Jungheinrich Electric Lift Truck ETG-Series: ETG350, ETG355 (from 01.2010) Workshop Manual

Original Illustrated Factory Workshop Manual for Jungheinrich JETI Electric Lift Truck ETG-Series.

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:
ETG350 (from 01.2010)
ETG355 (from 01.2010)

Format: PDF, 355 Pages
Language: English

Contents:

GENERAL INFORMATION
    Scope
    Truck Models Covered
    Dimensions
    Dimensions Chart
    General Information (Standard Models)
CONTROLLER
    System Configuration and Outline
    System Configuration
    Outline
    Logic unit
    Inverter
    Output unit (RI01, RI02)
    Display unit
    EPS (Electronic Power Steering) unit
    External View
    Logic unit
    Inverter
    Output unit
    Display unit
    EPS (Electronic Power Steering) unit
    Controller Area Network (CAN)
    AC Motor System Basics
    Feature of AC motor
    Speed control of induction motors
    Inverter
    Function
    Traction Control Function
    Powering
    Limitation of maximum travel speed
    Regeneration
    Controlled roll-back
    Steering
    Stall timer
    Free lift
    Hydraulic Control Function
    Hydraulic controller type
    Priority
    Inhibition of simultaneous operation
    Attachments 2 and 3
    Steering Control Function
    IPS (Integrated Presence System) Function
    Preventing operator's absence
    Preventing lever and pedal operations
    Other Functions
    BDI (Battery Discharge Indicator)
    Service indicator
    Tire size
    Hour meter function
    Chime control function
    Battery voltage monitor
    Load sensor function (option)
    Display Function
    Normal operation display
    Display transition
    Error display
    Password entry
    User setting function
    Setup Option display
    Data monitor display
    Output check display
    History folder display
    Software version display
    Setup Option Function
    Outline
    Procedures for setting Setup Option
    Details of Setup Options
    History Folder Function
    Outline
    Fault data display
    Fault data deletion
    Data Monitor Function
    Outline
    Data monitoring
    Output Check Function
    Outline
    Output checking
    Removal and Installation
    Inspection Before Replacing Controllers
    Checking power supply
    Checking inverter and DSP card
    Checking logic card
    Checking power supply card
    Checking output unit
    Checking display unit
    Discharging Electric Charges From Inverters and EPS Unit
    Replacing Inverter
    Replacing DSP (Digital Signal Processor) Card
    Replacing Logic Unit
    Replacing Logic Card
    Replacing Power Supply Card
    Replacing Output Unit
    Replacing EPS (Electronic Power Steering) Unit
    Basic Check
    Basic Items
    Testing Tools
    Measurement of Card Voltage
    Checking Contactor
    Checking contactor coil
    Checking contactor tip
    Checking Inverter
    Regeneration Check
TROUBLESHOOTING FOR CONTROL CIRCUITS
    General Information
    Before replacing devices
    Connection of the service tool
    How to clean harness connectors and system components
    CAN-BUS Test Stand Up End Control AC
    Troubleshooting
    EO Traction Motor R.H., Overheating
    E1 Traction Motor L.H., Overheating
    E2 Pump Motor, Overheating (Transistor Control Type)
    E2 Pump Motor, Overheating
    E5 Traction Inverter R.H., Overheating
    E6 Traction Inverter L.H., Overheating
    E7 Pump Inverter, Overheating (Transistor Control Type Only)
    BR Pump Motor, Worn Brushes
    14 Traction Motor Current Sensor R.H. Fault
    15 Traction Motor R.H., Over-current
    16 Traction Motor R.H., Stall Timer
    24 Traction Motor Current Sensor L.H. Fault
    25 Traction Motor L.H., Over-current
    26 Traction Motor L.H., Stall Timer
    34 Pump Motor Current Sensor Fault (Transistor Control Type Only)
    35 Pump Motor Over-current (Transistor Control Type Only)
    40 Line Contactor Fault
    41 Steering Contactor Fault
    45 Traction Motor R.H. Open
    46 Traction Motor L.H. Open
    47 Pump Motor Open (Transistor Control Type Only)
    51 Traction Lever Sensor Fault
    52 Traction Motor R.H. Pulse Input Fault
    53 Traction Motor L.H. Pulse Input Fault
    55 FC Solenoid Fault
    56 FC Solenoid Current Leak
    57 Pump Motor Pulse Input Fault (Transistor Control Type Only)
    60 Display Communication Fault (60) or (COMM ERROR)
    61 Logic Card Initialize Failure
    62 Logics Fault
    63 Traction Inverter R.H. Fault
    64 Traction Inverter L.H. Fault
    65 Pump Inverter Fault (Transistor Control Type Only)
    68 Output Unit 1 Fault
    70 Output Unit 2 Fault
    71 EPS Controller Fault
    72 Contactor Coil Fault
    75 Electromagnetic Brake Solenoid Fault
    76 Chime Fault
    77 Travel Alarm Fault
    78 Battery Voltage Too Low
    79 Battery Voltage Too High
    81 Load Sensor Fault
    83 Lift Lever Fault
    84 Traction Pedal Fault
    (E) Traction Pedal or Traction Lever, Faulty Setting
    (L) Presence Pedal, Faulty Setting
    (H1) Lift Lever, Faulty Setting
    (H2) Tilt Switch, Faulty Setting
    (H3) Attachment 1 Switch, Faulty Setting
    (H4) Attachment 2 Switch, Faulty Setting
    (H5) Attachment 3 Switch, Faulty Setting
    (Lo) Battery Consumption Too Much
    Battery Consumption
    Electrical Diagrams
    Wiring Schematic
    Wiring Diagram
    English/French Legend
    Spanish/Portuguese Legend
    Location of Major Components
    Troubleshooting For Control Circuits
    Electric Steer Controller (EPS)
    Power Connecting Diagram
    Stepper Motor with Feedback Potentiometer and
    Toggle Switches Diagram
    EPS Steer Controller
    Feedback Sensor
    Toggle Switches
    Connections
    CNA Connector
    CNB Connector
    CNC Connector
    Stepper Motor Connections
    Feedback Pot Connections
    Digital Input Connections
    Safety Contacts
    Digital Output Connections
    Handset
    Electric Steer Controller (EOS) Flowchart
    Set Model
    Parameter Change
    Parameter Change: (Electric Steer Controller "EPS")
    Testing: (Electric Steer Controller "EPS")
    Set Options
    Set Options: (Electric Steer Controller "EPS")
    Adjustments: (Electric Steer Controller "EPS")
FRONT DRIVE AXLE
    Removal
    Front Wheel
    Removal Sequence
    Suggestions
    Method 1
    Method 2
    Method 3
    Installation
    Front Drive Axle Disassembly
    Front Drive Axle Assembly
    Recommended Lubricants
    Filling the Drive Axle
    Changing the Drive Axle Oil
REAR AXLE ASSEMBLY
    Removal
    Rear Wheels
    Removal Sequence
    Suggestions
    Installation
    Rear Wheels
    Rear Axle Assembly
    Description
    Removal
    Steer Yoke Assembly
    Description
    Replacing the Steering Bearing
    Disassembly
    Assembly
    Replacing the Yoke Assembly
    Disassembly
    Assembly
    Replacing the Steering Gear
    Disassembly
    Assembly
    Replacing the Steer Hub Assembly
    Disassembly
    Assembly
    Complete Disassembly Procedure
    Complete Assembly Procedure
    Installation
    Installation of Steering Yoke and Tires
BRAKE ASSEMBLY
    Description
    General Information
    Disassembly
    Reassembly
    Brake Assembly, Inspection and Adjustment
    Inspections
    Friction Disc
    Inspections
    Adjustment of Air Gap—Brake Applied
    Friction Disc Replacement
    Release Screws
STEERING SYSTEM
    Steering Gear
    Suggestion
    Steering Wheel Removal
    Installation
    Steering Control Disassembly and Reassembly
    Replacing the Stepper Motor
    Tightening Torque for Bolts
    Replacing the Steer Motor
    Installation
    Tightening Torque for Bolts
HYDRAULIC SYSTEM
    Description
    Generic Schematic for Trucks
    General Information
    Hydraulic Tank
    Changing Hydraulic Oil
    Recommended Oil and Lubricants
    Checking the Hydraulic Oil Fluid Level
    Hydraulic Pump
    Main Control Valve
    Main Control Valve Schematic
    Hydraulic Pump Operation
    Pressure Loading Principle
    Lift Cylinders
    Tilt Cylinder
    Down Safety Valve
    Hydraulic Pump Removal
    Sequence
    Installation
    Hydraulic Pump Applications
    Disassembly
    Sequence
    Working Tips and Rules
    Oil Seal
    Suggestions
    Removing the End Cover
    Removing the Seals
    Removing the Flange
    Removing the Shaft Seal
    Removing the O-ring and Seals
    Removing the Bushings
    Removing the Drive Shaft
    Separating the Gear Pack
    Removing the Rear Bushes
    Inspection after Disassembly
    Body
    Mounting Flange Face
    Bushes and Balance Plate
    Gears
    Reassembly
    Sequence
    Start By
    Reassembling the Rear Bushes
    Reassembling the Balance Plate
    Reassembling the Gear Pack
    Reassembling the Front Bushes
    Reassembling the O-rings and Seals
    Reassembling the Shaft Seal
    Reassembling the Flange
    Reassembling the Rear O-ring and Seals
    Reassembling the End Cover
    Inspection after Reassembly
    Running In After Assembly
    Control Valve Removal
    Sequence
    Start By
    Control Valve Installation
    Tightening Torques for Hoses
    Control Valve
    Main Relief Valve
    Hydraulic Tank
    Hydraulic Tank Refill Capacities
    Suction Strainer and Return Filter
    Removal
    Inspection
    Installation
    Duplex and Triplex Mast
    Installation
    Mast Cylinder—Second Lift Cylinder For Triplex Mast
    Disassembly
    Sequence
    Reassembly
    Sequence
    Suggestions For Reassembly
    Mast Cylinder—Second Lift Cylinder for Triplex Mast
    Disassembly
    Sequence
    Reassembly
    Sequence
    Suggestions for Reassembly
    Mast Cylinder— First Lift Cylinder for Duplex and
    Triplex Mast
    Disassembly
    Sequence
    Reassembly
    Sequence
    Suggestions for Reassembly
    Tilt Cylinder
    Removal
    Sequence
    Start By
    Suggestions for Removal
    Installation
    Disassembly
    Sequence
    Suggestions for Disassembly
    Inspection After Disassembly
    Precautions for Reassembly of Lift and Tilt Cylinders
    Troubleshooting
    Service Data
ELECTRICAL COMPONENTS
    Acceleration and Direction Control (Control Handle)
    Structure
    Disassembly Procedure
    Assembly Procedure
    Torque Specifications
    Driver Control (Operator and Hydraulic) Pedals
    Structure
    Sequence
    Test and Inspecting
    Electrical Connections Chart
    Electrical Connectors Chart
STEER MOTOR
    Structure
    Replacing the Planetary Gear on the Steer Motor
    Disassembly
    Assembly
    Replacing the Steer Pinion
    Disassembly
    Assembly
    Replacing the Steer Motor Pinion Bearing
    Disassembly
    Assembly
    Replacing the Steer Motor Terminal
    Disassembly
    Assembly
    Replacing the Steer Motor Bearing
    Disassembly
    Assembly
MOTORS
    Motors
    Structures
    Drive Motor
    Pump Motor
    Drove Motor
    Sequence
    Procedures and Suggestions for Removal and Installation of Drive Motors
    Installation
    Hydraulic Motor
    Sequence
    Suggestions for Disassembly and Assembly
    Hydraulic Pump Motor Removal
    Removal
    Installation
    Tightening of High-power Cable Terminals
    AC Motors
    External Inspection
    Disassembly and Reassembly
    Suggestions for Disassembly and Reassembly
    Troubleshooting—AC Motor
    Motor Thermal Sensor Temperature Testing
    Right Traction Motor
    Left Traction Motor
    Pump Motor
    Service Data
MAST AND FORKS
    Mast
    Mast Systems
    Mast Serial Number
    Contents
    Periodic Maintenance
    Inspection
    500 hour Inspection
    Troubleshooting
    Mast Removal—Duplex
    Carriage—Duplex
    Description
    Carriage Removal
    Carriage Reassembly
    Carriage Inspection
    Cylinders—Duplex
    Free Lift Cylinder Description
    Main Lift Cylinder Description
    Cylinder Operation
    Cylinders Raising
    Cylinders Lowering
    Main Lift Cylinder Removal
    Reassembly
    Free Lift Cylinder Removal
    Reassembly
    Main Lift Cylinder Disassembly
    Cleaning and Inspection
    Main Lift Cylinder Reassembly
    Piston Rod and Piston
    Retainer / Retainer Assembly
    Free Lift Cylinder Disassembly
    Cleaning and Inspection
    Free Lift Cylinder Reassembly
    Piston Rod and Piston
    Retainer Assembly
    Piston Removal
    Reassembly
    Cylinder Bleeding
    Lowering Control Valve Cartridge—Duplex
    Reassembly
    Uprights—Duplex
    Upright Description
    Outer Upright Description
    Inner Upright Description
    Upright Operation
    Fully Lowered
    Free Lift
    Full Extension
    Lowering
    Upright Disassembly
    Upright Inspection
    Upright Reassembly
    Mast Installation —Duplex
    Mast Skewing Adjustment—Duplex
    Chains—Duplex
    Inspection and Tension
    General Guidelines
    Inspecting the Chains
    Chain Lubrication
    Upright Chain Inspection
    Other Chain Service Notes
    Measuring Chain Stretch
    Free Lift Chain Adjustment
    Free Lift Chain Service
    Internal Reeving —Duplex
    Internal Reeving Installation
    For Double IHR or Left Hand IHR
    Mast Removal —Triplex
    Carriage—Triplex
    Description
    Carriage Removal
    Carriage Reassembly
    Carriage Inspection
    Cylinders—Triplex
    Free Lift Cylinder Description
    Main Lift Cylinder Description
    Cylinder Operation
    Cylinders Raising
    Cylinders Lowering
    Main Lift Cylinder Removal
    Reassembly
    Free Lift Cylinder Removal
    Reassembly
    Main Lift Cylinder Disassembly
    Cleaning and Inspection
    Main Lift Cylinder Reassembly
    Piston Rod and Piston
    Retainer / Retainer Assembly
    Free Lift Cylinder Disassembly
    Cleaning and Inspection
    Free Lift Cylinder Reassembly
    Piston Rod and Piston
    Retainer Assembly
    Piston Removal
    Reassembly
    Cylinder Bleeding
    Lowering Control Valve Cartridge—Triplex
    Reassembly
    Uprights—Triplex
    Upright Description
    Outer Upright Description
    Intermediate Upright Description
    Inner Upright Description
    Upright Operation
    Fully Lowered
    Free Lift
    Full Extension
    Lowering
    Upright Disassembly
    Upright Inspection
    Upright Reassembly
    Free Lift Hose Cylinder Supply—Triplex
    Hose Tracking Adjustment
    Mast Installation —Triplex
    Mast Skewing Adjustment—Triplex
    Chains—Triplex
    Inspection and Tension
    General Guidelines
    Inspecting the Chains
    Chain Lubrication
    Upright Chain Inspection
    Other Chain Service Notes
    Measuring Chain Stretch
    Main Lift Chain Adjustment
    Free Lift Chain Adjustment
    Main Lift Chain Service
    Free Lift Chain Service
    Internal Reeving —Triplex
    Internal Reeving Hi-Vis Installation
    Mast Removal —Quad
    Carriage—Quad
    Description
    Carriage Removal
    Reassembly
    Carriage Inspection
    Cylinders—Quad
    Free Lift Cylinder Description
    Main Lift Cylinder Description
    Cylinder Operation
    Cylinders Raising
    Cylinders Lowering
    Main Lift Cylinder Removal
    Reassembly
    Free Lift Cylinder Removal
    Reassembly
    Main Lift Cylinder Disassembly
    Cleaning and Inspection
    Main Lift Cylinder Reassembly
    Piston Rod and Piston
    Retainer / Retainer Assembly
    Free Lift Cylinder Disassembly
    Cleaning and Inspection
    Free Lift Cylinder Reassembly
    Piston Rod and Piston
    Retainer Assembly
    Piston Removal
    Reassembly
    Cylinder Bleeding
    Lowering Control Valve Cartridge—Quad
    Removal
    Mast Uprights—Quad
    Upright Descriptions
    Outer Upright Assembly
    Outer Intermediate Upright Assembly
    Inner Intermediate Upright Assembly
    Inner Upright Assembly
    Upright Operation
    Fully Lowered
    Free Lift
    Full Extension
    Lowering
    Upright Disassembly
    Upright Inspection
    Upright Reassembly
    Roller Shimming
    Thrust Plug/Block Replacement
    Mast Installation —Quad
    Mast Skewing Adjustment—Quad
    Chains—Quad
    Inspection and Tension
    General Guidelines
    Inspecting the Chains
    Chain Lubrication
    Upright Chain Inspection
    Other Chain Service Notes
    Measuring Chain Stretch
    Outer and Inner Main Lift Chain Adjustment
    Free Lift Chain Adjustment
    Outer Main Lift Chain Replacement
    Inner Main Lift Chain Replacement
    Free Lift Chain Replacement
    Internal Reeving —Quad
    Internal Reeving Hi-Vis Installation
    Dual Function IHR
    Hoses and Bracket Adjustment
    Forks
    Inspection and Adjustments
MAINTENANCE SERVICE DATA
    Tightening Torques for Standard Bolts and Nuts
    Fine Thread - With Spring Washer
    Fine Thread - Without Spring Washer
    Coarse Thread - With Spring Washer
    Coarse Thread - Without Spring Washer
    Inspection Guide
    Lubrication and Maintenance Chart
    Lubricant Specifications
    Recommended Lubricants
    Refill Capacities
    Inspection and Maintenance Schedule
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