Jungheinrich ForkliftDFG 540 DFG 545 DFG S50 TFG 540 TFG 545 TFG S50 Operation & Maintenance Manual

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Contents

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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 6

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 21 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 40 41 43

D

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

45

1 1.1 1.2 2 2.1

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

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

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

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

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

45 45 47 48 48

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2.2 2.3 3 3.1 3.2 3.3

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

Fuel display (DFG only) .......................................................................... .

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

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

Twin LPG bottle holder (o) .................................................................... .

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

50 51 52 52 54 57

E

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

59

1 2 2.1 3 3.1 3.2 3.3 4 4.1 4.2 4.3 4.4 5 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 5.14 5.15 5.16 5.17 6 7 7 .1 7 .2 7.3 7.4 7 .5 7.6 7.7 7.8 8 8.1 8.2

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

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

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

Description of the Display and Controls on the Armrest (o) .................. .

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

Function symbols for the Pilots .............................................................. ..

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

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

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

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

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

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

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

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

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

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

Battery Isolator ....................................................................................... .

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

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

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

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 SOLO-PILOT on the Armrest.. .... .

Operating Additional Attachments for MULTI-PILOT on the Armrest.. .. ..

Operating Additional Attachments for DUO-PILOT on the Armrest.. ...... .

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

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

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

Heating ....................................................................................................

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

Adding window washer system fluid ...................................................... ..

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

Control Layout "N" on the Armrest.. ........................................................ .

USB charger module in armrest ............................................................ ..

StVZO road traffic regulations equipment .............................................. .

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

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

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

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

59 61 63 67 69 70 72 76 76 77 78 84 85 85 88 91 92 93 94 95 97 98 99 101 106 109 111 114 117 120 122 124 124 124 125 126 141 143 144 145 146 146 149

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F

Industrial Truck Maintenance.................................................. 155

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

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

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

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

2.3 Wheels.....................................................................................................

2.4 Lift Chains................................................................................................

2.5 Hydraulic system ................. ...... ............... ............. ........ ....... ......... ..... .....

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

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

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

3.2 Lubrication Schedule...............................................................................

3.3 Consumables...........................................................................................

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

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

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

4.3 Opening the Engine Cover......................................................................

4.4 Opening the Engine Cover with Comfort Seat (o) .. .. ...... .. .. .. .... ...... .. .. ....

4.5 Removing the Covers ..............................................................................

4.6 Removing the Floor Plate........................................................................

4. 7 Checking the Wheel Mounting.................................................................

4.8 Replacing wheels .. ...... ... ........... ............... ....... ....... ......... ...... ........ ..... .....

4.9 Hydraulic system .. .............. ................ ...... .. .. .. ............ .... ...... .. .. .. .... .... .. .. .

4.1 O Engine maintenance................................................................................

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

4.12 Cleaning ..................................................................................................

4.13 Starter battery..........................................................................................

4.14 Exhaust system .... .. .. ............. .. .. ............ .. .. ......... .. ......... .... .. ......... .... .. .....

4.15 Transmission and Drive Axle...................................................................

4.16 Brake ....... .. .. ... ........ .. .... ........ .. .... .......... .. .. ........ .. .. .. ........ .. .. .. ........ .. .. .. .....

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

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

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

5.2 During decommissioning .. .. .............. ................ ............ .............. .............

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

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

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

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

155 156 157 157 157 158 158 159 161 161 163 164 167 167 168 169 170 174 175 176 177 179 182 195 201 203 204 205 206 207 208 209 209 210 211 212 212

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Maintenance and Inspection ................................................... 213

1 1.1 1.2 2 2.1 2.2

Maintenance checklist DFG 540-550 ......................................................

Owner ... .. .. ........... .. ............ .. .. ........... .. ............ .. ............ .. ............ .. .... .......

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

Maintenance checklist TFG 540-550.......................................................

Owner......................................................................................................

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

214 214 216 222 222 224

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CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL