel (sitting on the truck) all controls must be deactivated, the travel direction switch must be set to neutral “N” and then the required direction selected.

  • Page 84: Steering

    Steering Steering Procedure Very little steering effort is required; you should therefore turn the steering wheel (7) sensitively. • To negotiate a right-hand bend: Turn the steering wheel clockwise according to the required steering radius. • To negotiate a left-hand bend: Turn the steering wheel anti-clockwise according to the required steering radius.
  • Page 85 4.9.1 Service brake In normal travel mode you brake by throttling back using the accelerator pedal (74,77,76). The truck will brake hydrostatically depending on the travel program. This allows for sensitive metering of the brake force. As soon as the truck stops it is automatically held by the parking brake, The parking brake indicator (89) lights up.
  • Page 86 4.9.2 Parking brake DANGER! Accident risk The parking brake will hold the truck with km/h maximum load on a clean ground surface, on inclines of up to 15%. Do not park and abandon the truck on an incline. Applying the parking brake button during travel will cause the truck to brake to a halt at maximum force.
  • Page 87 Item Control / Function display Parking brake indicator t Comfort feature, displayed when the parking brake indicator lights Truck prevented from rolling away but not parked securely. Parking brake is activated automatically when the truck stops. The parking brake is automatically released when the accelerator pedal is applied.

  • Page 88: Setting The Time

    4.10 Setting the time Procedure • To prepare the truck for operation, see "Preparing the truck for operation" on page 76 km/h • Press the “h/time” (110) and "up" (103) keys simultaneously • The set time appears on the display. The first digit (hour display) will flash.

  • Page 89: Adjusting The Forks

    4.11 Adjusting the forks WARNING! Trapping hazard There is a trapping hazard when you perform this operation. Wear work gloves and safety shoes. WARNING! Unsecured and incorrectly adjusted forks can cause accidents Before adjusting the forks make sure the retaining bolts (129) are fitted. Adjust the forks so that both forks are equidistant from the outside edge of the fork carriage.

  • Page 90: Replacing The Forks

    4.12 Replacing the forks WARNING! Unsecured forks can cause injury You can injure your legs when replacing the forks. Never pull the forks towards your body. Always push the forks away from your body. Secure heavy forks with lifting slings and a crane before pushing them down from the fork carriage.

  • Page 91: Lifting, Transporting And Depositing Loads

    4.13 Lifting, transporting and depositing loads WARNING! Unsecured and incorrectly positioned loads can cause accidents. Before lifting a load the operator must make sure that it has been correctly palletised and does not exceed the truck’s capacity. Instruct other people to move out of the hazardous area of the truck. Stop working with the truck if people do not leave the hazardous area.
  • Page 92 NOTE Loads must not be deposited on travel or escape routes, in front of safety mechanisms or operating equipment that must be accessible at all times. Transporting loads Requirements – Load raised correctly. – Load handler lowered for transport (approx. 150 - 200 mm above the ground). –...

  • Page 93: Operating The Lift Mechanism And Integrated Attachments

    4.14 Operating the lift mechanism and integrated attachments WARNING! Operating the lifting device and integrated attachments can be hazardous Other people can be injured in the truck's hazardous area. The hazardous area is defined as the area in which people are at risk from the truck movement, the load handler, attachments etc.
  • Page 94 Tilting the mast forward / backward Requirements – To prepare the truck for operation, see "Preparing the truck for operation" on page 76 Procedure • Pull the SOLO-PILOT lever (147) in direction R to tilt the mast back. • Push the SOLO-PILOT lever (147) in direction V to tilt the mast forward.
  • Page 95 Positioning the forks with an integrated fork positioner (option) CAUTION! Do not use the fork positioner to clamp loads. Requirements – Truck prepared for operation, see "Preparing the truck for operation" on page 76. Procedure • Press the toggle switch (149) and at the same time pull the SOLO-PILOT (146) in direction Z: the forks will move towards each other.
  • Page 96 4.14.2 Operating the lift mechanism with the MULTI-PILOT Lifting and lowering Requirements – To prepare the truck for operation, see "Preparing the truck for operation" on page 76 Procedure • Pull the MULTI-PILOT (78) in direction H to raise the load. •...
  • Page 97 Twin operation Requirements – To prepare the truck for operation, see "Preparing the truck for operation" on page 76 Procedure • To lower the load handler and tilt the mast forward at the same time, push the MULTI-PILOT forward and to the right. •...
  • Page 98 Positioning the forks with an integrated fork positioner (option) CAUTION! Do not use the fork positioner to clamp loads. Requirements – Truck prepared operation, "Preparing the truck for operation" on page 76. Procedure • Press the (85) button and at the same time turn the MULTI-PILOT (78) anti- clockwise, the forks will spread apart.

  • Page 99: Safety Instructions For Operating Additional Attachments

    4.15 Safety instructions for operating additional attachments Optionally, trucks can be fitted with one or more auxiliary hydraulic functions to operate attachments. The auxiliary hydraulics are indicated with ZH1 and ZH2. Auxiliary hydraulic functions for exchangeable equipment are fitted with replacement couplings on the fork carriage.
  • Page 100 Safety instructions for sideshifter and fork positioner attachments WARNING! Restricted visibility and reduced tilt resistance can cause accidents When using sideshifters and fork positioners, the change in centre of gravity can result in reduced lateral tilt resistance and accidents. Note that this affects visibility as well. Adapt the travel speeds to the visibility and load.
  • Page 101 Safety instructions for attachments when transporting suspended loads WARNING! Swinging loads and a reduced residual capacity can result in accidents. Transporting hanging loads can reduce the stability of the truck. Adapt the travel speed to the load, less than walking pace. Secure swinging loads for example with lifting slings.

  • Page 102: Operating Additional Attachments For The Solo-Pilot

    4.16 Operating additional attachments for the SOLO-PILOT WARNING! Incorrect symbols can cause accidents Symbols on controls that do not depict the function of the attachments can cause accidents. Mark the controls with symbols that indicate their function. Specify the attachments’ direction of movement in accordance with ISO 3691-1 so that they match the controls’...
  • Page 103 4.16.2 SOLO-PILOT with control of ZH1 and ZH2 hydraulic ports Depending on the attachments used the lever / button (146, 148, 149) is assigned the function of the attachment. Unused levers have no function. For connections see "Fitting additional attachments" on page 105. Procedure •...

  • Page 104: Operating Additional Attachments For The Multi-Pilot

    4.17 Operating additional attachments for the MULTI-PILOT WARNING! Incorrect symbols can cause accidents Symbols on controls that do not depict the function of the attachments can cause accidents. Mark the controls with symbols that indicate their function. Specify the attachments’ direction of movement in accordance with ISO 3691-1 so that they match the controls’...
  • Page 105 4.17.3 MULTI-PILOT with control of ZH1, ZH2 and ZH3 hydraulic ports Depending on the attachments used the buttons (150, 151, 85) and the lever (78) are assigned the function of the attachment. Levers that are not required are void. For connections "Fitting additional attachments"...

  • Page 106: Fitting Additional Attachments

    4.18 Fitting additional attachments WARNING! Incorrectly connected attachments can cause accidents. Attachments with incorrectly connected hydraulic attachments can result in accidents. Attachments must only be assembled and commissioned by trained, specialist personnel. Observe the manufacturer’s operating instructions. Before starting, check the fasteners are positioned correctly and securely and make sure they are complete.
  • Page 107 Depressurising hydraulic replacement coupling Requirements – Ignition switched on, engine off. – Driver’s seat occupied. – All control handles in neutral. km/h Procedure • Apply the ZH1 lever for more than 5 seconds. Depressurised mode is activated. All travel functions are inhibited, parking brake cannot be deactivated. Info message 186 is displayed.
  • Page 108 Spilled hydraulic oil must be set using a suitable agent and disposed of in accordance with environmental regulations. If hydraulic oil comes into contact with the skin, wash it off immediately with soap and water. If it comes into contact with the eyes rinse them immediately with flowing water and call for a doctor.

  • Page 109: Towing Trailers

    Towing trailers DANGER! Inappropriate speeds and excessive trailer loads can be dangerous If you do not adapt your speed and / or use an excessive trailer load, the truck can pull apart when cornering and braking. The truck should only be used occasionally to tow trailers. The overall weight of the trailer should not exceed the capacity indicated on the capacity plate, see "Identification points and data plates"...
  • Page 110 Attaching the trailer CAUTION! Trapping hazard There is a trapping risk when you attach a trailer. Follow the instructions of the coupling manufacturer if using special trailer couplings. Secure the trailer to prevent it from rolling away before coupling it. Do not get caught between the truck and the tiller when coupling the trailer.

  • Page 111: Optional Equipment

    Optional equipment Keypad (CanCode) (o) 6.1.1 Code lock The code lock allows a user or group of users to assign an individual user code. Travel programs can also be assigned to the individual user codes. The user code is configured with a master code and is described in the following sections in this chapter.
  • Page 112 154 155 156 The keypad consists of 10 digit keys, a Set key (157) and a o key (159) Digit keys The digit keys are used to enter the user or master code and select the travel program. The green LEDs of the digit keys 1, 2 and 3 (154, 155, 156) show the travel program setting.
  • Page 113 6.1.2 Preparing the truck for operation with the keypad (CanCode) Preparing the truck for operation by entering a valid operator code Procedure • Pull the Emergency Disconnect to unlock it, see "Emergency Disconnect" on page 80. The LED (158) lights up red. •...
  • Page 114 6.1.4 Changing the master code To change the length of the master code you must follow the procedure in "Choose length of the new master code (4-6 digit) and add user codes", see "Choose length of the new master code (4-6 digit) and add user codes" on page 122. If there are still user codes stored in the code lock, the master code to be changed must be the same length as the saved user codes.
  • Page 115 Error displays changing the master code For the following events the LED (158) flashes red: Cause Remedy – New master code is already – Switch off the truck, see "Switching off the truck occupied by a user code with the keypad (CanCode)" on page 112. –...
  • Page 116 6.1.5 Add operator code 154 155 156 Requirements – To prepare the truck for operation, see "Preparing the truck for operation with the keypad (CanCode)" on page 112. Procedure • Press the O key (159). • Enter the valid master code with the digit keys. When you enter the valid master code the LED (158) flashes green.
  • Page 117 Error displays adding a user code For the following events the LED (158) flashes red: Cause Remedy – The user code entered is not – Switch off the truck, see "Switching off the truck the same length as the with the keypad (CanCode)" on page 112. master code –...
  • Page 118 6.1.6 Change operator code 154 155 156 Requirements – To prepare the truck for operation, see "Preparing the truck for operation with the keypad (CanCode)" on page 112. Procedure • Press the O key (159). • Enter the valid master code with the digit keys. When you enter the valid master code the LED (158) flashes green.
  • Page 119 Error displays changing a user code For the following events the LED (158) flashes red: Cause Remedy – The user code entered is not – Switch off the truck, see "Switching off the truck the same length as the with the keypad (CanCode)" on page 112. master code –...
  • Page 120 6.1.7 Delete individual user codes 154 155 156 Requirements – To prepare the truck for operation, see "Preparing the truck for operation with the keypad (CanCode)" on page 112. Procedure • Press the O key (159). • Enter the valid master code with the digit keys. When you enter the valid master code the LED (158) flashes green.
  • Page 121 Error displays deleting individual user codes For the following events the LED (158) flashes red: Cause Remedy – The user code entered is not – Switch off the truck, see "Switching off the truck the same length as the with the keypad (CanCode)" on page 112. master code –...
  • Page 122 6.1.8 Delete all user codes, 154 155 156 Requirements – To prepare the truck for operation, see "Preparing the truck for operation with the keypad (CanCode)" on page 112. Procedure • Press the O key (159). • Enter the valid master code with the digit keys. When you enter the valid master code the LED (158) flashes green.
  • Page 123 6.1.9 Choose length of the new master code (4-6 digit) and add user codes The master code is factory set to a four-digit entry: If necessary, the four-digit master code can be changed to a five or six-digit entry. Before the master code length can be changed, all user codes must be deleted.
  • Page 124 6.1.10 Setting the automatic truck cutout (timeframe) 154 155 156 Requirements – To prepare the truck for operation, see "Preparing the truck for operation with the keypad (CanCode)" on page 112. Procedure • Press the O key (159). • Enter the valid master code with the digit keys. When you enter the correct master code the LED (158) flashes green.
  • Page 125 Error displays setting the automatic cutout period of the truck For the following events the LED (158) flashes red: Cause Remedy – Cutout time entered is out of – Switch off the truck, see "Switching off the truck range with the keypad (CanCode)" on page 112. –...
  • Page 126 6.1.11 Assigning the travel program The travel programs are fixed to the user code and can be released or blocked with a configuration code. The configuration code can also be used to assign a starting travel program to each user code. The starting travel program is the travel program that is activated when the truck is switched on and is displayed by the (154,155,156) LEDs.
  • Page 127 Specifying a configuration code: Setting Description – Travel program 1 is blocked for the user code selected 1st digit – Travel program 1 is enabled for the user code selected – Travel program 2 is blocked for the user code selected 2nd digit –...
  • Page 128 Adapting the travel program configuration to the user code 154 155 156 Procedure • Press the O key (159). • Enter the valid master code with the digit keys. When you enter the valid master code the green LED (158) flashes green. •...
  • Page 129 Error displays configuring the travel programs For the following events the LED (158) flashes red: Cause Remedy – Blocked travel program – Switch off the truck, see "Switching off the truck defined as start travel with the keypad (CanCode)" on page 112. program –...

  • Page 130: Assistance Systems

    Assistance systems The Access, Drive and Lift Control systems help the driver operate the truck with regard to safety regulations, see "Safety regulations for truck operation" on page 74 of the present operating instructions. Travel conduct The operator must adapt the travel speed to local conditions. The truck must be driven at slow speed when negotiating bends or narrow passageways, when passing through swing doors and at blind spots.
  • Page 131 6.2.2 Drive Control This option restricts the travel speed of the truck depending on of the steer angle. From a factory-set lift height (approx. 1.50 metres) the maximum travel speed is reduced to walking pace (approx. 3 km/h) and the slow travel indicator is activated. When the forks fall below this height, the truck accelerates at reduced levels to the speed prescribed by the accelerator pedal to prevent sudden acceleration when changing from slow travel to normal travel.

  • Page 132: Steel Cab

    Steel cab For trucks fitted with a steel cabin, both doors can be closed. CAUTION! An open door can cause accidents (160) Do not travel with an open door (160). When opening the door make sure there is nobody in the door’s swing range. Always close the door tightly and make sure it is locked.

  • Page 133: Gate

    Gate CAUTION! A faulty gate can be hazardous Never use the truck with a non-functional gate. Have the gate checked by authorised specialist personnel after an accident. Do not modify the gate. Always close the gate securely and make sure it is locked. Closing the gate does not release the driver from his responsibility to wear a seat belt, see "Seat Belt"...

  • Page 134: Panel Door

    Panel door CAUTION! An open door can cause accidents (160) Do not travel with an open door (160). When opening the door make sure there is nobody in the door’s swing range. Always close the door tightly and make sure it is locked. Closing the door does not release the driver from his responsibility to wear a seat belt, see "Seat Belt"...

  • Page 135: Heating And Air Conditioning System

    Heating and air conditioning system Replacing the air conditioning filter Procedure • Turn the twist off knob (169) anti-clockwise. • Pull the filter cassette (168) out in the direction of the arrow. • Replace the filter. • Insert the filter cassette (168) into the heating console (167).
  • Page 136 6.8.1 Heating Item Description Item Description Body jets 174 Recirculating air flap: Recirculates the air in the Temperature controller 175 Foot compartment jet Fan settings 176 Windscreen jets Air distribution control Heating operation Procedure • Press the switch (172) to switch on the fan. •...
  • Page 137 6.8.2 Air conditioning system CAUTION! Extreme temperature differences can affect your health. When using the air conditioning system make sure the temperature is no higher than 6°C more than the outside air temperature. Keep the doors and windows closed when the air conditioning system is switched Do not direct discharge jets at other people.

  • Page 138: Driver's Seat Heating / Backrest Extension

    Driver’s seat heating / backrest extension km/h Heating the seat Procedure • Press the seat heating button (120). • Press the switch (178): 1 = seat heating ON; 0 = seat heating OFF. Adjusting the backrest extension CAUTION! Accident risk when adjusting the backrest during travel Do not adjust the backrest extension while travelling.

  • Page 139: Removable Load Backrest

    6.10 Removable load backrest CAUTION! Trapping hazard and heavy load backrest weight Wear safety gloves and safety shoes when carrying out this operation. Two people are required to remove and attach the load backrest. Load backrest disassembly Procedure • Loosen the screws (179). •...

  • Page 140: Sideshifter Centre Position

    6.12 Sideshifter centre position Automatic sideshifter centring control Requirements – Checks and operations performed before starting work each day (see "Checks and km/h operations to be performed before starting daily operation" on page 65). – Check automatic sideshifter centring with the P1 function key (113).

  • Page 141: Rockinger Coupling With Hand Lever Or Remote Control

    6.15 Rockinger coupling with hand lever or remote control Refer to the instructions for towing trailers, see "Towing trailers" on page 108. CAUTION! Incorrectly coupled trailers can cause accidents Make sure the coupling is engaged securely before starting the truck. The contro pin (184) must be flush with the control sleeve (185).

  • Page 142: Camera System

    6.16 Camera system CAUTION! Accident risk from hidden work areas The camera system acts as an aid to assist safe operation. Practice travelling and working with the camera system. Align the camera so that the hidden work area can be seen. When using the camera to reverse, the monitor automatically switches on when you engage reverse gear.

  • Page 143: Optional Equipment For Working In Dusty Environments

    6.17 Optional equipment for working in dusty environments When working in areas with high dust levels (lint, splinters) the truck can be fitted with an optional lint filter on the cooler. CAUTION! Clogged lint filters can cause fires The lint filter must be cleaned regularly according to how much it is clogged. Procedure •...

  • Page 144: Control Layout "N

    6.19 Control layout “N” WARNING! Persons standing under or on a raised load handler are at risk of accidents Do not allow anyone to stand under or on a raised load. Do not stand on the load handler. Do not lift any persons on the load handler. Instruct other people to move out of the hazardous area of the truck.

  • Page 145: Troubleshooting

    Troubleshooting Troubleshooting This chapter enables the operator to localize and rectify basic faults or the results of incorrect operation himself. When trying to locate a fault, proceed in the order shown in the remedy table. If, after carrying out the following remedial action, the truck cannot be restored to operation or if a fault in the electronics system is displayed with a corresponding error code, contact the manufacturer’s service department.
  • Page 146 Operating Error Displays NOTE When the overtemperature indicator (92) is lit the performance of the truck km/h automatically reduces to 0% at a steady rate from the point of the temperature limit, as the temperature rises. The truck can still be taken to the nearest workshop.
  • Page 147 km/h Info messages Information messages are shown in the display (126). Display Meaning Hydraulics zero position on power up – A hydraulic function or the horn applied during power up. – The hydraulic function applied will not be performed. – Depressurised mode activated. –...
  • Page 148 Fault Possible Cause Remedy Starter does not turn – Battery charge too low. – Check the battery charge and charge – Battery connection cable battery if necessary. loose or terminals oxidized. – Clean and grease terminals, tighten battery – Starter motor cable connection cable.
  • Page 149 Fault Possible Cause Remedy Excessive steering play – Air in steering system. – Check hydraulic oil level and top up if necessary, then turn the steering wheel several times from one end to the other. Engine does not start – Air filter contaminated. –...

  • Page 150: Operating The Truck Without Its Own Drive System

    Operating the truck without its own drive system 7.2.1 Towing the truck WARNING! Accident risk Other people can be injured if the truck is towed incorrectly. Only use vehicles to tow the truck which have sufficient tow and brake forces for the trailer load without its own braking system.
  • Page 151 7.2.2 Release the parking brake. WARNING! Uncontrolled truck movement When the brakes are released the truck must be parked securely on a level surface, since the brakes are no longer effective. Do not release the parking brake on slopes or inclines. Apply the parking brake again when you reach your destination.
  • Page 152 7.2.3 Emergency lowering The mast can be lowered manually if a fault occurs in the hydraulic system. WARNING! Lowering the mast can result in injuries Instruct other people to move out of the hazardous area of the truck during emergency lowering. Never stand underneath a raised load handler.
  • Page 153 7.2.4 Starting aid WARNING! Danger from overheating Use only an ISO 6722 battery jump lead with fully insulated terminal pliers and a lead diameter of at least 25 mm The jump start connection (199) is located in the main fuse box on the starter battery. Procedure •...

  • Page 154: F Industrial Truck Maintenance

    F Industrial Truck Maintenance Operational Safety and Environmental Protection The checks and servicing operations contained in this chapter must be performed in accordance with the maintenance checklist service intervals. WARNING! Risk of accidents and damage to components Any modification to the truck, in particular the safety mechanisms, is prohibited. Do not alter the truck's operating speeds under any circumstances.

  • Page 155: Maintenance Safety Regulations

    Maintenance Safety Regulations Maintenance and repair personnel The manufacturer has a service department specially trained for these tasks. A maintenance contract with the manufacturer will ensure trouble-free operation. Truck maintenance and repair work must only be carried out by specially trained personnel.

  • Page 156: Working On The Electrical System

    Working on the electrical system CAUTION! Accident risk from Working on the electrical system: Make sure the electrical system is voltage-free before starting work on it. Remove any rings or metal bracelets etc. before working on electrical components. Only trained personnel may work on the electrical system. Switch off the truck securely (see "Parking the truck securely"...

  • Page 157: Lift Chains

    Lift Chains WARNING! Non-lubricated and incorrectly cleaned lift chains can cause accidents Lift chains are safety-critical parts. They must not contain any serious contamination. Lift chains and pivot pins must always be clean and well lubricated. Lift chains should only be cleaned with paraffin derivatives e.g. petroleum or diesel fuels.

  • Page 158: Working In The Vicinity Of The Engine

    WARNING! Holes or hairline cracks in the hydraulic hoses can cause injury and infection Pressurised hydraulic oil permeating through fine holes or hairline cracks in the hydraulic hoses can penetrate the skin, causing severe injury. Call for a doctor immediately if you are injured. Do not touch pressurised hydraulic hoses.

  • Page 159: Lubricants And Lubrication Schedule

    Lubricants and Lubrication Schedule Handling consumables safely Handling consumables Consumables must always be handled correctly. Follow the manufacturer’s instructions. WARNING! Improper handling is hazardous to health, life and the environment Consumables can be flammable. Keep consumables away from hot components and naked flames. Always keep consumables in prescribed containers.
  • Page 160 WARNING! Improper handling of oils can be hazardous Oils (chain spray / hydraulic oil) are flammable and poisonous. Dispose of used oils in accordance with regulations. Store used oil safely until it can be disposed of in accordance with regulations. Do not spill oil.

  • Page 161: Lubrication Schedule

    Lubrication Schedule g Contact surfaces Hydraulic oil drain plug s Grease nipple Coolant filler cap Ö Engine oil filler neck Hydraulic oil filler neck...

  • Page 162: Consumables

    Consumables Code Order no. Quantit Capaci Description Used for 51037495 Hydraulic system Renolin B46 51037499 50055726 400 gr Grease Mast roller and K-P-2K sideshifter contact surfaces; steer axle 29201280 0.4 l Chain spray Chains 51210409 4.0 l 4.5 l Titan GT 1 Pro C- Engine oil 3 SAE 5W-30 51118018...
  • Page 163 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. DANGER! Anti-freeze is poisonous Anti-freeze contains ethylene glycol and other components which can result in...

  • Page 164: Maintenance And Repairs

    Maintenance and repairs Preparing 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: Procedure • Switch off the truck securely, see "Parking the truck securely"...

  • Page 165: Lifting And Jacking Up The Truck Safely

    Lifting and jacking up the truck safely WARNING! A truck tipover can cause accidents In order to raise the truck, use only suitable lifting gear at the points specially provided for this purpose. Note the weight of the truck on the data plate. Always use a jack with a minimum capacity of 5000 kg kg.

  • Page 166: Unlocking The Engine Bonnet

    Closing the panel Procedure • Place the rear panel in position. • Secure two quick release fasteners (200). The rear panel is now closed. Unlocking the engine bonnet Unlocking the engine bonnet Requirements – For trucks with a closed cab open both cabin doors before lifting the engine cover (o).

  • Page 167: Opening The Engine Cover

    Opening the engine cover NOTE Opening the engine cover The engine panel can be locked in the 50° and 70° positions. The 50° position 15 205 is locked by gas pressure spring (204) while the 70° position is locked by gas pressure spring (205).
  • Page 168 Closing the engine cover Procedure • Raise the engine cover (15) slightly and hold it in place. • From the 70° stage push in the red lock (206) of the right hand gas pressure spring. The engine cover is unlocked. •...

  • Page 169: Replacing Wheels

    Replacing wheels WARNING! A truck tipover can cause accidents In order to raise the truck, use only suitable lifting gear at the points specially provided for this purpose. Note the weight of the truck on the data plate. Always use a jack with a minimum capacity of 5000 kg kg. Raise the unladen truck on a level surface.
  • Page 170 Fitting the wheels Procedure • Assemble the wheel, using a suitable mounting lever if necessary. • Fit the wheel attachment. • Remove the hard wooden blocks. • Lower the truck. • Torque the wheel attachment (208) crosswise with a torque wrench, for torques see "Tyre type" on page 27.

  • Page 171: Checking The Wheel Attachments

    Checking the wheel attachments. WARNING! Using different tyres can cause accidents The quality of tyres affects the stability and performance of the truck. The diameter of the wheels must differ by no more than 15 mm. Always replace tyres in pairs. After replacing the tyres check the wheel nuts are secure after 10 service hours.

  • Page 172: Hydraulic System

    Hydraulic system CAUTION! The hydraulic oil is pressurised during operation and is a hazard to health and to the environment. Do not touch pressurised hydraulic lines. Dispose of used oil in accordance with regulations. Store used oil safely until it can be disposed of in accordance with regulations.
  • Page 173 4.8.1 Checking the hydraulic oil level Requirements – Park the truck on a level surface. – Start the engine and fully raise and lower the mast once. – Switch off the engine. Procedure • Remove the hydraulic oil dipstick (209) from the hole wipe it with a clean cloth and insert it fully again.
  • Page 174 4.8.3 Replacing the hydraulic oil filter Procedure • Unscrew the cap of the hydraulic oil filter (211). • Remove the filter from the cover. • Insert a new filter and screw the lid back on. 4.8.4 Replacing the ventilation/discharge filter Procedure •...

  • Page 175: Engine Maintenance

    Engine maintenance WARNING! Turning and hot components can cause trapping and burning hazards when the engine is running. When the cover is open turning and hot components are freely accessible and can cause injury if touched. Before starting work make sure that the Emergency Disconnect switch can be reached to switch off the engine.
  • Page 176 4.9.2 DFG engine maintenance NOTE Used oil contaminates the environment Dispose of used oil and used engine oil filters in accordance with environmental regulations. CAUTION! Hot oil can cause burning. Wear appropriate safety gloves when replacing the oil and oil filter. NOTE When the engine is cold the engine oil can be viscous.
  • Page 177 Draining the engine oil Procedure • Remove the floorboard. • Unscrew the filler cap (210). • Thoroughly clean the oil drain plug (215) and around the drain hole. • Unscrew the oil drain plug. • Collect any oil that emerges. •...
  • Page 178 NOTE The incorrect amount of oil will damage the engine. After replacing the oil and oil filter carry out a test run and check the oil pressure km/h display (88). Check that the oil drain plug and oil filter housing are tight.
  • Page 179 4.9.3 Replacing the fuel filter NOTE Fuel can cause environmental damage Bind any spilled diesel fuel using suitable absorbing agents. Dispose of the absorbed diesel fuel and the fuel filter in accordance with the relevant environmental protection laws. – Mark the fuel hoses (219) and loosen the clamps (218) from the fuel filter.
  • Page 180 4.9.5 TFG engine maintenance NOTE Used oil contaminates the environment Dispose of used oil and used engine oil filters in accordance with environmental regulations. CAUTION! Hot oil can cause burning. Wear appropriate safety gloves when replacing the oil and oil filter NOTE When the engine is cold the engine oil can be viscous.
  • Page 181 Draining the engine oil Procedure • Remove the floorboard. • Unscrew the filler cap (210). • Thoroughly clean the oil drain plug (215) and around the drain hole. • Unscrew the oil drain plug. • Collect any oil that emerges. •...
  • Page 182 Adding engine oil Procedure • Add fresh engine oil (see "Consumables" on page 161) through the filler port (210). • Check the engine oil level with the dipstick (214) and top up if necessary. • Screw the filler cap back on. •...
  • Page 183 4.9.7 Check V-belt for damage NOTE A damaged V-belt will result in malfunctions. If the V-belt (222) is not in good condition, first rectify the damage before using the truck. Procedure • Check V-belt (222) cracks, deformation and wear.
  • Page 184 4.9.8 Cooling system NOTE Lack of coolant can cause malfunctions The coolant level should be between the “MIN” and “MAX” markings on the expansion vessel. If the coolant is below the MIN marking, this indicates possible leakage in the radiator system. Do not continue using the truck.
  • Page 185 Check the coolant concentrate Tools and Material Required – Anti-freeze tester for coolants Procedure • Slowly unscrew the filler cap (227) from the expansion vessel (225). • Check the anti-freeze content of the coolant with an anti-freeze tester. NOTE The incorrect coolant concentration can cause malfunctions If there is insufficient anti-freeze content arrange for trained personnel to restore...
  • Page 186 Check the cooler and fan and clean if necessary Requirements – Park the truck securely on a level surface see "Parking the truck securely" on page 79. Procedure • Remove minor contamination from the fan grille (228) with weak suctioned air. CAUTION! Risk of incorrect disassembly/assembly of fan unit Only trained personnel may remove major cooler contamination.
  • Page 187 4.9.9 Replace air filter cartridge DANGER! A running engine can be dangerous Carry out all maintenance work with the engine switched off. Do not start the engine if the air filter cartridge is removed. Replace air filter cartridge Procedure • Undo the 2 mounting clamps (230) and remove the dust collector pot.
  • Page 188 4.9.10 Heating and air conditioning system (o) Replacing the air conditioning filter Procedure • Turn the twist off knob (169) anti-clockwise. • Pull the filter cassette (168) out in the direction of the arrow. • Replace the filter. • Insert the filter cassette (168) into the heating console (167).

  • Page 189: Checking Electrical Fuses

    4.10 Checking electrical fuses Checking electrical fuses Requirements – Prepare the truck for maintenance and repairs (see "Preparing the truck for maintenance and repairs" on page 163). Procedure • Open the rear cover of the truck, see "Opening the rear panel" on page 164. •...
  • Page 190 4.10.1 Fuse ratings 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 xs 182 xs 180 Item Component...
  • Page 191 Seat heating / compressor o Rear window wiper 9F14 o Rear work lights 5F1.2 10 / 5 Air mass meter (DFG 425s-435s only) 9F25 Shutoff valve (TFG only) t Charge control generator 9F31 t Horn t ECU terminal 15 engine controller...
  • Page 192 t= Series equipment o= Optional equipment...
  • Page 193 11 12 13 xs 182 xs 180 Relays Item Model To protect: Rating o Rear window heating t X contact 9K3.1 o Seat heating t Horn t Engine start with bonnet open t Starter relay t Ignition on – engine not running 9K23 t Ignition on - engine running 9K24...
  • Page 194 Check main fuses (engine compartment) Requirements – Prepare the truck for maintenance and repairs (see "Preparing the truck for maintenance and repairs" on page 163). Procedure • Open the engine cover, see "Unlocking the engine bonnet" on page 165. • Remove the fusebox cover. •...

  • Page 195: Cleaning

    4.11 Cleaning CAUTION! Fire hazard The truck must not be cleaned with flammable fluids. If flammable materials are not removed from the engine compartment, they can come into contact with hot components and cause a fire. Carry out all necessary safety measures to prevent sparking before cleaning (e.g. by short-circuiting).
  • Page 196 CAUTION! Risk of electrical system damage Cleaning the assemblies (controllers, sensors, motors etc.) of the electronic system with water can damage the electrical system. Do not clean the electrical system with water. Clean the electrical system with weak suction or compressed air (use a compressor with a water trap) and not a conductive, anti-static brush.

  • Page 197: Starter Battery

    4.12 Starter battery Checking the battery condition, acid level* and acid density* *not for maintenance-free batteries WARNING! Batteries can be hazardous Batteries contain an acid solution which is poisonous and corrosive. Avoid contact with battery acid at all times. Dispose of used battery acid in accordance with regulations. Always wear protective clothing and goggles when working with batteries.

  • Page 198: Exhaust System

    4.13 Exhaust system NOTE Check emissions at regular intervals Check the combustion engine exhaust emissions at regular intervals in accordance with national regulations. Black or blue exhaust smoke is an indicator of high emission levels resulting from combustion engine damage or wear. In this case the truck must be examined by specialist personnel.

  • Page 199: Restoring The Truck To Service After Maintenance And Repairs

    4.14 Restoring the truck to service after maintenance and repairs Procedure • Thoroughly clean the truck, see "Cleaning" on page 194. • Lubricate the truck according to the lubrication schedule, see "Lubrication Schedule" on page 160. • Clean the starter battery, grease the terminals and connect the starter battery. WARNING! Faulty brakes can cause accidents As soon as the truck has been started, test the brakes several times.

  • Page 200: Decommissioning The Industrial Truck

    Decommissioning the industrial truck If the truck is to be out of service for more than a month, it must be stored in a frost- free and dry room. All necessary measures must be taken before, during and after decommissioning as described hereafter. When the truck is out of service it must be jacked up so that all the wheels are clear of the ground.

  • Page 201: Prior To Decommissioning

    Prior to decommissioning Procedure • Thoroughly clean the truck, see "Cleaning" on page 194. • Prevent the truck from rolling away. • Check the hydraulic oil level and replenish if necessary, see "Checking the hydraulic oil level" on page 172. •...

  • Page 202: Restoring The Truck To Service After Decommissioning

    Restoring the truck to service after decommissioning Procedure • Thoroughly clean the truck, see "Cleaning" on page 194. • Lubricate the truck according to the lubrication schedule, see "Lubrication Schedule" on page 160. • Clean the starter battery, grease the terminals and connect the starter battery. •...

  • Page 203: Safety Tests To Be Performed At Intervals And After Unusual Incidents

    Safety tests to be performed at intervals and after unusual incidents Perform a safety check in accordance with national regulations. The manufacturer recommends the truck be checked to FEM guideline 4.004. The manufacturer has a service department specially trained for these tasks. The truck must be inspected at least annually (refer to national regulations) or after any unusual event by a qualified inspector.

  • Page 204: Final De-Commissioning, Disposal

    Final de-commissioning, disposal Final de-commissioning or disposal of the truck in must be performed in accordance with the regulations of the country of use. In particular, regulations governing the disposal of batteries, consumables and electronic and electrical systems must be observed.

  • Page 205: Servicing And Inspection

    Servicing and Inspection WARNING! Risk of accident due to neglected maintenance Failure to perform regular servicing can lead to truck failure and poses a potential hazard to personnel and equipment. Thorough and expert servicing is one of the most important requirements for the safe operation of the industrial truck.

  • Page 206: Maintenance Checklist Dfg

    Maintenance checklist DFG 10.1 Operating company 10.1.1 Standard equipment Brakes W A B C Test brakes. Electrical System W A B C Test warning and safety devices in accordance with operating instructions. Test displays and controls. Test the panel switch and check for damage. Test Emergency Disconnect switch.
  • Page 207 10.1.2 Optional equipment Work lights Electrical System W A B C Test lighting. Strobe light/beacon Electrical System W A B C Test strobe light / beacon and check for damage. Heating Chassis and Superstructure W A B C Test the heating. Check heating vent filter for contamination and clean if necessary.
  • Page 208 Fork adjuster Hydraulic operations W A B C Check attachment lubrication; clean and lubricate if necessary. Optional equipment Chassis and Superstructure W A B C Check that optional equipment such as mirrors, storage compartments, grips, windscreen wipers and washing systems etc. are working correctly and check for damage.

  • Page 209: Customer Service

    10.2 Customer service 10.2.1 Standard equipment Brakes W A B C Test brakes. Electrical System W A B C Test warning and safety devices in accordance with operating instructions. Test displays and controls. Test the panel switch and check for damage. Test Emergency Disconnect switch.
  • Page 210 Travel W A B C Replace engine oil filter. Check V belt / multi-V belt is tensioned and check for damage. Replace air filter. Check air filter, replace if necessary. Check engine for noise and leakage. Replace engine oil. Check engine oil level, top up if necessary. Check engine suspension.
  • Page 211 Hydraulic operations W A B C Check lateral clearance of the mast connections and the fork carriage. Visually inspect the mast rollers and check contact surface wear level. Check running surfaces of the mast for wear and damage, and lubricate if necessary. Test hydraulic system.
  • Page 212 Audible warning devices Electrical System W A B C Test the buzzer / warning alarm, check for damage and make sure it is secure. Trailer coupling Chassis and Superstructure W A B C Check trailer coupling or tow mechanism stop. Work Platform Hydraulic operations W A B C...
  • Page 213 Belt lock control Chassis and Superstructure W A B C Test the belt lock control and check for damage. Heating Chassis and Superstructure W A B C Test the heating. Replace heating breather. Check hoses for leaks and damage and make sure they are secure. Clamping device Hydraulic operations W A B C...
  • Page 214 Load backrest Hydraulic operations W A B C Check attachment is properly secured to the truck and the supporting elements. Lift Control Hydraulic operations W A B C Check the "Lift Control". Particle filter Travel W A B C Note: Any work carried out on the particle filter system must only be performed by specialist personnel.
  • Page 215 Hydraulic operations W A B C Check attachment lubrication; clean and lubricate if necessary. Check hydraulic ports and tighten if necessary. Test the sideshifter, check settings and check for damage. Check cylinder seals. Check cylinder piston rods and bushings. Sideshifter centring Hydraulic operations W A B C Test sideshifter centring operation.
  • Page 216 Video system System Components W A B C Check wiring is secure and check for damage. Test the camera, make sure it is secured and clean. Test the monitor, make sure it is secured and clean. Weigher sensors / switches Electrical System W A B C Test weigher system and check for damage.
  • Page 217 Access module Electrical System W A B C Test access module, check for damage and make sure it is secure. Optional equipment Chassis and Superstructure W A B C Check that optional equipment such as mirrors, storage compartments, grips, windscreen wipers and washing systems etc. are working correctly and check for damage.

  • Page 218: Maintenance Checklist Tfg

    Maintenance checklist TFG 11.1 Operating company 11.1.1 Standard equipment Brakes W A B C Test brakes. Electrical System W A B C Test warning and safety devices in accordance with operating instructions. Test displays and controls. Test the panel switch and check for damage. Test Emergency Disconnect switch.
  • Page 219 11.1.2 Optional equipment Work lights Electrical System W A B C Test lighting. Strobe light/beacon Electrical System W A B C Test strobe light / beacon and check for damage. Heating Chassis and Superstructure W A B C Test the heating. Check heating vent filter for contamination and clean if necessary.
  • Page 220 Fork adjuster Hydraulic operations W A B C Check attachment lubrication; clean and lubricate if necessary. Optional equipment Chassis and Superstructure W A B C Check that optional equipment such as mirrors, storage compartments, grips, windscreen wipers and washing systems etc. are working correctly and check for damage.

  • Page 221: Customer Service

    11.2 Customer service 11.2.1 Standard equipment Brakes W A B C Test brakes. Electrical System W A B C Test warning and safety devices in accordance with operating instructions. Test displays and controls. Test the panel switch and check for damage. Test Emergency Disconnect switch.
  • Page 222 Travel W A B C Check tyre air pressure and top up if necessary. Check wheels for wear and damage. Check wheel suspension and attachment. Test starter and generator, Check wires and attachment. Replace engine oil filter. Check V belt / multi-V belt is tensioned and check for damage. Replace air filter.
  • Page 223 Hydraulic operations W A B C Check load chain setting and tension if necessary. Check load chain lubrication and lubricate if necessary. Check lateral clearance of the mast connections and the fork carriage. Visually inspect the mast rollers and check contact surface wear level.
  • Page 224 11.2.2 Optional equipment Discharge strap Electrical System W A B C Check anti-static discharge strap is present and not damaged. Audible warning devices Electrical System W A B C Test the buzzer / warning alarm, check for damage and make sure it is secure.
  • Page 225 Fire extinguisher Agreed performance levels W A B C Check fire extinguisher is present, secure and Check test interval. Belt lock control Chassis and Superstructure W A B C Test the belt lock control and check for damage. Heating Chassis and Superstructure W A B C Test the heating.
  • Page 226 Crane hook Hydraulic operations W A B C Check attachment is properly secured to the truck and the supporting elements. Load backrest Hyd. operations W A B C Check attachment is properly secured to the truck and the supporting elements. Lift Control Hydraulic operations W A B C...
  • Page 227 Sideshifter centring Hydraulic operations W A B C Test sideshifter centring operation. Seat heating Electrical System W A B C Check electric wiring for damage (insulation damage, connections). Make sure wire connections are secure. Road traffic approval (StVZO) Electrical System W A B C Test lighting.
  • Page 228 Weigher sensors / switches Electrical System W A B C Test weigher system and check for damage. Weather-proof system Electrical System W A B C Check fuse ratings. Chassis and Superstructure W A B C Test the window heating and check for damage. Test the doors and check for damage.
  • Page 229 Optional equipment Chassis and Superstructure W A B C Check that optional equipment such as mirrors, storage compartments, grips, windscreen wipers and washing systems etc. are working correctly and check for damage. Issued on: 20.11.2012 16:52:11...

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Dfg 430sDfg 435sTfg 425sTfg 430sTfg 435s

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