Jungheinrich Forklift DFG 540s DFG 545s DFG 550s TFG 540s TFG 545s TFG 550s Operating Instructions M

DFG / TFG 540s - 550s Operating instructions

04.12 -

G

51195781 03.13

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

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

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.

Z

Used before notices and explanations. t o

Indicates standard equipment Indicates optional equipment

Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG.

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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

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 ....................................................................................................

15 15 16 16 17 18 20 20 22 24 25 27 28 29 30 30 31 33 34 35 35

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..............................................................................................

Liquid gas tank ........................................................................................

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

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

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

43 43 45 46 46 48 49 49 54 55 55 55

E

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

57

1 2 2.1 2.2 2.3 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 5 6 6.1 6.2

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

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

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

Control panel buttons ..............................................................................

Display.....................................................................................................

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

Checks and operations to be performed before starting daily operation .

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............................................................................

Travel.......................................................................................................

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 ................................

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

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

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

Keypad (CanCode) (o) ...........................................................................

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

57 59 62 65 68 69 69 71 71 72 77 78 78 81 82 83 84 85 86 88 88 92 93 94 95 97 103 106 108 110 113 115 115 133

6.3 6.4 6.5 6.6 6.7 6.8

7 7.1 7.2

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

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

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

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

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

Heating and air conditioning system........................................................ ing / backrest extension...............................................

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

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

Sideshifter centre position .......................................................................

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

Tilt angle display......................................................................................

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

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

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

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

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

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

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

F

Industrial Truck Maintenance .................................................. 161

1 2 2.1 2.2 2.3 2.4 2.5 2.6 3 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

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 ......................................................

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 attachments.............................................................

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 ........................................................................

6.10 6.11 6.12 6.13 6.14 6.15 6.16 6.17 6.18

135 135 136 138 138 139 142 143 143 144 144 145 146 147 148 148 149 150 150 155

161 162 163 163 163 164 164 165 166 166 168 169 171 171 172 173 173 175 177 179 180 183 197 203 205 206 207 208 209 9

5.2 5.3 6 7 8 9 10 10.1 10.2 11 11.1 11.2

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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.....................................................................................

209 210 211 212 212 213 214 214 217 225 225 228

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 95.

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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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. and commercial environments. range -20°C to 40°C. rfaces with sufficient capacity. ssible surface and spot load limits on the travel routes. that are visible and approved by the operating company. to a maximum of 15 %. an angle on inclines. Travel with the load facing uphill. 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 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.

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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

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B Truck Description 1

Application The DFG / TFG 540s - 550s is a four-wheel sit-down industrial truck with a combustion engine. The DFG series are diesel engine trucks, while the TFG series are fitted with a petrol engine for LPG operation.

The DFG / TFG 540s - 550s is a cantilever counterbalanced truck which can lift, transport and deposit loads using the load handler attached in front.

The DFG / TFG 540s - 550s is equipped with a hydrostatic drive. The combustion engine drives high pressure pumps for the hydraulic functions and two hydraulic motors to drive the wheels.

1.1

Truck models and rated capacity The rated capacity depends on the model. The rated capacity can be derived from the model name.

DFG540s DFG 5 40 s

Model name Series Rated capacity x 100 kg Hydrostatic Drive System

The rated capacity is not generally the same as the permissible capacity. The capacity can be found on the capacity plate attached to the truck.

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2

Assemblies and Functional Description

2.1

Travel direction definition 1

2

3

4 The following conventions have been agreed for travel direction specification: Item 1 2 3 4

16

Travel direction Links Reverse Forward Right

2.2

Assembly Overview

5

6

7

8

9

10

11

12

19

18

17

Item Component 5 t Driver's seat 6 t Overhead guard 7 t Steering wheel 8 t Mast 9 t Fork carriage 10 t Fork tines 11 t Lifting mechanism control 12 t Operating and control unit t = Standard equipment

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15

Item 13 t 14 t 15 t 16 t 17 t 18 t 19 t

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13

Component Drive system Emergency Disconnect switch Engine bonnet Steer axle Counterweight Trailer coupling LPG bottle (TFG only)

o= Optional equipment

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2.3

Functional Description Chassis The chassis, in conjunction with the counterweight, forms the supporting base structure of the truck. It is used to support the main components.

The 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.

Operator position and overhead guard The overhead guard (6) comes in a range of models and protects the driver from falling objects and other external influences.

All the controls are ergonomically arranged. The steering column and driver's seat can be adjusted individually.

The controls and warnings on the display unit (12) enable the system to be monitored during operation, thereby ensuring a very high level of safety.

Steering The steer cylinder of the hydrostatic steering is integrated in the steer axle (16) and is controlled by the power steering. The steer axle is fully floating in the chassis to ensure excellent grip even on non-level surfaces.

Wheels All wheels are located within the truck geometry. A choice of pneumatic or superelastic tyres are available.

Motor High performance, water-cooled diesel and LPG engines with long useful lives and low consumption and emission levels.

The diesel motors have a standard, additive-free particle filter system. The LPG motors have a controlled three-way catalytic converter option.

Electrical System 12-volt system with 3-phase alternator. A repeat start block prevents malfunctions when the truck is powered up. For diesel engines, a rapid pre-heat system is installed; LPG motors have an electronic ignition system for rapid and trouble-free engine starting. The key switch is used to start and stop the engine.

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