Jungheinrich Electric Forklift EFG-DH Series: 12.5 15A (08.1994-07.1996) Workshop Manual
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🏷️ Basic Information Identification Make: Jungheinrich Model: EFG-DH Series Model Variant 1: 12.5 Model Variant 2: 15A Codes Series Designation: EFG-DH Production Period: 08.1994-07.1996 👋 Introduction Market Position Market Position: Original factory workshop manual for a specific generation of Jungheinrich electric forklift trucks, catering to businesses and technicians requiring in-depth maintenance and repair information for these industrial vehicles. Target Audience: Maintenance technicians, service engineers, fleet managers, and repair workshops specializing in Jungheinrich material handling equipment. Competitive Analysis Competitive Analysis: Provides authoritative, factory-backed technical data, surpassing generic repair guides. Crucial for maintaining optimal performance and longevity of Jungheinrich EFG-DH series forklifts. Offers precise specifications and diagrams essential for specialized industrial equipment. Value Proposition: Provides authorized and accurate repair procedures, crucial for minimizing downtime and ensuring safety and compliance in industrial environments. Offers direct access to factory-level technical data. Key Features Key Features: Illustrated instructions, high-quality images, detailed circuit diagrams, searchable text, printable pages, comprehensive coverage of electrical, hydraulic, and mechanical systems, emphasis on safety and accident prevention during maintenance. Documentation Quality: Original factory manual ensures accuracy and completeness of information, with a focus on high-quality visuals and schematics essential for complex repairs. 📋 Manual Details Coverage Areas Covered Models And Years: Jungheinrich EFG-DH Series forklifts, specifically models 12.5 and 15A, manufactured between August 1994 and July 1996. Page Count Page Count: 222 Manual Type Manual Type: Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Systems Covered: Electrical systems (contactor rack, alarm messages, basic circuit diagrams, wiring diagram designations, truck circuit diagrams, truck operating diagrams, electronic assemblies), hydraulic systems (hydr. truck circuit, hydraulic cylinder, tilting cylinder, lowering brakes, pipe failure safety devices), braking systems (main brake cylinder, parking brakes, braking distances), chassis and frame, mast systems, fork tines, lubrication, battery discharge monitoring, hour meter functions. Electrical System Details: Detailed coverage including EFG-DH Contactor rack, alarm messages, basic and truck circuit diagrams, wiring diagram designations, and procedures for electrical assemblies. Hydraulic System Details: Includes hydr. truck circuit, hydraulic cylinder (Freimuth make), tilting cylinder, lowering brakes, and pipe failure safety devices. Braking System Details: Comprehensive coverage of main brake cylinder (1-stage), installation of brake tubes, tightening torques, brake fluid change, and parking brakes. Mast And Fork System Details: Procedures for checking and adjustment of masts with oblique support rollers, and fork tines. General Truck Data: Provides essential 'General truck data EFG-DH 12.5/15', forming a foundational reference for all maintenance and repair activities. Procedures Included Procedures Included: Functional tests, setting and checking values, operating controls and displays description, servicing checklists, lubrication schedules, fuel and oil specifications, servicing and maintenance operations, fuse identification and replacement, neutral zone adjustment, brake cylinder maintenance, brake tube installation, brake system tightening torques, brake fluid change, parking brake checks, mast roller adjustments, load chain length checks, fork tine installation/replacement, tilting cylinder adjustments, screwed joint directives, accident and damage prevention during servicing, cleaning operation guidelines, lubrication recommendations. Diagnostic Procedures: Includes checking sequences for functional tests, alarm message interpretation, setting and checking values, and troubleshooting for various systems. Adjustment And Calibration Procedures: Covers adjustment to neutral zone, mast roller adjustments, and tilting cylinder adjustments. Preventative Maintenance Procedures: Detailed lubricating schedule, servicing check lists, and instructions for servicing and maintenance operations. Specialized Procedures: Includes directives for executing screwed joints, measurement of minimum braking and stopping distances, and installation of brake tubes, highlighting precision requirements. Technical Depth Technical Depth: Comprehensive, covering operational instructions, regular maintenance, detailed servicing procedures, troubleshooting diagnostics, component-specific repairs (e.g., brake systems, hydraulic cylinders), and electrical system analysis with circuit diagrams. Suitable for both maintenance technicians and repair specialists. Schematic Diagrams: Contains basic circuit diagrams, hydr. truck circuit diagrams, wiring diagram designations, truck circuit diagrams, and truck operating diagrams. Technical Specifications: Includes general truck data, technical specification - block diagram, and legend of technical modifications, modification kits, and technical specifications. Safety And Operational Guidelines: Includes excerpts from operating instructions, description of operating controls and displays, and extensive directives for accident and damage prevention during servicing and cleaning. Code Lists: Contains a 'Code List - Cable Colours', essential for accurate identification and troubleshooting of electrical wiring. Modification Information: Includes a 'Legend of technical modifications, modification kits and technical specifications', vital for tracking updates and ensuring correct part usage. 📊 Manual Specifications File Format File Format: PDF Searchability: Searchable Text Print Quality Print Quality: High quality, original factory standard, with high-quality images and searchable text. Printability: All Manuals Printable Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Electric Motor (Specific motor details not provided in product information, but manual covers electrical system diagnostics and components). Electric Drive System: The manual focuses on the diagnostics and maintenance of the electric drive motor, controllers, and associated power components. Performance Performance Details: Manual contains general truck data for...
Original factory workshop manual for a specific generation of Jungheinrich electric forklift trucks, catering to businesses and technicians requiring in-depth maintenance and repair information for these industrial vehicles.
Target Audience:
Maintenance technicians, service engineers, fleet managers, and repair workshops specializing in Jungheinrich material handling equipment.
Competitive Analysis
Competitive Analysis:
Provides authoritative, factory-backed technical data, surpassing generic repair guides. Crucial for maintaining optimal performance and longevity of Jungheinrich EFG-DH series forklifts. Offers precise specifications and diagrams essential for specialized industrial equipment.
Value Proposition:
Provides authorized and accurate repair procedures, crucial for minimizing downtime and ensuring safety and compliance in industrial environments. Offers direct access to factory-level technical data.
Key Features
Key Features:
Illustrated instructions, high-quality images, detailed circuit diagrams, searchable text, printable pages, comprehensive coverage of electrical, hydraulic, and mechanical systems, emphasis on safety and accident prevention during maintenance.
Documentation Quality:
Original factory manual ensures accuracy and completeness of information, with a focus on high-quality visuals and schematics essential for complex repairs.
📋 Manual Details
Coverage Areas
Covered Models And Years:
Jungheinrich EFG-DH Series forklifts, specifically models 12.5 and 15A, manufactured between August 1994 and July 1996.
Detailed coverage including EFG-DH Contactor rack, alarm messages, basic and truck circuit diagrams, wiring diagram designations, and procedures for electrical assemblies.
Hydraulic System Details:
Includes hydr. truck circuit, hydraulic cylinder (Freimuth make), tilting cylinder, lowering brakes, and pipe failure safety devices.
Braking System Details:
Comprehensive coverage of main brake cylinder (1-stage), installation of brake tubes, tightening torques, brake fluid change, and parking brakes.
Mast And Fork System Details:
Procedures for checking and adjustment of masts with oblique support rollers, and fork tines.
General Truck Data:
Provides essential 'General truck data EFG-DH 12.5/15', forming a foundational reference for all maintenance and repair activities.
Procedures Included
Procedures Included:
Functional tests, setting and checking values, operating controls and displays description, servicing checklists, lubrication schedules, fuel and oil specifications, servicing and maintenance operations, fuse identification and replacement, neutral zone adjustment, brake cylinder maintenance, brake tube installation, brake system tightening torques, brake fluid change, parking brake checks, mast roller adjustments, load chain length checks, fork tine installation/replacement, tilting cylinder adjustments, screwed joint directives, accident and damage prevention during servicing, cleaning operation guidelines, lubrication recommendations.
Diagnostic Procedures:
Includes checking sequences for functional tests, alarm message interpretation, setting and checking values, and troubleshooting for various systems.
Adjustment And Calibration Procedures:
Covers adjustment to neutral zone, mast roller adjustments, and tilting cylinder adjustments.
Preventative Maintenance Procedures:
Detailed lubricating schedule, servicing check lists, and instructions for servicing and maintenance operations.
Specialized Procedures:
Includes directives for executing screwed joints, measurement of minimum braking and stopping distances, and installation of brake tubes, highlighting precision requirements.
Technical Depth
Technical Depth:
Comprehensive, covering operational instructions, regular maintenance, detailed servicing procedures, troubleshooting diagnostics, component-specific repairs (e.g., brake systems, hydraulic cylinders), and electrical system analysis with circuit diagrams. Suitable for both maintenance technicians and repair specialists.
Includes general truck data, technical specification - block diagram, and legend of technical modifications, modification kits, and technical specifications.
Safety And Operational Guidelines:
Includes excerpts from operating instructions, description of operating controls and displays, and extensive directives for accident and damage prevention during servicing and cleaning.
Code Lists:
Contains a 'Code List - Cable Colours', essential for accurate identification and troubleshooting of electrical wiring.
Modification Information:
Includes a 'Legend of technical modifications, modification kits and technical specifications', vital for tracking updates and ensuring correct part usage.
📊 Manual Specifications
File Format
File Format:
PDF
Searchability:
Searchable Text
Print Quality
Print Quality:
High quality, original factory standard, with high-quality images and searchable text.
Printability:
All Manuals Printable
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Electric Motor (Specific motor details not provided in product information, but manual covers electrical system diagnostics and components).
Electric Drive System:
The manual focuses on the diagnostics and maintenance of the electric drive motor, controllers, and associated power components.
Performance
Performance Details:
Manual contains general truck data for EFG-DH 12.5/15, which would implicitly include performance-related settings and checks, though specific HP/torque figures are not listed in the product description.
Fuel System
Fuel System:
N/A (Electric Forklift)
🔧 Transmission
Standard
Transmission Type:
Electric Drive System (Details covered by electrical and hydraulic system sections, including motor controls and drive components).
Optional
Optional Transmission Features:
N/A
Features
Transmission Features:
The manual covers diagnostics and maintenance of the electric drive system, including related control circuits and components critical for smooth operation and power delivery.
Drive Control Systems:
Coverage includes the electronic control systems managing the electric drive, crucial for precise operation and energy efficiency.
📐 Dimensions
Exterior
Exterior Dimensions:
General truck data for EFG-DH 12.5/15 is available, but specific exterior dimensions are not detailed in the product description. The manual likely contains this information.
Interior
Interior Dimensions:
N/A (Focus is on operational controls and maintenance, not passenger cabin dimensions).
Cargo
Cargo Specifications:
Model designations (12.5 and 15A) likely refer to load capacities (e.g., 1250 kg, 1500 kg), but specific capacity details are not in the product description. The manual will contain operational data.
Weights
Weight Specifications:
General truck data for EFG-DH 12.5/15 is available, implying weight information is contained within the manual, though not explicitly listed in the product description.
Weight And Load Considerations:
Manual contains data relevant to weight distribution and load handling, critical for safe operation and maintenance.
🛡️ Safety Features
Ratings
Safety Ratings:
The manual includes 'Instructions for the prevention of accidents and damage to equipment when performing servicing, checking and repair operations on fork lift trucks equipped with electronic assemblies', indicating a strong focus on safe operation and maintenance practices.
Active Features
Active Safety Features:
The manual covers functional tests and diagnostic procedures for systems like the braking system (including lowering brakes and pipe failure safety devices), which are critical active safety components.
Passive Features
Passive Safety Features:
While not explicitly detailed as passive features (like seatbelts, roll cages), the manual's comprehensive coverage of mast integrity, fork tine condition, and structural component maintenance contributes to the overall passive safety of the forklift.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Industrial forklift, not equipped with infotainment systems).
Driver Assistance
Driver Assistance Features:
The manual covers 'Description of the operating controls and displays' and includes a 'Battery discharge monitor (EW) / Hour meter (BZ) with LCD-display', which are key operational monitoring technologies.
Operator Interface Controls:
Detailed explanation of dashboard indicators, control levers, and warning systems to ensure proper operation and fault detection.
Connectivity
Connectivity Options:
N/A (Industrial forklift, typical connectivity features are not applicable).
🔧 Maintenance
Service Intervals
Service Intervals:
The manual includes a 'Servicing check list EFG-DH' and a 'Lubricating schedule EFG-DH 12,5 / 15', indicating defined service intervals and tasks, though specific frequencies are detailed within the manual's pages.
Fluid Specifications
Fluid Specifications:
The manual specifies 'Fuels and oils' and provides a 'List of lubricants for HJC-fork lift trucks', offering detailed recommendations for all necessary fluids and lubricants used in the forklift.
Hydraulic Fluid Types:
Specific recommendations for hydraulic fluids are provided, critical for the proper functioning of the lift and tilt mechanisms.
Lubricant Types:
Detailed list of lubricants for various components, including those for the mast, drive system, and auxiliary mechanisms.
Known Issues
Common Issues And Troubleshooting:
The manual provides 'Alarm messages' and comprehensive diagnostic procedures for electrical and hydraulic systems, which are essential for identifying and resolving common issues encountered in these types of forklifts.
Troubleshooting Guides:
Includes specific troubleshooting procedures for common electrical faults, hydraulic leaks, and braking system anomalies.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Jungheinrich is a globally recognized manufacturer of material handling equipment, known for its innovation and quality in industrial trucks, including electric forklifts.
Model Evolution
Model Evolution:
The EFG-DH series represents a specific generation of Jungheinrich electric forklifts from the mid-1990s, showcasing advancements in electric drivetrain technology and hydraulic systems of that era.
Production
Production Period:
August 1994 - July 1996
Manufacturing Era:
Represents mid-1990s industrial forklift technology, covering the transition and integration of electronic controls.
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