Jungheinrich DFG 540 User manual


11.09 -11.09 -
08.1208.12
5116769051167690
DFG / TFG 540 - 550DFG / TFG 540 - 550
Operating instructionsOperating instructions  GG
DFG 545DFG 545
DFG 550DFG 550
TFG 540TFG 540
TFG 545TFG 545
TFG 550TFG 550
DFG 540DFG 540
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Declaration of ConformityDeclaration of Conformity
Jungheinrich AG, Am Stadtrand 35, D-22047 HamburgJungheinrich AG, Am Stadtrand 35, D-22047 Hamburg
Manufacturer or agent acting in the European UnionManufacturer or agent acting in the European Union
Additional informationAdditional information
On behalf ofOn behalf of
DateDate

EU Conformity DeclarationEU Conformity Declaration
The undersigned hereby declare that the powered industrial truck described below inThe undersigned hereby declare that the powered industrial truck described below in
detail complies with the European Directives 2006/42/EC (Machinery Directive) anddetail complies with the European Directives 2006/42/EC (Machinery Directive) and
2004/108/EEC (Electromagnetic Compatibility - EMC) including amendments as well2004/108/EEC (Electromagnetic Compatibility - EMC) including amendments as well
as the legislative decree to incorporate the directives in national as the legislative decree to incorporate the directives in national law. The signatorieslaw. The signatories
are in each case individually authorized to compile the technical documents.are in each case individually authorized to compile the technical documents.
TTyyppee OOppttiioonn SSeerriiaal l nnoo.. YYeeaar r ooff
manufacturemanufacture
DFG 540DFG 540
DFG 545DFG 545
DFG 550DFG 550
TFG 540TFG 540
TFG 545TFG 545
TFG 550TFG 550
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ForewordForeword
Notes on the operating instructionsNotes on the operating instructions
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provideThe present ORIGINAL OPERATING INSTRUCTIONS are designed to provide
sufficient instruction for the safe operation of the industrial truck. The information issufficient instruction for the safe operation of the industrial truck. The information is
provided clearly and concisely. The chapters are arranged by letter and the pages provided clearly and concisely. The chapters are arranged by letter and the pages areare
numbered continuously.numbered continuously.
The operator manual details different industrial truck models. When operating andThe operator manual details different industrial truck models. When operating and
servicing the industrial truck, make sure that the particular section applies to yourservicing the industrial truck, make sure that the particular section applies to your
truck model.truck model.
Our trucks are subject to ongoing development. Jungheinrich reserves the right toOur trucks are subject to ongoing development. Jungheinrich reserves the right to
alter the design, equipment and technical features of the system. No guarantee ofalter the design, equipment and technical features of the system. No guarantee of
particular features of the truck should therefore be assumed from the presentparticular features of the truck should therefore be assumed from the present
operating instructions.operating instructions.
Safety notices and text mark-upsSafety notices and text mark-ups
Safety instructions and important explanations are indicated by the followingSafety instructions and important explanations are indicated by the following
graphics:graphics:
DANGER!
DANGER!
Indicates an extremely hazardous situation. Failure to comply with this Indicates an extremely hazardous situation. Failure to comply with this instruction willinstruction will
result in severe irreparable injury and even death.result in severe irreparable injury and even death.
WARNING!WARNING!
Indicates an extremely hazardous situation. Failure to comply with this instructionIndicates an extremely hazardous situation. Failure to comply with this instruction
may result in severe irreparable injury may result in severe irreparable injury and even death.and even death.
CAUTION!CAUTION!
Indicates a hazardous situation. Failure to comply with this instruction may result inIndicates a hazardous situation. Failure to comply with this instruction may result in
slight to medium injury.slight to medium injury.
NOTE
NOTE
Indicates a material hazard. Failure to comply with this instruction may result inIndicates a material hazard. Failure to comply with this instruction may result in
material damage.material damage.
ZZ Used before notices and explanations.Used before notices and explanations.
CopyrightCopyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.Copyright of these operating instructions remains with JUNGHEINRICH AG.
tt Indicates standard equipmentIndicates standard equipment
oo Indicates optional equipmentIndicates optional equipment
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66
Jungheinrich AktiengesellschaftJungheinrich Aktiengesellschaft
Am Stadtrand 35Am Stadtrand 35
22047 Hamburg - Germany22047 Hamburg - Germany
Tel: [phone]Tel: [phone]
www.jungheinrich.comwww.jungheinrich.com
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ContentsContents
AA Correct Use and AppCorrect Use and Applicationlication ...................................................................................................... 1111
11 GeGeneneral..ral...................................................................................................................................................................................................... 1111
22 CoCorrrrecect t apappliplicacatition..on.................................................................................................................................................................... 1111
33 ApApprprovoved ed apapplplicicatatioion n cocondndititioions..ns.......................................................................................................................... 1212
44 PrPropopririetetor or rerespspononsisibibililititieses ................................................................................................................................................ 1313
55 AdAddiding ang attttacachmhmenents ats andnd/o/or acr accecessssororieies..s.................................................................................................. 1313
BB TrTrucuck k DeDescscririptptioionn ........................................................................................................................................ 1515
11 ApApplplicicatatioionn .............................................................................................................................................................................................. 1515
1.1.11 TrTrucuck modk modelels and rs and ratated caed capapacicity..ty........................................................................................................................ 1515
22 AsAssesembmblilies aes and Fnd Fununctctioionanal Del Descscririptptioion..n.................................................................................................... 1616
2.2.11 AsAssesembmbly ly OvOvererviviewew .................................................................................................................................................................. 1616
2.2.22 FuFuncnctitiononal al DeDescscririptptioionn .......................................................................................................................................................... 1717
33 TeTechchninicacal l SpSpececifificicatatioionsns .................................................................................................................................................... 1919
3.3.11 PePerfrforormamancnce e dadatata ........................................................................................................................................................................ 1919
3.23.2 DimDimensensionionss............................................................................................................................................................................................ 2121
3.33.3 WeiWeightghts....s.................................................................................................................................................................................................... 2323
3.3.44 MaMast st veversrsionionss .................................................................................................................................................................................... 2424
3.53.5 TyrTyre e typtype....e................................................................................................................................................................................................ 2626
3.63.6 EngEngine ine DatDataa.......................................................................................................................................................................................... 2727
3.73.7 EN EN nornorms...ms............................................................................................................................................................................................... 2828
3.3.88 CoCondndititioions ns of of use...use....................................................................................................................................................................... 2929
3.3.99 ElElecectrtricical al rerequiquireremementntss ........................................................................................................................................................ 2929
44 IdIdenentitifificacatition pon poiointnts ans and dad data pta plalatetess ................................................................................................................ 3030
4.4.11 DaData ta plplateate ................................................................................................................................................................................................ 3232
4.4.22 TrTrucuck k cacapapacicity ty plplatate...e............................................................................................................................................................... 3333
4.4.33 AtAttatachchmement capnt capacacitity platy platee .............................................................................................................................................. 3434
55 StStababililitityy ........................................................................................................................................................................................................ 3434
CC TrTrananspsporort t anand d CoCommmmisissisiononiningg ................................................................................................ 3535
11 TrTrananspsporortt .................................................................................................................................................................................................. 3535
22 TrTrucuck k laladedenn............................................................................................................................................................................................ 3535
2.2.11 CeCentntre ore of grf gravavitity of ty of the the truruckck ...................................................................................................................................... 3535
2.2.22 LiLiftftining the tg the trucruck by crk by crananee .................................................................................................................................................. 3636
2.2.33 LoLoadadining wig with ath anonothther ier indndusustrtriaial trl trucuckk .............................................................................................................. 3737
33 SeSecucuriring ng ththe te truruck ck duduriring ng trtrananspsporortt .................................................................................................................. 3838
44 UsUsining tg the he TrTrucuck fk for or ththe Fe Firirst st TiTimeme ...................................................................................................................... 3939
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88
DD FuFuelelliling ng ththe e TrTrucuck..k...................................................................................................................................... 4141
11 GeGenenerarall........................................................................................................................................................................................................ 4141
1.1.11 SaSafefety ty reregugulalatitionons s fofor r hahandlndlining g didiesesel el fufuel el anand d LPLPG...G............................................................. 4141
1.1.22 LPLPG G sysyststem reliem relief valvef valvee...................................................................................................................................................... 4343
22 AdAddiding ng didieseesell ...................................................................................................................................................................................... 4444
2.12.1 FueFuellillingng ........................................................................................................................................................................................................ 4444
2.2.22 FuFuelelliling wing with fueth fuel conl contataininererss ........................................................................................................................................ 4545
33 LPLPG G cocontntainainerers....s............................................................................................................................................................................ 4646
3.13.1 LPG LPG bottbottles....les........................................................................................................................................................................................ 4646
3.3.22 LiLiququid id gas gas tatanknk ................................................................................................................................................................................ 4949
44 FuFuel el lelevevel l inindidicacator.tor..................................................................................................................................................................... 5050
4.14.1 DisDisplaplay y unitunit............................................................................................................................................................................................ 5050
4.4.22 LeLevevel l inindidicacatotor r fofor r LPLPG G bobottttleles s ((oo).....)............................................................................................................... 5050
EE OpOpereratatioionn ................................................................................................................................................................ 5151
11 SaSafefety ty ReRegugulalatitionons s fofor r ththe e OpOpereratatioion n of of ththe e FoForkrklilift ft TrTrucuck..k............................................ 5151
22 DiDispsplalays ys anand d CoContntrorols.ls........................................................................................................................................................... 5353
2.12.1 DisDisplaplay y unitunit............................................................................................................................................................................................ 5555
2.2.22 InInststrurumement nt papanenel sl swiwitctchehes (s (oo)) ................................................................................................................................ 5757
2.2.33 TrTravavel del dirirecectition son swiwitctch/h/gegear sar selelecectotorr .............................................................................................................. 5858
33 PrPrepepararining thg the Tre Trucuck fok for Opr Opereratatioionn ...................................................................................................................... 5959
3.3.11 ChChececks ks anand od opeperaratitionons ts to bo be pe pererfoformrmed ed bebefofore re ststarartiting ng dadailily oy opeperaratitionon .. 5959
3.23.2 EntEntry ry and and exiexit....t.................................................................................................................................................................................. 6060
3.3.33 TrTrucucks ks wiwith th rereduduceced d heheadadroroom om X X ((oo)) .......................................................................................................... 6060
3.3.44 SeSettttining up the opg up the opereratoator posr posititioion...n........................................................................................................................... 6161
3.53.5 SeaSeat t BeltBelt.................................................................................................................................................................................................... 6565
44 InInduduststririal al TrTrucuck k OpOpereratatioionn .............................................................................................................................................. 6666
4.4.11 SaSafefety rty regegululatatioions fons for trr trucuck opk opereratatioionn............................................................................................................ 6666
4.4.22 PrPrepepararining thg the tre trucuck fok for opr operaeratitionon.......................................................................................................................... 6868
4.4.33 PaParkrkining the trug the truck seck secucurerelyly .............................................................................................................................................. 7171
4.4.44 EmEmerergegencncy y DiDiscscononnenect..ct...................................................................................................................................................... 7272
4.54.5 TraTravel..vel............................................................................................................................................................................................................ 7373
4.64.6 SteSteerieringng ...................................................................................................................................................................................................... 7474
4.4.77 BrBrakakeses .......................................................................................................................................................................................................... 7575
4.4.88 AdAdjujuststining g ththe e foforkrkss ...................................................................................................................................................................... 7777
4.4.99 ReReplplacacining g ththe e foforkrkss.................................................................................................................................................................... 7878
4.14.100 LifLiftinting, g, tratranspnsportiorting ng and and depdeposiositinting g loaloadsds ................................................................................................ 7979
4.4.1111 OpOpereratatining thg the lie lift mft mecechahaninism asm and ind intntegegrarateted atd attatachchmementntss ............................................ 8181
4.4.1212 SaSafefety inty inststruructctioions fons for oper operaratiting adng addidititiononal atal attatachchmementntss .................................................. 8686
4.4.1313 OpOpereratatining adg addidititionaonal atl attatachchmementnts fos for thr the SOe SOLOLO-PI-PILOLOTT .................................................... 8989
4.14.144 FitFittinting g addadditiitionaonal l attattachachmenments......ts.............................................................................................................................. 9191
55 ToTowiwing ng trtrailailererss .................................................................................................................................................................................. 9393
66 OpOptitiononal al eqequiuipmpmenentt .................................................................................................................................................................. 9595
6.16.1 SteSteel el cab..cab.................................................................................................................................................................................................. 9595
6.6.22 SlSlididining g wiwindndowowss .............................................................................................................................................................................. 9595
6.6.33 PaPanenel l dodooror .............................................................................................................................................................................................. 9696
6.6.44 BaBackckrerest st exextetensnsionion .................................................................................................................................................................... 9696
6.56.5 HeaHeatintingg ........................................................................................................................................................................................................ 9797
6.6.66 ReRemomovavablble e loload backad backrerestst ................................................................................................................................................ 9999
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6.6.77 FiFire re exextitingunguisisheherr ............................................................................................................................................................................ 9999
6.6.88 RoRockckiningeger cour couplplining witg with hanh hand levd lever or rer or rememotote cone contrtrol.ol......................................................... 101000
6.96.9 CamCamera era syssystemtem .............................................................................................................................................................................. 101101
6.16.100 OptOptionional eal equiquipmepment fnt for wor workorking ing in ain areareas wis with hth heaveavy acy accumcumulaulatiotion of n of dustdust 102102
6.16.111 TilTilt t angangle le disdisplaplayy............................................................................................................................................................................ 102102
6.16.122 SpeSpeed ed redreductuctionion ............................................................................................................................................................................ 103103
6.16.133 TraTransmnsmissission ion bloblock......ck.............................................................................................................................................................. 103103
6.16.144 RevReversersing ing BloBlock...ck........................................................................................................................................................................... 103103
6.16.155 DirDirectection ion swiswitch mtch mounounted ted to tto the she steeteerinring cog columlumnn ........................................................................ 103103
6.16.166 TemTemperperatuature re concontrotrol l syssystem.....tem................................................................................................................................... 104104
6.16.177 ConControtrol layout with Carl layout with Cardan funcdan functiotion....n.............................................................................................................. 105105
77 TrTrououblbleseshohoototiningg.............................................................................................................................................................................. 101066
7.17.1 TroTroublublesheshootooting.....ing......................................................................................................................................................................... 106106
7.7.22 OpOpereratatining thg the tre truck wuck witithohout iut its ots own dwn dririve sve sysystetemm ........................................................................ 101099
FF InInduduststririal al TrTrucuck k MaMainintetenanancncee .................................................................................................... 111133
11 OpOpereratatioionanal Safl Safetety and Envy and Envirirononmementntal Pral Prototecectition.on..................................................................... 111133
22 MaMainintetenanancnce e SaSafefety ty ReRegugulalatitions..ons........................................................................................................................ 111144
33 SeServrvicicining g anand d InInspspecectitionon .................................................................................................................................................. 111199
44 MaMainintetenannance ce checheckcklilistst .......................................................................................................................................................... 121200
55 LuLubrbricicanants ts anand d LuLubrbricicatatioion n ScSchehedudulele ............................................................................................................ 121288
5.15.1 HanHandlidling ng conconsumsumableables s safsafely.....ely............................................................................................................................... 128128
5.25.2 LubLubricricatiation on SchScheduledulee .............................................................................................................................................................. 130130
5.35.3 ConConsumsumablables...es................................................................................................................................................................................... 131131
66 MaMainintetenanancnce ae and nd rerepapairirss .................................................................................................................................................. 131333
6.6.11 PrPrepepararining thg the tre trucuck fok for mar mainintetenanancnce ane and red repapairirss ........................................................................ 131333
6.26.2 OpeOpeninning g the the engengine ine covcoverer .............................................................................................................................................. 134134
6.36.3 CheCheckicking ng the the wheewheel l attattachachmenments...ts....................................................................................................................... 135135
6.46.4 HydHydrauraulic lic systsystemem .......................................................................................................................................................................... 136136
6.56.5 EngEngine ine maimaintenntenancancee................................................................................................................................................................ 139139
6.66.6 CheCheckicking ng eleelectrctricaical l fusfuses......es............................................................................................................................................ 151151
6.76.7 StaStarterter battr battery....ery................................................................................................................................................................................ 156156
6.86.8 ExhExhausaust t syssystemtem .............................................................................................................................................................................. 157157
6.96.9 SeaSeat t belbelt t maimaintentenannance......ce.................................................................................................................................................... 158158
6.16.100 TraTransmnsmississionion ...................................................................................................................................................................................... 158158
6.16.111 BraBrakeke .............................................................................................................................................................................................................. 159159
6.16.122 ResRestortoring ing the the trutruck ck to to serservicvice ae aftefter mr mainaintentenancance ae and nd reprepairairss .................................. 160160
77 DeDecocommmmisissisiononining g ththe e ininduduststririal al trutruckck ............................................................................................................ 161611
7.17.1 PriPrior or to to decdecommommississionioninging ................................................................................................................................................ 162162
7.27.2 DurDuring ing decdecommommississionioninging .................................................................................................................................................. 162162
7.7.33 ReReststororining the tg the truruck to sck to serervivice afce afteter decr decomommimissssionioniningg .......................................................... 161633
88 SaSafefety ty teteststs s to to be be peperfrforormemed d at at inintetervrvalals s anand d afafteter r ununususuaual l inincicidedentntss .......... 161644
99 FiFinanal l dede-c-comommimissssioioniningng, d, disispoposasal...l..................................................................................................................... 161655
1010 HuHumaman n vivibrbratatioion n memeasasururememenentt .............................................................................................................................. 165165
1111 HUHUSS FSS FS - MK S - MK SeSeriries Des Dieiesesel Pal Partrticicle Fle Fililteter Opr Opereratatining Ing Inststruructctioions (ns (oo) .) . 116666
11.11.11 ImpImportortant Generaant General l InsInstrutructictionsons ................................................................................................................................ 166166
11.11.22 ImpImportortant ant safsafety ety insinstrutructictions..ons...................................................................................................................................... 166166
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1010
11.11.33 FunFunctictionaonal l DesDescricriptiptionon .......................................................................................................................................................... 167167
11.11.44 HUSHUSS S ConControl Operatrol Operatiotionn .................................................................................................................................................. 168168
11.11.55 HUSHUSS ContrS Control Operol Operatiating Instrng Instructuctionionss............................................................................................................ 169169
11.11.66 RegRegeneeneratirationon ...................................................................................................................................................................................... 170170
11.11.77 MaiMaintentenannancece ........................................................................................................................................................................................ 171171
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AA Correct Use and ApplicationCorrect Use and Application
11 GGeenneerraall
The industrial truck described in the present operating instructions is designed forThe industrial truck described in the present operating instructions is designed for
lifting, lowering and transporting load units.lifting, lowering and transporting load units.
It must be used, operated and serviced in accordance with the present instructions.It must be used, operated and serviced in accordance with the present instructions.
Any other type Any other type of use is beyond of use is beyond the scope of application the scope of application and can result in and can result in damage todamage to
personnel, the industrial truck or property.personnel, the industrial truck or property.
22 CCoorrrreecct at apppplliiccaattiioonn
NOTE
NOTE
The maximum load and load distance are indicated The maximum load and load distance are indicated on the load chart and must not on the load chart and must not bebe
exceeded.exceeded.
The load must rest on the load The load must rest on the load handler or be lifted by an handler or be lifted by an attachment approved by theattachment approved by the
manufacturer.manufacturer.
The load must rest on the back The load must rest on the back of the fork carriage and of the fork carriage and centrally between the forks.centrally between the forks.
–– Lifting and lowering loads.Lifting and lowering loads.
–– Transporting lowered loads over short distances.Transporting lowered loads over short distances.
–– Do not travel with a raised load (>30 cm).Do not travel with a raised load (>30 cm).
–– Do not carry or lift passengers.Do not carry or lift passengers.
–– Do push or pull load units.Do push or pull load units.
–– Occasional towing of trailer loads.Occasional towing of trailer loads.
–– When towing trailer loads the load must be secured on the trailer.When towing trailer loads the load must be secured on the trailer.
–– The permissible trailer load must not be exceeded.The permissible trailer load must not be exceeded.
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