11.0908.12 51167690 DFG / TFG 540 - 550 Operating instructions G DFG 545 DFG 550 TFG 540 TFG 545 TFG 550 DFG 540
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Declaration of Conformity
Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg Manufacturer or agent acting in the European Union
TypeOptionSerial no.Year of manufacture
DFG 540
DFG 545
DFG 550
TFG 540
TFG 545
TFG 550
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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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. Jungheinrich reserves 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.
Used before notices and explanations.
t Indicates standard equipment
o Indicates optional equipment
Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG.
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Z
Jungheinrich Aktiengesellschaft
Am Stadtrand 35 22047 Hamburg - Germany
Tel: +49 (0) 40/6948-0
www.jungheinrich.com
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7 Contents ACorrect Use and Application...................................................11 1General................. ...........11 2Correct application.............. ...........11 3Approved application conditions..............................................................12 4Proprietor responsibilities..... ...........13 5Adding attachments and/or accessories........... ...........13 BTruck Description....................................................................15 1Application...............................................................................................15 1.1Truck models and rated capacity............... .............15 2Assemblies and Functional Description...................................................16 2.1Assembly Overview.............. ...........16 2.2Functional Description........ ...........17 3Technical Specifications..........................................................................19 3.1Performance data........ ...........19 3.2Dimensions..............................................................................................21 3.3Weights............ ...........23 3.4Mast versions......... ...........24 3.5Tyre type..................................................................................................26 3.6Engine Data............ ...........27 3.7EN norms................ ...........28 3.8Conditions of use.....................................................................................29 3.9Electrical requirements....... ...........29 4Identification points and data plates........................................................30 4.1Data plate................................................................................................32 4.2Truck capacity plate............ 33 4.3Attachment capacity plate.......................................................................34 5Stability....................................................................................................34 CTransport and Commissioning................................................35 1Transport................ ...........35 2Truck laden............... .............35 2.1Centre of gravity of the truck.............. ...........35 2.2Lifting the truck by crane.........................................................................36 2.3Loading with another industrial truck....... ........37 3Securing the truck during transport........... .............38 4Using the Truck for the First Time...........................................................39
8 DFuelling the Truck....................................................................41 1General................. ...........41 1.1Safety regulations for handling diesel fuel and LPG................................41 1.2LPG system relief valve...........................................................................43 2Adding diesel................... ...........44 2.1Fuelling....................................................................................................44 2.2Fuelling with fuel containers....................................................................45 3LPG containers......... .............46 3.1LPG bottles..............................................................................................46 3.2Liquid gas tank................ ...........49 4Fuel level indicator........... ...........50 4.1Display unit..............................................................................................50 4.2Level indicator for LPG bottles (o)..........................................................50 EOperation................................................................................51 1Safety Regulations for the Operation of the Forklift Tr uck.......................51 2Displays and Controls........... ...........53 2.1Display unit............. ...........55 2.2Instrument panel switches (o)................................................................57 2.3Travel direction switch/gear selector........... ...........58 3Preparing the Truck for Operation...........................................................59 3.1Checks and operations to be performed before starting daily operation.59 3.2Entry and exit................. ...........60 3.3Trucks with reduced headroom X (o).....................................................60 3.4Setting up the operator position............... ........61 3.5Seat Belt............... ...........65 4Industrial Truck Operation.......................................................................66 4.1Safety regulations for truck operation.......... ...........66 4.2Preparing the truck for operation............. ........68 4.3Parking the truck securely.... ...........71 4.4Emergency Disconnect......... ...........72 4.5Travel.......................................................................................................73 4.6Steering................ ...........74 4.7Brakes.......................................................................................... 75 4.8Adjusting the forks...................................................................................77 4.9Replacing the forks............. ...........78 4.10Lifting, transporting and depositing loads.... ...........79 4.11Operating the lift mechanism and integrated attachments......................81 4.12Safety instructions for operating additional attachments.........................86 4.13Operating additional attachments for the SOLO-PILOT..........................89 4.14Fitting additional attachments............. ...........91 5Towing trailers........ ...........93 6Optional equipment.................................................................................95 6.1Steel cab............... ...........95 6.2Sliding windows........ .............95 6.3Panel door...............................................................................................96 6.4Backrest extension............. ...........96 6.5Heating....................................................................................................97 6.6Removable load backrest........................................................................99
9 6.7Fire extinguisher......................................................................................99 6.8Rockinger coupling with hand lever or remote control. .............100 6.9Camera system.......................................................................................101 6.10Optional equipment for working in areas with heavy accumulation of dust102 6.11Tilt angle display............ ...........102 6.12Speed reduction......................................................................................103 6.13Transmission block............. ...........103 6.14Reversing Block.......................................................................................103 6.15Direction switch mounted to the steering column....................................103 6.16Temperature control system.. ...........104 6.17Control layout with Cardan function.........................................................105 7Troubleshooting............. ...........106 7.1Troubleshooting........... ...........106 7.2Operating the truck without its own drive system....................................109 FIndustrial Truck Maintenance..................................................113 1Operational Safety and Environmental Protection...................................113 2Maintenance Safety Regulations............... .............114 3Servicing and Inspection.........................................................................119 4Maintenance checklist.............................................................................120 5Lubricants and Lubrication Schedule................. ........128 5.1Handling consumables safely ..................................................................128 5.2Lubrication Schedule............ ...........130 5.3Consumables.......... ...........131 6Maintenance and repairs.........................................................................133 6.1Preparing the truck for maintenance and repairs...... .............133 6.2Opening the engine cover.......................................................................134 6.3Checking the wheel attachments.............................................................135 6.4Hydraulic system...... .............136 6.5Engine maintenance................................................................................139 6.6Checking electrical fuses...... ...........151 6.7Starter battery......... ...........156 6.8Exhaust system.......................................................................................157 6.9Seat belt maintenance.......... ...........158 6.10Transmission........................................................................................... 158 6.11Brake.......................................................................................................159 6.12Restoring the truck to service after maintenance and repairs.................160 7Decommissioning the industrial truck......................................................161 7.1Prior to decommissioning..... ...........162 7.2During decommissioning...... ...........162 7.3Restoring the truck to service after decommissioning.............................163 8Safety tests to be performed at intervals and after unusual incidents.....164 9Final de-commissioning, disposal.............. .............165 10Human vibration measurement...............................................................165 11HUSS FS - MK Series Diesel Particle Filter Operating Instructions (o).166 11.1Important General Instructions................................................................166 11.2Important safety instructions............... ...........166
10 11.3Functional Description.............................................................................167 11.4HUSS Control Operation...... ...........168 11.5HUSS Control Operating Instructions......................................................169 11.6Regeneration...........................................................................................170 11.7Maintenance............. .............171
ACorrect Use and Application
1General
The industrial truck described in the present operating instructions is designed for lifting, lowering and transporting load units.
It must be used, operated and serviced in accordance with the present instructions. Any other type of use is beyond the scope of application and can result in damage to personnel, the industrial truck or property.
2Correct application
NOTE
The maximum load and load distance are indicated on the load chart 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 rest on the back of the fork carriage and centrally between the forks.
s over short distances. raised load (>30 cm).
l load units. trailer loads. must be secured on the trailer. load must not be exceeded.
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3Approved application conditions
DANGER!
Do not exceed the permissible surface and spot load limits on the travel routes. At blind spots get a second person to assist. The driver must ensure that the loading dock / ramp cannot move or come loose during loading / unloading.
and commercial environments. e range -20 to 40°C. rfaces with sufficient capacity. visible and approved by the proprietor. to a maximum of 15 %. at an angle. Transporting loads downhill.
WARNING!
Extreme conditions
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 is not authorised for use 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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4Proprietor responsibilities
For the purposes of the present operating 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 for which 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 and operating, servicing and repair guidelines must be followed. The proprietor must ensure that all users have read and understood these operating instructions.
NOTE
Failure 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 third parties without the permission of the manufacturer.
5Adding attachments and/or accessories
Adding accessories
The mounting or installation of additional equipment which affects or enhances the performance of the forklift truck requires the written permission of the manufacturer. Local authority approval may also need to be obtained. Local authority approval does not however constitute
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• You can download the complete manual from: www.heydownloads.com by clicking the link below
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