DFG/TFG 540s–550s

Diesel and gas forklifts with hydrostatic drive units (4000, 4500, 5000 kg)

Large capacity industrial engines with high torque and a long service life

Hydrostatic drive unit for fast acceleration and direction changes

Isolated, cushion mounted cab

Oil immersed multi-disk parking brake with automatic operation

Comfortable operator’s cab featuring exemplary ergonomics

Jungheinrich diesel and gas forklift trucks with hydrostatic drive units have an incredible handling capacity. Their strengths come particularly to the fore in applications that require lots of direction changes, such as any continual loading and unloading processes. These strengths include dynamic acceleration, fast reversing and
precision control. The driving characteristics can be changed easily via the service laptop.

Large capacity industrial engines generate high torque even at low speeds. The benefits of this include lower fuel consumption and minimised noise development. These robust engines are specially designed for use in forklift trucks. That ensures high reliability and a long service life even for tough applications.

All the engines feature low emissions and comply with the future EU Directives. The gas versions are fitted as standard with a catalytic converter. A closed-loop 3-way catalytic converter (TFG) and various particulate filter systems (DFG) are available as options.

The operator’s cab has an ergonomic layout and is designed around the operator. This ensures safety, protects health and enables the operator to concentrate fully on his work whilst being in a relaxed &
stress free environment. Overall this ensures maximum productivity for arduous shifts.

Ergonomic operator’s cab
The comfortable operator’s cab helps maximise the operator’s work capacity and offers outstanding ergonomics:

Large visible step provides easy safe entrance and exit from the cab.
Cushion cab mountings noticeably reduce vibrations and oscillations.
Deluxe seat can be adjusted in three ways. Air suspension is available as an option.
Infinitely adjustable steering column.
Large, comfortable footwell with automotive style pedal layout.
Hydraulic levers and directional control are ergonomically positioned to the right of the operator.
Excellent forward visibility through panoramic mast and carriage.
Clear visible analogue instrument panel has extensive warning and control lights.
The optional deluxe cab provides a warm comfortable operating environment in all weathers.

Engines
Large capacity industrial engines, specially designed for the requirements of forklift trucks provide power in every situation:

4.4 litre diesel engine (Perkins), developing 61.5 kW of power with a maximum torque of 302 Nm at 1400 rpm. Clean emissions and quiet combustion by means of indirect injection.
4.3 litre V6 gas engine (GM), developing 67 kW of power with a maximum torque of 260Nm at 2200 rpm.
Long service life due to robust construction and low engine speed.
500 hour servicing interval.
Standard catalytic converter (TFG) for low emissions (NOx, CO, HC), closed-loop 3- way catalyst is optional.
Low particulate emissions (DFG), with various optional particulate filter systems.
70 litre diesel tank integrated in the chassis.

Hydrostatic drive and control system
The hydrostatic drive system is electrically controlled enabling precise control. 2 gears forward and reverse change automatically with travel speed.

High productivity in rapid direction change applications.
Driving characteristics can be changed easily via a laptop.
Automatic engine speed increase with use of any hydraulic function.
Single pedal control (accelerator) of travel speed and stopping.
Optional twin pedal control.
Low servicing costs due to the hydrostatic drive unit having no wearing parts (clutch, differential, gearbox, brakes).
Driving characteristics can be easily changed via a laptop.

Electrical system
12 Volt battery with 95 Ah (TFG/DFG) and 66A AC alternator. LPG engine with maintenance- free, non-contact electronic ignition.

Tyres
Super elastic tyres as standard. Non-marking SE tyres or pneumatic tyres available as options.

Steering
Hydrostatic steering provides low effort shock free steering, for maximum operator comfort and safety. The steer axle with integrated steering cylinder is fixed to the chassis through rubber bearings.

Brake
The hydrostatic truck abandons the need for a conventional brake. Only in emergencies should the brake pedal be depressed:

Complete wear-free hydrostatic braking.
Hydrostatic braking eliminates the need to use the brake pedal, accelerator pedal controls acceleration and braking.
Additional oil immersed multi-disk parking brake with spring accumulator requires no maintenance.
Safety on ramps – handbrake engages automatically when truck comes to a halt or when the engine is switched off.

Hydraulic system
The high performance filter system ensures clean oil and therefore the long service life of all the components:

suction filter and filter in the return line.
70 litre hydraulic tank integrated in the chassis.
The hydraulic tank is vented through a filter.
Pressure limiting valves prevent excessive pressure and overloads.

Mast
All components of the mast are designed for excellent visibility, high stability and a long service life:

Slim line mast sections with lift cylinders hidden behind, give an excellent field of view for safe operation.
Visibility through the carriage is excellent.
Carriages comply with FEM/ISO-2328-3A (540s, 545s) or FEM/ISO-2328-4A (550s).

Options
Various special options and mounted equipment are available for adapting to a range of application requirements or customer wishes.