Jungheinrich DFG 540 parts for servicing and the operator seat

Every service on a diesel forklift such as the Jungheinrich DFG 540 starts with oil, so the engine oil filter is the obvious place to begin. A well kept truck also needs a sound seat, a working lap belt and a seat contact switch that does its job. More than 30 parts for the DFG 540 are collected here, made by GRAMMER, HELLA, GRANIT, FEBI and BOSCH.

Changing the oil filter

Two engine oil filters are listed for this truck. Wipe a thin film of clean engine oil on the rubber seal of the new filter, spin it on by hand until the seal touches, then give it roughly three quarters of a turn more. Cranking it on with a filter wrench makes the next change a struggle, and a dry seal may weep on first start. Let the engine tick over for a minute, then look for any trace of oil around the filter.

The seat contact switch

This switch tells the truck that an operator is in the seat. When the DFG 540 refuses to drive although someone is sitting on it, the switch is a sensible first suspect. A flattened seat cushion can cause the same symptom, because it no longer presses the switch properly. For the seat itself there are:

• seat cushions in black fabric and back cushions in black PVC
• a tilt adjustable right armrest
• an adjustable back extension for GRAMMER seats from MSG 65 to MSG 97
• shock absorbers and a gas strut
• lap belts, including a Duo-Sensitiv belt also used on other DFG trucks

Small electrical items

Rounding things off are a halogen bulb for head, fog and work lights, a changeover relay, a round reflector, a warning bulb, a cover and the red hazard light symbol. Minor items, but a missing reflector or a hazard switch without its symbol tends to get noted at the next inspection.

Confirming fit

Check the data plate to make sure you have a DFG 540. Oil filters carry their number on the canister, which you compare with the reference number shown for the product. Seat parts depend on the MSG model printed on the seat label. With a relay, count the pins underneath the old one.

Worn seat parts are worth replacing together. Fitting cushions, armrest and back extension in one go means taking the seat apart once rather than three times.

All other trucks from the maker, diesel, LPG or electric, are listed on the Jungheinrich parts page.