Jungheinrich Service Manuals, Wiring diagram. Fault Codes

German-made Jungheinrich loading equipment is distinguished by excellent durability and
performance. Benefit from consistently high handling speeds with maximum comfort. This European-quality equipment perfectly adapts to various operating conditions, meets strict safety standards,
is distinguished by high working and driving qualities for moving and storing goods for work both in an open area and inside a closed warehouse or a freight railway container.

Jungheinrich LPG trucks, like trucks from other brands of this type, have a number of advantages. This is a universal warehouse
equipment, which is very economical if, when buying it, you correctly calculate the basic requirements for the height of lifting of loads, carrying capacity, speed of movement, weight of the
machine, its dimensions and, of course, the types of cargo with which the machine has to deal. If the calculation is carried out carefully, and the optimal model is chosen, the costs for it,
given the low price of gas, will pay off in a few months. And due to its high ecological class, it can work on a shift all day long with practically different cargoes that require specific
transportation conditions. The peculiarity of gas forklifts is that you can start them in any weather without any problems, which can not be said about diesel or gasoline ones.

The distribution of weight to the front axle is 3805/1270.

Carrying capacity – 1500 kg.

Total weight 2870 kg.

running – 4 kW;

lifting – 6 kW.

The maximum speed is 12.5 km / h.

Clearance – 100 mm.

The wheelbase is 1200 mm.

The center of gravity of the load on the forks is 500 mm.

Mast – 2000-3550 mm.

Working corridor width:

across – 3114 mm;

along – 3236 mm.

The total width is 990 mm.

The total length is 2935 mm.

The service brake is hydraulic.

The maximum lifting height is 3000 mm.

The maximum climb is 16 degrees.

Fork dimensions (LxWxH) – 1150x100x35 mm.

Lifting speed with / without load – 240/500 mm / s.

Lowering speed with / without load – 580/600 mm / s.

It is worth noting that it is quite difficult to find a new Jungheinrich EFG 115 loader in the domestic market. However, these
forklifts are quite widely used, and here the price depends on the condition of the machine. In general, the cost can vary from 3,000 to 10,000 euros. The new EFG 115 will cost about 18,500

The second series of EFG loaders differs from the first in a large set of technical options. All this could not but affect the cost, which will be
slightly higher than the 115 model. However, first, let’s look at the technical specifications:

The distribution of weight to the front axle is 3870/1310.

Total weight 2978 kg.

running – 4.6 kW;

lifting – 11.5 kW.

Storage battery (voltage V / capacity kW * h) – 48/500.

The maximum speed is 16 km / h.

The wheelbase is 1249 mm.

Mast – 2000-3560 mm.

across – 3104 mm;

Along – 3226 mm.

The total width is 1060 mm.

The total length is 2924 mm.

The service brake is electromechanical.

The maximum climb is 35 degrees.

Turning radius – 1440 mm.

Lifting speed with / without load – 460/600 mm / s.

Lowering speed with / without load – 550/550 mm / s.

As you can see from the technical characteristics, this car has almost the same dimensions as the previous model, but with more powerful motors and
improved other indicators.

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Jungheinrich Service Manuals, Wiring diagram. Fault Codes

Jungheinrich Service Manual

Jungheinrich DFG/TFG
660-690 Operating Instructions

Models: DFG 670; DFG
680; DFG 690; DFG S80; DFG S90; TFG 660; TFG 670; TFG 680; TFG 690; TFG S80; TFG S90; DFG S90.

Jungheinrich DFG S80
Service Manual

Models: TFG 680; DFG 670; DFG 660; DFG 680;  DFG 690; DFG S80; DFG S90; TFG 660; TFG 670; TFG 690;  TFG S80; TFG S90.

Jungheinrich DFG TFG
316-435 Operating Instructions

Models: TFG 430; DFG 320; DFG 425; DFG 430; DFG 435; TFG 316; TFG 320; TFG 425; TFG 435.

Jungheinrich EFG-Vac 22-30/ 25L/S/SL Service Manual Download

Jungheinrich ECE 225 (90309857) Spare Parts Catalogue Download

Jungheinrich EJC 110/112 Operating instructions Download

Jungheinrich DFG/TFG 16 – 50 A/B/C-K Operating instructions Download

Jungheinrich DFG 660 Service Manual

Jungheinrich DFG 670 Service Manual

Jungheinrich DFG S80 Service Manual

Jungheinrich DFG_TFG 316-435 Operating Instructions

Jungheinrich ECE 225 Spare Parts Catalogue

Jungheinrich EFG 213-320 Operating Manual Download

Jungheinrich EFG-Vac 22 Service Manual

Jungheinrich EFG-Vac 25L Service Manual

Jungheinrich EFG-Vac 30 Service Manual

Jungheinrich EJD 220 Service Manual

Jungheinrich ERE 120 Service Manual

Jungheinrich ETM 214 Service Manual

Jungheinrich ETM 216 Service Manual

Jungheinrich ETM 325 Service Manual

Jungheinrich ETV 214 Service Manual

Jungheinrich ETV 216 Service Manual

Jungheinrich ETV 318Service Manual

Jungheinrich ETV 320 Service Manual

Jungheinrich ETV 325 Service Manual

Jungheinrich EZS 330 XL Operating Instructions Manual

Jungheinrich EZS 350 XL Operating Instructions Manual

Jungheinrich SLH 200 Service Manual

Jungheinrich TFG 660 Service Manual

Jungheinrich Fault Codes

Jungheinrich Fault Codes Download

Jungheinrich EJC112 & E1202 Event Messages Codes List

Jungheinrich Error Codes List


Jungheinrich System Error Codes list

Jungheinrich System Error Codes list Download

The manufacturer of forklifts is Jungheinrich, which is a leader in the production and sale of industrial, warehouse and material handling equipment. The company began its journey from 1953, when
a small loader company was founded, and by 2011 the company had several factories at its disposal.

Forklifts are mainly used to work in warehouses, but without them they are very rarely managed in large-scale industries. They carry loads that are placed on pallets. Due to the version with a
closed cabin, they are able to work even in places with unfavorable external environment, namely, with wind, dust, sparks, sawdust, steam, and so on.

Electric loaders are represented by 5 series, which differ in load capacity, low unloading height, technology, maneuverability, as well as convenience of the operator’s workplace.

1 series EFG 110/113/115. The letters mean that this is an electric forklift, the first number indicates the series, and the second two are the maximum carrying
capacity in hundreds of kilograms. These are lightweight and compact loaders that have just one rear wheel. Thanks to these parameters, they have excellent maneuverability and can move even
inside the truck body. However, these “kids” are able to work with a weight of from 1 to 1.5 tons and lift the load to a height of 6.5 meters. AC control electronics may be updated.

EFG 213/215 / 216k / 216 / 218k / 218/220. The index k near some models indicates that the model has a smaller battery, a shorter base and a shorter fork body. This series has
the same dimensions and related benefits. However, the maximum load capacity is increased, as well as equipped with a large number of technologies. In the loader, an electric power steering was
added, the ability to independently configure 5 work programs, replace batteries, a more thoughtful security system, an automatic parking brake, smart electronics, and a maintenance-free brake
system and electric motor. The case in these loaders is integral, which provides greater stability when maneuvering.

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EFG 316 / 316k / 318 / 318k / 320. The main differences between these trucks from previous models is that they have 4 wheels and a fully enclosed cab with front and rear window
cleaner. The control system is now electro-hydraulic, which provides better handling. Cab stances were enhanced, and the lighting system and battery compartment received additional protection.

EFG 540k / 540 / 545k / 545/550 / S40 / S30. These are the most powerful and big electric lift trucks. The maximum unloading height has also been increased, but only to 7.18
meters. You can use various packages of additional functions that determine the operation of the loader. In this series, more attention is paid to operator safety, as well as comfort and
ergonomics of the workplace.

YALE Pallet Lift Truck Fault Codes DTC

Error: no LEDs or LCDs on

What the issue is: Inoperative

Cause of Problem: B+ and / or B- missing at controller, defective battery charger, or defective battery charger

What to do: Ensure the battery is connected, the key switch is on, and the brake override circuit is in the run position; also test your battery charger and motor controller and replace any
nonworking parts

What the issue is: Forklift functions as normal

Cause of Problem: open connection between display and controller, defective display, or defective LEDs

What to do: make sure harnesses are connected at MDI and connector B on controller; test the dash display by connecting a handset to it and testing for communication; test LEDs by disconnecting
them, connecting the handset, and testing the handset; replace any non-working parts

What the issue is:  Forklift functions as normal

Cause of Problem: Because this condition is similar to the last, it will take a handset to determine its cause. If the handset displays “NO COMMUNICATION,” the controller is defective.

What to do: replace controller

What the issue is: Traction and hydraulic functions not working

Cause of Problem: improper startup sequence by jack operator

What to do: check brake switch, accelerator, steer handle, and hydraulic inputs

What the issue is: Hydraulic function not working

Cause of Problem: battery voltage is low or controller voltage calibration is incorrect

What to do: Charge or replace battery; otherwise, use handset to determine the voltage read by the controller and compare it to an actual voltmeter reading; replace controller if the two readings
differ by more than 1.5 volts

Cause of Problem: incorrect battery selected, damaged battery, or damaged connection to batter

What to do: check that you have the right voltage for your truck, manually check the voltage of your battery, inspect it for any damage, and check its connecting crimps and cables for damage as

What the issue is: Traction and hoist functions not working

Cause of Problem: control card throttle or lift/lower calibration is out of range; control card is damaged or defective

What to do: Use the tester function on a handset to see if either calibration is greater than 1 volt at neutral; replace control card if damaged or defective, which can be checked by seeing if
both “forward switch” and “backward switch” are on at the same time when testing

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Cause of Problem: incomplete connection between control card and controller; traction reversing switch not connected; damaged or defective tiller card

What to do: Check connections between control card and controller; use a handset to test for operation of traction reversing switch; replace control card if tiller card is damaged

What the issue is:  Traction and hydraulic functions not working

Cause of Problem: main contactor tips are welded closed or motor field circuit is broken

What to do: disconnect power leads at contactor and test for an open circuit; check connections between motor field and controller

Cause of Problem: damaged connection to lowering valve; damaged lowering coil or lowering valve cartridge

What to do: check electrical connection between valve coil and controller; check lowering valve coil for resistance, replace if not approximately 17.7 ohms; replace lowering valve cartridge if

Cause: damaged connection to brake or brake coil damaged

What to do: check connection between electric brake and controller; check brake coil for resistance in both directions and replace if not between 27.36 and 30.24 ohms

Cause of Problem: Damaged connection to traction motor; traction motor armature resistance is too low; field wires are loose or damaged; motor field winding is shorted or too low.

What to Do: Check electrical connection between traction motor, field wires, and controller; check traction motor armature for shorts; check motor field resistance and correct if not between 0.5
and 1.5 ohms; check contactor coil for resistance of 52 ohms

What the issue is: traction functions reduced below 14°F or above 167°F and not working above 194°F

Cause of Problem: controller temperature is too hot or cold; controller temperature is not calibrated correctly; controller sensor or controller itself is damaged

What to do: move truck to a warmer or cooler location; use a handset to check that controller temperature matches room temperature (if not, replace controller)

Cause of Problem: over current in driven component

What to do: check main harness for damaged connections to main contactor, brake, and electric valve coils; check contactor, brake, and electric valve coils for correct resistance (52 ohms for
contactor, between 27.36 and 30.24 ohms for brake coil, and 17.7 ohms for electric valve coils)

Cause of Problem: controller is damaged; damaged wire connection; short circuit in harness; ground between motor windings and chassis; motor field winding is shorted to chassis; field current
driver circuit has failed; watchdog hardware circuit is damaged

What to do: Cycle key switch off and on and replace controller if problem not solved; check wire connections at contactor, pump motor, and traction motor; check main harness for shorts; check for
grounds or shorts between motor windings and chassis; check motor field resistance (should be about 1.5 ohms); measure voltage between F1 and B- and F2 and B- on field current driver (should be
half the voltage between B+ and B-)

What the issue is: Traction and hydraulic functions not working for one minute.

Cause of Problem: No fault is occurring. The controller is installing hour meter memory from MDI display if controller has been replaced.

What to do:  No solution necessary. Fork truck will operate as soon as data transfer is complete.

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