Jungheinrich Electric Lift Truck EFG-Vac 16, EFG-Vac 16L, EFG-Vac 18, EFG-Vac 18L, EFG-Vac 20 Workshop Service Manual

tUNGHEINRICH EFG-V /AC 12.07 0.1 @) TABLE OF CONTENTS - OVERVIEW Operator's Manual 1 9 Technical Description of Components 2 10 General Truck Data Test and Setting Values 3 11 Truck Maintenance 4 12 Service Manual Items 5 AS 4812F and AS 4814H CAN - Bus Control System 6 Electrical Diagrams 7 Hydraulic Diagrams 8

tUNGHEINRICH EFG-V /AC 09.99 1.1 @) Operator's Manual Lang. JAG Order No. STB Order No. CD) 50 050 480 50 732 19 @> 50 052 554 50 828 50 CD 50 050 558 50 732 22 QD 50 052 557 50 828 51 CD 50 052 556 50 828 55 ® 50 052 560 50 828 53

EFG-Vac 1 6/1 6L/1 8/1 8L/20 Operating instructions 50052554 12.03 tUNGHEINRICH

Foreword The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide suf¬ ficient instruction for the safe operation of the industrial truck. The information is pro¬ vided 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: (jffij) Used before safety instructions which must be observed to avoid danger to person- w nel. Used before notices which must be observed to avoid material damage. |gg=> Used before notices and explanations. • 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 in¬ structions. 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 CD C5 h- o uo o

Table of contents A Correct use and application of the truck B Truck description 1 Description of application B 1 2 Description of assemblies and functions B 2 2.1 Description of truck B 3 3 Technical data of standard version B 4 3.1 Performance data B6 3.2 Weights (all weights in kg) B 6 3.3 Tyre equipment B 6 3.4 EN standards B 7 3.5 Conditions for application B7 4 Location of instruction labels and identification plates B 8 4.1 Truck identification plate B 9 4.2 Capacity label Truck B9 4.3 Capacity label Fork tines (basic device) B 10 4.4 Capacity label Attachment B 10 C Transportation and commissioning 1 Transportation by crane C 1 2 First commissioning C1 3 Moving of the truck without own drive C 2 D Battery - Servicing, recharging, replacing 1 Safety regulations governing the handling of lead-acid batteries D 1 2 Battery types D 2 3 Opening the battery hood with support system (optional) D 3 4 Open battery hood D 4 5 Charging the battery D 5 6 Removing and installing the battery D 6 7 Closing battery cover D 7 8 Battery discharge indicator, battery discharge monitor, operating hour meter D 7 CQ CD d LO CO CM CO O LO I 1

E Operation 1 Safety instructions for floor conveyor operation E 1 2 Description of the operating controls and indicators E 2 2.1 Dashboard switches E 4 2.2 Operating console switches E 4 3 Information and service indication E 5 3.1 Information indication E 5 3.2 LED warning indicators E 6 3.3 Keyboard assignment E 6 3.4 Plain text alarm messages in the display E 7 3.5 Indication of driving programs E 7 3.6 Display indicators E 8 3.7 Changing truck parameters E 9 4 Commissioning the truck E 10 4.1 Checks and actions before routine start-up E 10 4.2 Adjustment of driver's seat E 10 4.3 Adjusting the steering column E 11 4.4 Provide operatability E 11 4.5 Setting the time E 1 1 4.6 Safety belt E 12 5 Working with the floor conveyor E 16 5.1 Safety regulations applicable when operating the truck E 16 5.2 Driving E 17 5.3 Steering E 20 5 4 Braking F 20 5.5 Operating the lifting device and attachments (control lever) E 22 5.6 Operating the lifting device and attachments (Multi Pilot) E 23 5.7 Picking up, transporting and setting down of loads E 25 5.8 Safe parking of the truck E 28 5.9 Trailer towing E 28 5.10 Trailer loads E 29 6 Fault location F 30 6.1 Temperature monitoring E 30 CO CD o io 00 <N 00 o LO

F Maintenance of the truck 1 Operating safety and environmental protection F 1 2 Safety regulations applicable to truck maintenance F 1 3 Servicing and inspection F3 4 Maintenance check list for EFG-Vac 16/18/20 F4 5 Lubrication plan for EFG-Vac 16/1 8/20 F 7 5.1 Consumption type materials F 8 6 Description of servicing operations F 9 6.1 Preparation of the truck for servicing and maintenance operation ....F 9 6.2 Open rear cover F9 6.3 Check fixing of the wheels F9 6.4 Check hydraulic oil level F 10 6.5 Check the transmission oil level F 11 6.6 Let off oil F 11 6.7 Refill oil F 1 1 6.8 Changing of hydraulic oil filter F 11 6.9 Checking the brake fluid F 12 6.10 Safety belt maintenance F 12 6.11 Checking the electric fuses F 13 6.12 Recommissioning the truck F 14 7 Decommissioning the fork lift truck F 14 7.1 Operations to be performed prior to decommissioning F 14 7.2 Measures to be taken during decommissioning F 14 7.3 Recommissioning the truck F 15 8 Safety checks to be performed at regular intervals and following any untoward incidents (CD): Accident prevention check according to BGV D27) F 15 CQ CD o LO CO Cvj CO o LO I 3

A Correct use and application of the truck |g|p 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 oper¬ ating 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 oper¬ ating 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 operator must ensure that damaged and/or poorly readable load diagrams are renewed. 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 prevail. 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 consid¬ ered 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 op¬ erating duties. The user must ensure that the truck is not abused and only used within its design lim¬ its 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 mainte¬ nance guidelines, are observed. The user must also ensure that all persons operating the truck have read and understood these operating instructions. If these operating instructions 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. Trailing and slipping loads: The truck may only be used for trailing or slipping loads for which the truck has been approved. CQ CD d LO CO CM CO O LO A 1

B Truck description 1 Description of application EFG-Vac is an electric four-wheel driver-seat fork lift truck. The truck is a cantilever counterweight stacker which is able to unload trucks by means of the load lifting de¬ vice mounted to the stacker front and depose the load on ramps or on stacks. Also closed-ground pallets can be picked up. Vehicle types and maximum load capacity. Model max. load capacity*) Load centre EFG-Vac 16 1600 kg 500 mm EFG-Vac 16 L 1600 kg 500 mm EFG-Vac 18 1800 kg 500 mm EFG-Vac 18 L 1800 kg 500 mm EFG-Vac 20 2000 kg 500 mm *) The capacity labels fixed to the vehicle are binding for the load capacity CD d B 1

2 Description of assemblies and functions 1 Item Designation 1 • Overhead guard 2 • Driver's seat 3 • Counterweight 4 • Batteries 5 • Drive axle 6 • Fork carrier 7 • Hoist frame 8 • Steering system CO CD o 10 00 <N 00 o in B 2

Jungheinrich Electric Lift Truck EFG-Vac 16, EFG-Vac 16L, EFG-Vac 18, EFG-Vac 18L, EFG-Vac 20 Workshop Service Manual

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