Jungheinrich DFG TFG 316-435 Forklift Operating Instructions Manual 51167624 – PDF

Description

Jungheinrich DFG/TFG 316-435 Operating Instructions Manual — Document 51167624

This is the complete original operating instructions manual for the Jungheinrich DFG 316-435 and TFG 316-435 series four-wheel IC motor sit-down forklift trucks. Published under document number 51167624, edition 08.11, it covers both the diesel-powered DFG range and the LPG/petrol-powered TFG range, giving operators, fleet managers, and service technicians a single authoritative reference for safe operation, daily checks, maintenance planning, and fault diagnosis across all ten model variants.

File Details

• Manual Type: Original Operating Instructions
• Brand: Jungheinrich
• Models Covered: DFG 316, DFG 320, DFG 425, DFG 430, DFG 435, TFG 316, TFG 320, TFG 425, TFG 430, TFG 435
• Document Number: 51167624
• Edition: 08.11
• Language: English
• Page Count: 186
• File Format: PDF
• Manufacturer: Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg

Chapters Covered

• A — Introduction: General, Correct Application, Approved Application Conditions, Proprietor Responsibilities, Adding Attachments and/or Accessories
• B — Truck Description: Application, Assemblies and Functional Description, Technical Specifications, Identification Points and Data Plates, Stability
• C — Transport and Commissioning: Transport, Truck Laden, Securing the Truck During Transport, Using the Truck for the First Time
• D — Fuel and LPG Systems: Safety Regulations for Diesel Fuel and LPG, LPG System Relief Valve, Adding Diesel, LPG Containers, Fuel Level Indicator
• E — Operation: Safety Regulations, Displays and Controls, Preparing the Truck for Operation, Industrial Truck Operation, Towing Trailers, Optional Equipment, Troubleshooting
• F — Industrial Truck Maintenance: Operational Safety and Environmental Protection, Maintenance Safety Regulations, Servicing and Inspection, Maintenance Checklists, Lubricants and Lubrication Schedule, Maintenance and Repairs, Decommissioning, Safety Tests, Final De-commissioning and Disposal, Human Vibration Measurement

Chapter A — Introduction, Safety, and Application Rules

Opens with the manual’s full safety notice system — DANGER, WARNING, CAUTION, and NOTE callouts — then sets out the correct application scope for the DFG and TFG trucks: lifting and lowering loads, transporting lowered loads, no travelling with raised loads above 30 cm, no passengers, and trailer towing limitations. Approved application conditions include a permissible temperature range of -20 to 40°C, operation only on secure level surfaces with sufficient capacity, and negotiation of inclines up to a maximum of 15%. Proprietor responsibilities, warranty conditions, and the rules for adding attachments or accessories are also covered.

Chapter B — Truck Description and Technical Data

Explains the DFG/TFG 316-435 as a cantilever counterbalanced four-wheel IC motor sit-down forklift, with the DFG series using diesel engines and the TFG series using petrol engines for LPG operation. Includes an illustrated assembly overview identifying the overhead guard, driver’s seat, steering wheel, control/display unit, mast, fork carriage, forks, drive axle, lift mechanism control, engine cover, steer axle, trailer coupling, counterweight, and LPG bottle. Full technical specifications cover performance data (travel speed, lift speed, lowering speed, gradeability, acceleration, working pressure, and oil flow for attachments), dimensions, weights, mast versions, tyre types and pressures, engine data, EN norms, conditions of use, and electrical requirements. Data plates, truck capacity plate, attachment capacity plate, and stability factors are all documented.

Chapter C — Transport and Commissioning

Covers the two approved transport methods (vertically with mast assembled or with mast dismantled for large heights), truck centre of gravity, lifting the truck by crane using the designated strap points, loading with another industrial truck, and securing the truck during transport with tensioning belts and retaining wedges. First-time commissioning after delivery or transport includes checks of the equipment, engine oil, hydraulic oil, transmission oil, brake fluid, battery connections, and battery acid level.

Chapter D — Fuel and LPG Systems

Safety regulations for handling diesel fuel and LPG, including ignition risks, frostbite from liquid gas, storage and transport requirements, and personnel authorisation. Documents the LPG system relief valve with its plastic cover indicator, diesel fuelling procedures for both tank system and fuel container methods, LPG bottle replacement (including the twin bottle system with changeover valve), refillable liquid gas tanks with dispensing valve and filling stop valve, and fuel level indicators for both DFG and TFG trucks.

Chapter E — Operation

The largest operating chapter covers driver authorisation, rights and responsibilities, hazardous area definitions, and safety devices. Displays and controls are documented with the complete control panel layout for both DFG and TFG, including all warning indicators: transmission oil temperature, engine oil pressure, soot filter, brake fluid, parking brake, diesel filter, charge current, air filter, neutral, pre-heat, direction indicator, time/service hours, and coolant temperature. Covers daily pre-operation checks, entry and exit, reduced headroom trucks, operator position setup (seat weight adjustment, backrest, lumbar support, steering column, armrest), seat belt use, starting procedures for both DFG and TFG, travel, steering, brakes (service, parking, emergency disconnect), fork adjustment and replacement, lifting/transporting/depositing loads, operating the lift mechanism and integrated attachments via SOLO-PILOT, towing trailers, and the full range of optional equipment including steel cab, sliding windows, panel door, heating and air conditioning, camera system, and more. Troubleshooting tables and procedures for operating the truck without its own drive system (towing, emergency lowering, starting aid) complete the chapter.

Chapter F — Industrial Truck Maintenance

Opens with operational safety and environmental protection, then detailed maintenance safety regulations covering lifting and jacking, cleaning, electrical system work, consumables, welding, tyre types, lift chains, and hydraulic hoses. Servicing and inspection intervals are defined as W (every 50 service hours, at least weekly), A (every 500 service hours), B (every 1000 service hours, or at least annually), and C (every 2000 service hours, or at least annually). Separate maintenance checklists are provided for the DFG and TFG series, split between owner responsibilities and customer service tasks, covering brakes, electrical system, power supply, travel, hydraulics, steering, and all optional equipment. The lubricants and lubrication schedule section includes consumables tables with order numbers, package quantities, and capacities for hydraulic oil, brake fluid, grease, chain spray, transmission fluid, axle oil, engine oil, and coolant. Maintenance and repair procedures cover preparing the truck, opening the rear panel, unlocking the engine bonnet, checking wheel attachments, hydraulic system (oil level, filter, ventilation filter), engine maintenance for both DFG and TFG (oil level, oil drain, oil filter, fuel filter, bleeding, V-belts, spark plugs, cooling system, air filter), electrical fuses with full fuse rating tables, starter battery, exhaust system, seat belt, transmission, brake, and restoring the truck to service. Decommissioning, safety tests, final disposal, and human vibration measurement close the manual.

What This Manual Enables You to Do

Whether you are running a DFG 316 on a loading dock, maintaining a fleet of TFG 430 trucks in a warehouse, or diagnosing a fault on a DFG 435, this manual gives you the exact procedures and specifications the truck was built around. You get the complete daily inspection routine to catch problems before they become breakdowns, the correct starting procedure for both diesel and LPG engines, the safe way to change an LPG bottle or refill a liquid gas tank, the proper method for lifting and transporting loads, and the maintenance intervals that keep the truck running at peak performance.

For technicians, the maintenance checklists alone are worth the download — they lay out every W, A, B, and C interval task for both DFG and TFG models, from brake lining checks and hydraulic oil filter replacement to V-belt tension adjustment and spark plug torque. The fuse rating tables, hydraulic oil capacities, tyre pressures, torque values, and engine data give you the numbers you need without hunting through scattered sources. The troubleshooting section helps you identify and rectify basic faults, and the emergency lowering procedure tells you what to do if the hydraulic system fails.

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Instant PDF Delivery — No Shipping, No Waiting

This Jungheinrich DFG TFG 316-435 operating instructions manual is delivered as an instant PDF download. No physical book to ship, no waiting for the post. After payment you can open it on any device — laptop, tablet, or smartphone — and print whichever pages you need for the workshop or the driver’s cab. The 186-page document is organised with clear chapter lettering and continuous page numbering, so you can navigate straight to the section you need. Keep it on your service laptop for quick reference, print the maintenance checklist for the workshop wall, or share the relevant operating procedures with your drivers. One download gives you the complete factory operating instructions for all ten DFG and TFG 316-435 model variants.