LUIGONG - CLG2040H,45H,CLG2050H
LUIGONG - CLG2040H,45H,CLG2050H
LUIGONG - CLG2040H,45H,CLG2050H
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.
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 Safety
Maintenance Intervals
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
EC DECLARATION OF CONFORMITY
AMSTERDAM,
THE NETHERLANDS
(PLACE) (DATE) (COMPANY STAMP AND LEGAL SIGNATURE)
5
Preface
Decal location
74A3303
74A3301
9
Safety Information
Safety Decals and Decal Locations
74A3161
74A3625
11
Safety Information
Safety Decals and Decal Locations
74A3192
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
74A3292
74A3300
13
Safety Information
Safety Decals and Decal Locations
74A3136
74H2054
14
Safety Information
Safety Decals and Decal Locations
74A2826
74A3529
16
Safety Information
Safety Decals and Decal Locations
74A2807
74A2841
17
Safety Information
Safety Decals and Decal Locations
74A3228
18
Safety Information
Safety Decals and Decal Locations
74H2055
19
Safety Information
General Hazard Information
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High-pressure Fluid
Disposal of Waste Fluids
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
Oil
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.
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.
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
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.
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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
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.
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.
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.
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.
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.
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.
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.
Cautions about Machine Chock the wheel of the trailer to make it unable
to move.
Maintenance
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.
Load Barycenter
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
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
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
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
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
Machine 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
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
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
CAPACITY CHART
MAST
MAST
MAST
MAST
MAST
CAPACITY
MAST
MAST
LOAD CENTER
CAPACITY CHART
MAST
MAST
MAST
CAPACITY
LOAD CENTER
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
Daily inspection
Battery Terminal
Mute indicator
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
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.
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
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
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.
Seat Belt
Load Backrest
Drawbar
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
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.
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
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
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.
Rear tires
3. Place a jack under the counterweight as 6. Remove the nuts of the wheels, replace the
shown below. rear tires.
Fork Removal
Figure 2
3
1. Carriage Bars
2. Fork
3. Blocks
73
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.
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.
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 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
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 ○ ○ ○
Hose aging
condition ○ ○ ○
Power Train
Inching pedal
free travel and ○ ○ ○ ○ ○
move condition
Replace oil
●
suction filter
First 200 hours ● ●
element
Leakage
condition ○ ○ ○ ○ ○
Tire
Steering System
Check clearance ○ ○ ○ ○ ○
Check operation
condition ○ ○ ○ ○ ○
Check operation
condition ○ ○ ○ ○ ○
Brake System
Operation
performance ○ ○ ○ ○
Lever,
cable, etc. Connection loose
or not ○ ○ ○ ○
Damage,
leakage, crack ○ ○ ○ ○
condition
Line
Connection,
clamp parts ○ ○ ○ ○
loose condition
Leakage
condition ○ ○ ○ ○
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
anchor pin
corroded 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 ○ ○ ○
Sprockets distort,
damage condition ○ ○ ○ ○
Sprocket bearing
loosen or not ○ ○ ○ ○
Hydraulic System
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
Dirt, damage
condition ○ ○ ○ ○ ○
Rearview
mirror Rear view
condition ○ ○ ○ ○ ○
Frame and
crossbeam
damaged, cracked ○
or not
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
Tighten the bolts used in the machine according to the torque requirements shown in the following table
unless other specified:
Metric system
M8 19±2.9(26±4)
British system
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.
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.
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.
Tire Information
AT LEAST 15m(50ft) AT LEAST 500m(1500ft)
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.
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.
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.
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.
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
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
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.
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
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.
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
101
Maintenance Manual
Important Maintenance Procedures
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
1. Gasket
103
Maintenance Manual
Important Maintenance Procedures
Fuel---Heat
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
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
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.
107
Maintenance Manual
Important Maintenance Procedures
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.
108
Maintenance Manual
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.
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.
Electrical System
Battery
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
(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 Recycle
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
Seat Belt--Check
Troubleshooting
Power Loss
Noisy Transmission
Oil Leaks
Malfunction Analysis
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
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
For the malfunctions of steering system caused by flow divider valve and the troubleshooting,
see the table below.
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
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
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
Run-in .............................................................75
Running Operation ..........................................63 U