Jungheinrich Electric Lift Truck EFG 213, EFG 215, EFG 216, EFG 218, EFG 220 (02.04-12.08) Workshop Service Manual

tUNGHEINRICH EFG 2xx / 3xx 03.12 0.1 (S§) Service Manual EFG 2xx 13xx Index Chapter 1 Operating Instructions Chapter 2 Technical Description of Components Chapter 3 Test and Setting Values / General Truck Data EFG 2xx / 3xx Chapter 4 Truck Maintenance Chapter 5 Service Manual Items Chapter 6 AS 4812F and AS 4814H CAN Bus Controllers Chapter 7 LISA and Parameters Chapter 8 Electrical Wiring Diagrams Chapter 9 Hydraulic Diagrams Used before safety instructions which must be observed to avoid danger to personnel. S Used before notices which must be observed to avoid material damage. Used before explanations.

tUNGHEINRICH EFG 2xx / 3xx 05.04 1.1 (SB) 1. Operating Instructions EFG 2xx Order no. Order no. CD 52025576 © 52025602 (GB) 52025577 <TR) 52025603 CD 52025578 (RUS) 52025604 <NL) 52025579 © 52025605 CD 52025580 © 52025606 ÿ 52025591 (USA) 52025607 (DK) 52025592 CD 52025593 (RUS) 52025594 © 52025595 CD 52025596 (GR) 52025597 © 52025598 CD 52025599 (PL) 52025600 © 52025601 EFG 3xx Order no. Order no. © 52025615 © 52025655 (GB) 52025616 (TR) 52025656 © 52025617 (RUS) 52025658 © 52025618 ® 52025660 © 52025619 © 52025663 0 52025620 (USA) 52025664 (DK) 52025641 © 52025645 (RUS) 52025647 © 52025648 © 52025649 (GR) 52025650 © 52025651 © 52025652 (PL) 52025653 © 52025654

tUNGHEINRICH EFG 2xx / 3xx 10.08 2.1 (S§) 2. Technical Description of Components Used before safety instructions which must be observed to avoid danger to personnel. A Used before notices which must be observed to avoid material damage. p»j Used before explanations. Index Multi-Pilot 2xx Component Arrangement 2.3 Solo Pilot 2xx Component Arrangement 2.4 Multi-Pilot 3xx Component Arrangement 2.5 Solo Pilot 3xx Component Arrangement 2.6 Chassis/Superstructure: 2.7 Drive 2.8 Traction motor 2.9 fÿl For sensor bearing disassembly / assembly refer to 004 014 293 00008 Transmission 2.10 Wheels/Axles 2.11 Travel switch/Accelerator pedal 2.12 Brake system 2.13 Brake pedal 2.13 Parking brake 2.13 Multi-plate brake 2.14 Steering system 2.15 Steering column 2.15 EFG 2xx swivelling bolster 2.16 EFG 3xx Steering Axle 2.17 Power steering pump 2.18 Steering system block diagram 2.19 Chassis / load section connection 2.20 Tilt cylinder 2.20 Hydraulic system 2.21 Control panel 2.21 Control valve 2.22 Pump motor / pump / pressure filter 2.23 Electrical System 2.24 Solo Pilot block diagram 2.25 Multi Pilot block diagram 2.26 Information and Service Display 2.27 INFO displays 2.27 Effective hours on/off, sound on/off 2.27 Resetting the service interval counter 2.28 Resetting the UW interval counter 2.28 Activating / deactivating operating programs 2.29

tUNGHEINRICH EFG 2xx / 3xx 10.08 2.3 (SB) Multi-Pilot 2xx Component Arrangement Item Description 1 Mast 2 Mast lift cylinder 3 Steering 4 Information and Service Display 5 Main switch and switch controls Aux. electrical system (optional) 6 Traction motors 7 Interface 4 8 Control valve 9 Pump motor 10 Main contactor (K1) 10a Voltage switch contactor K6 11 Main current fuses 12 Steering swivelling bolster 13 Steering unit 14 Lift controller / Lift main fuse 15 Traction controller / Travel main fuse 16 Control current fuses

tUNGHEINRICH EFG 2xx / 3xx 10.08 2.4 (SB) Solo Pilot 2xx Component Arrangement ÿ 1 Item Description 1 Mast 2 Mast lift cylinder 3 Steering 4 Information and Service Display 5 Main switch and switch controls Aux. electrical system (optional) 6 Control valve 7 Traction motors 8 Interface 3 9 Pump motor 10 Main contactor (K1) 10a Voltage switch contactor K6 11 Main current fuses 12 Steering swivelling bolster 13 Steering unit 14 Lift controller / Lift current fuse 15 Traction controller / traction current fuse 16 Control current fuses

tUNGHEINRICH EFG 2xx / 3xx 10.08 2.5 (SB) Multi-Pilot 3xx Component Arrangement Item Description 1 Mast 2 Mast lift cylinder 3 Steering 4 Comfort display 5 Main switch and switch controls Aux. electrical system (optional) 6 Traction motors 7 Interface 4 8 Prop, control valve 9 Pump motor 10 Main contactor (K1) 10a Voltage switch contactor K6 11 Main current fuses 12 Steering cylinder / steering axle 13 Steering motor 14.1 Traction controller, LH / traction current fuse 14.2 Traction controller, RH / traction current fuse 15 Lift controller / Lift current fuse 16 Control current fuses

tUNGHEINRICH EFG 2xx / 3xx 10.08 2.6 (SB) Solo Pilot 3xx Component Arrangement Item Description 1 Mast 2 Mast lift cylinder 3 Steering 4 Comfort display 5 Main switch and switch controls Aux. electrical system (optional) 6 Control valve block 7 Traction motors 8 Interface 3 9 Pump motor 10 Main contactor (K1) 10a Voltage switch contactor K6 11 Main current fuses (Travel, Lifting, Steering) 12 Steering cylinder / steering axle 13 Steering motor 14.1 Traction controller, LH / traction current fuse 14.2 Traction controller, RH / traction current fuse 15 Lift controller / Lift current fuse 16 Control current fuses

tUNGHEINRICH EFG 2xx / 3xx 10.08 2.7 (SB) Description 1 Base plate Base plate attachment Mast bearing Tilt cylinder bearing Chassis/Superstructure S Dismantle the base plate (1) to access the traction motors.

HUNGHEINRICH EFG 2xx / 3xx 10.08 2.8 (GB) Drive i - (hM (n) For torques, see chapter 3 Design A drive unit consists of a traction motor and a two-stage wheel hub transmission with integrated multi-plate brake system. Threephase motors (28 volt / 4 kW) form the drive units. The traction motor is attached to the transmission through one M8x50 and two M8x75 hex. bolts. The complete drive unit is attached to the chassis through five M16x90 and two M16x60 ratchet bolts. Item Description Item Description 1 M16 bolt 5 Stop nut 2 Transmission 6 0 ring 76x2.5 3 Wedge 7 M8 bolt 4 Traction motor

tUNGHEINRICH EFG 2xx / 3xx 10.08 2.9 (SB) Traction motor 0 Design Threephase motors (28 volts/4 kW) form the drive units. The traction motors are designed for regenerative braking. The thermo sensor for temperature control is located in the motor coil, the speed sensor is located in the sensor ball bearing (SL). For sensor bearing disassembly / assembly refer to 004 014 293 00008 Motor overtemperature is displayed via warning lights in the multi¬ function display. -x/ ~\ r- i - i 1 r - ih Sensor lead

Jungheinrich Electric Lift Truck EFG 213, EFG 215, EFG 216, EFG 218, EFG 220 (02.04-12.08) Workshop Service Manual

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