Jungheinrich DFG 540 Operating Instructions Manual Download

Page: 1 / 171

11.09 -

08.12

51167690

DFG / TFG 540 - 550

Operating instructions

DFG 545

DFG 545
DFG 550

DFG 550
TFG 540

TFG 540
TFG 545

TFG 545
TFG 550

TFG 550

DFG 540

https://www.besttruckmanuals.com/

Summary of Contents for DFG 540

Page 1: ...1167690 51167690 DFG TFG 540 550 DFG TFG 540 550 Operating instructions Operating instructions G G DFG 545 DFG 545 DFG 550 DFG 550 TFG 540 TFG 540 TFG 545 TFG 545 TFG 550 TFG 550 DFG 540 DFG 540 https...

Page 2: ...2006 42 EC Machinery Directive and detail complies with the European Directives 2006 42 EC Machinery Directive and 2004 108 EEC Electromagnetic Compatibility EMC including amendments as well 2004 108...

Page 3: ...0 0 8 8 1 1 2 2 E E N N 4 4 https www besttruckmanuals com...

Page 4: ...tructions operating instructions Safety notices and text mark ups Safety notices and text mark ups Safety instructions and important explanations are indicated by the following Safety instructions and...

Page 5: ...h Aktiengesellschaft Jungheinrich Aktiengesellschaft Am Stadtrand 35 Am Stadtrand 35 22047 Hamburg Germany 22047 Hamburg Germany Tel 49 0 40 6948 0 Tel 49 0 40 6948 0 www jungheinrich com www junghein...

Page 6: ...i Weight ghts s 23 23 3 3 4 4 Ma Mast st ve vers rsion ions s 24 24 3 5 3 5 Tyr Tyre e typ type e 26 26 3 6 3 6 Eng Engine ine Dat Data a 27 27 3 7 3 7 EN EN nor norms ms 28 28 3 3 8 8 Co Cond ndit it...

Page 7: ...head adro room om X X o o 60 60 3 3 4 4 Se Sett ttin ing up the op g up the oper erato ator pos r posit itio ion n 61 61 3 5 3 5 Sea Seat t Belt Belt 65 65 4 4 In Indu dust stri rial al Tr Truc uck k...

Page 8: ...30 5 3 5 3 Con Consum sumabl ables es 131 131 6 6 Ma Main inte tena nanc nce a e and nd re repa pair irs s 13 133 3 6 6 1 1 Pr Prep epar arin ing th g the tr e truc uck fo k for ma r main inte tena na...

Page 9: ...7 167 11 11 4 4 HUS HUSS S Con Control Opera trol Operatio tion n 168 168 11 11 5 5 HUS HUSS Contr S Control Oper ol Operati ating Instr ng Instruct uction ions s 169 169 11 11 6 6 Reg Regene enerati...

Page 10: ...nce are indicated on the load chart and must not on the load chart and must not be be exceeded exceeded The load must rest on the load The load must rest on the load handler or be lifted by an handler...

Page 11: ...roprietor 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 cross...

Page 12: ...revention regulations safety regulations and operating servicing and repair guidelines must be followed The proprietor must operating servicing and repair guidelines must be followed The proprietor mu...

Page 13: ...0 0 8 8 1 1 2 2 E E N N 14 14 https www besttruckmanuals com...

Page 14: ...G 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 function combination of crawl speed and brake pedal and acti...

Page 15: ...e Drive 2 2 t t D Dr ri iv ve er r s s s se ea at t 9 9 t t Lifting device control Lifting device control 3 3 t t S St te ee er ri in ng g w wh he ee el l 1 10 0 t t Engine cover Engine cover 4 4 t t...

Page 16: ...suring a very high level of safety high level of safety Steering Steering The steer cylinder of the hydrostatic steering is integrated in the steer axle 11 and The steer cylinder of the hydrostatic st...

Page 17: ...poses Worn drum brakes are automatically adjusted The parking brake operates through mechanical actuation of the parking adjusted The parking brake operates through mechanical actuation of the parking...

Page 18: ...inclines of more than 15 DFG 540 545 550 DFG 540 545 550 D De es sc cr ri ip pt ti io on n D DF FG G 5 54 40 0 D DF FG G 5 54 45 5 D DF FG G 5 55 50 0 Q Q Capacity Capacity where C 500 mm where C 500...

Page 19: ...di is st ta an nc ce e 5 50 00 0 5 50 00 0 6 60 00 0 Travel Travel speed speed with with without load without load 2 24 4 4 4 2 25 5 8 8 2 23 3 8 8 2 25 5 8 8 2 22 2 3 3 2 25 5 8 8 Lift Lift speed spe...

Page 20: ...er ra al ll l l le en ng gt th h 4 41 14 45 5 4 41 14 45 5 4 42 26 60 0 m mm m l l2 2 H He ea ad dl le en ng gt th h 2 29 99 95 5 2 29 99 95 5 3 31 11 10 0 m mm m b b1 1 O Ov ve er ra al ll l w wi id...

Page 21: ...0 0 8 8 1 1 2 2 E E N N 22 22 https www besttruckmanuals com...

Page 22: ...550 D DF FG G T TF FG G 5 54 40 0 D DF FG G T TF FG G 5 54 45 5 D DF FG G T TF FG G 5 55 50 0 T Ta ar re e w we ei ig gh ht t 6 62 27 79 9 6 66 66 69 9 7 74 43 34 4 Axle load w o load front Axle load...

Page 23: ...15 50 0 3 35 54 40 0 6 62 21 15 5 1 15 57 70 0 6 60 00 00 0 1 15 50 0 3 37 79 90 0 6 67 71 15 5 1 16 69 90 0 6 65 50 00 0 1 15 50 0 4 40 04 40 0 7 72 21 15 5 1 17 76 60 0 ZZ ZZ 2 27 77 75 5 1 13 37 7...

Page 24: ...60 00 00 0 1 15 50 0 3 37 79 90 0 6 68 86 63 3 1 17 76 60 0 6 65 50 00 0 1 15 50 0 4 40 04 40 0 7 73 36 63 3 1 18 82 20 0 ZZ ZZ 2 27 72 25 5 1 12 22 25 5 2 21 14 40 0 3 36 64 40 0 1 11 14 40 0 2 29 97...

Page 25: ...version Other tyres can The models listed in the table correspond to the standard version Other tyres can be used depending on the truck s be used depending on the truck s equipment equipment D De es...

Page 26: ...uel consumption Fuel consumption 60 VDI duty cycles h 60 VDI duty cycles h 4 4 7 7 5 5 2 2 5 5 7 7 l l h h k kg g h h TFG 540 545 550 TFG 540 545 550 D De es sc cr ri ip pt ti io on n T TF FG G 5 54 4...

Page 27: ...h the human vibrations of the 2002 44 EC Vibrations operator directive The manufacturer offers a special service to 44 EC Vibrations operator directive The manufacturer offers a special service to mea...

Page 28: ...ions of extreme temperature or air humidity fluctuations 3 3 9 9 El Ele ect ctri rica cal l re requ quir ire em men ents ts The manufacturer certifies compliance with the requirements for the design a...

Page 29: ...all times Replace if necessary be legible at all times Replace if necessary I It te em m C Co om mp po on ne en nt t 15 15 Do no Do not tra t travel w vel with r ith rais aised lo ed load or m ad or m...

Page 30: ...n load han d handle dler Do r Do not s not stan tand und d under lo er load ha ad handl ndler R er Risk o isk of f trapping when mast extended trapping when mast extended 2 25 5 M Ma ax x b bo od dy s...

Page 31: ...ri ip pt ti io on n I It te em m D De es sc cr ri ip pt ti io on n 3 32 2 T Ty yp pe e 3 37 7 Y Ye ea ar r o of f m ma an nu uf fa ac ct tu ur re e 3 33 3 S Se er ri ia al l n nu um mb be er r 3 38 8...

Page 32: ...table with a given load centre of gravity D in mm and the required lift height H mm and the required lift height H in mm in mm The capacity plate 18 of the truck indicates the truck s capacity with th...

Page 33: ...es are reduced by the difference of the altered centre of gravity by the difference of the altered centre of gravity 5 5 S St ta ab bi il li it ty y The truck s stability has been tested according to...

Page 34: ...ed and hydraulic lines between the basic truck and the mast separated 2 2 T Tr ru uc ck k l la ad de en n 2 2 1 1 Ce Cent ntre re of of gr grav avit ity o y of t f the he t tru ruck ck WARNING WARNING...

Page 35: ...mast must have a minimum clear length must have a minimum clear length of 2 m of 2 m Crane slings should be fastened in such a way that they do not come into contact Crane slings should be fastened i...

Page 36: ...truck with a second industrial truck Loading the truck with a second industrial truck Requirements Requirements Park the truck securely see Parking the truck securely on page Park the truck securely s...

Page 37: ...ng Use only tensioning belts or tie down Use only tensioning belts or tie down straps or with sufficient strength straps or with sufficient strength S Se ec cu ur ri in ng g w wi it th h a a m ma as s...

Page 38: ...ve been delivered make sure that the serial numbers of the load If several trucks have been delivered make sure that the serial numbers of the load handlers masts and basic trucks always match handler...

Page 39: ...0 0 8 8 1 1 2 2 E E N N 40 40 https www besttruckmanuals com...

Page 40: ...oned where they are clearly Labels indicating the hazard are must be positioned where they are clearly visible visible Do not store flammable materials in this area Do not store flammable materials in...

Page 41: ...nk system follow the instructions of the tank system and LPG container manufacturer as well as and LPG container manufacturer as well as statutory and local regulations when filling up statutory and l...

Page 42: ...e gas system must be check by suitably qualified and trained personnel The gas system must be check by suitably qualified and trained personnel The user must check that the plastic cover is present ea...

Page 43: ...0 550 70 l Use only DIN EN 590 diesel with a Use only DIN EN 590 diesel with a cetane rating above 51 Use of fuels cetane rating above 51 Use of fuels that do not that do not comply with this standard...

Page 44: ...n pe into th to the open t e open tank ank filler neck filler neck Mak Make sure t e sure the fue he fuel con l contai tainer an ner and outl d outlet et pipe are connected tightly to each pipe are co...

Page 45: ...ays rest on an engaged bottle holder so that the hose connection of the shutoff valve is facing vertically down connection of the shutoff valve is facing vertically down For bottle types of other coun...

Page 46: ...erting a new LPG bottle Inserting a new LPG bottle Vorgehensweise Vorgehensweise Inser Insert the t the LPG b LPG bottle ottle 14 14 into into the br the bracket acket 55 55 Ali Align the h gn the hos...

Page 47: ...by the gas hose connection on the shut off valve 50 and the routing the shut off valve 50 and the routing towards the LPG bottles e g RH side towards the LPG bottles e g RH side of toggle valve up LH...

Page 48: ...on the LPG pump LPG pump Vorgehensweise Vorgehensweise Clo Close th se the dis e dispen pensin sing val g valve 6 ve 63 3 Unscr Unscrew the ew the cap cap 60 of 60 of the f the filling illing stop v s...

Page 49: ...the level indicator for LPG bottles o o is lit this indicates that the LPG bottle is is lit this indicates that the LPG bottle is empty empty The remaining travel time will be 8 12 minutes depending o...

Page 50: ...estrian operated shall be afforded all due rights Safety shoes must be worn for pedestrian operated trucks trucks Unauthorised use of truck Unauthorised use of truck The driver is responsible for the...

Page 51: ...hazardous area stop the truck immediately immediately DANGER DANGER Accident risk Accident risk The driver must remain within the protected area of the overhead guard while the The driver must remain...

Page 52: ...52 52 0 0 8 8 1 1 2 2 E E N N 2 2 D Di is sp pl la ay ys s a an nd d C Co on nt tr ro ol ls s 67 67 73 73 70 70 74 74 72 72 77 77 75 75 6 68 8 6 69 9 7 71 1 76 76 66 66 https www besttruckmanuals com...

Page 53: ...ring column tilt Adjusts the steering column tilt 7 73 3 P Pa ar rk ki in ng b g br ra ak ke l e le ev ve er r t t T To apply o apply release the parking brake release the parking brake Pull up lever...

Page 54: ...uel supply 6 65 5 F Fu ue el l s su up pp pl ly y i in nd di ic ca at to or r DFG DFG t t When lit indicates the fuel supply is When lit indicates the fuel supply is too low too low 7 78 8 P Pa ar rk...

Page 55: ...been properly attached has not been properly attached 87 87 Flashing indicator Flashing indicator o o Right left indicator lamps activated Right left indicator lamps activated 8 88 8 N Ne eu ut tr ra...

Page 56: ...wiper Switches the window wiper on and off Switches the window wiper on and off P Pa ar rk ki in ng g l li ig gh ht t S Sw wi it tc ch he es s p pa ar rk ki in ng g l li ig gh ht t o on n a an nd d o...

Page 57: ...ravel direction switch is in the middle position the gear is in neutral middle position the gear is in neutral Procedure Procedure To se To selec lect the f t the forw orward g ard gear ear pus push t...

Page 58: ...yst ulic system in the visib em in the visible area for dam le area for damage and leak age and leaks s Check t Check the drive he driver s seat h r s seat has been adj as been adjusted to t usted to...

Page 59: ...to observe the recommended Failure to observe the recommended body size can cause stress and endanger body size can cause stress and endanger the driver and may lead to lasting ill health the driver a...

Page 60: ...nment can be clearly seen working environment can be clearly seen 3 3 4 4 1 1 Ad Adju just stin ing th g the dr e driv iver er s s s sea eat t WARNING WARNING Risk of accidents and damage to health Ri...

Page 61: ...the lever After s After setting etting the wei the weight mo ght move the l ve the lever 9 ever 95 back 5 back in full in full The driver s weight is now set The driver s weight is now set Adjusting t...

Page 62: ...t fo s seat forwards o rwards or backwa r backwards to th rds to the desire e desired positi d position on Engag Engage the dr e the driver s iver s seat lo seat locking l cking lever 9 ever 97 in p 7...

Page 63: ...ard as required backward as required Pus Push the ste h the steeri ering whe ng wheel adj el adjust usting le ing lever ver 102 in the direction of the arrow 102 in the direction of the arrow 3 3 4 4...

Page 64: ...irs Z Z Protect the seat belt from contamination e g cover it when the truck is idle and Protect the seat belt from contamination e g cover it when the truck is idle and clean it regularly Frozen belt...

Page 65: ...ways when passing at slow speed when negotiating bends or narrow passageways when passing through swing doors and at blind spots The driver must always observe an adequate through swing doors and at b...

Page 66: ...driver after the truck has come to a halt and must exit the lift before the truck The driver must ensure that the loading ramp bridge must ensure that the loading ramp bridge cannot move or come loos...

Page 67: ...ions to be performed Checks and operations to be performed before starting daily operation on before starting daily operation on pa page ge 59 59 Switching on the industrial truck Switching on the ind...

Page 68: ...seconds Now s Now set th et the ign e igniti ition st on starte arter key t r key to the o the III position III position Z Z Only apply the starter for a maximum of Only apply the starter for a maxim...

Page 69: ...88 and charge current indicator 110 88 and charge current indicator 110 should go out after a short while If not should go out after a short while If not stop the start up process and rectify the sto...

Page 70: ...elect a place to park where no other people are at risk of injury from lowering forks forks Do not park and abandon the truck on an incline Do not park and abandon the truck on an incline Parking and...

Page 71: ...cy Disconnect switch must not be affected by any objects placed in its way objects placed in its way Applying the Emergency Disconnect Applying the Emergency Disconnect Procedure Procedure Pre Press t...

Page 72: ...ravel travel direct direction w ion with t ith the tr he travel avel direction switch 71 direction switch 71 NOTE NOTE Only change direction when the truck has Only change direction when the truck has...

Page 73: ...s a service brake This intended as a crawl speed aid The pedal should not be used as a service brake This operating mode can only be used for max 5 seconds when the engine is running at operating mode...

Page 74: ...ing distance when travelling with an attached load 4 4 7 7 1 1 Se Ser rvi vice b ce bra rake ke The brake pedal hydraulically actuates the The brake pedal hydraulically actuates the drum brakes of the...

Page 75: ...and injury When leaving the industrial truck always engage the parking brake An audible When leaving the industrial truck always engage the parking brake An audible warning will sound if the parking...

Page 76: ...d centrally between the forks located centrally between the forks Adjusting the forks Adjusting the forks Requirements Requirements Park Park the the truck truck securely securely see see Parking Park...

Page 77: ...re the the bolts bolts are are seated correctly Retaining bolt torque 85 Nm seated correctly Retaining bolt torque 85 Nm WARNING WARNING Trapping hazard Trapping hazard There is a trapping hazard when...

Page 78: ...rsing Never exceed the maximum loads specified in Never exceed the maximum loads specified in the capacity chart the capacity chart Never stand underneath a raised load handler Never stand underneath...

Page 79: ...s t crossings an ings and passa d passageways geways Alway Always tra s travel w vel with a ith a lookou lookout at t at blind blind spots spots On slope On slopes and inclin s and inclines always ca...

Page 80: ...ugh the mast Do not reach through the mast The controls should only be operated from the driver s seat and never suddenly The controls should only be operated from the driver s seat and never suddenly...

Page 81: ...utral and the lifting device remains in the position it has reached the position it has reached Procedure Procedure Set t Set the tra he travel di vel direc rectio tion swit n switch 71 ch 71 to to ne...

Page 82: ...atically from the pressure relief valve release the lever The lever will revert automatically to neutral to neutral Tilting the mast forward backward Tilting the mast forward backward Requirements Req...

Page 83: ...t the driver s viewpoint Pu Push t sh the S he SOL OLO O PI PILO LOT le T leve ver r 1 119 19 in in direction V to move the load handler to the direction V to move the load handler to the left from th...

Page 84: ...ional equipment Requirements Requirements Truck Truck ready for ready for operation see operation see Preparing Preparing the truc the truck for operat k for operation on page ion on page 68 68 The fo...

Page 85: ...hment manufacturer for Only use attachments that have been designed by the attachment manufacturer for use with the respective industrial truck use with the respective industrial truck Only use attach...

Page 86: ...e attachment make sure that the hydraulic lines of the attachment are connected to the right ports see Fitting additional attachments attachment are connected to the right ports see Fitting additional...

Page 87: ...sectional area only carry loads that are resting along the entire length of the fork extension resting along the entire length of the fork extension Only use fork extensions with the same fork cross s...

Page 88: ...so that they match the controls direction of movement that they match the controls direction of movement 4 13 1 4 13 1 Solo Pilot wit Solo Pilot with control of ZH1 hydr h control of ZH1 hydraulic por...

Page 89: ...4 13 3 4 13 3 Solo Pilot with Solo Pilot with control of ZH1 control of ZH1 ZH2 and ZH3 ZH2 and ZH3 hydraulic ports hydraulic ports Z Z Functions are assigned to the levers Functions are assigned to t...

Page 90: ...f the ignition nition set th set the ignit e ignition sta ion starter sw rter switch 0 itch 0 Turn the i Turn the ignitio gnition on again s n on again set the igni et the ignition star tion starter...

Page 91: ...ironmental regulations If hydraulic oil comes into contact with the skin wash it off immediately with soap If hydraulic oil comes into contact with the skin wash it off immediately with soap and water...

Page 92: ...Identification points and Identification points and data plates on data plates on page page 30 If a load 30 If a load is is also transported on the forks the trailer load must be reduced by the same a...

Page 93: ...than 10 and never facing up Attaching the trailer Attaching the trailer Requirements Requirements Truck and trailer are on a level surface Truck and trailer are on a level surface Trailer prevented fr...

Page 94: ...Seat Belt on p Belt on page age 65 65 Opening and closing the door Opening and closing the door Procedure Procedure To un To unloc lock the ca k the cabin do bin door tur or turn the ke n the key ant...

Page 95: ...nd hold on with both hands Tilt steering wheel and hold on with both hands Tilt your body in the opposite direction of fall your body in the opposite direction of fall Requirements Requirements On On...

Page 96: ...ng hours and replace it at the latest after 1000 operating hours operating hours 129 129 I It te em m N Na am me e I It te em m N Na am me e 1 13 30 0 W Wi in nd ds sc cr re ee en n j je et ts s 1 13...

Page 97: ...oller 13 oller 132 to the right to in 2 to the right to increase th crease the cab temper e cab temperature ature Turn the tem Turn the temperatu perature contro re controller 132 ller 132 to the left...

Page 98: ...t fro t from the fo m the fork rk carriage and put it down securely carriage and put it down securely Load backrest assembly Load backrest assembly Procedure Procedure Attac Attach the loa h the load...

Page 99: ...e trailer pull er pull rod to t rod to the heig he height of th ht of the coupl e coupling ing Pull Pull the han the hand leve d lever 138 r 138 re remote c mote control ontrol 139 139 o o up up Z Z...

Page 100: ...m on or off Press the button 142 on the monitor to switch the camera system on or off Press the button 143 to lighten or darken the screen day night settings Press the button 143 to lighten or darken...

Page 101: ...lint filter must be cleaned regularly according to how much it is clogged Procedure Procedure Rem Remove t ove the co he cover ver 147 147 aft after th er the loc e lock k 148 is opened 148 is opened...

Page 102: ...ion can only be changed reversing if the industrial truck is travelling at less than 3 km h If the driver attempts to change direction without braking at a at less than 3 km h If the driver attempts t...

Page 103: ...from the ha m the hazardou zardous area i s area if neces f necessary sary Lower Lower the f the fork c ork carriag arriage and e and load load secure securely ly Switc Switch the dr h the drive to n...

Page 104: ...in control ntrol lever lever to the to the right right and and forward to tilt the mast forward and raise the forward to tilt the mast forward and raise the load load Push Push the m the main c ain co...

Page 105: ...stomer services to react quickly and specifically to the fault the In order for customer services to react quickly and specifically to the fault the following information is essential following inform...

Page 106: ...tact spray contact spray Sp Spark plugs damp ark plugs damp oily oily or loose or loose Dry Dry clean and tighten clean and tighten spark plugs spark plugs S Sp pa ar rk k p pl lu ug gs s f fa au ul l...

Page 107: ...el direction switch to required direction direction Par Parkin king br g brake ake app applie lied d Rel Releas easing ing the the par parkin king br g brake ake Truck does Truck does not reach not re...

Page 108: ...ke released One person must be seated in the recovery truck to steer it and one person must One person must be seated in the recovery truck to steer it and one person must be seated on the towed truck...

Page 109: ...supervisor Report any defects immediately to your supervisor Tag out and decommission a faulty lift truck Tag out and decommission a faulty lift truck Only return the truck to service when Only return...

Page 110: ...ed nal of the feeder batte er battery to the negat ry to the negative term ive terminal with th inal with the e black lead black lead To star To start the truc t the truck switch o k switch on the ign...

Page 111: ...111 111 0 0 8 8 1 1 2 2 E E N N https www besttruckmanuals com...

Page 112: ...ve changes to authorised the respective changes to the capacity data plates the capacity data plates decals and stickers as well as the operator and service manuals decals and stickers as well as the...

Page 113: ...ler raised cab if they have been secured if they have been secured with a sufficiently strong chain or the with a sufficiently strong chain or the fastening bolt fastening bolt In order to raise and j...

Page 114: ...water Do not clean the electrical system with water Do not clean the electrical system with water Clean the electrical system with weak suction or compressed air use a compressor Clean the electrical...

Page 115: ...ings or metal bracelets etc before working on electrical components Remove any rings or metal bracelets etc before working on electrical components Consumables and used parts Consumables and used part...

Page 116: ...ns are safety critical parts They must not contain any serious contamination Lift chains and pivot pins must always be clean and well lubricated Lift chains and pivot pins must always be clean and wel...

Page 117: ...an penetrate the skin through fine holes or hairline cracks Pressurised hydraulic oil can penetrate the skin through fine holes or hairline cracks in the hydraulic lines causing severe injury in the h...

Page 118: ...y if the truck is to be used in operating conditions They must be reduced accordingly if the truck is to be used in conditions of extreme dust temperature fluctuations or multiple shifts conditions of...

Page 119: ...gear ear oil oil suc suctio tion fi n filte lter an r and di d disch scharg arge e t t 2 2 7 7 Ch Chan angi ging ng th the g e gea ear o r oil il fi filt lter er t t 2 2 8 8 Ch Chec eck dr k driv ive...

Page 120: ...1 1 Ch Chec eck m k mas ast a t att ttac achm hmen ent t t t 6 2 6 2 Che Check ck and and lub lubric ricate ate the the mas mast s t susp uspens ension ion t t 6 6 3 3 Ch Chec eck op k oper erat atio...

Page 121: ...tio tions ar ns are sec e secure a ure and ch nd check f eck for da or damag mage e t t 8 3 8 3 T Test a est all wa ll warni rning de ng devic vices an es and saf d safety s ety swit witche ches s t t...

Page 122: ...d ng distan istance ce t t 12 12 2 2 T Test l est lif ift and l t and lowe owerin ring spe g speeds eds t t 12 12 3 3 T Test s est safe afety de ty devic vices an es and cut d cutout outs s t t Servic...

Page 123: ...m speed wi d without thout load load adjust adjust if nec if necessary essary t t Service intervals Service intervals S St ta an nd da ar rd d W W A A B B C C Coolant Coolant 2 1 2 1 Check the coolan...

Page 124: ...e Repl plac acin ing th g the fu e fuel f el fil ilte ter r t t 6 2 6 2 Che Check fue ck fuel w l wate ater sepa r separat rator or and dis and discha charge if ne rge if neces cessar sary y t t 6 3 6...

Page 125: ...imum spee m speed wi d without thout load load adjust adjust if nec if necessary essary t t Service intervals Service intervals S St ta an nd da ar rd d W W A A B B C C Coolant Coolant 2 1 2 1 Check t...

Page 126: ...p replac laced ed by by spe specia cialis list t t t 6 3 6 3 Hav Have L e LPG PG sys system tem exa examin mined ed by by spe specia cialis list t t t 6 4 6 4 Have the exhaust pollutant levels checked...

Page 127: ...onding agent consumable mixture must be disposed of in accordance with regulations regulations WARNING WARNING Oils chain spray hydraulic oil are flammable Oils chain spray hydraulic oil are flammable...

Page 128: ...ls must be disposed of in accordance with the relevant environmental protection regulations To change the oil contact the manufacturer s environmental protection regulations To change the oil contact...

Page 129: ...io on n v ve es ss se el l s s G Gr re ea as se e n ni ip pp pl le e E E S St te ee er r a ax xl le e l lu ub br ri ic ca at ti io on n S S H Hy yd dr ra au ul li ic c o oi il l f fi il ll le er r n n...

Page 130: ...distilled water DFG TFG 540 550 DFG TFG 540 550 C Co od de e O Or rd de er r n no o P Pa ac ck ka ag g e e quantit quantit y y C Ca ap pa ac ci it ty y D De es sc cr ri ip pt ti io on n U Us se ed d...

Page 131: ...ed at least annually e g at the start of the cold season the cold season If the correct procedures are not applied the manufacturer cannot be held liable for If the correct procedures are not applied...

Page 132: ...77 77 to prevent the truck from being switched to prevent the truck from being switched on accidentally on accidentally WARNING WARNING Risk of accidents when working under the load handler driver s...

Page 133: ...he engine cover in the raised damper keeps the engine cover in the raised position position Mak Make sur e sure the e e the engi ngine co ne cover h ver has en as engag gaged ed correctly before opera...

Page 134: ...yres of the same make model and profile Checking the wheel attachment Checking the wheel attachment Requirements Requirements Prepare Prepare the the truck truck for for maintenance maintenance and an...

Page 135: ...ot smoke when handling hydraulic oil Do not smoke when handling hydraulic oil Avoid contact and digestion If you swallow Avoid contact and digestion If you swallow oil do not induce vomiting but call...

Page 136: ...should lie just For hot oil The hydraulic oil should lie just above the MAX marking above the MAX marking Add Add hyd hydrau raulic o lic oil if il if nec necess essary ary Re Repe peat at th the t e...

Page 137: ...ter in pla n place ag ce again ain Z Z Collect any spilled hydraulic oil Dispose of the hydraulic oil and hydraulic oil filter Collect any spilled hydraulic oil Dispose of the hydraulic oil and hydrau...

Page 138: ...when replacing the oil and oil filter oil and oil filter NOTE NOTE When the engine is cold the engine oil can be viscous When the engine is cold the engine oil can be viscous Only change the engine o...

Page 139: ...h and manually unscrew it and manually unscrew it Thoro Thoroughly ughly clean clean the s the sealing ealing faces faces of the of the oil oil filter flange filter flange Apply Apply a thin a thin la...

Page 140: ...do the f the filter ilter housin housing wit g with a h a filter filter wrench wrench and manually unscrew it and manually unscrew it Turn Turn the fi the filter i lter insert nsert anticl anticlockwi...

Page 141: ...lt be lt betwe tween th en the fan V e fan V belt pulley 166 and the generator belt pulley 166 and the generator V belt pulley 167 using a force of V belt pulley 167 using a force of 45 N 45 N It shou...

Page 142: ...ilter industrial truck is horizontal Always replace the engine oil and engine oil filter together together Checking the engine oil level Checking the engine oil level Requirements Requirements Park Pa...

Page 143: ...ually unscrew it Thorou Thoroughly ghly clean clean the s the sealing ealing faces faces of th of the oil e oil filter flange filter flange Apply Apply a thin a thin layer layer of eng of engine oi in...

Page 144: ...p k plu lugs gs Procedure Procedure Rem Remove sp ove spark pl ark plug con ug connec nector 1 tor 170 70 Tho Thorou roughl ghly clea y clean arou n around the sp nd the spark pl ark plugs ugs on the...

Page 145: ...Chec ecki king t ng the V b he V bel elt te t tens nsio ion n Z Z The V belt tension is maintained by an The V belt tension is maintained by an automatic belt tensioner 171 No manual automatic belt te...

Page 146: ...hen the filler cap is opened escaping when the filler cap is opened Checking the coolant level Checking the coolant level Procedure Procedure Park Park the t the truck ruck secure securely on ly on a...

Page 147: ...freeze tester NOTE NOTE The incorrect coolant concentration The incorrect coolant concentration can cause malfunctions can cause malfunctions If there is insufficient anti freeze content If there is i...

Page 148: ...sing with compressed air Always use a clean cloth to clean the air filter housing Always use a clean cloth to clean the air filter housing Rem Remove t ove the ai he air fil r filter c ter cart artrid...

Page 149: ...e eng ngin ine co e cove ver r Make su Make sure there i re there is suffic s sufficient win ient windscree dscreen fluid in t n fluid in the conta he container iner If ne If neces cessar sary top up...

Page 150: ...e and repa nance and repairs on page irs on page 133 133 Procedure Procedure Op Open t en the e he eng ngin ine co e cove ver r Check c Check conditi ondition and rat on and rating of the f ing of the...

Page 151: ...It te em m E El le ec ct tr ri ic c c ci ir rc cu ui it t R Ra at ti in ng g A A 7 7 o o H He ea at ti in ng g 1 15 5 8 8 o o F Fr ro on nt t w wi in nd do ow w w wi ip pe er r 1 10 0 9 9 o o W Wi in...

Page 152: ...in ng g l li ig gh ht t l le ef ft t t ta ai il l l li ig gh ht t 7 7 5 5 18 18 o o B Br ra ak ke e l li ig gh ht t 7 7 5 5 Fuse box options 1 black fuse box Fuse box options 1 black fuse box I It te...

Page 153: ...le ec ct tr ri ic c c ci ir rc cu ui it t R Ra at ti in ng g A A 27 27 t t P Pr re e h he ea at t 1 10 00 0 28 28 t t F Fu ue el l p pu um mp p 1 15 5 t t Series equipment Series equipment o o Option...

Page 154: ...onnect fuse box I It te em m E El le ec ct tr ri ic c c ci ir rc cu ui it t R Ra at ti in ng g A A 29 29 t t E En nt ti ir re e t tr ru uc ck k 5 50 0 30 30 t t S Se ea at t m mo on ni it to or ri in...

Page 155: ...oxi ove any oxidisati disation on remains from the battery terminals Lubricate the remains from the battery terminals Lubricate the battery terminals with an acid free battery terminals with an acid f...

Page 156: ...o be inspected by specialist personnel exhaust system to be inspected by specialist personnel The exhaust system has now been checked for leaks The exhaust system has now been checked for leaks NOTE N...

Page 157: ...ty seat belt can cause injury A faulty seat belt can cause injury Using a faulty seat belt can result in injury Using a faulty seat belt can result in injury Only operate the truck with the seat belt...

Page 158: ...ice in this case 6 11 2 6 11 2 Check Checking the brak ing the brake fluid leve e fluid level l Procedure Procedure Und Undo the sc o the screw rews of the le s of the left ft han hand pane d panel l...

Page 159: ...s customer service department is specially trained to carry out these operations these operations WARNING WARNING Faulty brakes can cause accidents Faulty brakes can cause accidents As soon as the tru...

Page 160: ...dentally Jack up the truck only on a level surface and prevent it from moving accidentally Always Always use use a a jack jack with with sufficient sufficient capacity capacity When When jacking jacki...

Page 161: ...io ication n Schedu Schedule le on p on page age 130 130 Disco Disconnect t nnect the batt he battery cl ery clean it a ean it and grea nd grease the te se the termina rminals ls Z Z In addition follo...

Page 162: ...ecessar essary y Z Z The manufacturer s customer service department is specially trained to carry out The manufacturer s customer service department is specially trained to carry out these operations...

Page 163: ...r shall be sufficiently instructed and experienced to be able to assess the condition of the truck and the effectiveness of experienced to be able to assess the condition of the truck and the effectiv...

Page 164: ...the manufacturer Note the manufacturer s safety instructions as specified in the service documentation instructions as specified in the service documentation 10 10 H Hum uman an vi vibr brat atio ion...

Page 165: ...and VERT VERT specifies specifies in in particular particular the the requirements requirements for for tunnel tunnel building building projects and major construction sites projects and major constru...

Page 166: ...the exhaust The level of the diesel particle filter is shown on the HUSS Control display enabling The level of the diesel particle filter is shown on the HUSS Control display enabling regeneration to...

Page 167: ...ounted within the operator s field of vision Z Z The HUSS control system only works with The HUSS control system only works with the ignition is switched on the ignition is switched on Display Display...

Page 168: ...be started regeneration must be started regeneration must be performed performed A ATTENTION in a hazardous TTENTION in a hazardous situation the industrial truck situation the industrial truck can b...

Page 169: ...rt regeneration in art regeneration in 5 sec 5 sec Green LED Green LED Other displays after the 5 seconds Other displays after the 5 seconds The fan is set to pre cooling The fan is set to pre cooling...

Page 170: ...tware functions are tested All the hardware and software functions are tested during regeneration during regeneration Any faults will cause the regeneration to be Any faults will cause the regeneratio...

Page 171: ...171 171 0 0 8 8 1 1 2 2 E E N N https www besttruckmanuals com...

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Jungheinrich DFG 540, Operating Instructions Manual

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Summary of Contents for DFG 540

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