Jungheinrich DFG 316s, TFG 316s, DFG 320s, TFG 320s Operating Instructions Manual

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Operating Instructions

51105427

DFG/TFG 316s-320s

04.08 -

07.08

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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:

Used before safety instructions which must be observed to avoid danger to personnel.

Used before notices which must be observed to avoid material damage.

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.

Jungheinrich Aktiengesellschaft

Am Stadtrand 35 22047 Hamburg - GERMANY

Telephone: +49 (0) 40/6948-0

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

The “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.

Failure 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

see 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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2 Assemblies and Functional Description

Item Description Item Description

1 t Lift cylinder 8 t Trailer coupling 2 t Load chain 9 t Counterweight 3 t Mast 10 t Steering axle 4 t Dashboard 11 t Engine cover 5 t Steering column 12 t Hydrostatic drive axle 6 t Overhead guard 13 t Fork carriage 7 t Driver's seat 14 t Fork

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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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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

Technical 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 b

(mm) 895 895

3.7 Track width, rear b

(mm) 870 (offset) 870 (offset)

Dimensions

4.1 Mast/chassis tilt, front/rear Degrees 7/10 7/10

4.2 Lowered mast height h

(mm) 2080 2080

4.3 Free lift h

(mm) 100 100

4.4 Lift height h

(mm) 3090 3090

4.5 Extended mast height h

(mm) 3670 3670

4.7 Overhead guard height (cabin) h

(mm) 2130 2130

4.8 Seat height / headroom (SIP 100 mm) h

(mm) 1005/1065 1005/1065

4.12 Hitch height h

(mm) 375/545 375/545

4.19 Overall length l

(mm) 3245 3300

4.20 Length to fork surface l

(mm) 2245 2300

4.21 Overall width b

1/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 b

(mm) 1000/849 1000/849

4.31 Ground clearance laden below mast m

(mm) 115 115

4.32 Ground clearance (centre wheelbase) m

(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 ( /cm

) 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 h

(mm) 2080 2080

4.3 Free lift h

(mm) 100 100

4.4 Lift height h

(mm) 3090 3090

4.5 Extended mast height h

(mm) 3670 3670

4.7 Overhead guard height (cabin) h

(mm) 2130 2130

4.8 Seat height / headroom (SIP 100 mm) h

(mm) 1005/1065 1005/1065

4.12 Hitch height h

(mm) 375/545 375/545

4.19 Overall length l

(mm) 3245 3300

4.20 Length to fork surface l

(mm) 2245 2300

4.21 Overall width b

1/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 b

(mm) 1000/849 1000/849

4.31 Ground clearance laden below mast m

(mm) 115 115

4.32 Ground clearance (centre wheelbase) m

(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 ( /cm

) 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

Permissible 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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Electrical system

Hydraulic system

Conditions of use

For constant use below 0°C it is recommended to fill the hydraulic system with frostresistant 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:

t interference emission (EN 50081-1) t resistance (EN 50 082-2) t electrostatic 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 t during 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

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4.1 Truck data plate

For queries regarding the truck or ordering spare parts always quote the truck serial number (24).

Item Description Item Description

23 Type 28 Manufacturer

24 Serial no. 29 Net weight in kg

25 Rated capacity in kg 30 Load centre of gravity (mm)

26 Rated output (kW) 31 Year of manufacture

27 Manufacturer’s logo 32 Option

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4.2 Truck load chart

The load chart (16) gives the capacity (Q) of the truck in kg with a vertical mast. The diagram will differ, depending on the height of the mast used. The maximum capacity is shown as a table with a given load centre of gravity D (in mm) and the required lift height H (in mm). The truck load chart shows the truck's capacity with new forks (as supplied). From a fork length of 1300 mm this means a decrease in load. Trucks supplied without fork tines are given a standard data plate.

The arrow shape markings (38 and 39) on the inner and outer masts show the driver when the specified lift limits have been reached. These arrows are attached to all masts with a heightdependent capacity rating.

4250

3600

2900

1250 1250

850

500

600 700

1105

850

600

Example:

38 39

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B 14

4.3 Attachment load chart

The attachment load chart gives the truck’s capacity Q in combination with the respective attachment in kg. The serial number specified in the load chart must match the data plate of the attachment, as the capacity for each truck is specifically indicated by the manufacturer. It is shown in the same way as the truck’s capacity and can be determined accordingly.

For loads with a centre of gravity above 500 mm upward, the capacities are reduced by the difference of the altered centre of gravity.

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C Transport and Commissioning

1 Transport

Transport can be carried out in two different ways, depending on the height of the mast and the local conditions.

– Vertically, with the mast assembled (for low heights) – Vertically, with the mast dismantled (for large heights), all hydraulic lines between

the basic truck and the mast separated.

Safety Instructions for Assembly and Commissioning

On site assembly of the truck, commissioning and driver instruction may only be carried out by personnel trained and authorised by the manufacturer.

The hydraulic lines may only be connected to the basic truck / mast interface and the truck commissioned when the mast has been properly assembled.

2 Lifting by crane

Only use lifting gear with sufficient capacity (for transport weight see truck data plate).

– Parking the truck securely

(see Chapter E).

– Attach the crane slings to the

top cross member of the mast (1) and the trailer coupling (2).

Only suspend crane belts/chains to the top eye of the counterbalance weight and the eyes of the upper cross member (mast). The mast must be tilted back fully. The crane belt or the chain on the mast must be at least 2m long.

Lifting slings should be fastened to the harness in such a way that they do not come into contact with any attachments or the overhead guard when it is being raised.

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C 2

3 Securing the truck during transport

The truck must be securely fastened when being transported on a lorry or a trailer. The lorry / trailer must have fastening rings and a wooden floor.

Loading must be carried out by specially trained staff in accordance with recommendations contained in Guidelines VDI 2700 and VDI 2703. In each case correct measurements must be made and appropriate safety measures adopted.

– To secure the truck with the mast assembled, use the eyes on the upper cross

member of the mast and the trailer pins.

– If the truck is to be transported without a mast, it must be tied down at the front of

the chassis.

The attached picture shows the approximate centre of gravity location.

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4 Using the truck for the first time

Commissioning and driver instruction must be performed by trained personnel. If several trucks have been delivered, make sure that always the serial numbers of the load handlers, masts and basic trucks match each other.

To prepare the truck after delivery or after transport, proceed as follows:

– Make sure the truck’s equipment is complete and in a satisfactory condition. – Check the engine oil level. – Hydrostatic drive axle oil level – Check hydraulic oil level. – Check battery terminals and acid level.

Start up the truck as indicated.

5 Operating the truck without its own drive system

The brake system is designed so that the multi-plate brakes are automatically activated when the truck comes to rest. It must therefore be released for towing as described below.

Support the mast and carriage on blocks before working underneath the forklift truck.

Releasing the mechanical brake

Should you need to tow the truck, observe the following procedure:

Components

73 Ball

74 Plug

75 Washer

76 O ring

– Plug (74) position

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C 4

– Remove the four plugs (74) from the

hydrostatic drive axle.

Leave the drive axle housing balls in place.

– Pull out the washers (75) and

O rings (76).

– Refit the plugs (74) in pairs while

applying a torque of 30 Nm.

– Tow the truck slowly. You may

notice some resistance on the first quarter turn of the wheels. This depends on the period of time the truck has not been in operation.

Towing a truck with a decommissioned engine will cause the hydrostatic drive axle to overheat. To avoid this, the truck must only be towed a short distance at a maximum speed of 4 km/h.

– After towing the truck it is essential to refit the washers and O rings. Failure to

comply with this instruction will prevent the emergency or parking brakes from working.

– Remove the plugs (74) and washers (75) and attach new O rings (76). Torque the

plugs to 60 ± 6 Nm.

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Hitch point

A rigid tow bar must be used to move a forklift truck.

The tow point of the truck is indicated (77).

Using the hitch point

– Push the tow pin (78) down and turn

it 90 degrees.

– Pull the tow pin up and insert the tow

eye or tiller of the trailer vehicle into the opening (79).

– Insert the tow pin, push it down, turn

it 90 degrees and engage it.

One person must be seated in the towed truck to steer it. Tow the truck at walking pace.

As the steering auxiliary unit is not operational, extra effort is required to steer the truck.

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D Fuelling the Truck

1 Safety regulations for handling diesel fuel and LPG

Before filling up or replacing the LPG bottle, first park the truck securely (see Chapter E).

Fire protection: When handling fuels and LPG, smoking, naked flames and other ignition sources are strictly prohibited in the immediate vicinity. Labels indicating the hazard zone must be positioned where they are clearly visible. It is prohibited to store flammable materials in this area. Fire equipment in full working order must be provided within easy reach of the filling area.

Use only a carbon dioxide dry fire extinguisher or a carbon dioxide gas extinguisher to fight LPG fires.

Storage and transport: The diesel and LPG storage and transport devices must comply with statutory requirements. If there is no filling point available, the fuel must be stored and transported in clean, approved containers. The contents must be clearly indicated on the container. Unsealed LPG bottles must be brought immediately into the open air, stored in well ventilated areas and the supplier must be notified. Spilled diesel must be set using a suitable agent and disposed of in accordance with environmental regulations.

Personnel for filling fuel and replacing LPG bottles: Personnel handling LPG must be have sufficient knowledge of the nature of liquid gases to ensure safe operation.

Filling up the LPG tank: LPG tanks remain connected to the truck and are filled up at LPG stations. Always follow the instructions of the tank system and LPG container manufacturer as well as statutory and local regulations when filling up.

Hose / pipe safety valve

Attention: A hose / pipe safety valve must be present when using fluid gas, to prevent the gas from escaping suddenly if a line fails.

– Use only gas bottles with a hose / pipe safety valve. – The bottle connection to the truck must have a hose / pipe safety valve (available

from the factory).

The owner must comply with all legal requirements, technical standards and health and safety regulations applicable to liquid gas.

Liquid gas produces frost damage when it comes into contact with bare skin.

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2 Filling with diesel

The truck must only be filled at locations specifically designed for this purpose.

– Park the truck securely before filling

up (see Chapter E). – Open the cap (1). – Fill up with clean diesel.

Do not overfill the tank.

Level:

DFG 316s/320s: 42 l

Only use DIN 590 diesel with a cetane rating above 50.

The fuel indicator (2) shows the fuel level. When the indicator points to the red area the tank must be filled up.

Never allow the fuel tank to run dry. Air in the fuel system will result in malfunctions.

– Tighten the cap back on after filling

with fuel.

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3 Replace the LPG bottle

The LPG bottle must only be replaced at designated areas by trained and authorised personnel.

– Park the truck securely before

filling up (see Chapter E). – Close the shut-off valve (3)

securely. – Start the engine and allow the

LPG system to run empty in

neutral. – Unscrew the union nut (4) with

an appropriate key while holding

against the handle (6). – Remove the hose (5) and

immediately screw the valve cap

onto the empty LPG bottle. – Slacken the sealing straps (8)

and remove the cover (7). – Carefully remove the LPG bottle

from the bracket and place it

down securely.

Use only 18 kg (29l) LPG replacement bottles.

– Insert the new LPG bottle in the

bracket and turn it so that the

neck of the shut off valve is

facing down. – Secure the LPG bottle with the

sealing straps. – Refit the hose in accordance with

regulations. – Carefully open the shut off valve

and check the connection is

sealed using a foam-based

agent.

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o Reusable LPG bottles with central filling device

Refillable liquid gas bottles contain a dispensing valve (10), a filling stop valve (11), a relief valve (12) and a level display (13). To fill the tank close the dispensing valve, unscrew the cover of the filling stop valve and insert the nozzle of the LPG pump into the filling port. The filling stop valve automatically stops the gas from being filled when the bottle reaches the maximum level. At filling, screw the lid back on.Observe any guidelines or regulations on filling LPG bottles that are attached to the LPG pump.

Safety notices:

– The tank and the fittings must be checked regularly for physical damage, corrosion

and other damage in accordance with the regulations of the country of use. – Tank repairs must only be carried out by trained personnel.

o Lift trucks with two LPG bottles

A twin LPG bottle container may only be used if the truck is equipped with an operational reverse camera system and outer mirrors on both sides.

A supply valve is also attached to the unit in addition to the shutoff valves on both gas bottles. This valve can be used to select from which of the two bottles the gas is to be taken. The two bottles cannot be used together.

Close both shutoff valves on the gas bottles to interrupt the supply of gas.

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E Operation

1 Safety Regulations for the Operation of Forklift Trucks

Driver authorisation: The forklift truck may only be used by suitably trained

personnel, who have demonstrated to the proprietor or his representative that they can drive and handle loads and have been authorised to operate the truck by the proprietor or his representative.

Driver’s rights, obligations and responsibilities: The driver must be: informed of his rights and duties; trained in the operation of the forklift truck; and familiar with the contents of these operating instructions. The driver shall be afforded all due rights. Safety shows must be worn for pedestrian operated trucks.

Unauthorised use of truck: The driver is responsible for the truck during the time it is in use. He shall prevent unauthorised persons from driving or operating the truck. Do not carry passengers or lift other people.

Damage and Faults: The supervisor must be immediately informed of any damage or faults to the forklift truck or attachment. Trucks which are unsafe for operation (e.g. wheel or brake problems) must not be used until they have been rectified.

Repairs: The driver must not carry out any repairs or alterations to the industrial truck without the necessary training and authorisation to do so. The driver must never disable or adjust safety mechanisms or switches.

Hazardous area: A hazardous area is defined as the area in which a person is at risk due to truck movement, lifting operations, the load handler (e.g. forks or attachments) or the load itself. This also includes areas which can be reached by falling loads or lowering operating equipment.

Unauthorised persons must be kept away from the hazardous area. Where there is danger to personnel, warning shall be sounded in good time. If unauthorised personnel are still within the hazardous area the truck shall be brought to a halt immediately.

Safety devices and warning signs: Safety devices, warning signs and warning instructions shall be strictly observed.

Trucks with reduced headroom are equipped with a warning sign within the driver's line of sight. The max. recommended body size indicated on this sign must be observed.

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2 Controls and Displays

Item Control /

display item

Function

1 Parking brake

indicator

t When lit, indicates that the parking

brake is applied.

2 Fuel display (DFG) t Indicates how much fuel is left in the

tank.

3 Coolant temperature

indicator

t Indicates the coolant temperature.

4 Neutral position t When lit, indicates that the travel

direction switch is in neutral.

5 o Not used.

6 Hydrostatic drive

indicator

o When lit, indicates that the hydrostatic

drive is faulty. Slow flashing indicates a minor error

in the hydrostatic drive, such as accelerator potentiometer, mast lever or engine actuator.

Rapid flashing indicates a more serious error in the hydrostatic drive (truck automatically brakes), such as the pump potentiometer, brake pedal, error in 5 volt circuit.

A permanently lit indicator during travel indicates an error in the engine speed sensor.

7Light o Indicates that the headlights are on.

8 Engine oil pressure

indicator

t When lit, indicates insufficient engine

lubricant oil pressure.

9 Not used o

10 Not used o

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Item Control /

display item

Function

11 t Not used.

12 Seat belt indicator o When lit indicates that the seat belt

has not been properly attached.

13 Indicator control light o Shows the indicator status (right/left).

14 Fuel supply

indicator (DFG)

t When lit, indicates the fuel supply is

too low.

15 Time / service hours

display

t Indicates the time or number of

service hours operated.

16 Preheat control light

(DFG)

t Indicates the cold start mechanism is

operating.

17 Charge current

indicator

t When lit, indicates that the battery is

not charged.

18 Steering wheel t Steers truck in desired direction.

19 Set heating/air

connection

20 Steering column

adjusting lever

t Adjusts the steering column tilt.

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Item Control /

display item

Function

21 Heating

o Controls the heating (page E13)

22 Accelerator pedal t Controls the engine speed and / travel and

lift speeds.

23 Raise/lower

control lever

t Raises and lowers the fork carriage. To

raise the fork carriage: pull the lever back. To lower the fork carriage: push the lever

forward.

24 Mast tilt control

lever

t Tilts the mast forward and back.

To tilt the mast forward: push the lever forward. To tilt the mast back: pull the lever back.

25 Switch o Lamps, demister etc.

26 Ignition / starter

switch

t Switches power supply on and off.

Starts and stops the engine. Removing the ignition key prevents the truck from being switched on by unauthorised personnel.

27 Main switch /

isolator (emergency disconnect)

t Interrupts the main circuit, all electrical

functions are deactivated. The engine switches off. The truck brakes suddenly. This switch should only be used to stop in

an emergency. In normal circumstances the stopping

instructions listed on page E 25 should be observed.

28 Warning switch

t Activates a warning sound.

29 Travel direction

lever

t Selects the travel direction.

30 Slow travel /

brake pedal

t 1st zone: controls slow travel.

2nd zone: applies service brake.

31 Parking brake

switch

t Applies / releases parking brake.

To engage, turn switch to position 1. To release, turn switch to position 0.

32 5 level selector t Each level increases or reduces the

acceleration and brake speeds.

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3 Operating the lift and tilt mechanisms (o)

Symbol Purpose Symbol Purpose

1. Tilt mast forward. 5. Tilt mast back.

2. Raise forks and tilt mast forward.

6. Lower forks and tilt mast back.

3. Raise forks. 7. Lower forks.

4. Raise forks and tilt mast back.

8. Lower forks and tilt mast forward.

Main control mechanism

Main control lever

Additional control levers

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4 Twin Pedal Operation (o)

Introduction

This option enables the driver to control the travel direction with two pedals. The system offers precise speed and direction control through two user-friendly pedals. Right foot: forward. Left foot: backward.

Twin pedal

Direction / Accelerator Pedals

Pressing the direction pedal increases the engine speed and travel speed. When you release your foot from the pedal, the truck slows down. Suddenly removing your foot from the pedal causes the truck to slow down in a controlled manner and then stop.

Brake / slow travel pedal

When the brake / slow travel pedal is used in conjunction with a direction or accelerator pedal, the speed and direction of the truck are controlled with precision.

Reverse /

accelerator pedal

Brake /

slow travel pedal

Forward /

accelerator pedal

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t Gear shift lever

When the gear shift lever is in the middle position, the gear is in neutral.

– To select forward gear, push the

lever forward.

– To select reverse gear, push the

lever back.

The engine will not start when the gear shift lever is in the forward or reverse position.

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o Gear selector mounted o the steering column

If your truck is equipped with a steering column lever, it replaces the standard gear selector.

When the steering column lever is in the middle position, the gear is in neutral.

– To select forward gear, push the

lever forward.

– To select reverse gear, push the

lever back.

The engine cannot start when the lever is in the forward or reverse position.

t 5 stage switch for travel mode

The Total Control System (TCS) can control 36 performance parameters. This provides a wide range of setting options. To simplify the complexity of this, five preprogrammed combinations can be selected by the switch. The software parameters have been designed to correspond to five typical truck applications. By simply shifting over the 5 stage switch the truck’s characteristics can be set to suit the application at hand.

5 stage

switch

Parking brake

switch

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Stop the truck and apply the parking brake. Select the required travel mode.

The travel mode can only be altered when the truck is idle.

The truck can only be operated when the travel mode has been set correctly.

The travel characteristics of trucks not fitted with a 5 stage switch are factory-set.

Loading / depositing: maximum performance and productivity for intensive loading/unloading operations over short distances and at low heights.

Outdoor operation: fast outdoor duty cycles over short to medium distances, with medium heights. Fast-reacting auxiliary hydraulics.

Mixed application: good all-round performance for mixed operations.

Indoor operation: reduced engine speed. Basic travel characteristics, high lift speeds. For controlled working in tight areas.

Safety: reduced performance and exhaust levels and low fuel consumption. For working with fragile loads, in pedestrian zones, at night or noise-sensitive areas.

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o Heating controller

– Turn the thermostat control button (41)

anti-clockwise to reduce the driver's cab temperature.

– Turn the fan control button (42)

clockwise to control the air flow. To switch it off, turn the fan control button to the O position.

– Push the air flow controller (43) as far

down as possible to direct the air flow to the cabin floor. Push the air flow controller (43) as far up as possible to switch off the air flow to the cabin floor. The air flow to the windscreen is controlled independently of this lever.

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Horn

– Press the button (25) to sound the

horn.

5 Tests and tasks to be performed before starting the truck

Truck

Visually inspect the whole of the truck (especially the wheels and the lifting device) for obvious signs of damage.

– Test the seat belt (see page E21). – Make sure the load chains are evenly tensioned.

Checking the engine oil - TFG

– Open the engine bonnet

(see page E 43).

– Remove the oil dipstick (44 / 46

or 48).

– Wipe the dipstick with a lint-free cloth

and put in back fully into its port.

– Remove the dipstick again and

check whether the oil level is between the MIN and MAX markings.

– If the oil level is below the centre

point, remove the fuel cap (43) and add the correct grade of oil to the engine until the oil level has reached the MAX mark on the dipstick.

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Checking the engine oil - DFG

– Remove the dipstick (50). – Wipe the dipstick with a lint-free cloth

and put in back fully into its port.

– Remove the dipstick again and check

whether the oil level is between the MIN and MAX markings.

– If the oil level is below the centre point,

remove the fuel cap (49) and add the correct grade of oil to the engine until the oil level has reached the MAX mark on the dipstick.

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Checking the hydraulic oil level

If the oil is cold

– Fully extend and retract the mast a

single time.

– Stop the engine.

– Remove the dipstick (53) and wipe it

with a clean cloth. Check the hydraulic oil level. It should lie between the MIN and MAX markings on the dipstick. If necessary, top up to the MIN marking on the dipstick.

If the oil is hot

– Fully extend and retract the mast a

single time. – Stop the engine. – Remove the dipstick (53) and wipe it

with a clean cloth. Check the hydraulic

oil level. It should lie just above the

MAX marking on the dipstick. If

necessary, top up to just above the

MAX marking on the dipstick.

If the engine goes out or does not run smoothly when the mast is extended, lower the mast fully.

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Checking the coolant level

– Cheeck the coolant level on the

reservoir (56).

The coolant level should be between the “MIN” and “MAX” markings.

If the coolant is below the MIN marking, this indicates possible leakage in the radiator system. In this case the truck should only be used once the cause has been removed.

If the engine is hot, the radiator system is pressurised. Slowly open the reservoir lid until the pressure has dropped.

When adding the coolant include a premixed solution of water and antifreeze in the same concentration levels as for a car.

Bleeding the coolant system

It should be possible to empty the system by opening the drain taps in the radiator and on the side of the cylinder block. When bleeding the coolant system remove the reservoir lid. Prevent the truck against authorised use.

Checking the fuel supply - (DFG)

– Set the ignition / starter key (26) to the

“I” position. – Check the fuel supply on the fuel

gauge (2). – If necessary, add diesel (see

Chapter D, Section 2).

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Checking the windscreen fluid level

– Make sure there is sufficient

windscreen fluid in the container (1).

Top up if required. – In winter, use windscreen fluid with

anti-freeze.

Wheels and Tyres

– Check wheels and tyres for wear (see

Chapter F). Measure the tyre pressure

(pneumatic tyres only) (see tyre

pressure table in Chapter B).

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6 Starting up the truck

Before the truck can be commissioned, operated or a load unit lifted, the driver must ensure that there is nobody within the hazardous area.

o Trucks with reduced headroom X

Failure to observe the recommended body size can cause stress and endanger the driver and may lead to lasting ill health due to an unhealthy posture and excessive strain on the driver. The owner must ensure that truck operators do not exceed the max. body size indicated. In addition the owner must check that the driver’s used can sit in an upright position without having to strain.

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6.1 Adjusting the driver’s seat

To achieve optimum seat cushioning, the driver’s seat must be adapted to the driver’s weight.

Adjusting the seat to the driver's weight:

– Sit on the driver’s seat. When the correct weight adjustment has been made, the

arrow of the driver weight display (59) will be above the calibration line. If the arrow

is facing too far to the left or right, the seat must be adjusted to the driver's weight. – To do this, move the weight adjustment lever (1) approx. 90° forward. – To set the seat to a lesser weight, push the weight adjustment lever (1) down. – To set the seat to a greater weight, push the weight adjustment lever (1) up. – After adjusting, return the lever to its original position.

To adjust the backrest:

– Sit on the driver’s seat. – Lift up the backrest adjuster (2) and adjust the backrest tilt. – Release the backrest tilt adjuster (2) to lock the backrest in position.

To adjust the seat position:

– Pull up the longitudinal adjuster (3) and push the driver’s seat forwards or

backwards to the desired position. – Engage the longitudinal adjuster (3) in position again.

The longitudinal adjuster must be securely located in the desired position. The driver’s seat setting must not be changed during travel.

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6.2 Adjusting the steering column

– Release the steering column adjusting

lever (20) in the direction of the arrow

towards the driver’s seat (L). – Tilt the steering column (62) forward or

backward as required. – Push the steering column adjusting

lever in the direction of the arrow (F).

6.3 Seat belt

Put on the seat belt each time before starting the industrial truck. The belt protects against serious injury.

Protect the belt from contamination (e.g. cover it when the truck is idle) and clean it regularly. Frozen belt locks or pulleys must be thawed out and dried to prevent them from freezing up again.

The dry temperature of the warm air should not exceed +60 °C.

Do not alter the belt setting. This will increase the risk of malfunctioning.

– Always replace the seat belt after an accident. – Only original spare parts must be used for retrofits or repairs.

Damaged or non-operational belts must only be replaced by contractual dealers or branches.

– Withdraw the belt completely and check the belt is frayed. – Check the belt lock and that the belt enters the take up roller mechanism.

Check the cover for damage

Testing the automatic blocking system:

– Park the truck horizontally. – Jerk the belt outwards.

The automatic system should lock the belt in the retractor.

– Open the engine bonnet by approx. 30°.

The automatic system should lock the belt in the retractor.

Starting the industrial truck on steep slopes

The automatic blocking system locks the belt in the retractor when the truck is positioned on a steep slope. This prevents the belt from being pulled out of the retractor.

Carefully drive the truck off the slope and then put on the belt.

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7 Starting the truck

Before starting the truck.

Before starting the truck, inspect the overhead guard for cracks and repair or replace if damaged.

If the engine has not been run for several weeks or if the oil filter has been changed, start the engine (see section 4.1 or 4.2) and leave it to run in idle for a few minutes before starting.

Starting the engine

The truck should only be operated from the driver’s seat.

– Set the key switch to the I position. – Set the travel direction lever to neutral “N”.

The engine can only be started if the travel direction lever is in neutral and the parking brake switch in the I position.

Key operated ignition

Key settings

Position Function

O=O° Disconnects all main circuits, the

key can be removed.

I=30° All consumers off

II=60° All consumers on

pre-heat Pre-heat

III=90° Start

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7.1 Starting procedure for the TFG

Note the safety regulations for handling liquid gas (see Chapter D, section 1).

– Slowly open the shutoff valve (63) on

the LPG bottle. – Put the key in the ignition / starter

switch (26). – Set the ignition / starter key to the “II”

position. – Press the warning switch (28) and test

the horn.

The charging current (17), engine oil pressure (8), neutral setting (4) and parking brake (1) indicators light up.

– Gently apply the accelerator pedal

(22). – Now move the ignition / starter key to

the “III” position.

Only apply the starter for a maximum of 15 seconds without interruption. Before starting again, wait 30-60 seconds and reset the ignition / starter switch to 0.

– Release the key as soon as the engine

starts. It automatically reverts to the

“II“ position.

When working with LPG trucks always observe the following safety regulations.

If the truck does not start:

– Close the gas bottle shutoff valve. – Turn off the ignition / starter O. – Call for a trained, authorised customer

service engineer.

All indicators lights except for neutral setting (4) and parking brake (1) should go out as soon as the engine starts. If not, stop the engine immediately and rectify the fault.

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7.2 Starting procedure for the DFG

– Put the key in the ignition / starter

switch (26). – Set the ignition / starter key to the “II”

position. – Press the warning switch (28) and test

the horn. – After setting the ignition / starter (26) to

the II position, the charge current (17),

engine oil pressure (8), neutral setting

(4) and parking brake (1) indicators

will light up. – Keep turning the key slowly until the

pre-heat indicator (16) goes on.

On the DFG 316s/320s models if the bulb does not go out, turn the ignition key to the “III” position after approx. 4 seconds.

Only apply the starter for a maximum of 15 seconds without interruption. Before starting again, wait 30-60 seconds and reset the ignition / starter switch to 0.

– Release the key as soon as the engine

starts. It automatically reverts to the

II position.

All indicators lights except for neutral setting (4) and parking brake (1) should go out as soon as the engine starts. If not, stop the engine immediately and rectify the fault.

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Once the engine has started, Carry out a test run and perform the following checks:

– Test the parking brake (31) and

service brake (30). – Test the engine speed with the

accelerator pedal (22) over a range of

speeds while checking the freedom of

movement of the pedal. – Test the operation of the raise/lower

(23), tilt (24) and if applicable the

attachment hydraulic control

functions. – Turn the steering wheel (18) as far as

it will go in both directions and test the

steering.

Do not run up the engine in idle The engine soon reaches operating temperature at a moderate charge and when the speed alternates. Only fully charge the engine when the engine coolant temperature display (3) shows operating temperature (indicator horizontal).

The truck is ready for operation once all the functional controls have been satisfactorily performed and operating temperature is reached.

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7.3 Operating Error Displays

When the following indicators are lit:

– Engine oil pressure (8), – Charge current (17), – Coolant temperature (3), – Hydrostatic drive (6),

the engine must be stopped immediately.

The engine should only be started again once the fault has been removed.

For troubleshooting procedures, see section 6.

When the truck is operating check the fuel display (3) (DFG).

7.4 Switching off the engine

Do not switch off the engine from full charge. Instead, let it run for a short while to allow the temperature to compensate.

– Stop the truck. – Set the travel direction switch (29)

to neutral. – Apply the parking brake lever (31). – Set the ignition / starter switch

(26) to “0”.

Additional requirements for the TFG:

Close the shutoff valve (63) on the LPG bottle.

If the ignition key is set to “0” while the engine is running, the engine will continue to run for a short while. This ensures that the remaining gas in the lines between the engine and the automatic shutoff valve of the gas system is used up.

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8 Industrial Truck Operation

8.1 Safety regulations for truck operation

Travel routes and work areas: Only use lanes and routes specifically designated for

truck traffic. Unauthorised third parties must remain clear of the work area. Loads must only be stored in places specially designated for this purpose.

Driving conduct: The driver must adapt the travel speed to local conditions. The truck must be driven at slow speed when negotiating bends or narrow passageways, when passing through swing doors and at blind spots. The driver must always observe an adequate braking distance between the forklift truck and the vehicle in front and must be in control of the truck at all times. Abrupt stopping (except in emergencies), rapid U turns and overtaking at dangerous or blind spots are not permitted. Do not lean out or reach beyond the working and operating area.

Travel visibility: The driver must look in the direction of travel and must always have a clear view of the route ahead. When carrying loads which affect visibility, these must be stored at the rear of the truck. If this is not possible, a second person must walk in front of the truck as a lookout.

Negotiating slopes and inclines: Slopes or inclines may only be negotiated if they are designated traffic routes, are clean and have a non-slip surface and providing they can be safely negotiated in accordance with the technical specifications of the truck. The truck must always be driven with the load unit facing uphill. The industrial truck must not be turned, operated at an angle or parked on inclines or slopes. Inclines must only be negotiated at slow speed, with the driver ready to brake at any moment.

Negotiating lifts and docks: Lifts and docks must only be used if they have sufficient capacity, are suitable for driving on and authorised for truck traffic by the owner. The driver must satisfy himself of the above before entering these areas. The truck must enter lifts with the load in front and must take up a position which does not allow it to come into contact with the walls of the lift shaft. People travelling in the lift with the forklift truck must only enter the lift after the truck has come to a halt and must exit the lift before the truck.

Nature of loads to be carried: The operator must make sure that the load is in a satisfactory condition. Loads must always be positioned safely and carefully. Use suitable precautions, e.g. a load guard, to prevent parts of the load from tipping or falling down.

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Towing trailers

(see page E46)

Exhaust emissions: The truck must only be operated in well ventilated areas. If the truck is operated in enclosed areas, this can lead to a build-up of harmful exhaust emissions, resulting in dizziness, tiredness and even death.

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.

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9 Travel

Adapt the travel speed to the conditions of the travel lane, the work area and the load

– Set the travel direction switch (29) to

neutral. – Raise the fork carriage approx. 200

mm so that the forks are clear of the

ground. – Tilt the mast fully backward: – Release the parking brake.

Forward travel

– Set the travel direction switch (29)

forward.

In normal operation do not set the isolator (27) from max. speed to “OFF”. The truck brakes automatically. (full braking).

– Slowly apply the accelerator pedal

(22) until you reach the required travel

speed.

Changing direction

– Set the travel direction switch (29) via

neutral to the required direction. – Slowly apply the accelerator pedal

(22) until you reach the required travel

speed.

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Reversing

Make sure you have sufficient space to reverse into.

– Move the travel direction switch (29) backwards.

Accelerating

– Slowly apply the accelerator pedal (22) until the truck starts to move. – Continue to depress the accelerator. The engine and travel speeds will increase.

Braking

The brake pattern depends largely on the ground conditions. The driver must take this into consideration when handling the truck. Brake carefully to prevent the load from slipping.

Braking

– Take your foot off the accelerator pedal (22). The truck brakes slowly. – Depress the brake pedal (30) fully to increase the brake force.

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9.1 Steering

Very little steering force is required for the hydrostatic steering, therefore turn the steering wheel (26) with caution.

9.2 Brakes

Service brake

The parking brake acts on the multi-plate brakes via a hydraulic pressure system. This system is fail-safe as the parking brakes automatically apply in the event of pressure loss.

– Take your foot off the accelerator

pedal (22).

The truck will brake hydrostatically depending on the travel program that is active.

Additional braking can be achieved by pressing the brake / slow travel pedal (30).

The parking brake is applied during the last movement of the brake / slow travel pedal.

Parking brake

The parking brake switch secures the automatic multi-plate brake in the brake position.

To apply the parking brake set the switch (31) to the I position.

To release the parking brake set the switch (31) to the O position.

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Before leaving the truck apply the parking brake switch and switch off the engine.

An audible warning will sound if the parking brake is not applied.

The parking brake will keep the truck with the maximum permissible load, on a clean concrete surface, at a 15% incline.

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10 Mast and Attachment Operation

The control levers must only be operated from the driver’s seat.

The lift mechanism is operated by the control levers on the right-hand side of the driver's seat.

Lifting/lowering the fork carriage

Never reach through the mast!

– Pull the control lever (23) back to raise

the fork carriage. – Push the control lever (23) forward to

lower the fork carriage.

Tilting the mast forward / backward

When tilting the mast back, do not position any part of your body between the mast and the front wall.

– Pull the control lever (24) back to tilt

the mast back. – Push the control lever (24) forward to

tilt the mast forward.

Operating attachments

Attachments are operated via the control levers (25.26) to the right of control lever (24) (mast tilt).

Note the manufacturer’s operating instructions and the capacity of the attachment.

Auxiliary hydraulics ZH1

The auxiliary hydraulics ZH 1 (control lever 25) can be used to control hydraulic attachments (e.g. sideshift). They are applied by pressing the lever forward or pulling it back.

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Auxiliary hydraulics ZH2 +ZH3

The auxiliary hydraulics ZH2 (e.g. for fork positioners) are controlled in the same way as for ZH1 by applying the control lever (26). You can toggle from ZH2 to ZH3 with the switch (1).

o Intergrated sideshift ISS

The fork carriage can be moved sideways using the ISS.

– Sideshift left: Push the control lever (25) forward. – Sideshift right: Pull the control lever (25) back.

Note the reduced capacity for sideshift (Chapter B, page 14)

o Integrated fork positioner

The integrated fork positioner allows the distance between the forks to be changed.

– Push the lever (26) to increase the fork spread – Pull the lever (26) to reduced the fork spread

To synchronise the alignment of the forks, open them as far as the stop and then close them again.

Other attachments

Always follow the manufacturer’s operating instructions when using other attachments.

Mark the control levers with symbols to indicate their function.

The attachments must have a e mark. The reduced residual capacity must be

re-calculated and indicated on a separate capacity plate.

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10.1 Controlling the speed of the lifting device

Moving the control levers (23-26) and changing the engine speed governs the operating speed of the hydraulic cylinders.

When the control levers are released (23-26) they automatically revert to neutral and the lifting device remains in the position it has reached.

Always apply the control lever sensitively, never with a sudden jerk. Release the control lever as soon as you reach the stop.

– Set the travel direction switch (23) to

neutral – Keep moving the control lever back to

increase the speed of the lifting

device.

On the hydrostatic drive the engine speed automatically increases as the control lever is moved. (greater angle = higher speed)

The engine speed does not affect the lowering speed of the fork carriage.

Do not lift other people with the lifting device.

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10.2 Lifting, transporting and depositing load units

The control levers must only be operated from the driver’s seat.

Before lifting a load the driver must make sure that it has been correctly palletised and does not exceed the truck’s capacity.

Note the capacity chart.

Adjusting the forks

Adjust the forks in such a way that both are equidistant from the outer edge of the fork carriage and the load centre of gravity lies between the forks.

– Raise the locking lever (65). – Push the forks (66) into the correct

position on the fork carriage (67).

– Turn the locking lever down and move

the forks until the locking pin engages in a slot.

Lifting loads

– Carefully approach the load to be

lifted.

– Set the travel direction switch (29) to

neutral.

– Raise the forks to the correct height for

the load.

– Set the travel direction lever to forward

travel.

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– Carefully enter the load until ideally it

touches the fork shank.

At least two thirds of the length of the load fork must extend into the load.

– Set the travel direction lever (29) to

neutral.

– Raise the fork carriage until the load

rests freely on the forks.

– Set the travel direction lever to

reverse.

Make sure you have enough space to reverse into.

– Reverse carefully and slowly until the

load is outside the storage area.

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Do not stand underneath a raised load.

– Tilt the mast back fully.

– Lower the load as far as is absolutely

necessary for transport (ground clearance approx. 150…200mm).

The higher the load is transported, the less secure the truck will be.

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11 Transporting loads

If the load is stacked so high that it affects forward visibility, then reverse.

– Gently accelerate with the accelerator

pedal (22) and slowly brake with the slow travel / brake pedal (30), while being ready to brake at all times.

– Adapt your travel speed to the

conditions of the route and the load you are transporting.

– Watch out for other traffic at crossings

and passageways.

– Always travel with a lookout at

blindspots.

On slopes and inclines always carry the load facing uphill, never approach at an angle or turn.

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Depositing a load

– Drive carefully up to the rack. – Set the travel direction switch (29) to

neutral.

– Raise the forks to the correct height for

the rack space. – Set the mast vertical. – Set the travel direction lever to forward

travel. – Carefully enter the load into the rack

space. – Slowly lower the load until the forks

are clear.

Avoid placing the load down suddenly to avoid damaging the load and the load aid.

Handling individually suspended loads

Travel at max. crawl speed when transporting suspended loads. For operations involving suspended loads, the safety of the truck must be individually assessed by a specialist.” The capacity is reduced by at least 1/3.

THE RATED CAPACITY OF THE TRUCK AND THE ATTACHMENT MUST NOT BE EXCEEDED.

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12 Hazardous situations

If the truck is about to tip over, never undo the restraint belt and try to jump out. This will only increase the risk of injury.

Correct procedure:

– Lean your upper body over the

steering wheel.

– Grip the steering wheel with both

hands and brace feet.

– Lean your body against the opposite

direction of fall

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12.1 Parking the truck safely

When you leave the truck it must be securely parked even if you only intend to leave it for a short time.

Never park and abandon a truck with a raised load.

– Drive the truck onto a level surface.

LPG powered trucks must not be operated on ground floors with a basement.

Liquid gas is colourless, heavier than air and does not easily dissipate. It tends to sink to the lowest possible level and can collect in pits, drains, basements and other recesses.

This means that LPG gas can gather in areas far away from the truck and constitutes a hazard for people who are unaware of the potential risks from explosions and frostbite.

– Fully lower the load fork and tilt the mast forward. – Set the travel direction switch (29) to neutral. – Set the parking brake switch (31) to the I position.

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13 Engine bonnet and service covers

Engine bonnet

Before opening the engine compartment push the steering column as far forward as it will go and push the seat fully back along its guide rails.

– To open the engine compartment fit a

suitable instrument (e.g. screwdriver

(68)) through the access hole and

push it onto the locking device of the

engine bonnet (69). – Lift up the engine bonnet fully. A gas

pressure damper keeps the engine

bonnet in the raised position.

If a forklift truck is equipped with a steel cabin, both cabin doors must be opened before raising the motor panel.

Make sure the engine bonnet has engaged correctly before operating the truck again.

To aid visibility the truck is shown without a protective plate.

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13.1 Service covers

When the engine bonnet has been opened the service covers (70) can be removed as follows:

To remove:

– Tilt the top of the cover plate away

from the truck and lift off the service

cover.

To assemble:

– Insert the bottom bracket of the

cover plate in the receptacles

provided. – Push the top of the service cover

towards the truck until it engages.

o Steel cabin

If a truck is fitted with a steel cabin, both doors can be closed.

– To unlock the cabin door turn the

key anti-clockwise.

– To lock the cabin door turn the key

clockwise.

– To open the cabin door, unlock the

door and remove the handle (71).

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13.2 Towing the truck

– See chapter C, item 5

13.3 Towing trailers

The truck can occasionally be used to tow a light trailer on a dry, level and well maintained surface.

The max. tow load is the capacity indicated on the capacity data plate (see decals diagram in chapter B).

The tow load consists of the weight of the trailer and the stated capacity. If a load is transported on the forks, the tow load must be reduced by the same amount.

Important notes for safe towing

• A truck must not be continually operated with trailers.

• No supporting loads are permitted.

• The maximum speed is 5 km/h.

• Towing must only be performed on level, secure travel routes.

• Follow the instructions of the coupling manufacturer if using special trailer couplings.

• The owner must test trailer operation with the permissible tow load by means of a trial run under the applicable operating conditions on site.

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14 Troubleshooting

This chapter allows the user to identify and rectify basic faults or the effects of incorrect operation. When locating a fault, proceed in the order shown in the table.

If the fault cannot be rectified after carrying out the remedial procedure, notify the manufacturer’s service department, as any further troubleshooting can only be performed by specially trained and qualified service personnel.

Fault Possible Cause Action

Starter does not turn

yTravel direction lever not in

neutral

yBattery charge too low

yBattery terminal cable loose or

terminals oxidized.

yStarter cable loose or broken

yStarter solenoid jammed

ySet the travel direction lever to neutral.

yCheck battery charge, charge battery if

necessary

yClean and grease terminals, tighten battery

terminal cable

yCheck starter cable, tighten or replace as

required

yCheck if the magnetic switch audibly engages

Engine does not start

yAir filter contaminated

Additional for LPG

yLPG bottle shutoff valve closed

yLPG bottle empty

yIgnition distributor cap damp

ySpark plugs damp, oily or loose

ySpark plugs faulty

Additional for diesel

yFuel tank empty, injection

system has suctioned in air

yWater in fuel system

yClean / replace air filter

yShutoff valve open

yReplace LPG bottle

yDry ignition distributor cap, if necessary apply

contact spray

yDry, clean and tighten spark plugs

yReplace spark plugs

yFill up with diesel and bleed the injection system

yDrain the fuel system, fill up the truck, bleed the

fuel system

Engine does not start (continued)

yFuel filter blocked

yParaffin separation from the

diesel (flakes forming)

yCheck fuel flow, replace fuel filter if necessary

yPark the truck in a warm room and wait until the

separation has returned to its original state. Replace the fuel filter if necessary. Add winter diesel fuel

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Fault Possible Cause Action

Engine oil indicator lit during operation

yEngine oil level too low yCheck engine oil level, top up if necessary

Engine temperature display in red zone

yEngine oil level too low

yRadiator contaminated

yCoolant level too low

yFan V belt slipping

yCheck engine oil level, top up if necessary

yClean radiator

yCheck engine radiator system for leaks, add

coolant if necessary

yCheck V belt tension, tighten or replace as

required

Transmission oil indicator lit during operation

yTransmission oil level too low

yRadiator contaminated

yCheck transmission oil level, top up if necessary

yClean radiator

Engine running but truck does not travel

ySet the travel direction lever to

neutral.

yParking brake applied

ySet travel direction lever to required direction

yRelease parking brake

Truck does not reach max. speed

yTransmission oil level too low yCheck transmission oil level, top up if necessary

Lift speed too low

yHydraulic reservoir oil level too

low

yHydraulic reservoir discharge

system contaminated or blocked

yCheck hydraulic oil, if necessary top up

yClean / replace hydraulic reservoir discharge

system

Load cannot be raised to max. height.

yHydraulic reservoir oil level too

low

yCheck hydraulic oil, if necessary top up

Steering is sluggish

ySteering axle tyre air pressure

too low

yCheck tyre air pressure, increase to correct

pressure if necessary

Excessive steering play

yAir in steering system yCheck hydraulic oil level and top up if necessary,

then turn the steering wheel several times from one end to the other.

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F Truck Maintenance

1 Operational Safety and Environmental Protection

The servicing and inspection duties contained in this chapter must be performed in accordance with the intervals indicated in the maintenance checklists.

Any modification to the forklift truck assemblies, in particular the safety mechanisms, is prohibited. Do not alter the truck operating speeds under any circumstances.

Only original spare parts have been certified by our quality assurance department. To ensure safe and reliable operation of the truck, use only the manufacturer's spare parts. Used parts, oils and fuels must be disposed of in accordance with the relevant environmental protection regulations. For oil changes, contact the manufacturer’s specialist department.

At the end of testing, cleaning and service operations carry out the procedures listed under section 14 “Initial tests and tests after major repairs or modifications”.

2 Maintenance Safety Regulations

Maintenance personnel: The fork lift truck must only be serviced and maintained by

trained personnel of the manufacturer. The manufacturer’s service department has field technicians specially trained for these tasks. We therefore recommend a maintenance contract with the manufacturer’s local service centre.

Lifting and jacking up: When an industrial truck is to be lifted, the lifting gear must only be secured to the points specially provided for this purpose. When the truck is to be jacked up, take appropriate measures to prevent the truck from slipping or tipping over (e.g. wedges, wooden blocks). You may only work underneath a raised load handler if it is supported by a sufficiently strong chain.

For jack points see Chapter B.

Cleaning: Do not use flammable liquids to clean the industrial truck. Prior to cleaning, all safety measures required to prevent sparking (e.g. through short circuits) must be taken. For battery-operated trucks, the battery connector must be removed. Only weak suction or compressed air and non-conductive antistatic brushes may be used for cleaning electric or electronic assemblies.

If the truck is to be cleaned with a water jet or a high-pressure cleaner, all electrical and electronic components must be carefully covered beforehand as moisture can cause malfunctions. Do not clean with pressurised water.

Switch off the engine and remove the ignition key before opening any doors or bonnets or removing any panels. Always let the engine cool down before carrying out maintenance and repair work.

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Electrical System: Only suitably trained personnel may operate on the truck’s electrical system. Before commencing work on the electrical system, take all precautionary measures to avoid electric shocks.

Welding: Disconnect the battery (batteries) and generator before carrying out any welding operations to avoid damaging electric or electronic components. The computer system on hydrostatic trucks must be unplugged. Welding operations on forklift trucks must only be carried out by suitably qualified personnel.

Settings: When repairing or replacing hydraulic, electric or electronic components or assemblies, always note the truck-specific settings.

Wheels/tyres: The quality of tyres affects the stability and performance of the truck. Changes can only be made with the approval of the manufacturer. When replacing wheels or tyres make sure that the forklift truck does not become uneven (i.e. when replacing wheels always replace left and right together).

Lift chains: Lift chains wear rapidly if not lubricated. The intervals stated in the service checklist apply to normal duty use. More demanding conditions (dust, temperature) require more regular lubrication. The prescribed chain spray must be used in accordance with the instructions. Applying grease externally will not provide sufficient lubrication.

Hydraulic hoses: The hoses must be replaced every six years. When replacing hydraulic components replace also the hoses in the hydraulic system.

Starter battery disposal: Batteries may only be disposed of in accordance with national environmental protection regulations or disposal laws. Do not dispose of used batteries with general waste. The manufacturer’s disposal instructions must be followed. End users, both private and commercial, are legally obliged to return used truck starter batteries to the battery manufacturer through the trade, i.e. wherever batteries are sold, or through authorized disposal agents. If in doubt, contact the Jungheinrich service department.

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3 Servicing and Inspection

Thorough and expert servicing is one of the most important requirements for the safe operation of the industrial truck. Failure to perform regular servicing can lead to truck failure and poses a potential hazard to personnel and equipment.

The application conditions of an industrial truck have a considerable impact on the wear of the service components. We recommend that a Jungheinrich customer adviser carries out an application analysis on site to work out specific service intervals to prevent damage due to wear. The service intervals stated are based on single shift operation under normal operating conditions. They must be reduced accordingly if the truck is to be used in conditions of extreme dust, temperature fluctuations or multiple shifts.

The following maintenance checklist states the tasks and intervals after which they should be carried out. Maintenance intervals are defined as:

W = Every 50 service hours, at least weekly A = Every 500 service hours B = Every 1000 service hours, or at least annually. C = Every 2000 service hours, or at least annually.

W service intervals must be performed by the owner.

– During the run-in period – after approx. 100 service hours – the owner must check

the wheel nuts/bolts and re-tighten if necessary.

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4 DFG/TFG maintenance checklist

Maintenance Intervals

Standard = z WA BC

Cold store = 7

Chassis/ Superstructure:

1.1 Check all load bearing components for damage

1.2 Check screw connection

1.3 Check overhead guard for damage and make sure it is secure

1.4 Check trailer hitch

Drive system: 2.1 IC engine – see separate checklist

2.2 Check transmission for noise and leakage

2.3 Check pedal mechanism, adjust and lubricate if necessary

2.4 Check transmission oil level

2.5 Change transmission oil

2.6 Clean transmission oil suction filter and discharge

2.7 Change transmission oil filter

2.8 Check drive axle for noise and leakage

2.9 Check drive axle oil level (hydrokinetic only)

2.10 Replace drive axle oil level (hydrokinetic only)

2.11 Check switching mechanism on switch lever for wear and lubricate the contact surfaces (hydrokinetic only)

2.12 Lubricate drive axle / mast swivel axle (hydrokinetic only).

Brake system:

3.1 Test operation and settings

3.2 Check brake lining wear (hydrokinetic only)

3.3 Check brake mechanism, adjust and lubricate if necessary (hydrokinetic only)

3.4 Check brake lines, connections and brake fluid level (hydrokinetic only)

3.5 Change brake fluid (hydrokinetic only)

Wheels: 4.1 Check wheels for wear and damage

4.2 Check suspension and attachment

4.3 Check air pressure

Steering: 5.1 Check the steering play

5.2 Check the mechanical parts of the steering column; grease if necessary

5.3 Check steering axle, axle knuckle, stops for wear and deformation

5.4 Test operation of hydraulic components and check for leaks

Mast: 6.1 Check mast attachment

6.2 Check and lubricate mast suspension

6.3 Check operation, wear and setting

6.4 Visually inspect rollers, slide pieces and stops

6.5 Check lift chains and guides for wear, adjust and lubricate.

6.6 Check lateral slack and ensure mast sections are parallel

6.7 Check forks and fork carriage for wear and damage

6.8 Check protective mechanisms for damage and make sure they are secure

6.9 Check tilt cylinder suspension and attachment

6.10 Check mast tilt angle

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Maintenance intervals

Standard = z WA BC

Cold store = 7

Hydraulic System

7.1 Test operation z

7.2 Check connections and ports for leaks and damage z

7.3 Check hydraulic cylinder for leaks and damage and make sure it is secure

7.4 Check oil level z

7.5 Replace hydraulic oil

7.6 Replace filter cartridge z

7.7 Clean hydraulic oil suction filter and discharge z

7.8 Test operation of pressure relief valves z

7.9 Test hose guide and check for damage z

Electrical system

8.1 Test operation z

8.2 Make sure wire connections are secure and check for damage z

8.3 Test all warning devices and safety switches. z

8.4 Test operation of instruments and displays z

Battery: 9.1 Check acid density, acid level and battery voltage z

9.2 Check terminals are securely attached, and apply terminal screw grease

9.3 Check battery cables for damage, replace if necessary. z

Attachment: 10.1 Test operation z

10.2 Check attachment on truck and load bearing components z

10.3 Check position of bearings, guides and stops for wear and damage, grease these components.

Lubrication: 11.1 Lubricate truck in accordance with Lubrication Schedule. z

General Measurements:

12.1 Test travel speed and braking distance z

12.2 Test lift and lowering speeds z

12.3 Test safety devices and cutouts z

Demonstration:

13.1 Test run with rated load z

13.2 After carrying out maintenance, present the truck to the supervisor.

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5 DFG maintenance checklist

d) Replace coolant annually.

Maintenance intervals

Standard = z WA BC

Cold store = 7

Engine: 1.1 Check engine for noise and leaks z

1.2 Check injection pump flow start, adjust if necessary z

1.3 Check injection nozzle pressure, adjust if necessary z

1.4 Tighten cheese head screws z

1.5 Check valve play, adjust if necessary z

1.6 Check engine oil level, top up if necessary z

1.7 Replace the engine oil. z

1.8 Replace the engine oil filter z

1.9 Check V belt for tension and damage z

1.10 Check maximum speed (without load), adjust if necessary z

Coolant: 2.1 Check coolant level, top up if necessary z

2.2 Check anti-freeze content, top up if necessary z

Exhaust: 3.1 Check exhaust system for leaks and damage z

3.2 Check exhaust levels, adjust if necessary z

Air filter: 4.1 Clean air filter cartridge z

4.2 Replace air filter cartridge z

Hydraulic system:

5.1 Check and lubricate the hydraulic pump drive z

Fuel system: 6.1 Replace the fuel filter z

6.2 Check fuel/water separator, and discharge if necessary z

6.3 Check fuel tank and lines for leaks and damage z

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6 TFG maintenance checklist

d) Replace coolant annually.

Maintenance intervals

Standard = z WA BC

Cold store = 7

Engine: 1.1 Check engine for noise and leaks z

1.2 Check spark plugs, replace if necessary z

1.3 Check ignition time, adjust if necessary z

1.4 Check ignition distributor, adjust if necessary z

1.5 Check valve play, adjust if necessary z

1.6 Check engine oil level, top up if necessary z

1.7 Replace the engine oil z

1.8 Replace the engine oil filter z

1.9 Check V belt for tension and damage z

1.10 Check maximum speed (without load), adjust if necessary z

Coolant: 2.1 Check coolant level, top up if necessary z

2.2 Check anti-freeze content, top up if necessary z

Exhaust: 3.1 Check exhaust system for leaks and damage z

3.2 Check exhaust levels, adjust if necessary z

Air filter: 4.1 Clean air filter cartridge z

4.2 Replace air filter cartridge z

Hydraulic system:

5.1 Check and lubricate the hydraulic pump drive z

LPG system: 6.1 Check LPG system for leaks and damage z

6.2 Have LPG filter replaced by specialist z

6.3 Have LPG system examined by specialist z

6.4 Have the exhaust pollutant levels checked by a specialist and adjust to the lowest level achievable.

6.5 Check and service Impco units z

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7 Coolant specification

The quality of the coolant has a considerable effect on the efficiency and useful life of the cooling system. The following instructions are designed to provide the best servicing in terms of frost and corrosion protection.

– Always use clean, soft water.

– To avoid frost and corrosion damage use an ethylene-glycol based anti-freeze mix-

ture. Use a standard anti-freeze with a pH value of 7.0 – 8.5.

– Make sure the mixture ratio is correct when using an anti-freeze. The frost protec-

tion level must satisfy the above standard.

The manufacturer cannot be held liable for frost or corrosion damage caused by incorrect procedures.

The anti-freeze contains ethylene-glycol and other poisonous substances. Ingression into the human body can result if large quantities come into contact with the skin for long or repeated periods.

When handling anti-freeze always observe the following safety measures:

– NEVER swallow anti-freeze. If anti-freeze is accidentally swallowed, seek IMMEDI-

ATE medical attention. – Avoid prolonged skin contact with anti-freeze. – Wipe off spray from the skin immediately. – If anti-freeze is sprayed into the eyes, rinse them immediately. – Clothing sprayed with anti-freeze must be removed and washed before being worn

again. – Wear protective clothing if you are regularly handling anti-freeze (plastic or rubber

gloves, boots and non-permeable overalls or aprons).

Anti-corrosion solutions contain additives which are poisonous if swallowed and which can be absorbed in poisonous quantities through persistent, repeated contact with the skin. Observe the same safety precautions as for anti-freeze.

U.S.A. ASTM D4985 or SAE J1941 Ethylene—glycol based engine coolant

Lowest temperature

required for protection

% volume of anti-freeze Volume ratio

of anti-freeze:

water

-37 °C 50 1:1

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8 Consumables

Handling consumables: Consumables must always be handled correctly. Follow

the manufacturer’s instructions.

Improper handling is hazardous to health, life and the environment. Consumables must only be stored in appropriate containers. They may be flammable and must therefore not come into contact with hot components or naked flames.

Only use clean containers when filling up with consumables. Do not mix consumables of different grades. The only exception to this is when mixing is expressly stipulated in the Operating Instructions.

Spilled liquids must be removed immediately with suitable bonding agents and the bonding agent / consumable mixture must be disposed of in accordance with regulations.

The volumes indicated are approximate.

Bio oils

Bio-degradeable hydraulic oils may only be used after consultation with the relevant JH service department.

Grease guidelines

9 DFG fuel specifications

Use only DIN EN 590 diesel with a Cetane rating above 50.

Code Order no. Capacity Description Used for

A 52017728 55 l HVLP46 Hydraulic system

B 50055726 K-P-2K grease

C 29201280 Chain spray Chains

D 51094056

4.3 l TFG

8.2 l DFG

Titan Unic Plus SAE 10W-40 Engine oil

Code Saponification Dew point °CWorked penetra-

tion at 25 °C

NLG1 class Application

temperature °C

E Lithium 185 265-295 2 -35/+120

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10 Lubrication chart

Key to lubrication chart 10.1 - DFG/TFG

Item Description Lub. type

1. Chain rollers B

2. Lift chains C

3. Mast channels B

4. Tilt cylinder bolts B

5. Hydrostatic drive axle. A

6. Hydropump A

7. Displacement pump A

8. Hydraulic oil and filter A

9. Hinges and locks B

10. Steering axle hub B

11. Steering knuckle pins B

12. Knuckle bolts B

13. Engine oil and filter D

14. Pedals B

15. Mast and fork carriage rollers B

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10.1 Lubrication chart - DFG/TFG

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11 Maintenance and repairs

11.1 Preparing the truck for maintenance and repairs

All necessary safety measures must be taken to avoid accidents when carrying out maintenance and repairs. The following preparations must be made:

– Park the truck securely (see Chap-

ter E, Section 5.8). – Pull the key out of the ignition/

starter switch (2) to prevent the

truck from being switched on acci-

dentally. – Turn off the main switch/isolator (1). – When work has to be performed

under the raised fork or under the

jacked up truck, suitable meas-

ures must be taken to prevent any

dropping, tilting or slipping of the

fork or truck.

Note the following when raising the forklift truck:

Only use lifting gear with sufficient capacity (for transport weight see truck data plate).

– Park the truck securely (see Chapter E, Section 5.8). – Attach crane slings to the mast at the appropriate points. – Attach the crane slings to the counterweight of the trailer coupling.

The crane lifting gear couplings must be fitted in such a way that they do not touch any attachments or the overhead guard during lifting.

11.2 Starting aid

Only use an ISO 6722 battery jump lead with fully insulated terminal pliers and a lead diameter of at least 25 mm

Procedure:

– First connect the red lead to the positive terminal – Connect the black lead to the feeder battery and the earth point on the engine block – Start the engine with the ignition key – When the engine has started first remove the negative lead-then remove the posi-

tive lead

Note: If the starter motor does not switch on the engine after connecting the battery terminals, check that the battery terminal clips are positioned correctly.

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11.3 Servicing the engine - TFG 316s/320s

Replacing the engine oil and engine oil filter

Only change the engine oil when the engine is at operating temperature and the truck is horizontal. Always replace the engine oil and engine oil filter together.

Draining the engine oil

– Unscrew the lid (3). – Thoroughly clean the oil drain plug

(4) and around the drain hole. – Unscrew the oil drain plug and

drain the oil into a suitable con-

tainer.

Risk of scalding through hot oil.

– Screw in the oil drain plug with a

new seal.

Dispose of used oil in accordance with environmental regulations.

Replace the engine oil filter

– Undo the oil filter (5) with a filter

wrench and manually unscrew it.

Collect any emerging oil and dispose of the oil and oil filter in accordance with environmental regulations.

– Thoroughly clean the raised faces

of the oil filter flange.

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– Apply a thin layer of fresh engine

oil to the seal of the new oil filter.

Hand-tighten the oil filter.

Adding engine oil

– Add fresh engine oil through the filler

port in accordance with the consum-

ables table (see Section 8).

Capacity: 4.3 l

– Check the engine oil level with the

dipstick (6) and adjust as neces-

sary (see Chapter E, Section 3). – Screw the lid back on. – Fully insert the dipstick again.

After changing the oil and the oil filter, note the engine oil pressure indicator (7) when running the engine again and check the oil drain plug and oil filter are sealed.

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Replacing the spark plugs

– Remove spark plug connector (8). – Thoroughly clean around the spark

plugs on the cylinder head. – Unscrew the spark plugs. – Check the electrode distance of

the new spark plugs with a feeler

gauge, and adjust as required.

Rated value: 0.8 mm

Only use original spark plugs.

– Manually screw in the spark plugs

and then torque them to 20 Nm.

Checking the V belt tension

– Insert the V belt between the fan V

belt pulley (9) and the generator V

belt pulley (10) using a force of 45 N.

It should be possible to insert the V belt after approx. 11 mm.

Adjusting the V belt tension

– Undo the screws (11) and pull the

AC generator (12) until you reach

the prescribed V belt tension. – Re-tighten the screws. – Check the V belt tension again and

repeat the adjustment if neces-

sary.

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11.4 Engine servicing - DFG 316s/320s

Replacing the engine oil and engine oil filter

Only change the engine oil when the engine is at operating temperature and the truck is horizontal. Always replace the engine oil and engine oil filter together.

Draining the engine oil

– Unscrew the lid (13). – Thoroughly clean the oil drain plug

(14) and around the drain hole. – Unscrew the oil drain plug and

drain the oil into a suitable con-

tainer.

Risk of scalding from hot oil.

– Screw in the oil drain plug with a

new seal.

Dispose of used oil in accordance with environmental regulations.

Replace the engine oil filter

– Undo the oil filter (15) with a filter

wrench and manually unscrew it.

Collect any emerging oil and dispose of the oil and oil filter in accordance with environmental regulations.

– Thoroughly clean the raised faces of the oil filter flange. – Apply a thin layer of fresh engine oil to the seal of the new oil filter. – Hand-tighten the oil filter.

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Adding engine oil

– Add fresh engine oil through the

filler port (16) in accordance with

the consumables table (see Sec-

tion 8).

Capacity: 8.2 l

– Check the engine oil level with the

dipstick (6) and adjust as neces-

sary (see Chapter E, Section 3). – Screw the lid back on. – Fully insert the dipstick again.

After changing the oil and the oil filter, note the engine oil pressure indicator (18) when running the engine again and check the oil drain plug and oil filter are sealed.

Checking the V belt tension

– Insert the V belt between the fan V

belt pulley (19) and the generator

V belt pulley (20) using a force of

100 N.

It should be possible to insert the V belt after approx. 5 mm.

Adjusting the V belt tension

– Undo the screws (21) and pull the

AC generator (22) until you reach

the prescribed V belt tension. – Re-tighten the screws. – Check the V belt tension again and

repeat the adjustment if neces-

sary.

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Replacing the fuel filter

– Drain the fuel from the filter into a

suitable container. – Undo the fuel filter (23) with a filter

wrench and manually unscrew it.

Dispose of the fuel filter and fuel in accordance with environmental regulations.

– Screw the fuel filter with a new O

ring into the new fuel filter. – Before assembling, apply a thin

layer of diesel to the O ring. – Thoroughly clean the raised faces

of the filter flange. – Apply a thin layer of diesel to the

seal of the new fuel filter. – Manually screw in the fuel filter

until the seal contacts the filter

flange. – Tighten the fuel filter another third

of a turn. – Bleed the fuel system

Bleeding the fuel system

Collect any emerging fuel and dispose of it in accordance with environmental regulations.

– Open the discharge screw (24). – Apply the manual pump lever on

the fuel pump (25) until fuel

escapes from the discharge screw

without bubbles. – Tighten the discharge screw. – Set the ignition / starter key to the I

position for approx. 10 seconds. – Wait for 10 seconds. – Repeat the process until the

engine starts up.

While running the engine check the fuel filter, the discharge valve and the union nuts of the injection nozzles for leaks.

If the engine does not start up or stops after a short time, repeat the bleeding procedure.

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11.5 Checking the coolant concentration

Do not open the radiator lid when the engine is hot.

To prevent the build up of lime as well as front and corrosion damage, and to raise the boiling point temperature, the cooling circuit must be filled each year with a mixture of water and anti-freeze with anti-corrosion additives.

– If there is insufficient anti-

freeze, drain the coolant and

add anti-freeze to the reservoir

(68) until you obtain the correct

proportion in the mixture.

Use anti-freeze in accordance with the coolant specifications (see section 7).

The water/anti-freeze mixture proportion and the degree of frost protection to be achieved can be taken from the anti-freeze specifications.

Cooling circuit capacity:

DFG 316s/320s: 9.0 l

TFG 316s/320s: 9.0 l

11.6 Filling the cooling circuit

Leave the engine to cool down in order to fill it with coolant. Slowly open the lid; dangerously hot coolant can escape if the coolant circuit is still pressurized. Do not add too much coolant to the circuit. The lid contains a safety valve which opens to let hot coolant dissipate if the fluid level is too high.

If coolant is added in the course of servicing, it must meet the specifications of the original fluid (see Section 7). If you add coolant too quickly or if the truck is not horizontal, air will enter the cooling circuit. Running the engine with air in the coolant circuit will result in excessive operating temperatures and can damage the engine.

Jungheinrich DFG 316s, TFG 316s, DFG 320s, TFG 320s Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual