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

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 GapBrake 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 CylinderSecond Lift Cylinder For Triplex Mast Disassembly Sequence Reassembly Sequence Suggestions For Reassembly Mast CylinderSecond 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 TroubleshootingAC 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 RemovalDuplex CarriageDuplex Description Carriage Removal Carriage Reassembly Carriage Inspection CylindersDuplex 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 CartridgeDuplex Reassembly UprightsDuplex 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 AdjustmentDuplex ChainsDuplex 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 CarriageTriplex Description Carriage Removal Carriage Reassembly Carriage Inspection CylindersTriplex 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 CartridgeTriplex Reassembly UprightsTriplex 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 SupplyTriplex Hose Tracking Adjustment Mast Installation Triplex Mast Skewing AdjustmentTriplex ChainsTriplex 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 CarriageQuad Description Carriage Removal Reassembly Carriage Inspection CylindersQuad 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 CartridgeQuad Removal Mast UprightsQuad 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 AdjustmentQuad ChainsQuad 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