LUIGONG - CLG2040H,45H,CLG2050H

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Important Safety Information

Most accidents involving product operation, maintenance and repair are caused by failure to observe
safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should
also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair on this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and
understood the operation, lubrication, maintain and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as
"WARNING" as shown following.

The meaning of this safety alert symbol is as follows:


Attention. Be alert. Your safety is involved.
The message that appears under the warning, explaining the hazard, can be either written or pictorially
presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
LiuGong cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are therefore not all inclusive. If a tool, procedure, work
method or operating technique not specifically recommended by LiuGong is used, you must satisfy
yourself that it is safe for you and others. You should also ensure that the product will not be damaged or
made unsafe by the operation, lubrication, maintenance or require procedures you choose.
The information, specification, and illustrations in this publication are on the basis of information
available at the time when it was written. The specification, torques, pressures, measurements,
adjustments, illustrations, and other items can change at any time. These changes can affect the service
given to the product. Obtain the complete and most current information before starting any job. LiuGong
has the most current information available.

CALIFORNIA PROPOSITION 65

Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer,
birth defects and other reproductive harm.
Battery post, terminal and related accessories contain lead and lead compounds, Always wash hands
after handling.
1

CONTENTS

Preface Operation Manual


Before Operation ............................................ 51
Safety Information
Operator Controls and Instrument Panels ..... 52
Safety Decals and Decal Locations .................. 6
Engine Starting .......................................... 62
General Hazard Information ............................ 19
Operation Techniques .................................... 63
Crushing and Cutting Prevention .................... 22
Transportation Information ............................. 69
Burn Prevention .............................................. 22

Fire & Explosion Prevention ............................ 23 Maintenance Manual


Fire Extinguishers and First-aid Kit ................. 25 Run-in ............................................................. 75

Electrical Storm Injury Prevention ................... 25 Maintenance Interval Schedule ...................... 76

Fuel ................................................................. 26 General Torque Specifications ....................... 86

Tire Explosion Prevention ............................... 26 Lubrication Specifications ............................... 87

Attachment Cautions ....................................... 27 Tire Information .............................................. 89

Cautions about Machine Operation ................ 27 Working Implement System ............................ 90

Cautions about Machine Maintenance ............ 37 Important Maintenance Procedures ............... 92

Stability and Barycenter .................................. 38 Troubleshooting ............................................ 116

Sound .............................................................. 40 Malfunction Analysis ..................................... 119

Vibration Level ................................................ 40 Maintenance Note Table ............................. 126

Key Spare Parts to be Periodically Changed 41


INDEX
Tightening Torque of the Bolts .................... 41

Application and Specification


Applications ..................................................... 42

Main Specifications ......................................... 43


2
1
Preface

Preface Safety

The safety section lists basic safety precautions.


In addition this section identifies the text and
This manual includes important instructions locations of warning signs and labels used on the
concerning operation, lubrication, checking machine.
testing, adjusting the machine and permanent
key components. Read and understand the basic precautions
listed in the safety section before operating or
This manual should always be kept safe, clean performing lubrication, maintenance or repairs
and with the machine where it is convenient to on this machine.
find for operators to use. This manual should not
be separated from the machine even when Operation
reselling or leasing.
Some photographs and illustrations in this The operation section is a reference for the new
manual show details of attachments those may operator and a refresher for the experienced
be different from your machine. Guards and operator. Read, understand and reference it
covers may have been removed for the purpose whenever necessary. This section includes a
of illustration. description of gauges, machine controls,
switches and other controls at the operators’
Read this manual carefully and follow all station. It also provides transportation and towing
instructions for proper operation and information.
maintenance of this machine. Instructions in this
manual should help the reader avoid possible Photographs and illustrations guide the operator
personal injury or damage to the machine. The through correct procedures of checking, starting,
operator should proficiently and correctly operate operating and stopping the machine.
the machine to ensure safety. Operating techniques outlined in this publication
Use this machine only for the purpose described are basic. Skill and techniques develop as the
in this manual. Contact your Liugong dealer for operator gains knowledge of the machine and its
approval before making any modifications or capabilities.
adding attachments to the machine. The addition
of any unauthorized attachment may cause Maintenance
operation of the machine to become unsafe and
reduce the service life of the machine. Guangxi The maintenance section is a guide for
Liugong accepts no liability for any damage equipment care. The illustrated, step-by-step
resulting from the use of unapproved instructions are grouped by servicing intervals.
attachments or working practices. Items without specific intervals are listed under
the "When Required" service interval. Items in
Only trained or experienced personnel should be the "Maintenance Intervals" are referenced to
allowed to operate or maintain this machine. detailed instructions that follow.
Correctly record the machine type, serial
number, engine serial number and all major
component serial numbers for your reference
when ordering parts or in the event of theft.
Record the correct numbers to both the
operator’s manual and a secure place outside
the machine.
2
Preface

Maintenance Intervals

Use the service hour meter to determine


servicing intervals. Calendar intervals shown
(daily, weekly, monthly, etc) can be used instead
of service hour meter intervals if they provide
more convenient servicing schedules and
approximate the indicated service hour meter
reading. Recommended service should always
be performed at the interval that occurs first.
Under extremely severe, dusty or wet operating
conditions, more frequent lubrication than is
specified in the "Maintenance Intervals" may be
necessary.
Perform service on items at multiples of the
original requirement. For example, at every 500
service hours, also service those items listed
under every 250 service hours, 50 service hours
and every 8 service hours or daily.
All the information, figures, tables and
specifications are the latest product information
obtainable at the time of publication. Guangxi
Liugong Company will reserve the right to make
change without notice.

Certified Engine Maintenance

Correct maintenance and repair methods are


essential to keeping the engine and machine
systems operating correctly. As the owner, you
are responsible for performance of required
maintenance listed in the Maintenance Manual
for this machine. It is prohibited for person
engaged in the business of repairing, servicing,
selling, leasing or trading engines or machines to
remove, alter or render inoperative any
emissions related device or element of design
installed on or in an engine or machine that is in
compliance with the regulations. Certain
elements of the machine such as exhaust
system, fuel system, electrical system, air intake
system and cooling system may be emission
related and should not be altered unless
approved by Liugong.
3
Preface

Main Components of the Machine

1. Seat 9. Counterweight
2. Steering wheel 10. Engine hood
3. Mast 11. Steering axle
4. Chains 12. Rear wheel
5. Lifting cylinder 13. Frame
6. Fork 14. Titling cylinder
7. Overhead guard 15. Drive axle
8. Rear cover 16. Front wheel

Serial Number of the Machine and Parts

Product Identification Number (PIN) and Serial Numbers


Manufactures Name Guangxi Liugong Machinery Co., Ltd
Product Identification Number(PIN)
Serial Number of Engine
Serial Number of Transmission
Serial Number of Front Axle
Serial Number of Rear Axle
4
Preface

EC DECLARATION OF CONFORMITY

THE FOLLOWING EQUIPMENT:


PRODUCT NAME: FORK LIFT TRUCK
MODEL: CLG2050H(LIGHT) SERIAL NUMBER:
ENGINE MODEL: CUMMINS-B3.3TAA RATED NET POWER: 60 kW
MEASURED SOUND POWER LEVEL: 102 dB GUARANTEED SOUND POWER LEVEL: 103 dB

IS HEREWITH CONFIRMED TO FULFILL ALL THE RELEVANT PROVISIONS OF MACHINERY


DIRECTIVE 2006/42/EC AND ELECTROMAGNETIC COMPATIBILITY DIRECTIVE 2004/108/EC AND
COMPLY WITH NOISE EMISSION DIRECTIVE 2000/14/EC,AMENDED BY 2005/88/EC
AND THE FOLLOWING HARMONIZED STANDARD HAVE BEEN COMPLIED WITH:
EN 1726-1: 1998+A1: 2003
EN ISO 12100-1: 2003+A1: 2009
EN ISO 12100-2: 2003+A1: 2009
AND THE DETAILS AS FOLLOWS HAVE BEEN CONFIRMED:
NOTIFIED BODY ISSUED CERTIFICATE FOR SAMPLE: EUROPEAN CERTIFYING ORGANIZATION
CATEGORY IN 2006/42/EC AND NOT REFERRED TO IN ANNEX IV, 2006/42/EC
CONFORMITY ASSESSMENT PROCEDURE: ANNEX VIII, 2006/42/EC
CATEGORY IN 2000/14/EC AND ARTICLE 13, ANNEX I, ITEM 36, 2000/14/EC
CONFORMITY ASSESSMENT PROCEDURE: ANNEX V, 2000/14/EC

RESPONSIBLE FOR MARKING THIS DECLARATION IS THE:


MANUFACTURER □ REPRESENTATIVE ESTABLISHED WITHIN THE EU ■
MANUFACTURE'S NAME GUANGXI LIUGONG MACHINERY CO., LTD.
MANUFACTURER'S ADDRESS NO. 1 LIUTAI ROAD, LIUZHOU, GUANGXI 545007, PR CHINA.
AUTHORIZED REP'S NAME LIUGONG MACHINERY EUROPE B.V.

AUTHORIZED REP'S ADDRESS ZUIDPLEIN 36 4.16/4.17 H


1077 XV AMSTERDAM,THE NETHERLANDS
PERSON RESPONSIBLE FOR COMPILING AND KEEPING THE TECHNICAL FILES ESTABLISHED
WITHIN THE EU:
SURNAME, NAME DENGTAO

ADDRESS ZUIDPLEIN 36 4.16/4.17 H


1077 XV AMSTERDAM,THE NETHERLANDS
PERSON RESPONSIBLE FOR SIGNING THIS DECLARATION:
SURNAME, NAME LUOGUOBING
POSITION/TITLE PRESIDENT EUROPE

AMSTERDAM,
THE NETHERLANDS
(PLACE) (DATE) (COMPANY STAMP AND LEGAL SIGNATURE)
5
Preface

CE marking on nameplate(Only applies to


machines marketed within the EU/EEA)

This CE marking is located on front right side of


the overhead guard.

A-Weighted sound power level in an


operational cycle.
6
Safety Information
Safety Decals and Decal Locations

Safety Information "Caution" is also used to indicate safety


information relating to unsafe operations which
may cause personal injuries. "Danger"
represents the most dangerous conditions. The
Safety Symbol safety signs "Danger" or "Warning" are placed
near particular dangerous places. General notice
information is placed on the safety sign
The symbol for safety alerting appears
"Caution."
on machines, safety signs, manuals or
for important safety information at
other places. When you see this Safety Decals and Decal
symbol, you should follow the instructions in the
safety information, guarding against any Locations
possibility of personal injuries or death.
There are several specific safety decals on your
Safety Signs machine. The exact location of and description of
the hazards are reviewed in this section. Take
time to read, understand and familiarize yourself
Definitions of the safety signs with the words with each and every one of these safety decals.
"Danger", "Warning" and "Caution" which appear
in this manual and on the machine are as Make sure that you can read all safety decals.
follows: Clean or replace if you cannot read the words or
see the pictures. When cleaning the decals use a
cloth, water and soap. Do not use solvent,
gasoline, or other harsh chemicals to clean the
safety decals. Solvents, gasoline or harsh
● Danger: this word denotes an impending chemicals could loosen the adhesive backing of
danger, failure to observe instructions could decals causing them to fall off the machine.
result in death or serious injuries. You must replace a decal if it is damaged,
missing or cannot be read. If a decal is on a part
that is replaced, make sure a new decal is
installed on the replacement part. Pay attention
● Warning: this word denotes potential danger, to the instructional and safety decals located in
failure to observe instructions could result in the cab before starting.
death or serious injuries.

● Caution: this word denotes potential danger,


failure to observe instructions could result in
minor to medium degree of injury.
7
Safety Information
Safety Decals and Decal Locations

Decal location

1. WARNING DECAL 10. SYMBOL


2. SYMBOL 11. WARNING DECAL
3. DANGER DECAL 12. WARNING DECAL
4. LUBRICATION CHART 13. NOTICE DECAL
5. SYMBOL 14. SYMBOL
6. WARNING DECAL 15. SYMBOL
7. WARNING DECAL 16. CAUTION DECAL
8. WARNING DECAL 17. DANGER DECAL
9. CAUTION DECAL 18. SYMBOL
8
Safety Information
Safety Decals and Decal Locations

Decal information (uses for CE standard market)

Fig. 1 WARNING DECAL


(Located on the middle beam of mast)
CRUSH HAZARD. Keep clear of mast.

74A3303

Fig. 3 DANGER DECAL


(Located on left side of mast)
No passengers on or under fork.

74A3301
9
Safety Information
Safety Decals and Decal Locations

Decal information (uses for CE standard market)


Fig. 6 WARNING DECAL
(Located on the instrument stand)
Before starting: Only trained qualified
operators should operate forklift truck. Check
every control and alarm system before
operating forklift truck. Never operate forklift
truck that has mechanical problems. Always
consider the weight of any device or
attachment being used when calculating load.
When loading or unloading materials: Never
exceed forklift rated load capacity. Always
ensure the security of goods being lifted. Fully
insert fork under load before lifting clear of
load bearing surface. Never operate any part
of the machine from outside of operator's
seat. Never load with a single fork. Observe
overhead clearance when passing under
height limitations. Mast forward tilt
movements should be minimized when mast
is raised and a load applied. Beware load
may fall towards truck with mast raised.
When operating: Never carry passengers on
any part of the forklift truck. Slow down in wet
or slippery areas and when turning. Use
caution when driving on a ramp or slope.
Always travel straight up and down a ramp or
slope. Never attempt to turn forklift when
travelling on a ramp or slope. When travelling
on a gradient of 1/10, travel up gradient
forwards travel down gradient backwards.
Special attention is required when travelling
on uneven or temporary surfaces. Loads
should be carried as close to ground as
possible with mast rolled back to provide
stability.
When parking machine: Lower forks to
ground and apply parking brake, place
transmission in neutral and stop engine.
When parking machine on gradient or slope
apply parking brake and choke the wheels. 74A3305
10
Safety Information
Safety Decals and Decal Locations

Decal information (uses for CE standard market)

Fig. 7 WARNING DECAL


(Located near the tire)
IMPACT HAZARD. During inflation of tire,
stand forward or behind wheel. Release
pressure before repair. Read and understand
Operation& Maintenance Manual for proper
procedure.
74A3304

Fig. 8 WARNING DECAL


(Located near the engine fan)
CUTTING HAZARD. Keep clear or stop
engine before servicing.

74A3161

Fig. 9 CAUTION DECAL


(Located on the top of the radiator, near the
high exaust pipe)
Hot surface, keep clear

74A3625
11
Safety Information
Safety Decals and Decal Locations

Decal information (uses for CE standard market)

Fig. 11 WARNING DECAL


(Located on the rear cover)
Do not step on this surface.

74A3192

Fig. 12 WARNING DECAL


(Located on the top of the radiator)
Hot liquid under pressure, service when cool.

74A3180
Fig. 13 NOTICE DECAL
(Located on the instrument stand)
Inspect before starting the forklift.
Check hydraulic oil level. The level should
reach the mark at the middle of the sight
glass.
Check hoses, pipes, fittings, pump and valves
for leakage and damage.
Check service brake:
1. The idle stroke of service brake pedal
should be between 20-30 mm (0.8 in-1.2 in).
2. The clearance between the front bottom
plate and service brake pedal should be more
than 20 mm (0.8 in) after applying service
brake.
Check parking brake:
Machine should be able to park stably on a
slope with 15% gradient without load when
pulling the brake lever to its maximum stroke.
Check instruments, lights, terminal plugs,
switches and other electrical wirings for
normal working condition. 74H2070
12
Safety Information
Safety Decals and Decal Locations

Decal information (uses for CE standard market)

Fig. 16 CAUTION DECAL


(Located at the right side of the machine)
Do not mount machine from right side.

74A3292

Fig. 17 DANGER DECAL


(Located on right side of mast)
No passengers on or under fork.

74A3300
13
Safety Information
Safety Decals and Decal Locations

Decal information (uses for North American market)

Fig. 1 WARNING DECAL


(Located on the middle beam of mast)
CRUSH HAZARD. Keep clear of mast.

74A3136

Fig. 3 DANGER DECAL


(Located on left side of mast)
No passengers on or under fork.

74H2054
14
Safety Information
Safety Decals and Decal Locations

Decal information (uses for North American market)


Fig. 6 WARNING DECAL
(Located on the instrument stand)
Before starting: Only trained qualified
operators should operate forklift truck. Check
every control and alarm system before
operating forklift truck. Never operate forklift
truck that has mechanical problems. Always
consider the weight of any device or
attachment being used when calculating load.
When loading or unloading materials: Never
exceed forklift rated load capacity. Always
ensure the security of goods being lifted. Fully
insert fork under load before lifting clear of
load bearing surface. Never operate any part
of the machine from outside of operator's
seat. Never load with a single fork. Observe
overhead clearance when passing under
height limitations. Mast forward tilt
movements should be minimized when mast
is raised and a load applied. Beware load
may fall towards truck with mast raised.
When operating: Never carry passengers on
any part of the forklift truck. Slow down in wet
or slippery areas and when turning. Use
caution when driving on a ramp or slope.
Always travel straight up and down a ramp or
slope. Never attempt to turn forklift when
travelling on a ramp or slope. When travelling
on a gradient of 1/10, travel up gradient
forwards travel down gradient backwards.
Special attention is required when travelling
on uneven or temporary surfaces. Loads
should be carried as close to ground as
possible with mast rolled back to provide
stability.
When parking machine: Lower forks to
ground and apply parking brake, place
transmission in neutral and stop engine.
When parking machine on gradient or slope
apply parking brake and choke the wheels. 74H2065
15
Safety Information
Safety Decals and Decal Locations

Decal information (uses for North American market)

Fig. 7 WARNING DECAL


(Located near the tire)
IMPACT HAZARD. During inflation of tire,
stand forward or behind wheel. Release
pressure before repair. Read and understand
Operation& Maintenance Manual for proper
procedure.
74A3224

Fig. 8 WARNING DECAL


(Located near the engine fan)
CUTTING HAZARD. Keep clear or stop
engine before servicing.

74A2826

Fig. 9 CAUTION DECAL


(Located on the top of the radiator, near the
high exaust pipe)
Hot surface, keep clear

74A3529
16
Safety Information
Safety Decals and Decal Locations

Decal information (uses for North American market)

Fig. 11 WARNING DECAL


(Located on the counterweight )
No step

74A2807

Fig. 12 WARNING DECAL


(Located on the top of the radiator)
Hot liquid under pressure, service when cool.

74A2841
17
Safety Information
Safety Decals and Decal Locations

Decal information (uses for North American market)


Fig. 13 NOTICE DECAL
(Located on the instrument stand)
Inspect before starting the forklift.
Check hydraulic oil level. The level should
reach the mark at the middle of the sight
glass.
Check hoses, pipes, fittings, pump and valves
for leakage and damage.
Check service brake:
1. The idle stroke of service brake pedal
should be between 20-30 mm (0.8 in-1.2 in).
2. The clearance between the front bottom
plate and service brake pedal should be more
than 20 mm (0.8 in) after applying service
brake.
Check parking brake:
Machine should be able to park stably on a
slope with 20% gradient without load when
pulling the brake lever to its maximum stroke.
Check instruments, lights, terminal plugs,
switches and other electrical wirings for
normal working condition. 74H2070

Fig. 16 CAUTION DECAL


(Located at the right side of the machine)
Do not mount machine from right side.

74A3228
18
Safety Information
Safety Decals and Decal Locations

Decal information (uses for North American market)

Fig. 17 DANGER DECAL


(Located on right side of mast)
No passengers on or under fork.

74H2055
19
Safety Information
General Hazard Information

General Hazard Information

Be familiar with all safety cautions, failure to


observe could result in property damage, serious
injury or even death.
Only trained and qualified personnel should be
allowed to operate or maintain the machine.

Wear relevant personal protective equipment


(PPE) such as a hard hat, ear protection, safety
glasses, safety shoes and gloves when
operating or servicing the machine.

Do not operate the machine if you feel sick,


sleepy or after taking some medication. Check
with your doctor if unsure. Never operate
machinery while under the influence of drugs or
alcohol.
Attach a DO NOT OPERATE or similar warning
tag to start switch or control levers before
servicing or repairing the machine.

Using goggles, safety glasses or full face mask


can protect your eyes from being injured by high
G

pressure liquids, when maintaining storage


IN
N
AR
W

batteries, by flying scraps when the engine is in


er ot
!

op o n

e
at

operation or you are using tools to strike objects.


d

When removing springs or resilient parts, add


r:
te
ra

acid/electrolyte to batteries, you should wear a


pe
O

:
ate
D

full face protective mask. When carrying out


welding operations or gas cutting operations with
Do not wear loose fitting clothing, dangling
a welding torch, wear specific safety goggles
jewelry or long hair that can catch on controls or
suitable for the task being performed. Consult
in other moving parts of the machine.
your welding equipment dealer for more
information.
20
Safety Information
General Hazard Information

Pay attention when opening fluid compartments


to prevent foreign materials from entering the
system. Always remove loose materials from
near caps and plugs.

When working under high noise conditions, wear


appropriate safety equipment to protect your
hearing, such as approved earmuffs or plugs.
Avoid the damage caused by exposure to high Know the appropriate worksite hand signals and
noise on your hearing. who gives them. Accept signals from one person
only.
Never put maintenance fluids into glass
containers.
Observe the relevant laws and regulations when
handling harmful articles such as lubricants,
fuels, coolants, solvents, filters, batteries and
other materials.
Use all cleaning solutions with care. Do not use
any flammable material to wash components, for
example, diesel oil or gasoline. They may easily
catch fire.
Make sure all protective guards and covers are
secured in place on the machine. Always replace
protective guards and covers removed for
servicing or maintenance. Repair damaged
guards and covers before operation.
Keep the machine, especially the panels,
accesses, step and ladders, free of foreign
material, such as debris, oil, tools and other
items which are not part of the machine.
Secure all loose items such as lunch boxes, tools
and others.
Report all required repairs in time.
Do not allow unauthorized personnel on or
around the machine.
Guangxi Liugong bears no responsibility for
failures caused by modifications to machine
structure without Liugong’s permission.
21
Safety Information
General Hazard Information

Compressed Air Even a pin-hole size leak can cause serious


injury, If you are hit by spraying high-pressure oil,
Compressed air can cause personal injury. When see a doctor for treatment at once.
using compressed air for cleaning, wear a
protective face shield, protective clothing,
hearing protection and protective shoes. Never
aim compressed air at yourself or others.
Compressed air could penetrate your skin and
cause serious injury or death. The maximum air
pressure used should not exceed 25psi
(0.2Mpa).

High-pressure Fluid
Disposal of Waste Fluids

Improper handling of the waste fluid will cause


Avoid injury from high-pressure oil. When pollution of the environment. Obey all local
repairing hydraulic lines, ensure that regulations for disposal of waste fluids.
system pressure is completely released Collect all waste fluids when performing
before beginning the repair. Hydraulic oil inspections, maintenance, testing, adjusting and
under pressure contacting the skin could repairs to the machine.
cause serious injury or damage.
Prepare to collect fluids with suitable containers
before opening any compartment or
Use caution before disconnecting hydraulic lines
disassembling any component that contains
or connectors. High pressure oil that is released
fluids.
can cause a hose to whip.
Use suitable containers to collect waste fluids.
Always support attachments and release
Do not use food containers or beverage bottles
residual pressure before attempting to
as they could mislead people to drink the
disconnect hydraulic lines. Pressure applied by
contents.
loads on attachments could cause hydraulic oil to
spray when lines are removed.
Wear safety glasses and leather gloves. Never
check for high-pressure leaks with your
unprotected hand. Use a board or cardboard
when checking for leaks.
22
Safety Information
Crushing and Cutting Prevention

Asbestos Danger For those parts fitted with shields, if it is


necessary to remove shields in order to perform
Breathing asbestos dust can be hazardous to maintenance, always install the shields after the
your health. Equipment and replacement parts maintenance is performed.
shipped from Liugong have no asbestos in them.
Rotating or moving parts have cutting or crush
Liugong recommends the use of genuine factory
hazard. Keep clear or stop engine before
spare parts only. Observe the following rules if
servicing.
you are handling any spare parts that contain
asbestos or asbestos fibers:
Never use compressed air to clean up asbestos.
Use a wet method in order to clean up asbestos
materials. Water the area down to clear asbestos
dust.
A vacuum cleaner that is equipped with a high
efficiency particulate air filter (HEPA) can also be
used.
Do not grind materials that contain asbestos. Keep hands and objects away from moving fan
Obey environmental regulations for the disposal blades. They can throw or cut any object that
of asbestos. contacts the moving blades.

Shower after contact with asbestos. Never attempt adjustments while the machine is
moving or the engine is running unless otherwise
Wear an approved respirator if there is no other specified.
way to control the dust.
If the machine must be repaired with engine
running, make sure that a qualified operator is
available in the cab to shut down the engine if
required.
Do not use a kinked or frayed wire cable. Wear
gloves when handling wire cables.
Retainer pins, when struck with force, can fly out
and injure nearby persons. Make sure the area is
clear of people when driving retainer pins. Wear
protective glasses when striking a retainer pin to
avoid injury to your eyes.
Crushing and Cutting Preven-
Chips or other debris can fly off objects when
tion struck. Make sure no one can be injured by flying
debris before striking any object.
Don't put hands, arms, or any other parts of the
body in the way of removable parts.
Burn Prevention
Support equipment and attachments properly
when working beneath them. Do not depend on
Some parts of the machine become hot during
hydraulic cylinders to hold up the implement/
normal operation. Use caution when maintaining
attachment. The implement/attachment can fall if
the engine and hydraulics. Allow the machine to
a control lever is accidentally moved, or if a
cool after it has been operating for a long period
hydraulic line breaks.
of time.
23
Safety Information
Fire & Explosion Prevention

Coolant Relieve all residual pressure in air, oil, fuel or


cooling systems before any lines, connectors or
At operating temperature, the engine coolant is related items are disconnected or removed.
hot and under pressure. The radiator and all
lines to heaters and the engine contain hot water Batteries
or steam. Any contact can cause severe burns.
Batteries give off flammable fumes which can
explode.
Batteries and battery terminals may contain lead;
do not touch batteries with your bare hands.
Always wash your hands right after maintaining a
battery.
Do not smoke when observing the battery
electrolyte levels.
Electrolyte is an acid and causes personal injury
if it contacts skin or eyes. If contact occurs flush
Check the coolant level only after the engine has with water and seek medical attention right away.
been stopped and the coolant filler cap is cool
enough to remove with your bare hand. Always wear protective glasses and gloves when
checking batteries.
Remove the cooling system filler cap slowly to
relieve pressure
Coolant contains alkali that can cause personal
injury. Avoid contact with the skin, eyes and
mouth.

Oil

Hot oil and components can cause personal


injury. Do not allow hot oil or components to
contact the skin.

Fire & Explosion Prevention

All fuels, most lubrication and some coolant


mixtures are flammable.
Fuel leaked or split onto hot surfaces or electrical
components can cause a fire.
At operating temperature the hydraulic oil tank is
hot and can be under pressure.
Remove the hydraulic oil tank cap only after the
engine has been stopped and the cap is cool
enough to remove with your bare hand.
Remove the hydraulic oil tank oil filling cap
slowly to relieve pressure.
24
Safety Information
Fire & Explosion Prevention

Do not smoke while refueling or in a refueling Ether


area, or where flammable materials are stored.

EXPLOSION HAZARD. Do not use ether.


Machine is equipped with electrical cold
weather start aid device.

Starting the machine by use of ether could result


Clean and tighten all electrical connections. in serious damage to the engine or personal
Check daily for loose or frayed electrical wires. injury or death.
Have all loose or frayed electrical wires
tightened, repaired or replaced before operating
the machine.
Check the electric circuit periodically to avoid fire
caused by overload or short circuit.
Keep all fuels and lubrications stored in properly
marked containers and away from all
unauthorized persons.
Store all oily rags or other flammable materials in
a protective container away from naked flames Cautions Concerning Lines, Tubes and
or other sources of ignition. Hoses
Do not weld or flame cut pipes that contain
flammable fluids. Clean the flammable fluids Do not bend or strike high-pressure lines. Do not
before welding or flame cutting on them. install bent or damaged tubes or hoses.
Remove all flammable materials such as fuel, Tighten any loose fuel or oil pipes, hydraulic
lubrication and other debris before they system tubes or hoses. Repair any damaged fuel
accumulate on the machine. or oil lines, tubes or hoses. Leaks can cause
fires. Contact Liugong or your Liugong Dealer for
Do not operate the machine near an open flame.
factory authorized replacement parts.
Keep all open flames or sparks away from the
If you see evidence of any of the following
battery. Do not smoke in battery charging areas.
situations, replace the part before using:
When using jumper cables always connect
● Connectors damaged or leaking.
positive (+) cable to positive (+) terminal of
battery connected to starter solenoid and ● Outer covering frayed or cut and reinforcing
negative(-) cable from external source to starter wire exposed.
negative(-) terminal. If starter negative terminal is ● Outer covering ballooning.
not equipped with, connect it to the engine block.
● Evidence of kinking or crushing.
Do not charge a frozen battery. This may cause
an explosion. ● Reinforcing steel wire of the hose embedded
in the outer covers.
● Connectors incorrectly fitted or tensioned.
25
Safety Information
Fire Extinguishers and First-aid Kit

Make sure that all clamps, guards and heat Inspect and service the fire extinguisher
shields are properly installed. During operation regularly. Obey the recommendations on the
this will prevent vibration, abrasion, friction with instruction plate and all local laws and
other parts and guard from excessive heat. regulations relating to fire extinguishers.
Before removing or servicing any lines of the air
conditioning system, always ensure there is not Electrical Storm Injury Pre-
an open fire nearby; any escaping gas coming
into contact with fire could result in poisonous vention
fumes. Never smoke when servicing or repairing
the air conditioning system, any escaping gas When lightning is striking in the vicinity of the
that burns and inhaled can cause bodily harm or machine, the operator should never attempt to
death. mount and dismount the machine.
If you are in the cab during an electrical storm,
Fire Extinguishers and First- stay in the cab. If you are on the ground during
aid Kit an electrical storm, stay away from the machine.

A fire extinguisher that meets with all local fire


extinguisher laws and regulations should be
available on the machine.
Maintain the fire extinguisher in accordance with
all local laws and regulations. Contact your local
fire department for further information.
Know how to use the fire extinguisher and first-
aid kit.
A first-aid kit should be available at the work site.
Periodically check the contents of the kit and
replace used medical supplies as necessary.
Keep telephone numbers of doctors, first-aid
centers or fire stations etc with you so you can
contact them in case of an emergency. Post the
contact telephone numbers in regulated places.
Ensure that all persons know where the
telephone numbers are located and know the
correct contact method.
26
Safety Information
Fuel

Fuel Tire Explosion Prevention

Use the correct fuel type for your forklift. The use Maintenance, removal, repair and installation of
of wrong fuel will impair forklift performance and the tires and wheel rims must be performed with
lead to unpredictable faults or damage. special equipment and a trained repairer.
Therefore, it is better to repair and maintain the
Fuel should be provided by designated gas
tires in a tire service shop.
station. There should be good ventilation and no
sparks or flames in gas station, and fire fighting
equipment should be furnished there.
Fuel is flammable and may cause fire, explosion.
When refilling, it is strictly prohibited to make fire.
When refueling, the key to start switch must be
pulled out.
Wrong disposal of fuel will cause serious
accident. Therefore, the spilled fuel must be
wiped out.
After refueling, you should not forget to tighten
the cap of fuel tank. Explosions of tires have resulted from gas heat-
induced and combustion inside the tires.
Explosions can be caused by heat that is
generated by welding, by heating rim
components, by external fire, or by excessive
use of brakes.
A tire explosion is much more violent than a
blowout. The explosion can propel the tire, the
rim components, and the drive train components
as far as 500m (1500 ft) or more from the
machine. Both the force of the explosion and the
flying debris can cause property damage,
personal injury, or death.
Do not approach a warm tire. Maintain a
minimum distance (at least 15m), as shown
below. Stay outside the shadow area.

AT LEAST 15m(50ft) AT LEAST 500m(1500ft)


27
Safety Information
Attachment Cautions

Dry nitrogen is recommended for inflation of Face the machine when getting on or off, grab
tires. If the tires were originally inflated with air, the handrails with both hands and step onto the
nitrogen is still preferred for adjusting the steps or ladders. Touch three points
pressure. Nitrogen mixes properly with air. simultaneously (two feet and one hand or two
Nitrogen inflated tires reduce the potential of a hands and one foot) to ensure stability of the
tire explosion because nitrogen does not aid body.
combustion. Nitrogen helps to prevent oxidation
of the rubber, deterioration of rubber, and
corrosion of rim components.
Liugong can provide the pneumatic tire or
cushion tire for you according your requirement.

Attachment Cautions

Attachments should only be installed by Never jump off the machine.


authorized people who have been trained to
operate and maintain the attachment according Never get on or off a moving machine.
to the operator’s manual. Be careful not to touch any control levers when
Refer to the instructions in the operation manual getting on or off the machine.
and any other related information when installing Do not try to climb on or off the machine when
and using attachments. carrying tools or supplies. Use a rope to pull
Incorrect installation of attachments or optional equipment up onto the platform or have an
parts not only will result in safety problems, but assistant pass them to you.
also will negatively influence the operation and
service life of the machine and the attatchments. Understand Your Machine

It is forbidden to modify the machine or any Be able to operate all the equipment on your
attachments without permission from your machine.
Liugong dealer.
Understand the purpose of all control systems,
Liugong bears no responsibility for injuries, instruments and indicators.
accidents or machine damage resulting from the
use of unauthorized attachments. Understand the rated load, speed range, the
characteristics of braking and steering, turning
radius and the space clearance for operation.
Cautions about Machine Remember that rain, snow, ice, gravel and soft
Operation earth may change the performance of the
machine.
Mounting and Dismounting Understand the safety signs on the machine
(Danger, Warning, Caution) and any other signs.
Before mounting or dismounting the machine,
check the condition of handrails, ladders and
steps. Clean them of grease, lubricants and dirt
before use. Repair any damaged parts and
tighten loose bolts.
Mount and dismount the machine only where
there are handrails, steps or ladders.
28
Safety Information
Cautions about Machine Operation

Understand Your Working Area Replace all damaged or lost parts and carry out
lubrication according to the maintenance interval
Before starting, inspect the area where you will schedule.
be working. You should check: adequate
Remove all loose objects from operating room.
ventilation, the position of any slopes, visible
Loose objects may affect the operation and
ditches, falling or hanging objects, conditions of
cause accidents.
soils (soft or hard), accumulated water and
swamp areas, rocks or stumps, hidden Make sure that all the windows (if equipped) are
groundwork, posts or the outer limits of walls, the clean and the screenwiper (if equipped) works
outer limits of the areas where garbage is buried normally.
or that are filled in with earth, holes or openings,
Adjust the operators seat to a position that is
obstacles, mud or ice, traffic, heavy dust, heavy
most comfortable and provides for easiest
smoke, heavy fog, the exact locations of cables
operation of the machine. Check the seat belt
or pipes for power supply, gas supply, phone
and the condition of mounting hardware. Repair
service, water supply, sewage disposal and other
or replace any items that are damaged. Replace
utilities that are hidden or hung. If necessary
the seat belt after three years of use or any time
before starting work you should ask the utility
the belt shows signs of wear or damage.
companies to mark out, close or move out these
utilities. Check all the illumination equipment before
operation in low light, and ensure that the
Before Starting the Engine illumination system is in good condition.

Inspect the machine carefully before starting the Engine Starting


engine, ensure all systems are in good
operational condition. Make sure nobody is on or Do not start the engine if there is a DO NOT
around the machine before starting the engine. OPERATE or similar tag attached to the start
switch or control levers.
Keep the steps and handrail clean. Clear any dirt
and sand from your shoes before mounting the
machine.
Check all structural members, covers and
G
IN
N
AR

fenders for deformation or damage.


W

er ot
!

op o n

e
at

Check the condition of safety items such as


d

doors, guards and covers. Repair any damage


as necessary.
r:
te
ra
pe
O

:
ate
D

Check the hydraulic system for oil leakage.


Check the condition of hoses and pipes. Do not start the engine until seated in the
operators seat and the seat belt is firmly
Check all fasteners for security.
fastened.
Check the condition of the electrical wiring
harness and fuses, replace or repair as
necessary. Also check the connectors for good
connection.
Check the fuel level and fuel system for normal
condition, drain any water or sediment in the
water/fuel separator. Dispose of fluids in
accordance with local regulations.
29
Safety Information
Cautions about Machine Operation

Ensure the control levers are all in the NEUTRAL Check the emission value in a safe outdoor area
position and the shift control lever is in the periodically. Pay attention to avoid fire, especially
NEUTRAL position before starting the engine. the leakage of oil or fuel when checking. Do not
leave the scrap cloth or paper on the engine;
Sound the horn to alert personnel before starting
know the location of the fire extinguisher and
the engine.
know how to use it.
Only start the engine from the operators seat in
Check the emission value again after engine
the operating room. Never start the engine by
maintenance and adjustment, and ensure the
short-circuiting the starter motor terminals.
value meets the relative requirements of local
Starting the engine by short-circuiting could
laws and regulations.
result in damage of the electrical system,
personal injury or death.
Before Operating the Machine
After the engine is started, you should observe,
instruments and warning lights, and make sure Make sure the machine is clear of personnel and
that they work and every reading is within fasten the seat belt before operation.
working range.
Keep all the windows, lightshades and rearview
Observe machine movements and listen mirrors clean. Secure doors and windows in
carefully for unusual noises. If there is any fault either the open or close position.
or abnormality, you should stop the engine
Adjust the rearview mirrors for best vision,
immediately. Locate the source of the problem
especially close to the machine.
and repair before further operation.
Clear all obstacles from where the machine will
be working. Be aware of hazards such as high
voltage wires, ditches, etc.
Make sure the horn, backup alarm (optional) and
all other alert devices are working properly.

Machine Operation

Before operating the machine on roads, check


whether the machine meets the requirements of
Never run the engine in a closed or poorly
the local laws and regulations for road operation.
ventilated environment. If working inside a
Make sure that you get the road operating
building, open the doors and windows to ensure
permission from relevant road administration
enough ventilation and try to prevent exhaust
offices. Observe the local traffic regulations when
gas poisoning. Use a power exhaust system
driving the machine on roads.
when working in an enclosed area.
Before operation, check the conditions of the
forklift. If any fault is found, report to relevant
personnel immediately or get it repaired. Do not
use the machine until the fault has been
eliminated.
30
Safety Information
Cautions about Machine Operation

Keep a correct posture on the seat. There may Don't overload. Make sure weights of loads are
be an accident if you sit on the seat incorrectly or within the rated capacity of the forklift truck.
operate the machine without sitting on the seat. Before picking up a load, check the load weight
For the machine equipped with a service and gravity center.
interlocking device, it will not be able to run and
operate if you don't sit on the seat correctly.

Before starting, make sure that the surrounding While driving, do not reach your arms or legs
areas are safe, the shift control lever is in the outside the forklift truck or into the mast. Never
correct position and the load has been unloaded try to go over the mast to deal with work unless
completely. when the machine stops for repair.

The operator has a primary responsibility to


protect the safety of pedestrians. Priority must
always be given to pedestrians. Take particular
Nobody is allowed to go under a raised fork,
care when turning. Never deliberately frighten
before raising the fork, make sure that there is
pedestrians to give way by flashing the lights or
nobody around it. Whether the fork is loaded or
sounding the horn.
unloaded, nobody (you are not an exception) is
allowed to stand or go under the fork.

It would be better to use a rotating beacon


(optional) and backup alarm to make it easy for
people to notice the forklift.
31
Safety Information
Cautions about Machine Operation

Do not use this machine to lift personnel. Do not Adjust the fork width as wide as possible before
allow anybody to ride on the fork. Use it for loading goods onto the fork, make sure that the
carrying goods only. width of the pallet or the goods matches well with
the width of the fork.

Make sure that the goods on pallet are secured.


Secure the goods with ropes before shipping.

Use the proper size pallet for loading. Check the


condition, strength and loading capacity of the
pallet.

The goods on the fork should be placed evenly


so as to be perfectly balanced. When loading the
goods in large size or with the center of gravity
on one side, you should be cautious not to
overturn the forklift when operating it, and also
cautious of the goods in long size such as a steel
bar or timber.
32
Safety Information
Cautions about Machine Operation

Never raise the goods on a rough road surface, Carry loads as close to the ground as possible.
pay attention to road conditions all the time when Keep the forks 15 to 20mm off the ground in
driving on a rough road surface. most cases. Never travel with the load raised
higher than necessary.

Always use the load backrest extension and


overhead guard for high stacking, especially be Keep the load tightly against the backrest, with
cautious of falling objects when stacking. Make the mast tilted backward. Never lift or lower loads
sure no loose articles are lying on top of the load. with the forklift truck in motion. Make sure that
the length of the forks matches that of the load.

Do not lift the load with the mast tilted forward.


The mast should be vertical or tilted backward Keep your forklift truck under control at all times,
when lifting a load. Never tilt forward when lifting always drive at a safe speed. Be sure you
a load. Tilt the mast forward only when putting understand your limitations.
the load on a stack or directly over the unloading
area.
33
Safety Information
Cautions about Machine Operation

Keep a safe distance between machines so as to Slow down the forklift when driving on a wet road
be able to stop the machine safely under any surface and slippery ground.
circumstance.

In the areas where the visibility is not good, you


Never overtake other machines. Never pass should drive the forklift at a low speed. If there is
other machines moving in the same direction, at rearview mirror, you should use it. If there is a
intersections, blind spots and other dangerous “Stop” sign, you should stop the forklift
places. Be prepared for the unexpected completely, sound your horn if necessary, and
circumstances. carefully drive forward.

It is forbidden to operate the forklift in a playful When taking a turn, pay attention to the swing of
way. Concentrate and watch where the forklift is its rear parts. The forklift uses the rear wheels for
going. steering which may cause swing when turning.
Especially be careful when operating at a narrow
road or place.
34
Safety Information
Cautions about Machine Operation

It is not allowed to drive across unsolidified Pay attention to the overhead goods and the
obstacles on the road. It is better to remove the clearance between the mast and the obstacle.
obstacles before going across and avoid driving The distance between the equipment at the
across uneven road surface to prevent loosening ceiling (such as lamp, cable, various
the loads. decorations, fire fighting system, door opening,
conveyor belt and head of machine) and the top
of the forklift should be large enough. In the
places where the ceiling is relatively low, lower
the mast.

Pay attention to the plate hardness when driving


across a plate. Not all of the plate has enough
hardness to support the machine, which is
loaded or unloaded. Also pay attention to the
block hardness. Watch left and right side clearance, especially
with wide loads. Where possible, drive in the
center of the aisle to avoid endangering
personnel or equipment.

It is not allowed to make the tip of the fork bump


into any objects. When driving close to platforms,
stacks, or any fixtures, and the people nearby,
you should pay more attention and lower the fork
during driving.
35
Safety Information
Cautions about Machine Operation

When carrying goods with huge size and the Drive the machine forward when going up a hill
front sight has been blocked, you should drive with a load. Drive the machine in reverse when
with reverse gear, or move forward under a going down a hill with a load to avoid tipping
signalman’s help. over. If your sight is affected by a bulky load, it is
recommended to drive the machine slowly under
the help of a signalman.

When loading and unloading goods, make sure


that the truck has stopped securely and its
wheels have been blocked. Make sure that the Shut down the forklift truck when leaving it.
parking brake of the truck has been engaged and Always park on flat ground with the forks
secured enough, otherwise, an accident could lowered. Make sure that the parking brake lever
happen. is engaged and the shift control lever is in the
NEUTRAL position. Then take out the key and
keep it with you.
36
Safety Information
Cautions about Machine Operation

Check the condition of the forklift after finishing Stop the engine, if the electronic choke engine is
work everyday. Report any faults of the machine unavailable, you need to pull back the choke
to relevant personnel if any fault is found. switch to stop the engine, then take out the key
from the switch.
Turn the battery disconnect switch to OFF
position (if equipped) or take out battery
connector (if equipped) to avoid battery
discharge.
When leaving the machine, lock all equipment
covers and doors with the key. Remove the key
and keep it with you.

Parking the Machine

When possible, park the machine on flat ground,


apply the parking brake, always lower any
attachment onto the ground and ensure the
machine will not move.
Consider any overhead hazards such as the Lowering the Attachment/ Implement with
possibility of falling rocks, any powerlines or any Engine Stopped
other overhead hazards that may exist.
Consider the ground conditions. Do not park the Before lowering the work implement, make sure
machine near the edge of a cliff, close to an open the machine is clear of personnel.
excavation or pit.
Consider environmental conditions such as the
possibility of flooding, heavy snow fall, electrical
storms and exposure to wind and cold. Any of In order to lower the implement, the engine
these conditions may cause damage to the start switch must be at ON position. Turn the
machine. engine start switch to OFF position after
lowering the implement.
If it is necessary to park the machine on a slope
or incline, place chocks under the wheels at the Push the lifting lever to lower the implement onto
downhill side on both sides to prevent the the ground or trailer. Push or pull the tilting lever
machine from moving. to ensure that the work implement is lowered flat
onto the ground.
Understand and obey all regulations relating to
public roads, if the machine is parked on a public
Store Accessories Safely
road. Additional sign or lighting may be required.
Put the control levers to the NEUTRAL position Store accessories and tools safely so as to
and the shift control lever to the NEUTRAL prevent them from falling and causing serious
position. injury or death. Keep playful children and
bystanders away from the storage area or any
Keep the engine running at idle speed for five
area accessories are being stored while in use.
minutes to let the engine cool down gradually.
37
Safety Information
Cautions about Machine Maintenance

Cautions about Machine Chock the wheel of the trailer to make it unable
to move.
Maintenance

Prepare the Working Area

Choose a clean and flat area with adequate


space, enough light, and good ventilation to carry
out any repair work. Clean the ground surface,
wipe up fuel, lubricating oil and water, and
spread sand or other absorptive materials on the
slippery ground. Keep the work area clean and
dry.

Support the Machine Correctly

Lower to the ground or support any attachments 1. Wedge


with stands or other methods. Ensure that any 2. Block
attachment can not move during maintenance or 3. Angle (Max. angle is 15°)
4. Distance between the ramps
repair work, use wheel chocks or other devices 5. Ramp
to prevent machine movement.
Use loading ramps appropriate for the machine
Do not work under any part of the machine or being moved. Consider: size, strength, departure
attachment that is not adequately supported. Do angle and proper height. Make sure that the
not rely on hydraulic systems as support. Use loading ramp is anti-slip and free of mud and
stands or other measures that are secure and snow.
can support the weight being applied to them.
Use chains and blocks to secure the machine to
Transportation Information the trailer.
Keep the bystanders away.
Obey the appropriate laws that govern the
parameters of the load (weight, length, width, Place all the working equipment in the
and height). transportation position, secure all the equipment
and attachments or additional equipment with
Understand the correct procedures for loading chains or other secure methods to prevent
and unloading. accidental movement.
Carry out the loading and unloading operations
on flat ground. Welding Operation

Any personnel engaging in welding operations


must have occupational certificates and carry out
the operation at a place with appropriate devices
equipped. When carrying out the welding
operation, the personnel must follow the
instructions below:
Before carrying out the welding operation, turn
off the battery isolator switch, disconnect the
battery, disconnect the controllers and other
electrical parts.
38
Safety Information
Stability and Barycenter

Remove all paint from the place to be welded, so When carrying out the cleaning operation, wear
as to prevent harmful gas from being produced. suitable PPE. Consider exposure to: chemicals,
slippery surfaces, high pressure water spray and
Do not inhale smoke produced by burning paint.
material splash.
Never weld pipes close to rubber hose and
electrical wires. Always remove residual
pressure from the machine. Never weld pipes
that are fitted to the machine.
Always wear correct PPE for welding, protect
bystanders by using screens and signs advising
of the operation being performed.
Ensure good ventilation.
Remove all the inflammable materials, supply
the work area with a fire extinguisher.

Do not spray the water directly onto sensors,


connectors or instruments of the electrical
system. If water enters the electrical system,
malfunction may occur.

Stability and Barycenter

Load Barycenter

Confirm the barycentric location according to the


shape of the goods. Because various goods
Clean the Equipment Periodically have different barycenters, so it is very important
to confirm the barycentric location.
To avoid possible injury or damage to the
machine, all the oil and scraps accumulated
should be removed. The engine, radiator,
storage battery, hydraulic hose, fuel tank and cab
should be kept clean.

1. Barycenter
39
Safety Information
Stability and Barycenter

Forklift Stability
4
Use front wheel as a pivot, two side weights keep
3
in balance. Barycenter of the load and forklift
determines the forklift stability. 2

2. Vehicle barycenter
3. Resultant barycenter
4. Load barycenter
Empty forklift is much easier to tip over
transversely than the full load forklift. The
following factors should be considered for empty
Relations between Barycenter and Stability forklift:
● Mast up and down positions;
The forklift stability is determined by the
barycenter which varies with the loading ● Load size, weight, and shape;
condition. Without load, the forklift stability is ● Loading position;
determined by the barycenter of the forklift itself,
with load, it is determined by the resultant ● Load lift height;
barycenter of the forklift and goods. The ● Tilting angle (forward, backwards);
barycenter will move forward or backwards if the
forks tilt forward or backwards; similarly, the ● Tire air pressure;
barycenter will move if the forks move upwards ● Accelerate, stop, running condition;
or downwards.
● Road surface condition and slope.

2 3 4
40
Safety Information
Sound

Stable Range of Barycenter Sound


In order to keep the forklift in stable condition, the
barycenter should be in the triangle stable range The sound performance offered for this machine
surrounded by the grounding points of two front has met the requirements in 2000/14/EC sound
wheels and the pivot of rear axle (three points). If directive.
the resultant barycenter is located in front of the A-Weighted emission sound pressure level at the
triangle, the forklift will tip over forward, and it will operator's position measured according to work
tip over sideward if the resultant barycenter is cycle procedures specified in
located on sides of the triangle. “EN12053:2001+A1:2008 Safety of industrial
trucks-Test methods for measuring noise
emissions” is 85dB.

NOTICE: Rough or uneven road surface


will result in tire distortion easily which could
cause a big noise to the machine.

Vibration Level
1
NOTICE: Whole body vibrations
generated by construction machines, are to a
1. Safety area
high degree influenced by different factors,
Max. Lift Capacity e.g. working methods, ground conditions and
traveling speed selected by the operator.
Load center is the distance from the goods
center on the forks to fork vertical. Max. lift The mean value of acceleration value in vertical
capacity is the max. weight that can be lifted at direction at operator's seat measured in
the standard load center. Max. lift capacity was accordance with the stipulated procedures in
marked on the load curve. Load center moves “EN13059:2002+A1:2008 Safety of industrial
forward, the relevant load capacity will decrease trucks-Test methods for measuring vibrations“ is
gradually. 1.34m/s2.
41
Safety Information
Key Spare Parts to be Periodically Changed

Key Spare Parts to be Periodically Changed

No. Key spare parts to be periodically changed Changing intervals (year)


1 Brake hose or tube 1~2
2 Hydraulic hose of lift system 1~2
3 Lift chains 2~4
4 High pressure hose or tube of hydraulic system 2
5 Oil cup of brake liquid 2~4
6 Brake pump, cover of the pump and dust cover 1
7 Fuel hose 2
8 Seals and rubbers in the hydraulic system 2

Tightening Torque of the Bolts

Position Torque N.m


Bolt on the half shaft of drive axle 95~110
Mounting nut of front wheel(wheel hub ) 260~347
Mounting nut brake drum 280~320
Mounting nut brake pedal 95~110
Nut of rear wheel hub 189~256

Remove the wheel hub nut only when removing the tire. Do not loosen the nuts and bolts of the
wheel hub before releasing the air pressure inside the tire, otherwise serious person injury or
death could result.
42
Application and Specification
Applications

Application and
Specification In windy condition, do not lift the mast too
high in order to prevent the falling of goods
and cause accidental body injury.
Applications

The forklift is an industrial machine for carrying


goods over short distances and is suited to
operate on smooth and hard road surfaces. It
can be used in warehouses, railway stations,
docks, construction sites and large open paved
yards for loading and unloading, stacking
operations and short distance transportation.
This machine is a kind of common industrial
machine which is unsuitable to work in
flammable, explosive, dusty and air poisonous
environments.

Requirements of Work Environments

1. Altitude: ≤3048m
2. Environmental temperature: -15°C~40°C
(The cold starting Aid device is not available)
3. Air relative humidity: ≤90%( When the
environmental temperature is 25°C)
4. Wind speed: ≤5m/s

Preventive measures for operation,


maintenance and safety rules outlined on
this manual are only suitable for the
stipulated applications of the machine. Do
not use the machine beyond the stipulated
application scope, Guangxi Liugong
Machinery Co., Ltd will not bear any safety
liability, and these safety liabilities will be
born by users. Under any cases, do not use
the forbidden operation outlined in this
manual.
43
Application and Specification
Main Specifications

Main Specifications

All rated lift capacities specification are collected from the machine operation on a hard and flat ground.
When the machine is operated in conditions that different from the above-mentioned condition (e. g. on
soft or uneven ground, on a slope ), these conditions shall be taken into account by the operator.
Exterior Drawing
44
Application and Specification
Main Specifications

Machine Specifications

1 Model CLG2040H CLG2040H


2 Power Type Diesel Diesel
General
3 Base Capacity rated load center kg 4000 4000
4 Load Center mm 500 500
5 Service Weight unloaded kg 6450 6450
Weights 6 loaded/unloaded, front kg 9225/2903 9225/2903
Axle Load
7 loaded/unloaded, rear kg 1225/3547 1225/3547
8 Tire Type Pneumatic Pneumatic
9 Wheels front / rear 2/2 2/2
10 Wheelbase mm 2000 2000
Tires
11 front 300-15-18PR 300-15-18PR
Tire Size
12 rear 7.0-12-12PR 7.0-12-12PR
13 Tread Width front/rear mm 1180/1190 1180/1190
14 Max. Fork Height with std 2-stage mast mm 3000 3000
15 Freelift with std 2-stage mast mm 195 195
16 Height, Upright Lowered with std 2-stage mast mm 2290 2290
17 Height, Upright Extended with std 2-stage mast mm 4350 4350
Mast
18 Mast Tilt, Fwd/Back with std 2-stage mast deg 6o / 12o 6o / 12o
19 Carriage width mm 1450 1450
20 Fork Spread minimum/maximum mm 320/1210 320/1210
21 Fork Dimension TxWxL mm 50 x 122 x 1070 50 x 122 x 1070
22 Length to Fork Face with std 2-stage mast mm 3080 3080
23 Overall Width mm 1480 1480
24 Overhead Guard Height mm 2280 2280
25 Turning Radius minimum outside mm 2740 2740
Chassis 26 Fork Overhang with std 2-stage mast mm 555 555
add load length and
27 Right Angle Stack mm 4565 4565
clearance
28 minimum loaded mm 120 120
Gound Clearance
29 center of wheelbase mm 135 135
30 Travel Speed loaded/unloaded km/h 24/25 24/25
31 Lift Speed loaded/unloaded m/s 0.42/0.54 0.42/0.54
Performance 32 Lower Speed loaded/unloaded m/s 0.53/0.48 0.53/0.48
33 Max. Drawbar Pull loaded kg 3300 3300
34 Max. Gradeability loaded / unloaded % 20/20 20/20
35 service Foot / Hyd Foot / Hyd
Brakes
36 parking Hand / Mech Hand / Mech
37 manufacturer LuoTuo Cummis
38 model LR4B3-22 B3.3
Systems 39 emission compliance China Tier II EPA/Euro Tier III
40 Engine cylinders 4 4
41 displacement liter 4.58 3.3
42 rated power kw/rpm 57/2200 60/2200
43 max. torque N.m/rpm 285/1500 304/1600
45
Application and Specification
Main Specifications

Machine Specifications

1 Model CLG2045H CLG2045H


2 Power Type Diesel Diesel
General
3 Base Capacity rated load center kg 4500 4500
4 Load Center mm 500 500
5 Service Weight unloaded kg 6650 6650
Weights 6 loaded/unloaded, front kg 10035/2993 10035/2993
Axle Load
7 loaded/unloaded, rear kg 1115/3657 1115/3657
8 Tire Type Pneumatic Pneumatic
9 Wheels front / rear 2/2 2/2
10 Wheelbase mm 2000 2000
Tires
11 front 300-15-18PR 300-15-18PR
Tire Size
12 rear 7.0-12-12PR 7.0-12-12PR
13 Tread Width front/rear mm 1180/1190 1180/1190
14 Max. Fork Height with std 2-stage mast mm 3000 3000
15 Freelift with std 2-stage mast mm 195 195
16 Height, Upright Lowered with std 2-stage mast mm 2290 2290
17 Height, Upright Extended with std 2-stage mast mm 4350 4350
Mast
18 Mast Tilt, Fwd/Back with std 2-stage mast deg 6o / 12o 6o / 12o
19 Carriage width mm 1450 1450
20 Fork Spread minimum/maximum mm 348/1238 348/1238
21 Fork Dimension TxWxL mm 50 x 150 x 1070 50 x 150 x 1070
22 Length to Fork Face with std 2-stage mast mm 3080 3080
23 Overall Width mm 1480 1480
24 Overhead Guard Height mm 2280 2280
25 Turning Radius minimum outside mm 2740 2740
Chassis 26 Fork Overhang with std 2-stage mast mm 555 555
add load length and
27 Right Angle Stack mm 4565 4565
clearance
28 minimum loaded mm 120 120
Gound Clearance
29 center of wheelbase mm 135 135
30 Travel Speed loaded/unloaded km/h 24/25 24/25
31 Lift Speed loaded/unloaded m/s 0.42/0.54 0.42/0.54
Performance 32 Lower Speed loaded/unloaded m/s 0.53/0.48 0.53/0.48
33 Max. Drawbar Pull loaded kg 3300 3300
34 Max. Gradeability loaded / unloaded % 20/20 20/20
35 service Foot / Hyd Foot / Hyd
Brakes
36 parking Hand / Mech Hand / Mech
37 manufacturer LuoTuo Cummis
38 model LR4B3-22 B3.3
Systems 39 emission compliance China Tier II EPA/Euro Tier III
40 Engine cylinders 4 4
41 displacement liter 4.58 3.3
42 rated power kw/rpm 57/2200 60/2200
43 max. torque N.m/rpm 285/1500 304/1600
46
Application and Specification
Main Specifications

Machine Specifications

CLG2050H CLG2050H
1 Model
(LIGHT) (LIGHT)
General 2 Power Type Diesel Diesel
3 Base Capacity rated load center kg 5000 5000
4 Load Center mm 500 500
5 Service Weight unloaded kg 6850 6850
Weights 6 loaded/unloaded, front kg 10665/3083 10665/3083
Axle Load
7 loaded/unloaded, rear kg 1185/3767 1185/3767
8 Tire Type Pneumatic Pneumatic
9 Wheels front / rear 2/2 2/2
10 Wheelbase mm 2000 2000
Tires
11 front 300-15-18PR 300-15-18PR
Tire Size
12 rear 7.0-12-12PR 7.0-12-12PR
13 Tread Width front/rear mm 1180/1190 1180/1190
14 Max. Fork Height with std 2-stage mast mm 3000 3000
15 Freelift with std 2-stage mast mm 195 195
16 Height, Upright Lowered with std 2-stage mast mm 2290 2290
17 Height, Upright Extended with std 2-stage mast mm 4350 4350
Mast
18 Mast Tilt, Fwd/Back with std 2-stage mast deg 6o / 12o 6o / 12o
19 Carriage width mm 1450 1450
20 Fork Spread minimum/maximum mm 348/1238 348/1238
21 Fork Dimension TxWxL mm 50 x 150 x 1070 50 x 150 x 1070
22 Length to Fork Face with std 2-stage mast mm 3150 3150
23 Overall Width mm 1480 1480
24 Overhead Guard Height mm 2280 2280
25 Turning Radius minimum outside mm 2800 2800
Chassis 26 Fork Overhang with std 2-stage mast mm 555 555
add load length and
27 Right Angle Stack mm 4625 4625
clearance
28 minimum loaded mm 120 120
Gound Clearance
29 center of wheelbase mm 135 135
30 Travel Speed loaded/unloaded km/h 24/25 24/25
31 Lift Speed loaded/unloaded m/s 0.42/0.54 0.42/0.54
Performance 32 Lower Speed loaded/unloaded m/s 0.53/0.48 0.53/0.48
33 Max. Drawbar Pull loaded kg 3300 3300
34 Max. Gradeability loaded / unloaded % 20/20 20/20
35 service Foot / Hyd Foot / Hyd
Brakes
36 parking Hand / Mech Hand / Mech
37 manufacturer LuoTuo Cummis
38 model LR4B3-22 B3.3
Systems 39 emission compliance China Tier II EPA/Euro Tier III
40 Engine cylinders 4 4
41 displacement liter 4.58 3.3
42 rated power kw/rpm 57/2200 60/2200
43 max. torque N.m/rpm 285/1500 304/1600
47
Application and Specification
Main Specifications

Main Parts Specifications

Item Specifications
Model LuoTuo LR4B3-22 Cummins B3.3TAA
4-stroke, direct injection, overhead 4-stroke, direct injection, overhead
Type
valve valve
Type of cooling Water cooling Water cooling
Order of ignition 1-3-4-2 1-2-4-3
Cylinder bore.× stroke Φ108X125 Φ95X115
Capacity 4.58 3.26

Engine Compression ratio 13 17


Rated power / speed 57kW/2200r/min 60kW/2200r/min
Max. torque / speed 300Nm/1500r/min 304Nm/1600r/min
Diesel engine net weight 410kg 255kg
Max. speed (unload) 2511 2450
Idle speed 720r/min 800r/min
Start motor 24V-4.5kW 24V-4.5kW
Generator 28V-27A 24V-60A
CBK-F444-AFΦ(4T)
Pump
CBK-F427-AFΦ+CBK-F427-AFΦL(4.5/5T)
System maximum flow 44L/min(4T)/ 54L/min(4.5/5T)
Main overflow valve set pressure 21 MPa
Safety valve set pressure: lifting
19.5 MPa(4T)/17.5 MPa(4.5/5T)
and tilting
Hydraulic Switch-over overflow valve set
12MPa
System pressure
Lifting cylinder quantity, bore × rod 2-φ63×φ60×1495 mm(4T)
diameter × stroke 2-φ70×φ60×1495 mm(4.5/5T)
Lifting cylinder limited speed when retracted
Tilting cylinder quantity, bore × rod
2-φ90×φ45×171mm
diameter × stroke
Tilting cylinder front titling selflock when stretched out
Work Mast Height 2290mm (standard configuration)
Impleme
nts Fork Length 1070mm(Optional)

Traveling Drive wheel 2 unit


Device Steer wheel 2 units
Electric
System voltage 24V
System
48
Application and Specification
Main Specifications

Work Scope

Operate the machine according to the rated load capacity in the load curve chart.

(The load chart is used for CLG2040H, CLG2050H(LIGHT) with rotating function, mast)

(The load chart is used for CLG2045H, CLG2050H(LIGHT) with sideshift, mast)
49
Application and Specification
Main Specifications

(The load chart is used for CLG2050H(LIGHT), mast)

CAPACITY CHART

MAST
MAST
MAST

MAST
MAST
CAPACITY

MAST
MAST

LOAD CENTER

(The load chart is used for CLG2050H(LIGHT) with hook, mast)


50
Application and Specification
Main Specifications

CAPACITY CHART
MAST

MAST
MAST
CAPACITY

LOAD CENTER

(The load chart is used for CLG2050H(LIGHT) with bucket, mast)

External Dimension and Weight of Dismountable Components

External Dimension
No. Components Weight (kg)
length×width×height (mm)
1 Mast (no fork) 645×1430×2130 1100
CLG2040H 741×1460×1100 2100
Counterweigh
2 CLG2045H 741×1460×1100 2240
t
CLG2050H(LIGHT) 770×1460×1100 2400
3 Overhead guard 1600×1400×1515 110
51
Operation Manual
Before Operation

Operation Manual

Before Operation

Mounting and Dismounting

● Before mounting or dismounting the


machine, check the condition of handrails,
ladders and steps. Clean them of grease,
lubricants and dirt before use. Repair any
damaged parts and tighten loose bolts.
● Mount and dismount the machine only where
there are handrails, steps or ladders.
● Never get on or off a moving machine.
● Be careful not to touch any control levers
when getting on or off the machine.
● Do not mount or dismount the machine from
the right side.

Daily inspection

Check the condition of the battery.


Check the level and the density of the electrolyte
(not for internal combustion forklift truck).
Check tire pressure.
Check wheel nuts.
Check the level of the hydraulic oil.
Check the steering system performance.
Check the brake system performance.
Check of the mast system performance.
Check the connection and tightness of the wire
and connectors.
For more information, refer to "Maintenance
Interval Schedule--Daily inspection".
52
Operation Manual
Operator Controls and Instrument Panels

Operator Controls and Instrument Panels

1. Parking Brake Lever 9. Tilt lever


2. Horn 10. Attachment lever
3. Shift Control Lever 11. Attachment lever
4. Steering wheel 12. Choke switch
5. Fine adjustment pedal 13. Combination switch
6. Brake pedal 14. Start switch
7. Accelerator pedal 15. Switch assembly
8. Lift lever 16. Steering column adjust handle
53
Operation Manual
Operator Controls and Instrument Panels

Start Switch CAUTION: 1. Do not keep the start switch


to the PREHEAT position after stopping the
engine, to do this will discharge the battery.
The start switch (also called ignition switch) is
located on the right side of the steering column, 2. Do not turn the start switch to the START
and has four positions progressing in a clockwise position when running the engine in order to
direlction. avoid damage to the engine.

3. Do not engage the start motor for more


than 5 seconds at a time, wait at least 30
seconds and then restart. Do not exceed
three consecutive attempts after waiting 3
minutes. Failure to comply could result in a
reduction of the service life of the battery and
damage to the starter motor and solenoid.

4.The shift control lever must be in


“NEUTRAL” before starting the engine.

Battery Terminal

The battery terminals connect all the electric


units of the battery. You should make the start
switch at OFF position when connecting or
disconnecting the battery terminal.
Keep the battery terminals connected under
normal condition.

PREHEAT------ Not available on this machine.


OFF------ The position where the start switch key
is inserted into or taken out.Turn the start switch
key from ON position to OFF position to stop the
machine (equipped with CUMMINS engine) or
cut off the power supply of the electrical system
(equipped with YTO-LUOYANG LR4B3-22
engine).
ON------ Turn the start switch key to this position
to turn on power for the machine. Then all of the
electrical appliances are connected with power. CAUTION: Disconnect the battery
START----To start the engine, turn the start terminal before checking the electrical
switch key clockwise to the START position. system. If abnormal station occurs during the
When the start switch key is released, the start operating, disconnect the battery terminal at
switch will return to ON position. once. Do not disconnect the terminal when
the start switch key at ON position.
54
Operation Manual
Operator Controls and Instrument Panels

Instrument Panel Service hour meter

The meter indicates the total operating


5 1 2 3 4 1 6 time of the machine in hours. Note the
service hour of the machine, and take time-
check, display lubrication and maintenance time
according to the notes. The service hour meter
does not flash and count hours before the engine
is started; it flashes and counts hours after the
generator generates electric power.

General alert indicator

The indicator will light when any one of


the engine oil pressure alert light,
parking brake alert indicator, torque converter oil
1. Turn indicator temperature alert indicator lights, it indicates that
2. Neutral indicator the vehicle has faults which needs repair at once.
3. Service hour meter
4. General alert indicator
5. Engine coolant temperature gauge Engine coolant temperature gauge
6. Fuel level gauge
This gauge shows the coolant
Turn indicators temperature of the engine. The green
zone shows normal work temperature; the yellow
The left indicator flashes when the zone shows low temperature and the red zone
machine turns left, the front & rear left shows high temperature. If the pointer is in the
turn signal light will also flash red zone, you should park the machine and
simultaneously. slowdown the engine to cool down the machine
The right indicator flashes when the until the pointer goes back to green zone.
machine turns right, the front & rear
right turn signal light will also flash Fuel level gauge
simultaneously.
The gauge displays the fuel level of the
Neutral indicator fuel tank. The pointer on the left side
indicates the fuel is used up and on the right side
The indicator will light when the start indicates the fuel tank is full. Refilling after
switch is at ON position and the shift finishing working to avoid the water steam stored
control lever is at Neutral position. The indicator in the fuel tank.
will go out when the shift control lever is at other
position.
55
Operation Manual
Operator Controls and Instrument Panels

Mute indicator

Not available on this machine.


1 2 3 4 5 6 7
Preheat indicator

The machine equipped with diesel


engine: Turn the start switch from OFF
position to ON position, the preheat system will
1. Instrument power supply work automatically within 10 seconds and the
2. Charge indicator preheat indicator will go out after 10 seconds. If
3. Torque converter oil temperature alert indicator
4. Engine oil pressure alert indicator
the indicator keeps lighting, it indicates that there
5. Mute indicator is fault in the preheat system. Check it and
6. Preheat indicator repair.
7. Parking brake indicator
The machine equipped with LPG engine doesn’t
Instrument power supply have preheat function.

Turn on the start switch, this indicator Parking brake alert indicator
lights, and it goes out when the start
switch is turned off. Only the machine equipped with OPS
(Operator Position System) has this
Charge indicator function. This indicator lights when the parking
brake is engaged and it goes out after the
The indicator indicates the charge parking brake is disengaged.
state of the battery. If the indicators
turns on when the engine isn’t started, it OPS alert indicator
indicates that alternator doesn’t work. It goes out
after the engine is started and the alternator Only the machine equipped with OPS
works. If the indicator turns on during working, it (Operator Position System) has this
indicates that there is fault in charge circuit, you function. When the engine start switch is at “ON”
should park the machine on a safe and position, this indicator lights as long as the driver
convenient place for repair at once. leaves the seat for about 3 seconds. It will go out
after the driver sits down again correctly.
Torque converter oil temperature
alert indicator

The limited work range is 120°C. It


alerts when the temperature is higher than
120°C, stop the machine and check.

Engine oil pressure alert indicator

The engine oil pressure alert indicator


will light when the start switch is at ON
position without starting the machine. It will flash
to alert when the engine oil pressure is too low
during working, and the buzzer will sound at the
same time. Stop the engine to check.
56
Operation Manual
Operator Controls and Instrument Panels

Operator Controls Pull the lift lever back to lift the fork, the
hydraulic oil will go into the lifting
cylinder to push the fork upwards.
Shift Control Lever
Push the lift lever forward to lower the
fork, the hydraulic oil returns to oil tank
and the fork is lowering after the
gravity effect.
Pull the tilt lever back and tilt the mast
to stack the goods.

Push the tilt lever forward and tilt the


mast to unload the goods.

CAUTION: Do not operate the lever too


fast. Never operate the tilt lever when the fork
Forward: push the handle forward, the machine is at the highest point. Never operate the lift
drive forward. lever and tilt lever at the same time. The
control valve has self-lock function, when the
Reverse: pull back the handle, the machine drive
engine is power off, operate the tilt lever can
reverse.
not tilt the mast.
Neutral: keep the handle in middle position, it is
neutral. Parking Brake Lever
CAUTION: The Shift Control Lever must The parking brake lever is located at the left side
be in “Neutral” before starting the engine. of the steering wheel.
You must stop the machine before change
the direction.
3
Control Valve Lever
1 2
The control valve lever is used to lift and stack
the goods.

1. Disengage position
1 2. Engage position
2 3. Lock button
Pull the parking brake lever backwards to
engage parking brake when parking the
machine. Before driving, push the lever forward
to disengage parking brake.
1. Lift lever
2. Tilt lever
57
Operation Manual
Operator Controls and Instrument Panels

It is very dangerous to run the machine without Accelerator Pedal


disengaging the brake as this will damage the
brake performance. Therefore, disengage the The accelerator pedal is located at the front right
parking brake before running the machine. side of the driver ’s seat.

CAUTION: Depress the brake pedal at the When the accelerator pedal is not depressed, the
same time when engaging the parking brake. engine is at idle speed. Depressing the
Hold the parking brake lever in hand when accelerator pedal increases the fuel supply to the
the machine is running on a slope. Place a engine and increases the power output of the
wedge under the tires when parking the engine.
machine on the slope.
Steering Wheel
Brake Pedal

The brake pedal located in the front right side of


the operator’s seat.

An ordinary steering wheel is provided for this


machine. The steering wheel is located inside
2 3 the cab (a closed cab is optional) and connected
1
with the hydraulic metering pump. The steering
1. Fine Adjustment pedal wheel cannot automatically reset after released.
2. Brake pedal Therefore, reverse the steering wheel after
3. Accelerator pedal turning so that the machine can run straightly.
Depress down the brake pedal engages the
When the engine power is off, you can steer the
brakes of both the front and rear axles and also
machine but it is very difficult. So you must start
turns on the brake lights. Release the brake
the engine before next steering.
pedal to release the brakes, and the brake lights
go out.

Fine Adjustment Pedal

The fine adjustment pedal is located in the front


left side of the operator’s seat.
Use hand to press down the Fine Adjustment
Pedal to check the free stroke until you feel the
resistance. Depress down the Fine Adjustment
Pedal and check for any obstacle or abnormity.
The maintenance is needed if any abnormity.
58
Operation Manual
Operator Controls and Instrument Panels

Steering Column Choke Switch

Press down the adjusting handle of the steering If the machine equipped the homemade diesel
column by one hand and adjust the steering engine, you should pull back the choke switch to
wheel forward and backwards to the desired stop the engine.
angle by the other hand. After adjusting, pull up
If the machine equipped the CUMMINS diesel
the handle to lock the steering wheel in that
engine (imported), you can stop the engine by
position.
turning the start switch to "OFF" position.
CAUTION: Before drive the machine,
make sure that the steering wheel has been Main Parts of Forklift Body
properly adjusted. Do not adjust the steering
wheel when the machine is running.
Seat
Horn Button
1
The horn button is located in the center of the
steering wheel. Press the horn button in the
center of the steering wheel to sound the horn.

1. Document box (optional)


2. Safe belt
3. Fore-and-aft adjustment lever
4. Armrest angle adjustment nut
The document box (optional) is located behind
the seat. You can store the operation and
maintenance manual or other document in it.
59
Operation Manual
Operator Controls and Instrument Panels

The operator’s seat can be adjusted forward and


backward by adjusting the fore-and-aft
adjustment lever. Pull the lever left or right to
adjust the seat forwards or backwards, and
loosen the lever to fix the seat.
The armrest angle can be adjusted by adjusting
the armrest angle adjustment nut.

Seat Belt

Fasten the seat belt before driving the machine.


Before using the seat belt, check it for good
condition. Replace it in time if necessary.
For seat belt replacement, consult with Liugong
Fastening seat belt can reduce the risk of
dealer.
personnel injuries and death when a
Adjust length of the seat belt before use in order turnover accident happens.
to ensure safety and comfortability. Length of the
seat belt can be adjusted by moving position of To prevent the driver from serious injury or
catch on the seat belt. death in case of a turnover accident, fasten
The buckle of the seat belt is located at the rear the seat belt when driving the machine. Stay
right side of the seat. Insert catch of the seat belt in the seat when a turnover happens. Do not
into the buckle to lock it. jump out of the machine. Hold the steering
wheel tightly and lean to the opposite
A red button is provided by side of the buckle. direction of the turnover.
Press the button down, the catch will spring up
from the buckle.
Before using the seat belt, check whether the
buckle of the seat belt can lock and release
normally.
60
Operation Manual
Operator Controls and Instrument Panels

Overhead Guard Fork

Overhead guard is an important safety part to


avoid goods falling off from the machine and
hurts the operator. Do not drill holes, welding on
the overhead guard or reconstruct it, which will
affect its safety performance, and lead to serious
accident. In addition, loosened installation, and
use after disassembly may cause serious
accident too.

Load Backrest

Load backrest is an important safety part to avoid


goods on the fork sliding to the operator. Lift and loosen the locking pins on the both side
Loosened installation, and use after disassembly of the fork to adjust the fork left or right, tighten
or reconstruction all are very dangerous. Choose the locking pins to lock the fork.
the proper load backrest by the size of goods.
Keep the load center in he middle line of the
Engine Hood machine when adjusting the fork.
Before carrying any goods, you must make sure
that the fork has been secured with the locking
pins.

Drawbar

The drawbar is located behind the counterweight


is only used to tow the machine when the wheels
1 get into trench or mud puddle. Refer to "Machine
Specifications " on page 44 for detailed values of
2 towing capacity.

1. Engine hood
2. Grab handle
The engine hood is located under the operator’s
seat.
Opening: Pull up the handle to open the engine
hood. (If you machine equipped the switch of the
engine hood, you can open or close the engine
hood according the indication on the switch
label.)
Closing: Press the bracket of the air spring, and
then pull the engine hood downwards to close it. CAUTION: The drawbar can not be used
to tow another forklift or other vehicle or
trailer.
61
Operation Manual
Operator Controls and Instrument Panels

Safety in Attachment Installation, 2. When operating a multi-purpose attachment


Adjustment and Use (with sideshift, clamp and rotating function,
etc), do not carry out two actions at the same
Attachment Installation time. Change to the next action only after the
first is finished.
Install the attachment securely to ensure that the 3. Do not overload the attachment. It's better
attachment will not move along the fork arm not to load unevenly at high order (especially
carrier, or safety problems will result during for sideshift type clamp which is controlled by
working. combination valve, that is, the clamp used by
As for those attachments with hook, engage the sideshift cylinder and positioning cylinder) as
hook into the notch of the top carriage bar after high order operation is only suitable for
installing to let the deviation allowance from specified period, slow operation and the
center line of the attachment to the fork arm deviation should be within about 100mm for
carrier center stays within 50mm, otherwise left and right.
lateral instability will result. 4. Do not drive the forklift with attachment at
As for those attachments with rotating function high order position.
(such as paper roll clamp, bale clamp, multi- 5. No passengers is allowed to stand within
purpose clamp and drum clamp), weld two stop 1.5m from the dashed area which covers the
blocks to the both sides where the top carriage right below part of the attachment and goods
bar is connected with the attachment after (except for the position at driver's seat
installing to prevent the attachment from moving protected by overhead guard) to avoid
left and right during working. accident.
As for those attachments with position hook, 6. Do not engage brake suddenly during
adjust the clearance between the hook and the driving. Drive slowly when carrying with a
bottom bar of the carriage. load.
Nearly all of the attachment for medium and 7. It is prohibited to modify the attachment
small ton forklift is installed with hook. In order to without the technical permission of Liugong
ensure the installation safety, it's recommended as the modification could cause safety
to select the appropriate attachment for the problem and change the attachment function.
forklift according to the ISO2328 standard
Mounting Dimensions requirements of Forklift
Hook-On Type Fork and Carriages.
"Attachment Capacity" stated by the
Attachment Use
attachment company is only a reference
value for the attachment, not the maximum
1. Operating the forklift attachment should be
capacity value to the forklift.
based on the operation experience of the
forklift, instructions on the forklift nameplate
The rated capacity of the machine installed
and familiarity on the operation manual
with attachment is the minimum value
(especially operation and installation
among forklift capacity, attachment capacity
manuals from the attachment company).
or integrated capacity. Generally, the
Know the performance and operation of the
integrated capacity has the minimum rated
attachment, especially the allowable load, lift
capacity value after calculation. The forklift
height, goods dimension and application
can meet the need in different operation
range.
condition as long as the goods do not
exceed the rated capacity.
62
Operation Manual
Engine Starting

OPS (Optional) 2. Make sure the shift control lever is at


NEUTRAL position. If not, put it at
The machine equipped with OPS (Operator NEUTRAL.
Position System) has the following function:
1. Safe driving warning: When the start switch is
at “ON” position, the seat alert indicator on
the instrument panel lights when the driver Start the engine only after the shift control
leaves the seat. The OPS function will start to lever is at NEUTRAL position so as to
work automatically when the driver leaves prevent unexpected accidents due to
the seat for about 3 seconds. At this time, sudden actions.
the reverse solenoid valve returns to Neutral 3. Engage the parking brake lever.
position automatically. The machine can not
move forward or reverse and the buzzer on
the instrument panel sounds. Only after the
driver sits down again and turns the shift
control lever to Neutral position, the machine 1 2
can move forward or reverse when turning
the shift control lever to forward gear or
reverse gear.
2. Parking warning: When the start switch is at
“OFF” position, the driver leaves the seat for
about 3 seconds and doesn’t engage the
parking brake, the buzzer on the instrument
panel sounds until the driver sits down again 1. Disengage position
or engages the parking brake. 2. Engage position
4. Insert the key in the start switch and turn it to
Engine Starting the ON position clockwise to turn on the
power relay. Sound the horn to alert
personnel that the machine will be starting
and do not allow personnel to approach the
machine.
Clear personnel from around the machine.
Clear away any obstacles; make sure no one
is under the machine. Do not allow any one
to stand on any part of the machine.

1. Check that the functioning of the seat belt is


normal and fasten the seat belt.
63
Operation Manual
Operation Techniques

5. Slightly depress the accelerator pedal, turn Operation Techniques


the key clockwise to START position
engaging the starter motor of the diesel
engine. When the start switch key is Running Operation
released, the key will return to the ON
position automatically.

Before driving the machine onto roads,


Continuous starter engagement should not make sure that the driver knows the local
exceed 15 seconds. If the engine doesn’t traffic laws and regulations. Observe the
start after 15 seconds, release the Start local road regulations when driving on
switch at once. Wait 30 seconds before roads.
trying to start again. You should check the
machine, if the engine can’t be started after Raise the forks 15 to 20 cm off the ground.
cranking three times.

OPS control box (Optional) == starting


protection: disconnect the start relay
automatically when continuous starter
engagement exceeds 15 seconds; you need
to turn off the start switch and restart or wait
30 seconds before trying to start again.

6. Warm up the engine at idle speed of 800 r/


min after the engine is started. Operate the
engine with full load only after the coolant
temperature of the engine reaches green
range.
1. Depress down the brake pedal and loosen
7. Check the readings of all the gauges to make the parking brake lever, release the brake,
sure they are in the normal range. Check that and then loosen the brake pedal slowly.
all the lights, indicators, horn, windshield
2. Through the shift control lever to get the
wiper and brake lights work normally.
speed and the direction.

In the unloaded condition, 2nd gear may be


used for start and travel, but in the loaded
condition, 1st gear should always be used
to start.

3. Turn the steering wheel and check the


machine’s ability to turn in both directions.
64
Operation Manual
Operation Techniques

4. Check the brake performance of the


machine. With the machine running in 1st or
2nd forward, release the accelerator pedal
and smoothly step down on the brake pedal,
the machine should reduce speed and stop.

After depressing down on the brake pedal, if


you can not feel any obvious slowdown in
the forklift, then immediately engage the
parking brake lever so as to force it to stop.
4. Turn the steering wheel clockwise when the
5. Check the engagement of each gear. machine turns rightwards; turn the steering
wheel counterclockwise while the machine
turns leftwards. Reverse the steering wheel
so that the forklift can run in the straight
direction after finish steering operation.
Bring the vehicle to a full stop before
shifting direction. 5. Turn the turn indicator switch to NEUTRAL
after finish steering operation. Then the turn
signal lights and turn indicator will go out.
Steering Operation
6. Depress down the accelerator pedal to get
the desired engine speed.
1. Release the accelerator pedal to reduce the
speed of the engine firstly.
2. Depress down the brake pedal to reduce the
speed of the machine. It is dangerous to perform turning
operations on slopes and this will make the
3. Turn the combination switch forwards when
machine tip over. This forklift is steered by
the machine is turning leftwards, then the left
the rear wheels. Turn the steering wheel
turn signal light will turn on; turn the
slowly when steering to avoid tail swing
combination switch backwards when the
caused by a sharp brake.
machine is turning rightwards, then the right
turn signal and indicator on the instrument
will turn on to indicate that the machine is Brake Operation
steering so that the passerbys and
neighboring cars can keep away.
When parking the machine, first release the
accelerator pedal, then depress down on the
brake pedal smoothly to perform service brake
operations.

When the machine is running at high speed,


unless an urgent situation develops, do not
rapidly fully depress the brake pedal as this
could cause an accident and damage of the
machine and personal injury could result.
65
Operation Manual
Operation Techniques

Downhill Operation 2. Drive the forklift slowly to approach the


goods. Align the fork with the center line of
goods at a slow speed to avoid damage the
1. Before you operate down a hill, select the goods.
proper gear before you start down the grade.
When traveling downhill, never change gears
in most situations, the proper gear will be the
same gear that is required to drive up the
grade.
2. Use the service brake or the engine brake in 1
order to slow the machine until a lower gear 2
can be selected. Using the services brakes in
order to control the travel speed of the
machine or using the service brakes for
stopping from high speeds can cause the
brake and axle oil to overheat. This can result
in significant wear and/or damage to the 1. Lift lever
service brakes. 2. Tilt lever

3. When the machine travels on the slop with 3. Slowly push the lift lever forwards to
load, uphill running forward and downhill place the goods to the ground . Then push
running backward. Don’t descend with the
the tilt lever forwards to insert the fork
load in front. When driving forward up a ramp
with a load so big you can’t see ahead, get into the bottom of the goods.
someone to guide and make sure the way is
clear. 4. After the fork is inserted into bottom of the
goods, pull the lift lever backwards to
Loading Operation raise the fork to a height of 15mm to 20cm or
so.(If operating in a room, pay attention not to
1. Before loading, confirm whether the width of
touch the ceiling). Then pull the tilt lever
the pallet or the goods is suitablely matched
with the opening degree of two forks. If it isn’t backwards to tilt the mast backwards.
suitable, adjust the space between the two
forks manually (or adjust the space through 5. In order to main a balance, load the goods
operating the control valve if the forklift is evenly. When loading large sizes or heavy
equipped with fork positioner). goods, pay close attention to operation to
avoid an overturn of the forklift.
66
Operation Manual
Operation Techniques

6. When driving the forklift with a load down the Cold Weather Operation
hill, it is better to dirve the machine reversely
at a slow speed.

If the ambient temperature is too low, the


Do not tilt the mast forward or raise the engine can not easily be started, and the
forks too high when traveling with a load to radiator will be frozen.
keep balance.

1. Use fuel, hydraulic oil, and lubricant with low


Unloading Operation viscosity. For details on oil brands, refer to Oil
Specifications of the Maintenance Manual.
1. Drive the forklift slowly to approach the 2. Always fill the tank up to the top. This
unloading site. Then operate the lift lever to minimizes the air within the tank and thus
raise goods to a desired position. reduces possible freezing from moisture
condensation, rust in the fuel system and
2. Push the tilt lever forwards to tilt the mast,
hard starting
then unload the goods.
3. Make sure the cap on the fuel tank is closed
3. Withdraw the fork after the goods is
tightly so that no rain or snow can enter.
unloaded. Then lift the or lower the fork to a
height of 15mm or 20cm from the ground to 4. Add antifreeze into the coolant, and choose
prepare for the next task. Keep the mast at the antifreeze density according to the lowest
vertical or tilted position. local air temperature (10 degrees Celsius
bellow the lowest air temperature is
preferred).
Move Oversize Goods
Min. suitable environmental
-15 -35
temperature (°C)
1. Drive with special attention when carrying
Antifreeze(%) 30 50
oversize goods.
2. Drive slowly when turning or lifting or 5. Use anti-cold battery in severely cold district.
lowering the goods to avoid movement of the 6. Electrolyte in the battery could freeze if the
goods. Meanwhile, pay attention to the ambient temperature drops. To prevent the
surrounding to ensure safety. batter capacity from being affected by the
3. Use appropriate size fork arm carrier and fork frozen electrolyte, please cover the battery
when carrying oversize goods. The capacity with suitable guards or move it to a warm
of the widened fork arm carrier should be the place. Install it to the machine again the next
same with the standard carrier and within the day, then the engine can be started easily the
stimulated load center. Try to place the goods next day.
on the load center of the forklift. The 7. Thoroughly clean sludge, water, and snow
deviation allowance from the load center every day after finishing work to avoid them
should be within 100mm for 1-3.5t forklift and entering the seam and damaging sealing
150mm for 5-10t forklift. The lengthened fork performance.
should work on the load curve diagram
strictly and the capacity of it should be within 8. To prevent the forklift from being frozen on
the load center and the same with the the ground, park the machine on a dry hard
standard fork. Reduce the load when the load ground or wooden boards.
center moves forward.
67
Operation Manual
Operation Techniques

9. Replace fuel, hydraulic oil, and lubricant with Parking


half viscosity when the weather turns warm.
For details on oil brands, refer to Oil
Specifications of the Maintenance Manual. Stop the Machine
10. Before operating, you should idle the engine Stop the machine on a flat ground. If you have to
to warm it up. park the machine on a slope, place a wedge
under the wheels to avoid movement of the
Hot Weather Operation machine.

Pay attention to the following points when


operating the machine in hot weather:
Park the machine on a road which is free
from other machines.

1. Depress the service brake pedal to stop the


machine.
2. Turn the shift control lever to NEUTRAL
position.
3. Engage the parking brake lever.
4. Lower the forks onto the ground.

Stop the Engine

1. Cooling System: clogged radiator fins can


cause overheating. Clean them out regularly
with a blast of compressed air. Also check for Do not stop the engine immediately after
water leakage at the same time and clean out machine has been operated with load. This
water scale periodically. can cause overheating and accelerate wear
2. Check the fan belt tension and adjust it to the of engine components.
specified tension.
3. Even if the engine overheats and the coolant 1. Run the engine for 5 minutes at idle speed so
boils over, let the engine idle for a while until that all systems cool down evenly.
the temperature falls. 2. Turn the start switch to OFF position and take
4. Check the coolant to see if it is enough. out the key.
3. Turn each switch to NEUTRAL or OFF
position.

Do not open the cap of the radiator until the Leave the Machine
radiator cools down to prevent being burnt
by the splashed coolant. 1. Close the door of the cab (if equipped).
2. Remove all flammable debris in order to
reduce a fire hazard. Dispose of all debris
properly.
68
Operation Manual
Operation Techniques

3. If there is no anti-freeze in the machine, During Storage


when the machine is parked in the winter, to
prevent the water from freezing, open all Start the machine once every month. Lift and
drain valves of the engine and discharge the lower the forklift at least three times, and tilt the
coolant in the water tank. If the machine has mast forwards and backwards at least three
been filled with anti-freeze, refer to the times too. Drive the forklift forward and
instructions of the anti-freeze labels on the backwards for at least 50 meters. Lubricate all
rear part of the machine. the moving parts such as pins and shafts, also
4. Turn the battery disconnect switch to “O” charge the batteries.
position. Before starting the machine, wipe off the grease
5. Install all covers, lock all devices, and take from the hydraulic cylinder piston rods. After
operation, apply a new layer of grease to the
away the key.
cylinder piston rods.
Apply antirust to parts that easily get rusty.
Forklift Storage

Park the machine in a good-ventilated place that


is clean, dry and free from frost if the forklift has Open the doors and windows periodically to
not been used for over a month. Store the exhaust toxic gas when applying the anti-
machine as follows. rust compound indoor.

Before Storage
Before Reuse
Clean and dry every part of the machine and if
Change the lubrication oil of the engine,
possible store the machine in a dry warehouse.
transmission, axles and hydraulic oil, brake oil
As far as possible unload the truck and store it
and anti-freeze.
with the mast fully lowered in the minimum
position. Lubricate all moving pins and shafts.
Before storage, fill the fuel tank, lubricate every Before starting the machine, remove the grease
moving pin and shaft and change hydraulic oil from the hydraulic cylinder piston rods.
according the Oil Specifications of the
Tighten all the bolts and nuts on the attachment
Maintenance Manual.
and chassis.
Apply a thin layer of grease to the exposed part
of hydraulic cylinder piston rods.
If the machine has to be stored for long time,
apply antirust additive to parts that can rust. If the machine has not received antirust
additive each month during storage, consult
Remove batteries from the machine and store with your Liugong dealer.
them in a separate place.
If the air temperature is below freezing, add anti-
freeze to the engine radiator.
69
Operation Manual
Transportation Information

Transportation Information 7. Choke the forklift wheels with wedges and


fasten the forklift with ropes in order to
prevent the machine from moving during
Transportation transportation.

Observe the national and local laws and


regulations on the goods weight, length,
width and height before shipping.

1. Investigate the travel route for overpass


clearances and the allowed weight. Make
sure that the total height, total width and total
weight of the transportation car with this
machine inside does not violate the
stipulations.
2. Remove ice, snow, or other slippery material
from the loading platform and trailer before
shipment. This will help to prevent the
machine from slipping and moving during
transportation.
3. Before shipment, ensure that the trailer body
is strong enough.
4. Engage parking brake when parking the
trailer on the ground. Chock the trailer wheels
with wedges. 8. For installing those parts removed before
transportation, contact with liugong dealer to
install.
9. When it is necessary to remove the mast and
counterweight before transportation, remove
the mast first, then the counterweight. When
installing, first install the counterweight, then
the mast.

Tires--Replace
5. Never turn the forklift when driving the forklift
onto the trailer. Carry out this operation by Front tires
following the signalman's instructions.
6. Lower the fork or attachments onto the 1. Park the forklift on flat and hard ground.
ground after parking the forklift on the trailer, 2. Start the machine, lift the mast about 100 mm
then engage the parking brake. off ground.
3. Chock the rear wheels with wedges to
prevent the machine from moving.
70
Operation Manual
Transportation Information

4. Loosen the nuts of the wheels 8. Remove the nuts of the wheels, replace the
counterclockwise 1-2 turns. front tires.
5. Tilt the mast backwards, place blocks under
two sides of the outer mast.

1. Do not take out the bolt when removing


the wheel rim nut. 2. The block should be
one-piece and hard enough. 3. Do not enter
the bottom of machine when it is supported
only by blocks.

9. Install the nuts in symmetric order


alternatively, and tighten the nuts temporarily.

6. Tilt the mast forward until the front wheels are


lifted off ground.

Do not remove the nuts of the wheels before


the front wheels are lifted off the ground.

7. Place blocks under the front two sides of the


10. Start the machine, remove the blocks under
frame to support the machine, and then stop
the frame.
the machine.
11. Tilt the mast backwards, lower the forklift
slowly, and then remove all the blocks under
the mast and the wedges at the rear wheels.
12. Tighten the bolts of the wheels in symmetric
order alternatively in turn.
13. Adjust the tire pressure to specified value.

Rear tires

1. Park the forklift on flat and hard ground.


2. Engage the parking brake lever. Chock the
front wheels with wedges to prevent the
machine from moving.
71
Operation Manual
Transportation Information

3. Place a jack under the counterweight as 6. Remove the nuts of the wheels, replace the
shown below. rear tires.

1. Do not take out the bolt when removing


the wheel rim nut. 2. The block should be
one-piece and hard enough. 3. Do not enter
the bottom of machine when it is supported
only by blocks.

7. Install the nuts in symmetric order


alternatively, and tighten the nuts temporarily.

Make sure the minimum withstand weight of


the jack is 2/3 of the forklift total weight.

4. Loosen the nuts of the wheels


counterclockwise 1-2 turns.

Do not remove the nuts of the wheels before


the rear wheels are lifted off ground. 8. Remove the blocks under the frame. Lower
the forklift slowly onto the ground, and then
5. Lift the forklift slowly by the jack until the rear remove the wedges at the front wheels and
wheels are completely off the ground. Place the jack under the counterweight.
blocks under the rear two sides of the frame 9. Tighten the bolts of the wheels in turn to
to support the machine as illustrated. specified torque, refer to "General Torque
Specifications".
10. Adjust the tire pressure to specified value.
72
Operation Manual
Transportation Information

Fork Removal
Figure 2

The forks are held on the carriage by hooks. The 3 5


forks are kept in position by latch pins that fit
through the top fork hooks and into slots in the
top bar carriage. Always check the latch pins for
the forks to ensure that the forks are in position 2
on the carriage. Replace damaged latch pins
parts. The forks can be removed from the
carriage by aligning the forks with the fork 1
removal notch. The fork removal notch is in the
bottom bar of the carriage.
4

Do NOT try to remove a fork without a lifting 1. Forks


device. Each hook fork for these lift trucks 2. Carriage
can weigh 55 to 120 kg (121 to 265 lb). 3. Load backrest extension
4. Fork removal notch
A fork can be removed from the carriage for 5. Latch pin assembly
replacement of the fork or other maintenance.
Slide the fork to the fork removal notch in the Fork Install
bottom bar of the carriage. See Figure 1 and
Figure 2. Lower the fork onto blocks so the
bottom hook of the fork moves through the fork Move the fork and carriage so the top hook on
removal notch. Lower the carriage further so the the fork can engage the upper carriage bar.
top hook of the fork is disengaged from the top Raise the carriage to move the lower hook
carriage bar. Move the carriage away from the through the fork removal notch. Slide the fork on
fork, or use a lifting device to move the fork away the carriage so both upper and lower hooks
from the carriage. engage the carriage bars. Engage the latch pin
with a notch in the upper carriage bar.
Figure 1

Do not use welding or other methods to


repair the damaged fork, because forks are
made from special material by specific
1 2
technics. Therefore, replace the fork when it
was damaged to avoid loss.

3
1. Carriage Bars
2. Fork
3. Blocks
73
Operation Manual
Transportation Information

Towing Information Lifting Operation

1. Tow the machine to a safety place if the


machine is disabled.
2. The drawbar is located behind the Improper lifting and wrong fixing may cause
counterbalance. Use this drawbar to tow the the forklift to fall down and result in
machine out if the machine is trapped in mud machine damage and personnel injury or
or fixed on the trailer. Never try to use the death. Make sure that nobody is around
forklift as a tow tractor to tow other disabled when lifting the forklift.
machine.

Do not lift the machine by hoisting the


overhead guard.

1. Choose suitable crane and rope with


maximum capacity according to the
nameplate on the forklift to ensure safety
when lifting.
2. Ensure that the four lifting hooks on the lifting
ropes are weighted with even force when
lifting.

3. Please use the moving equipment (for


example, crane) to move the forklift that is
disabled.
74
Operation Manual
Transportation Information

3. A lifting decal is stuck on the mast and 1. Remove the hydraulic lines which connect
counterweight. Lift the machine by hoisting the fork and the sideshifter.
the lifting eye according to the lifting decal.

2. Remove the fixed plate at the bottom of the


sideshifter.

4. The lifting crane should be fixed stably to the


lifting eye. Ensure that the lifting ropes have
strong enough capacity to lift the forklift. 3. Lift the sideshifter by the lift eye.

Ensure that the lifting device do not


interfere with overhead guard and lights
during lifting.

Attachment--Remove and Lift

The attachment of the machine is removable.


Refer to the following steps for removal.
Take sideshifter for example
75
Maintenance Manual
Run-in

Maintenance Manual 5. Check temperatures and connections of the


electric system, power supply of the
alternator, service status of lights and the turn
signal lights.
Run-in

The run-in of new machine is an important


Check oil level according to the relevant
procedure for prolonging the service life of the
operation regulations.
machine, eliminating failure and avoiding
accidents. The user must read these guidelines
for running in a new machine and how to operate The following must be done after the run-in
and maintain the machine after purchase. period of the new machine is completed:

Run-in requirements for a new machine 1. Check the tightening of all bolts and nuts.
2. Check the condition of the fan belts, engine
1. The run-in period for a new machine is 100 belts.
hours.
3. Check the hydraulic system and brake
2. Race the machine for five minutes after system for leakage.
starting the machine. Start the machine at
low speed. Slowly increase speed step by 4. Replace engine oil, engine oil element.
step. 5. Replace the transmission oil and air filter.
3. Run-in should be done averagely in each 6. Replace drive axle lubrication oil.
forward or reverse gear.
7. Replenish the antirust oil of the lift chain.
4. Start the machine at low speed. Slowly
increase speed step by step. Avoid sudden
starting, turning, accelerating, braking.
5. Do not operating the machine too quickly or Replace transmission oil, axle lubrication oil
abruptly during run-in period. and secondary filter of the transmission
according to operational guidelines.
6. Pay close attention to lubrication of the
machine. Check for leakage of grease at
each hinge point and make sure the
lubrication pump of the centralized lubrication
system is functioning properly.
7. Check the tightening of all bolts and nuts.

The following must be done after the first 8


hours of operation during the run-in period:

1. Check the tightening of all bolts and nuts.


2. Check the condition of the fan belts, engine
belts.
3. Check oil level of the transmission, axles and
engine.
4. Check the hydraulic system and brake
system for leakage.
76
Maintenance Manual
Maintenance Interval Schedule

Maintenance Interval Schedule

CAUTION: Read and understand all the safety information, warnings and illustrations before
any operation and maintainance procedures.

The maintenance intervals stated in this manual are determined according to the service hour meter or
calendar intervals shown (daily, weekly, monthly, etc). Liugong recommends that maintenance should be
performed according to whichever of the above-mentioned intervals occurs first.
Under extremely severe, dusty or wet operating conditions, more frequent lubrication than is specified in
the "Maintenance Intervals" chart may be necessary.
Perform service on items at multiples of the original requirement. For example, at every 600 service
hours or 3 months, also service those items listed under every 200 service hours or monthly, and every 8
service hours or daily.
( “●” means replace, “Hr”= “service hours”)

Engine

Check Every day Every month 3 months 6 months Every year


Content Tool
Item (8Hr) (200Hr) (600Hr) (1200Hr) (2400Hr)
Observe and
check engine ○ ○ ○ ○ ○
running condition
Engine noise ○ ○ ○ ○ ○
Exhaust colour ○ ○ ○ ○ ○
Clean or replace
air filter element ○ ○ ● ●

Engine Check crankcase


and clean dirt ○ ○ ○

Check and adjust Thick gauge


valve clearance plug ○ ○

Tighten cylinder Torque


head bolt wrench ○

Check cylinder
compressed Manometer ○
pressure
Check valve and
Crankcase
ventilation
pipe block or ○ ○
damage condition
Governor
or Check max. idle
injection rpm
Tachometer ○
pump
77
Maintenance Manual
Maintenance Interval Schedule

Engine leaks oil


or not ○ ○ ○ ○ ○

Check oil level,


cleanliness ○ ○ ○ ○ ○
Lubricatio
n system Replace engine ●
oil First 50 hours ● ● ●

Replace engine ●
oil filter element ● ● ●
First 200 hours
Observe and
check oil tube, oil
pump, and oil ○ ○ ○ ○ ○
tank leak oil or
not
Check fuel filter
block or not ○ ○ ○

Replace fuel filter ● ● ●


Fuel
system Check nozzle,
Injection
adjust pressure
tester ○ ○
and state
Injection time ○
Fuel tank
drainage ○ ○ ○

Clean fuel tank ○ ○


Check fuel level ○ ○ ○ ○ ○
Coolant level ○ ○ ○ ○ ○
Leakage
condition ○ ○ ○ ○ ○

Hose aging
condition ○ ○ ○

Cooling Water tank cap


system performance and ○ ○ ○ ○
fixing condition
Clean, replace
coolant ● ● ●

Check fan belt


tension and ○ ○ ○ ○ ○
damage condition
78
Maintenance Manual
Maintenance Interval Schedule

Power Train

Every day Every month 3 months 6 months Every year


Check Item Content Tool
(8Hr) (200Hr) (600Hr) (1200Hr) (2400Hr)
Leakage
condition ○ ○ ○ ○ ○

Check oil level or


replace oil ○ ○ ● ●

Shift control lever


operating and ○ ○ ○ ○
loose condition
Control valve
Hydraulic
performance ○ ○ ○ ○ ○
transmission
Inching valve
performance ○ ○ ○ ○ ○

Inching pedal
free travel and ○ ○ ○ ○ ○
move condition
Replace oil

suction filter
First 200 hours ● ●
element
Leakage
condition ○ ○ ○ ○ ○

Front axle Replace oil ● ●


Fixing bolt loose Detect
condition hammer ○ ○ ○ ○

Tire

Check Every day Every month 3 months 6 months Every year


Content Tool
Item (8Hr) (200Hr) (600Hr) (1200Hr) (2400Hr)
Charge pressure Barometer ○ ○ ○ ○ ○
Crack or damage ○ ○ ○ ○ ○
Depth
Wear condition
gauge ○ ○ ○ ○
Tire
Abnormal wear
conditon ○ ○ ○ ○ ○

If there are nails,


stones or other ○ ○ ○ ○
things on the tire
Check bolts for Detect
loose condition hammer ○ ○ ○ ○ ○
Tire
installation Check damage
condition ○ ○ ○ ○ ○
79
Maintenance Manual
Maintenance Interval Schedule

Wheel rim, wheel


Wheel rim, arm, and hub
wheel arm damage ○ ○ ○ ○ ○
condition
Check loose
condition and ○ ○ ○ ○
Axle noise
bearing
Clean and
lubricate ● ●

Check axle body


distortion, crack
Axle
or damage ○ ○ ○ ○
condition

Steering System

Check Every day Every month 3 months 6 months Every year


Content Tool
Item (8Hr) (200Hr) (600Hr) (1200Hr) (2400Hr)

Check clearance ○ ○ ○ ○ ○

Check axial loose


condition ○ ○ ○ ○ ○
Steering
wheel Check radial loose
condition ○ ○ ○ ○ ○

Check operation
condition ○ ○ ○ ○ ○

Metering Check fixing bolts


pump for loose condition ○ ○ ○ ○

Check main pin for


loose or damage ○ ○ ○ ○
condition
Rear axle Check bend,
steering distortion, crack or ○ ○ ○ ○
spindle damage condition
Check installation Detect
condition hammer ○ ○ ○ ○

Check operation
condition ○ ○ ○ ○ ○

Steering Check for leakage ○ ○ ○ ○ ○


cylinder
Check loose
condition when
installing and ○ ○ ○ ○
hinging
Lock Check lubrication
mechanism condition ○ ○ ○ ○
80
Maintenance Manual
Maintenance Interval Schedule

Brake System

Check Every day Every month 3 months 6 months Every year


Content Tool
Item (8Hr) (200Hr) (600Hr) (1200Hr) (2400Hr)
Free travel ○ ○ ○ ○ ○
Pedal travel Scale ○ ○ ○ ○ ○
Brake pedal Operation
condition ○ ○ ○ ○ ○

Air enters into


brake line or not ○ ○ ○ ○ ○

Brake is safe and


reliable or not,
Parking and with enough ○ ○ ○ ○ ○
brake travel
operation
Operation
performance ○ ○ ○ ○ ○

Operation
performance ○ ○ ○ ○
Lever,
cable, etc. Connection loose
or not ○ ○ ○ ○

Damage,
leakage, crack ○ ○ ○ ○
condition
Line
Connection,
clamp parts ○ ○ ○ ○
loose condition
Leakage
condition ○ ○ ○ ○

Check oil level,


replace oil ○ ○ ○ ● ●

Master cylinder,
secondary pump ○
Brake move condition
master Master cylinder,
cylinder, secondary pump
secondary leakage, damage ○
pump condition
Master cylinder,
brake piston cup,
check valve wear
and damage ●
condition,
replace
81
Maintenance Manual
Maintenance Interval Schedule

Brake drum fixing Detect


parts loose or not hammer ○ ○ ○ ○

Friction disc wear Vernier


condition scale ○

Brake shoe move


condition ○

anchor pin
corroded or not ○

Brake drum Return spring


and brake damage Scale ○
shoe condition
Check the
clearance is
proper or not
when operating ○
self-regulated
device
Brake drum
wear, damage ○
condition
Brake support
distorted or not ○

Brake support
Brake
cracked or not
Scanner ○
support
Loose or not
Detect
during
hammer ○
installation

Electrical System

Every Every
Check Every day 3 months 6 months
Content Tool month year
Item (8Hr) (600Hr) (1200Hr)
(200Hr) (2400Hr)
Pinion
Start motor engagement ○ ○ ○
condition
Harness damage,
loose condition ○ ○ ○ ○
Wire Circuit
connection loose ○ ○ ○
condition
82
Maintenance Manual
Maintenance Interval Schedule

Lift System

Every Every
Check Every day 3 months 6 months
Content Tool month year
Item (8Hr) (600Hr) (1200Hr)
(200Hr) (2400Hr)
Fork damage,
distortion, wear ○ ○ ○ ○ ○
condition
Dowel pin damage,
Fork
wear condition ○ ○ ○

Fork root hook


welding part crack ○ ○ ○ ○
and wear condition
The welding part
between crossbeam
and inner mast, outer ○ ○ ○ ○
mast cracked,
damaged or not
Welding between
tilting cylinder
bracket and mast is ○ ○ ○ ○
not good, cracked or
damaged
Inner mast and outer
mast welding is not
good, cracked or ○ ○ ○ ○
damaged
Fork arm carrier
welding is good or
Mast not, cracked or ○ ○ ○ ○
Fork arm damaged
carrier
Roller loosen or not ○ ○ ○ ○
Mast support
bushing wear, ○
damage condition

Mast support cover Detect
bolt loosen or not hammer
Only the first ○ ○
time
Lifting cylinder head
end bolt, piston rod ○
Detect
head bolt, U bolt,
hammer
Only the first ○ ○
walking beam rail time
bolt loosen or not
Roller, roller bearing,
and welding part
crack and damage ○ ○ ○ ○
condition
83
Maintenance Manual
Maintenance Interval Schedule

Check the tension


condition of chain,
distorted, damaged, ○ ○ ○ ○ ○
rusted or not
Lubricate the chain ○ ○ ○ ○
Chain,
sprockets Rivet pin loose
condition ○ ○ ○ ○

Sprockets distort,
damage condition ○ ○ ○ ○

Sprocket bearing
loosen or not ○ ○ ○ ○

Check the condition


Attachment
is normal or not ○ ○ ○ ○

Piston rod, piston rod


thread, and
Detect
connection loose,
hammer ○ ○ ○ ○ ○
distortion, damage
condition
Lifting Operation condition ○ ○ ○ ○ ○
cylinder
Leakage condition ○ ○ ○ ○ ○

Pin and cylinder


bearing wear, ○ ○ ○ ○
damage condition
Hydraulic pump
leaks or not, it has ○ ○ ○ ○ ○
Hydraulic cacophony or not
pump Hydraulic pump
driving gear wear ○ ○ ○ ○
condition
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Maintenance Manual
Maintenance Interval Schedule

Hydraulic System

Check Every day Every month 3 months 6 months Every year


Content Tool
Item (8Hr) (200Hr) (600Hr) (1200Hr) (2400Hr)
Check oil level ○ ○ ○ ○ ○
Replace oil ●
Hydraulic Replace oil
tank suction filter ● ●
element
Clear impurities ○ ○ ○
Return oil Replace return
oil filter element ● ●
filter
Connection
loosen or not ○ ○ ○ ○ ○
Control
valve rod Operation
condition ○ ○ ○ ○ ○

Leakage ○ ○ ○ ○ ○
Relief valve and
tilting self-locking
Control valve operation ○ ○ ○ ○
valve condition
Oil
Measure relief
valve pressure
pressure ○ ○
gauge
Leakage, loosen,
crack, distortion,
damage ○ ○ ○ ○ ○
Line
connector condition

Replace tube ●
1-2 years

Safety Devices and Attachment

Check Every day Every month 3 months 6 months Every year


Content Tool
Item (8Hr) (200Hr) (600Hr) (1200Hr) (2400Hr)
Installation is Detect
Overhead stable or not hammer
guard and
load Check distortion,
backrest crack, damage ○ ○ ○ ○ ○
condition
Turn signal Work and fix
lights condition ○ ○ ○ ○ ○

Work and fix


Horn
condition ○ ○ ○ ○ ○

Lights and Work and fix


bulbs condition ○ ○ ○ ○ ○
85
Maintenance Manual
Maintenance Interval Schedule

Backup Work and fix


buzzer condition ○ ○ ○ ○ ○

Dirt, damage
condition ○ ○ ○ ○ ○
Rearview
mirror Rear view
condition ○ ○ ○ ○ ○

Instrument Work condition ○ ○ ○ ○ ○


Check bolt for
Seat
damage or loosen ○ ○

Frame and
crossbeam
damaged, cracked ○
or not

Vehicle rivets, bolts Detect


loosened or not hammer ○
body
Check the
repaired parts ○ ○ ○ ○ ○
again if necessary
Check entirely ○
Check the chassis
lubricating Grease
Lubricate condition after gun ○ ○ ○ ○
or replace clean
oil
Check the oil level
in the oil tank ○

When using different oil, coolant or antifreeze, their maintenance intervals are different from the
intervals stipulated in this manual. Therefore, the maintenance time should shorten to half or 1/
4 of the time provided in this manual.

Replace the high viscosity oil frequently though it has a wide work temperature range. Because
the additive will deteriorate slowly, and the oil viscosity will reduce, which will damage the
hydraulic system badly in high temperature.
86
Maintenance Manual
General Torque Specifications

General Torque Specifications

Tighten the bolts used in the machine according to the torque requirements shown in the following table
unless other specified:
Metric system

Standard Torque lb.ft (N.m)


Thread Size
8.8 Grade Strength 10.9Grade Strength
M6 7.7±1.1(10.5±1.5)

M8 19±2.9(26±4)

M10 38±5(52±7) 53±4(72±6)

M12 66±9(90±12) 89±7(120±10)

M14 107±15(145±20) 144±11(195±15)

M16 166±26(225±35) 225±18(305±25)

M18 229±33(310±45) 306±26(415±35)

M20 302±37(410±50) 443±37(600±50)

M22 443±59(600±80) 590±52(800±70)

M24 561±74(760±100) 752±74(1020±100)

M27 811±111 (1100±150) 1106±74(1500±100)

M30 1106±148 (1500±200) 1364±11(1850±150)

M33 1512±221 (2050±300) 2139±295(2900±400)

M36 1955±258 (2650±350) 2286±184(3100±250)

British system

Thread Size Standard Torque lb.ft (N.m)


1/4 9±3 (12±4)
5/16 18±5 (25±7)
3/8 33±5 (45±7)
7/16 52±11 (70±15)
1/2 74±11 (100±15)
9/16 110±15 (150±20)
5/8 148±18 (200±25)
3/4 266±37 (360±50)
7/8 420±59 (570±80)
1 645±74 (875±100)
87
Maintenance Manual
Lubrication Specifications

Lubrication Specifications

Oil Specifications

Oils that used in this machine should meet the following specifications when refilling or replacing to
ensure the normal use of the machine.

Type of oil Capacity Oil type and classification

Hydraulic transmission oil 10.5 L HU-30 (GB2537-88 in summer) /6# hydraulic transmission oil
(GB2512-81 in winter)
Up CD or CF class
-10~30°C: SAE viscosity level 20
-10~35°C: SAE viscosity level 30
-5 ~40°C: SAE viscosity level 40
-40~10°C: SAE viscosity level 5W
-30~15°C: SAE viscosity level 10W
Engine oil 9L
-40~10°C: SAE viscosity level 5W/20
-40~35°C: SAE viscosity level 5W/30
-30~35°C: SAE viscosity level 10W/30
-20~40°C: SAE viscosity level 15W/40
-15~40°C: SAE viscosity level 20W/40
-10~35°C: SAE viscosity level 20/20W
Above 8°C: 5#
Above 4°C: 0#
Above -5°C: -10#
Diesel oil 100 L
-5~ -14°C: -20#
-14~ -29°C: -35#
-29~ -44°C: -50#
Gear oil of drive axle 15L 85W/90(all-year), 80W/90(winter)
L-HM32# anti-wear hydraulic oil (summer),
Hydraulic oil 90 L
L-HV32# low temperature anti-wear hydraulic oil (winter)
Brake oil 0.8L DOT 3 Mobil synthetic brake oil
Grease 0.5 Kg 3# common lithium base grease (-20°C~ +120°C)
Antifreeze + water 20 L Mobil (concentrated) / Shell(100%)antifreeze

1. Do not use low viscosity engine oil such as 10W-30, such oil may help to start the engine, and
provides good engine oil liquidity when the ambient temperature is lower than -5°C(23°F), but
use low viscosity engine oil frequently will reduce the service life of the engine.

2. Do not mix oils of different brands even if they have the same specifications. Clean the
system before refilling the different oil.
3. If the machine is used at low temperature in severe cold areas for a long time, HV-46 low
temperature anti-wear hydraulic oil should be used, and ATF220 or DEXRON-III or Donax TC
transmission oil should be used.
88
Maintenance Manual
Lubrication Specifications

4. Replace the lubricant periodically even though the lubricant is very clean because the
lubricant might go bad after a long time use.

5. Choose the oil according to the lowest air temperature in the local area where the machine is
used.

Oil Change Intervals and Refill Capacities

Care must be taken in order to ensure that fluids are contained during performance of
inspection, maintenance, testing, adjusting and repair of the equipment. Collect the fluid with a
suitable container before opening any compartment or disassembling any component that
contains fluids. Obey all local regulation for the disposal of the liquid.

Type Oil change intervals(hours) Approximate Filling capacity(L)


Hydraulic transmission oil 1200 10.5
Engine oil 250 8
Diesel oil 2000 100
Gear oil of drive axle 1000 15
Hydraulic oil 2000 90
Brake oil 0.8
Grease 0.5
89
Maintenance Manual
Tire Information

Tire Information
AT LEAST 15m(50ft) AT LEAST 500m(1500ft)

Tire can be classified into pneumatic tire and


cushion tire according to different work principle.
Pneumatic tire is suitable for high-speed running
while cushion tire isn't because the cushion tire
has a big load carrying capacity.

To avoid damage caused by tire overheating,


do not drive those machines which are The inflation pressure for nitrogen and air are the
installed with cushion tires on roads. Never same when charging the tires. Consult your tire
drive the machine with overload at a high dealer for operating pressures.
speed; never drive the machine for a long
distance and a long time. As for the tire inflation pressure under normal
temperature, refer to the tire pressure decal on
the machine.
Tire Inflation Information
Cushion Tire--Replace
Liugong recommends the use of dry nitrogen gas
for tire inflation and for tire pressure adjustments. Replace the tire when it is worn to the abrasion
It includes all machines with rubber tires. mark. If any fault is found to the tire before it is
Nitrogen is an inert gas that will not aid worn to the abrasion mark, replace it
combustion inside the tire. immediately. Follow the below procedures when
The use of nitrogen for tire inflation can not only installing and removing the tire to ensure safety:
reduce the risk of explosion, but also help to 1. The installation and removal of the tire should
prevent oxidation, aging of the rubber, and only be done by trained professional service
corrosion of the wheel rim parts. This is man by using special instruments.
especially important for tires that are expected to
have a long service life of at least four years. 2. Install the tire on specified wheel rim. Keep
the wheel rim free from deformation, rust,
crack, solder skips, melt-through, rough
welding seams, porosity and sharp edges.
Training in using the equipment is necessary 3. Install the tire on the shaft with the same
to avoid over inflation. A tire blowout or a rim specification, structure, brand, size and
failure can cause personal injury. pattern. Replace the tires on the same shaft
simultaneously.
Do not set the tire inflation equipment
regulator higher than 20 psi (140 kPa) over 4. Check the wheel rim for deformation, crack
the recommended tire pressure. and compatibility of tire and wheel rim before
installing the tire. If there is any defect, repair
Check and adjust the tire inflation pressure after or replace the wheel rim.
them cooling enough. Ask all other persons to
leave the dangerous areas (around the rim).
90
Maintenance Manual
Working Implement System

5. In order to offer a better installation, spray or Clean the grease fitting thoroughly before
apply lubricant such as soapsuds etc onto lubricating. Wipe the grease that overflows
the bottom of the wheel hub and wheel rim, outside after lubricating is finished.
do not use grease etc. that may affect the tire
quality.

When it needs to lubricate from a high


position, perform lubrication by standing on
Do not use any industrial grease or other a platform and take proper measures to
commonly used lubricant etc. since it will ensure safety, otherwise, serious personnel
swell the rubber and damage the tire. injury could result.

The rim must be installed to the correct


position and the bolt must be tightened, Chain--Lubricate
otherwise the slide ring will be loose and the
tire will separate from the wheel rim, which Apply lubricant onto the chain.
could cause danger to personnel body.

Ensure that the tires and shaft are located at Maintenance Beside the Mast and
the same center when installing. Do not Fork
install tires with different brands or
conditions onto a same machine or shaft.
Do not mix cushion tire and pneumatic tire
when installing, otherwise, damage or
personnel injuries could be resulted.
Never repair or adjust in front of the fork
without the following safety protective
Storage and Maintenance of device when the mast and fork arm carrier
are being lifted. The following measures are
Cushion Tires applicable only to common check and
lubrication to the forklift. As for repairing
Do not store the cushion tires in bright, hot, oily the mast, changing cylinder or chain and so
and chemical environment because the rubber on that needs further safety measures,
will deteriorate quickly in above-mentioned contact the Liugong forklift dealer.
environment. Do not expose the tires directly
under the above-mentioned environment when Chain adjustment: Keep the mast straight,
storing. Lay the cushion tires flatly to avoid lower the fork onto the ground and the
personnel injuries. cylinder to the end. Adjust the chain by
pressing the middle of it to the maximum,
the displacement D is 30~50 mm (as shown
Working Implement System below). After maintenance, when the forks
are lowered onto the ground, the two chains
must be in tension state at the same time,
Mast--Lubricate otherwise please adjust the chain bolts.

Lubricate according to lubrication diagram.


91
Maintenance Manual
Working Implement System

3. Lower the inner mast slowly until it is hung by


the chain.

Secure the mast to prevent tipping back

To prevent mast from tipping back, place a hard Drop-resistant measures of full free two stage
wooden block A (110mm×110mm× 800mm) mast
between the mast and the machine body.
Even operated in a very low space, this kind of
mast can still raise freely. The middle lift cylinder
raises the fork to a particular free height through
chain wheel, and then the second-grade rear lift
cylinder raises the inner mast and fork arm
carrier at the same time. The middle lift cylinder
is installed on the inner mast.

A
Choose suitable chain according to different
height of the mast and do not exceed the
Drop-resistant measures of common two maximum lift height.
stage mast
1. Lift the mast.
When the inner mast rises, the chain wheel will 2. Fasten upper beam A of the outer mast and
rotate, and the fork arm carrier will rise with the lower beam B of the inner mast with a chain.
inner mast at a speed ratio of 2:1.
3. Lower the inner mast slowly until it is hung by
the chain.

Choose suitable chain according to different


height of the masts. Never exceed the
maximum lift height.

1. Lift the mast.


2. Fasten upper beam A of the outer mast and
lower beam B of the inner mast with a chain.
92
Maintenance Manual
Important Maintenance Procedures

4. Lower the fork arm carrier completely. 1. Lift the mast.


2. Fasten upper beam A of the outer mast and
lower beam B of the inner mast with a chain.
3. Lower the inner mast slowly until it is hung by
the chain.
A
4. Lower the fork arm carrier completely.

B Important Maintenance Pro-


cedures

Drop-resistant measures of three stage mast


Power System

The middle lift cylinder first raises the fork to a Coolant Level--Check
particular free height through chain wheel, then
the two second-grade rear lift cylinders raise the
inner mast. Under the effect of chain wheel, the
lifting speed of the inner mast is two times
quicker than that of the rear lift cylinders. The Hot coolant can cause serious burns. To
middle lift oil cylinder is installed on the inner open the cap, stop engine until the radiator
mast. cools down. Then loosen cap slowly to
release the pressure.

The coolant is in the radiator located at the


middle of the machine.

Checking method for coolant level:

1. Stop the engine and loosen the screw on the


plate.

Choose suitable chain according to different


height of the mast and do not exceed the
maximum lift height.
93
Maintenance Manual
Important Maintenance Procedures

2. After the engine coolant temperature drops Anti-freeze density and coolant additive
down below 50°C, slowly screw out the density-check
radiator coolant filler cap to release pressure
in order to avoid being scalded by high When adding or replenishing engine coolant
temperature vapor or splashing coolant. after cleaning the cooling system, first choose
the anti-freeze density of the coolant according
to the lowest local air temperature (10 °C below
the lowest air temperature is preferred).
Calculate the required capacity of anti-freeze
according to the total capacity of the cooling
system of the engine.
Brand and performance of anti-freeze
recommended by Liugong are as follows:

Min. suitable
Mobile anti-freeze
environmental
(concentration)(%)
temperature (°C)
-46 56
-40 51
3. Check if the coolant level is within 10 cm -33 45
below the water filler, replenish coolant if -25 40
necessary.
-20 38
4. Check the seals of the coolant filler cap, -15 33
replace if damaged. -10 28
5. Screw in the coolant filler cap. 0 0

When adding anti-freeze, use the same brand


anti-freeze.
Do not open the radiator cap or touch the
radiator surface directly before the
temperature drops down to avoid being
injured by the splashing coolant or burned by Anti-freeze is flammable. Never expose anti-
high temperature. freeze to an open fire. Never use plain water
as the coolant as it will cause corrosion
Check the cooling system of the engine for damage to the system.
leakage everyday. If leakage is found, repair Coolant must contain additive (SCA) to prevent
the leakage and replenish coolant until it the engine parts which contact with coolant from
reaches the proper level. rusting, scaling, pitting, and corrosion. Additive
(SCA) of low density doesn’t have effect, additive
(SCA) of high density will have a negative impact
on engine, it may result in water pump leakage
and corrosion of cooling system solder and
aluminum parts.
94
Maintenance Manual
Important Maintenance Procedures

The density of coolant additive should be 3. Open the radiator cap and slowly replenish
maintained at about 3%. Anti-freeze already coolant until the level reaches 10mm below
contains additive, but the additive will be the water inlet of the radiator and remains
consumed up during running the engine. stable in that position for 10 minutes.
Therefore, check the coolant density every 500
work hours or six months. Refill additive by
changing the coolant filter periodically.
Refer to the Operation and Maintenance Manual
of Diesel Engine provided with the machine for
the additive density inspection method and
detailed instructions.

Coolant--Replenish

Pressurized system: Hot coolant can cause


serious burns. To open the cap, stop the
engine and wait until the radiator is cool.
Then loosen the cap slowly to relieve the
When replenishing coolant, exhaust air from
pressure.
the cooling system line of the engine.

Replenish coolant as follows: 4. Keep the radiator cap open, start the engine,
run at idle speed for 5 minutes and then run
1. Mix water and coolant completely according at high speed for another 5 minutes until the
to desired density level of coolant. coolant temperature reaches over 80 °C.
2. Insert the key in the start switch and turn
clockwise to the “ON” position to turn on the
power of the machine.
Close the radiator filler cap before stopping
the engine, or coolant will spray out from
the filler.

5. Check the coolant level again. Continue to


replenish coolant if necessary until it reaches
10 mm below the water inlet of the radiator.
6. Check the sealing of the radiator cap.
Replace cap if damaged.
95
Maintenance Manual
Important Maintenance Procedures

Coolant-- Replace 2. Start the engine, run at idle speed for 5


minutes, and then stop the engine. Slowly
screw out the radiator cap to release
pressure after the coolant temperature is
below 50°C.
Care must be taken in order to ensure that
fluids are contained during performance of
inspection, maintenance, testing, adjusting
and repair of the equipment. Prepare to
collect the fluid with suitable containers
before opening any compartment or
disassembling any component that contains
fluids. Obey all local regulation for the
disposal of liquids.

Pressurized system: Hot coolant can cause


serious burns. To open the cap, stop the
engine and wait until the radiator is cool.
Then loosen the cap slowly to release the
pressure.
3. Open the water release valve on the bottom
of the coolant radiator, drain out the coolant
Replace coolant when the foreign material is
of the engine and collect with a container. For
suspended in the hot coolant. Hot coolant
more information, refer to Coolant--Drain
can cause injury or burns.
Out.

Completely change the coolant every 2400


operating hours or two years (which ever comes
first) and clean the cooling system. Clean the
cooling system before that interval if the coolant
is polluted, the engine is running excessively hot
or bubbles appear in the radiator.

Steps for cleaning the cooling system:

1. Insert the key in the start switch and turn


clockwise to the “ON” position to turn on the
power of the machine. 4. After draining out coolant of the engine, close
the water release valve on the bottom of the
radiator.
96
Maintenance Manual
Important Maintenance Procedures

5. Add cleanser mixed with water and sodium Coolant--Drain Out


carbonate into the cooling system of the
engine, its proportion is 0.5 kilograms of
sodium carbonate with 23 liters of water. The
level should reach normal level of the engine
and be kept stable for 10 minutes. It is dangerous to drain the coolant before
the engine cools down.

1. Make sure the machine is on flat ground.


When adding cleanser into the cooling 2. Open the filling cap of the radiator.
system, drain out air from the cooling
system pipes of the engine. During cleaning 3. Put a container under the drain valve. Open
of the cooling system, never cover the the drain valve and drain the coolant, and
radiator coolant filler cap while running the make sure the coolant is drained smoothly.
engine.

6. Keep the radiator coolant filler cap open.


Start the engine. When the coolant
temperature reaches over 80 °C, continue to
run the engine for another 5 minutes.
7. Stop the engine, drain out cleanser.
8. Add clean water until it reaches the normal
level and the level remains unchanged for 10
minutes. Keep the radiator coolant filler cap
open and start the engine. When the coolant
temperature reaches over 80 °C, run the 4. Open the drain plug at the bottom of the
engine for another 5 minutes. radiator to drain out the coolant.
9. Stop the engine and drain out the cooling 5. Wash the cooling system with water.
system water. If the discharged water is still
dirty, continue cleaning the system again until
the discharged water is clean.
10. Replace cooling filter, close the discharge
valve and refill the radiator with new coolant
according to the rules previously described in
the "Coolant--Replenish" on page 104 of this
manual.

Engine coolant is poisonous. Do not drink


it! Remove according to the local laws and
regulations concerning waste products.
97
Maintenance Manual
Important Maintenance Procedures

Engine Air Filter--Clean 4. Clean the main filter element if it is good.


First blow it out along the pleats inside the
CAUTION: Check the air filter regularly, main filter element. Then repeat blowing
service the air filter when blockage is found. along the pleats inside and outside the main
When maintaining the air filter, stop the filter element.
engine to prevent damage.
The method of cleaning the main filter
1. Stop the engine and open the engine cover. element:

Compressed air (below 200kPa);


High pressure water (below 280kPa);
Detergent (Dip the element in the neutral
detergent for about 30 minutes and then wash
it.);
Clean main filter element

2. Remove the cover of the air filter.

CAUTION: Do not heat the main filter


element when cleaning it, or damage could
result.

5. After washing, dry it in the air or blow it by the


3. Take out the main filter element and check it. blower (cold). Never blow it by compressed
Replace it if pleats, gasket or seal is air or firing it.
damaged.
98
Maintenance Manual
Important Maintenance Procedures

6. After cleaning the main filter element, check 2. Remove the cover of the air filter.
the element with a bulb. If small holes as well
3. Remove the main filter element.
as damage of the sealing area are found,
replace with a new main filter element. 4. Remove the safety filter element.
Check the main filter element 5. Clean inner wall of the air filter.
6. Secure a new safety filter element, ensure
even contact and good sealing of the seal
ring on the safety filter.

Fuel Level--Check

7. Secure a clean main filter element inside the


air filter and ensure even contact of the end
face of the main filter element.
8. Clean and secure the cap of the air filter.
Make sure that there is even contact between
the gasket of the inner cap of the air filter and
air filter cap.
9. Replace the main filter element after it has
been cleaned for six times. Replace once
every year even if it hasn’t been cleaned for
six times.

Air Filter Safety Element--Replace

The fuel tank is located at the left side of the


machine. Refer to the specification section for
the diesel fuel tank’s capacity.
Start the engine and operate the machine under
normal condition, check the fuel oil level in the
fuel level gauge/ voltmeter.
The fuel level gauge: it locates on the instrument
panel. When the pointer is in the green range
indicates the fuel level is located in the 20%-
CAUTION: Always replace the safety 100%; and the pointer is in the red range
filter element with a new filter element. Do not indicates the fuel level is located in the 0-20%.
use again after cleaning. When the pointer is in the red range replenish
the fuel in time.
1. Stop the engine and open the engine cover.
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Fuel--Replenish 2. Screw out the drain plug to drain out the


remaining fuel.
CAUTION: Replenish the fuel tank before
it is completely emptied. Any residual diesel
fuel at the bottom of the tank contains water
and moisture that will affect the proper
running of the engine.

1. The fuel cap located on the left side of the


machine.

3. Repeat washing until the tank is clean and


drain remaining oil.
4. Check the flange and seals of drain plug,
replace them if necessary.
5. Wash the fuel cap in the non-flammable
clean scour.
6. Screw on the drain plug and the fuel cap.
2. Remove the cap counterclockwise and
Fuel System Water and Impurity--
replenish the diesel oil.
Remove
3. After replenishing, screw down the fuel cap to
prevent the water and dirt into the fuel tank. The diesel fuel pump and engine fuel injection
nozzles (only for the machine equipped with
CAUTION: When replenishing, stop the diesel engine) are precision devices. If the diesel
engine and no smoking. fuel is mixed with water or impurity, the fuel pump
and iinjection nozzles can’t work properly and
Fuel Tank--Clean quickly wear out. Measures should be taken to
remove water and impurity from the fuel.
NOTICE: Care must be taken to ensure
1. If conditions permit, fuel should be deposited
that fluids are contained during performance
for 72 hours before being filled into the fuel
of inspection, maintenance, testing,
tank. Then add supper clean diesel oil / gas
adjusting and repair of the product. Be
without water and impurity (for the machine
prepared to collect the fluid with suitable
with NISSAN engine---double fuel system
containers before opening any compartment
only).
or disassembling any component containing
fluids. And dispose of all fluids according to 2. Before replenishing fuel, screw out the drain
local regulations and mandates. plug at the bottom of the tank once every
week to drain out water and impurity at the
1. Open the fuel cap and wash the inner surface bottom of the tank.
of the tank with clean diesel fuel. 3. After completing daily work, replenish fuel
and remove the humid air in the fuel tank.
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4. After replenishing the tank every time, wait 2. Air exhaust plug
for 5 ~ 10 minutes before starting the engine 2. Loosen the air exhaust plug of the injection
so that water and impurity sink into the pump by rotating it. Operate the manual oil
bottom of the tank. supply pump until the fuel is drained out
5. After completing daily work, loosen the water without air, then tighten the plug.
drain plug of the fuel pre-filter and the fuel
filter to drain out water and impurity.

1
Refill the fuel in time. Any residual fuel at
the bottom of the fuel tank contains water 2
and impurity that will affect the normal
running of the engine. Drain and clean fuel
tank before replenishing.

Fuel System Air--Remove (for YTO 1. Air exhaust plug


Engine) 2. Injection pump

Under the normal work condition, the air can Fuel System Air--Remove (for
enter the fuel system in the following ways: CUMMINS Engine)
1. Drain out oil from the oil tank when the
Controlled venting is provided at the injection
machine is working.
pump through the fuel drain manifold. Small
2. Low / high pressure oil hose is broken, or the amounts of air introduced by changing the filters
connector is loosen. Once the air enters the or injection pump supply line will be vented
fuel system, you must remove it before automatically if the fuel filter is changed in
starting the engine. accordance with the instructions. No manual
bleeding of fuel lines is required.
Methods for removing the air:
Manual bleeding is required in the following
condition:
1. Loosen the air exhaust plug of the fuel filter
by rotating it. Operate the manual oil supply ● The fuel filter is not filled prior to installation.
pump until fuel is drained out without air, then
● The injection pump is replaced.
tighten the plug.
● High-pressure fuel line connections are
loosened or lines replaced.
● Engine is initially started or started after an
extended period of no engine operation.
2
● Vehicle fuel tank has run empty.

1. Fuel filter
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1. The low pressure fuel lines are bled by 3. Tighten the line fittings and check for leaks.
pressing the hand lever on the filter head. Retighten line fittings
Low pressure fuel lines

WARNING: Do not bleed a hot engine as


2. Venting is accomplished by loosening one or
this could cause fuel to spill onto a hot
more fittings at the injectors and cranking the
exhaust manifold creating a fire.
engine to allow entrapped air to bleed from
the lines.
4. Exhaust air in the fuel line by the hand lever
High pressure fuel lines on the filter head and supply fuel to the
injection pump.
Injection pump vent

WARNING: The pressure of the fuel in the


line is sufficient to penetrate the skin and
cause seious bodily harm.
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Fuel Filter--Replace 4. Install a new gasket on the thread connector


of the support of the fuel filter. Apply a coat of
CAUTION: Do not fill fuel before the fuel engine oil on the seal surface of the filter. Fill
filter is installed. Fuel contamination will the fuel filter with clean fuel.
quicken the damage of the parts of the fuel Prepare a new fuel filter
system.

1. First clean the fuel filter and the support.


2. Remove the fuel filter from the support with a
wrench.
Removing the fuel filter

5. Install the filter to the support with hand. After


the gasket of the filter contacts with the
support, continue to tighten 1/2 ~ 3/4 of a
turn. Do not over tighten the filter with the
wrench to avoid damaging the filter.
Install a new fuel filter
3. Remove the gasket on the thread connector
of the support. Clean the sealing surface of
the support with a non-fibrous cloth.
Clean the sealing surface of the support

1. Gasket
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Fuel-Water Separator--Maintain 1. Drive the loader to a flat area, stop the


(CUMMINS Engine) engine and engage the parking brake .
2. After stopping the engine, wait for 10 minutes
Drain the water and sediment from the separator to let the engine oil in the crankcase return to
everyday. the engine oil pan.
3. Open the engine hood, take out the dipstick.
Wipe it with a clean cloth and completely
reinsert the dipstick into the end of the oil
filler of the engine. Take the dipstick again
and check the oil level. The oil level on the
dipstick should be between the low (L) and
high (H) graduation marks.

1. Stop the engine. Open the drain valve by


hand. Turn the drain valve counterclockwise
4 complete turns until the drain valve drops
down 1 inch (25.4mm). Drain water from the
water sump of the filter until the drained fuel
is clean.

CAUTION: Do not overtighten the drain


valve to avoid damaging the thread of the 4. If the oil level is below L, replenish oil. If the
drain valve . oil level is above the H, screw out the oil
drain plug at the bottom of the engine oil pan
2. Lift up the drain valve and turn it clockwise to to drain excessive oil.
close the drain valve. Oil level range

CAUTION: If the drained amount exceeds


two ounces (56.7g), replenish fuel to the filter
to avoid start failure.

Fuel---Heat

If it is necessary to heat the fuel at low


temperature, ensure that the temperature of fuel
doesn’t exceed 35°C when heating. Otherwise
power loss could result.

Engine Oil Level--Check

Too much engine oil or too little can result in


damage to the engine.
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Engine Oil--Replace 5. Stop the engine and wait for about 10


minutes, let the engine oil fully return to the
oil pan, check the engine oil level again, if it is
insufficient, replenish engine oil until the
engine oil is at H on the dipstick.
Care must be taken to ensure that fluids are
Check engine oil level
contained during performance of
inspection, maintenance, testing, adjusting
and repair of the product. Be prepared to
collect the fluid with suitable containers
before disassembling any component
containing fluids or dismounting any
hydraulic lines. Dispose of all fluids
according to local regulations.

High-temperature lubricant can cause


personal injury. Replace the lubricant only
when the lubricant is warm and the impurity
is floating.
Engine Oil Filter--Replace
1. Park the machine on flat ground, start the
engine and wait until the water temperature 1. Clean the area around the support of the
reaches 50°C, and engine oil temperature engine oil filter.
reaches 40°C.
2. Remove the engine oil filter with a belt
2. Stop the engine and engage the parking spanner.
brake.
3. Clean the surface of the gasket of the
3. Remove the oil drain plug on the bottom of support with a clean cloth. If old O-ring
the engine oil pan to discharge oil. Collect adheres to the support, remove it.
with a container.
Clean the support

4. Tighten the oil drain plug and replenish clean


engine oil from the oil filler of the engine till
the engine oil is at H on the oil dipstick. Run
the engine at idle speed to check the engine
oil filter and oil drain plug for leakage.
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Important Maintenance Procedures

4. Install a new O-ring, replenish the oil filter Power Train System
with clean engine oil, and apply a coat of
clean engine oil on the gasket surface.
Hydraulic Torque Converter--Check
Install new engine oil filter

High

Low

Park the machine on flat ground. Turn the shift


control lever to NEUTRAL position, engage the
Fill the filter with clean engine oil before the parking brake to prevent movement of the
engine oil filter is installed. If an empty machine. Lower the fork on the floor, stop the
engine oil filter is installed, the engine could engine.
be damaged due to a lack of lubricant.
Open the engine cover, take out the oil dipstick,
5. Secure the engine oil filter on the support and wipe it with clean cloth, insert it back and then
tighten the gasket of the engine oil filter until take it out again to check the oil level. The oil
it contacts with the support .Tighten engine level must be between the High and Low limits. If
oil filter according to the specified insufficient, replenish some oil.
requirements with the spanner.
Transmission Oil--Replace

Replace the transmission oil at the first 100


Excessively tightening the engine oil filter service hours, then replace it every 1200 service
could result in damage to the thread or the hours later on. Replace the transmission oil at
seal of engine oil filter element. least once every year.

Care must be taken to ensure that fluids are


contained during performance of inspection,
maintenance, testing, adjusting and repair of
the product. Be prepared to collect the fluid
with suitable containers before
disassembling any component containing
fluids or disconnecting any hydraulic lines.
Dispose of all fluids according to local
regulations.
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1. Park the machine on flat ground and turn the 4. Replace the transmission oil filter. For more
shift control lever to NEUTRAL. Engage the information, refer to "Transmission Oil Filter--
parking brake and lower the fork onto the Replace".
ground.
5. Install the drain plug and seals.
2. Start the engine and run it at idle speed.
6. Unscrew the oil filler cap on top of the
When the transmission oil temperature
transmission. Replenish clean transmission
reaches the operating temperature (80~90
oil to the oil filler, and tighten the oil filler cap
degrees Celsius), stop the engine.
after the transmission is filled with
3. Screw out the drain plug on the lower rear transmission oil.
side of the transmission to drain oil. Collect
7. Take out the oil dipstick of the transmission;
with a container.
replenish clean transmission oil until the level
is above High (H) graduation mark.

High

Low

8. Start the engine and run it at idle speed.


Check the level again and replenish the
2 transmission oil until the oil level is above
Low graduation. At that time, the
transmission could produce a slightly
abnormal sound due to insufficient level of
transmission oil. The abnormal sound will
disappear after the transmission oil reaches
the specified level.
1. Oil dipstick (oil filler) 9. When the transmission oil reaches operating
2. Oil drain plug
temperature (80~90 degrees Celsius), check
the level again. The level should be at the
High (H) graduation of the dipstick. If the oil
level is insufficient, add oil. If the oil level is
Because the transmission oil temperature is
excessive, drain some oil.
still high when draining, wear protective
clothing and be careful to prevent injury. 10. Insert the dipstick, and tighten it clockwise.

Drain out the oil of the transmission, torque Before replacing transmission oil, cover the
converter and radiator simultaneously. parking brake with cloth to prevent the
friction disc from touching the oil to protect
the parking brake performance.
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Important Maintenance Procedures

Transmission Oil Filter--Replace Axle Oil Level--Check

The oil filter of the transmission is located at the


top of the transmission. When changing the
transmission oil, also change the transmission oil
filter. Be careful the splashing hot oil when
refilling, draining, or loosening the plug.

1. Park the machine on flat ground. Clean the


area around the oil filler.

1 1

2
1. Oil filler
1. Clean the area around the oil filter of the
transmission. 3
2. Remove the oil filter from the support with a
belt spanner. 1. Oil filler
2. Oil level hole
3. Clean the sealing surface of the support with 3. Oil drain hole
a clean cloth. 2. Turn the shift control lever to NEUTRAL, pull
4. Apply a coat of transmission oil to the gasket up the parking brake lever to prevent
of the new oil filter. movement of the machine.

5. Secure the oil filter on the support until the 3. Remove the plug of the oil level hole and
gasket contacts with the sealing surface of check. The oil level of the axles should reach
the support and then further tighten it 1/3 or the lower edge of the oil level hole. If the oil
1/2 turn manually. level is below the lower edge of the oil level
hole, replenish with clean axle oil. Observe
for about 5 minutes after replenishing. The oil
level should remain stable.
4. Screw on the plug of the oil level hole.
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Important Maintenance Procedures

Axle Oil--Replace Hydraulic System

Hydraulic Oil Level--Check

Care must be taken to ensure that fluids are


contained during performance of inspection,
maintenance, testing, adjusting and repair of
the product. Be prepared to collect the fluid When checking the hydraulic oil level, park
with suitable containers before the machine on level ground and lay level the
disassembling any hydraulic line or fork flatly on the ground.
component containing fluids. Dispose of all
fluids according to local regulations. Hydraulic oil tank location

Drain oil after the machine runs for a period


time to let the impurities deposited in the oil
suspend.

1. Drive the machine for a period of time until


the foreign material in the axles becomes
suspended. Park the machine on flat ground.
2. Stop the engine, turn the shift control lever to
NEUTRAL, and pull up the parking brake
lever to prevent movement of the machine.
3. Screw out the oil drain plug at the bottom of The hydraulic tank is located on the right side of
the drive axles to drain oil. Collect the oil with the seat. The oil level gauge indicating the
a suitable waste container. hydraulic oil level is located under the control
valve cover.

Because the axle oil temperature is still high


when draining, wear protective clothing and
be careful to prevent injury.

4. Screw on the oil drain plug at the bottom of


the drive axle.
5. Screw out the oil filler plug on top of the axle
and replenish with clean axle oil until the oil
level reaches the lower edge of the oil level
hole. Observe for about 5 minutes after
replenishing. The oil level should remain
stable.
6. Screw on the oil filler plug on top of the drive
axle.
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Important Maintenance Procedures

Hydraulic Oil--Replace 4. Clean the hydraulic oil tank drain plug. Screw
out the oil drain plug to drain out hydraulic oil
and collect with a waste container. You can
open the oil fill cover over the tank to quicken
the oil release.
Care must be taken to ensure that fluids are
contained during performance of inspection, Hydraulic oil drain plug
maintenance, testing, adjusting and repair of
the product. Be prepared to collect the fluid
with suitable containers before
disassembling any hydraulic line or
component containing fluids. And dispose all
fluids according to local regulations.

Pay close attention to the cleanliness during


replacing the hydraulic oil, do not allow dirt
enter the hydraulic system.

If the operating condition is bad or the


hydraulic oil becomes deteriorated due to Hydraulic oil tank oil filler cap
pollution, such as black color and bubbles on
the oil level, change hydraulic oil in time.

1. Park the machine on flat, open ground. Put


the shift control lever in NEUTRAL, hold the
parking brake lever to stop the machine.
2. Start the engine and run at idle speed for 10
minutes. Repeat the operation while lifting
and lowering the fork and tilting the mast
forward & backward.
3. Lower the fork on the floor and stop the
engine.

Because the hydraulic oil temperature is still


high when draining, wear protective clothing
and be careful to prevent injury.

5. Remove all the oil inlet/outlet pipe and the


flange cover of the hydraulic oil cooler and
check the seal of the oil fill cover for wear out.
Wash the bottom and four walls of the
hydraulic tank with diesel oil, and dry with
clean cloth.
6. Secure into place the oil drain plug of the
hydraulic tank, the top cover, and the inlet
pipe of the hydraulic oil radiator.
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Important Maintenance Procedures

7. Replenish clean hydraulic oil at the oil inlet of Check and repair the brake system immediately
the hydraulic tank until the oil level reaches if the brake oil runs out quickly as an oil leakage
the upper graduation of the hydraulic oil level might result.
sight gauge. Tighten the tank cover.
8. Operate the lifting handle and tilting lever to Parking Brake Performance--Check
raise and lower the fork 2~3 times. Tilt the
mast forward and backward and turn from left
to right to the maximum angle to fill cylinders
with hydraulic oil fully.
Check the parking brake performance
9. Then run the engine at idle speed for five frequently to ensure the machine can safely
minutes to discharge air in the system. stop and ensure its emergency braking
capability.
Brake System
1. Lift the fork to a height of 15cm to 20cm from
the ground, and make sure the brake
Brake Oil Level--Check
performance of the machine is in good
condition.
2. Start the machine and drive it onto a slope
with 15% (8.53°) grade. The sloep surface
should be flat and dry.

3. Depress the service brake pedal, stop the


machine. Turn the shift control lever to
Neutral position then turn off the engine.
4. Turn the parking brake lever backwards and
release the service brake pedal slowly.
Check to see if the machine stays at the
original position.
The brake oil holder is on the assistor pump,
which is located under the brake pedal.
Check the level of the brake oil in oil holder. The
oil level should be within 5 mm from the bottom Personnel injury may result if the machine
of the strainer. If the brake oil level is lower than moves while checking. Keep others away
the down limit, replenish brake oil to appropriate from the machine while checking the braking
level. system.
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Important Maintenance Procedures

Service Brake Performance--Check Battery--Check

The battery is located under the engine hood and


on top of the hydraulic oil tank.

Before checking the service brake ability,


make sure the machine's parking brake
system works normally, in case of an
emergency.

Drive the forklift on a flat and dry road at a speed


of 20 kilometers/hour. Depress the service brake
pedal to stop the machine completely. After the
machine is stopped, turn the shift control lever to
NEUTRAL position and turn the parking brake
lever backwards, then release the service brake
pedal. Check for the brake distance of the Clean the battery terminals and the battery
machine. The brake distance should not exceed surface with a clean cloth. Check the battery
5m. electric charge state with eyeballing when the ray
is bright enough. Green--- battery is charged
fully. Dark--- battery should be charged. Clear ---
air bubbles could be in indicator, remove bubble
Personnel injury may result if the machine by slightly if it is still whitened after shaking the
moves while checking. Keep others away battery, the electrolyte is lost, this battery is
from the machine while checking the braking damaged and replace.
system.
Hydrometer

Electrical System

Battery

Never let burning cigarette or open fire close


to the batteries.

Wear safety glasses and rubber gloves when


touching batteries during work.

Stop the engine before working with


batteries. Do not over discharge and use up the
electrolyte. Tighten the nut in the center of
the lock plate to prevent loose battery. Check
the battery terminals frequently for
looseness.
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Important Maintenance Procedures

Battery--Install Battery--Charge

1. Turn the engine start switch key to OFF and Reasons for electricity insufficiency of the
remove the key. battery:
2. Clean the battery terminals and surface with ● Long use of the electricity appliances without
a clean cloth. Do not use petrol or other starting the engine.
organic solvent or cleanser.
● Long-time stop, electricity leakage and the
3. When connecting: large current or extra electricity appliance
installation will result in an electricity
(a) Connect the positive post of one battery
insufficiency.
to the negative terminal of the other
battery with the cable. ● Frequent starting of the machine.
(b) Connect one end of the battery positive ● Failure of the machine charging system, such
lead terminal to the battery positive post, as malfunction of the alternator or its
the other end to start motor. electronic units, low charging voltage, loose
engine belt, etc., which result in abnormal
(c) Connect one end of the battery negative
charging of the batteries, battery electrolyte
lead terminal to the battery negative post,
loss, black hydrometer, and even starting
the other end to ground cable.
failure.
To start motor ● The batteries have been stored over six
months before being used.
5 3
The batteries under the above-mentioned
condition can work again by recharging.
4

Keep ventilated when charging. Charge the


1 To ground battery under normal temperature.
cable
Do not smoke when charging the battery,
2 avoid producing spark and open fire when
charging.
1. Battery
2. Battery
3. Cable
Do not start the machine when charging.
4. Battery negative lead
5. Battery positive lead Operations when charging:
4. Tighten the nut. ● Turn the start switch to OFF position and
remove the key.
● Remove the battery from the machine.
Disconnect the battery negative terminal
A wrong installation of the negative and before removing the battery.
positive terminal will result in a serious
damage to the battery. Distinguish the right ● Clean the battery terminals and surface with
positive (+) and negative terminal (-). a clean cloth, remove oxidized surface.
Check the outlook of the battery before
charging:
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Important Maintenance Procedures

(a) If the battery housing cracks or there is As for the battery with a voltage under 11.0V, it
an acid leakage. Discard it. may not be able to be charged at the beginning.
(b) If the terminal cracks. Discard it. Due to the serious insufficiency of electricity,
sulfuric acid gravity in the battery is close to pure
(c) Do not charge the battery if it is over- water, therefore, the battery resistance is higher.
charged or over-discharged. Discard it. As the battery is charged, sulfuric acid gravity in
the battery is increased, the battery resumes
● Positive of the charger is connected to the
normal charge current.
positive of the battery and negative of the
charger is connected to the negative of the
battery.
● It is recommended that 16.0 volt of constant
voltage (no more than 16.2 volt) should be Tighten the two terminals. Do not charge the
used to charge battery. The battery charge is battery of 24V voltage in series.
finished if the voltage of the battery end
comes to 16.0V voltage and the voltage During charging the battery, much sulfuric
difference is less than 0.05V within one hour. acid is ejected at the battery outlet, stop
charging and find out the reason.
● If the battery is charged with constant voltage
as no condition is permitted, charge the ● During charging the battery, stop charging
battery with constant voltage according to the the battery if the battery temperature is over
following standard. 45°C. After the battery temperature reduces
(a) Choose 2A current with rated capacity to ambient temperature, reduce the charge
current in half and charge again.
charge.
(b) Table of corresponding relation between ● During charging the battery, check indicator
condition once every hour. The battery
charge time and battery voltage for
charge is finished if the voltage of the battery
reference as shown below:.
end comes to 16.0V voltage and the voltage
Battery Voltage Charge Time difference is less than 0.05V within one hour.
12.55-12.45v 2h
12.45-12.35v 3h
12.35-12.20v 4h
If the hydrometer is black, check for loose
12.20-12.05v 5h cable and clean connecting terminal. Check
12.05-11.95v 6h whether the voltage has reached 16V. If the
hydrometer is clear, it is likely that air bubble
11.95-11.80v 7h
exist in it. If the hydrometer is still clear after
11.80-11.65v 8h slight shaking (indicates that the electrolyte
11.65-11.50v 9h loss), replace with a new battery.
11.50-11.30v 10h
● It is recommended applying Vaseline on the
11.30-11.00v 12h
battery terminals to avoid electric corrosion
Below 11.00v 14h after charge is completed.

Battery Maintenance during the


Machine Storage
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Important Maintenance Procedures

● Disconnect the negative terminal of the Other Maintenance


battery if the machine is stored exceeds
15days.
Fuses--Check/Replace
● Check the electricity state of the battery
every 4 months. The fuse box is located at the right side of the
(a) If the voltage exceeds 12.4V, the battery opened front over. The fuse is used to protect the
is in normal condition. electrical system and prevent damages caused
by the overloading of circuit. If lights do not
(b) If the voltage is under 12.4V, the battery illuminate or electrical equipment doesn't work,
lacks for electricity. these may be caused by the broken fuse. Check
● Recharge if the battery lacks for electricity. and replace the fuse. If the newly-replaced fuse
Recharge according to special procedures. burns out again, check the circuit and repair it if
needed.
● As for the machine which has not
disconnected the battery terminals, check the
battery voltage state every month. If the
voltage is under12.4V, recharge it according
to special procedures.
● As for the machine which is stored over 1
year, replace with a new battery and dispose
the old one if the above- mentioned
requirements can not be followed.

Battery Recycle

When discarding the battery, its inner material


such as lead, acid and plastic shell can pollute Check and replace the fuse as follows:
the environment due to its outer frayed structure
or other reasons. Therefore, do not throw the old 1. Turn the start switch to OFF position.
battery randomly, dealing with it by collecting for 2. Remove the cover of the fuse box, and take
the battery dispose station or put it into the the melted fuse out by fuse clamp.
recycle bin set by the manufacturer (if there is
3. Replace it with a new fuse with same
any) in the local place.
specification.
4. Install the cover of the fuse box.

Replacing the broken fuse with a new one


with same specification and series from
different manufactures is allowed. There may
be a circuit failure if frequent fuse
replacement occurs. Contact Liugong dealer
if necessary.
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Maintenance Manual
Important Maintenance Procedures

See the following table for slice fuse color with Adjust the seat belt's length before using it so as
different specifications: to ensure its protecting function and comfort
ability. Move the position of retractor on seat belt
Model Color to adjust the length of the seat belt.
BX2011C-10A Red(RD)
No matter how well the seat belt looks like,
BX2011C-20A Yellow(YL) replace it every three years.
BX2011C-5A Orange(OR)
Consult your Liugong dealer for the replacement
BX2011C-15A Blue(BU) of the seat belt.
BX2011C-30A Green(GN)
BX2011C-7.5A Brown(BR) Machine Electrical Schematic

Backup Alarm--Test Refer to Parts Manual of this machine for


electrical schematic.

The backup alarm is installed beside the battery.


In order to test the alarm for proper function, turn
the engine start switch to ON position.
Hold the parking brake lever to engage the park
brake.
Turn the start switch to START position to start
the engine.
Turn the shift control lever backwards, the
backup alarm should sound immediately.
Turn the shift control lever to Neutral position or
Forward position, the backup alarm should stop
hooting.

Seat Belt--Check

Check the seat belt for good condition before


using it. If necessary, replace it in time.
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Maintenance Manual
Troubleshooting

Troubleshooting

Power Loss

Parts Cause of malfunction Method of inspection Troubleshooting


A. Oil pressure is too low:
(1) oil level is too low Check the oil level Refilling
(2)Air is taken into the oil suction Retighten the connector and
Check connector and oil pipe
side replace the seals
(3)Oil filter is blocked Remove and check Clean and replace

Torque (4)Poor displacement of fuel


Remove and check Replace
converter supply pump
(5) Spring of main relief valve is
Check the tension of spring
distorted.
(6) Damage or abrasion to seal-
Remove and check Replace
ring or O-ring seal
B. Damage to flywheel, or Take out a small amount of oil and
Replace
collision with other parts check for any foreign impurity
A. Misuse of oil or foaming Check
(1) Air has been taken in oil Retighten the connector or
Check connector and oil pipe
intake side replace it
Transmission (2) Oil pressure of torque
Test the pressure Adjust the pressure
converter is too low or foaming
B. Incorrect positions of Fine
Adjustment Lever and shift Check and test Adjust
control lever
Check rev at stall speed;
Check the sounds when the engine
The power of the engine
Engine is working under neutral position Regulate or repair the engine
decreases
(neutral gear) conditions; Check for
the maximum rev of the engine
117
Maintenance Manual
Troubleshooting

Abnormal Oil Temperature

Parts Cause of malfunction Method of inspection Troubleshooting


(1)Oil level is low Check the oil level Refilling
(2) Filter is blocked Remove and check Clean and replace
Discharge the oil from filter or oil
(3) Flywheel collides with other
reservoir and check for any foreign Replace
parts
impurity
Torque
Tighten the connector or
converter (4)Air is taken in Check connector and oil pipe
replace the gasket
(5)Oil is mixed with water Discharge the oil and check Replace the oil
Check the pipeline for any damage or
(6) Oil flow is low Repair or replace
distortion.
(7)Bearing is worn or blocked Remove and check Repair or replace
Gear-box (1) Bearing is worn or blocked Remove and check replace

Noisy Transmission

Parts Cause of malfunction Method of inspection Troubleshooting


Check the sounds when it is in
(1) Break of spring plate Replace the spring plate
operation
(2)Bearing is worn or damaged Remove and check replace
Torque (3)Break of gear Remove and check replace
converter
(4)Spline is worn Remove and check replace
(5) The noise of oil pump is loud Remove and check Repair or replace
(6) Loose bolt Remove and check tighten or replace
(1) Bearing is worn or blocked Remove and check replace
(2) Break of gear Remove and check replace
Gear box
(3) Spline is worn Remove and check replace
(4) Loose bolt Remove and check tighten or replace
118
Maintenance Manual
Troubleshooting

Oil Leaks

Parts Cause of malfunction Method of inspection Troubleshooting


Removal and inspection, to see if the oil
(1) Oil seal is damaged seal lip or other parts relating to the slide is Replace oil seal
worn.
Tighten or replace the
(2)The housing is connected Inspection
gasket

Torque (3)Loose connector and oil Tighten or replace the


Inspection
converter pipe pipe
and gear 4)Loose fuel drain plug Inspection tighten or replace
box
Discharge the oil and check the oil to see if
any water is mixed in with it; Check the oil Replace the oil
(5) Oil erupts from vent hole intake connector to see if and air has been Tighten or replace oil seal
taken in; Check the vent hole of the Repair
ventilation device
(6)Too much oil Check the oil level Discharge the extra oil

Low Transmission Efficiency

Parts Cause of malfunction Method of inspection Trouble shooting


Check the sounds when it is in
(1) Break of spring plate operation,and check if the front cover replace
operates
(2) Oil storage is not enough Inspection of the oil level Add oil
Torque
(3)Malfunction of drive system of
converter Removal and inspection replace
oil pump
(4) Break of shaft Removal and inspection replace
Check the oil intake side of the oil pump
(5) Oil pressure is low replace
to see if any suction pressure is formed
(1)Oil storage is not enough Inspection of the oil level Refilling
(2)Seal ring is broken Removal and inspection replace
Gear box
(3)Shaft is broken Remove and check replace
(4) The spline of the shaft is worn Remove and check replace
119
Maintenance Manual
Malfunction Analysis

Malfunction Analysis

Parking Brake Malfunction Analysis

Malfunction Causes Troubleshooting


Leakage of brake fluid in brake system Repair
The friction plate clearance is adjusted incorrectly. Adjust
Brake is overheated Check for any slip
Brake force is The contact between brake drum and f friction plate is not
Adjust
not enough good
Impurity adheres to the surfaces of friction plate and shoe Repair or replace
Brake fluid is mixed with impurity Replace the brake fluid
The brake pedal has been adjusted incorrectly Adjust
The surfaces of the friction plates and shoes is hardened and
Repair or replace
contain impurities
Loose bolt, distortion of bottom plate Repair or replace
Noise exists
when brake is Distortion of the friction plate and shoe after assembly or
Repair or replace
in operation incorrect assembly
Uneven wear and tear of the friction plate replace
Wheel bearing is not good replace
Impurity adheres to the surfaces of friction plate and shoe Repair or replace
The operation of the secondary pump is not good Repair or replace
Uneven brake Eccentric brake drum Repair or replace
The friction plate clearance is adjusted incorrectly Adjust
Tire pressure is not proper Adjust
Leakage of brake fluid from brake system Repair

Soft and weak The friction plate clearance is adjusted incorrectly Adjust. repair
pedal Brake system is mixed with air Exhaust
The pedal is adjusted incorrectly Readjust
120
Maintenance Manual
Malfunction Analysis

Steering Gear Malfunction and Troubleshooting

Malfunction Cause Symptom Troubleshooting


Leakage of oil from valve
Dirt on the joint surface body, partition, stator and the Wash it again
joint surface of rear cover
Leakage of oil at the neck of the
Leakage of oil
shaft because of the damaged Replace the rubber ring
rubber ring
leakage of oil at the stop bolt
Flatten or replace the gasket
because of uneven gasket
The steering wheel becomes Choose appropriate oil pump or
light when being turned check the flow divider valve of
Shortage of oil supply
slowly and becomes heavy the oil pump to see if any
when being turned quickly abnormity
Foams exists in oil; irregular
sounds can be heard; the
Discharge the air in the system,
cylinder sometimes move
Air exists in steering system and check the oil suction
and sometimes does not
pipeline
move when the steering
wheel is turning
Heavy steering Oil tank is not full Add oil to the specified level.
wheel Use the oil with recommended
Oil viscidity is too high
viscidity
Heavy steering wheel when
If the steel ball is missing, you
the steering wheel is turning
The steel ball check valve inside should install a φ8 steel ball. If
slowly or quickly, and no
the vale body is not effective the steel ball is struck by dirty
pressure for the steering
object, you should wash it.
operation
The pressure of the flow divider Light steering wheel when
valve is lower than the working there is no any (or little) load, Regulate the pressure of the
pressure, or the flow divider valve and heavy steering wheel flow divider valve or wash it.
is struck by dirty object. when the load increases
121
Maintenance Manual
Malfunction Analysis

The steering wheel can not


automatically return to the
Replace the damaged spring
Break of spring leaf middle position, and the
leaf
pressure drop at the middle
position becomes big
Pressure oscillation
increases obviously, and the
Break or distortion of pin Replace the pin
turning movement even can
not be made
Pressure oscillation
Malfunction of Break or distortion of the opening increases obviously, and the
Replace the linked shaft
steering wheel of the linked shaft turning movement even can
not be made
Oil distribution is in disorder,
The rotor and the linked shaft
and the steering wheel turns Reassemble it according to the
have been installed one another
automatically or swing (e) section in Assembly Notice
to the wrong positions
around
The cylinder does not move
Malfunction of two-way overload
(maybe turns very slowly)
valve (the steel ball is struck by
when the vehicle pulls to one Wash two-way overload valve
dirty objects or the spring does
side or the steering wheel is
not work)
turned
(1) The steering column is
The pressure drop at middle
different from the valve core
Steering wheel position become increasingly
(2) The steering column pushes
can not return to big or the steering gear fails
the valve towards the axle and Fix the problems according to
the middle to discharge the load when
lock it up the causes of malfunctions
position the steering wheel stops
(3)The resistance is too big when
automatically turning (the vehicle pulls to
the steering column turns
one side)
(4) Break of spring leaf
The driver has no strong
feeling about the cylinder
piston reaching the terminal
The steering
The radial clearance between position in the case of power
wheel can not be Replace rotor and stator
rotor and stator is too big steering. In the case of
turned manually
manual steering, the steering
wheel turns but the cylinder
does not move.
122
Maintenance Manual
Malfunction Analysis

Steering System Troubleshooting

Malfunction Causes Troubleshooting


1.The pressure of the flow divider valve is too low Regulate the pressure:4~5t is 12Mpa.
Discharge the air, and check whether there is
2.Air exists in steering system
leakage in the oil suction pipeline

Heavy steering 3.The orifice of the flow divider valve jammed and
Clean the flow divider valve
wheel caused the shortage of oil supply
4. Malfunction of steering wheel return, spring in
Replace the spring leaf
the metering pump breaks or loses elasticity.
5.Distortion of the steering axle or lock up of the
Repair, replace, add enough lubricate grease
main steering pin or poor lubrication of the bearing
Poor steering
ability, the
The radial and axial clearance of the metering
steering wheel Replace the rotor and stator
pump stator is too big, and efficiency is declined
is very light
when steering

Loosen of the 1. The main steering pin bearing damaged Replace


steering wheel 2.The hub bearing loosened Adjust

For the malfunctions of steering system caused by flow divider valve and the troubleshooting,
see the table below.

Malfunction Causes Troubleshooting


The steering wheel is stagnant Flow control valve lever is blocked Take it out for repair or replace it
when fast turn is made Flow control valve lever is worn Completely replace
Safety valve is always open (unable to be
Oil pressure can not rise Completely replace
closed)
Oil pressure is higher than the valve Safety valve is always closed (unable to be
Completely replace
pressure regulated opened)
Noise of safety valve Safety valve shakes Completely replace
Safety valve is always closed (unable to be
Oil temperature is too high Completely replace
opened)
Safety valve is always open (unable to be
It is very difficult to operate the Completely replace
closed)
steering wheel when the engine
Flow control valve lever is blocked Take it out for repair or replace it
operates at idle speed
Flow control valve lever is worn Completely replace
Safety valve shakes Completely replace
Steering force changes Flow control valve lever is blocked Take it out for repair or replace it
Flow control valve lever is worn Completely replace
Safety valve is always open (unable to be
Completely replace
It is very difficult to operate the closed)
steering wheel Flow control valve lever is blocked Take it out for repair or replace it
Flow control valve lever is worn Completely replace
123
Maintenance Manual
Malfunction Analysis

Hydraulic Transmission Troubleshooting

Malfunction Causes Troubleshooting


1. The friction plate is locked up or worn; the
friction plate agglutination is touched or warped Adjust or replace
unevenly.
2.Wear of the oil feed pump or too low of the oil
level causes the oil feed insufficiency of the oil Replace, or renew oil
Efficiency is feed pump
declined and oil
temperature is Alleviate the load and parking or idle speed
3. Overloading for a long time
too high operation
4.The bearing is damaged Replace
5.The lubricate oil lines jammed Check the oil lines, clean dirt
6.Unilateral wheel of the torque converter is
Replace
locked up
1.Seal pieces are broken Replace
Oil leakage
2.Rubber pieces aging, and damaged Replace

Drive Axle Troubleshooting

Malfunction Causes Troubleshooting


1.Over abrasion of the bevel gear or the
Replace the gear or adjust the joggle clearance
joggle clearance is too big
2.Over abrasion of the differential
Noise in the drive Replace
planetary gear shaft
axle is abnormal
3.Over abrasion and looseness of the
Replace or adjust
taper roller bearing
4.Insufficiency of the lubricant Fill oil
124
Maintenance Manual
Malfunction Analysis

Brake System Troubleshooting

Malfunction Causes Troubleshooting


1. The clearance between the brake drum and the
friction shoe linings is too big, or the friction plate Adjust the clearance
clearance is adjusted unevenly.
2.Leakage of the secondary pump Replace the rubber cup
3.Leakage of the braking system, and mixed with
Repair, and exhaust
Malfunction of air
the brake, the
4.Wear and tear of the friction shoe linings or
brake drum Repair or replace
contain impurities
heats
5.Brake is overheated Check for any slip
6.Brake fluid is mixed with impurities Check and remove the impurities.
Adjust the clearance, repeat brake forward and
7.The two wheels can not brake at the same time backward for several times, and exhaust the air in
pipe.
Malfunction of
The brake pedal free stroke over bigness Adjust
the foot brake
Malfunction of
the manual The rope of the manual brake over loosen Adjust
brake
1.Distortion of the bottom plate, loose bolt Repair, replace
2.Distortion of the friction plate and shoe or
Repair, replace
incorrect assembly
Brake noise
3.Wear and tear of the friction shoe linings or the
Repair, replace
surfaces is hardened
4.Loosen of the wheel bearing Repair
125
Maintenance Manual
Malfunction Analysis

Lifting System Troubleshooting

Malfunction Causes Troubleshooting


1.Wear and tear of the gear pump, and too much clearance in Replace the wearing parts or
movement oil pump
2.Seal piece failure of lifting cylinder, there is in-leakage Replace the seal piece
3.Main relief valve spring failure of the control valve Replace the spring
4.Too high temperature of hydraulic oil, oil watery or Insufficient Decrease the oil temperature,
Weak lifting power or flow check causes
unable to lift Replace the oil with wrong
5.The relief valve orifice of the control valve jammed
code
6.Wear and tear of the control valve, there is in-leakage Replace the wearing parts
Load according to the
7.Over loading
standard
8.Air exists in the hydraulic system Exhaust
The decrease speed
No installation or lock up of the limit speed valve spool Check and adjust
is too fast
1.Too much in-leakage in the system, especially in the control Check the system and replace
Too much sliding in valve the control valve
lifting cylinder
2.Seal piece failure of lifting cylinder Replace the seal piece
1.Wear in the tilting cylinder seal piece Replace
Self tilting fork arm
2.Spring failure of tilting valve stem Replace
carrier and mast
3.Serious wear in the fork arm carrier roller and mast Replace

Difficult in fork arm 1.Oil cylinder piston locked the cylinder wall, or piston rod
Replace
carrier lifting and winding and distortion
tilting 2.Too much impurities in the cylinder, and sealed over tightness Clean, replace the seal piece
126
Maintenance Manual
Maintenance Note Table

Maintenance Note Table


127
INDEX

INDEX

A Coolant--Replenish ......................................... 94
Crushing and Cutting Prevention .................... 22
Cushion Tire--Replace .................................... 89
Abnormal Oil Temperature ............................117
Accelerator Pedal ............................................57
Air Filter Safety Element--Replace ..................98 D
Application and Specification ..........................42
Applications .....................................................42 Downhill Operation ......................................... 65
Attachment Cautions .......................................27 Drawbar .......................................................... 60
Attachment--Remove and Lift .........................74 Drive Axle Troubleshooting .......................... 123
Axle Oil Level--Check ...................................107 During Storage ............................................... 68
Axle Oil--Replace ..........................................108

E
B
EC Declaration of Conformity ........................... 4
Backup Alarm--Test ......................................115 Electrical Storm Injury Prevention .................. 25
Battery ...........................................................111 Electrical System ....................................81, 111
Battery Maintenance during the Machine Storage Emission ......................................................... 41
.......................................................................113 Engine ............................................................ 76
Battery Recycle .............................................114 Engine Air Filter--Clean .................................. 97
Battery Terminal ..............................................53 Engine Hood ................................................... 60
Battery--Charge ............................................112 Engine Oil Filter--Replace ............................ 104
Battery--Check ..............................................111 Engine Oil Level--Check ............................... 103
Battery--Install ...............................................112 Engine Oil--Replace ..................................... 104
Before Operation .............................................51 Engine Starting ............................................... 62
Before Reuse ..................................................68
Before Storage ................................................68
Brake Operation ..............................................64 F
Brake Pedal ....................................................57
Brake System ......................................... 80, 110
Fine Adjustment Pedal ................................... 57
Brake System Troubleshooting .....................124
Fire &Explosion Prevention ............................ 23
Burn Prevention ..............................................22
Fire Extinguishers and First-aid Kit ................. 25
Fork ................................................................ 60
C Fork Install ...................................................... 72
Fork Removal ................................................. 72
Forklift Storage ............................................... 68
Cautions about Machine Maintenance ............37 Fuel ................................................................. 26
Cautions about Machine Operation ................27 Fuel Filter--Replace ...................................... 102
Chain--Lubricate .............................................90 Fuel Level--Check .......................................... 98
Choke Switch ..................................................58 Fuel System Water and Impurity--Remove .... 99
Cold Weather Operation .................................66 Fuel System Air--Remove (for CUMMINS
Control Valve Lever ........................................56 Engine) ......................................................... 100
Coolant Level--Check .....................................92 Fuel System Air--Remove (for YTO Engine) 100
Coolant-- Replace ...........................................95 Fuel Tank--Clean ............................................ 99
Coolant--Drain Out ..........................................96
128
INDEX

Fuel---Heat ....................................................103 M
Fuel--Replenish ...............................................99
Fuel-Water Separator--Maintain (CUMMINS
Engine) ..........................................................103 Machine Electrical Schematic ....................... 115
Fuses--Check/Replace .................................114 Main Components of the Machine .................... 3
Main Parts of Forklift Body ............................. 58
Main Specifications ......................................... 43
G Maintenance Beside the Mast and Fork ......... 90
Maintenance Interval Schedule ...................... 76
General Hazard Information ............................19 Maintenance Manual ...................................... 75
General Torque Specifications ........................86 Maintenance Note Table .............................. 126
Malfunction Analysis ..................................... 119
Mast--Lubricate ............................................... 90
H Move Oversize Goods .................................... 66

Horn Button .....................................................58 N


Hot Weather Operation ...................................67
Hydraulic Oil Level--Check ...........................108
Hydraulic Oil--Replace ..................................109 Noisy Transmission ...................................... 117
Hydraulic System ............................................84
Hydraulic System Maintenance ....................108 O
Hydraulic Torque Converter--Check .............105
Hydraulic Transmission Troubleshooting ......123
Oil Change Interval and Refill Capacities ....... 88
Oil Leaks ....................................................... 118
I Oil Specifications ............................................ 87
Operation Manual ........................................... 51
Important Maintenance Procedures ................92 Operation Techniques .................................... 63
Important Safety Information .............................1 Operator Controls ........................................... 56
Instrument Panel .............................................54 Operator Controls and Instrument Panels ...... 52
OPS (Optional) ............................................... 62
Other Maintenance ....................................... 114
K Overhead Guard ............................................. 60

Key Spare Parts to be Periodically Changed ..41 P

L Parking ........................................................... 67
Parking Brake Lever ....................................... 56
Parking Brake Malfunction Analysis ............. 119
Leave the Machine ..........................................67
Parking Brake Performance--Check ............. 110
Lift System ......................................................82
Power Loss ................................................... 116
Lifting Operation ..............................................73
Power System ................................................ 92
Lifting System Troubleshooting .....................125
Power Train .................................................... 78
Load Backrest .................................................60
Power Train System ..................................... 105
Loading Operation ..........................................65
Preface ............................................................. 1
Low Transmission Efficiency .........................118
Lubrication Specifications ...............................87
129
INDEX

R Transportation Information ............................. 69


Troubleshooting ............................................ 116

Run-in .............................................................75
Running Operation ..........................................63 U

S Unloading Operation ....................................... 66

Safety Decals and Decal Locations ..................6 V


Safety Devices and Attachment ......................84
Safety in Attachment Installation, Adjustment and Vibration Level ................................................ 40
Use ..................................................................61
Safety Information .............................................6
Safety Signs ......................................................6 W
Safety Symbol ...................................................6
Seat Belt .........................................................59
Working Implement System ............................ 90
Seat Belt--Check ...........................................115
Seat .................................................................58
Serial Number of the Machine and Parts ..........3
Service Brake Performance--Check .............111
Shift Control Lever ..........................................56
Sound ..............................................................40
Stability and Barycenter ..................................38
Start Switch .....................................................53
Steering Column .............................................58
Steering Gear Malfunction and Troubleshooting
.......................................................................120
Steering Operation ..........................................64
Steering System ..............................................79
Steering System Troubleshooting .................122
Steering Wheel ...............................................57
Steps for cleaning the cooling system ............95
Stop the Engine ..............................................67
Stop the Machine ............................................67
Storage and Maintenance of Cushion Tires ....90

Tightening Torque of the Bolts ........................41


Tire ..................................................................78
Tire Explosion Prevention ...............................26
Tire Inflation Information .................................89
Tire Information ...............................................89
Tires--Replace ................................................69
Towing Information .........................................73
Transmission Oil Filter--Replace ...................107
Transmission Oil--Replace ............................105
Transportation .................................................69
130
INDEX

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