2006-2014 Jungheinrich Fork Truck DFG 316, DFG 320, TFG 316, TFG320 Service & Repair Manual

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

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: F Used before safety instructions which must be observed to avoid danger to personnel. M Used before notices which must be observed to avoid material damage. Z Used before notices and explanations. t Used to indicate standard equipment. o Used 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: +49 (0) 40/6948-0 www.jungheinrich.com

I 1 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

I 2 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

I 3 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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2006-2014 Jungheinrich Fork Truck DFG 316, DFG 320, TFG 316, TFG320 Service & Repair Manual

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