Jungheinrich EFG-Series Forklifts (EFG422/EFG425/EFG425K/EFG425S/EFG425KS/EFG430) Service & Repair Manual
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tUNGHEINRICH EFG 422-430
06.06 1 (GB)
Safety instructions
Component Layout
Technical Specifications
Operating Instructions
Wiring diagrams (electrical / hydraulic)
Parameter
HUNGHEINRICH 001 000 000 00025
04.07 1 (GB)
Brakes
h
ÿMinimum
braking and braking distance
measurement (see service manual D
6360.03)
Guidelines for installing brake pipe lines
(see service manual D 6360.16)
Parking brakes (see service manual D
6360.21)
Wheel brake
ÿ
Multi Plates
Brake system
Operating Brake
ÿ
Bleeding the brakes
Check and release the spring-loaded
brake
Manual release of the spring-loaded brake
ÿMain
brake cylinder (single stage)
(See service manual GB 4001)
ÿSpring-loaded parking brake
ÿSpring loaded cylinder
HUNGHEINRICH 002 000 000 00020
07.07 1 (GB)
Electrical
H
ÿ
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 design
Truck Block Diagram
Switches / Switch mechanism
ÿ
Contactors, charging contactor operation
Misc. Electrical
ÿTraction-
and lift controller functional
description
Basic Operation of Threephase Currents
for Lift and Traction Drive Systems
Replacing control system components up
to 06.05 models
ÿControl
system installation position
Fuse Rating
ÿCANION
installation position
ÿCANION
function description
0
PTO
tUNGHEINRICH 002 000 000 00020
07.07 2 (GB)
Wiring
Display
-Multi-function display
(see SHB J 5003)
-
Displays
(see SHB J 5002)
- Error Logbook Representation
- Reset to its delivery status
• Service LISA from 06.05
-Design
-Commissioning with the Service LISA
-Parameter review
-Parameter settings
-Changing parameters
• Lisa diagnosis mode up to 06.05 models
• Lisa diagnosis mode from 06.05 models
-SOLO PILOT Connector Layout
-
Pre- 06.05 Connector Layout
- Post- 06.05 Connector Layout
-Multi-Function Steering Wheel Connector
Layout
tUNGHEINRICH 004 000 000 00014
07.07 1 (GB)
- Drive system components
Electric motor
-Traction motor
Electrical
mech. Transmission
-Dismantling the drive unit
Wheels
•Traction/lift controller functional and
description
• Disassembly / Assembly of Traction - Lift
Controller
• Drive wheel
•Speed sensor
•Sensor Bearing
•Dismantling the drive axle
g
PTO
Travel
tUNGHEINRICH 004 000 000 00014
07.07 2 (GB)
Controls
Travel switch/Accelerator pedal
tUNGHEINRICH 005 000 000 00016
06.10 1 (GB)
Labels / Documentation
Operator Position
Chassis and basic truck
•Auxiliary weight disassembly
•Armrest
•Operating Instructions
•Wiring diagrams
Truck design
llUNGHEINRICH 006 000 000 00012
05.05 1 (GB)
Hydraulic Operations
o
4
—J £r
k
Hydraulic system
ÿ
Pump motor / pump / pressure filter
design
For assembly, see service manual I 5006.
ÿSOLO
PILOT pilot valve
ÿMULTI-PILOT
pilot valve
-
standard
version
ÿ
Pilot valve default setting
SOLO-PILOT ; MULTI-PILOT;
pressure
limitation valve (see service manual I
5005 )
Mast, mechanical
ÿChains
(for chain elongation testing see
service manual G 6355.01)
ÿMast
rollers (lifting frame with inclined
support rollers, see service manual G
6233.01)
Load handler
Forks (see service manual G1 6401 .01)
Mast tilt
ÿCylinder
PTO
tUNGHEINRICH 006 000 000 00012
05.05 2 (GB)
Electrical
• Sensors
(Sensor bearing, see 004 014 293 00002)
Controls
- Control panel
tUNGHEINRICH 007 000 000 00015
04.14 1 (GB)
Commissioning I Maintenance / Customer Service
h
Commissioning
-Commissioning
(see Operating Instructions, Chapter C)
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
-
Regular safety inspection
(at least annually)
ÿMaintenance
checklist B
ÿMaintenance
checklist C
ÿMaintenance
checklist (cold store) B
ÿMaintenance
checklist (cold store) C
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Get your hands on the Original Illustrated Factory Workshop Service Manual for Jungheinrich EFG-Series Forklifts (EFG422/EFG425/EFG425K/EFG425S/EFG425KS/EFG430). This comprehensive manual features high-quality images, detailed circuit diagrams, and clear operating instructions to guide both professional mechanics and DIY enthusiasts in the maintenance and repair of these electric lift trucks.
- Covered models:
- EFG 422 (12.2003-10.2009)
- EFG 425 (12.2003-10.2009)
- EFG 425K (12.2003-10.2009)
- EFG 425KS (12.2003-10.2009)
- EFG 425S (12.2003-10.2009)
- EFG 430 (12.2003-10.2009)
This manual spans 590 pages and is available in English. It includes essential content such as safety instructions, component layout, technical specifications, operating procedures, and wiring diagrams for both electrical and hydraulic systems. Additional topics covered include brake systems, control systems, drive and mechanical components, hydraulic systems, load handlers, maintenance practices, and steering components.
Whether you are a professional mechanic or a DIY enthusiast, this service and repair manual provides the essential technical information needed to effectively operate, maintain, and repair your Jungheinrich EFG-Series Forklifts.
