DFG/TFG 316 / 320. Operating instructions

Transcription

1 DG/TG 316 / Operating instructions G

2 oreword The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide sufficient instruction for the safe operation of the industrial truck. The information is provided clearly and concisely. The chapters are arranged by letter. Each chapter starts with page 1. The page identification consists of a chapter letter and a page number. or 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. M Z t o Safety instructions and important explanations are indicated by the following graphics: Used before safety instructions which must be observed to avoid danger to personnel. Used before notices which must be observed to avoid material damage. Used before notices and explanations. 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. Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG. Jungheinrich Aktiengesellschaft Am Stadtrand Hamburg - GERMANY Telephone: +49 (0) 40/ GB

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4 Index A B Correct Application Truck Description 1 Application... B 1 2 Assemblies and unctional Description... B Truck... B 3 3 Standard Version Specifications... B Performance Data DG... B Engine data... B Tyre Type... B Mast Versions... B EN norms... B Conditions of use... B 12 4 Identification points and data plates... B Truck data plate... B Truck load chart... B Attachment load chart... B 15 C Transport and Commissioning 1 Lifting by crane... C 1 2 Securing the truck during transport... C 2 3 Using the truck for the first time... C 3 4 Towing the truck... C 3 D illing the Truck with uel 1 Safety regulations for handling diesel fuel and LPG... D 1 2 illing with diesel... D 2 3 Replace the LPG bottle... D GB I 1

5 E Operation 1 Safety Regulations for the Operation of orklift Trucks... E 1 2 Controls and Displays... E 3 3 Starting up the truck... E Checks and operations to be performed before starting daily work... E Trucks with reduced headroom X (o)... E Adjusting the driver s seat... E Safety restraint belt... E Adjusting the steering column... E Starting the truck... E Starting procedure for the TG... E Starting procedure for the DG... E Operational ault Displays... E Stopping the engine1.... E 18 4 Industrial truck operation... E Safety regulations for truck operation... E Travel... E Steering... E Braking... E Mast and Attachment Operation... E Collecting, transporting and depositing loads... E Parking the truck securely... E Towing trailers... E Tow loads... E 32 5 Troubleshooting... E GB I 2

6 Industrial Truck Maintenance 1 Operational safety and environmental protection Maintenance Safety Regulations Servicing and inspection DG/TG maintenance checklist DG maintenance checklist TG maintenance checklist Coolant specification DG fuel specifications Lubrication schedule uels, coolants and lubricants Maintenance and Repairs Preparing the truck for maintenance and repairs Engine cover Servicing the engine DG Engine servicing TG Check the hydraulic oil level Gas system drain tap Checking the coolant level Checking the coolant concentration illing the cooling circuit Cleaning/replacing the air filter cartridge DG/TG transmission: Brake Checking the wheel attachments Hydraulic system Clean/replace hydraulic reservoir Electrical System Exhaust system Restoring the truck to service after cleaning or repairs Decommissioning the industrial truck Prior to decommissioning: During decommissioning: Returning the truck to operation after decommissioning Safety checks to be performed at regular intervals and following any unusual incidents (D: Accident prevention check according to BGV D inal de-commissioning, disposal GB I 3

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8 A Z Correct Application 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 operating instructions is an industrial truck designed for lifting and transporting loads. It must be applied, operated and serviced in accordance with the instructions contained in the present manual. Any other type of use is beyond the scope of application and can result in damage to personnel, the truck or property. In particular, avoid overloading the truck with loads which are too heavy or placed on one side. The data plate attached to the truck or the load diagram are binding for the maximum load capacity. The industrial truck must not be used in fire or explosion endangered areas, or areas threatened by corrosion or excessive dust. M Proprietor responsibilities: or the purposes of the present operator manual the proprietor 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. The proprietor must ensure that the industrial truck is used only for the purpose it is intended for and that danger to life and limb of the user and third parties are excluded. urthermore, accident prevention regulations, safety regulations and operating, servicing and repair guidelines must be followed. The proprietor must ensure that all truck users have read and understood this operator manual. ailure to comply with the operator manual shall invalidate the warranty. The same applies if improper work is carried out on the truck by the customer or third parties without the permission of the manufacturer s customer service department. Attaching accessories: The mounting or installation of additional equipment which affects or enhances the performance of the industrial truck requires the written permission of the manufacturer. In some cases, local authority approval shall be required. Approval of the local authorities however does not constitute the manufacturer s approval. Trailing and towed loads: The truck may only be used for trailing or towed loads for which the truck has been approved GB A 1

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10 B Truck Description 1 Application The DG/TG series are IC engine, 4-wheel rider trucks. The DG series are diesel engine trucks, while the TG series are fitted with a petrol engine for LPG operation. The DG/TG is equipped with a hydrodynamic drive system. The left pedal is a combination of crawl speed and brake pedal, and activates the rapid lift function during slow travel. The middle pedal is a standard brake as well as an emergency brake pedal. The capacity depends on the model. The type description indicates the maximum load rating. or example, a DG/TG 316 can carry loads of up to 1600 kg and a DG/TG 320 loads of up to 2,000 kg. Truck models and maximum capacity: Type Max. capacity *) Load centre of gravity DG/TG 316 1,600 kg 500 mm DG/TG 320 2,000 kg 500 mm *) The load diagrams attached to the truck are binding in terms of capacity 0207.GB B 1

11 2 Assemblies and unctional Description Item Description Item Description 1 t Driver's seat 8 t Load fork 2 t Steering column 9 t ork carriage 3 t Dashboard 10 t Drive axle 4 t Overhead guard 11 t Engine cover 5 t Mast 12 t Steering axle 6 t Load chain 13 t Trailer coupling 7 t Lift cylinder 14 t Counterweight 0207.GB B 2

12 2.1 Truck Chassis/Superstructure: A solid, 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 engine housing (11). The hydraulic oil reservoir is integrated on the right-hand side and the fuel tank for the DG series on the opposite side in the chassis. The LPG bottle for the TG series is secured to a bracket on the counterbalance weight (14). The exhaust system prevents exhaust from entering the driver s position. Driver s position: Non-slip steps and a handle on the posts of the overhead guard provide easy entry and exit. The driver is protected by the overhead guard (4). On the driver s seat the seat cushioning and the seat position are adjustable, while the steering wheel tilt can be set on the steering column (2). Easy operation through ergonomically arranged controls and a practically vibration-proof cab mean that the driver is subjected to minimum stress. The controls and warning indicators on the dashboard (3) provide system monitoring during operation. This results in a very high level of safety. Before the truck is started, the overhead guard must be inspected for cracks, and if damaged, must be repaired or replaced. Engine: Silent, water-cooled engines featuring high performance and low consumption. In the DG series diesel engines are used with very clean fuel combustion under all operating conditions and soot levels below the visibility level. or the TG series, petrol engines are used with very low residual exhaust levels. Drive system: A power shift gear with radiator and torque converter is directly flanged to the engine. This transfers the force to the drive axle (10). The travel direction switch on the left hydraulic control lever regulates forward/reverse travel and the neutral position. Steering: Hydrostatic steering consists of a steer cylinder integrated in the steering axle (12). The steering axle is fully floating in the chassis to ensure excellent grip even on non-level surfaces. Brakes: The slow travel / brake pedal actuates two drum brakes which are applied to the drive wheels. Worn drum brakes are automatically adjusted. The parking brake operates through mechanical actuation of the parking brake lever on the drum brake via Bowden cables. Wheels: All wheels are located within the geometry of the truck. A choice of air or superelastic tyres is available GB B 3

13 Hydraulic system: The gear pump of the hydraulic system is powered by the engine through a power take off. The pump speed and hence the supply flow are controlled by the accelerator pedal through the engine speed. Hydraulic functions are controlled by the control lever through a multiple control valve. Electrical System: The 12 volt system consists of a starter battery and a threephase generator with integrated controller. A repeat start block prevents incorrect operation during start-up and a safety switch ensures the engine can only start when the travel direction switch is in neutral. or diesel motors, a rapid pre-heat system is installed, LPG motors have a non-contact electronic ignition system for rapid and trouble-free engine starting. The ignition / starter switch is used to switch off the engine. Mast (5): The target has been to maximize visibility. The maximum strength steel section are narrow, allowing for good fork visibility in particular with the three-stage mast. Equally good results have been achieved for the fork carriage. The mast and the fork carriage run on permanently lubricated and hence maintenance-free angled backing rollers. Attachments: The trucks can be optionally fitted with mechanical and hydraulic attachments GB B 4

14 3 Standard Version Specifications Z Technical specification details in accordance with VDI Technical modifications and additions reserved. 3.1 Performance Data DG Description DG 316 DG 320 Q Capacity Kg C Load centre of gravity mm Travel speed w / w.o. load 18/19 18/19 km/h Lift speed w / w.o. load 0.6/ /0.62 m/s Lowering speed w / w.o. load 0.55/ /0.49 m/s Gradeability w / w.o. load % TG performance data Description TG 316 TG 320 Q Capacity (where C = 600 mm) Kg C Load centre of gravity mm Travel speed w / w.o. load 18/19 18/19 km/h Lift speed w / w.o. load 0.6/ /0.63 m/s Lowering speed w / w.o. load 0.55/ /0.49 m/s Gradeability w / w.o. load % 0207.GB B 5

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16 Dimensions DG Description DG 316 DG 320 a/2 Safety distance mm h 1 Mast height (retracted) mm h 2 ree lift mm h 3 Lift mm h 4 Mast height (extended) mm h 6 Overhead guard height mm h 7 Seat height (SIP) mm L 1 Length including forks mm L 2 Headlength mm b 1 Overall width mm e ork width mm m 1 Ground clearance with load below mast mm m 2 Ground clearance from centre of wheelbase mm Ast Aisle width for pallets 800 x 1200 longit mm Ast Aisle width 1200 x 800 transverse pallets mm Wa Turning radius mm x Load distance mm y Wheelbase mm Truck weight Kg 0207.GB B 7

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18 TG dimensions Description TG 316 TG 320 a/2 Safety distance mm h 1 Mast height (retracted) mm h 2 ree lift mm h 3 Lift mm h 4 Mast height (extended) mm h 6 Overhead Guard Height mm h 7 Seat height (SIP) mm L 1 Length including forks mm L 2 Headlength mm b 1 Overall width mm e ork width mm m 1 Ground clearance with load below mast mm m 2 Ground clearance from centre of wheelbase mm Ast Aisle width for pallets 800 x 1200 longit mm Ast Aisle width 1200 x 800 transverse pallets mm Wa Turning radius mm x Load distance mm y Wheelbase mm Truck weight Kg 0207.GB B 9

19 3.2 Engine data Engine - DG Type S4Q2 four cylinder Ignition sequence Capacit cc Control speed 2350 RPM (unloaded) 680 RPM (idle) Valve clearance Inlet and outlet 0.25 mm cold Tray capacity 8.0 l uel tank capacity 48 l Coolant capacity 5.5 l + system = 14.0 l Engine - TG Type 2.1 L L4 four cylinder, four stroke, LPG Ignition sequence Capacit cc Control speed 2700 ±50 RPM (unloaded) 850 ±50 RPM (idle) Spark plug type NGH R2A-D Spark plug electrode distance mm Tray capacity 3.8 litres Coolant capacity 3.5 litre + system = 13 litres 3.3 Tyre Type ull rubber SE tyres (=Solid) DG/TG 316 DG/TG 320 Drive axle Steering axle 18x7-8 18x7-8 Pneumatic tyres (diagonal tyres) DG/TG 316 DG/TG 320 Drive axle PR PR Steering axle 18x7-8 14PR 18x7-8 14PR Z Tyre pressure DG / TG 316 DG / TG 320 Drive axle 10 bar 10 bar Steering axle 9.0 bar 9.0 bar Permissible tyre type forsolid: Solideal Magnum Pneumatic: Solideal ED (Extra Deep) 0207.GB B 10

20 3.4 Mast Versions (all dimensions in mm) DG/TG 316/320 VDI 3596 Description ZT ZZ DZ Mast table Lift ree lift Extended height Retracted height h h 3 h 1 2 h GB B 11

21 3.5 EN norms Noise level: 79 db(a) +/- 3dB (depending on tolerances and features) Z in accordance with EN as harmonized with ISO 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. MSG 65 Vibration: 0.50 m/s 2 Z in accordance with EN The vibration acceleration acting on the body in the operating position is, in accordance with standard procedures, the linearly integrated, weighted acceleration in the vertical direction. It is calculated when travelling over bumps at constant speed. Electromagnetic Compatibility ( Z The manufacturer confirms that equipment complies with tolerance levels for electromagnetic emissions and resistance as well as static electricity discharge testing in accordance with EN including the normative procedures contained therein. No changes to electric or electronic components or their arrangement may be made without the written agreement of the manufacturer. 3.6 Conditions of use Z Ambient temperature - operating at -20 C to 40 C Special equipment and authorisation are required if the truck is to be constantly used in conditions of extreme temperature or air humidity fluctuations GB B 12

22 (mm) D (mm) Q (kg) Identification points and data plates GB Item Description 15 Warning: Read operator manual. 16 Load fork, Capacity / Load Centre of Gravity / Lift Height Chart 17 Travel with raised load prohibited / Mast forward tilt with raised load prohibited warning 18 "Attach Safety Restraint Belt" decal 19 Strap points for crane lifting 20 Procedure when truck in danger of tipover notice 21 "Do not stand under load lifting device / Do not stand under load lifting device / Risk of trapping when mast extended combined notice 22 Maximum body size noticeo 23 UVV test sticker (D only) 24 Jack contact points 25 Serial number, on chassis below the engine cover 26 Do not carry passengers warning 27 Truck data plate under the engine cover B 13

23 4.1 Truck data plate Z Item Description Item Description 28 Type 33 Manufacturer s logo 29 Serial no. 34 Net weight 30 Rated capacity (kg) 35 Load centre of gravity (mm) 31 Output (kw) 36 Year of manufacture 32 Manufacturer 37 Option or queries regarding the truck or ordering spare parts always quote the truck serial number (29). 4.2 Truck load chart The load chart (16) gives the capacity (Q) of the truck in kg with a vertical mast. The diagram will differ, depending on the height of the mast used. The maximum capacity is shown as a table with a given load centre of gravity D (in mm) and the required lift height H (in mm). The truck load chart shows the truck's capacity with new forks (as supplied). rom a fork length of 1300 mm this means a decrease in load. Trucks supplied without fork tines are given a standard data plate. Example of how to calculate the maximum capacity: With a load centre of gravity D of 600 mm and a maximum lift height H of 3600 mm. the max. capacity Q is 1105 kg. or example: GB B 14

24 The arrow shape markings (38 and 39) on the inner and outer masts show the driver when the specified lift limits have been reached. These arrows are attached to all masts with a heightdependent capacity rating Attachment load chart Z The attachment load chart gives the truck s capacity Q in combination with the respective attachment in kg. The serial number specified in the load chart must match the data plate of the attachment, as the capacity for each truck is specifically indicated by the manufacturer. It is shown in the same way as the truck s capacity and can be determined accordingly. or loads with a centre of gravity above 500mm upward, the capacities are reduced by the difference of the altered centre of gravity GB B 15

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26 C Transport and Commissioning 1 Lifting by crane M M M Only use lifting gear with sufficient capacity (for transport weight see truck data plate). Park the truck securely (see Chapter E). Attach the crane slings to the cross member of the mast (1) and the trailer coupling (2). Only suspend crane belts/chains to the top eye of the counterbalance weight and the eyes of the upper cross member (mast). The mast must be tilted back fully. The crane belt or the chain on the mast must be at least 2m long. Lifting slings should be fastened to the harness in such a way that they do not come into contact with any attachments or the overhead guard when it is being raised GB C 1

27 2 Securing the truck during transport The truck must be securely fastened when being transported on a lorry or a trailer. The lorry / trailer must have fastening rings and a wooden floor. Loading shall be carried out by staff especially trained for that purpose in accordance with recommendations contained in Guidelines VDI 2700 and VDI In each case correct measurements must be taken and appropriate safety measures adopted. To secure the truck with the mast assembled, use the eyes on the upper cross member of the mast and the trailer pins. See top picture (fastening with mast assembled) and centre picture (fastening without a mast). If the truck is to be transported without a mast, it must be tied down at the front over the overhead guard. See centre picture. The lower picture shows the approximate position of the centre of gravity GB C 2

28 3 Using the truck for the first time 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: Check the truck for completeness and satisfactory condition of the equipment. Check motor oil level. Check power shift transmission oil level. Check brake fluid level Check battery terminals and acid level. Commission the truck in accordance with instructions (see Chapter E). 4 Towing the truck As the gear unit of the forklift motor is powered, it is not lubricated and will overheat if a truck has to be towed with the motor switched off. To avoid this, the truck can only be towed at a max. speed of 4 km per hour. Hitch point A rigid tow bar must be used for moving a forklift truck. The tow point of the truck is marked (57) Z Attach the tow bar / rope to the trailer coupling of the recovery vehicle and the truck to be recovered. Release the parking brake. One person must be seated in the towed truck to steer it. Tow the truck at crawl speed. As the steering auxiliary unit is not applied, extra effort is required to steer the truck GB C 3

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30 D illing the Truck with uel 1 Safety regulations for handling diesel fuel and LPG Before filling up or replacing the LPG bottle, first park the truck securely (see Chapter E). ire protection: When handling fuels and LPG, smoking, naked flames and other ignition sources are strictly prohibited in the immediate vicinity. Labels indicating the hazard zone must be positioned where they are clearly visible. It is prohibited to store flammable materials in this area. Operational fire equipment must be provided within easy reach of the filling area. Only use carbon dioxide dry extinguishers or carbon dioxide gas extinguishers for fire protection. Storage and transport: The dieself and LPG storage and transport devices must comply with statutory requirements. If there is no filling point available, the fuel must be stored and transported in clean, approved containers. The contents must be clearly indicated on the container. Unsealed LPG bottles must be brought immediately into the open air, stored in well ventilated areas and the supplier must be notified. Spilled diesel must be set using a suitable agent and disposed of in accordance with environmental regulations. Personnel for filling fuel and replacing LPG bottles: Personnel handling LPG must be have sufficient knowledge of the nature of liquid gases to ensure safe operation. illing up the LPG tank: LPG tanks remain connected to the truck and are filled up at LPG stations. Always follow the instructions of the tank system and LPG tank manufacturer as well as statutory and local regulations when filling up. Liquid gas produces frost damage to naked skin GB D 1

31 2 illing with diesel The truck must only be filled at locations specifically designed for this purpose. Z M M Park the truck securely before filling up (see Chapter E). Open the cap (1). ill up with clean diesel. Do not overfill the tank. Capacity: 48 l Only use DIN diesel with a cetane rating below 45. The fuel guage (2) indicates the fuel level. If it points to the red zone, fill the tank. Never allow the fuel tank to run dry! Air in the fuel system will result in malfunctions. Tighten the cap back on after filling with fuel GB D 2

32 3 Replace 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. Unscrew the union nut (4) with an appropriate key while holding against the handle (6). Remove the hose (5) and immediately screw the valve cap onto the empty LPG bottle. Remove the stop bolt (7) and rotate the LPG bottle and bracket around the handle (9). old back the lever of the toggle-type fastener (8) and unhook the tensioning pivot from the bracket. Remove the tensioning belt. Carefully remove the LPG bottle from the bracket and place it down securely. Only use 18 kg (29 l) LPG replacement bottles Insert the new LPG bottle in the bracket and turn it so that the neck of the shut off valve is facing up. it the tensioning belt around the LPG bottle. Hook in the tensioning pivot and tension the belt with the lever (8). Rotate the LPG bottle and the bracket around the handle (9). Press in the stop bolt (7). Refit the hose (5) in accordance with regulations. Carefully open the shut off valve and check the connection is sealed using a foambased agent GB D 3

33 o When the reserve indicator for LPG bottle (2) is lit, this indicates that the bottle is empty. o Reusable LPG bottles with central filling device The bottle is fitted with a filling stop valve. The discharge valve (10) must be sealed. Remove the seal (11). Insert the nozzle of the liquid gas pump into the filler port. ill the LPG bottle until you can see on the fluid gauge that the bottle is full. Remove the nozzle and refit the seal (11). Note all guidelines and regulations concerning the filling of LPG bottles on the LPG pump GB D 4

34 E Operation 1 Safety Regulations for the Operation of orklift 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. Driver s rights, obligations and responsibilities: The driver must be informed of his duties and responsibilities and be instructed in the operation of the truck and shall be familiar with the operator manual. The driver shall be afforded all due rights. Safety shoes must be worn for pedestrian operated trucks. Unauthorised Use of Truck: The driver is responsible for the truck during the time it is in use. The drive must prevent unauthorised persons from driving or operating the truck. Do not carry passengers or lift other people. Damage and aults: The supervisor must be immediately informed of any damage or faults to the forklift truck or attachment. Trucks which are unsafe for operation (e.g. wheel or brake problems) must not be used until they have been rectified. Repairs: The driver must not carry out any repairs or alterations to the forklift truck without the necessary training and authorisation to do so. The driver must never disable or adjust safety mechanisms or switches. M Hazardous area: A hazardous area is defined as the area in which a person is at risk due to truck movement, lifting operations, the load handler (e.g. forks or attachments) or the load itself. This also includes areas which can be reached by falling loads or lowering operating equipment. Unauthorised persons must be kept away from the hazardous area. Where there is danger to personnel, a warning must be sounded with sufficient notice. If unauthorised personnel are still within the hazardous area the truck shall be brought to a halt immediately. Safety Devices and Warning Signs: Safety devices, warning signs and warning instructions shall be strictly observed. Trucks with reduced headroom are equipped with a warning sign within the driver's line of sight. The max. recommended body size indicated on this sign must be observed GB E 1

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36 2 Controls and Displays Item Control / Display unction 1 Soot filter indicator t 2 Engine oil pressure indicator t 3 Charging current indicator t Indicates that the soot filter is contaminated. When lit, indicates insufficient engine lubricant oil pressure. When lit, indicates that the battery is not charged. 4 Transmission oil temperature indicator t When lit, indicates that the transmission oil temperature is too high. 5 Parking brake indicator t When lit, indicates that the parking brake is applied. 6 uel supply indicator (DG) t When lit, indicates the fuel supply is too low. 7 Brake fluid indicator t 8 Air filter indicator t 9 Diesel filter indicator t When lit, indicates the brake fluid level is too low. When lit, indicates that the air filter is contaminated. When lit, indicates that the diesel filter is contaminated. 10 Coolant temperature indicator t Indicates the coolant temperature Time / service hours display Indicator control light t Indicates the time or number of service hours operated. t Shows the indicator status (right/left). 13 Preheat control light (DG) t 14 Neutral position t Indicates the operation of the cold start mechanism. When lit, indicates that the travel direction switch is in neutral (see Neutral Interlock in this chapter) 0406.GB 15 uel display (DG) t Indicates how much fuel is left in the tank. E 3

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38 Item Control / Display unction 16 Parking brake lever Applies / releases parking brake. To engage, turn switch to position 1. t To release, turn switch to position 0. Pull up lever to engage. Push lever forward to release. 17 Steering wheel t Steers truck in desired direction. 18 Steering column adjusting lever t Adjusts the steering column tilt. 19 Ignition / starter switch Switches power supply on and off. Starts and stops the engine. Removing the t ignition key prevents the truck from being switched on by unauthorised personnel. 20 Options switch t Options 21 Brake pedal Standard emergency braking 22 Accelerator pedal Controls engine speed / travel and lift t speed. 23 Auxiliary hydraulics (ZH1) o Moves the forks to the right / left. Sideshift 24 Auxiliary hydraulics (ZH2) o Intended for hydraulic attachments. 25 Mast tilt control lever Tilts the mast forward and backward. To tilt the mast forward: push the lever t forward. To tilt the mast back: pull the lever back. 26 Lift/lower control lever Raises and lowers the fork carriage To raise the fork carriage: pull the lever t back. To lower the fork carriage: push the lever forward. 27 Horn button t Triggers an audible warning. 28 Travel direction switch t Select the travel direction. 29 Slow travel / brake pedal 1st range: controls slow travel. t 2nd range: applies service brake GB E 5

39 t Z Z Travel direction switch When the travel direction switch (28) 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 engine will not start if a travel direction is pre-selected. Neutral Interlock 28 If the truck is abandoned without taking it out of gear, the truck is automatically set to neutal. This is shown by the neutral indicator in the dashboard. When travel is resumed (by sitting on the truck), the travel direction switch must be set to neutral (N). Travel can now resume. Heating and an Turn the thermostat control button (31) anti-clockwise to increase the temperature in the driver s cab. Press the switch (30) to activate the fan Horn To activate the horn press the warning button (27) in the hydraulic lever GB E 6

40 3 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. 3.1 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. The entire truck (in particular wheels and load lifting devices) must be inspected for damage. Make sure the load chains are evenly tensioned. Check the operation of the seat belt buckle and the belt returning to the retractor. or further information see section Trucks with reduced headroom X (o) M ailure to comply with the recommended body size may result in overload and constitute a danger to the driver, possibly resulting in permanent damage caused by an unhealthy posture and excessive physical exertions on the part of the driver. The owner must ensure that the truck operator does not exceed the maximum body size indicated. The owner must also check that the drivers can sit normally, in an upright position without having to exert himself GB E 7

41 Z Covers may need to be opened for the inspection. Checking the fuel supply - DG Set the ignition / starter key (19) to the I position. Read off the fuel supply from the fuel gauge (15). If necessary, add diesel (see Chapter D) o Testing the windscreen fluid level The windscreen wiper fluid container (32) is located at the rear right spar (33) of the cabin. Make sure there is sufficient windscreen fluid in the container. Top up if required. Use a windscreen fluid with antifreeze solution. Wheels and Tyres Check wheels and tyres for wear (see Chapter ). Measure the tyre pressure (pneumatic tyres only) (see Chapter B) GB E 8

42 3.3 Adjusting the driver s seat Standard seat MSG 65 To achieve optimal seat damping 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 (37) will be above the calibration line. If the arrow is facing too far to the left or right, the seat must be adjusted to the driver's weight. To do this, move the weight adjustment lever (36) approx. 90 forward. To set the seat to a lesser weight, push the weight adjustment lever (36) down. To set the seat to a greater weight, push the weight adjustment lever up. After adjusting, return the lever to its original position. Adjusting the backrest incline: Sit on the driver s seat. Lift up the backrest tilt adjuster (34) and adjust the incline of the backrest. Release the backrest tilt adjuster (34) to lock the backrest in position. Adjusting the seat position: 34 Pull up the longitudinal adjuster (35) and push the driver s seat forwards or backwards to the desired position. Engage the longitudinal adjuster (35) in position again. The longitudinal adjuster must be securely located in the desired position. The driver s seat setting must not be changed during travel GB E 9

43 3.4 Safety restraint belt Z The driver must check the operation and condition of the seat belt every day before using the industrial truck. aulty operation can only be detected in good time through regular inspection. 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. rozen belt locks or pulleys must be thawed out and dried to prevent them from freezing up again. The dry temperature of the warm air should not exceed +60 C. Do not alter the belt setting. This will increase the risk of malfunctioning. Always replace the safety restraint belt after an accident. Only original spare parts must be used for retrofits or repairs. Damaged or non-operational belts must only be replaced by contractual dealers or branches. Withdraw the belt completely and check the belt for possible fraying. Check the belt lock and make sure that the belt enters the retractor correctly. Check the cover for damage Testing the automatic blocking system: M M Z Park the truck in a horizontal position. orcibly extract the belt. The automatic system should lock the belt in the retractor. Open the engine bonnet approx. 30 degrees The automatic system should lock the belt in the retractor. Starting the industrial truck on steep slopes The automatic blocking system locks the belt in the retractor when the truck is positioned on a steep slope. This prevents the belt from being pulled out of the retractor. Carefully drive the truck off the slope and then put on the belt GB E 10

44 Procedure in unusual situations If the truck is about to tip over, never undo the restraint belt and try to jump out. Jumping increases the risk of injury. Correct procedure: Lean your upper body over the steering wheel. Grip the steering wheel with both hands and brace feet. Lean your body against the opposite direction of fall 0406.GB E 11

45 3.5 Adjusting the steering column Release the steering column adjusting lever (18) in the direction of the arrow (L). Tilt the steering column (38) forward or backward as required. Push the steering column adjusting lever in the direction of the arrow (). L GB E 12

46 3.6 Starting the truck Before starting the truck If the engine has not been run for several weeks or if the oil filter has been changed, start the engine (see section 3.7 or 3.8) and leave it to run in idle for a few minutes before starting. Z Z Z Start the engine The truck should only be operated from the driver s seat. Apply the parking brake. Set the travel direction switch (28) to neutral N. The engine will only start when the travel direction switch is in neutral. TG starting procedure (see section 3.7) DG starting procedure (see section 3.8) Key operated ignition Operation: O - I - All main circuits are cut out and the key can be removed. Controls and instruments are switched on. Engine preheating (diesel only). II - Starting the engine (automatically returns to the I position) GB E 13

47 3.7 Starting procedure for the TG 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 to the I position. Press the horn button (27) and test the horn. The charging current (3), engine oil pressure (2), neutral setting (14) and parking brake (5) indicators light up M Gently apply the accelerator pedal (22). Set the ignition / starter key now to the II position. Only apply the starter for a maximum of15 seconds without interruption. Before starting again, wait seconds and reset the ignition / starter switch to 0. Release the key as soon as the engine starts. It automatically returns to the I position. When working with LPG trucks it is essential to always observe the following safety regulations. If a truck will not start: 27 M Close the gas bottle shutoff valve. Turn off the ignition / starter O. Call for a trained, authorised customer service engineer. All indicators lights except for neutral setting (14) and parking brake (5) should go out as soon as the engine starts. If not, stop the engine immediately and rectify the fault GB E 14

48 3.8 Starting procedure for the DG Put the key in the ignition / starter switch (19). Set the ignition / starter key to the I position. Press the horn button (27) and test the horn. After setting the ignition / starter (19) to the I position, the charging current (3), engine oil pressure (2), neutral setting (14) and parking brake (5) indicators and the preheat (13) control light will light up. Apply the accelerator pedal (22) fully and wait until the preheat control light goes out Z The preheat time depends on the engine temperature, but normally lasts approx. 4 seconds. Set the ignition / starter key now to the II position. M Only apply the starter for a maximum of15 seconds without interruption. Before starting again, wait seconds and reset the ignition / starter switch to 0. M Release the key as soon as the engine starts. It automatically returns to the I position. All indicators lights except for neutral setting (14) and parking brake (5) should go out as soon as the engine starts. If not, stop the engine immediately and rectify the fault GB E 15

49 M After starting the engine, carry out a test run and check the following functions: Test the parking brake (16) and the slow travel / brake pedal (29). Test the engine speed with the accelerator pedal (22) over a range of speeds while checking the freedom of movement of the pedal. Test the operation of the raise/lower (26), tilt (25) and if applicable the attachment hydraulic control functions. Turn the steering wheel (17) as far as it will go in both directions and test the steering. 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 when the engine coolant temperature display (10) shows operating temperature. The truck is ready for operation once all the functional controls have been satisfactorily performed and operating temperature is reached GB E 16

50 3.9 Operational ault Displays When the following indicators are lit: Engine oil pressure (2), Charging current (3), Coolant temperature (10), Transmission oil temperature (4), the engine must be stopped immediately. M Z The engine should only be started again once the fault has been removed. or troubleshooting procedures, see section Check the fuel display during operation (15, DG only) GB E 17

51 3.10 Stopping the engine1. M Do not stop the engine 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 (28) to neutral. Apply the parking brake (16). Turn the ignition / starter switch (19) to the 0 position GB E 18

52 4 Industrial truck operation 4.1 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. Travel conduct: The driver 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. The driver must always observe an adequate braking distance between the forklift truck and the vehicle in front and must be in control of the truck at all times. Abrupt stopping (except in emergencies), rapid U turns and overtaking at dangerous or blind spots are not permitted. It is forbidden to lean out of or reach beyond the working and operating area. Travel visibility: The driver must look in the direction of travel and must always have a clear view of the route ahead. Loads which affect visibility must be positioned at the rear of the truck, or else the truck must reverse. If this is not possible, a second person must walk in front of the truck as a lookout. Negotiating slopes and inclines: Negotiating slopes or inclines is only permitted if such roads are clean and have a non-slip surface and providing such journeys are safely undertaken in accordance with the technical specifications for the truck in question. The truck must always be driven with the load unit facing uphill. The industrial truck must not be turned, operated at an angle or parked on inclines or slopes. Inclines must only be negotiated at slow speed, with the driver ready to brake at any moment. Negotiating lifts and docks: Lifts and docks must only be used if they have sufficient capacity, are suitable for driving on and authorised for truck traffic by the owner. The driver must satisfy himself of the above before entering these areas. The truck must enter lifts with the load in front and must take up a position which does not allow it to come into contact with the walls of the lift shaft.. People travelling in the lift with the forklift truck must only enter the lift after the truck has come to a halt and must exit the lift before the truck. Type of loads to be carried: The operator must make sure that the load is in a satisfactory condition. Do not carry loads unless they are positioned safely and carefully. Use suitable precautions, e.g. a load guard, to prevent parts of the load from tipping or falling down GB E 19

53 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. Do not permanently operate the truck with trailers. While the truck is pulling there must be no load on the forks. Do not exceed the maximum trailer load specified for the forklift truck for trailers with or without brakes. The specified trailer load only applies for the auxiliary coupling in the counterbalance of the forklift. If a different trailer coupling is used on the truck, the instructions of the coupling manufacturer must be observed.. After coupling and before starting the driver must ensure that the trailer coupling cannot become detached. Trucks pulling a load must be operated in such a manner that the trailing vehicle is driven safely and can be stopped at all times. Exhaust emissions: The truck must only be operated in well ventilated areas. If the truck is operated in enclosed areas, this can lead to a build-up of harmful exhaust emissions, resulting in dizziness, tiredness and even death. Emergency Disconnect with truck electronic system deactivation: All electrical functions are deactivated. Set the keyswitch to the O position. or trucks with a cabin or a canvas top the doors must be open. Press the pushbutton in the leg area. The engine cover opens, remove blue quick release lock from the battery pool. or gas operated trucks the shutoff valve on the gas tank or gas bottle must be tightened to prevent the gas from entering the engine area GB E 20

54 4.2 Travel Adapt the travel speed to the conditions of the travel lane, the work area and the load Set the travel direction switch (28) to neutral. Raise the fork carriage approx. 200 mm so that the fork tines are clear of the ground. Tilt the mast fully backward: Release the parking brake. orward travel Set the travel direction switch (28) forward. Slowly apply the accelerator pedal (22) until you reach the required travel speed. M Changing direction Only change direction when the truck has stopped. Set the travel direction switch (28) via neutral to the required direction. Slowly apply the accelerator pedal (22) until you reach the required travel speed. Reversing Make sure you have sufficient space to reverse into. Set the travel direction switch (28) to the rear. Accelerating Slowly apply the accelerator pedal (22) until the truck starts to move. Continue to depress the accelerator pedal. The engine and travel speeds increase. Braking The braking pattern of the truck depends to a large extent on the condition of the ground. The driver must take this into consideration when handling the truck. Carefully brake the truck to prevent the load from slipping GB E 21

55 Braking Take your foot off the accelerator pedal (22). Gently depress the slow travel / brake pedal (29). In the first pedal displacement zone, the flow of force is reduced by the torque converter. Continue to depress the slow travel / brake pedal (29). As you continue to depress, the truck automatically comes to a halt. Slow travel with the slow travel / brake pedal M Sensitive application of the slow travel / brake pedal (29) allows for excellent shunting in confined areas through slow travel. This operating mode can only be used for max. 5 seconds when the engine is running at high speed GB E 22

56 4.3 Steering Very little steering force is required for the hydrostatic steering, therefore turn the steering wheel (17) with caution. 4.4 Braking Operating Brake The slow travel / brake pedal hydraulically actuates the drum brakes of the front wheels. Apply the slow travel / brake pedal (29) until you feel the brake pressure. The flow of force is controlled in the power shift transmission in the first pedal displacement zone. As you continue to depress the pedal, the front wheel drum brakes are applied Alternatively you can use the brake pedal (21); this will actuate the drum brakes without decoupling the gear unit. Parking brake The parking brake lever mechanically actuates the drum brakes of the front wheels. Pull back the parking brake lever (16) beyond the pressure point as far as the stop. The parking brake is engaged and the parking brake lever is locked in this position. To release the parking brake, push the parking brake lever forward beyond the pressure point GB E 23