08.1994-07.1996 Jungheinrich Electric Forklift Truck EFG-DH Series: 12.5, 15A Service & Repair Manual

1/UNGHE/NRICH SHA EFG-DH 8671.01 GB VK-B 12/94 0.1 Table of contents EFG-DH 12,5/15 Page Checking sequence for functional tests 1.1 -1.3 EFG-DH Contactor rack 1.1 07/94 Alarm messages 1.2-1.3 07/94 Settings and checking values 2.1 -2.4 General truck data EFG-DH 12.5/15 2.1 -2.4 Basic circuit diagrams 3.1 Hydr. truck circuit 66 928 920 07/94 Wiring diagram designations EFG 99 890 323 1/2 -2/2 07/94 Truck circuit diagram 68 989 310 1/4 -3/4 07/94 Truck operating diagram 68 989 300 1/4 - 3/4 07/94 Technical specification - Block diagram 68 989 300 4/4 Basic circuit diagrams are not subject to automatic amendment. Always refer to the applicable wring diagrams in the wiring diagram file.

tUNGHEINRICH SHA EFG-DH 8671.01 GB VK-B 12/94 0.2 Excerpts from operating instructions 4.1 Description of the operating controls and displays E 86.001 .GB 2-10/3-10 0694 Servicing check list EFG-DH F 86.001 .GB 1 -2/2-2 0694 Lubricating schedule EFG-DH 12,5 / 15 F 86.003.GB 1-2 0694 Fuels and oils F 86.003.GB 2-2 0694 Instructions for the servicing and maintenance operations F 86.001 .GB 8-13/-10/13 0694 Fuses F 86.001.GB 11-13 0694 Service manual items 5.1 Legend of technical modifications, 6.1 modification kits and technical specifications Personal information 7.1 - 7.2 Used before safety instructions that must be observed to prevent any danger to persons. A Used before instructions that must be observed to prevent any damage to material or assemblies. |g5=> Used before explanations.

1/UNGHE/NRICH SHA EFG-DH 8671.01 GB VK-B 11/94 1.1 EFG-DH Contactor rack Item Description 1 Main contactor K1 2 Brake contactor 1K28 3 Driving contactor 1K1 forward 4 Driving contactor 1K2 reversing 5 Red LED located on the 1U1 drive control system indicating alarm messages by means of a flashing code. The meaning of the individual flashing codes can be seen from the table "Alarm messages". 6 Red LED located on the 2U2 lifting drive control system indicating alarm messages by means of a flashing code. The meaning of the individual flashing codes can be seen from the table "Alarm messages".

tUNGHEINRICH SHA EFG-DH 8671.01 GB VK-B 12/94 1.2 Alarm messages Flashing code at 1U1 Flashing code at 2U2 Possible faults/Rectification 1 flashes 1 flashes EEPROM fault during reading: Switch on and off again. ; In order, if alarm message goes off, otherwise: - > Replace the control board. Watchdog fault: Switch the truck several times off and on again: 1 flashes 1 flashes - In order, if the alarm message goes off, otherwise - Control component defective -> replace. 1 flashes 1 flashes No reading operations possible, when the controller is otherwise engaged. Switch the truck several times off and on again: - In order, if the alarm message goes off, otherwise: - Control component defective -> replace. Data connection to controller defective, or controller is otherwise engaged. Switch the truck several times off and on again: 1 flashes 1 flashes - In order, if the alarm message goes off, otherwise: - Check the connection. - Fuse 2F10 in order? - Control component defective -> replace. — 2 flashes - Function switch "Lifting" operated, when the truck is switched on; - Incorrect wiring. - Travelling direction contactor 1K1/1K2 binding; - Has main contactor picked up? - Motor lead interrupted. - Fuse 1F3 in order? 3 flashes 3 flashes - Short circuit against -E battery. - Short circuit VMN against -E battery; - Power component defective -> Replace the drive control system 3 flashes 3 flashes - GND not firmly wired (poor connection?) - Power component or control board defective -> Replace the complete drive control system. — 3 flashes Replace the complete drive control system! 4 flashes — - Controller defective -> replace. — 4 flashes Check the wiring and the lifting potentiometer -> replace, if required. 5 flashes 5 flashes Power component (current sensor) or control board defective. -> Replace the complete drive control system! 5 flashes 5 flashes Does the truck still move (current measurement using clip-on probe)? No: - Test the periphery (high impedance?) Yes: - Power component (current sensor) is defective. -> Replace the complete drive control system

1/UNGHE/NRICH SHA EFG-DH 8671.01 GB VK-B 12/94 1.3 Flashing code at 1U1 Flashing code at 2U2 Possible faults/Rectification 6 flashes 6 flashes - The contactor coil has a short-circuit or continuously draws excessive current. - Control board defective -> replace. 6 flashes 6 flashes - Driver defective due to overvoltage at the negative connection of the contactors. - Control board defective -> replace. First rectify fault, then replace the control board! 7 flashes 7 flashes If the temperature in the drive control system is less than 50°C: -> replace the complete drive control system. 8 flashes — - Travelling direction contactor not connected or defective. - Contact contaminated or one of the contacts does not close. - Motor not correctly connected or connection interrupted. - Coil defective. - Contactor wiring defective. 8 flashes — - Brake contactor 1K28 or coil defective. - Wiring interrupted or interchanged. - Control board defective -> replace. 8 flashes 8 flashes - Contactor contacts are binding. - Short circuit between E battery and VMN caused by fault in the periphery. - Power component defective -> replace complete drive control system. 9 flashes — - Brake contactor binding. - Wiring interchanged. - Control board defective -> replace. 9 flashes — - Travelling direction contactor 1K1/1K2 binding. - Motor not correctly connected or wiring interrupted. - Control board defective -> replace. Permanent¬ ly alight — - Wiring defective. - Travelling direction switch defective -> replace, - otherwise replace the control board.

1/UNGHE/NRICH SHA EFG-DH 8671.01 GB VK-D 12/94 2.1 Settings and checking values General truck data EFG-DH 12.5/15 EFG-DH EFG-DH Remarks 12,5 15 Truck Dead weight: (without load, incl. battery) approx. kg 2830 2985 Travelling speed : with/without load V = km/h 10.7/12.3 10.3/12.1 Lifting : with/without load m/s 0.27/0.45 0.25/0.45 Lowering : with/without load m/s 0.48/0.40 0.49/0.40 Turning radius : * (+25mm with DZ hoist frame) mm 1456* 1510* A Chassis/Superstructure Rear weight M20x100 Nm 425±5 4— 2 screws - Rear weight, left M16x70 Nm 210-5 4— 1 screw - Rear weight, left M16x90 Nm 210±5 4— 1 screw - Rear weight, right M16x60 Nm 210-5 4— 1 screw - Rear weight, right M16x70 Nm 210±5 4— 1 screw -Hinge M10x30 Nm 49-5 4— 4 screws -Hinge M10x35 Nm 49+5 4— 4 screws B Drive unit Drive motor type GF146- 14/5.6 4— - Output (max. 60 min) kW 4.0 4— - Carbon brush length New/wear limit mm 32/15 4— - Fan wheel/screw Nm 18 4— secured with Loctite 243 Transmission 'total 18 4— - Transmission oil charge I 0.75 4— - Transmission flange/motor M12x30 Nm 85±5 4— 6 screws - Bogie/motor M8x30 Nm 25±2 4— 6 screws Checking of spring in controller page 2.4 D Brake - Brake drum diameter, new mm 200 4— - Brake drum diameter, wear limit mm 201.4 4—

tUNGHEINRICH SHA EFG-DH 8671.01 GB VK-D 11/94 2.2 Settings and checking values General truck data EFG-DH 12.5/15 EFG-DH EFG-DH Remarks 12,5 15 - Brake lining thickness new mm 5 4— - Brake lining thickness wear limit mm 1.2 4— - Brake release gap max. mm 0.5 autom. brake adjustment - Brake backing plate/chassis Nm 85±5 4— 6 screws Brake drum/wheel hub Nm 45±5 4- 1 0 screws M10x25 Max. braking distance 4- D 6360.03 with/without load m Vx0.21 D 6360.21 E Wheels/axles Tyre diameter max./min. mm 457/* <- * page 2.4 Wheel nuts Nm 120-5 4— F Steering system Steering press, limiting system - Max. pressure at connection bar 4— P,EF - Max. press, at connection CF bar «- - Max. press, at connection L,R bar «- - Max. press, at connection LS bar «- - Max. pressure at connection T bar 4— - Priority valve, initial pressure bar 4 <- Pressure switch/Start-up press. bar 0.3 4— Steering unit M10x20 Nm 30 «- 4 screws Oil motor/ Steering chain adjustment page 2.4 G Hoist frame/load bearing assembly Lifting cylinder - Cylinder head Nm 300 «- - Lowering brake (free lift) S = mm 18.5 «- ZZ/ DZ - Line rupture guard solid rod S = mm 0.6 ZT - Line rupture guard solid rod S = mm 0.8 ZZ - Line rupture guard hollow rod S = mm 1.1 ZZ - Line rupture guard hollow rod S = mm 0.8 DZ - Line rupture guard solid rod S = mm 0.6 4— DZ

1/UNGHE/NRICH SHA EFG-DH 8671.01 GB VK-D 12/94 2.3 Settings and checking values General truck data EFG-DH 12.5/15 EFG-DH EFG-DH Remarks 12,5 15 H Chassis/load bearing assembly ZT hoist frame tilting forward/backward o 5/7 h1<2600 ZT hoist frame tilting forward/backward o 5/3 4— h1>2850 ZZ hoist frame tilting forward/backward o 5/7 4— DZ hoist frame tilting forward/backward o 5/7 4— h1<2050 DZ hoist frame tilting forward/backward o 5/3 4— h1>2200 Tilting speed °/s 3 4— Tilting cylinder setting page 2.4 I Hydraulic system Control valve - Pressure limitation bar +15 +15 max. 200 - Initial pressure valve (tilting function) bar 80+5 90+5* * permanet- ly set - Operating pressure (DZ-hoist frame) max. bar 145 165 - Operating pressure (ZT and ZZ-hoist frame) max. bar 135 155 Pump motor type - Output (15% ED) kW 7.6 4— - Pump/motor Nm 50+10 4 screws - Fan wheel/screw Nm 18 4— secured with Loctite 243 - Carbon brush length new/wear limit mm 32/15 4— Oil charge I 20.9 page 2.4 J Electric system Fuses refer to 4.1 page F 11 K Battery V/Ah 24/700 24/800

tUNGHEINRICH SHA EFG-DH 8671.01 GB VK-D 11/94 2.4 B Drive Unit Checking of inner spring in controller: - Disengage the outer tension spring at the accelerator. - Depress the accelerator. - Accelerator automatically resumes its initial position - The spring in the controller is in order. - Accelerator remains in the depressed position - Replace the controller. E Wheels Tyre wear limit: - In the case of solid rubber tyres no minimum tread depth is specified. The upper edge of the wear marking on the CSE tyre (60 Joule ledge) constitutes the max. wear and retreading limit. F Steering system Steering chain tension: - Deflection of the steering chain approx. 5 mm when applying a test force of 50N! G1 Lateral traversing device Integrated lateral traversing device Following the removal of the lateral traversing frame, the lateral traversing device must not be hydraulically operated, as the plunger has no internal stroke limitation. H Chassis/load bearing assembly Tilting cylinder: A When replacing the tilting cylinders, perform the required tolerance compensating operations (synchronous movement). - Check the synchronous movement of the tilting cylinders and readjust, if required. For adjustment of the tilting cylinders refer to SHB H 6644.03. I Hydraulic system Oil charge: - After the overall hydraulic system has been filled via the oil reservoir, the oil reservoir must be filled with approx. 20.9 Itr.

ÿ 8671.01 GB UUNGHEINRICH SHA EFG-DH w„p n7/Q/l —— VK-B 07/94 3.1 Basic circuit diagrams Hydr. truck circuit 66 928 920 07/94 Wiring diagram designations EFG 99 890 323 1/2 - 2/2 07/94 Truck circuit diagram 68 989 310 1/4 - 3/4 07/94 Truck operating diagram 68 989 300 1/4 - 3/4 07/94 Technical specification - Block diagram 68 989 300 4/4

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08.1994-07.1996 Jungheinrich Electric Forklift Truck EFG-DH Series: 12.5, 15A Service & Repair Manual

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