Doka 582778000 User manual

The Formwork Experts
03/2011
en-GB
999260002
Original Operating Instructions
Please retain for future reference
Shifting carriage TG
Art.n° 582778000
2003 models onward

2999260002 - 03/2011
Original Operating Instructions Shifting carriage TG
The Formwork Experts
Basic drawings of product
The Shifting carriage TG comes with 3 swivel casters
(ø20.0 cm), 2 of which have an integral parking brake.
a ... 1480 mm
b ... 190 mm to 950 mm
c ... 984 mm
d ... 1280 mm
e ... 1520 mm
f ... 270 mm
Data on rating plate
Doka Industrie Gmbh, A-3300 Amstetten
Designation: Shifting carriage TG
Max. load: 1000 kg
Dead weight: 168.0 kg
Art.n°: 582778000
Year of manufacture: see rating plate
Use for the designated purpose
only:
The Shifting carriage TG is a lifting appliance. It may
only be used for erecting, striking, and horizontal trav-
elling of Doka load-bearing towers Aluxo, Staxo and d2.
Before every use
➤Check for any signs of damage or visible deforma-
tion.
After taking delivery of the Shifting
carriage TG
Damage in transit
The Shifting carriage TG is given thorough inspection
and testing before being dispatched from the manufac-
turer's factory. In order to make sure that no damage
has occurred in transit, the Shifting carriage TG should
be inspected thoroughly as soon as it is delivered. Any
damage must be reported to the sender in writing. Until
this notice of defect has been dealt with, the Shifting
carriage TG may not be put into service.
Warranty conditions
The warranty shall lapse in the event of overloading or
other improper use of the equipment.
Familiarising personnel with the
Operating Instructions and the
required guidelines
Operator authorisation
The only persons allowed to operate the equipment are
those who have been given sufficient instruction in how
to use it, and who are familiar with all applicable oper-
ating manuals and regulations.
The client must obtain suitable evidence of the person-
nel's ability to operate and handle this vehicle.
Please also observe the VDMA guidelines on proper
use of industrial trucks for their designated purpose.
Max. capacity: 1000 kg per carriage
☞
●It is forbidden to use the product for anything
but its intended purpose!
●Doka accepts no liability for products that
have been altered!
●Repairs may only be carried out by the man-
ufacturer!
●Store lifting accessories in a dry and well
ventilated place, protected from the weather
and from all corrosive substances.
●Load-carrying equipment must be inspected
once a year by an expert.
d
ce
b
582778000-2
a
f
Any deformed and damaged parts must be
immediately replaced by an expert. For safety
reasons, only genuine OEM spares may be
used.
●Crack-free and notch-free welds
●No deformation
●Rating plate must be in place and clearly
legible

Original Operating Instructions Shifting carriage TG
3999260002 - 03/2011
The Formwork Experts
Positioning the Shifting carriage TG
When a load-bearing tower needs to be lifted, two
Shifting carriages TG are required.
➤Take the load off the load-bearing tower.
➤Push the Shifting carriages TG up against the end
faces of the load-bearing towers.
➤Lower the Shifting carriages TG
➤Unlock both safety bolts (C) by turning them and pull-
ing them out.
➤The slot-in lifting profile reaches under the bottom
cross-bar (E) of the tower frame.
➤The slot-in lifting profile reaches under the bottom
cross-bar of the tower frame.
➤Push both safety bolts (C) back in and turn them to
lock them.
➤Turn all the swivel casters to point in the direction in
which you want to wheel the load-bearing tower.
➤Push the feet into the frames and secure them to
prevent them dropping out.
➤Using both Shifting carriages TG, evenly lower the
load-bearing tower to the desired height.
Travelling the tower without an
Attachable drive unit DF
Travelling the tower with an
Attachable drive unit DF
a ... max. 50 mm
☞
●Max. gradient of floor 5%.
9260-201-01
A
a
A B
9260-207-01
a
☞
●Max. gradient of floor 3%.
●When travelling the tower with an Attachable
drive unit DF, both safety bolts must be
pushed in and locked in place.
AShifting carriage TG
BAttachable drive unit DF
CSafety bolt
DBottom cross-bar (load-bearing tower)
ESlot-in lifting profile
Follow the directions in the "Attachable drive
unit DF" Operating Instructions!
☞
Important points to remember when wheel-
ing load-bearing towers:
●Only use with Doka Aluxo, Staxo and d2
load-bearing towers.
●Ground clearance of the frame feet max.
50 mm.
●It is forbidden to use any other mechanical
assistance for the travelling operation!
Exception: Attachable drive unit DF
●Max. speed 4 km/h (walking pace)
●The floor must be stable, firm and sufficiently
smooth (e.g. concrete).
●Max. configuration that can be transported
using two Shifting carriages TG:
Tables with 3 cross-frames per section and a
max. height of 5.0 m.
●The conveyance of persons is forbidden - fol-
low the danger notice.
●Particular care is needed with:
- Height offsets
- Steps
- Break-throughs
- Strong wind
●Either bridge any openings in the floor with
sufficiently strong planking/boards secured
so that they cannot slip away to either side,
or close off openings with sufficiently strong
side railings!
●Keep the travel route clean and free of any
obstacles.
●It is forbidden for any other persons to stand
in the immediate danger zone (e.g. near the
frame feet).
●When hoisting the Shifting carriage TG by
crane, only use the lifting-bracket provided.
●For longer breaks between operations, or
when the Shifting carriages TG are perma-
nently parked, they must NOT be carrying a
load-bearing tower.
●After wheeling the Shifting carriage TG to its
new position, fix it with its parking brakes so
that it cannot be moved accidentally.
9260-206-01
C
D
E

4999260002 - 03/2011
Original Operating Instructions Shifting carriage TG
The Formwork Experts
Lifting and lowering (with/without
load)
Der Hubwagen TG ist mit einer von Hand bedienbaren
Hydraulikpumpe ausgestattet.
Stellungen des Zuggriffs
Normal lift
To shift the pump into the high-pressure position, lift the
trigger handle until the safety catch engages. In this
position, the rapid-action pump piston is disengaged.
With every stroke of the pump, the slot-in lifting profile
is raised 17 mm. Loads of up to 1000 kg can be raised
in this position.
Lowering
To lower the load, slowly pull up the trigger handle.
Slowly lower both Shifting carriages TG simultane-
ously. When this is done and you let go of the trigger
handle, this is automatically returned to the middle
position.
Hydraulic system - general notes
Venting
To vent the lifting cylinder, pump the slot-in lifting profile
all the way to the top and then rapidly lower it again.
Safety precautions
The overpressure valve is set in such a way that the
max. capacity of the Shifting carriage TG is 1000 kg.
It is forbidden to tamper with the setting screw on the
overpressure valve.
Maintenance
Change the hydraulic oil
●after every 1000 operating hours
●at least 1x a year
The hydraulic system is filled with a special low-temper-
ature oil that has a viscosity in accordance with ISO VG
10 (e.g. Aero Shell Fluid 4). The oil is additivised with:
Wynn's Hydraulic System Concentrate.
This concentrate is added in a mixing ratio of 2.5:100.
The concentrate lessens friction and wear-and-tear,
and gives protection against corrosion. A ready-to-use
hydraulic-oil / additive mixture is available from your
dealer.
Filling-quantity of hydraulic oil: 0.75 l. If the slot-in lifting
profile can be raised to the highest position, then there
is sufficient oil in the system.
Maintenance (general remarks)
Cleaning & maintenance
Clean the Shifting carriage TG whenever it has been
made dirty. Pay particular attention to the hydraulic sys-
tem, the moving parts of the guide mechanisms, the
bearing surfaces of the supporting frame, and the
swivel casters.
Before starting up at a new site
●Lubricate with grease via the lubricating nipples pro-
vided.
●Lubricate the load chain and the deflection pulleys
with lubricating grease.
Once a year, when lubricating the chain, inspect it care-
fully for any signs of alteration and damage.
Troubleshooting
The load is not being lifted, even though you
have made several attempts to "pump"
Possible causes:
●Load too heavy (> 1000 kg)
●Not enough hydraulic oil
●Hydraulic tubing is leaking
●Air trapped in the hydraulic system
●Valve control system not working (low-pressure
valve core)
●Faulty over-pressure valve (integrated in the low-
pressure valve core)
●The valve-face does not shut tightly (high-pressure
valve core)
☞
Moving the unloaded shifting carriage:
●Be particularly careful when wheeling the
unloaded shifting carriage backwards - it can
easily topple over!
ADrawbar handle
BTrigger handle
CSafety catch
9260-202-01
A
B
C
9260-204-01
9260-205-01
CAUTION
Hydraulic oil is harmful to the environment!
➤For this reason, always properly seal any
leaks immediately!
➤Intercept any leaking hydraulic oil and dis-
pose of it in accordance with the applicable
regulations!

Original Operating Instructions Shifting carriage TG
5999260002 - 03/2011
The Formwork Experts
The load is not being raised to the maximum
height
Possible causes:
●Not enough hydraulic oil
The load can only be "pumped upwards" with
great difficulty
Possible causes:
●The releasing pin is stuck in the control valve (in the
rubber knob or in the valve housing)
●The valve control system is faulty (low-pressure-
valve core)
The load is being lowered of its own accord
Possible causes:
●Hydraulic tubing is leaking
●The valve control system is faulty (low-pressure-
valve core)
●The valve-face does not shut tightly (high-pressure
valve core)
The load cannot be lowered
Possible causes:
●The setting of the lowering mechanism has been
misadjusted
●The releasing pin is stuck in the control valve (in the
rubber knob or in the valve housing)
●The valve control system is faulty (low-pressure-
valve core)
The load is being lifted jerkily and/or
"bounces"
Possible causes:
●Air trapped in the hydraulic system
●Lowering mechanism is not optimally adjusted
Component overview
9260-801
J
ASafety catch
BTrigger handle
CFilling opening
DBleeder screw
EPump piston
FValve block
GHigh-pressure valve core
HLow-pressure valve core
9260-802
E
F

6999260002 - 03/2011
Original Operating Instructions Shifting carriage TG
The Formwork Experts
© by Doka Industrie GmbH, A-3300 Amstetten
EC Declaration of Conformity
pursuant to EC Directive 2006/42/EC.
The manufacturer declares that by reason of its conception and
design, the following product
Shifting carriage TG, Art.n° 582778000
conforms – in the version marketed by ourselves – to the pertinent
fundamental health and safety stipulations of the relevant EC Direc-
tives.
The following harmonized Standards were applied:
●EN ISO 12100-1:2009
●EN ISO 12100-2:2009
●EN 349:1993+A1:2008
Person authorised to compile technical documentation
(pursuant to European Directive on Machinery Annex II):
Ing. Johann Peneder
Josef Umdasch Platz 1
A-3300 Amstetten
Amstetten, 03.03.2011
Doka Industrie GmbH
Josef Umdasch Platz 1
A-3300 Amstetten
Ludwig Pekarek,
Executive Manager
Johann Peneder, Authorised
Officer, Head of Product and
Service Development