DFG 320

DFG/TFG 316/320/425/430/435 08.
07-
G
Operating Instructions
51077668
09.08
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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:
F Used before safety instructions which must be observed to avoid danger to

personnel.
M Used before notices which must be observed to avoid material damage.
Z Used before notices and explanations.
t Used to indicate standard equipment.

o Used to indicate optional equipment.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to
alter the design, equipment and technical features of the truck. No guarantee of
particular features of the truck should therefore be inferred from the present operating
instructions.
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Am Stadtrand 35
22047 Hamburg - GERMANY
Telephone: +49 (0) 40/6948-0

www.jungheinrich.com
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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
3 Standard version specifications .......................................................... B 5
3.1 Performance data DFG 316-320 ......................................................... B 5
3.2 Engine Data ........................................................................................ B 12
3.3 Tyres ................................................................................................ B 14
3.4 Mast Versions ..................................................................................... B 15
3.5 EN standards ...................................................................................... B 18
3.6 Operating Conditions .......................................................................... B 18
4 Identification points, warning labels and data plates ........................... B 19
4.1 Truck data plate .................................................................................. B 20
4.2 Truck load diagram ............................................................................. B 20
4.3 Attachment load diagram .................................................................... B 21
C Transport and Commissioning
1 Lifting by crane .................................................................................... C 1

2 Securing the truck during transport. .................................................... C 2
3 Using the truck for the first time .......................................................... C 3
4 Towing the truck .................................................................................. C 3
D Fuelling the Truck
1 Safety regulations for handling fuel ..................................................... D 1

2 Filling with diesel ................................................................................. D 2
3 Replace the LPG bottle ....................................................................... D 3
E Operation
1 Safety regulations for the operation of industrial trucks ...................... E 1

2 Controls and displays .......................................................................... E 3
3 Starting up the truck ............................................................................ E 8
3.1 Daily checks and operations to be performed before starting work .... E 8
3.2 Trucks with reduced headroom X (o) ................................................. E 8
3.3 Adjusting the driver’s seat ................................................................... E 10
3.4 Safety restraint belt ............................................................................. E 11
3.5 Adjust steering column ........................................................................ E 13
3.6 Starting the truck ................................................................................. E 14
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3.7 Starting procedure for the TFG ........................................................... E 15

3.8 Starting procedure for the DFG ........................................................... E 16
I1

3.9 Operational Fault Displays .................................................................. E 18
3.10 Stopping the engine1. ......................................................................... E 19
4 Industrial Truck Operation ................................................................... E 20
4.1 Safety regulations for truck operation ................................................. E 20
4.2 Travel .................................................................................................. E 22
4.3 Steering ............................................................................................... E 24
4.4 Braking ................................................................................................ E 24
4.5 Mast and Attachment Operation ......................................................... E 25
4.6 Collecting, transporting and depositing loads ..................................... E 29
4.7 Parking the truck securely ................................................................... E 33
4.8 Towing trailers ..................................................................................... E 35
5 Troubleshooting .................................................................................. E 36
F Industrial Truck Maintenance
1 Operational safety and environmental protection ................................ F 1

2 Maintenance safety regulations .......................................................... F 1
3 Servicing and inspection ..................................................................... F 3
4 DFG/TFG maintenance checklist ........................................................ F 4
5 DFG maintenance checklist ................................................................ F 6
6 TFG maintenance checklist ................................................................. F 7
7 Coolant specification ........................................................................... F 8
8 DFG fuel specifications ....................................................................... F 9
9 Lubrication Schedule ........................................................................... F 10
9.1 Consumables ...................................................................................... F 11
10 Maintenance and repairs ..................................................................... F 13
10.1 Preparing the truck for maintenance and repairs ................................ F 13
10.2 Engine panel ....................................................................................... F 14
10.3 Starting aid .......................................................................................... F 14
10.4 Servicing the engine DFG ................................................................... F 15
10.5 Engine servicing TFG .......................................................................... F 19
10.6 Checking the hydraulic oil level ........................................................... F 22
10.7 Gas system drain tap .......................................................................... F 23
10.8 Checking the coolant level .................................................................. F 24
10.9 Checking the coolant concentration .................................................... F 25
10.10 Filling the cooling circuit ...................................................................... F 25
10.11 Cleaning/replacing the air filter cartridge ............................................. F 26
10.12 DFG/TFG transmission: ...................................................................... F 27
10.13 Brake ................................................................................................... F 28
10.14 Checking the wheel attachments. ....................................................... F 29
10.15 Hydraulic system ................................................................................. F 29
10.16 Clean/replace hydraulic reservoir discharge system ........................... F 29
10.17 Electrical Equipment ........................................................................... F 30
11 Exhaust system ................................................................................... F 34
12 Restoring the truck to service after cleaning or repairs ....................... F 34
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13 Decommissioning the industrial truck .................................................. F 34

13.1 Prior to decommissioning: ................................................................... F 34
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13.2 During decommissioning: .................................................................... F 35
13.3 Returning the truck to operation after decommissioning ..................... F 35
14 Safety checks to be performed at regular intervals and following
any unusual incidents .......................................................................... F 36
15 Final de-commissioning, disposal ....................................................... F 36
16 HUSS FS - MK Series Diesel Particle Filter Operating Instructions .... F 37
16.1 Important General Instructions ............................................................ F 37
16.2 Important safety instructions ............................................................... F 37
16.3 Functional description ......................................................................... F 38
16.4 HUSS Control Operation ..................................................................... F 39
16.5 HUSS Control Operating Instructions ................................................. F 40
16.6 Regeneration ....................................................................................... F 41
16.7 Maintenance ........................................................................................ F 44
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A Correct Use and Application
Z 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.
All other types of use lie beyond the scope of application and can result in damage to
personnel, the 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 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 user must comply with legal
requirements, technical standards and health and safety regulations when operating
an IC engine powered lift truck in closed rooms. The owner must ensure that all truck
users have read and understood these operating instructions.
M 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.
Trailing and towed loads: The truck may only be used for trailing or towed loads for
which the truck has been approved.
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B Truck Description
1 Application
The DFG/TFG series are IC engine, 4-wheel rider trucks. The DFG series are diesel
engine trucks, while the TFG series are equipped with a petrol engine for LPG
operation.
The DFG/TFG 316-435 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. The middle pedal is a standard brake as well as emergency brake
pedal.
The capacity depends on the model. The model reference indicates the maximum
load rating. For example, a DFG/TFG 316 can carry loads of up to 1600 kg and a
DFG/TFG 435 loads of up to 3500 kg.
Truck models and maximum capacity:
Model max. capacity *) Load centre of gravity

DFG/TFG 316 1600 kg 500 mm
DFG/TFG 320 2000 kg 500 mm
DFG/TFG 425 2500 kg 500 mm
DFG/TFG 430 3000 kg 500 mm
DFG/TFG 435 3500 kg 500 mm
*) The load diagrams attached to the truck are binding in terms of capacity
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B1

2 Assemblies and functional description
5
4
6
3
7
2 8
10
11
14 13 12
Item Description Item Description

1 t Driver’s seat 8 t Fork
2 t Steering column 9 t Fork carriage
3 t Dashboard 10 t Drive axle
4 t Overhead guard 11 t Engine panel
5 t Mast 12 t Steering axle
6 t Load chain 13 t Trailer coupling
7 t Lift cylinder 14 t Counterweight
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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.
A wide opening panel (11) facilitates service and maintenance work. 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 (14). The exhaust system prevents exhaust
gases from entering the driver’s position.
Driver’s position: A non-slip step and a handle on the posts of the overhead guard
provide easy entry and exit. The driver is protected by the overhead guard (4). On the
driver’s seat (1) the seat cushioning and the seat position are adjustable, while the
steering wheel tilt can be set on the steering column (2). Easy operation through
ergonomically arranged controls and a practically vibration-proof cab mean that the
driver is only subjected to minimum stress. The controls and warning indicators on
the dashboard (3) provide system monitoring during operation. This 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 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 system: A power shift gear with radiator and torque converter is directly
flanged to the engine. This transfers the force to the drive axle (10).
The travel direction switch on the left hydraulic control lever regulates forward/reverse
travel and the neutral position.
Steering: The hydrostatic steering consists of a steer cylinder integrated in the

steering axle (12). The steering axle is fully floating in the chassis to ensure excellent
grip even on non-level surfaces.
Brakes: The brake pedal actuates two drum brakes which are applied to the drive
wheels. The drum brakes are also actuated by the slow travel / brake pedal, although
this is only intended as a crawl speed aid. The pedal should not be used for normal
braking purposes. Worn drum brakes are automatically adjusted. The parking brake
operates through mechanical actuation of the parking brake lever on the drum brake
via Bowden cables.
Wheels: All wheels are located within the geometry of the truck. A choice of air or
superelastic tyres is available.
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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. A repeat start block prevents incorrect operation
during start-up and a safety switch ensures 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 and trouble-free
engine starting. The ignition / starter switch is used to switch off the engine.
Mast (5): The aim is to optimize 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 casters.
Attachments: The trucks can be optionally fitted with mechanical and hydraulic
attachments.
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3 Standard version specifications
Z Technical specification details in accordance with VDI 2198. Technical modifications

and additions reserved.
3.1 Performance data DFG 316-320
Model DFG 316 DFG 320

Q Capacity 1600 2000 kg
C Load centre of gravity distance 500 500 mm
Travel Speed
18/19 18/19 km/h
w/w.o. load
Lift Speed
0.6/0.62 0.6/0.62 m/s
w/w.o. load
Lower Speed
0.55/0.49 0.55/0.49 m/s
w/w.o. load
Gradeability
23 20 %
w/w.o. load
TFG 316-320 Performance Data
Model TFG 316 TFG 320

Q Capacity 1600 2000 kg
C Load centre of gravity distance 500 500 mm
Travel Speed
18/19 18/19 km/h
w/w.o. load
Lift Speed
0.6/0.63 0.6/0.63 m/s
w/w.o. load
Lower Speed
0.55/0.49 0.55/0.49 m/s
w/w.o. load
Gradeability
25 22 %
w/w.o. load
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B5

Performance data DFG/TFG 425-435
Model DFG 425 DFG 430 DFG 435

Q Capacity 2500 3000 3500 kg
C Load centre of gravity distance 500 500 500 mm
Travel Speed 17/19 18/19 18/19 km/h
w/w.o. load
Lift Speed 0.59/0.60 0.53/0.59 0.49/0.53 m/s
w/w.o. load
Lower Speed 0.55/0.45 0.55/0.45 0.55/0.42 m/s
w/w.o. load
Gradeability 27 23 18 %
w/w.o. load
Model TFG 425 TFG 430 TFG 435

Q Capacity 2500 3000 3500 kg
C Load centre of gravity distance 500 500 500 mm
Travel Speed 17/19 18/19 18/19 km/h
w/w.o. load
Lift Speed 0.5/0.6 0.46/0.55 0.41/0.51 m/s
w/w.o. load
Lower Speed 0.55/0.45 0.55/0.45 0.55/0.42 m/s
w/w.o. load
Gradeability 27 23 19 %
w/w.o. load
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B7

Dimensions DFG
Model DFG 316 DFG 320

a/2 Safety distance 100 100 mm
h1 Mast height retracted 2185 2185 mm
h2 Free lift 150 150 mm
h3 Lift 3300 3300 mm
h4 Mast height extended 3920 3920 mm
h6 Overhead guard height 2145 2145 mm
h7 Seat height (SIP) 1049 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 clearance centre wheel base 130 130 mm
Working aisle width for pallets 800 x 1200
Ast 3618 3640 mm
longit.
Working aisle width for pallets 1200 x 800
Ast 3818 3840 mm
transverse
Wa Turning radius 2020 2042 mm
x Load distance 398 398 mm
y Wheel base 1495 1495 mm
Truck weight 2870 3280 kg
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Dimensions
Model DFG 425 DFG 430 DFG 435

a/2 Safety distance 100 100 100 mm
h1 Mast height retracted 2080 2080 2180 mm
h2 Free lift 150 150 150 mm
h3 Lift 2900 2900 3100 mm
h4 Mast height extended 3685 3685 3885 mm
h6 Overhead guard height 2220 2250 2250 mm
h7 Seat Height 1068 1068 1068 mm
L1 Length including forks 3690 3810 3945 mm
L2 Headlength 2540 2660 2795 mm
b1 Overall width 1174 1300 1300 mm
e Fork width 120 125 125 mm
m1 Ground clearance with load below mast 125 125 125 mm
m2 Ground clearance centre wheel base 130 140 140 mm
Working aisle width 4215 4331 4511 mm
Ast
for pallets 800 x 1200 longit.
Ast
for pallets 1200 x 800 transverse
Wa Turning radius 2290 2370 2550 mm
x Load distance 473 515 515 mm
y Wheel base 1685 1685 1785 mm
Truck weight 4290 4730 5098 kg
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TFG dimensions
Model TFG 316 TFG 320

a/2 Safety distance 100 100 mm
h1 Mast height retracted 2185 2185 mm
h2 Free lift 150 150 mm
h3 Lift 3300 3300 mm
h4 Mast height extended 3920 3920 mm
h6 Overhead guard height 2145 2145 mm
h7 Seat height (SIP) 1049 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 clearance centre wheel base 130 130 mm
Working aisle width
Ast 3618 3640 mm
Working aisle width
Ast 3818 3840 mm
Wa Turning radius 2020 2042 mm
x Load distance 398 398 mm
y Wheel base 1495 1495 mm
Truck weight 2840 3250 kg
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Model TFG 425 TFG 430 TFG 435
a/2 Safety distance 100 100 100 mm
h1 Mast height retracted 2080 2080 2180 mm
h2 Free lift 150 150 150 mm
h3 Lift 2900 2900 3100 mm
h4 Mast height extended 3685 3685 3885 mm
h6 Overhead guard height 2220 2250 2250 mm
h7 Seat height 1068 1068 1068 mm
L1 Length including forks 3690 3810 3945 mm
L2 Headlength 2540 2660 2795 mm
b1 Overall width 1174 1300 1300 mm
e Fork width 120 125 125 mm
m1 Ground clearance with load below mast 125 125 125 mm
m2 Ground clearance centre wheel base 130 140 140 mm
Ast
Ast
Wa Turning radius 2290 2370 2550 mm
x Load distance 473 515 515 mm
y Wheel base 1685 1685 1785 mm
Truck weight 4190 4630 4998 kg
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3.2 Engine Data
Engine - DFG316 - 320
Model S4Q2 four cylinder

Ignition sequence 1 3 4 2
Capacity 2505 cc
2350 rpm (without load)
Control speed
680 rpm (idle)
Valve play Inlet and outlet 0.25 mm cold
Oil volume 8.0 l
Tank volume 48 l
Coolant volume 5.5 l + system = 14.0 l
DFG 425-435 Engine
Model S4S four cylinder

Capacity 3331 cc
2350 rpm (without load)
Control speed
680 rpm (idle)
Valve play Inlet and outlet 0.25 mm cold
Oil volume 10.0 l
Tank volume 58 l
Coolant volume 5.5 l + system = 15.0 l
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B 12

Engine - TFG 316-320
Model 2.1 L L4 four cylinder, four stroke, LPG

Capacity 2065 cc
2700 ±50 rpm (without load)
Control speed
850 ±50 rpm (idle)
Valve play Inlet and outlet 0.38 mm warm
Spark plug type NGH FR2A-D
Spark plug electrode distance 0.8-0.9 mm
Oil volume 3.8 litres
Coolant volume 3.5 litre + system = 13 litres
TFG 425-435 Engine
Model 2.5 L L4 four cylinder, four stroke, LPG

Capacity 2488 cc
2700 ±50 rpm (without load)
Control speed
850 ±50 rpm (idle)
Valve play Inlet and outlet 0.38 mm warm
Spark plug type NGH FR2A-D
Spark plug electrode distance 0.8-0.9 mm
Oil volume 3.8 litres
Coolant volume 3.5 litre - system = 13 litres
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3.3 Tyres
Full rubber SE tyres

DFG/TFG 316 DFG/TFG 320
(= Solid)
Drive axle 6.50-10 6.50-10
Steering axle 18x7-8 18x7-8
Pneumatic tyres
DFG/TFG 316 DFG / TFG 320
(diagonal tyres)
Drive axle 6-50-10 14PR 6-50-10 14PR
Steering axle 18x7-8 14PR 18x7-8 14PR
Tyre pressure DFG / TFG 316 DFG / TFG 320

Drive axle 10 bar 10 bar
Steering axle 9.0 bar 9.0 bar
Full rubber SE tyres DFG / TFG 425 DFG / TFG 430 DFG / TFG 435
(= Solid)
Drive axle 7.00x12 28x9-15 250x15
Steering axle 6.50x10 6.50x10 6.50x10
Pneumatic tyres DFG / TFG 425 DFG / TFG 430 DFG / TFG 435
(diagonal tyres)
Drive axle 7.00x12 16PR 28x9-15 14PR 250x15 16PR
Steering axle 6.50x10 14PR 6.50x10 14PR 6.50x10 14PR
Tyre pressure DFG / TFG 425 DFG / TFG 430 DFG / TFG 435
Drive axle 10.0 bar 9,0 bar 8,25 bar
Steering axle 10.0 bar 10.0 bar 10.0 bar
Z Permissible tyre types: Only use tyres approved by the lift truck manufacturer, if in
doubt contact your local JH service branch.
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3.4 Mast Versions
(all dimensions in mm)

DFG/TFG 316/320
Mast table
VDI 3596 Lift Free lift Extended height
Retracted height h1
Description h3 h2 h4
2900 150 1985 3520
3100 150 2085 3720
3300 150 2185 3920
3600 150 2335 4220
3800 150 2435 4420
ZT
4000 150 2535 4620
4500 150 2835 5120
5000 150 3085 5620
5500 150 3435 6120
5800 150 3635 6420
2900 1290 1940 3550
3100 1390 2040 3750
3300 1490 2140 3950
ZZ 3600 1640 2290 4250
3800 1740 2390 4450
4000 1840 2490 4650
4500 2140 2790 5150
4200 1290 1940 4850
4350 1340 1990 5000
4500 1390 2040 5150
4800 1490 2140 5450
DZ
5000 1565 2215 5650
5500 1740 2390 6150
6000 1940 2590 6650
6500 2190 2840 7150
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DFG/TFG 425/430
Mast table
VDI 3596 Lift Free lift Retracted height h1 Extended height
ZT 2900 150 2080 3510
3100 150 2180 3710
3300 150 2280 3910
3500 150 2380 4110
3700 150 2480 4310
4000 150 2630 4610
4300 150 2830 4910
4500 150 2930 5110
4700 150 3030 5310
5000 150 3180 5610
5500 150 3480 6110
5800 150 3630 6410
6000 150 3730 6610
ZZ 2900 1480 2080 3500
3100 1580 2180 3700
3300 1680 2280 3900
3500 1780 2380 4100
3700 1880 2480 4300
4000 2030 2630 4600
4300 2230 2830 4900
4500 2330 2930 5100
DZ 4400 1480 2080 5000
4700 1580 2180 5300
5000 1680 2280 5600
5500 1880 2480 6100
6000 2080 2680 6600
6500 2280 2880 7100
7000 2480 3080 7600
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DFG/TFG 435
Mast table
VDI 3596 Lift Free lift Retracted height h1 Extended height
ZT 3100 150 2180 3870
3500 150 2380 4270
4000 150 2630 4770
4500 150 2930 5270
5000 150 3180 5770
4700 1417 2180 5463
5000 1517 2280 5763
DZ 5500 1717 2480 6263
6000 1917 2680 6763
6500 2117 2880 7263
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3.5 EN standards
Noise emission level: 79 dB(A) +/- 3dB

(depending on tolerances and equipment)
in accordance with EN 12053 as harmonised with

ISO 4871.
Z 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 sound
pressure level is measured at the ear.
MSG 65
Vibration : DFG/TFG 316-320 0.50 m/s2

DFG/TFG 425-435 0.73 m/s2
In accordance with EN 13059.
Z 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.
Electromagnetic compatibility (EMC)
The manufacturer confirms that equipment complies with

tolerance levels for electromagnetic emissions and
resistance as well as static electricity discharge testing in
accordance with EN 12895 including the normative
procedures contained therein.
Z No changes to electric or electronic components or their arrangement may be made

without the written agreement of the manufacturer.
3.6 Operating Conditions
Ambient temperature
- operating at -20 °C to 40 °C
Z Special equipment and authorisation are required if the truck is to be constantly used
in conditions of extreme temperature or air humidity fluctuations.
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B 18

4 Identification points, warning labels and data plates
17 19
18
(mm) Q (kg)
20
D (mm)
16
27
15
21
22
23
19
24 11 10
12
9
0
8 7 6
200
25 5
1
4 3 2
24
26
Item Description
15 Attention: Read operating instructions.
16 Load fork, Capacity / Load Centre of Gravity / Lift Height diagram
17 “Travel with raised load prohibited” / “Mast forward tilt with raised load
prohibited” warning
18 "Attach safety restraint belt" notice
19 Strap points for crane lifting
20 “Procedure when truck in danger of tipover” notice
21 "Do not stand under load handler” / “Do not stand under load handler” /
“Risk of trapping when mast extended” combined notice
22 “Maximum body size” notice o
23 Test sticker (o)
24 Jack contact points
25 Serial number, on chassis below the engine cover
26 “Do not carry passengers” warning
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27 Data plate, truck, below engine panel (316-320=left; 425-435=right)
B 19

4.1 Truck data plate
37
28
36
29 35
30 34
31
32 33
Item Description Item Description

28 Model 33 Manufacturer’s logo
29 Serial no. 34 Net. weight
30 Rated capacity (kg) 35 Load centre of gravity (mm)
31 Output (kW) 36 Year of manufacture
32 Manufacturer 37 Option
Z For queries regarding the truck or ordering spare parts always quote the truck serial
number (29).
4.2 Truck load diagram
The load diagram (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 diagram 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.
Example of how to calculate the maximum capacity:

For a load centre of gravity D of 600 mm and a maximum lift height H of 3600 mm the
maximum capacity Q is 1105 kg.
For example:
16
4250 850 850 600

1105 1105 850
3600
1250 1250 850
2900
500 600 700

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B 20

The arrow shape markings (38 and 39)
38 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 height-
dependent capacity rating.
4.3 Attachment load diagram
The attachment load diagram gives the truck’s capacity Q in combination with
the respective attachment in kg. The serial number specified in the load diagram 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.
Z For loads with a centre of gravity above 500mm upward, the capacities are reduced
by the difference of the altered centre of gravity.
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C Transport and Commissioning
1 Lifting by crane
M Only use lifting gear with sufficient

capacity (for transport weight see truck
data plate). 1
– Parking the truck securely
(see Chapter E).
– Attach the crane slings to the cross
member of the mast (1) and the trailer 2
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.
The crane belt or the chain on the mast
must be at least 2m long.
M 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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2 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
contained in Guidelines VDI 2700 and
VDI 2703.
In each case correct measurements

must be determined and appropriate
safety measures applied.
To secure the truck with the mast

assembled, use the eyes on the upper
cross member of the mast and the trailer
pins. See top picture (fastening with
mast assembled) and centre picture
(fastening without a mast).
If the truck is to be transported without a
mast, it must be tied down at the front
over the overhead guard. See centre
picture.
The lower picture shows the
approximate centre of gravity.
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3 Using the truck for the first time
F 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 engine oil level.
– Check power shift transmission oil level.
– Check brake fluid level
– Check battery terminals and acid level.
– Start up the truck in accordance with instructions (see Chapter E).
4 Towing the truck
As the gear unit of the forklift engine is powered, it is not lubricated and will overheat
if a truck has to be towed with the engine switched off. To avoid this, the truck can
only be towed at a max. speed of 4 km per hour for a maximum length of 5 km.
Hitch point
A rigid tow bar must be used for moving

a forklift truck.
56
The tow point of the truck is marked (57) .
57
– Attach the tow bar / rope to the trailer coupling of the recovery vehicle and the truck
to be recovered.
– Release the parking brake.
F One person must be seated in the towed truck to steer it. Tow the truck at crawl
speed.
Z As the steering auxiliary unit is not applied, extra effort is required to steer the truck.
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D Fuelling the Truck
1 Safety regulations for handling fuel
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. Operational fire equipment must be provided within
easy reach of the filling area.
F Only use carbon dioxide dry extinguishers or carbon dioxide gas extinguishers for fire
protection.
Storage and transport: The diesel fuel 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 tank
manufacturer as well as statutory and local regulations when filling up.
Hose / Pipe break safety device
M Attention: A hose / pipe break safety device 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 break safety device
– The bottle connection to the truck must have a hose / pipe break safety device
(available from the factory)
The owner must comply with all legal requirements, technical standards and health
and safety regulations applicable to liquid gas.
F Liquid gas produces frost damage to naked skin.

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2 Filling with diesel
F 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.
Z Do not overfill the tank.

1
Capacities:
DFG 316 - 320= 48 l
DFG 425 - 435= 58l
M Only use DIN EN 590 diesel with a

cetane rating above 50. 1
The fuel gauge (2) indicates the fuel

level. If it points to the red zone, fill the 2
tank. This is also displayed by the spare
indicator (1).
M Never allow the fuel tank to run dry!

Air in the fuel system will result in
malfunctions. DFG
– Tighten the cap back on after filling

with fuel.
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3 Replace the LPG bottle
F 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 9 3
system to run empty in neutral.
– Unscrew the union nut (4) with an 4
appropriate key while holding against
the handle (6). 6
– Remove the hose (5) and immediately
screw the valve cap onto the empty
LPG bottle. 5
– Remove the stop bolt (7) and rotate
the LPG bottle and bracket around 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 it down
securely.
F Only use 18–kg (29 l) 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 up.
– Fit the tensioning belt around the LPG
bottle.
– Hook in the tensioning pivot and
tension the belt with the lever (8).
– Rotate the LPG bottle and the bracket
around the handle (9).
– Press in the stop bolt (7).
– Refit the hose (5) 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 “Rotarex” gas limit display operating instructions
Functional description
The gas limit display is a threshold device for

the fluid phase, known as an MLD (Minimum
Liquid Detector). The MLD indicates when
there is just a small amount of gas left in
the container. The remaining travel time will
then depend on the application and ambient
conditions. Normally it is 8 - 12 minutes. This
is then displayed via the spare indicator (2) on
the dashboard.
Z Note: if the container level is low, the spare

indicator can briefly light up or flicker due to
fluctuations in the liquid gas level produced
during travel. Only when the indicator is permanently lit does this indicate that the tank
is almost empty.
M Safety Notices
- All maintenance, assembly and disassembly of the MLD fitting must be carried out
solely by qualified personnel trained in gas systems. Such personnel must have
detailed knowledge of ECE R67-01 and/or Directive 97/23/EC and all standards and
regulations referred to therein.
- The user is responsible for the cleanliness of the container used. It must be free of
grease, metal particles, plastic particles or anything else that could hinder the
operation of the valve.
- The MLD must not be subjected to impacts or other mechanical effects. It is

prohibited to continue using bent or otherwise damaged fittings.
- It is prohibited to approach the Propane/Butane installation with fire or a naked
flame
- The markings on the fitting must not be removed or altered.

- All users must strictly observe national and regional regulations on assembling and
using Propane/Butane gas valves.
- The user is responsible for all accidents and material or non-material, direct and
indirect damage caused by improper handling and servicing or non-authorised use.
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Reusable LPG bottles with central filling device
F Refillable liquid gas bottles contain a

dispensing valve (10), a filling stop 10 12 11
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.
Z Safety notices : 13
- Do not carry out any work on the tank.
Repairs must only be carried out by trained personnel
- The user must always check the fittings for damage and wear before using the tank
- 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.
Lift trucks with two LPG bottles
F 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.
Z 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.
M Close both shutoff valves on the gas bottles to interrupt the supply of gas.
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08.07.GB
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E Operation
1 Safety regulations for the operation of industrial trucks
Permission to operate: The industrial 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 duties and responsibilities and be instructed in the operation of the truck and shall
be familiar with the operator manual. He shall be afforded all due rights.
Safety shoes must be worn for pedestrian operated trucks.
Prohibition of unauthorized use: The driver is responsible for the truck during the
time it is in use. The driver must 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 industrial 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.
Dangerous 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.
F Unauthorised persons must be kept away from the hazardous area. Where there is
danger to personnel, a warning must be sounded with sufficient notice.
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.
M 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.
03.08.GB
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1 3 5 7 8 1 3 5 7
2 4 6 9 2 4 6
15 14 13 12 11 10 14 12 11 10
28
16 17
27 29
18
19
20
21
22
26 25 24 23
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2 Controls and displays
Item Control /Display Function
When lit, indicates that the air filter

1 Air filter indicator t
is contaminated.
When lit, indicates insufficient engine

2 Engine oil pressure indicator t
lubricant oil pressure.
When lit, indicates that the battery

3 Charging current indicator t
is not charged.
When lit, indicates that the

Transmission oil temperature
4 t transmission oil temperature is too
indicator
high.
When lit, indicates that the parking

5 Parking brake indicator t
brake is applied.
When lit, indicates the fuel supply

6 Fuel supply indicator (DFG) t
is too low.
When lit, indicates the brake fluid

7 Brake fluid indicator t
level is too low.
Lights up to indicate that the soot filter

8 Soot filter indicator t
is clogged.
Lights up to indicate that the diesel

9 Diesel filter indicator t
filter is clogged.
10 Coolant temperature indicator t Indicates the coolant temperature.
Indicates the time or number of

11 Time / Service hour display t
service hours operated.
12 Indicator control light t Shows the indicator status (right/left).
Indicates the cold start mechanism

13 Preheat control light (DFG) t
is operating.
Lights up to indicate that the travel

14 Neutral position t direction switch is in neutral
(see Neutral Interlock in this chapter)
Indicates how much fuel is left in

15 Fuel display (DFG) t
the tank.
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1 3 5 7 8 1 3 5 7
2 4 6 9 2 4 6
15 14 13 12 11 10 14 12 11 10
28
16 17
27 29
18
19
20
21
22
26 25 24 23
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Item Control /Display Function
Applies / releases parking brake.
To engage, turn switch to position 1.
16 Parking brake lever t To release, turn switch to position 0.
Pull up lever to engage.
Push lever forward to release.
17 Steering wheel t Steers truck in desired direction.
Steering column adjusting
18 t Adjusts the steering column tilt.
lever
Switches power supply on and off.
Starts and stops the engine. Removing
19 Ignition / starter switch t the ignition key prevents the truck from
being switched on by unauthorised
personnel.
20 Options switch t Options
21 Brake pedal Standard emergency braking
Controls engine speed / travel and lift
22 Accelerator pedal t
speed.
23 Auxiliary hydraulics (ZH2) o Used for hydraulic attachments.
24 Auxiliary hydraulics (ZH1) o Used for hydraulic attachments.
Tilts the mast forward and backward.
To tilt the mast forward: push the lever
25 Mast tilt control lever t forward.
To tilt the mast backward: pull the lever
back.
Raises and lowers the fork carriage
To raise the fork carriage: pull the lever
26 Lift/lower control lever t back.
To lower the fork carriage: push the lever
forward.
27 Horn button t Triggers an audible warning.
28 Travel direction switch t Select the travel direction.
1st range: controls slow travel.
29 Slow travel / brake pedal t
2nd range: applies service brake.
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t Travel direction switch
Z 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
28
the switch back.
Z The engine will not start if a travel

direction is pre-selected.
o Aisle selector (option) attached

to steering column
The standard aisle selector at-

tached to the right of the driver's
seat can optionally be replaced by
an aisle selector attached to the
steering column (30).
Z When the aisle selector (30) is in the

centre position, the transmission is
30
in idle.
– To select forward gear, push the

lever forward.
– To select reverse gear, push the

lever back.
Z The engine will not start if a travel direction is pre-selected.
Neutral Interlock
If the truck is abandoned without taking it out of gear, the truck is automatically set to
neutral. This is shown by the neutral indicator in the dashboard. When travel is
resumed (by sitting on the truck), the travel direction switch must be set to neutral (N).
Travel can now resume.
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Heating and Fan
– Turn the thermostat control

button (31) anti-clockwise to increase
the temperature in the driver’s cab.
– Press the switch (30) to activate
the fan.
30
31
Horn
– To activate the horn press the warning

button (27) in the hydraulic lever.
27
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3 Starting up the truck
F Before the truck can be started, operated or a load lifted, the driver must ensure that
there is nobody within the hazardous area.
3.1 Daily checks and operations to be performed before starting work
Truck
– The entire truck (in particular wheels and load handler) must be inspected for
damage.
– Make 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 headroom X (o)
M 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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Z 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
19
gauge (15).
– If necessary, add diesel (see
Chapter D).
15
o Testing the windscreen fluid level 32

– The windscreen wiper fluid
container (32) is located at the rear 33
right spar (33) of the cabin.
– Make sure there is sufficient
windscreen fluid in the container.
Top up if required.
– Use a windscreen fluid with anti-
freeze solution.
Wheels and Tyres
– Check wheels and tyres for wear (see

Chapter F). Measure the tyre pressure (pneumatic tyres only) (see Chapter B).
03.08.GB
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3.3 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.
37
36
35
34
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.
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 (36) approx. 90° forward.
– To set the seat 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.
Adjusting the backrest incline:

– Sit on the driver’s seat.
– Lift up the backrest tilt adjuster (34) and adjust the incline of the backrest.
– Release the backrest tilt adjuster (34) to lock the backrest in position.
Adjusting the seat position:
– Pull up the longitudinal adjuster (35) and push the driver’s seat forwards or
backwards to the desired position.
– Engage the longitudinal adjuster (35) in position again.
F 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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3.4 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.
F Put on the safety restraint 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.
Z The dry temperature of the warm air should not exceed +60 °C.
F Do not alter the belt setting.

This will increase the risk of malfunctioning.
– Always replace the safety restraint 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.
– Pull out the belt completely and check for fraying

– Test the belt buckle and make sure the belt returns correctly into the retractor.
Check the cover for damage
Testing the automatic blocking system:
– Park the truck on a horizontal surface
– Pull out the belt with a jerk.
M The automatic system should lock the belt in the retractor.
– Open the engine bonnet approx. 30 degrees
M 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.
Z Carefully drive the truck off the slope and then put on the belt.
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How to act in unusual situations
F 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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3.5 Adjust 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).
18
L
38
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3.6 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.
Start the engine
F The truck should only be 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 Starting procedure for the TFG (see section 3.7)

Starting procedure for the DFG (see section 3.8)
Key operated ignition

Operation:
O- All main circuits are cut out
and the key can be removed.
I- Controls and instruments are
switched on. Engine
preheating (diesel only).
II - Starting the engine

(automatically returns to the I 28
position).
03.08.GB
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3.7 Starting procedure for the TFG
F Note the safety regulations for

handling liquid gas (see Chapter D, 3 5
section 1). 2
– 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” position.
– Press the horn button (27) and
test the horn. 14
The charging current (3), engine oil

pressure (2), neutral setting (14)
and parking brake (5) indicators 19 22
light up.
– Gently apply the accelerator

pedal (22).
– Set the ignition / starter key now
to the II 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 27
engine starts. It automatically
returns to the I position.
F When working with LPG trucks it is

essential to always observe the
following safety regulations.
If a truck will not start:

– Close the gas bottle shutoff valve.
– Turn off the ignition / starter O.
– Call for a trained, authorised customer service engineer.
M All indicators lights except for neutral setting (14) and parking brake (5) should go out
as soon as the engine starts. If not, stop the engine immediately and rectify the fault.
03.08.GB
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3.8 Starting procedure for the DFG
– Put the key in the ignition / starter

switch (19). 3 5
2
– 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 parking brake (5)
14
indicators and the preheat (13)
control light will light up.
– Apply the accelerator pedal (22)
22
fully and 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 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

engine starts. It automatically
returns to the I position. 27
M All indicators lights except for

neutral setting (14) and parking brake (5) should go out as soon as the engine starts.
If not, stop the engine immediately and rectify the fault.
03.08.GB
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F 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+21).
– Test the engine speed with
the accelerator pedal (22)
over a range of speeds
while checking the freedom 10
of movement of the pedal.
– Test the operation of the
raise/lower (26), tilt (25) and
if applicable the attachment
hydraulic control functions.
– Turn the steering
wheel (17) as far as it will
go in both directions and
26
test the steering.
M Do not run up the engine in

idle. The engine soon reaches
25
operating temperature at a
moderate charge and when
the speed alternates.
Only fully charge the engine
when the engine coolant
17
temperature display (10)
shows operating temperature.
The truck is ready for
operation once all the
functional controls have been
satisfactorily performed and
operating temperature is
reached.
22
03.08.GB
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3.9 Operational Fault Displays
When the following indicators are lit:

3
– Engine oil pressure (2), 2 4
– Charging 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 troubleshooting procedures, see

section 5.
15 10
Check the fuel display (15, DFG only)

during operation.
3
2 4
10
o Temperature control system

The warning indicator (10) goes on and an audible warning is sounded when the
permissible coolant temperature is exceeded. The truck will only travel for another 30
seconds, after which the drive is automatically switched to neutral.
03.08.GB
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As soon as the permissible coolant temperature is exceeded, proceed as follows:
- Remove the truck from the hazardous area if necessary

- Lower the fork carriage and load securely
- Switch the drive to neutral and apply the parking brake
- Run the engine at a slightly higher speed (to improve the cooling effect of the fan)
until the temperature drops back to the normal level.
Z If the temperature does not drop, park the truck securely, switch the engine off and
have the truck examined
M Attention: In each case the cause of the overheating must be established and
rectified by a trained and authorised customer service engineer.
Z Note: In acutely hazardous situations, after the 30 second residual travel period,
the truck can be operated again for a further 30 seconds by switching off the ignition
and starting the engine again.
3.10 Stopping the engine1.
M Do not stop the engine from

full charge. Instead, let it run
for a short while to allow the
temperature to compensate.
16
– Stop the truck.
– Set the travel direction 19
switch (28) to neutral.
– Apply the parking
brake (16).
– Turn the ignition / starter 28
switch (19) to the 0
position.
03.08.GB
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4 Industrial Truck Operation
4.1 Safety regulations for truck operation
Travel routes and work areas: Only use lanes and routes specifically designated for
truck traffic. Unauthorised third parties must stay away from work areas. 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 industrial 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. It is forbidden to lean out of 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. Loads which affect visibility must be positioned at
the rear of the truck, or else the truck must reverse. If this is not possible, a second
person must walk in front 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 undertaken in accordance with the technical specifications for the truck in
question. 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.
Persons riding in the lift with the industrial truck must only enter the lift after the truck
has come to a rest and must leave the lift before the truck.
Nature of loads to be carried: The operator must make sure that the load is in a
satisfactory condition. Do not carry loads unless they are positioned safely and
carefully. Use suitable precautions, e.g. a load guard, to prevent parts of the load from
tipping or falling down.
03.08.GB
E 20

Towing trailers: see chapter 4.8, page E35.
F 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.
M 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.
Emergency Disconnect with truck electronic system deactivation: All electrical
functions are switched off.
Set the key switch to the O position. For trucks with a cabin or a canvas top the doors
must be open. Press the pushbutton in the leg area. The engine panel opens, remove
blue quick release lock from the battery pool.
F For gas operated trucks the shutoff valve on the gas tank or gas bottle must be
tightened to prevent the gas from entering the engine area.
03.08.GB
E 21

4.2 Travel
F 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.
– Tilt the mast fully backward:
– Release the parking brake.
Forward travel
– Set the travel direction switch (28) forward.
– Slowly apply the accelerator pedal (22) until you reach the required travel speed.
Changing direction
M Only change direction when 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 have sufficient space to

reverse into.
– Set the travel direction switch (28) to
the rear.
Accelerating
– Slowly apply the accelerator
pedal (22) until the truck starts to
move. 21
– Continue to depress the accelerator.
The engine and travel
speedsincrease.
Slowing down the truck
F The braking pattern of the truck depends

to a large extent on the condition of the
ground. The driver must take this into
consideration when handling the truck. 29 28
Carefully brake the truck to prevent 22
the load from slipping.
03.08.GB
E 22

Braking
- Take your foot off the accelerator pedal (22).
- Depress the brake pedal (21).
Slow travel with the slow travel / brake pedal
Sensitive application of the slow travel / brake pedal (29) allows for excellent shunting
in confined areas and rapid lifting at a slow travel speed.
The slow travel / brake pedal can also actuate the drum brakes but this is only
intended as a crawl speed aid. The pedal should not be used for normal braking
purposes
M This operating mode can only be used for max. 5 seconds when the engine is
running at high speed.
o Speed reduction
Speed reduction restricts the maximum speed to a predefined level. For example,
it could be set to the maximum speed permissible on the company premises. At first,
the full engine speed and performance are available when the truck is in idle and
accelerating. When a certain speed threshold is exceeded the engine speed is
brought back to the required level.
The maximum speed is factory set and can be adjusted by trained and authorised
customer service personnel.
o Reversing Block
The reversing block reduces the stress and hence wear on the powertrain and
the tyres. Two functions are essentially fulfilled:
The travel direction can only be changed (reversing) if the lift truck is travelling at less
than 3 km/h. If the driver attempts to change direction without braking at a faster
speed, the system automatically activates idle speed. The required travel level can
only be applied when the speed is reduced accordingly.
The drive cannot be set from neutral to travel if the engine is more than 300 rpm
above idle speed. Travel is only activated when the speed falls below this limit.
03.08.GB
E 23

4.3 Steering
F Very little steering force is required

for the hydrostatic steering, therefore
turn the steering wheel (17) with
caution.
4.4 Braking
Service brake
29
The brake pedal hydraulically

actuates the drum brakes of the front 21
wheels.
- When the brake pedal (21) is
applied the drum brakes are applied
without disengaging the
transmission.
- Applying the slow travel / brake
pedal (29) controls the flow of power
in the power shift gear. This
pedal can also be used to brake
gently during crawl speed operations.
Parking brake
The parking brake lever mechanically
actuates the drum brakes of the front
wheels.
– Pull back the parking brake lever
(16) beyond the pressure point as
far as the stop.
The parking brake is engaged and
the parking brake lever is locked in
this position.
– To release the parking brake, push
the parking brake lever forward
beyond the pressure point.
03.08.GB
E 24

4.5 Mast and Attachment Operation
F 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
F Never reach through the mast!

– Pull the control lever (26) back to raise
the fork carriage.
– Push the control lever (26) forward to
26
lower the fork carriage.
Tilting the mast forward / backward
F When tilting the mast back, do not

position any part of your body between
25
the mast and the front wall.
– Pull the control lever (25) back to tilt

the mast back.
– Push the control lever (25) forward to
tilt the mast forward.
24
o Operating Attachments 23
Auxiliary hydraulics ZH1
The auxiliary hydraulics ZH 1 (control
lever 24) can be used to control
hydraulic attachments (e.g. sideshift).
They are applied by pressing the lever
forward or pulling it back.

The auxiliary hydraulics ZH2 (e.g. for fork positioners) are operated like ZH1 by
applying the control lever (23).Refer also to the manufacturer’s operating instructions
when operating an attachment.
03.08.GB
E 25

Use button (1) to toggle control lever (23) from ZH2 to ZH3.
To activate ZH3, press button (1) when the

control lever is in the neutral position and
apply the lever. When the button is
depressed, ZH3 is permanently activated. If
the button is released after moving the
control lever out of its neutral position, ZH3
will only remain activated until the control
lever is restored to the neutral position. To
toggle back from ZH2 to ZH3 press the
button again.
03.08.GB
E 26

Operating the integrated sideshift (ISS)
The integrated sideshift allows the fork carriage to be moved to the side.Sideshift left
(as seen by driver):
– Push the control lever (24) forward.
Sideshift right (as seen by driver):

– Pull the control lever (24) back.
Integrated fork positioner
The integrated fork positioner allows the distance between the forks to be set.
Pushing the lever (23) forward opens the forks, pulling the lever back closes them.
If the forks are no longer even, the fork positioner can be re-synchronised. To do this,
open the forks as far as the stop and close them again.
Other Attachments
Always follow the manufacturer’s operating instructions when using other

attachments.
The control levers of the attachments are indicated by symbols to show the function
of the attachment.
M Attention: Only use attachments that have CE approval. The reduced residual
capacity must be re-calculated and indicated by a separate capacity plate.
F Note reduced capacity for extending (see Chapter B).

03.08.GB
E 27

Controlling the speed of the
lifting device
24
Moving the control lever and
changing the engine speed governs 23
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.
M 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

(28) to neutral.
– Increase the engine speed with
the accelerator pedal (22) and 28
– Keep moving the control lever
back to increase the speed of the
lifting device.
Z The engine speed does not affect

the lowering speed of the fork
carriage.
22
03.08.GB
E 28

4.6 Collecting, transporting and depositing loads
F The control levers must only be operated from the driver’s seat.
M Before collecting 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 39
F Adjust the fork tines in such a way that

both are equally distanced from the 41
40
outer edge of the fork carriage and the

load centre of gravity is in the middle of
the fork tines.
– Raise the locking lever (39).

– Push the forks (40) into the correct
position on the fork carriage (41).
– Turn the locking lever down and move
the forks until the locking pin engages
in a slot.
03.08.GB
E 29

Lifting loads
F Do not lift other people with the lifting

device.
– Carefully approach the load to be

lifted.
neutral.
28
– Raise the forks to the correct height for

the load.
– Set the mast vertical.
– Set the travel 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.
– Raise the fork carriage until the load rests freely on the forks.
– Set the travel direction switch to reverse.
– Make sure you have enough space to reverse into.

– Reverse carefully and slowly until the load is outside the storage area.
F Do not allow anyone

underneath a raised load.
to stand
03.08.GB
E 30

– 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

less the operating safety of the truck.
Transporting loads
If the load is stacked up so high that it

affects forward visibility, you must 22
reverse.
29
– Gently accelerate with the accelerator
pedal (22) and slowly brake with the
slow travel / brake pedal (29). Be
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.
F On slopes and inclines always carry the

load facing uphill, never approach at an
angle or turn.
03.08.GB
E 31

Depositing a load
– Drive the truck carefully up to the rack.

neutral.
– Raise the forks to the correct height for
the rack space.
28

forward. Carefully enter the load into
the rack space.
– Slowly lower the load until the forks
are free.
– Set the mast vertical.
M Avoid placing the load down suddenly to

avoid damaging the load and the load
handler.
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.
03.08.GB
E 32

4.7 Parking the truck securely
F 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. 16
– Drive the truck onto a level surface. 28
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 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 forks and tilt the mast forward.

– Apply the parking brake lever (16).
03.08.GB
E 33

Stopping the engine DFG
– Set the ignition / starter switch (19) 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.
– Wait until the engine comes to a stop. 42
– Turn the ignition / starter switch (19)
to “0”.
– Remove the key from the ignition /
starter switch (19).
M If the ignition key is set to “0” while

the engine is running, the engine will
continue to run for a short time. This
ensures that the remaining gas in the
lines between the engine and the
automatic shutoff valve of the gas
system is used up.
o Steel cab
For trucks fitted with a steel cabin, both
doors can be closed. 43
– 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 (43).
03.08.GB
E 34

4.8 Towing trailers
The truck is designed only for occasional towing of trailers within commercial
premises.
The max. tow load is the capacity indicated on the capacity plate (see decals diagram
on page B21).
The tow load consists of the weight of the trailer and the capacity load.
If a load is transported on the forks, the tow load must be reduced by the same
amount.
F Important instructions for safe towing:
– The truck must only be used for occasional towing operations. It must not be
continually operated with trailers.
– No supporting loads permitted!
– The maximum speed is 5 km/h (walking pace)
– Towing must only be performed on level, secure travel routes.
– If using other trailer couplings, observe the regulations of the coupling
manufacturer.
– The owner must test trailer operation with the permissible tow load by means of a
trial run under the applicable operating conditions on site.
03.08.GB
E 35

5 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 – Turn travel direction switch to neutral
not turn not in neutral (see Neutral Interlock in this chapter)
– Battery charge too low – Check battery charge, charge battery if
necessary
– Battery terminal cable – Clean and grease terminals, tighten
loose or terminals battery terminal cable
oxidized.
– Starter cable loose or – Check starter cable, tighten or replace
broken as required
– Starter magnetic switch – Check if the magnetic switch audibly
jammed engages
Engine does – Air filter contaminated – Clean / replace air filter
not start – Bowden cable faulty or – Check Bowden cable
hanging
Additional for LPG
– LPG bottle shutoff valve – Shutoff valve open
closed
– LPG bottle empty – Replace the LPG bottle
– Ignition distributor cap – Ignition distributor cap dry, if
damp necessary apply contact spray
– Spark plugs damp, oily – Dry, clean and tighten spark plugs
or loose
– Spark plugs faulty – Replacing spark plugs
Additional for diesel
– Fuel tank empty, – Fill up with diesel and bleed the
injection system has injection system
suctioned in air
– Water in fuel system – Discharge the fuel system
Add fuel
Discharge fuel system
– Fuel filter contaminated – Check the flow of fuel, if necessary
replace the fuel filter
– Paraffin separation from – Park the truck in a warm room and wait
the diesel (flakes until the separation has returned to its
forming) original state.
If necessary replace the fuel filter
Fill up with winter diesel
03.08.GB
E 36

Fault Probable Cause Action
Engine oil – Engine 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 – Radiator contaminated – Clean radiator
zone – Coolant level too low – Check engine radiator system for
leaks, add coolant if necessary
– Fan V belt slipping – Check V belt tension, tighten or
replace as required
Transmission – Transmission oil level – Check transmission oil level, top up if
oil indicator lit too low necessary
during – Radiator contaminated – Clean radiator
operation
Engine running – Travel direction switch – Set travel direction switch to required
but truck does in neutral direction
not travel – Parking brake applied – Release parking brake
Truck does not – Transmission oil level – Check transmission oil level, top up if
reach max. too low necessary
speed
Lift speed too – Hydraulic reservoir oil – Check hydraulic oil, if necessary top
low level too low up
– Hydraulic reservoir – Clean / replace hydraulic reservoir
discharge system discharge system
contaminated or
blocked
Load cannot be – Hydraulic reservoir oil – Check hydraulic oil, if necessary top
raised to max. level too low up
height.
Steering is – Air pressure in steering – Check tyre air pressure, increase to
sluggish axle tyres too low correct pressure if necessary
Excessive – Air in steering system – Check hydraulic oil level and top up if
steering play necessary, then turn the steering
wheel several times from one end to
the other.
03.08.GB
E 37

Z If the truck cannot be restored to operation despite carrying out the remedies above,
please contact the manufacturer's service department.
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.
In order for Customer Services to react quickly and specifically to the fault, the
following information is essential:
-Truck serial number
-Fault description
-Current location of truck
03.08.GB
E 38

F Industrial 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 servicing checklists.
F Any modifications to the industrial truck assemblies, in particular the safety

mechanisms, is prohibited. The operational speeds of the truck must not be changed
under any circumstances.
M 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.
Upon completion of inspection and servicing, the tasks contained in the
“Recommissioning” section must be performed (see Chapter F).
M In the event of irregularities in the truck’s traction and operating qualities, inform the
manufacturer’s service department immediately.
2 Maintenance safety regulations
Maintenance personnel: Industrial trucks must only be serviced 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 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 jacking up the
truck, 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.
Z For jack points see Chapter B.

Cleaning operations: Do not use flammable liquids to clean the industrial truck. Prior
to cleaning, implement all necessary safety measures to prevent sparking (e.g.
through short circuits). For battery-operated trucks, the battery connector must be
removed. Use only low vacuum air, low compressed air and non-conducting,
antistatic brushes for the cleaning of electric or electronic assemblies.
M 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.
Cleaning by means of a steam jet is not permitted.
After cleaning the truck, carry out the activities detailed in the “Recommissioning”
section.
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Work on the electric 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.
Tyres: The quality of tyres affects the stability and performance of the truck. When
replacing tyres 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 does not slew (e.g. when replacing
wheels always left and right simultaneously).
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, also replace 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 specifications for the disposal
must be heeded. 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 preconditions for 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.
M 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 listed 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 specifies the tasks and intervals after which they
should be carried out. The servicing intervals are defined as follows:
W = Every 50 service hours, at least weekly

B = Every 500 service hours, or at least every six months.
B = Every 1000 service hours, or at least annually.
C = Every 2000 service hours, or at least annually.
Z 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 = t W A B C
Brake 1.1 Check effectiveness of operating and parking brakes, t

adjust where necessary and measure braking distance.
1.2 Check brake lining wear and check brake drum diameter t
1.3 Check brake fluid level in container and top up if t
necessary
1.4 Change brake fluid annually, bleed the system if t
required
1.5 Check connections and lines for leaks t
1.6 Check brake mechanism, adjust and lubricate if t
necessary
Electrics 2.1 Test operation of instruments, displays and control t

switches
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 t
damage
2.5 Test lighting t
2.6 Test micro switch setting t
2.7 Test relay t
Energy 3.1 Battery visual inspection t

supply 3.2 Check battery connections are secure, grease terminals t
if necessary.
3.3 Check acid density, acid level and battery voltage t
Truck Design 4.1 Check mast attachment t

4.2 Check chassis for damage. t
4.3 Check the counterweight is secure. t
4.4 Check the overhead guard / cabin for damage. t
4.5 Check driver’s seat and restraint system t
4.6 Check labels t
4.7 Check trailer coupling / tow mechanism t
4.8 Check the screw connections, in particular the t
connections between the counterweight and the chassis
and between the front axle and the chassis
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Hydraulic 5.1 Check mast bearings t

operation 5.2 Check setting of slide pieces and stops, and adjust if t
necessary
5.3 Visually inspect the mast rollers and check contact t
surface wear level
5.4 Check lateral clearance of mast connections and of fork t
carriage
5.5 Check load chain setting and tighten if necessary t
5.6 Check forks and fork carriage for wear and damage t
5.7 Check mast tilt angle t
5.8 Check position of tilt cylinder, check piston head jam nut t
is secure and tighten if necessary
5.9 Test hydraulic system operation t
5.10 Check that hose and pipe lines and their connections t
are secure, check for leaks and damage, and tighten
connections if necessary.
5.11 Check cylinders and piston rods for damage and leaks, t
and make sure they are secure
5.12 Check hydraulic oil level and top up if necessary t
5.13 Replace hydraulic oil (this may have to be performed via t
a specialist environmental service truck)
5.14 Replace the hydraulic oil filter t
5.15 Replace hydraulic reservoir discharge paper filter t
5.16 Check attachments and auxiliary equipment are secure, t
test operation and check for damage
Sign off/Dem- 6.1 Lubricate truck in accordance with Lubrication t

onstration Schedule.
6.2 Test run t
6.3 Demonstration after servicing t
Steering 7.1 Check function of steering t

system 7.2 Check mechanical parts of steering column t
7.3 Check steering axle and steering knuckle for wear and t
damage
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5 DFG maintenance checklist
Travel 7.1 Check engine for noise and leaks t

7.2 Check engine oil level, top up if necessary t t
7.3 Change engine oil t
7.4 Replace engine oil filter t
7.5 Check valve play, adjust if necessary t
7.6 Test glow plugs, electric t
7.7 Check V belt for tension and damage t
7.8 Check maximum speed (without load), adjust if t
necessary
7.9 Check coolant level, top up if necessary t t
7.10 Add anti-freeze to coolant t
7.11 Test anti-freeze, top up if necessary t
7.12 Test water pump and fan t
7.13 Check radiator and clean if necessary t t
7.14 Test starter and generator 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 discharge if t
necessary
7.20 Check fuel tank and lines for leaks and damage t
7.21 Check the transmission for noise and leakage t
7.22 Check travel mechanism, adjust and lubricate if t
necessary
7.23 Check transmission oil level, top up if necessary t
7.24 Replace transmission oil t
7.25 Clean transmission oil suction filter and discharge t
7.26 Replace transmission oil filter t
7.27 Check drive axle for noise and leakage t
7.28 Check drive axle oil level and top up if necessary t
7.29 Replace drive axle oil t
7.30 Check wheels for wear and damage t
7.31 Check wheel bearings and attachments t
7.32 Check tyre air pressure, adjust if necessary t t
Z For optional DPF: check condensate separator, empty if necessary

(W: weekly check)
Z For optional DPF: air blast the filter (A: 500 h)
Z For optional DPF: check diesel motor emissions in accordance with TRGS 554
(B: 1000 h or annually)
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6 TFG maintenance checklist
Travel 8.1 Check engine for noise and leaks t

8.2 Replace spark plugs t
8.3 Check ignition system and ignition point t
8.4 Check valve play, adjust if necessary t
8.5 Check engine oil level, top up if necessary t t
8.6 Change engine oil t
8.7 Replace engine oil filter t
8.8 Check V belt for tension and damage t
8.9 Check maximum speed (without load), adjust if t
necessary
8.10 Check coolant level, top up if necessary t t
8.11 Add anti-freeze to coolant t
8.12 Test anti-freeze, top up if necessary t
8.13 Test water pump and fan t
8.14 Check radiator and clean if necessary t t
8.15 Test starter and generator t
8.16 Check exhaust 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 damage (to be t
performed by authorised specialist personnel)
8.21 Clean LPG filter (to be performed by authorised t
specialist personnel)
8.22 Check transmission for noise and leakage t
8.23 Check travel mechanism, adjust and lubricate if t
necessary
8.24 Check transmission oil level, top up if necessary t
8.25 Replace transmission oil t
8.26 Clean transmission oil suction filter and discharge t
8.27 Replace transmission oil filter t
8.28 Check drive axle for noise and leakage t
8.29 Check drive axle oil level and top up if necessary t
8.30 Replace drive axle oil t
8.31 Check wheels for wear and damage t
8.32 Check wheel suspension and attachments t
8.33 Check tyre air pressure, adjust if necessary t t
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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

mixture. Use a standard anti-freeze with a pH value of 7.0 – 8.5.
U.S.A. ASTM D4985 or SAE J1941 Ethylene—glycol based engine coolant
– Make sure the mixture ratio is correct when using an anti-freeze. The frost
protection level must satisfy the above standard.
Lowest temperature % volume of anti-freeze Anti-freeze volume ratio

required for protection Water
-37 °C 50 1:1
The manufacturer cannot be held liable for frost or corrosion damage caused by
incorrect procedures.
F 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.
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F8

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.
– 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).
F 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.
8 DFG fuel specifications
Use only DIN EN 590 diesel with a Cetane rating above 50.
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F9

9 Lubrication Schedule
E(cardan shaft)
(steering axle)
g Contact surfaces b Transmission oil filler neck

s Grease nipple a Transmission oil drain plug
Mineral oil filler neck for brake
Hydraulic oil filler neck t
system
c Hydraulic oil drain plug K Oil dipstick
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9.1 Consumables
Handling consumables: Consumables must always be handled correctly. Follow

the manufacturer’s instructions.
F 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.
DFG/TFG 316-320.
Order no. Quantity Description Used for

A 52017728 55 l HVLP46 Hydraulic system
Brake fluid
D 00002832 0.25 l Braking system
SAE J 1703
E 50055726 K-P-2K grease
G 29201280 Chain spray Chains
N 05099205 5.4 l ATF Dexron II D Transmission
Titan Supergear
52030273 4l Axle
80W-90
8l (DFG) TITAN UNIC PLUS
51094056 Engine oil;
4l (TFG) SAE 10W-40
DFG / TFG 425-435
Order no. Quantity Description Used for

A 52017728 55 l HVLP46 Hydraulic system
Brake fluid
D 00002832 0.25 l Braking system
SAE J 1703
E 50055726 K-P-2K grease
G 29201280 Chain spray Chains
N 05099205 5.5 l ATF Dexron II D Transmission
Titan Supergaer
52030273 5l Axle
80W-90
8l (DFG) TITAN UNIC PLUS Engine oil;
51094056
4l (TFG) SAE 10W-40
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F 11

Z Bio oils
Bio-degradeable hydraulic oils may only be used after consultation with the relevant
JH service department.
Grease data
Code Saponification Dew point Worked NLG1 class Applicationtemp

°C penetration at erature °C
25 °C
E Lithium 185 265-295 2 -35/+120
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10 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).
– Pull the key out of the ignition/starter
switch (1) to prevent the truck from
being switched on accidentally.
– When working 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

industrial truck:
M Only use lifting gear with sufficient capacity (for transport weight see truck data plate).
– Park the truck securely (see Chapter E).
– Attach crane slings to the mast at the appropriate points.
– Attach the crane slings to the counterweight of the trailer coupling.
M 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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10.2 Engine panel
Z Before opening the motor panel the

steering column and the steering column
adjustment lever (18) must be pushed 54
18
forward fully.
Push the driver’s seat forward.
The stop bolt on the left hand seat guide
rail should engage facing up.
– Press the pushbutton in the leg

compartment and raise the engine
cover (54) slightly.
– Fully raise the engine cover (54).
A gas pressure damper keeps the
engine cover in the raised position.
M If a forklift truck is equipped with a steel cabin, both cabin doors and the rear window
must be opened before raising the engine cover.
When you close the engine cover, pull the stop bolt down and push the driver’s seat
back again.
M Make sure the engine cover has engaged correctly before operating the truck again.
10.3 Starting aid
M Only use an ISO 6722 battery

jump lead with fully insulated
terminal pliers and a lead
diameter of at least 25 mm2.
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
– To start the lift truck with the
engine panel open, press the
switch on the battery retainer
and then start the engine with
the ignition key
– When the engine has started
first remove the negative
lead-then remove the positive
lead
Z 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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10.4 Servicing the engine DFG
Checking the engine oil - DFG

– Remove the dipstick (8). 8
– Wipe the dipstick with a lint-free cloth
and put in back fully into its port. 2
– 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 and add the
correct grade of oil to the engine until
the oil level has reached the MAX
mark on the dipstick.
31
32
4 3
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Replacing the engine oil and engine oil filter
M 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 (2) lid.

– Thoroughly clean the oil drain plug (4)
and around the drain hole. 2
– Unscrew the oil drain plug and drain
the oil into a suitable container.
F Risk of scalding through hot oil.

– Screw in the oil drain plug 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)- 4 3
– Pull off the hose.
– Undo the air filter attachment (11) and
place the air filter to one side.
– Undo the oil filter (3) with a filter
wrench and manually unscrew it.
F Collect any emerging oil and dispose of

the oil and oil filter in accordance with
– 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.
– Fit the air filter, insert the hoses and
tighten with hose clamps.
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Adding engine oil
– Add fresh engine oil through the filler

port (2) in accordance with the
consumables table.
Capacity: 8,0 l
Check the engine oil level with the

dipstick (1) and adjust as necessary.
Screw the lid backon.
– Fully insert the dipstick (1).
M After changing the oil and the oil filter,

note the engine oil pressure indicator (9) 9
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 belt pulley
using a force of 45 N.
It should be possible to insert the V belt
after approx. 10 mm.
Adjusting the V belt tension
10
– Undo the screws (10) and pull the AC
generator until you reach the
prescribed V belt tension. Re-tighten
the screws.
– Check the V belt tension again and
repeat the adjustment if necessary.
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F 17

Replacing the fuel filter
Drain the fuel from the filter into a

suitable container.
11
Undo the fuel filter (13) with a filter
F Dispose of the fuel filter and fuel in

accordance with environmental
12
regulations. 13

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

regulations.
– Open the discharge screw (12).
– Apply the manual pump lever (11) on the fuel pump until fuel escapes from the
discharge screw without bubbles.
– Tighten the bleed screw (12).
– Apply the starter motor via the key switch for approx. 10 secs.
– Wait for 10 seconds.
– Repeat the process until the engine starts up.
M While running the engine check the fuel filter, the discharge valve and the union nuts
of the injection nozzles for leaks.
Z If the engine does not start up or stops after a short time, repeat the bleeding
procedure.
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10.5 Engine servicing TFG
Checking the engine oil - TFG

– Remove the oil dipstick (32).
– 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, 31
remove the fuel cap (31) and add the
32
correct grade of oil to the engine until
the oil level 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 replace
the engine oil and engine oil filter
together.
Draining the engine oil
– Unscrew the (18) lid. 18

– Thoroughly clean the oil drain plug 19
(21) and around the drain hole.
– Unscrew the oil drain plug and drain 20
the oil into a suitable container.
F Risk of scalding through hot oil.

21
– Screw in the oil drain plug with a new
seal.
F Dispose of used oil in accordance with environmental regulations.

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F 19

Replacing the engine oil filter
– Undo the oil filter (20) with a filter

F Collect any emerging oil and dispose of

the oil and oil filter in accordance with

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.
Adding engine oil

– Add fresh engine oil through the filler port in accordance with the consumables
table (see Section 9.1).
Capacity: 4,0 l
– Check the engine oil level with the
dipstick (19) and adjust as necessary.. 18
– Screw the lid back on.
– Insert the dipstick back fully.
M 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.
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F 20

Replacing spark plugs
– Remove spark plug connector (19) .

– 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.
19
Rated value: 1.0 mm
M 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 and the generator V belt pulley 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 (20) and pull the AC
generator until you reach the
prescribed V belt tension.
– Re-tighten the screws.
Check the V belt tension again and 20
repeat the adjustment if necessary.
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F 21

10.6 Checking the hydraulic oil level
If the oil is cold
– Fully raise and lower the mast in one

operation.
– Stop the engine.
– Remove the dipstick (35) and clean 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.
35
If the oil is hot
– Fully raise and lower the mast in one
operation.
– Stop the engine.
– Remove the dipstick (35) and clean 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 cuts out or does not run smoothly when the mast is raise, the mast must
be gently lowered before continuing with this procedure.
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F 22

10.7 Gas 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!
Drain closed
Drain open
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F 23

10.8 Checking the coolant level
– Open the cover lock and turn it to the right

– Remove the panel
– Check the coolant level on the
reservoir.
The coolant should lie between the
MIN and MAXmarkings (36).
M If the coolant is below the MIN

marking, this indicates possible
37
leakage in the radiator system. The

truck must only be used once the
cause has been removed.
F If the engine is hot, the radiator

system is pressurised. Only open
the expansion vessel (37) lid when
36
the engine has cooled down.
When topping up, add a premixed water and antifreeze solution in equal quantities
into the existing solution.
It should be possible to empty 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 driver's seat as an indicator
that the engine does not contain any coolant.
For details on recommended concentrations and safety measures, refer to Chapter F.
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F 24

10.9 Checking the coolant concentration
F 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. 21
– If there is insufficient anti-freeze, drain the coolant and add anti-freeze to the
reservoir (21) until you obtain the correct proportion in the mixture. Use anti-freeze
in accordance with the coolant specifications (see section 7).
M 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
10.10 Filling the cooling circuit
F 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.
M 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.
M 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. Start the engine. Switch off the engine
when it reaches operating temperature and then let it cool down. Slowly open the
reservoir lid and if necessary add coolant in accordance with the manual instructions
until you obtain the correct level. Refit the lid.
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10.11 Cleaning/replacing the air filter cartridge
M Carry out all maintenance work with the

engine switched off. Do not start the
engine if the air filter cartridge is 29
removed.
– Undo the quick release lock (29) and
lift it up.
– Raise the air filter housing.
– Undo the 2 mounting clamps (30) and
remove the dust collector pot. 30
– Carefully remove the internal and
external air filter cartridges from the
filter housing.
– Apply dry compressed air from the
inside of 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 clean cloth.
– Replace any damaged or heavily contaminated air filter cartridges.
– Thoroughly clean the dust collector pot, to do this remove the rubber element.
– Insert the air filter cartridges back in the filter housing and secure them.
M Take care not to damage the air filter cartridges when assembling.
– Insert the dust collector pot and secure it with the 2 mounting clamps (30).
– Fit the air filter housing in the assembly position.
– Close the quick release lock (29).
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F 26

10.12 DFG/TFG transmission:
M 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
23 24
Z Only use clean, fresh oil from clean
containers to fill or top up the
transmission. Damage will arise from
contamination or water entering the
transmission.
You access the transmission 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 wait until the
transmission has reached operating temperature.
– When the engine is running in idle, remove the dipstick (24).
– 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 level is below the centre point, add the right grade of transmission oil through
the filler port (23) into the transmission unit, until it reaches the MAX marking on the
dipstick.
– Refit the dipstick in the port.
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F 27

10.13 Brake
Checking the parking brake
The parking brake (25) must be able to

keep the truck plus maximum
permissible load on an incline of 15 %. If
this is not the case, the parking brake 25
must be adjusted.
Checking the brake fluid level 26
– Undo the screws of the left-hand panel 27

(26).
– Remove the left-handpanel (26).
– Check the brake fluid level in the brake
fluid reservoir (27).
The brake fluid level should lie between

the MIN and MAX markings .
– If necessary, add brake fluid.
Level: 0.25 l
– After adding brake fluid, refit the
panel.
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F 28

10.14 Checking the wheel attachments.
– Parking the truck securely

(see Chapter E).
– Tighten the wheel nuts (36) crosswise with a
torque wrench.
Torque
36
Typ VFG 316-320 VFG 425-435

Drive wheels 200 NM 380 NM
Rear wheels 200 NM 200 NM
10.15 Hydraulic system
Replacing the hydraulic oil filter

– Unscrew the lid (31).
– Remove the hydraulic 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 with environmental
regulations. 31
30
10.16 Clean/replace hydraulic reservoir discharge system
– Unscrew the hydraulic reservoir lid (31).

– Lift up the cap (30).
– Remove the filter insert form under the cap.
– Clean the filter insert.
M If the contamination cannot be removed by cleaning, replace the filter insert.

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F 29

10.17 Electrical Equipment
Checking the battery condition, the acid level and acid density
F 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. If the eyes have been affected,
immediately seek medical attention. Neutralise spilled battery acid immediately.
– Check the battery 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 between the top and bottom markings.
– Clean the area around the inspection plugs.
– Unscrew the inspectionplugs.
– If necessary, add distilled water to the top mark.
– Check the acid density.
If the battery is charged sufficiently, the acid density should be 1.24 to 1.28 kg/l.
– If necessary, re-charge the battery.
– Screw the inspection plugs back on.
Z It is not necessary to check the acid level or the acid density in batteries with low
maintenance requirements.
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F 30

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
– Check the fuse rating and condition in accordance with the table; replace if
necessary.
– Fit the panels.
59 58
57
56
55
54
53
52
60 51
t Standard fuse box (DFG)

Item Ref. To protect: Rating
39 2F14 Pre-heat relay, diesel valve 5A
40 4F1 Air filter control, travel direction valves, seat switch, horn 10 A
41 7F5 Diesel filter control, brake fluid control, handbrake control 5A
42 4F8 Display unit 5A
43 F19 12 volt system 10 A
44 9F7 Ignition on options relay 10 A
t Standard fuse box (TFG)

39 2F14 Gas valve, ignition distributor 5A
40 4F1 Air filter control, travel direction valves, seat switch, horn 10 A
41 7F5 Brake fluid control, handbrake control 5A
42 4F8 Display unit 5A
43 F19 12 volt system 10 A
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F 31

DFG main current
Item Ref. Rati

To protect:
ng
55 9F11 Preheat fuse 70 A
56 9F8 Engine running option relay 50 A
58 9F16 Key switch 20 A
59 9F17 Pre-fuse for F19 20 A
50A generator 50 A
60 9F19 80A generator 70 A
120A generator 120A
TFG main current
Item Ref. Rati

To protect:
ng
51 9F8 Engine running option relay 50 A
53 9F16 Key switch 20 A
54 9F17 Pre-fuse for F19 20 A
50A generator 50 A
60 9F19
80A generator 70 A
o Fuse box for optional equipment (DFG/TFG)

Item Ref. Ratin
To protect:
g
45 4F4 Beacon 7.5 A
46 9F1 Windscreen wiper 7.5 A
47 5F6 Cab 15 A
48 5F1 Searchlights 25 A
49 5F3 Reverse lights 15 A
50 5F5.2 Road traffic parking light 15 A
F To avoid damaging the electrical system, only use fuses with the correct ratings. 0908.GB
F 32

o Road traffic system fuse box
62 4F5 Warning indicator system control fuse 10 A
63 4F6 Brake light control fuse 10 A
64 5F4 Tail light control fuse 5A
65 5F4.1 Tail light control fuse 5A
66 5F5 Lighting control fuse 7.5 A
67 5F5.1 Left lights control fuse 7.5 A
o DFG options fuse box

68 F14 Heating fuse 15 A
69 9F2 Seat heating control fuse 10 A
70 9F12 Catalyser fuse 7.5 A
71 9F13 Catalyser control fuse 5A
o TFG options fuse box

68 F14 Heating fuse 15 A
69 9F2 Seat heating control fuse 10 A
70 9F21 Speed signal generator fuse 5A
71 6F7 Soot filter electronics control fuse 5A
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F 33

11 Exhaust system
The exhaust system must be checked for emissions at regular intervals. Black or blue
exhaust smoke is an indicator of high emission levels. Seek assistance from
specialist personnel.
The soot filter must be serviced in accordance with manufacturer’s instructions
(starting F37).
12 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.
– Test horn.
– Test main switch operation.
– Test brakes.
– Lubricate the truck in accordance with the lubrication chart.
13 Decommissioning the industrial truck
If the industrial truck is to be decommissioned for more than two months, e.g. for
operational reasons, it must be parked in a frost-free 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 ground. This is the only way of ensuring that the wheels and wheel bearings are
not damaged.
If the truck is to be out of service for more than 6 months, further measures must be
taken in consultation with the manufacturer’s service department.
13.1 Prior to decommissioning:
– Thoroughly clean the truck.

– Check the brakes.
– Check the hydraulic oil level and replenish as necessary (see Chapter F).
– Apply a thin layer of oil or grease to any non-painted mechanical components.
– Lubricate the truck in accordance with the lubrication schedule (see Chapter F).
– Charge the battery.
– Disconnect the battery, clean it and apply grease to the battery poles.
Z In addition, follow the battery manufacturer’s instructions.

– Spay all exposed electrical contacts with a suitable contact spray.
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F 34

13.2 During decommissioning:
Every 2 months:
13.3 Returning the truck to operation after decommissioning
Z It is advisable to have the truck restored to service after decommissioning by an

engineer of the manufacturer.
– 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.
– Check transmission oil for condensed water and replace if necessary.
– Check hydraulic oil for condensed water and replace if necessary.
– Start up the truck (see Chapter E).
F Perform several brake tests immediately after re-commissioning the truck.

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14 Safety checks to be performed at regular intervals and following any unusual
incidents
Z 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.
The truck must be inspected at least annually (refer to national regulations) 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. The inspector shall be sufficiently instructed and experienced to be
able to assess the condition of the truck and the effectiveness of the safety
mechanisms based on the technical regulations and principles governing the
inspection of forklift trucks.
A thorough test of the truck 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 results must be kept
for at least the next 2 inspections.
The owner is responsible for ensuring that faults are immediately rectified.
Z A test plate is attached to the truck as proof that it has passed the safety inspection.
This plate indicates the due date for the next inspection.
15 Final de-commissioning, disposal
Z Final, proper decommissioning or disposal of the truck must be performed in

accordance with the regulations of the country of application. In particular, regulations
governing the disposal of batteries, fuels and electronic and electrical systems must
be observed.
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F 36

o Optional
16 HUSS FS - MK Series Diesel Particle Filter Operating Instructions
16.1 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. Therefore use only DIN EN 590 diesel with a
Cetane rating above 50.
Z The HUSS diesel particle filter complies with TRGS 554, TA Air and VERT
(Switzerland).
Application range of TRGS 554 (Technical Regulations for Hazardous Materials), TA
Air and VERT:
– These Technical Regulations apply to work environments where diesel engine

emissions may be contained in the air in the workplace.
– In Switzerland, VERT specifies in particular the requirements for tunnel building
projects and major construction sites.
16.2 Important safety instructions
M Attention:
The safe and proper use of the diesel particle filter requires careful operation and
maintenance.
M Operation and regeneration:

The diesel particle filter may only be operated and regenerated by persons who have
been trained in filter regeneration and are aware of the potential hazards. Only trained
and authorized personnel may work on the diesel particle filter. Remove the diesel
particle filter from service immediately if it is clearly damaged or not working properly.
Avoid any build up of flammable materials near the filter.
M Risk of burning
During regeneration the entire diesel particle filter system heats up and hot exhaust
emerges from the exhaust pipe.
M 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.
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F 37

16.3 Functional description
As the engine runs the diesel engine exhaust flows through the filter element which
retains virtually all the harmful soot particles.
The longer the diesel engine runs, the more the diesel particle filter fills up and the
greater the backpressure on the exhaust.
The level of the diesel particle filter is shown on the HUSS Control display, enabling
regeneration to be made at the right time.
When a defined maximum backpressure or maximum charge time is reached, the
HUSS Control activates the “Filter Full” alarm.
To burn off the soot particles in the filter element, the HUSS Control system starts
regeneration when the engine is switched off.
A starter interlock and engine forced cutout are incorporated in the control system to
protect the engine and diesel particle filter.
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F 38

16.4 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.
Important!
The HUSS control system only workswith the igitionis

switched on.
Display screen
The top line shows the functional stages; in the bottom line a bar indicates the
condition of the filter (backpressure / regeneration time)
Keys
Control (control key ) Mode (mode key ) Function (function key)

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F 39

16.5 HUSS Control Operating Instructions
Normal operation Display Function LED

Switch on the ignition. The Self test Green and
buzzer sounds for min. 1 red LEDs lit
second and both LEDs light up
at the same time.
If a message is stored it will be e.g. alarm / filter Red LED
displayed, in conjunction with full flashing
the flashing red LED. HHHHHHHHHHH
Stored message: Before the
last cutout the exhaust
backpressure exceeded the
upper limit for at least 20
seconds or regeneration was
interrupted. The buzzer sounds
continuously
Note to this message: The lift

truck cannot be started,
M Attention:
regeneration must be in a hazardous

performed. situation the lift
truck can be
started by
continually
pressing on the
“M” and “F”
buttons.
If no message is stored the Engine ready
engine can be started.
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F 40

Messages in normal mode that indicate the status of the diesel
particle filter:
with this message>>> Filter condition Green LED

Normal mode possible HHHHHHHH Flashes
with this message>>> Regenerate Red LED flashing
Regeneration required HHHHHHHH
10 regenerations had to be Call service department /
made within the maximum White ash
charge time, call the JH service
department
Diesel particle filter Maintenance
maintenance required, the JH
service department must be
called.
16.6 Regeneration
Z Regenerate daily even if the filter is not full
M Risk of fire and explosion

Pay attention when handling fuel Avoid naked flames when handling fuel. Do not
smoke. This applies even in areas where the fuel can only be smelled.
M Risk of fire and poisoning

High temperatures and exhaust with poisonous content result every time combustion
takes place.
The entire exhaust system becomes very hot during and immediately after operation.
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F 41

Regeneration Display ---------------Function LED
Park the truck on a level surface

Switch off the engine.
Ignition ON: HUSS Control is energised. Start regeneration in 5 seconds
>>>>>>>>Green LED
Press the “M” button and hold it down for
5 seconds. Regeneration starts after 5
seconds.
Other displays after the 5 seconds Pre-cooling glow plug

The fan is set to pre-cooling.
The glow plug is switched on. Regeneration

Start glow plug
The fuel-air mixture is ignited. Regeneration start ignition
The diesel particle filter is regenerated.

The display shows the remaining Regeneration on
regeneration time.
Regeneration is complete. Regeneration completed

This display appears for 3 minutes.
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F 42

Regeneration Display ---------------Function LED
Regeneration can be interrupted by

switching off the ignition with the ignition
key or by pressing the “F” button on the “Filter full” alarm >>
control system. The display counts down red LED flashes
from 5 seconds until the regeneration
process is switched off. The buzzer
sounds continuously.
M Important
If you press the “M” and “F”

buttons simultaneously the engine
can also be started in hazardous
situations even when “Alarm/Filter
full”.
M Faults
All the hardware and software
functions are tested during Glow plug fault
regeneration.
Fuel pump fault
Any faults will cause the Solenoid fault
regeneration to be cancelled. Fan fault
Faults are displayed on the HUSS Temperature gauge fault
control. The battery voltage is also Regeneration fault
checked. If the minimum level is
Regeneration interrupted
not reached, regeneration is
cancelled. If one of the faults Low voltage
indicated here is displayed, call
the JH service department to
rectify the fault
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F 43

16.7 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
engineers are authorised to make changes to these settings.
0908.GB
F 44

DFG 320

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DFG/TFG 316/320/425/430/435 08.

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Safety instructions and important explanations are indicated by the following

F Used before safety instructions which must be observed to avoid danger to

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

Z Used before notices and explanations.

t Used to indicate standard equipment.

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

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C Transport and Commissioning

1 Lifting by crane .................................................................................... C 1

D Fuelling the Truck

1 Safety regulations for handling fuel ..................................................... D 1

1 Safety regulations for the operation of industrial trucks ...................... E 1

3.7 Starting procedure for the TFG ........................................................... E 15

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F Industrial Truck Maintenance

1 Operational safety and environmental protection ................................ F 1

13 Decommissioning the industrial truck .................................................. F 34

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Model max. capacity *) Load centre of gravity

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Item Description Item Description

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Chassis/superstructure: A rigid chassis which protects the units and controls,

Steering: The hydrostatic steering consists of a steer cylinder integrated in the

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Z Technical specification details in accordance with VDI 2198. Technical modifications

3.1 Performance data DFG 316-320

Model DFG 316 DFG 320

TFG 316-320 Performance Data

Model TFG 316 TFG 320

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Model DFG 425 DFG 430 DFG 435

Model TFG 425 TFG 430 TFG 435

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Model DFG 316 DFG 320

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Model DFG 425 DFG 430 DFG 435

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Model TFG 316 TFG 320

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Engine - DFG316 - 320

Model S4Q2 four cylinder

DFG 425-435 Engine

Model S4S four cylinder

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Model 2.1 L L4 four cylinder, four stroke, LPG

TFG 425-435 Engine

Model 2.5 L L4 four cylinder, four stroke, LPG

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Full rubber SE tyres

Tyre pressure DFG / TFG 316 DFG / TFG 320

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(all dimensions in mm)