Jungheinrich DFG 316s Operating Instructions Manual
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Jungheinrich DFG 316s Operating Instructions Manual

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

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  • Page 1 DFG/TFG 316s-320s 04.08 - Operating Instructions 51105427 07.08...
  • Page 2 Used to indicate standard equipment. 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.

  • Page 4: Table Of Contents

    Table of contents Correct Use and Application Truck Description Application ................... B 1 Assemblies and Functional Description ..........B 2 Truck ....................B 3 Load handler ..................B 4 Standard Version Specifications ............B 5 DFG/TFG 316s/320s Specifications ............ B 8 Identification points and data plates ............
  • Page 5 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 ..........
  • Page 6 14.3 Returning the truck to operation after decommissioning ..... F 28 Periodic safety checks and after unusual events ........ F 29 Final de-commissioning, disposal ............F 29 HUSS FS - MK Series Diesel Particle Filter Operating Instructions ..F 30 17.1 Important General Instructions ............

  • Page 8: A Correct Use And Application

    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.

  • Page 10: B Truck Description

    B Truck Description 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.

  • Page 11: Assemblies And Functional Description

    Assemblies and Functional Description Item Description Item Description t Lift cylinder t Trailer coupling t Load chain t Counterweight t Mast t Steering axle t Dashboard t Engine cover t Steering column t Hydrostatic drive axle t Overhead guard t Fork carriage t Driver's seat t Fork...

  • Page 12: Truck

    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).

  • Page 13: Load Handler

    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.

  • Page 14: Standard Version Specifications

    Standard Version Specifications Technical specification details in accordance with VDI 2198. Technical modifications and additions reserved.
  • Page 15 DFG 316s/320s Specification Sheet Description Code AH-J (Unit) Manufacturer Jungheinrich Jungheinrich Model DFG 316s DFG 320s Drive system: electric, diesel, petrol, LPG, other Diesel Diesel Steering: manual, pedestrian truck, stand-up, sit-down, Sit-down Sit-down order picker Capacity Q(t) Load centre of gravity...
  • Page 16 TFG 316s/320s Specification Sheet Description Code AH-J (Unit) Manufacturer Jungheinrich Jungheinrich Model TFG 316s TFG 320s Drive system: electric, diesel, petrol, LPG, other Steering: manual, pedestrian truck, stand-up, sit-down, Sit-down Sit-down order picker Capacity Q(t) Load centre of gravity c(mm)

  • Page 17: Dfg/Tfg 316S/320S Specifications

    NUMBER OF TURNS STOP TO STOP Drive axle MODEL Radial piston axle MODEL ESE 02 LUBRICANT CAPACITY Engine - DFG 316s/320s 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...
  • Page 18 Wheels and Tyres TYRE SIZE See specifications sheet TYRE PRESSURE Model Drive axle - bar Steer axle - bar 6.50-10 DFG/TFG 316s/320s 7.75 23x9-10 DFG/TFG 316s/320s WHEEL NUT TORQUE Model Drive axle - Nm Steer axle - Nm DFG/TFG 316s/320s Tires APPLICATION AREA TYRE SIZE...
  • Page 19 Electrical system SYSTEM 12 volt negative earth ELECTROMAGNETIC COMPATIBILITY Within the following limits in accordance with “Industrial Truck Electromagnetic Compatibility (EMC) (9/95)” product standards: t interference emission (EN 50081-1) t resistance (EN 50 082-2) t electrostatic discharge (EN 61000-4-2) Hydraulic system HYDRAULIC PUMP 1PX series CONTROL VALVE...

  • Page 20: Identification Points And Data Plates

    Identification points and data plates Item Description "Do not stand under the load handler" warning 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 Forks, capacity / load centre of gravity / lift height load chart Sideshift, capacity / load centre of gravity / lift height load chart Truck data plate...

  • Page 21: Truck Data Plate

    Truck data plate Item Description Item Description Type Manufacturer Serial no. Net weight in kg Rated capacity in kg Load centre of gravity (mm) Rated output (kW) Year of manufacture Manufacturer’s logo Option For queries regarding the truck or ordering spare parts always quote the truck serial number (24).

  • Page 22: Truck Load Chart

    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).

  • Page 23: Attachment Load Chart

    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.

  • Page 24: C Transport And Commissioning

    C Transport and Commissioning 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.

  • Page 25: Securing The Truck During Transport

    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.

  • Page 26: Using The Truck For The First Time

    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: –...
  • Page 27 – 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. –...
  • Page 28 Hitch point A rigid tow bar must be used to move a forklift truck. point truck 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).

  • Page 30: D Fuelling The Truck

    D Fuelling the Truck 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.

  • Page 31: Filling With Diesel

    – 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.

  • Page 32: Replace The Lpg Bottle

    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.
  • Page 33 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.

  • Page 34: E Operation

    E Operation 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.

  • Page 36: Controls And Displays

    Controls and Displays Item Control / Function display item Parking brake When lit, indicates that the parking brake is applied. indicator Fuel display (DFG) Indicates how much fuel is left in the tank. Coolant temperature Indicates the coolant temperature. indicator Neutral position When lit, indicates that the travel direction switch is in neutral.
  • Page 38 Item Control / Function display item Not used. Seat belt indicator When lit indicates that the seat belt has not been properly attached. Indicator control light Shows the indicator status (right/left). Fuel supply When lit, indicates the fuel supply is too low.
  • Page 40 Item Control / Function display item Heating Controls the heating (page E13) Accelerator pedal Controls the engine speed and / travel and lift speeds. Raise/lower Raises and lowers the fork carriage. To control lever raise the fork carriage: pull the lever back. To lower the fork carriage: push the lever forward.

  • Page 41: Operating The Lift And Tilt Mechanisms (O)

    Operating the lift and tilt mechanisms (o) Main control mechanism Main control lever Additional control levers Symbol Purpose Symbol Purpose 1. Tilt mast forward. 5. Tilt mast back. 2. Raise forks and tilt mast 6. Lower forks and tilt mast back. forward.

  • Page 42: Twin Pedal Operation (O)

    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 Brake / Reverse / slow travel pedal accelerator pedal...
  • Page 43 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.
  • Page 44 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.
  • Page 45 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.
  • Page 46 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. –...

  • Page 47: Tests And Tasks To Be Performed Before Starting The Truck

    Horn – Press the button (25) to sound the horn. 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. –...
  • Page 48 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.
  • Page 49 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.
  • Page 50 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.
  • Page 51 Checking the windscreen fluid level – Make sure there 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).

  • Page 52: Starting Up The Truck

    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. 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...

  • Page 53: Adjusting The Driver's Seat

    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.

  • Page 54: Adjusting The Steering Column

    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).

  • Page 55: Starting The Truck

    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.

  • Page 56: Starting Procedure For The Tfg

    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). –...

  • Page 57: Starting Procedure For The Dfg

    – 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.
  • Page 58 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.

  • Page 59: Operating Error Displays

    Operating Error Displays When the following indicators are lit: – Engine oil pressure (8), – Charge current (17), – Coolant temperature (3), – Hydrostatic drive (6), engine must stopped immediately. The engine should only be started again once the fault has been removed.

  • Page 60: Industrial Truck Operation

    Industrial Truck Operation 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.
  • Page 61 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.

  • Page 62: Travel

    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.
  • Page 63 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.

  • Page 64: Steering

    Steering Very little steering force is required for the hydrostatic steering, therefore turn the steering wheel (26) with caution. 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.
  • Page 65 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.

  • Page 66: Mast And Attachment Operation

    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! –...
  • Page 67 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). Intergrated sideshift ISS The fork carriage can be moved sideways using the ISS.

  • Page 68: Controlling The Speed Of The Lifting Device

    10.1 Controlling the speed of the lifting device Moving the control levers (23-26) and changing the engine speed governs the operating speed 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.

  • Page 69: Lifting, Transporting And Depositing Load Units

    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.
  • Page 70 – 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.
  • Page 71 Do not stand underneath a raised load. – Tilt the mast back fully. – Lower the load as far as is absolutely necessary transport (ground clearance approx. 150…200mm). The higher the load is transported, the less secure the truck will be. E 38...

  • Page 72: Transporting Loads

    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. –...
  • Page 73 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.

  • Page 74: Hazardous Situations

    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.

  • Page 75: Parking The Truck Safely

    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.

  • Page 76: Engine Bonnet And Service Covers

    Engine bonnet and service covers Engine bonnet Before opening engine compartment push 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).

  • Page 77: Service Covers

    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: –...

  • Page 78: Towing The Truck

    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).

  • Page 79: Troubleshooting

    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.
  • Page 80 Fault Possible Cause Action Engine oil Engine oil level too low Check engine oil level, top up if necessary indicator lit during operation Engine Engine oil level too low Check engine oil level, top up if necessary temperature display in red Radiator contaminated Clean radiator zone...
  • Page 81 E 48...

  • Page 82: F Truck Maintenance

    F Truck Maintenance 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.
  • Page 83 Electrical System: Only suitably trained personnel may operate on the truck’s elec- trical system. Before commencing work on the electrical system, take all precaution- ary 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.

  • Page 84: Servicing And Inspection

    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 anal- ysis on site to work out specific service intervals to prevent damage due to wear.

  • Page 85: Dfg/Tfg Maintenance Checklist

    DFG/TFG maintenance checklist Maintenance Intervals Standard = Cold store = Chassis/ Check all load bearing components for damage Superstruc- Check screw connection ture: Check overhead guard for damage and make sure it is secure Check trailer hitch Drive system: 2.1 IC engine –...
  • Page 86 Maintenance intervals Standard = Cold store = Hydraulic Test operation System Check connections and ports for leaks and damage Check hydraulic cylinder for leaks and damage and make sure it is secure Check oil level Replace hydraulic oil Replace filter cartridge Clean hydraulic oil suction filter and discharge Test operation of pressure relief valves Test hose guide and check for damage...

  • Page 87: Dfg Maintenance Checklist

    DFG maintenance checklist Maintenance intervals Standard = Cold store = Engine: Check engine for noise and leaks Check injection pump flow start, adjust if necessary Check injection nozzle pressure, adjust if necessary Tighten cheese head screws Check valve play, adjust if necessary Check engine oil level, top up if necessary Replace the engine oil.

  • Page 88: Tfg Maintenance Checklist

    TFG maintenance checklist Maintenance intervals Standard = Cold store = Engine: Check engine for noise and leaks Check spark plugs, replace if necessary Check ignition time, adjust if necessary Check ignition distributor, adjust if necessary Check valve play, adjust if necessary Check engine oil level, top up if necessary Replace the engine oil Replace the engine oil filter...

  • Page 89: Coolant Specification

    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 serv- icing in terms of frost and corrosion protection. – Always use clean, soft water. –...

  • Page 90: Consumables

    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.

  • Page 91: Lubrication Chart

    Lubrication chart Key to lubrication chart 10.1 - DFG/TFG Item Description Lub. type Chain rollers Lift chains Mast channels Tilt cylinder bolts Hydrostatic drive axle. Hydropump Displacement pump Hydraulic oil and filter Hinges and locks Steering axle hub Steering knuckle pins Knuckle bolts Engine oil and filter Pedals...

  • Page 92: Lubrication Chart - Dfg/Tfg

    10.1 Lubrication chart - DFG/TFG F 11...

  • Page 93: Maintenance And Repairs

    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).

  • Page 94: Servicing The Engine - Tfg 316S/320S

    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.
  • Page 95 – 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 –...
  • Page 96 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.

  • Page 97: Engine Servicing - Dfg 316S/320S

    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.
  • Page 98 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).
  • Page 99 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 reg- ulations.

  • Page 100: Checking The Coolant Concentration

    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; dan- gerously hot coolant can escape if the coolant circuit is still pressurized.

  • Page 101: Cleaning/Replacing The Air Filter Cartridge

    The truck must be horizontal. Slowly open the reservoir lid. Using a funnel, slowly fill the coolant circuit to the level indicated in the manufacturer's manual. The funnel will create the pressure required to force air out of the coolant circuit. Wait until all the air bubbles have escaped and then refit the lid.

  • Page 102: Checking The Wheel Attachment And Air Pressure

    11.8 Checking the wheel attachment and air pressure Checking attachment. – Park the truck securely (see Chapter E). – Tighten the wheel nuts (29) cross- wise with a torque wrench. Torque Drive wheels: 210 Nm Steered wheels: 176 Nm F 21...

  • Page 103: Hydraulic System

    11.9 Hydraulic system Replacing the hydraulic oil filter – Open the lid (74) of the hydraulic oil filter. – Remove and replace the hydraulic oil filter. – Insert the hydraulic oil filter and screw the lid back on. Collect any spilled hydraulic oil. Dis- pose of the hydraulic oil and hydraulic oil filter in accordance with environ- mental regulations.

  • Page 104: 11.10 Electrical System

    The manufacturer’s disposal instructions must be followed. The owners are legally obliged to return used truck starter batteries to the battery manufacturer via the reseller or publicly authorised disposal companies. If in doubt, contact the Jungheinrich service department. F 23...
  • Page 105 11.10.1Checking electrical fuses If errors occur in the electrical system, the fuses under the engine bonnet must be checked. – Open the engine bonnet and remove the fuse box cover. – Check the fuse rating and condition BLACK in accordance with the table; replace if necessary.
  • Page 106 Fuse box for optional equipment 3 (green) - Cabin Black Green Item Protects: Rated output Heating fan 15 A Front wiper motor 10 A Windscreen washing system/seat heating 7.5 A Rear window heating 15 A Rear wiper motor 7.5 A Interior lighting 10 A Floating fuse...

  • Page 107: 11.11 Relay Layout

    Emergency Disconnect fuse Item Description: Rated output Fuse 50 A To avoid damaging the electrical system, only use fuses with the correct ratings. 11.11 Relay layout Item Reference: 36 V fuse shape C 100 A N.O. contact relay 1 2V 50 A N.O.

  • Page 108: Exhaust System

    Exhaust system The exhaust system must be checked for emissions at regular intervals. Black or blue exhaust is a sign of high emission levels and requires the attention of specialist per- sonnel. Soot filter servicing in accordance with manufacturer’s instructions. Restoring the truck to service after cleaning or repairs The truck may only be restored to service after cleaning or repair work, once the fol- lowing operations have been performed.

  • Page 109: During Decommissioning

    14.2 During decommissioning: Every 2 months: – Charge the battery. 14.3 Returning the truck to operation after decommissioning It is advisable to have the truck restored to service after decommissioning by an engi- neer of the manufacturer. – Thoroughly clean the truck. –...

  • Page 110: Periodic Safety Checks And After Unusual Events

    Periodic safety checks and after unusual events Carry out a safety check in accordance with national regulations. Junheinrich recommends checks in accordance with FEM Guideline 4.004. Jungheinrich has a special safety department with trained personnel to carry out such checks.

  • Page 111: Huss Fs - Mk Series Diesel Particle Filter Operating Instructions

    Optional HUSS FS - MK Series Diesel Particle Filter Operating Instructions 17.1 Important General Instructions Read the operating instructions carefully before using the soot particle filter. The general accident prevention and other health and safety regulations must be observed. The use of additive-based fuels can have a negative effect on the exhaust and thus the useful life of the diesel particle filter.

  • Page 112: Functional Description

    Starting the truck in a hazardous situation (with starter interlock active): Depress and hold down both the “M” and “F” buttons on the HUSS control and at the same time start the truck. 17.3 Functional description As the engine runs the diesel engine exhaust flows through the filter element which retains virtually all the harmful soot particles.

  • Page 113: Huss Control Operation

    17.4 HUSS Control Operation The diesel particle filter is operated by the HUSS Control unit. The control unit is mounted within the operator’s field of vision. Display screen The top line shows the functional stages; in the bottom line a bar indicates the condi- tion of the filter (backpressure / regeneration time) Keys ontrol...

  • Page 114: Huss Control Operating Instructions

    17.5 HUSS Control Operating Instructions Normal operation Display Function LED Switch on the ignition. The buzzer Self test Green and red sounds for min. 1 second and both LEDs lit LEDs light up at the same time. If a message is stored it will be dis- e.g.

  • Page 115: Regeneration

    Messages in normal mode that indicate the status of the diesel particle filter: with this message>>> Normal Filter condition Green LED flashing operation possible HHHHHHHH with this message>>> Regenera- Regenerate Red LED flashing tion required HHHHHHHH 10 regenerations had to be made Call service department / within the maximum charge time, White ash...
  • Page 116 Regeneration Display ------------------------------------------ --Function LED Park the truck on a level surface Start regeneration in 5 seconds >>>>>>>>Green LED Switch off the engine. Ignition ON: HUSS Control is energised. Press the “M” button and hold it down for 5 seconds. Regeneration starts after 5 seconds.
  • Page 117 Interrupting Regeneration Display ------------------------------------ Function LED Regeneration can be interrupted by “Filter full” alarm >>red LED flashes switching off the ignition with the ignition key or by pressing the “F” button on the control system. The display counts down from 5 seconds until the regeneration process is switched off.

  • Page 118: Maintenance

    17.7 Maintenance The HUSS control displays the scheduled maintenance times. Call the JH service department to carry out maintenance. The Huss control system is factory-set for the truck. Only trained JH service engi- neers are authorised to make changes to these settings. F 37...
  • Page 119 F 38...

This manual is also suitable for:

Tfg 316sDfg 320sTfg 320s

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