Jungheinrich DFG 316s User manual

Operating Instructions
51105427
DFG/TFG 316s-320s
G
04.08 -
07.08

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

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Table of contents
A Correct Use and Application
B Truck Description
1 Application ........................................................................................... B 1
2 Assemblies and Functional Description .............................................. B 2
2.1 Truck ................................................................................................... B 3
2.2 Load handler ....................................................................................... B 4
3 Standard Version Specifications ......................................................... B 5
3.1 DFG/TFG 316s/320s Specifications .................................................... B 8
4 Identification points and data plates .................................................... B 11
4.1 Truck data plate .................................................................................. B 12
4.2 Truck load chart .................................................................................. B 13
4.3 Attachment load chart ......................................................................... B 14
C Transport and Commissioning
1 Transport ............................................................................................. C 1
2 Lifting by crane .................................................................................... C 1
3 Securing the truck during transport ..................................................... C 2
4 Using the truck for the first time .......................................................... C 3
5 Operating the truck without its own drive system ................................ C 3
D Fuelling the Truck
1 Safety regulations for handling diesel fuel and LPG ........................... D 1
2 Filling with diesel ................................................................................. D 2
3 Replace the LPG bottle ....................................................................... D 3
E Operation
1 Safety Regulations for the Operation of Forklift Trucks ...................... E 1
2 Controls and Displays ......................................................................... E 3
3 Operating the lift and tilt mechanisms (o) .......................................... E 8
4 Twin Pedal Operation (o) ................................................................... E 9
5 Tests and tasks to be performed before starting the truck .................. E 14
6 Starting up the truck ............................................................................ E 19
6.1 Adjusting the driver’s seat ................................................................... E 20
6.2 Adjusting the steering column ............................................................. E 21
6.3 Seat belt .............................................................................................. E 21
7 Starting the truck ................................................................................. E 22
7.1 Starting procedure for the TFG ........................................................... E 23
7.2 Starting procedure for the DFG ........................................................... E 24
7.3 Operating Error Displays ..................................................................... E 26
7.4 Switching off the engine ...................................................................... E 26

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8 Industrial Truck Operation ................................................................... E 27
8.1 Safety regulations for truck operation ................................................. E 27
9 Travel .................................................................................................. E 29
9.1 Steering ............................................................................................... E 31
9.2 Brakes ................................................................................................. E 31
10 Mast and Attachment Operation ......................................................... E 33
10.1 Controlling the speed of the lifting device ........................................... E 35
10.2 Lifting, transporting and depositing load units ..................................... E 36
11 Transporting loads .............................................................................. E 39
12 Hazardous situations ........................................................................... E 41
12.1 Parking the truck safely ....................................................................... E 42
13 Engine bonnet and service covers ...................................................... E 43
13.1 Service covers ..................................................................................... E 44
13.2 Towing the truck .................................................................................. E 45
13.3 Towing trailers ..................................................................................... E 45
14 Troubleshooting .................................................................................. E 46
F 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 Consumables ...................................................................................... F 9
9 DFG fuel specifications ....................................................................... F 9
10 Lubrication chart .................................................................................. F 10
10.1 Lubrication chart - DFG/TFG ............................................................... F 11
11 Maintenance and repairs ..................................................................... F 12
11.1 Preparing the truck for maintenance and repairs ................................ F 12
11.2 Starting aid .......................................................................................... F 12
11.3 Servicing the engine - TFG 316s/320s ................................................ F 13
11.4 Engine servicing - DFG 316s/320s ..................................................... F 16
11.5 Checking the coolant concentration .................................................... F 19
11.6 Filling the cooling circuit ...................................................................... F 19
11.7 Cleaning/replacing the air filter cartridge ............................................. F 20
11.8 Checking the wheel attachment and air pressure ............................... F 21
11.9 Hydraulic system ................................................................................. F 22
11.10 Electrical system ................................................................................. F 23
11.11 Relay layout ........................................................................................ F 26
12 Exhaust system ................................................................................... F 27
13 Restoring the truck to service after cleaning or repairs ....................... F 27
14 Decommissioning the industrial truck .................................................. F 27
14.1 Prior to decommissioning .................................................................... F 27
14.2 During decommissioning: .................................................................... F 28

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14.3 Returning the truck to operation after decommissioning ..................... F 28
15 Periodic safety checks and after unusual events ................................ F 29
16 Final de-commissioning, disposal ....................................................... F 29
17 HUSS FS - MK Series Diesel Particle Filter Operating Instructions .... F 30
17.1 Important General Instructions ............................................................ F 30
17.2 Important safety instructions ............................................................... F 30
17.3 Functional description ......................................................................... F 31
17.4 HUSS Control Operation ..................................................................... F 32
17.5 HUSS Control Operating Instructions ................................................. F 33
17.6 Regeneration ....................................................................................... F 34
17.7 Maintenance ........................................................................................ F 37

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A 1
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A Correct Use and 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.
It must be used, operated and serviced in accordance with the present instructions.
Any other type of use is beyond the scope of application and can result in damage to
personnel, the industrial 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 chart 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 owner must ensure that all
users have read and understood these operating instructions.
MFailure to comply with the operating instructions 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.
Towing trailers
Zsee Chapter E, Section 13.3.

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B 1
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B Truck Description
1 Application
The DFG/TFG series trucks are 4-wheel sit-down IC engine forklifts. The DFG series
are diesel engine trucks, while the TFG series are fitted with a petrol engine for LPG
operation.
The DFG/TFG 316-320s is equipped with a hydrostatic drive system. The IC engine
drives a high pressure pump for the hydraulic functions and two hydraulic motors to
drive wheels.
Truck models and maximum capacity.
*) The load charts attached to the truck are binding in terms of capacity
Model Capacity (kg)*) Wheel base (mm)
DFG/TFG 316s 1600 1400
DFG/TFG 320s 2000 1400

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

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2.1 Truck
Chassis/Superstructure: A rigid chassis which protects the units and controls,
provides the truck with maximum static safety. The operator position is articulating,
which cushions vibrations and noise.
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 (9). The exhaust system and exhaust pipe prevents exhaust
from entering the operator position and reduces exhaust noise.
Operator 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 (6). On the
driver’s seat (7) the seat cushioning and the seat position are adjustable, while the
steering wheel tilt can be set on the steering column (5). Easy operation through
ergonomically arranged controls and a practically vibration-proof cab mean that the
driver is only subjected to minimum stress. The control and warning displays on the
dashboard (4) enable the system to be monitored during operation, thereby ensuring
a very high level of safety.
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: Both drive wheels are powered by individual hydraulic motors which in turn are
driven by a hydraulic pump. Forward/reverse or neutral can be set with the travel lever
on the control panel.
Steering: Hydrostatic steering with a steering cylinder integrated in the steering axle
(10). The steering axle is fully floating in the chassis to ensure excellent grip even on
non-level surfaces.
Brakes: The truck brakes to a halt via the hydraulic motors, keeping energy
consumption to a minimum. The parking brake is an automatic multi-plate brake.
Hydraulic system: All operations can be performed sensitively, proportionally and
simultaneously.
Hydraulic functions are controlled by the control lever through a multiple control valve.

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B 4
Electrical system: 12 volt system with starter battery and AC 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 lever
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 / start switch is used to stop the engine.
2.2 Load handler
Mast: The aim is to optimise visibility. The maximum strength steel section are
narrow, allowing for good fork visibility in particular with the three-stage mast. The
same standard has been achieved for the fork carriage. The mast and the fork
carriage run on permanently-lubricated and hence maintenance-free angled castors.
Attachments: The trucks can be optionally fitted with mechanical and hydraulic
attachments.

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3 Standard Version Specifications
ZTechnical specification details in accordance with VDI 2198. Technical modifications
and additions reserved.

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B 6
DFG 316s/320s Specification Sheet
No. Description Code
(Unit)
AH-J
Specification
1 Manufacturer Jungheinrich Jungheinrich
1.2 Model DFG 316s DFG 320s
1.3 Drive system: electric, diesel, petrol, LPG, other Diesel Diesel
1.4 Steering: manual, pedestrian truck, stand-up, sit-down,
order picker
Sit-down Sit-down
1.5 Capacity Q(t) 1.6 2.0
1.6 Load centre of gravity c(mm) 500 500
1.8 Load distance x(mm) 395 395
1.9 Wheel base y(mm) 1400 1400
Weight
2:1 Weight - unladen (kg) 3020 3270
2.2 Axle load, laden, front/rear (kg) 4000/620 4600/670
2.3 Axle load, unladen, front/rear (kg) 1320/1700 1240/2030
Longitudinal stability 1.66 1.59
Tyres/chassis
3.1 Tyre type: elastic, super elastic, pneumatic -
Polyurethane tyres
SE(L)/SE(L) SE(L)/SE(L)
3.2 Tyre size: Front 6.50-10 (14PR) 6.50-10 (14PR)
3.3 Tyre size: rear 18x7-8 (16PR) 18x7-8 (16PR)
3.5 No. of wheels front/rear (x = mechanical pull) 2x/2 2x/2
3.6 Track width, front b10(mm) 895 895
3.7 Track width, rear b11(mm) 870 (offset) 870 (offset)
Dimensions
4.1 Mast/chassis tilt, front/rear Degrees 7/10 7/10
4.2 Lowered mast height h1(mm) 2080 2080
4.3 Free lift h2(mm) 100 100
4.4 Lift height h3(mm) 3090 3090
4.5 Extended mast height h4(mm) 3670 3670
4.7 Overhead guard height (cabin) h6(mm) 2130 2130
4.8 Seat height / headroom (SIP 100 mm) h7(mm) 1005/1065 1005/1065
4.12 Hitch height h10(mm) 375/545 375/545
4.19 Overall length l1(mm) 3245 3300
4.20 Length to fork surface l2(mm) 2245 2300
4.21 Overall width b1/b2(mm) 1070 1070
4.22 Fork dimensions s/e/l(mm) 40/100/1000 40/100/1000
4.23 Carriage DIN 15173, ISO 2328, class/type A,B ISO 2A ISO 2A
4.24 Fork carriage width / outer forks b3(mm) 1000/849 1000/849
4.31 Ground clearance laden below mast m1(mm) 115 115
4.32 Ground clearance (centre wheelbase) m2(mm) 135 135
4.33 Working aisle width for pallets 1000 x 1200 traverse Ast(mm) 3570 3615
4.34 Working aisle width for pallets 800 x 1200 lengthwise Ast(mm) 3770 3815
4.35 Turning radius Wa(mm) 1975 2020
Power
5.1 Travel speed w. / w.o. load (km/h) 18.5/19 18.5/19
5.2 Lift speed w. / w.o. load (m/s) 0.61/0.65 0.60/0.65
5.3 Lower speed w. / w.o. load (m/s) 0.55/0.52 0.55/0.53
5.5 Tow force w. / w.o. load (kN) 16.5/8.4 16.2/7.6
5.7 Gradeability w. / w.o. load (%) 36/28 29/22
5.9 Acceleration time w. / w.o. load s 5.1/4.8 5.3/5.0
5.10 Service brake type Hydrostatic Hydrostatic
Engine
7.1 Engine: Manufacturer/Model 404D.22 404D.22
7.2 Engine output in accordance with ISO 1585 (kw) 34.1 34.1
7.3 Speed (rpm) 2400 2400
7.4 Number of cylinders/capacity ( /cm3) 4/2216 4/2216
Max. torque Nm/rpm 143/1800 143/1800
Misc.
8.1 Drive type Hydrostatic Hydrostatic
8.2 Hydraulic oil pressure for attachments (bar) 160 160
8.3 Oil flow for attachments l/min 45 45

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TFG 316s/320s Specification Sheet
No. Description Code
(Unit)
AH-J
Specification
1 Manufacturer Jungheinrich Jungheinrich
1.2 Model TFG 316s TFG 320s
1.3 Drive system: electric, diesel, petrol, LPG, other LPG LPG
1.4 Steering: manual, pedestrian truck, stand-up, sit-down,
order picker
Sit-down Sit-down
1.5 Capacity Q(t) 1.6 2.0
1.6 Load centre of gravity c(mm) 500 500
1.8 Load distance x(mm) 395 395
1.9 Wheel base y(mm) 1400 1400
Weight
2:1 Weight - unladen (kg) 3000 3250
2.2 Axle load, laden, front/rear (kg) 4030/570 4630/620
2.3 Axle load, unladen, front/rear (kg) 1270/1730 1190/2060
Longitudinal stability 1.69 1.61
Tyres/chassis
3.1 Tyre type: elastic, super elastic, pneumatic -
Polyurethane tyres
SE(L)/SE(L) SE(L)/SE(L)
3.2 Tyre size: Front 6.50-10 (14PR) 6.50-10 (14PR)
3.3 Tyre size: rear 18x7-8 (16PR) 18x7-8 (16PR)
3.5 No. of wheels front/rear (x = mechanical pull) 2x/2 2x / 2
3.6 Track width, front b10(mm) 895 895
3.7 Track width, rear b11(mm) 870 (offset) 870 (offset)
Dimensions
4.1 Mast/chassis tilt, front/rear Degrees 7/10 7/10
4.2 Lowered mast height h1(mm) 2080 2080
4.3 Free lift h2(mm) 100 100
4.4 Lift height h3(mm) 3090 3090
4.5 Extended mast height h4(mm) 3670 3670
4.7 Overhead guard height (cabin) h6(mm) 2130 2130
4.8 Seat height / headroom (SIP 100 mm) h7(mm) 1005/1065 1005/1065
4.12 Hitch height h10(mm) 375/545 375/545
4.19 Overall length l1(mm) 3245 3300
4.20 Length to fork surface l2(mm) 2245 2300
4.21 Overall width b1/b2(mm) 1070 1070
4.22 Fork dimensions s/e/l(mm) 40/100/1000 40/100/1000
4.23 Carriage DIN 15173, ISO 2328, class/type A,B ISO 2A ISO 2A
4.24 Fork carriage width / outer forks b3(mm) 1000/849 1000/849
4.31 Ground clearance laden below mast m1(mm) 115 115
4.32 Ground clearance (centre wheelbase) m2(mm) 135 135
4.33 Working aisle width for pallets 1000 x 1200 traverse Ast(mm) 3570 3615
4.34 »Working aisle width for pallets 800 x 1200 lengthwise Ast(mm) 3770 3815
4.35 Turning radius Wa(mm) 1975 2020
Power
5.1 Travel speed w. / w.o. load (km/h) 18.0/18.5 18.0/18.5
5.2 Lift speed w. / w.o. load (m/s) 0.56/0.65 0.55/0.65
5.3 Lower speed w. / w.o. load (m/s) 0.55/0.52 0.55/0.53
5.5 Tow force w. / w.o. load (kN) 14.6/7.4 14.5/7.1
5.7 Gradeability w. / w.o. load (%) 32/25 28/22
5.9 Acceleration time w. / w.o. load s 4.8/4.6 4.9/4.7
5.10 Service brake type Hydrostatic Hydrostatic
Engine
7.1 Engine: Manufacturer/Model FE 2.0 FE 2.0
7.2 Engine output in accordance with ISO 1585 (kw) 26 26
7.3 Revolutions (rpm) 2400 2400
7.4 Number of cylinders/displacement ( /cm3) 4/1998 4/1998
Max. torque Nm/rpm 120/1600 120/1600
Misc.
8.1 Drive type Hydrostatic Hydrostatic
8.2 Hydraulic oil pressure for attachments (bar) 160 160
8.3 Oil flow for attachments l/min 45 45

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3.1 DFG/TFG 316s/320s Specifications
Steering system
Drive axle
Engine - DFG 316s/320s
Engine - TFG 316s/320s
Air filter
Brake system
MODEL Fully hydrostatic
PUMP As for main hydraulic system
NUMBER OF TURNS STOP TO STOP 5
MODEL Radial piston axle
MODEL ESE 02
LUBRICANT CAPACITY N/A
MODEL 404D.22 four cylinder
IGNITION ORDER 1 3 4 2
CONTROL SPEED 2400 rpm (unladen) / 880 rpm (idle)
VALVE CLEARANCE (inlet/outlet) 0.20mm cold
OIL PRESSURE 4.5 bar @ 2300 rpm
OIL CAPACITY 8.9 litres
FUEL TANK 42 litres
COOLANT CAPACITY 9.0 litres
MODEL FE 2.0 four cylinder
IGNITION ORDER 1 3 4 2
CAPACITY 1998cc
CONTROL SPEED 3100 rpm (unladen) / 830 rpm (idle)
OIL PRESSURE 3.0 bar @ 2300 rpm
SPARK PLUG TYPE NGK BPR 2E or DENSO W9EXR-U
SPARK PLUG ELECTRODE DISTANCE 0.80mm
OIL CAPACITY 4.3 litres
FUEL TANK N/A
COOLANT CAPACITY 9.0 litres
MODEL Cyclopac – dry element
MODEL Multiplate brake
PARKING BRAKE Disc works via a hydraulic pressure system

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Wheels and Tyres
Tires
ZPermissible tyre types: Only use tyres approved by the lift truck manufacturer, if in
doubt contact your local JH service branch.
Noise Emissions
Vibrations
TYRE SIZE See specifications sheet
TYRE PRESSURE
6.50-10
Model Drive axle - bar Steer axle - bar
DFG/TFG 316s/320s 7.75 9.0
23x9-10 DFG/TFG 316s/320s 9.0 9.0
WHEEL NUT TORQUE Model Drive axle - Nm Steer axle - Nm
DFG/TFG 316s/320s 210 176
APPLICATION AREA TYRE SIZE TYPE MODEL
Drive axle 6.50x10 10PR Pneumatic tyres diagonal DFG/TFG 316s/320s
Steer axle 18x7-8 14PR
Drive axle 6.50x10 Full rubber profile DFG/TFG 316s/320s
Steer axle 18x7-8
Drive axle 23x9x10 18PR Pneumatic tyres diagonal DFG/TFG 316s/320s
Steer axle 18x7-8 14PR
Drive axle 23x9x10 Full rubber profile DFG/TFG 316s/320s
Steer axle 18x7-8
NOISE EMISSION LEVEL in accordance with
EN 12053 as harmonised with ISO 4871.
<80 dB(A)
Cyclopac – dry element
The noise emission level is calculated in
accordance with standard procedures and takes
into account the noise level when travelling,
lifting and when idle. The noise level is
measured at the driver’s ear.
WHOLE BODY VIBRATIONS THROUGH
AVERAGE VALUE in accordance with EN 13059
0.57 m/s
The vibration acceleration acting on the body in
the operating position is, in accordance with
standard procedures, the linearly integrated,
weighted acceleration in the vertical direction. It
is calculated when travelling over bumps at
constant speed.

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B 10
Electrical system
Hydraulic system
Conditions of use
ZFor constant use below 0°C it is recommended to fill the hydraulic system with frost-
resistant oil as indicated by the manufacturer. Special equipment and authorisation
are required if the truck is to be used in cold stores or conditions of extreme
temperature or air humidity fluctuations.
SYSTEM 12 volt negative earth
ELECTROMAGNETIC COMPATIBILITY
(EMC)
Within the following limits in accordance with
“Industrial Truck Electromagnetic Compatibility
(9/95)” product standards:
tinterference emission (EN 50081-1)
tresistance (EN 50 082-2)
telectrostatic discharge (EN 61000-4-2)
HYDRAULIC PUMP 1PX series
CONTROL VALVE 5000 series
STEER PRESSURE 106 bar
MAIN PRESSURE 215 bar
TANK CAPACITY 46 litres
HYDRAULIC SYSTEM CAPACITY 51 litres
AMBIENT TEMPERATURE
tduring operation -15°C to +40°C

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4 Identification points and data plates
Item Description
15 "Do not stand under the load handler" warning
16 Strap points for crane lifting
17.1 “Do not travel with a raised load” warning
17.2 “Do not tilt the mast forward with a raised load” warning
18 Forks, capacity / load centre of gravity / lift height load chart
19 Sideshift, capacity / load centre of gravity / lift height load chart
20 Truck data plate
21 Jack contact points decal
22 “Maximum body size” notice
22