tUNGHEINRICH DFG / TFG 16-50 A/B/C -K / -S
01.11 0.1
@>
Chapter Overview
Operating Instructions 1 Masts 9
Technical Description of Components 2 Hydraulic System and Diagrams 10
General Truck Data
Operational Tests / Test and Setting Values
3 Electric System and Wiring Diagrams 11
Truck Maintenance 4 Diesel Particle Filter (HUSS) 12
Drive System V
Combustion Engines
5
Drive System V
Power Shift Transmission / Hydrostatic Drive
System
6
Brake System 7
Steering 8
HUNGHEINRICH
DFG / TFG 16-50 A/B/C -K / -S 09.04 1.1
(GB)
01 Operating Manuals
Language Series JAG Order No.
®
50 045 346
(gb) 50 045 345
CD
50 045 347
©
50 045 349
CD
50 045 350
®
50 045 352
(DK) 50 045 351
®
50 045 353
(RN)
DFG/TFG 16-50 A/B/C-K
50 045 354
(NL) 50 045 348
®
50 045 355
©
50 045 356
®
50 045 357
(PL) 50 045 358
(GR) 50 146 308
(SK) 50 147 855
(SLO) 50 147 859
(RUS) 50 310 992
Language Series JAG Order No.
®
50 045 360
(GB) 50 045 359
©
50 045 361
©
50 045 363
®
50 045 364
®
50 045 366
(DK) 50 045 365
©
50 045 367
@>
DFG/TFG 16-50 A/B/C-S
50 045 368
(NL) 50 045 362
©
50 045 369
©
50 045 370
®
50 045 371
(PL) 50 045 372
©
50 146 311
©
50 147 858
(SLO) 50 147 860
(RUS) 50 310 991
tUNGHEINMCH DFG 1TFG 1 6-50 A/B/C -K / -S
04.07 2.1 (GB)
02 Technical Description of Components
Notes
<stop>
Used before safety instructions which must be observed to avoid
danger to personnel.
Used before notices which must be observed to avoid material
damage.
p>|
Used before explanations.
Index
General 2.4
Models 2.5
Drive System / Diesel Engine 2.6
General Description of Engines 2.6
Drive System / LPG engine 2.9
General Description of Engines 2.9
Drive System / Power Shift Transmission 2.11
Power Shift Transmission Overview 2.11
Power Shift Transmission Design 2.12
Inch mechanism 2.12
Series AK Power Take Off 2.12
Series BK / CK Power Take Off 2.12
AK Series Transmission Pump 2.12
Series BK / CK Transmission Pump 2.12
Transmission control valve 2.12
Power Shift Transmission Assembly Overviews 2.13
DFG/TFG 16/20 Power Shift Transmission 2.13
Power Shift Transmission DFG/TFG 16/20
(TXL 15/25) supermodulised (from 04.04) 2.14
DFG/TFG 20-30 (TXL 30) Power Shift Transmission 2.15
DFG/TFG 20-30 (TXL 30/S) Power Shift Transmission ..... 2.16
DFG/TFG 40-50 Power Shift Transmission 2.17
Power Shift Transmission Hydraulic Diagram 2.18
DFG/TFG 16/20 hydraulic diagram 2.18
Hydraulic Diagram DFG/TFG 16/20
(TXL 15/25) supermodulised (from 04.04) 2.19
DFG/TFG 20-30 hydraulic diagram 2.20
DFG/TFG 20-30 hydraulic diagram 2.21
DFG/TFG 40-50 hydraulic diagram 2.22
DFG/TFG 40-50 Power Shift Transmission
Functional Description 2.23
Neutral position 2.23
1st forward gear starting phase 2.24
1st forward gear -inching 2.25
1st forward gear engaged 2.26
2nd forward gear engaged 2.27
Clutch Design and Functions (Schematic) 2.28
DFG/TFG 16/20 Clutches 2.28
DFG/TFG 20-30 Clutches 2.29
DFG/TFG 40-50 Clutches 2.30
tUNGHEINRICH DFG 1TFG 1 6-50 A/B/C -K / -S
04.07 2.2 (GB)
Drive System / Hydrostatic 2.31
Design and Function 2.31
Block Diagram 2.32
Displacement Pump Functional Principle 2.33
Hydraulic Axle Hydraulic Diagram 2.34
Hydrostatic System Design (Schematic) 2.35
Functional Description of Key Components 2.36
Brake system 2.39
Brakes, General 2.39
Drum brake / Knott 2.40
Drum brake / Akebono 2.40
Automatic Adjuster / Knott 2.41
Parking brake 2.42
Vacuum pump 2.42
Brake booster 2.42
Brake force limiter 2.42
Steering 2.44
Functional Diagram 2.44
A series steering axle 2.45
B and C series steering axle 2.46
Steer cylinder 2.47
Chassis / Mast Connection 2.48
Chassis Attachment 2.48
Mast attachment 2.48
Tilt cylinder 2.49
Masts 2.50
Hydraulic system 2.51
Control valve / standard 2.51
Control valve / multi-functional 2.52
Electrical System 2.53
Travel direction switch 2.53
Operator displays and controls 2.54
Display item description 2.55
Controls 2.58
Display 2.60
Hourmeter 2.60
Lamp check 2.60
Display item description 2.62
Controls 2.64
Display 2.66
Hourmeter 2.66
Lamp check 2.66
LPG systems 2.67
Technical Description of Components 2.67
Assembly Overview 2.67
Power supply system 2.68
Main locking device and line break safety device 2.68
Relief valve 2.68
High pressure hose 2.68
Filter / shutoff valve, VFF 30 model 2.69
Evaporator/ pressure controller, model K 2.70
Evaporator /pressure controller, model K functional description
tUNGHEINRICH DFG 1TFG 1 6-50 A/B/C -K / -S
04.07 2.3 (GB)
2.71
Gas air mixer, model CA 100 2.72
Gas air mixer, model CA 100 functional description 2.73
Gas air mixer, model CA 55 2.74
Mazda FE / Hoof speed limiter 2.74
DFG/TFG 40-50 CS solenoids 2.75
DFG/TFG 40-50 CS hydraulic spring-loaded brake 2.76
TFG 20-30 BK/BS and TFG 40-50 CK/CS ignition module ...2.76
You're Reading a Preview
What's Included?
Lifetime Access
Fast Download Speeds
Offline Viewing
Access Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$48.99
Jungheinrich Fork Truck DFG540S, DFG545S, DFG550S, TFG540S, TFG545S, TFG550S (05.2012-12.2014) Workshop Service Manual
Viewed 73 Times Today
What's Included?
Lifetime Access
Fast Download Speeds
Offline Viewing
Access Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$48.99
Secure transaction
What's Included?
Lifetime Access
Fast Download Speeds
Offline Viewing
Access Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
Description
Get your hands on the Original Illustrated Factory Workshop Service Manual for Jungheinrich Fork Truck Type DFG/TFG 540-550. This manual is a comprehensive resource containing high-quality images, circuit diagrams, and detailed instructions to assist you in the operation and repair of your truck. The manual is printable and searchable, making it convenient for both professional mechanics and DIY enthusiasts.
Language: English
Contained Set of Manuals:
- Service manual, 517 Pages
- Operating Manual, 236 Pages
Covered models:
- DFG 540S (05.2012-12.2014)
- DFG 545S (05.2012-12.2014)
- DFG 550S (05.2012-12.2014)
- TFG 540S (05.2012-12.2014)
- TFG 545S (05.2012-12.2014)
- TFG 550S (05.2012-12.2014)
Contents:
- Safety Information
- Component Layout
- Technical Specifications
- Operating Instructions
- Circuit Diagrams (Electrical / Hydraulic)
- Parameters
- System Error Messages
- Special Tools
- BUS Systems Used
- Parking Brake
- Parking Brake Disassembly
- Parking Brake Assembly
- Parking Brake Release
- Misc. Electrical
- Fuses (see Operating Instructions, Chapter F)
- E box circuit diagram (see circuit diagrams)
- LPG systems - maintenance, testing and adjustment see service manual C 3001
- Impco LPG system
- Liquid gas container
- Controls
- Dual Pedal
- Hydrostatic Drive System
- Wheel Motor
- Variable Displacement Pump
- Cooling System
- TFG Cooling System
- DFG Cooling System
- Combustion Engines
- DFG
- TFG
- DFG Combustion Engine
- Starter Motor / Threephase Alternator
- Injection System
- Exhaust Return Line
- Air Mass Sensor Assembly Position
- Intake Pipe
- Sensors and Actuators
- Belt Drive
- Assembly/Disassembly
- Sealing Flange and Flywheel
- Charge-Air System
- Particle Filter
- Cooler Design
- TFG Combustion Engine
- Starter Motor / Threephase Alternator
- Belt Drive and Timing Chain
- Lubrication
- Sealing Flange and Flywheel
- Cooler Design
- Labels / Documentation
- Operating Instructions
- Wiring Diagrams
- Operator Position
- Armrest
- Sliding Windows
- Covers / Panel
- Engine Cover
- Hydraulic System
- Manifold
- Hydraulic System (filling and bleeding)
- Mast
- Securing the Mast
- Load Handler
- For forks see service manual G1 6401.01
- Commissioning
- Using the Truck for the First Time (see Operating Instructions, Chapter C)
- Maintenance
- LPG systems - maintenance, testing and adjustment see service manual C 3001
- DFG maintenance
- Regular safety inspection (at least annually)
- Maintenance checklist A
- Maintenance checklist B
- Maintenance checklist C
- TFG maintenance
- Regular safety inspection (at least annually)
- Maintenance checklist A
- Maintenance checklist B
- Maintenance checklist C
- Steering Axle
- Steering Axle
- Mechanical Components
- Steering Column
