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

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DFG/TFG 316 / 320
04.06-
G
Operating instructions
51011137
02.07

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Summary of Contents for Jungheinrich DFG 316

  • Page 1 DFG/TFG 316 / 320 04.06- Operating instructions 51011137 02.07...
  • 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

    Index Correct Application Truck Description Application ................... B 1 Assemblies and Functional Description ..........B 2 Truck ....................B 3 Standard Version Specifications ............B 5 Performance Data DFG ..............B 5 Engine data ..................B 10 Tyre Type ..................B 10 Mast Versions ..................
  • Page 5 Operation Safety Regulations for the Operation of Forklift Trucks ...... E 1 Controls and Displays ................. E 3 Starting up the truck ................E 7 Checks and operations to be performed before starting daily work ..E 7 Trucks with reduced headroom X (o) ..........E 7 Adjusting the driver’s seat ..............
  • Page 6 Industrial Truck Maintenance Operational safety and environmental protection ........ F 1 Maintenance Safety Regulations ............F 1 Servicing and inspection ..............F 3 DFG/TFG maintenance checklist ............F 4 DFG maintenance checklist ..............F 6 TFG maintenance checklist ..............F 7 Coolant specification ................

  • Page 8: A Correct Application

    A Correct 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. The truck described in the present operating instructions is an industrial truck designed for lifting and transporting loads.

  • Page 10: B Truck Description

    B Truck Description Application The DFG/TFG series are IC engine, 4-wheel rider trucks. The DFG series are diesel engine trucks, while the TFG series are fitted with a petrol engine for LPG operation. The DFG/TFG 316-320 is equipped with a hydrodynamic drive system. The left pedal is a combination of crawl speed and brake pedal, and activates the rapid lift function during slow travel.

  • Page 11: Assemblies And Functional Description

    Assemblies and Functional Description Item Description Item Description 1 t Driver's seat 8 t Load fork 2 t Steering column 9 t Fork carriage 3 t Dashboard 10 t Drive axle 4 t Overhead guard 11 t Engine cover 5 t Mast 12 t Steering axle 6 t Load chain 13 t Trailer coupling...

  • Page 12: Truck

    Truck Chassis/Superstructure: A solid, rigid chassis which protects the units and controls, provides the truck with maximum static safety. 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.
  • Page 13 Hydraulic system: The gear pump of the hydraulic system is powered by the engine through a power take off. The pump speed and hence the supply flow are controlled by the accelerator pedal through the engine speed. Hydraulic functions are controlled by the control lever through a multiple control valve. Electrical System: The 12 volt system consists of a starter battery and a threephase generator with integrated controller.

  • Page 14: Standard Version Specifications

    Standard Version Specifications Technical specification details in accordance with VDI 2198. Technical modifications and additions reserved. Performance Data DFG Description DFG 316 DFG 320 Q Capacity 1600 2000 C Load centre of gravity Travel speed 18/19 18/19 km/h w / w.o. load Lift speed 0.6/0.62...
  • Page 16 Dimensions DFG Description DFG 316 DFG 320 a/2 Safety distance Mast height (retracted) 2185 2185 Free lift Lift 3300 3300 Mast height (extended) 3920 3920 Overhead guard height 2145 2145 Seat height (SIP) 1049 1049 Length including forks 3386 3416...
  • Page 18 TFG dimensions Description TFG 316 TFG 320 a/2 Safety distance Mast height (retracted) 2185 2185 Free lift Lift 3300 3300 Mast height (extended) 3920 3920 Overhead Guard Height 2145 2145 Seat height (SIP) 1049 1049 Length including forks 3386 3416 Headlength 2236 2266...

  • Page 19: Engine Data

    Engine data Engine - DFG Type S4Q2 four cylinder Ignition sequence 1 3 4 2 Capacit. 2505 cc 2350 RPM (unloaded) Control speed 680 RPM (idle) Valve clearance Inlet and outlet 0.25 mm cold Tray capacity 8.0 l Fuel tank capacity 48 l Coolant capacity 5.5 l + system = 14.0 l...

  • Page 20: Mast Versions

    Mast Versions (all dimensions in mm) DFG/TFG 316/320 Mast table VDI 3596 Lift Free lift Extended height Retracted height h Description 2900 1985 3520 3100 2085 3720 3300 2185 3920 3600 2335 4220 3800 2435 4420 4000 2535 4620 4500 2835 5120 5000...

  • Page 21: Norms

    EN norms Noise level: 79 dB(A) +/- 3dB (depending on tolerances and features) in accordance with EN 12053 as harmonized with ISO 4871. 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.

  • Page 22: Identification Points And Data Plates

    Identification points and data plates (mm) Q (kg) D (mm) Item Description Warning: Read operator manual. Load fork, Capacity / Load Centre of Gravity / Lift Height Chart “Travel with raised load prohibited” / “Mast forward tilt with raised load prohibited”...

  • Page 23: Truck Data Plate

    Truck data plate Item Description Item Description Type Manufacturer’s logo Serial no. Net weight Rated capacity (kg) Load centre of gravity (mm) Output (kW) Year of manufacture Manufacturer Option For queries regarding the truck or ordering spare parts always quote the truck serial number (29).

  • Page 24: Attachment Load Chart

    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 attached to all masts with a height- dependent capacity rating. Attachment load chart The attachment load chart gives the truck’s capacity Q in combination with the respective attachment in kg.
  • Page 25 B 16...

  • Page 26: C Transport And Commissioning

    C Transport and Commissioning Lifting by crane Only use lifting gear with sufficient capacity (for transport weight see truck data plate). – Park the truck securely (see Chapter E). – Attach the crane slings to the cross member of the mast (1) and the trailer coupling (2).

  • Page 27: 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 shall be carried out by staff especially trained for that purpose in accordance with recommendations...

  • Page 28: 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 lifting devices, masts and basic trucks match each other. To prepare the truck after delivery or after transport, proceed as follows: –...

  • Page 30: D Filling The Truck With Fuel

    D Filling the Truck with Fuel 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

    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. Capacity: 48 l Only use DIN 51601 diesel with a cetane rating below 45.

  • 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 motor and allow the LPG system to run empty in neutral.
  • Page 33 When the reserve indicator for LPG bottle (2) is lit, this indicates that the bottle is empty. Reusable LPG bottles with central filling device The bottle is fitted with a filling stop valve. The discharge valve (10) must be sealed. Remove the seal (11). Insert the nozzle of the liquid gas pump into the filler port.

  • Page 34: Safety Regulations For The Operation Of Forklift Trucks

    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 35 15 14 13 12 11 10 12 11 10 26 25 24 23...

  • Page 36: Controls And Displays

    Controls and Displays Control / Item Function Display Indicates that the soot filter is Soot filter indicator contaminated. When lit, indicates insufficient engine Engine oil pressure indicator t lubricant oil pressure. When lit, indicates that the battery is Charging current indicator not charged.
  • Page 37 15 14 13 12 11 10 12 11 10 26 25 24 23...
  • Page 38 Control / Item Function Display Applies / releases parking brake. To engage, turn switch to position 1. 16 Parking brake lever To release, turn switch to position 0. Pull up lever to engage. Push lever forward to release. t Steers truck in desired direction. 17 Steering wheel Steering column adjusting t Adjusts the steering column tilt.
  • Page 39 Travel direction switch When the travel direction switch (28) is in the central position, the transmission is in idle. – To select the forward gear, push the switch forward. – To select the reverse gear, push the switch back. The engine will not start if a travel direction is pre-selected.

  • Page 40: 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. Checks and operations to be performed before starting daily work Truck – Visually inspect the whole of the truck (especially the wheels and the lifting device) for obvious signs of damage.
  • Page 41 Covers may need to be opened for the inspection. Checking the fuel supply - DFG – Set the ignition / starter key (19) to the “I” position. – Read off the fuel supply from the fuel gauge (15). – If necessary, diesel (see...

  • Page 42: Adjusting The Driver's Seat

    Adjusting the driver’s seat Standard seat MSG 65 To achieve optimal seat damping the driver’s seat must be adjusted according 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 (37) will be above the calibration line.

  • Page 43: Safety Restraint Belt

    Safety restraint belt The driver must check the operation and condition of the seat belt every day before using the industrial truck. Faulty operation can only be detected in good time through regular inspection. Put on the safety restraint belt each time before starting the industrial truck. The belt protects against serious injury.
  • Page 44 Procedure in unusual situations If the truck is about to tip over, never undo the restraint belt and try to jump out. Jumping increases 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 45: Adjusting The Steering Column

    Adjusting the steering column – Release the steering column adjusting lever (18) in the direction of the arrow (L). – Tilt the steering column (38) forward or backward as required. – Push the steering column adjusting lever in the direction of the arrow (F). E 12...

  • Page 46: Starting The Truck

    Starting the truck Before starting the truck If the engine has not been run for several weeks or if the oil filter has been changed, start the engine (see section 3.7 or 3.8) and leave it to run in idle for a few minutes before starting.

  • Page 47: 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 on the LPG bottle. – Put the key in the ignition / starter switch (19). – Set the ignition / starter key to the “I”...

  • Page 48: Starting Procedure For The Dfg

    Starting procedure for the DFG – Put the key in the ignition / starter switch (19). – Set the ignition / starter key to the “I” position. – Press the horn button (27) and test the horn. – After setting the ignition / starter (19) to the I position, the charging current (3), engine oil pressure (2), neutral setting (14) and...
  • Page 49 After starting the engine, carry out a test run and check the following functions: – Test the parking brake (16) and the slow travel / brake pedal (29). – Test the engine speed with the accelerator pedal (22) over a range of speeds while checking the freedom of movement of the pedal.

  • Page 50: Operational Fault Displays

    Operational Fault Displays When the following indicators are lit: – Engine oil pressure (2), – Charging current (3), – Coolant temperature (10), – Transmission oil temperature (4), engine must stopped immediately. The engine should only be started again once the fault has been removed. For troubleshooting procedures, see section 6.

  • Page 51: Stopping The Engine1

    3.10 Stopping the engine1. Do not stop 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 (28) to neutral. – Apply the parking brake (16).

  • Page 52: 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 stay away from work areas. Loads must only be stored in places specially designated for this purpose. Travel conduct: The driver must adapt the travel speed to local conditions.
  • Page 53 Towing trailers or the truck itself being towed are only permitted occasionally, on secure, level routes, with a maximum deviation of +/- 1% and at a max. speed of 5 km/h. Do not permanently operate the truck with trailers. While the truck is pulling there must be no load on the forks. Do not exceed the maximum trailer load specified for the forklift truck for trailers with or without brakes.

  • Page 54: Travel

    Travel Adapt the travel speed to the conditions of the travel lane, the work area and the load – Set the travel direction switch (28) to neutral. – Raise the fork carriage approx. 200 mm so that the fork tines are clear of the ground.
  • Page 55 Braking – Take your foot off the accelerator pedal (22). – Gently depress the slow travel / brake pedal (29). In the first pedal displacement zone, the flow of force is reduced by the torque converter. – Continue to depress the slow travel / brake pedal (29). As you continue to depress, the truck automatically comes to a halt.

  • Page 56: Steering

    Steering Very little steering force is required for the hydrostatic steering, therefore turn the steering wheel (17) with caution. Braking Operating Brake The slow travel / brake pedal hydraulically actuates drum brakes of the front wheels. – Apply the slow travel / brake pedal (29) until you feel the brake pressure.

  • Page 57: Mast And Attachment Operation

    Mast and Attachment Operation The control levers must only be operated from the driver’s seat. The lifting device is operated from the control levers on the right-hand side of the driver's seat. Lifting/lowering the fork carriage Never reach through the mast! –...
  • Page 58 Operating the integrated sideshift (ISS) The references to left and right are with reference to the load handler as viewed from the operator’s position. Sideshift left (from driver’s position): – Push the control lever (24) forward. Sideshift right (from driver’s position): –...

  • Page 59: Collecting, Transporting And Depositing Loads

    Collecting, transporting and depositing loads The control levers must only be operated from the driver’s seat. Before lifting a load, the driver must ensure that it is correctly palletised and that the capacity of the truck is not exceeded. Note the load chart. Adjusting the forks Adjust the fork tines in such a way that both are equally distanced from the...
  • Page 60 Raising a load Do not lift other people with the lifting device. – Carefully approach the load to be raised. – Set the travel direction switch (28) to neutral. – Raise the forks to the correct height for the load. –...
  • Page 61 allow anyone stand underneath a raised load. – Lower the load as far as is absolutely necessary transport (ground clearance approx. 150...200 mm). – Tilt the mast fully backward: The higher the load is transported, the less the operating safety of the truck. E 28...
  • Page 62 Transporting a load If the load is stacked up so high that it affects forward visibility, you must reverse. – Gently accelerate with the accelerator pedal (22) and slowly brake with the slow travel / brake pedal (29). Be ready to brake at all times. –...

  • Page 63: Parking The Truck Securely

    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 reduces by at least 1/3." Parking the truck securely When you leave the truck it must be securely parked even if you only intend to leave it for a short time.
  • Page 64 Stopping the engine DFG – Set the ignition / starter switch (19) to “0”. – Remove the key from the ignition / starter switch (19). Stopping the engine TFG – Close the shut-off valve (42) of the LPG bottle securely. –...

  • Page 65: Towing Trailers

    Towing trailers The truck can occasionally be used to tow a light trailer on a dry, level and well maintained surface. The truck must not be permanently used with trailers. To ensure safe transport always observe the following instructions when towing trailers.

  • Page 66: Troubleshooting

    Troubleshooting This chapter is designed to help the user identify and rectify basic faults or the results of incorrect operation. When locating a fault, proceed in the order shown in the table. Fault Probable Cause Action Starter does – Travel direction switch –...
  • Page 67 Fault Probable Cause Action Motor oil – Motor oil level too low – Check engine oil level, top up if indicator lit necessary during operation Engine – Engine oil level too low – Check engine oil level, top up if temperature necessary display in red...
  • Page 68 If, after carrying out the remedial action, the truck cannot be restored to operation or if a fault in the electronics system is displayed with a corresponding error code, contact the manufacturer’s service department. Additional troubleshooting must only be performed by the manufacturer’s specialist service engineers.
  • Page 69 E 36...

  • Page 70: F Industrial Truck Maintenance

    F Industrial 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 71 Electrical System: Only suitably trained personnel may operate on the truck’s electrical system. Before working on the electrical system, take all precautionary measures to avoid electric shocks. Welding: To avoid damaging electric or electronic components, remove these from the truck before performing welding operations. Settings: When repairing or replacing hydraulic, electric or electronic components or assemblies, always note the truck-specific settings.

  • Page 72: Servicing And Inspection

    The application conditions of an industrial truck considerably affect the wear levels of the service components. We recommend an application analysis carried out on site by a Jungheinrich customer adviser to establish specific maintenance intervals in order to restrict damage caused by wear.

  • Page 73: Dfg/Tfg Maintenance Checklist

    DFG/TFG maintenance checklist Maintenance intervals = t W A B C Standard Brakes 1.1 Check effectiveness of operating and parking brakes, adjust where necessary and measure braking distance. 1.2 Check brake lining wear and check brake drum diameter 1.3 Check brake fluid level in container and top up if necessary 1.4 Change brake fluid annually, bleed the system if required...
  • Page 74 Maintenance intervals = t W A B C Standard Hydraulic 5.1 Check mast bearings operation 5.2 Check setting of slide pieces and stops, and adjust if necessary 5.3 Visually inspect the mast rollers and check contact surface wear level 5.4 Check lateral clearance of mast connections and of fork carriage 5.5 Check load chain setting and tighten if necessary 5.6 Check forks and fork carriage for wear and damage...

  • Page 75: Dfg Maintenance Checklist

    DFG maintenance checklist Maintenance intervals = t W A B C Standard Travel 7.1 Check engine for noise and leaks 7.2 Check engine oil level, top up if necessary 7.3 Replace engine oil 7.4 Replace engine oil filter 7.5 Check valve play, adjust if necessary 7.6 Test glow plugs, electric 7.7 Check V belt for tension and damage 7.8 Check maximum speed (without load), adjust if...

  • Page 76: Tfg Maintenance Checklist

    TFG maintenance checklist Maintenance intervals = t W A B C Standard Travel 8.1 Check engine for noise and leaks 8.2 Replace spark plugs 8.3 Check ignition system and ignition point 8.4 Check valve play, adjust if necessary 8.5 Check engine oil level, top up if necessary 8.6 Replace engine oil 8.7 Replace engine oil filter 8.8 Check V belt for tension and damage...

  • Page 77: 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 servicing in terms of frost and corrosion protection. – Always use clean, soft water. –...

  • Page 78: Dfg Fuel Specifications

    When handling anti-freeze always observe the following safety measures: – NEVER swallow anti-freeze. If anti-freeze is accidentally swallowed, seek IMMEDIATE 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. –...

  • Page 79: Lubrication Schedule

    Lubrication schedule Contact surfaces Transmission oil filler neck Grease nipple Transmission oil drain plug Mineral oil filler neck for brake Hydraulic oil filler neck system Hydraulic oil drain plug Oil dipstick F 10...

  • Page 80: Fuels, Coolants And Lubricants

    Fuels, coolants and lubricants 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.

  • Page 81: Maintenance And Repairs

    Maintenance and Repairs 10.1 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 Chapter E). –...

  • Page 82: Engine Cover

    10.2 Engine cover Before opening the engine cover the steering column and the steering column adjustment lever (2) must be pushed forward fully. Push the driver’s seat forward. The stop bolt on the left hand seat guide rail should engage facing up. –...

  • Page 83: Servicing The Engine Dfg

    10.3 Servicing the engine DFG Checking the engine oil - DFG – Remove the dipstick (4). – 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 84 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 (6) lid. –...
  • Page 85 Adding engine oil – Add fresh engine oil through the filler port (6) in accordance with the consumables table. Capacity: 8.0 l – Check the engine oil level with the dipstick (12) and adjust as necessary. – Screw the lid (6) back on. –...
  • Page 86 Replacing the fuel filter Drain the fuel from the filter into a suitable container. Undo the fuel filter (17) 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.

  • Page 87: Engine Servicing Tfg

    10.4 Engine servicing TFG Checking the engine oil - TFG – Remove the dipstick (19). – 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 88 Replacing the engine oil filter – Undo the oil filter (20) 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. –...
  • Page 89 Replacing spark plugs – Remove spark plug connector (23) . – 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.

  • Page 90: Check The Hydraulic Oil Level

    10.5 Check the hydraulic oil level If the oil is cold – Fully raise and lower the mast in one operation. – Stop the engine. – Remove the dipstick (25) and clean it with a clean cloth. Check the hydraulic oil level.

  • Page 91: Gas System Drain Tap

    10.6 Gas system drain tap The gas system drain tap must always be closed during operation (it should only be opened by service personnel for maintenance purposes). If the drain is opened gas may escape! Drain closed Drain open F 22...

  • Page 92: Checking The Coolant Level

    10.7 Checking the coolant level – Open the cover lock and turn it to the right – Remove the cover – Check the coolant level on the reservoir. The coolant should lie between the MIN and MAX markings (26). If the coolant is below the MIN marking, this indicates possible leakage in the radiator system.

  • Page 93: Filling The Cooling Circuit

    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/TFG: 14.0 l 10.9 Filling the cooling circuit Leave the engine to cool down in order to fill it with coolant.

  • Page 94: 10.10 Cleaning/Replacing The Air Filter Cartridge

    10.10 Cleaning/replacing the air filter cartridge Carry out all maintenance work with the engine switched off. Do not start the engine if the air filter cartridge is removed. – Undo the quick release lock (29) and lift it up. – Raise the air filter housing. –...

  • Page 95: 10.11 Dfg/Tfg Transmission

    10.11 DFG/TFG transmission: It is important to check the oil level correctly. The oil is a lubricant which also acts as a coolant and operates the clutches. A low oil level will result in loss of transmission and pressure. It also causes overheating and resultant transmission failure. Checking the transmission oil level Only use clean, fresh oil from clean containers...

  • Page 96: 10.12 Brake

    10.12 Brake Checking the parking brake The parking brake (33) must be able to keep truck plus maximum permissible load on an incline of 15%. If this is not the case, the parking brake must be adjusted. Checking the brake fluid level –...

  • Page 97: 10.13 Checking The Wheel Attachments

    10.13 Checking the wheel attachments. – Park the truck securely (see Chapter E). – Tighten the wheel nuts (36) crosswise with a torque wrench. Torque Drive wheels: 200 Nm Rear wheels: 200 Nm 10.14 Hydraulic system Replacing the hydraulic oil filter –...

  • Page 98: 10.16 Electrical System

    10.16 Electrical System Checking the battery condition, the acid level and acid density Battery acid is highly corrosive. Therefore it is essential to avoid contact with battery acid. If clothing, skin or eyes have nevertheless come into contact with battery acid, immediately rinse the affected parts with water.
  • Page 99 Checking electrical fuses – Prepare the truck for maintenance and repair work (see “Preparing the Truck for Maintenance and Repairs” in this chapter) – for rear mounted fuses, open the rear panel lock and turn it to the right – Remove the panel –...
  • Page 100 DFG main current Item Ref. To protect: Rating 9F11 Preheat fuse 70 A Engine running option relay 50 A Ignition on options relay 50 A 9F16 Key switch 20 A 9F17 Pre-fuse for F19 20 A 50A-Generator 50 A 9F19 80A-Generator 70 A TFG main current...

  • Page 101: 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 personnel. 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 following operations have been performed.

  • Page 102: During Decommissioning

    13.2 During decommissioning: Every 2 months: – Charge the battery. 13.3 Returning the truck to operation after decommissioning It is advisable to have the truck restored to service after decommissioning by an engineer of the manufacturer. – Thoroughly clean the truck. –...

  • Page 103: Safety Checks To Be Performed At Regular Intervals And Following Any Unusual Incidents

    Safety checks to be performed at regular intervals and following any unusual incidents (D: Accident prevention check according to BGV D27 The truck must be inspected at least annually or after any unusual event by a qualified inspector. The inspector shall assess the condition of the truck from purely a safety viewpoint, without regard to operational or economic circumstances.

This manual is also suitable for:

Dfg 320Tfg 316Tfg 320

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