Jungheinrich Fork Truck Type DFG/TFG 316S/320S/420S/425S/430S/540S/545S/550S Workshop Service Manual

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

tUNGHE/NRICH DFG 1TFG 1 6-50 A/B/C -K / -S 04.07 2.4 (GB) General The DFG/TFG "K" and "S" series are four-wheel, IC engine powered sit-down trucks with diesel engines or LPG petrol engines. The basic frame with the hydraulic and fuel reservoirs supports the drive unit and the steerin axle and also bears the counterweight. The hydrodynamicand hydrostatic variants of the series differ only in the power train when the same drive motors are used. In accordance with the concept of the predecessor model, the operator position module for all series is vibration-free. The driver's position module includes the motor and transmission covers, driver's seat, all controls and the overhead guard. tjUNGH£!M>aj

tUNGHEINRICH DFG / TFG 16-50 A/B/C -K / -S 04.07 2.5 (GB) Models Hydrodynamic drive system Hydrostatic drive system Predecessor Models from 11.93-05.97 Series A from 05.97 DFG/TFG 16 AF DFG 16 K TFG 16 K DFG 16 S TFG 16 S DFG/TFG 20 AF DFG 20 K TFG 20 K DFG 20 S TFG 20 S Series B from 05.97 DFG/TFG 20 TF DFG 20 K TFG 20 K DFG 20 S TFG 20 S DFG/TFG 25 TF DFG 25 K TFG 25 K DFG 25 S TFG 25 S DFG/TFG 30 TF DFG 30 K TFG 30 K DFG 30 S TFG 30 S Series C from 06.99 DFG/TFG 35/40 LF DFG 40 K TFG 40 K DFG 40 S TFG 40 S 45 n.a. DFG 45 K TFG 45 K DFG 45 S TFG 45 S DFG/TFG 50 MF DFG 50 K TFG 50 K DFG 50 S TFG 50 S K = hydrodynamic drive (with torque converter) S = hydrostatic drive with hydraulic drive system

tUNGHEINMCH DFG 1TFG 1 6-50 A/B/C -K / -S 04.07 2.6 (GB) Drive System I Diesel Engine General Description of Engines Diesel engine 1 type Perkins 104.22 Perkins 404C-22 Perkins 704.30 Perkins 704.26 Perkins 404C-22T Perkins 1004.42 Perkins 1 1 04C-44 In series DFG 16/20 AK/AS DFG 16/20 AK/AS (from 01 .02) DFG 20-30 BK/BS DFG 20-30 BK/BS (from 12.03/ 05.03) DFG 20-30 BS (from 11.06) DFG 40-50 CK/CS DFG 40-50 CK/CS (from 09.03) Power 31 kW 38 kW 40 kW 41 kW 43 kW 60 kW 64 kW Capacity 2216 ccm 2216 ccm 3000 ccm 2602 ccm 2216 ccm 4230 ccm 4400 ccm Cylinder block Water cooled 4 cylinder, four stroke Camshaft At the bottom Valve cover without integrated air intake manifold, oil filler neck or open crankcase discharge with integrated air intake manifold, oil filler neck or open crankcase discharge without integrated air intake manifold, oil filler neck or open crankcase discharge with integrated air intake manifold, oil filler neck or open crankcase discharge without integrated air intake manifold, oil filler neck or open crankcase discharge

tUNGHEINRICH DFG 1TFG 1 6-50 A/B/C -K / -S 04.07 2.7 (GB) Diesel engine / type Perkins 104.22 Perkins 404C-22 Perkins 704.30 Perkins 704.26 Perkins 404C-22T Perkins Perkins 1004.42 1 1 04C-44 Exhaust system Inlet/outlet manifold located on same side of the cylinder head (counter-current) Inlet and outlet manifold located on opposite sides of the cylinder head (cross¬ current) Inlet/outlet manifold located on same side of the cylinder head (counter- current) Inlet and outlet manifold located on opposite sides of the cylinder head (cross¬ current) Crankshaft assembly 5 fold positioning; sealed crankshaft positioning 5 fold positioning; divided crankshaft positioning Valves Tappet clearance setting required. Timing gear 3 helical timing gears, camshaft gearwheel, intermediate gear with rotor oil pump and crankshaft gearwheel. 3 helical timing gears, camshaft gearwheel with speed centrifugal governor, intermediate gear and crankshaft gearwheel. Drive wheel for the separate injection pump camshaft. 3 helical timing gears, camshaft gearwheel, intermediate gear with rotor oil pump and crankshaft gearwheel. 3 helical timing gears, camshaft gearwheel with speed centrifugal governor, intermediate gear and crankshaft gearwheel. Drive wheel for the separate injection pump camshaft. Injection pump Type PFR plug-in injection pump (cassette design) Distributor - injection pump Injection process Whirl chamber process Direct injection Whirl chamber process Direct injection

tUNGHEINRICH DFG 1TFG 1 6-50 A/B/C -K / -S 04.07 2.8 (GB) Diesel engine / type Perkins Perkins 104.22 404C-22 Perkins Perkins 704.30 704.26 Perkins 404C-22T Perkins 1004.42 Perkins 1 1 04C-44 Fuel pump driven by the camshaft Separate drive shaft driven by the camshaft Separate drive shaft Lubrication system Rotor oil pump integrated in timing gear intermediate gear Integrated rotor oil pump Rotor oil pump integrated in timing gear intermediate gear Separate oil pump powered by another gearwheel Cooling System V-belt powered water pump Gear-driven water pump Electrical system 12 volt single connector system Preheater system Pencil-type glow plugs without pre-heating time control Pencil-type glow plugs with pre-heating time control Pencil-type glow plugs without pre¬ heating time control Flame heater plug Pencil-type glow plugs without pre¬ heating time control

Jungheinrich Fork Truck Type DFG/TFG 316S/320S/420S/425S/430S/540S/545S/550S Workshop Service Manual

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