This manual covers the Jungheinrich DFG/TFG K Series forklifts, produced between May 1997 and July 2004. These robust industrial material handling vehicles are available in Diesel (DFG) and LPG (TFG) variants, with lift capacities ranging from 1.6 to 5.0 tons, designated by model codes such as DFG 16K through DFG 50K and TFG 16K through TFG 50K. Jungheinrich is recognized for its quality and innovation in material handling equipment, and the K series represents a significant generation of reliable diesel and LPG forklift trucks designed for demanding operational environments.
This comprehensive Workshop Service Repair Manual, presented in English, provides extensive coverage for the operation, maintenance, and repair of the Jungheinrich DFG/TFG K Series forklifts. It includes detailed procedures for all major systems, including the powertrain (engine, transmission, drive system), chassis (brakes, steering, masts, hydraulics), and electrical systems, along with specific information on the Diesel Particle Filter (DPF) system. The manual is designed to assist owners, mechanics, and technicians in performing routine maintenance, complex repairs, and accurate troubleshooting, thereby ensuring efficient operation and minimizing downtime.
Original Illustrated Factory Workshop Service Manual for Jungheinrich Fork Truck Type DFG/TFG.
Original factory manuals for Jungheinrich Forklift Trucks, contains high quality images, circuit diagrams and instructions to help you to operate and repair your truck. All Manuals Printable and contains Searchable Text
Covered models:
DFG 16K (05.1997-07.2004)
DFG 20K (05.1997-07.2004)
DFG 25K (05.1997-07.2004)
DFG 30K (05.1997-07.2004)
DFG 40K (05.1997-07.2004)
DFG 45K (05.1997-07.2004)
DFG 50K (05.1997-07.2004)
TFG 16K (05.1997-07.2004)
TFG 20K (05.1997-07.2004)
TFG 25K (05.1997-07.2004)
TFG 30K (05.1997-07.2004)
TFG 40K (05.1997-07.2004)
TFG 45K (05.1997-07.2004)
TFG 50K (05.1997-07.2004)
Language: English
Format: ZIP, Contained set of PDF Manuals
Service Manual, PDF, 753 Pages
Contents:
Technical Description of Components
General Truck Data. Operational Tests / Test and Setting Values
Truck Maintenance
Drive System V. Combustion Engines
Drive System V. Power Shift Transmission / Hydrostatic Drive
System
Brake System
Steering
Masts
Hydraulic System and Diagrams
Electric System and Wiring Diagrams
Diesel Particle Filter (HUSS)
Operating Manual, PDF, 142 Pages
Contents:
A Correct Use and Application of the Truck
B Description of Truck
1 Description of Use
2 Description of Assemblies and Function
2.1 Truck
2.2 Mast
2.3 Changes in operational requirements
2.4 Safety devices
3 Technical Data -- Standard Equipment
3.1 Data tables -- DFG/TFG 16/20 AK
3.2 Data tables -- DFG/TFG 20--30 BK
3.3 Data tables -- DFG/TFG 40--50 CK
4 Labels and Plates
4.1 Truck Rating Plate
4.2 Load diagrams
C Transportation and Commissioning
1 Transportation
2 Commissioning
D Truck Refuelling
1 Safety Conditions for Handling Diesel Fuel and Liquid Petroleum Gas
2 Filling with Diesel Fuel
3 Changing the Gas Bottle
E Operation
1 Safety Regulations Governing the Operation of the Forklift Truck
2 Description of Drivers Controls and Display Elements
3 Checks and Activities Before Daily Use
4 Using the Truck
4.1 Start Process TFG
4.2 Start Process DFG
4.3 Fault Displays during Operation
5 Operation of the Forklift Truck
5.1 Safety regulations applicable when operating the truck
5.2 Driving
5.3 Steering
5.4 Braking
5.5 Operating the Mast and Attachments
5.6 Picking Up, Transporting and Setting Down Load Units
5.7 Instructions for the use of restraint belts
5.8 Parking the Truck Safely
5.9 Engine housing and service covers
5.10 Towing
5.11 Towing Trailers
5.12 Trailer loads
6 Fault Locating Operations
F Truck Maintenance
1 Operational Safety and Environmental Protection
2 Safety Regulations Applicable to Truck Maintenance
3 Servicing and Inspection
4 Maintenance Check-list DFG/TFG
5 Maintenance Check-list DFG
6 Maintenance Check-list TFG
7 Coolant Specification
8 Lubricant Specifications
9 Fuel specification -- DFG
10 Lubrication Chart
10.1 Lubrication Diagram -- DFG/TFG 16--50 AS/BS/CS
11 Description of Maintenance and Repair Work
11.1 Preparing the Truck for Maintenance and Repair Work
11.2 Engine Maintenance TFG 16/20 AS
11.3 Engine Maintenance DFG 16/20 AS
11.4 Engine Maintenance TFG 20--30 BS
11.5 Engine Maintenance DFG 20--30 BS
11.6 Engine Maintenance TFG 40--50 CS
11.7 Engine Maintenance DFG 40--50 CS
11.8 Check Coolant Concentration
11.9 Clean/Change Air Filter Cartridge
11.10 Brakes
11.11 Change Wheels
11.12 Hydraulic System
11.13 Electrical System
11.14 Switch Gear and Control Potentiometers
12 Exhaust System
13 Decommissioning
14 Inspection
14.1 Safety checks to be performed at regular intervals and following any untoward incidents (D: Accident prevention check according to BGV D27)
15 Storage
16 Disposal
Appendix for Diesel Engine Exhaust Gas Filter -- STX Type
1 Introduction
2 Regeneration
Original Illustrated Factory Workshop Service Manual for Jungheinrich Fork Truck Type DFG/TFG.
Original factory manuals for Jungheinrich Forklift Trucks, contains high quality images, circuit diagrams and instructions to help you to operate and repair your truck. All Manuals Printable and contains Searchable Text
Covered models:
DFG 16K (05.1997-07.2004)
DFG 20K (05.1997-07.2004)
DFG 25K (05.1997-07.2004)
DFG 30K (05.1997-07.2004)
DFG 40K (05.1997-07.2004)
DFG 45K (05.1997-07.2004)
DFG 50K (05.1997-07.2004)
TFG 16K (05.1997-07.2004)
TFG 20K (05.1997-07.2004)
TFG 25K (05.1997-07.2004)
TFG 30K (05.1997-07.2004)
TFG 40K (05.1997-07.2004)
TFG 45K (05.1997-07.2004)
TFG 50K (05.1997-07.2004)
Language: English
Format: ZIP, Contained set of PDF Manuals
Service Manual, PDF, 753 Pages
Contents:
Technical Description of Components
General Truck Data. Operational Tests / Test and Setting Values
Truck Maintenance
Drive System V. Combustion Engines
Drive System V. Power Shift Transmission / Hydrostatic Drive
System
Brake System
Steering
Masts
Hydraulic System and Diagrams
Electric System and Wiring Diagrams
Diesel Particle Filter (HUSS)
Operating Manual, PDF, 142 Pages
Contents:
A Correct Use and Application of the Truck
B Description of Truck
1 Description of Use
2 Description of Assemblies and Function
2.1 Truck
2.2 Mast
2.3 Changes in operational requirements
2.4 Safety devices
3 Technical Data -- Standard Equipment
3.1 Data tables -- DFG/TFG 16/20 AK
3.2 Data tables -- DFG/TFG 20--30 BK
3.3 Data tables -- DFG/TFG 40--50 CK
4 Labels and Plates
4.1 Truck Rating Plate
4.2 Load diagrams
C Transportation and Commissioning
1 Transportation
2 Commissioning
D Truck Refuelling
1 Safety Conditions for Handling Diesel Fuel and Liquid Petroleum Gas
2 Filling with Diesel Fuel
3 Changing the Gas Bottle
E Operation
1 Safety Regulations Governing the Operation of the Forklift Truck
2 Description of Drivers Controls and Display Elements
3 Checks and Activities Before Daily Use
4 Using the Truck
4.1 Start Process TFG
4.2 Start Process DFG
4.3 Fault Displays during Operation
5 Operation of the Forklift Truck
5.1 Safety regulations applicable when operating the truck
5.2 Driving
5.3 Steering
5.4 Braking
5.5 Operating the Mast and Attachments
5.6 Picking Up, Transporting and Setting Down Load Units
5.7 Instructions for the use of restraint belts
5.8 Parking the Truck Safely
5.9 Engine housing and service covers
5.10 Towing
5.11 Towing Trailers
5.12 Trailer loads
6 Fault Locating Operations
F Truck Maintenance
1 Operational Safety and Environmental Protection
2 Safety Regulations Applicable to Truck Maintenance
3 Servicing and Inspection
4 Maintenance Check-list DFG/TFG
5 Maintenance Check-list DFG
6 Maintenance Check-list TFG
7 Coolant Specification
8 Lubricant Specifications
9 Fuel specification -- DFG
10 Lubrication Chart
10.1 Lubrication Diagram -- DFG/TFG 16--50 AS/BS/CS
11 Description of Maintenance and Repair Work
11.1 Preparing the Truck for Maintenance and Repair Work
11.2 Engine Maintenance TFG 16/20 AS
11.3 Engine Maintenance DFG 16/20 AS
11.4 Engine Maintenance TFG 20--30 BS
11.5 Engine Maintenance DFG 20--30 BS
11.6 Engine Maintenance TFG 40--50 CS
11.7 Engine Maintenance DFG 40--50 CS
11.8 Check Coolant Concentration
11.9 Clean/Change Air Filter Cartridge
11.10 Brakes
11.11 Change Wheels
11.12 Hydraulic System
11.13 Electrical System
11.14 Switch Gear and Control Potentiometers
12 Exhaust System
13 Decommissioning
14 Inspection
14.1 Safety checks to be performed at regular intervals and following any untoward incidents (D: Accident prevention check according to BGV D27)
15 Storage
16 Disposal
Appendix for Diesel Engine Exhaust Gas Filter -- STX Type
1 Introduction
2 Regeneration
