Jungheinrich DFG/TFG 16-50 A/B/C -K/-S Forklift Service & Repair Manual

*ЦЛТЩШЫЧТОЧЭШ Operating instructions 52027109 DFG/TFG 316-550 G 03.01 - 12.06

Foreword The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide suf- ficient instruction for the safe operation of the industrial truck. The information is pro- vided clearly and concisely. The chapters are arranged by letter. Each chapter starts with page 1. The page identification consists of a chapter letter and a page number. For example: Page B 2 is the second page in chapter B. The operating instructions detail different truck models. When operating and servicing the truck, make sure that the instructions apply to your truck model. Safety instructions and important explanations are indicated by the following gra- phics: f Used before safety instructions which must be observed to avoid danger to person- nel. m Used before notices which must be observed to avoid material damage. A Used before notices and explanations. t Used to indicate standard equipment. o Used to indicate optional equipment. Our trucks are subject to ongoing development. Jungheinrich reserves the right to al- ter the design, equipment and technical features of the truck. No guarantee of partic- ular features of the truck should therefore be assumed from the present operating instructions. Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG Jungheinrich Aktiengesellschaft Am Stadtrand 35 D-22047 Hamburg - Germany Telephone: +49 (0) 40/6948-0 www.jungheinrich.com

0704.GB Contents A Correct Use and Application of the Truck B Description of Truck 1 Description of Use B1 ................................................... 2 Description of Assemblies and Function B2 ................................ 2.1 Truck B3 .............................................................. 2.2 Mast B4 ............................................................... 2.3 Changes in operational requirements B4 .................................. 2.4 Safety devices B4 ...................................................... 3 Technical Data -- Standard Equipment B5 .................................. 3.1 Data tables -- DFG/TFG 316/320 B 14 ...................................... 3.2 Data tables -- DFG/TFG420--430 B 16 ...................................... 3.3 Data tables -- DFG/TFG540--550 B 19 ...................................... 4 Labels and Plates B 23 ................................................... 4.1 Truck Rating Plate B 24 ................................................... 4.2 Load diagrams B 25 ...................................................... C Transportation and Commissioning 1 Transportation C1 ...................................................... 2 Commissioning C4 ...................................................... D Truck Refuelling 1 Safety Conditions for Handling Diesel Fuel and Liquid Petroleum Gas D1 ...... 2 Filling with Diesel Fuel D2 ............................................... 3 Changing the Gas Bottle D3 ............................................. 4 Trucks fitted with Twin--Gas Bottles D5 .................................... E Operation 1 Safety Regulations Governing the Operation of the Forklift Truck E1 .......... 2 Description of Drivers Controls and Display Elements E3 .................... 3 Checks and Activities Before Daily Use E 11 ................................. 4 Using the Truck E 17 ..................................................... 4.1 Start Process TFG E 19 ................................................... 4.2 Start Process DFG E 20 .................................................. 4.3 Fault Displays during Operation E 22 ....................................... 5 Operation of the Forklift Truck E 24 ......................................... 5.1 Safety regulations applicable when operating the truck E 24 ................... 5.2 Driving E 26 ............................................................. 5.3 Steering E 28 ............................................................ 5.4 Braking E 28 ............................................................. 5.5 Operating the Mast and Attachments E 30 ................................... 5.6 Picking Up, Transporting and Setting Down Load Units E 32 .................................................... 5.7 Instructions for the use of restraint belts E 39 ................................ 5.8 Parking the Truck Safely E 41 .............................................. 5.9 Engine housing and service covers E 42 .................................... 5.10 Towing E 44 ............................................................. 5.11 Towing Trailers E 44 ...................................................... 5.12 Trailer loads E 45 ........................................................ 6 Fault Locating Operations E 46 ............................................

0704.GB F Truck Maintenance 1 Operational Safety and Environmental Protection F1 ........................ 2 Safety Regulations Applicable to Truck Maintenance F1 ..................... 3 Servicing and Inspection F2 ............................................. 4 Maintenance Check-list DFG/TFG F3 ..................................... 5 Maintenance Check-list DFG F5 .......................................... 6 Maintenance Check-list TFG F6 .......................................... 7 Coolant Specification F7 ................................................ 8 Lubricant Specifications F9 .............................................. 9 Fuel specification -- DFG F 13 ............................................. 10 Lubrication Chart F 14 .................................................... 10.1 Lubrication Diagram -- DFG/TFG 316--430 F 15 .............................. 10.2 Lubrication Diagram -- DFG/TFG 540--550 F 16 .............................. 11 Description of Maintenance and Repair Work F 17 ........................... 11.1 Preparing the Truck for Maintenance and Repair Work F 17 ................... 11.2 Engine Maintenance TFG 316/320 F 17 ..................................... 11.3 Engine Maintenance DFG 316/320 F 20 .................................... 11.4 Engine Maintenance TFG 420--430 F 23 ................................... 11.5 Engine Maintenance DFG 420--430 F 25 ................................... 11.6 Engine Maintenance TFG 540--550 F 28 ................................... 11.7 Engine Maintenance DFG 540--550 F 30 ................................... 11.8 Check Coolant Concentration F 33 ......................................... 11.9 Clean/Change Air Filter Cartridge F 34 ...................................... 11.10 Transmission unit -- DFG/TFG 316/320 F 35 ................................. 11.11 Transmission unit -- DFG/TFG 420--430 F 36 ................................ 11.12 Transmission unit -- DFG/TFG 540--550 F 37 ................................ 11.13 Brakes F 38 ............................................................. 11.14 Change Wheels F 40 ..................................................... 11.15 Hydraulic System F 41 .................................................... 11.16 Electrical System F 42 .................................................... 12 Exhaust System F 45 ..................................................... 13 Decommissioning F 45 ................................................... 14 Inspection F 46 .......................................................... 14.1 Safety checks to be performed at regular intervals and following any untoward incidents (D: Accident prevention check according to BGV D27) F 47 15 Storage F 48 ............................................................ 16 Disposal F 52 ............................................................ Appendix for Diesel Engine Exhaust Gas Filter -- STX Type 1 ......... 1 Introduction 1 ......................................................... 2 Regeneration 1 .......................................................

A1 0704.GB A Correct Use and Application of the Truck The Guidelines for the Correct Use and Application of Industrial Trucks (VDMA) is included in the scope of delivery for this truck. The guidelines are part of these operating instructions and must always be heeded. National regulations are fully applicable. The forklift truck described in these operating instructions is a truck that is suitable for lifting and transporting loads. It must be used, operated and maintained according to the information in these operating instructions. Any other uses are outside the design envelope and can lead to injury to persons or damage to equipment and property. Above all, overloading caused by excessively heavy or unbalanced loads must be avoided. The max. admissible load to be picked up can be seen from the identification plate or load diagram label shown on the truck. The fork--lift truck must not be operated in spaces subject to fire or explosion hazards, or in spaces where corrosive or very dusty atmospheres prevail. Duties of the user: User within the meaning of these operating instructions is any natural person or legal person who either uses the fork--lift truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting), the user is considered the person, who, in accordance with existing contractual agreements between the owner and the user of the fork--lift truck, is charged with the observance of the operating duties. The user must ensure that the truck is not abused and only used within its design limits and that all danger to life and limb of the operator, or third parties, is avoided. In addition to this, it must be ensured that the relevant accident prevention regulations and other safety--related provisions, as well as the operating, servicing and maintenance guidelines, are observed. The user must also ensure that all persons operating the truck have read and understood these operating instructions. If these Operating Instructions are not observed the warranty becomes void. The same applies if improper work is carried out on the device by the customer and/or third parties without permission of our Customer Service. Mounting of attachments: The mounting or installation of any attachments which will interfere with, or supplement, the functions of the truck is permitted only after written approval by the manufacturer has been obtained. If necessary, the approval of local authorities has to be obtained. Any approval obtained from local authorities does not, however, make the approval by the manufacturer unnecessary. Trailing and slipping loads: The truck may only be used for trailing or slipping loads for which the truck has been approved. A

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Jungheinrich DFG/TFG 16-50 A/B/C -K/-S Forklift Service & Repair Manual

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