Jungheinrich DFG 316 Operating Instructions Manual Download Page 29

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406

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C 4

Summary of Contents for DFG 316

Page 1: ...Operating instructions 51011137 DFG TFG 316 320 G 04 06 02 07...

Page 2: ...explanations are indicated by the following graphics F Used before safety instructions which must be observed to avoid danger to personnel M Used before notices which must be observed to avoid materi...

Page 3: ...0108 GB...

Page 4: ...EN norms B 12 3 6 Conditions of use B 12 4 Identification points and data plates B 13 4 1 Truck data plate B 14 4 2 Truck load chart B 14 4 3 Attachment load chart B 15 C Transport and Commissioning 1...

Page 5: ...ing the steering column E 12 3 6 Starting the truck E 13 3 7 Starting procedure for the TFG E 14 3 8 Starting procedure for the DFG E 15 3 9 Operational Fault Displays E 17 3 10 Stopping the engine1 E...

Page 6: ...n tap F 22 10 7 Checking the coolant level F 23 10 8 Checking the coolant concentration F 23 10 9 Filling the cooling circuit F 24 10 10 Cleaning replacing the air filter cartridge F 25 10 11 DFG TFG...

Page 7: ...0406 GB I 4...

Page 8: ...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 cha...

Page 9: ...0406 GB A 2...

Page 10: ...e pedal and activates the rapid lift function during slow travel The middle pedal is a standard brake as well as an emergency brake pedal The capacity depends on the model The type description indicat...

Page 11: ...iption 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...

Page 12: ...his results in a very high level of safety F Before the truck is started the overhead guard must be inspected for cracks and if damaged must be repaired or replaced Engine Silent water cooled engines...

Page 13: ...es the engine can only start when the travel direction switch is in neutral For diesel motors a rapid pre heat system is installed LPG motors have a non contact electronic ignition system for rapid an...

Page 14: ...entre of gravity 500 500 mm Travel speed w w o load 18 19 18 19 km h Lift speed w w o load 0 6 0 62 0 6 0 62 m s Lowering speed w w o load 0 55 0 49 0 55 0 49 m s Gradeability w w o load 23 20 Descrip...

Page 15: ...0207 GB B 6...

Page 16: ...49 1049 mm L1 Length including forks 3386 3416 mm L2 Headlength 2236 2266 mm b1 Overall width 1080 1080 mm e Fork width 100 100 mm m1 Ground clearance with load below mast 120 120 mm m2 Ground clearan...

Page 17: ...0207 GB B 8...

Page 18: ...49 1049 mm L1 Length including forks 3386 3416 mm L2 Headlength 2236 2266 mm b1 Overall width 1080 1080 mm e Fork width 100 100 mm m1 Ground clearance with load below mast 120 120 mm m2 Ground clearan...

Page 19: ...L L4 four cylinder four stroke LPG Ignition sequence 1 3 4 2 Capacit 2065 cc Control speed 2700 50 RPM unloaded 850 50 RPM idle Spark plug type NGH FR2A D Spark plug electrode distance 0 8 0 9 mm Tray...

Page 20: ...2335 4220 3800 150 2435 4420 4000 150 2535 4620 4500 150 2835 5120 5000 150 3085 5620 5500 150 3435 6120 5800 150 3635 6420 ZZ 2900 1290 1940 3550 3100 1390 2040 3750 3300 1490 2140 3950 3600 1640 229...

Page 21: ...weighted acceleration in the vertical direction It is calculated when travelling over bumps at constant speed Electromagnetic Compatibility The manufacturer confirms that equipment complies with tole...

Page 22: ...nts for crane lifting 20 Procedure when truck in danger of tipover notice 21 Do not stand under load lifting device Do not stand under load lifting device Risk of trapping when mast extended combined...

Page 23: ...e 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 Example of how to calculate...

Page 24: ...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 truc...

Page 25: ...0207 GB B 16...

Page 26: ...of the mast 1 and the trailer coupling 2 M 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 Th...

Page 27: ...elines VDI 2700 and VDI 2703 In each case correct measurements must be taken and appropriate safety measures adopted To secure the truck with the mast assembled use the eyes on the upper cross member...

Page 28: ...acid level Commission the truck in accordance with instructions see Chapter E 4 Towing the truck As the gear unit of the forklift motor is powered it is not lubricated and will overheat if a truck ha...

Page 29: ...0406 GB C 4...

Page 30: ...nsport 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 indicate...

Page 31: ...er E Open the cap 1 Fill up with clean diesel Z Do not overfill the tank Capacity 48 l M Only use DIN 51601 diesel with a cetane rating below 45 The fuel guage 2 indicates the fuel level If it points...

Page 32: ...nd the handle 9 Fold back the lever of the toggle type fastener 8 and unhook the tensioning pivot from the bracket Remove the tensioning belt Carefully remove the LPG bottle from the bracket and place...

Page 33: ...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 Fill the LPG bottle until you can see on the flu...

Page 34: ...klift 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 alterat...

Page 35: ...0406 GB E 2 1 2 3 5 4 2 4 9 7 8 6 1 3 5 7 6 15 14 13 12 11 10 14 12 11 10 17 16 18 19 20 21 22 26 25 24 23 29 28 27...

Page 36: ...uel supply is too low 7 Brake fluid indicator t When lit indicates the brake fluid level is too low 8 Air filter indicator t When lit indicates that the air filter is contaminated 9 Diesel filter indi...

Page 37: ...0406 GB E 4 1 2 3 5 4 2 4 9 7 8 6 1 3 5 7 6 15 14 13 12 11 10 14 12 11 10 17 16 18 19 20 21 22 26 25 24 23 29 28 27...

Page 38: ...21 Brake pedal Standard emergency braking 22 Accelerator pedal t Controls engine speed travel and lift speed 23 Auxiliary hydraulics ZH1 Sideshift o Moves the forks to the right left 24 Auxiliary hyd...

Page 39: ...the truck is abandoned without taking it out of gear the truck is automatically set to neutal This is shown by the neutral indicator in the dashboard When travel is resumed by sitting on the truck the...

Page 40: ...ake sure the load chains are evenly tensioned Check the operation of the seat belt buckle and the belt returning to the retractor For further information see section 3 3 3 2 Trucks with reduced headro...

Page 41: ...l see Chapter D o Testing the windscreen fluid level The windscreen wiper fluid container 32 is located at the rear right spar 33 of the cabin Make sure there is sufficient windscreen fluid in the con...

Page 42: ...at to a lesser weight push the weight adjustment lever 36 down To set the seat to a greater weight push the weight adjustment lever up After adjusting return the lever to its original position Adjusti...

Page 43: ...traint belt after an accident Only original spare parts must be used for retrofits or repairs F Damaged or non operational belts must only be replaced by contractual dealers or branches Withdraw the b...

Page 44: ...o 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...

Page 45: ...ering 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...

Page 46: ...e operated from the driver s seat Apply the parking brake Z Set the travel direction switch 28 to neutral N Z The engine will only start when the travel direction switch is in neutral Z TFG starting p...

Page 47: ...position M Only apply the starter for a maximum of15 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 en...

Page 48: ...wait until the preheat control light goes out Z The preheat time depends on the engine temperature but normally lasts approx 4 seconds Set the ignition starter key now to the II position M Only apply...

Page 49: ...if applicable the attachment hydraulic control functions Turn the steering wheel 17 as far as it will go in both directions and test the steering M Do not run up the engine in idle The engine soon re...

Page 50: ...harging current 3 Coolant temperature 10 Transmission oil temperature 4 the engine must be stopped immediately M The engine should only be started again once the fault has been removed Z For troublesh...

Page 51: ...he 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 Turn the...

Page 52: ...nt of the truck as a lookout Negotiating slopes and inclines Negotiating slopes or inclines is only permitted if such roads are clean and have a non slip surface and providing such journeys are safely...

Page 53: ...ensure that the trailer coupling cannot become detached Trucks pulling a load must be operated in such a manner that the trailing vehicle is driven safely and can be stopped at all times F Exhaust emi...

Page 54: ...the truck has stopped Set the travel direction switch 28 via neutral to the required direction Slowly apply the accelerator pedal 22 until you reach the required travel speed Reversing F Make sure you...

Page 55: ...nverter Continue to depress the slow travel brake pedal 29 As you continue to depress the truck automatically comes to a halt Slow travel with the slow travel brake pedal Sensitive application of the...

Page 56: ...sion in the first pedal displacement zone As you continue to depress the pedal the front wheel drum brakes are applied Alternatively you can use the brake pedal 21 this will actuate the drum brakes wi...

Page 57: ...age Push the control lever 26 forward to lower the fork carriage Tilting the mast forward backward F When tilting the mast back do not position any part of your body between the mast and the front wal...

Page 58: ...eed governs the operating speed of the hydraulic cylinders When the control levers are released 23 24 they automatically revert to neutral and the lifting device remains in the position it has reached...

Page 59: ...the truck is not exceeded Note the load chart Adjusting the forks F Adjust the fork tines in such a way that both are equally distanced from the outer edge of the fork carriage and the load centre of...

Page 60: ...direction switch to forward travel F At least two thirds of their length must extend into the load Drive the truck with forks spread as far apart as possible underneath the load Set the travel directi...

Page 61: ...stand underneath a raised load Lower the load as far as is absolutely necessary for transport ground clearance approx 150 200 mm Tilt the mast fully backward F The higher the load is transported the l...

Page 62: ...ings and passageways Always travel with a lookout at blindspots F On slopes and inclines always carry the load facing uphill never approach at an angle or turn Depositing a load Drive the truck carefu...

Page 63: ...truck with a raised load Drive the truck onto a level surface F LPG powered trucks must not be operated on ground floors with a basement Liquid gas is colourless heavier than air and does not easily d...

Page 64: ...ottle securely Wait until the engine comes to a stop Turn the ignition starter switch 19 to 0 Remove the key from the ignition starter switch 19 o Steel cabin For trucks fitted with a steel cabin both...

Page 65: ...0 degrees and engage it 4 9 Tow loads Before coupling the driver must ensure the maximum trailer load is not exceeded Permissible towed loads for towing without a load on the forks for 1 inclines and...

Page 66: ...oes not start Air filter contaminated Bowden cable faulty or hanging Additional for LPG LPG bottle shutoff valve closed LPG bottle empty Ignition distributor cap damp Spark plugs damp oily or loose Sp...

Page 67: ...ravel direction switch in neutral Parking brake applied Set travel direction switch to required direction Release parking brake Truck does not reach max speed Transmission oil level too low Check tran...

Page 68: ...Additional troubleshooting must only be performed by the manufacturer s specialist service engineers The manufacturer has a customer service department specially trained for these tasks To provide tar...

Page 69: ...0406 GB E 36...

Page 70: ...rviced and maintained by the manufacturer s trained personnel The manufacturer s service department has field technicians specially trained for these tasks We therefore recommend a maintenance contrac...

Page 71: ...fitted at the factory only use the manufacturer s original spare parts Otherwise the data sheet specifications of the truck cannot be guaranteed When changing wheels and tyres ensure that the truck d...

Page 72: ...by 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 te...

Page 73: ...s 2 1 Test operation of instruments displays and control switches t 2 2 Test warning and safety devices t 2 3 Check fuse ratings t 2 4 Make sure wire connections are secure and check for damage t 2 5...

Page 74: ...s and damage and tighten connections if necessary t 5 11 Check cylinders and piston rods for damage and leaks and make sure they are secure t 5 12 Check hydraulic oil level and top up if necessary t 5...

Page 75: ...or t 7 15 Check exhaust system for leaks and damage t 7 16 Clean the air filter cartridge t 7 17 Replace air filter cartridge t 7 18 Replace fuel filter t 7 19 Check the fuel water separator and disch...

Page 76: ...haust system for leaks and damage t 8 17 Check exhaust levels adjust if necessary t 8 18 Clean the air filter cartridge t 8 19 Replace air filter cartridge t 8 20 Test LPG system check for leaks and d...

Page 77: ...ue of 7 0 8 5 Make sure the mixture ratio is correct when using an anit freeze The frost protection level must satisfy the above standard The manufacturer cannot be held liable for frost or corrosion...

Page 78: ...ediately 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...

Page 79: ...ation schedule g Contact surfaces b Transmission oil filler neck s Grease nipple a Transmission oil drain plug Hydraulic oil filler neck t Mineral oil filler neck for brake system c Hydraulic oil drai...

Page 80: ...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...

Page 81: ...rking under a raised load fork or a raised truck secure them to prevent them from lowering tipping or sliding away F Note the following when raising the forklift truck M Only use lifting gear with suf...

Page 82: ...in the leg compartment and raise the engine cover 3 slightly Fully raise the engine cover 3 A gas pressure damper keeps the engine cover in the raised position M If a forklift truck is equipped with a...

Page 83: ...t 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 fue...

Page 84: ...g with a new seal F Dispose of used oil in accordance with environmental regulations Replacing the engine oil filter Undo the hose clamp 10 from the hose 9 Pull off the hose Undo the air filter attach...

Page 85: ...essure indicator 13 when you run 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 and the generator V...

Page 86: ...al contacts the filter flange Tighten the fuel filter another third of a turn Bleed the fuel system Bleeding the fuel system F Collect any emerging fuel and dispose of it in accordance with environmen...

Page 87: ...l has reached the MAX mark on the dipstick 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 repl...

Page 88: ...h 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 consumables table see Section 9 1 Capac...

Page 89: ...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 and the generator V belt pulley using a force of...

Page 90: ...cessary top up to the MIN marking on the dipstick If the oil is hot 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 hyd...

Page 91: ...s system drain tap Z The gas system drain tap must always be closed during operation it should only be opened by service personnel for maintenance purposes F If the drain is opened gas may escape Drai...

Page 92: ...pty the system by opening the drain taps in the radiator and on the side of the cylinder block The drain plugs may be made of brass When draining remove the expansion vessel lid and lay it on the driv...

Page 93: ...ng 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 i...

Page 94: ...the external cartridge to the outside until no more dust emerges Carefully wipe the internal cartridge with a lint free cloth M Do not apply compressed air to the filter housing instead wipe with a cl...

Page 95: ...ission oil dipstick on the right hand side of the transmission looking in the direction of travel Start the engine and with the parking brake applied first engage forward gear followed by reverse and...

Page 96: ...the case the parking brake must be adjusted Checking the brake fluid level Undo the screws of the left hand panel 34 Remove the left handpanel 34 Check the brake fluid level in the brake fluid reservo...

Page 97: ...lic oil filter integrated in the lid Insert a new hydraulic oil filter and screw the lid back on F Collect any spilled hydraulic oil Dispose of the hydraulic oil and hydraulic oil filter in accordance...

Page 98: ...tery housing for cracks and any spilled acid Remove any oxydation remains from the battery terminals Lubricate the battery terminals with an acid free grease Check the acid level The acid should lie b...

Page 99: ...tem Ref To protect Value 39 2F14 Pre heat relay diesel valve 5 A 40 4F1 Air filter control travel direction valves seat switch horn 10 A 41 7F5 Diesel filter control brake fluid control handbrake cont...

Page 100: ...8 9F16 Key switch 20 A 59 9F17 Pre fuse for F19 20 A 60 9F19 50A Generator 50 A 80A Generator 70 A Item Ref To protect Rating 51 9F8 Engine running option relay 50 A 52 9F7 Ignition on options relay 5...

Page 101: ...and dry location and all necessary measures must be taken before during and after decommissioning as described M On decommissioning the truck must be jacked up so that all the wheels are clear of the...

Page 102: ...ufacturer Thoroughly clean the truck Lubricate the truck in accordance with the lubrication schedule see Chapter F Clean the battery grease the terminals and connect the battery Charge the battery Che...

Page 103: ...ruck must be undertaken with regard to its technical condition from a safety aspect The truck must also be examined for damage caused by possible improper use A test report shall be provided The test...

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Summary of Contents for DFG 316

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