Jungheinrich DFG 316 User manual

Operating instructions
51011137
DFG/TFG 316 / 320
G
04.06-
02.07

0108.GB
Foreword
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide
sufficient instruction for the safe operation of the industrial truck. The information is
provided clearly and concisely. The chapters are arranged by letter. Each chapter
starts with page 1. The page identification consists of a chapter letter and a page
number.
For example: Page B 2 is the second page in chapter B.
The operating instructions detail different truck models. When operating and servicing
the truck, make sure that the instructions apply to your truck model.
Safety instructions and important explanations are indicated by the following
graphics:
FUsed before safety instructions which must be observed to avoid danger to
personnel.
MUsed before notices which must be observed to avoid material damage.
ZUsed before notices and explanations.
tUsed to indicate standard equipment.
oUsed to indicate optional equipment.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to
alter the design, equipment and technical features of the truck. No guarantee of
particular features of the truck should therefore be inferred from the present operating
instructions.
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Am Stadtrand 35
22047 Hamburg - GERMANY
Telephone: [phone]
www.jungheinrich.com

0108.GB

I 1
0406.GB
Index
A Correct Application
B Truck Description
1 Application ........................................................................................... B 1
2 Assemblies and Functional Description .............................................. B 2
2.1 Truck ................................................................................................... B 3
3 Standard Version Specifications ......................................................... B 5
3.1 Performance Data DFG ...................................................................... B 5
3.2 Engine data ......................................................................................... B 10
3.3 Tyre Type .......................................................................................... B 10
3.4 Mast Versions ..................................................................................... B 11
3.5 EN norms ............................................................................................ B 12
3.6 Conditions of use ................................................................................ B 12
4 Identification points and data plates .................................................... B 13
4.1 Truck data plate .................................................................................. B 14
4.2 Truck load chart .................................................................................. B 14
4.3 Attachment load chart ......................................................................... B 15
C Transport and Commissioning
1 Lifting by crane .................................................................................... C 1
2 Securing the truck during transport ..................................................... C 2
3 Using the truck for the first time .......................................................... C 3
4 Towing the truck .................................................................................. C 3
D Filling the Truck with Fuel
1 Safety regulations for handling diesel fuel and LPG ........................... D 1
2 Filling with diesel ................................................................................. D 2
3 Replace the LPG bottle ....................................................................... D 3

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I 2
E Operation
1 Safety Regulations for the Operation of Forklift Trucks ...................... E 1
2 Controls and Displays ......................................................................... E 3
3 Starting up the truck ............................................................................ E 7
3.1 Checks and operations to be performed before starting daily work .... E 7
3.2 Trucks with reduced headroom X (o) ................................................. E 7
3.3 Adjusting the driver’s seat ................................................................... E 9
3.4 Safety restraint belt ............................................................................. E 10
3.5 Adjusting the steering column ............................................................. E 12
3.6 Starting the truck ................................................................................. E 13
3.7 Starting procedure for the TFG ........................................................... E 14
3.8 Starting procedure for the DFG ........................................................... E 15
3.9 Operational Fault Displays .................................................................. E 17
3.10 Stopping the engine1. ......................................................................... E 18
4 Industrial truck operation ..................................................................... E 19
4.1 Safety regulations for truck operation ................................................. E 19
4.2 Travel .................................................................................................. E 21
4.3 Steering ............................................................................................... E 23
4.4 Braking ................................................................................................ E 23
4.5 Mast and Attachment Operation ......................................................... E 24
4.6 Collecting, transporting and depositing loads ..................................... E 26
4.7 Parking the truck securely ................................................................... E 30
4.8 Towing trailers ..................................................................................... E 32
4.9 Tow loads ............................................................................................ E 32
5 Troubleshooting .................................................................................. E 33

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F Industrial Truck Maintenance
1 Operational safety and environmental protection ................................ F 1
2 Maintenance Safety Regulations ........................................................ F 1
3 Servicing and inspection ..................................................................... F 3
4 DFG/TFG maintenance checklist ........................................................ F 4
5 DFG maintenance checklist ................................................................ F 6
6 TFG maintenance checklist ................................................................. F 7
7 Coolant specification ........................................................................... F 8
8 DFG fuel specifications ....................................................................... F 9
9 Lubrication schedule ........................................................................... F 10
9.1 Fuels, coolants and lubricants ............................................................. F 11
10 Maintenance and Repairs ................................................................... F 12
10.1 Preparing the truck for maintenance and repairs ................................ F 12
10.2 Engine cover ....................................................................................... F 13
10.3 Servicing the engine DFG ................................................................... F 14
10.4 Engine servicing TFG .......................................................................... F 18
10.5 Check the hydraulic oil level ................................................................ F 21
10.6 Gas system drain tap .......................................................................... F 22
10.7 Checking the coolant level .................................................................. F 23
10.8 Checking the coolant concentration .................................................... F 23
10.9 Filling the cooling circuit ...................................................................... F 24
10.10 Cleaning/replacing the air filter cartridge ............................................. F 25
10.11 DFG/TFG transmission: ...................................................................... F 26
10.12 Brake ................................................................................................... F 27
10.13 Checking the wheel attachments. ....................................................... F 28
10.14 Hydraulic system ................................................................................. F 28
10.15 Clean/replace hydraulic reservoir ........................................................ F 28
10.16 Electrical System ................................................................................. F 29
11 Exhaust system ................................................................................... F 32
12 Restoring the truck to service after cleaning or repairs ....................... F 32
13 Decommissioning the industrial truck .................................................. F 32
13.1 Prior to decommissioning: ................................................................... F 32
13.2 During decommissioning: .................................................................... F 33
13.3 Returning the truck to operation after decommissioning ..................... F 33
14 Safety checks to be performed at regular intervals and following
any unusual incidents (D: Accident prevention check according
to BGV D27 ......................................................................................... F 34
15 Final de-commissioning, disposal ....................................................... F 34

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I 4

A 1
0406.GB
A Correct Application
ZThe “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are
supplied with the truck. The guidelines form part of these operating instructions and
must be observed. National regulations apply in full.
The truck described in the present operating instructions is an industrial truck
designed for lifting and transporting loads.
It must be applied, operated and serviced in accordance with the instructions
contained in the present manual. Any other type of use is beyond the scope of
application and can result in damage to personnel, the truck or property. In particular,
avoid overloading the truck with loads which are too heavy or placed on one side. The
data plate attached to the truck or the load diagram are binding for the maximum load
capacity. The industrial truck must not be used in fire or explosion endangered areas,
or areas threatened by corrosion or excessive dust.
Proprietor responsibilities: For the purposes of the present operator manual the
“proprietor” is defined as any natural or legal person who either uses the industrial
truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting)
the proprietor is considered the person who, in accordance with existing contractual
agreements between the owner and user of the industrial truck, is charged with
operational duties.
The proprietor must ensure that the industrial truck is used only for the purpose it is
intended for and that danger to life and limb of the user and third parties are excluded.
Furthermore, accident prevention regulations, safety regulations and operating,
servicing and repair guidelines must be followed. The proprietor must ensure that all
truck users have read and understood this operator manual.
MFailure to comply with the operator manual shall invalidate the warranty. The same
applies if improper work is carried out on the truck by the customer or third parties
without the permission of the manufacturer’s customer service department.
Attaching accessories: The mounting or installation of additional equipment which
affects or enhances the performance of the industrial truck requires the written
permission of the manufacturer. In some cases, local authority approval shall be
required.
Approval of the local authorities however does not constitute the manufacturer’s
approval.
Trailing and towed loads: The truck may only be used for trailing or towed loads for
which the truck has been approved.

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A 2

B 1
0207.GB
B Truck Description
1 Application
The DFG/TFG series are IC engine, 4-wheel rider trucks. The DFG series are diesel
engine trucks, while the TFG series are fitted with a petrol engine for LPG operation.
The DFG/TFG 316-320 is equipped with a hydrodynamic drive system. The left pedal
is a combination of crawl speed and brake pedal, and activates the rapid lift function
during slow travel. The middle pedal is a standard brake as well as an emergency
brake pedal.
The capacity depends on the model. The type description indicates the maximum
load rating. For example, a DFG/TFG 316 can carry loads of up to 1600 kg and a
DFG/TFG 320 loads of up to 2,000 kg.
Truck models and maximum capacity:
*) The load diagrams attached to the truck are binding in terms of capacity
Type Max. capacity *) Load centre of gravity
DFG/TFG 316 1,600 kg 500 mm
DFG/TFG 320 2,000 kg 500 mm

0207.GB
B 2
2 Assemblies and Functional Description
Item Description Item Description
1tDriver's seat 8 tLoad fork
2tSteering column 9 tFork carriage
3tDashboard 10 tDrive axle
4tOverhead guard 11 tEngine cover
5tMast 12 tSteering axle
6tLoad chain 13 tTrailer coupling
7tLift cylinder 14 tCounterweight
7
1
2
3
4
9
10
11
1314 12
8
6
5

B 3
0207.GB
2.1 Truck
Chassis/Superstructure: A solid, rigid chassis which protects the units and
controls, provides the truck with maximum static safety.
Maintenance and servicing are made easy through the wide opening cover and the
two side panels of the engine housing (11). The hydraulic oil reservoir is integrated
on the right-hand side and the fuel tank for the DFG series on the opposite side in the
chassis. The LPG bottle for the TFG series is secured to a bracket on the
counterbalance weight (14). The exhaust system prevents exhaust from entering the
driver’s position.
Driver’s position: Non-slip steps and a handle on the posts of the overhead guard
provide easy entry and exit. The driver is protected by the overhead guard (4). On the
driver’s seat the seat cushioning and the seat position are adjustable, while the
steering wheel tilt can be set on the steering column (2). Easy operation through
ergonomically arranged controls and a practically vibration-proof cab mean that the
driver is subjected to minimum stress. The controls and warning indicators on the
dashboard (3) provide system monitoring during operation. This results in a very high
level of safety.
FBefore the truck is started, the overhead guard must be inspected for cracks, and if
damaged, must be repaired or replaced.
Engine: Silent, water-cooled engines featuring high performance and low
consumption. In the DFG series diesel engines are used with very clean fuel
combustion under all operating conditions and soot levels below the visibility level.
For the TFG series, petrol engines are used with very low residual exhaust levels.
Drive system: A power shift gear with radiator and torque converter is directly
flanged to the engine. This transfers the force to the drive axle (10).
The travel direction switch on the left hydraulic control lever regulates forward/reverse
travel and the neutral position.
Steering: Hydrostatic steering consists of a steer cylinder integrated in the steering
axle (12). The steering axle is fully floating in the chassis to ensure excellent grip even
on non-level surfaces.
Brakes: The slow travel / brake pedal actuates two drum brakes which are applied
to the drive wheels. Worn drum brakes are automatically adjusted. The parking brake
operates through mechanical actuation of the parking brake lever on the drum brake
via Bowden cables.
Wheels: All wheels are located within the geometry of the truck. A choice of air or
superelastic tyres is available.

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B 4
Hydraulic system: The gear pump of the hydraulic system is powered by the engine
through a power take off. The pump speed and hence the supply flow are controlled
by the accelerator pedal through the engine speed.
Hydraulic functions are controlled by the control lever through a multiple control valve.
Electrical System: The 12 volt system consists of a starter battery and a threephase
generator with integrated controller. A repeat start block prevents incorrect operation
during start-up and a safety switch ensures the engine can only start when the travel
direction switch is in neutral. For diesel motors, a rapid pre-heat system is installed,
LPG motors have a non-contact electronic ignition system for rapid and trouble-free
engine starting. The ignition / starter switch is used to switch off the engine.
Mast (5): The target has been to maximize visibility. The maximum strength steel
section are narrow, allowing for good fork visibility in particular with the three-stage
mast. Equally good results have been achieved for the fork carriage.
The mast and the fork carriage run on permanently lubricated and hence
maintenance-free angled backing rollers.
Attachments: The trucks can be optionally fitted with mechanical and hydraulic
attachments.

B 5
0207.GB
3 Standard Version Specifications
ZTechnical specification details in accordance with VDI 2198. Technical modifications
and additions reserved.
3.1 Performance Data DFG
TFG performance data
Description DFG 316 DFG 320
Q Capacity 1600 2000 Kg
C Load centre of gravity 500 500 mm
Travel speed
w / w.o. load 18/19 18/19 km/h
Lift speed
w / w.o. load 0.6/0.62 0.6/0.62 m/s
Lowering speed
w / w.o. load 0.55/0.49 0.55/0.49 m/s
Gradeability
w / w.o. load 23 20 %
Description TFG 316 TFG 320
QCapacity
(where C = 600 mm) 1600 2000 Kg
C Load centre of gravity 500 500 mm
Travel speed
w / w.o. load 18/19 18/19 km/h
Lift speed
w / w.o. load 0.6/0.63 0.6/0.63 m/s
Lowering speed
w / w.o. load 0.55/0.49 0.55/0.49 m/s
Gradeability
w / w.o. load 25 22 %

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B 6

B 7
0207.GB
Dimensions DFG
Description DFG 316 DFG 320
a/2 Safety distance 100 100 mm
h1Mast height (retracted) 2185 2185 mm
h2Free lift 150 150 mm
h3Lift 3300 3300 mm
h4Mast height (extended) 3920 3920 mm
h6Overhead guard height 2145 2145 mm
h7Seat height (SIP) 1049 1049 mm
L1Length including forks 3386 3416 mm
L2Headlength 2236 2266 mm
b1Overall width 1080 1080 mm
e Fork width 100 100 mm
m1Ground clearance with load below mast 120 120 mm
m2Ground clearance from centre of wheelbase 130 130 mm
Ast Aisle width
for pallets 800 x 1200 longit. 3618 3640 mm
Ast Aisle width
1200 x 800 transverse pallets 3818 3840 mm
Wa Turning radius 2020 2042 mm
x Load distance 398 398 mm
y Wheelbase 1495 1495 mm
Truck weight 2870 3280 Kg

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B 8

B 9
0207.GB
TFG dimensions
Description TFG 316 TFG 320
a/2 Safety distance 100 100 mm
h1Mast height (retracted) 2185 2185 mm
h2Free lift 150 150 mm
h3Lift 3300 3300 mm
h4Mast height (extended) 3920 3920 mm
h6Overhead Guard Height 2145 2145 mm
h7Seat height (SIP) 1049 1049 mm
L1Length including forks 3386 3416 mm
L2Headlength 2236 2266 mm
b1Overall width 1080 1080 mm
e Fork width 100 100 mm
m1Ground clearance with load below mast 120 120 mm
m2Ground clearance from centre of wheelbase 130 130 mm
Ast Aisle width
for pallets 800 x 1200 longit. 3618 3640 mm
Ast Aisle width
1200 x 800 transverse pallets 3818 3840 mm
Wa Turning radius 2020 2042 mm
x Load distance 398 398 mm
y Wheelbase 1495 1495 mm
Truck weight 2840 3250 Kg

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B 10
3.2 Engine data
Engine - DFG
Engine - TFG
3.3 Tyre Type
ZPermissible tyre type forSolid: Solideal Magnum
Pneumatic: Solideal ED (Extra Deep)
Type S4Q2 four cylinder
Ignition sequence 1 3 4 2
Capacit. 2505 cc
Control speed 2350 RPM (unloaded)
680 RPM (idle)
Valve clearance Inlet and outlet 0.25 mm cold
Tray capacity 8.0 l
Fuel tank capacity 48 l
Coolant capacity 5.5 l + system = 14.0 l
Type 2.1 L L4 four cylinder, four stroke, LPG
Ignition sequence 1 3 4 2
Capacit. 2065 cc
Control speed 2700 ±50 RPM (unloaded)
850 ±50 RPM (idle)
Spark plug type NGH FR2A-D
Spark plug electrode distance 0.8-0.9 mm
Tray capacity 3.8 litres
Coolant capacity 3.5 litre + system = 13 litres
Full rubber SE tyres
(=Solid) DFG/TFG 316 DFG/TFG 320
Drive axle 6.50-10 6.50-10
Steering axle 18x7-8 18x7-8
Pneumatic tyres (diagonal
tyres) DFG/TFG 316 DFG/TFG 320
Drive axle 6-50-10 14PR 6-50-10 14PR
Steering axle 18x7-8 14PR 18x7-8 14PR
Tyre pressure DFG / TFG 316 DFG / TFG 320
Drive axle 10 bar 10 bar
Steering axle 9.0 bar 9.0 bar

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0207.GB
3.4 Mast Versions
(all dimensions in mm)
DFG/TFG 316/320
Mast table
VDI 3596
Description
Lift
h3
Free lift
h2
Retracted height h1
Extended height
h4
ZT
2900 150 1985 3520
3100 150 2085 3720
3300 150 2185 3920
3600 150 2335 4220
3800 150 2435 4420
4000 150 2535 4620
4500 150 2835 5120
5000 150 3085 5620
5500 150 3435 6120
5800 150 3635 6420
ZZ
2900 1290 1940 3550
3100 1390 2040 3750
3300 1490 2140 3950
3600 1640 2290 4250
3800 1740 2390 4450
4000 1840 2490 4650
4500 2140 2790 5150
DZ
4200 1290 1940 4850
4350 1340 1990 5000
4500 1390 2040 5150
4800 1490 2140 5450
5000 1565 2215 5650
5500 1740 2390 6150
6000 1940 2590 6650
6500 2190 2840 7150