Jungheinrich Electric Lift Truck EFG-V20L, EFG-V25, EFG-V25L, EFG-V30 Workshop Service Manual

tUNGHEINRICH EFG-V 20L-30 06.04 0.1 (GB) CHAPTER OVERVIEW Operating Instructions 1 9 Technical Description of Assemblies 2 10 General Truck Data Test and Setting Values 3 11 Truck Maintenance 4 12 Service Manual Items 5 LT 200 traction controller / lift controller 6 Electrical diagrams 7 Hydraulic diagrams 8

EFG-V 20 L/25/25 L/30 07.95- Operating instructions Щ 50002120 04.96 EFG-V 20-25

Foreword The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide suf- ficient instruction for the safe operation of the industrial truck. The information is provided clearly and concisely. The chapters are arranged by letter. Each chapter starts with page 1. The page identification consists of a chapter letter and a page number. For example: Page B 2 is the second page in chapter B. The operating instructions detail different truck models. When operating and servicing the truck, make sure that the instructions apply to your truck model. Safety instructions and important explanations are indicated by the following gra- phics: f Used before safety instructions which must be observed to avoid danger to person- nel. m Used before notices which must be observed to avoid material damage. A Used before notices and explanations. t Used to indicate standard equipment. o Used to indicate optional equipment. Our trucks are subject to ongoing development. Jungheinrich reserves the right to al- ter the design, equipment and technical features of the truck. No guarantee of partic- ular features of the truck should therefore be assumed from the present operating instructions. Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG Jungheinrich Aktiengesellschaft Am Stadtrand 35 D-22047 Hamburg - Germany Telephone: +49 (0) 40/6948-0 www.jungheinrich.com 0507.GB

Table of contents I 1 A Correct use and application of the truck A1 B Description of the truck 1 2 2.1 2.2 3 3.1 3.2 3.3 3.4 3.5 3.6 4 4.1 4.2 4.3 Application............................................................................. Assembly description and functional description........... Truck........................................................................................ Load lifting system................................................................ Technical data - Standard version................................... Dimensions ........................................................................... Standard mast versions....................................................... Performance data................................................................. Weights................................................................................... Tyres........................................................................................ EN standards......................................................................... Location of instruction labels and identification plates.. Truck identification plate..................................................... Label: Order number, inventory number, service number.................................................................................... Load diagrams...................................................................... B1 B2 B3 B5 B6 B6 B7 B8 B8 B8 B9 B10 B11 B11 B12 C Transport and commissioning 1 2 3 Hoisting the truck by crane.................................................. Commissioning..................................................................... Moving a defective truck...................................................... C1 C1 C2 D Battery - Servicing, recharging, replacement 1 2 3 4 5 6 7 8 Safety regulations governing the handling of lead-acid batteries ........................................................... Battery type............................................................................ Battery access....................................................................... Charging the battery............................................................. Removing and installing the battery.................................. Checking the battery for condition, acid level and acid density............................................................................ Battery charge and malfunction indicator......................... Hour meter............................................................................. D1 D1 D2 D3 D4 D5 D6 D6 187.001. GB 1-2 0296

E Operation 1 2 3 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 5 Safety regulations governing the operation of the truck.............................................................................. Description of the operating controls and displays........ Start-up of truck.................................................................... Truck operation..................................................................... Driving safety rules............................................................... Travelling................................................................................ Steering.................................................................................. Braking.................................................................................... Operating the lifting device................................................. Picking up, transporting and depositing loads ............... Rendering the truck safe...................................................... Troubleshooting.................................................................... E1 E2 E4 E6 E6 E7 E8 E9 E10 E12 E15 E16 F Truck maintenance 1 2 3 4 5 5.1 6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 7 7.1 7.2 7.3 8 Operational safety and environmental protection .......... Maintenance safety regulations......................................... Servicing and inspection..................................................... Maintenance Check-list EFG-V 20 L-30.......................... Lubrication Schedule EFG-V 20 L-30............................... Fuels, coolants and lubricants ........................................... Servicing and maintenance activities............................... Preparing the truck for servicing and maintenance activities ................................................................................. Removing the rear cover..................................................... Checking the wheels for security....................................... Checking the hydraulic oil level......................................... Checking the gearbox oil level........................................... Checking the brake fluid level .......................................... Checking the electric fuses................................................. Recommissioning of the truck............................................. Decommissioning the truck................................................. Operations to be performed prior to decommissioning.................................................................. Measures to be taken during decommissioning............. Recommissioning of the truck............................................. Safety checks to be performed at regular intervals and following any untoward incidents (Ь: Accident prevention check according to VBG 36)........................... F1 F1 F3 F4 F6 F7 F8 F8 F8 F9 F9 F10 F10 F11 F12 F12 F12 F12 F13 F13 I 2 187.001. GB 2-2 0296

A 1 A Correct use and application of the truck A The Guidelines for the Correct Use and Application of Industrial Trucks (VDMA) are included in the scope of delivery for this truck. The guidelines are part of these operating instructions and must always be heeded. National regulations are fully applica- ble. The fork-lift truck described in these operating instructions is a truck that is suitable for lifting and transporting loads. It must be used, operated and maintained according to the information in these operating instructions. Any other uses are outside the design envelope and can lead to injury to persons or damage to equipment and property. Above all, overloading caused by excessively heavy or unbalanced loads must be avoided. The max. admis- sible load to be picked up is indicated on the identification plate or load diagram label shown on the truck. The fork-lift truck must not be operated in spaces subject to fire or explosion hazards, or in spaces where corrosive or very dusty atmospheres pre- vail. Duties of the user: A user within the meaning of these operating instructions is de- fined as any natural or legal person who either uses the fork-lift truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting), the user is conside- red the person, who, in accordance with existing contractual agreements between the owner and the user of the fork-lift truck, is charged with the observance of the operating duties. The user must ensure that the truck is not abused and only used within its design li- mits and that all danger to life and limb of the operator, or third parties, is avoided. In addition to this, it must be ensured that the relevant accident prevention regulations and other safety-related provisions, as well as the operating, servicing and maintenance guidelines, are observed. The user must also ensure that all persons operating the truck have read and understood these operating instructions. m If these Operating Instruction are not observed the warranty becomes void. The same applies if improper works are carried out at the device by the customer and/or third parties without permission of our Customer Service. Mounting of attachments: The mounting or installation of any attachments which will interfere with, or supplement, the functions of the truck is permitted only after writ- ten approval by the manufacturer has been obtained. If necessary, the approval of local authorities has to be obtained. Any approval obtained from local authorities does not, however, make the approval by the manufacturer unnecessary. 0600.GB

B Description of the truck B1 1 Application The EFG-V 20 L-30 is designed as a four-wheeled, electrically-driven, rider- seated truck for picking up, transporting and lifting the load outside of its wheel- base. It is a self-supporting counterweight truck which can be used to unload lorries with the load carrying device mounted at the front of the truck and to set them down on ramps or in racking. The truck can stack and transport standard DIN 15142 pallets, wire mesh pallets to DIN 15144 and other loads on pallets. Truck types and maximum load capacities: *) The load capacity diagrams on the trucks specify the maximum load. Type Max. load capacity *) Load centre of gravity EFG-V 20 L 2000xkg 500 mm EFG-V 25, 25 L 2500xkg 500 mm EFG-V 30 3000 kg 500 mm EFG-V 20-25 B87.001.GB 1-12 0797

B2 2 Assembly description and functional description Item Description 1 Driver seat 2 Overhead guard 3 Steering column 4 Control valve cover 5 Drive axle 6 Master switch 7 Steer axle EFG-V 20-25 1 5 4 B02 2 3 6 7 B87.001.GB 2-12 1295

B3 2.1 Truck Safety installations: The enclosed truck contour, featuring rounded edges, ensures safe handling of the EFG-V 20 L-30 truck. The driver is protected by the overhead guard (2). The master switch (6) ensures instant cut-out of all electric functions in an emer- gency. A red warning light in the information and service display indicates when the parking brake is applied. Slow lowering valves in the lift cylinders limit the lowering speed of the load in the event of a pressure failure. Indicating instruments: Hour meter, battery charge and malfunction indicator with travel and lifting movement cut-out function. Drive system: The complete front axle, including the drive unit (5), is secured to the truck chassis. The drive motor has an output of 11.5 kW at a high degree of efficiency and it drives the front wheels via a helical spur gear and a mechanical differential. An electronic drive control system, provided as standard equipment, ensures smooth starting, powerful acceleration and electronically controlled regenerative braking. Brake system: Two independent brake systems act on the front wheels. The service brake is designed as a hydraulic drum brake with asbestos-free brake linings and it is applied by means of the foot pedal. The parking brake is a manu- ally operated cable brake. It acts mechanically on the front wheel drum brakes. A red warning light in the information and service display is illuminated when the parking brake is applied. Steering and steer axle: The hydraulic power steering allows easy steering with kickbacks being absorbed completely. The steer axle (7) is equipped with a double-acting cylinder which transmits the steering force directly to the steering knuckle arm. This ensures balanced, symmetrical steering and reduces wear. The steer axle (7) oscillates in the chassis to balance out any unevenness of the ground. Driver position: The driver position is ergonomically designed, offering gene- rous leg room. A step facilitates getting in and out of the truck. The driver seat (1) and steering column (3) can be adjusted for maximum driver comfort. The travelling direction switch and the valve levers on the control valve cover (4) are arranged for ease of operation. Accelerator and brake pedals are arranged as found in normal vehicles. B87.001.GB 3-12 0797

B4 Item Description 8 Lift chains 9 Mast 10 Fork carriage 11 Forks EFG-V 20-25 8 10 11 9 B04 B87.001.GB 4-12 1295

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Jungheinrich Electric Lift Truck EFG-V20L, EFG-V25, EFG-V25L, EFG-V30 Workshop Service Manual

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