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LiuGong CLG2015A-S Operation And Maintenance Manual

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CLG2015A-S/18A-S/20A-S/25A-S
BATTERY FORKLIFT TRUCK
( 英文 )
OPERATION AND
MAINTENANCE MANUAL

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  • Page 1 CLG2015A-S/18A-S/20A-S/25A-S BATTERY FORKLIFT TRUCK ( 英文 ) OPERATION AND MAINTENANCE MANUAL...

  • Page 3: Important Safety Information

    The specification, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service given to the product. Obtain the complete and most current information before starting any job. LiuGong has the most current information available.

  • Page 5: Table Of Contents

    CONTENTS Preface Operator Controls and Instrument Panels ..54 Machine Starting ..........70 Safety Information Operation Techniques ........70 Safety Decals and Decal Locations ....10 Transportation Information ......76 General Hazard Information ......18 Maintenance Manual Crushing and Cutting Prevention .....21 Burn Prevention ..........21 Run-in ..............

  • Page 7: Preface

    Skill and techniques develop as the Use this machine only for the purpose described operator gains knowledge of the machine and its in this manual. Contact your Liugong dealer for capabilities. approval before making any modifications or adding attachments to the machine. The addition...
  • Page 8 250 service hours, 50 service hours and every 8 service hours or daily. All the information, figures, tables and specifications are the latest product information obtainable at the time of publication. Guangxi Liugong Company will reserve the right to make change without notice.

  • Page 9: Main Components

    Preface Main Components 1. Mast 9. Parking brake lever 17. Seat 2. Mast hydraulic system 10. Rear wheel 18. Front floodlight 3. Load-backrest 11. Steering axle 19. Emergency button 4. Fork arm carrier 12. Counterweight 20. Control lever 5. Fork 13.
  • Page 10 Preface Serial Number of the Machine and Parts Manufactures Name Guangxi Liugong Machinery Co., Ltd Product Identification Number (PIN) Serial Number of Battery Serial Number of Reduction Box Serial Number of Rear Axle Serial Number of Frame Serial Number of Travel Motor...
  • Page 11 As proof that the requirements are met, the machine is supplied with an EU Declaration of This CE marking is located on the right side of Conformity, issued by Liugong CE for each the front frame. separate machine. This EU declaration does not cover attachments manufactured by Liugong.

  • Page 12: Ec Declaration Of Conformity

    RESPONSIBLE FOR MARKING THIS DECLARATION IS THE: MANUFACTURER □ REPRESENTATIVE ESTABLISHED WITHIN THE EU ■ MANUFACTURE'S NAME GUANGXI LIUGONG MACHINERY CO., LTD. MANUFACTURER'S ADDRESS NO. 1 LIUTAI ROAD, LIUZHOU, GUANGXI 545007, PR CHINA. AUTHORIZED REP'S NAME LIUGONG MACHINERY EUROPE B.V.
  • Page 13 RESPONSIBLE FOR MARKING THIS DECLARATION IS THE: MANUFACTURER □ REPRESENTATIVE ESTABLISHED WITHIN THE EU ■ MANUFACTURE'S NAME GUANGXI LIUGONG MACHINERY CO., LTD. MANUFACTURER'S ADDRESS NO. 1 LIUTAI ROAD, LIUZHOU, GUANGXI 545007, PR CHINA. AUTHORIZED REP'S NAME LIUGONG MACHINERY EUROPE B.V.
  • Page 14 RESPONSIBLE FOR MARKING THIS DECLARATION IS THE: MANUFACTURER □ REPRESENTATIVE ESTABLISHED WITHIN THE EU ■ MANUFACTURE'S NAME GUANGXI LIUGONG MACHINERY CO., LTD. MANUFACTURER'S ADDRESS NO. 1 LIUTAI ROAD, LIUZHOU, GUANGXI 545007, PR CHINA. AUTHORIZED REP'S NAME LIUGONG MACHINERY EUROPE B.V.
  • Page 15 RESPONSIBLE FOR MARKING THIS DECLARATION IS THE: MANUFACTURER □ REPRESENTATIVE ESTABLISHED WITHIN THE EU ■ MANUFACTURE'S NAME GUANGXI LIUGONG MACHINERY CO., LTD. MANUFACTURER'S ADDRESS NO. 1 LIUTAI ROAD, LIUZHOU, GUANGXI 545007, PR CHINA. AUTHORIZED REP'S NAME LIUGONG MACHINERY EUROPE B.V.

  • Page 16: Safety Information

    Safety Information Safety Decals and Decal Locations "Caution" is also used to indicate safety Safety Information information relating to unsafe operations which may cause personal injuries. "Danger" represents the most dangerous conditions. The Safety Symbol safety signs "Danger" or "Warning" are placed near particular dangerous places.
  • Page 17 Safety Information Safety Decals and Decal Locations Decal Location 1. DECAL 10. DECAL 19. DECAL 2. NOTICE DECAL 11. NOTICE DECAL 20. WARNING DECAL 3. WARNING DECAL 12. NAMEPLATE 21. SYMBOL 4. WARNING DECAL 13. REFLECTOR 22. RIVET 5. SYMBOL 14.
  • Page 18 Safety Information Safety Decals and Decal Locations Decal Information 2. NOTICE DECAL (Located on front side of overhead guard) Do not spray water to clean machine, damage to traction motor or electronic components will result. 74A3308 3. WARNING DECAL (Located on No-Step location) FALLING HAZARD.
  • Page 19 Safety Information Safety Decals and Decal Locations Decal Information 4. WARNING DECAL (Located on the cover of battery) No passengers. 74A3306 7. DANGER DECAL (Located on right side of mast) No passengers on or under fork. 74A3300...
  • Page 20 Safety Information Safety Decals and Decal Locations Decal Information 8. CAUTION DECAL (Located on mast) Do not mount machine from right side. 74H3292 9. WARNING DECAL (Located on the cover of battery) Read and understand Operation and Maintenance Manual before operating or performing maintenance on this machine, death or serious injury could result.
  • Page 21 Safety Information Safety Decals and Decal Locations Decal Information 14. WARNING DECAL (Located on the middle beam of mast) CRUSH HAZARD. Keep clear of mast. 74A3303 16. NOTICE DECAL (Located on the front of the frame) Do not take overhead guard as lifting point 74A3295...
  • Page 22 Safety Information Safety Decals and Decal Locations Decal Information 17. DANGER DECAL (Located on left side of mast) No passengers on the fork. 74A3301 18. DANGER DECAL (Located at crush area) CRUSH HAZARD. Do not enter working area of forklift. 74A3293...
  • Page 23 Safety Information Safety Decals and Decal Locations Decal Information 20. WARNING DECAL (Located on the cover of the battery) 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 24: General Hazard Information

    Safety Information General Hazard Information General Hazard Information Be familiar with all safety cautions, failure to observe could result in property damage, serious injury or even death. Only trained and qualified personnel should be allowed to operate or maintain the machine. Wear relevant personal protective equipment (PPE) such as a hard hat, ear protection, safety glasses, safety shoes and gloves when...
  • Page 25 Secure all loose items such as lunch boxes, tools around the machine . and others. Guangxi Liugong bears no responsibility for Pay attention when opening fluid compartments failures caused by modifications to machine to prevent foreign materials from entering the structure without Liugong’s permission.
  • Page 26 Safety Information General Hazard Information Compressed Air Compressed air can cause personal injury. When using compressed air for cleaning, wear a protective face shield, protective clothing, hearing protection and protective shoes. Never aim compressed air at yourself or others. Compressed air could penetrate your skin and cause serious injury or death.

  • Page 27: Crushing And Cutting Prevention

    Equipment and replacement parts maintenance is performed. shipped from Liugong have no asbestos in them. If the machine must be repaired with machine Liugong recommends the use of genuine factory running, make sure that a qualified operator is spare parts only.

  • Page 28: Fire & Explosion Prevention

    Tighten any loose oil pipes, hydraulic system fire. tubes or hoses. Repair any damaged oil lines, tubes or hoses. Leaks can cause fires. Contact Liugong or your Liugong Dealer for factory authorized replacement parts.

  • Page 29: Fire Extinguishers And First-Aid Kit

    Safety Information Fire Extinguishers and First-aid Kit If you see evidence of any of the following Keep telephone numbers of doctors, first-aid situations, replace the part before using: centers or fire stations etc with you so you can contact them in case of an emergency. Post the Connectors damaged or leaking.

  • Page 30: Tire Explosion Prevention

    Nitrogen helps to prevent oxidation tires in a tire service shop. of the rubber, deterioration of rubber, and corrosion of rim components. Liugong can provide the pneumatic tire or cushion tire for you according your requirement. Attachment Cautions Attachments should only be installed by...
  • Page 31 Safety Information Cautions about Machine Operation Face the machine when getting on or off, grab Understand Your Working Area the handrails with both hands and step onto the steps or ladders. Touch three points Before starting, inspect the area where you will simultaneously (two feet and one hand or two be working.
  • Page 32 Safety Information Cautions about Machine Operation Remove all loose objects from operator After the machine is started, you should observe, compartment. Loose objects may affect the instruments and warning lights, and make sure operation and cause accidents. that they work and every reading is within working range.
  • Page 33 Safety Information Cautions about Machine Operation Before operation, check the conditions of the The operator has a primary responsibility to forklift. If any fault is found, report to relevant protect the safety of pedestrians. Priority must personnel immediately or get it repaired. Do not always be given to pedestrians.
  • Page 34 Safety Information Cautions about Machine Operation While driving, do not reach your arms or legs outside the forklift truck or into the mast. Never try to go over the mast to deal with work unless when the machine stops for repair. Use the proper size pallet for loading.
  • Page 35 Safety Information Cautions about Machine Operation Make sure that the goods on pallet are secured. Always use the load backrest extension and Secure the goods with ropes before shipping. overhead guard for high stacking, especially be cautious of falling objects when stacking. Make sure no loose articles are lying on top of the load.
  • Page 36 Safety Information Cautions about Machine Operation Carry loads as close to the ground as possible. Keep a safe distance between machines so as to Keep the forks 15 to 20mm off the ground in be able to stop the machine safely under any most cases.
  • Page 37 Safety Information Cautions about Machine Operation Slow down the forklift when driving on a wet road It is not allowed to drive across unsolidified surface and slippery ground. obstacles on the road. It is better to remove the obstacles before going across and avoid driving across uneven road surface to prevent loosening the loads.
  • Page 38 Safety Information Cautions about Machine Operation Pay attention to the overhead goods and the When carrying goods with huge size and the clearance between the mast and the obstacle. front sight has been blocked, you should drive The distance between the equipment at the with reverse gear, or move forward under a ceiling (such as lamp, cable, various signalman’s help.
  • Page 39 Safety Information Cautions about Machine Operation Drive the machine forward when going up a hill Check the condition of the forklift after finishing with a load. Drive the machine in reverse when work everyday. Report any faults of the machine going down a hill with a load to avoid tipping to relevant personnel if any fault is found.

  • Page 40: Cautions About Machine Maintenance

    Safety Information Cautions about Machine Maintenance Push the lift lever forward to lower the fork onto Do not work under any part of the machine or ground. Pull the tilt lever backward or push the tilt attachment that is not adequately supported. Do lever forward to lay the fork flatly on the ground.

  • Page 41: Stability And Barycenter

    Safety Information Stability and Barycenter Place all the working equipment in the Clean the Equipment Periodically transportation position, secure all the equipment and attachments or additional equipment with To avoid possible injury or damage to the chains or other secure methods to prevent machine, all the oil and scraps accumulated accidental movement.
  • Page 42 Safety Information Stability and Barycenter 1. Barycenter Forklift Stability Use front wheel as a pivot, two side weights keep in balance. Barycenter of the load and forklift determines the forklift stability. 2. Vehicle barycenter 3. Resultant barycenter 4. Load barycenter Empty forklift is much easier to tip over transversely than the full load forklift.

  • Page 43: Sound And Vibration

    “EN12053:2001+A1:2008 Safety of industrial trucks-Test methods for measuring noise emissions” is 67dB for CLG2015A-S/18A-S and 71dB for CLG2020A-S/25A-S. Rough or uneven road surface will result in tire distortion easily which could cause a big noise to the machine.

  • Page 44: Key Spare Parts To Be Periodically Changed

    Safety Information Key Spare Parts to be Periodically Changed Key Spare Parts to be Periodically Changed Key spare parts to be periodically Q’ty Changing intervals changed Every year or every 2000h (To see which one Filter element of hydraulic oil tank comes earlier) Seals of steering system Hose assembly (pump to metering pump)

  • Page 45: Application And Specification Applications

    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 46: Main Specifications

    Application and Specification Main Specifications Main Specifications All rated lift capacities specification are collected from the machine operation on a hard and flat ground. When the machine is operated in conditions that different from the above-mentioned condition (e. g. on soft or uneven ground, on a slope), these conditions shall be taken into account by the operator.
  • Page 47 Application and Specification Main Specifications Machine Specifications (CLG2015A-S, CLG2018A-S) Model CLG2015A-S CLG2018A-S Power Type Electric Electric General Base Capacity rated load center 1500 1800 Load Center Service Weight unloaded 3050 3150 Weights loaded/unloaded, front 4034/1526 4442/1717 Axle Load loaded/unloaded, rear...
  • Page 48 Application and Specification Main Specifications Machine Specifications (CLG2020A-S, CLG2025A-S) Model CLG2020A-S CLG2025A-S Power Type Electric Electric General Base Capacity rated load center 2000 2500 Load Center Service Weight unloaded 3500 3900 Weights loaded/unloaded, front 4841/1660 5698/1648 Axle Load loaded/unloaded, rear 659/1840 702/2252 Tire Type...
  • Page 49 Application and Specification Main Specifications Main component specifications LengthxWidthxHeight:912X49 CLG2015A-S/18A-S Standard 420AH 4X675 configuration, 715kg LengthxWidthxHeight:912X49 CLG2015A-S/18A-S Optional 480Ah 4X675 configuration, 850kg LengthxWidthxHeight:912X49 CLG2015A-S/18A-S High 540Ah 4X675 configuration, optional 900kg Battery LengthxWidthxHeight:888X65 CLG2020A-S/25A-S Standard 560AH 5X680 configuration, 915kg LengthxWidthxHeight:888X65 CLG2020A-S/25A-S Optional...
  • Page 50 Application and Specification Main Specifications Pump Gear pump System maximum flow 38L/min Main relief valve set pressure 18.1MPa Safety valve set pressure: lift and 18.1MPa tilt Hydraulic Steering relief valve set pressure 8MPa system Lift cylinder quantity, bore × rod (CLG2020A-S) 2-φ45×φ36×1495 mm diameter ×...
  • Page 51 Work Scope Please operate the machine according to the rated load capacity in the load curve chart. (The load chart used for CLG2015A-S forklift with two stage mast.) (The load chart used for CLG2015A-S forklift with sideshift and two stage mast.)
  • Page 52 Application and Specification Main Specifications (The load chart used for CLG2015A-S forklift with three stage mast.) (The load chart used for CLG2015A-S forklift with sideshift and three stage mast.)
  • Page 53 Application and Specification Main Specifications (The load chart used for CLG2018A-S forklift with two stage mast.) (The load chart used for CLG2018A-S forklift with sideshift and two stage mast.)
  • Page 54 Application and Specification Main Specifications (The load chart used for CLG2018A-S forklift with three stage mast.) (The load chart used for CLG2018A-S forklift with sideshift and three stage mast.)
  • Page 55 Application and Specification Main Specifications (The load chart used for CLG2020A-S forklift with two stage mast.) (The load chart used for CLG2020A-S forklift with sideshift and two stage mast.)
  • Page 56 Application and Specification Main Specifications (The load chart used for CLG2020A-S forklift with three stage mast.) (The load chart used for CLG2025A-S forklift with two stage mast.)
  • Page 57 Application and Specification Main Specifications ≤ ≤ ≤ ≤ (The load chart used for CLG2025A-S forklift with sideshift and two stage mast.) ≤ ≤ ≤ ≤ (The load chart used for CLG2025A-S forklift with three stage mast)
  • Page 58 Application and Specification Main Specifications (The load chart used for CLG2025A-S forklift with sideshift and three stage mast.)

  • Page 59: Operation Manual

    Operation Manual Before Operation Operation Manual Before Operation Mounting and Dismounting Before mounting or dismounting the ● machine, check the condition of handrails, ladders and steps. Clean them of grease, lubricants and dirt before use. Repair any damaged parts and tighten loose bolts. Mount and dismount the machine only where ●...

  • Page 60: Operator Controls And Instrument Panels

    Operation Manual Operator Controls and Instrument Panels Operator Controls and Instrument Panels 1. Steering wheel 8. Lift lever 2. Start switch 9. Tilt lever 3. Combination switch 10. Sideshift lever (optional) 4. Parking brake lever 11. Aux lever (optional) 5. Service brake pedal 12.

  • Page 61: Start Switch

    Operation Manual Operator Controls and Instrument Panels Start Switch Battery Connector Start switch (also called ignition switch) is located at the left side of the gauge which is used to turn on the power for the machine. OFF and ON positions are available.

  • Page 62: Instrument Panel

    Operation Manual Operator Controls and Instrument Panels Instrument Panel Brake oil low level alert indicator (for spare use) Gauge(SME) The indicator will turn red and alert the operator when the brake oil level is too low. Electricity level symbol The symbol has 9 bars. The numbers of bars indicate the level of electricity.
  • Page 63 Operation Manual Operator Controls and Instrument Panels Service symbol Reverse indicator The symbol is shown when the fault is The reverse indicator flashes when the found or during the maintenance shift control lever is turned to R. intervals. Neutral indicator Service hour meter The neutral indicator flashes when the The meter indicates the total...

  • Page 64: Combination Switch

    Operation Manual Operator Controls and Instrument Panels Electricity level symbol Rotating beacon The symbol indicates the It will turn on when turn the rotating beacon electricity level and it will switch forwards. illuminates when the number of bar is two. Charge the battery at this time.

  • Page 65: Other Controls

    Operation Manual Operator Controls and Instrument Panels A knob is provided on the top of the right switch, There are three positions of the wiper switch: which is used to control the lights. Turn the knob Lower position, Middle position and Upper from OFF to I position, the position light will turn position.

  • Page 66: Steering Column

    Operation Manual Operator Controls and Instrument Panels Steering Column Reverse Switch Pull up the steering column adjusting handle to Reverse switch is provided on the lift lever. adjust the steering wheel forwards and The running direction of the machine can be backwards to desired angle.

  • Page 67: Parking Brake Lever

    Operation Manual Operator Controls and Instrument Panels Parking Brake Lever Service Brake Pedal The parking brake lever is located at the right The brake pedal is located at the front of the side of the steering wheel. operator's seat. Depress the brake pedal to engage service brake.

  • Page 68: Emergency Button

    Operation Manual Operator Controls and Instrument Panels Emergency Button Lift Lever Before operating the machine, pull the The machine is not able to travel and operate if emergency button upwards until a click is heard you don't sit on the seat correctly. Turn on the start switch, and then the forklift can work normally.

  • Page 69: Tilt Lever

    Operation Manual Operator Controls and Instrument Panels Others Seat It is strictly prohibited to carry people on the forks. The seat has suspended vibration-absorbing function. It can be adjusted along fore-and-aft Tilt Lever direction and height direction, and the backrest angle can also be adjusted to adapt itself to meet The tilt lever is used to tilt the mast forwards and the needs of different drivers and occasions.
  • Page 70 Operation Manual Operator Controls and Instrument Panels Backrest Angle Adjustment (Optional) Weight Adjustment and Suspension (Optional) Rotating the adjusting handle clockwise to increase the tilt angle and counterclockwise to Three positions are available for this weight decrease. Release the handle if it comes to a adjustment.
  • Page 71 Before using the seat belt, check it for good condition. Replace it in time if necessary. Fastening seat belt can reduce the risk of For seat belt replacement, consult with Liugong personnel injuries and death when a dealer. turnover accident happens.
  • Page 72 Operation Manual Operator Controls and Instrument Panels Overhead Guard Side Shroud of the Hood 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 73 Operation Manual Operator Controls and Instrument Panels Rear Hood Battery Box Cover--Open The battery box cover is used to support the Fix the rod of counterweight to position 1 to driver's seat and protect the battery. secure the rear hood after the hood is open. Fix the rod to position 2 before close the rear hood.
  • Page 74 Operation Manual Operator Controls and Instrument Panels 4. Open the battery box cover. The rod will lock Fork and fix the battery cover automatically once it reaches the limit position. Pull up and unscrew lock pins at both ends of the fork, and move the fork leftwards and rightwards.
  • Page 75 7. It is prohibited to modify the attachment Nearly all of the attachment for medium and without the technical permission of Liugong small ton forklift is installed with hook. In order to as the modification could cause safety ensure the installation safety, it's recommended problem and change the attachment function.

  • Page 76: Machine Starting

    Operation Manual Machine Starting 5. Insert the start switch key and turn it Machine Starting clockwise to “ON” position to turn on power for the machine. Hoot the horn to announce that the machine is about to start and other people are not allowed to approach the machine.

  • Page 77: Steering Operation

    Operation Manual Operation Techniques 1. Keep the correct posture during operation, 6. Check engagement conditions for front and always sitting on the seat correctly, don't put rear gear. your hands, foot and other parts of your body out of the overhead guard. 2.

  • Page 78: Brake Operation

    Operation Manual Operation Techniques 4. Depress the accelerator pedal to obtain a Press the lock button on top of the parking brake desired motor speed. lever, then push the parking brake lever forwards to disengage brake. Never turn the forklift leftwards or rightwards on slope, otherwise, the forklift An alert symbol will flash in the forklift may overturn.

  • Page 79: Loading Operation

    Operation Manual Operation Techniques Run the forklift reversely if it is full-loaded and 5. In order to main a balance, please load the travel on a slope with a grade more than 10%. goods evenly. When loading large sizes or heavy goods, please pay close attention to operation to avoid an overturn of the forklift.

  • Page 80: Hot Weather Operation

    Operation Manual Operation Techniques To prevent the forklift from being frozen on the Move Oversize Goods ground, park the machine on dry hard ground or wooden boards. 1. Drive with special attention when carrying Replace hydraulic oil and lubricant with medium- oversize goods.

  • Page 81: Before Storage

    Dispose all debris vapor may accumulate. Contact with properly. liugong dealer for further maintenance 5. Install all covers, lock all devices, and take procedures if the forklift is parked over away the key.

  • Page 82: Transportation Information

    Operation Manual Transportation Information Start the machine once every month. Lift and Transportation Information lower the fork at least three times, and tilt the mast forwards and backwards at least three times too. Drive the forklift forwards and Transportation backwards for at least 50 meters. Lubricate all the movable parts such as pins and shafts.
  • Page 83 6. Tilt the mast forward until the front wheels are lifted off ground. 8. For installing those parts removed before transportation, contact with liugong dealer to install. 9. When it is necessary to remove the mast and Do not remove the nuts of the wheels before counterweight before transportation, remove the front wheels are lifted off the ground.
  • Page 84 Operation Manual Transportation Information 7. Place blocks under the front two sides of the Rear tires frame to support the machine, and then stop the machine. 1. Park the forklift on flat and hard ground. 2. Engage the parking brake lever. Chock the front wheels with wedges to prevent the machine from moving.

  • Page 85: Fork Removal

    Operation Manual Transportation Information 5. Lift the forklift slowly by the jack until the rear 10. Adjust the tire pressure to specified value. wheels are completely off the ground. Place blocks under the rear two sides of the frame Fork Removal to support the machine as illustrated.

  • Page 86: Lifting Operation

    Operation Manual Transportation Information The drawbar is located behind the counterbalance. Use this drawbar to tow the Figure 2 machine out if the machine traps in mud or is fixed on the trailer. Never try to use the forklift as a tow tractor to tow other disable machine.
  • Page 87 Operation Manual Transportation Information 4. Ensure that the four lifting hooks on the lifting ropes are weighted with even force when lifting. 1. Choose suitable crane and rope with maximum capacity according to the nameplate on the forklift to ensure safety when lifting.
  • Page 88 Operation Manual Transportation Information Lift the sideshifter by the lift eye. Ensure that the lifting device do not interfere with overhead guard and lights during lifting. Attachment--Remove and Lift The attachment of the machine is removable. Refer to the following steps for removal. Take sideshifter for example.

  • Page 89: Maintenance Manual Run-In

    Maintenance Manual Run-in 5. Check the rubber of cable connector if it is Maintenance Manual aging under high temperature. Run-in Replace axle lubrication oil according to The run-in of new machine is an important operational guidelines. procedure for prolonging of the service life of the machine, eliminating failure and avoiding accidents.

  • Page 90: 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 91 Maintenance Manual Maintenance Interval Schedule Check the consistency and liquid level of Hydrometer ○ ○ ○ ○ ○ electrolyte, also Voltmeter check the voltage of the motor Check if the cables of the battery are ○ ○ damaged, replacing them if necessary Check if the terminal ○...
  • Page 92 Maintenance Manual Maintenance Interval Schedule Check the instruments and ○ ○ ○ display for good condition Check if the alarm Other device and electrical ○ ○ ○ emergency switch units are in good condition Check the specifications of the ○ ○...
  • Page 93 Maintenance Manual Maintenance Interval Schedule Wheels Three Every Day Every Month Half Year Every Year Items Description Tools Months (8hours) (200hours) (1200hours) (2400hours) (600hours) Inflation pressure Pressure ○ ○ ○ ○ ○ (only for pneumatic gauge tires) Check for cracks or ○...
  • Page 94 Maintenance Manual Maintenance Interval Schedule Check for loose ○ ○ ○ ○ bolts Metering pump Check the seals of ○ ○ ○ ○ ○ each connector Check the main pin ○ ○ ○ ○ for looseness or damages steering Check for knuckle of deformation, ○...
  • Page 95 Maintenance Manual Maintenance Interval Schedule Operation ○ ○ ○ ○ Bar, ropes performance and cables, Check for ○ ○ ○ ○ looseness Check for damage, ○ ○ ○ ○ leakage and cracks Circuits Check those connection parts ○ ○ ○ ○...
  • Page 96 Maintenance Manual Maintenance Interval Schedule Check the mounting bolts and Test screws of the ○ ○ ○ ○ hammer brake pump for looseness Check the friction ○ plate for good Scale condition Check if the fixed ○ Brake drum pin is corroded (Only for Check the return drum type...
  • Page 97 Maintenance Manual Maintenance Interval Schedule Check the welding position among the inner mast, outer ○ ○ ○ ○ mast and the beam for cracks and damages Check the welding position of tilt cylinder bracket ○ ○ ○ ○ and mast for poor welding, cracks or damages Check the inner...
  • Page 98 Maintenance Manual Maintenance Interval Schedule Check if the chain is tensioned and ○ ○ ○ ○ ○ deformed, damag- ed corroded ○ ○ ○ ○ Lubricate chain Check the rivet ○ ○ ○ ○ Chain and pins for looseness chain wheel Check the chain wheel for ○...
  • Page 99 Maintenance Manual Maintenance Interval Schedule Check the oil level ○ ○ ○ ○ ○ Replace oil ● Hydraulic oil Clean the suction ○ ○ ○ tank filter element Remove ○ ○ ○ contaminants Return oil Change the return ● ● filter oil filter Check for looseness...
  • Page 100 Maintenance Manual Maintenance Interval Schedule Check for good Horn installation and ○ ○ ○ ○ ○ operation condition Check for good Light and ○ ○ ○ ○ ○ installation and bulbs operation condition Check for good Backup installation and ○ ○...

  • Page 101: General Torque Specifications

    Maintenance Manual General Torque Specifications General Torque Specifications Tighten the bolts used in the machine according to the torque requirements shown in the following table unless other specified: Metric system Standard Torque lb.ft (N.m) Thread Size 8.8 Grade Strength 10.9Grade Strength 7.7±1.1(10.5±1.5) 19±2.9(26±4) 38±5(52±7)

  • Page 102: Lubricant Specifications

    Maintenance Manual Lubricant Specifications Lubricant Specifications Oil Specifications Oils that used in this machine should meet the following specifications when refill or replace to ensure the normal use of the machine. L-HV32 anti-wear hydraulic oil with ambient temperature between -20~-5°C; L-HM32 anti-wear hydraulic oil with ambient temperature between -5~30°C;...
  • Page 103 Maintenance Manual Lubricant Specifications Oil change intervals and refill capacities Care must be taken in order to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the equipment. Prepare to collect the fluid with suitable containers before removing any hydraulic oil line or disassembling any component that contains fluids.
  • Page 104 Maintenance Manual Lubricant Specifications Lubrication Chart Sliding surface lubrication Grease fitting lubrication Gear oil injection Gear oil releasing Hydraulic oil injection Brake oil injection...

  • Page 105: Tire Information

    Tire Inflation Information Cushion Tire--Replace Liugong recommends the use of dry nitrogen gas for tire inflation and for tire pressure adjustments. Replace the tire when it is worn to the abrasion It includes all machines with rubber tires.

  • Page 106: Working Implement System

    Maintenance Manual Working Implement System 5. In order to offer a better installation, spray or Working Implement System apply lubricant such as soapsuds etc onto the bottom of the wheel hub and wheel rim, do not use grease etc. that may affect the tire Mast--Lubricate quality.
  • Page 107 As for repairing the mast, changing cylinder or chain and so on that needs further safety measures, contact the Liugong forklift dealer. Chain adjustment: Keep the mast straight, lower the fork onto the ground and the Drop-resistant measures of common two cylinder to the end.
  • Page 108 Maintenance Manual Working Implement System Drop-resistant measures of full free two stage Drop-resistant measures of three stage mast mast The middle lift cylinder first raises the fork to a Even operated in a very low space, this kind of particular free height through chain wheel, then mast can still raise freely.

  • Page 109: Important Maintenance Procedures

    Maintenance Manual Important Maintenance Procedures Important Maintenance Hydraulic System Procedures Power Train System Axle Oil Level--Check Park the machine on flat ground. Push the control lever to NEUTRAL position. Before checking, disconnect the battery connector, engage the parking brake lever and lower the fork onto ground.
  • Page 110 Maintenance Manual Important Maintenance Procedures The hydraulic oil tank locates at the right rear Hydraulic Oil-- Replace Periodically side of the frame. An oil dipstick is provided on the oil filler. Normally, the oil level should reach 22L on the oil dipstick. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component...
  • Page 111 Maintenance Manual Important Maintenance Procedures 5. Clean the hydraulic oil tank outlet. Screw out 6. Remove and clean the flange cover of the the oil drain plug to drain out hydraulic oil and hydraulic oil tank. Then remove the return oil collect with a container.
  • Page 112 Maintenance Manual Important Maintenance Procedures 2. Remove the bolt from the head of slide valve Main Safety Valve Pressure--Adjust and the hexagon cap screw from the cover side. Remove the slide valve which contains The pressure of the main safety valve has leather cup, O-ring and seal plate from the already adjusted before leaving the factory.

  • Page 113: Brake System

    Maintenance Manual Important Maintenance Procedures Brake System Parking Brake Force-Adjust Disengage the parking brake to release brake Brake Oil--Check force. Hang a spring scale to the middle of the parking brake lever, then pull the spring scale backwards to measure the brake force. Turn the adjusting screw to adjust the brake force.

  • Page 114: Electrical System

    Maintenance Manual Important Maintenance Procedures 4. Turn the parking brake lever backwards and Electrical System release the service brake pedal slowly. Check to see if the machine stays at the Battery Maintenance original position. Observe the operation instruction carefully and stick this sign to an visible position of the charge site.

  • Page 115: Cautions For Battery

    Maintenance Manual Important Maintenance Procedures Battery Inspection for New Machine Inspect whether the positive and negative terminals are connected correctly; Check the cables for good connection. Inspect the voltage of the battery Inspect the proportion of the electrolyte; Inspect the liquid level of the electrolyte; Clean the dirt and dust on the surface of the battery.
  • Page 116 Electrolyte densimeter is not an accessory Check battery every week routinely. Use clean of battery. Please contact Liugong's dealer and wet cloth to clean the surface of the battery for information. to keep the battery clean, which can prevents...

  • Page 117: Electrical Schematic

    Maintenance Manual Important Maintenance Procedures If the battery electrolyte sprays or leaks in the job Obey the local environmental laws and site, it may damage the floor and other material regulations on recycling the battery. and cause pollution to air. Neutralize the Lead, electrolyte and plastics inside the lead- electrolyte with acid neutralization agent such as acid battery are the recycling materials.
  • Page 118 Maintenance Manual Important Maintenance Procedures Check the tightness of bolts and cables on the 1. Electrical control unit 2. Fasteners of cable battery terminals. Tighten them if they are loose. 3. Main relay CURTIS controller unit 1. Fasteners of travel motor 1.
  • Page 119 Maintenance Manual Important Maintenance Procedures Discharging procedure: Take out the battery Fuse--Check/Replace socket to cut off power supply. Then connect the positive and negative terminals with wires for an The fuse box is located at the right rear of the instant to discharge the capacitor completely.

  • Page 120: Lighting System

    This machine is equipped with front floodlight, BK/ATC-30A Green(GN) rotating beacon, LED rear combination light, etc. Contact Liugong dealer if the LED combination Fuse Replacement of the Electronic Control light is damaged. Unit In order to make it convenient for the users to...

  • Page 121: Other Maintenance

    Move the position of retractor on seat belt to adjust the length of the seat belt. No matter how well the seat belt looks like, replace it every three years. Consult your Liugong dealer for the replacement of the seat belt.

  • Page 122: Troubleshooting

    Maintenance Manual Troubleshooting Troubleshooting Machine Troubleshooting Features Possible reasons Solutions Battery exhausted. Check, charge or replace the battery. Tighten the battery terminal and smear a layer of non- Loose connection. acidic grease. Forklift is unable to start Fuse belowing out. Replace the fuse Emergency button engaged Disengage the Emergency button.
  • Page 123 Maintenance Manual Troubleshooting Drive Axle Troubleshooting Features Possible reasons Solutions Replace the gear or adjust The bevel gear wears out the too big meshing clearance the meshing clearance The planetary gear shaft of the differential wears Abnormal noise inside the Replace excessively drive axle...
  • Page 124 Maintenance Manual Troubleshooting Relief valve normal open (unable to close) Replace the whole unit Difficult steering Flow control valve stem blocked Remove for repair or replace Flow control valve stem worn Replace the whole unit Metering Pump Troubleshooting Failure Features Possible reasons Solutions Dirt on the joint surface.
  • Page 125 Maintenance Manual Troubleshooting (1)Steering column is different from Steering spool wheel The metering pump doesn't (2)Valve blockage due to axial unable to discharge (the forklift deviated from Remove trouble according to movement of steering column. return its route) when the steering wheel causes (3)Too much turning resistance of automaticall...
  • Page 126 Maintenance Manual Troubleshooting Lift System Troubleshooting Feature Possible reasons Solutions Too much axial and radial clearance in oil pump Repair or replace the oil pump Use required oil and pay attention to weather Too high viscosity or temperature of hydraulic oil impact on oil temperature Weak lifting, low lifting...
  • Page 127 Maintenance Manual Troubleshooting Electronic Control System Troubleshooting(SME) Fault codes usually appear on the display if any fault occurs. The table of fault codes is shown as follows as a reference for troubleshooting by users. Code Possible reasons Overvoltage of battery Undervoltage of battery Output voltage of accelerator exceeds the setting voltage, or the accelerator pedal is normal open EPROM memory...
  • Page 128 Maintenance Manual Troubleshooting Electronic Control System Troubleshooting(CURTIS) PROGRAM MER LCD EXPLANATION POSSIBLE CAUSE CODE DISPLAY No power or defective LED OFF controller controller fault (E.g MCU Solid ON failure, etc) Controller operational, no ■ ¤ faults 1.EEPROM data lost or damaged 2.EEPROM data verification error ¤...
  • Page 129 Maintenance Manual Troubleshooting 1.Any contactor coil open or not connected. Missing contactor or main ¤¤¤ ¤¤¤¤ 2.Main contactor faults. contacator did not close(DNC) 3. Wrong setting of CONTACT CNTRL 1. Battery voltage is lower than LOVOLT CUTBACK setting value ¤¤¤¤ ¤ Low battery voltage 2.

  • Page 130: Electrical System Troubleshooting

    Maintenance Manual Troubleshooting Electrical System Troubleshooting Features Possible reasons Solutions 1.Battery connector. 1.Check the battery connector, connect it correctly. 2.Fuse of control circuit is 2.Check the fuse, replace if necessary. No Instrument power burnt. 3.Check the emergency button for power. Turn it on if it does not after the start switch 3.Emergency button is power on.

  • Page 131: Battery Troubleshooting

    Maintenance Manual Troubleshooting Electrical Motor Troubleshooting Features Possible reasons Solutions 1.Check the fixed screw and connection for 1.The controller can not check the coder. loosen, or replace the coder. The motor vibrates 2.The coder damaged. 2.Replace the coder when working. 3.The cable loosen.

  • Page 132: Maintenance Note Table

    Maintenance Manual Maintenance Note Table Maintenance Note Table...

  • Page 133: Index

    INDEX INDEX Accelerator Pedal ..........61 Daily Maintenance for Hydraulic System ..103 Application and Specification ......39 Daily Maintenance of Battery ......110 Applications .............39 Downhill Operation ......... 72 Attachment Cautions ........24 Drive Axle Troubleshooting ......117 Attachment--Remove and Lift ......82 Aux Lever (Optional) ........63 Axle Oil Level--Check ........103 EC Declaration of Conformity ....
  • Page 134 INDEX Metering Pump Troubleshooting ....118 Move Oversize Goods ........74 Horn Button .............60 Hot Weather Operation ........74 Hydraulic Oil Level--Check ......103 Hydraulic Oil-- Replace Periodically ....104 Oil change intervals and refill capacities ..97 Hydraulic System ..........103 Oil Specifications ..........96 Operation Manual ...........
  • Page 135 INDEX Side Shroud of the Hood .........66 Sideshift Lever (Optional) .......63 Sound and Vibration ........37 Stability and Barycenter ........35 Start Switch .............55 Steering Column ..........60 Steering Operation ..........71 Steering System Troubleshooting ....117 Steering Wheel ..........59 Steering Wheel--Check ........59 Stop the Engine ..........75 Stop the Machine ..........74 Storage and Maintenance of Cushion Tires ..100 Testing Method for Electrolyte Density ..109...
  • Page 136 INDEX...

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