Jungheinrich Forklift DFG 540s TFG 540s DFG 545s TFG 545s DFG 550s TFG Operation &Maintenance Manual

DFG / TFG 540s - S50s Operating instructions

02.15 -

G

51356018 02.15

DFG 540s DFG 545s DFG 550s DFG S50s TFG 540s TFG 545s TFG 550s TFG S50s

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2

Declaration of Conformity

Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg Manufacturer or agent acting in the European Union Type

Option

Serial no.

Year of manufacture

DFG 540s TFG 540s DFG 545s TFG 545s DFG 550s TFG 550s DFGS50s TFGS50s

Additional information

On behalf of

Date

G EU Conformity Declaration The undersigned hereby declare that the powered industrial truck described below in detail complies with the European Directives 2006/42/EC (Machinery Directive) and 2004/108/EEC (Electromagnetic Compatibility - EMC) including amendments as well as the legislative decree to incorporate the directives in national law. The signatories are in each case individually authorized to compile the technical documents.

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4

Foreword Notes on the operating instructions The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide sufficient instruction for the safe operation of the industrial truck. The information is provided clearly and concisely. The chapters are arranged by letter and the pages are numbered continuously.

The operator manual details different industrial truck models. When operating and servicing the industrial truck, make sure that the particular section applies to your truck model.

Our trucks are subject to ongoing development. We reserve the right to alter the design, equipment and technical features of the system. No guarantee of particular features of the truck should therefore be assumed from the present operating instructions.

Safety notices and text mark-ups Safety instructions and important explanations are indicated by the following graphics: DANGER! Indicates an extremely hazardous situation. Failure to comply with this instruction will result in severe irreparable injury and even death.

WARNING! Indicates an extremely hazardous situation. Failure to comply with this instruction may result in severe irreparable injury and even death.

CAUTION! Indicates a hazardous situation. Failure to comply with this instruction may result in slight to medium injury.

NOTE Indicates a material hazard. Failure to comply with this instruction may result in material damage.

Z

Used before notices and explanations. t o

Indicates standard equipment Indicates optional equipment

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Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG. Jungheinrich Aktiengesellschaft Am Stadtrand 35 22047 Hamburg - Germany Tel: +49 (0) 40/6948-0 www.jungheinrich.com

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Contents A

Correct Use and Application ...................................................

11

1 2 3 4 5

General....................................................................................................

Correct application...................................................................................

Approved application conditions ..............................................................

Proprietor responsibilities ........................................................................

Adding attachments and/or optional equipment ......................................

11 11 12 13 13

B

Truck Description ....................................................................

15

1 1.1 2 2.1 2.2 2.3 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 4 4.1 4.2 4.3 5 5.1

Application ...............................................................................................

Truck models and rated capacity.............................................................

Assemblies and Functional Description...................................................

Travel direction definition.........................................................................

Assembly Overview .................................................................................

Functional Description .............................................................................

Technical Specifications ..........................................................................

Performance data ....................................................................................

Dimensions..............................................................................................

Weights....................................................................................................

Mast versions ..........................................................................................

Tyre type..................................................................................................

Engine Data.............................................................................................

EN norms.................................................................................................

Conditions of use.....................................................................................

Electrical Requirements...........................................................................

Identification Points and Data Plates .......................................................

Data plate ................................................................................................

Truck capacity plate.................................................................................

Attachment capacity plate .......................................................................

Stability ....................................................................................................

Wind loads...............................................................................................

15 15 16 16 17 18 20 20 22 24 25 27 28 29 30 30 31 33 34 36 36 36

C

Transport and Commissioning ................................................

37

1 2 2.1 2.2 2.3 3 4

Transport .................................................................................................

Truck laden ..............................................................................................

Centre of gravity of the truck ...................................................................

Lifting the truck by crane .........................................................................

Loading with another industrial truck .......................................................

Securing the truck during transport .........................................................

Using the Truck for the First Time ...........................................................

37 37 37 38 39 40 41

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8

D

Fuelling the Truck....................................................................

43

1 1.1 1.2 2 2.1 2.2 3 3.1 3.2 4 4.1 4.2

General....................................................................................................

Safety regulations for handling diesel fuel and LPG................................

LPG system relief valve...........................................................................

Adding diesel ...........................................................................................

Fuelling ....................................................................................................

Fuelling with fuel containers ....................................................................

LPG containers........................................................................................

LPG bottles..............................................................................................

LPG tank (o) ...........................................................................................

Fuel level indicator...................................................................................

Display unit ..............................................................................................

Level indicator for LPG bottles (o)..........................................................

43 43 45 46 46 47 48 48 53 54 54 54

E

Operation ................................................................................

55

1 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 3 3.1 3.2 3.3 3.4 3.5 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16 4.17 4.18

Safety Regulations for the Operation of the Forklift Truck.......................

Displays and Controls..............................................................................

Controls ...................................................................................................

Pilots........................................................................................................

Control panel with display unit.................................................................

Button allocation of the display................................................................

Symbols in the display.............................................................................

Armrest Control Panel Switch..................................................................

Operating Programs ................................................................................

Preparing the Truck for Operation ...........................................................

Checks and Operations to Be Performed Before Starting Daily Work ....

Entry and exit...........................................................................................

Trucks with reduced headroom (o).........................................................

Setting up the operator position...............................................................

Seat Belt ..................................................................................................

Industrial Truck Operation .......................................................................

Safety regulations for truck operation......................................................

Preparing the truck for operation .............................................................

Starting procedure for the DFG ...............................................................

Starting procedure for the TFG................................................................

Parking the truck securely .......................................................................

Emergency Disconnect............................................................................

Single pedal.............................................................................................

Steering ...................................................................................................

Brakes .....................................................................................................

Setting the Time ......................................................................................

Adjusting the forks ...................................................................................

Replacing the forks..................................................................................

Lifting, transporting and depositing loads ................................................

Operating the Lift Mechanism and Integrated Attachments ....................

Safety instructions for operating additional attachments .........................

Operating additional attachments for the SOLO-PILOT ..........................

Operating additional attachments for the Multi Pilot ................................

Operating additional Attachments for Duo-Pilot ......................................

55 57 57 59 60 61 62 65 67 68 68 70 70 71 78 79 79 82 83 84 85 86 87 90 91 95 96 97 98 100 110 113 115 117

4.19 5 6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12 6.13 6.14 6.15 6.16 6.17 6.18 6.19 6.20 6.21 6.22 6.23 6.24 6.25 6.26 6.27 6.29 6.30 6.31 6.32 6.33 6.34 7 7.1 7.2

Fitting additional attachments..................................................................

Towing trailers .........................................................................................

Optional equipment .................................................................................

Keyless Access System ..........................................................................

General Information on Using the Display Unit .......................................

Commissioning the Keypad and the Transponder Reader......................

Using the Display:....................................................................................

Using the Keypad ....................................................................................

Using the Transponder Reader ...............................................................

Assistance systems .................................................................................

Steel cab..................................................................................................

Split Door.................................................................................................

Sliding windows .......................................................................................

Gate.........................................................................................................

Panel door ...............................................................................................

Operator position extension.....................................................................

Heating and air conditioning system........................................................

USB Charger Module in Armrest .............................................................

Auxiliary Functions on the Armrest ..........................................................

Operating hydraulics cutout.....................................................................

Load Weighing.........................................................................................

Lift cutout override ...................................................................................

Fork Tilt Horizontal ..................................................................................

Sideshifter Centre Position ......................................................................

Control layout “N” ....................................................................................

Operating the Auxiliary Hydraulics without Pressing the Acknowledgement Key .................................................................................................

Load Damping .........................................................................................

Removable load backrest ........................................................................

Fire extinguisher ......................................................................................

Rockinger coupling with hand lever or remote control.............................

Camera system .......................................................................................

Optional equipment for working in dusty environments ...........................

Roof window wiper ..................................................................................

Floor spot.................................................................................................

Horn Button on Overhead Guard.............................................................

Travel Direction Switch on Steering Column ...........................................

Troubleshooting.......................................................................................

Troubleshooting.......................................................................................

Operating the truck without its own drive system ....................................

119 121 123 123 124 124 127 131 135 139 141 142 144 144 146 146 147 150 151 153 153 153 154 154 155

F

Industrial Truck Maintenance .................................................. 185

1 2 2.1 2.2 2.3 2.4 2.5 2.6 3

Operational Safety and Environmental Protection...................................

Maintenance Safety Regulations.............................................................

Working on the electrical system .............................................................

Consumables and used parts..................................................................

Wheels.....................................................................................................

Lift Chains................................................................................................

Hydraulic system .....................................................................................

Working in the vicinity of the engine ........................................................

Lubricants and Lubrication Schedule ......................................................

157 161 163 163 165 167 169 170 171 172 173 175 175 179

185 186 187 187 187 188 188 189 190 9

3.1 3.2 3.3 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 5 5.1 5.2 5.3 6 7 8 9 10 10.1 10.2 11 11.1 11.2

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Handling consumables safely..................................................................

Lubrication Schedule ...............................................................................

Consumables...........................................................................................

Maintenance and repairs .........................................................................

Preparing the truck for maintenance and repairs ....................................

Lifting and jacking up the truck safely......................................................

Opening the rear panel............................................................................

Unlocking the engine bonnet ...................................................................

Opening the engine cover .......................................................................

Replacing wheels ....................................................................................

Checking the Wheel Mounting.................................................................

Hydraulic system .....................................................................................

Engine maintenance................................................................................

Checking electrical fuses.........................................................................

Cleaning ..................................................................................................

Starter battery..........................................................................................

Exhaust system .......................................................................................

Restoring the truck to service after maintenance and repairs .................

Decommissioning the Industrial Truck.....................................................

Prior to decommissioning ........................................................................

During decommissioning .........................................................................

Restoring the truck to service after decommissioning .............................

Safety tests to be performed at intervals and after unusual incidents .....

Final de-commissioning, disposal............................................................

Human vibration measurement ...............................................................

Servicing and Inspection .........................................................................

Maintenance checklist DFG.....................................................................

Operating Company ................................................................................

Customer Service ....................................................................................

Maintenance checklist TFG .....................................................................

Operating Company ................................................................................

Customer Service ....................................................................................

190 192 193 195 195 196 197 197 199 202 204 205 208 222 228 230 231 232 233 234 234 235 236 237 237 238 239 239 242 250 250 254

A Correct Use and Application 1

General The truck must be used, operated and serviced in accordance with the present instructions. All other types of use are beyond its scope of application and may result in damage to personnel, the industrial truck or property.

2

Correct application NOTE The maximum load and load distance are indicated on the capacity plate and must not be exceeded.

The load must rest on the load handler or be lifted by an attachment approved by the manufacturer.

The load must be fully raised, see "Lifting, transporting and depositing loads" on page 98.

The following operations are in accordance with regulations and are permitted: – Lifting and lowering loads.

– Transporting lowered loads over short distances.

– Occasional towing of trailer loads.

– When towing trailers the load must be secured on the trailer.

– The permissible trailer load must not be exceeded.

The following operations are prohibited: – Travelling with a raised load (>30 cm).

– Carrying and lifting passengers.

– Pushing or pulling loads.

– Transporting hanging loads. If the truck is to be operated with hanging loads, proof of sufficient safety distance under local operating conditions must be obtained from a specialist assessor.

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3

Approved application conditions DANGER! Do not exceed the permissible surface and point loading on the travel lanes.

At blind spots get a second person to assist.

The driver must ensure that the loading dock /dock leveller cannot be removed or come loose during loading/unloading.

– Operation in industrial and commercial environments.

– Permissible temperature range -20°C to +40°C. – Operation only on secure, level surfaces with sufficient capacity.

– Do not exceed the permissible surface and spot load limits on the travel routes.

– Operation only on routes that are visible and approved by the operating company.

– Negotiating inclines up to a maximum of 15 %.

– Do not travel across or at an angle on inclines. Travel with the load facing uphill.

– Operation in partially public traffic.

– Do not operate LPG trucks under ground level areas.

WARNING! Operating an LPG truck under ground level areas could result in explosions.

LPG is heavier than air. An explosive LPG/air mixture could therefore form under ground level areas without sufficient ventilation.

Do not use LPG trucks under ground level areas.

WARNING! Use under extreme conditions Using the truck under extreme conditions can result in malfunctions and accidents.

Special equipment and authorisation are required if the truck is to be constantly used in extreme conditions, especially in dusty or corrosive atmospheres.

The truck cannot be used in areas at risk of explosion.

In adverse weather conditions (thunder, lightning) the industrial truck must not be operated outside or in endangered areas.

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4

Proprietor responsibilities For the purposes of the present operating instructions the “operating company” is defined as any natural or legal person who either uses the industrial truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting) the proprietor is considered the person who, in accordance with existing contractual agreements between the owner and user of the industrial truck, is charged with operational duties.

The proprietor must ensure that the industrial truck is used only for the purpose it is intended for and that danger to life and limb of the user and third parties are excluded.

Furthermore, accident prevention regulations, safety regulations and operating, servicing and repair guidelines must be followed. The operating company must ensure that all users have read and understood these operating instructions.

NOTE Failure to comply with the operating instructions invalidates the warranty. The same applies if improper work is carried out on the truck by the customer or third parties without the permission of the manufacturer.

5

Adding attachments and/or optional equipment The mounting or installation of additional equipment which affects or enhances the performance of the industrial truck requires the written permission of the manufacturer. Local authority approval may also need to be obtained.

Local authority approval however does not constitute the manufacturer’s approval.

13

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