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

Original Illustrated Factory Workshop Service Manual for Jungheinrich Fork Truck Type DFG/TFG 316-550. 
 
Original factory manuals for Jungheinrich Forklift Trucks, contains high quality images, circuit diagrams and instructions to help you to operate and repair your truck. All Manuals Printable and contains Searchable Text
 
 
Covered models:
 
    DFG 316 (07.2004-07.2008)
 
    DFG 320 (07.2004-07.2008)
 
    DFG 420 (07.2004-07.2008)
 
    DFG 425 (07.2004-07.2008)
 
    DFG 430 (07.2004-07.2008)
 
    DFG 540 (07.2004-07.2008)
 
    DFG 545 (07.2004-07.2008)
 
    DFG 550 (07.2004-07.2008)
 
    TFG 316 (07.2004-07.2008)
 
    TFG 320 (07.2004-07.2008)
 
    TFG 420 (07.2004-07.2008)
 
    TFG 425 (07.2004-07.2008)
 
    TFG 430 (07.2004-07.2008)
 
    TFG 540 (07.2004-07.2008)
 
    TFG 545 (07.2004-07.2008)
 
    TFG 550 (07.2004-07.2008)
 
 
Language: English
 
Format: ZIP, Contained set of PDF Manuals
 
Service Manual,  PDF, 753 Pages
 
Contents:
 
    Technical Description of Components
 
    General Truck Data. Operational Tests / Test and Setting Values
 
    Truck Maintenance
 
    Drive System V. Combustion Engines
 
    Drive System V.  Power Shift Transmission / Hydrostatic Drive
 
    System
 
    Brake System
 
    Steering
 
    Masts
 
    Hydraulic System and Diagrams
 
    Electric System and Wiring Diagrams
 
    Diesel Particle Filter (HUSS)
 
 
Operating Manual,  PDF, 144 Pages
 
Contents:
 
    A Correct Use and Application of the Truck
 
    B Description of Truck
 
        1 Description of Use 
 
        2 Description of Assemblies and Function 
 
        2.1 Truck 
 
        2.2 Mast  
 
        2.3 Changes in operational requirements 
 
        2.4 Safety devices 
 
        3 Technical Data -- Standard Equipment 
 
        3.1 Data tables -- DFG/TFG 316/320 
 
        3.2 Data tables -- DFG/TFG 420--430
 
        3.3 Data tables -- DFG/TFG 540--550
 
        4 Labels and Plates 
 
        4.1 Truck Rating Plate 
 
        4.2 Load diagrams 
 
    C Transportation and Commissioning
 
        1 Transportation 
 
        2 Commissioning 
 
    D Truck Refuelling
 
        1 Safety Conditions for Handling Diesel Fuel and Liquid Petroleum Gas 
 
        2 Filling with Diesel Fuel
 
        3 Changing the Gas Bottle
 
        4 Trucks fitted with Twin--Gas Bottles 
 
    E Operation
 
        1 Safety Regulations Governing the Operation of the Forklift Truck 
 
        2 Description of Drivers Controls and Display Elements
 
        3 Checks and Activities Before Daily Use 
 
        4 Using the Truck  
 
        4.1 Start Process TFG 
 
        4.2 Start Process DFG 
 
        4.3 Fault Displays during Operation 
 
        5 Operation of the Forklift Truck 
 
        5.1 Safety regulations applicable when operating the truck 
 
        5.2 Driving
 
        5.3 Steering
 
        5.4 Braking 
 
        5.5 Operating the Mast and Attachments 
 
        5.6 Picking Up, Transporting and Setting  Down Load Units
 
        5.7 Instructions for the use of restraint belts 
 
        5.8 Parking the Truck Safely 
 
        5.9 Engine housing and service covers 
 
        5.10 Towing 
 
        5.11 Towing Trailers
 
        5.12 Trailer loads 
 
        6 Fault Locating Operations 
 
    F Truck Maintenance
 
        1 Operational Safety and Environmental Protection 
 
        2 Safety Regulations Applicable to Truck Maintenance
 
        3 Servicing and Inspection 
 
        4 Maintenance Check-list DFG/TFG 
 
        5 Maintenance Check-list DFG
 
        6 Maintenance Check-list TFG
 
        7 Coolant Specification 
 
        8 Lubricant Specifications
 
        9 Fuel specification -- DFG 
 
        10 Lubrication Chart
 
        10.1 Lubrication Diagram -- DFG/TFG 316--430
 
        10.2 Lubrication Diagram -- DFG/TFG 540--550
 
        11 Description of Maintenance and Repair Work
 
        11.1 Preparing the Truck for Maintenance and Repair Work
 
        11.2 Engine Maintenance TFG 316/320 
 
        11.3 Engine Maintenance DFG 316/320
 
        11.4 Engine Maintenance TFG 420--430 
 
        11.5 Engine Maintenance DFG 420--430 
 
        11.6 Engine Maintenance TFG 540--550 
 
        11.7 Engine Maintenance DFG 540--550 
 
        11.8 Check Coolant Concentration
 
        11.9 Clean/Change Air Filter Cartridge 
 
        11.10 Transmission unit -- DFG/TFG 316/320 
 
        11.11 Transmission unit -- DFG/TFG 420--430
 
        11.12 Transmission unit -- DFG/TFG 540--550
 
        11.13 Brakes
 
        11.14 Change Wheels
 
        11.15 Hydraulic System 
 
        11.16 Electrical System 
 
        12 Exhaust System 
 
        13 Decommissioning 
 
        14 Inspection
 
        14.1 Safety checks to be performed at regular intervals and following any untoward incidents (D: Accident prevention check according to BGV D27) 
 
        15 Storage
 
        16 Disposal
 
    Appendix for Diesel Engine Exhaust Gas Filter -- STX Type 
 
        1 Introduction
 
        2 Regeneration 
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