This workshop service repair manual provides comprehensive technical information for the Jungheinrich EFG 5 Series Electric Forklift, covering model variants such as EFG 535K, EFG 540, EFG 545, EFG 550, and their respective 'S' and 'K' sub-models produced between September 2013 and June 2014. These heavy-duty electric counterbalance forklift trucks are engineered for demanding industrial applications, featuring robust construction, energy-efficient electric drive systems, advanced control technologies including electric steering, and substantial lifting capacities ranging from 3500 kg to 5000 kg. The EFG 5 series is recognized for its reliability, productivity, and operator comfort, representing a significant advancement in Jungheinrich's material handling equipment.
This 856-page English-language manual is designed to assist owners, mechanics, and technicians in maintaining and repairing the EFG 5 Series. It covers essential areas including safety information, component layouts, detailed technical specifications, operating instructions, and crucial circuit diagrams for both electrical and hydraulic systems. Specific sections address drive brake systems, control modules, traction and hydraulic controllers, mechanical transmissions, drive units, electrical systems, mast mechanics, load handling, hydraulic systems, and steering systems. The manual offers extensive maintenance procedures, diagnostic guidance for event messages and common issues, general tightening torques, and component replacement instructions, ensuring the safe and efficient operation and longevity of the forklift.
Original Illustrated Factory Workshop Service Manual for Jungheinrich Electric Lift Truck Type EFG 535K-S50.
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:
EFG 535K (09.2013-06-2014)
EFG 535KS (09.2013-06-2014)
EFG 540 (09.2013-06-2014)
EFG 540K (09.2013-06-2014)
EFG 540KS (09.2013-06-2014)
EFG 540S (09.2013-06-2014)
EFG 545 (09.2013-06-2014)
EFG 545K (09.2013-06-2014)
EFG 545KS (09.2013-06-2014)
EFG 545S (09.2013-06-2014)
EFG 550 (09.2013-06-2014)
EFG 550S (09.2013-06-2014)
EFG S40 (09.2013-06-2014)
EFG S40S (09.2013-06-2014)
EFG S50 (09.2013-06-2014)
EFG S50S (09.2013-06-2014)
Format: PDF, 856 Pages
Language: English
Contents:
Safety Information
Component Layout
Technical Specifications
Operating Instructions
Circuit Diagrams (Electrical / Hydraulic)
Parameters
Event Message
General Tightening Torques
Drive Brake
-Parking Brake, Mechanical
-Foot Brake
-Parking Brake, Hydraulic
-Multi-Plate Brake
Controls
-CANCODE
- ISM Access Module (see "ISM" service manual)
- ISM component assembly
Truck Lighting
- Beacon (LED)
Misc. Electrical
-Fuses
-Connector Overview / Connector Layout
-On-Board Power Supply
-Saab Connector PIN Layout
-DC/DC converter iCE-PIO
-DC/DC converter iCE-POC
Traction and Hydraulic Controllers
-Drive & Lift Controller
Mechanical Transmission
-Transmission
Drive System
-Drive Unit
-Thermal Sensor
Wheels
-Wheel Bolts
Electrical System
-Drive & Lift Controller
-DC/DC Converter iCE-PIO
-DC/DC Converter iCE-POC
Operator Position
-Armrest
Mast, Mechanical
- Mast Rollers (for masts with angled backing rollers see service manual G 6233.01)
- Mast Rollers (mast without roller recess)
-Chains (for chain elongation testing see service manual G 6355.01)
-Securing the Mast
Load Handler
-Forks (see service manual G1 6401.01)
Hydraulic System ...
-Valve Block
-Hydraulic Unit
-Hydraulic Reservoir
-Thermal Sensor
Controls
-Solopilot
-Multipilot
Maintenance
- Notes on how to avoid malfunctions and material damage when cleaning an industrial truck See service manual Z 0000.15
- Notes on how to avoid accidents and material damage during maintenance, test and repair work on industrial trucks with electronic components See service manual J 6900-09
Electrical System
-Steering Actual Value Sensor (3U9)
-Setpoint Sensor RSC 28 MH (3U10)
-Thermal Sensor (3B26)
Steer Axle
- Steer Axle
Mechanical Components
-Steering Column
Steering
-Steering Controller Assembly (3U8)
-Steering Controller ICE-EPS (3U8)
-Electric Steering
Original Illustrated Factory Workshop Service Manual for Jungheinrich Electric Lift Truck Type EFG 535K-S50.
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:
EFG 535K (09.2013-06-2014)
EFG 535KS (09.2013-06-2014)
EFG 540 (09.2013-06-2014)
EFG 540K (09.2013-06-2014)
EFG 540KS (09.2013-06-2014)
EFG 540S (09.2013-06-2014)
EFG 545 (09.2013-06-2014)
EFG 545K (09.2013-06-2014)
EFG 545KS (09.2013-06-2014)
EFG 545S (09.2013-06-2014)
EFG 550 (09.2013-06-2014)
EFG 550S (09.2013-06-2014)
EFG S40 (09.2013-06-2014)
EFG S40S (09.2013-06-2014)
EFG S50 (09.2013-06-2014)
EFG S50S (09.2013-06-2014)
Format: PDF, 856 Pages
Language: English
Contents:
Safety Information
Component Layout
Technical Specifications
Operating Instructions
Circuit Diagrams (Electrical / Hydraulic)
Parameters
Event Message
General Tightening Torques
Drive Brake
-Parking Brake, Mechanical
-Foot Brake
-Parking Brake, Hydraulic
-Multi-Plate Brake
Controls
-CANCODE
- ISM Access Module (see "ISM" service manual)
- ISM component assembly
Truck Lighting
- Beacon (LED)
Misc. Electrical
-Fuses
-Connector Overview / Connector Layout
-On-Board Power Supply
-Saab Connector PIN Layout
-DC/DC converter iCE-PIO
-DC/DC converter iCE-POC
Traction and Hydraulic Controllers
-Drive & Lift Controller
Mechanical Transmission
-Transmission
Drive System
-Drive Unit
-Thermal Sensor
Wheels
-Wheel Bolts
Electrical System
-Drive & Lift Controller
-DC/DC Converter iCE-PIO
-DC/DC Converter iCE-POC
Operator Position
-Armrest
Mast, Mechanical
- Mast Rollers (for masts with angled backing rollers see service manual G 6233.01)
- Mast Rollers (mast without roller recess)
-Chains (for chain elongation testing see service manual G 6355.01)
-Securing the Mast
Load Handler
-Forks (see service manual G1 6401.01)
Hydraulic System ...
-Valve Block
-Hydraulic Unit
-Hydraulic Reservoir
-Thermal Sensor
Controls
-Solopilot
-Multipilot
Maintenance
- Notes on how to avoid malfunctions and material damage when cleaning an industrial truck See service manual Z 0000.15
- Notes on how to avoid accidents and material damage during maintenance, test and repair work on industrial trucks with electronic components See service manual J 6900-09
Electrical System
-Steering Actual Value Sensor (3U9)
-Setpoint Sensor RSC 28 MH (3U10)
-Thermal Sensor (3B26)
Steer Axle
- Steer Axle
Mechanical Components
-Steering Column
Steering
-Steering Controller Assembly (3U8)
-Steering Controller ICE-EPS (3U8)
-Electric Steering
