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 ofOn 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 yourservicing 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 ofalter 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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Jungheinrich AktiengesellschaftJungheinrich Aktiengesellschaft
Am Stadtrand 35Am Stadtrand 35
22047 Hamburg - Germany22047 Hamburg - Germany
Tel: +49 (0) 40/6948-0Tel: +49 (0) 40/6948-0
www.jungheinrich.comwww.jungheinrich.com
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ContentsContents
AA 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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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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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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AA Correct Use and ApplicationCorrect Use and Application
11 GGeenneerraall
The industrial truck described in the present operating instructions is designed forThe 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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33 AApppprroovveed d aapppplliiccaattiioon n ccoonnddiittiioonnss
DANGER!
DANGER!
Do not exceed the permissible surface and spot load limits on the travel routes.Do not exceed the permissible surface and spot load limits on the travel routes.
At blind spots get a second person to assist.At blind spots get a second person to assist.
The driver must ensure that the loading dock / ramp cannot move or come looseThe driver must ensure that the loading dock / ramp cannot move or come loose
during loading / unloading.during loading / unloading.
–– Operation in industrial and commercial environments.Operation in industrial and commercial environments.
–– Permissible temperature range -20 to 40°C.Permissible temperature range -20 to 40°C.
–– Operation only on secure, level surfaces with sufficient capacity.Operation only on secure, level surfaces with sufficient capacity.
–– Operation only on routes that are visible and approved by the proprietor.Operation only on routes that are visible and approved by the proprietor.
–– Negotiating inclines up to a maximum of 15 %.Negotiating inclines up to a maximum of 15 %.
–– Do not negotiate inclines crosswise or at an angle. Transporting loads downhill.Do not negotiate inclines crosswise or at an angle. Transporting loads downhill.
–– Operation in partially public traffic.Operation in partially public traffic.
WARNING!WARNING!
Extreme conditionsExtreme conditions
Special equipment and authorisation are required if the truck is to be constantlySpecial equipment and authorisation are required if the truck is to be constantly
used in extreme conditions, especially in dusty or corrosive atmospheres.used in extreme conditions, especially in dusty or corrosive atmospheres.
The truck is not authorised for use The truck is not authorised for use in areas at risk of explosion.in areas at risk of explosion.
In adverse weather conditions (thunder, lightning) the industrial truck must not beIn adverse weather conditions (thunder, lightning) the industrial truck must not be
operated outside or in endangered areas.operated outside or in endangered areas.
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44 PPrroopprriieettoor r rreessppoonnssiibbiilliittiieess
For the purposes of the present operating instructions the “proprietor” is defined asFor the purposes of the present operating instructions the “proprietor” is defined as
any natural or legal person who either uses the industrial truck himself, or on whoseany natural or legal person who either uses the industrial truck himself, or on whose
behalf it is used. In special cases behalf it is used. In special cases (e.g. leasing or renting) the (e.g. leasing or renting) the proprietor is consideredproprietor is considered
the person who, in accordance with existing contractual agreements between thethe person who, in accordance with existing contractual agreements between the
owner and user of the industrial truck, is charged with operational duties.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 forThe proprietor must ensure that the industrial truck is used only for the purpose for
which it is intended and that there is no danger to life and limb of the user and thirdwhich it is intended and that there is no danger to life and limb of the user and third
parties. Furthermore, accident prevention regulations, safety regulations andparties. Furthermore, accident prevention regulations, safety regulations and
operating, servicing and repair guidelines must be followed. The proprietor mustoperating, servicing and repair guidelines must be followed. The proprietor must
ensure that all users have read and understood these operating instructions.ensure that all users have read and understood these operating instructions.
NOTE
NOTE
Failure to comply with the operating instructions shall invalidate the warranty. TheFailure to comply with the operating instructions shall invalidate the warranty. The
same applies if improper work is carried out on the truck by the customer or thirdsame applies if improper work is carried out on the truck by the customer or third
parties without the permission of the manufacturer.parties without the permission of the manufacturer.
55 AAddddining g aattttaacchhmmeenntts s aannd/d/oor r aacccceessssoorrieiess
Adding accessoriesAdding accessories
The mounting or installation of additional equipment which affects or enhances theThe mounting or installation of additional equipment which affects or enhances the
performance of the forklift truck requires the written permission of the manufacturer.performance of the forklift truck requires the written permission of the manufacturer.
Local authority approval may also need to be obtained.Local authority approval may also need to be obtained.
Local authority approval does not however constitute the manufacturer’s approval.Local authority approval does not however constitute the manufacturer’s approval.
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BB TTrruucck k DDeessccrriippttiioonn
11 AApppplliiccaattiioonn
The DFG / TFG 540 - 550 is a four-wheel IC motor sit-down forklift truck. The DFGThe DFG / TFG 540 - 550 is a four-wheel IC motor sit-down forklift truck. The DFG
series are diesel engine trucks, while the series are diesel engine trucks, while the TFG series are fitted with a petrol engine TFG series are fitted with a petrol engine forfor
LPG operation.LPG operation.
The DFG / TFG 540 - 550 is a cantilever counterbalanced truck which can lift,The DFG / TFG 540 - 550 is a cantilever counterbalanced truck which can lift,
transport and deposit loads using the load handler attached in front.transport and deposit loads using the load handler attached in front.
Closed bottom pallets can also be lifted.Closed bottom pallets can also be lifted.
The DFG / TFG 540 - 550 is equipped with a hydrodynamic drive. The left pedal is aThe DFG / TFG 540 - 550 is equipped with a hydrodynamic drive. The left pedal is a
combination of crawl speed and brake pedal, and activates the rapid lift functioncombination of crawl speed and brake pedal, and activates the rapid lift function
during slow travel. The middle pedal is a standard brake during slow travel. The middle pedal is a standard brake as well as emergency brakeas well as emergency brake
pedal.pedal.
1.1.11 TrTrucuck mk mododelels s anand rd ratated ed cacapapacicityty
The rated capacity depends on the model. The rated capacity can be derived fromThe rated capacity depends on the model. The rated capacity can be derived from
the model description.the model description.
The rated capacity does not generally match the permissible capacity. The capacityThe rated capacity does not generally match the permissible capacity. The capacity
can be found on the load chart attached to the rack.can be found on the load chart attached to the rack.
DFG540DFG540
DDFFGG MMooddeel l nnaammee
55 SSeerriieess
4400 RRaatteed d ccaappaacciitty y x x 11000 0 kkgg
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22 AAsssseemmbbllieies s aannd d FFuuncncttioionnaal l DDeessccrriiptptiioonn
22..11 AAsssseemmbblly Oy Ovveerrvviieeww
22 55 4433
99
77
66
88
111112121133 11001414
11
IItteemm DDeessccrriippttiioonn IItteemm DDeessccrriippttiioonn
11 tt OOvveerrhheeaad d gguuaarrdd 88 tt DriveDrive
22 tt DDrriivveerr''s s sseeaatt 99 tt Lifting device controlLifting device control
33 tt SStteeeerriinng g wwhheeeell 1100 tt Engine coverEngine cover
44 tt MMaasstt 1111 tt Steer axleSteer axle
55 tt Control Control / / display display unit unit 1212 tt Trailer couplingTrailer coupling
66 tt Fork Fork carriage carriage 1313 tt CounterweightCounterweight
77 tt FFoorrk k ttiinneess 1144 tt LPG bottle (TFG only)LPG bottle (TFG only)
tt= Standard equipment= Standard equipment oo= Optional equipment= Optional equipment
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22..22 FFuunnccttioionnaal Del Dessccrriippttiioonn
ChassisChassis
The chassis, in conjunction with the counterweight, forms the supporting baseThe chassis, in conjunction with the counterweight, forms the supporting base
structure of the truck. It is used structure of the truck. It is used to support the main components.to support the main components.
The hydraulic oil reservoir is integrated on the right-hand side and the fuel tank for theThe hydraulic oil reservoir is integrated on the right-hand side and the fuel tank for the
DFG series is on the left side in the chassis.DFG series is on the left side in the chassis.
Operator position and overhead guardOperator position and overhead guard
The overhead guard (1) comes in a range of models and protects the driver fromThe overhead guard (1) comes in a range of models and protects the driver from
falling objects and other external influences.falling objects and other external influences.
All All the the controls controls are are ergonomically ergonomically arranged. arranged. The The steering steering column column and and driver's driver's seatseat
can be adjusted individually.can be adjusted individually.
The controls and warnings on the display unit (5) enable the system to be monitoredThe controls and warnings on the display unit (5) enable the system to be monitored
during operation, thereby ensuring a very during operation, thereby ensuring a very high level of safety.high level of safety.
SteeringSteering
The steer cylinder of the hydrostatic steering is integrated in the steer axle (11) andThe steer cylinder of the hydrostatic steering is integrated in the steer axle (11) and
is controlled by the power steering. The steer axle is fully floating in the chassis tois controlled by the power steering. The steer axle is fully floating in the chassis to
ensure excellent grip even on non-level surfaces.ensure excellent grip even on non-level surfaces.
WheelsWheels
All All wheels wheels are are located located within within the the truck truck geometry. geometry. A A choice choice of of pneumatic pneumatic oror
superelastic tyres are available.superelastic tyres are available.
EngineEngine
High performance, water-cooled diesel and LPG engines with long useful lives andHigh performance, water-cooled diesel and LPG engines with long useful lives and
low consumption and emission levels.low consumption and emission levels.
Electrical systemElectrical system
12 volt system with threephase alternator. A start block prevents malfunctions when12 volt system with threephase alternator. A start block prevents malfunctions when
the truck is powered up. For diesel engines, a rapid the truck is powered up. For diesel engines, a rapid pre-heat system is installed; LPGpre-heat system is installed; LPG
motors have an electronic ignition system for rapid and trouble-free engine starting.motors have an electronic ignition system for rapid and trouble-free engine starting.
The key switch is used to stop the engine.The key switch is used to stop the engine.
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Drive systemDrive system
A power A power shift transmission shift transmission with radiator with radiator and and torque torque converter transfers converter transfers the the force toforce to
the drive axle (8).the drive axle (8).
The travel direction switch on the engine cover controls forward/reverse travel andThe travel direction switch on the engine cover controls forward/reverse travel and
the neutral position. This switch is used to select between the two travel stages forthe neutral position. This switch is used to select between the two travel stages for
forward and reverse travel.forward and reverse travel.
BrakesBrakes
The brake pedal actuates two drum brakes which are applied to the drive wheels. AnThe brake pedal actuates two drum brakes which are applied to the drive wheels. An
additional slow travel / brake pedal facilitates creep speed applications. The pedaladditional slow travel / brake pedal facilitates creep speed applications. The pedal
should not be used for normal braking should not be used for normal braking purposes. Worn drum brakes are automaticallypurposes. Worn drum brakes are automatically
adjusted. The parking brake operates through mechanical actuation of the parkingadjusted. The parking brake operates through mechanical actuation of the parking
brake lever on the drum brake via Bowden cables.brake lever on the drum brake via Bowden cables.
Hydraulic systemHydraulic system
A multi-pilot valve allows A multi-pilot valve allows for sensitive operation of for sensitive operation of the functions via the controls. the functions via the controls. TheThe
flow rate of the gear pump is regulated by the engine speed.flow rate of the gear pump is regulated by the engine speed.
MastMast
Two or three-stage masts, optionally with free lift function; narrow mast sectionsTwo or three-stage masts, optionally with free lift function; narrow mast sections
ensure excellent visibility of the forks and attachments. Fork carriage and mast runensure excellent visibility of the forks and attachments. Fork carriage and mast run
on permanently lubricated and hence maintenance-free support rollers.on permanently lubricated and hence maintenance-free support rollers.
AttachmentsAttachments
The trucks can be optionally fitted with mechanical and hydraulic attachments.The trucks can be optionally fitted with mechanical and hydraulic attachments.
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33 TTeecchhnniiccaal l SSppeecciiffiiccaattiioonnss
All technical details refer to standard trucks.All technical details refer to standard trucks.
Values indicated with *) may vary, depending Values indicated with *) may vary, depending on theon the
types of equipment used (e.g. mast, cabin, tyres etc.).types of equipment used (e.g. mast, cabin, tyres etc.).
ZZ Technical data specified in accordance with VDI Technical data specified in accordance with VDI 2198.2198.
Technical modifications and additions reserved.Technical modifications and additions reserved.
33..11 PPeerrffoorrmmaanncce e ddaattaa
1)1)for vertical mast.for vertical mast.
2)2) The values shown represent the maximum gradeability to overcome short The values shown represent the maximum gradeability to overcome short
differences in height and surface unevenness (surface edges). The truck must notdifferences in height and surface unevenness (surface edges). The truck must not
operate on inclines of more than 15%.operate on inclines of more than 15%.
DFG 540/545/550DFG 540/545/550
DDeessccrriippttiioonn DDFFG G 554400 DDFFG G 554455 DDFFG G 555500
QQ CapacityCapacity
(where C = 500 mm)(where C = 500 mm)1)1) 44000000 44550000 55000000 kkgg
CC LLooaad d cceennttrre e ddiissttaannccee 550000 550000 660000 mmmm
Travel Travel speed* speed* with with //
without loadwithout load 2244//2244..55 2233//2233..55 2222//2222..55 kkmm//hh
Lift Lift speed, speed, with / with / withoutwithout
loadload 00..4499//00..5533 00..4499//00..5533 00..4488//00..553 3 mm//ss
Lowering Lowering speed speed with with //
without loadwithout load 00..5511//00..4499 00..5511//00..4499 00..5511//00..449 9 mm//ss
Gradeability Gradeability 2)2)**
with / without loadwith / without load 2255//2266 2244//2266 2233//226 6 %%
Acceleration* Acceleration* with /with /
without load to 15 mwithout load to 15 m 55//44..55 55//44..55 55..11//44..55 ss
Available workingAvailable working
pressure for attachmentspressure for attachments 116600 116600 116600 bbaar r
OOiil l fflloow w ffoor r aattttaacchhmmeennttss 3300 3300 3300 ll//mmiinn
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1)1)
for vertical mast.for vertical mast.
2)2) The values shown represent the maximum gradeability to overcome short The values shown represent the maximum gradeability to overcome short
differences in height and surface unevenness (surface edges). The truck must notdifferences in height and surface unevenness (surface edges). The truck must not
operate on inclines of more than 15%.operate on inclines of more than 15%.
TFG 540/545/550TFG 540/545/550
DDeessccrriippttiioonn TTFFG G 554400 TTFFG G 554455 TTFFG G 555500
QQ CapacityCapacity
(where C = 500 mm)(where C = 500 mm)1)1) 44000000 44550000 55000000
CC LLooaad d cceennttrre e ddiissttaannccee 550000 550000 660000
Travel Travel speed* speed* with with //
without loadwithout load 2244..44//2255..88 2233..88//2255..88 2222..33//2255..88
Lift Lift speed, speed, with / with / withoutwithout
loadload 00..4499//00..5533 00..4488//00..5533 00..4488//00..5533
Lowering Lowering speed speed with with //
without loadwithout load 00..5511//00..4499 00..5511//00..4499 00..5511//00..4499
Gradeability Gradeability 2)2)**
with / without loadwith / without load 2255//2266 2244//2266 2233//2266
Acceleration* Acceleration* with /with /
without load to 15 mwithout load to 15 m 44..88//44..22 55//44..55 55..55//44..55
Available workingAvailable working
pressure for attachmentspressure for attachments 116600 116600 116600
OOiil l fflloow w ffoor r aattttaacchhmmeennttss 3300 3300 3300
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33..22 DDiimmeennssiioonnss
*) The data listed in the table *) The data listed in the table corresponds to the standard version.corresponds to the standard version.
1)1)573 mm with DZ mast; 573 mm with DZ mast; with integrated SS: x=596 mm (605 mm with integrated SS: x=596 mm (605 mm with DZ mast); withwith DZ mast); with
SS attachment: x=636 mm (645 mm with DZ mast)SS attachment: x=636 mm (645 mm with DZ mast)
DFG/TFG 540/545/550DFG/TFG 540/545/550
DDeessccrriippttiioonn DDFFG G / / TTFFGG
55440 0 55445 5 555500
aa//22 SSaaffeetty y ddiissttaannccee 110000 110000 110000 mmmm
hh11 MMaasst t hheeiigghht t rreettrraacctteedd** 22554400 22554400 22554400 mmmm
hh22 FFrreee e lliifftt** 115500 115500 115500 mmmm
hh33 LLiifftt** 33550000 33550000 33550000 mmmm
hh44 MMaasst t hheeiigghht t eexxtteennddeedd** 44221155 44221155 44336633 mmmm
hh66 OOvveerrhheeaad d gguuaarrd d hheeiigghht t ((ccaabbiinn))** 22337755 22337755 22337755 mmmm
hh77 SSeeaat t hheeiigghhtt* * 11225555 11225555 11225555 mmmm
hh1010 CCoouupplliinng g hheeiigghhtt 553355//770000 553355//770000 553355//770000 mmmm
MMaasst t ttiilltt, , ffwwdd..** 77 77 77 °°
ßß MMaasst t ttiilltt, , bbaacckk** 66 66 66 °°
ll11 OOvveerraalll l lleennggtth h ** 44114455 44114455 44226600 mmmm
ll22 HHeeaaddlleennggtthh** 22999955 22999955 33111100 mmmm
bb11 OOvveerraalll l wwiiddtthh** 11440000//-- 11445500//-- 11445500//-- mmmm
ss//ee//ll FFoorrk k ddiimmeennssiioonnss** 5500xx112255
x1150x1150
50x15050x150
x1150x1150
60x15060x150
x1150x1150
mmmm
mm11 Ground clearance with load belowGround clearance with load below
mast*mast*
119900 119900 119900 mmmm
mm22 Ground clearance centreGround clearance centre
wheelbase*wheelbase*
223300 223300 223300 mmmm
Fork carriage ISO 2328 class /Fork carriage ISO 2328 class /
type A, Btype A, B
3 3 AA 3 3 AA 4 4 AA
bb33 FFoorrk k ccaarrrriiaagge e wwiiddtthh** 11226600 11226600 11226600 mmmm
AstAst Working aisle Working aisle width for pwidth for pallets 800allets 800
x 1200 longit.x 1200 longit.
44661199 44661199 44776699 mmmm
AstAst Working aisle width for palletsWorking aisle width for pallets
1000 x 1200 traverse1000 x 1200 traverse
44441199 44441199 44556699 mmmm
WWaa TTuurrnniinng g rraaddiiuuss 22665555 22665555 22779900 mmmm
bb1313 SSmmaalllleesst t ttuurrnniinng g rraaddiiuuss 990000 990000 990000 mmmm
xx LLooaad d ddiissttaannccee** 5566441)1) 5645641)1) 5795791)1) mmmm
cc LLooaad d cceennttrre e oof f ggrraavviittyy 550000 550000 660000 mmmm
yy WWhheeeellbbaassee 11998855 11998855 11998855 mmmm
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