Jungheinrich DFG 320 User manual

Operating Instructions
51077668
DFG/TFG 316/320/425/430/435
G
08.07-
09.08

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
3 Standard version specifications .......................................................... B 5
3.1 Performance data DFG 316-320 ......................................................... B 5
3.2 Engine Data ........................................................................................ B 12
3.3 Tyres ................................................................................................ B 14
3.4 Mast Versions ..................................................................................... B 15
3.5 EN standards ...................................................................................... B 18
3.6 Operating Conditions .......................................................................... B 18
4 Identification points, warning labels and data plates ........................... B 19
4.1 Truck data plate .................................................................................. B 20
4.2 Truck load diagram ............................................................................. B 20
4.3 Attachment load diagram .................................................................... B 21
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 Fuelling the Truck
1 Safety regulations for handling fuel ..................................................... D 1
2 Filling with diesel ................................................................................. D 2
3 Replace the LPG bottle ....................................................................... D 3
E Operation
1 Safety regulations for the operation of industrial trucks ...................... E 1
2 Controls and displays .......................................................................... E 3
3 Starting up the truck ............................................................................ E 8
3.1 Daily checks and operations to be performed before starting work .... E 8
3.2 Trucks with reduced headroom X (o) ................................................. E 8
3.3 Adjusting the driver’s seat ................................................................... E 10
3.4 Safety restraint belt ............................................................................. E 11
3.5 Adjust steering column ........................................................................ E 13
3.6 Starting the truck ................................................................................. E 14
3.7 Starting procedure for the TFG ........................................................... E 15
3.8 Starting procedure for the DFG ........................................................... E 16

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3.9 Operational Fault Displays .................................................................. E 18
3.10 Stopping the engine1. ......................................................................... E 19
4 Industrial Truck Operation ................................................................... E 20
4.1 Safety regulations for truck operation ................................................. E 20
4.2 Travel .................................................................................................. E 22
4.3 Steering ............................................................................................... E 24
4.4 Braking ................................................................................................ E 24
4.5 Mast and Attachment Operation ......................................................... E 25
4.6 Collecting, transporting and depositing loads ..................................... E 29
4.7 Parking the truck securely ................................................................... E 33
4.8 Towing trailers ..................................................................................... E 35
5 Troubleshooting .................................................................................. E 36
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 Consumables ...................................................................................... F 11
10 Maintenance and repairs ..................................................................... F 13
10.1 Preparing the truck for maintenance and repairs ................................ F 13
10.2 Engine panel ....................................................................................... F 14
10.3 Starting aid .......................................................................................... F 14
10.4 Servicing the engine DFG ................................................................... F 15
10.5 Engine servicing TFG .......................................................................... F 19
10.6 Checking the hydraulic oil level ........................................................... F 22
10.7 Gas system drain tap .......................................................................... F 23
10.8 Checking the coolant level .................................................................. F 24
10.9 Checking the coolant concentration .................................................... F 25
10.10 Filling the cooling circuit ...................................................................... F 25
10.11 Cleaning/replacing the air filter cartridge ............................................. F 26
10.12 DFG/TFG transmission: ...................................................................... F 27
10.13 Brake ................................................................................................... F 28
10.14 Checking the wheel attachments. ....................................................... F 29
10.15 Hydraulic system ................................................................................. F 29
10.16 Clean/replace hydraulic reservoir discharge system ........................... F 29
10.17 Electrical Equipment ........................................................................... F 30
11 Exhaust system ................................................................................... F 34
12 Restoring the truck to service after cleaning or repairs ....................... F 34
13 Decommissioning the industrial truck .................................................. F 34
13.1 Prior to decommissioning: ................................................................... F 34

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13.2 During decommissioning: .................................................................... F 35
13.3 Returning the truck to operation after decommissioning ..................... F 35
14 Safety checks to be performed at regular intervals and following
any unusual incidents .......................................................................... F 36
15 Final de-commissioning, disposal ....................................................... F 36
16 HUSS FS - MK Series Diesel Particle Filter Operating Instructions .... F 37
16.1 Important General Instructions ............................................................ F 37
16.2 Important safety instructions ............................................................... F 37
16.3 Functional description ......................................................................... F 38
16.4 HUSS Control Operation ..................................................................... F 39
16.5 HUSS Control Operating Instructions ................................................. F 40
16.6 Regeneration ....................................................................................... F 41
16.7 Maintenance ........................................................................................ F 44

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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.
All other types of use lie 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 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 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 user must comply with legal
requirements, technical standards and health and safety regulations when operating
an IC engine powered lift truck in closed rooms. The owner must ensure that all truck
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.
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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B 1
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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 equipped with a petrol engine for LPG
operation.
The DFG/TFG 316-435 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 emergency brake
pedal.
The capacity depends on the model. The model reference indicates the maximum
load rating. For example, a DFG/TFG 316 can carry loads of up to 1600 kg and a
DFG/TFG 435 loads of up to 3500 kg.
Truck models and maximum capacity:
*) The load diagrams attached to the truck are binding in terms of capacity
Model max. capacity *) Load centre of gravity
DFG/TFG 316 1600 kg 500 mm
DFG/TFG 320 2000 kg 500 mm
DFG/TFG 425 2500 kg 500 mm
DFG/TFG 430 3000 kg 500 mm
DFG/TFG 435 3500 kg 500 mm

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B 2
2 Assemblies and functional description
Item Description Item Description
1tDriver’s seat 8 tFork
2tSteering column 9 tFork carriage
3tDashboard 10 tDrive axle
4tOverhead guard 11 tEngine panel
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

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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.
A wide opening panel (11) facilitates service and maintenance work. 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
gases from entering the driver’s position.
Driver’s position: A non-slip step 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 (1) 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 only 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: The 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 brake pedal actuates two drum brakes which are applied to the drive
wheels. The drum brakes are also actuated by the slow travel / brake pedal, although
this is only intended as a crawl speed aid. The pedal should not be used for normal
braking purposes. 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 aim is to optimize 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 casters.
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.
3.1 Performance data DFG 316-320
TFG 316-320 Performance Data
Model DFG 316 DFG 320
Q Capacity 1600 2000 kg
C Load centre of gravity distance 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
Lower Speed
w/w.o. load 0.55/0.49 0.55/0.49 m/s
Gradeability
w/w.o. load 23 20 %
Model TFG 316 TFG 320
Q Capacity 1600 2000 kg
C Load centre of gravity distance 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
Lower 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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Performance data DFG/TFG 425-435
Model DFG 425 DFG 430 DFG 435
Q Capacity 2500 3000 3500 kg
C Load centre of gravity distance 500 500 500 mm
Travel Speed
w/w.o. load
17/19 18/19 18/19 km/h
Lift Speed
w/w.o. load
0.59/0.60 0.53/0.59 0.49/0.53 m/s
Lower Speed
w/w.o. load
0.55/0.45 0.55/0.45 0.55/0.42 m/s
Gradeability
w/w.o. load
27 23 18 %
Model TFG 425 TFG 430 TFG 435
Q Capacity 2500 3000 3500 kg
C Load centre of gravity distance 500 500 500 mm
Travel Speed
w/w.o. load
17/19 18/19 18/19 km/h
Lift Speed
w/w.o. load
0.5/0.6 0.46/0.55 0.41/0.51 m/s
Lower Speed
w/w.o. load
0.55/0.45 0.55/0.45 0.55/0.42 m/s
Gradeability
w/w.o. load
27 23 19 %

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B 8
Dimensions DFG
Model 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 centre wheel base 130 130 mm
Ast
Working aisle width for pallets 800 x 1200
longit. 3618 3640 mm
Ast
Working aisle width for pallets 1200 x 800
transverse 3818 3840 mm
WaTurning radius 2020 2042 mm
x Load distance 398 398 mm
y Wheel base 1495 1495 mm
Truck weight 2870 3280 kg

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Dimensions
Model DFG 425 DFG 430 DFG 435
a/2 Safety distance 100 100 100 mm
h1Mast height retracted 2080 2080 2180 mm
h2Free lift 150 150 150 mm
h3Lift 2900 2900 3100 mm
h4Mast height extended 3685 3685 3885 mm
h6Overhead guard height 2220 2250 2250 mm
h7Seat Height 1068 1068 1068 mm
L1Length including forks 3690 3810 3945 mm
L2Headlength 2540 2660 2795 mm
b1Overall width 1174 1300 1300 mm
e Fork width 120 125 125 mm
m1Ground clearance with load below mast 125 125 125 mm
m2Ground clearance centre wheel base 130 140 140 mm
Ast
Working aisle width
for pallets 800 x 1200 longit.
4215 4331 4511 mm
Ast
Working aisle width
for pallets 1200 x 800 transverse
3900 4015 4195 mm
WaTurning radius 2290 2370 2550 mm
x Load distance 473 515 515 mm
y Wheel base 1685 1685 1785 mm
Truck weight 4290 4730 5098 kg

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B 10
TFG dimensions
Model 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 centre wheel base 130 130 mm
Ast
Working aisle width
for pallets 800 x 1200 longit. 3618 3640 mm
Ast
Working aisle width
for pallets 1200 x 800 transverse 3818 3840 mm
WaTurning radius 2020 2042 mm
x Load distance 398 398 mm
y Wheel base 1495 1495 mm
Truck weight 2840 3250 kg

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Model TFG 425 TFG 430 TFG 435
a/2 Safety distance 100 100 100 mm
h1Mast height retracted 2080 2080 2180 mm
h2Free lift 150 150 150 mm
h3Lift 2900 2900 3100 mm
h4Mast height extended 3685 3685 3885 mm
h6Overhead guard height 2220 2250 2250 mm
h7Seat height 1068 1068 1068 mm
L1Length including forks 3690 3810 3945 mm
L2Headlength 2540 2660 2795 mm
b1Overall width 1174 1300 1300 mm
e Fork width 120 125 125 mm
m1Ground clearance with load below mast 125 125 125 mm
m2Ground clearance centre wheel base 130 140 140 mm
Ast
Working aisle width
for pallets 800 x 1200 longit.
4215 4331 4511 mm
Ast
Working aisle width
for pallets 1200 x 800 transverse
3900 4015 4195 mm
WaTurning radius 2290 2370 2550 mm
x Load distance 473 515 515 mm
y Wheel base 1685 1685 1785 mm
Truck weight 4190 4630 4998 kg