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LiuGong F7030M Operation And Maintenance Manual

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202312002
F7030M / F7035M
FORKLIFT TRUCK
( 英语 )
OPERATION AND
MAINTENANCE MANUAL

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Summary of Contents for LiuGong F7030M

  • Page 1 202312002 F7030M / F7035M FORKLIFT TRUCK ( 英语 ) OPERATION AND MAINTENANCE MANUAL...

  • Page 3: Important Safety Information

    Operations that could cause damage to the machine are marked both in this manual and on the machine itself using the labels “Caution” or “Warning”. LiuGong cannot predict every hazard in the work environment; therefore the warnings in this manual and on the machine should not be considered exhaustive. When using a tool, procedure, working method, or operation technique that is not explicitly recommended by LiuGong, you must pay special attention to the safety of yourself and others.

  • Page 5: Table Of Contents

    CONTENTS December 27, 2023 F7030M/F7035M CONTENTS Preface Main Specifications .......... 38 Frame Number & Machine Number ....4 Operation Manual Main Structural Component .......5 Before Operating the Machine ......47 Safety Information Operator Controls and Instrument Panels Safety Decals and Decal Locations ....8 Engine Starting ..........
  • Page 6 CONTENTS December 27, 2023 F7030M/F7035M INDEX Hydraulic System Schematic Diagram ...135 Electrical System Schematic Diagram ...138 Brake System Schematic Diagram ....141...

  • Page 7: Preface

    Please refer modification are your sole responsibility. back to it often. LiuGong provides a full warranty for users who Graphics indicate the correct operational steps operate and maintain the machine in accordance for inspecting, starting, operating, and stopping with the instructions in this manual.
  • Page 8 Certain specifications. Otherwise, LiuGong will not bear elements of the machine, such as the exhaust any legal responsibility for the consequences.

  • Page 9: Main Components Of The Machine

    12. Steering 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...

  • Page 10: Frame Number & Machine Number

    Preface December 27, 2023 Frame Number & Machine Number F7030M/F7035M Frame Number & Machine Number The frame number (1) is located on the right side of the front frame. The machine number (MEIN) (2) is located on the left side of the mast.

  • Page 11: Main Structural Component

    Preface December 27, 2023 Main Structural Component F7030M/F7035M Main Structural Component 1. Mast 2. Carriage 3. Fork 4. Frame...
  • Page 12 Preface December 27, 2023 Main Structural Component F7030M/F7035M Mast 1. Outer mast 2. Inner mast 3. Chains 5. Roller 4. Sprocket Carriage 1. Carriage 2. Main roller 3. Side roller...
  • Page 13 Preface December 27, 2023 Main Structural Component F7030M/F7035M Fork 1. Lock mechanism 2. Upper hook 3. Lower hook Frame 1. Frame 2. Carriage Bars 3. Antislip pedal 4. Fuel tank cap...

  • Page 14: Safety Information

    Safety Information December 27, 2023 Safety Decals and Decal Locations F7030M/F7035M Safety Information Safety Decals and Decal Locations Safety Warning Symbols Safety decals can be found on the machine. This section describes the locations of these decals and explanations of the safety hazards they Safety warning symbols are important;...
  • Page 15 Safety Information December 27, 2023 Safety Decals and Decal Locations F7030M/F7035M Decal location 1. WARNING DECAL 5. DANGER DECAL 9. WARNING DECAL 2. NOTICE DECAL 6. DANGER DECAL 10. WARNING DECAL 3. WARNING DECAL 7. WARNING DECAL 11. WARNING DECAL 4.
  • Page 16 Safety Information December 27, 2023 Safety Decals and Decal Locations F7030M/F7035M Decal information 1. WARNING DECAL (Located in the cab) 1. Weight of load must not exceed rated capacity of forklift. Ensure load is stable and position on the forks to prevent load slipping when lifting or travel.
  • Page 17 Safety Information December 27, 2023 Safety Decals and Decal Locations F7030M/F7035M Decal information 3. WARNING DECAL (Located in the cab) 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.
  • Page 18 Safety Information December 27, 2023 Safety Decals and Decal Locations F7030M/F7035M Decal information 4. DANGER DECAL (Located on left side of mast) CRUSH HAZARD. Do not enter working area of forklift. 74A3293 5. DANGER DECAL (Located on left side of mast) No passengers on or under fork.
  • Page 19 Safety Information December 27, 2023 Safety Decals and Decal Locations F7030M/F7035M Decal information 7. WARNING DECAL (Located on the middle beam of mast) CRUSH HAZARD. Keep clear of mast. 74A3303 8. WARNING DECAL (Located near the tire) IMPACT HAZARD. During inflation of tire, stand forward or behind wheel.
  • Page 20 Safety Information December 27, 2023 Safety Decals and Decal Locations F7030M/F7035M Decal information 10. WARNING DECAL (Located near the engine fan, where can be observed easily) CUTTING HAZARD. Keep clear or stop engine before servicing. 74A3251 11. WARNING DECAL (Located near the engine belt) ENTANGLEMENT HAZARD Keep clear or stop engine before servicing.

  • Page 21: General Safety Considerations

    Safety Information December 27, 2023 General Safety Considerations F7030M/F7035M General Safety Considerations Please read these safety precautions carefully. Failure to do so could lead to severe injury or death. Only trained and qualified personnel should operate or maintain this machine.
  • Page 22 It is prohibited to modify the machine without passages, and ladders. Put away loose items LiuGong's authorization, and LiuGong is not such as lunch boxes, tools, etc. responsible for any consequences of such When inspecting an open fuel tank or water tank, modifications.

  • Page 23: Preventing Crushing And Cutting

    Safety Information December 27, 2023 Preventing Crushing and Cutting F7030M/F7035M Wear safety goggles and leather gloves when checking for leaks. Use wood or cardboard to check for leaks, never bare hands. Even leaks the size of a pinhole can pierce flesh, Preventing Crushing and causing serious injury or death.

  • Page 24: Burn Prevention

    Safety Information December 27, 2023 Burn Prevention F7030M/F7035M Make sure that the engine fan blades are free of When checking the coolant level, shut off the debris and miscellaneous items. Fan blades can engine and wait until the water refilling cap is cut through or throw out tools or debris that fall cool to the touch before opening.

  • Page 25: Fire And Explosion Prevention

    Promptly repair any loose or damaged fuel or flammable liquids. Clean up any flammable lubricant lines and hydraulic system hoses and liquids before welding or flame cutting. pipes. Leaks can cause fires. Contact a LiuGong Machine Works authorized dealer for repairs or replacements.

  • Page 26: Fire Extinguishers And First-Aid Kit

    Safety Information December 27, 2023 Fire Extinguishers and First-Aid Kit F7030M/F7035M If any of the following problems are found, Prepare in advance the phone numbers of replacement is necessary. relevant personnel to contact in case of emergency (physicians, emergency services, fire Fittings are damaged or leaking.

  • Page 27: Fuel

    Do not approach heated tires. Stay at least 50 feet (15 meters) away. Stand outside the shaded area (as shown). AT LEAST 15m(50ft) AT LEAST 500m(1500ft) LiuGong can provide pneumatic or solid tires according to your specific needs.

  • Page 28: Information On Attachments

    Check all structural and covering parts for distortion due to collision. LiuGong is not responsible for any injuries, accidents, or damage to the machine caused by Check that all safety and protective devices such the use of unauthorized attachments.
  • Page 29 Safety Information December 27, 2023 Cautions about Machine Operation F7030M/F7035M Remove any loose objects from the driver’s cab. Only start the engine from inside the driver’s cab. They can interfere with the controls and cause It is strictly forbidden to short-circuit the starter accidents.
  • Page 30 Safety Information December 27, 2023 Cautions about Machine Operation F7030M/F7035M Regularly check the exhaust emission values in Maintain proper posture on the seat. Accidents a safe area outdoors. To avoid fires when can occur when you are not seated properly or checking the emissions, pay special attention to when you leave the seat to operate the machine.
  • Page 31 Safety Information December 27, 2023 Cautions about Machine Operation F7030M/F7035M Use the rotary beacon (optional accessory) and No one is ever allowed underneath a raised fork. reverse signal alarm to make others aware of the Before lowering the fork, check that no one else machine’s presence.
  • Page 32 Safety Information December 27, 2023 Cautions about Machine Operation F7030M/F7035M Use appropriately-sized loading platforms. The load must be balanced properly on the fork. Check the loading platform’s condition, strength, When handling wide or lopsided loads, take and safe loading capacity.
  • Page 33 Safety Information December 27, 2023 Cautions about Machine Operation F7030M/F7035M Do not lift loads when the mast is tilted forward. Tilt the mast backwards while driving, keeping The mast must be vertical or tilted backward the load against the backrest. Do not lift or lower when lifting, never forward.
  • Page 34 Safety Information December 27, 2023 Cautions about Machine Operation F7030M/F7035M Overtaking is prohibited. In dangerous areas Drive slowly in areas with poor visibility. Mirrors such as intersections and places where vision is should be used where available. At stop signs, obstructed, never overtake or try to catch up with bring the vehicle to a complete stop.
  • Page 35 Safety Information December 27, 2023 Cautions about Machine Operation F7030M/F7035M Do not drive over any surface obstacles that are not firm. It is best to exit the vehicle, clear the obstacles, and then continue driving. To prevent loads from loosening, avoid driving over bumps or potholes.
  • Page 36 Safety Information December 27, 2023 Cautions about Machine Operation F7030M/F7035M When the load is so large that it blocks the view in front, drive in reverse or have an assistant guide you. Always shut off the power when leaving the machine.

  • Page 37: Cautions About Machine Maintenance

    Safety Information December 27, 2023 Cautions about Machine Maintenance F7030M/F7035M Parking the Machine Lowering Working Devices when the Engine is Off Park the machine on a level surface where there is no danger of falling stones or landslides. If the...

  • Page 38: Transportation Information

    Safety Information December 27, 2023 Cautions about Machine Maintenance F7030M/F7035M Do not work under any part of the machine or Place all the working equipment in the attachment that is not adequately supported. Do transportation position, secure all the equipment not rely on hydraulic systems as support.

  • Page 39: Stability And Center Of Gravity

    Safety Information December 27, 2023 Stability and Center of Gravity F7030M/F7035M Stability and Center of Gravity Clean the Equipment Periodically To avoid possible injury or damage to the Load Center machine, all the oil and scraps accumulated should be removed. The engine, radiator,...
  • Page 40 Safety Information December 27, 2023 Stability and Center of Gravity F7030M/F7035M Relationship Between Center of Gravity and movement status: accelerating, stopped, or ● Stability moving surface condition and slope The forklift’s stability is determined by its center ● of gravity. When unloaded, that is the center of Center of Gravity Stability Range gravity of the vehicle itself.

  • Page 41: Sound

    Safety Information December 27, 2023 Sound F7030M/F7035M Sound A-Weighted emission sound pressure level at the operator's position measured according to work cycle procedures specified in “EN12053:2001+A1:2008 Safety of industrial trucks—Test methods for measuring noise emissions” is below 105 dB. Rough or uneven road surface will result in tire distortion easily which could cause a big noise to the machine.

  • Page 42: Key Spare Parts To Be Periodically Changed

    Safety Information December 27, 2023 Key Spare Parts to be Periodically Changed F7030M/F7035M Key Spare Parts to be Periodically Changed Key spare parts to be periodically changed Changing intervals (year) Brake hose or tube Hydraulic hose of lift system Lift chains...

  • Page 43: Application And Specification

    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.

  • Page 44: Main Specifications

    Application and Specification December 27, 2023 Main Specifications F7030M/F7035M 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.
  • Page 45 Application and Specification December 27, 2023 Main Specifications F7030M/F7035M Machine specifications (F7030M) F7030M F7030M F7030M (XINCHAI Model (YANMAR (XINCHAI engine) engine) engine) General Power Type Diesel Diesel Diesel Base Capacity rated load center 3000 3000 3000 Load Center Service Weight...
  • Page 46 Application and Specification December 27, 2023 Main Specifications F7030M/F7035M service Foot / Hyd Brakes parking Hand / Mech manufacturer YANMAR XINCHAI XINCHAI model 4TNE98 A498BT1 4D32G31 Systems emission compliance Stage III Stage III China III Engine cylinders displacement liter 3.319...
  • Page 47 Application and Specification December 27, 2023 Main Specifications F7030M/F7035M Machine specifications (F7035M) F7035M F7035M F7035M (XINCHAI Model (XINCHAI (YANMAR engine) engine) engine) General Power Type Diesel Diesel Diesel Base Capacity rated load center 3500 3500 3500 Load Center Service Weight...
  • Page 48 Application and Specification December 27, 2023 Main Specifications F7030M/F7035M service Foot / Hyd Brakes parking Hand / Mech manufacturer XINCHAI XINCHAI YANMAR model 4D32G31 A498BT1 4TNE98 Systems emission compliance China III Stage III Stage III Engine cylinders displacement liter 3.319...

  • Page 49: Specifications

    Application and Specification December 27, 2023 Main Specifications F7030M/F7035M Main parts specifications Item Specifications Manufacturer XINCHAI XINCHAI YANMAR Model A498BT1 4D32G31 4TNE98 4-stroke, direct 4-stroke in line, 4-stroke, direct injection, water Type electronic control VE injection, water cooling, cooling, overhead...
  • Page 50 Application and Specification December 27, 2023 Main Specifications F7030M/F7035M Item Specifications Manufacturer Zhongchai Model YQXDY37AS1-C (A498BT1) / YQXDY37S1-C (YANMAR 4TNE98) Type solenoid valve shift hydraulic transmission Gear ratio(forward) F1: 18.9467 Transmi- Gear ratio(reverse) R1: 18.9467 ssion Torque converter YJH265 Main oil pressure(MPa) 1.1 - 1.4...
  • Page 51 December 27, 2023 Main Specifications F7030M/F7035M Work Scope Operate the machine according to the rated load capacity in the load curve chart. (The load chart used for F7030M forklift without sidelift.) (The load chart used for F7030M forklift with sidelift.)
  • Page 52 Application and Specification December 27, 2023 Main Specifications F7030M/F7035M (The load chart used for F7035M forklift without sidelift.) (The load chart used for F7035M forklift with sidelift.)

  • Page 53: Operation Manual

    Operation Manual December 27, 2023 Before Operating the Machine F7030M/F7035M Operation Manual Check the hydraulic oil level. Check the steering system functionality. Check the braking system functionality. Before Operating the Machine Check the mast system functionality. Check the condition of the electrical wiring,...

  • Page 54: Operator Controls And Instrument Panels

    Operation Manual December 27, 2023 Operator Controls and Instrument Panels F7030M/F7035M 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. Steering column adjust handle 5.
  • Page 55 Operation Manual December 27, 2023 Operator Controls and Instrument Panels F7030M/F7035M Start/ Choke Switch START------To start the engine, turn the start switch key clockwise to the START position. When the start switch key is released, the start The start/ choke switch (also called ignition switch will return to ON position.

  • Page 56: Battery Terminal

    Operation Manual December 27, 2023 Operator Controls and Instrument Panels F7030M/F7035M 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.

  • Page 57: Instrument Panel

    Operation Manual December 27, 2023 Operator Controls and Instrument Panels F7030M/F7035M Instrument Panel 19 18 1. Left turn indicator 12. Engine coolant temperature gauge 2. Engine oil pressure alert indicator 13. Charge indicator 3. Engine mode indicator 14. Engine mode selected key 4.
  • Page 58 Operation Manual December 27, 2023 Operator Controls and Instrument Panels F7030M/F7035M Gear indicator Charge indicator Different letter indicates different gear The indicator indicates the charge of the transmission: N-neutral, F- state of the battery. If the indicators forward, R-rearward. turns on when the engine isn’t started, it indicates that alternator doesn’t work.
  • Page 59 Operation Manual December 27, 2023 Operator Controls and Instrument Panels F7030M/F7035M Parking brake alert indicator OPS alert indicator Only the machine equipped with OPS Only the machine equipped with OPS (Operator Position System) has this (Operator Position System) has this function.

  • Page 60: Operator Controls

    Operation Manual December 27, 2023 Operator Controls and Instrument Panels F7030M/F7035M Operator Controls When complete a single maintenance, ways to turn off/ on the instrument maintenance prompt function is as follows: Shift Control Lever 1. Start the electric lock. 2. Press F1 to enter the instrument system, press F2 to turn the entry and select the “User Settings”...

  • Page 61: Brake Pedal

    Operation Manual December 27, 2023 Operator Controls and Instrument Panels F7030M/F7035M Pull the lift lever back to lift the fork, the It is very dangerous to run the machine without hydraulic oil will go into the lifting disengaging the brake as this will damage the cylinder to push the fork upwards.

  • Page 62: Accelerator Pedal

    Operation Manual December 27, 2023 Operator Controls and Instrument Panels F7030M/F7035M Accelerator Pedal Horn Button The accelerator pedal is located at the front right The button of the horn located in the center of side of the driver’s seat. the steering wheel. The horn will working by pressing the button.

  • Page 63: Steering Column

    Operation Manual December 27, 2023 Operator Controls and Instrument Panels F7030M/F7035M Steering Column The function of the handle (2): release the hook (5) from shaft (3) after pressing down handle (2), that is, to make the steering column rebound. Pull the steering column to the driver’s direction...
  • Page 64 Replace it when necessary. Contact your To prevent serious injury or death of the LiuGong dealer for seat belt replacements. driver due to a tipover, keep the seat belt Adjust length of the seat belt before use in order fastened when driving the machine.

  • Page 65: Overhead Guard

    Operation Manual December 27, 2023 Operator Controls and Instrument Panels F7030M/F7035M 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.
  • Page 66 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.

  • Page 67: Engine Starting

    Operation Manual December 27, 2023 Engine Starting F7030M/F7035M Engine Starting 2. Engage position 4. Insert the key in the start switch and turn it to the ON position clockwise to turn on the power relay. Sound the horn to alert...

  • Page 68: Operation Techniques

    Operation Manual December 27, 2023 Operation Techniques F7030M/F7035M Operation Techniques 4. Check the brake performance of the machine. With the machine running in 1st or 2nd forward, release the accelerator pedal Running Operation and smoothly step down on the brake pedal, the machine should reduce speed and stop.

  • Page 69: Downhill Operation

    Operation Manual December 27, 2023 Operation Techniques F7030M/F7035M Downhill Operation 1. Use the service brake or the engine brake in order to slow the machine until a lower gear can be selected. Using the services brakes in order to control the travel speed of the...
  • Page 70 Operation Manual December 27, 2023 Operation Techniques F7030M/F7035M Depositing Loads 3. Slowly push the lift lever forwards to place the goods to the ground. Then push the Slowly approach the area where the load is to be tilt lever forwards to insert the fork into deposited.

  • Page 71: Cold Weather Operation

    Operation Manual December 27, 2023 Operation Techniques F7030M/F7035M Cold-Weather Operation 8. Park the machine on hard and dry ground or surface to prevent it from freezing to the ground. 9. After the cold weather passes, replace all fuel, hydraulic oil, and lubricant with medium When the ambient temperature is too low, it viscosity fuel, hydraulic oil, and lubricant.

  • Page 72: Stop The Machine

    Operation Manual December 27, 2023 Operation Techniques F7030M/F7035M 4. Check whether the coolant needs to be 3. Turn the fuel conversion switch to OFF topped up. position and take off the key (only for the machine equipped with dual fuel systems).

  • Page 73: Transporting And Hoisting The Machine

    4. If the machine has to be stored for long time, with your Liugong dealer. apply antirust additive to parts that can rust. 5. Remove batteries from the machine and Transporting and Hoisting the store them in a separate place.
  • Page 74 6. Tilt the mast forward until the front wheels are lifted off the ground. Do not remove any nuts before the front wheels have been lifted off the ground. 8. For components removed for transport, contact an LiuGong authorized service center for reassembly.
  • Page 75 Operation Manual December 27, 2023 Transporting and Hoisting the Machine F7030M/F7035M 7. Place blocks on both sides of the front of the 13. Adjust the tire pressure to the specified forklift chassis to support the vehicle, then value. shut off the machine.

  • Page 76: Fork Removal

    Operation Manual December 27, 2023 Transporting and Hoisting the Machine F7030M/F7035M 5. Use the jack to raise the forklift slowly until 9. Tighten the nuts to the specified torque the rear wheels are lifted completely off the alternately from one side of the wheel to the ground.

  • Page 77: Towing Information

    Operation Manual December 27, 2023 Transporting and Hoisting the Machine F7030M/F7035M Fork Install A fork can be removed from the carriage for replacement of the fork or other maintenance. Slide the fork to the fork removal notch in the Move the fork and carriage so the top hook on bottom bar of the carriage.

  • Page 78: Lifting Operation

    Operation Manual December 27, 2023 Transporting and Hoisting the Machine F7030M/F7035M 3. A lifting decal is stuck on the mast and counterweight. Lift the machine by hoisting the lifting eye according to the lifting decal. 3. Please use the moving equipment (for example, crane) to move the forklift that is disabled.

  • Page 79: Maintenance Manual

    Maintenance Manual December 27, 2023 Breaking In a New Vehicle F7030M/F7035M Maintenance Manual 5. Check that the connections for the control handles and throttle cable are secure. 6. Check the temperature and connection of all components of the electrical system. Check...

  • Page 80: Maintenance Interval Schedule

    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.
  • Page 81 Maintenance Manual December 27, 2023 Maintenance Interval Schedule F7030M/F7035M Three Every Every day Every month Check Item Content Tool months months year (8Hr) (200Hr) (500Hr) (1000Hr) (2000Hr) Governor or Check max. idle injection Tachometer ○ pump Engine leaks oil ○...
  • Page 82 Maintenance Manual December 27, 2023 Maintenance Interval Schedule F7030M/F7035M Three Every Every day Every month Check Item Content Tool months months year (8Hr) (200Hr) (500Hr) (1000Hr) (2000Hr) Fuel tank ○ ○ ○ drainage Fuel system ○ ○ Clean fuel tank ○...
  • Page 83 Maintenance Manual December 27, 2023 Maintenance Interval Schedule F7030M/F7035M Tire Every day Every month 3 months 6 months Every year Check Item Content Tool (8Hr) (200Hr) (500Hr) (1000Hr) (2000Hr) ○ ○ ○ ○ ○ Charge pressure Barometer ○ ○ ○...

  • Page 84: Steering System

    Maintenance Manual December 27, 2023 Maintenance Interval Schedule F7030M/F7035M Steering System Every day Every month 3 months 6 months Every year Check Item Content Tool (8Hr) (200Hr) (500Hr) (1000Hr) (2000Hr) ○ ○ ○ ○ ○ Check clearance Check axial ○...

  • Page 85: Brake System

    Maintenance Manual December 27, 2023 Maintenance Interval Schedule F7030M/F7035M Brake System Every day Every month 3 months 6 months Every year Check Item Content Tool (8Hr) (200Hr) (500Hr) (1000Hr) (2000Hr) ○ ○ ○ ○ ○ Free travel ○ ○ ○...
  • Page 86 Maintenance Manual December 27, 2023 Maintenance Interval Schedule F7030M/F7035M Every day Every month 3 months 6 months Every year Check Item Content Tool (8Hr) (200Hr) (500Hr) (1000Hr) (2000Hr) Brake drum fixing Detect ○ ○ ○ ○ parts loose or not...

  • Page 87: Lift System

    Maintenance Manual December 27, 2023 Maintenance Interval Schedule F7030M/F7035M Lift System Every day Every month 3 months 6 months Every year Check Item Content Tool (8Hr) (200Hr) (500Hr) (1000Hr) (2000Hr) Fork damage, ○ ○ ○ ○ ○ distortion, wear condition...
  • Page 88 Maintenance Manual December 27, 2023 Maintenance Interval Schedule F7030M/F7035M Every day Every month 3 months 6 months Every year Check Item Content Tool (8Hr) (200Hr) (500Hr) (1000Hr) (2000Hr) Check the tension condition of chain, distorted, ○ ○ ○ ○ ○...
  • Page 89 Maintenance Manual December 27, 2023 Maintenance Interval Schedule F7030M/F7035M Hydraulic System Every day Every month 3 months 6 months Every year Check Item Content Tool (8Hr) (200Hr) (500Hr) (1000Hr) (2000Hr) ○ ○ ○ ○ ○ Check oil level Replace oil suction filter ●...
  • Page 90 Maintenance Manual December 27, 2023 Maintenance Interval Schedule F7030M/F7035M Electrical System Every day Every month 3 months 6 months Every year Check Item Content Tool (8Hr) (200Hr) (500Hr) (1000Hr) (2000Hr) Distributor cover ○ ○ ○ cracked or not Spark plug ○...
  • Page 91 Maintenance Manual December 27, 2023 Maintenance Interval Schedule F7030M/F7035M Safety Devices and Attachment Every day Every month 3 months 6 months Every year Check Item Content Tool (8Hr) (200Hr) (500Hr) (1000Hr) (2000Hr) Installation is Detect Overhead stable or not hammer...
  • Page 92 Maintenance Manual December 27, 2023 Maintenance Interval Schedule F7030M/F7035M 1. 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.

  • Page 93: General Torque Specifications

    Maintenance Manual December 27, 2023 General Torque Specifications F7030M/F7035M General Torque Specifications Unless otherwise stated, all bolts used in this machine should be tightened to the torques listed in the table below. Metric Thread Torque lbf·ft (Nm) Nominal Size Property Class 8.8 Property Class 10.9...

  • Page 94: Lubrication Specifications

    Maintenance Manual December 27, 2023 Lubrication Specifications F7030M/F7035M Lubrication Specifications Oil Change Intervals and Approximate Volumes Always prepare a suitable container to collect any liquids before inspecting, servicing, testing, or adjusting the machine, or removing or disassembling any hydraulic parts or any liquid- containing components.

  • Page 95: Lubrication System Diagram

    Maintenance Manual December 27, 2023 Lubrication Specifications F7030M/F7035M Lubrication System Diagram...

  • Page 96: Oil And Fuel Specifications

    Maintenance Manual December 27, 2023 Oil and Fuel Specifications F7030M/F7035M Oil and Fuel Specifications To ensure normal operation of the machine, use only the types and specifications of oils and fuels listed in the tables below. Recomme Ambient Type of Oil...

  • Page 97: Tires

    Maintenance Manual December 27, 2023 Tires F7030M/F7035M Tires AT LEAST 15m(50ft) AT LEAST 500m(1500ft) Tires can be divided into two categories: pneumatic and solid. Pneumatic tires are suitable for higher driving speeds. Solid tires are simple to use and have a...

  • Page 98: Working Device System

    Do not store tires in direct sunlight. Keep away the mast or replacing the cylinders or from light, heat, grease, acidic or alkaline chains. Contact your LiuGong dealer for chemicals, and other harmful substances. Store details. tires flat on the ground, not standing up, in order to prevent injuries from tipping over.
  • Page 99 Maintenance Manual December 27, 2023 Working Device System F7030M/F7035M Collapse prevention measures for ordinary 2- stage masts The sprocket rotates when the inner mast is lifted, and the movement speed ratio of the fork carriage to the inner mast is 2:1. The static load coefficient of the lifting attachment is 1.33.
  • Page 100 Maintenance Manual December 27, 2023 Working Device System F7030M/F7035M Collapse prevention measures for 2-stage Collapse prevention measures for 3-stage fully-automatic masts masts Even when working in low spaces, this type of The central lift cylinder lifts the forks to the...

  • Page 101: Important Maintenance Procedures

    Maintenance Manual December 27, 2023 Important Maintenance Procedures F7030M/F7035M Important Maintenance Procedures Power System Coolant--Check/Add Hot coolant can cause serious burns. To open the cap, stop engine until the radiator 3. If the water radiator recovery tank is empty, cools down. Then loosen cap slowly to open the recovery tank cover plate after the release the pressure.
  • Page 102 Maintenance Manual December 27, 2023 Important Maintenance Procedures F7030M/F7035M 2. Start the engine and let it idle for 5 minutes, then shut off the engine. Wait until the engine is cooling down, then slowly unscrew the radiator cap to release the pressure.
  • Page 103 Maintenance Manual December 27, 2023 Important Maintenance Procedures F7030M/F7035M 4. After the engine coolant has drained 6. Keeping the radiator cap open, start the completely, shut off the drain valve at the engine. After the coolant temperature bottom of the radiator.
  • Page 104 Maintenance Manual December 27, 2023 Important Maintenance Procedures F7030M/F7035M Coolant--Drain Out Radiator Fin--Check/Clean Do not drain the coolant before the engine is Wear safety glasses when servicing the cooled down and when the system is under machine and using the compressed air or pressure.
  • Page 105 Maintenance Manual December 27, 2023 Important Maintenance Procedures F7030M/F7035M Engine Air Filter--Clean 3. Remove the primary air filter element and inspect it. If the pleats, gaskets, or seals are damaged, then the primary filter element must be replaced. Do not remove the safety...
  • Page 106 Maintenance Manual December 27, 2023 Important Maintenance Procedures F7030M/F7035M Wash with detergent (soak the filter element in 8. Clean and re-install the air filter cover, water containing a mild detergent for about 30 ensuring that the air filter cover gasket makes minutes, then clean it);...

  • Page 107: Fuel System

    Maintenance Manual December 27, 2023 Important Maintenance Procedures F7030M/F7035M Fuel System Fuel--Add Fuel Level--Check 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.
  • Page 108 Maintenance Manual December 27, 2023 Important Maintenance Procedures F7030M/F7035M Fuel Tank--Clean Fuel System Water and Impurity-- Remove The diesel fuel pump and engine fuel injection nozzles (only for the machine equipped with Care must be taken to ensure that fluids are diesel engine) are precision devices.
  • Page 109 Maintenance Manual December 27, 2023 Important Maintenance Procedures F7030M/F7035M Methods for removing fuel system air: Fuel Filter-- Replace The fuel is inflammables. Keep away from cigarette, open fire, indicators, arc equipment and switches when maintains the fuel system. Keep venting in the service area to avoid serious personal injury or death.
  • Page 110 Maintenance Manual December 27, 2023 Important Maintenance Procedures F7030M/F7035M 7. Anticlockwise rotates to unlock the handle of Engine Oil Level--Check/Add the manual oil filling pump. Press the oil filling pump with pump until the handle cannot be pressed down. About 140~150 times for the empty filter and 20~60 times for the pre-filling filter.
  • Page 111 Maintenance Manual December 27, 2023 Important Maintenance Procedures F7030M/F7035M 7. Tighten the oil filler cap by hand. Excessively 4. Put a suitable container under the engine to tightening may damage the oil filler cap. collect the waste oil. Too much or too little engine oil can result in damage to the engine.

  • Page 112: Power Train System

    Maintenance Manual December 27, 2023 Important Maintenance Procedures F7030M/F7035M Power Train System Engine Oil Filter--Replace Hydraulic Torque Converter--Check High 1. Engine oil filter 2. Turn anticlockwise Park the machine on level ground, start the 3. Turn clockwise engine and let it idle for 5 minutes.
  • Page 113 Maintenance Manual December 27, 2023 Important Maintenance Procedures F7030M/F7035M Transmission Oil--Replace Replace the transmission oil at the first 100 service hours, then replace it every 1000 service Because the transmission oil temperature is hours later on. Replace the transmission oil at still high when draining, wear protective least once every year.
  • Page 114 Maintenance Manual December 27, 2023 Important Maintenance Procedures F7030M/F7035M Axle Oil Level--Check Transmission Oil Filter--Replace 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.

  • Page 115: Hydraulic System

    Maintenance Manual December 27, 2023 Important Maintenance Procedures F7030M/F7035M Hydraulic System Axle Oil--Replace Hydraulic Oil Level--Check Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting When checking the hydraulic level, park the and repair of the product.
  • Page 116 Maintenance Manual December 27, 2023 Important Maintenance Procedures F7030M/F7035M Park the machine on flat and open ground, keep 4. Clean the hydraulic oil tank drain plug. Screw the mast vertical and lower the fork to the out the oil drain plug to drain out hydraulic oil ground.
  • Page 117 Maintenance Manual December 27, 2023 Important Maintenance Procedures F7030M/F7035M Brake System 2. Start the machine and drive it onto a slope with 15% (8.53°) grade. The slope surface should be flat and dry. Brake Oil Level--Check 3. Depress the service brake pedal, stop the machine.

  • Page 118: Electrical System

    Maintenance Manual December 27, 2023 Important Maintenance Procedures F7030M/F7035M Electrical System Service Brake Performance--Check Battery Ensure the parking brake system works normally before check the service brake performance so that the parking brake lever Never place a lit cigarette or any open flame can work properly if an emergency happens.
  • Page 119 Maintenance Manual December 27, 2023 Important Maintenance Procedures F7030M/F7035M Hydrometer 1. Battery 2. Battery negative lead Do not over discharge and use up the 3. Battery positive lead electrolyte. Tighten the nut in the center of 4. Tighten the nut.
  • Page 120 Maintenance Manual December 27, 2023 Important Maintenance Procedures F7030M/F7035M The batteries have been stored over six If the battery is charged with constant voltage ● ● months before being used. as no condition is permitted, charge the battery with constant voltage according to the The batteries under the above-mentioned following standard.

  • Page 121: Other Maintenance

    Maintenance Manual December 27, 2023 Important Maintenance Procedures F7030M/F7035M During charging the battery, stop charging As for the machine which is stored over 1 ● ● the battery if the battery temperature is over year, replace with a new battery and dispose 45°C.
  • Page 122 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) OPS Function BX2011C-7.5A...

  • Page 123: Machine Assembly Procedure

    Maintenance Manual December 27, 2023 Machine Assembly Procedure F7030M/F7035M Machine Assembly Procedure Assemble the drive axle, transmission to Assemble tilting cylinders, the frame; Install steering axle, the oil pines, radiators, Frame assembly connecting plate, multiple valve, front control valves, frame wheels and rear wheels.

  • Page 124: Overhead Guard Disassembly And Assembly Procedures

    Maintenance Manual December 27, 2023 Overhead Guard Disassembly and Assembly Procedures F7030M/F7035M Overhead Guard Disassembly and Assembly Procedures 1. Open the engine hood. 2. Remove the cover plate. 3. Remove the OPS harnesses, rear light wires, front light wires and control box wires.

  • Page 125: Troubleshooting

    Maintenance Manual December 27, 2023 Troubleshooting F7030M/F7035M 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 Refill (2)Air is taken into the oil suction...
  • Page 126 Maintenance Manual December 27, 2023 Troubleshooting F7030M/F7035M Abnormal Oil Temperature Parts Cause of malfunction Method of inspection Troubleshooting (1)Oil level is low Check the oil level Refill (2) Filter is blocked Remove and check Clean and replace Discharge the oil from filter or oil...

  • Page 127: Oil Leaks

    Maintenance Manual December 27, 2023 Troubleshooting F7030M/F7035M 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.

  • Page 128: Malfunction Analysis

    Maintenance Manual December 27, 2023 Malfunction Analysis F7030M/F7035M 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...
  • Page 129 Maintenance Manual December 27, 2023 Malfunction Analysis F7030M/F7035M 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...
  • Page 130 Maintenance Manual December 27, 2023 Malfunction Analysis F7030M/F7035M Malfunction Cause Symptom Troubleshooting 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...
  • Page 131 Maintenance Manual December 27, 2023 Malfunction Analysis F7030M/F7035M Steering System Troubleshooting Malfunction Causes Troubleshooting 1.The pressure of the priority valve is too low Regulate the pressure: 12Mpa. Discharge the air, and check whether 2.Air exists in steering system there is leakage in the oil suction pipeline 3.The orifice of the priority valve jammed and...
  • Page 132 Maintenance Manual December 27, 2023 Malfunction Analysis F7030M/F7035M Hydraulic Transmission Troubleshooting Malfunction Causes Troubleshooting 1. The friction plate is locked up or worn; the friction Adjust or replace plate agglutination is touched or warped unevenly. 2.Wear of the oil feed pump or too low of the oil level...
  • Page 133 Maintenance Manual December 27, 2023 Malfunction Analysis F7030M/F7035M 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.
  • Page 134 Maintenance Manual December 27, 2023 Malfunction Analysis F7030M/F7035M Lift 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...

  • Page 135: Maintenance Note Table

    Maintenance Manual December 27, 2023 Maintenance Note Table F7030M/F7035M Maintenance Note Table...
  • Page 136 Maintenance Manual December 27, 2023 Maintenance Note Table F7030M/F7035M...
  • Page 137 INDEX December 27, 2023 F7030M/F7035M INDEX Abnormal Oil Temperature ......120 Depositing Loads ..........64 Accelerator Pedal ..........56 Downhill Operation ......... 63 Air Filter’s Safety Filter Element--Replace ..100 Drive Axle Troubleshooting ......126 Application and Specification ......37 Applications .............37 Axle Oil Level--Check ........108 Axle Oil--Replace ..........109...
  • Page 138 INDEX December 27, 2023 F7030M/F7035M Main Parts of Forklift Body ......57 Main Specifications ......... 38 Main Structural Component ......5 General Safety Considerations .......15 Maintenance Interval Schedule ...... 74 General Torque Specifications ......87 Maintenance Manual ........73 Maintenance Note Table ......129 Malfunction Analysis ........
  • Page 139 INDEX December 27, 2023 F7030M/F7035M Troubleshooting ..........119 Radiator Fin--Check/Clean ......98 Running Operation ..........62 Wheels--Change ..........68 Working Device System ......... 92 Safety Decals and Decal Locations ....8 Safety Devices and Attachment ......85 Safety in Attachment Installation, Adjustment and Use ..............60 Safety Information ..........8...
  • Page 140 INDEX December 27, 2023 F7030M/F7035M...
  • Page 141 December 27, 2023 F7030M/F7035M Hydraulic System Schematic Diagram Hydraulic System Schematic Diagram Double Spools...
  • Page 142 December 27, 2023 F7030M/F7035M Hydraulic System Schematic Diagram Three Spools...
  • Page 143 December 27, 2023 F7030M/F7035M Hydraulic System Schematic Diagram Four Spools...
  • Page 144 December 27, 2023 F7030M/F7035M Electrical System Schematic Diagram Electrical System Schematic Diagram YANMAR 4TNE98 Engine...
  • Page 145 December 27, 2023 F7030M/F7035M Electrical System Schematic Diagram Electrical System Schematic Diagram 50Y2951 Xinchai 4D32G31 Engine 36B0276 36B0277 36B0652 36B0651 36B0649 36B1092 38B0053 34B0007...
  • Page 146 December 27, 2023 F7030M/F7035M Electrical System Schematic Diagram Electrical System Schematic Diagram 50Y2687 Xinchai A498BT1 Engine 36B0276 36B0277 36B0652 36B0651 36B0649 36B1092 36B0527 38B0053 34B0007...
  • Page 147 December 27, 2023 F7030M/F7035M Brake System Schematic Diagram Brake System Schematic Diagram 50Y1497...
  • Page 148 December 27, 2023 F7030M/F7035M Brake System Schematic Diagram...

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