Jungheinrich DFG 316 User manual

Operating instructions
52027109
DFG/TFG 316-550
G
03.01 -
12.06

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.
AUsed 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
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.
AUsed 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
0108.GB

0106.GB
Contents
A Correct Use and Application of the Truck
B Description of Truck
1 Description of Use B 1...................................................
2 Description of Assemblies and Function B 2................................
2.1 Truck B3..............................................................
2.2 Mast B4...............................................................
2.3 Changes in operational requirements B 4..................................
2.4 Safety devices B 4......................................................
3 Technical Data -- Standard Equipment B 5..................................
3.1 Data tables -- DFG/TFG 316/320 B 14......................................
3.2 Data tables -- DFG/TFG 420--430 B 16......................................
3.3 Data tables -- DFG/TFG 540--550 B 19......................................
4 Labels and Plates B 23...................................................
4.1 Truck Rating Plate B 24...................................................
4.2 Load diagrams B 25......................................................
C Transportation and Commissioning
1 Transportation C 1......................................................
2 Commissioning C 4......................................................
D Truck Refuelling
1 Safety Conditions for Handling Diesel Fuel and Liquid Petroleum Gas D 1......
2 Filling with Diesel Fuel D 2...............................................
3 Changing the Gas Bottle D 3.............................................
4 Trucks fitted with Twin--Gas Bottles D 5....................................
E Operation E 1................................................
1 Safety Regulations Governing the Operation of the Forklift Truck E 1..........
2 Description of Drivers Controls and Display Elements E 3....................
3 Checks and Activities Before Daily Use E 11.................................
4 Using the Truck E 17.....................................................
4.1 Start Process TFG E 20...................................................
4.2 Start Process DFG E 21..................................................
4.3 Fault Displays during Operation E 23.......................................
5 Operation of the Forklift Truck E 25.........................................
5.1 Safety regulations applicable when operating the truck E 25...................
5.2 Driving E27.............................................................
5.3 Steering E 29............................................................
5.4 Braking E 29.............................................................
5.5 Operating the Mast and Attachments E 31...................................
5.6 Picking Up, Transporting and Setting
Down Load Units E 33....................................................
5.7 Instructions for the use of restraint belts E 40................................
5.8 Parking the Truck Safely E 42..............................................
5.9 Engine housing and service covers E 43....................................
5.10 Towing E45.............................................................
5.11 Towing Trailers E 45......................................................
5.12 Trailer loads E 46........................................................
6 Fault Locating Operations E 47............................................
0106.GB
Contents
A Correct Use and Application of the Truck
B Description of Truck
1 Description of Use B 1...................................................
2 Description of Assemblies and Function B 2................................
2.1 Truck B3..............................................................
2.2 Mast B4...............................................................
2.3 Changes in operational requirements B 4..................................
2.4 Safety devices B 4......................................................
3 Technical Data -- Standard Equipment B 5..................................
3.1 Data tables -- DFG/TFG 316/320 B 14......................................
3.2 Data tables -- DFG/TFG 420--430 B 16......................................
3.3 Data tables -- DFG/TFG 540--550 B 19......................................
4 Labels and Plates B 23...................................................
4.1 Truck Rating Plate B 24...................................................
4.2 Load diagrams B 25......................................................
C Transportation and Commissioning
1 Transportation C 1......................................................
2 Commissioning C 4......................................................
D Truck Refuelling
1 Safety Conditions for Handling Diesel Fuel and Liquid Petroleum Gas D 1......
2 Filling with Diesel Fuel D 2...............................................
3 Changing the Gas Bottle D 3.............................................
4 Trucks fitted with Twin--Gas Bottles D 5....................................
E Operation E 1................................................
1 Safety Regulations Governing the Operation of the Forklift Truck E 1..........
2 Description of Drivers Controls and Display Elements E 3....................
3 Checks and Activities Before Daily Use E 11.................................
4 Using the Truck E 17.....................................................
4.1 Start Process TFG E 20...................................................
4.2 Start Process DFG E 21..................................................
4.3 Fault Displays during Operation E 23.......................................
5 Operation of the Forklift Truck E 25.........................................
5.1 Safety regulations applicable when operating the truck E 25...................
5.2 Driving E27.............................................................
5.3 Steering E 29............................................................
5.4 Braking E 29.............................................................
5.5 Operating the Mast and Attachments E 31...................................
5.6 Picking Up, Transporting and Setting
Down Load Units E 33....................................................
5.7 Instructions for the use of restraint belts E 40................................
5.8 Parking the Truck Safely E 42..............................................
5.9 Engine housing and service covers E 43....................................
5.10 Towing E45.............................................................
5.11 Towing Trailers E 45......................................................
5.12 Trailer loads E 46........................................................
6 Fault Locating Operations E 47............................................

0106.GB
F Truck Maintenance
1 Operational Safety and Environmental Protection F 1........................
2 Safety Regulations Applicable to Truck Maintenance F 1.....................
3 Servicing and Inspection F 2.............................................
4 Maintenance Check-list DFG/TFG F 3.....................................
5 Maintenance Check-list DFG F 5..........................................
6 Maintenance Check-list TFG F 6..........................................
7 Coolant Specification F 7................................................
8 Lubricant Specifications F 9..............................................
9 Fuel specification -- DFG F 13.............................................
10 Lubrication Chart F 14....................................................
10.1 Lubrication Diagram -- DFG/TFG 316--430 F 15..............................
10.2 Lubrication Diagram -- DFG/TFG 540--550 F 16..............................
11 Description of Maintenance and Repair Work F 17...........................
11.1 Preparing the Truck for Maintenance and Repair Work F 17...................
11.2 Engine Maintenance TFG 316/320 F 17.....................................
11.3 Engine Maintenance DFG 316/320 F 20....................................
11.4 Engine Maintenance TFG 420--430 F 23...................................
11.5 Engine Maintenance DFG 420--430 F 25...................................
11.6 Engine Maintenance TFG 540--550 F 28...................................
11.7 Engine Maintenance DFG 540--550 F 30...................................
11.8 Check Coolant Concentration F 33.........................................
11.9 Clean/Change Air Filter Cartridge F 34......................................
11.10 Transmission unit -- DFG/TFG 316/320 F 35.................................
11.11 Transmission unit -- DFG/TFG 420--430 F 36................................
11.12 Transmission unit -- DFG/TFG 540--550 F 37................................
11.13 Brakes F38.............................................................
11.14 Change Wheels F 40.....................................................
11.15 Hydraulic System F 41....................................................
11.16 Electrical System F 42....................................................
12 Exhaust System F 45.....................................................
13 Decommissioning F 45...................................................
14 Inspection F 46..........................................................
14.1 Safety checks to be performed at regular intervals and following any
untoward incidents (D: Accident prevention check according to BGV D27) F 47..
15 Storage F 48............................................................
16 Disposal F 52............................................................
Appendix for Diesel Engine Exhaust Gas Filter -- STX Type 1.........
1 Introduction 1.........................................................
2 Regeneration 1.......................................................
0106.GB
F Truck Maintenance
1 Operational Safety and Environmental Protection F 1........................
2 Safety Regulations Applicable to Truck Maintenance F 1.....................
3 Servicing and Inspection F 2.............................................
4 Maintenance Check-list DFG/TFG F 3.....................................
5 Maintenance Check-list DFG F 5..........................................
6 Maintenance Check-list TFG F 6..........................................
7 Coolant Specification F 7................................................
8 Lubricant Specifications F 9..............................................
9 Fuel specification -- DFG F 13.............................................
10 Lubrication Chart F 14....................................................
10.1 Lubrication Diagram -- DFG/TFG 316--430 F 15..............................
10.2 Lubrication Diagram -- DFG/TFG 540--550 F 16..............................
11 Description of Maintenance and Repair Work F 17...........................
11.1 Preparing the Truck for Maintenance and Repair Work F 17...................
11.2 Engine Maintenance TFG 316/320 F 17.....................................
11.3 Engine Maintenance DFG 316/320 F 20....................................
11.4 Engine Maintenance TFG 420--430 F 23...................................
11.5 Engine Maintenance DFG 420--430 F 25...................................
11.6 Engine Maintenance TFG 540--550 F 28...................................
11.7 Engine Maintenance DFG 540--550 F 30...................................
11.8 Check Coolant Concentration F 33.........................................
11.9 Clean/Change Air Filter Cartridge F 34......................................
11.10 Transmission unit -- DFG/TFG 316/320 F 35.................................
11.11 Transmission unit -- DFG/TFG 420--430 F 36................................
11.12 Transmission unit -- DFG/TFG 540--550 F 37................................
11.13 Brakes F38.............................................................
11.14 Change Wheels F 40.....................................................
11.15 Hydraulic System F 41....................................................
11.16 Electrical System F 42....................................................
12 Exhaust System F 45.....................................................
13 Decommissioning F 45...................................................
14 Inspection F 46..........................................................
14.1 Safety checks to be performed at regular intervals and following any
untoward incidents (D: Accident prevention check according to BGV D27) F 47..
15 Storage F 48............................................................
16 Disposal F 52............................................................
Appendix for Diesel Engine Exhaust Gas Filter -- STX Type 1.........
1 Introduction 1.........................................................
2 Regeneration 1.......................................................

A1
0704.GB
A Correct Use and Application of the
Truck
The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) is
included in the scope of delivery for this truck. The guidelines are part of these
operating instructions and must always be heeded. National regulations are fully
applicable.
The forklift truck described in these operating instructions is a truck that is suitable for
lifting and transporting loads. It must be used, operated and maintained according to
the information in these operating instructions. Any other uses are outside the design
envelope and can lead to injury to persons or damage to equipment and property.
Above all, overloading caused by excessively heavy or unbalanced loads must be
avoided. The max. admissible load to be picked up can be seen from the identification
plate or load diagram label shown on the truck. The fork--lift truck must not be operated
in spaces subject to fire or explosion hazards, or in spaces where corrosive or very
dusty atmospheres prevail.
Duties of the user: User within the meaning of these operating instructions is any
natural person or legal person who either uses the fork--lift truck himself, or on whose
behalf it is used. In special cases (e.g. leasing or renting), the user is considered the
person, who, in accordance with existing contractual agreements between the owner
and the user of the fork--lift truck, is charged with the observance of the operating
duties.
The user must ensure that the truck is not abused and only used within its design limits
and that all danger to life and limb of the operator, or third parties, is avoided. In addition
to this, it must be ensured that the relevant accident prevention regulations and other
safety--related provisions, as well as the operating, servicing and maintenance
guidelines, are observed. The user must also ensure that all persons operating the
truck have read and understood these operating instructions.
If these Operating Instructions are not observed the warranty becomes void. The same
applies if improper work is carried out on the device by the customer and/or third parties
without permission of our Customer Service.
Mounting of attachments: The mounting or installation of any attachments which will
interfere with, or supplement, the functions of the truck is permitted only after written
approval by the manufacturer has been obtained. If necessary, the approval of local
authorities has to be obtained. Any approval obtained from local authorities does not,
however, make the approval by the manufacturer unnecessary.
Trailing and slipping loads: The truck may only be used for trailing or slipping loads
for which the truck has been approved.
A
A1
0704.GB
A Correct Use and Application of the
Truck
The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) is
included in the scope of delivery for this truck. The guidelines are part of these
operating instructions and must always be heeded. National regulations are fully
applicable.
The forklift truck described in these operating instructions is a truck that is suitable for
lifting and transporting loads. It must be used, operated and maintained according to
the information in these operating instructions. Any other uses are outside the design
envelope and can lead to injury to persons or damage to equipment and property.
Above all, overloading caused by excessively heavy or unbalanced loads must be
avoided. The max. admissible load to be picked up can be seen from the identification
plate or load diagram label shown on the truck. The fork--lift truck must not be operated
in spaces subject to fire or explosion hazards, or in spaces where corrosive or very
dusty atmospheres prevail.
Duties of the user: User within the meaning of these operating instructions is any
natural person or legal person who either uses the fork--lift truck himself, or on whose
behalf it is used. In special cases (e.g. leasing or renting), the user is considered the
person, who, in accordance with existing contractual agreements between the owner
and the user of the fork--lift truck, is charged with the observance of the operating
duties.
The user must ensure that the truck is not abused and only used within its design limits
and that all danger to life and limb of the operator, or third parties, is avoided. In addition
to this, it must be ensured that the relevant accident prevention regulations and other
safety--related provisions, as well as the operating, servicing and maintenance
guidelines, are observed. The user must also ensure that all persons operating the
truck have read and understood these operating instructions.
If these Operating Instructions are not observed the warranty becomes void. The same
applies if improper work is carried out on the device by the customer and/or third parties
without permission of our Customer Service.
Mounting of attachments: The mounting or installation of any attachments which will
interfere with, or supplement, the functions of the truck is permitted only after written
approval by the manufacturer has been obtained. If necessary, the approval of local
authorities has to be obtained. Any approval obtained from local authorities does not,
however, make the approval by the manufacturer unnecessary.
Trailing and slipping loads: The truck may only be used for trailing or slipping loads
for which the truck has been approved.
A

B1
1206.GB
B Description of Truck
1 Description of Use
Forklift trucks to series DFG/TFG are driver’s cab forklifts with 4 wheel construction and
combustion engine. Trucks to series DFG have diesel engines, trucks of series TFG a
liquid petroleum gas engine.
The DFG/TFG 316--550 has a hydrodynamic drive. A combined creep/brake pedal
allows rapid lifting during creep running.
As of Februry 2007 the DFG/TFG 540--550 is equippd with an additional pedal. 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 emergency
brake pedal.
The load--bearing capacity depends on type. The type description indicates the
maximum permitted load. A DFG/TFG 316 can lift, transport and stack loads up to 1600
kg, and a DFG/TFG 320 loads up to 2000 kg.
Model Load Capacity (kg) Wheel Base (mm)
DFG/TFG 316 1600 1400
DFG/TFG 320 2000 1400
DFG/TFG 420 2000 1685
DFG/TFG 425 2500 1685
DFG/TFG 430 3000 1685
DFG/TFG 540 4000 1985
DFG/TFG 545 4500 1985
DFG/TFG 550 5000 1985
B1
1206.GB
B Description of Truck
1 Description of Use
Forklift trucks to series DFG/TFG are driver’s cab forklifts with 4 wheel construction and
combustion engine. Trucks to series DFG have diesel engines, trucks of series TFG a
liquid petroleum gas engine.
The DFG/TFG 316--550 has a hydrodynamic drive. A combined creep/brake pedal
allows rapid lifting during creep running.
As of Februry 2007 the DFG/TFG 540--550 is equippd with an additional pedal. 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 emergency
brake pedal.
The load--bearing capacity depends on type. The type description indicates the
maximum permitted load. A DFG/TFG 316 can lift, transport and stack loads up to 1600
kg, and a DFG/TFG 320 loads up to 2000 kg.
Model Load Capacity (kg) Wheel Base (mm)
DFG/TFG 316 1600 1400
DFG/TFG 320 2000 1400
DFG/TFG 420 2000 1685
DFG/TFG 425 2500 1685
DFG/TFG 430 3000 1685
DFG/TFG 540 4000 1985
DFG/TFG 545 4500 1985
DFG/TFG 550 5000 1985

B2 1206.GB
2 Description of Assemblies and Function
1
2
3
456
7
8
9
101112
13
14
Item Description Item Description
1FLift cylinder 8FTowing coupling
2FLift chain 9FCounterweight
3FMast assembly 10 FSteer axle
4FInstrument panel 11 FEngine cover
5FSteering column 12 FDrive axle
6FDriver’s loadguard 13 FCarriage
7FDriver’s seat 14 FFork
B2 1206.GB
2 Description of Assemblies and Function
1
2
3
456
7
8
9
101112
13
14
Item Description Item Description
1FLift cylinder 8FTowing coupling
2FLift chain 9FCounterweight
3FMast assembly 10 FSteer axle
4FInstrument panel 11 FEngine cover
5FSteering column 12 FDrive axle
6FDriver’s loadguard 13 FCarriage
7FDriver’s seat 14 FFork

B3
1206.GB
2.1 Truck
Frame and Superstructure: A stable, torsionally rigid frame in which the equipment
and controls are installed protected, gives the truck a high static safety. The driver’s cab
is spring--mounted to dampen vibrations and noise.
A wide--opening top and two side panels on the engine cover (11) allow easy
maintenance and service. The hydraulic oil tank is side integrated into the frame on the
right and the fuel tank for the DFG series on the opposite side. The gas bottles for the
TFG series are attached to the counterweight (9) in a holder. The vertical free--standing
exhaust pipe which opens high above the machine prevents the transmission of
vibration and sound waves and the penetration of exhaust gases into the driver’s cab.
Driver’s Cab: Non--slip steps and a handle on the roof pillar ensure easy entrance and
exit. The driver is protected by the roof (6). On the driver’s seat (7), the seat cushioning
and position are adjustable, and on the steering column (5) the angle of the steering
wheel can be modified. Simple operation by ergonomically arranged controls and a
virtually vibration--free driver’s cab means that minimum load is exerted on the driver.
The control and warning displays on the instrument panel (4) allow monitoring of the
systems during operation. As a result, the safety standard is very high.
The driver’s overhead guard must be checked prior to starting the truck for cracks, and
if damaged, must be repaired or replaced.
Engine: A silent water--cooled engine with high power and low fuel consumption. The
DFG series are fitted with diesel engines with very clean combustion under all
operating conditions and with low soot output. In the TFG series, liquid petroleum gas
engines are fitted with a very low residual exhaust value.
Drive: A load gearbox with gear oil cooler and torque converter is flanged directly onto
the engine. This transfers the power to the drive axle (12).
The direction lever on the operating console selects forwards/reverse or neutral.
Steering: Hydrostatic steering with a steering cylinder integrated into the steering axle
(10). The steering axle is fully floating in the frame to ensure good ground holding even
on uneven surfaces.
Brakes: The creep/brake pedal operates two hydraulic drum brakes acting on the drive
wheels. The drum brakes adjust automatically for wear. The parking brake acts
mechanically via Bowden cables on the drum brakes when the parking brake lever is
operated.
Wheels: All wheels are within the truck contour. The tyres are either pneumatic or
super--elastic tyres.
Hydraulic System: The hydraulic system gear pump is driven by the engine via the
secondary take--off from the load gears. The pump speed and hence the transport
volume is controlled by the engine speed via the accelerator pedal.
The hydraulic functions are controlled by the control lever via a multiple control valve.
Electrical System: 12 Volt system with starter battery and 3--phase alternator with
integral regulator. The starting repeat block prevents incorrect operation during
starting and a safety circuit allows the engine to start only when the direction lever is in
neutral. For diesel engines, a fast preglow system is fitted, whereas LPG engines have
a contactless electronic ignition system for fast easy starting of the engine. The engine
is turned off using the ignition/starter switch.
f
B3
1206.GB
2.1 Truck
Frame and Superstructure: A stable, torsionally rigid frame in which the equipment
and controls are installed protected, gives the truck a high static safety. The driver’s cab
is spring--mounted to dampen vibrations and noise.
A wide--opening top and two side panels on the engine cover (11) allow easy
maintenance and service. The hydraulic oil tank is side integrated into the frame on the
right and the fuel tank for the DFG series on the opposite side. The gas bottles for the
TFG series are attached to the counterweight (9) in a holder. The vertical free--standing
exhaust pipe which opens high above the machine prevents the transmission of
vibration and sound waves and the penetration of exhaust gases into the driver’s cab.
Driver’s Cab: Non--slip steps and a handle on the roof pillar ensure easy entrance and
exit. The driver is protected by the roof (6). On the driver’s seat (7), the seat cushioning
and position are adjustable, and on the steering column (5) the angle of the steering
wheel can be modified. Simple operation by ergonomically arranged controls and a
virtually vibration--free driver’s cab means that minimum load is exerted on the driver.
The control and warning displays on the instrument panel (4) allow monitoring of the
systems during operation. As a result, the safety standard is very high.
The driver’s overhead guard must be checked prior to starting the truck for cracks, and
if damaged, must be repaired or replaced.
Engine: A silent water--cooled engine with high power and low fuel consumption. The
DFG series are fitted with diesel engines with very clean combustion under all
operating conditions and with low soot output. In the TFG series, liquid petroleum gas
engines are fitted with a very low residual exhaust value.
Drive: A load gearbox with gear oil cooler and torque converter is flanged directly onto
the engine. This transfers the power to the drive axle (12).
The direction lever on the operating console selects forwards/reverse or neutral.
Steering: Hydrostatic steering with a steering cylinder integrated into the steering axle
(10). The steering axle is fully floating in the frame to ensure good ground holding even
on uneven surfaces.
Brakes: The creep/brake pedal operates two hydraulic drum brakes acting on the drive
wheels. The drum brakes adjust automatically for wear. The parking brake acts
mechanically via Bowden cables on the drum brakes when the parking brake lever is
operated.
Wheels: All wheels are within the truck contour. The tyres are either pneumatic or
super--elastic tyres.
Hydraulic System: The hydraulic system gear pump is driven by the engine via the
secondary take--off from the load gears. The pump speed and hence the transport
volume is controlled by the engine speed via the accelerator pedal.
The hydraulic functions are controlled by the control lever via a multiple control valve.
Electrical System: 12 Volt system with starter battery and 3--phase alternator with
integral regulator. The starting repeat block prevents incorrect operation during
starting and a safety circuit allows the engine to start only when the direction lever is in
neutral. For diesel engines, a fast preglow system is fitted, whereas LPG engines have
a contactless electronic ignition system for fast easy starting of the engine. The engine
is turned off using the ignition/starter switch.
f